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JOHN DEERE 544K 4WD LOADER REPAIR TECHNICAL MANUAL TM13369X19 – PDF DOWNLOAD
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JOHN DEERE 544K 4WD LOADER REPAIR TECHNICAL MANUAL TM13369X19 – PDF DOWNLOAD
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Description
JOHN DEERE 544K 4WD LOADER REPAIR TECHNICAL MANUAL TM13369X19 – PDF DOWNLOAD
FILE DETAILS:
JOHN DEERE 544K 4WD LOADER REPAIR TECHNICAL MANUAL TM13369X19 – PDF DOWNLOAD
Language : English
Pages : 444
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
JOHN DEERE 544K 4WD LOADER REPAIR TECHNICAL MANUAL TM13369X19 – PDF DOWNLOAD
Foreword
- READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.)
- THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it.
- MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.
- RIGHT-HAND AND LEFT-HAND sides are determined by facing in the direction of forward travel.
- WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you order parts. File the identification numbers in a secure place off the machine.
- WARRANTY is provided as part of John Deere’s support program for customers who operate and maintain their equipment as described in this manual. The warranty is explained on the warranty certificate or statement which you should have received from your dealer.
- This warranty provides you the assurance that John Deere will back its products where defects appear within the warranty period. In some circumstances, John Deere also provides field improvements, often without charge to the customer, even if the product is out of warranty.
- Should the equipment be abused, or modified to change its performance beyond the original factory specifications, the warranty will become void and field improvements may be denied. Setting fuel delivery above specifications or otherwise overpowering machines will result in such action.
- THE TIRE MANUFACTURER’S warranty supplied with your machine may not apply outside the U.S.
TABLE OF CONTENTS:
JOHN DEERE 544K 4WD LOADER REPAIR TECHNICAL MANUAL TM13369X19 – PDF DOWNLOAD
Contents................................................................................................................0 General Information.................................................................................................0 Safety..........................................................................................................0 Safety and Operator Convenience Features....................................................................0 Recognize Safety Information................................................................................0 Follow Safety Instructions..................................................................................0 Operate Only If Qualified...................................................................................0 Wear Protective Equipment...................................................................................0 Avoid Unauthorized Machine Modifications....................................................................0 Inspect Machine.............................................................................................0 Stay Clear of Moving Parts..................................................................................0 Avoid High-Pressure Fluids..................................................................................0 Avoid High-Pressure Oils....................................................................................0 Work In Ventilated Area.....................................................................................0 Avoid Static Electricity Risk When Refueling................................................................0 Prevent Fires...............................................................................................0 In Case of Machine Fire.....................................................................................0 Prevent Battery Explosions..................................................................................0 Clean Debris from Machine...................................................................................0 Handle Chemical Products Safely.............................................................................0 Handle Starting Fluid Safely................................................................................0 Decommissioning — Proper Recycling and Disposal of Fluids and Components....................................0 Exhaust Filter Ash Handling and Disposal....................................................................0 Prepare for Emergencies.....................................................................................0 Add Cab Guarding for Special Uses...........................................................................0 Use Steps and Handholds Correctly...........................................................................0 Start Only From Operator's Seat.............................................................................0 Use and Maintain Seat Belt..................................................................................0 Prevent Unintended Machine Movement.........................................................................0 Avoid Work Site Hazards.....................................................................................0 Keep Riders Off Machine.....................................................................................0 Avoid Backover Accidents....................................................................................0 Avoid Machine Tip Over......................................................................................0 Use Special Care When Operating Loader......................................................................0 Operating on Slopes.........................................................................................0 Operating or Traveling On Public Roads......................................................................0 Inspect and Maintain ROPS...................................................................................0 Travel Safely...............................................................................................0 Prevent Acid Burns..........................................................................................0 Add and Operate Attachments Safely..........................................................................0 Park and Prepare for Service Safely.........................................................................0 Clean Exhaust Filter Safely.................................................................................0 Service Cooling System Safely...............................................................................0 Service Tires Safely........................................................................................0 Remove Paint Before Welding or Heating......................................................................0 Make Welding Repairs Safely.................................................................................0 Drive Metal Pins Safely.....................................................................................0 Torque Values...................................................................................................0 Metric Bolt and Cap Screw Torque Values.....................................................................0 Additional Metric Cap Screw Torque Values...................................................................0 Unified Inch Bolt and Cap Screw Torque Values...............................................................0 Service Recommendations for 37° Flare and 30° Cone Seat Connectors..........................................0 Service Recommendations for O-Ring Boss Fittings............................................................0 Service Recommendations for Flared Connections—Straight or Tapered Threads..................................0 Service Recommendations For Flat Face O-Ring Seal Fittings..................................................0 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations......0 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations....0 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations........0 Service Recommendations for Metric Series Four Bolt Flange Fitting..........................................0 Service Recommendations For Inch Series Four Bolt Flange Fittings...........................................0 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations..............................0 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings......................................0 Service Recommendations For O-Ring Boss Fittings With Shoulder..............................................0 Metric 24° O-Ring Seal DIN 20078 Service Recommendations....................................................0 Wheels..............................................................................................................0 Powered Wheels and Fasteners....................................................................................0 Wheel Remove and Install....................................................................................0 Tire Remove and Install.....................................................................................0 Axles and Suspension Systems........................................................................................0 Removal and Installation........................................................................................0 TeamMate™ IV Axles..........................................................................................0 Front Axle and Differential Remove and Install..............................................................0 Rear Axle and Differential Remove and Install...............................................................0 Axle Oscillating Supports Disassemble and Assemble..........................................................0 Input Drive Shafts and U-Joints.................................................................................0 Universal Joint and Drive Shaft Remove and Install..........................................................0 Axle Shaft, Bearings, and Reduction Gears.......................................................................0 TeamMate™ IV Axles..........................................................................................0 Hydraulic System................................................................................................0 Differential Lock Solenoid Valve Remove and Install.........................................................0 Axle Circulation Pumps Remove and Install...................................................................0 Transmission........................................................................................................0 Removal and Installation........................................................................................0 Transmission Remove and Install.............................................................................0 Gear, Shafts, and Power Shift Clutches..........................................................................0 Torque Converter and Housing Remove.........................................................................0 Torque Converter and Housing Install........................................................................0 Clutches and Input and Output Shafts Remove.................................................................0 Clutches and Input and Output Shafts Install................................................................0 Clutch Pack KV and KR Disassemble..........................................................................0 Clutch Pack KV and KR Assemble.............................................................................0 Clutch Pack K1, K2, and K3 Disassemble......................................................................0 Clutch Pack K1, K2, and K3 Assemble.........................................................................0 Clutch Pack K4 Disassemble..................................................................................0 Clutch Pack K4 Assemble.....................................................................................0 Input Shaft Disassemble....................................................................................0 Input Shaft Assemble.......................................................................................0 Output Shaft Disassemble...................................................................................0 Output Shaft Assemble......................................................................................0 Transmission Speed Sensors Remove and Install...............................................................0 Axle Disconnect Remove and Install..........................................................................0 Axle Disconnect Disassemble and Assemble....................................................................0 Hydraulic System................................................................................................0 Transmission Pump Remove and Install........................................................................0 Converter Minimum Pressure Regulator Valve Remove and Install...............................................0 Transmission Hydraulic Control Valve Remove and Install.....................................................0 Transmission Hydraulic Control Valve Cross Section View.....................................................0 Transmission Hydraulic Control Valve Disassemble and Assemble...............................................0 Torque Converter Relief Valve Remove, Disassemble, and Install..............................................0 Axle Disconnect Solenoid Valve Remove and Install...........................................................0 Engine..............................................................................................................0 Removal and Installation........................................................................................0 John Deere Engine...........................................................................................0 Engine Remove and Install...................................................................................0 Engine Auxiliary System.............................................................................................0 Cold Weather Starting Aids......................................................................................0 Cold Start Aid—Glow Plug Remove and Install.................................................................0 Cold Start Aid—Block Heater Remove and Install..............................................................0 Cooling Systems.................................................................................................0 Charge Air Cooler Remove and Install........................................................................0 Radiator Remove and Install.................................................................................0 Hydraulic Oil Cooler Remove and Install.....................................................................0 Transmission Oil Cooler Remove and Install..................................................................0 Fuel Cooler Remove and Install..............................................................................0 Axle Oil Coolers Remove and Install.........................................................................0 Cooling Package Plenum Remove and Install...................................................................0 Intake System...................................................................................................0 Air Cleaner Remove and Install..............................................................................0 Precleaner Remove and Install...............................................................................0 External Exhaust Systems........................................................................................0 Exhaust Tube Remove and Install.............................................................................0 Diesel Particulate Filter (DPF) Remove and Install..........................................................0 Exhaust Gas Aftertreatment System Remove and Install........................................................0 Selective Catalyst Reduction (SCR) Remove and Install.......................................................0 Diesel Exhaust Fluid (DEF) Tank Remove and Install..........................................................0 Diesel Exhaust Fluid (DEF) Tank Header Remove and Install...................................................0 Diesel Exhaust Fluid (DEF) Tank Header Suction Screen Remove and Install....................................0 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install...................................................0 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install...............................................0 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install............................................0 Service Filter Cleaning.....................................................................................0 External Fuel Supply Systems....................................................................................0 Fuel Tank Remove and Install................................................................................0 Primary Fuel Filter and Water Separator With Low-Pressure Fuel Pump Remove and Install......................0 Final Fuel Filter Remove and Install........................................................................0 Damper Drive........................................................................................................0 Elements........................................................................................................0 Output Damper Remove and Install............................................................................0 Steering System.....................................................................................................0 Hydraulic System................................................................................................0 NeverGrease™ Pin Joints.....................................................................................0 Orbital Steering Valve Remove and Install...................................................................0 Steering Column Remove and Install..........................................................................0 Steering Column Disassemble and Assemble....................................................................0 Steering Cylinders Remove and Install.......................................................................0 Steering Cylinder Bushings Remove and Install...............................................................0 Secondary Steering Pump Remove and Install..................................................................0 Secondary Steering Valve Remove and Install.................................................................0 Loader Start-Up Procedure (Steering Cylinder)...............................................................0 Service Brakes......................................................................................................0 Active Elements.................................................................................................0 Service Brake Assembly Remove and Install...................................................................0 Service Brake Pedal and Linkage Disassemble and Assemble....................................................0 Hydraulic System................................................................................................0 Service Brake Valve Remove and Install......................................................................0 Service Brake Accumulator Remove and Install................................................................0 Park Brake..........................................................................................................0 Active Elements.................................................................................................0 Park Brake Remove and Install...............................................................................0 Park Brake Disassemble and Assemble........................................................................0 Hydraulic System................................................................................................0 Park Brake Release Solenoid Valve Remove and Install........................................................0 Equipment Attaching.................................................................................................0 Hitches and Hitch Pins..........................................................................................0 Rear Hitch Remove and Install...............................................................................0 Electrical System...................................................................................................0 Removal and Installation........................................................................................0 Installation of Repair Wire Assembly (RWA)..................................................................0 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install...........................0 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble.....................0 Air Conditioner Freeze Control Switch Remove and Install....................................................0 Air Conditioner High/Low-Pressure Switch Remove and Install.................................................0 Pressure Switches and Sensors Remove and Install............................................................0 Replace Metri-Pack® (Push Type) Connectors..................................................................0 Replace Metri-Pack® Connectors..............................................................................0 Replace DEUTSCH® Circular Connectors........................................................................0 Replace DEUTSCH® Rectangular or Triangular Connectors.......................................................0 Install DEUTSCH® Contact....................................................................................0 Replace WEATHER PACK® Connector.............................................................................0 Install WEATHER PACK® Contact...............................................................................0 Replace CINCH™ Connectors...................................................................................0 Install CINCH™ Contact......................................................................................0 Repair 32 and 48 Way CINCH™ Connectors......................................................................0 Remove Connector Body from Blade Terminals..................................................................0 Frame or Supporting Structure.......................................................................................0 Frame Installation..............................................................................................0 Welding on Machine..........................................................................................0 Engine and Loader Frame Separate............................................................................0 Upper Pivot Bearing and Seals Remove and Install............................................................0 Lower Pivot Bearing and Seals Remove and Install............................................................0 Frame Bottom Guards.............................................................................................0 Front Axle Guard Remove and Install.........................................................................0 Transmission Bottom Guard Remove and Install................................................................0 Chassis Weights.................................................................................................0 Counterweights Remove and Install...........................................................................0 Operator's Station..................................................................................................0 Removal and Installation........................................................................................0 Cab Remove and Install......................................................................................0 Operator Enclosure..............................................................................................0 Windowpanes Remove and Install..............................................................................0 Cab Door Hold-Open Release Adjust...........................................................................0 Cab Door Hold-Open Latch Pin Adjust.........................................................................0 Front and Rear Windshield Wiper Motor Remove and Install....................................................0 Seat and Seat Belt..............................................................................................0 Seat Remove and Install.....................................................................................0 Seat Belt Remove and Install................................................................................0 Heating and Air Conditioning....................................................................................0 R134a Refrigerant Cautions and Proper Handling..............................................................0 R134a Refrigerant Oil Information...........................................................................0 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................0 Recover R134a Refrigerant...................................................................................0 Flush and Purge Air Conditioning System.....................................................................0 Evacuate R134a System.......................................................................................0 Charge R134a System.........................................................................................0 Heater/Evaporator Coil Remove and Install...................................................................0 Expansion Valve Remove and Install..........................................................................0 Receiver-Dryer Remove and Install...........................................................................0 Condenser Remove and Install................................................................................0 Compressor Remove and Install...............................................................................0 Sheet Metal and Styling.............................................................................................0 Hood or Engine Enclosure........................................................................................0 Hood Remove and Install.....................................................................................0 Engine Side Shields Remove and Install......................................................................0 Cooling Package Access Doors Remove and Install.............................................................0 Loader..............................................................................................................0 Bucket..........................................................................................................0 Bucket Remove and Install...................................................................................0 Welded Bucket Cutting Edges Remove and Install..............................................................0 Bucket Teeth and Shank Remove and Install...................................................................0 Bolt-On Cutting Edges Remove and Install....................................................................0 Cracked Cutting Edge Repair.................................................................................0 Frames..........................................................................................................0 Bucket Tilt Linkage Remove and Install......................................................................0 Bucket Tilt Linkage Disassemble and Assemble................................................................0 Loader Boom Bushings and Seals Remove and Install...........................................................0 Boom Remove and Install.....................................................................................0 Powerllel™ Leveling Link Disassemble and Assemble...........................................................0 Powerllel™ Bellcrank Remove and Install.....................................................................0 Powerllel™ Bucket Cylinder Remove and Install...............................................................0 Powerllel™ Bucket Link Disassemble and Assemble.............................................................0 Powerllel™ Guide Links Remove and Install...................................................................0 Powerllel™ Loader Boom Remove and Install...................................................................0 Powerllel™ Loader Boom Disassemble and Assemble.............................................................0 Standard Coupler Disassemble and Assemble...................................................................0 Hi-Vis Coupler Disassemble and Assemble.....................................................................0 Hydraulic System................................................................................................0 General Oil Cleanup Procedure...............................................................................0 Hydraulic Component Failure Cleanup Procedure...............................................................0 Main Hydraulic Pump Remove and Install......................................................................0 Loader Control Valve Remove and Install.....................................................................0 Loader Control Valve Disassemble and Assemble...............................................................0 Boom Section Disassemble and Assemble.......................................................................0 Inlet Valve Section Disassemble and Assemble................................................................0 Bucket Section Disassemble and Assemble.....................................................................0 Auxiliary Section Disassemble and Assemble..................................................................0 Main Relief Valve Disassemble and Assemble..................................................................0 Load Sense Relief Valve Disassemble and Assemble............................................................0 Circuit Relief With Anticavitation Valve Disassemble and Assemble...........................................0 Anticavitation Valve Disassemble and Assemble...............................................................0 Boom Cylinder Remove and Install............................................................................0 Bucket Cylinder Remove and Install..........................................................................0 Boom and Bucket Cylinder Disassemble and Assemble...........................................................0 Boom or Bucket Cylinder Bushings and Seals Remove and Install...............................................0 Loader Start-Up Procedure...................................................................................0 Hydraulic Reservoir Remove and Install......................................................................0 Pilot Control Valve Remove and Install......................................................................0 Pilot Control Valve Disassemble and Assemble................................................................0 Auxiliary Function Pilot Control Valve Remove and Install...................................................0 Auxiliary Function Pilot Control Valve Disassemble and Assemble.............................................0 Pilot Accumulator Remove and Install........................................................................0 Hydraulic Pump Manifold Remove and Install..................................................................0 Hydraulic Pump Manifold Disassemble and Assemble............................................................0 Ride Control Valve Remove and Install.......................................................................0 Ride Control Valve Disassemble and Assemble.................................................................0 Ride Control Accumulator Remove and Install.................................................................0 Pin Disconnect Valve Remove and Install.....................................................................0 Pin Disconnect Valve Disassemble and Assemble...............................................................0 Hydraulic Fan Pump Remove and Install.......................................................................0 Hydraulic Fan Motor Remove and Install......................................................................0 Reversing Fan Valve Remove and Install......................................................................0 Reversing Fan Valve Disassemble and Assemble................................................................0 Dealer Fabricated Tools.............................................................................................0 Dealer Fabricated Tools.........................................................................................0 DFT1132 Hydraulic Pump Removal And Installation Tool........................................................0 Page Number.............................................................................................................0 Section 00..........................................................................................................0 Group 0001......................................................................................................0 Group 0003......................................................................................................0 Section 01..........................................................................................................0 Group 0110......................................................................................................0 Section 02..........................................................................................................0 Group 0200......................................................................................................0 Group 0225......................................................................................................0 Group 0250......................................................................................................0 Group 0260......................................................................................................0 Section 03..........................................................................................................0 Group 0300......................................................................................................0 Group 0350......................................................................................................0 Group 0360......................................................................................................0 Section 04..........................................................................................................0 Group 0400......................................................................................................0 Section 05..........................................................................................................0 Group 0505......................................................................................................0 Group 0510......................................................................................................0 Group 0520......................................................................................................0 Group 0530......................................................................................................0 Group 0560......................................................................................................0 Section 07..........................................................................................................0 Group 0752......................................................................................................0 Section 09..........................................................................................................0 Group 0960......................................................................................................0 Section 10..........................................................................................................0 Group 1011......................................................................................................0 Group 1060......................................................................................................0 Section 11..........................................................................................................0 Group 1111......................................................................................................0 Group 1160......................................................................................................0 Section 15..........................................................................................................0 Group 1520......................................................................................................0 Section 16..........................................................................................................0 Group 1600......................................................................................................0 Section 17..........................................................................................................0 Group 1740......................................................................................................0 Group 1746......................................................................................................0 Group 1749......................................................................................................0 Section 18..........................................................................................................0 Group 1800......................................................................................................0 Group 1810......................................................................................................0 Group 1821......................................................................................................0 Group 1830......................................................................................................0 Section 19..........................................................................................................0 Group 1910......................................................................................................0 Section 31..........................................................................................................0 Group 3102......................................................................................................0 Group 3140......................................................................................................0 Group 3160......................................................................................................0 Section 99..........................................................................................................0 Group 9900......................................................................................................0
S.S 20/02/2025
