John Deere 544G 544G LL 544G TC 624G 644G Loader Technical Manual TM1530

[Martin Welker]

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John Deere 544G 544G LL 544G TC 624G 644G Loader Technical Manual TM1530
Size: 127.88 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Loader
Type of Manual: Technical Manual
Model: John Deere 544G 544G LL 544G TC 624G 644G Loader
Part Number: TM1530
Publication Date: 2018
Number of Pages: 3930 Pages

Contents:
1 Wheels
544G And 544G TC
544G LL
624G
644G
Install Tire
Remove Tire
Specifications
2 Axles And Suspension Systems
Install Rear Axle And Differential Assembly 1
Remove And Install Rear Differential Drive Line 1
Disassemble, Inspect, And Assemble Support Bearing And Drive Shaft 2
Install Rear Axle And Differential Assembly 2
Remove And Install Rear Differential Drive Line 2
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Disassemble, Inspect, And Assemble Support Bearing And Drive Shaft
Remove And Install Differential Lock Solenoid Valve
Remove And Install Front Axle And Differential
Remove Rear Axle And Differential
3 Transmission
Control Valve W6th Solenoid-544G (SN 548219-), 624G (SN 54839, 644G (SN 548303-) 1
Cross Section Of Thermal Bypass Valve 1
Disassemble And Assemble Clutch Packs 1
Disassemble And Assemble Thermal Bypass Valve 1
Install Fourth Gear Idler Gear-544G, 544G LL, 544G TC 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 Converter Minimum Pressure Regulator 1
Remove And Install Forward And First Drive Gears 1
Remove And Install Output Flange 1
Remove And Install Reverse And Second Drive Gears 1
Remove And Install Third And Fourth Drive Gears 1
Remove And Install Torque Converter 1
Remove And Install Transmission 1
Remove And Install Transmission Shift Lever 1
Remove Clutch Packs 1
Remove, Disassemble, Assemble And Install Transmission Drive Shaft 1
Install Fourth Gear Idler Gear-544G, 544G LL, 544G TC 2
Install Second And Reverse, First And Forward Gear Clutch Packs 2
Install Transmission Control Valve 2
Remove And Install Converter Minimum Pressure Regulator 2
Remove And Install Forward And First Drive Gears 2
Remove And Install Output Flange 2
Remove And Install Output Gear And Oil Shields 2
Remove And Install Output Shaft And Seals 2
Remove And Install Reverse And Second Drive Gears 2
Remove And Install Third And Fourth Drive Gears 2
Remove And Install Transmission 2
Remove And Install Transmission Shift Lever 2
Remove Oil Supply Flange And Oil Pump 2
Remove, Disassemble, Assemble And Install Transmission Drive Shaft 2
Remove And Install Transmission 3
Disassemble And Assemble Clutch Packs 4
Remove Clutch Packs 6
Install Third And Fourth Gear Clutch Pack, Adjust End Play 8
Remove Clutch Packs 8
Install Third And Fourth Gear Clutch Pack, Adjust End Play 15
Install Third And Fourth Gear Clutch Pack, Adjust End Play 17
Disassemble And Assemble Clutch Packs 20
Disassemble And Assemble Clutch Packs 27
Assemble Oil Pump
Assemble Oil Supply Flange
Clutch Packs
Disassemble And Assemble Clutch Packs
Disassemble And Assemble Thermal Bypass Valve
Disassemble Oil Pump
Install Oil Pump On Oil Supply Flange
Install Oil Supply Flange And Oil Pump
Install Third And Fourth Gear Clutch Pack, Adjust End Play
Remove And Install Fourth Gear Idler Gear-624G, 644G
Remove And Install Output Gear And Oil Shields
Remove And Install Output Shaft And Seals
Remove And Install Speed Control Magnetic Pickup
Remove And Install Suction Oil Strainer
Remove And Install Torque Converter
Remove And Install Transmission Oil Filter
Remove Clutch Packs
Remove Clutch Packs 6.1
Remove Oil Supply Flange And Oil Pump
Remove Transmission Control Valve
Specifications
4 Engine
Bleed Fuel System-544G, 624G 1
Bleed Fuel System-644G 1
Fuel Shut-Off Solenoid Adjustment-644G 1
Remove And Install Fan Drive-644G 1
Tighten Air Cleaner Hose Clamps 1
Bleed Fuel System-644G 2
Remove And Install Fuel Shut-Off Solenoid-644G 2
Remove And Install Fuel Tank 2
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Bleed Fuel System-544G, 624G
Bleed Fuel System-644G
Disassemble And Assemble Primary Filter (Water Separator)
Fuel Shut-Off Solenoid Adjustment-644G
Install Fuel Injection Pump-544G, 624G
Install Fuel Injection Pump-644G
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Remove And Install Air Filter Elements-644G
Remove And Install Compressor Belt (If Equipped) And Fan Belts - 544G, 624G, 644G (SN -557738)
Remove And Install Coolant Level Sensor
Remove And Install Dampener
Remove And Install Engine
Remove And Install Fan
Remove And Install Fuel Filter Check Valve-644G
Remove And Install Fuel Shut-Off Solenoid-644G
Remove And Install Fuel Tank
Remove And Install Oil Cooler
Remove And Install Oil Pan
Remove And Install Primary Filter (Water Separator)
Remove And Install Radiator
Remove And Install Serpentine Belt - 644G (SN 557739-)
Remove And Install Starting Aid Solenoid And Nozzle
Remove And Install Turbocharger
Remove And Install Water Pump-544G, 624G
Remove And Install Water Pump-644G
Remove Fuel Injection Pump-544G, 624G
Remove Fuel Injection Pump-644G
Specifications
Speed Control Linkage Adjustment
Test Air Intake System For Leaks
5 Steering
Assemble Steering Cylinder
Cross Section Of Priority Valve
Cross Section Of Steering Cylinder
Cross Section Of Steering Valve
Disassemble And Assemble Priority Valve
Disassemble And Assemble Secondary Steering Inlet Manifold (If Equipped)
Disassemble Steering Cylinder
Remove And Install Priority Valve
Remove And Install Secondary Steering Inlet Manifold (If Equipped)
Remove And Install Secondary Steering Pump, Motor And Relay (If Equipped)
Remove And Install Steering Column
Remove And Install Steering Cylinder Bushings
Remove And Install Steering Cylinders
Remove And Install Steering Valve
6 Brakes
Adjust Park Brake 1
Disassemble And Assemble Park Brake 1
Remove And Install Brake Assembly 1
Remove And Install Brake Assembly 2
Assemble Brake Pump
Disassemble And Assemble Brake Pump Pressure Compensator
Disassemble And Assemble Brake Valve
Disassemble Brake Pump
Hydraulic Brake Bleeding Procedure
Inspecting Service Brake Pads
Install Counterweight Drawbar
Remove And Install Brake Accumulator
Remove And Install Brake Pump
Remove And Install Brake Valve
Remove And Install Park Brake Pads
Remove And Install Park Brake Pressure Switch
Remove And Install Park Brake Release Solenoid Valve
Remove And Install Pressure Reducing Valve Manifold
7 Electrical System
Boom Height Kickout Adjustment 1
Clutch Cut-Off Switch Adjustment
Install DEUTSCH™ Contact
Install WEATHER PACK™ Contact
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Remove And Install Air Filter Restriction Switch
Remove And Install Alternator
Remove And Install Batteries
Remove And Install Battery Disconnect Switch
Remove And Install Brake Light Switch
Remove And Install Brake Low Pressure Switch
Remove And Install Engine Coolant Level Switch
Remove And Install Engine Oil Pressure Switch
Remove And Install Hydraulic Oil Filter Restriction Switch
Remove And Install Lights
Remove And Install Starting Motor
Remove And Install Transmission Oil Pressure Switch
Replace DEUTSCH™ Connectors
Replace Halogen Bulbs
Replace WEATHER PACK™ Connector
Return to Dig Adjustment
8 Frame
Remove And Install Counterweights
Remove And Install Lower Pivot Bearing And Seals
Remove And Install Upper Pivot Bearing And Seals
Separate Engine And Loader Frame
9 Operators Station
Remove And Install Defroster Fan-(SN 545145-) 1
Remove, Disassemble, Assemble And Install Rear Windshield Wiper 1
Adjust Front Windshield Wiper
Disassemble And Assemble Seat Belt
Remove And Install Cab Or Canopy
Remove And Install Defroster Fan-(SN -545144)
Remove And Install Windowpane And Molding
Remove And Install Windshield Washer
Remove, Disassemble, Assemble And Install Front Windshield Wiper
Specifications
10 Hvac
Remove And Install Condenser 1
Remove And Install Condenser 2
Assemble Compressor
Check And Adjust Compressor Belt Tension - 544G, 624G, 644G (SN -557738)
Clutch Pulley, Bearing And Hub Inspection
Disassemble And Assemble Blower Motor
Disassemble And Inspect Compressor
Freeze Control Temperature Cycling Switch Bench Test
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 Heater Core
Remove And Install Receiver Dryer And Low Pressure Switch
Replace Clutch Pulley Bearing
Replace Shaft Seal Seat
Shaft Seal Leak Test
Volumetric Efficiency Test-R12
11 Loader
Disassemble And Assemble Pilot Control Valve (Two-Lever Controller) 1
Disassemble And Assemble Valve (Single Lever Controller) - 644G (SN 563543-) 1
Disassemble And Assemble Pilot Control Valve (Two-Lever Controller) 2
Remove And Install Boom Bushings And Shims-544G, 624G And 644G 2
Assemble Boom Or Bucket Cylinder
Assemble Single Lever Controller - 544G, 624G (SN -563542)
Charge Ride Control Accumulator
Disassemble And Assemble Anti-Cavitation Valve
Disassemble And Assemble Auxiliary Valve (All Units) And Bucket Section (544G, 624G, And 644G)
Disassemble And Assemble Boom Valve (All Units) And Bucket Section (544G TC And 544G LL)
Disassemble And Assemble Bucket Tilt Linkage-544G TC And 544G LL
Disassemble And Assemble Loader Control Valve
Disassemble And Assemble Pilot Control Valve (Two Lever Controller)
Disassemble And Assemble Pin Disconnect Cylinder-544G TC
Disassemble And Assemble Pin Disconnect Solenoid Valve-544G TC
Disassemble And Assemble Ride Control Accumulator
Disassemble And Assemble Ride Control Valve
Disassemble And Assemble Ride Control Valve Solenoid
Disassemble And Assemble Screw Adjustable Circuit Relief Valve
Disassemble And Assemble System Relief Valve
Disassemble And Assemble Tool Carrier-544G TC
Disassemble And Assemble Valve (Single Lever Controller) - 644G (SN 563543-)
Disassemble Single Lever Pilot Controller - 544G, 624G, 644G (SN -563542)
Disassemble, Inspect And Assemble Main Hydraulic Pump
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
Pilot Control Valve Pressure Test (Bench) - 644G (SN 563543- )
Pilot Controller Valve (Single Lever Controller), Cross Section - 644G (SN 563543-)
Remove And Install Boom Bushings And Shims-544G TC And 544G LL
Remove And Install Boom Bushings And Shims-544G, 624G And 644G
Remove And Install Boom Cylinder
Remove And Install Boom Down Solenoid Valve
Remove And Install Bucket
Remove And Install Bucket Cylinder
Remove And Install Bucket Linkage Seals And Bushings-544G, 624G And 644G
Remove And Install Bucket Or Boom Cylinder Bushings And Seals
Remove And Install Bucket Tilt Linkage-544G, 624G And 644G
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) - 544G, 624G, 644G (SN -563542)
Remove And Install Pilot Controller Valve (Single Lever Controller) - 644G (SN 563543-)
Remove And Install Pressure Reducing Valve
Replace Pilot Control Lever Boot (Joystick) - 644G (SN 536543-)
Replace Pilot Control Lever Boot (Single Lever) - 644G (SN 563543- )
Replace Seals On Spool Retainers And Inspect Spool Assembly - 644G (SN 563543-)
Replace Universal Joint - 644G (SN 563543-)
Replacing Quickshift Switch In Controller Lever - 644G (SN 563543-)
Specifications
Specifications Frames