John Deere JD644C Loader Service Repair Manual Instant Download (tm1229)

1
JD644C Loader
JD646C Compactor
TECHNICAL MANUAL
TM1229
LITHO IN U.S.A. (REVISED)
2
644C LOADER AND 646C COMPACTOR TECHNICAL
MANUAL TM-1229 (MAR-84) SECTION AND GROUP CONTENTS
SECTION 0WENGINE-Continued Group 0407Oiling
System
SECTION IGENERAL INFORMATION Group
IIntroduction and Safety Information Group
IIGeneral Specifications Group IllTorque Values
Group IVFuels and Lubricants SECTION
01WHEELS Group 011 Powered Wheels and
Fastenings SECTION 02AXLES AND SUSPENSION SYSTEMS
Group 040 Group 040 Group 041
Ventilating System linder Head and Valves Exhaust
Manifold
Group 0413Fuel Injection System
Group 041 Group 041
Intake Manifold Turbocharger
Group 0417Water Pump
Group 041 Thermostats, Housings and
Piping
Group 020 Group 021 Group 022 Group 025
Removal and Installation Oifferential or Bevel
Drive lnput Drive Shafts and U-Joints Axle
Shafts, Bearings and Reductlon Gears Hydraulic
Systems TRANSMISSION Removal and
installation ontrols Input Drive Shafts and
UJoints ears, Shafts, Bearings and Power Shift
Clutch
Group 0419--OiI Cooler
Group 042 Fuel Filter
Group 0422Starting Motor and Fastenings
Group 042 Fan Drive Group 0433Flywheel, Housing
and Fastenings
Group 02d SECTION 0 Group 030 Group 031 Group
032 Group 035
SECTION 0 ENGINE AUXILIARY
SYSTEMS
Group 0505-Cold Weather Starting Aids
Group 051 ooling Systems
Group 051Speed Controls
Group 052 Group 053 Group 054 Group 056
Intake System External Exhaust Systems Mounting
Frame External Fuel Supply Systems
Group 0360Hydraulic System
SECTION 0 Group 040
ENGINE Engine Removal and Installation
SECTION OWTORQUE CONVERTER Group 0651Turbine,
Gears, Shafts and Bearings
Group 0401Crankshaft and Main Bearings
Group 0402Camshaft and Valve Actuating Means Grou
p 0403Connecting Rods and Pistons
Group 040 ylinder Btook
All in/o/zz/a/ion, illustrations and
specifications contained in this technical manual
are based on the latest information available at
the time of publication. The ripht is reserved to
make changes at any time 'ithout nofice.
i/I/herever applicable, specifications and design
informaflan are in acaorddnce w'ith SAE and ICED
standards. DEERE OOH\PANY Ajl rIghtgt
reserved A JOHN OEERE ILLUSTRUCTION Pravlous
Edition Copyghio 1ae1 we a company Copyñghz'
1980 Deka 6 Company
8 m
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TM-1229 (Mar-84)
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SECTION AND GROUP CONTENTWCONTINUED
SECTION 09-STEERING SYSTEM Group
0930Emergency Steering Group 096 Hydraulic System
SECTION 1WSHEET METAL AND STYLING Group 1910Hood
or Engine Enclosure Group 1921Grille and Grille
HOusing Group 1927Fenders
SECTION INSERVICE BRAKES Group 1011Active
Elements Group 101Controls Linkage Group 106
Hydraulic System SECTION 11PARKING-EMERGENCY
BRAIES Group 1111Active Elements Group
111Controls Linkage
SECTION 2 AFETY, CONVENIENCE
AND MISCELLANEOUS
Group 2002Mirror
Group 2003Fire Extinguisher
Group 200 Horn and Warning Devices
Group 2006-Cigar Lighter
SECTION 21MAIN HYDRAULIC SYSTEM Group
216 Hydraulic System
SECTION 1WELECTRICAL SYSTEMS Group
1671Batteries, Support and Cables Group
1672Alternator, Regulator and Charging System
Wiring Group 1673Lighting System
SECTION 31LOADER Group 3102Buckets
Group 167 Group 167 Group 167
Wiring Harness and Switches System
Controls Instruments and Indicators
Group 311 ontrols Linkage Group 314 Frames
Group 3160Hydraulic System
SECTION 90-SYSTEM TESTING
SECTION 17FRAME, CHASSIS, OR SUPPORTING STRUCTURE
Group 900 General InformationSeven Basic
Group 174 Group 174
Frame Installation Frame Bottom Guards
Steps of Diagnosis and Testing Engine Electrical
System Power Train Hydraulic System
Group 901 Group 901 Group 902 Group 902
Group 1749Chassis Weights
SECTION 18--OPERATORS STATION
Group 9031Heating and Air Conditioning
Group 180 Group 181
Removal and Installation perator Enclosure
Group 1821Geat and Seat Belt
SECTION 9WSPECIAL TOOLS
Group 183 Heating and Air Conditioning INDEX
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Litho in U.S.A.
TM-1229 (Feb-B4)
4
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up INTRODUCTION AND SAFETY INFORMATION
INTRODUCTION ThiG teehnioal manual is part of a
twin concept of service. FOS Manuals - for
reference Technical Manuals - for actual
service The two kinds of manuals work as a team
to give you both the general background and
technical details of shop service. Fundamentals
of Service FOSj Mant/a/s cover baGic theory of
operatlon, fundamentals of troubleshooting,
general maintenance, and basic types of failures
and their causes. FOS Manuals are for training
new personnel and for reference by experienced
technicians. Technical Manuals are concise
service guides for specific machines. Technical
manuals are on-the-job guides contain- ing only
the vital information needed by an experienced
service technician.
FEATURES OF THIS TECHNICAL MANUAL John Deere
ILLUSTRUCTION 1ormat emphasizing detailed
pictures and fewer words in easy-to-use
modules. Removal and installation groups
preceding some repair groups. A section of
sytem diagnostic testing. TabIe of contents of
all sections at the front of the manual and a
listing of all groups and headings at the front
of each section. SpeciaI tools and
specifications listed at the front of each group
they are used in. Special tools illustrated in
numerical order at end of manual. AIphabeticaI
listing of all major components, specifications,
and special oo1s. Safety rules, general
specifications, and lubrication
specificaitons. This teGhnical manual was planned
and written for you - an experienced service
technician. Keep a in a permanent binder in the
shop where it is handy. Refer to it when you need
to know correct service procedures or
specifications. Using the technical manual as a
guide will reduce error and costly delay. It will
also assure you the best in finished service work.
1-1-01
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TM-1226 (Mar-84)
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Introduction and Safety Information SAFETY AND
YOU CAUTION This safety symbol followed by the
word caution Identifier important safety mes-
sages in this manual and on the loqder or
compaetor. When you see this symbol, be alert to
the possibility of peraonal Injury and carefully
read the message that follows.
Be prepared if an accident or fire should occur.
Know where the first aid kit and the fire
extinguishers are located - know how to use
them. 02AT27504 N T09\tt03 S601B1
TM-1229 (Mar64)
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Introduction and Safely Information
AVOID HIGH-PRESSURE FLUIDS Escaping fluid under
pressure can penetrate the skin causing serious
injury. Relieve pressure before disconnect- ing
hydraulic or other lines. Tighten all connections
before applying pressure. Keep hands and body
away from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard or
paper to search for leaks. If ANY fluid is
injected into the skin, it must be surgically
removed within a few hours by a doctor familiar
with this type injury or gangrene may result.
KEEP SHOP AND STORAGE AREA CLEAN Maintenance
area should be adequately vented. Keep
maintenance area clean and dry. Store 1lammable
materials in a cool and well-vented area out of
reach of unauthorized personnel. O2AT2750B N
TOR7It07 Z60S8S
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Introduction and fiafety Infomiation
FOLLOW SAFE WORKING CONDITIONS Perform work on
equipment only if authorized to do so. Follow
recommended procedures. Do not service equipment
while it is being operated or engine is
running. Always use two service technicians -
one, the operator at the controls. the other
checking within sight of the operator. Keep hands
away from moving parts. Support all raised
equipment. Do not work under raised
bucket. Always lower bucket before working an
'it. If machine is on an incline, block it
securely. Use hoisting equipment for lifting
heavy parts. Wear safety glasses when drilling,
grinding or hammering metal. Do not use open
flame around machine.
START ENGINE FROM OPERATOR'S SEAT ONLY Avoid
possible injury or death from machinery
runaway. Do not start engine by shorting across
starter terminals. Machine will start in gear and
will move if normal circuitry is bypassed. NEVER
start engine while standing on ground. Start
engine only from operator's seat. Move range
selector lever to park position or apply park
brake.
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Flemoval and Installation SPECIAL TOOLS NOTE
Order tools from your SERVICE-GARD Catalog,
unless othernsae indicated.
Name Shop Stands
Number D-01182AA or D-2420gWK
Use Supports the unit while removing differentials
FRONT DIFFERENTIAL AND AXLE SPECIFICATIONS 1.
Nuts torque . (600 60 N m) 445 45 lb-ft
z. Cap screws torque ......(130 - 7 Num) 95 -I-
5 lb-ft
REAR DIFFERENTIAL AND AXLE SPECIFICATIONS 1.
Install shims to give an end play clearance of
(0.03 to 0.46 mm) 0.001 to 0.018 in.
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(No Transcript)
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• Removal and /nsta//a/'/pn
• FRONT AXLE AND DIFFERENTIAL ASSEMBLY PUT SHOP
  STANDS UNDER LOADER FRAME
• Lift loader boom as high as possible. Put a
  support with a rated capacity of approximately
  (1772 kg) 3900 lbs. under bucket and boom.
• Stop the engine.
• Operate the steering valve, brake valve and
  loader control valve to release hydraulic
  pressure in the systems. Put loader control lever
  into float position.
• Install lock bar 1).
• Disconnect battery ground cables (1).

6. Using a service jack under the front bottom
guard, remove nuts and lower the bottom guard if
equipped).
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1. Fasten a chain hoist (1) to the loader frame
   hooks and lift the front of the machine.
2. Put D-0O182AA (shown) or D-24206WX Shop Stands
   (2) under loader frame. Lower machine onto shop
   stands.
3. Remove wheels (Group 0110).

DISCONNECT HYDRAULIC LiNES AND DRIVE
SHAFT CAUTION Escaping hydraulic oil under pres-
s
sure can have sufficient force to penetrate the
skin, causing serious injury. Before disconnect-
ing lines, be sure to relieve pressure. Before
applying pressure, be sure connections are tight
and lines, pipes, and hoses are not damaged. Use
a piece of Gardboard or wood, rather than hands,
to search for leaks. If injured by escaping oil,
see a doctor at once. Serious infection or
reaction can develop if proper medical treatment
is not administered immediately. 1. Disconnect
hydraulic brake line (1) and differential lock
return hose (2).
0200-06
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• Removal and Installation
• Disconnect differential lock inlet line (1).
• Close all openings with caps and plugs to keep
  dirt from entering the hydraulic system.
• Remove four cap screws (2) to disconnect drive
  shaft
• from input quil

• LOWER DIFFERENTIAL AND AXLE
• ASSEMBLY
• Remove drain plug to drain approximately 22.5
  L) 6 gal. of oil from differential.
• Put a lifting strap (1) around each axle housing.

3. Put tension on svaps and remove eight bolts
and nuts.
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Removal and Installation
4. Lower axle and differential as an assembly.

• INSTALL DIFFERENTIAL AND AXLE ASSEMBLY
• Lift axle and differential assembly in loader
  frame.
• Install eight bolts, 16 washers and eight nuts
  1). Tighten nuts to (600 60 Nm) 445 45
  lb-ft.

CONNECT DRIVE SHAFT ANB HYDFIAULIC LINES Connect
drive shaft and fasten with cap screws
(2). Tighten cap screws to (130 13 N m) 95 5
lb-ft. 2. Connect differential lock inlet line
(1).
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Removal and Installation
3. Connect hydraulic brake line (1) and return
hose (2).

• REMOVE sHOP STANDS
• Install wheels (Group 0110).
• Lift loader frame with chain hoist (1) and remove
  shop stands (2).

• FILL DIFFERENTIAL WITH OIL
• Install drain plug.
• Fill the front differential SLOWLY with
  recommended oil to fill plug level. See Section
  I, Group IV for the type of oil used. Let the
  unit stand for approximately one minute and check
  the differential oil level. Add more oil if
  necessary.
• Gonnect battery cables, start the engine and
  lower boom and bucket assembly.
• Bleed brake hydraulic system (Group 1060).

0200-09
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• Removal and Installation
• REAR AXLE AND DIFFERENTIAL ASSEMBLY
• - PUT SHOP STANDS UNDER ENGINE FRAME
• Lower all equipment to the ground.
• Stop the engine.
• Operate the steering valve, brake valve and
  loader control valve to release hydraulic
  pressure in the systems.
• Install lock bar (1).

1. Disconnect battery ground cables (1).
2. Remove center bottom guard (if equipped).

7. Lift the rear of unit and put D-24206WK
(shown) or D-01182AA Shop Stands under engine
frame. B. Put lifting straps around each axle
housing and put equal tension on straps. 9.
Remove wheels (Group 0110).
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Removal and Installation DISCONNECT BRAKE
LINE NOTE.' View looking do 'n leh side of
enpine. CAUTION Escaping nydraulic oil under
pres- s sure can have sufficient force to
penetrate the
skin, causing serious injury. Before disconnect-
ing lines, be sure to relieve pressure. Before
applying pressure, be aure connections are tight
and lines, pipes, and hoses are not damaged. Use
a piece of cardboard or wood, rather than hands,
to search for leaks. If injured by escaping oil,
see a doctor at once. Serious infection or
reaction can develop if proper medical
treatment is not administered immediately.
1-Brake Line
LOWER DIFFERENTIAL AND AXLE
ASSEMBLY 1. Remove drain plug (1) to drain
approximately (22.5 L) 6 gal. of oil Jrom
differential.
2. Remove four cap screws to disconnect rear
differential drive line.
0200-12
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• Removal and /nsfa/law/on
• Remove four cap screws and nuts from front
  oscillating
• support.
• Disconnect oscillating grease line (2) 1rom
  fitting.

5. Disconnect oscillating pin grease line (1).
6. Remove four cap screws and nuts from rear
support.
7. Lower axle and differential as an assembly.
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Remsra/ and Installation INSTALL DU-F-EFiENTlAL
AND AXLE ASSEIIBLY i . Before installing
differential aSSGmbly, remove O-ring (1). 2.
Install rear suppor' assembly with front thrust
plate (2) on dowel pin. install rear thrust plate
(3) with straight edge of plate up. Grease
grooves in thrust plates must face each other. BO
NOT instal! any shims.
3. Lift axle and differentiaT assembly in engine
frame.

• ADJUST DIFFERENTIAL AND AXLE
• SSEMBLY
• InstaII and tigüten only two cap screws and nuts
  (1) in both front and rear support.
• With a pry bar, move the difterentiai and ax!e
  assembJy as far forward as possible.

3. With a feeler gauge, measure the clearance (1)
between the rear thrust plate and support.
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Removal and Installation
4. Measure the thickness of feeler gauge blades.
5. Measure each shim separately to equal a shim
pack thickness which will give an end play
clearance of (0.03 to 0.46 mm) 0.0O1 to 0.018 in.

• d. Lower differential and axle assembly and
  remove
• support.
• Install O-ring (2) and shim pack (1). Install
  shims between rear thrust plate and support.
• Install support.

FASTEN FRONT AND REAR SUPPORT Install dowels (1)
in rear support. 2. Put T43515 John Deere Loctite
retaining compound or an equivalent on mounting
surface of support.
Loatite is a trademark of the Loctite Corp.
0200-15
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TM-1229 (Aug-82)
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• Removal and Installation
• Install dowels (1) in front support.
• Make sure fitting (2) is positioned as shown.
• Put T43515 John Deere Loctite retaining compound
  or
• an equivalent on mounting surface of support.

6. Lift differential and axle assembly under
engine frame. Install cap screws, washers and
nuts to fasten front support. Tighten 5/8 in. cap
screws to (325 Num) 240 lb-ft. Tighten 20 mm cap
screws to (680 68 N'm) 500 -I- 50 lb-ft.
7. Install cap screws, washers and nuts to fasten
rear support. Tighten 5/B in. cap screws to (325
N-m) 240 lb-ft. Tighten 20 mm cap screws to (680
68 Nm) 500 50
CONNECT DIFFERENTIAL DRIVE LINE AND OSCILLATING
GREASE LINES 1. Connect rear differential drive
line and fasten with cap scrows. Tighten cap
screws to (130 7 Nm) 95 5 lb-ft.
0200-16
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Removal and Installation
2. Connect the oscillating grease lines (1) on
both front and rear supports.
CONNECT BRAKE LINE

• 1Brake Line
• REMOVE SHOP STAHDS
• Install wheels (Group 0110). Remove lifting
  straps.
• Lift the rear of unit 1o remove shop stands.

Litho in U.S.A.
0200-17
TM-1229 (Dec-80)
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• Removal and Retaliation
• FILL DIFFERENTIAL WITH OIL
• Install drain plug.
• Fill the rear differential SLOWLY with
  recommended oil to fill plug level. See Section
  I, Group IV for the type of oil used. Let the
  unit stand Jor approximately one minute and check
  1he differential oil level. Add more oil if
  necessary.
• Bleed brake hydraulic system (Group 1060).
• Install the center bottom guard (if equipped).

0200-18
Litho in U.S.A.
TM-1229 (May-83)
25
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