John Deere 544K 4WD Loader Repair Technical Manual (TM12100)

📘 Show Index

John Deere 544K 4WD Loader Index:

Contents
- General Information
  - Safety
    - Recognize Safety Information
    - Follow Safety Instructions
    - Operate Only If Qualified
    - Wear Protective Equipment
    - Avoid Unauthorized Machine Modifications
    - Add Cab Guarding for Special Uses
    - Inspect Machine
    - Stay Clear of Moving Parts
    - Avoid High-Pressure Fluids
    - Avoid High-Pressure Oils
    - Work In Ventilated Area
    - Prevent Fires
    - Clean Debris from Machine
    - Prevent Battery Explosions
    - Handle Chemical Products Safely
    - Dispose of Waste Properly
    - Prepare for Emergencies
    - Use Steps and Handholds Correctly
    - Start Only From Operator’s Seat
    - Use and Maintain Seat Belt
    - Prevent Unintended Machine Movement
    - Avoid Work Site Hazards
    - Use Special Care When Operating Loader
    - Keep Riders Off Machine
    - Avoid Backover Accidents
    - Avoid Machine Tip Over
    - Operating on Slopes
    - Operating or Traveling On Public Roads
    - Inspect and Maintain ROPS
    - Add and Operate Attachments Safely
    - Park and Prepare for Service Safely
    - Service Cooling System Safely
    - Service Tires Safely
    - Remove Paint Before Welding or Heating
    - Make Welding Repairs Safely
    - Drive Metal Pins Safely
  - Torque Values
    - Metric Bolt and Cap Screw Torque Values
    - Additional Metric Cap Screw Torque Values
    - Unified Inch Bolt and Cap Screw Torque Values
    - Service Recommendations for 37° Flare and 30° Cone Seat Connectors
    - Service Recommendations for O-Ring Boss Fittings
    - Service Recommendations For Flared Connections—Straight or Tapered Threads
    - Service Recommendations For Flat Face O-Ring Seal Fittings
    - O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations
    - O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations
    - O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations
    - Service Recommendations for Metric Series Four Bolt Flange Fitting
    - Service Recommendations For Inch Series Four Bolt Flange Fittings
    - Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
    - Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings
    - Service Recommendations For O-Ring Boss Fittings With Shoulder
    - Metric 24° O-Ring Seal DIN 20078 Service Recommendations
- Wheels
  - Powered Wheels and Fasteners
    - Wheel Remove and Install
    - Tire Remove and Install
- Axles and Suspension Systems
  - Removal and Installation
    - TeamMate™ IV Axles
    - Front Axle and Differential Remove and Install
    - Rear Axle and Differential Remove and Install
    - Axle Oscillating Supports Disassemble and Assemble
  - Input Drive Shafts and U-Joints
    - Universal Joint and Drive Shaft Remove and Install
  - Axle Shaft, Bearings, and Reduction Gears
    - TeamMate™ IV Axles
  - Hydraulic System
    - Differential Lock Solenoid Valve Remove and Install
    - Axle Oil Circulation Pumps Remove and Install—If Equipped
- Transmission
  - Removal and Installation
    - Transmission Remove and Install
  - Gear, Shafts, and Power Shift Clutches
    - Torque Converter and Housing Remove
    - Torque Converter and Housing Install
    - Clutches and Input and Output Shafts Remove
    - Clutches and Input and Output Shafts Install
    - Clutch Pack KV and KR Disassemble
    - Clutch Pack KV and KR Assemble
    - Clutch Pack K1, K2, and K3 Disassemble
    - Clutch Pack K1, K2, and K3 Assemble
    - Clutch Pack K4 Disassemble
    - Clutch Pack K4 Assemble
    - Input Shaft Disassemble
    - Input Shaft Assemble
    - Transmission Speed Sensors Remove and Install
    - Axle Disconnect Remove and Install
    - Axle Disconnect Disassemble and Assemble
  - Hydraulic System
    - Transmission Pump Remove and Install
    - Converter Minimum Pressure Regulator Valve Remove and Install
    - Transmission Hydraulic Control Valve Remove and Install
    - Transmission Hydraulic Control Valve Cross Section View
    - Transmission Hydraulic Control Valve Disassemble and Assemble
    - Torque Converter Relief Valve Remove, Disassemble, and Install
    - Axle Disconnect Solenoid Valve Remove and Install
- Engine
  - Removal and Installation
    - John Deere Engine
    - Engine Remove and Install
    - Serpentine Belt Remove and Install
    - Crankshaft Damper Remove and Install
- Engine Auxiliary System
  - Cold Weather Starting Aids
    - Cold Start Aid—Start Aid Nozzle Remove and Install
    - Cold Start Aid—Start Aid Solenoid Remove and Install
    - Cold Start Aid—Block Heater Remove and Install
  - Cooling Systems
    - Intercooler Remove and Install
    - Radiator Remove and Install
    - Hydraulic Oil Cooler Remove and Install
    - Transmission Oil Cooler Remove and Install
    - Axle Oil Coolers Remove and Install—If Equipped
    - Cooling Package Plenum Remove and Install
  - Intake System
    - Air Cleaner Remove and Install
    - Precleaner Remove and Install—If Equipped
  - External Exhaust Systems
    - Muffler Remove and Install
  - External Fuel Supply Systems
    - Fuel Tank Remove and Install
    - Primary Fuel Filter and Water Separator Remove and Install
    - Primary Fuel Filter and Water Separator with Low Pressure Fuel Pump Remove and Install—If Equipped
    - Final Fuel Filter and Water Separator Remove and Install
    - Auxiliary Fuel Filter and Water Separator Remove and Install—If Equipped
- Damper Drive
  - Elements
    - Output Damper Remove and Install
- Steering System
  - Hydraulic System
    - NeverGrease™ Pin Joints
    - Orbital Steering Valve Remove and Install
    - Steering Column Remove and Install
    - Steering Column Disassemble and Assemble
    - Steering Cylinders Remove and Install
    - Steering Cylinder Bushings Remove and Install
    - Secondary Steering Pump Remove and Install—If Equipped
    - Secondary Steering Valve Remove and Install—If Equipped
    - Joystick Steering Valve Remove and Install—If Equipped
    - Joystick Steering Valve Disassemble and Assemble—If Equipped
    - Loader Start-Up Procedure (Steering Cylinder)
- Service Brakes
  - Active Elements
    - Service Brake Pedal and Linkage Disassemble and Assemble
    - Service Brake Assembly Remove and Install
  - Hydraulic System
    - Service Brake Valve Remove and Install
    - Service Brake Accumulator Remove and Install
- Park Brake
  - Active Elements
    - Park Brake Remove and Install
    - Park Brake Disassemble and Assemble
  - Hydraulic System
    - Park Brake Release Solenoid Valve Remove and Install
- Frame or Supporting Structure
  - Frame Installation
    - Welding Major Structure
    - Engine and Loader Frame Separate
    - Upper Pivot Bearing and Seals Remove and Install
    - Lower Pivot Bearing and Seals Remove and Install
  - Frame Bottom Guards
    - Front Axle Guard Remove and Install
    - Transmission Bottom Guard Remove and Install
  - Chassis Weights
    - Counterweights Remove and Install
    - Rear Counterweight Remove and Install
- Operator’s Station
  - Removal and Installation
    - Cab Remove and Install
  - Operator Enclosure
    - Windowpanes Remove and Install
    - Cab Door Hold-Open Release Adjust
    - Cab Door Hold-Open Latch Pin Adjust
    - Front and Rear Windshield Wiper Motor Remove and Install
  - Seat and Seat Belt
    - Seat Remove and Install
    - Seat Belt Remove and Install
    - Steering Joystick Disassemble and Assemble—If Equipped
    - Joystick Steering Armrest Disassemble and Assemble—If Equipped
    - Joystick Steering Armrest Rear Pivot Adjustment—If Equipped
  - Heating and Air Conditioning
    - Refrigerant Cautions and Proper Handling
    - R134a Compressor Oil Charge Check
    - R134a Compressor Oil Removal
    - R134a Component Oil Charge
    - Refrigerant Leak Testing
    - Refrigerant Hoses and Tubing Inspection
    - R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure
    - R134a System Recover
    - R134a System Evacuate
    - R134a System Charge
    - Air Conditioner System Cleaning Procedures
    - Air Conditioner System Purge
    - Air Conditioner System Flush
    - Heater/Evaporator Coil Remove and Install
    - Expansion Valve Remove and Install
    - Freeze Control Switch Remove and Install
    - Freeze Control Switch Bench Test
    - Heater Control Valve Remove and Install
    - Heater Control Valve Leak Check
    - Blower Motor Assembly Remove and Install
    - Receiver-Dryer Remove and Install
    - Condenser Remove and Install
    - Air Conditioner High-Low Pressure Switch Remove and Install
    - Compressor Remove and Install
- Sheet Metal and Styling
  - Hood or Engine Enclosure
    - Hood Remove and Install
    - Engine Side Shields Remove and Install
    - Cooling Package Access Doors Remove and Install
- Loader
  - Bucket
    - Bucket Remove and Install
    - Welded Bucket Cutting Edges Remove and Install
    - Bolt-On Cutting Edges Remove and Install
    - Cracked Cutting Edge Repair
  - Frames
    - NeverGrease™ Pin Joints
    - Bucket Tilt Linkage Remove and Install
    - Bucket Tilt Linkage Disassemble and Assemble
    - Loader Boom Bushings and Seals Remove and Install
    - Boom Remove and Install
    - Powerllel™ Leveling Link Disassemble and Assemble
    - Powerllel™ Bellcrank Remove and Install
    - Powerllel™ Bucket Cylinder Remove and Install
    - Powerllel™ Bucket Link Disassemble and Assemble
    - Powerllel™ Guide Links Remove and Install
    - Powerllel™ Loader Boom Remove and Install
    - Powerllel™ Loader Boom Disassemble and Assemble
    - Standard Coupler Disassemble and Assemble
    - Hi-Vis Coupler Disassemble and Assemble
  - Hydraulic System
    - General Oil Cleanup Procedure
    - Hydraulic Component Cleanup Procedure
    - Main Hydraulic Pump Remove and Install
    - Main Hydraulic Pump Disassemble and Assemble
    - Loader Control Valve Remove and Install
    - Loader Control Valve Disassemble and Assemble
    - Boom Section Disassemble and Assemble
    - Inlet Valve Section Disassemble and Assemble
    - Bucket Section Disassemble and Assemble
    - Auxiliary Section Disassemble and Assemble—If Equipped
    - Main Relief Valve Disassemble and Assemble
    - Load Sense Relief Valve Disassemble and Assemble
    - Circuit Relief With Anticavitation Valve Disassemble and Assemble
    - Anticavitation Valve Disassemble and Assemble
    - Boom Cylinder Remove and Install
    - Bucket Cylinder Remove and Install
    - Boom and Bucket Cylinder Disassemble and Assemble
    - Boom or Bucket Cylinder Bushings and Seals Remove and Install
    - Loader Start-Up Procedure
    - Hydraulic Reservoir Remove and Install
    - Pilot Control Valve Remove and Install
    - Pilot Control Valve Disassemble and Assemble
    - Auxiliary Function Pilot Control Valve Remove and Install—If Equipped
    - Auxiliary Function Pilot Control Valve Disassemble and Assemble—If Equipped
    - Pilot Accumulator Remove and Install
    - Hydraulic Pump Manifold Remove and Install
    - Hydraulic Pump Manifold Disassemble and Assemble
    - Ride Control Valve Remove and Install—If Equipped
    - Ride Control Valve Disassemble and Assemble—If Equipped
    - Pin Disconnect Valve Remove and Install—If Equipped
    - Pin Disconnect Valve Disassemble and Assemble—If Equipped
    - Hydraulic Fan Pump Remove and Install
    - Hydraulic Fan Motor Remove and Install
    - Reversing Fan Valve Remove and Install—If Equipped
    - Reversing Fan Valve Disassemble and Assemble—If Equipped
- Dealer Fabricated Tools
  - Dealer Fabricated Tools
    - DFT1132 Hydraulic Pump Removal And Installation Tool