John Deere 544E, 544E LL, 544E TC, 624E, 644E 4WD Loader Workshop Repair Service Manual (TM1414) PDF - MJODTM1414.zip
A full workshop repair and service manual covering the John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, and 644E, offering dealer-level guidance for maintenance, troubleshooting, diagnostics, and repairs.
Inside the John Deere 4WD Loaders 544E, 544E LL, 544E TC, 624E, and 644E workshop service 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.
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