644K 4WD Loader

Engine 6068HDW80 (T3),

6068HDW83 (S2)
Repair
(S.N. —642443)

REPAIR TECHNICAL MANUAL

644K 4WD Loader Engine 6068HDW80
(T3), 6068HDW83 (S2)
TM10695 27JUN19 (ENGLISH)

Worldwide Construction
And Forestry Division
PRINTED IN U.S.A.
Thank you for your visiting. Please Click Here To
Download Complete Manual or Download Other
Similar Manuals. Open the home page then search
manual by keywords.

https://www.servicemanualbit.com
 Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
DX,TMIFC -19-15APR14-1/1

TM10695 (27JUN19) 644K 4WD Loader

062719

PN=2
 Introduction

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

TX1082004A —UN—15APR13
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. PIN Plate Location

Product Serial Number Identification

The product identification number (PIN) plate (1) is located
on left side of machine frame under the cab door. Each
machine has a 13-character PIN (2) or 17-character PIN

TX1081996A —UN—17SEP10
(3) shown on this plate. The last 6 characters of the PIN
represent the machine's product serial number.

1— PIN Plate 3— 17-Character PIN

2— 13-Character PIN

PIN Plate (13-character)

TX1082023 —UN—21SEP10

PIN Plate (17-character)

Continued on next page OUT4001,000069C -19-06JUN12-1/2

TM10695 (27JUN19) 644K 4WD Loader

062719

PN=3
 Introduction

Engine Model Number Identification

TX1082090A —UN—08NOV10
TX1082024 —UN—21SEP10
Engine Serial Number Plate Engine Serial Number Plate Location—6090HDW13
The engine serial number plate (4) is located on the right
side of the engine for engine model 6090HDW13. It
is located on the left side of engine for engine models
6068HDW80 and 6068HDW83. 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 Engine Emissions Level

TX1081900A —UN—15APR13
6090HDW13 Interim Tier 4/Stage III B
6068HDW80 Tier 3/Stage III A
6068HDW83 Stage II

For machines equipped with a 17-character PIN, where

the 11th character is “E”, “D”, or “C”, this character also
corresponds to a specific engine emissions level.
Engine Serial Number Plate Location—6068HDW80
NOTE: Later machines with a 17-character PIN identify
engine emissions level (“E”, “D”, or “C”) with
the 11th character. Earlier machines with a
17-character PIN do not identify engine emissions
level with the 11th character.
17-Character PIN (11th Engine Emissions Level
character)
xxxxxxxxxxExxxxxx Interim Tier 4/Stage III B
xxxxxxxxxxDxxxxxx Tier 3/Stage III A
xxxxxxxxxxCxxxxxx Stage II
TX1081901A —UN—15APR13

4— Engine Serial Number Plate 5— 9-Character Engine Model

Number

Engine Serial Number Plate Location—6068HDW83

OUT4001,000069C -19-06JUN12-2/2

TM10695 (27JUN19) 644K 4WD Loader

062719

PN=4
 Contents
Section 00—General Information
Group 0001—Safety Information Section 18—Operator’s Station
Group 0003—Torque Values Group 1800—Removal and Installation
Group 1810—Operator Enclosure
Section 01—Wheels Group 1821—Seat and Seat Belt
Group 0110—Powered Wheels and Fasteners Group 1830—Heating and Air Conditioning

Section 02—Axles and Suspension Systems Section 19—Sheet Metal and Styling
Group 0200—Removal and Installation Group 1910—Hood or Engine Enclosure
Group 0225—Axle Shafts and U-Joints
Group 0250—Axle Shaft, Bearings, Reduction Gears Section 31—Loader
Group 0260—Hydraulic System Group 3102—Bucket
Group 3140—Frames
Section 03—Transmission Group 3160—Hydraulic System
Group 0300—Removal and Installation
Group 0350—Gears, Shafts, Bearings and Power Shift Section 99—Dealer Fabricated Tools
Clutch Group 9900—Dealer Fabricated Tools
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

Original Instructions. 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.
COPYRIGHT © 2019
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ™ Manual
Previous Editions
Copyright © 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2016, 2017, 2018

TM10695 (27JUN19) i 644K 4WD Loader

062719

PN=1
 Contents

TM10695 (27JUN19) ii 644K 4WD Loader

062719

PN=2
 Section 00
General Information
Contents

Page
Page
Group 0001—Safety Information
Recognize Safety Information ................... 00-0001-1 Service Recommendations for
Follow Safety Instructions.......................... 00-0001-1 37° Flare and 30° Cone Seat
Operate Only If Qualified ........................... 00-0001-1 Connectors ............................................ 00-0003-4
Wear Protective Equipment....................... 00-0001-2 Service Recommendations for
Avoid Unauthorized Machine O-Ring Boss Fittings.............................. 00-0003-4
Modifications.......................................... 00-0001-2 Service Recommendation
Add Cab Guarding For Special O-Ring Boss Fittings In Aluminum HousingExcava-
Uses ...................................................... 00-0001-2 tors.............................................................00-0003-6
Inspect Machine ........................................ 00-0001-3 Service Recommendations for
Stay Clear of Moving Parts........................ 00-0001-3 Flared Connections—Straight or
Avoid High-Pressure Fluids ....................... 00-0001-3 Tapered Threads ................................... 00-0003-7
Avoid High-Pressure Oils .......................... 00-0001-4 Service Recommendations for Flat
Beware of Exhaust Fumes ........................ 00-0001-4 Face O-Ring Seal Fittings ..................... 00-0003-8
Prevent Fires ............................................. 00-0001-5 O-Ring Face Seal Fittings with SAE Inch Hex Nut and
Clean Debris from Machine ....................... 00-0001-5 Stud End for High Pressure.......................00-0003-9
Prevent Battery Explosions ....................... 00-0001-6 O-Ring Face Seal Fittings with Metric Hex Nut and
Handle Chemical Products Safely.............. 00-0001-6 Stud End for Standard Pressure..............00-0003-11
Dispose of Waste Properly ........................ 00-0001-6 O-Ring Face Seal Fittings with Metric Hex Nut and
Prepare for Emergencies........................... 00-0001-7 Stud End for High Pressure.....................00-0003-13
Use Steps and Handholds Service Recommendations for
Correctly ................................................ 00-0001-7 Metric Series Four Bolt Flange
Start Only From Operator's Seat ............... 00-0001-7 Fitting................................................... 00-0003-15
Use and Maintain Seat Belt ....................... 00-0001-7 Service Recommendations For
Prevent Unintended Machine Inch Series Four Bolt Flange
Movement.............................................. 00-0001-8 Fittings ................................................. 00-0003-16
Avoid Work Site Hazards........................... 00-0001-9 Inch Series Four Bolt Flange For High
Use Special Care When Operating Pressure ..................................................00-0003-17
Loader ................................................. 00-0001-10 Service Recommendations
Keep Riders Off Machine ........................ 00-0001-10 For Non-Restricted Banjo
Avoid Backover Accidents ....................... 00-0001-10 (Adjustable) Fittings............................. 00-0003-18
Avoid Machine Tip Over .......................... 00-0001-11 Service Recommendations For
Operating on Slopes................................ 00-0001-11 O-Ring Boss Fittings With
Operating or Traveling On Public Shoulder .............................................. 00-0003-19
Roads .................................................. 00-0001-12 Metric 24 O-Ring Seal DIN 20078.......00-0003-21
Inspect and Maintain ROPS .................... 00-0001-12
Add and Operate Attachments
Safely................................................... 00-0001-12
Park And Prepare For Service
Safely................................................... 00-0001-13
Service Cooling System Safely ............... 00-0001-13
Service Tires Safely................................. 00-0001-14
Remove Paint Before Welding or
Heating ................................................ 00-0001-14
Make Welding Repairs Safely ................. 00-0001-15
Drive Metal Pins Safely ........................... 00-0001-15

Group 0003—Torque Values

Torque Value
Metric Bolt and Cap Screw....................00-0003-1
Additional Metric Cap Screw
Torque Values ........................................ 00-0003-2
Unified Inch Bolt and Cap Screw ..........00-0003-3

TM10695 (27JUN19) 00-1 644K 4WD Loader

062719

PN=1
 Contents

TM10695 (27JUN19) 00-2 644K 4WD Loader

062719

PN=2
 Group 0001
Safety Information
Recognize Safety Information
This is the safety alert symbol. When you see this

T133555 —UN—15APR13
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

T133588 —19—28AUG00
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.

TX03679,00016CC -19-03NOV08-1/1

Follow Safety Instructions

Read the safety messages in this manual and on

T133556 —UN—24AUG00
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.
TX03679,00016F9 -19-18OCT07-1/1

Operate Only If Qualified

Do not operate this machine unless you have read the Know and observe all safety rules that may apply to your
operator's manual carefully and you have been qualified work situation and your work site.
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.
TX03679,00016FA -19-03NOV08-1/1

TM10695 (27JUN19) 00-0001-1 644K 4WD Loader

062719

PN=9
 Safety Information

Wear Protective Equipment

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.

TS206 —UN—15APR13
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.

Protective Equipment

TX03679,00016D0 -19-06JAN16-1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere reliability, and may create a hazard for the operator or
replacement parts to ensure machine performance. others near the machine. The installer of any modification
Never substitute genuine John Deere parts with alternate which may affect the electronic controls of this machine is
parts not intended for the application as these can responsible for establishing that the modification does not
create hazardous situations or hazardous performance. adversely affect the machine or its performance.
Non-John Deere Parts, or any damage or failures
resulting from their use, are not covered by any John Always contact an authorized John Deere dealer before
Deere warranty. making machine modifications that change the intended
use, weight, or balance of the machine, or that alter
Modifications of this machine, or addition of unapproved machine controls, performance, or reliability.
products or attachments, may affect machine stability or
AM40430,00000A9 -19-02JUN15-1/1

Add Cab Guarding For Special Uses

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

T141893 —UN—09JUN11
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.
TX03679,00017C6 -19-18OCT07-1/1

TM10695 (27JUN19) 00-0001-2 644K 4WD Loader

062719

PN=10
 Safety Information

Inspect Machine
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

T6607AQ —UN—15APR13
immediately. Pay special attention to hydraulic hoses and
electrical wiring.

TX03679,0001734 -19-03NOV08-1/1

Stay Clear of Moving Parts

T133592 —UN—15APR13
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.
TX03679,00016D2 -19-03NOV08-1/1

Avoid High-Pressure Fluids

Inspect hydraulic hoses periodically – at least once
per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.

X9811 —UN—23AUG88
Replace worn or damaged hose assemblies immediately
with John Deere approved replacement parts.
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.
with this type of injury should reference a knowledgeable
Search for leaks with a piece of cardboard. Protect hands medical source. Such information is available in
and body from high-pressure fluids. English from Deere & Company Medical Department in
Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1
If an accident occurs, see a doctor immediately. Any fluid 309-748-5636.
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
DX,FLUID -19-12OCT11-1/1

TM10695 (27JUN19) 00-0001-3 644K 4WD Loader

062719

PN=11
 Safety Information

Avoid High-Pressure Oils

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.

T133509 —UN—15APR13
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.

T133840 —UN—20SEP00
TX03679,00016D3 -19-03NOV08-1/1

Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.

T133546 —UN—24AUG00
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.

TX03679,00016D4 -19-03NOV08-1/1

TM10695 (27JUN19) 00-0001-4 644K 4WD Loader

062719

PN=12
 Safety Information

Prevent Fires

T133552 —UN—15APR13
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 -19-03NOV08-1/1

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—15APR13
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 -19-20AUG09-1/1

TM10695 (27JUN19) 00-0001-5 644K 4WD Loader

062719

PN=13
 Safety Information

Prevent Battery Explosions

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.

TS204 —UN—15APR13
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).

TX03679,000174A -19-03NOV08-1/1

Handle Chemical Products Safely

Exposure to hazardous chemicals can cause serious

T133580 —UN—25AUG00
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.
TX03679,00016D7 -19-03JAN07-1/1

Dispose of Waste Properly

Improper disposal of waste can threaten the environment.

T133567 —UN—25AUG00
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.
TX03679,0001733 -19-03NOV08-1/1

TM10695 (27JUN19) 00-0001-6 644K 4WD Loader

062719

PN=14
 Safety Information

Prepare for Emergencies

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.

TS291 —UN—15APR13
TX03679,000174B -19-03NOV08-1/1

Use Steps and Handholds Correctly

Prevent falls by facing the machine when getting on and

T133468 —UN—15APR13
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.

TX03679,00016F2 -19-24APR13-1/1

Start Only From Operator's Seat

T133715 —UN—15APR13
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.

TX03679,0001799 -19-22APR10-1/1

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to
fasten seat belt when loading and unloading from trucks T133716 —19—17APR13

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.
TX03679,00016DD -19-03NOV08-1/1

TM10695 (27JUN19) 00-0001-7 644K 4WD Loader

062719

PN=15