PDF Repair Technical Manual John Deere 444K Loader - 8 MB
This is the complete repair technical manual (TM10685) for the John Deere 444K Loader.
It contains in-depth information on every aspect of machine repair, from the engine to the hydraulics and electrical systems.
This manual is essential for any technician performing diagnostics and repairs on a 444K wheel loader.
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--- Page 1 ---
444K
Loader
Repair
TECHNICAL MANUAL
444K Loader
Repair
TM10685 03MAR11 (ENGLISH)
For complete service information also see:
444K Loader Test Manual .................................. TM10684
444K Loader Operator’s Manual ....................... OMT227993
PowerTech™ 4.5 L and 6.8 L Diesel
Engines—Base Engine ....................................... CTM104
PowerTech E™ 4.5 L and 6.8 L Diesel
Engines—Level 16 Electronic Fuel System
with Denso HPCR ................................................ CTM502
120 Series Hydraulic Cylinders .......................... CTM114319
125 Series Hydraulic Cylinders .......................... CTM109319
Super Caddy Oil Cleanup Procedure................. CTM310
JDLink™ / ZXLink™ Machine Monitoring
System.................................................................. CTM10006
Specifications Manual......................................... SP458
JDLink / ZXLink (MTG) Diagnosis and Tests
Manual .................................................................. TM114519
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
--- Page 3 ---
Safety Information
Prevent Fires
T133552 —UN—14SEP00
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
T133553 —UN—07SEP00
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. T133554 —UN—07SEP00
TX03679,00016F5 1903NOV081/1
Clean Debris from Machine
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.
T6669AG —UN—18OCT88
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.
OUT4001,00000E3 1920AUG091/1
TM10685 (03MAR11) 0000015 444K Loader
030311
PN=11
--- Page 4 ---
Section 01
Wheels
Contents
Page
Group 0110—Powered Wheels and Fasteners
Wheel Remove and Install......................... 0101101
Tire Remove and Install............................. 0101102
TM10685 (03MAR11) 011 444K Loader
030311
PN=1
--- Page 5 ---
Removal and Installation
CAUTION: Prevent crushing injury from heavy
component. Use appropriate lifting device
when lifting component.
Specification
Machine—Weight
(approximate)............................................................................11 786 kg
25 983 lb.
TX1005981A —UN—04APR06
8. Raise rear of machine using floor jack. Install floor
stands under frame on each side and under rear
corners of frame.
CAUTION: Prevent possible crushing injury
from heavy component. Use appropriate lifting
device when lifting component.
Floor Stand Under Frame
9. Remove rear wheels. See Wheel Remove and Install.
(Group 0110.)
IMPORTANT: Do not reuse drive shaft universal
joint cap screws. Replace cap screws to
avoid machine damage.
10. Remove cap screws to disconnect drive shaft.
CAUTION: Prevent possible crushing injury
from heavy component. Use appropriate lifting
device when lifting component.
Specification
Axle and Differential
with Oscillating
Supports—Weight
(approximate)................................................................................ 980 kg
2161 lb.
11. Install lowlift jack under axle and differential.
TX1005982A —UN—04APR06
1— Floor Stand (4 used)
Positioning Floor Stands
Continued on next page AA95137,0001B43 1914AUG082/6
TM10685 (03MAR11) 0202005 444K Loader
030311
PN=31
--- Page 6 ---
Group 0250
Axle Shaft, Bearings, Reduction Gears
Axle Planetary Pinion/Service Brake Housing Disassemble and Assemble
TX1002890 —UN—10MAY06
Axle Planetary Pinion/Service Brake Housing
1— Axle Planetary Pinion/Service 6— Inner Bearing Cone 11— ORing 16— Cylindrical Roller Bearing (3
Brake Housing 7— Spindle 12— Sun Gear used)
2— Plug (2 used) 8— Pinion Carrier End Plate 13— Planetary Pinion (3 used) 17— Snap Ring (3 used)
3— Brake Bleeder 9— SelfLocking Cap Screw (4 14— Planetary Pinion Carrier 18— Service Brake Disk
4— Outer Housing Seal used) 15— Pin Inspection Plug
5— Bearing Cone 10— End Cover 19— ORing
Continued on next page MH66088,0000996 1905SEP081/44
TM10685 (03MAR11) 0202501 444K Loader
030311
PN=41
--- Page 7 ---
Axle Shaft, Bearings, Reduction Gears
30. Clean Orings (37) using a volatile, nonpetroleum
base solvent and lintfree tissues. Apply a thin film of
oil to Orings and install.
31. Clean oil from guide ring (36) and guide ring grove
using a volatile, nonpetroleum base solvent and
lintfree tissues.
32. Align end points of guide ring in the 12 o‘clock position
TX1006515A —UN—17APR06
(as viewed when housing is installed on axle tube).
33. Apply a small amount of Quick Gel Super Glue at
both end points of guide ring to maintain its position.
1— Axle Planetary 37— ORing (2 used)
Pinion/Service Brake 38— Support Ring (2 used)
Housing
36— Guide Ring
Piston Seals
TX1006523 —UN—17APR06
CrossSectional View
MH66088,0000996 1905SEP0822/44
NOTE: The Illustration shows pins in correct
position for piston installation.
34. Orient piston as shown, shoulder side up.
35. Drive service brake piston pins (43) flush with
mounting surface (44).
35— Service Brake Piston 44— Mounting Surface
TX1006683A —UN—19APR06
43— Pin (6 used)
Service Brake Piston and Pins
Continued on next page MH66088,0000996 1905SEP0823/44
TM10685 (03MAR11) 02025011 444K Loader
030311
PN=51
--- Page 8 ---
Axle Shaft, Bearings, Reduction Gears
TM10685 (03MAR11) 02025021 444K Loader
030311
PN=61
--- Page 9 ---
Axle Shaft, Bearings, Reduction Gears
21. For rear axle, remove cap screws (72) and oscillating
support housing (73).
72— Cap Screw (4 used) 73— Oscillating Support
Housing
TX1007256A —UN—03MAY06
Oscillating Support Housing (Rear Axle Only)
MM16633,00024F3 1913AUG0817/22
22. Remove yoke nut (43) and washer. Remove yoke (41).
41— Yoke 43— Yoke Nut
TX1006524A —UN—17MAY06
Pinion Nut and Yoke
MM16633,00024F3 1913AUG0818/22
23. Remove pinion seal (39) from differential housing.
NOTE: Outer pinion bearing (38) will come out as
pinion is being removed.
24. Using a soft faced mallet, remove pinion (34) and
outer pinion bearing (38).
TX1007322A —UN—17MAY06
34— Pinion 39— Pinion Seal
38— Outer Pinion Bearing
Pinion Seal
Continued on next page MM16633,00024F3 1913AUG0819/22
TM10685 (03MAR11) 02025031 444K Loader
030311
PN=71
--- Page 10 ---
Axle Shaft, Bearings, Reduction Gears
NOTE: Attempt to obtain highest value within specification.
9. Using a torque wrench, check rolling torque of
the pinion bearings. If rolling torque is not within
specifications, correct with appropriate size spacer
ring.
Specification
Pinion Bearing—Torque...................................................... 1.1—2.3 N∙m
TX1007328A —UN—04MAY06
9.7—20.4 lbin.
10. When correct rolling torque has been obtained,
remove yoke.
11. Install yoke seal and repeat step 8.
Rolling Torque Check
MM16633,00024F4 1913AUG0811/34
NOTE: Make sure thrust washers (4) and (2) are installed
correctly within tabs of carrier (1).
12. Install spacer (3) and thrust washers (2) and (4) into
carrier (1).
13. Install side gear (5).
14. Install pinion gears (6) and beveled thrust washers (7).
TX1006502A —UN—17MAY06
NOTE: Access holes (46) are identified by holes that
go all the way through carrier.
15. Install pinion shaft (8) into bore in side of carrier,
opposite access holes (46).
16. Install pinion gears (6), thrust washers (7), and split
pinion shafts (9) into carrier. Rotate split pinion shafts Differential Components
so holes in end of shafts are seen in access holes (46).
1— Carrier 7— Beveled Thrust Washer (4
2— Thrust Washer used)
3— Spacer 8— Pinion Shaft
4— Thrust Washer 9— Split Pinion Shaft (2 used)
5— Side Gear 15— Pin (2 used)
6— Pinion Gear (4 used) 16— Spring Pin (2 used)
46— Access Holes
TX1007353A —UN—17MAY06
Pinion Shaft, Gears, and Carrier
Continued on next page MM16633,00024F4 1913AUG0812/34
TM10685 (03MAR11) 02025041 444K Loader
030311
PN=81
--- Page 11 ---
Axle Shaft, Bearings, Reduction Gears
49. If contact pattern differs considerably, correct with
appropriate size shim (51). See step 1.
51— Shim
TX1006642A —UN—18APR06
Shim
MM16633,00024F4 1913AUG0831/34
50. Insert shim (57) and axle shaft (58 ) into sun gear
shaft (56).
51. Install shaft assembly into axle tube (68) from
differential side.
56— Sun Gear Shaft 58— Axle Shaft
57— Shim
TX1006678A —UN—19APR06
Axle
MM16633,00024F4 1913AUG0832/34
CAUTION: Prevent possible injury from crushing.
Heavy component, use appropriate lifting
device when lifting component.
52. Install preassembled differential carrier assembly (70)
using DFT1273 Lifting Device (64).
Specification
TX1007049A —UN—03MAY06
Differential Assembly
—Weight (approximate).................................................................. 45 kg
100 lb
64— DFT1273 Lifting Device 70— Differential Carrier
67— Differential Housing Assembly
Installing Differential
Continued on next page MM16633,00024F4 1913AUG0833/34
TM10685 (03MAR11) 02025051 444K Loader
030311
PN=91
--- Page 12 ---
Group 0350
Gears, Shafts, Bearings and Power Shift Clutch
Torque Converter and Housing Remove
1. Remove transmission. See Transmission Remove
and Install. (Group 0350.)
CAUTION: Prevent possible injury from crushing.
T112589 —UN—19DEC97
Heavy component, use appropriate lifting device.
Specification
Transmission—Weight
(approximate)................................................................................ 504 kg
1110 lb
NOTE: Earlier JDG1129 Transmission Mounting Bracket Sketch Showing Revised Mounting Hole (A)
Brackets require that the right side bracket be
revised. Note bracket sketch showing revised
mounting hole (A). Revise hole by elongating
the existing hole as required.
2. Install transmission in repair stand using JDG1129
TX1022077A —UN—16APR07
Transmission Mounting Brackets (1).
A—Mounting Hole 1— JDG1129 Transmission
Mounting Bracket (2 used)
JDG1129 Transmission Mounting Brackets
SW03989,0000422 1925FEB081/10
3. Remove lock plate and cap screws from input flange
washer.
4. Remove washer and input flange from the shaft.
T108721 —UN—17APR97
Lock Plate and Cap Screws
Continued on next page SW03989,0000422 1925FEB082/10
TM10685 (03MAR11) 0303501 444K Loader
030311
PN=101
--- Page 13 ---
Gears, Shafts, Bearings and Power Shift Clutch
12. Remove transmission housing from repair stand.
Install transmission cover with clutch packs into repair
stand using JDG1129A Mounting Brackets. Fasten
transmission cover to mounting brackets using cap
screws, washers, and nuts as shown.
TX1028696A —UN—29AUG07
Mounting Bracket Positions
MH66O88,0000723 1910OCT0810/19
13. Rotate the repair stand so clutch packs are facing up.
This will allow them to be removed from the cover.
14. Remove washers and nuts retaining clutch packs.
TX1049945A —UN—09OCT08
MH66O88,0000723 1910OCT0811/19
15. Clutch pack layout viewed from torque converter side
of transmission.
6— First Speed Clutch (K1) 9— Forth Speed Forward
7— Second Speed Clutch (K2) Clutch (K4)
8— Third Speed Clutch (K3) 10— Reverse Clutch (KR)
TX1028698A —UN—29AUG07
11— Forward Clutch (KV)
View from Torque Converter Side
Continued on next page MH66O88,0000723 1910OCT0812/19
TM10685 (03MAR11) 03035011 444K Loader
030311
PN=111
--- Page 14 ---
Gears, Shafts, Bearings and Power Shift Clutch
23. Install dowel pins (2).
14— Dowel Pin (2 used)
TX1049939 —UN—09OCT08
Dowel Pin Installation
AA95137,0001B50 1910OCT0821/28
NOTE: Locate hanger in same position as it
was removed from.
24. Install housing cover cap screws and tighten to
specification.
Specification
T109078 —UN—15APR97
Housing Cover Cap
Screw—Torque..............................................................................46 N∙m
34 lbft
Torque Cap Screw
AA95137,0001B50 1910OCT0822/28
NOTE: Grease sealing lip of shaft seal.
25. Using JDG10837 Output Shaft Seal Installer, install
shaft seal with the lip facing inward.
T109079 —UN—15APR97
Shaft Seal Installation
Continued on next page AA95137,0001B50 1910OCT0823/28
TM10685 (03MAR11) 03035021 444K Loader
030311
PN=121
--- Page 15 ---
Gears, Shafts, Bearings and Power Shift Clutch
NOTE: Push against cone of bearing.
On clutch KR, there is no recess in the
shaft. Installation of snap ring will be in
contact of bearing cone.
16. Press idler gear against shoulder.
T108673 —UN—10APR97
Press Idler Gear Against Shoulder
MH66O88,00006EC 1914AUG0813/18
17. Retain idler gear by means of snap ring.
T108674 —UN—10APR97
Retain Idler Gear
MH66O88,00006EC 1914AUG0814/18
18. Assemble preassembled plate carrier until all plates
are engaged.
T108675 —UN—10APR97
Assemble Plate Carrier
Continued on next page MH66O88,00006EC 1914AUG0815/18
TM10685 (03MAR11) 03035031 444K Loader
030311
PN=131
--- Page 16 ---
Gears, Shafts, Bearings and Power Shift Clutch
18. Install end shim and snap ring.
T108738 —UN—10APR97
End Shim and Snap Ring Installation
MH66O88,0000980 1920AUG0814/23
NOTE: For the adjustment of the plate clearance there
are snap rings of different thicknesses available
that can be used if proper clearance cannot be
obtained. To ensure proper measuring result,
install plates temporarily without oil.
T108739 —UN—10APR97
19. Adjust plate clearance to specification.
Specification
K2 and K3 Clutch Pack
Plate—Clearance...................................1.8—2.0 mm (0.071—0.079 in.)
a. Press end shim and measure the dimension from
the end face/plate carrier to the end shim with depth
gauge. Record dimension (No. 1). End Shim Press
MH66O88,0000980 1920AUG0815/23
b. Press end shim against snap ring (upward) until
contact and measure with gauge. Record dimension
(No. 2).
Example for Clutch Pack Clearance Check
Dimension No. 1 8.00 mm (0.315 in.)
Dimension No. 2 6.00 mm (0.236 in.)
T108740 —UN—09MAY97
Difference = Plate Clearance 2.0 mm (0.079 in.)
Specification = Pack Clearance 1.8—2.0 mm (0.071—0.079 in.)
c. If a clutch pack clearance is not to specification,
correct by using the proper corresponding snap
ring from service parts to increase or decrease
clearance. Snap rings come in various sizes. Clutch Pack Clearance Check
d. After proper clearance is obtained, remove disks
and plates from assembly. 21. Reassemble clutch pack assembly.
20. Add oil to plates and disks.
Continued on next page MH66O88,0000980 1920AUG0816/23