544G, 544G LL,

544G TC, 624G,

and 644G
Loader
Repair

TECHNICAL MANUAL
544G, 544G LL, 544G TC, 624G, and
644G Loader Repair
TM1530 07APR98 (ENGLISH)

For complete service information also see:

544G, 544G LL, 544G TC, 624G, and 644G
Operation and Test . . . . . . . . . . . . . . . . . . . . TM1529
6059 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM8
6068 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM8
6076 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM42
6081 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86
Alternators and Starting Motors . . . . . . . . . . CTM77
1200 and 1400 Series Axles . . . . . . . . . . . . . CTM43

Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
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 Introduction
Foreword
This manual is written for an experienced technician.
Essential tools required in performing certain service
work are identified in this manual and are
recommended for use.
Live with safety: Read the safety messages in the
introduction of this manual and the cautions presented
throughout the text of the manual.
CAUTION: This is the safety-alert symbol.
When you see this symbol on the machine
or in this manual, be alert to the potential for
personal injury.
Technical manuals are divided in two parts: repair and
operation and tests. Repair sections tell how to repair
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
TM1530 (07APR98)
Information is organized in groups for the various
components requiring service instruction. At the
beginning of each group are summary listings of all
applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
testing, and repair.
Fundamental service information is available from
other sources covering basic theory of operation,
fundamentals of troubleshooting, general maintenance,
and basic type of failures and their causes.
DX,TMIFC –19–22MAY92–1/1
544G, 624G, and 644G Loader Repair
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 Introduction

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TM1530 544G,624G,644G Loader Repair Manual

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TM1530 (07APR98) 544G, 624G, and 644G Loader Repair

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 Introduction

TM1530 (07APR98) 544G, 624G, and 644G Loader Repair

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 Contents
00
SECTION 00—General Information SECTION 11—Park Brake
Group 01—Safety Information Group 1111—Active Elements
Group 02—General Specifications Group 1160—Hydraulic System
Group 0003—Torque Values
Group 0004—Fuels And Lubricants SECTION 15—Equipment Attaching
01
Group 0005—Inspection Procedures Group 1511—Drawbar

SECTION 01—Wheels SECTION 16—Electrical Systems

Group 0110—Powered Wheels And Fastenings
SECTION 02—Axles And Suspension Systems
Group 0200—Removal And Installation
Group 0225—Axle Shafts, Bearings And U-Joints
Group 0260—Hydraulic System
SECTION 03—Transmission
Group 0300—Removal And Installation
Group 0315—Control Linkage
Group 0325—Input Drive Shafts And U-Joints
Group 0350—Gear, Shafts, Bearings And Power
Shift Clutch
Group 0360—Hydraulic System
SECTION 04—Engine
Group 0400—Removal And Installation
SECTION 05—Engine Auxiliary Systems
Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
Group 0515—Speed Controls
Group 0520—Intake System
Group 0560—External Fuel Supply System
Group 1671—Batteries, Support And Cables
Group 1672—Alternator, Regulator And Charging
System Wiring 02
Group 1673—Lighting System
Group 1674—Wiring Harness And Switches
Group 1677—Motors And Actuators
SECTION 17—Frame Or Supporting Structure
03
Group 1740—Frame Installation
Group 1746—Frame Bottom Guards
Group 1749—Chassis Weights
SECTION 18—Operator’s Station
Group 1800—Removal And Installation 04
Group 1810—Operator Enclosure
Group 1821—Seat And Seat Belt
Group 1830—Heating And Air Conditioning
SECTION 31—Loader
05
Group 3102—Bucket
Group 3140—Frames
Group 3160—Hydraulic System
SECTION 99—Dealer Fabricated Tools
Group 9900—Dealer Fabricated Tools 07

SECTION 07—Dampener Drive

Group 0752—Elements
09
SECTION 09—Steering System
Group 0930—Secondary Steering
Group 0960—Hydraulic System

SECTION 10—Service Brakes 10

Group 1011—Active Elements
Group 1060—Hydraulic System

All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 11

COPYRIGHT  1997
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  1995,1994,1993

TM1530 (07APR98) i 544G, 624G, and 644G Loader Repair

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 Contents

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01

02

03

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10

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Contents
Page
Group 01—Safety Information
Handle Fluids Safely—Avoid Fires . . . . . . . . . .00-01-1
Prevent Battery Explosions . . . . . . . . . . . . . . . .00-01-1
Prepare for Emergencies. . . . . . . . . . . . . . . . . .00-01-1
Prevent Acid Burns . . . . . . . . . . . . . . . . . . . . . .00-01-2
Handle Chemical Products Safely . . . . . . . . . . .00-01-3
Avoid High-Pressure Fluids . . . . . . . . . . . . . . . .00-01-3
Park Machine Safely . . . . . . . . . . . . . . . . . . . . .00-01-4
Support Machine Properly . . . . . . . . . . . . . . . . .00-01-4
Wear Protective Clothing. . . . . . . . . . . . . . . . . .00-01-4
Work in Clean Area. . . . . . . . . . . . . . . . . . . . . .00-01-5
Service Machines Safely . . . . . . . . . . . . . . . . . .00-01-5
Work In Ventilated Area . . . . . . . . . . . . . . . . . .00-01-5
Illuminate Work Area Safely . . . . . . . . . . . . . . .00-01-5
Replace Safety Signs . . . . . . . . . . . . . . . . . . . .00-01-6
Use Proper Lifting Equipment . . . . . . . . . . . . . .00-01-6
Remove Paint Before Welding or Heating . . . . .00-01-6
Avoid Heating Near Pressurized Fluid Lines . . .00-01-7
Keep ROPS Installed Properly . . . . . . . . . . . . .00-01-7
Service Tires Safely . . . . . . . . . . . . . . . . . . . . .00-01-8
Avoid Harmful Asbestos Dust . . . . . . . . . . . . . .00-01-8
Practice Safe Maintenance . . . . . . . . . . . . . . . .00-01-9
Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . .00-01-9
Dispose of Waste Properly . . . . . . . . . . . . . . .00-01-10
Live With Safety . . . . . . . . . . . . . . . . . . . . . . .00-01-10
Group 02—General Specifications
544G Specifications . . . . . . . . . . . . . . . . . . . . .00-02-2
544G Drain And Refill Capacities . . . . . . . . . . .00-02-4
544G LL Specifications . . . . . . . . . . . . . . . . . . .00-02-5
544G LL Drain And Refill Capacities . . . . . . . . .00-02-7
544G TC Specifications. . . . . . . . . . . . . . . . . . .00-02-8
544G TC Drain And Refill Capacities . . . . . . .00-02-10
624G Specifications . . . . . . . . . . . . . . . . . . . .00-02-11
624G Drain And Refill Capacities . . . . . . . . . .00-02-13
644G Specifications . . . . . . . . . . . . . . . . . . . .00-02-14
644G Drain And Refill Capacities . . . . . . . . . .00-02-16
Group 0003—Torque Values
Hardware Torque Specifications . . . . . . . . . .00-0003-1
ROPS Torque Specifications . . . . . . . . . . . . .00-0003-1
Metric Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Additional Metric Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-3
TM1530 (07APR98)
00
Section 00
General Information
Page
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-5
Check Oil Lines And Fittings . . . . . . . . . . . . .00-0003-6
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-7
Service Recommendations for Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . . .00-0003-9
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . .00-0003-10
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . .00-0003-11
Group 0004—Fuels And Lubricants
Fuel Specifications . . . . . . . . . . . . . . . . . . . .00-0004-1
Storing Fuel. . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-1
Do Not Use Galvanized Containers. . . . . . . .00-0004-2
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-2
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-3
Hydraulic System Oil And Differential Oil. . . .00-0004-4
Transmission Oil . . . . . . . . . . . . . . . . . . . . . .00-0004-5
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0004-6
Alternative and Synthetic Lubricants . . . . . . .00-0004-7
Lubricant Storage . . . . . . . . . . . . . . . . . . . . .00-0004-7
Mixing of Lubricants . . . . . . . . . . . . . . . . . . .00-0004-8
Diesel Engine Coolant. . . . . . . . . . . . . . . . . .00-0004-9
Group 0005—Inspection Procedures
Planned Inspection Program I (PIP I) . . . . . .00-0005-1
Planned Inspection Program II (PIP II) . . . . .00-0005-1
Using The Checklists . . . . . . . . . . . . . . . . . .00-0005-2
Delivery Service . . . . . . . . . . . . . . . . . . . . . .00-0005-2
John Deere 544G, 624G And 644G
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0005-3
John Deere 544G, 624G, And 644G
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0005-6
00-1 544G, 624G, and 644G Loader Repair
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