John Deere 644h 644h Mh Repair Manual

Full download:
Return tohttp://manualplace.com/download/john-deere-644h-644h-mh-repair-manual/
INDEX

644H and 644H MH

Loader Repair

TECHNICAL MANUAL
644H and 644H MH Loader Repair
TM1638
TM1638 15JAN04 (ENGLISH)

For complete service information also see:

644H and 644H MH Loader Operation and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM1637
8.1 L Engine Repair . . . . . . . . . . . . . . . . . . . . CTM86
8.1 L Engine Operation and Diagnostics . . . CTM134
Alternators and Starting Motors . . . . . . . . . . CTM77
Electronic Fuel Injection Systems . . . . . . . . CTM68

Worldwide Construction
And Forestry Division
LITHO IN U.S.A.

This is the cut pages sample. Download all 544 page(s) at: ManualPlace.com
 Introduction
Foreword

This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.

DX,TMIFC –19–29SEP98–1/1

TM1638 (15JAN04) 644H and 644H MH Loader

011504
PN=2
 Introduction

Technical Information Feedback Form

We need your help to continually improve our technical

publications. Please copy this page and FAX or mail your
comments, ideas and improvements.

SEND TO: John Deere Dubuque Works

P.O. Box 538
Attn: Publications Supervisor, Dept. 303
Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one)

Poor Fair Good Very Good Excellent

1 2 3 4 5 6 7 8 9 10

Company Name:

Technician Name:

Address:

Phone:

Fax No.:

Dealer Acct. No.:

THANK YOU!

TX,TM,FAX –19–03JUL01–1/1

TM1638 (15JAN04) 644H and 644H MH Loader

011504
PN=3
 Introduction

TM1638 (15JAN04) 644H and 644H MH Loader

011504
PN=4
 Contents
00
SECTION 00—General Information SECTION 17—Frame Or Supporting Structure
Group 0001—Safety Information Group 1740—Frame Installation
Group 1746—Frame Bottom Guards
SECTION 01—Wheels Group 1749—Chassis Weights
Group 0110—Powered Wheels And Fasteners 01
SECTION 18—Operator’s Station
SECTION 02—Axles And Suspension Systems Group 1800—Removal And Installation
Group 0200—Removal And Installation Group 1810—Operator Enclosure
Group 0225—Axle Shafts And U-Joints Group 1830—Heating And Air Conditioning
Group 0250—Axle Shaft, Bearings, Reduction Group 1899—Dealer Fabricated Tools
Gears 02
Group 0260—Hydraulic System SECTION 19—Sheet Metal And Styling
Group 1910—Hood Or Engine Enclosure
Group 1921—Grille And Grille Housing
SECTION 03—Transmission
Group 0300—Removal And Installation
SECTION 31—Loader
Group 0350—Gears, Shafts, Bearings And Power 03
Group 3102—Bucket
Shift Clutch
Group 3140—Frames
Group 0360—Hydraulic System
Group 3160—Hydraulic System
Group 0399—Dealer Fabricated Tools
Group 3199—Dealer Fabricated Tools

SECTION 04—Engine 04
Group 0400—Removal And Installation

SECTION 05—Engine Auxiliary Systems

Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
05
Group 0515—Speed Controls
Group 0520—Intake System
Group 0530—External Exhaust System
Group 0560—External Fuel Supply Systems

SECTION 07—Dampener Drive 07

Group 0752—Elements

SECTION 09—Steering System

Group 0960—Hydraulic System
09
SECTION 10—Service Brakes
Group 1011—Active Elements
Group 1060—Hydraulic System

SECTION 11—Park Brake 10

Group 1111—Active Elements
Group 1160—Hydraulic System

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 11

COPYRIGHT  2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  1998, 2000

TM1638 (15JAN04) i 644H and 644H MH Loader

011504
PN=1
 Contents

00

01

02

03

04

05

07

09

10

11

TM1638 (15JAN04) ii 644H and 644H MH Loader

011504
PN=2
 Contents

17

18

19

31

INDX

TM1638 (15JAN04) iii 644H and 644H MH Loader

011504
PN=3
 Contents

17

18

19

31

INDX

TM1638 (15JAN04) iv 644H and 644H MH Loader

011504
PN=4
 00

Section 00
General Information
Contents

Page Page

Group 0001—Safety Information Handle Fuel Safely—Avoid Fires. . . . . . . . .00-0001-11

4WD Loader Safety Features . . . . . . . . . . . .00-0001-1 Prepare for Emergencies. . . . . . . . . . . . . . .00-0001-11
Recognize Safety Information . . . . . . . . . . . .00-0001-2 Handle Starting Fluid Safely . . . . . . . . . . . .00-0001-12
Understand Signal Words . . . . . . . . . . . . . . .00-0001-2 Clean Trash from Machine . . . . . . . . . . . . .00-0001-12
Follow Safety Instructions . . . . . . . . . . . . . . .00-0001-2 Protect Against Flying Debris . . . . . . . . . . .00-0001-12
Avoid Injury from Rollover Accidents Wear Protective Clothing. . . . . . . . . . . . . . .00-0001-13
-------------------------------- Wear Your Seat Protect Against Noise . . . . . . . . . . . . . . . . .00-0001-13
Belt -------------------------------- Do Not Handle Chemical Products Safely . . . . . . . .00-0001-13
Attempt to Jump Clear of Tipping Use Safety Lights and Devices . . . . . . . . . .00-0001-14
Machine—Serious or Fatal Crushing Keep ROPS Installed Properly . . . . . . . . . .00-0001-14
Injuries Will Result -------------------------------- Warn Others of Service Work . . . . . . . . . . .00-0001-15
Machine Will Tip Over Faster Than You Practice Safe Maintenance . . . . . . . . . . . . .00-0001-16
Can Jump Free . . . . . . . . . . . . . . . . . . . . .00-0001-3 Support Machine Properly . . . . . . . . . . . . . .00-0001-16
Avoid Injury from Backover Accidents Remove Paint Before Welding or
------------------------------------ Before Moving Heating . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17
Machine, Be Sure All Persons are Clear of Avoid Heating Near Pressurized Fluid
Area ------------------------------------ Always Be Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17
Alert for Bystanders Moving into the Work Avoid High-Pressure Fluids . . . . . . . . . . . . .00-0001-18
Area. Use Horn or Other Signal to Warn Clean the Machine Regularly . . . . . . . . . . .00-0001-18
Bystanders Before Moving Machine Service Cooling System Safely . . . . . . . . . .00-0001-19
------------------------------------ When Using a Store Attachments Safely . . . . . . . . . . . . . .00-0001-19
Signal Person, Keep Person in View at all Dispose of Waste Properly . . . . . . . . . . . . .00-0001-19
Times. Be Sure Signal Person is Clear
Before Backing Up. . . . . . . . . . . . . . . . . . .00-0001-4
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. . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5
Inspect Machine . . . . . . . . . . . . . . . . . . . . . .00-0001-5
Use Handholds and Steps. . . . . . . . . . . . . . .00-0001-6
Prevent Machine Runaway . . . . . . . . . . . . . .00-0001-6
Use Seat Belt Properly . . . . . . . . . . . . . . . . .00-0001-6
Maintain Seat Belt . . . . . . . . . . . . . . . . . . . . .00-0001-7
Secondary Exits . . . . . . . . . . . . . . . . . . . . . .00-0001-7
Travel Safely . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-8
Drive Machine Safely . . . . . . . . . . . . . . . . . .00-0001-8
Operate Machine with Caution . . . . . . . . . . .00-0001-9
Operating on Slopes . . . . . . . . . . . . . . . . . . .00-0001-9
Carrying Loads . . . . . . . . . . . . . . . . . . . . . .00-0001-10
Avoid Power Lines . . . . . . . . . . . . . . . . . . .00-0001-10
Beware of Exhaust Fumes . . . . . . . . . . . . .00-0001-10
Keep Riders Off Machine . . . . . . . . . . . . . .00-0001-11

TM1638 (15JAN04) 00-1 644H and 644H MH Loader

011504
PN=1
 Contents

00

TM1638 (15JAN04) 00-2 644H and 644H MH Loader

011504
PN=2
 Group 0001
Safety Information
00
4WD Loader Safety Features 0001
1

–19–04NOV98
T111699

TX,05,JC2303 –19–09NOV98–1/1

TM1638 (15JAN04) 00-0001-1 644H and 644H MH Loader

011504
PN=9
 Safety Information

00
0001 Recognize Safety Information
2

This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.

–UN–07DEC88
Follow recommended precautions and safe operating
practices.

T81389
DX,ALERT –19–29SEP98–1/1

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the
most serious hazards.

DANGER or WARNING safety signs are located near

–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.

TS187
DX,SIGNAL –19–03MAR93–1/1

Follow Safety Instructions

Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are

–UN–23AUG88
available from your John Deere dealer.

Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without TS201

instruction.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.

If you do not understand any part of this manual and need

assistance, contact your John Deere dealer.

DX,READ –19–03MAR93–1/1

TM1638 (15JAN04) 00-0001-2 644H and 644H MH Loader

011504
PN=10
 Safety Information

00
Avoid Injury from Rollover Accidents 0001
3
--------------------------------
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

To avoid rollovers:

Be careful when operating on a slope.

Avoid sharp turns.

Balance loads so weight is evenly distributed and load is

stable.

–19–22FEB90
Carry tools and loads close to the ground to aid visibility
and lower center of gravity.

T7242EA
Reduce speed before turning or swinging load.

Know capacity of machine. Do not overload.

Be careful when operating at the edge of an excavation,

trench, or drop-off, and loading or unloading from a trailer.

Read and understand the operating instructions in this

operator’s manual.

TX,05,DH1525 –19–21JUN91–1/1

TM1638 (15JAN04) 00-0001-3 644H and 644H MH Loader

011504
PN=11
 Safety Information

00
0001 Avoid Injury from Backover Accidents
4
------------------------------------
Before Moving Machine, Be Sure All Persons
are Clear of Area
------------------------------------
Always Be Alert for Bystanders Moving into

–UN–21FEB90
the Work Area. Use Horn or Other Signal to
Warn Bystanders Before Moving Machine
------------------------------------

T7241AY
When Using a Signal Person, Keep Person in
View at all Times. Be Sure Signal Person is
Clear Before Backing Up

To avoid backover accidents:

Always look around before you back up. Be sure that

everyone is in the clear.

Keep bystanders away from pivot area of an articulated

machine.

Keep reverse warning alarm in working condition, if

equipped.

Use a signal person when backing up if view is

obstructed. Always keep signal person in view.

Learn the meaning of all flags, signs, and markings used

on the job, and who has the responsibility for signaling.

Keep windows, mirrors, and lights clean and in good

condition.

Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper lighting.

Read and understand the operating instructions in this

operator’s manual.

TX,05,DH1573 –19–18MAR91–1/1

TM1638 (15JAN04) 00-0001-4 644H and 644H MH Loader

011504
PN=12
 Safety Information

00
Avoid Injury from Rollaway Accidents 0001
5
------------------------------------
To Prevent Rollaway, Always Make Sure
Machine is Properly Secured Before Leaving
Operator’s Seat
------------------------------------

–UN–21FEB90
Death or Serious Injury May Result if You
Attempt to Mount or Stop a Moving Machine

T7241AZ
To avoid rollaways:

Select level ground when possible to park machine.

Move transmission control lever to neutral "N", engage

neutral lock, and push park brake switch to ON.

Lower all equipment to ground.

Stop the engine.

Block all wheels if you must park on a grade. Position

machine to prevent rolling.

Park a reasonable distance from other machines.

Read and understand the operating instructions in this

operator’s manual.

TX,05,JC1888 –19–18FEB97–1/1

Inspect Machine

Inspect your machine carefully each day by walking

around it before you start it. (See Pre-Start Inspection
Chapter.) –UN–18OCT88
T6607AQ

T82,BHSA,CL –19–14MAR90–1/1

TM1638 (15JAN04) 00-0001-5 644H and 644H MH Loader

011504
PN=13
 Safety Information

00
0001 Use Handholds and Steps
6

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a

three point contact with the steps and handrails, and face

–UN–15JUN89
the machine. Do not use the steering wheel or any
controls as handholds.

Never jump on or off the machine. Never mount or

T6981AN
dismount a moving machine.

Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.

TX,05,DH553 –19–18MAR91–1/1

Prevent Machine Runaway

Avoid possible injury or death from a runaway machine.

DO NOT start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.

–UN–20OCT88
Never start engine while standing on ground. Start engine
only from operator’s seat with transmission control lever
locked in neutral and park brake engaged.

T6642EB
TX,05,DH2281 –19–06OCT92–1/1

Use Seat Belt Properly

Overturns may occur if proper operating instructions are

not followed.

Use your seat belt.

–UN–23AUG88
TS175

TX,05,JC1044 –19–12JAN96–1/1

TM1638 (15JAN04) 00-0001-6 644H and 644H MH Loader

011504
PN=14
 Safety Information

00
Maintain Seat Belt 0001
7

It is important to use the seat belt on ROPS equipped

machines to minimize the chance of injury from an
accident such as an overturn. Keep the seat belt in good
condition.

The complete seat belt assembly should be replaced

after three years of usage, regardless of appearance.

Between replacement intervals:

Carefully examine buckle, webbing, and attaching

hardware.

Be sure that the retractor, if equipped, locks to prevent

belt extension after latching buckle.

Be sure that attaching hardware is in place. Tighten, if

necessary.

Replace the seat belt if it does not operate properly, or if it

is damaged, worn, or deteriorated.

TX,05,JC242 –19–03MAR95–1/1

Secondary Exits

Machines equipped with cabs are equipped with

secondary exits. For additional secondary exit information,
see “Opening Side Window/Secondary Exit” in chapter 10
of this manual.

TX,05,JC1753 –19–09DEC96–1/1

TM1638 (15JAN04) 00-0001-7 644H and 644H MH Loader

011504
PN=15
 Safety Information

00
0001 Travel Safely
8

Know the location of bystanders before moving the

machine.

Always keep the reverse warning alarm in working

–UN–20DEC88
condition. It warns people when the machine starts to
move in reverse.

Use a signal person when moving the machine in

T6964AD
congested areas. Coordinate hand signals before starting
the machine.

TX,05,DH496 –19–02AUG89–1/1

Drive Machine Safely

Walk around machine to clear all persons from area of

operation and machine movement.

Always check area to rear before shifting to reverse.

–UN–25OCT88
Drive carefully in congested areas, over rough ground,
near ditches for excavations, and on slopes or curves.

T6582AS
Keep machine in gear when going down hills.

Use accessory lights and devices to warn operators of

other vehicles.

TX,05,DH1931 –19–21JUN91–1/1

TM1638 (15JAN04) 00-0001-8 644H and 644H MH Loader

011504
PN=16
 Safety Information

00
Operate Machine with Caution 0001
9

Check location of cables, gas lines, and water mains

before digging.

Keep loading area smooth.

–UN–18OCT88
Never lower a loaded bucket with the boom and bucket
control lever in the float position.

T6642EF
Increase the power gradually when pulling a heavy load or
when driving out of a ditch or excavation.

TX,05,DH1932 –19–06JUN91–1/1

Operating on Slopes

Avoid side slope travel whenever possible. Drive up slope

in forward and down in reverse. The danger of tipping is
always present.

In steep slope operation, do not allow engine to

overspeed. Select low gear speed before starting down
slope.

The grade of the slope you should attempt will be limited

by such factors as ground condition, and load being
handled.

–UN–03AUG89
T7050AB

TX,05,RR,171 –19–27APR89–1/1

TM1638 (15JAN04) 00-0001-9 644H and 644H MH Loader

011504
PN=17
 John Deere 644h 644h Mh Repair Manual
Full download: http://manualplace.com/download/john-deere-644h-644h-mh-repair-manual/
Safety Information

00
0001 Carrying Loads
10

Carry loader bucket as low as possible for better stability

and visibility.

Handle only those loads which are properly arranged. Do

–UN–03AUG89
not overload.

Do not start, stop, or turn quickly when transporting a

load.

T7050AA
Do not change forward or reverse directions quickly when
carrying a load.

TX,05,RR,172 –19–03JUN92–1/1

Avoid Power Lines

Serious injury or death can result from contact with

electric lines.

Never move any part of the machine or load closer to

–UN–20JUN89
electric line than 3 m (10 ft) plus twice the line insulator
length.

T6642EG
02T,05,J18 –19–06JUN91–1/1

Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

If you must operate in a building, be sure there is

–UN–18OCT88

adequate ventilation. Either use an exhaust pipe extension

to remove the exhaust fumes or open doors and windows
to bring enough outside air into the area.
T6458AO

TX,DH,2 –19–09FEB89–1/1

TM1638 (15JAN04) 00-0001-10 644H and 644H MH Loader

011504
PN=18
This is the cut pages sample. Download all 544 page(s) at: ManualPlace.com