Complete service repair manual for John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, 644E, with workshop information to maintain, diagnostic, repair, service like professional mechanics.

John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, 644E workshop service repair 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.
* 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.

TM1414 - John Deere 544E, 544E LL, 544E TC, 624E and 644E 4WD Loader Technical Manual (Repair).PDF

Total Pages: 782 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable)
Language: English

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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
   Dealer Fabricated Tools

TABLE OF CONTENTS
Section I: General Information...17
  Group I: Safety Information...17
    Handle Fluids Safely-Avoid Fires...20
    Prevent Battery Explosions...21
    Prepare for Emergencies...22
    Prevent Acid Burns...23
    Handle Chemical Products Safely...25
    Avoid High-Pressure Fluids...26
    Park Machine Safely...27
    Support Machine Properly...28
    Wear Protective Clothing...29
    Work in Clean Area...30
    Service Machines Safely...31
    Work In Ventilated Area...32
    Illuminate Work Area Safely...33
    Replace Safety Signs...34
    Use Proper Lifting Equipment...35
    Remove Paint Before Welding or Heating...36
    Avoid Heating Near Pressurized Fluid Lines...37
    Keep ROPS Installed Properly...38
    Service Tires Safely...39
    Avoid Harmful Asbestos Dust...40
    Practice Safe Maintenance...41
    Use Proper Tools...42
    Dispose of Waste Properly...43
    Live With Safety...44
  Group II: General Specifications...649
    544E Specifications...649
    544E Drain And Refill Capacities...53
    544E LL Specifications...649
    544E LL Drain And Refill Capacities...58
    544E TC Specifications...649
    544E TC Drain And Refill Capacities...63
    624E Specifications...649
    624E Drain And Refill Capacities...68
    644E Specifications...649
    644E Drain And Refill Capacities...73
  Group III: Torque Values...18
    Hardware Torque Specifications...649
    ROPS Torque Specifications...649
    Metric Bolt and Cap Screw Torque Values...77
    Additional Metric Cap Screw Torque Values...78
    Unified Inch Bolt and Cap Screw Torque Values...80
    Check Oil Lines And Fittings...81
    Service Recommendations for O-Ring Boss Fittings...82
    Service Recommendations for Flat Face O-Ring Seal Fittings...84
    Service Recommendations for Metric Series Four Bolt Flange Fitting...86
    Service Recommendations For Inch Series Four Bolt Flange Fittings...88
  Group IV: Fuels And Lubricants...18
    Fuel Specifications...649
    Storing Fuel...92
    Fuel Tank...93
    Engine Oil...94
    Transmission Oil...95
    Hydraulic System Oil...96
    Differential Oil...97
    Grease...98
    Alternative and Synthetic Lubricants...99
    Lubricant Storage...100
    Engine Coolant...101
Section 01: Wheels...102
  Group 0110: Powered Wheels And Fastenings...102
    Other Material...648
    Specifications...649
    Remove Tire...106
    Install Tire...108
    544E And 544E TC...110
    544E LL...111
    624E...112
    644E...113
Section 02: Axles And Suspension Systems...114
  Group 0200: Removal And Installation...114
    John Deere 1200 And 1400 Series Axles-Use CTM18...417
    Other Material...648
    Specifications...649
    Remove And Install Front Axle And Differential...119
    Remove Rear Axle And Differential...122
    Install Rear Axle And Differential Assembly...124
  Group 0225: Axle Shafts, Bearings And U-Joints...114
    Other Material...648
    Specifications...649
    Disassemble, Inspect, And Assemble Double Universal Joint, Support Bearing And Universal Joint Drive Shaft...130
    Remove, Disassemble, Assemble And Install Rear Differential Drive Line...132
  Group 0260: Hydraulic System...114
    Remove, Disassemble, Assemble And Install Differential Lock Solenoid Valve...135
Section 03: Transmission...137
  Group 0300: Removal And Installation...137
    Essential Tools...225
    Service Equipment And Tools...647
    Specifications...649
    Remove And Install Transmission...143
  Group 0315: Controls Linkage...137
    Other Material...648
    Specifications...649
    Disassemble And Assemble Transmission Control Linkage...152
    Transmission Direction Selector Linkage Adjustment...155
    Transmission Speed Selector Linkage Adjustment...156
  Group 0325: Input Drive Shafts And U-Joints...137
    Specifications...649
    Remove, Disassemble, Assemble And Install Transmission Drive Shaft...159
  Group 0350: Gear, Shafts, Bearings And Power Shift Clutch...137
    Essential Tools...225
    Service Equipment And Tools...647
    Other Material...648
    Specifications...649
    Install Repair Stand...166
    Remove And Install Torque Converter...167
    Remove Clutch Packs...191
    Remove And Install Forward And First Drive Gears...175
    Remove And Install Reverse And Second Drive Gears...177
    Remove And Install Third And Fourth Drive Gears...179
    Disassemble And Assemble Clutch Packs...191
    Clutch Packs...191
    Remove And Install Fourth Gear Idler Gear-544E, 544E LL, 544E TC...192
    Remove And Install Fourth Gear Idler Gear-624E, 644E...194
    Fourth Gear Idler Orifice Sizes...196
    Install Third And Fourth Gear Clutch Pack, Adjust End Play...197
    Install Second And Reverse, First And Forward Gear Clutch Packs...202
    Remove And Install Output Flange And Park Brake...210
    Remove And Install Output Shaft And Seals...214
    Remove And Install Output Gear And Oil Shields...221
  Group 0360: Hydraulic System...138
    Essential Tools...225
    Service Equipment And Tools...647
    Other Material...648
    Specifications...649
    Remove Oil Supply Flange And Oil Pump...229
    Disassemble Oil Supply Flange...232
    Assemble Oil Supply Flange...234
    Input Drive Shaft Orifice Sizes...236
    Disassemble Oil Pump...237
    Assemble Oil Pump...238
    Install Oil Pump On Oil Supply Flange...240
    Install Oil Supply Flange And Oil Pump...243
    Remove And Install Converter Minimum Pressure Regulator...247
    Remove And Install Transmission Oil Filter...248
    Remove And Install Suction Oil Strainer...249
    Remove Transmission Control Valve...250
    Disassemble Transmission Control Valve...252
    Disassemble And Assemble Cover Plate...253
    Disassemble And Assemble Pressure Regulating Valve, Pilot Valve, And Modulation Piston...255
    Disassemble And Assemble Direction Selector Valve...257
    Disassemble And Assemble Clutch Cut-Off Valve And Clutch Cut-Off Pilot Orifice...259
    Disassemble And Assemble Speed Selector Valve...261
    Assemble Transmission Control Valve...263
    Install Transmission Control Valve...264
    Remove And Install Main Hydraulic Filter...266
    Cross Section Of Thermal Bypass Valve...267
    Remove, Disassemble, Assemble And Install Thermal Bypass Valve...268
Section 04: Engine...270
  Group 0400: Removal And Installation...270
    John Deere 6076 Engine Repair-Use CTM6...272
    John Deere 6059 And 6068 Engine Repair-Use CTM8...273
    John Deere 6359 And 6414 Engine Repair-Use CTM4...274
    Special Or Essential Tools...566
    Service Equipment And Tools...647
    Other Material...648
    Specifications...649
    Disconnect Turbocharger Oil Inlet Line...282
    Remove And Install Engine...283
    Remove And Install Oil Pan...286
    Remove And Install Fuel Injection Pump-544E, 624E (DB2-Non-Retained Shaft)...287
    Remove And Install DB2 Fuel Injection Pump Drive Shaft-544E, 624E...289
    Remove Fuel Injection Pump-544E, 624E (DB4-Retained Shaft)...292
    Install Fuel Injection Pump-544E, 624E (DB4-Retained Shaft)...295
    Remove Fuel Injection Pump-644E...298
    Install Fuel Injection Pump-644E...300
    Remove And Install Fuel Filter Check Valve-644E...303
    Remove And Install Fuel Injection Nozzle-544E, 624E...304
    Remove Fuel Injection Nozzle-644E...306
    Inspect And Clean Cylinder Head Nozzle Bore-644E...307
    Inspect And Clean Nozzle Seating Surface-644E...308
    Install Fuel Injection Nozzle-644E...309
    Bleed Fuel System-544E, 624E...312
    Bleed Fuel System-644E...314
    Remove And Install Turbocharger...315
    Remove And Install Water Pump-544E, 624E...317
    Remove And Install Water Pump-644E...318
    Remove And Install Fan Drive-644E...320
Section 05: Engine Auxiliary Systems...321
  Group 0505: Cold Weather Starting Aids...321
    Specifications...649
    Remove And Install Starting Aid Solenoid And Nozzle...324
    Remove And Install Engine Coolant Heater...326
  Group 0510: Cooling System...321
    Specifications...649
    Remove And Install Compressor Belt (If Equipped) And Fan Belts...330
    Remove And Install Fan...331
    Remove And Install Radiator...332
    Remove And Install Oil Cooler...334
  Group 0515: Speed Controls...321
    Other Material...648
    Specifications...649
    Remove And Install Speed Control Linkage...339
    Engine Speed Control Linkage Adjustment...340
    Fuel Shut-Off Cable Adjustment-644E...342
  Group 0520: Intake System...321
    Specifications...649
    Remove And Install Air Filter Elements-544E, 624E...345
    Tighten Air Cleaner Hose Clamps...347
    Remove And Install Air Filter Elements-644E...348
    Test Air Intake System For Leaks...350
  Group 0560: External Fuel Supply System...321
    Other Material...648
    Specifications...649
    Remove And Install Fuel Tank-544E, 624E And 644E (Serial No. 537537-)...354
    Remove And Install Fuel Tank-644E (Serial No. -537536)...356
    Remove And Install Water Separator...358
    Disassemble And Assemble Water Separator...359
Section 07: Dampener Drive...360
  Group 0752: Elements...360
    Specifications...649
    Remove And Install Dampener...363
Section 09: Steering System...364
  Group 0930: Secondary Steering...364
    Remove And Install Secondary Steering Pump, Motor, And Relay...366
    Remove And Install Secondary Steering Inlet Manifold...367
    Disassemble And Assemble Secondary Steering Inlet Manifold...368
  Group 0960: Hydraulic System...364
    Special Or Essential Tools...566
    Service Equipment And Tools...647
    Other Material...648
    Specifications...649
    Remove And Install Steering Valve...374
    Disassemble Steering Valve...376
    Cross Section Of Steering Valve...379
    Assemble Steering Valve...380
    Remove, Disassemble, Assemble And Install Steering Column...384
    Remove And Install Steering Cylinders...386
    Disassemble Steering Cylinder...388
    Cross Section Of Steering Cylinder...392
    Assemble Steering Cylinder...393
    Remove And Install Steering Cylinder Bushings...399
    Remove And Install Priority Valve...400
    Cross Section Of Priority Valve...401
    Disassemble And Assemble Priority Valve...402
    Remove And Install Crossover Relief Valve...404
    Cross Section Of Crossover Relief Valve...406
    Disassemble And Assemble Crossover Relief Valve...407
    Remove And Install Steering Accumulator-644E Later Machines...409
    Disassemble And Assemble Steering Accumulator-644E Later Machines...411
    Charge Steering Accumulator-644E Later Machines...413
Section 10: Service Brakes...415
  Group 1011: Active Elements...415
    John Deere 1200 And 1400 Series Axles-Use CTM18...417
    Specifications...649
    Inspect Brakes...419
    Remove And Install Brake Assembly...420
    Inspect Brake Elements...421
  Group 1060: Hydraulic System...415
    Service Equipment And Tools...647
    Specifications...649
    Remove And Install Brake Valve...425
    Brake Valve Identification...427
    Disassemble And Assemble Brake Valve...428
    Remove And Install Brake Pump...430
    Disassemble Brake Pump...432
    Inspect Brake Pump Parts...434
    Assemble Brake Pump...435
    Disassemble And Assemble Compensator Valve...437
    Remove And Install Brake Accumulators...439
    Disassemble And Assemble Brake Accumulators...441
    Charge Brake Accumulator...443
    Hydraulic Brake Bleeding Procedure...445
Section 11: Park Brake...447
  Group 1111: Active Elements...447
    Specifications...649
    Other Material...648
    Remove And Install Park Brake...451
    Disassemble And Assemble Park Brake...452
  Group 1115: Controls Linkage...447
    Remove And Install Park Brake Linkage...454
    Adjust Park Brake Linkage...455
Section 15: Equipment Attaching...456
  Group 1511: Drawbar...456
    Specifications...649
    Install Counterweight/Drawbar...459
Section 16: Electrical Systems...460
  Group 1671: Batteries, Support And Cables...460
    Specifications...649
    Handle Batteries Safely...464
    Test Batteries Using Coolant And Battery Tester...465
    Test Batteries Using High Rate Discharge Test...466
    Charge Battery...467
    Remove And Install Batteries...468
  Group 1672: Alternator, Regulator And Charging System Wiring...460
    Alternator Repair-Use CTM77...470
    Service Equipment And Tools...647
    Specifications...649
    Remove And Install Alternator (Except BOSCH)...473
    Remove And Install BOSCH Alternator...475
  Group 1673: Lighting System...460
    Specifications...649
    Replace Halogen Bulbs...478
    Remove And Install Lights...480
  Group 1674: Wiring Harness And Switches...460
    Special Or Essential Tools...566
    Specifications...649
    Clutch Cut-Off Switch Adjustment...484
    Remove And Install Brake Low Pressure Switch...485
    Return-To-Dig Adjustment...487
    Boom Height Kickout Adjustment...488
    Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Company. Connectors...460
    Install DEUTSCH DEUTSCH is a trademark of the Deutsch Company. Contact...460
    Replace WEATHER PACK Weather Pack is a trademark of Packard Electric. Connector...460
    Install WEATHER PACK Weather Pack is a trademark of Packard Electric. Contact...460
    Remove Connector Body From Blade Terminals...498
    Remove Blade Terminals From Fuse Block...499
  Group 1677: Motors And Actuators...461
    Starting Motor Repair-Use CTM77...501
    Special Or Essential Tools...566
    Specifications...649
    Remove And Install Starting Motor...504
Section 17: Frame Or Supporting Structure...505
  Group 1740: Frame Installation...505
    Service Equipment And Tools...647
    Other Material...648
    Specifications...649
    Welding Repair Of Major Structure...510
    Separate Engine And Loader Frame...512
    Remove And Install Upper Pivot Bearing And Seals...515
    Remove And Install Lower Pivot Bushing And Seals...517
  Group 1746: Frame Bottom Guards...505
    Remove And Install Fuel Tank Bottom Guard...519
    Repair Bottom Guards...520
    Remove And Install Auxiliary Bottom Guards (If Equipped)...521
  Group 1749: Chassis Weights...505
    Specifications...649
    Remove And Install Counterweights...525
Section 18: Operator's Station...527
  Group 1800: Removal And Installation...527
    Special Or Essential Tools...566
    Service Equipments And Tools...531
    Other Material...648
    Specifications...649
    Remove And Install Cab Or Canopy...534
    Tilt Cab Or Canopy...540
  Group 1810: Operator Enclosure...527
    Special Or Essential Tools...566
    Other Material...648
    Specifications...649
    Remove And Install Windowpane And Molding...546
    Remove And Install Windshield Washer...548
    Remove, Disassemble, Assemble And Install Front Windshield Wiper...549
    Remove, Disassemble, Assemble And Install Rear Windshield Wiper...550
    Adjust Front Windshield Wiper...551
    Remove And Install Defroster Fan...552
    Remove And Install Door Handle And Door/Window Release...553
  Group 1821: Seat And Seat Belt...527
    Specifications...649
    Disassemble And Assemble Seat...557
  Group 1830: Heating And Air Conditioning...527
    Special Or Essential Tools...566
    Service Equipment And Tools...647
    Other Material...648
    Service Parts Kits For Compressor...572
    Specifications...649
    Proper Refrigerant Handling...574
    Refrigerant (R-12) Cautions...575
    Air Conditioning Gauge Set Installation Procedure...576
    Refrigerant Recovery...578
    Evacuate R12 System...580
    Charge R12 System...583
    Check And Add Compressor Oil...585
    Remove And Install Compressor And High Pressure Switch...587
    Volumetric Efficiency Test-R12...588
    Make Shaft Seal Leak Test...590
    Disassemble And Inspect Compressor...592
    Clutch Pulley, Bearing And Hub Inspection...598
    Replacing Clutch Pulley Bearing...599
    Replace Shaft Seal Seat...601
    Assemble Compressor...602
    Remove And Install Condenser...605
    Remove And Install Evaporator And Expansion Valve...607
    Expansion Valve Bench Test And Adjustment...609
    Remove And Install Receiver/Dryer And Low Pressure Switch...611
    Remove And Install Condenser Fan Motors...613
    Remove And Install Blower Wiring Harness...614
    Thermostat Switch Bench Test...615
    Disassemble And Assemble Blower Motor...617
    Remove And Install Heater Core...618
    Remove And Install Cab Heater Hoses And Controls...619
Section 31: Loader...620
  Group 3102: Bucket...620
    Other Material...648
    Specifications...649
    Remove And Install Bucket Tooth Shanks And Tips...625
    Remove And Install Bucket...627
    Replace Welded Bucket Cutting Edges...628
    Remove And Install Cutting Edges (For Bucket With Wear Plates)...629
    Repair Cracked Cutting Edge...630
  Group 3140: Frames...620
    Service Equipment And Tools...647
    Other Material...648
    Specifications...649
    Remove And Install Bucket Tilt Linkage-544E, 624E, And 644E...635
    Remove And Install Bucket Linkage Seals And Bushings-544E, 624E, And 644E...637
    Disassemble And Assemble Bucket Tilt Linkage-544E TC And 544E LL...639
    Disassemble And Assemble Tool Carrier-544E TC...641
    Remove And Install Boom Bushings And Shims-544E, 624E, And 644E...642
    Remove And Install Boom Bushings And Shims-544E TC And 544E LL...644
  Group 3160: Hydraulic System...620
    Service Equipment And Tools...647
    Other Material...648
    Specifications...649
    Remove And Install Main Hydraulic Pump...652
    Disassemble, Inspect And Assemble Main Hydraulic Pump...653
    Remove And Install Loader Control Valve...656
    Disassemble And Assemble Loader Control Valve-(Serial No. -534614)...658
    Disassemble And Assemble Loader Control Valve-(Serial No. 534615-)...659
    Service Bucket And Boom Section Pilot Orifice Check Valve-Later Machines Only...660
    Disassemble And Assemble Boom Valve Section-All Machines; And Bucket Valve Section-544E TC And 544E LL...661
    Disassemble And Assemble Auxiliary Valve Section-All Machines; And Bucket Section-544E, 624E, And 644E...665
    Disassemble And Assemble System Relief Valve...668
    Disassemble And Assemble Shim Adjustable Circuit Relief Valve...670
    Disassemble And Assemble Anti-Cavitation Valve...672
    Disassemble And Assemble Screw Adjustable Circuit Relief Valve...674
    Remove And Install Boom Cylinder...676
    Remove And Install Bucket Cylinder...678
    Cross Section Of Boom Or Bucket Cylinder...680
    Disassemble Boom Or Bucket Cylinder...682
    Assemble Boom Or Bucket Cylinder...684
    Remove And Install Bucket Or Boom Cylinder Bushings And Seals...690
    Remove, Disassemble, Assemble And Install Boom Solenoid Valve...691
    Remove And Install Hydraulic Reservoir...693
    Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy...745
    Remove And Install Pilot Control Valves (Two Lever Controller)...699
    Disassemble And Assemble Pilot Control Valve (Two-Lever Controller)...701
    Remove And Install Pilot Controller (Single Lever Controller)...707
    Cross Section Of Single Lever Pilot Controller (Serial No. -537112)...709
    Disassemble Single Lever Pilot Controller (Serial No. -537112)...711
    Assemble Single Lever Pilot Controller (Serial No. -537112)...716
    Disassemble Single Lever Pilot Controller (Serial No. 537113-)...722
    Assemble Single Lever Controller (Serial No. 537113-)...727
    Remove, Disassemble, Assemble And Install Pressure Reducing Valve...733
    Remove And Install Pin Disconnect Cylinders-544E TC...735
    Cross Section Of Pin Disconnect Cylinder-544E TC...736
    Disassemble Pin Disconnect Cylinder-544E TC...737
    Assemble Pin Disconnect Cylinder-544E TC...740
    Disassamble And Assemble Pin Disconnect Solenoid Valve-544E TC...743
    Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy...745
Section 99: Dealer Fabricated Tools...748
  Group 9900: Dealer Fabricated Tools...748
    DF1055 And JD38002 Yoke Holding Tool...750
    DF1056 Input Pinion Shaft Adjusting Tool...751
    DF1057 Axle Adjusting Tool...752
    DF1025 Oil Supply Flange Back-Off Brackets...753
    DF1026 Pre-Load Clutch Pack Compression Ring Assembly Jig...754
    DF1027 Stand Mounting Bracket...755
    DFT1071 Cab Tilt Pivots And Hinges...757
    JDG588 Shaft Alignment Tool...759
    DF1044 Air Deflector Bushing...760

John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, 644E Repair Service Manual (TM1414)