John Deere 544E 544E LL 544E TC 624E 644E 4WD Loader Workshop Repair & Test Manual (TM1413) PDF - MJODTM1413.zip

A comprehensive Diagnostics and Tests guide featuring Electrical Wiring Diagrams for the John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, and 644E, containing every detail shops need to service, troubleshoot, and test these machines at a professional level.

This workshop-level Diagnostics and Tests manual for John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, and 644E covers:

* 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