John Deere 444H, 544H Loader and TC44H, TC54H Tool Carrier Workshop Service Repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

John Deere 444H, 544H Loader and TC44H, TC54H Tool Carrier manual contains high quality images, instructions to help you to maintain, and repair. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

TM1605 - John Deere 444H, 544H Loader and TC44H, TC54H Tool Carrier Technical Manual - Repair.pdf

TABLE OF CONTENTS:
Contents.........5
  General Information.........7
    Safety Information.........9
      Handle Fluids Safely—Avoid Fires.........9
      Prevent Battery Explosions.........9
      Prepare for Emergencies.........9
      Prevent Acid Burns.........10
      Handle Chemical Products Safely.........10
      Avoid High-Pressure Fluids.........11
      Park Machine Safely.........11
      Support Machine Properly.........11
      Wear Protective Clothing.........12
      Work in Clean Area.........12
      Service Machines Safely.........12
      Work In Ventilated Area.........13
      Illuminate Work Area Safely.........13
      Replace Safety Signs.........13
      Use Proper Lifting Equipment.........14
      Remove Paint Before Welding or Heating.........14
      Avoid Heating Near Pressurized Fluid Lines.........14
      Keep ROPS Installed Properly.........15
      Service Tires Safely.........15
      Avoid Harmful Asbestos Dust.........16
      Practice Safe Maintenance.........16
      Use Proper Tools.........17
      Decommissioning — Proper Recycling and Disposal of Fluids and Components.........17
      Live With Safety.........18
    General Specifications.........19
      444H Specifications.........19
      Drain and Refill Capacities—444H.........20
      TC44H Specifications.........21
      Drain and Refill Capacities—TC44H.........22
      544H Specifications.........23
      Drain and Refill Capacities—544H.........25
      TC54H Specifications.........26
      Drain and Refill Capacities—TC54H.........28
    Torque Values.........29
      Hardware Torque Specifications.........29
      ROPS Torque Specifications.........29
      Metric Bolt and Screw Torque Values.........30
      Additional Metric Cap Screw Torque Values.........31
      Unified Inch Bolt and Screw Torque Values.........32
      Check Oil Lines And Fittings.........33
      Service Recommendations for O-Ring Boss Fittings.........33
      Service Recommendations For Flat Face O-Ring Seal Fittings.........35
      Service Recommendations for Metric Series Four Bolt Flange Fitting.........36
      Service Recommendations For Inch Series Four Bolt Flange Fittings.........37
    Fuels and Lubricants.........39
      Diesel Fuel.........39
      Lubricity of Diesel Fuels.........39
      Low Sulfur Diesel Fuel Conditioner.........39
      Diesel Fuel Storage.........40
      Fuel Tank.........40
      Diesel Engine Oil.........41
      Transmission, Hydraulic System, Park Brake, and Differential Oil.........42
      Grease.........43
      Alternative and Synthetic Lubricants.........43
      Lubricant Storage.........43
      Mixing of Lubricants.........44
  Wheels.........45
    Powered Wheels and Fasteners.........47
      Service Equipment and Tools.........47
      Specifications.........47
      Remove and Install Wheel.........47
      Remove Tire.........48
      Install Tire.........49
  Axles and Suspension Systems.........51
    Removal and Installation.........53
      John Deere TeamMateTeamMate is a trademark of Deere & Company.™ III Axles—Use CTM150.........53
      Service Equipment and Tools.........53
      Specifications.........54
      Remove and Install Front Axle and Differential.........55
      Remove Rear Axle and Differential.........58
      Install Rear Axle and Differential.........62
      Disassemble and Assemble Axle Oscillating Supports.........64
    Axle Shafts and U-Joints.........67
      Specifications.........67
      Remove and Install Universal Joint and Drive Shaft.........68
      Disassemble, Inspect, and Assemble Universal Joint Drive Shaft.........69
    Axle Shaft, Bearings, Reduction Gears.........71
      John Deere TeamMateTeamMate is a trademark of Deere & Company.™ III Axles—Use CTM150.........71
      Service Equipment and Tools.........71
      Specifications.........72
       Axle Disconnect Input Shaft, Cross-Sectional View.........73
      Remove and Install Axle Disconnect Input Shaft.........74
      Disassemble, Inspect, and Assemble Axle Disconnect Input Shaft.........74
    Hydraulic System.........85
      Specifications.........85
      Remove and Install Differential Lock Solenoid Valve.........85
      Axle Recirculation System.........86
      Axle Recirculation System With Optional Oil Coolers.........87
      Axle Oil Coolers—Exploded View.........88
      Remove and Install Front Axle Oil Cooler.........89
      Disassemble and Assemble Front Axle Oil Cooler.........91
      Remove and Install Rear Axle Oil Cooler.........92
  Transmission.........93
    Removal and Installation.........95
      Essential Tools.........95
      Service Equipment and Tools.........95
      Specifications.........95
      Remove and Install Transmission.........96
    Gears, Shafts, Bearings and Power Shift Clutch.........99
      Essential Tools.........99
      Service Equipment and Tools.........100
      Other Material.........100
      Specifications.........101
      Remove Torque Converter And Housing.........102
      Install Torque Converter And Housing.........105
      Remove Clutches, Input and Output Shafts.........109
      Install Clutches, Input and Output Shafts.........116
      Disassemble Clutch Pack KV and KR.........127
      Assemble Clutch Pack KV and KR.........130
      Disassemble Clutch Pack K1, K2, and K3.........138
      Assemble Clutch Pack K1, K2, and K3.........141
      Disassemble Clutch Pack K4.........149
      Assemble Clutch Pack K4.........150
      Disassemble Input Shaft.........158
      Assemble Input Shaft.........158
    Hydraulic System.........163
      Specifications.........163
      Remove Transmission Pump.........163
      Remove and Install Converter Minimum Pressure Regulator Valve.........165
      Install Transmission Pump.........166
      Remove Transmission Hydraulic Control Valve.........169
      Install Transmission Hydraulic Control Valve.........171
      Transmission Hydraulic Control Valve Cross Section View.........173
      Disassemble Transmission Control Valve.........174
      Assemble Transmission Control Valve.........177
      Remove, Disassemble and Install Converter Relief Valve.........184
      Transmission Internal Oil Pipes and Tubes Remove and Install.........186
    Dealer Fabricated Tools.........191
      DFT1148 Pre-Load Clutch Pack Compression Ring Tool.........191
      DFT1149 Pre-Load Clutch Pack Compression Ring Tool.........192
  Engine.........193
    Removal and Installation.........195
      PowerTechPowerTech is a trademark of Deere & Company.® 4.5 L (4045) and 6.8 L (6068) John Deere Engines—Use CTM104.........195
      Service Equipment and Tools.........195
      Specifications.........195
      Remove and Install Engine.........196
  Engine Auxiliary Systems.........203
    Cold Weather Starting Aids.........205
      Other Material.........205
      Specifications.........205
      Remove and Install Fluid Starting Aid Assembly.........205
      Remove and Install Engine Coolant.........207
    Cooling System.........209
      Specifications.........209
      Remove and Install Fan Belt.........209
      Serpentine Belt Routing.........211
      Remove and Install Fan and Fan Drive.........212
      Remove and Install Radiator and Oil Cooler.........214
      Disassemble and Assemble Radiator and Oil Cooler.........216
    Speed Controls.........219
      Service Equipment and Tools.........219
      Specifications.........219
      Remove and Install Speed Control Linkage.........220
      Adjust Speed Control Linkage.........221
      Adjust Slow and Fast Idle.........222
    Intake System.........223
      Essential Tools.........223
      Service Equipment and Tools.........223
      Specifications.........223
      Remove and Install Air Cleaner.........224
      Remove and Install Air Filter Elements.........225
      Clean Dusty Primary Element.........226
      Clean Oily or Sooty Primary Element.........227
      Inspect Element.........227
      Air Intake System Leakage Test.........228
    External Exhaust System.........229
      Specifications.........229
      Remove and Install Muffler.........230
    External Fuel Supply Systems.........233
      Specifications.........233
      Remove and Install Fuel Tank.........234
      Remove and Install Primary Fuel Filter (Water Separator).........236
      Bleed Fuel System.........237
  Dampener Drive.........239
    Elements.........241
      Specifications.........241
      Remove and Install Dampener.........241
  Steering System.........243
    Hydraulic System.........245
      Service Equipment and Tools.........245
      Other Material.........245
      Specifications.........245
      Remove and Install Steering Valve.........246
      Remove and Install Steering Column.........249
      Remove and Install Steering Cylinders.........250
      Loader Start-Up Procedure (Steering Cylinder).........250
      Remove and Install Steering Cylinder Bushings.........251
      Disassemble and Assemble Steering Cylinder.........251
      Loader Start-Up Procedure (Steering Cylinder—120 Series).........251
  Service Brakes.........253
    Active Elements.........255
      Service Equipment and Tools.........255
      Specifications.........255
      Inspect External Service Brakes.........255
      Remove and Install Brake Assembly.........256
    Hydraulic System.........257
      Specifications.........257
      Remove and Install Brake Valve.........257
      Remove and Install Brake Accumulator.........259
  Park Brake.........261
    Active Elements.........263
      Service Equipment and Tools.........263
      Other Material.........263
      Specifications.........263
      Remove and Install Park Brake.........264
      Disassemble and Assemble Park Brake.........266
    Hydraulic System.........271
      Specifications.........271
      Remove and Install Park Brake Release Solenoid Valve.........271
      Remove and Install Park Brake Pressure Switch.........272
  Electrical System.........275
    Batteries, Support and Cables.........277
      Specifications.........277
      Service Batteries Carefully.........277
      Check Battery Electrolyte Level and Terminals.........278
      Battery Charging Procedure.........279
      Using Booster Batteries—24 Volt System.........280
      Procedure for Testing Batteries.........281
      Remove and Install Batteries.........282
      Remove and Install Manual Battery Disconnect Switch.........283
    Alternator, Regulator and Charging System Wiring.........285
      Bosch Alternator Repair—Use CTM77.........285
      Remove and Install Alternator.........285
      Remove and Install Regulator.........288
    Lighting System.........289
      Remove and Install Work Lights.........289
      Remove and Install Front Turn Lights.........291
      Replace Halogen Bulbs.........291
      Remove and Install Stop, Turn and Tail Light.........293
    Wiring Harness and Switches.........295
      Essential Tools.........295
      Other Material.........296
      Remove and Install Transmission Control Valve Connector Body.........297
      Install Transmission Control Valve Connector Contact.........298
      Replace METRI-PACKMetri-Pack is a trademark of Packard Electrical.™ Connectors.........298
      Install METRI-PACKMetri-Pack is a trademark of Packard Electric.™ Contact.........299
      Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co.™ Connectors.........301
      Install DEUTSCHDEUTSCH is a trademark of the Deutsch Co.™ Contact.........302
      Replace WEATHER PACKWEATHER PACK is a trademark of Packard Electric.™ Connector.........303
      Install WEATHER PACKWEATHER PACK is a trademark of Packard Electric.™ Contact.........304
      Replace Chassis Computer Unit Connector Terminals.........305
      Install CINCHCINCH is a trademark of the Cinch Co.™ Contact.........307
      Remove Connector Body from Blade Terminals.........308
      Remove Blade Terminals From Fuse Block.........308
      Remove and Install Pressure Switches.........309
       Boom Height Kickout, Return-to-Carry and Return-to-Dig Kickout Adjustments.........309
    System Controls.........311
      Remove and Install Transmission Controller.........311
      Remove and Install Chassis Computer Unit.........313
      Remove and Install Monitor Display Unit.........314
      Reprogram Monitor Display Unit.........317
    Motors and Actuators.........319
      John Deere Starting Motor Repair—Use CTM77.........319
      Specifications.........319
      Remove and Install Starting Motor.........319
  Frame or Supporting Structure.........321
    Frame Installation.........323
      Service Equipment and Tools.........323
      Specifications.........323
      Welding Major Structure.........324
      Separate Engine and Loader Frame.........325
       Remove and Install Upper Pivot Bearing and Seals.........330
      Remove and Install Lower Pivot Bearing and Seals.........332
    Frame Bottom Guards.........335
      Specifications.........335
      Remove and Install Fuel Tank Guard.........335
      Remove and Install Front Axle Guard.........335
      Remove and Install Transmission Bottom Guard.........336
      Remove and Install Transmission Side Guards.........336
    Chassis Weights.........337
      Specifications.........337
      Remove and Install Counterweights.........337
  Operator’s Station.........339
    Removal and Installation.........341
      Essential Tools.........341
      Service Equipment and Tools.........341
      Specifications.........341
      Remove and Install Cab or Canopy.........342
    Operator Enclosure.........347
      Other Material.........347
      Specifications.........347
      Remove and Install Windowpanes.........347
      Adjust Cab Door Hold-Open Release.........347
      Remove and Install Windshield Washer.........348
      Remove and Install Front and Rear Windshield Wiper Motor.........349
      Adjust Front Windshield Wiper.........350
      Remove and Install Wrist Support.........351
    Seat and Seat Belts.........353
      Disassemble and Assemble Seat Belt.........353
      Disassemble and Assemble Seat.........354
    Heating and Air Conditioning.........357
      Essential Tools.........357
      Service Equipment and Tools.........358
      Air Conditioning System Fittings Reference Chart.........359
      Other Material.........360
      Specifications.........360
      Refrigerant Theory of Operation.........361
      R134a Refrigerant Cautions.........362
      R134a Compressor Oil Charge Check.........362
      R134a Compressor Oil Removal.........362
      R134a Component Oil Charge.........363
      Leak Testing.........363
      Refrigerant Hoses and Tubing Inspection.........364
      R134a Refrigerant, Recovery, Recycling and Charging Station Installation Procedure.........364
      Recover R134a System.........365
      Evacuate R134a System.........366
      Charge R134a System.........367
      Air Conditioner System Cleaning Procedures.........368
      Purge Air Conditioner System.........368
      Flush Air Conditioner System.........369
      Blower/Air Conditioner Harness (W20) Component Location.........370
      Connectors for Blower/Air Conditioner Harness (W20).........373
      Air Conditioning Module With Heater/Evaporator Coil.........374
      Remove and Install Heater/Evaporator Coil.........376
      Expansion Valve Remove and Install.........377
      Remove and Install Freeze Control Switch.........378
      Bench Test Freeze Control Switch.........378
      Remove and Install Heater Control Valve.........379
      Heater Control Valve Leak Check.........379
      Remove and Install Main Blower Assembly.........380
      Remove and Install Pressurizer Motor Assembly.........381
      Remove and Install Receiver-Dryer and Condenser.........382
      Remove and Install High and Low Pressure Switches.........383
      Remove and Install Fresh Air Filter.........384
      Remove and Install Recirculating Air Filter.........386
      Remove and Install Compressor.........387
      Disassemble and Assemble Compressor Clutch—R134a.........389
      Check Clutch Hub Clearance—R134a.........390
      Inspect Compressor Manifolds.........391
    Dealer Fabricated Tools.........393
      DFRW20 Compressor Holding Fixture.........393
  Sheet Metal and Styling.........395
    Hood or Engine Enclosure.........397
      Specifications.........397
      Remove and Install Hood.........397
      Remove and Install Engine Side Shields.........398
    Miscellaneous Shields.........401
      Remove and Install Transmission Shields.........401
      Remove and Install Battery Covers.........402
    Grille and Grille Housing.........403
      Service Equipment and Tools.........403
      Specifications.........403
      Remove and Install Grille and Grille Housing—544H.........403
    Miscellaneous Shields.........405
      Remove and Install Front Fenders.........405
      Remove and Install Rear Fenders.........406
  Safety and Convenience.........407
    Mirror.........409
      Remove and Install Rear View Mirror.........409
      Remove and Install Outside Mirror for Cab or Canopy.........409
    Fire Extinguisher.........411
      Remove and Install Fire Extinguisher and Bracket.........411
    Horn and Warning Devices.........413
      Remove and Install Horn.........413
      Remove and Install Reverse Warning Alarm.........414
      Change Volume Reverse Warning Alarm.........414
  Loader.........416
    Bucket.........417
      Specifications.........417
      Ride Control Accumulator Safety.........417
      Remove and Install Bucket Tooth Shanks and Tips.........418
      Remove and Install Bucket.........419
      Remove and Install Welded Bucket Cutting Edges.........420
      Remove and Install Bolt-On Cutting Edges and Wear Plates.........420
      Repair Cracked Cutting Edge.........421
    Frames.........423
      Service Equipment and Tools.........423
      Other Material.........423
      Specifications.........423
      Remove and Install Loader Bucket Tilt Linkage.........424
      Remove and Install Bucket Linkage Seals and Bushings.........425
      Disassemble and Assemble Upper Tool Carrier Tilt Linkage.........426
      Disassemble and Assemble Lower Tool Carrier Tilt Linkage.........427
      Disassemble and Assemble Tool Carrier.........428
      Remove and Install Loader Boom Bushings and Seals.........429
      Remove and Install Tool Carrier Boom Bushings and Seals.........430
    Hydraulic System.........431
      Essential Tools.........431
      Service Equipment and Tools.........431
      Other Material.........433
      Specifications.........434
      Remove and Install Loader Hydraulic Pump.........436
      Hydraulic Pump (PVG 65) and (PVG 75) Cross Section.........438
      Disassemble, Inspect and Assemble Hydraulic Pump.........439
      Remove and Install Hydraulic Pump Control Valve.........461
      Disassemble and Assemble Hydraulic Pump Control Valve.........462
      Remove and Install Loader Control Valve.........463
      Disassemble and Assemble Loader Control Valve.........465
      Disassemble and Assemble Auxiliary Valve Section and Bucket Section.........466
      Disassemble and Assemble Boom Valve Section.........467
      Disassemble and Assemble Relief Valve.........467
      Disassemble and Assemble Bucket Circuit Relief Valve.........468
      Disassemble and Assemble Load Sense Relief Valve.........468
      Disassemble and Assemble Boom Circuit Relief Valve.........469
      Remove and Install Boom Cylinder.........470
      Remove and Install Bucket Cylinder.........472
      Cross Section of 444H Boom and Bucket Cylinders—120 Series.........473
      Boom Cylinder Piston Wear Ring Configuration.........474
      Disassemble 444H Boom and Bucket Cylinders—120 Series.........475
      Assemble 444H Boom and Bucket Cylinders—120 Series.........477
      Cross Section of TC44H, TC54H and 544H Boom, Bucket and Tilt Cylinders—125 Series.........484
      Disassemble and Assemble TC44H, TC54H and 544H Boom, Bucket and Tilt Cylinders—125 Series Cylinders.........485
      Remove and Install Boom or Bucket Cylinder Bushings and Seals.........490
      Loader Start-Up Procedure (Boom Cylinder).........491
      Loader Start-Up Procedure (Bucket Cylinder).........491
      Remove and Install Hydraulic Reservoir.........492
      Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy.........493
      Pilot Controller Repair (Single Lever Controller).........494
      Pilot Controller Repair (Two Lever Controller) (S.N. —585560).........510
      Pilot Controller Repair (Two Lever Controller) (S.N. 585561—).........512
      Remove and Install Pressure Reducing Valve Manifold.........514
      Remove and Install Pressure Reducing Valve.........515
      Disassemble and Assemble Pressure Reducing Valve.........516
      Remove and Install Boom Down Solenoid Valve.........517
      Remove and Install Differential Lock Solenoid Valve.........518
      Remove and Install Pilot Enable Solenoid Valve.........519
      Ride Control Valve Remove and Install.........520
      Ride Control Valve Disassemble and Assemble.........523
      Ride Control Accumulator Remove and Install.........526
      Ride Control Accumulator Disassemble and Assemble.........526
      Remove and Install Pin Disconnect/Axle Disconnect Valve.........529
      Disassemble and Assemble Pin Disconnect Valve.........529
      Disassemble and Assemble Axle Disconnect Valve.........530
      Auxiliary Hydraulic Oil Cooler System—Exploded View.........531
      Remove and Install Auxiliary Hydraulic Oil Cooler.........533
      Remove and Install Cooling Pump.........535

John Deere 444H, 544H Loader and TC44H, TC54H Tool Carrier Workshop Service Repair Manual - TM1605