John Deere 644K 4WD Loader – Operator’s Manual

John Deere 644k 4wd Wheel Loader Engine Service Repair Manual

John Deere 644K 4WD Loader – Operator’s Manual (Typical Comprehensive Contents)

Manual Number: TM1499 (Typical reference for 644K Series)
Core Purpose: To instruct operators in safe, efficient machine operation, routine maintenance, basic troubleshooting, and technical specifications.

Major Manual Sections & Breakdown:

Section 1: Safety

Subsections: Signal Words (DANGER, WARNING, CAUTION, NOTICE); General Safety; Operating Safety; Maintenance Safety; Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS); Seat Belt; Fire Prevention; Battery Safety; Transport Safety.

Section 2: Component Identification & Instrumentation

Subsections: Machine Overview (Left/Right/Front/Rear Views); Operator’s Station Layout; Control Console Details (Joystick, Transmission Controls, Switches); Instrument Cluster Gauges and Warning Lights (Coolant Temp, Transmission Temp, Fuel, etc.); Monitoring System Display (JDLink™ if equipped) Messages.

Section 3: Operation

Subsections: Pre-Start Inspection and Walk-around; Starting Procedure (Normal and Cold Weather); Break-in Recommendations; Transmission Operation (Power Shift, Forward/Reverse, Kickdown); Steering Modes (4-Wheel, 2-Wheel, Crab); Hydraulic System Operation (Lift, Tilt, Attachments); Parking and Shutdown Procedures; Machine Storage Guidelines.

Section 4: Lubrication and Maintenance

CRITICAL for SEO/User Intent: This is the most referenced section.
Subsections:
- Maintenance Interval Charts: Organized by Service Meter Hours (e.g., Every 10, 50, 100, 250, 500, 1000, 2000 hours). This is a key search target.
- Fluid Specifications & Capacities: Engine oil (type, grade, quantity), Coolant, Transmission/Hydraulic Oil (Hy-Gard), Axles, Fuel Tank.
- Lubrication Points: Grease fittings (boom, linkage, bucket, articulation joint, etc.) with diagrams.
- Step-by-Step Tasks: Checking fluid levels; Draining and replacing filters (engine oil, fuel primary/secondary, hydraulic, transmission, air); Cleaning air pre-cleaner and cooler cores; Battery care; Tire pressure checks; Wiper blade replacement.

Section 5: Technical Specifications & Attachments

Subsections: General Machine Dimensions (with bucket); Weights; Engine Specifications (John Deere 6.8L Final Tier 4 / Stage V diesel, power rating); Hydraulic System Pressure & Flow; Transmission Type (4-speed power shift with lockup); Axle and Brake Specifications; Approved Attachments and Installation Guidelines.

Section 6: Troubleshooting & Diagnostics

Subsections: Problem-Symptom-Based Guides (e.g., Engine Will Not Crank, Engine Cranks But Will Not Start, Engine Lacks Power, Excessive Black/White Smoke, Transmission Slips/No Movement, Hydraulic System Slow/Weak, Steering Issues, Electrical Malfunctions).
Basic Diagnostic Procedures: Using the monitor to retrieve diagnostic codes; Visual inspection checklists.

Section 7: Major Systems Reference

Subsections (Detailed Technical Overviews):
- Engine: Starting/Charging system, Emissions System (Diesel Particulate Filter – DPF regeneration procedures).
- Transmission & Drivetrain: Power shuttle operation, differential lock.
- Hydraulics: Implement and steering pump functions, pressure relief settings.
- Electrical: Wiring diagrams (simplified), fuse panel locations and amperage charts.
- Brakes & Steering: Service brake and parking brake system overview.