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

Total Pages: 1,010 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

tm1413 - 544E, 544E LL, 544E TC, 624E, 644E Loader Operation and Test

Table of Contents

Foreword

Section 9000: 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

Dispose of Waste Properly

Live With Safety

Group 02: 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 03: 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 04: Fuels And Lubricants

Fuel Specifications

Storing Fuel

Fuel Tank

Engine Oil

Transmission Oil

Hydraulic System Oil

Differential Oil

Grease

Alternative and Synthetic Lubricants

Synthetic Lubricants

Lubricant Storage

Cold Weather Operation

Engine Coolant

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Record Sheet-544E, 624E, And 644E

Complete Machine Operational Checkout

Section 9010: Engine Operation And Tests

Group 05: Theory Of Operation

Cooling System Operation-544E, 624E

Cooling System Operation-644E

Thermostat Operation

Air Cleaner Operation

Turbocharger Operation

Engine Lubrication-544E, 624E

Engine Lubrication Operation-644E

Fuel System Operation-544E, 624E

Fuel System Operation-644E

Fuel Supply Pump Operation-544E, 624E

Fuel Pump Operation-644E

Fuel Filter Operation

Fuel Injection Pump Operation-544E, 624E

Fuel Injection Pump Operation-644E

Fuel Injection Nozzle Operation-544E, 624E

Fuel Injection Nozzle Operation-644E

Group 10: System Operational Checks

Engine Operational Checks

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Coolant Requirements

Group 20: Adjustments

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

D01084AA Tachometer Reader Installation Procedure

Valve Clearance Adjustment-544E, 624E

Valve Clearance Adjustment-644E

Fan Belt Tension Adjustment

Injection Pump Static Timing Adjustment-544E, 624E

Injection Pump Static Timing Adjustment-644E

Slow And Fast Idle Adjustment-544E, 624E

Slow Idle Adjustment-644E

Fast Idle Adjustment-644E

Speed Control Linkage Adjustment

Fuel Shut-Off Cable Adjustment-644E

Bleed The Fuel System-544E, 624E

Bleed The Fuel System-644E

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Dampener Runout Check

Valve Lift Check

Compression Pressure Test-544E, 624E

Compression Pressure Test-644E

Engine Oil Pressure Test-544E, 624E

Engine Oil Pressure Test-644E

Turbocharger Shaft Axial End Play Test

Turbocharger Shaft Radial Movement Test

Cooling System Test

Fuel Pump Pressure Test-544E, 624E

Fuel Pump Pressure Test-644E

Air Filter Restriction Indicator Switch Test

Radiator Air Flow Test

JT05529 Airflow Meter Test Record

Engine Power Test Using Engine Pulldown

Engine Power Test Using Turbocharger Boost Pressure

Air Intake System Leakage Test

Fuel Line Leakage Test

Section 9015: Electrical System Operation And Test

Group 00: Electrical System Operation And Test

Safety Precautions

Using Booster Batteries-12 Volt System

Visually Inspect Electrical System

Testing The Electrical System

Common Circuit Test

Electrical Operational Checks

Electrical Schematic Symbols

Wiring Diagram Information

Battery-Diagnose Malfunctions

Battery Operation

Battery Specifications

Fuse Specifications

Bulb Replacement Specifications

Diagnose Power And Ground Circuit Malfunctions

Power Circuit Operation

Power Circuit Wiring Diagram

Power Circuit Test

Diagnose Starter Circuit Malfunctions

Diagnose Fuel Shut-Off Malfunctions-544E, 624E

Starting Circuit And Fuel Shut-Off Solenoid Operational Checks

Starting Circuit And Fuel Shut-Off Solenoid Operation

Starter Operation

Start Circuit And Fuel Shut-Off Solenoid Wiring Diagram

Start Circuit And Fuel Shut-Off Solenoid Tests

Diagnose Charging Circuit Malfunctions-65 Amp Alternator

Alternator Operation-65 Amp Motorola

Charging Circuit Operation-65 Amp Motorola Alternator-(Serial No. -532819)

Charging Circuit Wiring Diagram-65 Amp Motorola-(S.N. -532819)

Charging Circuit Operation-65 Amp Motorola Alternator-(Serial No. 532820-)

Charging Circuit Wiring Diagram-65 Amp Motorola-(S.N. 532820-)

Diagnose Charging Circuit Malfunctions-90 Amp And 105 Amp Alternator

Alternator Operation-90 Amp And 105 Amp Delco Remy

Charging Circuit Operation-105 Amp Delco-Remy Alternator-(S.N. 518774-)

Charging Circuit Wiring Diagram-105 Amp Alternator-(S.N. 518774-)

Charging Circuit Operation-90 Amp Delco-Remy Alternator

Charging Circuit Wiring Diagram-90 Amp Delco-Remy Alternator

Diagnose Charging Circuit Malfunctions-130 Amp Alternator

Alternator Operation-130 Amp Motorola

Charging Circuit Operation-130 Amp Motorola Alternator

Charging Circuit Wiring Diagram-130 Amp Motorola Alternator

130 Amp Alternator Voltage Adjustment

Diagnose Logic Module And Warning Alarm Circuit Malfunctions

Logic Module And Warning Alarm Circuit Operation

Logic Module And Warning Alarm Wiring Diagram

Logic Module Test In Machine

Logic Module Bench Test

Diagnose Indicator Circuit Malfunctions-Top Row

Indicator Circuits Operation-Top Row

Indicator Circuits Wiring Diagram-Top Row

Diagnose Indicator Circuit Malfunctions-Middle Row

Indicator Circuits Operation-Middle Row

Indicator Circuits Wiring Diagram (Middle Row)

Park Brake Switch Adjustment

Pressure Switch And Sender Test

Diagnose Gauges And Horn Circuit Malfunctions

Gauges And Horn Circuits Operation

Gauges And Horn Circuit Wiring Diagram

Diagnose Return-To-Dig And Boom Height Kickout Malfunctions

Return-To-Dig And Boom Height Kickout Circuit Operation

Return-To-Dig And Boom Height Kickout Wiring Diagram

Boom Height Kickout Adjustment

Return-To-Dig Adjustment

Diagnose Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Malfunctions

Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Operation

Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Operation Wiring Diagram

Diagnose Secondary Steering System Malfunctions

Secondary Steering Circuit Operation

Secondary Steering Wiring Diagram

Secondary Steering Circuit Test

Secondary Steering Controller Test

Secondary Steering Pressure Switch

Diagnose Hour Meter Circuit Malfunctions

Hour Meter Circuit Operation

Hour Meter Circuit Wiring Diagram

Diagnose Boom Down Circuit Malfunctions

Boom Down Circuit Operation-(Serial No. -518527)

Boom Down Circuit Wiring Diagram-(Serial No. -518527)

Boom Down Circuit Operation-(Serial No. 518528-521102)

Boom Down Circuit Wiring Diagram-(Serial No. 518528-521102)

Boom Down Circuit Operation-(Serial No. 521103-)

Boom Down Circuit Wiring Diagram-(Serial No. 521103-)

Diagnose Differential Lock And Clutch Cut-Off Circuit Malfunctions

Differential Lock And Clutch Cut-Off Circuit Operation

Differential Lock And Clutch Cut-Off Circuits Wiring Diagram

Diagnose Turn Signal And Flasher Circuit Malfunctions

Turn Signal And Flasher Indicator Circuit Operation

Turn Signal And Flasher Indicator Circuit Wiring Diagram

Diagnose Drive, Work, Brake And Gauge Light Circuit Malfunctions

Drive, Work, Brake And Gauge Light Circuit Operation

Drive, Work, Brake And Gauge Light Circuits Wiring Diagram

Diagnose Windshield Wiper And Washer Circuit Malfunctions

Windshield Wiper And Washer Circuit Operation

Windshield Wiper/Washer Circuit Wiring Diagram

Diagnose Pin Disconnect Circuit Malfunctions

Pin Disconnect Circuit Operation

Pin Disconnect Circuit Wiring Diagram

Radio Circuit Operation

Electrical Component Location Drawing

Section 9020: Power Train Operation And Tests

Group 05: Theory Of Operation

Power Train Component Overview

Drive Dampener

Transmission Clutch Engagement

Torque Converter Operation

Transmission Operation-Neutral

Transmission Operation-1st Gear Forward

Transmission Operation-2nd Gear Forward

Transmission Operation-3rd Gear Forward

Transmission Operation-4th Gear Forward

Transmission Operation-1st Gear Reverse

Transmission Operation-2nd Gear Reverse

Transmission Operation-3rd Gear Reverse

Clutch Operation

Transmission Hydraulic Components

Transmission Hydraulic System

Transmission Pump Operation

Transmission Control Valve Components

Transmission Control Valve-1st Gear Neutral

Transmission Control Valve-4th Gear Forward

Shift Modulation

Shift Modulation-1st Gear (Full Engagement)

Shift Modulation-1st Gear (Shift Initiated-Clutch Filling)

Shift Modulation-1st Gear (Modulation Starting)

Shift Modulation-2nd, 3rd, And 4th Gears

Thermal Bypass Valve Operation

Differential Lock Operation

Final Drive Operation

Axle Outer Seal And Bearing Operation

Axle Disconnect Operation

Brake Hydraulic System

Brake Pump Operation

Accumulator Operation

Brake Valve Operation

Wet Chambered Brake Valve

Pressure Reducing Valve Operation-Neutral

Pressure Reducing Valve Operation-Differential Lock On

Group 10: System Operational Checks

Power Train Operational Checks

Group 15: Diagnostic Information

Diagnose Transmission System Malfunctions

Diagnose Service Brake Malfunctions

Diagnose Differential/Axle Malfunctions

Diagnose Drive Line Malfunctions

Diagnose Park Brake Malfunctions

Hydraulic Circuit Symbols

Brake, Differential Lock Circuit Schematic

Power Train Schematic

Power Train And Brakes System Component Location

Group 20: Adjustments

Transmission Control Valve Linkage-FNR And Neutral Lock Adjustment

Transmission Control Valve Linkage-Speed Control Adjustment

Brake Pedal Adjusting Screw Adjustment (Early Units Only)

Front Axle Disconnect Adjustment

Clutch Cut-Off Switch Adjustment

Brake Pad Inspection

Hydraulic Brake Bleeding Procedure

Charge Brake Accumulator

Park Brake Linkage Adjustment

Park Brake Indicator Switch Adjustment

Brake Pump And Differential Lock System Oil Clean-Up Procedure Using Portable Filter Caddy

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

D01084AA Tachometer/Temperature Reader Installation Procedure

Transmission Oil Warm-Up Procedure

Brake, Differential Lock, And Hydraulic System Oil Warm-Up Procedure

Transmission Pump Flow Test

Transmission System Pressure, Element Leakage, And Shift Modulation Test

Lube Pressure Test

Converter Relief Pressure Test

Converter-In Pressure Test

Converter-Out Pressure Test

Converter-Out Flow Test

Transmission Oil Cooler Backflush Procedure

Transmission Oil Cooler Restriction Test

Clutch Cut-Off Valve Pressure Test

Pressure Reducing Valve Manifold Leakage Test

Transmission Oil Cooler Thermal Bypass Valve Test

Transmission Oil Cooler Bypass Valve Pressure Test

Torque Converter Stall Speed Test

Brake Pump Flow Test

Brake Pump Standby Pressure Test

Brake Valve Pressure Test

Brake Accumulator Precharge Test

Brake Valve Leakage Test

Brake Accumulator Inlet Check Valve Leakage Test

Differential Lock Pressure Test

Differential Lock Leakage Test

Axle Bearing Adjustment Check

No-Spin Differential Test

Section 9025: Hydraulic System Operation And Test

Group 05: Theory Of Operation

Steering Circuit Component Location

Steering Circuit Components

Steering Circuit Operation-Right Turn

Main Hydraulic Pump Operation

Priority Valve Operation

Steering Valve Operation

Crossover Relief Valve Operation

Steering Cylinder Operation

Steering Accumulator Operation-644E Later Units

Secondary Steering System Operation

Inlet Manifold Operation

Loader Hydraulic System

Pressure Reducing Valve-Secondary Boom Lower Operation

Pilot Controller Operation

Boom Section Operation

Bucket Section Orifice Check Valve

Bucket Section Operation-544E, 624E, And 644E

Bucket Section Operation-544E TC And 544E LL

Auxiliary Section Operation

System Relief Valve Operation

Circuit Relief Valve Operation

Anti-Cavitation Valve Operation

Loader Cylinder Design

Return Filter Operation

Pin Disconnect Circuit Operation-544E TC

Group 10: System Operational Checks

Hydraulic Operational Checks

Group 15: Diagnostic Information

Diagnose Hydraulic System Malfunctions

Hydraulic Circuit Symbols

Main Hydraulic System Component Location

Main Hydraulic System Schematic

Main Hydraulic System Schematic (Tandem Valve)

Hydraulic System Component Location-544E TC And 544E LL

Group 20: Adjustments

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Boom Height Kickout Adjustment

Return-To-Dig Adjustment

Charge Steering Accumulator-644E Later Machines

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

D01084AA Tachometer/Temperature Reader Installation Procedure

Hydraulic Oil Warm-Up Procedure

Main Hydraulic Pump Flow Test

Loader System And Circuit Relief Valve Pressure Test

Hydraulic System Restriction Test

Loader Cylinder Drift Test

Boom And Bucket Cylinder Leakage Test

Hydraulic Oil Cooler Restriction Test

Steering System Leakage Test

Steering Valve Neutral Leakage Test

Steering Crossover Relief Valve

Steering Stop Wear Check

Priority Valve Pressure Test

Priority Valve "LS" Port Flow Test

Priority Valve Relief Cartridge Leakage Test

Secondary Steering Pump Relief Valve Pressure Test

Secondary Steering Manifold Primary Check Valve Leakage Test

Secondary Steering Manifold Secondary Check Valve Leakage Test

Pilot Control Valve Pressure Test

Pressure Reducing Valve Pressure Test

Cycle Time Test

Hydraulic Oil Filter Inspection Procedure

Pin Disconnect Solenoid Valve Leakage Test

Pin Disconnect Cylinder Leakage Test

Section 9031: Heating And Air Conditioning System Operation And Tests

Group 05: Theory Of Operation

Refrigerant System

Electrical System Wiring Diagram-Early Machines

Electrical System Schematic-Early Machines

Electrical System Wiring Diagram-Later Machines

Electrical System Schematic-Later Machines

Receiver-Dryer Operation

Expansion Valve Operation

Thermostat Control Switch Operation

Compressor Relief Valve Operation

Group 10: System Operational Checks

Air Conditioning Operational Checks

Group 15: Diagnostic Information

Diagnose Air Conditioning Electrical Malfunctions

Air Conditioning Component Location Drawing

Group 20: Adjustments

Refrigerant (R-12) Cautions

Check And Add Compressor Oil

Air Conditioning Gauge Set Installation Procedure

Refrigerant Recovery

Flush The System

Purge The System

Evacuate The System

Charge The System

Add Refrigerant To System

Check And Adjust Compressor Belt Tension

Group 25: Tests

Refrigerant (R-12) Cautions

Air Conditioning System Test

Operating Pressure Diagnostic Chart

Expansion Valve Operating Test

Expansion Valve Bench Test And Adjustment

Thermostat Control Switch Operating Test

Thermostat Control Switch Bench Test And Adjustment

Low Refrigerant Pressure Switch Test

High Refrigerant Pressure Switch Test

Leak Testing

Refrigerant Hoses And Tubing Inspection

Air Conditioner, Heater, And Defroster Circuit Test

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