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

Total Pages: 782 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

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

tm1414 - 544E, 544E LL, 544E TC, 624E, and 644E Loaders Repair

Table of Contents

Foreword

Section I: General Information

Group I: 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

Dispose of Waste Properly

Live With Safety

Group II: General Specifications

544E Specifications

544E Drain And Refill Capacities

544E LL Specifications

544E LL Drain And Refill Capacities

544E TC Specifications

544E TC Drain And Refill Capacities

624E Specifications

624E Drain And Refill Capacities

644E Specifications

644E Drain And Refill Capacities

Group III: Torque Values

Hardware Torque Specifications

ROPS Torque Specifications

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap 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 IV: Fuels And Lubricants

Fuel Specifications

Storing Fuel

Fuel Tank

Engine Oil

Transmission Oil

Hydraulic System Oil

Differential Oil

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Engine Coolant

Section 01: Wheels

Group 0110: Powered Wheels And Fastenings

Other Material

Specifications

Remove Tire

Install Tire

544E And 544E TC

544E LL

624E

644E

Section 02: Axles And Suspension Systems

Group 0200: Removal And Installation

John Deere 1200 And 1400 Series Axles-Use CTM18

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 Double Universal Joint, Support Bearing And Universal Joint Drive Shaft

Remove, Disassemble, Assemble And Install Rear Differential Drive Line

Group 0260: Hydraulic System

Remove, Disassemble, Assemble 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: Controls Linkage

Other Material

Specifications

Disassemble And Assemble Transmission Control Linkage

Transmission Direction Selector Linkage Adjustment

Transmission Speed Selector Linkage Adjustment

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-544E, 544E LL, 544E TC

Remove And Install Fourth Gear Idler Gear-624E, 644E

Fourth Gear Idler Orifice Sizes

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 And Park Brake

Remove And Install Output Shaft And Seals

Remove And Install Output Gear And Oil Shields

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

Disassemble Transmission Control Valve

Disassemble And Assemble Cover Plate

Disassemble And Assemble Pressure Regulating Valve, Pilot Valve, And Modulation Piston

Disassemble And Assemble Direction Selector Valve

Disassemble And Assemble Clutch Cut-Off Valve And Clutch Cut-Off Pilot Orifice

Disassemble And Assemble Speed Selector Valve

Assemble Transmission Control Valve

Install Transmission Control Valve

Remove And Install Main Hydraulic Filter

Cross Section Of Thermal Bypass Valve

Remove, Disassemble, Assemble And Install Thermal Bypass Valve

Section 04: Engine

Group 0400: Removal And Installation

John Deere 6076 Engine Repair-Use CTM6

John Deere 6059 And 6068 Engine Repair-Use CTM8

John Deere 6359 And 6414 Engine Repair-Use CTM4

Special Or Essential Tools

Service Equipment And Tools

Other Material

Specifications

Disconnect Turbocharger Oil Inlet Line

Remove And Install Engine

Remove And Install Oil Pan

Remove And Install Fuel Injection Pump-544E, 624E (DB2-Non-Retained Shaft)

Remove And Install DB2 Fuel Injection Pump Drive Shaft-544E, 624E

Remove Fuel Injection Pump-544E, 624E (DB4-Retained Shaft)

Install Fuel Injection Pump-544E, 624E (DB4-Retained Shaft)

Remove Fuel Injection Pump-644E

Install Fuel Injection Pump-644E

Remove And Install Fuel Filter Check Valve-644E

Remove And Install Fuel Injection Nozzle-544E, 624E

Remove Fuel Injection Nozzle-644E

Inspect And Clean Cylinder Head Nozzle Bore-644E

Inspect And Clean Nozzle Seating Surface-644E

Install Fuel Injection Nozzle-644E

Bleed Fuel System-544E, 624E

Bleed Fuel System-644E

Remove And Install Turbocharger

Remove And Install Water Pump-544E, 624E

Remove And Install Water Pump-644E

Remove And Install Fan Drive-644E

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

Remove And Install Compressor Belt (If Equipped) And Fan Belts

Remove And Install Fan

Remove And Install Radiator

Remove And Install Oil Cooler

Group 0515: Speed Controls

Other Material

Specifications

Remove And Install Speed Control Linkage

Engine Speed Control Linkage Adjustment

Fuel Shut-Off Cable Adjustment-644E

Group 0520: Intake System

Specifications

Remove And Install Air Filter Elements-544E, 624E

Tighten Air Cleaner Hose Clamps

Remove And Install Air Filter Elements-644E

Test Air Intake System For Leaks

Group 0560: External Fuel Supply System

Other Material

Specifications

Remove And Install Fuel Tank-544E, 624E And 644E (Serial No. 537537-)

Remove And Install Fuel Tank-644E (Serial No. -537536)

Remove And Install Water Separator

Disassemble And Assemble Water Separator

Section 07: Dampener Drive

Group 0752: Elements

Specifications

Remove And Install Dampener

Section 09: Steering System

Group 0930: Secondary Steering

Remove And Install Secondary Steering Pump, Motor, And Relay

Remove And Install Secondary Steering Inlet Manifold

Disassemble And Assemble Secondary Steering Inlet Manifold

Group 0960: Hydraulic System

Special Or Essential Tools

Service Equipment And Tools

Other Material

Specifications

Remove And Install Steering Valve

Disassemble Steering Valve

Cross Section Of Steering Valve

Assemble Steering Valve

Remove, Disassemble, Assemble 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

Remove And Install Crossover Relief Valve

Cross Section Of Crossover Relief Valve

Disassemble And Assemble Crossover Relief Valve

Remove And Install Steering Accumulator-644E Later Machines

Disassemble And Assemble Steering Accumulator-644E Later Machines

Charge Steering Accumulator-644E Later Machines

Section 10: Service Brakes

Group 1011: Active Elements

John Deere 1200 And 1400 Series Axles-Use CTM18

Specifications

Inspect Brakes

Remove And Install Brake Assembly

Inspect Brake Elements

Group 1060: Hydraulic System

Service Equipment And Tools

Specifications

Remove And Install Brake Valve

Brake Valve Identification

Disassemble And Assemble Brake Valve

Remove And Install Brake Pump

Disassemble Brake Pump

Inspect Brake Pump Parts

Assemble Brake Pump

Disassemble And Assemble Compensator Valve

Remove And Install Brake Accumulators

Disassemble And Assemble Brake Accumulators

Charge Brake Accumulator

Hydraulic Brake Bleeding Procedure

Section 11: Park Brake

Group 1111: Active Elements

Specifications

Other Material

Remove And Install Park Brake

Disassemble And Assemble Park Brake

Group 1115: Controls Linkage

Remove And Install Park Brake Linkage

Adjust Park Brake Linkage

Section 15: Equipment Attaching

Group 1511: Drawbar

Specifications

Install Counterweight/Drawbar

Section 16: Electrical Systems

Group 1671: Batteries, Support And Cables

Specifications

Handle Batteries Safely

Test Batteries Using Coolant And Battery Tester

Test Batteries Using High Rate Discharge Test

Charge Battery

Remove And Install Batteries

Group 1672: Alternator, Regulator And Charging System Wiring

Alternator Repair-Use CTM77

Service Equipment And Tools

Specifications

Remove And Install Alternator (Except BOSCH)

Remove And Install BOSCH Alternator

Group 1673: Lighting System

Specifications

Replace Halogen Bulbs

Remove And Install Lights

Group 1674: Wiring Harness And Switches

Special Or Essential Tools

Specifications

Clutch Cut-Off Switch Adjustment

Remove And Install Brake Low Pressure Switch

Return-To-Dig Adjustment

Boom Height Kickout Adjustment

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

Install DEUTSCH DEUTSCH is a trademark of the Deutsch Company. 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

Service Equipment And Tools

Other Material

Specifications

Welding Repair Of Major Structure

Separate Engine And Loader Frame

Remove And Install Upper Pivot Bearing And Seals

Remove And Install Lower Pivot Bushing And Seals

Group 1746: Frame Bottom Guards

Remove And Install Fuel Tank Bottom Guard

Repair Bottom Guards

Remove And Install Auxiliary Bottom Guards (If Equipped)

Group 1749: Chassis Weights

Specifications

Remove And Install Counterweights

Section 18: Operator's Station

Group 1800: Removal And Installation

Special Or Essential Tools

Service Equipments And Tools

Other Material

Specifications

Remove And Install Cab Or Canopy

Tilt 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

Remove, Disassemble, Assemble And Install Rear Windshield Wiper

Adjust Front Windshield Wiper

Remove And Install Defroster Fan

Remove And Install Door Handle And Door/Window Release

Group 1821: Seat And Seat Belt

Specifications

Disassemble And Assemble Seat

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

Refrigerant (R-12) Cautions

Air Conditioning Gauge Set Installation Procedure

Refrigerant Recovery

Evacuate R12 System

Charge R12 System

Check And Add Compressor Oil

Remove And Install Compressor And High Pressure Switch

Volumetric Efficiency Test-R12

Make Shaft Seal Leak Test

Disassemble And Inspect Compressor

Clutch Pulley, Bearing And Hub Inspection

Replacing Clutch Pulley Bearing

Replace Shaft Seal Seat

Assemble Compressor

Remove And Install Condenser

Remove And Install Evaporator And Expansion Valve

Expansion Valve Bench Test And Adjustment

Remove And Install Receiver/Dryer And Low Pressure Switch

Remove And Install Condenser Fan Motors

Remove And Install Blower Wiring Harness

Thermostat 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

Other Material

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-544E, 624E, And 644E

Remove And Install Bucket Linkage Seals And Bushings-544E, 624E, And 644E

Disassemble And Assemble Bucket Tilt Linkage-544E TC And 544E LL

Disassemble And Assemble Tool Carrier-544E TC

Remove And Install Boom Bushings And Shims-544E, 624E, And 644E

Remove And Install Boom Bushings And Shims-544E TC And 544E LL

Group 3160: Hydraulic System

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-(Serial No. -534614)

Disassemble And Assemble Loader Control Valve-(Serial No. 534615-)

Service Bucket And Boom Section Pilot Orifice Check Valve-Later Machines Only

Disassemble And Assemble Boom Valve Section-All Machines; And Bucket Valve Section-544E TC And 544E LL

Disassemble And Assemble Auxiliary Valve Section-All Machines; And Bucket Section-544E, 624E, And 644E

Disassemble And Assemble System Relief Valve

Disassemble And Assemble Shim Adjustable Circuit Relief Valve

Disassemble And Assemble Anti-Cavitation Valve

Disassemble And Assemble Screw Adjustable Circuit Relief Valve

Remove And Install Boom Cylinder

Remove And Install Bucket Cylinder

Cross Section Of Boom Or Bucket Cylinder

Disassemble Boom Or Bucket Cylinder

Assemble Boom Or Bucket Cylinder

Remove And Install Bucket Or Boom Cylinder Bushings And Seals

Remove, Disassemble, Assemble And Install Boom Solenoid Valve

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)

Remove And Install Pilot Controller (Single Lever Controller)

Cross Section Of Single Lever Pilot Controller (Serial No. -537112)

Disassemble Single Lever Pilot Controller (Serial No. -537112)

Assemble Single Lever Pilot Controller (Serial No. -537112)

Disassemble Single Lever Pilot Controller (Serial No. 537113-)

Assemble Single Lever Controller (Serial No. 537113-)

Remove, Disassemble, Assemble And Install Pressure Reducing Valve

Remove And Install Pin Disconnect Cylinders-544E TC

Cross Section Of Pin Disconnect Cylinder-544E TC

Disassemble Pin Disconnect Cylinder-544E TC

Assemble Pin Disconnect Cylinder-544E TC

Disassamble And Assemble Pin Disconnect Solenoid Valve-544E TC

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

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

DFT1071 Cab Tilt Pivots And Hinges

JDG588 Shaft Alignment Tool

DF1044 Air Deflector Bushing

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