REPAIR MANUAL - JOHN DEERE 744K 4WD LOADER TM10683 PDF DOWNLOAD

744K 4WD Loader (SN.-632967) with Engines 6090HDW06 (T3), 6090HDW08 (S2) Repair

REPAIR TECHNICAL MANUAL 4WD Loaders models 744K (SN. before 632967) TM10683 22 FEB 16 (ENGLISH)

For complete service information also see: JDLink (MTG) Technical Manual

TM114519

744K 4WD Loader (SN.-632967) with Engines 6090HDW06 (T3), 6090HDW08 (S2)

TM10682

Alternators and Starting Motors

CTM77

TeamMate II 1200, 1400,and 1600 Series Inboard Planetary Axles

CTM43

PowerTech 9.0L OEM Diesel Engines 6090 Tier 3 / Stage IIIA Emissions Certified Base Engine Repair

CTM400

PowerTech 6090 Diesel Engine Level 14 ElectronicFuel System with the Denso CTM385 High Pressure Common Rail (HPCR) Level 14 ECU Super Caddy Oil Cleanup Procedure

CTM310

TeamMate II 1600 Series Inboard Planetary Axles

CTM138719

120 Series Hydraulic Cylinders

CTM120519

185 Series Hydraulic Cylinders

CTM114919

120 Series Hydraulic Cylinders

CTM114319

125 Series Hydraulic Cylinders

CTM109319

COOLANT HEATER SERVICE MANUAL

CTM10090X19

JDLINK/ZXLINK Machine Monitoring System

CTM10006

John Deere Construction and Forestry Pinted by Belgreen

TM10683-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD MANUAL IDENTIFICATION—READ THIS FIRST! Section 00 - GENERAL INFORMATION Group 0001 - Safety Information Section 01 - WHEELS Group 0110 - Powered Wheels and Fasteners Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0200 - Removal and Installation Group 0225 - Input Drive Shafts And U-Joints Group 0250 - Axle Shaft, Bearings, And Reduction Gears Group 0260 - Hydraulic System Section 03 - TRANSMISSION Group 0300 - Removal and Installation Group 0350 - Gears, Shafts, Bearings and Power Shift Clutch Group 0360 - Hydraulic System Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEMS Group 0505 - Cold Weather Starting Aids Group 0510 - Cooling System Group 0520 - Intake System Group 0530 - External Exhaust System Group 0560 - External Fuel Supply Systems Section 07 - DAMPENER DRIVE Group 0752 - Elements Section 09 - STEERING SYSTEM Group 0960 - Hydraulic System Section 10 - SERVICE BRAKES Group 1011 - Active Elements Group 1060 - Hydraulic System Section 11 - PARK BRAKE Group 1111 - Active Elements Group 1160 - Hydraulic System Section 17 - FRAME OR SUPPORTING STRUCTURE Group 1740 - Frame Installation Group 1746 - Frame Bottom Guards Group 1749 - Chassis Weights Section 18 - OPERATOR’S STATION Group 1800 - Removal and Installation Group 1810 - Operator Enclosure Group 1821 - Seat and Seat Belts Group 1830 - Heating and Air Conditioning Section 19 - SHEET METAL AND STYLING Group 1910 - Hood or Engine Enclosure Group 1921 - Grille and Grille Housing Section 31 - LOADER Group 3102 - Bucket Group 3140 - Frames Group 3160 - Hydraulic System Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools <- Go to Global Table of contents

TM10683-REPAIR TECHNICAL MANUAL

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TM10683-REPAIR TECHNICAL MANUAL

TM10683-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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TM10683-REPAIR TECHNICAL MANUAL

TM10683-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Manual Identification—READ THIS FIRST! IMPORTANT: Use only supporting manuals designated for your specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) and engine model number when choosing the correct manual.

Choosing the Correct Supporting Manuals John Deere four wheel drive (4WD) loaders are available in different machine configurations based on the various markets into which they are sold. Different supporting manuals exist for different machine configurations.

When necessary, product serial numbers and engine model numbers are listed on the front covers of 4WD loader manuals.

These numbers are used to identify the correct supporting manual for your machine.

Product Serial Number Identification LEGEND: 1 2 3

PIN Plate 13-Character PIN 17-Character PIN

PIN Plate Location

PIN Plate (13-character)

PIN Plate (17-character) <- Go to Global Table of contents

TM10683-REPAIR TECHNICAL MANUAL

TM10683-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

The product identification number (PIN) plate (1) is located on left side of machine frame under the platform. Each machine has a 13-character PIN (2) or 17-character PIN (3) shown on this plate. The last 6 characters of the PIN represent the machine′s product serial number.

Engine Model Number Identification

Engine Serial Number Plate

Engine Serial Number Plate Location—6090HDW12

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TM10683-REPAIR TECHNICAL MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

Engine Serial Number Plate Location—6090HDW06

Engine Serial Number Plate Location—6090HDW08 LEGEND: 4 Engine Serial Number Plate 5 9-Character Engine Model Number The engine serial number plate (4) is located on the right side of the engine. Each engine has a 9-character engine model number (5) shown on this plate.

Engine Emissions Level Identification The 9-character engine model number corresponds to a specific engine emissions level.

Engine Model Number Classification Engine Model Number

Engine Emissions Level

6090HDW12

Interim Tier 4/Stage III B

6090HDW06

Tier 3/Stage III A

6090HDW08

Stage II

For machines equipped with a 17-character PIN, where the 11 th character is “E”, “D”, or “C”, this character also corresponds to a specific engine emissions level. →NOTE: Later machines with a 17-character PIN identify engine emissions level (“E”, “D”, or “C”) with the 11 th th character. Earlier machines with a 17-character PIN do not identify engine emissions level with the 11 character.

PIN Classification 17-Character PIN (11 th character)

Engine Emissions Level

xxxxxxxxxx E xxxxxx

Interim Tier 4/Stage III B

xxxxxxxxxx D xxxxxx

Tier 3/Stage III A

xxxxxxxxxx C xxxxxx

Stage II

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Section 00 page 3

TM10683-REPAIR TECHNICAL MANUAL

TM10683-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety Information ........................................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 1 Operate Only If Qualified ...................................................................................................................... 1 Wear Protective Equipment .................................................................................................................. 3 Avoid Unauthorized Machine Modifications .......................................................................................... 3 Add Cab Guarding For Special Uses ..................................................................................................... 3 Inspect Machine ................................................................................................................................... 4 Stay Clear of Moving Parts ................................................................................................................... 4 Avoid High-Pressure Oils ...................................................................................................................... 5 Avoid High-Pressure Fluids ................................................................................................................... 5 Beware of Exhaust Fumes .................................................................................................................... 6 Prevent Fires ........................................................................................................................................ 6 Clean Debris from Machine .................................................................................................................. 7 Prevent Battery Explosions ................................................................................................................... 7 Handle Chemical Products Safely ......................................................................................................... 8 Dispose of Waste Properly .................................................................................................................... 8 Prepare for Emergencies ...................................................................................................................... 9 Use Steps and Handholds Correctly ..................................................................................................... 9 Start Only From Operator′s Seat ........................................................................................................... 9 Use and Maintain Seat Belt ................................................................................................................ 10 Prevent Unintended Machine Movement ............................................................................................ 10 Avoid Work Site Hazards .................................................................................................................... 10 Use Special Care When Operating Loader .......................................................................................... 12 Keep Riders Off Machine .................................................................................................................... 12 Avoid Backover Accidents .................................................................................................................. 13 Avoid Machine Tip Over ...................................................................................................................... 13 Operating on Slopes ........................................................................................................................... 14 Operating or Traveling On Public Roads ............................................................................................. 15 Inspect and Maintain ROPS ................................................................................................................. 15 Add and Operate Attachments Safely ................................................................................................ 15 Park And Prepare For Service Safely .................................................................................................. 16 Service Cooling System Safely ........................................................................................................... 16 Service Tires Safely ............................................................................................................................ 18 Remove Paint Before Welding or Heating ........................................................................................... 18 Make Welding Repairs Safely ............................................................................................................. 19 Drive Metal Pins Safely ....................................................................................................................... 19

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TM10683-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Group 0001 - Safety Information Recognize Safety Information

Safety Alert Symbols

Safety Alert Symbols This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury.

Follow the precautions and safe operating practices highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Follow Safety Instructions

Follow Safety Instructions Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Replacement safety signs are available from your authorized John Deere dealer.

Be sure all operators of this machine understand every safety message. Replace operator′s manual and safety labels immediately if missing or damaged.

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Section 00 page 1

TM10683-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety Information

Operate Only If Qualified Do not operate this machine unless you have read the operator′s manual carefully and you have been qualified by supervised training and instruction.

Familiarize yourself with the job site and your surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work.

Know and observe all safety rules that may apply to your work situation and your work site.

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Section 00 page 2

TM10683-REPAIR TECHNICAL MANUAL