Complete service repair manual for John Deere 4WD Loaders 544G, 544G LL, 544G TC, 624G, 644G, with all the technical information to maintain, service, repair like professional mechanics.

John Deere 4WD Loaders 544G, 544G LL, 544G TC, 624G, 644G 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.

TM1530 - John Deere 544G, 544G LL, 544G TC, 624G and 644G 4WD Loader Technical Manual - Repair.PDF

TM1530 - John Deere 544G, 544G LL, 544G TC, 624G and 644G 4WD Loader Technical Manual - Repair.EPUB

Total Pages: 770 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality) & EPUB/MOBI/AZW for Kindle etc.
Language: English

Notes: for electrical wiring diagrams, please refer to TM1529.

MAIN SECTIONS
 Foreword
   Help!! Help!! Help!! Help!!
   General Information
      Safety Information
      General Specifications
      Torque Values
      Fuels And Lubricants
      Inspection Procedures
   Wheels
      Powered Wheels And Fastenings
   Axles And Suspension Systems
      Removal And Installation
      Axle Shafts, Bearings And U-Joints
      Hydraulic System
   Transmission
      Removal And Installation
      Control 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
      Hydraulic System
   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

tm1530 - 544G, 544G LL, 544G TC, 624G, and 644G Loader

Table of Contents

Foreword

Help!! Help!! Help!! Help!!

Section 00: General Information

Group 01: Safety Information

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Group 02: General Specifications

544G Specifications

544G Drain And Refill Capacities

544G LL Specifications

544G LL Drain And Refill Capacities

544G TC Specifications

544G TC Drain And Refill Capacities

624G Specifications

624G Drain And Refill Capacities

644G Specifications

644G Drain And Refill Capacities

Group 0003: Torque Values

Hardware Torque Specifications

ROPS Torque Specifications

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Group 0004: Fuels And Lubricants

Fuel Specifications

Storing Fuel

Do Not Use Galvanized Containers

Fuel Tank

Engine Oil

Hydraulic System Oil And Differential Oil

Transmission Oil

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Group 0005: Inspection Procedures

Planned Inspection Program I (PIP I)

Planned Inspection Program II (PIP II)

Using The Checklists

Delivery Service

John Deere 544G, 624G And 644G Loader

John Deere 544G, 624G, And 644G Loader

Section 01: Wheels

Group 0110: Powered Wheels And Fastenings

Other Material

Specifications

Remove Tire

Install Tire

544G And 544G TC

544G LL

624G

644G

Section 02: Axles And Suspension Systems

Group 0200: Removal And Installation

John Deere 1200 And 1400 Series Axles—Use CTM138519

Other Material

Specifications

Remove And Install Front Axle And Differential

Remove Rear Axle And Differential

Install Rear Axle And Differential Assembly

Group 0225: Axle Shafts, Bearings And U-Joints

Other Material

Specifications

Disassemble, Inspect, And Assemble Support Bearing And Drive Shaft

Remove And Install Rear Differential Drive Line

Group 0260: Hydraulic System

Specifications

Remove And Install Differential Lock Solenoid Valve

Section 03: Transmission

Group 0300: Removal And Installation

Essential Tools

Service Equipment And Tools

Specifications

Remove And Install Transmission

Group 0315: Control Linkage

Other Material

Specifications

Remove And Install Transmission Shift Lever

Group 0325: Input Drive Shafts And U-Joints

Specifications

Remove, Disassemble, Assemble And Install Transmission Drive Shaft

Group 0350: Gear, Shafts, Bearings And Power Shift Clutch

Essential Tools

Service Equipment And Tools

Other Material

Specifications

Install Repair Stand

Remove And Install Torque Converter

Remove Clutch Packs

Remove And Install Forward And First Drive Gears

Remove And Install Reverse And Second Drive Gears

Remove And Install Third And Fourth Drive Gears

Disassemble And Assemble Clutch Packs

Clutch Packs

Remove And Install Fourth Gear Idler Gear—624G, 644G

Fourth Gear Idler Gear Shaft Orifice Sizes

Install Fourth Gear Idler Gear—544G, 544G LL, 544G TC

Install Third And Fourth Gear Clutch Pack, Adjust End Play

Install Second And Reverse, First And Forward Gear Clutch Packs

Remove And Install Output Flange

Remove And Install Output Shaft And Seals

Remove And Install Output Gear And Oil Shields

Remove And Install Speed Control Magnetic Pickup

Group 0360: Hydraulic System

Essential Tools

Service Equipment And Tools

Other Material

Specifications

Remove Oil Supply Flange And Oil Pump

Disassemble Oil Supply Flange

Assemble Oil Supply Flange

Input Drive Shaft Orifice Sizes

Disassemble Oil Pump

Assemble Oil Pump

Install Oil Pump On Oil Supply Flange

Install Oil Supply Flange And Oil Pump

Remove And Install Converter Minimum Pressure Regulator

Remove And Install Transmission Oil Filter

Remove And Install Suction Oil Strainer

Remove Transmission Control Valve

Repair Transmission Control Valve 544G (SN —542218), 624G (SN —548398), 644G (SN —548302)

Control Valve W/6th Solenoid—544G (SN 548219—), 624G (SN 548398—), 644G (SN 548303—)

Install Transmission Control Valve

Cross Section Of Thermal Bypass Valve

Disassemble And Assemble Thermal Bypass Valve

Section 04: Engine

Group 0400: Removal And Installation

John Deere 6059 Engine Repair—Use CTM8

John Deere 6068 Engine Repair—Use CTM8

John Deere 6076 Engine Repair—Use CTM42

John Deere 6081 Engine Repair—Use CTM134

Special Or Essential Tools

Service Equipment And Tools

Other Material

Specifications

Disconnect Turbocharger Oil Inlet Line

Remove And Install Engine

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Specifications

Remove And Install Starting Aid Solenoid And Nozzle

Remove And Install Engine Coolant Heater

Group 0510: Cooling System

Specifications

Other Material

Remove And Install Compressor Belt (If Equipped) And Fan Belts — 544G, 624G, 644G (SN —557738)

Remove And Install Serpentine Belt — 644G (SN 557739—)

Remove And Install Fan

Remove And Install Radiator

Remove And Install Oil Cooler

Remove And Install Coolant Level Sensor

Group 0515: Speed Controls

Other Material

Specifications

Remove And Install Speed Control Linkage

Speed Control Linkage Adjustment

Fuel Shut-Off Solenoid Adjustment—644G

Group 0520: Intake System

Specifications

Remove And Install Air Filter Elements—544G, 624G

Tighten Air Cleaner Hose Clamps

Remove And Install Air Filter Elements—644G

Test Air Intake System For Leaks

Group 0560: External Fuel Supply System

Other Material

Specifications

Remove And Install Fuel Tank

Remove And Install Primary Filter (Water Separator)

Disassemble And Assemble Primary Filter (Water Separator)

Bleed Fuel System—544G, 624G

Bleed Fuel System—644G

Remove And Install Fuel Shut-Off Solenoid—644G

Fuel Shut-Off Solenoid Adjustment—644G

Section 07: Dampener Drive

Group 0752: Elements

Specifications

Remove And Install Dampener

Section 09: Steering System

Group 0930: Secondary Steering

Specifications

Remove And Install Secondary Steering Pump, Motor And Relay (If Equipped)

Remove And Install Secondary Steering Inlet Manifold (If Equipped)

Disassemble And Assemble Secondary Steering Inlet Manifold (If Equipped)

Group 0960: Hydraulic System

Service Equipment And Tools

Other Material

Specifications

Remove And Install Steering Valve

Disassemble Steering Valve

Cross Section Of Steering Valve

Assemble Steering Valve

Remove And Install Steering Column

Remove And Install Steering Cylinders

Disassemble Steering Cylinder

Cross Section Of Steering Cylinder

Assemble Steering Cylinder

Remove And Install Steering Cylinder Bushings

Remove And Install Priority Valve

Cross Section Of Priority Valve

Disassemble And Assemble Priority Valve

Section 10: Service Brakes

Group 1011: Active Elements

Essential Tools

Inspecting Service Brake Pads

Remove And Install Brake Assembly

Group 1060: Hydraulic System

Service Tools And Equipment

Specifications

Remove And Install Brake Valve

Disassemble And Assemble Brake Valve

Remove And Install Brake Pump

Disassemble Brake Pump

Assemble Brake Pump

Disassemble And Assemble Brake Pump Pressure Compensator

Remove And Install Brake Accumulator

Charge Brake Accumulator

Hydraulic Brake Bleeding Procedure

Remove And Install Pressure Reducing Valve Manifold

Section 11: Park Brake

Group 1111: Active Elements

Specifications

Remove And Install Park Brake Pads

Disassemble And Assemble Park Brake

Adjust Park Brake

Group 1160: Hydraulic System

Specifications

Remove And Install Park Brake Release Solenoid Valve

Remove And Install Park Brake Pressure Switch

Section 15: Equipment Attaching

Group 1511: Drawbar

Specifications

Install Counterweight/Drawbar

Section 16: Electrical Systems

Group 1671: Batteries, Support And Cables

Specifications

Service Batteries Carefully

Test Batteries Using Coolant And Battery Tester

Test Batteries Using High Rate Discharge Test

Charge Battery

Remove And Install Batteries

Remove And Install Battery Disconnect Switch

Group 1672: Alternator, Regulator And Charging System Wiring

Motorola 8EM And 8MR Alternator Repair—Use CTM77

Specifications

Remove And Install Alternator

Group 1673: Lighting System

Specifications

Replace Halogen Bulbs

Remove And Install Lights

Group 1674: Wiring Harness And Switches

Special Or Essential Tools

Other Material

Specifications

Clutch Cut-Off Switch Adjustment

Return-To-Dig Adjustment

Boom Height Kickout Adjustment

Remove And Install Brake Light Switch

Remove And Install Brake Low Pressure Switch

Remove And Install Hydraulic Oil Filter Restriction Switch

Remove And Install Engine Coolant Level Switch

Remove And Install Engine Oil Pressure Switch

Remove And Install Air Filter Restriction Switch

Remove And Install Transmission Oil Pressure Switch

Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Remove Connector Body from Blade Terminals

Remove Blade Terminals From Fuse Block

Group 1677: Motors And Actuators

Starting Motor Repair—Use CTM77

Special Or Essential Tools

Specifications

Remove And Install Starting Motor

Section 17: Frame Or Supporting Structure

Group 1740: Frame Installation

Specifications

Welding Repair Of Major Structure

Separate Engine And Loader Frame

Remove And Install Upper Pivot Bearing And Seals

Remove And Install Lower Pivot Bearing And Seals

Group 1746: Frame Bottom Guards

Specifications

Remove And Install Guards

Group 1749: Chassis Weights

Specifications

Remove And Install Counterweights

Section 18: Operator’s Station

Group 1800: Removal And Installation

Special Or Essential Tools

Specifications

Remove And Install Cab Or Canopy

Group 1810: Operator Enclosure

Special Or Essential Tools

Other Material

Specifications

Remove And Install Windowpane And Molding

Remove And Install Windshield Washer

Remove, Disassemble, Assemble And Install Front Windshield Wiper

Adjust Front Windshield Wiper

Remove, Disassemble, Assemble And Install Rear Windshield Wiper

Remove And Install Defroster Fan—(SN —545144)

Remove And Install Defroster Fan—(SN 545145—)

Remove And Install Door Handle And Door/Window Release

Group 1821: Seat And Seat Belt

Specifications

Disassemble And Assemble Seat

Disassemble And Assemble Seat Belt

Group 1830: Heating And Air Conditioning

Special Or Essential Tools

Service Equipment And Tools

Other Material

Service Parts Kits For Compressor

Specifications

Proper Refrigerant Handling

R12 And R134a Refrigerant Cautions

R12 Component Oil Charge

R12 Refrigerant Evacuation And Charging Station Installation Procedure

Recover R12 System

Evacuate R12 System

Charge R12 System

R134a Compressor Oil Information

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

R134a Refrigerant Recovery/Recycling And Charging Station Installation Procedures

R134a Refrigerant Recovery

Evacuate R134a System

Charge R134a System

Leak Testing

Check And Adjust Compressor Belt Tension — 544G, 624G, 644G (SN —557738)

Remove And Install Compressor And High Pressure Switch

Volumetric Efficiency Test—R12

Shaft Seal Leak Test

Disassemble And Inspect Compressor

Clutch Pulley, Bearing And Hub Inspection

Replace Clutch Pulley Bearing

Replace Shaft Seal Seat

Assemble Compressor

Remove And Install Condenser

Remove And Install Evaporator And Expansion Valve

Remove And Install Receiver/Dryer And Low Pressure Switch

Remove And Install Condenser Fan Motors

Freeze Control Temperature Cycling Switch Bench Test

Disassemble And Assemble Blower Motor

Remove And Install Heater Core

Remove And Install Cab Heater Hoses And Controls

Section 31: Loader

Group 3102: Bucket

Specifications

Remove And Install Bucket Tooth Shanks And Tips

Remove And Install Bucket

Replace Welded Bucket Cutting Edges

Remove And Install Cutting Edges (for Bucket With Wear Plates)

Repair Cracked Cutting Edge

Group 3140: Frames

Service Equipment And Tools

Other Material

Specifications

Remove And Install Bucket Tilt Linkage—544G, 624G And 644G

Remove And Install Bucket Linkage Seals And Bushings—544G, 624G And 644G

Disassemble And Assemble Bucket Tilt Linkage—544G TC And 544G LL

Disassemble And Assemble Tool Carrier—544G TC

Remove And Install Boom Bushings And Shims—544G, 624G And 644G

Remove And Install Boom Bushings And Shims—544G TC And 544G LL

Group 3160: Hydraulic System

Essential Tools

Service Equipment And Tools

Other Material

Specifications

Remove And Install Main Hydraulic Pump

Disassemble, Inspect And Assemble Main Hydraulic Pump

Remove And Install Loader Control Valve

Disassemble And Assemble Loader Control Valve

Disassemble And Assemble Boom Valve (All Units) And Bucket Section (544G TC And 544G LL)

Disassemble And Assemble Auxiliary Valve (All Units) And Bucket Section (544G, 624G, And 644G)

Disassemble And Assemble System Relief Valve

Disassemble And Assemble Anti-Cavitation Valve

Disassemble And Assemble Screw Adjustable Circuit Relief Valve

Service Bucket And Boom Section Pilot Orifice Check Valve

Remove And Install Boom Cylinder

Remove And Install Bucket Cylinder

Disassemble Boom Or Bucket Cylinder

Assemble Boom Or Bucket Cylinder

Remove And Install Bucket Or Boom Cylinder Bushings And Seals

Remove And Install Hydraulic Reservoir

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Remove And Install Pilot Control Valves (Two Lever Controller)

Disassemble And Assemble Pilot Control Valve (Two-Lever Controller)

Disassemble And Assemble Pilot Control Valve (Two Lever Controller)

Remove And Install Pilot Controller (Single Lever Controller) — 544G, 624G, 644G (SN —563542)

Disassemble Single Lever Pilot Controller — 544G, 624G, 644G (SN —563542)

Assemble Single Lever Controller — 544G, 624G (SN —563542)

Remove And Install Pilot Controller Valve (Single Lever Controller) — 644G (SN 563543—)

Pilot Controller Valve (Single Lever Controller), Cross Section — 644G (SN 563543—)

Disassemble And Assemble Valve (Single Lever Controller) — 644G (SN 563543—)

Replacing Quickshift Switch In Controller Lever — 644G (SN 563543—)

Replace Pilot Control Lever Boot (Joystick) — 644G (SN 536543—)

Replace Pilot Control Lever Boot (Single Lever) — 644G (SN 563543— )

Replace Universal Joint — 644G (SN 563543—)

Replace Seals On Spool Retainers And Inspect Spool Assembly — 644G (SN 563543—)

Pilot Control Valve Pressure Test (Bench) — 644G (SN 563543— )

Remove And Install Pressure Reducing Valve

Remove And Install Boom Down Solenoid Valve

Disassemble And Assemble Pin Disconnect Cylinder—544G TC

Disassemble And Assemble Pin Disconnect Solenoid Valve—544G TC

Ride Control Valve Remove And Install—If Equipped

Ride Control Valve Disassemble And Assemble—If Equipped

Ride Control Accumulator Remove and Install

Ride Control Accumulator Disassemble And Assemble—If Equipped

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DF1055 And JD38002 Yoke Holding Tool

DF1056 Input Pinion Shaft Adjusting Tool

DF1057 Axle Adjusting Tool

DF1025 Oil Supply Flange Back-Off Brackets

DF1026 Pre-Load Clutch Pack Compression Ring Assembly Jig

DF1027 Stand Mounting Bracket

JDG588 Shaft Alignment Tool

DF1044 Air Deflector Bushing

DFT1118 Spanner Wrench

John Deere 4WD Loaders 544G, 544G LL, 544G TC, 624G, 644G Repair Service Manual (TM1530)