John Deere 544E 544ELL 544ETC 624E 644E Loader Test Technical Manual TM1413 28OCT03

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
Cab Component And Vandal Protection Checks
Key Switch Check
Monitor Bulb Check Circuit Check
Monitor Indicator Circuit Check
Monitor Time Delay Check
Monitor Primary And Secondary Level Checks
Monitor Operating Information Indicator Checks (Turn Signals And Hazard Warning)
Fuel Gauge Check
Transmission Temperature Gauge Check
Hour Meter
Transmission Selector Lever And Neutral Lock Latch Checks
Neutral Start And Reverse Warning Alarm Circuit Checks
Engine Speed Control Linkage Check-544E, 624E
Engine Speed Control Linkage Check
Fuel Shut-Off Cable Linkage Check-644E
Front Axle Disconnect Check-If Equipped
Monitor Check
Park Brake Linkage Check
Park Brake Capacity Check
Park Brake Transmission Lockout Check
Service Brake Pump Flow Check
Service Brake Capacity Check
Brake Accumulator Precharge Check
Brake System Leakage Check
Service Brake Pedal Check
Service And Park Brake System Drag Checks
Differential Lock Check
Differential Lock Leakage Check
Clutch Cut-Off Check
Transmission Oil Warm-Up Procedure
Transmission Noise Check
Forward, Reverse And 4th Speed Clutch Pack Drag Check
1st, 2nd, And 3rd Speed Clutch Pack Drag Check
Transmission Pressure, Pump Flow, And Leakage Check
Transmission Shift Modulation Check
Hydraulic System Warm-Up Procedure
Hydraulic Pump Performance Check
Control Valve Lift Check
Bucket Rollback Circuit Relief Valve Check
Bucket Dump Circuit Relief Valve Pressure Check
Bucket Dump Circuit Relief Valve High Pressure Check
Boom Raise Circuit Relief Valve Check
Pilot Control Valve Pressure Check
Boom And Bucket Cylinder Drift
Boom Down Solenoid Valve Check
Boom Down Solenoid Valve Leakage Check
Pilot Controller Check
Pilot Control Pressure And Boom Float Check
Return-To-Dig Check-If Equipped
Boom Height Kickout Check-If Equipped
Return-To-Dig And Boom Raise Proximity Switch Check-If Equipped
Return-To-Dig And Boom Raise Proximity Switch Check-If Equipped
Pin Disconnect Cylinder Check
Steering Valve Check
Steering System Leakage Check
Priority Valve Pressure Check
Secondary Steering System Check-If Equipped
Secondary Steering System Primary Check Valve Check
Operating Lights Check
Work Light Check
Turn Signal And Flasher Check
Brake Light Check
Dome Light Check
Horn Circuit Check
Windshield Washer And Wiper Check-If Equipped
Cigar Lighter Check
Defroster Blower Check
Heater/Air Conditioner Blower Check
Heater Functional Check
Air Conditioner Functional Check
Start Aid System Check
Cab Door Latch Check
Cab Door And Window Hold-Open Latch Check
Cab Door Lock Check
Cab Window Check
Cab Window Hold-Open Latch And Rod Check
Steering Column Adjustment Check
Seat And Seat Belt Check
Air Intake Filter Door Check
Engine Side Panels Check
Radiator Cap Access Door Check
Service Decal Check
Key Switch Check
Monitor Bulb Check Circuit Check
Monitor Indicator Circuit Check
Monitor Time Delay Check
Monitor Primary And Secondary Level Checks
Monitor Operating Information Indicator Checks (Turn Signals And Hazard Warning)
Fuel Gauge Check
Transmission Temperature Gauge Check
Hour Meter
Transmission Selector Lever And Neutral Lock Latch Checks
Neutral Start And Reverse Warning Alarm Circuit Checks
Engine Speed Control Linkage Check-544E, 624E
Engine Speed Control Linkage Check
Fuel Shut-Off Cable Linkage Check-644E
Front Axle Disconnect Check-If Equipped
Monitor Check
Park Brake Linkage Check
Park Brake Capacity Check
Park Brake Transmission Lockout Check
Service Brake Pump Flow Check
Service Brake Capacity Check
Brake Accumulator Precharge Check
Brake System Leakage Check
Service Brake Pedal Check
Service And Park Brake System Drag Checks
Differential Lock Check
Differential Lock Leakage Check
Clutch Cut-Off Check
Transmission Oil Warm-Up Procedure
Transmission Noise Check
Forward, Reverse And 4th Speed Clutch Pack Drag Check
1st, 2nd, And 3rd Speed Clutch Pack Drag Check
Transmission Pressure, Pump Flow, And Leakage Check
Transmission Shift Modulation Check
Hydraulic System Warm-Up Procedure
Hydraulic Pump Performance Check
Control Valve Lift Check
Bucket Rollback Circuit Relief Valve Check
Bucket Dump Circuit Relief Valve Pressure Check
Bucket Dump Circuit Relief Valve High Pressure Check
Boom Raise Circuit Relief Valve Check
Pilot Control Valve Pressure Check
Boom And Bucket Cylinder Drift
Boom Down Solenoid Valve Check
Boom Down Solenoid Valve Leakage Check
Pilot Controller Check
Pilot Control Pressure And Boom Float Check
Return-To-Dig Check-If Equipped
Boom Height Kickout Check-If Equipped
Return-To-Dig And Boom Raise Proximity Switch Check-If Equipped
Return-To-Dig And Boom Raise Proximity Switch Check-If Equipped
Pin Disconnect Cylinder Check
Steering Valve Check
Steering System Leakage Check
Priority Valve Pressure Check
Secondary Steering System Check-If Equipped
Secondary Steering System Primary Check Valve Check
Operating Lights Check
Work Light Check
Turn Signal And Flasher Check
Brake Light Check
Dome Light Check
Horn Circuit Check
Windshield Washer And Wiper Check-If Equipped
Cigar Lighter Check
Defroster Blower Check
Heater/Air Conditioner Blower Check
Heater Functional Check
Air Conditioner Functional Check
Start Aid System Check
Cab Door Latch Check
Cab Door And Window Hold-Open Latch Check
Cab Door Lock Check
Cab Window Check
Cab Window Hold-Open Latch And Rod Check
Steering Column Adjustment Check
Seat And Seat Belt Check
Air Intake Filter Door Check
Engine Side Panels Check
Radiator Cap Access Door Check
Service Decal Check
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 Speed And Performance Checks
Radiator Cap Checks
Coolant Level And Coolant Condition Checks
Radiator Outside Air Flow Check
Radiator Internal Core Check
Radiator Bubble Check
Hoses, Clamps, And Water Pump Checks
Fan Checks
Fan Shroud And Fan Guard Checks
Fan Belt Checks
Air Filter Restriction Indicator Switch Check
Starting Aid Checks
Exhaust Smoke Check
Oil Level Check
Water Trap Check
Fuel Cap And Fuel Strainer
Inner Fuel Tank Check
Fuel Pump Check-544E, 624E Only
Fuel System Check
Engine Speed Check
Engine Power Check
Low Compression Check
Engine Blow-By Check
Loose Or Worn Engine Parts
Radiator Cap Checks
Coolant Level And Coolant Condition Checks
Radiator Outside Air Flow Check
Radiator Internal Core Check
Radiator Bubble Check
Hoses, Clamps, And Water Pump Checks
Fan Checks
Fan Shroud And Fan Guard Checks
Fan Belt Checks
Air Filter Restriction Indicator Switch Check
Starting Aid Checks
Exhaust Smoke Check
Oil Level Check
Water Trap Check
Fuel Cap And Fuel Strainer
Inner Fuel Tank Check
Fuel Pump Check-544E, 624E Only
Fuel System Check
Engine Speed Check
Engine Power Check
Low Compression Check
Engine Blow-By Check
Loose Or Worn Engine Parts
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
Power Circuit Operational Checks
Battery State Of Charge
Key Switch
Accessory Relay
Battery State Of Charge
Key Switch
Accessory Relay
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
Key Switch
Neutral Start Switch
Neutral Start Relay
Start Relay
Starter Solenoid
Starter Motor Check
Injection Pump Fuel Shut-Off Solenoid-544E, 624E
Key Switch
Neutral Start Switch
Neutral Start Relay
Start Relay
Starter Solenoid
Starter Motor Check
Injection Pump Fuel Shut-Off Solenoid-544E, 624E
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
Charging Circuit Operational Checks-65 Amp Alternator
Alternator Output-65 Amp Motorola
Alternator Excitation Circuit-65 Amp
Alternator Diode Trio-65 Amp Motorola
Alternator And Regulator-65 Amp Motorola
Alternator Output-65 Amp Motorola
Alternator Excitation Circuit-65 Amp
Alternator Diode Trio-65 Amp Motorola
Alternator And Regulator-65 Amp Motorola
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-)
Charging Circuit Operational Checks-90 Amp And 105 Amp Alternator
Alternator Output-90 Amp And 105 Amp
Alternator Excitation Circuit-90 Amp And 105 Amp
Alternator And Regulator Check-90 Amp And 105 Amp
Alternator Output-90 Amp And 105 Amp
Alternator Excitation Circuit-90 Amp And 105 Amp
Alternator And Regulator Check-90 Amp And 105 Amp
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
Charging Circuit Operational Checks-130 Amp Alternator
Alternator Relay-130 Amp
Alternator Output-130 Amp
Alternator Regulator Voltage Adjustment-130 Amp
Alternator Regulator-130 Amp
Alternator Internal Excitation Circuit-130 Amp
Alternator Shorted Rectifier Diode-130 Amp
Alternator Relay-130 Amp
Alternator Output-130 Amp
Alternator Regulator Voltage Adjustment-130 Amp
Alternator Regulator-130 Amp
Alternator Internal Excitation Circuit-130 Amp
Alternator Shorted Rectifier Diode-130 Amp
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
Indicator Circuit Operational Checks-Top Row
Engine Coolant Temperature (Stop) Indicator Switch
Engine Coolant Temperature (Stop) Indicator Light
Engine Oil Pressure Indicator Switch
Engine Oil Pressure Indicator Light
Engine Alternator Indicator Circuit-65 Amp Alternator
Engine Alternator Indicator Circuit-90 Amp Alternator
Engine Alternator Indicator Circuit-130 Amp Alternator
Engine Alternator Indicator Light Check-All Alternators
Engine Alternator Indicator Light Relay
Engine Air Filter Restriction Indicator Switch
Engine Air Filter Restriction Indicator Light
Engine Coolant Temperature (Stop) Indicator Switch
Engine Coolant Temperature (Stop) Indicator Light
Engine Oil Pressure Indicator Switch
Engine Oil Pressure Indicator Light
Engine Alternator Indicator Circuit-65 Amp Alternator
Engine Alternator Indicator Circuit-90 Amp Alternator
Engine Alternator Indicator Circuit-130 Amp Alternator
Engine Alternator Indicator Light Check-All Alternators
Engine Alternator Indicator Light Relay
Engine Air Filter Restriction Indicator Switch
Engine Air Filter Restriction Indicator Light
Indicator Circuits Operation-Top Row
Indicator Circuits Wiring Diagram-Top Row
Indicator Circuit Operational Checks-Middle Row
Transmission Oil Pressure Indicator Switch
Transmission Oil Pressure Indicator Light
Park Brake Indicator Switch
Park Brake Indicator Relay
Park Brake Indicator Light
Brake Low Pressure Indicator Switch
Brake Low Pressure Indicator Light
Hydraulic Filter Restriction Indicator Switch
Hydraulic Filter Restriction Indicator Light
Secondary Steering Relay
Secondary Steering Indicator Light
Transmission Oil Pressure Indicator Switch
Transmission Oil Pressure Indicator Light
Park Brake Indicator Switch
Park Brake Indicator Relay
Park Brake Indicator Light
Brake Low Pressure Indicator Switch
Brake Low Pressure Indicator Light
Hydraulic Filter Restriction Indicator Switch
Hydraulic Filter Restriction Indicator Light
Secondary Steering Relay
Secondary Steering Indicator Light
Indicator Circuits Operation-Middle Row
Indicator Circuits Wiring Diagram (Middle Row)
Park Brake Switch Adjustment
Pressure Switch And Sender Test
Gauges And Horn Circuit Operational Checks
Fuel Gauge
Fuel Gauge Sender
Gauge Backlight
Transmission Temperature Gauge
Transmission Temperature Sender
Horn Switch
Horn
Fuel Gauge
Fuel Gauge Sender
Gauge Backlight
Transmission Temperature Gauge
Transmission Temperature Sender
Horn Switch
Horn
Gauges And Horn Circuits Operation
Gauges And Horn Circuit Wiring Diagram
Return-To-Dig And Boom Kickout Circuit Operational Checks
Boom Float Detent
Return-To-Dig Detent
Boom Kickout Detent
Return-To-Dig Switch
Boom Kickout Switch
Boom Float Detent
Return-To-Dig Detent
Boom Kickout Detent
Return-To-Dig Switch
Boom Kickout Switch
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
Start Aid, Reverse Warning Alarm, And Cigar Lighter Operational Checks
Start Aid Switch
Start Aid Solenoid Check
Reverse Warning Alarm Switch
Reverse Warning Alarm
Cigar Lighter
Start Aid Switch
Start Aid Solenoid Check
Reverse Warning Alarm Switch
Reverse Warning Alarm
Cigar Lighter
Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Operation
Start Aid, Reverse Warning Alarm, And Cigar Lighter Circuit Operation Wiring Diagram
Secondary Steering Circuit Operational Checks
Secondary Steering Pressure Switch
Secondary Steering Controller
Secondary Steering Motor Relay
Secondary Steering Motor
Secondary Steering Pressure Switch
Secondary Steering Controller
Secondary Steering Motor Relay
Secondary Steering Motor
Secondary Steering Circuit Operation
Secondary Steering Wiring Diagram
Secondary Steering Circuit Test
Secondary Steering Controller Test
Secondary Steering Pressure Switch
Hour Meter Circuit Operational Checks
Hour Meter
Boom Down Relay-(Serial No. 518528-521102)
Engine Oil Pressure Switch-(Serial No. 521103-)
Engine Oil Pressure Switch Diode-(Serial No. 521103-)
Hour Meter Relay-(Serial No. 521103-)
Key On Indicator-(Serial No. 521103-)
Hour Meter
Boom Down Relay-(Serial No. 518528-521102)
Engine Oil Pressure Switch-(Serial No. 521103-)
Engine Oil Pressure Switch Diode-(Serial No. 521103-)
Hour Meter Relay-(Serial No. 521103-)
Key On Indicator-(Serial No. 521103-)
Hour Meter Circuit Operation
Hour Meter Circuit Wiring Diagram
Boom Down Relay Circuit Operational Checks
Engine Oil Pressure Switch-(Serial No. -518527) And (Serial No. 518528-521102)
Boom Down Relay-(Serial No. -518527) And (Serial No. 518528-521102)
Boom Down Switch-(Serial No. 521103-)
Boom Down Solenoid-(Serial No. 521103-)
Boom Down Solenoid-(Serial No. -518527) And (Serial No. 518528-521102)
Engine Oil Pressure Switch-(Serial No. -518527) And (Serial No. 518528-521102)
Boom Down Relay-(Serial No. -518527) And (Serial No. 518528-521102)
Boom Down Switch-(Serial No. 521103-)
Boom Down Solenoid-(Serial No. 521103-)
Boom Down Solenoid-(Serial No. -518527) And (Serial No. 518528-521102)
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-)
Differential Lock And Clutch Cut-Off Circuit Operational Checks
Differential Lock Switch
Differential Lock Solenoid
Clutch Cut-Off Dash Switch
Clutch Cut-Off Pedal Switch
Park Brake Switch
Clutch Cut-Off Solenoid Check
Differential Lock Switch
Differential Lock Solenoid
Clutch Cut-Off Dash Switch
Clutch Cut-Off Pedal Switch
Park Brake Switch
Clutch Cut-Off Solenoid Check
Differential Lock And Clutch Cut-Off Circuit Operation
Differential Lock And Clutch Cut-Off Circuits Wiring Diagram
Turn Signal And Flasher Circuit Operational Checks
Turn Signal Flasher
Turn Signal Switch
Turn Signal Light-Front Signal
Turn Signal Light-Rear Signal
Turn Signal Flasher
Turn Signal Switch
Turn Signal Light-Front Signal
Turn Signal Light-Rear Signal
Turn Signal And Flasher Indicator Circuit Operation
Turn Signal And Flasher Indicator Circuit Wiring Diagram
Drive, Work, Brake And Gauge Light Circuit Operational Checks
Light Switch-First Position
Light Switch-Second Position
Work Light Relay
Work And Driving Light
Brake And Taillight Light
Brake Light Switch
Light Switch-First Position
Light Switch-Second Position
Work Light Relay
Work And Driving Light
Brake And Taillight Light
Brake Light Switch
Drive, Work, Brake And Gauge Light Circuit Operation
Drive, Work, Brake And Gauge Light Circuits Wiring Diagram
Windshield Wiper And Washer Circuit Checks
Windshield Wiper And Washer Switch-Low Speed
Windshield Wiper And Washer Switch-High Speed
Windshield Wiper And Washer Switch-Wash Position
Windshield Wiper Motor-Low Speed
Windshield Wiper Motor-High Speed
Windshield Wiper And Washer Switch-Low Speed
Windshield Wiper And Washer Switch-High Speed
Windshield Wiper And Washer Switch-Wash Position
Windshield Wiper Motor-Low Speed
Windshield Wiper Motor-High Speed
Windshield Wiper And Washer Circuit Operation
Windshield Wiper/Washer Circuit Wiring Diagram
Pin Disconnect Circuit Checks-544E TC
Pin Disconnect Switch
Pin Disconnect Solenoid
Pin Disconnect Switch
Pin Disconnect Solenoid
Pin Disconnect Circuit Operation
Pin Disconnect Circuit Wiring Diagram
Radio Circuit Operation
Electrical Component Location Drawing
Section 9020 – POWER TRAIN OPERATION AND TESTS
Group 05 – Theory Of Operation
Power Train Component Overview
Drive Dampener
Transmission Clutch Engagement
Torque Converter Operation
Transmission Operation-Neutral
Transmission Operation-1st Gear Forward
Transmission Operation-2nd Gear Forward
Transmission Operation-3rd Gear Forward
Transmission Operation-4th Gear Forward
Transmission Operation-1st Gear Reverse
Transmission Operation-2nd Gear Reverse
Transmission Operation-3rd Gear Reverse
Clutch Operation
Transmission Hydraulic Components
Transmission Hydraulic System
Transmission Pump Operation
Transmission Control Valve Components
Transmission Control Valve-1st Gear Neutral
Transmission Control Valve-4th Gear Forward
Shift Modulation
Shift Modulation-1st Gear (Full Engagement)
Shift Modulation-1st Gear (Shift Initiated-Clutch Filling)
Shift Modulation-1st Gear (Modulation Starting)
Shift Modulation-2nd, 3rd, And 4th Gears
Thermal Bypass Valve Operation
Differential Lock Operation
Final Drive Operation
Axle Outer Seal And Bearing Operation
Axle Disconnect Operation
Brake Hydraulic System
Brake Pump Operation
Accumulator Operation
Brake Valve Operation
Wet Chambered Brake Valve
Pressure Reducing Valve Operation-Neutral
Pressure Reducing Valve Operation-Differential Lock On
Group 10 – System Operational Checks
Driving Checks
Front Axle Disconnect Check-If Equipped
Park Brake Linkage Check
Park Brake Capacity Check
Park Brake Transmission Lockout Check
Service Brake Pump Flow Check
Service Brake Capacity Check
Brake Accumulator Precharge Check
Brake System Leakage Check
Service Brake Pedal Check
Service And Park Brake System Drag Checks
Differential Lock Check
Differential Lock Leakage Check
Clutch Cut-Off Check
Transmission Oil Warm-Up Procedure
Transmission Selector Lever And Neutral Lock Latch Checks
Transmission Noise Check
Forward, Reverse And 4th Speed Clutch Pack Drag Check
1st, 2nd, And 3rd Speed Clutch Pack Drag Check
Transmission Pressure, Pump Flow, And Leakage Check
Transmission Shift Modulation Check
Front Axle Disconnect Check-If Equipped
Park Brake Linkage Check
Park Brake Capacity Check
Park Brake Transmission Lockout Check
Service Brake Pump Flow Check
Service Brake Capacity Check
Brake Accumulator Precharge Check
Brake System Leakage Check
Service Brake Pedal Check
Service And Park Brake System Drag Checks
Differential Lock Check
Differential Lock Leakage Check
Clutch Cut-Off Check
Transmission Oil Warm-Up Procedure
Transmission Selector Lever And Neutral Lock Latch Checks
Transmission Noise Check
Forward, Reverse And 4th Speed Clutch Pack Drag Check
1st, 2nd, And 3rd Speed Clutch Pack Drag Check
Transmission Pressure, Pump Flow, And Leakage Check
Transmission Shift Modulation Check
Group 15 – Diagnostic Information
Diagnose Transmission System Malfunctions
Diagnose Service Brake Malfunctions
Diagnose Differential/Axle Malfunctions
Diagnose Drive Line Malfunctions
Diagnose Park Brake Malfunctions
Hydraulic Circuit Symbols
Brake, Differential Lock Circuit Schematic
Power Train Schematic
Power Train And Brakes System Component Location
Group 20 – Adjustments
Transmission Control Valve Linkage-FNR And Neutral Lock Adjustment
Transmission Control Valve Linkage-Speed Control Adjustment
Brake Pedal Adjusting Screw Adjustment (Early Units Only)
Front Axle Disconnect Adjustment
Clutch Cut-Off Switch Adjustment
Brake Pad Inspection
Hydraulic Brake Bleeding Procedure
Charge Brake Accumulator
Park Brake Linkage Adjustment
Park Brake Indicator Switch Adjustment
Brake Pump And Differential Lock System Oil Clean-Up Procedure Using Portable Filter Caddy
Group 25 – Tests
JT05801 Clamp-On Electronic Tachometer Installation
JT05800 Digital Thermometer Installation
D01084AA Tachometer/Temperature Reader Installation Procedure
Transmission Oil Warm-Up Procedure
Brake, Differential Lock, And Hydraulic System Oil Warm-Up Procedure
Transmission Pump Flow Test
Transmission System Pressure, Element Leakage, And Shift Modulation Test
Lube Pressure Test
Converter Relief Pressure Test
Converter-In Pressure Test
Converter-Out Pressure Test
Converter-Out Flow Test
Transmission Oil Cooler Backflush Procedure
Transmission Oil Cooler Restriction Test
Clutch Cut-Off Valve Pressure Test
Pressure Reducing Valve Manifold Leakage Test
Transmission Oil Cooler Thermal Bypass Valve Test
Transmission Oil Cooler Bypass Valve Pressure Test
Torque Converter Stall Speed Test
Brake Pump Flow Test
Brake Pump Standby Pressure Test
Brake Valve Pressure Test
Brake Accumulator Precharge Test
Brake Valve Leakage Test
Brake Accumulator Inlet Check Valve Leakage Test
Differential Lock Pressure Test
Differential Lock Leakage Test
Axle Bearing Adjustment Check
No-Spin Differential Test
Section 9025 – HYDRAULIC SYSTEM OPERATION AND TEST
Group 05 – Theory Of Operation
Steering Circuit Component Location
Steering Circuit Components
Steering Circuit Operation-Right Turn
Main Hydraulic Pump Operation
Priority Valve Operation
Steering Valve Operation
Crossover Relief Valve Operation
Steering Cylinder Operation
Steering Accumulator Operation-644E Later Units
Secondary Steering System Operation
Inlet Manifold Operation
Loader Hydraulic System
Pressure Reducing Valve-Secondary Boom Lower Operation
Pilot Controller Operation
Boom Section Operation
Bucket Section Orifice Check Valve
Bucket Section Operation-544E, 624E, And 644E
Bucket Section Operation-544E TC And 544E LL
Auxiliary Section Operation
System Relief Valve Operation
Circuit Relief Valve Operation
Anti-Cavitation Valve Operation
Loader Cylinder Design
Return Filter Operation
Pin Disconnect Circuit Operation-544E TC
Group 10 – System Operational Checks
Steering System Checks
Hydraulic System Warm-Up Procedure
Hydraulic Pump Performance Check
Control Valve Lift Check
Bucket Rollback Circuit Relief Valve Check
Bucket Dump Circuit Relief Valve Low Pressure Check
Bucket Dump Circuit Relief Valve High Pressure Check
Boom Raise Circuit Relief Valve Check
Pilot Control Valve Pressure Check
Boom Cylinder Drift Check
Boom Cylinder Leakage Check
Bucket Cylinder Drift Check
Bucket Cylinder Leakage Check
Boom Lower Solenoid Valve Check
Boom Lower Solenoid Valve Leakage Check
Pilot Controller
Return-To-Dig Check-If Equipped
Boom Height Kickout Check-If Equipped
Boom Float Check
Pin Disconnect Cylinder Check
Cycle Time Check
Steering Valve Check
Steering System Leakage Check
Priority Valve Pressure Check
Secondary Steering System Check (If Equipped)
Secondary Steering System Primary Check Valve Check
Hydraulic System Warm-Up Procedure
Hydraulic Pump Performance Check
Control Valve Lift Check
Bucket Rollback Circuit Relief Valve Check
Bucket Dump Circuit Relief Valve Low Pressure Check
Bucket Dump Circuit Relief Valve High Pressure Check
Boom Raise Circuit Relief Valve Check
Pilot Control Valve Pressure Check
Boom Cylinder Drift Check
Boom Cylinder Leakage Check
Bucket Cylinder Drift Check
Bucket Cylinder Leakage Check
Boom Lower Solenoid Valve Check
Boom Lower Solenoid Valve Leakage Check
Pilot Controller
Return-To-Dig Check-If Equipped
Boom Height Kickout Check-If Equipped
Boom Float Check
Pin Disconnect Cylinder Check
Cycle Time Check
Steering Valve Check
Steering System Leakage Check
Priority Valve Pressure Check
Secondary Steering System Check (If Equipped)
Secondary Steering System Primary Check Valve Check
Group 15 – Diagnostic Information
Diagnose Hydraulic System Malfunctions
Hydraulic Circuit Symbols
Main Hydraulic System Component Location
Main Hydraulic System Schematic
Main Hydraulic System Schematic (Tandem Valve)
Hydraulic System Component Location-544E TC And 544E LL
Group 20 – Adjustments
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
Boom Height Kickout Adjustment
Return-To-Dig Adjustment
Charge Steering Accumulator-644E Later Machines
Group 25 – Tests
JT05801 Clamp-On Electronic Tachometer Installation
JT05800 Digital Thermometer Installation
D01084AA Tachometer/Temperature Reader Installation Procedure
Hydraulic Oil Warm-Up Procedure
Main Hydraulic Pump Flow Test
Loader System And Circuit Relief Valve Pressure Test
Hydraulic System Restriction Test
Loader Cylinder Drift Test
Boom And Bucket Cylinder Leakage Test
Hydraulic Oil Cooler Restriction Test
Steering System Leakage Test
Steering Valve Neutral Leakage Test
Steering Crossover Relief Valve
Steering Stop Wear Check
Priority Valve Pressure Test
Priority Valve “LS” Port Flow Test
Priority Valve Relief Cartridge Leakage Test
Secondary Steering Pump Relief Valve Pressure Test
Secondary Steering Manifold Primary Check Valve Leakage Test
Secondary Steering Manifold Secondary Check Valve Leakage Test
Pilot Control Valve Pressure Test
Pressure Reducing Valve Pressure Test
Cycle Time Test
Hydraulic Oil Filter Inspection Procedure
Pin Disconnect Solenoid Valve Leakage Test
Pin Disconnect Cylinder Leakage Test
Section 9031 – HEATING AND AIR CONDITIONING SYSTEM OPERATION AND TESTS
Group 05 – Theory Of Operation
Refrigerant System
Electrical System Wiring Diagram-Early Machines
Electrical System Schematic-Early Machines
Electrical System Wiring Diagram-Later Machines
Electrical System Schematic-Later Machines
Receiver-Dryer Operation
Expansion Valve Operation
Thermostat Control Switch Operation
Compressor Relief Valve Operation
Group 10 – System Operational Checks
Air Conditioner/Heater Defrost Circuit Checks
All Lines And Hoses
Air Conditioner Compressor
Condenser Cores And Condenser Fans
Evaporator Core
Temperature Control Switch Sensing Tube
Expansion Valve
Heater Valve And Engine Block Shut-Off Valve To Heater
Cab Door And Window Seals
Temperature Control Switch Check
Blower Motor Check
Compressor Relay Check
Low Pressure Switch And Schrader Valve Check
High Pressure Switch And Schrader Valve Check
Compressor Clutch Check
System Performance Check
Receiver/Dryer Check
Expansion Valve Check
Evaporator Check
Evaporator Housing Drain Check
Air Conditioner Compressor- Factory Installed
Defrost Or Heater/Air Conditioner Fan Switch Check
Defrost Or Heater/Air Conditioner Fan Motor Resistor Check
Defrost Or Heater/Air Conditioner Fan Motor Check
Air Conditioner Temperature Control Switch Check
Low Pressure Switch Check
High Pressure Switch Check
Compressor Clutch Coil Check
Air Conditioner Relay Check
Condenser Fan Fuse Check
Condenser Fan Motor Check
All Lines And Hoses
Air Conditioner Compressor
Co