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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 : 446
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 544K 4WD Loader Repair Technical Manual TM13369X19 – PDF DOWNLOAD
- 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.
TABLE OF CONTENTS:
John Deere 544K 4WD Loader Repair Technical Manual TM13369X19 – PDF DOWNLOAD
Contents................................................................................................................ 5 General Information................................................................................................. 7 Safety.......................................................................................................... 9 Safety and Operator Convenience Features.................................................................... 9 Recognize Safety Information................................................................................ 10 Follow Safety Instructions.................................................................................. 10 Operate Only If Qualified................................................................................... 10 Wear Protective Equipment................................................................................... 11 Avoid Unauthorized Machine Modifications.................................................................... 11 Inspect Machine............................................................................................. 11 Stay Clear of Moving Parts.................................................................................. 11 Avoid High-Pressure Fluids.................................................................................. 12 Avoid High-Pressure Oils.................................................................................... 12 Work In Ventilated Area..................................................................................... 12 Avoid Static Electricity Risk When Refueling................................................................ 13 Prevent Fires............................................................................................... 13 In Case of Machine Fire..................................................................................... 14 Prevent Battery Explosions.................................................................................. 14 Clean Debris from Machine................................................................................... 14 Handle Chemical Products Safely............................................................................. 15 Handle Starting Fluid Safely................................................................................ 15 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................... 16 Exhaust Filter Ash Handling and Disposal.................................................................... 16 Prepare for Emergencies..................................................................................... 16 Add Cab Guarding for Special Uses........................................................................... 17 Use Steps and Handholds Correctly........................................................................... 17 Start Only From Operator's Seat............................................................................. 17 Use and Maintain Seat Belt.................................................................................. 17 Prevent Unintended Machine Movement......................................................................... 18 Avoid Work Site Hazards..................................................................................... 19 Keep Riders Off Machine..................................................................................... 19 Avoid Backover Accidents.................................................................................... 20 Avoid Machine Tip Over...................................................................................... 20 Use Special Care When Operating Loader...................................................................... 21 Operating on Slopes......................................................................................... 21 Operating or Traveling On Public Roads...................................................................... 21 Inspect and Maintain ROPS................................................................................... 22 Travel Safely............................................................................................... 22 Prevent Acid Burns.......................................................................................... 23 Add and Operate Attachments Safely.......................................................................... 23 Park and Prepare for Service Safely......................................................................... 24 Clean Exhaust Filter Safely................................................................................. 25 Service Cooling System Safely............................................................................... 26 Service Tires Safely........................................................................................ 26 Remove Paint Before Welding or Heating...................................................................... 27 Make Welding Repairs Safely................................................................................. 27 Drive Metal Pins Safely..................................................................................... 27 Torque Values................................................................................................... 29 Metric Bolt and Cap Screw Torque Values..................................................................... 29 Additional Metric Cap Screw Torque Values................................................................... 30 Unified Inch Bolt and Cap Screw Torque Values............................................................... 31 Service Recommendations for 37° Flare and 30° Cone Seat Connectors.......................................... 32 Service Recommendations for O-Ring Boss Fittings............................................................ 32 Service Recommendations for Flared Connections—Straight or Tapered Threads.................................. 34 Service Recommendations For Flat Face O-Ring Seal Fittings.................................................. 35 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations...... 36 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations.... 38 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations........ 40 Service Recommendations for Metric Series Four Bolt Flange Fitting.......................................... 42 Service Recommendations For Inch Series Four Bolt Flange Fittings........................................... 43 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations.............................. 44 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings...................................... 45 Service Recommendations For O-Ring Boss Fittings With Shoulder.............................................. 46 Metric 24° O-Ring Seal DIN 20078 Service Recommendations.................................................... 48 Wheels.............................................................................................................. 49 Powered Wheels and Fasteners.................................................................................... 51 Wheel Remove and Install.................................................................................... 51 Tire Remove and Install..................................................................................... 52 Axles and Suspension Systems........................................................................................ 53 Removal and Installation........................................................................................ 55 TeamMate™ IV Axles.......................................................................................... 55 Front Axle and Differential Remove and Install.............................................................. 55 Rear Axle and Differential Remove and Install............................................................... 57 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 Circulation Pumps Remove and Install................................................................... 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 and Install...................................................................................175 Engine Auxiliary System.............................................................................................179 Cold Weather Starting Aids......................................................................................181 Cold Start Aid—Glow Plug Remove and Install.................................................................181 Cold Start Aid—Block Heater Remove and Install..............................................................181 Cooling Systems.................................................................................................183 Charge Air Cooler Remove and Install........................................................................183 Radiator Remove and Install.................................................................................184 Hydraulic Oil Cooler Remove and Install.....................................................................185 Transmission Oil Cooler Remove and Install..................................................................186 Fuel Cooler Remove and Install..............................................................................187 Axle Oil Coolers Remove and Install.........................................................................188 Cooling Package Plenum Remove and Install...................................................................189 Intake System...................................................................................................195 Air Cleaner Remove and Install..............................................................................195 Precleaner Remove and Install...............................................................................196 External Exhaust Systems........................................................................................197 Exhaust Tube Remove and Install.............................................................................197 Diesel Particulate Filter (DPF) Remove and Install..........................................................198 Exhaust Gas Aftertreatment System Remove and Install........................................................200 Selective Catalyst Reduction (SCR) Remove and Install.......................................................202 Diesel Exhaust Fluid (DEF) Tank Remove and Install..........................................................203 Diesel Exhaust Fluid (DEF) Tank Header Remove and Install...................................................205 Diesel Exhaust Fluid (DEF) Tank Header Disassemble and Assemble.............................................206 Diesel Exhaust Fluid (DEF) Tank Cleaning Procedure..........................................................207 Diesel Exhaust Fluid (DEF) Dosing Unit Remove and Install...................................................208 Diesel Exhaust Fluid (DEF) Dosing Injector Remove and Install...............................................209 Diesel Exhaust Fluid (DEF) Decomposition Tube Remove and Install............................................210 Service Filter Cleaning.....................................................................................210 External Fuel Supply Systems....................................................................................211 Fuel Tank Remove and Install................................................................................211 Primary Fuel Filter and Water Separator With Low-Pressure Fuel Pump Remove and Install......................213 Final Fuel Filter Remove and Install........................................................................213 Damper Drive........................................................................................................215 Elements........................................................................................................217 Output Damper Remove and Install............................................................................217 Steering System.....................................................................................................219 Hydraulic System................................................................................................221 NeverGrease™ Pin Joints.....................................................................................221 Orbital Steering Valve Remove and Install...................................................................223 Steering Column Remove and Install..........................................................................224 Steering Column Disassemble and Assemble....................................................................226 Steering Cylinders Remove and Install.......................................................................227 Steering Cylinder Bushings Remove and Install...............................................................229 Secondary Steering Pump Remove and Install..................................................................230 Secondary Steering Valve Remove and Install.................................................................231 Loader Start-Up Procedure (Steering Cylinder)...............................................................231 Service Brakes......................................................................................................233 Active Elements.................................................................................................235 Service Brake Assembly Remove and Install...................................................................235 Service Brake Pedal and Linkage Disassemble and Assemble....................................................235 Hydraulic System................................................................................................237 Service Brake Valve Remove and Install......................................................................237 Service Brake Accumulator Remove and Install................................................................238 Park Brake..........................................................................................................239 Active Elements.................................................................................................241 Park Brake Remove and Install...............................................................................241 Park Brake Disassemble and Assemble........................................................................243 Hydraulic System................................................................................................249 Park Brake Release Solenoid Valve Remove and Install........................................................249 Equipment Attaching.................................................................................................251 Hitches and Hitch Pins..........................................................................................253 Rear Hitch Remove and Install...............................................................................253 Electrical System...................................................................................................255 Removal and Installation........................................................................................257 Installation of Repair Wire Assembly (RWA)..................................................................257 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install...........................261 Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble.....................262 Air Conditioner Freeze Control Switch Remove and Install....................................................263 Air Conditioner High/Low-Pressure Switch Remove and Install.................................................264 Pressure Switches and Sensors Remove and Install............................................................264 Replace Metri-Pack® (Push Type) Connectors..................................................................265 Replace Metri-Pack® Connectors..............................................................................265 Replace DEUTSCH® Circular Connectors........................................................................267 Replace DEUTSCH® Rectangular or Triangular Connectors.......................................................268 Install DEUTSCH® Contact....................................................................................269 Replace WEATHER PACK® Connector.............................................................................270 Install WEATHER PACK® Contact...............................................................................271 Replace CINCH™ Connectors...................................................................................272 Install CINCH™ Contact......................................................................................273 Repair 32 and 48 Way CINCH™ Connectors......................................................................274 Remove Connector Body from Blade Terminals..................................................................276 Frame or Supporting Structure.......................................................................................277 Frame Installation..............................................................................................279 Welding on Machine..........................................................................................279 Engine and Loader Frame Separate............................................................................280 Upper Pivot Bearing and Seals Remove and Install............................................................282 Lower Pivot Bearing and Seals Remove and Install............................................................284 Frame Bottom Guards.............................................................................................287 Front Axle Guard Remove and Install.........................................................................287 Transmission Bottom Guard Remove and Install................................................................288 Chassis Weights.................................................................................................289 Counterweights Remove and Install...........................................................................289 Operator's Station..................................................................................................291 Removal and Installation........................................................................................293 Cab Remove and Install......................................................................................293 Operator Enclosure..............................................................................................299 Windowpanes Remove and Install..............................................................................299 Cab Door Hold-Open Release Adjust...........................................................................299 Cab Door Hold-Open Latch Pin Adjust.........................................................................299 Front and Rear Windshield Wiper Motor Remove and Install....................................................300 Seat and Seat Belt..............................................................................................305 Seat Remove and Install.....................................................................................305 Seat Belt Remove and Install................................................................................306 Heating and Air Conditioning....................................................................................307 R134a Refrigerant Cautions and Proper Handling..............................................................307 R134a Refrigerant Oil Information...........................................................................308 R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure..........................309 Recover R134a Refrigerant...................................................................................309 Flush and Purge Air Conditioning System.....................................................................310 Evacuate R134a System.......................................................................................311 Charge R134a System.........................................................................................312 Heater/Evaporator Coil Remove and Install...................................................................313 Expansion Valve Remove and Install..........................................................................314 Receiver-Dryer Remove and Install...........................................................................316 Condenser Remove and Install................................................................................316 Compressor Remove and Install...............................................................................317 Sheet Metal and Styling.............................................................................................319 Hood or Engine Enclosure........................................................................................321 Hood Remove and Install.....................................................................................321 Engine Side Shields Remove and Install......................................................................322 Cooling Package Access Doors Remove and Install.............................................................323 Loader..............................................................................................................326 Bucket..........................................................................................................327 Bucket Remove and Install...................................................................................327 Welded Bucket Cutting Edges Remove and Install..............................................................328 Bucket Teeth and Shank Remove and Install...................................................................329 Bolt-On Cutting Edges Remove and Install....................................................................330 Cracked Cutting Edge Repair.................................................................................330 Frames..........................................................................................................331 Bucket Tilt Linkage Remove and Install......................................................................331 Bucket Tilt Linkage Disassemble and Assemble................................................................333 Loader Boom Bushings and Seals Remove and Install...........................................................334 Boom Remove and Install.....................................................................................335 Powerllel™ Leveling Link Disassemble and Assemble...........................................................338 Powerllel™ Bellcrank Remove and Install.....................................................................342 Powerllel™ Bucket Cylinder Remove and Install...............................................................346 Powerllel™ Bucket Link Disassemble and Assemble.............................................................352 Powerllel™ Guide Links Remove and Install...................................................................358 Powerllel™ Loader Boom Remove and Install...................................................................364 Powerllel™ Loader Boom Disassemble and Assemble.............................................................368 Standard Coupler Disassemble and Assemble...................................................................373 Hi-Vis Coupler Disassemble and Assemble.....................................................................378 Hydraulic System................................................................................................383 General Oil Cleanup Procedure...............................................................................383 Hydraulic Component Failure Cleanup Procedure...............................................................385 Main Hydraulic Pump Remove and Install......................................................................386 Loader Control Valve Remove and Install.....................................................................388 Loader Control Valve Disassemble and Assemble...............................................................389 Boom Section Disassemble and Assemble.......................................................................390 Inlet Valve Section Disassemble and Assemble................................................................392 Bucket Section Disassemble and Assemble.....................................................................394 Auxiliary Section Disassemble and Assemble..................................................................396 Main Relief Valve Disassemble and Assemble..................................................................397 Load Sense Relief Valve Disassemble and Assemble............................................................398 Circuit Relief With Anticavitation Valve Disassemble and Assemble...........................................399 Anticavitation Valve Disassemble and Assemble...............................................................401 Boom Cylinder Remove and Install............................................................................402 Bucket Cylinder Remove and Install..........................................................................403 Boom and Bucket Cylinder Disassemble and Assemble...........................................................404 Boom or Bucket Cylinder Bushings and Seals Remove and Install...............................................404 Loader Start-Up Procedure...................................................................................405 Hydraulic Reservoir Remove and Install......................................................................406 Pilot Control Valve Remove and Install......................................................................410 Pilot Control Valve Disassemble and Assemble................................................................412 Auxiliary Function Pilot Control Valve Remove and Install...................................................414 Auxiliary Function Pilot Control Valve Disassemble and Assemble.............................................417 Pilot Accumulator Remove and Install........................................................................418 Hydraulic Pump Manifold Remove and Install..................................................................419 Hydraulic Pump Manifold Disassemble and Assemble............................................................420 Ride Control Valve Remove and Install.......................................................................423 Ride Control Valve Disassemble and Assemble.................................................................424 Ride Control Accumulator Remove and Install.................................................................424 Pin Disconnect Valve Remove and Install.....................................................................425 Pin Disconnect Valve Disassemble and Assemble...............................................................426 Hydraulic Fan Pump Remove and Install.......................................................................427 Hydraulic Fan Motor Remove and Install......................................................................428 Reversing Fan Valve Remove and Install......................................................................431 Reversing Fan Valve Disassemble and Assemble................................................................432 Dealer Fabricated Tools.............................................................................................433 Dealer Fabricated Tools.........................................................................................435 DFT1132 Hydraulic Pump Removal And Installation Tool........................................................435 Page Number............................................................................................................. 5 Section 00.......................................................................................................... 7 Group 0001...................................................................................................... 9 Group 0003...................................................................................................... 29 Section 01.......................................................................................................... 49 Group 0110...................................................................................................... 51 Section 02.......................................................................................................... 53 Group 0200...................................................................................................... 55 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..........................................................................................................179 Group 0505......................................................................................................181 Group 0510......................................................................................................183 Group 0520......................................................................................................195 Group 0530......................................................................................................197 Group 0560......................................................................................................211 Section 07..........................................................................................................215 Group 0752......................................................................................................217 Section 09..........................................................................................................219 Group 0960......................................................................................................221 Section 10..........................................................................................................233 Group 1011......................................................................................................235 Group 1060......................................................................................................237 Section 11..........................................................................................................239 Group 1111......................................................................................................241 Group 1160......................................................................................................249 Section 15..........................................................................................................251 Group 1520......................................................................................................253 Section 16..........................................................................................................255 Group 1600......................................................................................................257 Section 17..........................................................................................................277 Group 1740......................................................................................................279 Group 1746......................................................................................................287 Group 1749......................................................................................................289 Section 18..........................................................................................................291 Group 1800......................................................................................................293 Group 1810......................................................................................................299 Group 1821......................................................................................................305 Group 1830......................................................................................................307 Section 19..........................................................................................................319 Group 1910......................................................................................................321 Section 31..........................................................................................................326 Group 3102......................................................................................................327 Group 3140......................................................................................................331 Group 3160......................................................................................................383 Section 99..........................................................................................................433 Group 9900......................................................................................................435
S.S 26/02/2025
