John Deere 544E 544ELL 544ETC 624E 644E Loader ARepair Technical Manual TM1414 05MAY99

Contents
General Information
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
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
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
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
Wheels
Powered Wheels And Fastenings
Other Material
Specifications
Remove Tire
Install Tire
544E And 544E TC
544E LL
624E
644E
Axles And Suspension Systems
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
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
Hydraulic System
Remove, Disassemble, Assemble And Install Differential Lock Solenoid Valve
Transmission
Removal And Installation
Essential Tools
Service Equipment And Tools
Specifications
Remove And Install Transmission
Controls Linkage
Other Material
Specifications
Disassemble And Assemble Transmission Control Linkage
Transmission Direction Selector Linkage Adjustment
Transmission Speed Selector Linkage Adjustment
Input Drive Shafts And U-Joints
Specifications
Remove, Disassemble, Assemble And Install Transmission Drive Shaft
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
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
Engine
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
Engine Auxiliary Systems
Cold Weather Starting Aids
Specifications
Remove And Install Starting Aid Solenoid And Nozzle
Remove And Install Engine Coolant Heater
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
Speed Controls
Other Material
Specifications
Remove And Install Speed Control Linkage
Engine Speed Control Linkage Adjustment
Fuel Shut-Off Cable Adjustment—644E
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
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
Dampener Drive
Elements
Specifications
Remove And Install Dampener
Steering System
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
Hydraulic System
Special Or Essential Tools
Service Equipment And Tools
Other Material
Specifications
Remove And Install Steering Valve
Disassemble Steering Valve
Cross Section Of Steering Valve
Assemble Steering Valve
Remove, Disassemble, Assemble And Install Steering Column
Remove And Install Steering Cylinders
Disassemble Steering Cylinder
Cross Section Of Steering Cylinder
Assemble Steering Cylinder
Remove And Install Steering Cylinder Bushings
Remove And Install Priority Valve
Cross Section Of Priority Valve
Disassemble And Assemble Priority Valve
Remove And Install Crossover Relief Valve
Cross Section Of Crossover Relief Valve
Disassemble And Assemble Crossover Relief Valve
Remove And Install Steering Accumulator—644E Later Machines
Disassemble And Assemble Steering Accumulator—644E Later Machines
Charge Steering Accumulator—644E Later Machines
Service Brakes
Active Elements
John Deere 1200 And 1400 Series Axles—Use CTM18
Specifications
Inspect Brakes
Remove And Install Brake Assembly
Inspect Brake Elements
Hydraulic System
Service Equipment And Tools
Specifications
Remove And Install Brake Valve
Brake Valve Identification
Disassemble And Assemble Brake Valve
Remove And Install Brake Pump
Disassemble Brake Pump
Inspect Brake Pump Parts
Assemble Brake Pump
Disassemble And Assemble Compensator Valve
Remove And Install Brake Accumulators
Disassemble And Assemble Brake Accumulators
Charge Brake Accumulator
Hydraulic Brake Bleeding Procedure
Park Brake
Active Elements
Specifications
Other Material
Remove And Install Park Brake
Disassemble And Assemble Park Brake
Controls Linkage
Remove And Install Park Brake Linkage
Adjust Park Brake Linkage
Equipment Attaching
Drawbar
Specifications
Install Counterweight/Drawbar
Electrical Systems
Batteries, Support And Cables
Specifications
Handle Batteries Safely
Test Batteries Using Coolant And Battery Tester
Test Batteries Using High Rate Discharge Test
Charge Battery
Remove And Install Batteries
Alternator, Regulator And Charging System Wiring
Alternator Repair—Use CTM77
Service Equipment And Tools
Specifications
Remove And Install Alternator (Except BOSCH)
Remove And Install BOSCH Alternator
Lighting System
Specifications
Replace Halogen Bulbs
Remove And Install Lights
Wiring Harness And Switches
Special Or Essential Tools
Specifications
Clutch Cut-Off Switch Adjustment
Remove And Install Brake Low Pressure Switch
Return-To-Dig Adjustment
Boom Height Kickout Adjustment
Replace DEUTSCH™Connectors
Install DEUTSCH™Contact
Replace WEATHER PACK™Connector
Install WEATHER PACK™Contact
Remove Connector Body From Blade Terminals
Remove Blade Terminals From Fuse Block
Motors And Actuators
Starting Motor Repair—Use CTM77
Special Or Essential Tools
Specifications
Remove And Install Starting Motor
Frame Or Supporting Structure
Frame Installation
Service Equipment And Tools
Other Material
Specifications
Welding Repair Of Major Structure
Separate Engine And Loader Frame
Remove And Install Upper Pivot Bearing And Seals
Remove And Install Lower Pivot Bushing And Seals
Frame Bottom Guards
Remove And Install Fuel Tank Bottom Guard
Repair Bottom Guards
Remove And Install Auxiliary Bottom Guards (If Equipped)
Chassis Weights
Specifications
Remove And Install Counterweights
Operator’s Station
Removal And Installation
Special Or Essential Tools
Service Equipments And Tools
Other Material
Specifications
Remove And Install Cab Or Canopy
Tilt Cab Or Canopy
Operator Enclosure
Special Or Essential Tools
Other Material
Specifications
Remove And Install Windowpane And Molding
Remove And Install Windshield Washer
Remove, Disassemble, Assemble And Install Front Windshield Wiper
Remove, Disassemble, Assemble And Install Rear Windshield Wiper
Adjust Front Windshield Wiper
Remove And Install Defroster Fan
Remove And Install Door Handle And Door/Window Release
Seat And Seat Belt
Specifications
Disassemble And Assemble Seat
Heating And Air Conditioning
Special Or Essential Tools
Service Equipment And Tools
Other Material
Service Parts Kits For Compressor
Specifications
Proper Refrigerant Handling
Refrigerant (R-12) Cautions
Air Conditioning Gauge Set Installation Procedure
Refrigerant Recovery
Evacuate R12 System
Charge R12 System
Check And Add Compressor Oil
Remove And Install Compressor And High Pressure Switch
Volumetric Efficiency Test—R12
Make Shaft Seal Leak Test
Disassemble And Inspect Compressor
Clutch Pulley, Bearing And Hub Inspection
Replacing Clutch Pulley Bearing
Replace Shaft Seal Seat
Assemble Compressor
Remove And Install Condenser
Remove And Install Evaporator And Expansion Valve
Expansion Valve Bench Test And Adjustment
Remove And Install Receiver/Dryer And Low Pressure Switch
Remove And Install Condenser Fan Motors
Remove And Install Blower Wiring Harness
Thermostat Switch Bench Test
Disassemble And Assemble Blower Motor
Remove And Install Heater Core
Remove And Install Cab Heater Hoses And Controls
Loader
Bucket
Other Material
Specifications
Remove And Install Bucket Tooth Shanks And Tips
Remove And Install Bucket
Replace Welded Bucket Cutting Edges
Remove And Install Cutting Edges (For Bucket With Wear Plates)
Repair Cracked Cutting Edge
Frames
Service Equipment And Tools
Other Material
Specifications
Remove And Install Bucket Tilt Linkage—544E, 624E, And 644E
Remove And Install Bucket Linkage Seals And Bushings—544E, 624E, And 644E
Disassemble And Assemble Bucket Tilt Linkage—544E TC And 544E LL
Disassemble And Assemble Tool Carrier—544E TC
Remove And Install Boom Bushings And Shims—544E, 624E, And 644E
Remove And Install Boom Bushings And Shims—544E TC And 544E LL
Hydraulic System
Service Equipment And Tools
Other Material
Specifications
Remove And Install Main Hydraulic Pump
Disassemble, Inspect And Assemble Main Hydraulic Pump
Remove And Install Loader Control Valve
Disassemble And Assemble Loader Control Valve—(Serial No. —534614)
Disassemble And Assemble Loader Control Valve—(Serial No. 534615—)
Service Bucket And Boom Section Pilot Orifice Check Valve—Later Machines Only
Disassemble And Assemble Boom Valve Section—All Machines; And Bucket Valve Section—544E TC And 544E LL
Disassemble And Assemble Auxiliary Valve Section—All Machines; And Bucket Section—544E, 624E, And 644E
Disassemble And Assemble System Relief Valve
Disassemble And Assemble Shim Adjustable Circuit Relief Valve
Disassemble And Assemble Anti-Cavitation Valve
Disassemble And Assemble Screw Adjustable Circuit Relief Valve
Remove And Install Boom Cylinder
Remove And Install Bucket Cylinder
Cross Section Of Boom Or Bucket Cylinder
Disassemble Boom Or Bucket Cylinder
Assemble Boom Or Bucket Cylinder
Remove And Install Bucket Or Boom Cylinder Bushings And Seals
Remove, Disassemble, Assemble And Install Boom Solenoid Valve
Remove And Install Hydraulic Reservoir
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
Remove And Install Pilot Control Valves (Two Lever Controller)
Disassemble And Assemble Pilot Control Valve (Two-Lever Controller)
Remove And Install Pilot Controller (Single Lever Controller)
Cross Section Of Single Lever Pilot Controller (Serial No. —537112)
Disassemble Single Lever Pilot Controller (Serial No. —537112)
Assemble Single Lever Pilot Controller (Serial No. —537112)
Disassemble Single Lever Pilot Controller (Serial No. 537113—)
Assemble Single Lever Controller (Serial No. 537113—)
Remove, Disassemble, Assemble And Install Pressure Reducing Valve
Remove And Install Pin Disconnect Cylinders—544E TC
Cross Section Of Pin Disconnect Cylinder—544E TC
Disassemble Pin Disconnect Cylinder—544E TC
Assemble Pin Disconnect Cylinder—544E TC
Disassemble And Assemble Pin Disconnect Solenoid Valve—544E TC
Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy
Dealer Fabricated Tools
Dealer Fabricated Tools
DF1055 And JD38002 Yoke Holding Tool
DF1056 Input Pinion Shaft Adjusting Tool
DF1057 Axle Adjusting Tool
DF1025 Oil Supply Flange Back-Off Brackets
DF1026 Pre-Load Clutch Pack Compression Ring Assembly Jig
DF1027 Stand Mounting Bracket
DFT1071 Cab Tilt Pivots And Hinges
JDG588 Shaft Alignment Tool
DF1044 Air Deflector Bushing
Page Numbers
Section I
Group I
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Group II
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Section 01
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Section 02
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Section 03
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Section 04
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Section 05
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Section 07
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Section 09
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Section 10
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Section 11
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Section 15
Group 1511
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Section 16
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Section 17
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Section 18
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Section 31
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Section 99
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