John Deere 544G, 544G LL, 544G TC, 624G, 644G 4WD Loader Operation and Test Service Manual (TM1529) PDF - MJODTM1529.zip
A full Operation and Test guide featuring Electrical Wiring Diagrams for the John Deere 4WD Loaders 544G, 544G LL, 544G TC, 624G, and 644G, containing everything needed to service, troubleshoot, and repair these machines at a professional mechanic's level.
Covered within this John Deere 4WD Loaders 544G, 544G LL, 544G TC, 624G, 644G workshop Diagnostics and Test manual:
* 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.
TM1529 - John Deere 544G, 544G LL, 544G TC, 624G and 644G 4WD Loader Technical Manual - Repair.PDF
TM1529 - John Deere 544G, 544G LL, 544G TC, 624G and 644G 4WD Loader Technical Manual - Repair.epub
Total Pages: 1,104 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
Operational Checkout Procedure
Operational Checkout Procedure
Engine Operation And Tests
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train Operation And Tests
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Tests
Hydraulic System Operation And Tests
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Test
Air Conditioning System
Theory Of Operation
System Operational Checks
Diagnostic Information
Adjustments
Tests
tm1529 - 544G, 544G LL, 544G TC, 624G, 644G 4WD Loader
Table of Contents
Foreword
Help!! Help!! Help!! Help!!
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 And Prepare For Service Safely
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 03: 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 04: 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)
Section 9005: Operational Checkout Procedure
Group 10: Operational Checkout Procedure
Operational Checkout Record Sheet—544G, 624G, And 644G
Complete Machine Operational Checkout
Section 9010: Engine Operation And Tests
Group 05: Theory Of Operation
Air Cleaner Operation
Fuel System Operation—544G And 624G
Fuel System Operation—644G
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
Display Monitor Tachometer
JT07158 TIME TRAC TIME TRAC is a registered trademark of the Stanadyne Automotive Corp. Installation
Injection Pump Timing
Fan Belt Tension Adjustment
Slow And Fast Idle Adjustment—544G, 624G
Slow Idle Adjustment—644G
Fast Idle Adjustment—644G
Speed Control Linkage Adjustment
Fuel Shut-Off Solenoid Adjustment—644G
Primary Fuel Filter, Drain Water—544G, 624G
Primary Fuel Filter, Drain Water—644G
Bleed The Fuel System—544G, 624G
Bleed The Fuel System—644G
Group 25: Tests
Display Monitor Tachometer
Display Monitor Hydraulic Oil Temperature
Display Monitor Hydraulic Oil Pressure
Air Filter Restriction Indicator Switch Test
Radiator Cap Pressure Test
Cooling System Pressure Test
Radiator Air Flow Test
Engine Power Test Using Engine Pulldown
Engine Power Test Using Turbocharger Boost Pressure
Compression Pressure Test
Air Intake System Leakage Test
Fuel Supply Pump Pressure Test
Fuel Line Leakage Test
Section 9015: Electrical System
Group 05: System Information
Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic
Example Of Simple Electrical Test To Find Problem
Visually Inspect Electrical System
Electrical Circuit Malfunctions
High Resistance Circuit
Open Circuit
Grounded Circuit
Shorted Circuit
Multimeter
Seven Step Electrical Test Procedure
Wiring Diagram And Schematic Information
Reading A System Functional Schematic
Reading A Wiring Diagram
Electrical Schematic Symbols
Group 10: System Diagrams
Component Identification Table
Fuse Block
Wiring And Schematic Diagrams Legend
System Functional Schematic Section Legend
System Functional Schematic
Steering Column Harness (W2) Wiring Diagram
Steering Column Harness (W2) Component Location
Loader Frame Harness (W3) Wiring Diagram
Loader Frame Harness (W3) Component Location
Transmission Harness (W4) Wiring Diagram
Transmission Harness (W4) Component Location
Load Center Harness (W5) Wiring Diagram (Page 1 of 4)
Load Center Harness (W5) Wiring Diagram (Page 2 of 4)
Load Center Harness (W5) Wiring Diagram (Page 3 of 4)
Load Center Harness (W5) Wiring Diagram (Page 4 of 4)
Load Center Harness (W5) Component Location
Load Center Harness (W5) Component Location—Continued (Detail A)
Load Center Harness (W5) Component Location—Continued (Detail B)
Load Center Harness (W5) Component Location—Continued (Detail C)
Load Center Harness (W5) Component Location—Continued (Detail D)
Load Center Harness (W5) Component Location—Continued (Detail E)
Canopy Work Lights Harness (W6) Wiring Diagram
Canopy Work Lights Harness (W6) Component Location
Cab Work Lights Harness (W7) Wiring Diagram
Cab Work Lights Harness (W7) Component Location
Left Panel Temperature Control Harness (W8) Wiring Diagram
Left Panel Temperature Control Harness (W8) Component Location
Engine Frame Harness (W9) Wiring Diagram
Engine Frame Harness (W9) Component Location
Engine Harness (W10) Wiring Diagram
Engine Harness (W10) Component Location
Rear Frame Harness (W11) Wiring Diagram
Rear Frame Harness (W11) Component Location
A/C Compressor Harness (W12) Wiring Diagram
A/C Compressor Harness (W12) Component Location
Secondary Steering Harness (W13) Wiring Diagram
Secondary Steering Harness (W13) Component Location
Start Aid Lead (W14) Wiring Diagram
Start Aid Lead (W14) Component Location
Ride Control Harness (W15) Wiring Diagram
Ride Control Harness (W15) Component Location
Pin Disconnect Harness (W16) Wiring Diagram
Pin Disconnect Harness (W16) Component Location
Group 15: Sub-System Diagnostics
Special Or Essential Tools
Power Circuit Operational Information
Power Circuit Theory Of Operation
Power Circuit Functional Schematic
Power Circuit Diagnostics
Charging Circuit Operational Information
Charging Circuit Theory Of Operation
Charging Circuit Functional Schematic
Charging Circuit Diagnostics
Start Aid And Fuel Control Circuit Operational Information
Start Aid And Fuel Control Circuit Theory Of Operation
Start Aid And Fuel Control Circuit Functional Schematic
Start Aid And Fuel Control Circuit Diagnostics
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Specifications
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Operational Information
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Theory Of Operation
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Functional Schematic
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Diagnostics
Transmission Control Circuit Operational Information
Transmission Control Circuit Theory Of Operation
Transmission Control Circuit Functional Schematic
Jumper Wire For Display Monitor
Replace CPC, Large MATE-N-LOK and METRIMATE CPC, MATE-N-LOK, and METRIMATE are trademarks of AMP Inc. Pin Type Connectors
Pin Identification On Transmission Controller
Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic
Transmission Control Circuit Diagnostics
Start Circuit Operational Information
Start Circuit Theory Of Operation
Start Circuit Functional Schematic
Start Circuit Diagnostics
Park Brake Circuit Operational Information
Park Brake Circuit Theory Of Operation
Park Brake Circuit Functional Schematic
Park Brake Circuit Diagnostics
Secondary Steering Circuit Specifications
Secondary Steering Circuit Operational Information
Secondary Steering Circuit Theory Of Operation
Secondary Steering Circuit Functional Schematic
Secondary Steering Circuit Diagnostics
Differential Lock And Boom Down Circuit Operational Information
Differential Lock And Boom Down Circuit Theory Of Operation
Differential Lock And Boom Down Circuit Functional Schematic
Differential Lock And Boom Down Circuit Diagnostics
Switch Inputs To Monitor Circuit Specifications
Switch Inputs To Monitor Circuit Operational Information
Switch Inputs To Monitor Circuit Theory Of Operation
Switch Inputs To Monitor Circuit Functional Schematic
Switch Inputs To Monitor Circuit Diagnostics
Electronic Monitor Signals Circuit Operational Information
Electronic Monitor Signals Circuit Theory Of Operation
Electronic Monitor Signals Circuit Functional Schematic
Electronic Monitor Signals Circuit Diagnostics
Electronic Monitor And Gauge Inputs Circuit Specifications
Electronic Monitor/Gauge Inputs Circuit Operational Information
Electronic Monitor/Gauge Inputs Circuit Theory Of Operation
Electronic Monitor/Gauge Inputs Circuit Functional Schematic
Electronic Monitor/Gauge Inputs Circuit Diagnostics
Boom Height Kickout And Return-To-Dig Circuit Operational Information
Boom Height Kickout And Return-To-Dig Circuit Theory Of Operation
Boom Height Kickout And Return-To-Dig Circuit Functional Schematic
Boom Height Kickout And Return-To-Dig Circuit Diagnostics
Front And Rear Wiper Circuit Operational Information
Front And Rear Wiper Circuit Theory Of Operation
Front And Rear Wiper Circuit Functional Schematic
Front And Rear Wiper Circuit Diagnostics
Brake Light Circuit Specifications
Brake Light Circuit Operational Information
Brake Light Circuit Theory Of Operation
Brake Light Circuit Functional Schematic
Brake Light Circuit Diagnostics
Heater/Pressurizer Circuit Operational Information
Heater/Pressurizer Circuit Theory Of Operation
Heater/Pressurizer Circuit Functional Schematic
Heater/Pressurizer Circuit Diagnostics
Air Conditioning Circuit Specifications
Air Conditioning Circuit Operational Information