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John Deere 544K 4WD Loader Repair Technical Manual TM12099 – PDF DOWNLOAD
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Description
John Deere 544K 4WD Loader Repair Technical Manual TM12099 – PDF DOWNLOAD
FILE DETAILS:
John Deere 544K 4WD Loader Repair Technical Manual TM12099 – PDF DOWNLOAD
Language : English
Pages : 472
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 544K 4WD Loader Repair Technical Manual TM12099 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere 544K 4WD Loader Repair Technical Manual TM12099 – PDF DOWNLOAD
Contents................................................................................................................ 5 General Information................................................................................................. 7 Safety.......................................................................................................... 9 Recognize Safety Information................................................................................ 9 Follow Safety Instructions.................................................................................. 9 Operate Only If Qualified................................................................................... 9 Wear Protective Equipment................................................................................... 10 Avoid Unauthorized Machine Modifications.................................................................... 10 Add Cab Guarding for Special Uses........................................................................... 10 Inspect Machine............................................................................................. 11 Stay Clear of Moving Parts.................................................................................. 11 Avoid High-Pressure Fluids.................................................................................. 11 Avoid High-Pressure Oils.................................................................................... 12 Work In Ventilated Area..................................................................................... 12 Prevent Fires............................................................................................... 13 Clean Debris from Machine................................................................................... 13 Prevent Battery Explosions.................................................................................. 14 Handle Chemical Products Safely............................................................................. 14 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 15 Exhaust Filter Ash Handling and Disposal.................................................................... 15 Prepare for Emergencies..................................................................................... 15 Use Steps and Handholds Correctly........................................................................... 16 Start Only From Operator's Seat............................................................................. 16 Use and Maintain Seat Belt.................................................................................. 16 Prevent Unintended Machine Movement......................................................................... 17 Avoid Work Site Hazards..................................................................................... 18 Use Special Care When Operating Loader...................................................................... 19 Keep Riders Off Machine..................................................................................... 19 Avoid Backover Accidents.................................................................................... 19 Avoid Machine Tip Over...................................................................................... 20 Operating on Slopes......................................................................................... 20 Operating or Traveling On Public Roads...................................................................... 21 Inspect and Maintain ROPS................................................................................... 21 Add and Operate Attachments Safely.......................................................................... 21 Park and Prepare for Service Safely......................................................................... 22 Clean Exhaust Filter Safely................................................................................. 23 Service Cooling System Safely............................................................................... 24 Service Tires Safely........................................................................................ 24 Remove Paint Before Welding or Heating...................................................................... 25 Make Welding Repairs Safely................................................................................. 25 Drive Metal Pins Safely..................................................................................... 25 Torque Values................................................................................................... 27 Metric Bolt and Cap Screw Torque Values..................................................................... 27 Additional Metric Cap Screw Torque Values................................................................... 28 Unified Inch Bolt and Cap Screw Torque Values............................................................... 29 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 30 Service Recommendations for O-Ring Boss Fittings............................................................ 30 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 32 Service Recommendations For Flat Face O-Ring Seal Fittings.................................................. 33 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations...... 34 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations.... 36 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations........ 38 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 40 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 41 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations.............................. 42 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 43 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 44 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 46 Wheels.............................................................................................................. 47 Powered Wheels and Fasteners.................................................................................... 49 Wheel Remove and Install.................................................................................... 49 Tire Remove and Install..................................................................................... 50 Axles and Suspension Systems........................................................................................ 51 Removal and Installation........................................................................................ 53 TeamMate™ IV Axles.......................................................................................... 53 Front Axle and Differential Remove and Install.............................................................. 53 Rear Axle and Differential Remove and Install............................................................... 55 Axle Oscillating Supports Disassemble and Assemble.......................................................... 59 Input Drive Shafts and U-Joints................................................................................. 62 Universal Joint and Drive Shaft Remove and Install.......................................................... 62 Axle Shaft, Bearings, and Reduction Gears....................................................................... 65 TeamMate™ IV Axles.......................................................................................... 65 Hydraulic System................................................................................................ 67 Differential Lock Solenoid Valve Remove and Install......................................................... 67 Axle Oil Circulation Pumps Remove and Install—If Equipped................................................... 67 Transmission........................................................................................................ 69 Removal and Installation........................................................................................ 71 Transmission Remove and Install............................................................................. 71 Gear, Shafts, and Power Shift Clutches.......................................................................... 73 Torque Converter and Housing Remove......................................................................... 73 Torque Converter and Housing Install........................................................................ 76 Clutches and Input and Output Shafts Remove................................................................. 80 Clutches and Input and Output Shafts Install................................................................ 86 Clutch Pack KV and KR Disassemble.......................................................................... 95 Clutch Pack KV and KR Assemble............................................................................. 99 Clutch Pack K1, K2, and K3 Disassemble......................................................................106 Clutch Pack K1, K2, and K3 Assemble.........................................................................109 Clutch Pack K4 Disassemble..................................................................................116 Clutch Pack K4 Assemble.....................................................................................118 Input Shaft Disassemble....................................................................................125 Input Shaft Assemble.......................................................................................127 Output Shaft Disassemble...................................................................................129 Output Shaft Assemble......................................................................................129 Transmission Speed Sensors Remove and Install...............................................................130 Axle Disconnect Remove and Install..........................................................................131 Axle Disconnect Disassemble and Assemble....................................................................133 Hydraulic System................................................................................................141 Transmission Pump Remove and Install........................................................................141 Converter Minimum Pressure Regulator Valve Remove and Install...............................................146 Transmission Hydraulic Control Valve Remove and Install.....................................................148 Transmission Hydraulic Control Valve Cross Section View.....................................................154 Transmission Hydraulic Control Valve Disassemble and Assemble...............................................155 Torque Converter Relief Valve Remove, Disassemble, and Install..............................................166 Axle Disconnect Solenoid Valve Remove and Install...........................................................167 Transmission Internal Oil Pipes and Tubes Remove and Install................................................168 Engine..............................................................................................................173 Removal and Installation........................................................................................175 John Deere Engine...........................................................................................175 Engine Remove...............................................................................................175 Engine Install..............................................................................................181 Serpentine Belt Remove and Install..........................................................................187 Engine Auxiliary System.............................................................................................189 Cold Weather Starting Aids......................................................................................191 Cold Start Aid—Glow Plug Remove and Install.................................................................191 Cold Start Aid—Block Heater Remove and Install..............................................................191 Cooling Systems.................................................................................................193 Charge Air Cooler Remove and Install........................................................................193 Radiator Remove and Install.................................................................................194 Hydraulic Oil Cooler Remove and Install.....................................................................195 Transmission Oil Cooler Remove and Install..................................................................197 Fuel Cooler Remove and Install..............................................................................198 Axle Oil Coolers Remove and Install.........................................................................199 Cooling Package Plenum Remove and Install...................................................................200 Intake System...................................................................................................207 Air Cleaner Remove and Install..............................................................................207 Precleaner Remove and Install—If Equipped...................................................................208 External Exhaust Systems........................................................................................209 Diesel Particulate Filter (DPF) Remove and Install..........................................................209 Exhaust Filter Remove and Install...........................................................................210 Exhaust Filter Disassemble and Assemble.....................................................................211 Service Filter Cleaning.....................................................................................211 External Fuel Supply Systems....................................................................................213 Fuel Tank Remove and Install................................................................................213 Primary Fuel Filter and Water Separator with Low Pressure Fuel Pump Remove and Install......................215 Final Fuel Filter Remove and Install........................................................................216 Damper Drive........................................................................................................217 Elements........................................................................................................219 Output Damper Remove and Install............................................................................219 Steering System.....................................................................................................221 Hydraulic System................................................................................................223 NeverGrease™ Pin Joints.....................................................................................223 Orbital Steering Valve Remove and Install...................................................................225 Steering Column Remove and Install..........................................................................227 Steering Column Disassemble and Assemble....................................................................229 Steering Cylinders Remove and Install.......................................................................230 Steering Cylinder Bushings Remove and Install...............................................................232 Secondary Steering Pump Remove and Install—If Equipped......................................................233 Secondary Steering Valve Remove and Install—If Equipped.....................................................235 Joystick Steering Valve Remove and Install..................................................................236 Joystick Steering Valve Disassemble and Assemble............................................................237 Loader Start-Up Procedure (Steering Cylinder)...............................................................238 Service Brakes......................................................................................................239 Active Elements.................................................................................................241 Service Brake Assembly Remove and Install...................................................................241 Hydraulic System................................................................................................243 Service Brake Valve Remove and Install......................................................................243 Service Brake Accumulator Remove and Install................................................................244 Park Brake..........................................................................................................245 Active Elements.................................................................................................247 Park Brake Remove and Install...............................................................................247 Park Brake Disassemble and Assemble........................................................................249 Hydraulic System................................................................................................255 Park Brake Release Solenoid Valve Remove and Install........................................................255 Frame or Supporting Structure.......................................................................................257 Frame Installation..............................................................................................259 Welding Major Structure.....................................................................................259 Engine and Loader Frame Separate............................................................................260 Upper Pivot Bearing and Seals Remove and Install............................................................263 Lower Pivot Bearing and Seals Remove and Install............................................................265 Frame Bottom Guards.............................................................................................269 Front Axle Guard Remove and Install.........................................................................269 Transmission Bottom Guard Remove and Install................................................................270 Chassis Weights.................................................................................................271 Counterweights Remove and Install...........................................................................271 Rear Counterweight Remove and Install.......................................................................273 Operator's Station..................................................................................................275 Removal and Installation........................................................................................277 Cab Remove and Install......................................................................................277 Operator Enclosure..............................................................................................283 Windowpanes Remove and Install..............................................................................283 Cab Door Hold-Open Release Adjust...........................................................................283 Cab Door Hold-Open Latch Pin Adjust.........................................................................283 Front and Rear Windshield Wiper Motor Remove and Install....................................................284 Seat and Seat Belt..............................................................................................289 Seat Remove and Install.....................................................................................289 Seat Belt Remove and Install................................................................................290 Steering Joystick Disassemble and Assemble—If Equipped......................................................291 Joystick Steering Armrest Disassemble and Assemble—If Equipped..............................................300 Joystick Steering Armrest Rear Pivot Adjustment—If Equipped.................................................304 Heating and Air Conditioning....................................................................................309 Refrigerant Cautions and Proper Handling....................................................................309 R134a Compressor Oil Charge Check...........................................................................310 R134a Compressor Oil Removal................................................................................310 R134a Component Oil Charge..................................................................................311 Refrigerant Leak Testing....................................................................................311 Refrigerant Hoses and Tubing Inspection.....................................................................312 R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure............................312 R134a System Recover........................................................................................314 R134a System Evacuate.......................................................................................315 R134a System Charge.........................................................................................316 Air Conditioner System Cleaning Procedures..................................................................317 Air Conditioner System Purge................................................................................317 Air Conditioner System Flush................................................................................318 Heater/Evaporator Coil Remove and Install...................................................................320 Expansion Valve Remove and Install..........................................................................322 Freeze Control Switch Remove and Install....................................................................323 Freeze Control Switch Bench Test............................................................................324 Heater Control Valve Remove and Install.....................................................................324 Heater Control Valve Leak Check.............................................................................325 Blower Motor Assembly Remove and Install....................................................................325 Receiver-Dryer Remove and Install...........................................................................327 Condenser Remove and Install................................................................................328 Air Conditioner High-Low Pressure Switch Remove and Install.................................................329 Compressor Remove and Install...............................................................................330 Sheet Metal and Styling.............................................................................................331 Hood or Engine Enclosure........................................................................................333 Hood Remove and Install.....................................................................................333 Engine Side Shields Remove and Install......................................................................335 Cooling Package Access Doors Remove and Install.............................................................336 Loader..............................................................................................................338 Bucket..........................................................................................................339 Bucket Remove and Install...................................................................................339 Welded Bucket Cutting Edges Remove and Install..............................................................341 Bolt-On Cutting Edges Remove and Install....................................................................342 Cracked Cutting Edge Repair.................................................................................342 Frames..........................................................................................................343 NeverGrease™ Pin Joints.....................................................................................343 Bucket Tilt Linkage Remove and Install......................................................................344 Bucket Tilt Linkage Disassemble and Assemble................................................................346 Loader Boom Bushings and Seals Remove and Install...........................................................349 Boom Remove and Install.....................................................................................351 Powerllel™ Leveling Link Disassemble and Assemble...........................................................354 Powerllel™ Bellcrank Remove and Install.....................................................................358 Powerllel™ Bucket Cylinder Remove and Install...............................................................362 Powerllel™ Bucket Link Disassemble and Assemble.............................................................368 Powerllel™ Guide Links Remove and Install...................................................................374 Powerllel™ Loader Boom Remove and Install...................................................................380 Powerllel™ Loader Boom Disassemble and Assemble.............................................................384 Standard Coupler Disassemble and Assemble...................................................................390 Hi-Vis Coupler Disassemble and Assemble.....................................................................394 Hydraulic System................................................................................................401 General Oil Cleanup Procedure...............................................................................401 Hydraulic Component Cleanup Procedure.......................................................................403 Main Hydraulic Pump Remove and Install......................................................................405 Main Hydraulic Pump Disassemble and Assemble................................................................408 Loader Control Valve Remove and Install.....................................................................413 Loader Control Valve Disassemble and Assemble...............................................................414 Boom Section Disassemble and Assemble.......................................................................415 Inlet Valve Section Disassemble and Assemble................................................................417 Bucket Section Disassemble and Assemble.....................................................................419 Auxiliary Section Disassemble and Assemble—If Equipped......................................................421 Main Relief Valve Disassemble and Assemble..................................................................422 Load Sense Relief Valve Disassemble and Assemble............................................................423 Circuit Relief With Anticavitation Valve Disassemble and Assemble...........................................424 Anticavitation Valve Disassemble and Assemble...............................................................426 Boom Cylinder Remove and Install............................................................................427 Bucket Cylinder Remove and Install..........................................................................429 Boom and Bucket Cylinder Disassemble and Assemble...........................................................430 Boom or Bucket Cylinder Bushings and Seals Remove and Install...............................................430 Loader Start-Up Procedure...................................................................................431 Hydraulic Reservoir Remove and Install......................................................................432 Pilot Control Valve Remove and Install......................................................................438 Pilot Control Valve Disassemble and Assemble................................................................440 Auxiliary Function Pilot Control Valve Remove and Install...................................................442 Auxiliary Function Pilot Control Valve Disassemble and Assemble.............................................445 Pilot Accumulator Remove and Install........................................................................446 Hydraulic Pump Manifold Remove and Install..................................................................447 Hydraulic Pump Manifold Disassemble and Assemble............................................................448 Ride Control Valve Remove and Install.......................................................................451 Ride Control Valve Disassemble and Assemble.................................................................452 Ride Control Accumulator Remove and Install.................................................................452 Pin Disconnect Valve Remove and Install.....................................................................453 Pin Disconnect Valve Disassemble and Assemble—If Equipped...................................................454 Hydraulic Fan Pump Remove and Install.......................................................................455 Hydraulic Fan Motor Remove and Install......................................................................456 Reversing Fan Valve Remove and Install—If Equipped..........................................................458 Reversing Fan Valve Disassemble and Assemble—If Equipped....................................................459 Dealer Fabricated Tools.............................................................................................461 Dealer Fabricated Tools.........................................................................................463 DFT1132 Hydraulic Pump Removal And Installation Tool........................................................463 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 0001...................................................................................................... 9 Group 0003...................................................................................................... 27 Section 01.......................................................................................................... 47 Group 0110...................................................................................................... 49 Section 02.......................................................................................................... 51 Group 0200...................................................................................................... 53 Group 0225...................................................................................................... 62 Group 0250...................................................................................................... 65 Group 0260...................................................................................................... 67 Section 03.......................................................................................................... 69 Group 0300...................................................................................................... 71 Group 0350...................................................................................................... 73 Group 0360......................................................................................................141 Section 04..........................................................................................................173 Group 0400......................................................................................................175 Section 05..........................................................................................................189 Group 0505......................................................................................................191 Group 0510......................................................................................................193 Group 0520......................................................................................................207 Group 0530......................................................................................................209 Group 0560......................................................................................................213 Section 07..........................................................................................................217 Group 0752......................................................................................................219 Section 09..........................................................................................................221 Group 0960......................................................................................................223 Section 10..........................................................................................................239 Group 1011......................................................................................................241 Group 1060......................................................................................................243 Section 11..........................................................................................................245 Group 1111......................................................................................................247 Group 1160......................................................................................................255 Section 17..........................................................................................................257 Group 1740......................................................................................................259 Group 1746......................................................................................................269 Group 1749......................................................................................................271 Section 18..........................................................................................................275 Group 1800......................................................................................................277 Group 1810......................................................................................................283 Group 1821......................................................................................................289 Group 1830......................................................................................................309 Section 19..........................................................................................................331 Group 1910......................................................................................................333 Section 31..........................................................................................................338 Group 3102......................................................................................................339 Group 3140......................................................................................................343 Group 3160......................................................................................................401 Section 99..........................................................................................................461 Group 9900......................................................................................................463
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