John Deere 544E 544E LL 544E TC 624E 644E Loaders Repair Technical Manual TM1414

[Martin Welker]

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John Deere 544E 544E LL 544E TC 624E 644E Loaders Repair Technical Manual TM1414
Size: 26.90 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Loaders
Type of Manual: Repair Technical Manual
Model: John Deere 544E 544E LL 544E TC 624E 644E Loaders
Part Number: TM1414
Number of Pages: 1139 Pages

Contents:
0 GENERAL
544E LL Specifications 1
624E Specifications 1
644E Specifications 1
624E Specifications 2
644E Specifications 2
544E Drain And Refill Capacities
544E LL Drain And Refill Capacities
544E LL Specifications
544E Specifications
544E TC Drain And Refill Capacities
544E TC Specifications
624E Drain And Refill Capacities
644E Drain And Refill Capacities
Additional Metric Cap Screw Torque Values
Check Oil Lines And Fittings
Fuel Specifications
Install Counterweight Drawbar
ROPS Torque Specifications
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Flat Face O-Ring Seal Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations for O-Ring Boss Fittings
1 WHEELS
544E And 544E TC
544E LL
624E
644E
Install Tire
Remove Tire
Specifications
3 SUSPENSION
DISASSEMBLE INSPECT And ASSEBLY DOUBLE UNIVERSAL JOINT
INSTALL REAR AXLE And DIFFERENTIAL ASSEMBLY
OTHER MATERIAL
OTHER MATERIAL1
REMOVE And INSTALL FRONT AXLE And DIFFERENTIAL
REMOVE DISASSEMBLE ASSEMBLE And INSTALL DIFFERENTIAL LOCK SOLENOID VALVE
REMOVE DISASSEMBLY ASSEMBLE And INSTALL REAR DIFFERENTAIL DRIVE LINE
REMOVE REAR AXLE And DIFFERENTIAL
SPECIFICATION
SPECIFICATION1
4 TRANSMISSION
Disassemble And Assemble Clutch Packs 1
Disassemble And Assemble Cover Plate 1
Disassemble And Assemble Pressure Regulating Valve, Pilot Valve, And Modulation Piston 1
Install Second And Reverse, First And Forward Gear Clutch Packs 1
Install Third And Fourth Gear Clutch Pack, Adjust End Play 1
Install Transmission Control Valve 1
Remove And Install Forward And First Drive Gears 1
Remove And Install Fourth Gear Idler Gear-544E, 544E LL, 544E TC 1
Remove And Install Output Flange And Park Brake 1
Remove And Install Output Gear And Oil Shields 1
Remove And Install Output Shaft And Seals 1
Remove And Install Reverse And Second Drive Gears 1
Remove And Install Third And Fourth Drive Gears 1
Remove Oil Supply Flange And Oil Pump 1
Remove Transmission Control Valve 1
Disassemble And Assemble Clutch Packs 2
Disassemble And Assemble Cover Plate 2
Disassemble And Assemble Pressure Regulating Valve, Pilot Valve, And Modulation Piston 2
Disassemble Oil Supply Flange 2
Install Transmission Control Valve 2
Remove And Install Forward And First Drive Gears 2
Remove And Install Output Flange And Park Brake 2
Remove And Install Output Gear And Oil Shields 2
Remove And Install Reverse And Second Drive Gears 2
Remove And Install Third And Fourth Drive Gears 2
Remove Oil Supply Flange And Oil Pump 2
Remove Transmission Control Valve 2
Remove, Disassemble, Assemble And Install Thermal Bypass Valve 2
Disassemble And Assemble Clutch Packs 3
Disassemble Oil Supply Flange 4
Install Third And Fourth Gear Clutch Pack, Adjust End Play 9
Remove And Install Output Shaft And Seals 9
Remove And Install Output Shaft And Seals 14
Install Third And Fourth Gear Clutch Pack, Adjust End Play 15
Install Second And Reverse, First And Forward Gear Clutch Packs 18
Install Third And Fourth Gear Clutch Pack, Adjust End Play 18
Install Second And Reverse, First And Forward Gear Clutch Packs 19
Remove And Install Output Shaft And Seals 27
Assemble Oil Pump
Assemble Oil Supply Flange
Assemble Transmission Control Valve
Clutch Packs
Cross Section Of Thermal Bypass Valve
DISASSEMBLE And ASSEMBLE TRANSMISSION CONTROL LINKAGE
Disassemble Oil Pump
Disassemble Oil Supply Flange
Disassemble Transmission Control Valve
ESSENTIAL TOOLS
ESSENTIAL TOOLS1
Fourth Gear Idler Orifice Sizes
INSTALL REPAIR STAnd
Install Oil Pump On Oil Supply Flange
Install Oil Supply Flange And Oil Pump
Install Second And Reverse, First And Forward Gear Clutch Packs
OTHER MATERIAL
OTHER MATERIAL1
REMOVE And INSTALL TORQUE CONVERTER
REMOVE And INSTALL TRANSMISSION
REMOVE CLUTCH PACKS
Remove And Install Converter Minimum Pressure Regulator
Remove And Install Fourth Gear Idler Gear-544E, 544E LL, 544E TC
Remove And Install Fourth Gear Idler Gear-624E, 644E
Remove And Install Main Hydraulic Filter
Remove And Install Suction Oil Strainer
Remove And Install Transmission Oil Filter
Remove, Disassemble, Assemble And Install Thermal Bypass Valve
SERVICE EQUIPMENT And TOOLS
SPECIFICATIONS
SPECIFICATIONS1
SPECIFICATIONS2
Specifications Hydraulics
TRANSMISSION DIRECTION SELECTOR LINKAGE ADJUSTMENT
TRANSMISSION DRIVE SHAFT
TRANSMISSION SPEED SELECTOR LINKAGE ADJUSTMENT
5 ENGINE
Engine Speed Control Linkage Adjustment 1
Fuel Shut-Off Cable Adjustment-644E 1
Remove And Install Engine Coolant Heater 1
Remove And Install Fan Drive-644E 1
Remove And Install Fuel Tank-544E, 624E And 644E (Serial No. 537537-) 1
Remove And Install Fuel Tank-644E (Serial No. -537536) 1
Engine Speed Control Linkage Adjustment 2
Fuel Shut-Off Cable Adjustment-644E 2
Remove And Install Engine Coolant Heater 2
Remove And Install Fan Drive-644E 2
Remove And Install Fuel Tank-544E, 624E And 644E (Serial No. 537537-) 2
Remove And Install Fuel Tank-644E (Serial No. -537536) 2
Remove And Install Starting Aid Solenoid And Nozzle 2
Bleed Fuel System-544E, 624E
Bleed Fuel System-644E
Disassemble And Assemble Water Separator
Disconnect Turbocharger Oil Inlet Line
Inspect And Clean Cylinder Head Nozzle Bore-644E
Inspect And Clean Nozzle Seating Surface-644E
Install Fuel Injection Nozzle-644E
Install Fuel Injection Pump-544E, 624E (DB4-Retained Shaft)
Install Fuel Injection Pump-644E
Remove And Install Air Filter Elements-544E, 624E
Remove And Install Air Filter Elements-644E
Remove And Install Compressor Belt (If Equipped) And Fan Belts
Remove And Install DB2 Fuel Injection Pump Drive Shaft-544E, 624E
Remove And Install Engine
Remove And Install Fan
Remove And Install Fuel Filter Check Valve-644E
Remove And Install Fuel Injection Nozzle-544E, 624E
Remove And Install Fuel Injection Pump-544E, 624E (DB2-Non-Retained Shaft)
Remove And Install Oil Cooler
Remove And Install Oil Pan
Remove And Install Radiator
Remove And Install Starting Aid Solenoid And Nozzle
Remove And Install Turbocharger
Remove And Install Water Pump-544E, 624E
Remove And Install Water Pump-644E
Remove And Install Water Separator
Remove Fuel Injection Nozzle-644E
Remove Fuel Injection Pump-544E, 624E (DB4-Retained Shaft)
Remove Fuel Injection Pump-644E
Specifications
Specifications Cooling
Specifications Fuel supply
Test Air Intake System For Leaks
Tighten Air Cleaner Hose Clamps
6 DAMPENER DRIVE
Disassemble And Assemble Secondary Steering Inlet Manifold
Remove And Install Dampener
Remove And Install Secondary Steering Inlet Manifold
Remove And Install Secondary Steering Pump, Motor, And Relay
7 STEERING
Cross Section Of Priority Valve 1
Cross Section Of Steering Cylinder 1
Disassemble And Assemble Priority Valve 1
Disassemble Steering Cylinder 1
Remove And Install Crossover Relief Valve 1
Remove, Disassemble, Assemble And Install Steering Column 1
Assemble Steering Cylinder 2
Cross Section Of Priority Valve 2
Cross Section Of Steering Cylinder 2
Disassemble And Assemble Priority Valve 2
Disassemble And Assemble Steering Accumulator-644E Later Machines 2
Remove And Install Steering Accumulator-644E Later Machines 2
Disassemble Steering Cylinder 9
Assemble Steering Cylinder 10
Disassemble Steering Cylinder 10
Assemble Steering Cylinder
Charge Steering Accumulator-644E Later Machines
Cross Section Of Crossover Relief Valve
Cross Section Of Steering Valve
Disassemble And Assemble Crossover Relief Valve
Disassemble And Assemble Steering Accumulator-644E Later Machines
Remove And Install Priority Valve
Remove And Install Steering Accumulator-644E Later Machines
Remove And Install Steering Cylinder Bushings
Remove And Install Steering Cylinders
Remove And Install Steering Valve
Remove, Disassemble, Assemble And Install Steering Column
Specifications Brakes
8 BRAKES
Disassemble And Assemble Brake Accumulators 1
Disassemble And Assemble Compensator Valve 1
Disassemble And Assemble Park Brake 1
Disassemble Brake Pump 1
Remove And Install Brake Assembly 1
Assemble Brake Pump 2
Disassemble And Assemble Brake Accumulators 2
Disassemble And Assemble Compensator Valve 2
Disassemble Brake Pump 2
Hydraulic Brake Bleeding Procedure 2
Remove And Install Park Brake 2
Remove And Install Brake Valve 3
Adjust Park Brake Linkage
Assemble Brake Pump
Brake Valve Identification
Charge Brake Accumulator
Disassemble And Assemble Brake Valve
Disassemble And Assemble Park Brake
Disassemble Brake Pump
Hydraulic Brake Bleeding Procedure
Inspect Brake Elements
Inspect Brake Pump Parts
Inspect Brakes
Remove And Install Brake Accumulators
Remove And Install Brake Assembly
Remove And Install Brake Pump
Remove And Install Brake Valve
Remove And Install Park Brake
Remove And Install Park Brake Linkage
Specifications
Specifications Brake Hydraulics
9 ELECTRICAL
Boom Height Kickout Adjustment
Clutch Cut-Off Switch Adjustment
Install DEUTSCH ™ Contact
Install WEATHER PACK ™ Contact
John Deere Alternators And Starter Motors Component Technical Manual CTM77
Remove And Install Alternator (Except BOSCH) 130AMP
Remove And Install Alternator (Except BOSCH) 65AMP
Remove And Install Alternator (Except BOSCH) 90AMP
Remove And Install BOSCH Alternator
Remove And Install Batteries
Remove And Install Brake Low Pressure Switch
Remove And Install Lights
Remove And Install Starting Motor
Remove Blade Terminals From Fuse Block
Remove Connector Body From Blade Terminals
Replace DEUTSCH ™ Connectors
Replace WEATHER PACK ™ Connector
Return-To-Dig Adjustment
10 FRAME
Remove And Install Lower Pivot Bushing And Seals 1
Remove And Install Upper Pivot Bearing And Seals 1
Remove And Install Upper Pivot Bearing And Seals 2
Remove And Install Counterweights
Remove And Install Lower Pivot Bushing And Seals
Remove And Install Upper Pivot Bearing And Seals
Separate Engine And Loader Frame
Welding Repair Of Major Structure
11 OPERATORS STATION
Adjust Front Windshield Wiper 1
Adjust Front Windshield Wiper 2
Disassemble And Assemble Seat
Remove And Install Cab Or Canopy
Remove And Install Defroster Fan
Remove And Install Windowpane And Molding
Remove And Install Windshield Washer
Remove, Disassemble, Assemble And Install Front Windshield Wiper
Remove, Disassemble, Assemble And Install Rear Windshield Wiper
Tilt Cab Or Canopy
12 HVAC
Remove And Install Condenser 1
Remove And Install Heater Core 1
Remove And Install Condenser 2
Assemble compressor
Charge R12 System
Check And Add Compressor Oil
Clutch Pulley, Bearing And Hub Inspection
Disassemble And Assemble Blower Motor
Disassemble And Inspect Compressor
Evacuate R12 System
Expansion Valve Bench Test And Adjustment
Make Shaft Seal Leak Test
Remove And Install Blower Wiring Harness
Remove And Install Cab Heater Hoses And Controls
Remove And Install Compressor And High Pressure Switch
Remove And Install Condenser Fan Motors
Remove And Install Evaporator And Expansion Valve
Remove And Install Receiver Dryer And Low Pressure Switch
Replace Shaft Seal Seat
Replacing Clutch Pulley Bearing
Specifications
Thermostat Switch Bench Test
Volumetric Efficiency Test-R12
13 LOADER
Assemble Boom Or Bucket Cylinder 1
Assemble Pin Disconnect Cylinder-544E TC 1
Cross Section Of Single Lever Pilot Controller (Serial No. -537112) 1
Disassemble And Assemble Bucket Tilt Linkage-544E TC And 544E LL 1
Remove And Install Boom Bushings And Shims-544E TC And 544E LL 1
Remove And Install Boom Bushings And Shims-544E, 624E, And 644E 1
Remove And Install Bucket Linkage Seals And Bushings-544E, 624E, And 644E 1
Remove And Install Bucket Tilt Linkage-544E, 624E, And 644E 1
Assemble Boom Or Bucket Cylinder 2
Cross Section Of Single Lever Pilot Controller (Serial No. -537112) 2
Disassemble And Assemble Bucket Tilt Linkage-544E TC And 544E LL 2
Disassemble Pin Disconnect Cylinder-544E TC 2
Remove And Install Boom Bushings And Shims-544E TC And 544E LL 2
Remove And Install Bucket Linkage Seals And Bushings-544E, 624E, And 644E 2
Remove And Install Bucket Tilt Linkage-544E, 624E, And 644E 2
Assemble Pin Disconnect Cylinder-544E TC 3
Assemble Pin Disconnect Cylinder-544E TC
Assemble Single Lever Controller (Serial No. 537113-)
Assemble Single Lever Pilot Controller (Serial No. -537112)
Cross Section Of Pin Disconnect Cylinder-544E TC
Disassamble And Assemble Pin Disconnect Solenoid Valve-544E TC
Disassemble And Assemble Anti-Cavitation Valve
Disassemble And Assemble Auxiliary Valve Section-All Machines; And Bucket Section-544E, 624E, And 644E
Disassemble And Assemble Boom Valve Section-All Machines; And Bucket Valve Section-544E TC And 544E LL
Disassemble And Assemble Loader Control Valve-(Serial No. -534614)
Disassemble And Assemble Loader Control Valve-(Serial No. 534615-)
Disassemble And Assemble Pilot Control Valve (Two-Lever Controller)
Disassemble And Assemble Screw Adjustable Circuit Relief Valve
Disassemble And Assemble Shim Adjustable Circuit Relief Valve
Disassemble And Assemble System Relief Valve
Disassemble And Assemble Tool Carrier-544E TC
Disassemble Pin Disconnect Cylinder-544E TC
Disassemble Single Lever Pilot Controller (Serial No. -537112)
Disassemble Single Lever Pilot Controller (Serial No. 537113-)
Disassemble, Inspect And Assemble Main Hydraulic Pump
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
Remove And Install Boom Bushings And Shims-544E, 624E, And 644E
Remove And Install Boom Cylinder
Remove And Install Bucket
Remove And Install Bucket Cylinder
Remove And Install Bucket Or Boom Cylinder Bushings And Seals
Remove And Install Bucket Tooth Shanks And Tips
Remove And Install Cutting Edges (For Bucket With Wear Plates)
Remove And Install Hydraulic Reservoir
Remove And Install Loader Control Valve
Remove And Install Main Hydraulic Pump
Remove And Install Pilot Control Valves (Two Lever Controller)
Remove And Install Pilot Controller (Single Lever Controller)
Remove And Install Pin Disconnect Cylinders-544E TC
Remove, Disassemble, Assemble And Install Boom Solenoid Valve
Remove, Disassemble, Assemble And Install Pressure Reducing Valve
Repair Cracked Cutting Edge
Replace Welded Bucket Cutting Edges
Service Bucket And Boom Section Pilot Orifice Check Valve-Later Machines Only
Specifications Hydraulics