John Deere 544G, 544G LL, 544G TC, 624G, 644G 4WD Loader Repair Service Manual TM1530 PDF - MJODTM1530.zip
This is a full workshop service and repair manual covering the John Deere 4WD Loaders 544G, 544G LL, 544G TC, 624G, and 644G. It contains every technical detail needed to maintain, troubleshoot, and rebuild these machines to the same standard as a professional technician.
Inside the John Deere 4WD Loaders 544G, 544G LL, 544G TC, 624G, 644G workshop service and repair manual, you'll find:
* 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