John Deere 544L 4WD Loader Repair Service Manual (TM14345X19)
Complete Repair Service Technical Manual for John Deere 544L 4WD Loader, with all the shop information to maintain, repair, and rebuild like professional mechanics.
John Deere 544L 4WD Loader workshop technical manual (repair) 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.
tm14345x19 - 544L 4WD Loader Technical Manual - Repair.pdf
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PRODUCT DETAILS:
Total Pages: 688 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
TABLE OF CONTENTS
Section 00: General Information....15
Group 0001: Safety....15
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance....21
Recognize Safety Information....25
Follow Safety Instructions....26
Operate Only If Qualified....27
Wear Protective Equipment....28
Protect Against Noise....29
Avoid Unauthorized Machine Modifications....30
Inspect Machine....31
Stay Clear of Moving Parts....32
Avoid High-Pressure Fluids....33
Avoid High-Pressure Oils....34
Work In Ventilated Area....35
Avoid Static Electricity Risk When Refueling....36
Prevent Fires....38
In Case of Machine Fire....39
Prevent Battery Explosions....40
High Debris Applications....41
Clean Debris from Machine....42
Handle Chemical Products Safely....43
Handle Starting Fluid Safely....44
Decommissioning — Proper Recycling and Disposal of Fluids and Components....45
Prepare for Emergencies....46
Exhaust Filter Ash Handling and Disposal....47
Add Cab Guarding for Special Uses....48
Group 0003: Torque Values....15
Metric Bolt and Cap Screw Torque Values....51
Additional Metric Cap Screw Torque Values....53
Unified Inch Bolt and Cap Screw Torque Values....55
Service Recommendations for 37° Flare and 30° Cone Seat Connectors....57
Service Recommendations for O-Ring Boss Fittings....59
Service Recommendations for Flared Connections—Straight or Tapered Threads....61
Service Recommendations for Flat Face O-Ring Seal Fittings....63
O-Ring Face Seal Fittings With SAE Inch Hex Nut and Stud End for High-Pressure Service Recommendations....65
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for Standard Pressure Service Recommendations....67
O-Ring Face Seal Fittings With Metric Hex Nut and Stud End for High-Pressure Service Recommendations....70
Service Recommendations for Metric Series Four Bolt Flange Fitting....73
Service Recommendations For Inch Series Four Bolt Flange Fittings....75
Inch Series Four Bolt Flange Fitting for High-Pressure Service Recommendations....77
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings....79
Service Recommendations For O-Ring Boss Fittings With Shoulder....82
Metric 24° O-Ring Seal DIN 20078 Service Recommendations....85
Section 01: Wheels....89
Group 0110: Powered Wheels and Fasteners....89
Wheel Remove and Install....92
Tire Remove and Install....94
Section 02: Axles and Suspension Systems....97
Group 0200: Removal and Installation....97
TeamMate™ IV Axles....116
Front Axle and Differential Remove and Install....100
Rear Axle and Differential Remove and Install....103
Axle Oscillating Supports Disassemble and Assemble....106
Group 0225: Input Drive Shafts and U-Joints....97
Universal Joint and Drive Shaft Remove and Install....112
Group 0250: Axle Shaft, Bearings, and Reduction Gears....97
TeamMate™ IV Axles....116
Group 0260: Hydraulic System....97
Differential Lock Solenoid Valve Remove and Install....118
Axle Circulation Pumps Remove and Install....119
Section 03: Transmission....121
Group 0300: Removal and Installation....121
Transmission Remove and Install....126
Group 0350: Gear, Shafts, and Power Shift Clutches....121
Torque Converter and Housing Remove....135
Torque Converter and Housing Install....140
Clutches and Input and Output Shafts Remove....145
Clutches and Input and Output Shafts Install....153
Clutch Pack KV and KR Disassemble....165
Clutch Pack KV and KR Assemble....169
Clutch Pack K1, K2, and K3 Disassemble....179
Clutch Pack K1, K2, and K3 Assemble....184
Clutch Pack K4 Disassemble....194
Clutch Pack K4 Assemble....197
Input Shaft Disassemble....207
Input Shaft Assemble....209
Output Shaft Disassemble....212
Output Shaft Assemble....213
Transmission Speed Sensors Remove and Install....215
Group 0360: Hydraulic System....121
Transmission Pump Remove and Install....224
Converter Minimum Pressure Regulator Valve Remove and Install....231
Transmission Hydraulic Control Valve Remove and Install....232
Transmission Hydraulic Control Valve Cross Section View....240
Transmission Hydraulic Control Valve Disassemble and Assemble....241
Torque Converter Relief Valve Remove, Disassemble, and Install....256
Transmission Internal Oil Pipes and Tubes Remove and Install....258
Section 04: Engine....263
Group 0400: Removal and Installation....263
John Deere Engine....265
Engine Remove and Install....266
Section 05: Engine Auxiliary System....275
Group 0505: Cold Weather Starting Aids....275
Cold Start Aid—Glow Plug Remove and Install....278
Cold Start Aid—Block Heater Remove and Install....279
Group 0510: Cooling Systems....275
Axle Oil Coolers Remove and Install....283
Radiator Remove and Install....285
Hydraulic Oil Cooler Remove and Install....289
Transmission Oil Cooler Remove and Install....291
Charge Air Cooler Remove and Install....293
Cooling Package Plenum Remove and Install....295
Fuel Cooler Remove and Install....306
Group 0520: Intake System....275
Air Cleaner Remove and Install....310
Precleaner Remove and Install....312
Group 0530: External Exhaust Systems....275
Exhaust Tube Remove and Install....316
Exhaust Filter Remove and Install....318
Diesel Oxidation Catalyst Remove and Install....321
Diesel Particulate Filter (DPF) Remove and Install....322
Exhaust Gas Aftertreatment System Remove and Install....323
Selective Catalyst Reduction (SCR) Remove and Install....325
Diesel Exhaust Fluid (DEF) Tank Remove and Install....328
Diesel Exhaust Fluid (DEF) Tank Header Remove and Install....332
Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble....334
Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure....336
Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install....338
Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install....340
Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install....343
Group 0560: External Fuel Supply Systems....275
Final Fuel Filter Remove and Install....346
Primary Fuel Filter and Water Separator With Low-Pressure Fuel Pump Remove and Install....347
Fuel Tank Remove and Install....348
Section 07: Damper Drive....352
Group 0752: Elements....352
Output Damper Remove and Install....355
Section 09: Steering System....357
Group 0960: Hydraulic System....357
Orbital Steering Valve Remove and Install....362
Steering Column Remove and Install....366
Steering Column Disassemble and Assemble....369
Steering Cylinders Remove and Install....371
Steering Cylinders Disassemble and Assemble....374
Steering Cylinder Bushings Remove and Install....375
Secondary Steering Pump Remove and Install....376
Secondary Steering Valve Remove and Install....379
Loader Start-Up Procedure (Steering Cylinder)....380
Section 10: Service Brakes....381
Group 1011: Active Elements....381
Service Brake Assembly Remove and Install....383
Service Brake Pedal and Linkage Disassemble and Assemble....384
Group 1060: Hydraulic System....381
Service Brake Valve Remove and Install....389
Service Brake Accumulator Remove and Install....392
Section 11: Park Brake....394
Group 1111: Active Elements....394
Park Brake Remove and Install....398
Park Brake Disassemble and Assemble....401
Group 1160: Hydraulic System....394
Park Brake Release Solenoid Valve Remove and Install....410
Section 15: Equipment Attaching....411
Group 1520: Hitches and Hitch Pins....411
Rear Hitch Remove and Install....414
Section 16: Electrical System....416
Group 1600: Removal and Installation....416
Installation of Repair Wire Assembly (RWA)....426
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install....435
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble....437
Air Conditioner Freeze Control Sensor Remove and Install....439
Air Conditioner High/Low-Pressure Switch Remove and Install....442
Pressure Switches and Sensors Remove and Install....445
Replace (Push-Type) Metri-Pack® Connectors....446
Replace Metri-Pack® Connectors....447
Replace DEUTSCH® Circular Connectors....449
Replace DEUTSCH® Rectangular or Triangular Connectors....451
Install DEUTSCH® Contact....453
Replace Weather Pack™ Connector....455
Install Weather Pack™ Contact....457
Replace Cinch™ Connectors....459
Install Cinch™ Contact....461
Repair 32 and 48-Way Cinch™ Connectors....463
Remove Connector Body From Blade Terminals....468
Front Turn/Marker Light Remove and Install....469
Section 17: Frame or Supporting Structure....471
Group 1740: Frame Installation....471
Welding on Machine....474
Engine and Loader Frame Separate....476
Upper Pivot Bearing and Seals Remove and Install....481
Lower Pivot Bearing and Seals Remove and Install....484
Group 1746: Frame Bottom Guards....471
Front Axle Guard Remove and Install....490
Transmission Bottom Guard Remove and Install....492
Group 1749: Chassis Weights....471
Counterweights Remove and Install....497
Rear Counterweight Remove and Install....500
Section 18: Operator's Station....502
Group 1800: Removal and Installation....502
Cab Remove and Install....506
Group 1810: Operator Enclosure....502
Front and Rear Windshield Wiper Motor Remove and Install....513
Group 1821: Seat and Seat Belt....502
Seat Remove and Install....519
Seat Belt Remove and Install....521
Group 1830: Heating and Air Conditioning....502
R134a Refrigerant Cautions and Proper Handling....524
R134a Refrigerant Oil Information....525
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure....527
Recover R134a Refrigerant....529
Flush and Purge Air Conditioning System....530
Evacuate R134a System....533
Charge R134a System....535
Heater/Evaporator Coil Remove and Install....537
Expansion Valve Remove and Install....541
Receiver-Dryer Remove and Install....544
Condenser Remove and Install....546
Compressor Remove and Install....549
Section 19: Sheet Metal and Styling....551
Group 1910: Hood or Engine Enclosure....551
Hood Remove and Install....554
Engine Side Shields Remove and Install....556
Cooling Package Access Doors Remove and Install....558
Section 31: Loader....560
Group 3102: Bucket....560
Bucket Remove and Install....564
Welded Bucket Cutting Edges Remove and Install....566
Bucket Teeth and Shank Remove and Install....567
Bolt-On Cutting Edges Remove and Install....569
Cracked Cutting Edge Repair....571
Group 3140: Frames....560
Bucket Tilt Linkage Remove and Install....575
Bucket Tilt Linkage Disassemble and Assemble....578
Boom Remove and Install....581
Quick Coupler Remove and Install....584
Standard Coupler Disassemble and Assemble....587
Hi-Vis Coupler Disassemble and Assemble....589
Loader Boom Bushings and Seals Remove and Install....591
Group 3160: Hydraulic System....560
General Oil Cleanup Procedure....597
Hydraulic Component Failure Cleanup Procedure....601
Main Hydraulic Pump Remove and Install....604
Loader Control Valve Remove and Install....607
Loader Control Valve Disassemble and Assemble....609
Boom Section Disassemble and Assemble....611
Inlet Valve Section Disassemble and Assemble....614
Bucket Section Disassemble and Assemble....616
Auxiliary Section Disassemble and Assemble....619
Main Relief Valve Disassemble and Assemble....622
Load Sense Relief Valve Disassemble and Assemble....625
Circuit Relief With Anticavitation Valve Disassemble and Assemble....631
Anticavitation Valve Disassemble and Assemble....631
Boom Cylinder Remove and Install....633
Bucket Cylinder Remove and Install....636
Boom and Bucket Cylinders Disassemble and Assemble....640
Boom or Bucket Cylinder Bushings and Seals Remove and Install....641
Loader Start-Up Procedure....643
Hydraulic Reservoir Remove and Install....644
Pilot Control Valve Remove and Install....650
Pilot Control Valve Disassemble and Assemble....652
Pilot Accumulator Remove and Install....653
Park Brake Valve Remove and Install....654
Park Brake Valve Disassemble and Assemble....657
Hydraulic Pump Manifold Remove and Install....659
Hydraulic Pump Manifold Disassemble and Assemble....662
Ride Control Valve Remove and Install....663
Ride Control Valve Disassemble and Assemble....666
Ride Control Accumulator Remove and Install....668
Pin Disconnect Valve Remove and Install....669
Pin Disconnect Valve Disassemble and Assemble....671
Hydraulic Fan Pump Remove and Install....674
Hydraulic Fan Motor Remove and Install....676
Reversing Fan Valve Remove and Install....679
Reversing Fan Valve Disassemble and Assemble....681
Section 99: Dealer Fabricated Tools....683
Group 9900: Dealer Fabricated Tools....683
DFT1132 Hydraulic Pump Removal And Installation Tool....685
John Deere 544L 4WD Loader Repair Service Manual (TM14345X19)
