Complete Repair manual for John Deere 4WD Loaders Models 744K with Engine 6090HDW06 (T3), 6090HDW08 (S2) (SN. 632968—664100) (PIN: 1DW744KZ**C632968-664100; 1DW744KZ**D632968-664100), with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere 744K 4WD Loader workshop 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.

TM11745 - John Deere 744K 4WD Loaders  (S.N. 632968—664100) Technical Manual - Repair.pdf
tm11990 - John Deere Cargadora de tracción en las cuatro ruedas 744K (N.S. 632968—664100).pdf
tm11991 - John Deere Chargeur à transmission quatre roues motrices 744K (632968—664100).pdf
tm11992 - John Deere Погрузчик 744K с полным приводом (4WD) (сер. № 632968–664100).pdf

Total Pages: 754 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Category: Repair
Language: French Spanish English Russian
Published on 2020/02/02
Models: John Deere - 4WD Loader - (632968- ) Engine 6090HDW06, 6090HDW08

MAIN SECTIONS
 Foreword
   Manual Identification-READ THIS FIRST!
   General Information
      Safety Information
      Torque Values
   Wheels
      Powered Wheels and Fasteners
   Axles and Suspension Systems
      Removal and Installation
      Input Drive Shafts And U-Joints
      Axle Shaft, Bearings, And Reduction Gears
      Hydraulic System
   Transmission
      Removal and Installation
      Gears, Shafts, Bearings and Power Shift Clutch
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling System
      Intake System
      External Exhaust System
      External Fuel Supply Systems
   Damper 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
      Seat and Seat Belts
      Heating and Air Conditioning
   Sheet Metal and Styling
      Hood or Engine Enclosure
      Grille and Grille Housing
   Loader
      Bucket
      Frames
      Hydraulic System
   Dealer Fabricated Tools
   
tm11745 - 744K 4WD Loader (S.N. 632968—664100)
Table of Contents
Foreword
Manual Identification—READ THIS FIRST!
Section 00: General Information
Group 01: Safety Information
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Oils
Avoid High-Pressure Fluids
Work In Ventilated Area
Prevent Fires
Clean Debris from Machine
Prevent Battery Explosions
Handle Chemical Products Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Prepare for Emergencies
Add Cab Guarding For Special Uses
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
Service Tires 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
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™ II 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
Group 0250: Axle Shaft, Bearings, And Reduction Gears
TeamMate™ II Axles
Group 0260: Hydraulic System
Differential Lock Solenoid Valve Remove and Install
Axle Circulation Pump Remove and Install
Section 03: Transmission
Group 0300: Removal and Installation
Transmission Remove and Install
Group 0350: Gears, Shafts, Bearings and Power Shift Clutch
Torque Converter Input Shaft Remove and Install
Torque Converter Housing Disassemble and Assemble
Transmission Input Shaft Remove and Install
Transmission Input Shaft Disassemble and Assemble
Transmission Drive Two Disassemble and Assemble
Transmission Drive Three Disassemble and Assemble
Output Shaft Drive Disassemble and Assemble
Clutch Packs Remove and Install
Low Range Forward Clutch (KV) and First Speed Clutch (K1) Disassemble and Assemble
High Range Forward Clutch (K4) and Third Speed Clutch (K3) Disassemble and Assemble
Reverse Clutch (KR) and Second Speed Clutch (K2) Disassemble and Assemble
Low Range Forward Clutch (KV) and First Speed Clutch (K1) Bearing Preload Adjustment
High Range Forward Clutch (K4) and Third Speed Clutch (K3) Bearing Preload Adjustment
Reverse Clutch (KR) and Second Speed Clutch (K2) Bearing Preload Adjustment
Transmission Speed Sensors Remove and Install
Group 0360: Hydraulic System
Transmission Pump Remove and Install
Transmission Pump Disassemble and Assemble
Transmission Hydraulic Control Valve Remove and Install
Transmission Hydraulic Control Valve Disassemble and Assemble
Transmission Suction Screen Remove and Install
Section 04: Engine
Group 0400: Removal and Installation
PowerTech™ Plus 9.0L (6090) John Deere Engine—Engine Model 6090HDW06
PowerTech™ Plus 9.0L (6090) John Deere Engine—Engine Model 6090HDW08
Engine Remove and Install
Crankshaft Damper Remove and Install
Serpentine Belt Remove and Install
Section 05: Engine Auxiliary Systems
Group 0505: Cold Weather Starting Aids
Start Aid Nozzle Remove and Install
Start Aid Solenoid Remove and Install—If Equipped
Engine Coolant Heater Remove and Install
Group 0510: Cooling System
Intercooler Remove and Install
Radiator Remove and Install
Hydraulic Oil Cooler Remove and Install
Transmission Oil Cooler Remove and Install
Axle Oil Cooler Remove and Install
Cooling Package Plenum Remove and Install
Group 0520: Intake System
Air Cleaner Remove and Install
Precleaner Remove and Install
Group 0530: External Exhaust System
Muffler Remove and Install
Group 0560: External Fuel Supply Systems
Fuel Tank Remove and Install
Auxiliary Fuel Filter/Water Separator Remove and Install—If Equipped
Fast Fill Fuel System Disassemble and Assemble—If Equipped
Section 07: Damper Drive
Group 0752: Elements
Output Damper Remove and Install
Section 09: Steering System
Group 0960: Hydraulic System
NeverGrease™ Pin Joints
Orbital Steering Valve Remove and Install
Steering Column Remove and Install
Steering Column Disassemble and Assemble
Steering Cylinders Remove and Install
Steering Cylinder Bushings Remove and Install
Secondary Steering Pump Remove and Install—If Equipped
Secondary Steering Valve Remove and Install—If Equipped
Joystick Steering Valve Remove and Install—If Equipped
Joystick Steering Valve Disassemble and Assemble—If Equipped
Loader Start-Up Procedure (Steering Cylinder)
Section 10: Service Brakes
Group 1011: Active Elements
Service Brake Assembly Remove and Install
Service Brake Pedal and Linkage Disassemble and Assemble
Group 1060: Hydraulic System
Service Brake Valve Remove and Install
Service 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
Section 16: Electrical System
Group 1600: Removal and Installation
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble
Pressure Switches and Sensors Remove and Install
Replace Metri-Pack® (Push Type) Connectors
Replace Metri-Pack® Connectors
Replace DEUTSCH® Circular Connectors
Replace DEUTSCH® Rectangular or Triangular Connectors
Install DEUTSCH® Contact
Replace WEATHER PACK® Connector
Install WEATHER PACK® Contact
Replace CINCH™ Connectors
Install CINCH™ Contact
Repair 32 and 48 Way CINCH™ Connectors
Remove Connector Body from Blade Terminals
TPM—Tire Pressure Sensor Remove and Install
Section 17: Frame or Supporting Structure
Group 1740: Frame Installation
Welding Major Structure
Engine and Loader Frame Separate
Upper Pivot Bearing and Seals Remove and Install
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
Section 18: Operator’s Station
Group 1800: Removal and Installation
Cab Remove and Install
Group 1810: Operator Enclosure
Windowpanes Remove and Install
Cab Door Hold-Open Release Adjust
Cab Door Hold-Open Latch Pin Adjust
Front and Rear Windshield Wiper Motor Remove and Install
Group 1821: Seat and Seat Belts
Seat Remove and Install
Seat Belt Remove and Install
Steering Joystick Disassemble and Assemble
Joystick Steering Armrest Disassemble and Assemble
Joystick Steering Armrest Rear Pivot Adjustment
Group 1830: Heating and Air Conditioning
Refrigerant Cautions and Proper Handling
R134a Compressor Oil Charge Check
R134a Compressor Oil Removal
R134a Component Oil Charge
Refrigerant 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
Heater/Evaporator Coil 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
Blower Motor Assembly Remove and Install
Receiver-Dryer Remove and Install
Condenser Remove and Install
Air Conditioner High-Low Pressure Switch Remove and Install
Fresh Air Filter Remove and Install
Compressor Remove and Install
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 Grille Housing
Grille and Grille Housing Remove and Install
Section 31: Loader
Group 3102: Bucket
Bucket Remove and Install
Welded Bucket Cutting Edges Remove and Install
Bolt-On Cutting Edges 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
Group 3160: Hydraulic System
General Oil Cleanup Procedure
Hydraulic Component Failure Cleanup Procedure
Loader Hydraulic Pump Remove and Install
Main Hydraulic Pump Disassemble and Assemble
Steering/Loader Hydraulic Pump Remove and Install
Loader Control Valve Remove and Install
Loader Control Valve Disassemble and Assemble
Boom Section Disassemble and Assemble
Bucket Section Disassemble and Assemble
Auxiliary Section Disassemble and Assemble—If Equipped
Main Relief Valve Disassemble and Assemble
Circuit Relief With Anticavitation Valve Disassemble and Assemble
Anticavitation Valve Disassemble and Assemble
Auxiliary, Bucket, and Boom Section Pilot Orifice Check Valve
Boom Cylinder Remove and Install
Bucket Cylinder Remove and Install
Boom and Bucket Cylinder Disassemble and Assemble
Boom or Bucket Cylinder Bushings and Seals Remove and Install
Loader Start-Up Procedure
Hydraulic Reservoir Remove and Install
Pilot Control Valve Remove and Install
Pilot Control Valve Disassemble and Assemble
Auxiliary Function Pilot Control Valve Remove and Install—If Equipped
Auxiliary Function Pilot Control Valve Disassemble and Assemble—If Equipped
Pilot Accumulator Remove and Install
Hydraulic Pump Manifold Remove and Install
Hydraulic Pump Manifold Disassemble and Assemble
Ride Control Valve Remove and Install—If Equipped
Ride Control Valve Disassemble and Assemble
Ride Control Accumulator Remove and Install
Pin Disconnect Valve Remove and Install—If Equipped
Pin Disconnect Valve Disassemble and Assemble—If Equipped
Hydraulic Fan Motor Remove and Install
Hydraulic Fan Pump Remove and Install
Hydraulic Fan Proportional/Relief Solenoid Valve Remove and Install
Hydraulic Fan Proportional/Relief Solenoid Valve Disassemble and Assemble
Reversing Fan Valve Remove and Install—If Equipped
Reversing Fan Valve Disassemble and Assemble—If Equipped
Section 99: Dealer Fabricated Tools
Group 9900: Dealer Fabricated Tools
DFT1044 Air Deflector Bushing

John Deere 4WD Loaders 744K with Engine 6090HDW06 (T3), 6090HDW08 (S2) Repair Service Manual (TM11745)