John Deere 644H and 644H MH Loader Repair Manual TM1638

Description

Contents:
Contents
General Information
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 ——————————– Mach
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
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 Attem
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
Dispose of Waste Properly
Wheels
Powered Wheels And Fasteners
Wheel
Remove and Install
Tire
Remove
Install
Axles And Suspension Systems
Removal And Installation
Front Axle and Differential
Remove and Install
Rear Axle and Differential
Remove
Install
Axle Oscillating Supports
Disassemble and Assemble
Axle Shafts And U-Joints
Universal Joint and Drive Shaft
Remove and Install
Disassemble, Inspect and Assemble
Axle Shaft, Bearings, Reduction Gears
Essential Tools
Service Equipment And Tools
Other Material
Specifications
Final Drive Assembly
Install in Repair Stand
Remove from Repair Stand
Oscillating Support Wear Sleeves
Remove and Install
Final Drive Assembly
Remove
Install
Disassemble
Inspect
Assemble
Replace Brakes
Differential Case Cover
Remove
Install
Differential
Remove
Adjust Preload and Backlash
Install
Hydraulic Diff-Lock Differential
Cross-Sectional View
Disassemble, Inspect, and Assemble
Standard Differential
Cross-Sectional View
Disassemble, Inspect, and Assemble
Limited Slip Differential
Cross-Sectional View
Disassemble and Inspect
Assemble
Limited Slip Differential
Measure End Play Gap
Limited Slip Differential
Continue Assembly
Input Pinion Shaft
Cross-Sectional View
Remove
Install
Differential Drive Shaft
Cone Point Shim Pack Adjustment
Input Drive
Assemble
Input Pinion Shaft
Adjust
Input Shaft
Continue Installation
Axle Disconnect Input Shaft
Cross-Section View
Remove and Install Disconnect
Disassemble, Inspect and Assemble
Hydraulic System
Differential Lock Solenoid Valve
Remove and Install
Transmission
Removal And Installation
Transmission
Remove and Install
Gears, Shafts, Bearings And Power Shift Clutch
Torque Converter
Remove (Engine Removed)
Install (Engine Removed)
Torque Converter and Housing
Remove
Install
Clutches, Input and Output Shafts
Remove
Clutches, Output and Input Shafts
Install
Clutch Pack KV and KR
Disassemble
Assemble
Clutch Pack K1, K2 and K3
Disassemble
Assemble
Clutch Pack K4
Disassemble
Assemble
Input Shaft
Dissasemble
Assemble
Hydraulic System
Transmission Pump
Remove
Converter Minimum Pressure Regulator Valve
Remove and Install
Transmission Pump
Install
Hydraulic Control Valve
Remove
Install
Cross Section View
Transmission Control Valve
Disassemble
Assemble
Converter Relief Valve
Remove, Disassemble and Install
Replace Oil Pipes And Tubes
Dealer Fabricated Tools
DFT1149 Pre-Load Clutch Pack Compression Ring Tool
DFT1063 Lifting Bracket
DFT1158 Torque Converter Adapter Plate
Engine
Removal And Installation
6081 John Deere Engine
Use CTM86
Use CTM134 Operation and Diagnostics
Remove and Install Engine
Engine Auxiliary Systems
Cold Weather Starting Aids
Fluid Starting Aid Assembly
Remove and Install
Engine Coolant Heater
Remove and Install
Cooling System
Serpentine Belt
Remove and Install
Fan and Fan Drive
Remove and Install
Remove And Install Radiator, Oil, And Air Cooler
Disassemble And Assemble Radiator, Oil, And Air Cooler (S.N. —585560)
Speed Controls
Speed Control Linkage
Remove and Install
Intake System
Air Cleaner
Remove and Install
External Exhaust System
Muffler
Remove and Install
External Fuel Supply Systems
Fuel Tank
Remove and Install
Dampener Drive
Elements
Dampener
Remove and Install
Steering System
Hydraulic System
Essential Tools
Service Equipment and Tools
Other Material
Specifications
Steering Valve
Remove and Install
Steering Column
Remove and Install
Steering Cylinder
Remove and Install
Disassemble and Assemble Steering Cylinder
Steering Cylinder Bushings
Remove and Install
Service Brakes
Active Elements
External Service Brakes
Inspect
Brake Assembly
Remove and Install
Hydraulic System
Brake Valve
Remove and Install
Brake Accumulator
Remove and Install
Park Brake
Active Elements
Park Brake
Remove and Install
Disassemble and Assemble
Hydraulic System
Park Brake Release Solenoid Valve
Remove and Install
Park Brake Pressure Switch
Remove and Install
Frame Or Supporting Structure
Frame Installation
Major Structure
Welding
Engine and Loader Frame
Separate
Upper Pivot Bearing and Seals
Remove and Install
Lower Pivot Bearing and Seals
Remove and Install
Frame Bottom Guards
Fuel Tank Guard
Remove and Install
Front Axle Guard
Remove and Install
Transmission Bottom Guard
Remove and Install
Transmission Side Guards
Remove and Install
Chassis Weights
Counterweights
Remove and Install
Operator’s Station
Removal And Installation
Cab or Canopy
Remove and Install
Operator Enclosure
Front Windshield Wiper
Adjust
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
R134a System
Recover
Evacuate
Charge
Air Conditioner System Cleaning Procedures
Purge Air Conditioner System
Flush Air Conditioner System
Air Conditioning Module With Heater/Evaporator Coil
Heater/Evaporator Coil
Remove and Install
Expansion Valve
Remove and Install
Freeze Control Switch
Remove and Install
Bench Test
Heater Control Valve
Remove and Install
Leak Check
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
Remove And Install Fresh Air Filter
Recirculating Air Filter
Remove and Install
Compressor
Remove and Install
Compressor Clutch
Disassemble and Assemble
Compressor
Check Clutch Hub Clearance
Compressor Manifold
Inspect
Compressor
Disassemble, Inspect, and Assemble
Dealer Fabricated Tools
DFRW20 Compressor Holding Fixture
Sheet Metal And Styling
Hood Or Engine Enclosure
Remove And Install Hood
Remove And Install Engine Side Shields
Grille And Grille Housing
Remove And Install Grille And Grille Housing
Loader
Bucket
Ride Control Accumulator
Safety
Bucket Tooth Shanks and Tips
Remove and Install
Bucket
Remove and Install
Welded Bucket Cutting Edge
Remove and Install
Bolt-on Bucket Cutting Edge
Remove and Install
Cutting Edge
Repair Cracks
Frames
Service Equipment And Tools
Other Material
Specifications
Bucket Tilt Linkage
Remove and Install
Bucket Linkage Seals and Bushings
Remove and Install
Loader Boom Bushings and Seals
Remove and Install
Hydraulic System
Other Material
Specifications
Loader Hydraulic Pump
Remove and Install
Hydraulic Pump
Disassemble, Inspect and Assemble
Hydraulic Pump Control Valve
Remove and Install
Disassemble and Assemble
Hydraulic Pump Stroke Limiter
Adjust
Loader Control Valve
Remove and Install
Disassemble and Assemble
Auxiliary Valve Section and Bucket Section
Disassemble and Assemble
Boom Valve Section
Disassemble and Assemble
System 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
Disassemble and Assemble Boom and Bucket Cylinder—185 Series
Boom and Bucket Cylinder Bushings and Seals
Remove and Install
Hydraulic Reservoir
Remove and Install
Hydraulic Oil Clean-Up With 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—)
Pressure Reducing Valve Manifold
Remove and Install
Pressure Reducing Valve
Remove and Install
Disassemble and Assemble
Boom Down Solenoid Valve
Remove and Install
Differential Lock Solenoid Valve
Remove and Install
Pilot Enable Solenoid Valve
Remove and Install
Ride Control
Remove and Install
Ride Control Valve
Disassemble and Assemble
Ride Control Accumulator
Disassemble and Assemble
Charge
Pin Disconnect/Axle Disconnect Valve
Remove and Install
Pin Disconnect Valve
Disassemble and Assemble
Axle Disconnect Valve
Disassemble and Assemble
Dealer Fabricated Tools
Dealer Fabricated Tool
DFT1132 Hydraulic Pump Tool
Page Numbers