Complete service repair manual for John Deere 744H 4WD Loader & 744H MH Material Handler, with workshop information to maintain, repair, and service like professional mechanics.

John Deere 744H 4WD Loader & 744H MH Material Handler 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.

TM1603 - John Deere 744H 4WD Loader and 744H MH Material Handler Technical Manual (Repair).PDF
TM1603 - John Deere 744H 4WD Loader and 744H MH Material Handler Technical Manual (Repair).EPUB

Total Pages: 873 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

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
      Hydraulic System
   Transmission
      Transmission, Remove and Install
      Gears, Shafts, Bearings and Power Shift Clutch Packs
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling Systems
      Speed Controls
      Intake System
      External Exhaust System
      External Fuel Supply Systems
   Flex Plate Drive
      Elements
   Steering System
      Hydraulic System
   Service Brakes
      Active Elements
      Hydraulic System
   Park Brake
      Active Elements
      Hydraulic System
   Electrical Systems
      Batteries, Support and Cables
      Alternator, Regulator and Charging System Wiring
      Lighting System
      Wiring Harness and Switches
      System Controls
   Frame or Supporting Structure
      Frame Installation
      Frame Bottom Guards
      Chassis Weights
   Operator’s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belts
      Heating and Air Conditioning
   Sheet Metal and Styling
      Hood or Engine Enclosure
      Miscellaneous Shields
      Grille and Grille Housing
   Safety and Convenience
      Mirror
      Fire Extinguisher
      Horn and Warning Devices
   Loader
      Bucket
      Frames
      Hydraulic System
   Dealer Fabricated Tools

tm1603 - 744H Loader and 744H MH Material Handler

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety Information

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding For Special Uses

Inspect Machine

Stay Clear Of Moving Parts

Avoid High-Pressure Fluids

Beware Of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps And Handholds Correctly

Start Only From Operator's Seat

Use And Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Use Special Care When Operating Loader

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating on Slopes

Operating Or Traveling On Public Roads

Inspect and Maintain ROPS

Add And Operate Attachments Safely

Park And Prepare For Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

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

Service Equipment and Tools

Specifications

Remove and Install Wheel

Remove Tire

Install Tire

Section 02: Axles and Suspension Systems

Group 0200: Removal and Installation

John Deere 1600 Series Axles—Use CTM138719

Service Equipment and Tools

Specifications

Remove and Install Front Axle and Differential

Remove Rear Axle and Differential

Install Rear Axle and Differential

Group 0225: Axle Shafts and U-Joints

Specifications

Remove and Install Front, Articulation and Rear Drive Shafts

Disassemble, Inspect, and Assemble Front, Articulation and Rear Drive Shafts

Group 0260: Hydraulic System

Specifications

Remove and Install Differential Lock Solenoid Valve

Remove and Install Pin Disconnect/Axle Disconnect Valve

Disassemble and Assemble Pin Disconnect Valve

Section 03: Transmission

Group 0300: Transmission, Remove and Install

Essential Tools

Service Equipment and Tools

Specifications

Remove and Install Transmission

Group 0350: Gears, Shafts, Bearings and Power Shift Clutch Packs

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Torque Converter

Disassemble Torque Converter Housing

Remove and Install Transmission Power Take-Off (If Equipped)

Disassemble and Assemble Transmission Power Take-Off (If Equipped)

Assemble Torque Converter Housing

Remove Final Drive

Install Final Drive

Remove Clutch Packs

Disassemble 3rd Speed Clutch (K3)/Hi Range Forward Clutch (K4)

Assemble 3rd Speed Clutch (K3)/Hi Range Forward Clutch (K4)

Disassemble Reverse Clutch(KR)/2nd Speed Clutch (K2)

Assemble Reverse Clutch (KR)/2nd Speed Clutch (K2)

Disassemble Low Range Forward Clutch (KV)/1st Speed Clutch (K1)

Assemble Low Range Forward Clutch (KV)/1st Speed Clutch (K1)

Adjust Transmission Speed Sensor

Group 0360: Hydraulic System

Essential Tools

Other Material

Specifications

Remove and Install Transmission Oil Pump

Disassemble and Assemble Transmission Oil Pump

Disassemble Delivery Lines and Channel Plate

Install Breather, Channel Plate and Shift Control

Hydraulic Control Unit—Exploded View

Disassemble Hydraulic Control Unit

Assemble Hydraulic Control Unit

Install Transmission Filter

Section 04: Engine

Group 0400: Removal and Installation

John Deere Engine Repair—Use CTM100

Essential Tools

Service Equipment and Tools

Specifications

Other Material

Remove and Install Engine (S.N. —581927)

Remove and Install Engine (S.N. 581928— )

Remove and Install Oil Pan

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Other Material

Remove and Install Starting Aid Nozzle

Group 0510: Cooling Systems

Other Material

Specifications

Inspect Serpentine Belts (S.N. —581927)

Inspect Serpentine Belts (S.N. 581928— )

Remove and Install Serpentine Belts (S.N. —581927)

Remove and Install Serpentine Belts (S.N. 581928— )

Check and Adjust Air Conditioning Compressor Belt Tension—If Equipped

Belt Tensioner Spring Check

Remove and Install Fan and Fan Drive (S.N. —581927)

Remove and Install Fan and Fan Drive (S.N. 581928— )

Remove and Install Radiator (S.N. —581927)

Remove and Install Radiator (S.N. 581928— )

Remove and Install Hydraulic Oil Cooler (S.N. —581927)

Remove and Install Oil Cooler (S.N. 581928— )

Remove and Install Coolant Level Sensor (S.N. —581927)

Cooling System Fill and Deaeration Procedure (S.N. 581928— )

Group 0515: Speed Controls

Remove and Install Speed Control Linkage (S.N. —581927)

Remove and Install Speed Control Linkage (S.N. 581928— )

Analog Throttle Position Sensor Adjustment

Group 0520: Intake System

Service Equipment and Tools

Specifications

Tighten Air Cleaner Hose Clamps

Remove and Install Air Filter Elements

Air Intake System Leakage Test

Remove and Install Charge Air Cooler (S.N. 581928— )

Group 0530: External Exhaust System

Remove and Install Muffler (S.N. —581927)

Remove and Install Muffler (S.N. 581928—)

Group 0560: External Fuel Supply Systems

Specifications

Remove and Install Fuel Tank (S.N. —581927)

Remove and Install Fuel Tank (S.N. 581928— )

Section 07: Flex Plate Drive

Group 0752: Elements

Specifications

Remove and Install Flex Plate

Section 09: Steering System

Group 0960: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Remove and Install Steering Valve

Remove and Install Steering Column

Remove and Install Steering Cylinders

Disassemble Steering Cylinders

Steering Cylinder—Cross Section

Assemble Steering Cylinder

Remove and Install Steering Cylinder Bushings

Remove and Install Priority Valve

Disassemble and Assemble Priority Valve

Section 10: Service Brakes

Group 1011: Active Elements

Brake Element Repair for 1600 Series John Deere Axle—Use CTM138719

Specifications

Inspect Service Brake Pads

Remove and Install Brake Assembly

Brake Linkage Adjustment

Group 1060: Hydraulic System

Specifications

Remove and Install Brake Valve

Remove and Install Brake Accumulator

Hydraulic Brake Bleeding Procedure

Remove and Install Pressure Reducing Valve Manifold

Section 11: Park Brake

Group 1111: Active Elements

Service Equipment and Tools

Other Material

Specifications

Remove and Install Driveline Bearing Park Brake

Disassemble and Assemble Driveline Bearing Park Brake

Group 1160: Hydraulic System

Specifications

Remove and Install Driveline Bearing Park Brake Release Solenoid Valve

Remove and Install Driveline Bearing Park Brake Pressure Switch

Section 16: Electrical Systems

Group 1671: Batteries, Support and Cables

Service Batteries Carefully

Check Battery Electrolyte Level and Terminals

Battery Charging Procedure

Using Booster Batteries—24 Volt System

Procedure for Testing Batteries

Remove and Install Batteries (S.N. —581927)

Remove and Install Batteries (S.N. 581928— )

Remove and Install Manual Battery Disconnect Switch

Group 1672: Alternator, Regulator and Charging System Wiring

Alternators and Starter Motors—Use CTM77

Remove and Install Alternator

Remove and Install Regulator

Group 1673: Lighting System

Replace Halogen Bulbs

Remove and Install Work Lights

Remove and Install Turn, Tail, and Brake Lights (S.N. —581927)

Remove and Install Turn, Tail, and Brake Lights (S.N. 581928—)

Cab Work Lights Harness

Group 1674: Wiring Harness and Switches

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Fuse (Blade-Type) Color Codes

Fuse Specifications (S.N. —581927)

Fuse Specifications (S.N. 581928—)

Remove and Install Pressure Switches

Boom Height Kickout Adjustment

Return-To-Carry Kickout Adjustment

Return-to-Dig Adjustment (S.N. —564434)

Return-To-Dig Adjustment (S.N. 564435— )

Replace METRI-PACK Metri-Pack is a trademark of Packard Electrical. Connectors

Install METRI-PACK Metri-Pack is a trademark of Packard Electric. Contact

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Replace CINCH CINCH is a trademark of the Cinch Co. Connectors

Install CINCH CINCH is a trademark of the Cinch Co. Contact

Remove Connector Body from Blade Terminals

Remove Blade Terminals From Fuse Block

Group 1675: System Controls

Remove and Install Transmission Controller

Remove and Install Engine Controller

Remove and Install Chassis Computer Unit

Remove and Install Monitor Display Unit

Reprogram Monitor Display Unit

Monitor Display Unit Menus

Section 17: Frame or Supporting Structure

Group 1740: Frame Installation

Service Equipment and Tools

Specifications

Welding Repair of Major Structure

Separate Engine and Loader Frame

Upper Pivot Bearing and Seals Remove and Install

Lower Pivot Bearing and Seals Remove and Install

Group 1746: Frame Bottom Guards

Specifications

Remove and Install Guards

Group 1749: Chassis Weights

Specifications

Remove and Install Counterweights (S.N. —581927)

Section 18: Operator’s Station

Group 1800: Removal and Installation

Essential Tools

Service Equipment and Tools

Specifications

Remove and Install Cab

Tilt Cab

Group 1810: Operator Enclosure

Other Material

Specifications

Remove and Install Windowpanes

Remove and Install Windshield Washer

Remove and Install Front and Rear Windshield Wiper Motor

Adjust Front Windshield Wiper

Remove and Install Wrist Support (S.N. —581927)

Group 1821: Seat and Seat Belts

Disassemble and Assemble Seat Belt

Disassemble and Assemble Seat

Group 1830: Heating and Air Conditioning

Essential Tools

Air Conditioning System Fittings Reference Chart

Other Material

Specifications

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 Core

Remove and Install Heater/Evaporator Core

Expansion Valve Remove and Install

Remove and Install Freeze Control Switch

Bench Test A/C Thermostat 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 (S.N. —581927)

Remove and Install Receiver-Dryer and Condenser (S.N. 581928—)

Remove and Install High and Low Pressure Switches

Remove and Install Recirculating Air Filter

Remove and Install Fresh Air Filter

Remove and Install Compressor (S.N. —581927)

Remove and Install Compressor (S.N. 581928—)

Check and Adjust Compressor Belt Tension (S.N. —581927)

Belt Tensioner Spring Check (S.N. 581928— )

Disassemble and Inspect Compressor

Assemble Compressor

Inspect Compressor Manifolds

Section 19: Sheet Metal and Styling

Group 1910: Hood or Engine Enclosure

Specifications

Remove and Install Hood (S.N. —581927)

Remove and Install Hood (S.N. 581928— )

Remove and Install Engine Side Shields (S.N. —581927)

Remove and Install Engine Side Shields (S.N. 581928— )

Group 1913: Miscellaneous Shields

Remove and Install Transmission Shields

Remove and Install Battery Covers (S.N. —581927)

Remove and Install Battery Covers (S.N. 581928—)

Group 1921: Grille and Grille Housing

Essential Tools

Service Equipment and Tools

Specifications

Remove and Install Grille and Grille Housing (S.N. —581927)

Remove and Install

Section 20: Safety and Convenience

Group 2002: Mirror

Remove and Install Rear View Mirror

Remove and Install Outside Mirror for Cab or Canopy

Group 2003: Fire Extinguisher

Remove and Install Fire Extinguisher and Bracket

Group 2004: Horn and Warning Devices

Remove and Install Horn

Remove and Install Reverse Warning Alarm (S.N. —581927)

Remove and Install Reverse Warning Alarm (S.N. 581928—)

Change Reverse Warning Alarm Volume (S.N. —581927)

Change Reverse Warning Alarm Volume (S.N. 581928—)

Section 31: Loader

Group 3102: Bucket

Service Equipment and Tools

Specifications

Ride Control Accumulator Safety

Remove and Install Bucket Tooth Shanks and Tips

Remove and Install Bucket

Remove and Install Welded Bucket Cutting Edges

Remove and Install Wear Plate Bucket Cutting Edges

Repair Cracked Cutting Edge

Group 3140: Frames

Service Equipment and Tools

Other Material

Specifications

Remove and Install Bucket Tilt Linkage

Remove and Install Bucket Linkage Seals and Bushings

Remove and Install Boom

Remove and Install Boom Bushings, Seals and Shims

Group 3160: Hydraulic System

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Steering/Loader Hydraulic Pump

Remove and Install Loader Hydraulic Pump

Steering/Loader Hydraulic Pump (PVG 75)—Cross Section

Disassemble, Inspect and Assemble Steering/Loader Hydraulic Pump and Loader Hydraulic Pump

Remove and Install Hydraulic Pump Control Valve

Disassemble and Assemble Hydraulic Pump Control Valve

Remove and Install Loader Control Valve

Disassemble and Assemble Loader Control Valve

Disassemble and Assemble Auxiliary Valve Section and Bucket Valve Section

Disassemble and Assemble Boom Valve Section

Disassemble and Assemble System Relief Valve

Disassemble and Assemble Anti-Cavitation Valve

Service Bucket and Boom Section Pilot Orifice Check Valve

Remove and Install Boom Cylinder

Remove and Install Bucket Cylinder

Disassemble Boom or Bucket Cylinder

Assemble Boom or Bucket Cylinder

Remove and Install Boom or Bucket Cylinder Bushings and Seals

Loader Start-Up Procedure

Remove and Install Hydraulic Oil Reservoir

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Remove and Install Pilot Controller Valve (Single Lever Controller)

Cross Section of Pilot Controller Valve (Single Lever Controller)

Disassemble and Assemble Pilot Controller Valve (Single Lever Controller)

Remove and Install Pilot Controller Valve (Two Lever Controller)

Disassemble and Assemble Pilot Controller Valve (Two Lever Controller)

Remove and Install Pressure Reducing Valve

Remove and Install Boom Down Solenoid Valve

Ride Control Valve Remove and Install

Ride Control Valve Disassemble and Assemble

Ride Control Accumulator Remove and Install

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DFT1091 Cylinder Stand Shim

DF1044 Air Deflector Bushing

John Deere 744H 4WD Loader & 744H MH Material Handler Repair Service Manual (TM1603)