Complete Repair Technical Manual for John Deere 644J Loader. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

John Deere 644J Loader Repair Technical Manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

TM10246 - John Deere 644J Loader (S.N. 611232— ) Technical Manual (Repair).pdf
668 pages, bookmarked, Searchable, Printable, high quality PDF

CONTENTS
00 - General Information
01 - Tracks
02 - Axles and Suspension Systems
03 - Transmission
04 - Engine
05 - Engine Auxiliary Systems
07 - Dampener Drive
09 - Steering System
10 - Service Brakes
11 - Park Brake
17 - Frames, Chassis, or Supporting Structure
18 - Operator's Station
19 - Sheet Metal and Styling
31 - Loader
9900 - Dealer Fabricated Tools
...

tm10246 - 644J Loader (611232- )

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

Avoid High-Pressure Oils

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

Wheel Remove and Install

Tire Remove and Install

Section 02: Axles And Suspension Systems

Group 0200: Removal And Installation

TeamMate™ IV Axles

Front Axle and Differential Remove and Install

Rear Axle and Differential Remove and Install

Axle Oscillating Supports Disassemble and Assemble

Group 0225: Input Drive Shafts and U-Joints

Universal Joint and Drive Shaft Remove and Install

Universal Joint and Drive Shaft Disassemble and Assemble

Group 0250: Axle Shaft, Bearings, and Reduction Gears

TeamMate™ IV Axles

Group 0260: Hydraulic System

Differential Lock Solenoid Valve Remove and Install

Axle Circulation System

Axle Oil Coolers Disassemble and Assemble

Section 03: Transmission

Group 0300: Removal And Installation

Transmission Remove and Install

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

Torque Converter And Housing Remove

Torque Converter and Housing Install

Clutches, Input and Output Shafts Remove

Clutches, Input and Output Shafts Install

Clutch Pack KV and KR Disassemble

Clutch Pack KV and KR Assemble

Input Shaft Disassemble

Input Shaft Assemble

Group 0360: Hydraulic System

Transmission Pump Remove and Install

Converter Minimum Pressure Regulator Valve Remove and Install

Transmission Control Valve Remove and Install

Transmission Control Valve Disassemble and Assemble

Converter Relief Valve Repair

Transmission Internal Oil Pipes and Tubes Remove and Install

Section 04: Engine

Group 0400: Removal and Installation

PowerTech Plus POWERTECH is a trademark of Deere & Company 4.5 L (4045) and 6.8 L (6068) John Deere Engines

Engine Remove and Install

Engine Crankshaft Dampener Remove and Install

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Engine Coolant Heater Remove and Install

Group 0510: Cooling System

Serpentine Belt Remove and Install

Fan and Fan Drive Motor Remove and Install

Fan Drive and Axle Circulation Pump Remove and Install

Intercooler Remove and Install

Radiator Remove and Install

Hydraulic Oil Cooler Remove and Install

Transmission Oil Cooler Remove and Install

Cooling Package Plenum Remove and Install

Group 0520: Intake System

Air Cleaner Remove and Install

Group 0530: External Exhaust System

Muffler Remove and Install

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Section 07: Dampener Drive

Group 0752: Elements

Output Dampener Remove and Install

Section 09: Steering System

Group 0960: Hydraulic System

Steering Valve Remove and Install

Steering Column Remove and Install

Steering Column Disassemble and Assemble

Steering Cylinder Remove and Install (S.N. —618143)

Steering Cylinder Remove and Install (S.N. 618144— )

Steering Cylinder Bushings Remove and Install (S.N. —618143)

Steering Cylinder Bushings Remove and Install (S.N 618144— )

Section 10: Service Brakes

Group 1011: Active Elements

Brake Pedal and Linkage Disassemble and Assemble

Brake Assembly Remove And Install

Group 1060: Hydraulic System

Brake Valve Remove and Install

Brake Accumulator Remove and Install

Section 11: Park Brake

Group 1111: Active Elements

Park Brake Remove and Install

Park Brake Disassemble and Assemble

Group 1160: Hydraulic System

Park Brake Release Solenoid Valve Remove and Install

Park Brake Pressure Switch Remove and Install

Section 17: Frame Or Supporting Structure

Group 1740: Frame Installation

Engine and Loader Frame Separate

Remove and Install Upper Pivot Bearing and Seals

Lower Pivot Bearing and Seals Remove and Install

Group 1746: Frame Bottom Guards

Fuel Tank Guard Remove and Install

Front Axle Guard Remove and Install

Transmission Bottom Guard Remove and Install

Group 1749: Chassis Weights

Counterweights Remove and Install

Rear Counterweight Remove and Install

Section 18: Operator’s Station

Group 1800: Removal And Installation

Cab Remove

Cab Install

Group 1810: Operator Enclosure

Front Windshield Wiper Adjust

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

R134a System Recover

R134a System Evacuate

R134a System Charge

Air Conditioner System Cleaning Procedures

Air Conditioner System Purge

Air Conditioner System Flush

Air Conditioning Module With Heater/Evaporator Coil

Heater/Evaporator Core Remove and Install

Expansion Valve Remove and Install

Freeze Control Switch Remove and Install

Freeze Control Switch Bench Test

Heater Control Valve Remove and Install

Heater Control Valve Leak Check

Main Blower Assembly Remove And Install

Pressurizer Motor Assembly Remove and Install

Receiver-Dryer and Condenser Remove and Install

A/C Binary Pressure Switch Remove and Install

Fresh Air Filter Remove and Install

Recirculating Air Filter Remove and Install

Compressor Remove and Install

Compressor Clutch—R134a Disassemble and Assemble

Clutch Hub Clearance—R134a Check

Compressor Manifold—R134a Inspect

Compressor—R134a Disassemble, Inspect, and Assemble

Section 19: Sheet Metal And Styling

Group 1910: Hood or Engine Enclosure

Hood Remove and Install

Engine Side Shields Remove and Install

Group 1921: Grille and Fan Housing

Grille and Fan Housing Remove and Install

Section 31: Loader

Group 3102: Bucket

Bucket Remove and Install

Welded-On Bucket Cutting Edges Remove and Install

Bolt-On Cutting Edges and Wear Plates Remove and Install

Cracked Cutting Edge Repair

Group 3140: Frames

NeverGrease™ Pin Joints

Loader Bucket Tilt Linkage Remove and Install

Bucket Linkage Seals and Bushings Remove and Install

Loader Boom Bushings and Seals Remove and Install

Boom Remove and Install

Powerllel™ Leveling Link Disassemble and Assemble

Powerllel™ Bellcrank Remove and Install

Powerllel™ Bucket Cylinder Remove and Install

Powerllel™ Bucket Link Disassemble and Assemble

Powerllel™ Guide Links Remove and Install

Powerllel™ Coupler Disassemble and Assemble

Powerllel™ Loader Boom Disassemble and Assemble

Hi-Vis Coupler Disassemble and Assemble

Group 3160: Hydraulic System

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic Pump Start-Up Procedure

Hydraulic Pump Remove and Install

Hydraulic Pump Disassemble and Assemble

Hydraulic Pump Control Valve Remove and Install

Hydraulic Pump Control Valve Disassemble and Assemble

Loader Control Valve Remove and Install

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

Anti-Cavitation Relief Valve Disassemble and Assemble

Boom Cylinder Remove and Install—185 Series

Bucket Cylinder Remove and Install—185 Series

Boom Cylinder Piston Wear Ring Configuration

Loader Start-Up Procedure

Boom and Bucket Cylinder Bushings and Seals Remove and Install

Hydraulic Reservoir Remove and Install

Pilot Control Valve Remove and Install

Pilot Control Valve Disassemble and Assemble

Boom Down Accumulator Remove and Install

Pressure Reducing Valve Manifold Remove and Install

Pressure Reducing Valve Manifold Disassemble and Assemble

Ride Control Valve Remove and Install

Ride Control Valve Disassemble and Assemble

Ride Control Accumulator Remove and Install

Pin Disconnect Valve Remove and Install

Pin Disconnect Valve Disassemble and Assemble

Section 9900: Dealer Fabricated Tools

Group 0099: Dealer Fabricated Tools

DFT1132 Hydraulic Pump Removal And Installation Tool

DFT1149 Pre-Load Clutch Pack Compression Ring Tool

DFT1158 Torque Converter Adapter Plate

DFT1063 Lifting Bracket

DFRW20 Compressor Holding Fixture

John Deere 644J Loader Repair Technical Manual (TM10246)