Worldwide Construction And Forestry Division 444K User manual
444K
Loader
Repair
TECHNICAL MANUAL
444K Loader Repair
TM10685 24MAR09 (ENGLISH)
For complete service information also see:
444K Loader Test Manual .............. TM10684
444K Loader Operator’s Manual .........OMT227993
PowerTech4.5 L and 6.8 L Diesel
Engines—Base Engine ................. CTM104
PowerTech E4.5 & 6.8L Diesel
Engines—Level 16 Electronic Fuel System
with Denso HPCR ..................... CTM502
120 Series Hydraulic Cylinders .......... TM-H120A
125 Series Hydraulic Cylinders .......... TM-H125A
Super Caddy Oil Cleanup Procedure ...... CTM310
JDLink/ ZXLinkMachine Monitoring
System .............................. CTM10006
Specifications Manual .................. SP458
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
DX,TMIFC –19–29SEP98–1/1
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.
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.
TM10685 (24MAR09) 444K Loader
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Introduction
TX,II,FAX –19–10JUL01–1/1
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)
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Company Name:
Technician Name:
Address:
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THANK YOU!
TM10685 (24MAR09) 444K Loader
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Contents
00
SECTION 17—Frame or Supporting Structure
SECTION 00—General Information
Group 1740—Frame Installation
Group 0001—Safety Information
Group 1746—Frame Bottom Guards
Group 1749—Chassis Weights
SECTION 01—Wheels
Group 0110—Powered Wheels and Fasteners
01
SECTION 18—Operator’s Station
Group 1800—Removal and Installation
SECTION 02—Axles and Suspension Systems Group 1810—Operator Enclosure
Group 0200—Removal and Installation Group 1821—Seat and Seat Belt
Group 0225—Axle Shafts and U-Joints Group 1830—Heating and Air Conditioning
Group 0250—Axle Shaft, Bearings, Reduction
Gears SECTION 19—Sheet Metal and Styling
Group 0260—Hydraulic System Group 1910—Hood or Engine Enclosure
SECTION 31—Loader
SECTION 03—Transmission
Group 3102—Bucket
Group 0300—Removal and Installation
02
Group 3140—Frames
Group 0350—Gears, Shafts, Bearings and Power Group 3160—Hydraulic System
Shift Clutch
Group 0360—Hydraulic System SECTION 99—Dealer Fabricated Tools
Group 9900—Dealer Fabricated Tools
SECTION 04—Engine
Group 0400—Removal and Installation
SECTION 05—Engine Auxiliary Systems
Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
03
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
04
SECTION 10—Service Brakes
Group 1011—Active Elements
Group 1060—Hydraulic System
SECTION 11—Park Brake
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.
05
COPYRIGHT
2009
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION
Manual
Previous Editions
Copyright
2008
07
09
10
11
TM10685 (24MAR09)
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00
Section 00
General Information
Contents
Page
Group 0001—Safety Information
Recognize Safety Information ............00-0001-1
Follow Safety Instructions ...............00-0001-1
Operate Only If Qualified................00-0001-2
Wear Protective Equipment..............00-0001-2
Avoid Unauthorized Machine
Modifications .......................00-0001-2
Add Cab Guarding For Special Uses ......00-0001-3
Inspect Machine ......................00-0001-3
Stay Clear of Moving Parts ..............00-0001-3
Avoid High-Pressure Fluids ..............00-0001-4
Avoid High-Pressure Oils ...............00-0001-4
Beware of Exhaust Fumes ..............00-0001-5
Prevent Fires.........................00-0001-5
Clean Trash from Machine ..............00-0001-6
Prevent Battery Explosions ..............00-0001-6
Handle Chemical Products Safely .........00-0001-6
Dispose of Waste Properly ..............00-0001-7
Prepare for Emergencies................00-0001-7
Use Steps and Handholds Correctly .......00-0001-7
Start Only From Operator’s Seat ..........00-0001-8
Use and Maintain Seat Belt..............00-0001-8
Prevent Unintended Machine Movement ....00-0001-9
Avoid Work Site Hazards ..............00-0001-10
Use Special Care When Operating
Loader ...........................00-0001-11
Keep Riders Off Machine ..............00-0001-11
Avoid Backover Accidents ..............00-0001-12
Avoid Machine Tip Over ...............00-0001-13
Operating on Slopes ..................00-0001-13
Operating or Traveling On Public Roads . . .00-0001-14
Inspect and Maintain ROPS ............00-0001-14
Add and Operate Attachments Safely .....00-0001-14
Park And Prepare For Service Safely .....00-0001-15
Service Cooling System Safely ..........00-0001-15
Service Tires Safely ..................00-0001-16
Remove Paint Before Welding or
Heating ..........................00-0001-17
Make Welding Repairs Safely ...........00-0001-18
Drive Metal Pins Safely ................00-0001-18
TM10685 (24MAR09) 00-1 444K Loader
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Group 0001
Safety Information
00
0001
1
TX03679,00016CC –19–03NOV08–1/1
Recognize Safety Information
T133555 –UN–28AUG00T133588 –19–28AUG00
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.
TX03679,00016F9 –19–18OCT07–1/1
Follow Safety Instructions
T133556 –UN–24AUG00
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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Safety Information
00
0001
2
TX03679,00016FA –19–03NOV08–1/1
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.
TX03679,00016D0 –19–03NOV08–1/1
Wear Protective Equipment
TS206 –UN–23AUG88
Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
AM40430,00000A9 –19–14JAN08–1/1
Avoid Unauthorized Machine Modifications
John Deere recommends using only genuine John
Deere replacement parts to ensure machine
performance. Never substitute genuine John Deere
parts with alternate parts not intended for the
application as these can create hazardous situations or
hazardous performance. Non-John Deere Parts, or any
damage or failures resulting from their use are not
covered by any John Deere warranty.
Modifications of this machine, or addition of
unapproved products or attachments, may affect
machine stability or reliability, and may create a hazard
for the operator or others near the machine. The
installer of any modification which may affect the
electronic controls of this machine is responsible for
establishing that the modification does not adversely
affect the machine or its performance.
Always contact an authorized John Deere dealer
before making machine modifications that change the
intended use, weight or balance of the machine, or
that alter machine controls, performance or reliability.
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Safety Information
00
0001
3
TX03679,00017C6 –19–18OCT07–1/1
Add Cab Guarding For Special Uses
T141893 –UN–04MAY01
Special work situations or machine attachments may
create an environment with falling or flying objects.
Loading logs, using fork attachments, or operating in
waste management applications requires special work
tools. Added cab guarding to protect the operator may
also be required.
Use load-clamping grapples to keep bulky loads from
falling and add special screens or guarding when objects
may be directed toward the cab. Contact your authorized
John Deere dealer for information on devices intended to
protect the operator from falling or flying objects in special
work situations.
TX03679,0001734 –19–03NOV08–1/1
Inspect Machine
T6607AQ –UN–18OCT88
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
TX03679,00016D2 –19–03NOV08–1/1
Stay Clear of Moving Parts
T133592 –UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
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Safety Information
00
0001
4
DX,FLUID –19–03MAR93–1/1
Avoid High-Pressure Fluids
X9811 –UN–08DEC08
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
TX03679,00016D3 –19–03NOV08–1/1
Avoid High-Pressure Oils
T133509 –UN–17MAR06
T133840 –UN–20SEP00
This machine uses a high-pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
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Safety Information
00
0001
5
TX03679,00016D4 –19–03NOV08–1/1
Beware of Exhaust Fumes
T133546 –UN–24AUG00
Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in an enclosed space, provide
adequate ventilation. Use an exhaust pipe extension to
remove the exhaust fumes or open doors and windows to
bring outside air into the area.
TX03679,00016F5 –19–03NOV08–1/1
Prevent Fires
T133552 –UN–14SEP00T133553 –UN–07SEP00T133554 –UN–07SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly.
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Safety Information
00
0001
6
OUT4001,00000E3 –19–27FEB09–1/1
Clean Trash from Machine
T6669AG –UN–18OCT88
Keep engine compartment, radiator, batteries, hydraulic
lines, exhaust components, fuel tank, and operator’s
station clean and free of debris.
Clean any oil spills or fuel spills on machine surfaces.
Temperature in engine compartment may go up
immediately after engine is stopped. BE ON GUARD FOR
FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean
engine compartment.
TX03679,000174A –19–03NOV08–1/1
Prevent Battery Explosions
TS204 –UN–23AUG88
Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).
TX03679,00016D7 –19–03JAN07–1/1
Handle Chemical Products Safely
T133580 –UN–25AUG00
Exposure to hazardous chemicals can cause serious
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
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Safety Information
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0001
7
TX03679,0001733 –19–03NOV08–1/1
Dispose of Waste Properly
T133567 –UN–25AUG00
Improper disposal of waste can threaten the environment.
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your dealer for
more information.
TX03679,000174B –19–03NOV08–1/1
Prepare for Emergencies
TS291 –UN–23AUG88
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
TX03679,00016F2 –19–15MAR07–1/1
Use Steps and Handholds Correctly
T133468 –UN–30AUG00
Prevent falls by facing the machine when getting on and
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
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Safety Information
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0001
8
TX03679,0001799 –19–03JAN07–1/1
Start Only From Operator’s Seat
T133715 –UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,00016DD –19–03NOV08–1/1
Use and Maintain Seat Belt
T133716 –19–14SEP00
Use seat belt when operating machine. Remember to
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every 3 years, regardless of appearance.
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Safety Information
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0001
9
DP99999,00000A3 –19–02MAY08–1/1
Prevent Unintended Machine Movement
TX1041772A –UN–02MAY08
1—Park Brake Switch
2—Pilot Enable/Boom Down Switch
Lower all equipment to the ground during work
interruptions. Place transmission control in neutral, press
park brake switch (1) to engage park brake, press pilot
enable/boom down switch (2) to disable the hydraulics,
and stop engine before allowing anyone to approach the
machine.
Follow these same precautions before standing up,
leaving the operator’s seat, or exiting the machine.
TM10685 (24MAR09) 00-0001-9 444K Loader
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Safety Information
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0001
10
DP99999,0000113 –19–23JUN08–1/1
Avoid Work Site Hazards
T141894 –UN–15JUN01T141670 –UN–24APR01T141672 –UN–04MAY01
Avoid contact with gas lines, buried cables and water
lines. Call utility line location services to identify all
underground utilities before starting work.
Prepare work site properly. Avoid operating near
structures or objects that could fall onto the machine.
Clear away debris that could move unexpectedly if run
over.
Avoid boom or attachment contact with overhead
obstacles or overhead electrical lines. Never move
machine closer than 3 m (10 ft) plus twice the line
insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders
away from raised booms, attachments, and unsupported
loads. Avoid swinging or raising booms, attachments, or
loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a
signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to
support machine. Be especially alert working near
embankments or excavations.
Avoid working under over-hanging embankments or
stockpiles that could collapse under or on machine.
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc.). At high speeds
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seatbelt.
TM10685 (24MAR09)
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Table of contents
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