John Deere 444JR Forklift 4WD Loader Workshop Repair Service Manual TM11203 PDF - MJODTM11203.zip
Full-service repair guide covering the John Deere Forklift 444JR (SN. 620388-), packed with every detail garages need to service, fix, and overhaul equipment at an expert level.
The John Deere 444JR Forklift Truck workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM11203 - John Deere Forklift 444JR Technical Manual - Repair.PDF
TM11203 - John Deere Forklift 444JR Technical Manual - Repair.EPUB
Total Pages: 714 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety Information
Wheels
Powered Wheels and Fasteners
Axles and Suspension Systems
Removal and Installation
Axle Shafts and U-Joints
Axle Shaft, Bearings, Reduction Gears
Hydraulic System
Transmission
Removal and Installation
Gears, Shafts, Bearings and Power Shift Clutch
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary Systems
Cold Weather Starting Aids
Cooling System
Intake System
External Exhaust System
External Fuel Supply Systems
Dampener Drive
Elements
Steering System
Hydraulic System
Service Brakes
Active Elements
Hydraulic System
Park Brake
Active Elements
Hydraulic System
Frame or Supporting Structure
Frame Installation
Frame Bottom Guards
Chassis Weights
Operator’s Station
Removal and Installation
Operator Enclosure
Heating and Air Conditioning
Sheet Metal and Styling
Hood or Engine Enclosure
Forklifts
Removal and Installation
Forks
Masts
Hydraulic System
Dealer Fabricated Tools
tm11203 - 444JR Forklift(S.N. 620388— )
Table of Contents
Foreword
Technical Information Feedback Form
Section 00: General Information
Group 0001: Safety Information
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding For Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator's Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Use Special Care When Operating Forklift
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over
Operating on Slopes
Operating or Traveling On Public Roads
Drive Machine Safely
Inspect and Maintain ROPS
Add and Operate Attachments Safely
Park And Prepare For Service Safely
Service Tires Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Group 0003: Torque Values
Metric Bolt and Cap Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and Cap Screw Torque Values
Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Service Recommendations for O-Ring Boss Fittings
O-Ring Boss Fittings in Aluminum Housing Service Recommendations—Excavators
Service Recommendations for Flared Connections—Straight or Tapered Threads
Service Recommendations for Flat Face O-Ring Seal Fittings
O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings
Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
Service Recommendations For O-Ring Boss Fittings With Shoulder
Metric 24° O-Ring Seal DIN 20078 Service Recommendations
Section 01: Wheels
Group 0110: Powered Wheels and Fasteners
Wheel Remove and Install
Tire Remove
Tire Install
Section 02: Axles and Suspension Systems
Group 0200: Removal and Installation
Front Axle and Differential Remove and Install
Rear Axle and Differential Remove
Rear Axle and Differential Install
Axle Oscillating Supports Disassemble and Assemble
Group 0225: Axle Shafts and U-Joints
Universal Joint and Drive Shaft Remove and Install
Group 0250: Axle Shaft, Bearings, Reduction Gears
Axle Planetary Pinion/Service Brake Housing Disassemble and Assemble
Differential Disassemble
Differential Assemble
Group 0260: Hydraulic System
Differential Lock Solenoid Valve Remove and Install
Section 03: Transmission
Group 0300: Removal and Installation
Transmission Remove and Install
Group 0350: Gears, Shafts, Bearings and Power Shift Clutch
Torque Converter And Housing Remove
Torque Converter and Housing Install
Clutches, Input and Output Shafts Remove
Clutches, Input and Output Shafts Install
Clutch Pack KV and KR Disassemble
Clutch Pack KV and KR Assemble
Input Shaft Disassemble
Input Shaft Assemble
Group 0360: Hydraulic System
Transmission Pump Remove and Install
Converter Minimum Pressure Regulator Valve Remove and Install
Transmission Control Valve Remove and Install
Transmission Control Valve Cross Section View
Transmission Control Valve Disassemble and Assemble
Torque Converter Relief Valve Remove, Disassemble and Install
Transmission Internal Oil Pipes and Tubes Remove and Install
Section 04: Engine
Group 0400: Removal and Installation
PowerTech™ 4.5 L John Deere Engine
Serpentine Belt Remove and Install
Engine Remove and Install
Section 05: Engine Auxiliary Systems
Group 0505: Cold Weather Starting Aids
Starting Aid Nozzle Remove and Install
Start Aid Solenoid Remove and Install
Engine Coolant Heater Remove and Install
Group 0510: Cooling System
Intercooler Remove and Install
Radiator Remove and Install
Hydraulic Oil Cooler Remove and Install
Transmission Oil Cooler Remove and Install
Cooling Package Plenum Remove and Install
Group 0520: Intake System
Air Cleaner Remove and Install
Element Inspect
Group 0530: External Exhaust System
Muffler Remove and Install
Group 0560: External Fuel Supply Systems
Fuel Tank Remove and Install
Primary Fuel Filter (Water Separator) Remove and Install
Section 07: Dampener Drive
Group 0752: Elements
Output Dampener Remove and Install
Section 09: Steering System
Group 0960: Hydraulic System
Steering Valve Remove and Install
Steering Column Remove and Install
Steering Column Disassemble and Assemble
Steering Cylinders Remove and Install
Secondary Steering Valve Remove and Install
Secondary Steering Pump Remove and Install
Forklift Start-Up Procedure (Steering Cylinder)
Section 10: Service Brakes
Group 1011: Active Elements
Service Brake Assembly Remove and Install
Brake Pedal and Linkage Disassemble and Assemble
Service Brake Bleeding Procedure
Group 1060: Hydraulic System
Brake Valve Remove and Install
Brake Accumulator Remove and Install
Section 11: Park Brake
Group 1111: Active Elements
Park Brake Remove and Install
Park Brake Disassemble and Assemble
Group 1160: Hydraulic System
Park Brake Release Solenoid Valve Remove and Install
Section 17: Frame or Supporting Structure
Group 1740: Frame Installation
Welding Major Structure
Engine and Loader Frame Separate
Remove and Install Upper Pivot Bearing and Seals
Remove and Install Lower Pivot Bearing and Seals
Jib Boom Remove and Install
Group 1746: Frame Bottom Guards
Front Axle Guard Remove and Install
Transmission Bottom Guard Remove and Install
Group 1749: Chassis Weights
Counterweight Remove and Install
Section 18: Operator’s Station
Group 1800: Removal and Installation
Full Cab Remove and Install
Upper Half Cab Remove and Install
Group 1810: Operator Enclosure
Windowpanes Remove and Install
Cab Door Hold-Open Release Adjust
Front and Rear Windshield Wiper Motor Remove and Install
Group 1830: Heating and Air Conditioning
Air Conditioning System Fittings Reference Chart
R134a Refrigerant Cautions
R134a Compressor Oil Charge Check
R134a Compressor Oil Removal
R134a Component Oil Charge
Leak Testing
Refrigerant Hoses and Tubing Inspection
R134a Refrigerant, Recovery, Recycling and Charging Station Installation Procedure
R134a System Recover
R134a System Evacuate
R134a System Charge
Air Conditioner System Cleaning Procedures
Air Conditioner System Purge
Air Conditioner System Flush
Air Conditioning Module With Heater/Evaporator Coil
Heater/Evaporator Coil Remove and Install
Expansion Valve Remove and Install
Freeze Control Switch Remove and Install
Freeze Control Switch Bench Test
Heater Control Valve Remove and Install
Heater Control Valve Leak Check
Main Blower Assembly Remove and Install
Pressurizer Motor Assembly Remove and Install
Receiver-Dryer and Condenser Remove and Install
A/C Binary Pressure Switch Remove and Install
Fresh Air Filter Remove and Install
Recirculating Air Filter Remove and Install
Compressor Remove and Install
Compressor Clutch—R134a Disassemble and Assemble
Clutch Hub Clearance—R134a Check
Section 19: Sheet Metal and Styling
Group 1910: Hood or Engine Enclosure
Hood Remove and Install
Engine Side Shields Remove and Install
Section 45: Forklifts
Group 4500: Removal and Installation
Mast Remove and Install
Mast Lift Cylinder Bleed Procedure
Carriage Lift Cylinder Bleed Procedure
Group 4503: Forks
Forks Remove and Install
Group 4512: Masts
Carriage Remove and Install
Carriage Rollers Remove and Install
Mast Rollers Remove and Install
Mast Disassemble and Assemble
Mast Lift Chains Remove and Install
Carriage Lift Chains Remove and Install
Mast Height Adjust
Carriage Height Adjust
Mast Lift Chain Sheaves Remove and Install
Carriage Lift Chain Sheaves Remove and Install
Carriage Thrust Pad Adjust
Group 4560: Hydraulic System
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Hydraulic Pump Remove and Install
Hydraulic Pump Disassemble and Assemble
Forklift Control Valve Remove and Install
Forklift Control Valve Disassemble and Assemble
Lift Valve, Tilt Valve, and Fork Shift Valve Section Disassemble and Assemble
Inlet Valve Section Disassemble and Assemble
Outlet Valve Section Disassemble and Assemble
Relief Valve Disassemble and Assemble
Load Sense Relief Valve Disassemble and Assemble
Circuit Relief With Anticavitation Valve Disassemble and Assemble
Mast Lift Cylinder Remove and Install