Complete Diagnosis and Test manual with Electrical Wiring Diagrams for John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, 644E, with all the shop information to maintain, diagnose, test, and service like professional mechanics.

John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, 644E workshop Diagnostics and Test manual includes:
* 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.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* 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.

TM1413 - John Deere 544E, 544E LL, 544E TC, 624E and 644E 4WD Loader Technical Manual (Operation and Test ).PDF

Total Pages: 1,120 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

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omt131709 English - OPERATORS MANUAL 544E, 544E LL, AND 544E TC LOADERS 624E LOADER 644E LOADER Operator's Manual

MAIN SECTIONS
 Foreword
   General Information
      Safety Information
      General Specifications
      Torque Values
      Fuels And Lubricants
   Wheels
      Powered Wheels And Fastenings
   Axles And Suspension Systems
      Removal And Installation
      Axle Shafts, Bearings And U-Joints
      Hydraulic System
   Transmission
      Removal And Installation
      Controls Linkage
      Input Drive Shafts And U-Joints
      Gear, Shafts, Bearings And Power Shift Clutch
      Hydraulic System
   Engine
      Removal And Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling System
      Speed Controls
      Intake System
      External Fuel Supply System
   Dampener Drive
      Elements
   Steering System
      Secondary Steering
      Hydraulic System
   Service Brakes
      Active Elements
      Hydraulic System
   Park Brake
      Active Elements
      Controls Linkage
   Equipment Attaching
      Drawbar
   Electrical Systems
      Batteries, Support And Cables
      Alternator, Regulator And Charging System Wiring
      Lighting System
      Wiring Harness And Switches
      Motors And Actuators
   Frame Or Supporting Structure
      Frame Installation
      Frame Bottom Guards
      Chassis Weights
   Operator`s Station
      Removal And Installation
      Operator Enclosure
      Seat And Seat Belt
      Heating And Air Conditioning
   Loader
      Bucket
      Frames
      Hydraulic System

TABLE OF CONTENTS
Section 9000: General Information...16
  Group 01: Safety Information...16
    Handle Fluids Safely-Avoid Fires...19
    Prevent Battery Explosions...20
    Prepare for Emergencies...21
    Prevent Acid Burns...22
    Handle Chemical Products Safely...24
    Avoid High-Pressure Fluids...25
    Park Machine Safely...26
    Support Machine Properly...27
    Wear Protective Clothing...28
    Work in Clean Area...29
    Service Machines Safely...30
    Work In Ventilated Area...31
    Illuminate Work Area Safely...32
    Replace Safety Signs...33
    Use Proper Lifting Equipment...34
    Remove Paint Before Welding or Heating...35
    Avoid Heating Near Pressurized Fluid Lines...36
    Keep ROPS Installed Properly...37
    Service Tires Safely...38
    Avoid Harmful Asbestos Dust...39
    Practice Safe Maintenance...40
    Use Proper Tools...41
    Dispose of Waste Properly...42
    Live With Safety...43
  Group 02: General Specifications...16
    544E Specifications...48
    544E Drain And Refill Capacities...52
    544E LL Specifications...53
    544E LL Drain And Refill Capacities...57
    544E TC Specifications...58
    544E TC Drain And Refill Capacities...62
    624E Specifications...63
    624E Drain And Refill Capacities...67
    644E Specifications...68
    644E Drain And Refill Capacities...72
  Group 03: Torque Values...17
    Hardware Torque Specifications...74
    ROPS Torque Specifications...75
    Metric Bolt and Cap Screw Torque Values...76
    Additional Metric Cap Screw Torque Values...77
    Unified Inch Bolt and Cap Screw Torque Values...79
    Check Oil Lines And Fittings...80
    Service Recommendations for O-Ring Boss Fittings...81
    Service Recommendations for Flat Face O-Ring Seal Fittings...83
    Service Recommendations for Metric Series Four Bolt Flange Fitting...85
    Service Recommendations For Inch Series Four Bolt Flange Fittings...87
  Group 04: Fuels And Lubricants...17
    Fuel Specifications...90
    Storing Fuel...91
    Fuel Tank...92
    Engine Oil...93
    Transmission Oil...94
    Hydraulic System Oil...95
    Differential Oil...96
    Grease...97
    Alternative and Synthetic Lubricants...99
    Synthetic Lubricants...99
    Lubricant Storage...100
    Cold Weather Operation...101
    Engine Coolant...102
Section 9005: Operational Checkout Procedure...103
  Group 10: Operational Checkout Procedure...103
    Operational Checkout Record Sheet-544E, 624E, And 644E...108
    Complete Machine Operational Checkout...112
Section 9010: Engine Operation And Tests...166
  Group 05: Theory Of Operation...166
    Cooling System Operation-544E, 624E...169
    Cooling System Operation-644E...170
    Thermostat Operation...171
    Air Cleaner Operation...172
    Turbocharger Operation...174
    Engine Lubrication-544E, 624E...176
    Engine Lubrication Operation-644E...178
    Fuel System Operation-544E, 624E...180
    Fuel System Operation-644E...181
    Fuel Supply Pump Operation-544E, 624E...182
    Fuel Pump Operation-644E...183
    Fuel Filter Operation...185
    Fuel Injection Pump Operation-544E, 624E...186
    Fuel Injection Pump Operation-644E...188
    Fuel Injection Nozzle Operation-544E, 624E...189
    Fuel Injection Nozzle Operation-644E...190
  Group 10: System Operational Checks...166
    Engine Operational Checks...208
  Group 15: Diagnostic Information...166
    Diagnose Engine Malfunctions...236
    Coolant Requirements...248
  Group 20: Adjustments...166
    JT05801 Clamp-On Electronic Tachometer Installation...824
    JT05800 Digital Thermometer Installation...825
    D01084AA Tachometer Reader Installation Procedure...254
    Valve Clearance Adjustment-544E, 624E...255
    Valve Clearance Adjustment-644E...257
    Fan Belt Tension Adjustment...259
    Injection Pump Static Timing Adjustment-544E, 624E...261
    Injection Pump Static Timing Adjustment-644E...263
    Slow And Fast Idle Adjustment-544E, 624E...265
    Slow Idle Adjustment-644E...267
    Fast Idle Adjustment-644E...269
    Speed Control Linkage Adjustment...270
    Fuel Shut-Off Cable Adjustment-644E...272
    Bleed The Fuel System-544E, 624E...273
    Bleed The Fuel System-644E...274
  Group 25: Tests...167
    JT05801 Clamp-On Electronic Tachometer Installation...824
    JT05800 Digital Thermometer Installation...825
    Dampener Runout Check...278
    Valve Lift Check...279
    Compression Pressure Test-544E, 624E...280
    Compression Pressure Test-644E...282
    Engine Oil Pressure Test-544E, 624E...284
    Engine Oil Pressure Test-644E...285
    Turbocharger Shaft Axial End Play Test...287
    Turbocharger Shaft Radial Movement Test...288
    Cooling System Test...289
    Fuel Pump Pressure Test-544E, 624E...291
    Fuel Pump Pressure Test-644E...292
    Air Filter Restriction Indicator Switch Test...294
    Radiator Air Flow Test...296
    JT05529 Airflow Meter Test Record...298
    Engine Power Test Using Engine Pulldown...300
    Engine Power Test Using Turbocharger Boost Pressure...302
    Air Intake System Leakage Test...304
    Fuel Line Leakage Test...306
Section 9015: Electrical System Operation And Test...307
  Group 00: Electrical System Operation And Test...307
    Safety Precautions...314
    Using Booster Batteries-12 Volt System...317
    Visually Inspect Electrical System...320
    Testing The Electrical System...321
    Common Circuit Test...322
    Electrical Operational Checks...323
    Electrical Schematic Symbols...324
    Wiring Diagram Information...325
    Battery-Diagnose Malfunctions...327
    Battery Operation...328
    Battery Specifications...330
    Fuse Specifications...331
    Bulb Replacement Specifications...332
    Diagnose Power And Ground Circuit Malfunctions...333
    Power Circuit Operation...336
    Power Circuit Wiring Diagram...338
    Power Circuit Test...339
    Diagnose Starter Circuit Malfunctions...344
    Diagnose Fuel Shut-Off Malfunctions-544E, 624E...347
    Starting Circuit And Fuel Shut-Off Solenoid Operational Checks...348
    Starting Circuit And Fuel Shut-Off Solenoid Operation...354
    Starter Operation...356
    Start Circuit And Fuel Shut-Off Solenoid Wiring Diagram...359
    Start Circuit And Fuel Shut-Off Solenoid Tests...360
    Diagnose Charging Circuit Malfunctions-65 Amp Alternator...361
    Alternator Operation-65 Amp Motorola...365
    Charging Circuit Operation-65 Amp Motorola Alternator-(Serial No. -532819)...367
    Charging Circuit Wiring Diagram-65 Amp Motorola-(S.N. -532819)...368
    Charging Circuit Operation-65 Amp Motorola Alternator-(Serial No. 532820-)...369
    Charging Circuit Wiring Diagram-65 Amp Motorola-(S.N. 532820-)...370
    Diagnose Charging Circuit Malfunctions-90 Amp And 105 Amp Alternator...371
    Alternator Operation-90 Amp And 105 Amp Delco Remy...374
    Charging Circuit Operation-105 Amp Delco-Remy Alternator-(S.N. 518774-)...376
    Charging Circuit Wiring Diagram-105 Amp Alternator-(S.N. 518774-)...377
    Charging Circuit Operation-90 Amp Delco-Remy Alternator...378
    Charging Circuit Wiring Diagram-90 Amp Delco-Remy Alternator...379
    Diagnose Charging Circuit Malfunctions-130 Amp Alternator...380
    Alternator Operation-130 Amp Motorola...388
    Charging Circuit Operation-130 Amp Motorola Alternator...389
    Charging Circuit Wiring Diagram-130 Amp Motorola Alternator...390
    130 Amp Alternator Voltage Adjustment...391
    Diagnose Logic Module And Warning Alarm Circuit Malfunctions...392
    Logic Module And Warning Alarm Circuit Operation...393
    Logic Module And Warning Alarm Wiring Diagram...395
    Logic Module Test In Machine...396
    Logic Module Bench Test...399
    Diagnose Indicator Circuit Malfunctions-Top Row...401
    Indicator Circuits Operation-Top Row...409
    Indicator Circuits Wiring Diagram-Top Row...410
    Diagnose Indicator Circuit Malfunctions-Middle Row...411
    Indicator Circuits Operation-Middle Row...419
    Indicator Circuits Wiring Diagram (Middle Row)...421
    Park Brake Switch Adjustment...422
    Pressure Switch And Sender Test...423
    Diagnose Gauges And Horn Circuit Malfunctions...424
    Gauges And Horn Circuits Operation...430
    Gauges And Horn Circuit Wiring Diagram...431
    Diagnose Return-To-Dig And Boom Height Kickout Malfunctions...432
    Return-To-Dig And Boom Height Kickout Circuit Operation...437
    Return-To-Dig And Boom Height Kickout Wiring Diagram...439
    Boom Height Kickout Adjustment...818
    Return-To-Dig Adjustment...820
    Diagnose Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Malfunctions...444
    Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Operation...448
    Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Operation Wiring Diagram...449
    Diagnose Secondary Steering System Malfunctions...450
    Secondary Steering Circuit Operation...456
    Secondary Steering Wiring Diagram...458
    Secondary Steering Circuit Test...459
    Secondary Steering Controller Test...460
    Secondary Steering Pressure Switch...461
    Diagnose Hour Meter Circuit Malfunctions...462
    Hour Meter Circuit Operation...468
    Hour Meter Circuit Wiring Diagram...470
    Diagnose Boom Down Circuit Malfunctions...471
    Boom Down Circuit Operation-(Serial No. -518527)...476
    Boom Down Circuit Wiring Diagram-(Serial No. -518527)...477
    Boom Down Circuit Operation-(Serial No. 518528-521102)...478
    Boom Down Circuit Wiring Diagram-(Serial No. 518528-521102)...479
    Boom Down Circuit Operation-(Serial No. 521103-)...480
    Boom Down Circuit Wiring Diagram-(Serial No. 521103-)...481
    Diagnose Differential Lock And Clutch Cut-Off Circuit Malfunctions...482
    Differential Lock And Clutch Cut-Off Circuit Operation...487
    Differential Lock And Clutch Cut-Off Circuits Wiring Diagram...488
    Diagnose Turn Signal And Flasher Circuit Malfunctions...489
    Turn Signal And Flasher Indicator Circuit Operation...493
    Turn Signal And Flasher Indicator Circuit Wiring Diagram...494
    Diagnose Drive, Work, Brake And Gauge Light Circuit Malfunctions...495
    Drive, Work, Brake And Gauge Light Circuit Operation...501
    Drive, Work, Brake And Gauge Light Circuits Wiring Diagram...503
    Diagnose Windshield Wiper And Washer Circuit Malfunctions...504
    Windshield Wiper And Washer Circuit Operation...509
    Windshield Wiper/Washer Circuit Wiring Diagram...510
    Diagnose Pin Disconnect Circuit Malfunctions...511
    Pin Disconnect Circuit Operation...513
    Pin Disconnect Circuit Wiring Diagram...514
    Radio Circuit Operation...515
    Electrical Component Location Drawing...516
Section 9020: Power Train Operation And Tests...517
  Group 05: Theory Of Operation...517
    Power Train Component Overview...523
    Drive Dampener...526
    Transmission Clutch Engagement...527
    Torque Converter Operation...528
    Transmission Operation-Neutral...530
    Transmission Operation-1st Gear Forward...532
    Transmission Operation-2nd Gear Forward...534
    Transmission Operation-3rd Gear Forward...536
    Transmission Operation-4th Gear Forward...538
    Transmission Operation-1st Gear Reverse...540
    Transmission Operation-2nd Gear Reverse...542
    Transmission Operation-3rd Gear Reverse...544
    Clutch Operation...546
    Transmission Hydraulic Components...548
    Transmission Hydraulic System...550
    Transmission Pump Operation...552
    Transmission Control Valve Components...553
    Transmission Control Valve-1st Gear Neutral...555
    Transmission Control Valve-4th Gear Forward...557
    Shift Modulation...559
    Shift Modulation-1st Gear (Full Engagement)...561
    Shift Modulation-1st Gear (Shift Initiated-Clutch Filling)...563
    Shift Modulation-1st Gear (Modulation Starting)...565
    Shift Modulation-2nd, 3rd, And 4th Gears...567
    Thermal Bypass Valve Operation...569
    Differential Lock Operation...570
    Final Drive Operation...572
    Axle Outer Seal And Bearing Operation...574
    Axle Disconnect Operation...575
    Brake Hydraulic System...576
    Brake Pump Operation...578
    Accumulator Operation...580
    Brake Valve Operation...581
    Wet Chambered Brake Valve...583
    Pressure Reducing Valve Operation-Neutral...585
    Pressure Reducing Valve Operation-Differential Lock On...587
  Group 10: System Operational Checks...518
    Power Train Operational Checks...601
  Group 15: Diagnostic Information...518
    Diagnose Transmission System Malfunctions...622
    Diagnose Service Brake Malfunctions...631
    Diagnose Differential/Axle Malfunctions...633
    Diagnose Drive Line Malfunctions...636
    Diagnose Park Brake Malfunctions...637
    Hydraulic Circuit Symbols...807
    Brake, Differential Lock Circuit Schematic...639
    Power Train Schematic...640
    Power Train And Brakes System Component Location...641
  Group 20: Adjustments...518
    Transmission Control Valve Linkage-FNR And Neutral Lock Adjustment...643
    Transmission Control Valve Linkage-Speed Control Adjustment...644
    Brake Pedal Adjusting Screw Adjustment (Early Units Only)...645
    Front Axle Disconnect Adjustment...646
    Clutch Cut-Off Switch Adjustment...647
    Brake Pad Inspection...648
    Hydraulic Brake Bleeding Procedure...650
    Charge Brake Accumulator...652
    Park Brake Linkage Adjustment...654
    Park Brake Indicator Switch Adjustment...656
    Brake Pump And Differential Lock System Oil Clean-Up Procedure Using Portable Filter Caddy...657
  Group 25: Tests...518
    JT05801 Clamp-On Electronic Tachometer Installation...824
    JT05800 Digital Thermometer Installation...825
    D01084AA Tachometer/Temperature Reader Installation Procedure...826
    Transmission Oil Warm-Up Procedure...663
    Brake, Differential Lock, And Hydraulic System Oil Warm-Up Procedure...664
    Transmission Pump Flow Test...665
    Transmission System Pressure, Element Leakage, And Shift Modulation Test...667
    Lube Pressure Test...670
    Converter Relief Pressure Test...672
    Converter-In Pressure Test...674
    Converter-Out Pressure Test...676
    Converter-Out Flow Test...678
    Transmission Oil Cooler Backflush Procedure...680
    Transmission Oil Cooler Restriction Test...681
    Clutch Cut-Off Valve Pressure Test...683
    Pressure Reducing Valve Manifold Leakage Test...685
    Transmission Oil Cooler Thermal Bypass Valve Test...687
    Transmission Oil Cooler Bypass Valve Pressure Test...689
    Torque Converter Stall Speed Test...691
    Brake Pump Flow Test...692
    Brake Pump Standby Pressure Test...694
    Brake Valve Pressure Test...696
    Brake Accumulator Precharge Test...698
    Brake Valve Leakage Test...700
    Brake Accumulator Inlet Check Valve Leakage Test...702
    Differential Lock Pressure Test...704
    Differential Lock Leakage Test...706
    Axle Bearing Adjustment Check...708
    No-Spin Differential Test...709
Section 9025: Hydraulic System Operation And Test...710
  Group 05: Theory Of Operation...710
    Steering Circuit Component Location...714
    Steering Circuit Components...715
    Steering Circuit Operation-Right Turn...717
    Main Hydraulic Pump Operation...719
    Priority Valve Operation...720
    Steering Valve Operation...723
    Crossover Relief Valve Operation...724
    Steering Cylinder Operation...725
    Steering Accumulator Operation-644E Later Units...726
    Secondary Steering System Operation...727
    Inlet Manifold Operation...728
    Loader Hydraulic System...730
    Pressure Reducing Valve-Secondary Boom Lower Operation...732
    Pilot Controller Operation...734
    Boom Section Operation...736
    Bucket Section Orifice Check Valve...738
    Bucket Section Operation-544E, 624E, And 644E...739
    Bucket Section Operation-544E TC And 544E LL...741
    Auxiliary Section Operation...743
    System Relief Valve Operation...745
    Circuit Relief Valve Operation...746
    Anti-Cavitation Valve Operation...749
    Loader Cylinder Design...750
    Return Filter Operation...751
    Pin Disconnect Circuit Operation-544E TC...752
  Group 10: System Operational Checks...710
    Hydraulic Operational Checks...770
  Group 15: Diagnostic Information...710
    Diagnose Hydraulic System Malfunctions...797
    Hydraulic Circuit Symbols...807
    Main Hydraulic System Component Location...808
    Main Hydraulic System Schematic...809
    Main Hydraulic System Schematic (Tandem Valve)...810
    Hydraulic System Component Location-544E TC And 544E LL...811
  Group 20: Adjustments...711
    Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy...815
    Boom Height Kickout Adjustment...818
    Return-To-Dig Adjustment...820
    Charge Steering Accumulator-644E Later Machines...821
  Group 25: Tests...711
    JT05801 Clamp-On Electronic Tachometer Installation...824
    JT05800 Digital Thermometer Installation...825
    D01084AA Tachometer/Temperature Reader Installation Procedure...826
    Hydraulic Oil Warm-Up Procedure...828
    Main Hydraulic Pump Flow Test...829
    Loader System And Circuit Relief Valve Pressure Test...831
    Hydraulic System Restriction Test...835
    Loader Cylinder Drift Test...837
    Boom And Bucket Cylinder Leakage Test...840
    Hydraulic Oil Cooler Restriction Test...842
    Steering System Leakage Test...844
    Steering Valve Neutral Leakage Test...847
    Steering Crossover Relief Valve...849
    Steering Stop Wear Check...851
    Priority Valve Pressure Test...853
    Priority Valve "LS" Port Flow Test...855
    Priority Valve Relief Cartridge Leakage Test...857
    Secondary Steering Pump Relief Valve Pressure Test...859
    Secondary Steering Manifold Primary Check Valve Leakage Test...861
    Secondary Steering Manifold Secondary Check Valve Leakage Test...863
    Pilot Control Valve Pressure Test...865
    Pressure Reducing Valve Pressure Test...869
    Cycle Time Test...871
    Hydraulic Oil Filter Inspection Procedure...872
    Pin Disconnect Solenoid Valve Leakage Test...873
    Pin Disconnect Cylinder Leakage Test...875
Section 9031: Heating And Air Conditioning System Operation And Tests...877
  Group 05: Theory Of Operation...877
    Refrigerant System...880
    Electrical System Wiring Diagram-Early Machines...881
    Electrical System Schematic-Early Machines...883
    Electrical System Wiring Diagram-Later Machines...884
    Electrical System Schematic-Later Machines...886
    Receiver-Dryer Operation...887
    Expansion Valve Operation...889
    Thermostat Control Switch Operation...891
    Compressor Relief Valve Operation...893
  Group 10: System Operational Checks...877
    Air Conditioning Operational Checks...914
  Group 15: Diagnostic Information...877
    Diagnose Air Conditioning Electrical Malfunctions...936
    Air Conditioning Component Location Drawing...938
  Group 20: Adjustments...877
    Refrigerant (R-12) Cautions...959
    Check And Add Compressor Oil...942
    Air Conditioning Gauge Set Installation Procedure...943
    Refrigerant Recovery...945
    Flush The System...947
    Purge The System...949
    Evacuate The System...951
    Charge The System...953
    Add Refrigerant To System...955
    Check And Adjust Compressor Belt Tension...957
  Group 25: Tests...877
    Refrigerant (R-12) Cautions...959
    Air Conditioning System Test...960
    Operating Pressure Diagnostic Chart...963
    Expansion Valve Operating Test...967
    Expansion Valve Bench Test And Adjustment...969
    Thermostat Control Switch Operating Test...971
    Thermostat Control Switch Bench Test And Adjustment...973
    Low Refrigerant Pressure Switch Test...975
    High Refrigerant Pressure Switch Test...977
    Leak Testing...979
    Refrigerant Hoses And Tubing Inspection...980
    Air Conditioner, Heater, And Defroster Circuit Test...981

John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, 644E Operation & Test Service Manual (TM1413)