444J, 544J, 624J Loader Repair
TECHNICAL MANUAL 444J, 544J, 624J Loader Repair TM2136 TM2136 13DEC04 (ENGLISH)
For complete service information also see: 444J, 544J, 624J Loader Operation and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM2135 Alternators and Starting Motors . . . . . . . . . . CTM77 POWERTECH 4.5L & 6.8L Diesel Engines Base Engine. . . . . . . . . . . . . . . . . . . . . . . . . . CTM104 TEAMMATE III 1000, 1200, and 1400 Series Inboard Planetary Axles . . . . . . . . . . CTM150 POWERTECH 4.5L and 6.8L Diesel Engines Level 11 Electronic Fuel System with Denso HPCR . . . . . . . . . . . . . . . . . . . . . CTM220 POWERTECH 4.5L and 6.8L Diesel Engines Level 12 Electronic Fuel System with DE10 Pump . . . . . . . . . . . . . . . . . . . . . . CTM331 120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A 125 Series Hydraulic Cylinders . . . . . . . . . . TM-H125A SERVICE ADVISOR System Computer Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . T133991
Worldwide Construction And Forestry Division LITHO in U.S.A.
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. 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.
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.
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Introduction
Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO:
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Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!
TX,II,FAX –19–10JUL01–1/1
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Introduction
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Contents 00
SECTION 17—Frame or Supporting Structure Group 1740—Frame Installation Group 1746—Frame Bottom Guards Group 1749—Chassis Weights
SECTION 00—General Information Group 0001—Safety Information SECTION 01—Wheels Group 0110—Powered Wheels and Fasteners
01
SECTION 18—Operator’s Station Group 1800—Removal and Installation Group 1810—Operator Enclosure Group 1830—Heating and Air Conditioning
SECTION 02—Axles and Suspension Systems Group 0200—Removal and Installation Group 0225—Axle Shafts and U-Joints Group 0250—Axle Shaft, Bearings, Reduction Gears Group 0260—Hydraulic System
SECTION 19—Sheet Metal and Styling Group 1910—Hood or Engine Enclosure
02
SECTION 31—Loader Group 3102—Bucket Group 3140—Frames Group 3160—Hydraulic System
SECTION 03—Transmission Group 0300—Removal and Installation Group 0350—Gears, Shafts, Bearings and Power Shift Clutch Group 0360—Hydraulic System
03
SECTION 9900—Dealer Fabricated Tools Group 0099—Dealer Fabricated Tools
SECTION 04—Engine Group 0400—Removal and Installation
04
SECTION 05—Engine Auxiliary Systems Group 0505—Cold Weather Starting Aids Group 0510—Cooling System Group 0520—Intake System Group 0530—External Exhaust System Group 0560—External Fuel Supply Systems
05
SECTION 07—Dampener Drive Group 0752—Elements
07
SECTION 09—Steering System Group 0960—Hydraulic System 09
SECTION 10—Service Brakes Group 1011—Active Elements Group 1060—Hydraulic System SECTION 11—Park Brake Group 1111—Active Elements Group 1160—Hydraulic System
10
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 2004 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual
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Section 00
General Information Contents Page
Group 0001—Safety Information Recognize Safety Information . . . . . . . . . . . .00-0001-1 Follow Safety Instructions . . . . . . . . . . . . . . .00-0001-1 Operate Only If Qualified. . . . . . . . . . . . . . . .00-0001-2 Wear Protective Equipment . . . . . . . . . . . . . .00-0001-2 Avoid Unauthorized Machine Modifications . . . . . . . . . . . . . . . . . . . . . . .00-0001-2 Add Cab Guarding For Special Uses . . . . . .00-0001-3 Inspect Machine . . . . . . . . . . . . . . . . . . . . . .00-0001-3 Stay Clear Of Moving Parts. . . . . . . . . . . . . .00-0001-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-4 Beware Of Exhaust Fumes . . . . . . . . . . . . . .00-0001-4 Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Prevent Battery Explosions . . . . . . . . . . . . . .00-0001-5 Handle Chemical Products Safely . . . . . . . . .00-0001-6 Dispose of Waste Properly . . . . . . . . . . . . . .00-0001-6 Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-6 Use Steps And Handholds Correctly . . . . . . .00-0001-7 Start Only From Operator’s Seat . . . . . . . . . .00-0001-7 Use And Maintain Seat Belt . . . . . . . . . . . . .00-0001-7 Prevent Unintended Machine Movement . . . .00-0001-8 Avoid Work Site Hazards . . . . . . . . . . . . . . .00-0001-8 Use Special Care When Operating Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-9 Keep Riders Off Machine . . . . . . . . . . . . . . .00-0001-9 Avoid Backover Accidents . . . . . . . . . . . . . .00-0001-10 Avoid Machine Tip Over . . . . . . . . . . . . . . .00-0001-10 Operating on Slopes . . . . . . . . . . . . . . . . . .00-0001-11 Operating Or Traveling On Public Roads . .00-0001-11 Inspect and Maintain ROPS . . . . . . . . . . . .00-0001-12 Add And Operate Attachments Safely . . . . .00-0001-12 Park And Prepare For Service Safely . . . . .00-0001-13 Service Cooling System Safely . . . . . . . . . .00-0001-13 Remove Paint Before Welding or Heating . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-14 Make Welding Repairs Safely . . . . . . . . . . .00-0001-14 Drive Metal Pins Safely . . . . . . . . . . . . . . . .00-0001-15
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Group 0001
Safety Information 00 0001 1
Follow the precautions and safe operating practices highlighted by this symbol.
T133555
This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury.
–UN–28AUG00
Recognize Safety Information
T133588
On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
–19–28AUG00
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.
TX03679,00016CC –19–21AUG00–1/1
T133556
Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Replacement safety signs are available from your John Deere dealer.
–UN–24AUG00
Follow Safety Instructions
Be sure all operators of this machine understand every safety message. Replace operator’s manual and safety labels immediately if missing or damaged.
TX03679,00016F9 –19–13OCT03–1/1
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Safety Information
Operate Only If Qualified Do not operate this machine unless you have read the operator’s manual carefully and you have been qualified by supervised training and instruction.
machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to your work situation and your work site.
Familiarize yourself with the job site and your surroundings before operating. Try all controls and
TX03679,00016FA –19–30OCT00–1/1
Wear Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.
–UN–23AUG88
Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
TS206
00 0001 2
TX03679,00016D0 –19–30OCT00–1/1
Avoid Unauthorized Machine Modifications Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance.
Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.
TX03679,00016B7 –19–13OCT03–1/1
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Safety Information 00 0001 3
Use load-clamping grapples to keep bulky loads from falling and add special screens or guarding when objects may be directed toward the cab. Contact your authorized dealer for information on devices intended to protect the operator from falling or flying objects in special work situations.
T141893
Special work situations or machine attachments may create an environment with falling or flying objects. Loading logs, using fork attachments, or operating in waste management applications requires special work tools. Added cab guarding to protect the operator may also be required.
–UN–04MAY01
Add Cab Guarding For Special Uses
TX03679,00017C6 –19–01JUN01–1/1
Inspect Machine
T6607AQ
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.
–UN–18OCT88
Inspect machine carefully each day by walking around it before starting.
TX03679,0001734 –19–25SEP00–1/1
Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.
T133592
Entanglements in moving parts can cause serious injury.
–UN–12SEP01
Stay Clear Of Moving Parts
TX03679,00016D2 –19–30OCT00–1/1
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Safety Information
T133840
If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.
T133509
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping fluid. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.
–UN–20SEP00
This machine uses a high-pressure hydraulic system. Escaping fluid under pressure can penetrate the skin causing serious injury.
–UN–31OCT00
Avoid High-Pressure Fluids
TX03679,00016D3 –19–30OCT00–1/1
Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.
–UN–24AUG00
Beware Of Exhaust Fumes
T133546
00 0001 4
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Safety Information 00 0001 5
T133552 T133554
Keep A Fire Extinguisher Available: Always keep a multi-purpose fire extinguisher on or near the machine. Know how to use extinguisher properly.
–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.
T133553
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.
–UN–07SEP00
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.
–UN–14SEP00
Prevent Fires
TX03679,00016F5 –19–25SEP00–1/1
Prevent Battery Explosions
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
TS204
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
–UN–23AUG88
Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.
TX03679,000174A –19–14SEP00–1/1
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Safety Information
If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.
T133580
Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.
–UN–25AUG00
Handle Chemical Products Safely
TX03679,00016D7 –19–05AUG02–1/1
Never pour waste onto the ground, down a drain, or into any water source.
T133567
Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly.
–UN–25AUG00
Dispose of Waste Properly
Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more information.
TX03679,0001733 –19–14SEP00–1/1
Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
–UN–23AUG88
Keep a first aid kit and fire extinguisher handy.
TS291
00 0001 6
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Safety Information 00 0001 7
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.
T133468
Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds.
–UN–30AUG00
Use Steps And Handholds Correctly
TX03679,00016F2 –19–14SEP00–1/1
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.
T133715
Avoid unexpected machine movement. Start engine only while sitting in operator’s seat. Ensure all controls and working tools are in proper position for a parked machine.
–UN–07SEP00
Start Only From Operator’s Seat
TX03679,0001799 –19–02MAY01–1/1
Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.
T133716
Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses.
–19–14SEP00
Use And Maintain Seat Belt
The complete seat belt assembly should be replaced every three years, regardless of appearance.
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Safety Information
Prevent Unintended Machine Movement
Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.
T142001
Lower all equipment to the ground during work interruptions. Lock transmission control in neutral, engage park brake and stop engine before allowing anyone to approach the machine.
–UN–15MAY01
When co-workers are present, disable hydraulics.
TX03679,00017C7 –19–28OCT02–1/1
Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move any part of machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires. Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine.
T141894 –UN–24APR01
Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over.
T141670
Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before starting work.
–UN–15JUN01
Avoid Work Site Hazards
Avoid working under over-hanging embankments or stockpiles that could collapse on machine.
–UN–04MAY01
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations.
T141672
00 0001 8
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Safety Information 00 0001 9
Ensure that objects in the bucket are secure. Do not attempt to lift or carry objects that are too big or too long to fit inside the bucket unless secured with an adequate chain or other device. Keep bystanders away from raised loads. Be careful when lifting objects. Never attempt to lift objects too heavy for your machine. Assure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Use an adequate chain or sling and proper rigging techniques to attach and stabilize loads. Never lift an object above or near another person.
T141957 –UN–07MAY01
Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes or an unstable surface. Drive and turn slowly with a raised load.
T141902
Never use the loader to lift people. Do not allow anyone to ride in the bucket or use the bucket as a work platform.
–UN–15MAY01
Use Special Care When Operating Loader
TX03768,0000B70 –19–14MAY01–1/1
Keep Riders Off Machine
Riders may obstruct operator’s view or impair his ability to operate machine safely.
T141671
Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.
–UN–04MAY01
Only allow operator on machine.
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Safety Information
Be certain reverse warning alarm is working properly.
T141673
Before moving machine, be sure all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.
–UN–04MAY01
Avoid Backover Accidents
Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.
TX03679,000179C –19–20APR01–1/1
Be careful on slopes. Avoid sharp turns. Balance loads so weight is evenly distributed and load is stable. Carry tools and loads close to the ground to aid visibility and lower center of gravity. Use extra care on soft, rocky or frozen ground. Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability. Ensure solid footing. Use extra care in soft ground conditions that may not uniformly support the wheels, especially when raising the boom. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.
T133716 –UN–04MAY01
Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed.
T141676
Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.
–UN–04MAY01
Use seat belt at all times.
–19–14SEP00
Avoid Machine Tip Over
T141672
00 0001 10
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Safety Information 00 0001 11
Select low gear speed before starting down slope. The grade of the slope will be limited by ground condition and load being handled. Use service brakes to control speed. Sudden brake application with a loaded bucket on downhill side could cause machine to tip forward.
T141681
Avoid side slope travel whenever possible. Drive up steep slope in forward and down in reverse.
–UN–30APR01
Operating on Slopes
TX03679,000179E –19–14MAY01–1/1
Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.
T141891
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers.
–UN–22MAY01
Operating Or Traveling On Public Roads
TX03679,00017C8 –19–14JUN01–1/1
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Safety Information 00 0001 12
Inspect and Maintain ROPS A damaged roll-over protective structure (ROPS) should be replaced, not reused.
To maintain the ROPS:
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.
• Replace missing hardware using correct grade hardware. • Check hardware torque. • Check isolation mounts for damage, looseness or wear; replace them if necessary. • Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.
TX03679,000179F –19–20APR01–1/1
Add And Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability, and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify
that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.
TX03679,00016F0 –19–14SEP00–1/1
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Safety Information 00 0001 13
Park And Prepare For Service Safely
T133332
• Park machine on a level surface and lower equipment to the ground. • Engage park brake. • Stop engine and remove key. • Install articulation locking bar. • Attach a “Do Not Operate” tag in an obvious place in the operator’s station.
–19–14DEC01
Warn others of service work. Always park and prepare your machine for service or repair properly.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.
TS229
• Do not support machine with boom, bucket, or other hydraulically actuated equipment. • Do not support machine with cinder blocks or wooden pieces that may crumble or crush. • Do not support machine with a single jack or other devices that may slip out of place.
–UN–23AUG88
Securely support machine or attachment before working under it.
TX03679,00017A0 –19–18SEP01–1/1
Service Cooling System Safely
TS281
Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
–UN–23AUG88
Explosive release of fluids from pressurized cooling system can cause serious burns.
DX,RCAP –19–04JUN90–1/1
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Safety Information
Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.
• Remove paint a minimum of 101 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.
TS220
Remove paint before heating:
–UN–23AUG88
Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
NOTE: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors. Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
–UN–31AUG00
Make Welding Repairs Safely
T133547
00 0001 14
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.
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Safety Information 00 0001 15
Use a soft hammer or a brass bar between hammer and object to prevent chipping.
T133738
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.
–UN–14SEP00
Drive Metal Pins Safely
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Safety Information 00 0001 16
TM2136 (13DEC04)
00-0001-16
444J, 544J, 624J Loader 121304
PN=24
Section 01
Wheels Contents
01
Page
Group 0110—Powered Wheels and Fasteners Remove and Install Wheel . . . . . . . . . . . . . .01-0110-1 Remove Tire . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-2 Install Tire . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4
TM2136 (13DEC04)
01-1
444J, 544J, 624J Loader 121304
PN=1
Contents
01
TM2136 (13DEC04)
01-2
444J, 544J, 624J Loader 121304
PN=2
Group 0110
Powered Wheels and Fasteners Remove and Install Wheel 1. Raise machine and place 10-ton shop stand under axle. 01 0110 1
CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. 2. Place wheel lift under wheel. Fasten safety chain around upper part of tire. TX,01,111685 –19–01NOV02–1/2
3. Remove cap screws (A). Remove wheel. 4. Clean mounting surface on wheel and axle flange. 5. Install wheel. Tighten cap screws. Tighten Wheel Retainer Cap Screws—Specification Wheel Retainer Cap Screws—Dry Torque .......................................................................................... 620 N•m 460 lb-ft Valve Stem Retaining Nut— Torque .............................................................................................. 6 N•m 50 lb-in.
T7134FA
–UN–24MAY90
A—Wheel Cap Screw (14 used)
TX,01,111685 –19–01NOV02–2/2
TM2136 (13DEC04)
01-0110-1
444J, 544J, 624J Loader 121304
PN=27
Powered Wheels and Fasteners
Remove Tire CAUTION: Explosive separation of a tire and rim parts can cause serious injury or death. Only attempt to mount a tire if you have the proper equipment and experience to perform the job. Have it done by your John Deere dealer or a qualified repair service. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
–UN–23AUG88
Inspect tires and wheels daily. Do not operate with low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. Failure to follow proper procedures when demounting a tire from a wheel or rim can produce an explosion which may result in serious bodily injury. Do not attempt to demount a tire unless you have proper equipment and experience to perform the job safely. Have it done by a qualified tire repair service.
TS211
01 0110 2
NOTE: See John Deere Off-The-Road Tire Maintenance Manual to remove tire from wheel. Tire can be removed without removing wheel.
Continued on next page
TM2136 (13DEC04)
01-0110-2
TX,01,111686 –19–23OCT98–1/2
444J, 544J, 624J Loader 121304
PN=28
Powered Wheels and Fasteners Before attempting any demounting operation, always completely deflate tire. Remove cap (A) and valve core (B) from valve. Remove valve nut (C).
–UN–22OCT92
Inspect all parts for damage. Replace parts as necessary.
T7751GU
A—Cap B—Valve Core C—Valve Nut
TX,01,111686 –19–23OCT98–2/2
TM2136 (13DEC04)
01-0110-3
444J, 544J, 624J Loader 121304
PN=29
01 0110 3
Powered Wheels and Fasteners
Install Tire
–UN–22OCT88 T6564BR
01 0110 4
CAUTION: Failure to follow proper procedures when mounting a tire from a wheel or rim can produce an explosion which may result in serious bodily injury. Do not attempt to mount a tire unless you have proper equipment and experience to perform the job safely. Have it done by a qualified tire repair service.
NOTE: See John Deere Off-The-Road Tire Maintenance Manual to mount the tire on the wheel. To prevent slipping of the wheel under load, the inside and outside wheel must be free of paint, rust, oil, grease, dirt or other foreign material before installation.
A—Front Flange B—Bead Seat Band C—Lock Ring D—O-Ring E—Cap
Install valve stem in rim base and tighten retaining nut. Specification Valve Stem Retaining Nut— Torque ............................................................................................. 6 N•m 50 lb-in.
CAUTION: Serious bodily injury can occur from explosion when mounting and inflating tires if safe procedures are not followed. Use only recommended air pressure. Pressure over this limit can cause explosion. Inflate tire. Apply John Deere Non-Soap Lubricating Grease, or an equivalent, on threads of cap (E). Install cap on valve stem shield.
TX,01,111687 –19–23OCT98–1/1
TM2136 (13DEC04)
01-0110-4
444J, 544J, 624J Loader 121304
PN=30
Section 02
Axles and Suspension Systems Contents Page
Group 0200—Removal and Installation TEAMMATE Axles . . . . . . . . . . . . . . . . . . .02-0200-1 Front Axle and Differential Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-1 Rear Axle and Differential Remove . . . . . . .02-0200-6 Rear Axle and Differential Install . . . . . . . . .02-0200-12 Axle Oscillating Supports Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0200-14
02
Group 0225—Axle Shafts and U-Joints Universal Joint and Drive Shaft Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .02-0225-2 Group 0250—Axle Shaft, Bearings, Reduction Gears John Deere TeamMate III Axles—Use CTM150. . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Axle Disconnect Input Shaft, Cross-Sectional View. . . . . . . . . . . . . . . . .02-0250-2 Axle Disconnect Input Shaft Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-3 Axle Disconnect Input Shaft Disassemble, Inspect, and Assemble. . . . . . . . . . . . . . . .02-0250-3 Group 0260—Hydraulic System Differential Lock Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Axle Circulation System . . . . . . . . . . . . . . . .02-0260-2 Axle Oil Coolers . . . . . . . . . . . . . . . . . . . . . .02-0260-4 Axle Oil Coolers Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-5
TM2136 (13DEC04)
02-1
444J, 544J, 624J Loader 121304
PN=1
Contents
02
TM2136 (13DEC04)
02-2
444J, 544J, 624J Loader 121304
PN=2
Group 0200
Removal and Installation TEAMMATE Axles For additional information on TEAMMATE axles and components, see the following component technical manual (CTM). • See TeamMate III 1000, 1200, and 1400 Series Inboard Planetary Axles. (CTM150.)
TEAMMATE is a trademark of Deere & Company
BT40170,00000A8 –19–12DEC03–1/1
Front Axle and Differential Remove and Install 1. Apply park brake. –UN–03OCT96
2. Install frame locking bar (A).
T101610
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification 444J Machine—Weight— Approximate................................................................................ 10,254 kg 22,605 lb 544J Machine—Weight— Approximate................................................................................ 12,330 kg 27,184 lb 624J Machine—Weight— Approximate................................................................................ 14,304 kg 31,534 lb
A—Locking Bar B—12-1/2 Ton Floor Stand
3. Raise front of machine. Install floor stands (B) under loader frame. 4. Install boom lock. Move bucket to dumped position and lower. This will provide clearance to remove cap screws. 5. Stop engine.
Continued on next page
TM2136 (13DEC04)
02-0200-1
TX,02,111691 –19–24OCT03–1/7
444J, 544J, 624J Loader 121304
PN=33
02 0200 1
Removal and Installation
02 0200 2
CAUTION: Prevent possible injury from unexpected boom or bucket movement when equipped with ride control. Ride control accumulator energy must be discharged when working on hydraulic components. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds. 6. If equipped with ride control. With boom raised slightly, turn ignition switch to ON position. Cycle the ride control switch from OFF to ON (center position). Boom will jump up unexpectedly if ride control accumulator is energized. Press boom enable switch and move the control lever into the float position and hold for 5 seconds 7. Drain differential. Specification 444J Front Axle Differential— Capacity ............................................................................................ 17.5 L 18 Qt 544J Front Axle Differential— Capacity ............................................................................................... 20 L 21 Qt 624J Front Axle Differential— Capacity ............................................................................................... 25 L 26 Qt
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Weight may increase significantly due to buildup of mud or debris. 8. Remove bottom guard, if equipped. Specification 444J Loader Frame Bottom Guard—Weight—Approximate ......................................................... 54 kg 119 lb 544J Loader Frame Bottom Guard—Weight—Approximate ......................................................... 54 kg 119 lb
Continued on next page
TM2136 (13DEC04)
02-0200-2
TX,02,111691 –19–24OCT03–2/7
444J, 544J, 624J Loader 121304
PN=34
Removal and Installation Specification 624J Loader Frame Bottom Guard—Weight—Approximate .......................................................... 60 kg 132 lb
TX,02,111691 –19–24OCT03–3/7
9. Disconnect lines from ports (A—D) as equipped. Install caps and plugs in ports and hoses. 02 0200 3
10. Remove cap screws to disconnect drive shaft. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Remove wheels using a wheel lift.
T195715
–UN–30OCT03
A—Brake Port B—Circulation System Inlet Port C—Differential Lock Port D—Circulation System Outlet Port
Continued on next page
TM2136 (13DEC04)
02-0200-3
TX,02,111691 –19–24OCT03–4/7
444J, 544J, 624J Loader 121304
PN=35
Removal and Installation
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
–UN–03OCT96 T101609
02 0200 4
Specification 444J Front Axle and Differential— Weight—Approximate ...................................................................... 920 kg 2029 lb 544J Front Axle and Differential— Weight—Approximate .................................................................... 1080 kg 2381 lb 624J Front Axle and Differential— Weight—Approximate ......................................................................... 1280 2822 lb
TeamMate II Axle Shown A—Nut B—Low-Lift Jack
12. Install low-lift jack (B) under axle and differential. 13. Remove nuts (A) to remove cap screws. Lower axle and differential. 14. Repair or replace axle or differential. (See procedure in this group.) 15. Clean mounting surface on axle housings and loader frame. 16. Fill differential with oil. (Operator’s Manual.) 17. Install axle and differential. Install a washer under head of cap screws and a washer under the nuts. Hold the cap screws and tighten the nuts. Specification Cap Screw Nut—Torque .............................................................. 675 N•m 500 lb-ft
IMPORTANT: Do not reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage. 18. Connect drive shaft. Install new drive shaft universal joint cap screws and tighten cap screws. Specification Drive Shaft Universal Joint Cap Screw (444J)—Torque ................................................................... 45 N•m 32 lb-ft
Continued on next page
TM2136 (13DEC04)
02-0200-4
TX,02,111691 –19–24OCT03–5/7
444J, 544J, 624J Loader 121304
PN=36
Removal and Installation Specification Drive Shaft Universal Joint Cap Screw (544J and 624J)—Torque ................................................... 78 N•m 58 lb-ft
TX,02,111691 –19–24OCT03–6/7
19. Connect lines to ports (A—E) as equipped. 20. Remove jack. 02 0200 5
21. Install wheels. Tighten wheel cap screws. Front Axle and Differential:—Specification Wheel Cap Screw—Torque.......................................................... 675 N•m 500 lb-ft
NOTE: No bleeding of brakes is necessary. They are self bleeding. –UN–11DEC98
22. Install bottom guard, if equipped.
T118871
A—Brake Port B—Circulation System Inlet Port C—Differential Lock Port D—Axle Disconnect Port E—Circulation System Outlet Port
TX,02,111691 –19–24OCT03–7/7
TM2136 (13DEC04)
02-0200-5
444J, 544J, 624J Loader 121304
PN=37
Removal and Installation
Rear Axle and Differential Remove 1. Apply park brake. 2. Install frame locking bar. 3. Raise boom and install boom lock. Move bucket to dump position.
02 0200 6
4. Stop engine. Release hydraulic pressure by operating loader control while holding boom enable switch. If equipped with ride control see Group 3160 in this manual for releasing hydraulic energy in accumulators. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Weight may increase significantly due to buildup of mud or debris on guard. Specification Transmission Bottom Guard (444J, 544J)—Weight— Approximate...................................................................................... 65 kg 143 lb Transmission Bottom Guard (624J)—Weight—Approximate .......................................................... 74 kg 163 lb
5. Remove transmission bottom guard if equipped. 6. Drain differential. Specification (444J) Rear Differential Oil— Capacity—Approximate .................................................................... 17.5 L 18 qt (544J, 624J) Rear Differential Oil—Capacity—Approximate ............................................................... 20 L 21 qt
Continued on next page
TM2136 (13DEC04)
02-0200-6
CED,OUOE006,19 –19–27OCT03–1/5
444J, 544J, 624J Loader 121304
PN=38
Removal and Installation
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
T7134HD
–UN–20FEB90
Specification 444J Machine—Weight— Approximate................................................................................ 10,254 kg 22,605 lb 544J Machine—Weight— Approximate................................................................................ 12,330 kg 27,184 lb 624J Machine—Weight— Approximate................................................................................ 14,304 kg 31,534 lb
7. Raise rear of machine using floor jack. Install floor stands under frame on each side and at under rear corners of frame. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 8. Remove wheels. 9. Remove caps screws to disconnect drive shaft. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
T7134HE
–UN–06MAR90
Rear Axle and Differential:—Specification Axle and Differential with Oscillating Supports (444J)— Weight—Approximate ..................................................................... 980 kg 2161 lb Axle and Differential with Oscillating Supports (544J, 624J)—Weight—Approximate ....................................................... 1080 kg 2381 lb
10. Install low-lift jack under axle and differential. A—Floor Stand (4 used)
Continued on next page
TM2136 (13DEC04)
02-0200-7
CED,OUOE006,19 –19–27OCT03–2/5
444J, 544J, 624J Loader 121304
PN=39
02 0200 7
Removal and Installation 11. Disconnect lines from ports (A—D) as equipped. A—Brake Port B—Circulation System Inlet Port C—Differential Lock Port D—Circulation System Outlet Port
T195715
–UN–30OCT03
02 0200 8
Continued on next page
TM2136 (13DEC04)
02-0200-8
CED,OUOE006,19 –19–27OCT03–3/5
444J, 544J, 624J Loader 121304
PN=40
Removal and Installation
TP60252
–UN–18MAR98
02 0200 9
1—Special Jam Nut (2 used) 2—Fitting (2 used) 3—Nut (4 used) 4—Hydraulic Hose 5—Elbow Fitting (3 used) 6—Bushing (2 used) 7—Rear Oscillating Support
8—Thrust Bearing (6 used) 9—Thrust Plate 10—Washer (4 used) 11—Cap Screw (4 used) 12—O-Ring 13—Cover 14—Cap Screw (6 used)
15—Cap Screw (4 used) 16—Seal (3 used) 17—Cap Screw (4 used) 18—Rear Axle Support 19—Hydraulic Hose 20—Elbow Fitting
Continued on next page
TM2136 (13DEC04)
02-0200-9
21—Lubrication Fitting (2 used) 22—Washer (8 used) 23—Lubrication Fitting 24—Bushing 544J only (4 used)
CED,OUOE006,19 –19–27OCT03–4/5
444J, 544J, 624J Loader 121304
PN=41
Removal and Installation 12. Disconnect hydraulic hoses (4 and 19) from front and rear oscillating supports.
16. Remove cap screws from pivot cover (13) and thrust plate (9).
13. Remove cap screws (17 and 15) from oscillating supports.
17. Remove rear oscillating support (7) from differential assembly.
14. Lower supports, axle and differential assembly.
18. Repair or replace axle. See this group for repair.
15. Remove rear axle support (18) from differential assembly. 02 0200 10
CED,OUOE006,19 –19–27OCT03–5/5
TM2136 (13DEC04)
02-0200-10
444J, 544J, 624J Loader 121304
PN=42
Removal and Installation
02 0200 11
TM2136 (13DEC04)
02-0200-11
444J, 544J, 624J Loader 121304
PN=43
Removal and Installation
Rear Axle and Differential Install
TP60252
–UN–18MAR98
02 0200 12
Continued on next page
TM2136 (13DEC04)
02-0200-12
CED,OUOE003,2650 –19–27OCT03–1/2
444J, 544J, 624J Loader 121304
PN=44
Removal and Installation 1—Special Jam Nut (2 used) 2—Fitting (2 used) 3—Nut (4 used) 4—Hydraulic Hose 5—Elbow Fitting (3 used) 6—Bushing (2 used) 7—Rear Oscillating Support
8—Thrust Bearing (6 used) 9—Thrust Plate 10—Washer (4 used) 11—Cap Screw (4 used) 12—O-Ring 13—Cover 14—Cap Screw (6 used)
15—Cap Screw (4 used) 16—Seal (3 used) 17—Cap Screw (4 used) 18—Rear Axle Support 19—Hydraulic Hose 20—Elbow Fitting
21—Lubrication Fitting (2 used) 22—Washer (8 used) 23—Lubrication Fitting 24—Bushing (544J only) (4 used)
Drive Shaft Universal Joint Cap Screw Torque (544J, 624J)— Torque...................................................................................... 78 N•m 58 lb-ft
1. Fill differential with oil. (Operator’s Manual.) 2. Install rear axle and rear oscillating supports. 3. Tighten thrust plate cap screws (11) and pivot cover cap screws (14). Specification Oscillating Support Thrust Plate Cap Screw Torque—Torque.................................................. 350 N•m 255 lb-ft Oscillating Support Pivot Cover Cap Screw Torque—Torque.................................................. 140 N•m 105 lb-ft
NOTE: No bleeding of brakes is necessary. They are self bleeding. 8. Connect lubrication lines. 9. Install wheels. Tighten cap screws. Specification Wheel Cap Screw—Torque ................................................... 675 N•m 500 lb-ft
4. Install axle and differential. 10. Remove floor stands. 5. Tighten cap screws (15 and 17). 11. Install bottom guard, if equipped. Specification Axle and Differential Cap Screw—Torque ..................................................................... 675 N•m 500 lb-ft
6. Connect lines to differential. IMPORTANT: Do not reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.
12. Add oil to differential. Check differential oil level with machine on level ground. Specification Rear Differential Oil (444J)— Capacity—Approximate ............................................................. 17.5 L 18 qt Rear Differential Oil (544J, 624J)—Capacity—Approximate .................................................... 20 L 21 qt
7. Connect drive shaft. Install new drive shaft universal joint cap screws and tighten. Rear Axle and Differential:—Specification Drive Shaft Universal Joint Cap Screw Torque (444J)—Torque ................................................ 45 N•m 32 lb-ft
CED,OUOE003,2650 –19–27OCT03–2/2
TM2136 (13DEC04)
02-0200-13
444J, 544J, 624J Loader 121304
PN=45
02 0200 13
Removal and Installation
Axle Oscillating Supports Disassemble and Assemble
TP60252
–UN–18MAR98
02 0200 14
Continued on next page
TM2136 (13DEC04)
02-0200-14
TX,02,111694 –19–27OCT03–1/3
444J, 544J, 624J Loader 121304
PN=46
Removal and Installation 1—Special Jam Nut (2 used) 2—Fitting (2 used) 3—Nut (4 used) 4—Hydraulic Hose 5—Elbow Fitting (3 used) 6—Bushing (2 used) 7—Rear Oscillating Support
8—Thrust Bearing (6 used) 9—Thrust Plate 10—Washer (4 used) 11—Cap Screw (4 used) 12—O-Ring 13—Cover 14—Cap Screw (6 used)
15—Cap Screw (4 used) 16—Seal (3 used) 17—Cap Screw (4 used) 18—Rear Axle Support 19—Hydraulic Hose 20—Elbow Fitting
21—Lubrication Fitting (2 used) 22—Washer (8 used) 23—Lubrication Fitting 24—Bushing (544J only) (4 used)
NOTE: Axle oscillation support assembly does not contain any shims for setting end play. If excessive end play is incurred due to wear, end play should be no greater than 0.762 mm (0.03 in.). This can be checked with dial indicator measuring between front support and the differential housing. If greater than 0.762 mm (0.03 in.) thrust bearings should be replaced. Also check thrust plate (between both thrust bearings) for wear on front side. Disk should not have more than 0.254 mm (0.01 in.) wear step on face that contacts front thrust bearings. If out of specification, replace thrust plate and thrust bearings.
4. Remove rear oscillating support (7).
1. Remove rear axle and differential assembly. See procedure in this group.
7. Lube thrust bearings and bushings with grease and pack cavity of cover (13).
5. Repair and replace parts as necessary. 02 0200 15
6. Inspect thrust bearings (8) and bushings (6) for wear. Specification Axle Oscillating Support—End Play—Maximum ................................................................... 0.762 mm 0.03 in. Thrust Plate Between Thrust Bearings—Wear—Maximum on Front Side ............................................................................ 0.254 mm 0.01 in.
2. Remove rear axle support (18). 3. Remove cap screws (14 and 11) in pivot cover and thrust plate (9) in rear oscillating support.
Continued on next page
TM2136 (13DEC04)
02-0200-15
TX,02,111694 –19–27OCT03–2/3
444J, 544J, 624J Loader 121304
PN=47
Removal and Installation
–UN–04APR97
NOTE: If bushings were removed in front or rear oscillation supports note proper location of bushing (C) grease slots (D) in relation to the grease fitting (B). Slots should be facing up toward the grease fitting to allow proper lubrication of pivot area.
02 0200 16
T108815B
8. Carefully press bushings into front and rear supports being careful not to damage. 9. Install rear axle and rear oscillating supports to differential. 10. Tighten thrust plate cap screws (11) and pivot cover cap screws (14). Specification Thrust Plate Cap Screw—Torque ................................................ 350 N•m 255 lb-ft Pivot Cover Cap Screw—Torque ................................................. 140 N•m 105 lb-ft
A—Support B—Grease Fitting C—Bushing D—Grease Slot
11. See Rear Axle and Differential Install in this group.
TX,02,111694 –19–27OCT03–3/3
TM2136 (13DEC04)
02-0200-16
444J, 544J, 624J Loader 121304
PN=48
Group 0225
Axle Shafts and U-Joints
02 0225 1
TM2136 (13DEC04)
02-0225-1
444J, 544J, 624J Loader 121304
PN=49
Axle Shafts and U-Joints
Universal Joint and Drive Shaft Remove and Install
T195645
–UN–30OCT03
02 0225 2
T195645 Universal Joint and Drive Shaft Remove and Install Continued on next page
TM2136 (13DEC04)
02-0225-2
TX,02,111696 –19–18DEC03–1/2
444J, 544J, 624J Loader 121304
PN=50
Axle Shafts and U-Joints 1—Cap Screw 2—Cap Screw 3—Strap 4—Engine to Transmission Drive Shaft
5—Transmission to Rear Axle Drive Shaft 6—Cap 7—Transmission to Parking Brake Drive Shaft
CAUTION: Prevent possible injury from unexpected machine movement. Place blocks front and rear of tires to prevent machine from rolling. IMPORTANT: Do not reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.
8A—Parking Brake To Front Axle (Without Front Axle Disconnect) 8B—Parking Brake To Front Axle (With Front Axle Disconnect)
9—Universal Joint
Drive Shaft Universal Joint Cap Screw (544J, 624J)—Torque................................................... 78 N•m 58 lb-ft Engine Shaft Universal-to-Transmission Cap Screw—Torque ........................................................................ 45 N•m 32 lb-ft Engine Shaft-to-Engine Cap Screw—Torque ...................................................................... 140 N•m 105 lb-ft
1. Remove drive shaft universal joint cap screws. 2. Inspect and replace parts as necessary. 3. Install new drive shaft universal joint cap screws. Specification Drive Shaft Universal Joint Cap Screw (444J)—Torque............................................................. 45 N•m 32 lb-ft
TX,02,111696 –19–18DEC03–2/2
TM2136 (13DEC04)
02-0225-3
444J, 544J, 624J Loader 121304
PN=51
02 0225 3
Axle Shafts and U-Joints
02 0225 4
TM2136 (13DEC04)
02-0225-4
444J, 544J, 624J Loader 121304
PN=52
Group 0250
Axle Shaft, Bearings, Reduction Gears John Deere TeamMate III Axles—Use CTM150
TS225
–UN–17JAN89
For additional information on John Deere TEAMMATE III Axles See CTM 150— III 1000, 1200, and 1400 Series Inboard Planetary Axles.
TeamMate is a trademark of Deere & Company. TEAMMATE is a trademark of Deere & Company
TM2136 (13DEC04)
CED,OUOE006,18 –19–24SEP98–1/1
02-0250-1
444J, 544J, 624J Loader 121304
PN=53
02 0250 1
Axle Shaft, Bearings, Reduction Gears
Axle Disconnect Input Shaft, Cross-Sectional View
RW36308
–UN–17MAR97
02 0250 2
A—Disconnect Input Shaft B—Nut C—Spacer Washer D—Input Yoke E—Disconnect Housing F—Collar Engagement Spring (4 used) G—Collar Assembly Spring Retainer Plate
H—Collar Assembly Anti-Rotation Plug I—Collar Assembly Housing J—Piston Housing K—Housing-to-Differential Case Sealing Ring L—Auxiliary Yoke M—Differential Drive Shaft
N—Nut O—Spacer Washer P—Piston Assembly Packing Ring (2 used) Q—Piston Packing Ring (4 used) R—Piston (4 used) S—Needle Bearing Thrust Washer
T—Needle Roller Bearing (2 used) U—Collar V—Input Shaft Bearing Set W—Input Shaft Seal X—Dust Seal Y—Oil Ring
TX,02,111673 –19–21JUL97–1/1
TM2136 (13DEC04)
02-0250-2
444J, 544J, 624J Loader 121304
PN=54
Axle Shaft, Bearings, Reduction Gears
Axle Disconnect Input Shaft Remove and Install NOTE: Axle assembly is removed from vehicle. Loosen retaining cap screw (A). Install JDG1125 Lifting Screw (B) and JDG19 Special Mounting Bracket (C) and attach to an overhead hoist. 02 0250 3
Remove the disconnect assembly from the axle assembly.
–UN–17MAR97
Install in reverse order. Tighten the retaining cap screw.
RW36289
Specification Retaining Cap Screw—Torque .................................................... 310 N•m 230 lb-ft
A—Retaining Cap Screw B—JDG1125 Lifting Screw C—JDG19 Special Mounting Bracket
TX,02,111675 –19–15DEC98–1/1
Axle Disconnect Input Shaft Disassemble, Inspect, and Assemble
–UN–17MAR97
Remove disconnect assembly from axle assembly. (See Remove and Install Disconnect, this group.) Inspect auxiliary yoke (A) on differential drive shaft and remove and replace as necessary.
RW36290
Install JDG1142 Spanner Wrench and remove nut (B). Remove spacer washer and yoke from differential drive shaft. A—Auxiliary Yoke B—Nut
Install in reverse order. Tighten nut. Specification Differential Drive Shaft Nut— Torque .......................................................................................... 360 N•m 267 lb-ft
Continued on next page
TM2136 (13DEC04)
02-0250-3
TX,02,111677 –19–18DEC98–1/25
444J, 544J, 624J Loader 121304
PN=55
Axle Shaft, Bearings, Reduction Gears Install JDG1090 Yoke Holding Tool (A) to input shaft yoke. Remove nut and spacer from shaft. –UN–17MAR97
Remove yoke and oil ring from shaft.
RW36291
A—JDG1090 Yoke Holding Tool
02 0250 4
TX,02,111677 –19–18DEC98–2/25
Remove input shaft seal (A).
RW36292
–UN–17MAR97
A—Input Shaft Seal
TX,02,111677 –19–18DEC98–3/25
Remove housing-to-differential case sealing ring (A).
RW36293
–UN–17MAR97
A—Sealing Ring
Continued on next page
TM2136 (13DEC04)
02-0250-4
TX,02,111677 –19–18DEC98–4/25
444J, 544J, 624J Loader 121304
PN=56
Axle Shaft, Bearings, Reduction Gears Install disconnect assembly in a press and place a 4-5/16 in. driver disk and handle (A) on top of the piston housing.
–UN–17MAR97
Force the piston downward and remove snap ring (B).
RW36294
A—Disk Drive and Handle B—Snap Ring
TX,02,111677 –19–18DEC98–5/25
Remove piston housing assembly (A) using a 3-jaw puller and a slide hammer.
RW36295
–UN–17MAR97
A—Piston Housing Assembly
TX,02,111677 –19–18DEC98–6/25
Remove pistons from housing by tapping the backside of the housing with a hammer. Inspect housing (A), pistons (B), and packing rings (C). Replace parts as necessary.
–UN–17MAR97
Install pistons with packing rings into the piston housing.
RW36296
A—Housing B—Piston (4 used) C—Packing Ring (4 used)
Continued on next page
TM2136 (13DEC04)
02-0250-5
TX,02,111677 –19–18DEC98–7/25
444J, 544J, 624J Loader 121304
PN=57
02 0250 5
Axle Shaft, Bearings, Reduction Gears Remove piston packing rings (A). Remove collar assembly and anti-rotation plug (B). Remove collar assembly (C) from disconnect assembly. A—Piston Packing Ring (2 used) B—Anti-Rotation Plug (B) C—Collar Assembly
RW36297
–UN–17MAR97
02 0250 6
TX,02,111677 –19–18DEC98–8/25
Remove the collar assembly spring return plate (A) from the collar assembly housing.
RW36298
–UN–17MAR97
A—Collar Assembly Spring Return Plate
Continued on next page
TM2136 (13DEC04)
02-0250-6
TX,02,111677 –19–18DEC98–9/25
444J, 544J, 624J Loader 121304
PN=58
Axle Shaft, Bearings, Reduction Gears Remove parts (A—C) from housing (D). Inspect parts and replace as necessary. –UN–17MAR97
Assemble in reverse order.
RW36299
A—Needle Roller Bearing B—Shift Collar C—Needle Roller Bearing Thrust Washer D—Collar Assembly Housing E—Collar Assembly Spring Retainer Plate
TX,02,111677 –19–18DEC98–10/25
Remove collar engagement springs (A) from housing. Inspect springs. Specification New Spring—Free Length— Approximate.................................................................................... 73 mm 2.874 in. Test Length.................................................... 44.45 mm at 352—431 N•m 1.750 in. at 78—96 lb-force
RW36300
–UN–17MAR97
A—Collar Engagement Spring (4 used)
Continued on next page
TM2136 (13DEC04)
02-0250-7
TX,02,111677 –19–18DEC98–11/25
444J, 544J, 624J Loader 121304
PN=59
02 0250 7
Axle Shaft, Bearings, Reduction Gears Place the disconnect assembly in a press. Remove the input shaft (A) from the housing and outer bearing cone while supporting the shaft inside the case to prevent shaft from falling.
–UN–17MAR97
A—Input Shaft
RW36301
02 0250 8
TX,02,111677 –19–18DEC98–12/25
Remove outer bearing cone (A) from housing.
RW36302
–UN–17MAR97
A—Outer Bearing Cone
Continued on next page
TM2136 (13DEC04)
02-0250-8
TX,02,111677 –19–18DEC98–13/25
444J, 544J, 624J Loader 121304
PN=60
Axle Shaft, Bearings, Reduction Gears NOTE: The input shaft bearings are supplied as a matched set. When the replacement is required, replace all parts. Inspect and if necessary remove inner and outer bearing cups (A) from housing (B). Inspect bearing cup spacer snap ring (C) and remove if necessary.
–UN–17MAR97
Install new bearing cup spacer snap ring in housing.
RW36303
Install new bearing cups in housing using a 3 in. driver disk and a press. A—Bearing Cup (2 used) B—Housing C—Snap Ring
TX,02,111677 –19–18DEC98–14/25
Inspect disconnect input shaft (A), inner bearing cone (B), and bearing spacer (C) and replace as necessary.
–UN–17MAR97
If necessary, remove bearing spacer (C) from shaft and remove inner bearing (B) using a knife-edge puller and a press.
RW36304
CAUTION: Heat parts in a bearing heater. Use a thermometer and do not exceed 150°C (300°F). Plan a safe handling procedure to avoid burns. Heat bearing cone to 150°C (300°F) and install on shaft. A—Input Shaft B—Inner Bearing Cone C—Bearing Spacer
Continued on next page
TM2136 (13DEC04)
02-0250-9
TX,02,111677 –19–18DEC98–15/25
444J, 544J, 624J Loader 121304
PN=61
02 0250 9
Axle Shaft, Bearings, Reduction Gears NOTE: JDG1141-1 Centering Tool is part of the JDG1141 Bearing Installer Set. Install the disconnect housing in a press using JDG1141-1 Centering Tool (A) to support the input shaft (B) that is installed through the housing. A—JDG1141-1 Centering Tool B—Input Shaft
RW36310
–UN–11APR97
02 0250 10
TX,02,111677 –19–18DEC98–16/25
NOTE: JDG1141-2 Driver is part of the JDG1141 Bearing Installer Set. Install the outer bearing cone (A) onto the shaft using JDG1141-2 Driver (B).
RW36305
–UN–17MAR97
A—Outer Bearing Cone B—JDG1141-2 Driver
Continued on next page
TM2136 (13DEC04)
02-0250-10
TX,02,111677 –19–18DEC98–17/25
444J, 544J, 624J Loader 121304
PN=62
Axle Shaft, Bearings, Reduction Gears Install collar engagement springs (A) into disconnect housing.
RW36300
–UN–17MAR97
A—Collar Engagement Spring (2 used)
TX,02,111677 –19–18DEC98–18/25
Install collar assembly (C) into housing aligning the anti-rotation slot in the collar assembly housing with the opening in disconnect housing for the anti-rotation plug. Install anti-rotation plug (B). Install piston packing rings (A). Apply oil to the piston packing rings.
RW36297
–UN–17MAR97
A—Piston Packing Ring (2 used) B—Anti-Rotation Plug C—Collar Assembly
Continued on next page
TM2136 (13DEC04)
02-0250-11
TX,02,111677 –19–18DEC98–19/25
444J, 544J, 624J Loader 121304
PN=63
02 0250 11
Axle Shaft, Bearings, Reduction Gears Install piston assembly (A) into the housing. Place a 4-5/16 in. driver disk and handle (B) on top of the piston housing.
RW36306
A—Piston Assembly B—Driver Disk and Handle C—Snap Ring
TX,02,111677 –19–18DEC98–20/25
Install housing-to-differential case sealing ring (A).
–UN–17MAR97
A—Sealing Ring
RW36293
02 0250 12
–UN–17MAR97
Force the piston downward using a shop press and install snap ring (C).
Continued on next page
TM2136 (13DEC04)
02-0250-12
TX,02,111677 –19–18DEC98–21/25
444J, 544J, 624J Loader 121304
PN=64
Axle Shaft, Bearings, Reduction Gears Install input shaft seal (A) using JDG1092 Seal Installer with JDG926 Bearing Installer.
RW36292
–UN–17MAR97
A—Input Shaft Seal
TX,02,111677 –19–18DEC98–22/25
IMPORTANT: Do not apply oil to the seal or the yoke recess. Install the dust seal (A) into the yoke recess.
RW36191
–UN–09JAN97
A—Dust Seal
TX,02,111677 –19–18DEC98–23/25
Install yoke onto the shaft.
NOTE: Be sure no part of the oil ring is out of the chamfer on the yoke. –UN–17MAR97
Install oil ring (A).
RW36307
Install spacer, washer and nut. A—Oil Ring
Continued on next page
TM2136 (13DEC04)
02-0250-13
TX,02,111677 –19–18DEC98–24/25
444J, 544J, 624J Loader 121304
PN=65
02 0250 13
Axle Shaft, Bearings, Reduction Gears Install JDG1090 Yoke Holding Tool (A).
Remove tool. 02 0250 14
Install disconnect assembly to axle assembly. (See Remove and Install Axle Disconnect Input Shaft this group.)
RW36291
Specification Yoke Retaining Nut—Torque ....................................................... 360 N•m 267 lb-ft
–UN–17MAR97
Tighten yoke retaining nut.
A—JDG1090 Yoke Holding Tool
TX,02,111677 –19–18DEC98–25/25
TM2136 (13DEC04)
02-0250-14
444J, 544J, 624J Loader 121304
PN=66
Group 0260
Hydraulic System Differential Lock Solenoid Valve Remove and Install CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area. 1. Install frame locking bar. 2. Perform Brake Accumulator Precharge Test (Group 9025-25) until brake accumulators are totally discharged
02 0260 1
TX,02,111682 –19–27OCT98–1/2
3. Disconnect electrical harness from differential lock solenoid. 4. Remove differential lock solenoid (1). 5. Plug opening to prevent dirt from entering manifold. 6. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. 7. Install solenoid valve using new O-rings and backup rings. 8. Connect electrical connector. 9. Remove frame locking bar.
T193115A
–UN–11JUL03
1—Differential Lock Solenoid 2—Brake Accumulator Port 3—Return to Filter Hose 4—Differential Lock Hose
TX,02,111682 –19–27OCT98–2/2
TM2136 (13DEC04)
02-0260-1
444J, 544J, 624J Loader 121304
PN=67
Hydraulic System
Axle Circulation System
T196768
–UN–05DEC03
02 0260 2
T196768 Axle Circulation System Continued on next page
TM2136 (13DEC04)
02-0260-2
CED,OUOE003,2651 –19–13DEC98–1/2
444J, 544J, 624J Loader 121304
PN=68
Hydraulic System 1—Elbow Fitting 2—Adapter 3—Elbow Fitting 4—Hydraulic Hose
5—Hydraulic Hose 6—Oil Filter 7—Hydraulic Hose
8—Hydraulic Hose 9—O-Ring 10—O-Ring
11—O-Ring 12—O-Ring 13—O-Ring
CED,OUOE003,2651 –19–13DEC98–2/2
02 0260 3
TM2136 (13DEC04)
02-0260-3
444J, 544J, 624J Loader 121304
PN=69
Hydraulic System
Axle Oil Coolers
T196769
–UN–05DEC03
02 0260 4
T196769 Axle Oil Cooler—Exploded View Continued on next page
TM2136 (13DEC04)
02-0260-4
MX10672,0000036 –19–03DEC03–1/2
444J, 544J, 624J Loader 121304
PN=70
Hydraulic System 1—Flange Nut (8 used) 2—Screw (8 used) 3—Screw (4 used) 4—Washer (20 used) 5—Elbow Fitting (4 used) 6—O-Ring (6 used) 7—O-Ring (6 used)
8—Hydraulic Hose 9—Hydraulic Hose 10—Hydraulic Hose 11—Hydraulic Hose 12—Bracket (2 used) 13—Bracket 14—Bracket
15—Oil Cooler 16—Tie Band (4 used) 17—Grommet (18 used) 18—Grommet (12 used) 19—Oil Cooler 20—Elbow Fitting 21—Elbow Fitting (2 used)
22—O-Ring (2 used) 23—Adapter 24—O-Ring (2 used) 25—Hydraulic Hose 26—Hydraulic Hose 27—Oil Filter 28—O-Ring (2 used)
MX10672,0000036 –19–03DEC03–2/2
Axle Oil Coolers Disassemble and Assemble See Cooling Package Plenum Remove and Install. (Group 0520.) CED,OUOE003,2655 –19–03DEC03–1/1
TM2136 (13DEC04)
02-0260-5
444J, 544J, 624J Loader 121304
PN=71
02 0260 5
Hydraulic System
02 0260 6
TM2136 (13DEC04)
02-0260-6
444J, 544J, 624J Loader 121304
PN=72
Section 03
Transmission Contents Page
Group 0300—Removal and Installation Transmission Remove and Install . . . . . . . . .03-0300-1 Group 0350—Gears, Shafts, Bearings and Power Shift Clutch Remove Torque Converter And Housing . . . .03-0350-1 Install Torque Converter And Housing. . . . . .03-0350-3 Clutches, Input and Output Shafts Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-6 Clutches, Input and Output Shafts Install. . .03-0350-12 Clutch Pack KV and KR Disassemble . . . .03-0350-20 Clutch Pack KV and KR Assemble. . . . . . .03-0350-23 Input Shaft Disassemble . . . . . . . . . . . . . .03-0350-32 Input Shaft Assemble . . . . . . . . . . . . . . . . .03-0350-32
03
Group 0360—Hydraulic System Remove Transmission Pump. . . . . . . . . . . . .03-0360-1 Remove and Install Converter Minimum Pressure Regulator Valve . . . . . . . . . . . . .03-0360-3 Install Transmission Pump . . . . . . . . . . . . . .03-0360-4 Transmission Hydraulic Control Valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-6 Transmission Hydraulic Control Valve Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Transmission Hydraulic Control Valve Cross Section View . . . . . . . . . . . . . . . . . . . . . .03-0360-12 Transmission Control Valve Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0360-14 Transmission Control Valve Assemble . . . .03-0360-17 Remove, Disassemble and Install Torque Converter Relief Valve . . . . . . . . . . . . . . .03-0360-23 Oil Pipes and Tubes Replacement . . . . . . .03-0360-25
TM2136 (13DEC04)
03-1
444J, 544J, 624J Loader 121304
PN=1
Contents
03
TM2136 (13DEC04)
03-2
444J, 544J, 624J Loader 121304
PN=2
Group 0300
Removal and Installation Transmission Remove and Install 1. Perform Cab Remove and Install procedure until cab is removed from machine. (Group 1800.) 2. Drain hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 3. Disconnect all transmission drive shafts U-joints from engine, axle, and transmission.
03 0300 1
–UN–10MAR97
4. Remove all hoses to hydraulic pump and transmission. See Hydraulic System Component Location (Group 9025-15) and Power Train Component Location (Group 9020-15) for hose routings.
T107803
5. Drain transmission. Specification Transmission Oil—Capacity ................................................................ 20 L 21 qt A—Drive Shaft B—Drive Shaft C—Drive Shaft
6. Remove transmission oil fill tube. 7. Remove hydraulic pump from transmission. See Hydraulic Pump Remove and Install. (Group 3160.) CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. 8. Install hoist on transmission lifting brackets and support transmission. Specification Transmission with Hydraulic Pump Attached—Weight— Approximate..................................................................................... 431 kg 950 lb
9. Remove transmission isolator cap screws. 10. Remove transmission front mounts from transmission.
Continued on next page
TM2136 (13DEC04)
03-0300-1
DW09104,00000D0 –19–04DEC03–1/3
444J, 544J, 624J Loader 121304
PN=75
Removal and Installation
–UN–29APR97
11. Remove transmission and place in repair stand using JDG1129 transmission mounting bracket.
T109218
NOTE: After transmission repair, install hydraulic pump on transmission before installing transmission in machine. 12. Inspect hydraulic pump to transmission O-ring and install pump. 13. Install transmission in machine. Torque mounting hardware to specification.
03 0300 2
Specification Isolator Cap Screw—Torque ........................................................ 475 N•m 350 lb-ft Mounting Bracket-to-Transmission Cap Screw (Front)—Torque ......................................................... 435 N•m 320 lb-ft Mounting Bracket-to-Transmission Cap Screw (Rear)—Torque.......................................................... 350 N•m 255 lb-ft
14. Connect all hydraulic hoses and electrical harnesses to transmission and hydraulic pump.
NOTE: Do not reuse drive shaft cap screws. Replace with new hardware. 15. Install transmission drive shafts using new cap screws. 444J—Specification Transmission-to-Rear Axle Drive Shaft U-Joint—Torque .................................................................... 45 N•m 32 lb-ft 544J, 624J—Specification Transmission-to-Rear Axle Drive Shaft U-Joint—Torque .................................................................... 78 N•m 58 lb-ft Specification Engine-to-Transmission Drive Shaft U-Joint—Torque .................................................................... 41 N•m 30 lb-ft
16. Install cab. Perform Cab Remove and Install. (Group 1800.)
Continued on next page
TM2136 (13DEC04)
03-0300-2
DW09104,00000D0 –19–04DEC03–2/3
444J, 544J, 624J Loader 121304
PN=76
Removal and Installation 17. Fill transmission and hydraulic reservoir to specification. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities
DW09104,00000D0 –19–04DEC03–3/3
03 0300 3
TM2136 (13DEC04)
03-0300-3
444J, 544J, 624J Loader 121304
PN=77
Removal and Installation
03 0300 4
TM2136 (13DEC04)
03-0300-4
444J, 544J, 624J Loader 121304
PN=78
Group 0350
Gears, Shafts, Bearings and Power Shift Clutch Remove Torque Converter And Housing
–UN–19DEC97
CAUTION: Approximate weight of transmission is 504 kg (1110 lb). Specification Transmission—Weight.............................................. 504 kg—Approximate 1110 lb—Approximate
T112589
NOTE: Earlier JDG1129 Transmission Mounting Brackets require the right side bracket revised. Note bracket sketch showing revised mounting hole (A). Revise hole by elongating the existing hole as required.
Bracket Sketch Showing Revised Mounting Hole (A) A—Mounting Hole
1. Install transmission in repair stand using JDG1129 Mounting Brackets (A).
03 0350 1
T109146B
–UN–26JAN98
A—JDG1129 Mounting Bracket (2 used)
CED,OUOE002,1543 –19–09JUL02–1/10
2. Remove lock plate and hex head screws from input flange washer.
T108721
–UN–17APR97
3. Remove washer and pry input flange from the shaft.
CED,OUOE002,1543 –19–09JUL02–2/10
4. Remove torque converter housing cap screws.
T108722
–UN–17APR97
NOTE: Place a mark on the cover and housing for ease of assembly and proper alignment later.
Continued on next page
TM2136 (13DEC04)
03-0350-1
CED,OUOE002,1543 –19–09JUL02–3/10
444J, 544J, 624J Loader 121304
PN=79
Gears, Shafts, Bearings and Power Shift Clutch
CAUTION: Component weighs more than 23 kg (50 lb). Use hoist to remove.
T108723
–UN–17APR97
5. Separate torque converter with cover from gearbox, using a hoist and eye bolt.
CED,OUOE002,1543 –19–09JUL02–4/10
6. Press input shaft with converter out of the housing.
T108724
–UN–17APR97
03 0350 2
CED,OUOE002,1543 –19–09JUL02–5/10
T108717
–UN–17APR97
7. Remove snap ring and remove bearing from housing.
CED,OUOE002,1543 –19–09JUL02–6/10
T112416
–UN–05DEC97
8. Remove hex head screws and separate drive plate from converter.
Continued on next page
TM2136 (13DEC04)
03-0350-2
CED,OUOE002,1543 –19–09JUL02–7/10
444J, 544J, 624J Loader 121304
PN=80
Gears, Shafts, Bearings and Power Shift Clutch
T112415
–UN–05DEC97
9. Remove hex head screws and separate input shaft from drive plate.
CED,OUOE002,1543 –19–09JUL02–8/10
10. Remove speed sensor from converter housing.
T108720
–UN–17APR97
03 0350 3
CED,OUOE002,1543 –19–09JUL02–9/10
T108729
–UN–17APR97
11. Remove hex head screws and remove converter lower housing.
CED,OUOE002,1543 –19–09JUL02–10/10
Install Torque Converter And Housing 1. Fasten converter housing using hex head screws. Tighten screws.
T109095
–UN–15APR97
Specification Converter Housing (M10/10.9) Hex Head Screw—Torque ............................................................. 68 N•m 50 lb-ft
Continued on next page
TM2136 (13DEC04)
03-0350-3
TX,0350,RB228 –19–09JUL02–1/8
444J, 544J, 624J Loader 121304
PN=81
Gears, Shafts, Bearings and Power Shift Clutch 2. Fasten input shaft to plate with hex head screws and tighten.
T112415
–UN–05DEC97
Specification Input Shaft-to-Drive Plate (M12/10.9) Hex Head Screw— Torque .......................................................................................... 115 N•m 85 lb-ft
TX,0350,RB228 –19–09JUL02–2/8
–UN–05DEC97
Apply T43513 thread lock and sealer (high strength) to cap screws and tighten.
T112416
Specification Input Shaft Drive Plate-to-Torque Converter Cap Screw—Torque .................................................... 115 N•m 85 lb-ft
TX,0350,RB228 –19–09JUL02–3/8
4. Install converter in housing until contact is made
–UN–30APR97
T112417
–UN–05DEC97
NOTE: Speed pickup disk in the converter must be centered to the bore of the speed sensor. See art with arrow showing. This insures that the converter is seated properly.
T109098
03 0350 4
3. Install input shaft plate assembly to converter, using hex head screws and flat washers.
Continued on next page
TM2136 (13DEC04)
03-0350-4
TX,0350,RB228 –19–09JUL02–4/8
444J, 544J, 624J Loader 121304
PN=82
Gears, Shafts, Bearings and Power Shift Clutch
T109099
–UN–15APR97
5. Insert ball bearing until contact is obtained in bore and install snap ring.
TX,0350,RB228 –19–09JUL02–5/8
6. Assemble housing. 03 0350 5
Install input flange, washer and draw cover down with hex head screws evenly against shoulder.
T109100
–UN–15APR97
NOTE: Line up alignment marks on housings that were made while disassembling for proper assembly.
TX,0350,RB228 –19–09JUL02–6/8
7. Install cover with hex head screws and nuts on the converter housing. Tighten screws.
T109101
–UN–15APR97
Specification Torque Converter Top Cover Hex Head Screw—Torque ..................................................................... 46 N•m 34 lb-ft
Continued on next page
TM2136 (13DEC04)
03-0350-5
TX,0350,RB228 –19–09JUL02–7/8
444J, 544J, 624J Loader 121304
PN=83
Gears, Shafts, Bearings and Power Shift Clutch 8. Fasten input flange with hex head screws and tighten.
–UN–02MAY97
Specification Input and Output Flange-to-Drive Plate Hex Head Screw—Torque .................................................... 34 N•m 25 lb-ft
T109147B
Install locking plate using hammer and two deep well sockets (A) taped together with a hex nut between them for proper spread. A—Deep Well Socket (2 used)
Output Flange Shown
03 0350 6 TX,0350,RB228 –19–09JUL02–8/8
Clutches, Input and Output Shafts Remove 1. Remove lock plate, loosen hex head screws, and pry the rear output flange from the shaft. –UN–18APR97
2. Pry shaft seal out of the housing bore.
T108778
3. Turn gearbox 180° and remove front output flange in same manner.
TX,0350,ME280 –19–01OCT98–1/19
T196799A
–UN–08DEC03
4. Remove three sensors.
Remove Three Sensors
Continued on next page
TM2136 (13DEC04)
03-0350-6
TX,0350,ME280 –19–01OCT98–2/19
444J, 544J, 624J Loader 121304
PN=84
Gears, Shafts, Bearings and Power Shift Clutch 5. Loosen hex nuts and remove the two small manifold covers (Arrows).
T108780
–UN–29APR97
6. Remove cap screws from transmission cover.
TX,0350,ME280 –19–01OCT98–3/19
7. Drive both dowel pins (one on each end of transmission cover) down far enough to clear cover for removal of the cover.
T108781
–UN–29APR97
03 0350 7
TX,0350,ME280 –19–01OCT98–4/19
T108774
–UN–18APR97
8. Separate housing cover carefully from gearbox housing, using lifting device.
Continued on next page
TM2136 (13DEC04)
03-0350-7
TX,0350,ME280 –19–01OCT98–5/19
444J, 544J, 624J Loader 121304
PN=85
Gears, Shafts, Bearings and Power Shift Clutch 9. Figure shows the proper position of the single clutches as well as of the input and output.
T108775
–UN–29APR97
KV—Low Range Forward Clutch KR—Reverse Clutch K1—First Speed Clutch K2—Second Speed Clutch K3—Third Speed Clutch K4—High Range Forward Clutch AN—Input AB—Output
03 0350 8 TX,0350,ME280 –19–01OCT98–6/19
NOTE: For the removal of clutches, the output shaft must be removed first.
T108776
–UN–18APR97
10. Loosen socket head screws from covers and remove output shaft with covers.
Continued on next page
TM2136 (13DEC04)
03-0350-8
TX,0350,ME280 –19–01OCT98–7/19
444J, 544J, 624J Loader 121304
PN=86
Gears, Shafts, Bearings and Power Shift Clutch 11. Place cover back on transmission until it contacts the mounting surface so clutch packs can be removed from housing for repair or inspection.
–UN–30APR97
NOTE: Six 24H1300 Flat Washers and M10 Hex Nuts are substituted for special handles shown in photo.
T108777
12. Install six (24H1300) flat washers (A) and six (M10) hex nuts on end of clutch packs. This will hold packs in place while mounting cover in rollover repair stand. This method must be used to remove clutch pack from transmission housing.
Special Handles Shown
A—Flat Washer (6 used)
T109149B
–UN–09MAY97
03 0350 9
24H1300 and M10 Hardware Shown TX,0350,ME280 –19–01OCT98–8/19
T108786
–UN–18APR97
13. Separate housing cover along with all clutch packs from gearbox housing, using lifting device.
TX,0350,ME280 –19–01OCT98–9/19
NOTE: Transmission cover is used to properly remove packs from transmission housing.
T109149C
–UN–09MAY97
14. Remove transmission housing from repair stand and install cover with clutch packs.
Continued on next page
TM2136 (13DEC04)
03-0350-9
TX,0350,ME280 –19–01OCT98–10/19
444J, 544J, 624J Loader 121304
PN=87
Gears, Shafts, Bearings and Power Shift Clutch
–UN–09MAY97
15. Install cover with packs into stand using JDG1129 Mounting Brackets (A). Using shop hardware (B) (cap screws, washers and nuts) fasten cover to mounting brackets JDG1129 (A).
T109148B
A—Mounting Bracket (2 used) B—Shop Hardware
TX,0350,ME280 –19–01OCT98–11/19
T108788
–UN–18APR97
17. Remove six M10 nuts and six washers from clutch packs.
TX,0350,ME280 –19–01OCT98–12/19
CAUTION: Use special care while removing clutch packs from cover due to closeness of packs and spline engagement to each other.
T108789
–UN–18APR97
18. Remove clutch K2.
TX,0350,ME280 –19–01OCT98–13/19
–UN–18APR97
19. Remove clutch K1, at the same time lift clutch K4 to the side to allow clearance.
T108782
03 0350 10
16. Turn cover in stand so clutch packs are facing up. This will allow them to be removed from cover.
Continued on next page
TM2136 (13DEC04)
03-0350-10
TX,0350,ME280 –19–01OCT98–14/19
444J, 544J, 624J Loader 121304
PN=88
Gears, Shafts, Bearings and Power Shift Clutch
T108783
–UN–18APR97
20. Remove clutch K3.
TX,0350,ME280 –19–01OCT98–15/19
21. Remove clutch K4, at the same time lift input slightly.
T108784
–UN–18APR97
03 0350 11
TX,0350,ME280 –19–01OCT98–16/19
T108785
–UN–18APR97
22. Separate clutches KV and KR together with input from the housing cover.
TX,0350,ME280 –19–01OCT98–17/19
T108790
–UN–18APR97
23. Remove bearing outer race and pull output shaft out of the housing bore.
Continued on next page
TM2136 (13DEC04)
03-0350-11
TX,0350,ME280 –19–01OCT98–18/19
444J, 544J, 624J Loader 121304
PN=89
Gears, Shafts, Bearings and Power Shift Clutch
T108791
–UN–29APR97
24. Squeeze the square snap ring out and separate ball bearing from shaft.
TX,0350,ME280 –19–01OCT98–19/19
Clutches, Input and Output Shafts Install IMPORTANT: High tolerance bearings are used in all clutch pack applications. Use only John Deere sourced bearings when replacing.
–UN–30APR97
NOTE: If bearings are reused, they must be assembled in same bores.
T109004
1. Install all bearing outer races into the housing cover until contact is obtained. AB—Bearing Outer Race AN—Bearing Outer Race K1—Bearing Outer Race K2—Bearing Outer Race K3—Bearing Outer Race K4—Bearing Outer Race KR—Bearing Outer Race KV—Bearing Outer Race
TX,0350,JC2037 –19–02DEC04–1/31
2. Install clutch KR, input shaft and clutch KV into the housing cover.
–UN–29APR97
AN—Clutch KR—Clutch KV—Input Shaft and Clutch
T109005
03 0350 12
Continued on next page
TM2136 (13DEC04)
03-0350-12
TX,0350,JC2037 –19–02DEC04–2/31
444J, 544J, 624J Loader 121304
PN=90
Gears, Shafts, Bearings and Power Shift Clutch 3. Install clutch K4.
T109006
–UN–29APR97
K4—Clutch
TX,0350,JC2037 –19–02DEC04–3/31
4. Install clutch K3.
T109007
–UN–09MAY97
03 0350 13
TX,0350,JC2037 –19–02DEC04–4/31
T109008
–UN–29APR97
5. Position clutch K1.
TX,0350,JC2037 –19–02DEC04–5/31
T109009
–UN–29APR97
6. Insert clutch K2.
Continued on next page
TM2136 (13DEC04)
03-0350-13
TX,0350,JC2037 –19–02DEC04–6/31
444J, 544J, 624J Loader 121304
PN=91
Gears, Shafts, Bearings and Power Shift Clutch 7. Figure shows the installation position of the single clutches in the housing cover.
T109010
–UN–29APR97
K1—Single Clutches K2—Single Clutches K3—Single Clutches K4—Single Clutches KR—Single Clutches KV—Single Clutches
TX,0350,JC2037 –19–02DEC04–7/31
–UN–09MAY97 T109011
TX,0350,JC2037 –19–02DEC04–8/31
9. Install sealing rings (7 used) on clutch pack shafts.
T109012
–UN–29APR97
10. Grease sealing rings and align.
TX,0350,JC2037 –19–02DEC04–9/31
11. Turn housing cover 180°. 12. Mount eyebolts.
–UN–29APR97
13. Remove transmission cover with clutch packs from repair stand. 14. Install transmission housing into repair stand. 15. Install alignment studs in housing.
T109013
03 0350 14
8. Retain all clutches using six M10 hex nuts and six 24H1300 flat washers.
Continued on next page
TM2136 (13DEC04)
03-0350-14
TX,0350,JC2037 –19–02DEC04–10/31
444J, 544J, 624J Loader 121304
PN=92
Gears, Shafts, Bearings and Power Shift Clutch NOTE: Note the engagement of the oil pipes with the bores in the housing cover.
T109014
–UN–09MAY97
16. Install cover with clutch packs carefully onto housing. Make sure all components are properly seated.
TX,0350,JC2037 –19–02DEC04–11/31
17. Remove M10 hex nuts and 24H1300 flat washers (A) from clutch packs.
03 0350 15
T109149B
–UN–09MAY97
A—Flat Washer (6 used)
TX,0350,JC2037 –19–02DEC04–12/31
T109016
–UN–09MAY97
18. Remove housing cover from gearbox housing.
TX,0350,JC2037 –19–02DEC04–13/31
19. Output Shaft
T109066
–UN–15APR97
Assemble oil cover onto shaft and press both bearing inner races against shoulder until contact is obtained.
Continued on next page
TM2136 (13DEC04)
03-0350-15
TX,0350,JC2037 –19–02DEC04–14/31
444J, 544J, 624J Loader 121304
PN=93
Gears, Shafts, Bearings and Power Shift Clutch
T109068
–UN–29APR97
20. Insert bearing outer race into the housing bore until contact is obtained.
TX,0350,JC2037 –19–02DEC04–15/31
21. Position inner oil cover.
T109069
–UN–15APR97
03 0350 16
TX,0350,JC2037 –19–02DEC04–16/31
T109070
–UN–15APR97
22. Install output shaft with cover in housing.
TX,0350,JC2037 –19–02DEC04–17/31
NOTE: Insert socket head cap screws with medium strength thread lock and sealer. 23. Fasten both covers by means of socket head screws.
T109071
–UN–15APR97
Specification Oil Baffle Cover Socket Head Screw—Torque ............................................................................... 23 N•m 17 lb-ft
Continued on next page
TM2136 (13DEC04)
03-0350-16
TX,0350,JC2037 –19–02DEC04–18/31
444J, 544J, 624J Loader 121304
PN=94
Gears, Shafts, Bearings and Power Shift Clutch 24. Install sealing rings (6 used) into the recesses of the clutch shafts and hook them in.
T109072
–UN–29APR97
25. Grease sealing rings and align.
TX,0350,JC2037 –19–02DEC04–19/31
26. Lubricate and install both O-rings into the groove of the oil pipes.
T109075
–UN–29APR97
03 0350 17
TX,0350,JC2037 –19–02DEC04–20/31
27. Apply High Flex Form-In-Place Gasket to mounting face of cover.
–UN–15APR97
NOTE: Note the engagement of the oil pipe with the bores in the housing cover.
T109076
Install housing cover carefully against gearbox housing until contact is obtained, using lifting device.
TX,0350,JC2037 –19–02DEC04–21/31
T109077
–UN–29APR97
28. Install dowel pins.
Continued on next page
TM2136 (13DEC04)
03-0350-17
TX,0350,JC2037 –19–02DEC04–22/31
444J, 544J, 624J Loader 121304
PN=95
Gears, Shafts, Bearings and Power Shift Clutch NOTE: Locate hanger in same position as it was removed. 29. Install housing cover using hex head screws.
T109078
–UN–15APR97
Clutches, Input and Output Shafts:—Specification Housing Cover Hex Head Screw—Torque ............................................................................... 46 N•m 34 lb-ft
TX,0350,JC2037 –19–02DEC04–23/31
NOTE: Grease sealing lip.
T109079
–UN–15APR97
30. Install shaft seal with the seal lip facing inward, using proper driver. Drive until seated. Do not over drive.
TX,0350,JC2037 –19–02DEC04–24/31
31. Apply TY16021 High Flex Form-in-Place Gasket to contact area of washer. 32. Heat the output flange to maximum temperature. –UN–15APR97
Clutches, Output and Input Shafts:—Specification Heat Output Flange— Temperature ....................................................................................... 90°C 194°F
33. Install flange and washer with cap screws.
T109080
03 0350 18
Clutches, Output and Input Shafts:—Specification Output Flange Cap Screw— Torque ............................................................................................ 34 N•m 25 lb-ft
Continued on next page
TM2136 (13DEC04)
03-0350-18
TX,0350,JC2037 –19–02DEC04–25/31
444J, 544J, 624J Loader 121304
PN=96
Gears, Shafts, Bearings and Power Shift Clutch 34. Install locking plate using two 5/8 in. deep well sockets.
–UN–02MAY97
35. Install flange in same manner on opposite side.
T109147B
A—Deep Well Socket (2 used)
TX,0350,JC2037 –19–02DEC04–26/31
36. If removed, install flat gasket and cover. Fasten with hex head screws.
03 0350 19
T109094
–UN–15APR97
Specification Gasket-to-Cover Hex Head Screw—Torque ............................................................................... 23 N•m 17 lb-ft
TX,0350,JC2037 –19–02DEC04–27/31
T109115
–UN–15APR97
37. Install O-ring into groove of oil feed covers.
TX,0350,JC2037 –19–02DEC04–28/31
38. Install cover onto transmission studs with hex nuts. 39. Tighten hex nuts to specification.
–UN–15APR97
40. Install transmission oil fill tube. Tighten cap screws to specification.
T109116
Specification Oil Level Tube Screw—Torque ...................................................... 40 N•m 29 lb-ft
Continued on next page
TM2136 (13DEC04)
03-0350-19
TX,0350,JC2037 –19–02DEC04–29/31
444J, 544J, 624J Loader 121304
PN=97
Gears, Shafts, Bearings and Power Shift Clutch 41. Install engine speed sensor (48), middle gear speed sensor (47) and turbine speed sensor (21).
–UN–29APR97
Specification Speed Sensor—Torque .................................................................. 30 N•m 22 lb-ft
42. Install breather (shown at arrow head).
T109119
21—Turbine Speed Sensor 47—Middle Gear Speed Sensor 48—Engine Speed Sensor
03 0350 20 TX,0350,JC2037 –19–02DEC04–30/31
43. Install drain plug and tighten to specification.
T109120
–UN–15APR97
Specification Drain Plug—Torque ........................................................................ 80 N•m 59 lb-ft
TX,0350,JC2037 –19–02DEC04–31/31
Clutch Pack KV and KR Disassemble
–UN–29APR97
NOTE: 444J and 544J clutch pack internal components are not serviceable. Clutch packs must be replaced as an assembly. 624J clutch packs may be serviced as outlined in this procedure.
T108792
1. Remove sealing ring.
Continued on next page
TM2136 (13DEC04)
03-0350-20
TX,0350,ME284 –19–12DEC03–1/10
444J, 544J, 624J Loader 121304
PN=98
Gears, Shafts, Bearings and Power Shift Clutch
T108793
–UN–18APR97
2. Pull tapered roller bearing from the shaft using JDG1134 Bearing Puller and JDG1035 Bearing Puller Mandrel. Remove opposite tapered roller bearing accordingly.
TX,0350,ME284 –19–12DEC03–2/10
3. Separate plate carrier from shaft.
T108794
–UN–18APR97
03 0350 21
TX,0350,ME284 –19–12DEC03–3/10
T108795
–UN–18APR97
4. Remove plates.
TX,0350,ME284 –19–12DEC03–4/10
5. Preload compression spring with tool in press and remove snap ring. See DFT1149 Pre-Load Clutch Pack Compression Ring Tool. (Group 9900 for instructions to make tool.)
T108761
–UN–17APR97
6. Remove piston from carrier.
Continued on next page
TM2136 (13DEC04)
03-0350-21
TX,0350,ME284 –19–12DEC03–5/10
444J, 544J, 624J Loader 121304
PN=99
Gears, Shafts, Bearings and Power Shift Clutch
T108758
–UN–29APR97
7. Remove O-rings from piston.
TX,0350,ME284 –19–12DEC03–6/10
8. Remove inner circle snap ring.
T108759
–UN–17APR97
03 0350 22
TX,0350,ME284 –19–12DEC03–7/10
T108752
–UN–17APR97
9. Remove idler gear from shaft using a press.
TX,0350,ME284 –19–12DEC03–8/10
T108753
–UN–17APR97
10. Remove released needle bearing.
Continued on next page
TM2136 (13DEC04)
03-0350-22
TX,0350,ME284 –19–12DEC03–9/10
444J, 544J, 624J Loader 121304
PN=100
Gears, Shafts, Bearings and Power Shift Clutch
T108754
–UN–17APR97
11. Remove circle snap ring and remove bearing.
TX,0350,ME284 –19–12DEC03–10/10
Clutch Pack KV and KR Assemble 03 0350 23
–UN–29APR97
IMPORTANT: Check function of the drain valve. Check function of drain ball. Ball must move freely. If ball does not move freely, check for contamination or replace.
T108981
NOTE: Clutch KV and KR are assembled in the same manner. Art shown in the following story is clutch KV. Install both new O-rings (arrows) into the ID and OD of the piston and oil them.
TX,0350,ME288 –19–02OCT98–1/21
Assemble piston until it bottoms out in plate carrier.
T108662
–UN–10APR97
Pay attention to proper installation.
Continued on next page
TM2136 (13DEC04)
03-0350-23
TX,0350,ME288 –19–02OCT98–2/21
444J, 544J, 624J Loader 121304
PN=101
Gears, Shafts, Bearings and Power Shift Clutch
T108663
–UN–10APR97
Install spring and two guides.
TX,0350,ME288 –19–02OCT98–3/21
–UN–10APR97 T108664
03 0350 24
Press spring with DFT1149 compression ring tool in press and install snap ring into plate carrier groove. (Group 9900 for instructions to make tool.)
Continued on next page
TM2136 (13DEC04)
03-0350-24
TX,0350,ME288 –19–02OCT98–4/21
444J, 544J, 624J Loader 121304
PN=102
Gears, Shafts, Bearings and Power Shift Clutch
T109216
–UN–09MAY97
03 0350 25
444H (WG130)—Clutch Packs KV and KR 1—Plate Carrier 2—Piston 3—Disk (Friction) (one side fiber coated) (2 used)
4—Plate (Separator) (10 used) 5—Disk (Friction) (9 used)
IMPORTANT: Install one sided friction disk (3) with the fiber side always facing toward other disk or plate. Smooth side should be against piston or end shim depending which end of stack it is used on.
6—End Shim 7—Snap Ring
8—Idler
For proper adjustment of plate clearance install disk and plates temporarily without being oiled. Install one sided fiber disk into carrier with the fiber side facing out or away from piston.
NOTE: Plate and disk position is the same for clutch KV and KR—444H.
Continued on next page
TM2136 (13DEC04)
03-0350-25
TX,0350,ME288 –19–02OCT98–5/21
444J, 544J, 624J Loader 121304
PN=103
Gears, Shafts, Bearings and Power Shift Clutch Install plate and then disk alternately until eight plates and eight disks are installed in carrier. Install two plates. –UN–10APR97
Then one disk.
T108665
Install one sided fiber disk into carrier with the fiber side facing in or away from the end shim.
Continued on next page
TX,0350,ME288 –19–02OCT98–6/21
03 0350 26
TM2136 (13DEC04)
03-0350-26
444J, 544J, 624J Loader 121304
PN=104
Gears, Shafts, Bearings and Power Shift Clutch
T109294
–UN–08MAY97
03 0350 27
544J (WG160)—Clutch Packs KV and KR 1—Plate Carrier 2—Piston 3—Disk (Friction) (one side fiber coated) (2 used)
4—Plate (Separator) (10 used) 5—Disk (Friction) (9 used)
IMPORTANT: Install one sided friction disk (3) with the fiber side always facing toward other disk or plate. Smooth side should be against piston or end shim depending which end of stack it is used on.
6—End Shim 7—Snap Ring
8—Idler
For proper adjustment of plate clearance, install disk and plates temporarily without being oiled. Install one sided fiber disk into carrier with the fiber side facing out or away from piston.
NOTE: Plate and disk position is the same for Clutch KV and KR—544J.
Continued on next page
TM2136 (13DEC04)
03-0350-27
TX,0350,ME288 –19–02OCT98–7/21
444J, 544J, 624J Loader 121304
PN=105
Gears, Shafts, Bearings and Power Shift Clutch Install plate and then disk alternately until all ten plates and nine disks are installed in carrier.
T108665
–UN–10APR97
Install one sided fiber disk into carrier with the fiber side facing in or away from the end shim.
TX,0350,ME288 –19–02OCT98–8/21
Install end shim and snap ring.
T108666
–UN–10APR97
03 0350 28
TX,0350,ME288 –19–02OCT98–9/21
–UN–10APR97
NOTE: For the adjustment of the plate clearance there are snap rings of different thickness available through parts system that can be used if proper clearance is unable to be obtained. To ensure proper measuring result, install plates temporarily without oil. Adjust plate clearance to specification.
T108667
Specification KV and KR Clutch Pack Plate— Clearance .............................................................................. 2.5—2.7 mm 0.098—0.106 in
Press end shim and measure the dimension from the end face/plate carrier to the end shim with depth gage. Record dimension (No 1).
Continued on next page
TM2136 (13DEC04)
03-0350-28
TX,0350,ME288 –19–02OCT98–10/21
444J, 544J, 624J Loader 121304
PN=106
Gears, Shafts, Bearings and Power Shift Clutch Press end shim against snap ring (upward) until contact and measure with gage. Record dimension (No 2).
7.24 mm (0.285 in.)
Dimension No 2
4.75 mm (0.187 in.)
Difference = Plate Clearance
2.5 mm (0.098 in.)
Specification = Pack Clearance
2.5—2.7 mm (0.098—0.106 in.)
T108668
Dimension No 1
–UN–10APR97
Example for Clutch Pack Clearance Check
If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes. Specification KV and KR Clutch Pack Plate— Clearance .............................................................................. 2.5—2.7 mm 0.098—0.106 in.
03 0350 29
After proper clearance is obtained remove disks and plates from assembly. Add oil to plates and disks. Reassemble clutch pack assembly.
TX,0350,ME288 –19–02OCT98–11/21
Install idler gear until all inner plates are engaged. This step makes later assembling of the idler gear easier.
T108669
–UN–10APR97
Remove idler gear from clutch pack assembly.
Continued on next page
TM2136 (13DEC04)
03-0350-29
TX,0350,ME288 –19–02OCT98–12/21
444J, 544J, 624J Loader 121304
PN=107
Gears, Shafts, Bearings and Power Shift Clutch Apply thread lock and sealer (medium strength) to stud. Install stud on end of shaft if removed in assembly.
–UN–10APR97
Tighten to specification.
T108670
Specification Shaft Stud—Torque ........................................................................ 17 N•m 150 lb-in.
TX,0350,ME288 –19–02OCT98–13/21
Insert ball bearing until seated and install snap ring.
T108671
–UN–10APR97
03 0350 30
TX,0350,ME288 –19–02OCT98–14/21
T108672
–UN–10APR97
Install needle bearing.
TX,0350,ME288 –19–02OCT98–15/21
NOTE: Push against inner race of bearing.
T108673
–UN–10APR97
Press idler gear against shoulder.
Continued on next page
TM2136 (13DEC04)
03-0350-30
TX,0350,ME288 –19–02OCT98–16/21
444J, 544J, 624J Loader 121304
PN=108
Gears, Shafts, Bearings and Power Shift Clutch
T108674
–UN–10APR97
Retain idler gear by means of snap ring.
TX,0350,ME288 –19–02OCT98–17/21
NOTE: Clutch KR, there is no recess in the shaft. Assemble snap ring until contact on the bearing inner race is obtained.
03 0350 31
T108675
–UN–10APR97
Assemble pre-assembled plate carrier until all plates are engaged.
TX,0350,ME288 –19–02OCT98–18/21
T108676
–UN–10APR97
Make sure carrier face is flush with shaft spline.
TX,0350,ME288 –19–02OCT98–19/21
Press tapered roller bearing against shoulder.
T108677
–UN–10APR97
Install opposite tapered roller bearing with press.
Continued on next page
TM2136 (13DEC04)
03-0350-31
TX,0350,ME288 –19–02OCT98–20/21
444J, 544J, 624J Loader 121304
PN=109
Gears, Shafts, Bearings and Power Shift Clutch Check function of clutch by means of compressed air.
T108678
–UN–10APR97
NOTE: When you have correctly installed components, the clutch packs will move freely as you will be able to hear them moving while inducing compressed air.
TX,0350,ME288 –19–02OCT98–21/21
Input Shaft Disassemble
–UN–18APR97
NOTE: The turbine shaft is axially fixed by means of a snap ring which will be destroyed when pressing out.
T108772
If necessary, press turbine shaft out of the input shaft.
TX,0350,ME287 –19–05OCT98–1/2
Remove rectangular ring out. Pull off the tapered roller bearing using JDG1034 and JDG1035 Bearing Puller Mandrel. –UN–18APR97
Pull off the opposite tapered roller bearing.
T108773
NOTE: The separation of input shaft and gear is not possible (press fit).
TX,0350,ME287 –19–05OCT98–2/2
Input Shaft Assemble
–UN–14APR97
Cool the input shaft to about -80°C (-112°F). Heat gear to approximately 120°C (250°F) and assemble to shaft until seated.
T108997
03 0350 32
Continued on next page
TM2136 (13DEC04)
03-0350-32
TX,0350,ME292 –19–05OCT98–1/7
444J, 544J, 624J Loader 121304
PN=110
Gears, Shafts, Bearings and Power Shift Clutch
T108998
–UN–14APR97
Install snap ring to retain gear.
TX,0350,ME292 –19–05OCT98–2/7
Install snap ring into the recess of the turbine shaft.
T108999
–UN–14APR97
03 0350 33
TX,0350,ME292 –19–05OCT98–3/7
T109000
–UN–14APR97
Install turbine shaft until the snap ring snaps into the groove of the input shaft to retain turbine shaft.
TX,0350,ME292 –19–05OCT98–4/7
T109001
–UN–09MAY97
Press both bearing inner races against shoulder.
Continued on next page
TM2136 (13DEC04)
03-0350-33
TX,0350,ME292 –19–05OCT98–5/7
444J, 544J, 624J Loader 121304
PN=111
Gears, Shafts, Bearings and Power Shift Clutch Install ball bearing.
T109002
–UN–29APR97
Install sealing ring.
TX,0350,ME292 –19–05OCT98–6/7
Install output shaft into the housing bore until seated.
Insert all bearing outer races into transmission housing bores.
–UN–09MAY97
NOTE: If bearings are reused, they must be assembled in same bores.
T109003
03 0350 34
TX,0350,ME292 –19–05OCT98–7/7
TM2136 (13DEC04)
03-0350-34
444J, 544J, 624J Loader 121304
PN=112
Group 0360
Hydraulic System Remove Transmission Pump
T108730
–UN–17APR97
1. Loosen socket head screws.
TX,0360,ME278 –19–20OCT98–1/5
2. Placing a puller on the splines runout of the stator shaft, pull pump assembly out of the housing bore.
T108731
–UN–17APR97
03 0360 1
Continued on next page
TM2136 (13DEC04)
03-0360-1
TX,0360,ME278 –19–20OCT98–2/5
444J, 544J, 624J Loader 121304
PN=113
Hydraulic System
TP55490
–UN–15APR97
03 0360 2
Oil Pump Assembly 1—O-Ring 2—Snap Ring 3—Seal
4—Shim 5—Needle Bearing
6—Ring 7—Pump Assembly
8—O-Ring (10 used) 9—Cap Screw (10 used)
TX,0360,ME278 –19–20OCT98–3/5
3. Separate transmission pump from stator. 4. Separate cam plate from pump. Make note of drive gear spline location and two small dowel pins. –UN–17APR97
IMPORTANT: If traces of wear should be encountered in the pump housing or the cam disk, the complete pump has to be replaced.
T108732
5. Inspect and replace parts as required 6. Install cam disk and retain it by means of grooved pins (2 used).
Continued on next page
TM2136 (13DEC04)
03-0360-2
TX,0360,ME278 –19–20OCT98–4/5
444J, 544J, 624J Loader 121304
PN=114
Hydraulic System 7. Loosen hex head screws and remove oil feed housing.
T108725
–UN–17APR97
8. Remove flat gasket.
TX,0360,ME278 –19–20OCT98–5/5
Remove and Install Converter Minimum Pressure Regulator Valve
03 0360 3
T108726
–UN–17APR97
1. Remove converter minimum pressure regulator valve out of the housing bore.
TX,0350,ME279 –19–20OCT98–1/2
2. Preload compression spring carefully, drive roll pin out and remove components.
4. Install pre-assembled converter minimum pressure regulator valve into housing bore.
T109082
1—Piston 2—Compression Spring 3—Valve Insert 4—Roll Pin
–UN–29APR97
3. Inspect and replace parts as required.
TX,0350,ME279 –19–20OCT98–2/2
TM2136 (13DEC04)
03-0360-3
444J, 544J, 624J Loader 121304
PN=115
Hydraulic System
Install Transmission Pump
T109085
–UN–29APR97
1. Install alignment studs and install flat gasket.
TX,07,ME297 –19–05OCT98–1/8
2. Install oil feed housing, washers and hex head screws.
T109086
–UN–15APR97
3. Leave loose at this time. This allows for oil pump alignment later in assembly.
TX,07,ME297 –19–05OCT98–2/8
NOTE: Note the overlapping of the bores.
T109087
–UN–15APR97
4. Install alignment studs and stator shaft until it is bottomed in housing.
TX,07,ME297 –19–05OCT98–3/8
–UN–29APR97
5. Lubricate and install O-ring.
T109088
03 0360 4
IMPORTANT: Screw hex head screws until contact is obtained. Do not tighten.
Continued on next page
TM2136 (13DEC04)
03-0360-4
TX,07,ME297 –19–05OCT98–4/8
444J, 544J, 624J Loader 121304
PN=116
Hydraulic System
T109089
–UN–15APR97
6. Install transmission pump.
TX,07,ME297 –19–05OCT98–5/8
NOTE: Grease O-rings. 03 0360 5
T109090
–UN–29APR97
7. Install socket head screws with new O-rings.
TX,07,ME297 –19–05OCT98–6/8
8. Install transmission pump and socket head screws.
T109091
–UN–15APR97
Specification Socket Head Screw—Torque ......................................................... 46 N•m 34 lb-ft
TX,07,ME297 –19–05OCT98–7/8
NOTE: Note locations of hanger strap from original location.
T109092
Specification Pump Cap Screw—Torque ............................................................ 25 N•m 221 lb-in.
–UN–15APR97
9. Tighten cap screws.
TX,07,ME297 –19–05OCT98–8/8
TM2136 (13DEC04)
03-0360-5
444J, 544J, 624J Loader 121304
PN=117
Hydraulic System
Transmission Hydraulic Control Valve Remove
T108709
–UN–17APR97
1. Loosen socket head screws, install two alignment studs and separate control valve from manifold plate.
TX,0350,ME276 –19–15DEC98–1/3
2. Remove both gaskets (9, 11) and center plate (10).
T108710
–UN–17APR97
03 0360 6
TX,0350,ME276 –19–15DEC98–2/3
3. Loosen socket head screws and hex nuts. 4. Separate manifold plate from transmission housing.
T108714
–UN–17APR97
5. Remove gasket.
TX,0350,ME276 –19–15DEC98–3/3
TM2136 (13DEC04)
03-0360-6
444J, 544J, 624J Loader 121304
PN=118
Hydraulic System
03 0360 7
TM2136 (13DEC04)
03-0360-7
444J, 544J, 624J Loader 121304
PN=119
Hydraulic System
Transmission Hydraulic Control Valve Install
T193514
–UN–21AUG03
03 0360 8
Hydraulic Control Valve and Manifold 1—Stud (14 used) 2—Gasket 3—Manifold Plate
4—Spring 5—Nut (14 used) 6—Valve Spool
7—Switch 8—Cap Screw (37 used) 9—Plate (Center) Continued on next page
TM2136 (13DEC04)
03-0360-8
10—Cap Screw (23 used) 11—O-Ring 12—Fitting Plug TX,0360,ME282 –19–15DEC98–1/4
444J, 544J, 624J Loader 121304
PN=120
Hydraulic System 1. Install gasket, manifold plate, and fasten it with socket head screws hex nuts and washers. Tighten socket head screws.
T109106
–UN–15APR97
Specification Manifold Plate-to-Transmission Housing Socket Head Screw— Torque ............................................................................................ 25 N•m 221 lb-in.
T109107
–UN–15APR97
03 0360 9
TX,0360,ME282 –19–15DEC98–2/4
T109109
–UN–15APR97
2. Install two alignment studs. Install gasket (2), plate (3) and plate (9).
Continued on next page
TM2136 (13DEC04)
03-0360-9
TX,0360,ME282 –19–15DEC98–3/4
444J, 544J, 624J Loader 121304
PN=121
Hydraulic System 3. Install complete control valve unit on the manifold plate with socket head screws.
Specification Control Valve-to-Manifold Plate Socket Head Screw—Torque ........................................................ 9.5 N•m 85 lb-in
T109110
4. Tighten screw.
–UN–15APR97
IMPORTANT: Note the installation and position of the different gaskets.
03 0360 10 TX,0360,ME282 –19–15DEC98–4/4
TM2136 (13DEC04)
03-0360-10
444J, 544J, 624J Loader 121304
PN=122
Hydraulic System
03 0360 11
TM2136 (13DEC04)
03-0360-11
444J, 544J, 624J Loader 121304
PN=123
Hydraulic System
Transmission Hydraulic Control Valve Cross Section View
T122180
–19–07JUL99
03 0360 12
A—Pressure Regulating Valve—Piston B—Pressure Reducing Valve— Piston
C—Connector—Wiring Harness D—Cover (2 used)
E—Valve Block—Control Valve F—Housing (2 used) G—Modulation Circuit
H—Solenoid Valve— Proportional (6 used) I—Transmission Control Valve
TX,0360,ME273 –19–15DEC98–1/1
TM2136 (13DEC04)
03-0360-12
444J, 544J, 624J Loader 121304
PN=124
Hydraulic System
03 0360 13
TM2136 (13DEC04)
03-0360-13
444J, 544J, 624J Loader 121304
PN=125
Hydraulic System
Transmission Control Valve Disassemble
T192815
–UN–28JUL03
03 0360 14
Transmission Hydraulic Control Valve Components Continued on next page
TM2136 (13DEC04)
03-0360-14
TX,0360,ME274 –19–08DEC03–1/7
444J, 544J, 624J Loader 121304
PN=126
Hydraulic System 1—Cap Screw (64 used) 2—Clamp (Clip) 3—Cover 4—Wiring Harness 5—Gasket (2 used) 6—Solenoid Valve— Proportional (6 used) 7—Cap Screw (6 used) 8—Plate (6 used) 9—Housing (2 used)
10—Gasket (2 used) 11—Piston (Dampening Valve) (6 used) 12— Compression Spring (6 used) 13—Compression Spring 14—Piston—System Pressure Reducing Valve 15—Flow Control Hydraulic Valve
16—O-Ring (8 used) 17—Drain Plug (8 used) 18— Compression Spring 19— Piston (System Pressure Regulating Valve) 20—O-Ring (6 used) 21—Housing 22—Sheet 23—Plate 24—Cap Screw (18 used)
25—Cover 26—Screen (6 used) 27—Compression Spring (6 used) 28—Orifice (6 used) 29—Piston (Pressure Control valve) (6 used) 30—Hydraulically Actuated Control Valve
TX,0360,ME274 –19–08DEC03–2/7
1. Remove screws (1) and cover (25) and gasket (5). 03 0360 15
2. Disconnect harness connectors to solenoid valves (6).
T108686
–UN–16APR97
3. Remove screws (7) and retaining plates (8), and remove three solenoid valves (6).
T108687
–UN–16APR97
Hydraulic Control Valve
Continued on next page
TM2136 (13DEC04)
03-0360-15
TX,0360,ME274 –19–08DEC03–3/7
444J, 544J, 624J Loader 121304
PN=127
Hydraulic System 4. Loosen screw (1) to housing (9), remove housing and gasket (10).
–UN–12JAN01
5. Remove three pressure control valve pistons (29) and compression springs (27). 6. Remove three damping valve pistons (11) and compression springs (12).
T135928
7. Remove system pressure valve piston (19) compression spring (18). Remove Housing And Valves
03 0360 16 TX,0360,ME274 –19–08DEC03–4/7
T108689
–UN–16APR97
8. Remove clamp (clip) (2) from wire harness connector.
Clamp Removal from Harness Connector
TX,0360,ME274 –19–08DEC03–5/7
9. Remove screws (1) and cover (3) and gasket (5). 10. Disconnect harness connectors to solenoid valves (6).
T108682
–UN–16APR97
11. Remove screws (7) and retaining plates (8). Remove solenoid valves (6).
Continued on next page
TM2136 (13DEC04)
03-0360-16
TX,0360,ME274 –19–08DEC03–6/7
444J, 544J, 624J Loader 121304
PN=128
Hydraulic System 12. Loosen screw (1) to housing (9), remove housing and gasket (10).
–UN–16APR97
13. Remove three pressure control valve pistons (29) and compression springs (27). 14. Remove three damping valves pistons (11) and compression springs (12).
T108683
15. Remove pressure reducing valve piston (14) compression spring (13). 16. Inspect and replace parts as necessary.
03 0360 17 TX,0360,ME274 –19–08DEC03–7/7
Transmission Control Valve Assemble 1. Check all components for damage and replace if necessary. –UN–09MAY97
2. Prior to the installation, check free travel of moving parts in the housing.
T108684
3. Oil components prior to the reassembly. 4. Insert orifices (31) (if removed) until contact is obtained (6 pieces, see arrows). 5. Install screens (37) if removed.
TX,0360,ME275 –19–08DEC03–1/19
6. Install three pressure control valve pistons (29) and compression springs (27).
–UN–16APR97
7. Install three damping valve pistons (11) and compression springs (12).
T108683
8. Install system pressure reducing valve piston (14) compression spring (13).
Continued on next page
TM2136 (13DEC04)
03-0360-17
TX,0360,ME275 –19–08DEC03–2/19
444J, 544J, 624J Loader 121304
PN=129
Hydraulic System 9. Screw two alignment studs in valve housing. Install gasket, assemble flat gasket (10).
T108694
–UN–16APR97
NOTE: To aid assembly of solenoid housing, push spools into bore and retain by using a 5 mm pin or screw.
TX,0360,ME275 –19–08DEC03–3/19
–UN–16APR97 T108695
TX,0360,ME275 –19–08DEC03–4/19
11. Fasten housing (9) with screws (1) and tighten evenly. Remove assembly aid pins or screws. Tighten cap screw to specification.
T108696
–UN–16APR97
Specification Housing-to-Control Valve (M5 x 10.9) Screw—Torque ....................................................................... 5 N•m 44 lb-in.
TX,0360,ME275 –19–08DEC03–5/19
12. Insert three solenoid valves (6) into housing (9), equipped with O-ring, and fasten by means of retaining plate (8) and screws (7).
–UN–16APR97
NOTE: Install retaining plate with claw facing the housing bottom.
T108697
03 0360 18
10. Install housing (9) while routing wire harness (4) into position.
Continued on next page
TM2136 (13DEC04)
03-0360-18
TX,0360,ME275 –19–08DEC03–6/19
444J, 544J, 624J Loader 121304
PN=130
Hydraulic System 13. Install housing with solenoid valves onto control valve (15) and fasten with screws. Tighten screw to specification.
T108698
–UN–16APR97
Specification Solenoid Valve (M5 x 8.8) Screw—Torque ................................................................................ 5 N•m 44 lb-in
TX,0360,ME275 –19–08DEC03–7/19
14. Install harness connectors to solenoid valves (6).
T108691
–UN–16APR97
03 0360 19
TX,0360,ME275 –19–08DEC03–8/19
15. Screw two alignment studs in, and assemble flat gasket (5) and cover (3). 16. Tighten cap screw to specification.
T108692
–UN–16APR97
Specification Solenoid Cover-to-Housing (M5 x 10.9) Screw—Torque ....................................................................... 5 N•m 44 lb-in.
TX,0360,ME275 –19–08DEC03–9/19
17. Install Wire harness connector (4) with clamp-clip (2) to cover (3).
T108693
–UN–16APR97
NOTE: Make sure clamp snaps in.
Continued on next page
TM2136 (13DEC04)
03-0360-19
TX,0360,ME275 –19–08DEC03–10/19
444J, 544J, 624J Loader 121304
PN=131
Hydraulic System 18. Install three pressure control valve pistons (29) and springs (27).
–UN–12JAN01
19. Install three dampening valve pistons (11) and compression springs (12).
T135928
20. Install system pressure regulating valve (19), and spring (18).
TX,0360,ME275 –19–08DEC03–11/19
–UN–16APR97 T108703
TX,0360,ME275 –19–08DEC03–12/19
–UN–16APR97
22. Screw two alignment studs in, assemble gasket (5) and housing (9).
T108704
03 0360 20
21. Push spools of the pressure control valves (29) into position. A straight pin (5 mm) may be used as an assembly aid.
Continued on next page
TM2136 (13DEC04)
03-0360-20
TX,0360,ME275 –19–08DEC03–13/19
444J, 544J, 624J Loader 121304
PN=132
Hydraulic System 23. Install housing and tighten evenly. 24. Tighten cap screw to specification.
T108705
–UN–16APR97
Specification Housing-to-Control Valve Block Screw (M5 x 10.9)—Torque ............................................................. 5 N•m 44 lb-in.
03 0360 21 TX,0360,ME275 –19–08DEC03–14/19
25. Insert three solenoid valves (6), equipped with O-ring (20), and fasten by means of retaining plate (8) and screw (7).
–UN–16APR97
NOTE: Install retaining plate with the claw facing the housing bottom. 26. Tighten cap screw to specification.
T108698
Specification Solenoid Valve-to-Retaining Plate Screw—Torque ................................................................................. 5 N•m 44 lb-in
TX,0360,ME275 –19–08DEC03–15/19
27. Fasten harness connectors to solenoid valves.
–UN–30APR97
28. Screw two alignment studs in housing and assemble flat gasket (10) and cover (25). Tighten cap screws (1) to specification.
T108699
Specification Alignment Stud-to-Cover Screw— Torque .............................................................................................. 5 N•m 44 lb-in.
Continued on next page
TM2136 (13DEC04)
03-0360-21
TX,0360,ME275 –19–08DEC03–16/19
444J, 544J, 624J Loader 121304
PN=133
Hydraulic System 29. Install diagnostic plugs with O-rings, in ports, if removed during disassembly.
T108700
Specification Diagnostic Plug-to-Port (M10 x 1.0) Screw—Torque ......................................................................... 6 N•m 55 lb-in.
–UN–16APR97
30. Tighten cap screw to specification.
TX,0360,ME275 –19–08DEC03–17/19
–UN–16APR97 T108701
TX,0360,ME275 –19–08DEC03–18/19
32. Assemble manifold plate (23) to valve body with screws (24) and (remove alignment screws).
33. Tighten cap screw to specification. Specification Manifold Plate-to-Valve Body (M6 x 10.9) Screw—Torque ................................................................. 9.5 N•m 85 lb-in.
–UN–17APR97
NOTE: Tightening order of the screw start with inboard screws at first and continuing toward the outside.
T108708
03 0360 22
31. Screw two alignment studs in and assemble flat gasket (21).
TX,0360,ME275 –19–08DEC03–19/19
TM2136 (13DEC04)
03-0360-22
444J, 544J, 624J Loader 121304
PN=134
Hydraulic System
Remove, Disassemble and Install Torque Converter Relief Valve
T108715
–UN–17APR97
1. Pull converter relief valve out of the housing bore.
TX,0360,ME277 –19–20NOV03–1/4
2. Remove preload compression spring carefully, remove cylindrical pin as required to inspect and replace parts as needed.
03 0360 23
T109103
–UN–30APR97
1—Plate 2—Ball 3—Compression Spring 4—Valve Insert 5—Valve Sleeve 6—Roll Pin
Converter Relief Valve
TX,0360,ME277 –19–20NOV03–2/4
T109105
–UN–15APR97
3. Insert converter relief valve into the housing bore until it bottoms.
Continued on next page
TM2136 (13DEC04)
03-0360-23
TX,0360,ME277 –19–20NOV03–3/4
444J, 544J, 624J Loader 121304
PN=135
Hydraulic System
T109106
Specification Manifold Plate Socket Head Screw—Torque ............................................................................... 25 N•m 221 lb-in.
–UN–15APR97
4. Install gasket and channel manifold. Fasten it with socket head screws hex nuts and washers. Tighten socket head screws.
T109107
–UN–15APR97
03 0360 24
TX,0360,ME277 –19–20NOV03–4/4
TM2136 (13DEC04)
03-0360-24
444J, 544J, 624J Loader 121304
PN=136
Hydraulic System
Oil Pipes and Tubes Replacement
T193492
–UN–21AUG03
03 0360 25
Oil Pipes and Tubes 1—Pipe 2—Structural Tubing
3—Cap Screw
4—Pipe
5—O-Ring
TX,0360,ME293 –19–08DEC03–1/1
TM2136 (13DEC04)
03-0360-25
444J, 544J, 624J Loader 121304
PN=137
Hydraulic System
03 0360 26
TM2136 (13DEC04)
03-0360-26
444J, 544J, 624J Loader 121304
PN=138
Section 04
Engine Contents Page
Group 0400—Removal and Installation POWERTECH 4.5 L (4045) and 6.8 L (6068) John Deere Engines . . . . . . . . . . . .04-0400-1 Serpentine Belt Remove and Install . . . . . . .04-0400-1 Engine Remove and Install . . . . . . . . . . . . .04-0400-3
04
TM2136 (13DEC04)
04-1
444J, 544J, 624J Loader 121304
PN=1
Contents
04
TM2136 (13DEC04)
04-2
444J, 544J, 624J Loader 121304
PN=2
Group 0400
Removal and Installation POWERTECH 4.5 L (4045) and 6.8 L (6068) John Deere Engines For additional information on John Deere engines and components, see the following Component Technical Manuals. • PowerTech 4.5L and 6.8L Diesel Engines Base Engine. (CTM104.) • PowerTech 4.5L and 6.8L Diesel Engines Level 12 Electronic Fuel System with DE10 Pump (444J and 544J). (CTM331.) • PowerTech 4.5L and 6.8L Diesel Engines Level 11 Electronic Fuel System with Denso HPCR (624J only). (CTM220.) • Alternators and Starting Motors. (CTM77.)
04 0400 1
POWERTECH is a trademark of Deere & Company
MF82180,0000177 –19–12DEC03–1/1
Serpentine Belt Remove and Install 1. Open cooling package left access door.
TX,0510,111295 –19–06NOV03–1/3
IMPORTANT: If belt is stretched to where belt tensioner is against its stop, replace belt.
–UN–24OCT03
2. Check belt (2) regularly for wear, especially for cracks, frayed edges, and at bottom of grooves. 3. Remove rear engine access panel.
T195677A
4. Hold tension adjuster assembly (1) away from belt (2). Remove old belt; install new belt. Engine Drive Belt Access
1—Belt Tensioner Assembly 2—Engine Drive Belt
Continued on next page
TM2136 (13DEC04)
04-0400-1
TX,0510,111295 –19–06NOV03–2/3
444J, 544J, 624J Loader 121304
PN=141
Removal and Installation 5. Install new serpentine belt. 6. Install rear engine access panel.
T195684
–UN–07NOV03
3—Crankshaft Pulley 4—Idler 5—Alternator Pulley 6—Belt Tensioner 7—Water Pump 8—Air Conditioner Compressor
T195684
–UN–07NOV03
Belt Routing without Air Conditioning
T195685
04 0400 2
T195685 Belt Routing with Air Conditioning
TX,0510,111295 –19–06NOV03–3/3
TM2136 (13DEC04)
04-0400-2
444J, 544J, 624J Loader 121304
PN=142
Removal and Installation
Engine Remove and Install 1. Stop engine. Lower boom and bucket to ground.
–UN–23AUG88
2. Turn battery disconnect switch OFF.
TS281
CAUTION: Prevent possible injury from explosive release of fluids from pressurized cooling system. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 3. Attach hose to radiator drain valve. Drain engine coolant. 4. Remove cooling package doors. Perform See Radiator Remove and Install until cooling package doors are off machine. (Group 0510.) 5. Remove hood with air cleaner and exhaust stack. See Hood Remove and Install. (Group 1910.)
04 0400 3
6. Remove cold weather starting aid. See Cold Weather Starting Aids. (Group 0505.) 7. Remove intercooler tubes. See Intercooler Remove and Install. (Group 0510.) Plug and seal openings. 8. Remove radiator reservoir with hoses. 9. Remove radiator hoses.
Continued on next page
TM2136 (13DEC04)
04-0400-3
TX,0400,111403 –19–10NOV03–1/9
444J, 544J, 624J Loader 121304
PN=143
Removal and Installation
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–30OCT03
10. Support cooling package plenum baffle (1) with appropriate lifting device and remove mounting hardware (2).
T195758A
Specification Cooling Package Plenum Baffle— Weight................................................................................................ 82 Kg 180 lb
Cooling Package Plenum Baffle
11. Remove cooling package plenum baffle using appropriate lifting device.
1—Cooling Package Plenum Baffle 2—Cooling Package Plenum Baffle Mounting Hardware (4 used) 3—Left Rear Engine Mounting Hardware 4—Lower Radiator Hose 5—Transmission Cooler Hose
12. Remove engine serpentine belt. See Serpentine Belt Remove and Install. (Group 0510.)
04 0400 4
Continued on next page
TM2136 (13DEC04)
04-0400-4
TX,0400,111403 –19–10NOV03–2/9
444J, 544J, 624J Loader 121304
PN=144
Removal and Installation NOTE: It is not necessary to disconnect hydraulic hoses from pump when removing fan pump. 13. Remove hydraulic fan pump mounting hardware (7), and pump (6) from engine and tie band aside. 14. Remove crankcase drain hose from bottom left side of crankcase and tie band aside.
–UN–30OCT03
15. Remove heater hoses (8) from left side of engine. 16. Remove fuel hose from primary fuel filter.
T195783A
17. Remove muffler mounting hardware. 18. Remove muffler. See Muffler Remove and Install. (Group 0530.) Plug and seal all openings. 6—Hydraulic Fan Pump 7—Hydraulic Fan Pump Mounting Hardware (2 used) 8—Heater Hose
19. Remove muffler bracket mounting hardware and remove bracket. 20. Disconnect wiring harness and clamps from all engine locations.
04 0400 5
21. Remove alternator mounting hardware and remove alternator. 22. Remove positive battery cables and E01 white wires from starter. 23. Remove ground wire from starter mounting hardware. 24. Remove refrigerant. See Evacuate R134a System. (Group 1830.) Specification R134a Refrigerant—Weight ........................................................... 1.63 kg 3.6 lb
NOTE: It is not necessary to disconnect air conditioning hoses from compressor or receiver-dryer when removing compressor. 25. Remove air conditioning compressor. Use tie band to secure compressor aside. 26. Remove receiver-dryer mounting hardware and allow receiver-dryer to rest in engine compartment.
Continued on next page
TM2136 (13DEC04)
04-0400-5
TX,0400,111403 –19–10NOV03–3/9
444J, 544J, 624J Loader 121304
PN=145
Removal and Installation 27. Remove fuel return hose from fuel rail on right side of engine.
TX,0400,111403 –19–10NOV03–4/9
NOTE: Rotate the engine so the drive shaft U-joint bolts are accessible.
–UN–30OCT03
28. Remove four cap screws (10) from the engine-to-torque converter drive shaft (11) U-joints at the torque converter (9).
T195775A
9—Torque Convertor Housing 10—U-Joint Retaining cap screws (4 used) 11—Drive Shaft
Drive Shaft Mounting Hardware 04 0400 6
Continued on next page
TM2136 (13DEC04)
04-0400-6
TX,0400,111403 –19–10NOV03–5/9
444J, 544J, 624J Loader 121304
PN=146
Removal and Installation 29. Install lifting eyes JD 244-1 and JD 244-2 to engine. 30. Attach load positioning sling D010143AA to lifting eyes. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–30OCT03
31. Remove rear engine isolator support mounting hardware (17).
T195852A
32. Remove left front engine isolator support mounting hardware (18).
NOTE: Remove right front engine mount-to-engine mounting hardware and allow engine isolator support to remain bolted to frame.
Lifting Eyes 12—Lifting Eye Location 13—Load Positioning Sling
33. Remove right front engine support-to-engine mounting hardware (16).
04 0400 7
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 34. 444J Machines: Turn front of engine to the left, and slowly remove engine through right side of the machine. Repair as necessary. Specification 444J Engine—Weight— Approximate..................................................................................... 408 kg 900 lb 544J, 624J Engine—Weight— Approximate..................................................................................... 660 kg 1450 lb
Continued on next page
TM2136 (13DEC04)
04-0400-7
TX,0400,111403 –19–10NOV03–6/9
444J, 544J, 624J Loader 121304
PN=147
Removal and Installation
T195853
–UN–31OCT03
04 0400 8
T195853 Engine Mounting Brackets 14—M16 Nut (2 used) 15—M20 Nut (2 used) 16—M12 x 35 Cap Screw (6 used) 17—M20 x 120 Cap Screw (2 used)
18—M16 x 110 Cap Screw (2 used) 19—Washer (2 used) 20—Washer (2 used) 21—Washer (2 used) 22—Washer (2 used)
35. Inspect engine mounting parts. Replace as needed.
23—Left Rear Isolator Support 24—Right Rear Isolator Support 25—Left Front Isolator Support
36. Install engine into machine.
Continued on next page
TM2136 (13DEC04)
26—Right Front Isolator Support 27—Front Isolator (2 used) 28—Rear Isolator (2 used) 29—Washer (2 used)
04-0400-8
TX,0400,111403 –19–10NOV03–7/9
444J, 544J, 624J Loader 121304
PN=148
Removal and Installation 37. Install two rear mounting cap screws (17). Tighten cap screws to specification.
T195800A
–UN–30OCT03
Specification Rear Mounting Cap Screw— Torque ............................................................................... 348—522 N•m 256—384 lb-ft Front Mounting Cap Screw— Torque ................................................................................. 256—284 N•m 188—282 lb-ft
38. Install left front mounting cap screw (18), tighten to specification. Rear Engine Mounting Cap Screw
39. Align right front isolator support (26), and install hardware (16).
17—M20 x 120 Cap Screw (2 used)
40. Install four new engine-to-transmission drive shaft U-joint cap screws. Tighten to specification. Specification Drive Shaft U-Joint Cap Screw— Torque ............................................................................................ 41 N•m 30 lb-ft
04 0400 9
41. Connect engine wiring harness to engine at all locations. 42. Connect positive battery cables and E01 white wires to starter. Connect ground wire to starter mounting hardware. 43. Connect fuel hose to primary fuel filter. 44. Connect heater hoses (8) to left side of engine. 45. Connect crankcase drain hose at bottom left side of crankcase. 46. Install fan hydraulic pump (6) with mounting hardware (7). 47. Install fuel return line. 48. Install air conditioner compressor bracket. 49. Install air conditioner compressor. 50. Charge cooling system. See Charge R134a System. (Group 1830.)
Continued on next page
TM2136 (13DEC04)
04-0400-9
TX,0400,111403 –19–10NOV03–8/9
444J, 544J, 624J Loader 121304
PN=149
Removal and Installation 51. Install engine serpentine belt. 52. Lift cooling package plenum baffle in place with appropriate lifting device and install mounting hardware. 53. Install radiator hoses. 54. Install radiator reservoir with tubes to cooling plenum baffle. 55. Unplug openings and install intercooler hoses. 56. Connect cold weather starting aid. 57. Install muffler mounting bracket and muffler. 58. Install hood with air cleaner and exhaust stack. 59. Install hood mounting hardware. 04 0400 10
60. Install intake hose to turbo. 61. Fill radiator with coolant. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 62. Turn battery disconnect switch ON.
TX,0400,111403 –19–10NOV03–9/9
TM2136 (13DEC04)
04-0400-10
444J, 544J, 624J Loader 121304
PN=150
Section 05
Engine Auxiliary Systems Contents Page
Group 0505—Cold Weather Starting Aids Starting Aid Nozzle Remove and Install . . . .05-0505-1 Start Aid Solenoid Remove and Install . . . . .05-0505-2 Engine Coolant Heater Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-2 Group 0510—Cooling System Intercooler Remove and Install . . . . . . . . . . .05-0510-1 Radiator Remove and Install . . . . . . . . . . . . .05-0510-2 Hydraulic Oil Cooler Remove and Install . . . .05-0510-8 Transmission Oil Cooler Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-9 Cooling Package Plenum Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-9 Group 0520—Intake System Air Cleaner Remove and Install. . . . . . . . . . .05-0520-1 Inspect Element . . . . . . . . . . . . . . . . . . . . . .05-0520-3
05
Group 0530—External Exhaust System Muffler Remove and Install. . . . . . . . . . . . . .05-0530-1 Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-1 Primary Fuel Filter (Water Separator) Remove and Install . . . . . . . . . . . . . . . . . .05-0560-5
TM2136 (13DEC04)
05-1
444J, 544J, 624J Loader 121304
PN=1
Contents
05
TM2136 (13DEC04)
05-2
444J, 544J, 624J Loader 121304
PN=2
Group 0505
Cold Weather Starting Aids Starting Aid Nozzle Remove and Install NOTE: Fluid starting aid used on 444J and 544J only. 624J uses glow plugs. –UN–10NOV03
1. Open left engine door.
T196131A
2. Disconnect starting aid tube (2) from nozzle (1). 1—Nozzle 2—Starting Aid Tube 3—Red Paint Dot Indexing Mark
Cold Weather Starting Aid Nozzle Location
TX,0505,111474 –19–06NOV03–1/2
3. Loosen starting aid jam nut (4) from starting aid nozzle (1). 4. Remove nozzle (1) from air inlet. –UN–10NOV03
5. Clean or replace nozzle (1) as required. Inspect O-ring (5) and replace if necessary.
6. Install nozzle in air inlet with red paint dot (3) pointing upwards and tighten jam nut.
T196125
NOTE: Red paint dot on nozzle indicates direction of nozzle opening.
Cold Weather Starting Nozzle 1—Cold Weather Starting Aid Nozzle 4—Cold Weather Starting Aid Nozzle Jam Nut 5—Cold Weather Starting Aid Nozzle O-Ring
7. Connect starting aid tube (2) to nozzle (1).
TX,0505,111474 –19–06NOV03–2/2
TM2136 (13DEC04)
05-0505-1
444J, 544J, 624J Loader 121304
PN=153
05 0505 1
Cold Weather Starting Aids
Start Aid Solenoid Remove and Install 1. Open left cooling package access door. Remove start aid components (1—6). IMPORTANT: When operating machine without starting aid container installed, protect components from possible damage. Install starting aid plug (6) in solenoid. 2. Install start aid components. Remove safety cap from new canister (4). Turn canister clockwise in starting aid solenoid to install. 3. Tighten clamp (5). Close cooling package door.
T196126A
–UN–10NOV03
1—Electrical Connector 2—Start Aid Solenoid 3—Start Aid Mounting Bracket 4—Starting Fluid Container 5—Starting Fluid Container Mounting Clamp 6—Cold Weather Starting Aid Solenoid Dust Cap
Cold Weather Starting Aid
05 0505 2
MX10672,000001E –19–06NOV03–1/1
Engine Coolant Heater Remove and Install
T6642EK
–UN–01NOV88
CAUTION: Prevent possible injury from hot coolant. Wait until radiator is cool to the touch before draining radiator.
Continued on next page
TM2136 (13DEC04)
05-0505-2
TX,0505,111284 –19–15DEC98–1/2
444J, 544J, 624J Loader 121304
PN=154
Cold Weather Starting Aids 1. Open cooling package door to access radiator drain valve.
–UN–21OCT88
2. Drain engine coolant. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities
T6427AO
544J Drain and Refill Capacities 644J Drain and Refill Capacities 3. Remove power cord (A). Loosen nut (C) and pull heating element (G) from block. CAUTION: Do not plug coolant heater into electrical power unless heating element is immersed in coolant. Sheath could burst and result in personal injury.
A—Power Cord B—Cap C—Nut D—Adapter E—Gasket F—O-Ring G—Heating Element
Use a heavy-duty grounded cord to connect coolant heater to electrical power. 4. Disassemble parts (B—G). 5. Replace parts as necessary. 05 0505 3
6. Assemble parts (A—G). Put heating element in cylinder block so flats on threaded portion of element are vertical. 7. Turn element clockwise and then counterclockwise until element contacts casting. Move element to the center position. 8. Hold element using a wrench. Tighten nut. Specification Engine Coolant Heater Element Nut—Torque .................................................................................. 34 N•m 25 lb-ft
9. Install power cord (A). 10. Fill radiator with coolant.
TX,0505,111284 –19–15DEC98–2/2
TM2136 (13DEC04)
05-0505-3
444J, 544J, 624J Loader 121304
PN=155
Cold Weather Starting Aids
05 0505 4
TM2136 (13DEC04)
05-0505-4
444J, 544J, 624J Loader 121304
PN=156
Group 0510
Cooling System Intercooler Remove and Install 1. Open engine and cooling package access doors.
–UN–22OCT03
2. Remove upper intercooler tube (2) from intake manifold and intercooler (1). Cap and plug openings.
T195617A
3. Remove lower intercooler tube (3) from turbo charger and intercooler (1). Cap and plug openings. 4. Remove intercooler mounting hardware (4) and remove intercooler (1). 5. Install intercooler mounting hardware (4). 6. Remove cap and plugs, install lower intercooler tube (3) to turbo charger and intercooler (1).
1—Intercooler 2—Upper Intercooler Tube 3—Lower Intercooler Tube 4—Intercooler Mounting Hardware
7. Remove cap and plugs, install upper intercooler tube (2) to intake manifold and intercooler (1).
TX,0510,JC2023 –19–06NOV03–1/1
TM2136 (13DEC04)
05-0510-1
444J, 544J, 624J Loader 121304
PN=157
05 0510 1
Cooling System
Radiator Remove and Install 1. Park machine and lower bucket to ground and allow engine to cool. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 2. Open rear hood and release pressure from radiator overflow reservoir. 3. Open cooling package rear door to access radiator drain valve. 4. Drain engine coolant. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 05 0510 2
644J Drain and Refill Capacities
Continued on next page
TM2136 (13DEC04)
05-0510-2
TX,0510,JC2022 –19–31AUG04–1/9
444J, 544J, 624J Loader 121304
PN=158
Cooling System
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–22OCT03
5. Support rear hood (5), remove right hinge mounting hardware (2), and remove hood.
T195618A
Specification Rear Hood Door—Weight ................................................................. 17 kg 37 lb
1—Right Hinge Plate 2—Hinge Plate Mounting Hardware (3 used) 3—Air Conditioning Condenser 4—Air Conditioning Condenser Mounting Hardware (4 used) 5—Hood
Hood
TX,0510,JC2022 –19–31AUG04–2/9
6. Remove air conditioning condenser mounting hardware (4).
T195621A
–UN–03NOV03
3—Air Conditioning Condenser 14—Radiator 18—Radiator-to-Hydraulic Oil Cooler Mounting Hardware
Radiator Mounting Hardware
Continued on next page
TM2136 (13DEC04)
05-0510-3
TX,0510,JC2022 –19–31AUG04–3/9
444J, 544J, 624J Loader 121304
PN=159
05 0510 3
Cooling System NOTE: Upper and lower radiator mounting hardware use a spacer between the mounting frame and radiator.
–UN–30OCT03
7. Raise condenser (3) enough to access upper radiator mounting hardware (19) and remove hardware and spacer.
T195796A
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Upper Radiator Mounting Hardware
8. Remove both cooling package access doors by opening 30 degrees and lifting upward off hinge pins.
3—Air Conditioning Condenser 14—Radiator 19—Upper Radiator Hardware
Specification Access Door—Weight ....................................................................... 31 kg 68 lb
Continued on next page
05 0510 4
TM2136 (13DEC04)
05-0510-4
TX,0510,JC2022 –19–31AUG04–4/9
444J, 544J, 624J Loader 121304
PN=160
Cooling System 9. Remove rear engine access panel hardware (7) from cooling package plenum baffle and remove rear engine access panel (6). 10. Remove lower radiator hose (9) from radiator (14) and from engine outlet. 11. Remove upper radiator hose. 12. Remove coolant reservoir hose (8) from radiator.
–UN–22OCT03
13. Remove lower plate (10) between engine and radiator (14).
T195619A
6—Rear Engine Access Panel 7—Rear Engine Access Panel Mounting Hardware 8—Coolant Reservoir Hose 9—Lower Radiator Hose 10—Lower Plate 11—Left Side Radiator Mounting Hardware (8 used) 12—Transmission Oil Cooler 13—Transmission Oil Cooler Lower Hose 14—Radiator
Cooling Package Left Side
05 0510 5
TX,0510,JC2022 –19–31AUG04–5/9
14. Remove radiator drain valve (15).
T195620A
–UN–22OCT03
15—Radiator Drain Valve 16—Lower Radiator Mounting Hardware 17—Hydraulic Oil Cooler
Radiator Drain Valve
Continued on next page
TM2136 (13DEC04)
05-0510-5
TX,0510,JC2022 –19–31AUG04–6/9
444J, 544J, 624J Loader 121304
PN=161
Cooling System NOTE: Upper and lower radiator mounting hardware use a spacer between the mounting frame and radiator.
–UN–30OCT03
15. Remove upper and lower radiator mounting hardware (19 and 16). 16. Remove left side radiator mounting hardware (11).
T195796A
17. Slide radiator forward and remove through left side of machine. Upper Radiator Mounting Hardware
18. Install radiator through left side of machine.
3—Air Conditioning Condenser 14—Radiator 19—Upper Radiator Mounting Hardware
19. Install left side radiator mounting hardware (11). 20. Install hydraulic oil cooler-to-radiator mounting hardware (18). 21. Install upper radiator mounting hardware (19) with spacer. 22. Install lower radiator mounting hardware (16) with spacer. 23. Install radiator drain valve (15). 05 0510 6
24. Install lower plate (10) between engine and radiator (14). 25. Install coolant reservoir hose (8) to radiator.
Continued on next page
TM2136 (13DEC04)
05-0510-6
TX,0510,JC2022 –19–31AUG04–7/9
444J, 544J, 624J Loader 121304
PN=162
Cooling System 26. Install upper radiator hose. 27. Install lower radiator hose (9) to radiator (14) and engine outlet. 28. Install rear engine access panel (6) and rear engine access panel mounting hardware (7).
T201857A
–UN–23JUL04
29. Install cooling package access doors to both sides of machines.
TX,0510,JC2022 –19–31AUG04–8/9
30. Install air conditioning condenser (3) mounting hardware (4).
–UN–22OCT03
31. Support rear hood (5) and assembly to hinge. Install right hinge mounting hardware (2). 32. Fill radiator. See Drain and Refill Capacities. (Operator’s Manual.)
T195618A
444J Drain and Refill Capacities 544J Drain and Refill Capacities Hood
644J Drain and Refill Capacities 1—Right Hinge Plate 2—Hinge Plate Mounting Hardware (3 used) 3—Air Conditioning Condenser 4—Air Conditioning Condenser Mounting Hardware (4 used) 5—Hood
TX,0510,JC2022 –19–31AUG04–9/9
TM2136 (13DEC04)
05-0510-7
444J, 544J, 624J Loader 121304
PN=163
05 0510 7
Cooling System
Hydraulic Oil Cooler Remove and Install This procedure valid for 444J and 544J only. 624J hydraulic oil cooler can be removed without removing radiator. 1. Remove radiator. See Radiator Remove and Install. (Group 0510.)
MX10672,0000019 –19–21OCT03–1/2
2. Remove intercooler tubes (1), cap and plug openings. 3. Apply vacuum to hydraulic reservoir. 4. Disconnect upper and lower hydraulic hoses (4 and 6) at the hydraulic cooler (2) and seal. 5. Remove hydraulic hose fittings (5) from hydraulic oil cooler. 6. Remove mounting hardware (3) and hydraulic oil cooler (2). 7. Install hydraulic oil cooler (2) into cooling package through right side of machine. 8. Install mounting hardware (3).
–UN–22OCT03
9. Install hydraulic hose fittings (5) to the hydraulic oil cooler. 10. Connect upper and lower hydraulic hoses (4 and 6) to the hydraulic cooler (2).
T195658A
05 0510 8
11. Release vacuum from hydraulic oil reservoir. 12. Remove caps and plugs on turbocharger and intake manifold and install intercooler tubes to intercooler and engine. 13. Install radiator. See Radiator Remove and Install. (Group 0510.)
1—Intercooler Tube 2—Hydraulic Oil Cooler 3—Hydraulic Oil Cooler Mounting Hardware (3 used) 4—Upper Hydraulic Oil Cooler Hose 5—Hydraulic Oil Cooler Hose Fittings 6—Lower Hydraulic Oil Cooler Hose
MX10672,0000019 –19–21OCT03–2/2
TM2136 (13DEC04)
05-0510-8
444J, 544J, 624J Loader 121304
PN=164
Cooling System
Transmission Oil Cooler Remove and Install 1. Open left cooling package access door.
MX10672,000001B –19–21OCT03–1/2
2. Disconnect and plug transmission hoses (1) from transmission cooler (2). 3. Remove transmission cooler mounting hardware (3) and remove cooler (2). 4. Install transmission cooler into machine. 5. Install transmission cooler mounting hardware (3). 6. Connect cooler hoses (1) to transmission cooler (2). 7. Close cooling package access doors. 8. Check transmission oil level.
T195659A
–UN–30OCT03
1—Transmission Oil Cooler Hose 2—Transmission Oil Cooler 3—Transmission Oil Cooler Mounting Hardware (6 used)
Transmission Oil Cooler-Left Side of Machine
MX10672,000001B –19–21OCT03–2/2
Cooling Package Plenum Remove and Install Metric Lifting Eyebolt . . . . . . . . . . . . . . . . . . . JT05549 Used to remove cooling plenum housing
Continued on next page
TM2136 (13DEC04)
05-0510-9
MX10672,000001C –19–06NOV03–1/8
444J, 544J, 624J Loader 121304
PN=165
05 0510 9
Cooling System
Continued on next page
MX10672,000001C –19–06NOV03–2/8
05 0510 10
TM2136 (13DEC04)
05-0510-10
444J, 544J, 624J Loader 121304
PN=166
Cooling System
–UN–23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
X9811
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Park machine and lower bucket to ground and allow engine to cool. CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
05 0510 11
2. Open rear hood and release pressure from radiator overflow reservoir. 3. Open cooling package rear door to access radiator drain valve and drain engine coolant. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities
Continued on next page
TM2136 (13DEC04)
05-0510-11
MX10672,000001C –19–06NOV03–3/8
444J, 544J, 624J Loader 121304
PN=167
Cooling System
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Remove cooling package access door from both sides of machine by opening 30 degrees and lifting upward off hinge pins. Specification Access Door—Weight ....................................................................... 31 kg 68 lb
5. Remove refrigerant. See Evacuate R134a System. (Group 1830.) 6. Disconnect air conditioning hoses at condenser, cap and plug all openings. 7. Remove air conditioning hose clamps. 8. Disconnect three coolant hoses from radiator. 9. Disconnect intercooler pipes. Cap and plug all openings. 10. Apply vacuum to hydraulic oil reservoir. 05 0510 12
11. Disconnect hydraulic cooler hoses. Cap and plug all openings. 12. Disconnect transmission cooler hoses. Cap and plug all openings
Continued on next page
TM2136 (13DEC04)
05-0510-12
MX10672,000001C –19–06NOV03–4/8
444J, 544J, 624J Loader 121304
PN=168
Cooling System 13. Disconnect hydraulic hoses (2) from fan reversing valve (1) to plenum hose grommet (3). 14. Disconnect wiring harness (5) at reversing valve (1). 15. Disconnect wiring harness (6) to rear door at reversing valve wiring harness. 16. Remove cooling package plenum grommet mounting hardware (4). 17. Disconnect hydraulic hoses at axle coolers. –UN–22OCT03
18. Remove axle cooler mounting hardware and remove axle coolers.
T195672A
1—Fan Reversing Valve 2—Hydraulic Hoses to Plenum Grommet 3—Plenum Grommet 4—Plenum Grommet Mounting Hardware (3 used) 5—Wiring Harness to Fan Reversing Valve 6—Wiring Harness Connector to Rear Door
Reversing Valve Hoses and Harness
Continued on next page
TM2136 (13DEC04)
05-0510-13
MX10672,000001C –19–06NOV03–5/8
444J, 544J, 624J Loader 121304
PN=169
05 0510 13
Cooling System 19. Remove case drain hose (8) from fan motor (7). 20. Remove top rear mounting hardware from intercooler.
–UN–24OCT03
21. Remove top rear mounting hardware from transmission oil cooler.
T195675A
22. Install Metric Lifting Eyebolts JT05549 into threaded holes in top rear of intercooler mounting hardware holes and top rear of transmission oil cooler mounting hardware holes. Fan Motor
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
7—Fan Motor 8—Fan Motor Case Drain Hose
23. Support cooling package plenum with appropriate lifting device.
05 0510 14
Specification 444J Cooling Package Plenum Assembly—Weight .......................................................................... 303 kg 667 lb 544J Cooling Package Plenum Assembly—Weight .......................................................................... 305 kg 669 lb 624J Cooling Package Plenum Assembly—Weight .......................................................................... 343 kg 755 lb
Continued on next page
TM2136 (13DEC04)
05-0510-14
MX10672,000001C –19–06NOV03–6/8
444J, 544J, 624J Loader 121304
PN=170
Cooling System 24. Remove cooling package plenum mounting hardware (9) both sides.
–UN–22OCT03
NOTE: Feed plenum grommet (3) with hoses and harness down through opening When removing plenum package. 25. Remove cooling package plenum.
T195673A
26. Using appropriate lifting device lift cooling package plenum into place and feed plenum grommet (3) with hoses and harness up through opening. Cooling Package Plenum Mounting Hardware
27. Install cooling package plenum mounting hardware (9).
9—Cooling Package Plenum Mounting Hardware
28. Remove lifting eyelets. 29. Install intercooler and transmission oil cooler mounting hardware. 30. Install cooling package plenum grommet and mounting hardware (4). 31. Install case drain hose (8) to fan motor (7). 32. Install axle coolers and mounting hardware.
05 0510 15
33. Install hydraulic hoses to axle coolers. 34. Connect wiring harness (6) to rear door wiring harness at reversing valve (1). 35. Connect wiring harness (5) to reversing valve (1). 36. Connect hydraulic hoses (2) to fan reversing valve (1) from plenum hose grommet (3). 37. Remove plugs and caps and connect transmission cooler hoses to transmission oil cooler. 38. Remove plugs and caps and connect hydraulic cooler hoses to hydraulic oil cooler. 39. Remove plugs and caps and Install intercooler pipes from engine to intercooler. 40. Install three coolant hoses at the radiator.
Continued on next page
TM2136 (13DEC04)
05-0510-15
MX10672,000001C –19–06NOV03–7/8
444J, 544J, 624J Loader 121304
PN=171
Cooling System 41. Remove plugs and caps and install air conditioning hoses at condenser and install hose clamps inside of cooling package door.
NOTE: When reconnecting system using R134a refrigerant, be sure to apply thin coat of PAG (Polyakyleneglycol refrigerant oil) to the fittings and O-rings. 42. Install new O-rings on air conditioner hoses. 43. Charge air conditioning system. See Charge R134a System if equipped with air conditioning. (Group 1830.) 44. Fill coolant system. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities
MX10672,000001C –19–06NOV03–8/8
05 0510 16
TM2136 (13DEC04)
05-0510-16
444J, 544J, 624J Loader 121304
PN=172
Group 0520
Intake System Air Cleaner Remove and Install 1. Park machine and turn battery disconnect switch OFF. 2. Disconnect wiring harness connector from air filter restriction switch.
Continued on next page
MX10672,000002E –19–20NOV03–1/3
05 0520 1
TM2136 (13DEC04)
05-0520-1
444J, 544J, 624J Loader 121304
PN=173
Intake System
T193504
–UN–19AUG03
05 0520 2
Continued on next page
TM2136 (13DEC04)
05-0520-2
MX10672,000002E –19–20NOV03–2/3
444J, 544J, 624J Loader 121304
PN=174
Intake System 1—Lock Nut (4 used) 2—Elbow Fitting 3—Screw (4 used) 4—Washer (4 used) 5—Primary Filter Element 6—Secondary Filter Element
7—Air Filter Housing 8—Air Filter Housing Cover 9—Dust Valve 10—Air Filter Housing Mounting Bands (2 used) 11—Air Filter Hose to Turbocharger Clamp
12—Air Filter Hose Clamp (2 used) 13—Tie Band 14—Air Filter Restriction Switch
15—Air Intake Hose 16—Air Filter to Turbocharger Hose 17—Air Filter Mounting Spacer (4 used)
3. Loosen hose clamp (12) on hose (16) from turbocharger and separate from air cleaner.
7. Install air filter assembly with mounting hardware (1, 3, 4, and 17).
4. Remove screws (3), lock nuts (1) and washers (4) along with spacers (17).
8. Connect hose (16) from turbocharger to air filter housing (17) and tighten clamp (12).
5. Remove air filter assembly.
9. Connect wiring harness connector to air filter restriction switch.
6. Remove cover (8) and inspect elements for wear or damage. Replace as necessary.
10. Turn battery disconnect switch ON.
MX10672,000002E –19–20NOV03–3/3
Inspect Element IMPORTANT: A damaged or dirty element may cause engine damage.
T90684
1. If the element shows damage. 2. If element will not clean. 3. After 1000 hours service or annually.
–UN–10NOV88
Install a new primary element:
Install a new secondary element: 1. If the primary element is damaged and needs to be replaced. 2. If the element is visibly dirty. 3. After 1000 hours service or annually. Do not clean a secondary element. Install a new element carefully centering it in the canister. 1. Inspect element and gasket for damage. 2. Air restriction indicator will not signal correctly if an element has a break or is not correctly sealed in air cleaner housing. Throw away element that has the slightest damage. If gasket is broken or missing, install a new element.
03T,55,C67 –19–24JUL91–1/1
TM2136 (13DEC04)
05-0520-3
444J, 544J, 624J Loader 121304
PN=175
05 0520 3
Intake System
05 0520 4
TM2136 (13DEC04)
05-0520-4
444J, 544J, 624J Loader 121304
PN=176
Group 0530
External Exhaust System Muffler Remove and Install CAUTION: Prevent possible injury from hot muffler. Wait until muffler is cool to the touch before removing. 1. Park machine safely and lower bucket to ground. 2. Turn battery disconnect switch to OFF. 3. Open engine access doors.
TX,0530,111288 –19–15NOV03–1/2
4. Remove clamp (2) connecting muffler inlet to turbocharger. 4 5. Remove lock nuts (3) from U-bolt (4). 6. Rotate bottom of muffler forward to clear exhaust stack and remove out right side of machine.
05 0530 1
1 7. Install muffler. 8. Install clamp (2) at turbocharger and tighten to specification.
2
Specification Turbocharger-to Muffler Clamp— Torque .............................................................................................. 7 N•m 44 lb-in.
10. Turn battery disconnect switch to ON.
5
1—Muffler 2—Clamp 3—Lock Nut (2 used) 4—U-bolt 5—Muffler Bracket
T196253
11. Close engine access doors.
–UN–13NOV03
9. Install U-bolt (4) with lock nuts (3).
3 Muffler
TX,0530,111288 –19–15NOV03–2/2
TM2136 (13DEC04)
05-0530-1
444J, 544J, 624J Loader 121304
PN=177
External Exhaust System
05 0530 2
TM2136 (13DEC04)
05-0530-2
444J, 544J, 624J Loader 121304
PN=178
Group 0560
External Fuel Supply Systems Fuel Tank Remove and Install 1. Turn battery disconnect switch OFF. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Remove Counterweights. See Counterweights Remove and Install. (Group 1749.) Continued on next page
TX,0560,111289 –19–04NOV03–1/5
05 0560 1
TM2136 (13DEC04)
05-0560-1
444J, 544J, 624J Loader 121304
PN=179
External Fuel Supply Systems
T193515
–UN–19AUG03
05 0560 2
Fuel Tank Remove and Install
Continued on next page
TM2136 (13DEC04)
05-0560-2
TX,0560,111289 –19–04NOV03–2/5
444J, 544J, 624J Loader 121304
PN=180
External Fuel Supply Systems 1—Lock Nut 2—Cap Screw 3—Cap Screw 4—Adapter 5—O-Ring 6—Fuel Tank 7—Clamp 8—Clamp 9—Fitting
10—Compression Spring 11—Chain Link 12—Fitting 13—Hose 14—Hose 15—Fuel Sender 16—Screw 17—Washer 18—Gasket
19—Breather Tube 20—Hose Clamp 21—Tie Band 22—Breather 23—Clamp 24—Clamp 25—Clamp 26—O-Ring
3. Tag and disconnect hoses (14 and 19) from tank.
27—Filler Cap 28—Gasket 29—Funnel 30—O-Ring 31—Check Valve 32—Fuel Line 33—Fuel Line 34—Fuel Line
6. Tag and disconnect wiring harness from fuel gauge sending unit (15).
4. Tag and disconnect hose (13) from primary fuel filter. 5. Remove fuel from fuel tank and place in clean container for reuse.
Continued on next page
TX,0560,111289 –19–04NOV03–3/5
05 0560 3
TM2136 (13DEC04)
05-0560-3
444J, 544J, 624J Loader 121304
PN=181
External Fuel Supply Systems
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–24NOV03
7. Position appropriate lifting device (35) beneath fuel tank guard (36).
T196208A
8. Remove fuel tank guard mounting hardware and lower guard to ground. Specification Fuel Tank Guard (444J)— Weight—Approximate ...................................................................... 227 kg 500 lb Full Fuel Tank with Guard (444J)—Weight—Approximate ........................................................ 507 kg 1115 lb Fuel Tank Guard (544J)— Weight—Approximate ...................................................................... 273 kg 600 lb Full Fuel Tank with Guard (544J)—Weight—Approximate ........................................................ 634 kg 1395 lb Fuel Tank Guard (624J)— Weight—Approximate ...................................................................... 283 kg 623 lb Full Fuel Tank with Guard (624J)—Weight—Approximate ........................................................ 666 kg 1465 lb 05 0560 4
Fuel Tank Guard 35—Lifting device 36—Fuel Tank Guard
9. Remove fuel tank retaining straps and separate fuel tank from guard. 10. Replace parts as necessary. 11. Install fuel tank to guard. Install fuel tank retaining straps with mounting hardware. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Raise fuel tank guard and tank into place. Install mounting hardware and torque to specification. Specification Fuel Tank Mounting Hardware— Torque .......................................................................................... 318 N•m 235 lb-ft
Continued on next page
TM2136 (13DEC04)
05-0560-4
TX,0560,111289 –19–04NOV03–4/5
444J, 544J, 624J Loader 121304
PN=182
External Fuel Supply Systems 13. Connect wiring harness to fuel gauge sending unit (15). 14. Connect hoses (13, 14, and 19) to fuel tank. 15. Install counterweights. See Counterweight Remove and Install. (Group 1749.) 16. Turn battery disconnect switch ON.
TX,0560,111289 –19–04NOV03–5/5
Primary Fuel Filter (Water Separator) Remove and Install 1. Open left engine side shield to access primary fuel filter (water separator). 2. Put container under drain valves (4 and 5).
–UN–06NOV03
3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base.
T196173A
1—Bleed Screw (Primary Filter) 2—Bleed Screw (Final Filter) 3—Final Fuel Filter 4—Drain Valve (Primary Filter) 5—Drain Valve (Final Filter) 6—Primary Fuel Filter
Fuel Filter Location (444J Shown)
Continued on next page
TM2136 (13DEC04)
05-0560-5
TX,0560,111293 –19–06OCT98–1/2
444J, 544J, 624J Loader 121304
PN=183
05 0560 5
External Fuel Supply Systems 4. Remove fuel inlet line (1) and fuel drain plug (3). 5. Flush any debris from filter base (2).
–UN–06NOV03
6. Install fuel inlet drain plug and fuel inlet line. 7. Install filter element to fuel filter base.
T196172A
8. Close side shield. 9. Dispose of waste properly. Fuel Filter Base Identification
1—Fuel Inlet Base 2—Filter Base 3—Drain Plug
TX,0560,111293 –19–06OCT98–2/2
05 0560 6
TM2136 (13DEC04)
05-0560-6
444J, 544J, 624J Loader 121304
PN=184
Section 07
Dampener Drive Contents Page
Group 0752—Elements Remove and Install Dampener . . . . . . . . . . .07-0752-1
07
TM2136 (13DEC04)
07-1
444J, 544J, 624J Loader 121304
PN=1
Contents
07
TM2136 (13DEC04)
07-2
444J, 544J, 624J Loader 121304
PN=2
Group 0752
Elements Remove and Install Dampener
3. Remove covers (A) and dampener (B). Specification Dampener-to-Flywheel Cap Screw—Torque ............................................................................... 68 N•m 50 lb-ft
T6564AS
2. Remove drive shaft. See Universal Joint and Drive Shaft Remove and Install (See Group 0325.)
–UN–27OCT88
1. Remove engine side shields.
A—Cover B—Dampener
TX,0752,JC1987 –19–02APR97–1/1
07 0752 1
TM2136 (13DEC04)
07-0752-1
444J, 544J, 624J Loader 121304
PN=187
Elements
07 0752 2
TM2136 (13DEC04)
07-0752-2
444J, 544J, 624J Loader 121304
PN=188
Section 09
Steering System Contents Page
Group 0960—Hydraulic System Steering Valve Remove and Install . . . . . . . .09-0960-1 Steering Column Remove and Install . . . . . .09-0960-4 Steering Cylinders Remove and Install . . . . .09-0960-6 Loader Start-Up Procedure (Steering Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-8
09
TM2136 (13DEC04)
09-1
444J, 544J, 624J Loader 121304
PN=1
Contents
09
TM2136 (13DEC04)
09-2
444J, 544J, 624J Loader 121304
PN=2
Group 0960
Hydraulic System Steering Valve Remove and Install CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area. 1. Install frame locking bar.
T109460B
–UN–08MAY97
2. Stop engine.
TX,0960,JC2036 –19–07NOV03–1/4
–UN–23AUG88
CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures.
X9811
If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components. If ride control is operational, perform Ride Control Accumulator Hydraulic Discharge. (Group 9025-25.)
09 0960 1
3. Drain reservoir or pull vacuum on reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 4. Remove front cab shield. 5. Disconnect and identify five hoses. Plug and cap lines.
Continued on next page
TM2136 (13DEC04)
09-0960-1
TX,0960,JC2036 –19–07NOV03–2/4
444J, 544J, 624J Loader 121304
PN=191
Hydraulic System
T196804
–UN–08DEC03
09 0960 2
T196804 Remove Steering Terminal
Continued on next page
TM2136 (13DEC04)
09-0960-2
TX,0960,JC2036 –19–07NOV03–3/4
444J, 544J, 624J Loader 121304
PN=192
Hydraulic System 1—Isolator 2—Cap Screw 3—Washer
4—Bracket 5—Washer
6—Steering Column 7—Lock Nut
9—Washer 8—Isolator
6. Remove cover from steering column.
10. Repair or replace parts as necessary.
7. Remove lock nuts (7), washers (8), rubber mounts (9), and cap screws (10).
Steering Valve:—Specification Isolator Cap Screw—Torque ................................................... 57 N•m 42 lb-ft Valve-to-Plate Cap Screw— Torque...................................................................................... 27 N•m 20 lb-ft
8. Remove steering valve. 9. Remove cap screws (2) and washers (3) to remove bracket (4) from steering column (6).
TX,0960,JC2036 –19–07NOV03–4/4
09 0960 3
TM2136 (13DEC04)
09-0960-3
444J, 544J, 624J Loader 121304
PN=193
Hydraulic System
Steering Column Remove and Install
T195299
–UN–21OCT03
09 0960 4
Steering Column Remove and Install Continued on next page
TM2136 (13DEC04)
09-0960-4
TX,0960,MA15 –19–07NOV03–1/2
444J, 544J, 624J Loader 121304
PN=194
Hydraulic System 1—Cover 2—Switch 3—Nut 4—Lock Washer 5—Knob 6—Steering Wheel
7—Snap Ring 8—Sealing Washer 9—Screw 10—Cap Screw 11—Dowel Pin 12—Screw
1. Remove gear shift and directional controls.
13—Screw 14—Brush Set 15—Kit 16—Kit 17—Washer
18—Spring Assembly 19—Kit 20—Kit 21—Steering Column 22—Kit
5. Apply NEVER-SEEZ Lubricant or an equivalent to steering column pivot bores.
2. Disconnect spring (18). 6. Install parts. 3. Remove cap screws (9). 4. Remove parts (1-8) and (13-15). Apply NEVER-SEEZ Lubricant or an equivalent to threads of steering wheel retaining nut.
Steering Column:—Specification Steering Wheel-to-Steering Column Nut—Torque ............................................................... 68 N•m 50 lb-ft
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TX,0960,MA15 –19–07NOV03–2/2
09 0960 5
TM2136 (13DEC04)
09-0960-5
444J, 544J, 624J Loader 121304
PN=195
Hydraulic System
Steering Cylinders Remove and Install CAUTION: Install locking bar to prevent movement of frames. –UN–23AUG88
1. Install frame locking bar. Stop engine.
X9811
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 2. Turn steering wheel back and forth to release hydraulic pressure in the system. 3. Disconnect lines from cylinder. Close all openings using caps and plugs. CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device. 4. Remove pin from rod and head end of cylinder. 09 0960 6
Specification Steering Cylinder—Weight— Approximate....................................................................................... 50 kg 100 lb
CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device. 5. Remove cylinder from machine. Repair or replace as necessary.
Continued on next page
TM2136 (13DEC04)
09-0960-6
TX,0960,RB89 –19–23SEP98–1/2
444J, 544J, 624J Loader 121304
PN=196
Hydraulic System IMPORTANT: Pre-fill cylinders prior to connecting hydraulic lines. 6. Install cylinder and connect lines. 7. Install one spacer under head end. If required, install one spacer over head end until cylinder does not bind. Install head end pin. 8. Fill gap under rod end with spacers and then install one additional spacer. Fill gap over rod end with spacers. Install pin. IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the Loader Start-Up Procedure must be performed to prevent oil from “dieseling” inside the cylinder. 9. Perform Loader Start-Up Procedure (Steering Cylinder). (See procedure in this group.)
TX,0960,RB89 –19–23SEP98–2/2
09 0960 7
TM2136 (13DEC04)
09-0960-7
444J, 544J, 624J Loader 121304
PN=197
Hydraulic System
Loader Start-Up Procedure (Steering Cylinder) IMPORTANT: This procedure must be preformed whenever boom, or bucket cylinders are purged of oil. Failure to do so will result in internal damage to components. 1. Remove loader frame access cover. 2. Reduce system pressure to specifications. . (Group 9025-05.) Specification Load Sense Relief Valve— Pressure ......................................................................... 8274—8963 kPa 82.74—89.63 bar 1200—1300 psi
IMPORTANT: Perform procedure with engine at low idle (no acceleration). 3. Slowly articulate the loader 3/4 turn to the right and then 3/4 turn to the left. Do not make contact at loader frame stops. 4. Repeat previous step four times. 5. Articulate the loader fully to the right and then fully to the left. Repeat four times. 6. Adjust system pressure to specifications. See Maximum System Pressure Test. (Group 9025-05.) 7. Install loader frame access cover.
09 0960 8 CED,OUOE024,236 –19–23SEP98–1/1
TM2136 (13DEC04)
09-0960-8
444J, 544J, 624J Loader 121304
PN=198
Section 10
Service Brakes Contents Page
Group 1011—Active Elements Remove and Install Brake Assembly . . . . . . .10-1011-1 Group 1060—Hydraulic System Brake Valve Remove and Install . . . . . . . . . .10-1060-1 Brake Accumulator Remove and Install. . . . .10-1060-3
10
TM2136 (13DEC04)
10-1
444J, 544J, 624J Loader 121304
PN=1
Contents
10
TM2136 (13DEC04)
10-2
444J, 544J, 624J Loader 121304
PN=2
Group 1011
Active Elements Remove and Install Brake Assembly 1. Remove axle and differential. For front axle See Front Axle and Differential Remove and Install. (Group 0200.) For rear axle See Rear Axle and Differential Removal. (Group 200.) 2. Remove and inspect brakes, replace as necessary. See Replace Brakes. (CTM150.) 3. Install axle and differential. For front axle See Front Axle and Differential Remove and Install. (Group 0200.) For rear axle See Rear Axle and Differential Installation. (Group 0200.)
CED,OUOE003,2004 –19–04DEC03–1/1
10 1011 1
TM2136 (13DEC04)
10-1011-1
444J, 544J, 624J Loader 121304
PN=201
Active Elements
10 1011 2
TM2136 (13DEC04)
10-1011-2
444J, 544J, 624J Loader 121304
PN=202
Group 1060
Hydraulic System Brake Valve Remove and Install
X9811
–UN–23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source. 1. Lower boom to ground and place control lever in float position. 2. With machine OFF apply brakes approximately 30 times to discharge both accumulators. 3. Remove shielding trim on front and right side of cab for access. 4. Drain or apply vacuum to hydraulic reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities
10 1060 1
Continued on next page
TM2136 (13DEC04)
10-1060-1
TX,1060,JC2026 –19–04DEC03–1/3
444J, 544J, 624J Loader 121304
PN=203
Hydraulic System
T194460
–UN–02SEP03
10 1060 2
Continued on next page
TM2136 (13DEC04)
10-1060-2
TX,1060,JC2026 –19–04DEC03–2/3
444J, 544J, 624J Loader 121304
PN=204
Hydraulic System 1—Screw 2—Washer 3—Hose Fitting 4—Check Valve 6—Pedal Assembly 7—Push Rod 8—Clip 9—Pin 10—Boot 11—Clamp and Hardware Kit 12—Support 13—Lock Nut 14—Pin 15—Clamp 16—Snap Ring
17—Lock Washer 18—Kit 20—Pin 21—Roller 22—Pedal Assembly 23—Push Rod 25—Rocker Arm 26—Bearing 27—Switch 28—Check Valve 29—Kit 31—Nut 32—Screw 33—O-Ring
34—Linkage 35—Nut 36—Screw 37—Tie Rod End 38—O-Ring 39—Snap Ring 40—Support 41—Shaft 42—Sensor 43—Support 44—Brake Valve 45—Seal Kit 46—Seal 47—O-Ring
5. Disconnect hydraulic hoses and electrical harnesses. Remove valve.
48—Screw 49—Lock Nut 50—O-Ring 51—O-Ring 52—O-Ring 53—O-Ring 54—Gasket 55—Spring 56—Spring 57—O-Ring 59—Switch 60—Support 61—Washer 62—Snap Ring
8. Install brake valve. 9. Connect hydraulic hoses and electrical harnesses.
6. Disassemble and assemble as shown. 10. Fill hydraulic reservoir or remove vacuum. 7. Replace parts as necessary.
TX,1060,JC2026 –19–04DEC03–3/3
Brake Accumulator Remove and Install 1. Perform Ride Control Accumulator Hydraulic Discharge procedure. 2. Perform Brake Accumulator Precharge Test and Boom Down Accumulator Precharge Test until accumulators are fully discharged.
NOTE: See Hydraulic System Component Location (Group 9025-15) for brake accumulator hose routing. 3. Remove hoses from brake accumulators. 10 1060 3
4. Remove accumulator mounting brackets.
NOTE: Accumulator is not serviceable. New accumulators are precharged. 5. Replace parts as necessary. 6. Install accumulators and connect hydraulic hoses.
TX,1060,JC2028 –19–04DEC03–1/1
TM2136 (13DEC04)
10-1060-3
444J, 544J, 624J Loader 121304
PN=205
Hydraulic System
10 1060 4
TM2136 (13DEC04)
10-1060-4
444J, 544J, 624J Loader 121304
PN=206
Section 11
Park Brake Contents Page
Group 1111—Active Elements Park Brake Remove and Install . . . . . . . . . . .11-1111-1 Park Brake Disassemble and Assemble . . . .11-1111-4 Group 1160—Hydraulic System Park Brake Valve Remove and Install . . . . .11-1160-1
11
TM2136 (13DEC04)
11-1
444J, 544J, 624J Loader 121304
PN=1
Contents
11
TM2136 (13DEC04)
11-2
444J, 544J, 624J Loader 121304
PN=2
Group 1111
Active Elements Park Brake Remove and Install CAUTION: Prevent possible injury from unexpected machine movement. Never rely on loader bucket to keep machine from moving. Machine can unexpectedly roll, resulting in death or serious injury. Always block wheels to hold machine when working on park brake. 1. Park machine on level surface. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area. 2. Install frame locking bar. 3. Lower bucket to ground. 4. Stop engine. This will engage park brake. 5. Place blocks in front and behind tires.
Continued on next page
TX,1111,JC2031 –19–12OCT98–1/3
11 1111 1
TM2136 (13DEC04)
11-1111-1
444J, 544J, 624J Loader 121304
PN=209
Active Elements
–UN–23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
–UN–01OCT96
X9811
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 6. Remove park brake hydraulic line (C).
T104177
7. Remove drive shafts (A and D). 8. Remove mounting cap screws (E). CAUTION: Prevent possible crushing injury, use appropriate lifting device.
A—Front Drive Shaft B—Park Brake C—Park Brake Hydraulic Line D—Articulation Drive Shaft E—Cap Screw (4 used)
Specification Park Brake Assembly—Weight— Approximate....................................................................................... 43 kg 95 lb
9. Remove park brake (B).
Continued on next page
TX,1111,JC2031 –19–12OCT98–2/3
11 1111 2
TM2136 (13DEC04)
11-1111-2
444J, 544J, 624J Loader 121304
PN=210
Active Elements IMPORTANT: Do not overfill park brake. Fill only to port (A). Capacity of the park brake is 300 mL (10 oz). Specification Park Brake Oil—Capacity— Approximate.................................................................................... 300 mL 10 oz
10. Check park brake oil level at check port (A). Add oil as necessary to fill port (B). Allow oil to drain to bottom of port (A) before installing plug to prevent overfilling. 11. Install new park brake. Tighten mounting cap screws to specification.
–UN–18FEB97
Specification Park Brake Mounting Cap Screw—Torque ............................................................................. 350 N•m 255 lb-ft
12. Place NEVER-SEEZ on park brake shaft (C).
IMPORTANT: Do not reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.
T107465
13. Install universal yoke on park brake shaft such that holes between front and rear yokes are in alignment. Install drive shafts. A—Oil Level Check Port B—Oil Fill Port C—Park Brake Shaft
14. Install drive shaft universal joint cap screws. Tighten cap screws. Specification 444J Drive Shaft Cap Screw— Torque ............................................................................................ 45 N•m 32 lb-ft (544J, 624J) Drive Shaft Cap Screw—Torque ............................................................................... 78 N•m 58 lb-ft
15. Install park brake hydraulic line.
11 1111 3
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
TX,1111,JC2031 –19–12OCT98–3/3
11-1111-3
444J, 544J, 624J Loader 121304
PN=211
Active Elements
Park Brake Disassemble and Assemble
Continued on next page
TM2136 (13DEC04)
11-1111-4
TP55468
–UN–30APR97
11 1111 4
TX,1111,JC2032 –19–23OCT03–1/7
444J, 544J, 624J Loader 121304
PN=212
Active Elements 1—Brake 2—Cover Plate 3—Gasket 4—Housing 5—Bearing (2 used) 6—Bearing Cup 7—Bearing Cone 8—Universal Drive Shaft 9—Snap Ring 10—Snap Ring Retainer
11—Yoke 12—Washer (544J) 13—Nut 14—Retainer 15—Seal (2 used) 16—Seal (2 used) 17—Fitting (2 used) 18—Relief Valve 19—O-Ring (2 used) 20—Spring (18 used)
21—Compression Spring (18 used) 22—Pin (2 used) 23—Brake Disk 24—Piston 25—O-Ring 26—O-Ring 27—Screw (6 used) 28—Brake Disk (5 used—444J) (7 used—544J)
1. Remove flange nut (13), washer (12) (544J only), and yoke (11). CAUTION: Cover and cap screws are under pressure. Remove cap screws evenly to avoid possible injury.
29—Brake Disk (5 used—444J) (7 used—544J) 30—Washer (4 used) 31—Cap Screw (4 used) 32—Yoke 33—Elbow Fitting 34—O-Ring 35—O-Ring
5. Remove brake disk (23) from housing. 6. Remove springs (20), compression springs (21) and spring retainer (14). 7. Remove seals (15 and 16) from housing. 8. Remove bearing cup (6).
2. Remove cap screws (27) evenly. 3. Remove cover plate (2) from housing (4). 4. Remove shaft with brake disks and separator plates (28 and 29).
Continued on next page
TX,1111,JC2032 –19–23OCT03–2/7
11 1111 5
TM2136 (13DEC04)
11-1111-5
444J, 544J, 624J Loader 121304
PN=213
Active Elements 9. Remove bearing cone (7) using a bearing puller from one end of shaft. 10. Remove bearing, disks, and plates from shaft. 11. Press other bearing off shaft. 12. Remove piston (24) from cover plate. 13. Remove O-rings (25 and 26) from piston. 14. Remove seals (15 and 16) and bearing cup (6) from cover plate. 15. Replace parts as necessary.
–UN–03OCT96
IMPORTANT: High tolerance bearings are required in this application. Use only John Deere sourced bearings when replacing. 16. Press bearing cup (6) against shoulder in cover plate.
T101612
17. Lubricate O-rings (25 and 26) and piston (24) with J20C oil. Install inner and outer O-rings on piston.
Continued on next page
TX,1111,JC2032 –19–23OCT03–3/7
11 1111 6
TM2136 (13DEC04)
11-1111-6
444J, 544J, 624J Loader 121304
PN=214
Active Elements 18. Install piston (A) in cover so that dowel pins are centered between slots. 19. Press bearing cup (6) against shoulder in housing. 20. Install spring retainer (14), springs (20) and compression springs (21). 21. Remove dowel pins (22) from cover plate and install in housing. 22. Install brake disk (23). 23. Install bearing cone (7) on shaft end with long spline.
–UN–03OCT96
24. Dip brake disks and separator plates in J20C oil. Install brake disk (28) then alternate between separator plate (29) and brake disk ending with a separator plate on top. 25. Install bearing cone (7) against shoulder.
T101611
26. Insert shaft with brake disks and separator plates with long spline end first into housing. Align separator plates on dowel pins. 27. Install two M12 aligning studs into housing. A—Piston in Cover
28. Install gasket (3) on cover plate (2). 29. Install cover making sure dowel pins align in cover onto housing using cap screws. 30. Tighten cap screws (27) evenly. 31. Tighten cap screws to specification. Specification Park Brake Housing Cap Screw— Torque .......................................................................................... 122 N•m 90 lb-ft
NOTE: Bearing and race are a select pair to create a shaft end play of 0.051—0.305 mm (0.002—0.012 in.). 32. Install seals (15 and 16) against shoulder in housing.
11 1111 7
Continued on next page
TM2136 (13DEC04)
11-1111-7
TX,1111,JC2032 –19–23OCT03–4/7
444J, 544J, 624J Loader 121304
PN=215
Active Elements 33. Install seals (15 and 16) against shoulder in cover plate. 34. Install snap ring (9) and snap ring retainer (10) on universal drive shaft (8). 35. Place NEVER-SEEZ Lubricant on shaft splines. 36. Install yoke (11), washer (12) (544J only) and nut (13). Tighten nut. Specification Park Brake Yoke Nut—Torque .................................................... 407 N•m 300 lb-ft
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TX,1111,JC2032 –19–23OCT03–5/7
IMPORTANT: Do not overfill park brake. Fill only to port (A). Capacity of the park brake is 300 mL (10 oz). Specification Park Brake Oil—Capacity— Approximate.................................................................................... 300 mL 10 oz
37. Fill park brake at port (A) with 300 mL (10 oz) of oil. Allow oil to drain to bottom of level plug before installing plug to prevent overfilling. 38. Bench test the park brake. 39. Install a porta-power to the park brake.
–UN–01NOV96
40. Slowly increase pressure until the shaft rotates freely. Acceptable range 896—1068 kPa (8.9—10.6 bar) (130—155 psi). 41. Increase the pressure to 3450 kPa (34.5 bar) 500 psi.
T102286
42. Slowly release brake pressure until free rotation of the shaft stops. Acceptable range not more than 210 kPa (2.1 bar) (30 psi) less than the release pressure. 11 1111 8
A—Fill Port Plug B—Drain Port Plug
Continued on next page
TM2136 (13DEC04)
11-1111-8
TX,1111,JC2032 –19–23OCT03–6/7
444J, 544J, 624J Loader 121304
PN=216
Active Elements 43. Align yokes of park brake.
T102285
–UN–03OCT96
NOTE: Replace all drive line hardware when drive line is disassembled.
TX,1111,JC2032 –19–23OCT03–7/7
11 1111 9
TM2136 (13DEC04)
11-1111-9
444J, 544J, 624J Loader 121304
PN=217
Active Elements
11 1111 10
TM2136 (13DEC04)
11-1111-10
444J, 544J, 624J Loader 121304
PN=218
Group 1160
Hydraulic System Park Brake Valve Remove and Install
X9811
–UN–23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Operate controls to release hydraulic pressure with key on and engine off. CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area. 2. Install frame locking bar.
Continued on next page
TX,1160,RB184 –19–09DEC03–1/4
11 1160 1
TM2136 (13DEC04)
11-1160-1
444J, 544J, 624J Loader 121304
PN=219
T196823
11 1160 2
–UN–10DEC03
Hydraulic System
T196823 Park Brake Solenoid Valve Manifold
Continued on next page
TM2136 (13DEC04)
11-1160-2
TX,1160,RB184 –19–09DEC03–2/4
444J, 544J, 624J Loader 121304
PN=220
Hydraulic System 1—Screw (2 used) 2—Check valve 3—Check valve Seal Kit 4—Solenoid Valve 5—Flow Control Hydraulic Valve
6—Screw (2 used) 7—High Pressure Switch 8—O-Ring 9—O-Ring
10—O-Ring (2 used) 11—Adapter 12—O-Ring (2 used) 13—Elbow Fitting
14—O-Ring 15—Elbow Fitting 16—Solenoid Valve Seal Kit
3.
TX,1160,RB184 –19–09DEC03–3/4
Remove electrical harnesses from park brake valve manifold. 4. Remove all hydraulic lines. Cap and plug openings. 5. Remove park brake manifold mounting hardware (6) and remove manifold (5).
7. Inspect for dirty, worn or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly.
T192940A
8. Install park brake manifold (5) with mounting hardware (6).
–UN–09DEC03
6. Disassemble and assemble parts as shown.
9. Install all hydraulic lines. 10. Connect electrical harnesses. 11. Remove frame locking bar.
TX,1160,RB184 –19–09DEC03–4/4
11 1160 3
TM2136 (13DEC04)
11-1160-3
444J, 544J, 624J Loader 121304
PN=221
Hydraulic System
11 1160 4
TM2136 (13DEC04)
11-1160-4
444J, 544J, 624J Loader 121304
PN=222
Section 17
Frame or Supporting Structure Contents Page
Group 1740—Frame Installation Welding Major Structure . . . . . . . . . . . . . . . .17-1740-1 Separate Engine and Loader Frame . . . . . . .17-1740-3 Upper Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-6 Lower Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-8 Group 1746—Frame Bottom Guards Front Axle Guard Remove and Install . . . . . .17-1746-1 Transmission Bottom Guard Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-1 Group 1749—Chassis Weights Counterweights Remove and Install . . . . . . .17-1749-1
TM2136 (13DEC04)
17-1
444J, 544J, 624J Loader 121304
PN=1
17
Contents
17
TM2136 (13DEC04)
17-2
444J, 544J, 624J Loader 121304
PN=2
Group 1740
Frame Installation Welding Major Structure 17 1740 1
–UN–23AUG88
CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.
TS220
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Remove paint before welding. IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF. Disconnect both negative and positive battery cables and microprocessor unit. Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. Use one of the following weld processes: • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. • AWS-ER-70S-3f wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process. Specification Weld Metal—Tensile Strength................................................... 482.6 mPa 70,000 psi Yield Strength ............................................................................ 413.7 mPa 60,000 psi Elongation ............................................................................................ 22%
Continued on next page
TM2136 (13DEC04)
17-1740-1
WELD,II –19–04DEC03–1/2
444J, 544J, 624J Loader 121304
PN=225
Frame Installation Preheat area to be repaired to allow better weld penetration. 17 1740 2
To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). Specification Structural Assemblies—Preheat Temperature ....................................................................................... 38°C 100°F Ground Engaging Tools—Preheat Temperature ..................................................................................... 177°C 350°F
To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F).
WELD,II –19–04DEC03–2/2
TM2136 (13DEC04)
17-1740-2
444J, 544J, 624J Loader 121304
PN=226
Frame Installation
Separate Engine and Loader Frame 17 1740 3
1. Park machine on smooth level surface and align frames. 2. Stop engine. CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. 3. Avoid crushing injury from bucket. Install chain around bucket and connect to boom. 4. Place service jack under center of bucket. Service jack wheels must roll freely and straight ahead when loader frame is moved forward. 5. Connect appropriate lifting device to loader frame. 6. Install shop stands under front and rear of engine frame. 7. Perform Ride Control Accumulator Hydraulic Discharge procedure. (Group 9025-20.) 8. Perform Brake Accumulator Precharge Test and Boom Down Accumulator Precharge Test until accumulators are fully discharged. (Group 9025-25.) 9. Perform Cab Remove and Install procedure until cab is removed from machine. (Group 1800.) 10. Disconnect all electrical harnesses connecting front and rear loader frames. 11. Drain hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 12. Disconnect all hydraulic lines routed from front to rear loader frame. See Hydraulic System Component Location (Group 9025-15) for hose routing.
Continued on next page
TM2136 (13DEC04)
17-1740-3
TX,1740,RB78 –19–04DEC03–1/4
444J, 544J, 624J Loader 121304
PN=227
Frame Installation 13. Disconnect drive shaft U-joints. 17 1740 4 TX,1740,RB78 –19–04DEC03–2/4
14. Remove steering cylinder pins (B). 15. Remove cap screw (E), plate (F), and spacer (D). Remove lower pivot pin (C). See Lower Pivot Bearing and Seals Remove and Install. (Group 1740.) 16. Remove upper pivot pin (A). See Upper Pivot Bearing and Seals Remove and Installprocedure. (Group 1740.)
T108046
–UN–11MAR97
A—Upper Pivot Pin B—Steering Cylinder Pin (2 used) C—Lower Pivot Pin D—Spacer E—Cap Screw F—Plate
Continued on next page
TM2136 (13DEC04)
17-1740-4
TX,1740,RB78 –19–04DEC03–3/4
444J, 544J, 624J Loader 121304
PN=228
Frame Installation 17. Slowly roll loader frame, service jack, and overhead hoist forward and away from rear loader frame. 17 1740 5
18. Replace parts as necessary. 19. Attach loader frame to engine frame. Install upper (A) and lower (C) pivot pins. 20. Connect all hydraulic hoses and electrical harnesses. IMPORTANT: Do not reuse drive shaft U-joint cap screws. Replace cap screws to avoid machine damage.
544J, 624J—Specification Transmission-to-Rear Axle Drive Shaft U-Joint—Torque .................................................................... 78 N•m 58 lb-ft
T77721
444J —Specification Transmission-to-Rear Axle Drive Shaft U-Joint—Torque .................................................................... 45 N•m 32 lb-ft
–UN–24OCT88
21. Connect drive shafts U-joints. Torque U-joint cap screws to specification.
Specification Engine-to-Transmission Drive Shaft U-Joint—Torque .................................................................... 41 N•m 30 lb-ft
22. Connect steering cylinders. Install maximum number of washers between loader frame and steering cylinder rod end. Install equal number above and below rod end. 23. Fill hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities
NOTE: Bleeding brakes is not required. Brakes are self bleeding. 24. Start machine and check for leaks.
TX,1740,RB78 –19–04DEC03–4/4
TM2136 (13DEC04)
17-1740-5
444J, 544J, 624J Loader 121304
PN=229
Frame Installation
Upper Pivot Bearing and Seals Remove and Install
T107940
–UN–13MAR97
17 1740 6
A—Pin B—Engine Frame C—Upper Seal
D—Cover E—Shim (as needed) F—Loader Frame
G—Bearing (2 used) H—Lower Seal Spacer I—Lower Seal
1. Remove upper and lower pivot pins and separate frames. Remove cap screws (L) and cover (D) with upper seal (C). Remove parts (G, H, I, and K) from loader frame bore using a puller disk against lower seal spacer with seal (H).
J—Engine Frame K—Bearing Spacer L—Cap Screw (6 used)
2. Remove seal (I) from seal spacer (H). 3. Replace parts as necessary. 4. Apply a light coat of JDM J13E4 grease to rollers in bearings (G).
NOTE: Lower seal cannot be pushed through spacer. Remove seal spacer to remove seal.
Continued on next page
TM2136 (13DEC04)
17-1740-6
TX,1740,DU882 –19–04DEC03–1/2
444J, 544J, 624J Loader 121304
PN=230
Frame Installation 5. Press lower seal (I) into seal spacer (H) with lips facing out. The seal must seat against seal spacer shoulder. 6. Install seal spacer (H) in bottom of loader frame bore. 7. Press first bearing cup into bore against seal spacer. IMPORTANT: Do not apply load to bearing cone when pressing in cup. Use old bearing race to apply load on new bearing cup to prevent bearing damage. 8. Install first bearing cone in cup. IMPORTANT: Use the same spacer (K) which was removed from the bearing set. Spacer is not interchangeable with other bearings. 9. Install bearing spacer. 10. Press second bearing cup into bore against spacer. Install second bearing cone.
11. Install upper seal (C) into cover with lip facing out. Press seal to cover shoulder. 12. Hold cover in place, measure gap between cover and frame, take readings in three places. Cover must contact top of bearing. Calculate the average of these three reading to determine shim pack required. 13. Install shims to obtain a preload of 0.03—0.13 mm (0.001—0.005 in.) on bearings. Specification Upper Pivot Bearing—Preload ................................... 0.03—0.13 mm 0.001—0.005 in.
14. Apply grease to the top of bearing, fill cavity above bearing to machined surface, to prevent moisture from entering bearing through shims. 15. Tighten cap screws (L) to specification. Rotate inner race of bearing after tightening. Specification Upper Pivot Bearing Cover Cap Screw—Torque ...................................................................... 128 N•m 95 lb-ft
TX,1740,DU882 –19–04DEC03–2/2
TM2136 (13DEC04)
17-1740-7
444J, 544J, 624J Loader 121304
PN=231
17 1740 7
Frame Installation
Lower Pivot Bearing and Seals Remove and Install
T154105
–UN–18APR02
17 1740 8
Lower Pivot Bearing and Seals A—Pin Retaining Cap Screw B—Cap Screw (6 used) C—Plate D—Engine Frame E—Spacer (Engine Frame)
F—Spacer (Engine Frame) G—Cover Seal H—Cap Screw (6 used) I—Cover
1. Remove pin retaining cap screw (A), cap screws (B) and plate (C). Remove pivot pin (Q) and separate machine frames. 2. Remove cap screws (H), cover (I) with seal (G) and shims (J).
NOTE: Spacer seal can not be pushed through spacer. Remove seal and spacer to remove seal. 3. Remove (L, M, N and O) from engine frame, using a puller disk against seal spacer (O). Remove seal (N) from seal spacer (O).
J—Shims (as needed) K—Loader Frame L—Bearing Spacer M—Bearing (2 used)
N—Spacer Seal O—Spacer P—Loader Frame Q—Lower Pivot Pin
5. Replace parts as necessary. 6. Press spacer (E) into engine frame bore flush with bottom of frame. 7. Apply a light coat of JDM J13E4 grease to rollers in bearings (M). 8. Press seal into seal spacer, with lips facing out. Seal must seat against the seal spacer shoulder. 9. Install seal spacer to bottom of bore. 10. Press first bearing cup into engine frame bore against spacer.
4. Remove spacer (E) from engine frame bore.
Continued on next page
TM2136 (13DEC04)
17-1740-8
TX,1740,DU960 –19–04DEC03–1/2
444J, 544J, 624J Loader 121304
PN=232
Frame Installation IMPORTANT: Use the same bearing spacer (L) which was removed from the bearing set. Spacer is not interchangeable with other bearings. Do not apply load to bearing cone when pressing in cup. Use old bearing race to apply load on new bearing cup to prevent bearing damage.
15. Apply grease to the top of bearing, fill cavity above bearing to machined surface, to prevent moisture from entering bearing through shims. 16. Tighten lower pivot cap screws (H) to specification. Rotate inner race of bearing after tightening. Specification Lower Pivot Bearing Cap Screw—Torque ...................................................................... 128 N•m 95 lb-ft
11. Install first bearing cone. Install bearing spacer. Press second bearing cup in engine frame bore. Install second bearing cone. Then press second bearing cup into bore against spacer. 12. Install seal into bearing cover (I) with lips facing out. Press seal to cover shoulder. 13. Hold bearing cover in place, measure gap between cover and frame, take readings in three places. Bearing cover must contact top of bearing. Calculate the average of these three reading to determine shim pack required. 14. Install shim pack (J) within specification to obtain preload on bearings. Specification Lower Pivot Bearing—Shim pack thickness ............................................................ 0.03—0.13 mm 0.001—0.005 in.
17. Install spacer (F) into cover (I). 18. Move frames together and install pivot pin (Q) and plate (C). Install pin retaining cap screw (A) and cap screws (B) finger tight before tightening. 19. Tighten plate to loader frame cap screws (B) to specification. Tighten pin retaining cap screw (A) to specification, steel dowels or cap screws may be inserted into holes in top of pivot pin and a bar inserted between them to prevent pin from turning during tightening of cap screw. Specification Plate-to-Loader Frame Cap Screw—Torque ...................................................................... 128 N•m 95 lb-ft Pin Retaining Cap Screw— Torque.................................................................................. 2129 N•m 1570 lb-ft
TX,1740,DU960 –19–04DEC03–2/2
TM2136 (13DEC04)
17-1740-9
444J, 544J, 624J Loader 121304
PN=233
17 1740 9
Frame Installation
17 1740 10
TM2136 (13DEC04)
17-1740-10
444J, 544J, 624J Loader 121304
PN=234
Group 1746
Frame Bottom Guards Front Axle Guard Remove and Install 17 1746 1
Specification Front Axle Guard—Weight— Approximate....................................................................................... 32 kg 72 lb
T108117
Weight may increase due to build up of mud and debris.
–UN–12MAR97
CAUTION: Approximate weight of front axle guard is 32 kg (72 lb).
TX,17,RP3120 –19–05OCT98–1/1
Transmission Bottom Guard Remove and Install
Specification Transmission Bottom Guard— Weight—Approximate ........................................................................ 62 kg 137 lb
T108118
Weight may increase due to build up of mud and debris.
–UN–12MAR97
CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device.
TX,17,RP3121 –19–05OCT98–1/1
TM2136 (13DEC04)
17-1746-1
444J, 544J, 624J Loader 121304
PN=235
Frame Bottom Guards
17 1746 2
TM2136 (13DEC04)
17-1746-2
444J, 544J, 624J Loader 121304
PN=236
Group 1749
Chassis Weights Counterweights Remove and Install 17 1749 1
1. To prevent damaging engine compartment step, remove engine compartment step mounting hardware from left counterweight and remove step.
MX10672,000002F –19–21NOV03–1/2
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–10NOV03
2. Remove tapped hole plugs. Install JT01748 lifting brackets (1) into threaded holes.
T196207A
3. Attach appropriate lifting device to counterweight (3). Specification Rear Counterweight—Weight .......................................................... 454 kg 1000 lb
Counterweight
4. Remove counterweight mounting cap screws (2). 5. Remove counterweight. Repeat procedure for other counterweight.
1—Lifting Bracket (2 used) 2—Counterweight Mounting Cap Screw (2 used) 3—Counterweight
6. Using appropriate lifting device, align counterweight and install counterweight mounting cap screws and tighten to specification. Specification Counterweight Mounting Cap Screw—Torque ........................................................................... 1150 N•m 850 lb-ft
7. Install engine compartment step to left counterweight.
MX10672,000002F –19–21NOV03–2/2
TM2136 (13DEC04)
17-1749-1
444J, 544J, 624J Loader 121304
PN=237
Chassis Weights
17 1749 2
TM2136 (13DEC04)
17-1749-2
444J, 544J, 624J Loader 121304
PN=238
Section 18
Operator’s Station Contents Page
Page
Group 1800—Removal and Installation Cab Remove and Install. . . . . . . . . . . . . . . .18-1800-1
A/C Binary Pressure Switch Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-29 Fresh Air Filter Remove and Install . . . . . . .18-1830-30 Recirculating Air Filter Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-33 Compressor Remove and Install . . . . . . . . .18-1830-34 Compressor Clutch—R134a Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . .18-1830-36 Check Clutch Hub Clearance—R134a. . . . .18-1830-37
Group 1810—Operator Enclosure Windowpanes Remove and Install . . . . . . . .18-1810-1 Cab Door Hold-Open Release Adjust . . . . . .18-1810-1 Front and Rear Windshield Wiper Motor Remove and Install . . . . . . . . . . . . . . . . . .18-1810-2 Group 1830—Heating and Air Conditioning Air Conditioning System Fittings Reference Chart . . . . . . . . . . . . . . . . . . . .18-1830-1 R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-3 R134a Compressor Oil Charge Check . . . . .18-1830-3 R134a Compressor Oil Removal . . . . . . . . . .18-1830-4 R134a Component Oil Charge . . . . . . . . . . .18-1830-5 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant Hoses and Tubing Inspection . . .18-1830-6 R134a Refrigerant, Recovery, Recycling and Charging Station Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Recover R134a System . . . . . . . . . . . . . . . .18-1830-8 Evacuate R134a System . . . . . . . . . . . . . . . .18-1830-9 Charge R134a System . . . . . . . . . . . . . . . .18-1830-11 Air Conditioner System Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Purge Air Conditioner System . . . . . . . . . . .18-1830-13 Flush Air Conditioner System . . . . . . . . . . .18-1830-14 Air Conditioning Module With Heater/Evaporator Coil. . . . . . . . . . . . . . .18-1830-16 Heater/Evaporator Coil Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 Expansion Valve Remove and Install . . . . .18-1830-20 Freeze Control Switch Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20 Bench Test Freeze Control Switch . . . . . . .18-1830-21 Heater Control Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-22 Heater Control Valve Leak Check . . . . . . . .18-1830-23 Main Blower Assembly Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-24 Pressurizer Motor Assembly Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-25 Receiver-Dryer and Condenser Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .18-1830-25 TM2136 (13DEC04)
18-1
444J, 544J, 624J Loader 121304
PN=1
18
Contents
18
TM2136 (13DEC04)
18-2
444J, 544J, 624J Loader 121304
PN=2
Group 1800
Removal and Installation Cab Remove and Install CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area. 1. Install frame locking bar. 18 1800 1
2. Stop engine. 3. Discharge ride control accumulator. See Ride Control Accumulator Hydraulic Discharge. (Group 9025-20.) 4. Discharge brake accumulators. Perform Brake Accumulator Precharge Test until brake accumulators are totally discharged. (Group 9025-25.)
NOTE: For machines not equipped with auxiliary function control lever, do not remove pilot control trim panel. 5. Remove pilot control trim panel only on machines equipped with auxiliary function control lever. 6. Turn battery disconnect switch OFF. 7. Evacuate and recover refrigerant from air conditioning system. See Evacuate R134a System. (Group 1830.) 8. Remove platform from right side of machine. 9. Remove steps from left side of machine. 10. Remove cab shields.
Continued on next page
TM2136 (13DEC04)
18-1800-1
TX,1800,111302 –19–13NOV03–1/12
444J, 544J, 624J Loader 121304
PN=241
Removal and Installation 11. Remove heater/defroster duct hardware (3) and remove left and right duct (1 and 2).
T196378A
1—Right Heater/Defroster Duct 2—Left Heater/Defroster Duct 3—Heater/Defroster Duct Mounting Hardware (4 used)
Heater/Defroster Duct
TX,1800,111302 –19–13NOV03–2/12
NOTE: For machines equipped with secondary hydraulic steering, remove all hydraulic lines.
–UN–24NOV03
13. Remove steering valve lines (5) from steering valve (4). Cap and plug all openings. 14. Remove hydraulic lines from brake valve. Cap and plug all openings. 15. Drain radiator. Perform Radiator Remove and Install procedure until radiator is drained. (Group 0510.)
T196379A
18 1800 2
–UN–24NOV03
12. Apply vacuum to hydraulic reservoir.
Steering Valve
16. Open electrical access door on right side of machine.
4—Steering Valve 5—Steering Valve Lines 6—Heater/Defroster Duct Opening
Continued on next page
TM2136 (13DEC04)
18-1800-2
TX,1800,111302 –19–13NOV03–3/12
444J, 544J, 624J Loader 121304
PN=242
Removal and Installation NOTE: For machines equipped with auxiliary hydraulics, remove pilot control console to gain access to STC connectors at auxiliary hydraulic valve.
–UN–24NOV03
NOTE: STC tool supplied with vehicle and located in operator’s manual packet.
T196380A
17. Remove hydraulic hoses from pilot control valve using JDG1385 STC tool. Cap and plug all openings. 18. Remove all electrical connectors from pilot control valve. Pilot Control Lines 7—Pilot Control Valve 8—Pilot Control Valve Lines 9—Auxiliary Hydraulic Control Valve Lines
TX,1800,111302 –19–13NOV03–4/12
19. Disconnect pilot pressure and return hydraulic line bulkhead fittings (10) from right side of cab.
–UN–24NOV03
20. Disconnect three electrical connectors (12) from bottom right side of cab.
T196381A
21. Disconnect cab-to-frame ground strap (11) from right side of cab. 10—Pilot Pressure and Return Bulkhead Fittings 11—Cab-to-Frame Ground Strap 12—Right Side Cab Harness Connectors
Bulkhead Fittings
Continued on next page
TM2136 (13DEC04)
18-1800-3
TX,1800,111302 –19–13NOV03–5/12
444J, 544J, 624J Loader 121304
PN=243
18 1800 3
Removal and Installation 22. Remove hydraulic hose grommet retaining plate hardware (13). Remove plate (14) located inside of electrical access door.
–UN–24NOV03 T196382A
Hydraulic Hose Grommet
TX,1800,111302 –19–13NOV03–6/12
23. Disconnect wires (17—19) in starter harness (20) from starter.
–UN–24NOV03
17—White E01 Wire on Starter Solenoid 18—Red D02 Wire on Starter Solenoid 19—Black G01 Wire on Starter Motor Body 20—Starter to Cab Wiring Harness
T196384A
18 1800 4
13—Hydraulic Hose Grommet Retaining Plate Hardware (2 used) 14—Hydraulic Hose Grommet Retaining Plate 15—Hydraulic Hose Grommet 16—Hydraulic Hose
Starter Harness
Continued on next page
TM2136 (13DEC04)
18-1800-4
TX,1800,111302 –19–13NOV03–7/12
444J, 544J, 624J Loader 121304
PN=244
Removal and Installation 24. Disconnect air conditioning hoses (21) from right side of machine. Cap and plug openings.
–UN–24NOV03
25. Disconnect heater hoses from engine.
T196385A
21—Air Conditioning Hoses
Air Conditioning Hoses
TX,1800,111302 –19–13NOV03–8/12
26. Disconnect wiring harness couplers (22) from left side of cab.
–UN–24NOV03
27. Disconnect windshield washer fluid hose from left front of cab. 28. Disconnect rear window washer fluid hose at left rear of cab.
T196386A
29. Remove brake accumulator-to-pressure reducing valve hydraulic line. Cap and plug all openings. Left Side Wiring Harness
22—Wiring Harness Connectors (2 used)
Continued on next page
TM2136 (13DEC04)
18-1800-5
TX,1800,111302 –19–13NOV03–9/12
444J, 544J, 624J Loader 121304
PN=245
18 1800 5
Removal and Installation
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
30. Remove four cap screws from top of cab roof and install four JT01748 Lifting Brackets (23) to cab roof. Attach appropriate lifting device to brackets (23).
T196422A
18 1800 6
–UN–04DEC03
Specification Cab—Weight—Approximate............................................................ 771 kg 1700 lb
Lifting Brackets Installed in Cab Roof
31. Remove mounting hardware from bottom front and rear of cab.
23—Lifting Brackets (4 used)
NOTE: Feed main hydraulic and auxiliary hydraulic hoses with grommet down through opening as cab is being lifted. 32. Remove cab.
Continued on next page
TM2136 (13DEC04)
18-1800-6
TX,1800,111302 –19–13NOV03–10/12
444J, 544J, 624J Loader 121304
PN=246
Removal and Installation 33. Inspect cab mounting parts. Replace as needed.
NOTE: Feed main hydraulic and auxiliary hydraulic hoses with grommet up through opening as cab is being lowered into place. 34. Lower cab onto frame. 18 1800 7
35. Install cab mounting hardware. Specification Cab Mounting Cap Screw— Torque ........................................................................................ 1150 N•m 850 lb-ft
–UN–24NOV03
36. Connect brake accumulator-to-pressure reducing valve hydraulic line.
T196615
37. Connect front and rear window washer fluid hoses. 38. Connect both wiring harness connectors at left front of cab. Cab Mounts and Hardware
39. Connect heater hoses to engine. 24—Nut (2 used) 25—Washer (6 used) 26—Washer (4 used) 27—Rubber Mount (4 used) 28—Cap Screw (M24 x 150) (2 used) 29—Cap Screw (M24 x 120) (2 used)
40. Connect air conditioner hoses at right side of machine. 41. Connect wires (17—19) from wiring harness (20) to starter. 42. Connect cab-to-frame ground strap (11) at right side of cab. 43. Connect three electrical plugs (12) at right side of cab. 44. Install hydraulic hose grommet retaining plate (14). 45. Connect pilot pressure and return hydraulic lines (10) at bulkhead on right side of cab. 46. Connect all electrical connectors to pilot control valve. 47. Connect hydraulic hoses to pilot control valve. 48. Connect hydraulic hoses to auxiliary control valve. 49. Close electrical access door.
Continued on next page
TM2136 (13DEC04)
18-1800-7
TX,1800,111302 –19–13NOV03–11/12
444J, 544J, 624J Loader 121304
PN=247
Removal and Installation 50. Fill radiator to recommended capacity. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 18 1800 8
644J Drain and Refill Capacities 51. Install steering and brake valve lines. 52. Release vacuum from hydraulic reservoir. 53. Install heater/defroster ducts (1 and 2). 54. Install cab shields. 55. Install steps on left side of machine. 56. Install platform on right side of machine. 57. Charge air conditioning system. See Charge R134a System. (Group 1830.) 58. Install pilot control trim panel. 59. Remove frame locking bar. 60. Turn battery disconnect switch ON.
TX,1800,111302 –19–13NOV03–12/12
TM2136 (13DEC04)
18-1800-8
444J, 544J, 624J Loader 121304
PN=248
Group 1810
Operator Enclosure Windowpanes Remove and Install The adhesive used to hold the windowpanes in place is a urethane adhesive that is used on most automobile windshields. Urethane adhesive manufactured by Loctite Corporation or equivalent is recommended. Do not use any other type of adhesive. It is also recommended that an auto glass dealer install the windowpanes. IMPORTANT: Windowpanes must have an ultra-violet barrier around the edge of the glass since ultra-violet rays will deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultra-violet barrier. If the windowpane is purchased through a glass dealer, the dealer must put an ultra-violet barrier on the glass. Do not apply paint to the border of the glass. If an auto glass dealer is not installing the windowpanes, use the following procedure: 1. Purchase urethane adhesive from your local auto glass dealer. 2. If window frame is removable, remove frame from cab.
3. Scrape broken glass off existing adhesive. Do not remove adhesive from window frame or cab. IMPORTANT: Adhesive will not stick to bare metal. 4. If existing adhesive is removed from frame and paint is scraped off window frame, paint window frame. Paint must be fully cured before installing windowpane.
18 1810 1
5. Trim existing adhesive so it has a smooth surface. 6. Follow the manufacturer’s instructions for using the adhesive. 7. Apply a 6 mm (1/4 in.) bead of adhesive on top of the existing adhesive. 8. Put a new windowpane into position. Use hand pressure to force windowpane down around the edges until even with metal frame. 9. If windowpane is installed directly on cab, use duct tape to hold it in place while adhesive cures. 10. Allow adhesive to cure for 24 hours before operating machine.
T52,1810,C19 –19–05JUN98–1/1
Cab Door Hold-Open Release Adjust 1. Remove door striker cover from left rear side of ROPS. 2. Adjust cable length so door release latch releases door when lever is moved 1/3 of full travel distance. 3. Apply thread lock and sealer (medium strength) to cable eye retaining nut. Cable eye must remain loose.
CED,OUOE003,2658 –19–16DEC98–1/1
TM2136 (13DEC04)
18-1810-1
444J, 544J, 624J Loader 121304
PN=249
Operator Enclosure
Front and Rear Windshield Wiper Motor Remove and Install Front Windshield Wiper Motor Remove and Install 1. Park windshield wiper. 18 1810 2
Continued on next page
TM2136 (13DEC04)
18-1810-2
MX10672,0000033 –19–02DEC03–1/7
444J, 544J, 624J Loader 121304
PN=250
Operator Enclosure
18 1810 3
TM2136 (13DEC04)
18-1810-3
444J, 544J, 624J Loader 121304
PN=251
Operator Enclosure
T188479
–UN–25MAR03
18 1810 4
Front Wiper Assembly
Continued on next page
TM2136 (13DEC04)
18-1810-4
MX10672,0000033 –19–02DEC03–2/7
444J, 544J, 624J Loader 121304
PN=252
Operator Enclosure 1—Wiper Motor Bracket 2—Wiper Arm Mounting Kit 3—Link 4—Pivot 5—Washer Hose Elbow Bulkhead Fitting
6—Washer Hose Coupler 7—Windshield Washer 8—Washer Hose 9—Washer Hose Clip
10—Wiper Arm 11—Wiper Motor 12—Wiper Blade 13—Pivot Retaining Nut
2. Lift wiper arm covers and remove wiper arm retaining hardware (2). Remove wiper arms (10) with blades (12).
14—Pivot Washer 15—Windshield Wiper Assembly 16—Washer Hose
3. Disconnect windshield washer hose from fitting (6). 18 1810 5
MX10672,0000033 –19–02DEC03–3/7
4. Remove windshield wiper mounting plate (17) mounting hardware (18).
–UN–18DEC03
5. Remove wiper motor (11) with plate (17) and disconnect electrical harness from motor. 6. Disassemble parts as shown and replace as necessary.
T196713A
7. Connect electrical harness to motor. 8. Connect windshield washer hose (16) to fitting (6). Front Wiper Motor and Mounting Plate
9. Install wiper motor (11) with plate (17) with mounting hardware (18).
17—Front Wiper Motor Mounting Plate 18—Front Wiper Motor Mounting Plate Mounting Hardware
10. Install wiper arms and blades. Specification Wiper Arm Retaining Nut— Torque ......................................................................................... 14.9 N•m 132 lb-in.
Rear Windshield Wiper Remove and Install 1. Park rear windshield wiper. 2. Remove roof retaining hardware and move roof forward enough to access wiper motor wiring harness connectors. 3. Remove tie band and disconnect wiper motor harness.
Continued on next page
TM2136 (13DEC04)
18-1810-5
MX10672,0000033 –19–02DEC03–4/7
444J, 544J, 624J Loader 121304
PN=253
Operator Enclosure
T193133
–UN–18NOV03
18 1810 6
Rear Windshield Wiper Motor
Continued on next page
TM2136 (13DEC04)
18-1810-6
MX10672,0000033 –19–02DEC03–5/7
444J, 544J, 624J Loader 121304
PN=254
Operator Enclosure 1—Washer Hose Clip (2 used) 2—Grommet 3—Wiper Blade 4—Wiper Arm 5—Pivot Retaining Hardware Kit
6—Washer Hose Elbow Bulkhead Fitting 7—Pivot Retaining Nut 8—Pivot Washer
9—Rear Wiper Motor 10—Rear Wiper Motor Assembly 11—Rear Wiper Assembly
12—Washer Hose Coupler 13—Washer Hose 14—Washer Arm Hose
4. Disconnect washer hose (13) at coupler (12). 18 1810 7
MX10672,0000033 –19–02DEC03–6/7
5. Remove rear wiper motor mounting plate (15) mounting hardware (16). 6. Lower wiper motor with mounting plate and wiper arm. –UN–18DEC03
7. Remove wiper motor from mounting plate.
T196711A
8. Disassemble parts as shown and replace as necessary. 9. Install wiper motor to mounting plate. 10. Install wiper motor (9) and mounting plate (15) with mounting hardware (16). 11. Connect electrical harness to wiper motor.
Rear Windshield Wiper 15—Rear Wiper Motor Mounting Plate 16—Rear Wiper Motor Mounting Plate Mounting Hardware
12. Connect windshield washer hose (13) to fitting (12). 13. Install roof.
MX10672,0000033 –19–02DEC03–7/7
TM2136 (13DEC04)
18-1810-7
444J, 544J, 624J Loader 121304
PN=255
Operator Enclosure
18 1810 8
TM2136 (13DEC04)
18-1810-8
444J, 544J, 624J Loader 121304
PN=256
Group 1830
Heating and Air Conditioning Air Conditioning System Fittings Reference Chart The JT02098 Flush Fitting Kit contains fittings for flushing or leak testing sections or individual components to the air conditioning system. Following chart lists service fittings used at each specific location. 18 1830 1
Continued on next page
TM2136 (13DEC04)
18-1830-1
CED,TX03679,3535 –19–24JUL98–1/2
444J, 544J, 624J Loader 121304
PN=257
Heating and Air Conditioning Location
Size
SERVICEGARD Number
O-Ring Number
1. Suction Port (F)
7/8—18
JT02099
R113050
2. Discharge Port (F)
3/4—18
JT02100
3. Inlet End (M)
3/4—18
JT02102
R113050
4. Outlet End (F)
3/4—16 UNF-2B
JT02100
R113050
Compressor Manifold:
Compressor Discharge Hose: 18 1830 2
Condenser: 5. Inlet Port (M)
3/4—16 UNF-2A
JT02102
6. Outlet Port (M)
5/8—18
JT03183
7. Inlet End (F)
5/8—18
JT03188
R10093
8. Outlet End (M)
5/8—18
JT03197
R10093
9. Inlet Port (F)
5/8—18
JT03196 or JT02110
10. Outlet Port (M)
5/8—18
JT03183
11. Inlet End (F)
5/8—18
JT03188
12. Outlet End (M)
5/8—18
JT03183
13. Inlet End (F)
5/8—18
JT03188
R10093
14. Outlet End (M)
3/8
JT02106 and JT02104
R10093
15. Liquid Inlet (F)
3/8
JT02103
16. Liquid Outlet (F)
1/2
JT02104
Condenser to Receiver-Dryer Hose:
Receiver-Dryer:
Receiver-Dryer to Evaporator Hose: R10093
A/C Inlet Tube
Expansion Valve:
19. Gas Inlet (F)
5/8
JT02105
20. Gas Outlet (F)
3/4
JT02147
17. Inlet Tube (M)
1/2
JT02106 and JT02103
R113050
18. Outlet Tube (M)
5/8
JT02106 and JT02105
R33259
21. Inlet End (M)
3/4
TEV and JT02105
T143169
22. Outlet End (F)
1-1/16—14
Not Available
T143169
23. Inlet End (M)
1-1/16—14
Not Available
24. Outlet End (M)
7/8—18
JT02101
Evaporator Coil:
A/C Outlet Tube:
Evaporator to Compressor Hose:
SERVICEGARD is a trademark of Deere & Company.
TM2136 (13DEC04)
R33259
CED,TX03679,3535 –19–24JUL98–2/2
18-1830-2
444J, 544J, 624J Loader 121304
PN=258
Heating and Air Conditioning
R134a Refrigerant Cautions develop high pressure which can burst the container.
CAUTION: Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
If liquid refrigerant contacts eyes or skin, Do not rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment.
18 1830 3
Do not handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment.
Do not allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. Do not heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will
TX,9031,HH1465 –19–19AUG94–1/1
R134a Compressor Oil Charge Check Remove compressor if R134a leakage was detected and repaired. See Remove and Install Compressor in this group.
3. Flush the complete system with TY16134 air conditioning flushing solvent.
Drain oil from the compressor and record the amount. See Compressor Oil Removal procedure in this group.
4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil.
NOTE: Drain oil and save if this is a new compressor.
5. Install a new receiver-dryer.
If the oil drained from a compressor removed from operation is very black or the amount of oil is less than 6 mL (0.2 fl oz), perform the following:
6. Install required amount of TY22025 refrigerant oil in the compressor. (See R134a Component Oil Charge in this group.)
1. Remove and discard the receiver-dryer.
7. Connect all components, evacuate and charge the system.
2. Remove, clean, but do not disassemble the valve.
TX,9031,QQ2366 –19–07MAR95–1/1
TM2136 (13DEC04)
18-1830-3
444J, 544J, 624J Loader 121304
PN=259
Heating and Air Conditioning
R134a Compressor Oil Removal 1. Remove compressor from machine. See Remove and Install Compressor in this group. 2. Remove inlet/outlet manifold from compressor, and clutch dust cover. 18 1830 4
3. Drain oil into graduated container while rotating compressor shaft. 4. Record measured oil and discard oil properly. 5. Install new oil. See R134a Component Oil Charge in this group. 6. Install compressor. See Compressor Remove and Install in this group.
TX,9015,QQ2299 –19–17JUN94–1/1
TM2136 (13DEC04)
18-1830-4
444J, 544J, 624J Loader 121304
PN=260
Heating and Air Conditioning
R134a Component Oil Charge CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. Compressors can be divided into three categories when determining the correct oil charge for the system. • New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent Use the following procedure to determine the amount of system oil charge prior to installation of compressor on a machine. 1. When the complete system, lines, and components were flushed add the correct amount of oil as described. • New compressor from parts depot contains the amount of new oil of 230 ± 20 mL (7.7 ± .7 fl oz). System requires an additional amount of new oil of 135 mL (4.58 fl oz) of new oil. • Used compressor removed from operation, oil drained, and flushed requires 365 mL (12.35 fl oz) of new oil.
• Used compressor removed from operation and oil drained. See Compressor Oil Remove procedure in this group. Add 45 mL (1.5 fl oz) of new oil. • Used compressor removed from operation, oil drained, and flushed. Add 60 mL (2.0 fl oz) of new oil.
NOTE: Components listed below which have been removed, drained or flushed, require the removal of the compressor to determine the correct oil charge. Use the following chart as a guide for adding oil to components: Evaporator
158 mL (5.4 fl oz)
Condenser
70 mL (2.4 fl oz)
Receiver-Dryer
37 mL (1.25 fl oz)
Hoses
73 mL (2.5 fl oz)
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft). Approximate total length equals 727 cm (24 ft) If any section of hose is removed and flushed or replaced, measure the length of hose and use the formula to determine the correct amount of oil to be added.
2. When the complete system was not flushed add the correct amount of oil for the compressor plus the amount of oil for each component that was serviced. • New compressor from parts depot, drain and return 45 mL (1.5 fl oz) of oil to the compressor. See Compressor Oil Remove procedure in this group.
CAUTION: Do not leave the system or R134a compressor oil containers open. This oil easily absorbs moisture. Do not spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.
TX,1830,111266 –19–28SEP98–1/1
TM2136 (13DEC04)
18-1830-5
444J, 544J, 624J Loader 121304
PN=261
18 1830 5
Heating and Air Conditioning
Leak Testing
18 1830 6
1. Inspect all lines, fittings and components for oily or dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it.
3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at a rate of 25 mm (1 in.) per second.
2. A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.
4. Some Freon manufacturers add dye to Freon to aid in leak detection.
TX,1830,MM3175 –19–19OCT96–1/1
Refrigerant Hoses and Tubing Inspection IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.
material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts. Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.
Do not use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J51b requirements. When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign
To assist in making leak-proof joints in R134a systems, use a small amount of clean polyakyleneglycol (PAG) refrigerant oil on all hoses and tube connections. Dip O-rings in PAG oil before assembly.
TX,1830,MM3176 –19–19OCT96–1/1
TM2136 (13DEC04)
18-1830-6
444J, 544J, 624J Loader 121304
PN=262
Heating and Air Conditioning
R134a Refrigerant, Recovery, Recycling and Charging Station Installation Procedure ESSENTIAL TOOLS JT02045a R134a Refrigerant Recovery/Recycling and Charging Station a
JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.
18 1830 7
CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils.
–19–22FEB95
1. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (H). 2. Remove cap from low pressure test port (G).
4. Connect high pressure red hose (C) to high pressure quick disconnect (B). 5. Follow the manufactures instructions when using the refrigerant recovery, recycling and charging station.
T8422AC
3. Connect low pressure blue hose (D) from refrigerant recovery, recycling and charging station (H) to low pressure test port (G) on compressor. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station
TX,9031,QQ3015 –19–07MAR95–1/1
TM2136 (13DEC04)
18-1830-7
444J, 544J, 624J Loader 121304
PN=263
Heating and Air Conditioning
Recover R134a System ESSENTIAL TOOLS a
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station a
JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.
CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils.
–19–22FEB95
NOTE: Run the air conditioning system for three minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps. 1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.)
T8422AC
18 1830 8
2. Follow the manufacturer’s instructions when using the refrigerant recovery, recycling and charging station. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station
TX,9031,QQ3016 –19–07OCT98–1/1
TM2136 (13DEC04)
18-1830-8
444J, 544J, 624J Loader 121304
PN=264
Heating and Air Conditioning
Evacuate R134a System ESSENTIAL TOOLS a
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station D05267ST Vacuum Pump a
JT02046 and JT02050 Recovery and Charging Stations can be substituted for the JT02045 Station.
18 1830 9
CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils.
–19–22FEB95
Do not run compressor while evacuating.
T8422AC
1. Connect refrigerant recovery, recycling and charging station. See installation procedure in this group. 2. Open low and high pressure valves on refrigerant recovery, recycling and charging station. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station
3. Follow the manufacturers instructions and evacuate the system.
NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. 4. Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum. If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test the system for leaks. See Leak Testing. (Group 9031-25.) Correct any leaks. 5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off.
Continued on next page
TM2136 (13DEC04)
18-1830-9
TX,9031,QQ3017 –19–07OCT98–1/2
444J, 544J, 624J Loader 121304
PN=265
Heating and Air Conditioning 6. If the vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in the system. 7. Repair leak. 8. Start to evacuate. 18 1830 10
9. Open low-side and high-side valves. 10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 11. Close low-side and high-side valves. Stop evacuation. 12. See Charge R134a System in this group.
TX,9031,QQ3017 –19–07OCT98–2/2
TM2136 (13DEC04)
18-1830-10
444J, 544J, 624J Loader 121304
PN=266
Heating and Air Conditioning
Charge R134a System CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils.
18 1830 11
1. Connect JT02045 R134a refrigerant recovery, recycling and charging station. (See installation procedure in this group.) 2. Evacuate the system. (See Evacuate Air Conditioning System in this group.)
3. Follow the manufacturer’s instructions and charge the system. 4. Add refrigerant until system is charged with 2.381 kg (5.25 lb). 5. Verify air conditioning system is functioning properly.
T8422AC
–19–22FEB95
NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station
TX,1830,111267 –19–28SEP98–1/1
TM2136 (13DEC04)
18-1830-11
444J, 544J, 624J Loader 121304
PN=267
Heating and Air Conditioning
Air Conditioner System Cleaning Procedures
18 1830 12
Flushing: Flushing the system or component is a cleaning process using a liquid solvent to remove oil and debris. Purging is always necessary after flushing to remove solvent from the system or component.
Purging: Purging the system or a component is a cleaning process using a gas to force liquid from the system. Purging alone will not remove refrigerant oil from the system.
Following is a list of situations that require a flushing procedure be done:
Following is a list of situations that require a purging procedure be done:
• The compressor has an internal failure. • No oil remains in used compressor. • Oil drained from compressor appears or smells overheated. • System was contaminated with a mixture of refrigerant oils. • System was left open to the atmosphere long enough for dirt, moisture, or debris to enter the tubing or components. • System has an internal blockage.
• After flushing system with solvent, to prevent oil dilution • System was contaminated with nitrogen or two refrigerants. • System was left open to the atmosphere and flushing could not be performed. • Installation of new lines, condenser, or evaporator was required.
The following solvent is recommended for flushing air conditioner systems. Use only solvents with an equivalent MSDS.
Evacuating: Evacuating the system is a process to remove air and moisture from the system, creating a vacuum.
• TY16134 John Deere Air Conditioning System Flushing Solvent
TX,1830,MM3158 –19–17OCT96–1/1
TM2136 (13DEC04)
18-1830-12
444J, 544J, 624J Loader 121304
PN=268
Heating and Air Conditioning
Purge Air Conditioner System IMPORTANT: Air compressors used for purging systems require a water separator. Purging without a separator adds moisture, creating hydrofluoric acid when combined with refrigerant oil. Acid is corrosive to metal tubing.
18 1830 13
1. Connect dry nitrogen hose to gauge manifold center hose. 2. Connect gauge manifold suction hose to compressor suction port, and open valves. 3. Connect gauge manifold discharge hose to compressor discharge post, and open valve. Disconnect discharge hose from gauge manifold to allow purging nitrogen to atmosphere. 4. Open nitrogen tank valve and adjust regulator to 275 kPa (40 psi) (2.75 bar). Purge system for two minutes. Disconnect nitrogen supply. 5. Evacuate system using procedure in this group.
TX,1830,MM3156 –19–14OCT98–1/1
TM2136 (13DEC04)
18-1830-13
444J, 544J, 624J Loader 121304
PN=269
Heating and Air Conditioning
Flush Air Conditioner System Add flushing solvent to system with JT02075 Flusher and JT02098 Fitting Kit.
NOTE: Flushing can be performed on vehicle. 18 1830 14
IMPORTANT: Do not attempt to flush through compressor or receiver-dryer. Flushing through expansion valve is acceptable if refrigerant oil has normal odor and appearance.
1. Recover refrigerant using procedure in this group. 6. To Flush/Purge Condenser: 2. Remove compressor and measure oil drained from both manifold ports.
Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.
3. Clean compressor as follows: a. Pour 240 mL (8 fl oz) of flushing solvent into suction port and 120 mL (4 fl oz) into discharge port. Plug both ports in compressor manifold using JT02099 and JT02100 with JT03194 Caps. b. Turn compressor end for end and roll it side to side. c. Remove both plugs from manifold ports and drain solvent from compressor. d. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders.
7. Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose using JT03197 reducer. Put nozzle in container to collect flushing solvent. 8. Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections.
NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging. 9. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.
e. Invert compressor, roll end for end, and side to side. Drain thoroughly.
10. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.
f. Let compressor sit inverted for three to five minutes.
NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.
g. Repeat previous two steps at least three times.
11. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry.
4. Remove and discard receiver-dryer. 5. Divide system into two circuits:
12. Go to Step 13 to flush evaporator. Go to Step 22 if evaporator does not require flushing.
a. Condenser, including inlet and outlet hoses. (Steps 6—12)
13. To Flush Evaporator:
b. Evaporator, including inlet and outlet hoses. (Steps 13—26)
Continued on next page
TM2136 (13DEC04)
18-1830-14
TX,1830,MM3159 –19–14OCT98–1/2
444J, 544J, 624J Loader 121304
PN=270
Heating and Air Conditioning If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. Go to Step 18 to flush evaporator through expansion valve, if oil appears normal. See Heater/Evaporator Coil Remove and Install. (See procedure in this group.) 14. Force flushing solvent through evaporator inlet with compressed air.
20. Repeat steps 8, 9 and 10 to flush evaporator.
NOTE: Purging the evaporator circuit takes 12—15 minutes to thoroughly remove solvent. 21. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard. Continue purging until cardboard is dry. 22. Install a new receiver-dryer compatible with R134a refrigerant. Fasten connections and mounting bracket.
15. Purge system until dry. 16. Reinstall evaporator.
23. Add required oil using procedure in this group. 17. Go to Step 22. 24. Install compressor, and connect refrigerant lines to manifold.
18. To Flush Evaporator Through Expansion Valve:
25. Connect clutch coil wire. Install drive belt. Connect flusher outlet hose to connection of receiver-dryer outlet hose using JT03188 Adapter.
26. Purge system using procedure in this group.
19. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in a container to collect solvent.
TX,1830,MM3159 –19–14OCT98–2/2
TM2136 (13DEC04)
18-1830-15
444J, 544J, 624J Loader 121304
PN=271
18 1830 15
Heating and Air Conditioning
Air Conditioning Module With Heater/Evaporator Coil
T196858
–UN–10DEC03
18 1830 16
T196858 Air Conditioning Module With Heater/Evaporator Coil Continued on next page
TM2136 (13DEC04)
18-1830-16
MX10672,0000035 –19–03DEC03–1/2
444J, 544J, 624J Loader 121304
PN=272
Heating and Air Conditioning 1—Module 2—Nut 3—AC Compressor Switch 4—Hand Operated Valve 5—Structural Tubing 6—Resistor 7—Hose 8—Evaporator 9—Plate 10—Bolt 11—Valve 12—Tube 13—Clamp 14—Plate 15—Screw 16—Cap 17—Switch
18—Tube 19—Hose 20—Isolator 21—Hose 22—Hose 23—Housing 24—Clevis 25—Cap Screw 26—Clevis 27—Cap Screw 28—Cap Screw 29—Rivet 30—O-Ring 31—Screw 32—Plug 33—Plug
34—Grommet 35—Washer 36—Blower 37—Blower Motor 38—Clamp 39—Seal 40—Impeller 41—Clip 42—Tube 43—Nut 44—Cap Screw 45—Seal 46—Tube 47—Clevis 48—Cap Screw 49—Bolt
50—Isolator 51—Isolator 52—Isolator 53—Isolator 54—Isolator 55—Isolator 56—Air Plenum 57—Assembly 58—Clip 59—Cover 60—Washer 61—Screw 62—Clamp 63—Seal 64—Tube 65—Air Filter
18 1830 17
MX10672,0000035 –19–03DEC03–2/2
TM2136 (13DEC04)
18-1830-17
444J, 544J, 624J Loader 121304
PN=273
Heating and Air Conditioning
Heater/Evaporator Coil Remove and Install
T104545
–UN–29OCT96
18 1830 18
A—Pressurizer Motor B—Inlet Plenum C—Expansion Valve D—Freeze Control Switch
E—Resistor F—AC/Heater Main Blower Motor H—Cap Screw
1. Recover refrigerant from the system. See Recover R134A System in this group. 2. Open left-hand cab service door. Remove fresh air filter. (See Remove Fresh Air Filter in this group.)
I—Lower Housing J—Heater/Evaporator Coil K—Heater Hose (2 used) L—Heater Valve
M—Air Conditioning Lines N—Housing O—Knob
8. Remove cab left-hand shelf. 9. Remove cap screws from heater/evaporator coil top cover. Remove cover. 10. Remove freeze control switch (D) probe from coil.
3. Remove knob (O) to remove housing (N). 4. Remove rear cover behind seat.
11. Remove upper two cap screws from main blower motor (F).
5. Remove seat cap screws and move seat forward to access air conditioning/heater components.
12. Disconnect wire harness from freeze control switch (D) and resistor (E).
6. Remove cab recirculating filter. (See Remove Recirculating Filter in this group.)
13. Shut off heater hose shut-off valves on engine.
7. Remove upper two cap screws attaching inlet plenum (B) to heater/evaporator coil top cover (G).
14. Disconnect air conditioning lines (M) from expansion valve (C) and heater hoses (K) from coil.
Continued on next page
TM2136 (13DEC04)
18-1830-18
MX10672,0000034 –19–03DEC03–1/2
444J, 544J, 624J Loader 121304
PN=274
Heating and Air Conditioning 15. Remove expansion valve.
27. Install cab recirculating filter.
16. Remove heater/evaporator coil (J).
28. Install rear cover behind seat.
17. Install expansion valve on heater/evaporator coil.
29. Move seat back and install and tighten cap screws.
18. Check lower housing (I) to make sure drain tube is not plugged. 19. Install heater/evaporator coil.
30. Install fresh air filter in housing. 31. Carefully install housing and knob. Do not damage wiring.
20. Connect air conditioner lines and heater hoses. 32. If the system is contaminated, each component in the system must be flushed and purged individually. (See procedures in this group.)
21. Open heater hose shut-off valves on engine. 22. Install freeze control switch in coil. 23. Connect wire harness to freeze control switch and resistor.
33. Drain oil from compressor. (See procedure in this group.)
24. Install main blower motor.
34. If system was not completely flushed, see flushing procedure in this group.
25. Install evaporator top cover and cab left-hand shelf.
35. Purge, evacuate, and charge the system. using procedures in this group.
26. Install inlet plenum to heater/evaporator coil top cover.
MX10672,0000034 –19–03DEC03–2/2
TM2136 (13DEC04)
18-1830-19
444J, 544J, 624J Loader 121304
PN=275
18 1830 19
Heating and Air Conditioning
Expansion Valve Remove and Install 1. Remove rear cover behind seat. 2. Remove pressurizer motor (A). (See Remove Pressurizer Motor in this group.) 3. Disconnect air conditioning lines (C) from expansion valve (B). 4. Remove expansion valve (B) and replace. 5. Install expansion valve. 6. Connect air conditioning lines to expansion valve. 7. Install pressurizer motor.
–UN–29OCT96
8. Install rear cover behind seat.
T104605
A—Pressurizer Motor B—Expansion Valve C—Air Conditioning Lines
TX,1830,MM3161 –19–28SEP98–1/1
Freeze Control Switch Remove and Install 1. Remove rear cover behind seat.
–UN–23SEP96
2. Remove probe (B) of freeze control switch (A) from heater/evaporator coil. 3. Disconnect wire leads from freeze control switch and remove switch from cover.
T103844
18 1830 20
4. Test freeze control switch. (See Bench Test Freeze Control Switch in this group.) 5. Attach freeze control switch to heater/evaporator coil top cover.
A—Freeze Control Switch B—Probe
6. Connect wiring leads to freeze control switch. 7. Insert freeze control switch probe into heater/evaporator coil. 8. Install rear cover behind seat.
TX,1830,MM3162 –19–28SEP98–1/1
TM2136 (13DEC04)
18-1830-20
444J, 544J, 624J Loader 121304
PN=276
Heating and Air Conditioning
Bench Test Freeze Control Switch
2. Switch must open at test specification.
T83921
Freeze Control Switch Test:—Specification Switch Opens—Temperature ........................................... -0.56° ± 0.84°C 31° ± 1.5°F
–UN–08NOV88
1. Connect ohmmeter to freeze control switch terminals. Put end of probe into an ice and salt water solution.
3. Warm the water. 4. Switch must close at test specification. Freeze Control Switch Test:—Specification Switch Closes—Temperature ............................................ -2.22° ± 0.84°C 36° ± 1.5°F
If switch operates within specifications, reinstall switch and connect leads. If switch does not operate within specifications, replace with new switch and connect leads.
TX,1830,MM3163 –19–14OCT98–1/1
TM2136 (13DEC04)
18-1830-21
444J, 544J, 624J Loader 121304
PN=277
18 1830 21
Heating and Air Conditioning
Heater Control Valve Remove and Install 1. Open left-hand side door. Remove cab fresh air filter housing. (See Remove Fresh Air Filter in this group.) 2. Shut off the heater hose shut-off valves on the engine block. 3. Remove rear cover behind seat. 4. Disconnect temperature control switch cable from heater control valve. 5. Remove heater control valve (B) and test. (See Heater Control Valve Leak Check in this group.) 6. Inspect heater hoses (A) and replace as required.
–UN–29OCT96
IMPORTANT: Heater valve will leak if arrow on valve is not in the direction of coolant flow. 7. Install heater control valve with flow arrow (direction of coolant flow) on valve towards heater inlet (bottom port).
T104607
18 1830 22
8. Connect the temperature control cable. Tighten all hose connections. A—Hose B—Heater Control Valve
9. Install rear cover behind seat. 10. Turn on the heater hose shut-off valve. 11. Install cab fresh air filter housing. 12. Add coolant to the radiator. Start engine and run the heating system to check for leaks. 13. Add more coolant to account for coolant in the heater circuit.
TX,1830,MM3164 –19–19OCT96–1/1
TM2136 (13DEC04)
18-1830-22
444J, 544J, 624J Loader 121304
PN=278
Heating and Air Conditioning
Heater Control Valve Leak Check 1. Connect water pressure hose to control valve inlet and turn the valve arm to the closed position. 2. Check for leakage from the valve outlet.
NOTE: The heater control valve is not serviceable.
18 1830 23
3. Replace heater control valve if required.
TX,1830,MM3165 –19–09JUN98–1/1
TM2136 (13DEC04)
18-1830-23
444J, 544J, 624J Loader 121304
PN=279
Heating and Air Conditioning
Main Blower Assembly Remove and Install
T104545
–UN–29OCT96
18 1830 24
A—Pressurizer Motor B—Inlet Plenum C—Expansion Valve D—Freeze Control Switch
E—Resistor F—AC/Heater Main Blower Motor H—Cap Screw
I—Lower Housing J—Heater/Evaporator Coil K—Heater Hose (2 used) L—Heater Valve
M—Air Conditioning Lines N—Housing O—Knob
1. Remove rear cover behind seat.
8. Remove heater/evaporator coil top cover.
2. Remove upper two screws attaching inlet plenum (B) to heater/evaporator coil top cover.
9. Remove lower two screws from main blower motor (F).
3. Disconnect main blower motor cooling tube from heater/evaporator coil top cover.
10. Remove and inspect main blower motor assembly.
4. Remove screws from heater/evaporator coil top cover. 5. Remove freeze control switch (D) probe from coil.
11. Check lower housing (I) to make sure drain tube is plugged for the heater unit, or that drain tube is not plugged for the air conditioning unit. 12. Attach main blower motor assembly to lower housing (I) using two screws.
6. Remove upper two cap screws from main blower motor (F).
13. Install heater/evaporator coil top cover.
7. Disconnect wire harness from freeze control switch (D) and resistor (E).
14. Connect wiring harness to resistor and freeze control switch.
Continued on next page
TM2136 (13DEC04)
18-1830-24
TX,1830,MM3166 –19–28SEP98–1/2
444J, 544J, 624J Loader 121304
PN=280
Heating and Air Conditioning 15. Attach two upper screws to main blower motor. 16. Connect cooling tube to heater/evaporator top cover.
17. Install upper two screws attaching inlet plenum to heater/evaporator coil top cover. 18. Install rear cover behind seat. TX,1830,MM3166 –19–28SEP98–2/2
Pressurizer Motor Assembly Remove and Install
18 1830 25
1. Remove cab left-hand shelf. 2. Disconnect cooling tube (B). 3. Remove four screws from pressurizer motor (A). 4. Disconnect wiring harness from pressurizer motor. 5. Remove and inspect pressurizer motor. 6. Attach pressurizer motor assembly using screws. 7. Install cab left-hand shelf.
T104610
–UN–29OCT96
A—Pressurizer Motor B—Cooling Tube
TX,1830,MM3167 –19–09JUN98–1/1
Receiver-Dryer and Condenser Remove and Install Receiver-Dryer Remove and Install Continued on next page
TM2136 (13DEC04)
18-1830-25
MX10672,0000031 –19–02DEC03–1/4
444J, 544J, 624J Loader 121304
PN=281
Heating and Air Conditioning
T193561
–UN–21AUG03
18 1830 26
Continued on next page
TM2136 (13DEC04)
18-1830-26
MX10672,0000031 –19–02DEC03–2/4
444J, 544J, 624J Loader 121304
PN=282
Heating and Air Conditioning 1—Screw M10 x 50 (2 used) 2—Screw M10 x 110 (4 used) 3—Washer (4 used)
4—Receiver-Dryer 5—Hose 6—Vapor Condenser
7—Refrigerant Hose 8—Spacer (4 used) 9—O-Ring (2 used)
10—Washer (8 used) 11—Clamp (2 used) 12—Clamp (2 used)
1. Evacuate and recover refrigerant from air conditioning system. See Evacuate R134a System. (Group 1830.)
6. Apply compressor oil to new O-Rings. Remove plugs from receiver-dryer and immediately connect lines.
2. Disconnect hoses (5 and 7) from receiver-dryer (4).
7. See R134a Component Oil Charge. (Group 1830.)
3. Loosen screws (1) on receiver-dryer mounting clamps (11).
8. Tighten screws (1) on receiver-dryer mounting clamps (11).
4. Remove receiver-dryer.
9. Charge air conditioning system. See Charge R134a System. (Group 1830.)
IMPORTANT: A new receiver-dryer must always be installed after purging the system. Do not use a flushed or used receiver/dryer. Contamination of system can cause component failure.
Condenser Remove and Install 1. Evacuate and recover refrigerant from air conditioning system. See Evacuate R134a System. (Group 1830.)
5. Remove plug from new receiver/dryer and add 15 mL (0.5 fl. oz.) of compressor oil. Install plug.
Continued on next page
TM2136 (13DEC04)
18-1830-27
MX10672,0000031 –19–02DEC03–3/4
444J, 544J, 624J Loader 121304
PN=283
18 1830 27
Heating and Air Conditioning 2. Open cooling package door. Disconnect air conditioning condenser-to-compressor hose (5) and condenser-to-receiver-dryer hose (7). Cap and plug openings.
4. Remove air conditioning condenser mounting cap screws (2), washers (10), washer (3), and spacers (8).
T196690A
18 1830 28
–UN–18DEC03
3. Open rear hood.
5. Remove air conditioning condenser (6) and repair or replace as necessary. Air Conditioning Condenser Hoses
6. Install condenser (6) using hardware (2, 3, 8 and 10). 7. Connect condenser-to-compressor hose (5) and condenser-to-receiver dryer hose (7).
5—Air Conditioning Condenser-to-Compressor Hose 6—Air Conditioning Condenser 7—Air Conditioning Condenser-to-Receiver-Dryer Hose
8. Charge air conditioning system. See Charge System with R134a. (Group 1830.)
MX10672,0000031 –19–02DEC03–4/4
TM2136 (13DEC04)
18-1830-28
444J, 544J, 624J Loader 121304
PN=284
Heating and Air Conditioning
A/C Binary Pressure Switch Remove and Install 1. Open left rear cab access door (1) by lifting on release lever left of operators seat. 2. See Fresh Air Filter Remove and Install. (Group 1830.) 18 1830 29
T192988A
–UN–10JUL03
1—Left Rear Access Door
Left Access Door
MX10672,0000032 –19–02DEC03–1/3
3. Disconnect wiring harness (2) from pressure switch (3).
T192987A
–UN–04DEC03
2—Wiring Harness 3—Pressure Switch
Pressure Switch Electrical Connector
Continued on next page
TM2136 (13DEC04)
18-1830-29
MX10672,0000032 –19–02DEC03–2/3
444J, 544J, 624J Loader 121304
PN=285
Heating and Air Conditioning
–UN–03JAN95
NOTE: A Schrader valve is located in the connection to prevent the air conditioning from discharging when the switch is removed.
5. Connect wiring harness (2) to pressure switch (3). 6. Install air filter and close access door (1).
MX10672,0000032 –19–02DEC03–3/3
Fresh Air Filter Remove and Install
–UN–12DEC96
1. Open cab fresh air filter door by pulling up on lever (A) to the left of the operator’s seat.
T105479B
A—Cab Door
TX,18,111479 –19–09JUN98–1/4
2. Remove filter assembly by turning knob (A).
–UN–12DEC96
A—Knob
T103187C
18 1830 30
T8389AF
4. Remove pressure switch (3). Inspect and replace as required.
Continued on next page
TM2136 (13DEC04)
18-1830-30
TX,18,111479 –19–09JUN98–2/4
444J, 544J, 624J Loader 121304
PN=286
Heating and Air Conditioning NOTE: If operating in dusty conditions, cab fresh air filter should be checked and cleaned as necessary. 3. Release clips (B). B—Clip (2 used)
T105493B
–UN–12DEC96
18 1830 31
Continued on next page
TM2136 (13DEC04)
18-1830-31
TX,18,111479 –19–09JUN98–3/4
444J, 544J, 624J Loader 121304
PN=287
Heating and Air Conditioning 4. Remove filter (C). Replace if damaged.
CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. • Tap filter on a flat surface with the dirty side down. • Use compressed air opposite to the normal air flow. • Wash the filter in warm, soapy water. Flush the filter. Let it dry before using the heater, defroster, or air conditioner.
T105494B
18 1830 32
–UN–12DEC96
5. Clean filter in one of these ways:
C—Filter
6. Remove dust from filter housing. IMPORTANT: Do not damage wire harness when installing filter housing. Wiring can get pinched and damaged. 7. Install filter and filter duct work. 8. Install filter housing assembly. Close cab fresh air filter door.
TX,18,111479 –19–09JUN98–4/4
TM2136 (13DEC04)
18-1830-32
444J, 544J, 624J Loader 121304
PN=288
Heating and Air Conditioning
Recirculating Air Filter Remove and Install NOTE: The cab recirculating air filter is located next to the seat.
–UN–12DEC96
1. Turn latch (A) holding grille. Remove grille. 2. Remove filter.
T105499B
CAUTION: Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment, including eye protection. A—Air Filter Latch
3. Clean filter in one of these ways: • Tap it on a flat surface with the dirty side down. • Use compressed air opposite to the normal air flow. • Wash the filter in warm, soapy water. Flush the filter and let it dry before using the air conditioner. 4. Install filter. 5. Install grille.
TX,18,111480 –19–28SEP98–1/1
TM2136 (13DEC04)
18-1830-33
444J, 544J, 624J Loader 121304
PN=289
18 1830 33
Heating and Air Conditioning
Compressor Remove and Install
TP48357
–UN–17AUG96
18 1830 34
1—Hose (to evaporator) 2—Hose (to condenser) 3—Screw (4 used) 4—Ring (2 used) 5—Flange Nut
6—Bracket 7—Screw 8—Bracket 9—Bracket 10—Screw (4 used)
11—Bracket 12—Washer (2 used) 13—Cap Screw (2 used) 14—Spacer 15—Washer
Continued on next page
TM2136 (13DEC04)
18-1830-34
16—Screw 17—Flange Nut (4 used) 18—O-Ring 19—Manifold 20—Compressor
TX,1830,MM3171 –19–28SEP98–1/2
444J, 544J, 624J Loader 121304
PN=290
Heating and Air Conditioning 1. Recover refrigerant from the system using procedure in this group. 2. Disconnect hoses (1 and 2). Remove compressor belt cap screw.
7. If compressor was replaced due to an internal failure, flush and purge each component in the air conditioning system individually. using procedure in this group. 8. Install a new receiver-dryer.
3. Disconnect electrical connector. 4. Remove compressor.
9. Evacuate and charge the system using procedure in this group.
5. Install compressor.
10. Make sure belt alignment is checked.
18 1830 35
6. Connect hoses and wiring lead.
TX,1830,MM3171 –19–28SEP98–2/2
TM2136 (13DEC04)
18-1830-35
444J, 544J, 624J Loader 121304
PN=291
Heating and Air Conditioning
Compressor Clutch—R134a Disassemble and Assemble
T107716
–UN–09MAY97
RW21157
–UN–24JUN92
18 1830 36
A—JDG747 Compressor Clutch Spanner B—Clutch Shaft Bolt
C—Clutch Hub D—Pulley Snap Ring
1. Mount compressor on holding fixture. 2. Remove dust cover.
E—Pulley F—Clutch Coil Snap Ring
3. Hold the clutch hub using JDG747 Compressor Clutch Spanner (A) and remove the clutch shaft bolt (B).
Continued on next page
TM2136 (13DEC04)
G—Clutch Coil H—Shim (As Required)
18-1830-36
TX,18,DY5297 –19–26OCT98–1/2
444J, 544J, 624J Loader 121304
PN=292
Heating and Air Conditioning 4. Remove the clutch hub (C). Remove the shims (H) from the clutch hub and save for installation. 5. Remove and discard snap ring (D). Remove the pulley (E) using a plastic hammer or JDG220 Puller, JDG748 Jaws, and JDG771 Hub Protector. 6. Disconnect the clutch coil lead wire. Remove and discard the snap ring (F) and remove the clutch coil (G).
NOTE: The bearing in the pulley is not serviceable. 7. Check pulley bearing operation. Replace pulley and bearing as required.
8. Install the clutch coil and new snap ring with flat side of the snap ring down. Connect the clutch coil lead wire. 9. Install the pulley and new snap ring with flat side of the snap ring down. Apply grease to the shims (H) and install to the clutch hub. 10. Install clutch hub and shaft bolt and tighten. Install dust cover. Specification Clutch Shaft Bolt—Torque ....................................................... 14 N•m 120 lb-in.
TX,18,DY5297 –19–26OCT98–2/2
Check Clutch Hub Clearance—R134a NOTE: The clutch coil is not polarity sensitive. 1. Check pulley-to-clutch hub clearance using a dial indicator. Mount the gauge to the pulley as illustrated and connect a set of jumper wires from the compressor to a 12V battery. 2. Rotate the pulley and check clearance in three equally spaced locations around the clutch hub. Add or remove shims as required. Specification Clutch Hub—Clearance ..................................................... 0.35—0.65 mm 0.014—0.026 in
RW21159
Specification Clutch Shaft Bolt—Torque.............................................................. 14 N•m 120 lb-in.
–UN–24JUN92
3. Tighten clutch shaft bolt after correct clearance is obtained.
TX,1830,BA636 –19–14OCT98–1/1
TM2136 (13DEC04)
18-1830-37
444J, 544J, 624J Loader 121304
PN=293
18 1830 37
Heating and Air Conditioning
18 1830 38
TM2136 (13DEC04)
18-1830-38
444J, 544J, 624J Loader 121304
PN=294
Section 19
Sheet Metal and Styling Contents Page
Group 1910—Hood or Engine Enclosure Hood Remove and Install. . . . . . . . . . . . . . .19-1910-1 Engine Side Shields Remove and Install . . .19-1910-2 19
TM2136 (13DEC04)
19-1
444J, 544J, 624J Loader 121304
PN=1
Contents
19
TM2136 (13DEC04)
19-2
444J, 544J, 624J Loader 121304
PN=2
Group 1910
Hood or Engine Enclosure Hood Remove and Install 1. Disconnect wiring harness to engine air filter restriction switch (3) and intake air temperature sensor. –UN–25SEP03
2. Loosen clamps (6 and 7).
T195065A
3. Remove air intake tube (4) from pre-cleaner (5) and turbocharger inlet. Plug and seal openings. 4. Remove all overflow hoses and retaining clips from hood.
19 1910 1
3—Engine Air Restriction Switch 4—Air Intake Tube 5—Pre-Cleaner 6—Pre-Cleaner-to-Air Intake Tube Clamp 7—Air Intake Tube-to-Turbo Clamp
TX,1910,111304 –19–11NOV03–1/2
5. Remove hood mounting hardware (2) from frame.
–UN–22SEP03
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
T194863A
6. Remove hood with exhaust stack and pre-cleaner using appropriate lifting device. Specification Hood—Weight ................................................................................... 50 kg 110 lb 1—Hood 2—Hood Mounting Hardware
7. Lift hood into place. 8. Install hood mounting hardware. 9. Install all overflow hoses and retaining clips to hood (1). 10. Remove plugs and seals and install air intake tube (4) between pre-cleaner (5) and turbocharger. Tighten clamps (6 and 7). 11. Connect wiring harness to engine air filter restriction switch (3) and intake air temperature sensor.
TX,1910,111304 –19–11NOV03–2/2
TM2136 (13DEC04)
19-1910-1
444J, 544J, 624J Loader 121304
PN=297
Hood or Engine Enclosure
Engine Side Shields Remove and Install 1. Remove retaining clip (2) from right engine side shield cylinder (3) and remove cylinder from ball stud. Specification Engine Side Shield—Weight— Approximate....................................................................................... 23 kg 50 lb
2. Remove washer reservoir (4) and coolant overflow reservoir (5) from left side shield (1).
–UN–25SEP03
CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Engine Side Shield—Weight— Approximate....................................................................................... 23 kg 50 lb
T195067A
19 1910 2
Left Side Shield
3. Lift side shield vertically to clear hinge pins and remove from machine.
1—Engine Side Shield 2—Engine Side Shield Cylinder Retaining Clip 3—Engine Side Shield Cylinder 4—Washer Fluid Reservoir 5—Coolant Overflow Reservoir
Continued on next page
TM2136 (13DEC04)
19-1910-2
TX,1910,111305 –19–11NOV03–1/2
444J, 544J, 624J Loader 121304
PN=298
Hood or Engine Enclosure 4. Remove mounting hardware (7) from lower access panel (6) hinge. Remove panel and hinge assembly and repeat procedure for other side of machine. 5. Make necessary repairs. 6. Align lower access panel (6) hinge and install attaching hardware (7). Repeat procedure for other side. 7. Align side shield hinge pins and lower side shield into place using appropriate lifting device. Repeat procedure for other side. –UN–25SEP03
8. Install washer fluid reservoir (4) and coolant overflow reservoir (5) on left side shield (1).
6—Mounting Hardware 7—Lower Access Panel Hinge
T195068A
9. Install engine side shield cylinder on to ball stud. Install retaining clip (2).
Left Lower Engine Access Panel
TX,1910,111305 –19–11NOV03–2/2
TM2136 (13DEC04)
19-1910-3
444J, 544J, 624J Loader 121304
PN=299
19 1910 3
Hood or Engine Enclosure
19 1910 4
TM2136 (13DEC04)
19-1910-4
444J, 544J, 624J Loader 121304
PN=300
Section 31
Loader Contents Page
Page
Group 3102—Bucket Bucket Remove and Install . . . . . . . . . . . . . .31-3102-1 Powerllel Pin-On Bucket Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-3 Welded Bucket Cutting Edges Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-5 Bolt-On Cutting Edges and Wear Plates Remove and Install . . . . . . . . . . . . . . . . . .31-3102-6 Cracked Cutting Edge Repair . . . . . . . . . . . .31-3102-8
Loader Control Valve Disassemble and Assemble (444J, 544J S.N. —594432) (624J) . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-17 Loader Control Valve Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-18 Auxiliary Valve Section and Bucket Section Disassemble and Assemble (444J, 544J S.N. —594432) (624J) . . . . . . . . . . . . . . .31-3160-20 Auxiliary Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-21 Bucket Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-22 Boom Valve Section Disassemble and Assemble (444J, 544J S.N. —594432) (624J) . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-23 Boom Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-24 Inlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-25 Outlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-26 Relief Valve Disassemble and Assemble (444J, 544J S.N. —594432) (624J) . . . . .31-3160-27 Circuit Relief Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-27 Bucket Circuit Relief Valve Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-28 Load Sense Relief Valve Disassemble and Assemble (444J, 544J S.N. —594432) (624J) . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-29 Load Sense Relief Valve Disassemble and Assemble (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-30 Boom Anti-Cavitation Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-31 Boom Cylinder Remove and Install . . . . . . .31-3160-31 Bucket Cylinder Remove and Install . . . . . .31-3160-33
Group 3140—Frames Loader Bucket Tilt Linkage Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-1 Bucket Linkage Seals and Bushings Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-2 Upper Tool Carrier Tilt Linkage Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . .31-3140-4 Lower Tool Carrier Tilt Linkage Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . .31-3140-6 Tool Carrier Disassemble and Assemble. . . .31-3140-8 Loader Boom Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-9 Tool Carrier Boom Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . .31-3140-10 Powerllel Leveling Link Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3140-12 Powerllel Bell Crank Remove and Install . . .31-3140-16 Powerllel Bucket Cylinder Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-22 Powerllel Bucket Link Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3140-28 Powerllel Guide Links Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-34 Powerllel Coupler Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3140-38 Powerllel Loader Boom Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3140-42 Group 3160—Hydraulic System Hydraulic Pump Remove and Install . . . . . . .31-3160-1 Hydraulic Pump Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-4 Loader Control Valve Remove and Install (444J, 544J S.N. —594432) (624J) . . . . .31-3160-10 Loader Control Valve Remove and Install (444J, 544J S.N. 594433— ) . . . . . . . . . .31-3160-14 TM2136 (13DEC04)
31-1
Continued on next page
444J, 544J, 624J Loader 121304
PN=1
31
Contents
Page
31
Boom and Bucket Cylinder Repair. . . . . . . .31-3160-34 Loader Start-Up Procedure . . . . . . . . . . . . .31-3160-35 Hydraulic Reservoir Remove and Install . . .31-3160-37 Pilot Control Valve Remove and Install . . . .31-3160-40 Pilot Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-41 Pressure Reducing Valve Manifold Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .31-3160-45 Pressure Reducing Valve Manifold Disassemble and Assemble. . . . . . . . . . .31-3160-47 Ride Control Valve Remove and Install . . . .31-3160-48 Ride Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-52 Ride Control Accumulator Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-53 Pin/Axle Disconnect Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-56 Pin Disconnect Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-57 Axle Disconnect Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-58 Fan Pump Remove and Install . . . . . . . . . .31-3160-59
TM2136 (13DEC04)
31-2
444J, 544J, 624J Loader 121304
PN=2
Group 3102
Bucket Bucket Remove and Install
T108202
–UN–26NOV97
31 3102 1
A—Shim, Bucket Link to Bucket (As Needed) B—Pin, Bucket Link to Bucket
C—Spacer (3 used) D—Washer (3 used) E—Cap Screw (3 used)
F—Grease Fitting (2 used) G—Pin, Bucket to Boom (2 used)
CAUTION: Approximate weight of 444J bucket; 1.5 M (2.0 yd) 833 kg (1837 lb), 1.9 M (2.5 yd) 915 kg (2018 lb). Approximate weight of 544J bucket; 1.9 M (2.5 yd) 1006 kg (2218 lb), 2.3 M (3.0 yd) 1078 kg (2377 lb). 1. Lower bucket to the ground. Bucket—Specification 444J Bucket 1.5 M (2.0 yd)— Weight—Approximate ............................................................... 833 kg 1837 lb 444J Bucket 1.9 M (2.5 yd)— Weight—Approximate ............................................................... 915 kg 2018 lb
544J Bucket 1.9 M (2.5 yd)— Weight—Approximate ............................................................. 1006 kg 2218 lb 544J Bucket 2.3 M (3.0 yd)— Weight—Approximate ............................................................. 1078 kg 2377 lb
2. Remove cap screws (E), washers (D), spacers (C), and pins (B and G). 3. Align boom ends with bucket. Install shims (H) between boom ends and bucket as needed to obtain maximum clearance.
Continued on next page
TM2136 (13DEC04)
H—Shim, Bucket to Boom (As Needed)
31-3102-1
TX,31,ME119 –19–14OCT98–1/2
444J, 544J, 624J Loader 121304
PN=303
Bucket Specification Boom End-to-Bucket— Clearance—Maximum ................................................................ 1 mm 0.04 in.
Install an equal number of shims ± 1 on each side of boom end. Install pins (G), spacers (C), washers (D), and cap screws (E). 4. Align bucket link with bucket. Install shims (A) between bucket link and bucket to obtain maximum
clearance. Specification Link-to-Bucket—Clearance— Maximum .................................................................................... 2 mm 0.08 in.
Install an equal number of shims ± 1 on each side of bucket link. Install pin (B), spacers (C), washers (D), and cap screws (E).
31 3102 2
TX,31,ME119 –19–14OCT98–2/2
TM2136 (13DEC04)
31-3102-2
444J, 544J, 624J Loader 121304
PN=304
Bucket
Powerllel Pin-On Bucket Remove and Install
1 7
4 6
8
3
2
5
7
2
–UN–22SEP04
31 3102 3
3 5 2
4—Pin, Bucket-to-Bucket Link 5—Grease Fitting (2 used) 6—Shim, Bucket-to-Bucket Link (as required)
CAUTION: Powerllel pin-on bucket is heavy and can cause injury if not moved properly. Use adequate lifting device to move pin-on bucket. Powerllel Loader—Specification 444J Powerllel Pin-On Bucket—Weight ................................................... 752 kg Approximate 1658 lb Approximate
7—Bushing (3 used)
8—Shim, Bucket-to-Boom (as required)
544J Powerllel Pin-On Bucket—Weight ................................................... 929 kg Approximate 2048 lb Approximate 624J Powerllel Pin-On Bucket—Weight ................................................. 1033 kg Approximate 2278 lb Approximate
1. Lower bucket to the ground.
Continued on next page
TM2136 (13DEC04)
T203378
7
T203378 1—Powerllel Pin-On Bucket 2—Cap Screw (3 used) 3—Pin, Bucket-to-Boom (2 used)
8
31-3102-3
TE14778,0000053 –19–21SEP04–1/2
444J, 544J, 624J Loader 121304
PN=305
Bucket
CAUTION: Avoid injury from sudden linkage movement. Support powerllel bell crank before removing any pins. 2. Support bell crank with hoist. 3. Remove cap screws (2), bushings (7), and pins (3 and 4). 4. Apply NEVER-SEEZ Lubricant or an equivalent to bores of bucket, loader boom, bucket link, and corresponding pivot pins.
Specification Boom End-to-Bucket— Clearance—Maximum ....................................................................... 1 mm 0.04 in.
Install pins (3), bushings (7), and cap screws (2). 6. Align bucket link with bucket. Install shims (6) between bucket link and bucket to obtain maximum clearance.
T202191A
31 3102 4
–UN–23SEP04
5. Align boom ends with bucket. Install shims (8) between boom ends and bucket as needed to obtain maximum clearance.
Specification Link-to-Bucket—Clearance— Maximum ........................................................................................... 2 mm 0.08 in.
Install pin (4), bushings (7), and cap screws (2).
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
TE14778,0000053 –19–21SEP04–2/2
31-3102-4
444J, 544J, 624J Loader 121304
PN=306
Bucket
Welded Bucket Cutting Edges Remove and Install 1. Perform welding in an environment with a minimum ambient temperature of 10°C (50°F).
5. Tack weld preheated plates starting at center of bucket and working toward the outside ends.
2. Clean all joints to be welded of all foreign matter such as dirt, rust, mill scale, oil, etc. with grinders and/or solvents.
6. Final weld preheated plates starting at the center of the front edge of the bucket backing plate and working toward the outside ends.
3. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: gas metal arc welding (CO2 or argon CO2) AWS-E70S6 or flux cored arc welding AWS-E70T1.
Repeat this operation at back edge of loader blade.
4. Preheat parts to be welded (both tack and final welds) to minimum of 204°C (400°F). Preheat temperature must be throughout the entire thickness of the parts joined and at least 51 mm (2 in.) back from the joint. Maintain preheat throughout the entire welding operation. Tempilstiks should be used if possible.
Tack welds may be incorporated into the final weld, providing they have been made with electrodes that meet the requirements of the final welds and no cracking has occurred in the weld metal. Tack welds not meeting these requirements must be completely removed by grinding or air arc gouging just prior to making the final weld in that area. 31 3102 5
7. Do not remove bucket from welding environment until weld metal temperature has dropped to the ambient temperature. Do not force cooling rate of weld metal.
Specification Bucket Cutting Edge—Preheat Temperature—Minimum throughout entire thickness of parts ........................................................................................... 204°C 400°F Distance—Minimum back from joint ........................................................................................... 51 mm 2 in.
TX,31,ME120 –19–14OCT98–1/1
TM2136 (13DEC04)
31-3102-5
444J, 544J, 624J Loader 121304
PN=307
Bucket
Bolt-On Cutting Edges and Wear Plates Remove and Install
TP48319
–UN–17APR96
31 3102 6
1—Nut (12 used)
2—Cutting Edge (2 used)
CAUTION: Use a lifting device for heavy components.
3—Cap Screw (12 used)
1.
Continued on next page
TM2136 (13DEC04)
4—Cutting Edge (2 used)
31-3102-6
TX,31,RP3077 –19–23SEP98–1/2
444J, 544J, 624J Loader 121304
PN=308
T109256
–UN–29APR97
Bucket
1—Wear Plate (2 used)
2—Cap Screw (8 used)
3—Washer (8 used)
Remove hardware and lift cutting edge from bucket. Remove hardware from wear plates and install new wear plates and hardware. 2. To install, hold cutting edge in position and install new hardware.
4—Nut (8 used)
Bucket:—Specification Cutting Edge-to-Bucket Cap Screw—Torque ...................................................................... 495 N•m 365 lb-ft Wear Plates-to-Bucket Cap Screw—Torque ...................................................................... 300 N•m 225 lb-ft
TX,31,RP3077 –19–23SEP98–2/2
TM2136 (13DEC04)
31-3102-7
444J, 544J, 624J Loader 121304
PN=309
31 3102 7
Bucket
Cracked Cutting Edge Repair 1. If cutting edge has any cracks, clean the area to find end of crack. 2. Drill a small hole at end of crack to prevent spreading. 3. Grind V-grooves along crack on top and bottom of cutting edge. 4. Preheat the cracked area. Specification Cracked Cutting Edge—Preheat Temperature .......................................................................... 149°—260°C 300°—500°F
5. Fill the V-grooves with weld. Use E7018 electrodes. Extend the weld. 31 3102 8
Specification Cracked Cutting Edge— Distance—Beyond End of Crack .................................................... 13 mm 0.5 in.
TX,31,ME122 –19–23SEP98–1/1
TM2136 (13DEC04)
31-3102-8
444J, 544J, 624J Loader 121304
PN=310
Group 3140
Frames Loader Bucket Tilt Linkage Remove and Install
T108207
–19–03APR97
31 3140 1
A—Bucket Cylinder B—Shim (As Required) C—Bell Crank D—Shim (As Required)
E—Grease Fitting (3 used) F—Seal (4 used) G—Bucket Link
1. Lower bucket to the ground. CAUTION: Use a lifting device for heavy components. 2. Remove parts as necessary.
H—Pin I—Spacer (2 used) J—Washer (2 used)
K—Cap Screw (2 used) L—Pin M—Loader Boom
Specification Bucket Cylinder Rod End-to-Bell Crank— Clearance—Maximum ................................................................ 3 mm 0.12 in.
4. Apply NEVER-SEEZ Lubricant or an equivalent to bore of bell crank pivot pin.
3. Install shims (B) and (D) to obtain maximum clearance.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
TX,31,ME126 –19–26OCT98–1/1
31-3140-1
444J, 544J, 624J Loader 121304
PN=311
Frames
Bucket Linkage Seals and Bushings Remove and Install
T108214
–19–26NOV97
31 3140 2
A—Bell Crank B—Seal (2 used)
C—Bucket Link D—Seal (4 used)
E—Bushing (2 used) F—Shim (As Required)
1. Remove and install bushings and seals in bucket link and bell crank using disks from driver set. 2. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. 3. Install bushings below surface. Specification Bucket Linkage Bushing— Distance—Below Surface ........................................................ 6.4 mm 0.25 in.
G—Bushing
Specification Bell Crank-to-Bucket Link— Clearance—Maximum ................................................................ 3 mm 0.12 in.
6. Install shims between bell crank and bucket to obtain maximum clearance. Specification Bell Crank-to-Bucket— Clearance—Maximum ................................................................ 2 mm 0.08 in.
7. Install shims between bell crank and loader boom to obtain maximum clearance.
4. Install seals into bores against bushings. 5. Install shims between bell crank and bucket link to obtain maximum clearance.
NEVER-SEEZ is a trademark of Emhart Chemical Group
TM2136 (13DEC04)
Continued on next page
31-3140-2
TX,3140,RP3044 –19–14OCT98–1/2
444J, 544J, 624J Loader 121304
PN=312
Frames Specification Bell Crank-to-Loader Boom— Clearance—Maximum ................................................................ 3 mm 0.12 in.
TX,3140,RP3044 –19–14OCT98–2/2
31 3140 3
TM2136 (13DEC04)
31-3140-3
444J, 544J, 624J Loader 121304
PN=313
Frames
Upper Tool Carrier Tilt Linkage Disassemble and Assemble
T108217
–UN–26NOV97
31 3140 4
A—Bell Crank (2 used) B—Pin Anchor (4 used) C—Cap Screw (4 used) D—Bushing (2 used)
E—Boom Upper Right End F—Seal (8 used) G—Bushing (8 used) H—Link (2 used)
I—Grease Fitting (6 used) J—Pin (2 used) K—Pin (4 used) L—Spacer (6 used)
M—Washer (6 used) N—Cap Screw (6 used) O—Washer (As Required) P—Bell Crank (2 used)
Specification Tool Carrier Tilt Linkage Bushing—Distance—Below outer face of link ......................................................................... 8 mm 0.31 in.
1. Lower attachment to the ground. CAUTION: Use a lifting device for heavy components. 2. Disassemble upper tilt linkage.
4. Install seals (F) against bushing with lips toward outside of bore.
3. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores.
5. Install pins (J and K) with flags outboard.
Install bushings (G) below outer face of link (H) using disks from driver set.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
Continued on next page
31-3140-4
TX,3140,DU755 –19–23SEP98–1/2
444J, 544J, 624J Loader 121304
PN=314
Frames 6. Install washers (O) under flags to obtain clearance between the boom (E) and bell cranks (A and P) and bucket cylinder ends. Specification Upper Tool Carrier Boom End-to-Coupler—Clearance— Maximum .................................................................................... 3 mm 0.125 in.
TX,3140,DU755 –19–23SEP98–2/2
31 3140 5
TM2136 (13DEC04)
31-3140-5
444J, 544J, 624J Loader 121304
PN=315
Frames
Lower Tool Carrier Tilt Linkage Disassemble and Assemble
T108220
–19–26NOV97
31 3140 6
A—Link (2 used) B—Seal (4 used) C—Seal (8 used) D—Pin (4 used)
E—Grease Fitting (4 used) F—Washer (As Required) G—Cap Screw (4 used) H—Washer (4 used)
I—Spacer (4 used) J—Loader Boom, Left Lower End K—Bushing (2 used)
L—Link (4 used) M—Anchor (4 used) N—Cap Screw (4 used) O—Bushing (4 used)
Specification Tool Carrier Tilt Linkage Bushing—Distance—Below outer face of link ......................................................................... 8 mm 0.31 in.
1. Lower attachment to the ground. CAUTION: Use a lifting device for heavy components. 2. Disassemble lower tilt linkage.
5. Install seals (B and C) against bushing with lips toward outside of bore.
3. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores.
6. Install pins (D) with flags outboard.
4. Install bushings (K and O) below outer face of link (A) using disks from driver set.
NEVER-SEEZ is a trademark of Emhart Chemical Group
TM2136 (13DEC04)
Continued on next page
31-3140-6
TX,3140,RP3045 –19–23SEP98–1/2
444J, 544J, 624J Loader 121304
PN=316
Frames 7. Install washers (F) under flags to obtain maximum clearance between the boom (J) and links (L) and link (A). Specification Lower Tool Carrier Boom-to-Link—Clearance— Maximum .................................................................................... 3 mm 0.125 in.
TX,3140,RP3045 –19–23SEP98–2/2
31 3140 7
TM2136 (13DEC04)
31-3140-7
444J, 544J, 624J Loader 121304
PN=317
Frames
Tool Carrier Disassemble and Assemble
T7011AU
–UN–21APR89
31 3140 8
A—Cap Screw B—Pin
C—Seal D—Bushing
E—Tool Carrier
1. Remove attachment from tool carrier.
F—Spacer
5. Install seals (C) against bushing with seal lip toward outside of bore.
2. Disconnect hoses to pin disconnect cylinders. 3. Remove cap screws and pins (A and B). Remove cap screws and pin from bucket tilt linkage.
6. Install spacers (F) on inside of each boom end as needed to obtain maximum clearance. Specification Tool Carrier Boom End— Clearance—Maximum ................................................................ 1 mm 0.04 in.
4. Install new bushing (D), from either side, below outer surface of bore. Specification Tool Carrier Bushing— Distance—Below outer surface of bore......................................................................................... 8 mm 0.31 in.
TX,3140,DU756 –19–23SEP98–1/1
TM2136 (13DEC04)
31-3140-8
444J, 544J, 624J Loader 121304
PN=318
Frames
Loader Boom Bushings and Seals Remove and Install
T108266
–UN–26NOV97
31 3140 9
A—Bushing (6 used)
B—Seal (12 used)
1. Lower bucket to the ground and remove bucket from boom.
C—Loader Boom
5. Remove bushings from boom using discs from driver set. 6. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. Center new bushings in boom bores and press seals against bushings with lips outward.
CAUTION: Use a lifting device for heavy components 2. Remove bucket cylinder and tilt linkage. 3. Disconnect boom cylinder rod ends from boom. 4. Remove boom pivot pins from machine frame and remove boom.
7. Install boom on machine and replace cylinders, linkage and bucket. Install shims in original locations. Measure clearances and adjust shims as required.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
TX,3140,RP3046 –19–23SEP98–1/1
31-3140-9
444J, 544J, 624J Loader 121304
PN=319
Frames
Tool Carrier Boom Bushings and Seals Remove and Install
T108276
–UN–26NOV97
31 3140 10
Left Side of Boom Shown A—Tool Carrier Boom B—Bushing (4 used)
C—Seal (8 used) D—Seal (4 used)
E—Bushing (2 used) F—Seal (8 used)
1. Lower boom to ground and remove attachment from tool carrier. CAUTION: Use a lifting device for heavy components. 2. Remove bucket tilt linkage and cylinders. 3. Disconnect boom cylinder rod ends from boom.
G—Bushing (4 used)
6. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. Center new bushings in boom bores and press seals against bushings with lips outward. 7. Install boom on machine and replace cylinders, linkage and bucket. Install shims in original locations. Measure clearances and adjust shims as required.
4. Remove boom pivot pins and remove boom. 5. Remove bushings from boom using discs from driver set.
NEVER-SEEZ is a trademark of Emhart Chemical Group
TM2136 (13DEC04)
TX,3140,RP3047 –19–24SEP98–1/1
31-3140-10
444J, 544J, 624J Loader 121304
PN=320
Frames
31 3140 11
TM2136 (13DEC04)
31-3140-11
444J, 544J, 624J Loader 121304
PN=321
Frames
Powerllel Leveling Link Disassemble and Assemble
T202168
–UN–13AUG04
31 3140 12
T202168 Continued on next page
TM2136 (13DEC04)
31-3140-12
TE14778,0000044 –19–22JUN04–1/5
444J, 544J, 624J Loader 121304
PN=322
Frames 1—Cap Screw (7 used) 2—Shim (as required) 3—Guide Link (2 used) 4—Bucket Link 5—Bushing 6—Bushing
7—Bushing 8—Bell Crank 9—Pin (2 used) 10—Pin 11—Pin (2 used) 12—Leveling Link
13—Bushing (2 used) 14—Bushing 15—Grease Fitting (6 used) 16—Shim (as required) 17—Seal (4 used) 18—Seal (6 used)
19—Shim (as required) 20—Shim (as required) 21—Bushing (5 used) 22—Plate (2 used) 23—Safety Decal (2 used) 24—Seal (2 used)
TE14778,0000044 –19–22JUN04–2/5
T201101A
–UN–13AUG04
1. Support boom with jack stands. Roll bucket forward until touching ground. If bucket isn’t attached to coupler, roll coupler forward and support with jack stand.
Continued on next page
TM2136 (13DEC04)
31-3140-13
TE14778,0000044 –19–22JUN04–3/5
444J, 544J, 624J Loader 121304
PN=323
31 3140 13
Frames
CAUTION: Powerllel leveling link is heavy and can cause injury if not moved properly. Use adequate lifting device to move leveling link.
–UN–13AUG04
Powerllel Loader—Specification 444J Powerllel Leveling Link— Weight......................................................................... 245 kg Approximate 540 lb Approximate 544J Powerllel Leveling link— Weight......................................................................... 276 kg Approximate 609 lb Approximate 624J Powerllel Leveling link— Weight......................................................................... 285 kg Approximate 628 lb Approximate
2. Support leveling link (12) with hoist.
31 3140 14
T201099A
3. Remove loader frame-to-leveling link pins. If necessary, remove light brackets to drive pins out. 4. Remove bell crank to leveling link pin (11). 5. Mark position of leveling link to aid in assembly and remove using hoist.
12—Leveling Link
6. Remove seals (17 and 18). 7. Remove bushings (13 and 14) using disks from driver set). 8. Apply NEVER-SEEZ Lubricant or an equivalent to outer surface of new bushings and bores. Install bushings (13 and 14) below outer surface of leveling link using disks from driver set. Powerllel Loader—Specification Powerllel Leveling Link Bushing— Distance below outer face of link .............................................. 9—11 mm 0.355—0.433 in.
9. Install seals (17 and 18) against bushings (13) with lips toward outside of bore. 10. Apply NEVER-SEEZ Lubricant or an equivalent to bores of leveling link (12), bell crank (8), loader frame, and corresponding pivot pins.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
Continued on next page
31-3140-14
TE14778,0000044 –19–22JUN04–4/5
444J, 544J, 624J Loader 121304
PN=324
Frames 11. Using hoist, install leveling link in position as marked during removal. 12. Install shims in original locations. Measure clearances and adjust shims as required. Powerllel Loader—Specification Leveling link-to-Loader Frame— Clearance—Maximum ....................................................................... 3 mm 0.12 in. Leveling link-to-Bell Crank— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
13. Install pins. 14. Install light brackets if removed.
TE14778,0000044 –19–22JUN04–5/5
TM2136 (13DEC04)
31-3140-15
444J, 544J, 624J Loader 121304
PN=325
31 3140 15
Frames
Powerllel Bell Crank Remove and Install
T202168
–UN–13AUG04
31 3140 16
T202168 Continued on next page
TM2136 (13DEC04)
31-3140-16
TE14778,0000045 –19–23JUN04–1/6
444J, 544J, 624J Loader 121304
PN=326
Frames 1—Cap Screw (7 used) 2—Shim (as required) 3—Guide Link (2 used) 4—Bucket Link 5—Bushing 6—Bushing
7—Bushing 8—Bell Crank 9—Pin (2 used) 10—Pin 11—Pin (2 used) 12—Leveling Link
13—Bushing (2 used) 14—Bushing 15—Grease Fitting (6 used) 16—Shim (as required) 17—Seal (4 used) 18—Seal (6 used)
19—Shim (as required) 20—Shim (as required) 21—Bushing (5 used) 22—Plate (2 used) 23—Safety Decal (2 used) 24—Seal (2 used)
TE14778,0000045 –19–23JUN04–2/6
1. Support boom with jack stands. Roll bucket forward until touching ground. If bucket isn’t attached to coupler, roll coupler forward and support with jack stand. –UN–13AUG04
2. Support leveling link (12) with hoist. 3. Remove bell crank-to-leveling link pin (10).
T201101A
4. Start machine and curl bucket. 5. Lift leveling link with hoist.
Continued on next page
TM2136 (13DEC04)
31-3140-17
TE14778,0000045 –19–23JUN04–3/6
444J, 544J, 624J Loader 121304
PN=327
31 3140 17
Frames 6. Place 51 mm (2.00 in.) x 152 mm (6.00 in.) wood block between leveling link and boom. Lower leveling link onto wood block. Place another 51 mm (2.00 in.) x 152 mm (6.00 in.) wood block across boom cylinders and close to front pins. 7. Start machine and curl bucket until bell crank (8) contacts wood block. 8. Support bucket cylinder with hoist. –UN–13AUG04
9. Remove bucket cylinder-to-bell crank pin (11).
T201114A
10. Lower bucket cylinder to loader frame. Place wood block between bucket cylinder and loader frame. 31 3140 18
Continued on next page
TM2136 (13DEC04)
31-3140-18
TE14778,0000045 –19–23JUN04–4/6
444J, 544J, 624J Loader 121304
PN=328
Frames
CAUTION: Avoid injury from sudden linkage movement. Support powerllel bell crank before removing any pins. 11. Support bell crank with hoist. 12. Remove wood block. 13. Remove bell crank-to-bucket link pin (11). CAUTION: Powerllel bell crank is heavy and can cause injury if not removed properly. Use adequate lifting device to remove bell crank.
T202191A
–UN–23SEP04
Powerllel Loader—Specification 444J Powerllel Bell Crank— Weight......................................................................... 162 kg Approximate 357 lb Approximate 544J Powerllel Bell Crank— Weight......................................................................... 190 kg Approximate 420 lb Approximate 624J Powerllel Bell Crank— Weight......................................................................... 236 kg Approximate 521 lb Approximate
14. Mark position of bell crank to aid in assembly and remove using hoist. 15. Apply NEVER-SEEZ Lubricant or an equivalent to bores of bell crank, bucket link, leveling link, bucket cylinder rod end, and corresponding pivot pins. 16. Using hoist, install bell crank (8) in position as marked during removal. 17. Install shims (2) in original locations. Measure clearances and adjust shims as required. Powerllel Loader—Specification Bell Crank-to-Bucket Link— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
18. Install bell crank-to-bucket link pin (11).
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
Continued on next page
31-3140-19
TE14778,0000045 –19–23JUN04–5/6
444J, 544J, 624J Loader 121304
PN=329
31 3140 19
Frames 19. Place 51 mm (2.00 in.) x 152 mm (6.00 in.) wood block across boom cylinders, close to front pins, to support bell crank (8). 20. Lift bucket cylinder using hoist. 21. Start engine. Extend or retract bucket cylinder as needed to pin components. 22. Install shims (20) in original locations. Measure clearances and adjust shims as required. Powerllel Loader—Specification Bell Crank-to-Bucket Cylinder— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
23. Install bell crank-to-bucket cylinder pin (11). 31 3140 20
24. Lift leveling link (12) using hoist. 25. Start engine. Extend or retract bucket cylinder as needed to pin components. 26. Install shims (19) in original locations. Measure clearances and adjust shims as required. Powerllel Loader—Specification Bell Crank-to-Leveling Link— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
27. Install bell crank-to-leveling link pin (10).
TE14778,0000045 –19–23JUN04–6/6
TM2136 (13DEC04)
31-3140-20
444J, 544J, 624J Loader 121304
PN=330
Frames
31 3140 21
TM2136 (13DEC04)
31-3140-21
444J, 544J, 624J Loader 121304
PN=331
Frames
Powerllel Bucket Cylinder Remove and Install
T202168
–UN–13AUG04
31 3140 22
T202168 Continued on next page
TM2136 (13DEC04)
31-3140-22
TE14778,0000052 –19–21SEP04–1/6
444J, 544J, 624J Loader 121304
PN=332
Frames 1—Cap Screw (7 used) 2—Shim (as required) 3—Guide Link (2 used) 4—Bucket Link 5—Bushing 6—Bushing
7—Bushing 8—Bell Crank 9—Pin (2 used) 10—Pin 11—Pin (2 used) 12—Leveling Link
13—Bushing (2 used) 14—Bushing 15—Grease Fitting (6 used) 16—Shim (as required) 17—Seal (4 used) 18—Seal (6 used)
19—Shim (as required) 20—Shim (as required) 21—Bushing (5 used) 22—Plate (2 used) 23—Safety Decal (2 used) 24—Seal (2 used)
1. Lower boom to ground and remove attachment from coupler.
TE14778,0000052 –19–21SEP04–2/6
CAUTION: Avoid injury from sudden linkage movement. Secure coupler to loader boom torque tube before removing any pins. 31 3140 23
2. Roll coupler back and block with 102 mm (4.00 in.) x 102 mm (4.00 in.) wood block (25). Secure to loader boom torque tube with tie down ratchet winch (26). 3. Raise boom to gain access to bucket cylinder-to-bell crank pin.
T203563A
–UN–29SEP04
25—102 mm (4.00 in.) x 102 mm (4.00 in.) Wood Block 26—Tie Down Ratchet Winch
Continued on next page
TM2136 (13DEC04)
31-3140-23
TE14778,0000052 –19–21SEP04–3/6
444J, 544J, 624J Loader 121304
PN=333
Frames 4. Support boom with jack stand. 5. Support bucket cylinder with hoist. 6. Remove bucket cylinder-to-bell crank pin. 7. Retract bucket cylinder rod. 8. Support bucket cylinder with two slings. 9. Disconnect hydraulic lines.
T203567A
–UN–29SEP04
31 3140 24
Continued on next page
TM2136 (13DEC04)
31-3140-24
TE14778,0000052 –19–21SEP04–4/6
444J, 544J, 624J Loader 121304
PN=334
Frames
CAUTION: Powerllel bucket cylinder is heavy and can cause injury if not removed properly. Use adequate lifting device to remove bucket cylinder. Powerllel Loader—Specification 444J Powerllel Bucket Cylinder— Weight........................................................................... 90 kg Approximate 198 lb Approximate 544J Powerllel Bucket Cylinder— Weight......................................................................... 118 kg Approximate 260 lb Approximate 624J Powerllel Bucket Cylinder— Weight......................................................................... 163 kg Approximate 360 lb Approximate
10. Remove loader frame-to-bucket cylinder pin and remove bucket cylinder.
–UN–29SEP04
11. Apply NEVER-SEEZ Lubricant or an equivalent to bores of bell crank, bucket cylinder, loader frame, and corresponding pivot pins.
T203568A
12. Using hoist, lower bucket cylinder into loader frame. Place wood block between bucket cylinder and loader frame. 13. Install bucket cylinder-to-loader frame shims in original locations. Measure clearances and adjust shims as required. Powerllel Loader—Specification Bucket Cylinder-to-Loader Frame—Clearance—Maximum ......................................................... 3 mm 0.12 in.
14. Install loader frame-to-bucket cylinder pin. 15. Connect hydraulic lines. 16. Raise bucket cylinder using hoist. 17. Start engine. Extend or retract bucket cylinder as needed to pin components. 18. Install shims (20) in original locations. Measure clearances and adjust shims as required.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
Continued on next page
31-3140-25
TE14778,0000052 –19–21SEP04–5/6
444J, 544J, 624J Loader 121304
PN=335
31 3140 25
Frames Powerllel Loader—Specification Bell Crank-to-Bucket Cylinder— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
19. Install bell crank-to-bucket cylinder pin (11).
TE14778,0000052 –19–21SEP04–6/6
31 3140 26
TM2136 (13DEC04)
31-3140-26
444J, 544J, 624J Loader 121304
PN=336
Frames
31 3140 27
TM2136 (13DEC04)
31-3140-27
444J, 544J, 624J Loader 121304
PN=337
Frames
Powerllel Bucket Link Disassemble and Assemble
T202168
–UN–13AUG04
31 3140 28
T202168 Continued on next page
TM2136 (13DEC04)
31-3140-28
TE14778,0000046 –19–23JUN04–1/7
444J, 544J, 624J Loader 121304
PN=338
Frames 1—Cap Screw (7 used) 2—Shim (as required) 3—Guide Link (2 used) 4—Bucket Link 5—Bushing 6—Bushing
7—Bushing 8—Bell Crank 9—Pin (2 used) 10—Pin 11—Pin (2 used) 12—Leveling Link
13—Bushing (2 used) 14—Bushing 15—Grease Fitting (6 used) 16—Shim (as required) 17—Seal (4 used) 18—Seal (6 used)
19—Shim (as required) 20—Shim (as required) 21—Bushing (5 used) 22—Plate (2 used) 23—Safety Decal (2 used) 24—Seal (2 used)
TE14778,0000046 –19–23JUN04–2/7
T201101A
–UN–13AUG04
1. Support boom with jack stands. Roll bucket forward until touching ground. If bucket isn’t attached to coupler, roll coupler forward and support with jack stand.
TE14778,0000046 –19–23JUN04–3/7
CAUTION: Avoid injury from sudden linkage movement. Support powerllel bell crank before removing any pins. 2. Support bell crank (8) with sling. 3. Remove bell crank-to-bucket link pin (11).
T202191A
–UN–23SEP04
4. Lower bell crank and remove hoist support. Place wood block between bell crank and loader frame.
Continued on next page
TM2136 (13DEC04)
31-3140-29
TE14778,0000046 –19–23JUN04–4/7
444J, 544J, 624J Loader 121304
PN=339
31 3140 29
Frames 5. Support bucket link (4) with hoist. 6. Remove bucket link-to-coupler pin.
T201138A
–UN–13AUG04
4—Bucket Link
31 3140 30
Continued on next page
TM2136 (13DEC04)
31-3140-30
TE14778,0000046 –19–23JUN04–5/7
444J, 544J, 624J Loader 121304
PN=340
Frames 7. Using hoist, move bucket link towards cab. Rest guide links (3) against bellcrank. 8. Remove bucket link-to-guide links pin (9).
–UN–18AUG04
CAUTION: Powerllel bucket link is heavy and can cause injury if not removed properly. Use adequate lifting device to remove bucket link.
T201139A
Loader—Specification 444J Powerllel Bucket Link— Weight......................................................................... 133 kg Approximate 294 lb Approximate 544J Powerllel Bucket Link— Weight......................................................................... 182 kg Approximate 401 lb Approximate 624J Powerllel Bucket Link— Weight......................................................................... 215 kg Approximate 475 lb Approximate
3—Guide Link
31 3140 31
9. Mark position of bucket link to aid in assembly and remove using hoist. 10. Remove seals (17, 18, and 24). 11. Remove bushings (5, 6, and 7) using disks from driver set 12. Apply NEVER-SEEZ Lubricant or an equivalent to outer surface of new bushings and bores. Install bushings (5, 6, and 7) below outer surface of leveling link using disks from driver set. Powerllel Loader—Specification Powerllel Bucket Link Bushing— Distance below outer face of link .............................................. 9—11 mm 0.355—0.433 in.
13. Install seals (17, 18, and 24) against bushings (5, 6, and 7) with lips toward outside of bore. 14. Apply NEVER-SEEZ Lubricant or an equivalent to bores of bell crank, bucket link, guide links, and corresponding pivot pins. 15. Using hoist, install bucket link in guide links as marked during removal.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
Continued on next page
31-3140-31
TE14778,0000046 –19–23JUN04–6/7
444J, 544J, 624J Loader 121304
PN=341
Frames 16. Install shims (16) in original locations. Measure clearances and adjust shims as required. Loader—Specification Bucket Link-to-Guide Links— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
17. Install bucket link-to-guide link pin (9). 18. Rotate bucket link and guide links toward bucket. 19. Install bucket link-to-coupler shims in original locations. Measure clearances and adjust shims as required.
31 3140 32
Loader—Specification Bucket Link-to-Coupler— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
20. Install bucket link-to-coupler pin. 21. Raise bell crank with hoist. 22. Install shims (19) in original locations. Measure clearances and adjust shims as required. Loader—Specification Bucket Link-to-Bell Crank— Clearance—Maximum ....................................................................... 3 mm 0.12 in.
23. Install bell crank-to-bucket link pin (11).
TE14778,0000046 –19–23JUN04–7/7
TM2136 (13DEC04)
31-3140-32
444J, 544J, 624J Loader 121304
PN=342
Frames
31 3140 33
TM2136 (13DEC04)
31-3140-33
444J, 544J, 624J Loader 121304
PN=343
Frames
Powerllel Guide Links Remove and Install
T202168
–UN–13AUG04
31 3140 34
T202168 Continued on next page
TM2136 (13DEC04)
31-3140-34
TE14778,0000047 –19–24JUN04–1/7
444J, 544J, 624J Loader 121304
PN=344
Frames 1—Cap Screw (7 used) 2—Shim (as required) 3—Guide Link (2 used) 4—Bucket Link 5—Bushing 6—Bushing
7—Bushing 8—Bell Crank 9—Pin (2 used) 10—Pin 11—Pin (2 used) 12—Leveling Link
13—Bushing (2 used) 14—Bushing 15—Grease Fitting (6 used) 16—Shim (as required) 17—Seal (4 used) 18—Seal (6 used)
19—Shim (as required) 20—Shim (as required) 21—Bushing (5 used) 22—Plate (2 used) 23—Safety Decal (2 used) 24—Seal (2 used)
TE14778,0000047 –19–24JUN04–2/7
T201101A
–UN–13AUG04
1. Support boom with jack stands. Roll bucket forward until touching ground. If bucket isn’t attached to coupler, roll coupler forward and support with jack stand.
TE14778,0000047 –19–24JUN04–3/7
CAUTION: Avoid injury from sudden linkage movement. Support powerllel bell crank before removing any pins.
T202191A
–UN–23SEP04
2. Support bell crank (8) with hoist.
Continued on next page
TM2136 (13DEC04)
31-3140-35
TE14778,0000047 –19–24JUN04–4/7
444J, 544J, 624J Loader 121304
PN=345
31 3140 35
Frames
46
39 36
38
47
31 3140 36
48 42
43
40
32 45
49
41
35
37
44
35
34
31
T203509
33
–UN–29SEP04
46
T203509 31—Cap Screw (2 used) 32—Guard 33—Cap Screw (3 used) 34—Screw (2 used) 35—Washer (4 used)
36—Washer 37—O-Ring 38—Bracket 39—Arm 40—Potentiometer
41—Lock Nut (2 used) 42—Bushing 43—O-Ring 44—Snap Ring 45—Plate
3. Remove Return-To-Dig guard cover (45).
46—Cap Screw (3 used) 47—Torsion Spring 48—Plate 49—Spacer
properly. Use adequate lifting device to remove guide links.
4. Disconnect return-to-dig harness connector. 5. Remove return-to-dig guard (32), bracket (38), and plate (22). 6. Remove loader boom-to-guide link pin (9). 7. Lower bell crank to loader frame. Place wood block between bell crank and loader frame. 8. Support guide links (3) with hoist. CAUTION: Powerllel guide links are heavy and can cause injury if not removed
Loader—Specification 444J Powerllel Guide Link— Weight .................................................................... 23 kg Approximate 50 lb Approximate 544J Powerllel Guide Link— Weight .................................................................... 29 kg Approximate 64 lb Approximate 624J Powerllel Guide Link— Weight .................................................................... 47 kg Approximate 104 lb Approximate
9. Mark position of guide links to aid in assembly. Remove guide link-to-bucket link pin (9) and guide links.
Continued on next page
TM2136 (13DEC04)
31-3140-36
TE14778,0000047 –19–24JUN04–5/7
444J, 544J, 624J Loader 121304
PN=346
Frames 10. Apply NEVER-SEEZ Lubricant or an equivalent to bores of bucket link, loader boom, guide links, and corresponding pivot pins. 11. Install upper guide link-to-bucket link shims in original locations. Measure clearances and adjust shims as required.
13. Raise bell crank using hoist. 14. Install lower guide link-to-loader frame shims in original locations. Measure clearances and adjust shims as required. Powerllel Loader—Specification Guide Links-to-Loader Frame— Clearance—Maximum ................................................................ 3 mm 0.12 in.
Powerllel Loader—Specification Guide Links-to-Bucket Link— Clearance—Maximum ................................................................ 3 mm 0.12 in.
15. Install guide link-to-loader boom pin.
12. Install upper guide link-to-bucket link pin.
16. Install plate (22) and return-to-dig bracket (38).
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TE14778,0000047 –19–24JUN04–6/7
NOTE: When installed, return-to-dig arm must be on right side of pin inside bracket.
–UN–28SEP04
17. While holding return-to-dig arm (39) away from stop, install return-to-dig guard (32) over bracket (38). 18. Connect return-to-dig harness connector.
T203522A
19. Install return-to-dig guard cover.
T203523A
–UN–29SEP04
20. Recalibrate return-to-dig. See Return-to-Dig Adjustment. (Group 9015-20.)
TE14778,0000047 –19–24JUN04–7/7
TM2136 (13DEC04)
31-3140-37
444J, 544J, 624J Loader 121304
PN=347
31 3140 37
Frames
Powerllel Coupler Disassemble and Assemble
T202013
–UN–03AUG04
31 3140 38
T202013 Continued on next page
TM2136 (13DEC04)
31-3140-38
TE14778,0000054 –19–04OCT04–1/3
444J, 544J, 624J Loader 121304
PN=348
Frames 1—Lock Nut (2 used) 2—Cap Screw (3 used) 3—Hex Socket Head Cap Screw (2 used) 4—Washer (6 used) 5—Elbow Fitting
6—O-Ring (2 used) 7—O-Ring 8—Fitting 9—O-Ring 10—Hydraulic Cylinder 11—Coupler
12—Pin, Coupler-to-Bucket Link 13—Pin, Coupler-to-Boom (2 used) 14—Grease Fitting (4 used) 15—Shim, Coupler-to-Bucket Link (as required)
1. Remove attachment from coupler. CAUTION: Powerllel Coupler is heavy and can cause injury if not moved properly. Use adequate lifting device to move coupler. Powerllel Loader—Specification 444J Powerllel Coupler— Weight .................................................................. 327 kg Approximate 721 lb Approximate
544J Powerllel Coupler— Weight .................................................................. 368 kg Approximate 811 lb Approximate 624J Powerllel Coupler— Weight .................................................................. 448 kg Approximate 987 lb Approximate
2. Roll coupler forward and support with wood blocks on floor.
Continued on next page
TM2136 (13DEC04)
16—Shim, Coupler-to-Boom (as required) 17—Bushing (3 used) 18—Pin, Coupler-to-Bucket (2 used)
31-3140-39
TE14778,0000054 –19–04OCT04–2/3
444J, 544J, 624J Loader 121304
PN=349
31 3140 39
Frames
CAUTION: Avoid injury from sudden linkage movement. Support bell crank before removing any pins. 3. Support bell crank with hoist. 4. Remove coupler-to-bucket link pin (12). 5. Remove hydraulic hose support plate with hoses from coupler. 6. Disconnect hydraulic hoses from hydraulic cylinder (10). 7. Remove coupler-to-boom pins (13). 8. Remove hex socket head cap screws (3) from hydraulic cylinder (18). –UN–23SEP04
9. Remove hydraulic cylinder and pins. 10. Install pins and hydraulic cylinder into coupler. 11. Apply NEVER-SEEZ Lubricant or an equivalent to bores of coupler, bucket link, loader boom, and corresponding pivot pins. 12. Using hoist, move coupler in position. Support with wood blocks as required.
T202191A
31 3140 40
12—Pin
13. Install shims (15 and 16) in original locations. Measure clearances and adjust shims as required. Powerllel Loader—Specification Powerllel Coupler Boom End— Clearance—Maximum ....................................................................... 1 mm 0.04 in. Powerllel Coupler Bucket Link End—Clearance—Maximum ............................................................. 1 mm 0.04 in.
14. Install pins. 15. Install hydraulic hose support plate with hoses onto coupler. Connect hoses.
NEVER-SEEZ is a trademark of Emhart Chemical Group.
TM2136 (13DEC04)
TE14778,0000054 –19–04OCT04–3/3
31-3140-40
444J, 544J, 624J Loader 121304
PN=350
Frames
31 3140 41
TM2136 (13DEC04)
31-3140-41
444J, 544J, 624J Loader 121304
PN=351
Frames
Powerllel Loader Boom Disassemble and Assemble
T202168
–UN–13AUG04
31 3140 42
T202168 Continued on next page
TM2136 (13DEC04)
31-3140-42
TE14778,0000055 –19–04OCT04–1/6
444J, 544J, 624J Loader 121304
PN=352
Frames 1—Cap Screw (7 used) 2—Shim (as required) 3—Guide Link (2 used) 4—Bucket Link 5—Bushing 6—Bushing
7—Bushing 8—Bell Crank 9—Pin (2 used) 10—Pin 11—Pin (2 used) 12—Leveling Link
13—Bushing (2 used) 14—Bushing 15—Grease Fitting (6 used) 16—Shim (as required) 17—Seal (4 used) 18—Seal (6 used)
19—Shim (as required) 20—Shim (as required) 21—Bushing (5 used) 22—Plate (2 used) 23—Safety Decal (2 used) 24—Seal (2 used)
1. Lower boom to ground and remove attachment from coupler.
Continued on next page
TE14778,0000055 –19–04OCT04–2/6
31 3140 43
TM2136 (13DEC04)
31-3140-43
444J, 544J, 624J Loader 121304
PN=353
Frames
CAUTION: Avoid injury from sudden linkage movement. Secure coupler to loader boom torque tube before removing any pins. 2. Roll coupler back and block with 102 mm (4.00 in.) x 102 mm (4.00 in.) wood block (25). Secure to loader boom torque tube with tie down ratchet winch (26). 3. Support leveling link (12) with hoist 4. Remove bell crank-to-bucket link pin (11). 5. Lower leveling link and bell crank (8) to loader frame. Place wood block between bell crank and loader frame.
–UN–29SEP04
6. Raise loader and install boom lock.
T203563A
31 3140 44
CAUTION: Prevent crushing injury. DO NOT work or allow work underneath or on attachment unless it is properly supported or resting on the ground.
7. Support bell crank and leveling link with hoist. 8. Remove bell crank-to-bucket cylinder pin (11). 25—102 mm (4.00 in.) x 102 mm (4.00 in.) Wood Block 26—Tie Down Ratchet Winch
9. Remove loader frame-to-leveling link pins. If necessary, remove light brackets to drive pins out. CAUTION: Powerllel leveling link and bell crank are heavy and can cause injury if not moved properly. Use adequate lifting device to move leveling link and bell crank. Powerllel Loader—Specification 444J Powerllel Leveling Link and bell crank—Weight ..................................................... 407 kg Approximate 897 lb Approximate 544J Powerllel Leveling link and bell crank—Weight ..................................................... 467 kg Approximate 1029 lb Approximate 624J Powerllel Leveling link and bell crank—Weight ..................................................... 521 kg Approximate 1149 lb Approximate
10. Remove leveling link and bell crank with hoist.
Continued on next page
TM2136 (13DEC04)
31-3140-44
TE14778,0000055 –19–04OCT04–3/6
444J, 544J, 624J Loader 121304
PN=354
Frames 11. Remove boom lock and lower loader boom. 12. Disconnect return-to-dig harness and hydraulic lines. 13. Support loader boom with hoist. 14. Remove loader cylinder-to-loader boom pins. 15. Remove loader boom-to-loader frame pins. CAUTION: Powerllel loader boom and components are heavy and can cause injury if not moved properly. Use adequate lifting device to move loader boom and components. Powerllel Loader—Specification 444J Powerllel Boom, Coupler, Guide Links, and Bucket Link— Weight....................................................................... 1079 kg Approximate 2379 lb Approximate 544J Powerllel Boom, Coupler, Guide Links, and Bucket Link— Weight....................................................................... 1318 kg Approximate 2907 lb Approximate 624J Powerllel Boom, Coupler, Guide Links, and Bucket Link— Weight....................................................................... 1693 kg Approximate 3733 lb Approximate
31 3140 45
16. Remove boom, coupler, guide links, and bucket link with hoist. CAUTION: Powerllel bucket cylinder is heavy and can cause injury if not removed properly. Use adequate lifting device to remove bucket cylinder. Powerllel Loader—Specification 444J Powerllel Bucket Cylinder— Weight........................................................................... 90 kg Approximate 198 lb Approximate 544J Powerllel Bucket Cylinder— Weight......................................................................... 118 kg Approximate 260 lb Approximate 624J Powerllel Bucket Cylinder— Weight......................................................................... 153 kg Approximate 337 lb Approximate
17. Remove bucket cylinder using hoist.
Continued on next page
TM2136 (13DEC04)
31-3140-45
TE14778,0000055 –19–04OCT04–4/6
444J, 544J, 624J Loader 121304
PN=355
Frames
T202014
–UN–03AUG04
31 3140 46
T202014
Continued on next page
TM2136 (13DEC04)
31-3140-46
TE14778,0000055 –19–04OCT04–5/6
444J, 544J, 624J Loader 121304
PN=356
Frames 1—Powerllel Loader Boom 2—Bushing 3—Bushing
4—Bushing 5—Bushing
6—Seal 7—Seal
18. Remove seals (6—9) from boom. 19. Remove bushings (2—5) from boom using discs from driver set. 20. Apply NEVER-SEEZ Lubricant or an equivalent on outer surface of new bushings and bores. Install bushings (2—5) below outer surface of boom using disks from driver set.
Powerllel Loader—Specification Powerllel Bucket Link Bushing—Distance below outer face of boom ....................................................................... 9—11 mm 0.355—0.433 in.
21. Install boom on machine and replace cylinders, linkage and bucket. Install shims in original locations. Measure clearances and adjust shims as required.
NEVER-SEEZ is a trademark of Emhart Chemical Group
TM2136 (13DEC04)
8—Seal 9—Seal
TE14778,0000055 –19–04OCT04–6/6
31-3140-47
444J, 544J, 624J Loader 121304
PN=357
31 3140 47
Frames
31 3140 48
TM2136 (13DEC04)
31-3140-48
444J, 544J, 624J Loader 121304
PN=358
Group 3160
Hydraulic System Hydraulic Pump Remove and Install NOTE: Perform Hydraulic Pump Flow Test (Group 9025-25) before removing hydraulic pump for repair. 1. Turn machine to maximum right steering stop for access to hydraulic pump. 2. Stop engine. 3. Lower all equipment to ground.
Continued on next page
TM2136 (13DEC04)
31-3160-1
TX,31,ME134 –19–17NOV03–1/3
444J, 544J, 624J Loader 121304
PN=359
31 3160 1
Hydraulic System IMPORTANT: Escaping fluid under pressure can penetrate the skin causing serious injury.
–UN–23AUG88
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.
31 3160 2
X9811
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 4. Perform Ride Control Accumulator Hydraulic Discharge procedure before servicing machine. 5. Perform Brake Accumulator Precharge Test and Boom Down Accumulator Precharge Test until accumulators are fully discharged. 6. Turn battery disconnect switch OFF. 7. Drain hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 8. Remove side access panels from both sides of machine.
Continued on next page
TM2136 (13DEC04)
31-3160-2
TX,31,ME134 –19–17NOV03–2/3
444J, 544J, 624J Loader 121304
PN=360
Hydraulic System 9. Remove hose bracket (1) mounting hardware (2) and secure pilot hoses (3) aside. 10. Remove all hydraulic hoses from pump. Cap and plug all openings. See Hydraulic System Component Location. (Group 9025-15.) CAUTION: Prevent possible injury from crushing. Use appropriate lifting device.
–UN–20NOV03
11. Attach DFT1132 Hydrostatic Motor Removal Tool to hydraulic pump and remove pump mounting cap screws.
T196459A
Specification Hydraulic Pump—Weight— Approximate......................................................................................... 8 kg 84 lb
12. Remove hydraulic pump. 13. Repair and replace parts as necessary.
1—Hose Bracket 2—Hose Bracket Mounting Hardware 3—Pilot Hoses
14. Replace gasket on pump mounting surface. 15. Install pump and pump mounting cap screws. 16. Fill pump body with hydraulic oil through case drain line to ensure lubrication for startup. 17. Connect all hydraulic hoses to pump. 18. Fill hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 19. Install hose bracket (1) and mounting hardware (2). 20. Install side access panels to both sides of machine. 21. Turn battery disconnect switch ON. 22. Perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.)
TX,31,ME134 –19–17NOV03–3/3
TM2136 (13DEC04)
31-3160-3
444J, 544J, 624J Loader 121304
PN=361
31 3160 3
Hydraulic System
Hydraulic Pump Disassemble and Assemble 1. Drain or apply vacuum to hydraulic oil reservoir. 2. Perform Hydraulic Pump Remove and Install procedure (Group 9025-25) until pump is removed from machine.
Continued on next page
DW09104,00000B6 –19–18NOV03–1/5
31 3160 4
TM2136 (13DEC04)
31-3160-4
444J, 544J, 624J Loader 121304
PN=362
Hydraulic System
31 3160 5
TM2136 (13DEC04)
31-3160-5
444J, 544J, 624J Loader 121304
PN=363
Hydraulic System
T195348
–UN–13NOV03
31 3160 6
Continued on next page
TM2136 (13DEC04)
31-3160-6
DW09104,00000B6 –19–18NOV03–2/5
444J, 544J, 624J Loader 121304
PN=364
Hydraulic System 1—Lock Washer 2—Cap Screw 3—Cap Screw 4—Tee Fitting 5—Adapter
6—O-Ring 7—O-Ring 8—Hydraulic Pump 9—O-Ring 10—Tee Fitting
11—O-Ring 12—O-Ring 13—Flange Fitting 14—Fitting 15—Cover
NOTE: Internal components of the hydraulic pump rotate group are not serviceable individually. Entire rotate group must be serviced as an assembly.
16—Quick Coupler 17—Tube 18—O-Ring 19—O-Ring
3.
Continued on next page
DW09104,00000B6 –19–18NOV03–3/5
31 3160 7
TM2136 (13DEC04)
31-3160-7
444J, 544J, 624J Loader 121304
PN=365
Hydraulic System
T195349
–UN–13NOV03
31 3160 8
Continued on next page
TM2136 (13DEC04)
31-3160-8
DW09104,00000B6 –19–18NOV03–4/5
444J, 544J, 624J Loader 121304
PN=366
Hydraulic System 1—Lock Washer 2—Cap Screw 3—Cap Screw 4—Tee Fitting 5—Adapter
6—O-Ring 7—O-Ring 8—Hydraulic Pump 9—O-Ring 10—Tee Fitting
Disassemble parts as shown. 4. Inspect and repair pump as necessary.
11—O-Ring 12—O-Ring 13—Flange Fitting 14—Fitting 15—Cover
16—Quick Coupler 17—Tube 18—O-Ring 19—O-Ring
6. Perform Hydraulic Pump Remove and Install procedure (Group 9025-25) until pump is installed on machine.
5. Assemble parts as shown.
DW09104,00000B6 –19–18NOV03–5/5
31 3160 9
TM2136 (13DEC04)
31-3160-9
444J, 544J, 624J Loader 121304
PN=367
Hydraulic System
Loader Control Valve Remove and Install (444J, 544J S.N. —594432) (624J)
–UN–23AUG88
1. Perform Ride Control Accumulator Hydraulic Discharge procedure. (Group 9025-20.) 2. Install boom locking bar.
X9811
3. Stop engine. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. 31 3160 10
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 4. Perform Brake Accumulator Precharge Test and Boom Down Accumulator Precharge Test until accumulators are fully discharged. 5. Turn battery disconnect switch OFF. 6. Drain hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 7. Remove control valve access panel from front of machine.
Continued on next page
TM2136 (13DEC04)
31-3160-10
DW09104,00000B9 –19–01DEC03–1/4
444J, 544J, 624J Loader 121304
PN=368
Hydraulic System 8. Loosen hold-down clamps on bucket and boom cylinder lines.
Continued on next page
DW09104,00000B9 –19–01DEC03–2/4
31 3160 11
TM2136 (13DEC04)
31-3160-11
444J, 544J, 624J Loader 121304
PN=369
Hydraulic System
T196688
–UN–05DEC03
31 3160 12
Loader Control Valve
Continued on next page
TM2136 (13DEC04)
31-3160-12
DW09104,00000B9 –19–01DEC03–3/4
444J, 544J, 624J Loader 121304
PN=370
Hydraulic System A—“B” Workport B—Circuit Relief C—Auxiliary Pilot D—Bucket Rollback Pilot E—Boom Raise Pilot F—Bucket Rollback G—Boom Raise
H—Load Sense Relief Valve— Maximum System Pressure I—Load Sense to Pump J—Shuttle Check Valves K—Return L—Return from Ride Control M—Boom Lower
NOTE: There is an orifice installed in the return port of the boom control valve section. The orifice is a double ORFS plate that is placed between the return fitting and hydraulic hose.
N—Bucket Dump O—Anti-Cavitation P—Boom Lower Pilot Q—Pressure Switch (ride control) R—Bucket Dump Pilot S—Auxiliary Pilot
T—Circuit Relief U—“A” Workport V—Relief Valve (clipper) W—Inlet from Pump X—Load Sense from Steering Y—Stroke Adjuster Z—Loader Control Valve
12. Replace parts as necessary. 13. Install loader control valve. Connect all lines and hoses.
9. Remove all hoses and lines from control valve. Cap and plug all openings. 10. Remove cap screws. 11. Remove loader control valve. 31 3160 13
Specification Loader Control Valve— Weight—Approximate ................................................................. 41 kg 90 lb
DW09104,00000B9 –19–01DEC03–4/4
TM2136 (13DEC04)
31-3160-13
444J, 544J, 624J Loader 121304
PN=371
Hydraulic System
Loader Control Valve Remove and Install (444J, 544J S.N. 594433— )
–UN–23AUG88
1. Perform Ride Control Accumulator Hydraulic Discharge procedure. (Group 9025-20.) 2. Install boom locking bar.
X9811
3. Stop engine. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. 31 3160 14
Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 4. Perform Brake Accumulator Precharge Test and Boom Down Accumulator Precharge Test until accumulators are fully discharged. 5. Turn battery disconnect switch OFF. 6. Drain hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 7. Remove control valve access panel from front of machine.
Continued on next page
TM2136 (13DEC04)
31-3160-14
DW09104,00000B9 –19–01DEC03–1/3
444J, 544J, 624J Loader 121304
PN=372
Hydraulic System 8. Loosen hold-down clamps on bucket and boom cylinder lines.
Continued on next page
DW09104,00000B9 –19–01DEC03–2/3
31 3160 15
TM2136 (13DEC04)
31-3160-15
444J, 544J, 624J Loader 121304
PN=373
Hydraulic System X
E
D
C B I
V
U
A
F
H
G
L
J W
31 3160 16
N
M
K
O
–UN–15JUL04
T
S R X
T201490
T201490
P Q Loader Control Valve
A—Auxiliary Workport “B” B—Circuit Relief C—Auxiliary Pilot D—Bucket Rollback Pilot E—Boom Raise Pilot F—Bucket Rollback Pilot G—Boom Raise Workport
H—Load Sense Relief Valve— Maximum Relief Pressure I—Load Sense to Pump J—C1 and C2 Check Valves K—Return L—Return from Ride Control M—Boom Lower Workport
NOTE: There is an orifice installed in the return port of the boom control valve section. The orifice is a double ORFS plate that is placed between the return fitting and hydraulic hose.
N—Bucket Dump Workport O—Anti-Cavitation Valve P—Boom Lower Pilot Q—Bucket Dump Pilot R—Auxiliary Pilot S—Circuit Relief
T—Auxiliary Workport “A” U—Relief Valve (clipper) V—Inlet From Pump W—Load Sense From Steering X—Stroke Adjuster (if equipped)
12. Replace parts as necessary. 13. Install loader control valve. Connect all lines and hoses.
9. Remove all hoses and lines from control valve. Cap and plug all openings. 10. Remove cap screws. 11. Remove loader control valve. Specification Loader Control Valve— Weight—Approximate ................................................................. 41 kg 90 lb
DW09104,00000B9 –19–01DEC03–3/3
TM2136 (13DEC04)
31-3160-16
444J, 544J, 624J Loader 121304
PN=374
Hydraulic System
Loader Control Valve Disassemble and Assemble (444J, 544J S.N. —594432) (624J) 1. Remove nuts and washers. Separate valve sections. 2. Replace parts as necessary. For more information: • See Auxiliary Valve Section and Bucket Section Disassemble and Assemble in this group. • See Boom Valve Section Disassemble and Assemble in this group. 3. Install seals (F). 4. Assemble sections. Tighten tie-bolt nuts to specification.
T108899
Loader Control Valve Tie-Bolt Nut—Torque ................................................................................... 56 N•m 42 lb-ft
–19–09APR97
Specification
A—Inlet Manifold B—Auxiliary Section Valve C—Bucket Section Valve D—Boom Section Valve E—Outlet Manifold F—Seal (13 used)
DW09104,00000CA –19–01DEC03–1/1
TM2136 (13DEC04)
31-3160-17
444J, 544J, 624J Loader 121304
PN=375
31 3160 17
Hydraulic System
Loader Control Valve Disassemble and Assemble (444J, 544J S.N. 594433— ) 1
2 3
3
31 3160 18
4 2
5
2
3
4
3
2
5
2
3
4
3 5
2
3
4
3
T201943
T201943
–UN–28JUL04
2
Loader Control Valve Disassemble and Assemble Continued on next page
TM2136 (13DEC04)
31-3160-18
MF82180,0000035 –19–04OCT04–1/2
444J, 544J, 624J Loader 121304
PN=376
Hydraulic System 1—Tie-Bolt (4 used) 2—O-Ring (9 used)
3—Seal (8 used)
4—O-Ring (4 used)
5—O-ring (3 used)
• See Outlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). (Group 3160.)
1. Remove tie-bolts and washers. Seperate valve sections. 2. Replace parts as necessary. • See Auxiliary Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). (Group 3160.) • See Bucket Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). (Group 3160.) • See Boom Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). (Group 3160.) • See Inlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ). (Group 3160.)
3. Install o-rings and seals. 4. Assemble sections. Tighten tie-bolt nuts to specification. Specification Loader Control Valve Tie-Bolt Nut—Torque ..................................................................... 51—62 N•m 37—46 lb-ft
31 3160 19
MF82180,0000035 –19–04OCT04–2/2
TM2136 (13DEC04)
31-3160-19
444J, 544J, 624J Loader 121304
PN=377
Hydraulic System
Auxiliary Valve Section and Bucket Section Disassemble and Assemble (444J, 544J S.N. —594432) (624J)
T108913
–19–09APR97
31 3160 20
Bucket Section Shown Bucket Valve:—Specification Socket Head Cap Screw— Torque...................................................................................... 11 N•m 100 lb-in. Valve C1 Check Hex Head Cap—Torque ......................................................................... 169 N•m 125 lb-ft
NOTE: Bucket valve section shown. Disassemble valve. Replace all O-rings and backup rings. IMPORTANT: Coat all internal surfaces with clean hydraulic oil. Apply thread lock and sealer (high strength) to threads of socket head cap screws.
TX,31,ME141 –19–02DEC03–1/1
TM2136 (13DEC04)
31-3160-20
444J, 544J, 624J Loader 121304
PN=378
Hydraulic System
Auxiliary Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— )
6
4
1
7
8
6
5
5
4 3
2
9
2
1
T201855
–UN–27JUL04
3
31 3160 21
T201855 Auxiliary Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ) 1—Nut (2 used) 2—Cartridge (2 used) 3—Hex Head Socket Cap Screw (4 used)
4—Nut (2 used) 5—Circuit Relief Valve (2 used)
1. Disassemble valve. 2. Replace parts as necessary. Replace all o-rings and backup rings IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 3. Assemble valve. Apply thread lock and sealer (high strength) to threads of hex head socket cap screws and stripper bolt. Tighten parts to specification. Auxiliary Valve Section—Specification Stroke Adjuster Nut—Torque ................................... 17.74—21.8 N•m 157—193 lb-in. Stroke Adjuster Cartridge— Torque......................................................................... 28.9—35.5 N•m 256—314 lb-in.
6—Check Valve (2 used) 7—Load Check Valve
8—Compensator Cap 9—Stripper Bolt
Hex Head Socket Cap Screw— Torque....................................................................... 10.17—11.3 N•m 90—100 lb-in. Relief Valve Lock Nut—Torque ................................ 17.74—21.8 N•m 157—193 lb-in. Relief Valve—Torque.............................................. 90.84—112.5 N•m 67—83 lb-ft Check Valve—Torque................................................. 8.14—9.94 N•m 72—88 lb-in. Load Check Valve—Torque ................................... 90.84—112.5 N•m 67—83 lb-ft Compensator Cap—Torque.................................... 90.84—112.5 N•m 67—83 lb-ft Stripper Bolt—Torque ............................................... 17.74—21.8 N•m 157—193 lb-in.
MF82180,0000037 –19–04OCT04–1/1
TM2136 (13DEC04)
31-3160-21
444J, 544J, 624J Loader 121304
PN=379
Hydraulic System
Bucket Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— )
5
3
6
7
5
4
4
3 2
1
31 3160 22
1 –UN–30JUL04
8
T201854
2
T201854 Bucket Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ) 1—Plug (2 used) 3—Hex Head Socket Cap Screw (4 used)
4—Nut (2 used) 5—Circuit Relief Valve (2 used)
1. Disassemble valve. 2. Replace parts as necessary. Replace all o-rings and backup rings IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 3. Assemble valve. Apply thread lock and sealer (high strength) to threads of hex head socket cap screws and stripper bolt. Tighten parts to specification. Bucket Valve Section—Specification Plug—Torque ............................................................ 10.17—11.3 N•m 90—100 lb-in.
6—Check Valve (2 used) 7—Load Check Valve
8—Compensator Cap 9—Stripper Bolt
Hex Head Socket Cap Screw— Torque....................................................................... 10.17—11.3 N•m 90—100 lb-in. Relief Valve Lock Nut—Torque ................................ 17.74—21.8 N•m 157—193 lb-in. Relief Valve—Torque.............................................. 90.84—112.5 N•m 67—83 lb-ft Check Valve—Torque................................................. 8.14—9.94 N•m 72—88 lb-in. Load Check Valve—Torque ................................... 90.84—112.5 N•m 67—83 lb-ft Compensator Cap—Torque.................................... 90.84—112.5 N•m 67—83 lb-ft Stripper Bolt—Torque ............................................... 17.74—21.8 N•m 157—193 lb-in.
MF82180,0000038 –19–04OCT04–1/1
TM2136 (13DEC04)
31-3160-22
444J, 544J, 624J Loader 121304
PN=380
Hydraulic System
Boom Valve Section Disassemble and Assemble (444J, 544J S.N. —594432) (624J)
T196697
–UN–04DEC03
31 3160 23
A—Anti-Cavitation Check B—Boom Down Workport C—C3 Shuttle D—Compensator Cap E—Compensator Assembly F—Boom Raise Workport
G—Steering Load Sense H—Plug I—Nut J—Hex Head Cap Screw K—Plug L—Boom Raise Pilot
M—Shuttle Pin N—Bleed to Outlet Section O—Steering Load Sense to Isolation Valve P—Check Cap Q—C1 Check
R—To Outlet Auxiliary and Bucket Sections T—Boom Lower Pilot U—Socket Head Cap Screw V—Plug W—Plug
1. Disassemble valve.
3. Assemble valve. Torque hardware to specification.
2. Replace all O-rings and backup rings.
Specification Socket Head Cap Screw— Torque...................................................................................... 11 N•m 100 lb-in. C1 Check Hex Head Cap— Torque.................................................................................... 169 N•m 125 lb-ft
IMPORTANT: Coat all internal surfaces with clean hydraulic oil.
NOTE: When assembling valve, apply thread lock and sealer (high strength) to threads of cap screws.
DW09104,00000CB –19–02DEC03–1/1
TM2136 (13DEC04)
31-3160-23
444J, 544J, 624J Loader 121304
PN=381
Hydraulic System
Boom Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— )
7
5
6
7
4 3 2
1
31 3160 24
T201853
8
–UN–27JUL04
1 2
T201853 Boom Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ) 1—Plug (2 used) 2—Hex Head Socket Cap Screw (4 used)
3—Plug 4—Anti-Cavitation Valve
5—Load Check Valve 6—Compensator Cap
1. Disassemble valve. 2. Replace parts as necessary. Replace all o-rings and backup rings IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 3. Assemble valve. Apply thread lock and sealer (high strength) to threads of hex head socket cap screws and stripper bolt. Tighten parts to specification. Bucket Valve Section—Specification Pilot Plug—Torque.................................................... 10.17—11.3 N•m 90—100 lb-in.
7—Check Valve (2 used) 8—Stripper Bolt
Hex Head Socket Cap Screw— Torque....................................................................... 10.17—11.3 N•m 90—100 lb-in. Boom Raise Plug—Torque ..................................... 90.84—112.5 N•m 67—83 lb-ft Anti-Cavitation Valve—Torque ............................... 90.84—112.5 N•m 67—83 lb-ft Load Check Valve—Torque ................................... 90.84—112.5 N•m 67—83 lb-ft Compensator Cap—Torque.................................... 90.84—112.5 N•m 67—83 lb-ft Check Valve—Torque................................................. 8.14—9.94 N•m 72—88 lb-in. Stripper Bolt—Torque ............................................... 17.74—21.8 N•m 157—193 lb-in.
MF82180,0000039 –19–04OCT04–1/1
TM2136 (13DEC04)
31-3160-24
444J, 544J, 624J Loader 121304
PN=382
Hydraulic System
Inlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ) 1
3
3
31 3160 25
2
T201852
–UN–26JUL04
2
T201852 Inlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ) 1—System Relief Valve Item
2—Plug (2 used)
3—Oriface Assembly (2 used)
Measurement
Specification
System Relief Valve
Torque
59—66 N•m 39—49 lb-ft
Plug
Torque
20—27 N•m 180—240 lb-in.
Oriface Assembly
Torque
3.5—4.5 lb-in. 30—40 lb-in.
Inlet Valve Section
MF82180,000003A –19–04OCT04–1/1
TM2136 (13DEC04)
31-3160-25
444J, 544J, 624J Loader 121304
PN=383
Hydraulic System
Outlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— )
3 2 4
5
1 7 6
T201851
–UN–26JUL04
31 3160 26
T201851 Outlet Valve Section Disassemble and Assemble (444J, 544J S.N. 594433— ) 1—Screen Assembly 2—Load Sense Relief Valve Item
3—Relief Valve Locknut 4—Plug
5—Plug 6—Plug
7—Cap
Measurement
Specification
Screen Assembly
Torque
14—17 N•m 126—154 lb-in.
Load Sense Relief Valve
Torque
51—62 N•m 450—550 lb-in.
Relief Valve Locknut
Torque
3.5—4.5 N•m 30—40 lb-in.
Plug
Torque
90.84—112.5 N•m 67—83 lb-ft
Cap
Torque
90.84—112.5 N•m 67—83 lb-ft
Outlet Valve Section
MF82180,000003B –19–04OCT04–1/1
TM2136 (13DEC04)
31-3160-26
444J, 544J, 624J Loader 121304
PN=384
Hydraulic System
Relief Valve Disassemble and Assemble (444J, 544J S.N. —594432) (624J)
2. Inspect parts for wear or damage.
T104612
3. O-rings, backup ring and spring are the only repair parts available.
–UN–22OCT96
1. Remove the adjusting screw (E).
4. Assemble relief valve. 5. Check pressure setting. See Loader System Relief and Circuit Relief Valve Pressure Test. (Group 9025-25.) A—Return B—Inlet C—Poppet D—Floating Seat E—Adjuster F—Plunger
31 3160 27
DW09104,00000C2 –19–20NOV03–1/1
Circuit Relief Valve Disassemble and Assemble
Inspect parts for wear or damage.
T108956
O-rings, backup ring and spring are the only repair parts available.
–19–11APR97
Remove adjusting screw from body.
TX,3100,RP3062 –19–24SEP98–1/1
TM2136 (13DEC04)
31-3160-27
444J, 544J, 624J Loader 121304
PN=385
Hydraulic System
Bucket Circuit Relief Valve Disassemble and Assemble (444J, 544J S.N. 594433— )
1
2
3
4
5
6
7
8
9
14 18
19
16
17
11
12
15
13
T201944
10
–UN–30JUL04
31 3160 28
T201944 Bucket Circuit Relief Valve Disassemble and Assemble (444J, 544J S.N. 594433— ) 1—Cartridge 2—O-Ring 3—Back-Up Ring 4—Poppet 5—O-Ring
6—Seal 7—Cartridge 8—O-Ring 9—Pilot Poppet 10—Anti-Cavitation Pin
1. Remove adjusting screw from body.
11—Spring 12—Cartridge 13—O-Ring 14—Spring Guide 15—Spring
16—Slug 17—Adjusting Screw 18—O-Ring 19—Lock Nut
3. O-rings, backup ring and spring are the only repair parts available.
2. Inspect parts for wear or damage.
MF82180,000003C –19–04OCT04–1/1
TM2136 (13DEC04)
31-3160-28
444J, 544J, 624J Loader 121304
PN=386
Hydraulic System
Load Sense Relief Valve Disassemble and Assemble (444J, 544J S.N. —594432) (624J)
1
4
3
5
1. Remove adjusting screw (1) from body (2).
1—Adjustment Screw 2—Body 3—Poppet 4—Spring 5—Inlet Screen
2
T195537
3. O-rings, backup ring and spring are the only repair parts available.
–UN–17OCT03
2. Inspect parts for wear or damage.
DW09104,00000C6 –19–21NOV03–1/1
TM2136 (13DEC04)
31-3160-29
444J, 544J, 624J Loader 121304
PN=387
31 3160 29
Hydraulic System
Load Sense Relief Valve Disassemble and Assemble (444J, 544J S.N. 594433— )
11
12
9
8
10
8
7
6
5
4
3
2
31 3160 30
T201945
–UN–28JUL04
1
T201945 Load Sense Relief Valve Disassemble and Assemble (444J, 544J S.N. 594433— ) 1—Cartridge 2—Seat 3—O-Ring
4—O-Ring 5—Back-Up Ring 6—Poppet
1. Remove adjusting screw (11) from body.
7—Spring 8—O-Ring (2 used) 9—Cap
10—Spring Guide 11—Adjustment Screw 12—Lock Nut
3. O-rings, backup ring and spring are the only repair parts available.
2. Inspect parts for wear or damage.
MF82180,000003C –19–04OCT04–1/1
TM2136 (13DEC04)
31-3160-30
444J, 544J, 624J Loader 121304
PN=388
Hydraulic System
Boom Anti-Cavitation Valve Disassemble and Assemble 1. Separate poppet and tube from relief valve body. –UN–05DEC03
2. Inspect parts for wear or damage.
T196700
3. O-rings, backup ring, and spring are the only repair parts available. 1—Relief Valve 2—Tube 3—Spring 4—Poppet 5—O-Ring Seal 6—Backup Ring 7—Plug
TX,3100,RP3063 –19–04OCT04–1/1
Boom Cylinder Remove and Install NOTE: Boom cylinder may be disassembled on the machine for seal and packing replacement. 1. Install frame locking bar. CAUTION: Prevent possible injury from crushing. Use appropriate lifting device and support boom cylinder before removing cylinder. 2. Raise and support boom using a hoist or support stands. 3. Perform Ride Control Accumulator Hydraulic Discharge procedure. (Group 9025-20.) CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. 4. Connect hoist to cylinder using lifting straps. Specification Boom Cylinder—Weight— Approximate....................................................................................... 70 kg 153 lb
Continued on next page
TM2136 (13DEC04)
31-3160-31
DW09104,00000C1 –19–20NOV03–1/2
444J, 544J, 624J Loader 121304
PN=389
31 3160 31
Hydraulic System 5. Disconnect cylinder lines (A and B). 6. Remove rod and head end pins (C and D). 7. Remove cylinder. 8. Repair or replace as necessary. 9. Install cylinder. Connect lines. IMPORTANT: When machine is started for first time after cylinder rebuild or oil is drained from cylinder, perform Loader Start-Up Procedure to prevent oil from “dieseling” inside cylinder. 10. Perform Loader Start-Up Procedure. (Group 3160.)
T108857B
–UN–09APR97
A—Cylinder Head End Line B—Cylinder Rod End Line C—Rod End Pin D—Head End Pin
–UN–09APR97
544 Shown
T108860B
31 3160 32
544 Shown
DW09104,00000C1 –19–20NOV03–2/2
TM2136 (13DEC04)
31-3160-32
444J, 544J, 624J Loader 121304
PN=390
Hydraulic System
Bucket Cylinder Remove and Install NOTE: Bucket cylinder may be disassembled on the machine for seal and packing replacement. –UN–05NOV96
1. Lower equipment to the ground.
T104844
2. Perform Ride Control Hydraulic Discharge procedure. (Group 9025-20.) 3. Install frame locking bar. 4. Remove bucket level indicator (A). 5. Remove clamps and disconnect wiring lead (B) to return-to-dig switch.
A—Bucket Level Indicator B—Wiring Lead
CAUTION: Prevent possible injury from crushing. Use appropriate lifting device.
31 3160 33
6. Connect hoist to cylinder using lifting straps. Specification Bucket Cylinder—Weight— Approximate....................................................................................... 70 kg 153 lb
DW09104,00000C0 –19–20NOV03–1/2
7. Disconnect head and rod end cylinder lines. 8. Remove head and rod end pins (A and B).
–UN–05NOV96
9. Remove cylinder. 10. Repair or replace as necessary.
IMPORTANT: When machine is started for first time after cylinder rebuild or oil is drained from cylinder, perform Loader Start-Up Procedure to prevent oil from “dieseling” inside cylinder.
T104843
11. Install cylinder. Connect lines.
A—Rod End Pin B—Head End Pin
12. Perform Loader Start-Up Procedure. (Group 3160.)
DW09104,00000C0 –19–20NOV03–2/2
TM2136 (13DEC04)
31-3160-33
444J, 544J, 624J Loader 121304
PN=391
Hydraulic System
Boom and Bucket Cylinder Repair To repair 120 Series cylinders, See Disassemble Cylinder. (120 Series Hydraulic Cylinders, TM-H120A, Group 01.) To repair 125 Series cylinders, See Disassemble Cylinder. (125 Series Hydraulic Cylinders, TM-H125A, Group 01.)
DW09104,00000C3 –19–20NOV03–1/1
31 3160 34
TM2136 (13DEC04)
31-3160-34
444J, 544J, 624J Loader 121304
PN=392
Hydraulic System
Loader Start-Up Procedure IMPORTANT: This procedure must be preformed whenever boom, or bucket cylinders are purged of oil. Failure to do so will result in internal damage to components. The following procedure is recommended to purge all air from system. 1. Pre-fill cylinder before connecting hydraulic lines. 2. Remove loader frame access cover. 3. Reduce maximum system pressure to specifications. See Maximum System Pressure Test. (Group 9025-05.) 31 3160 35
4. Boom Cylinder IMPORTANT: Perform procedure with engine at low idle (no acceleration). Raise boom until you are within 2—4 feet of full height. 5. Slowly lower the boom until bucket is 2—4 feet from ground and stop. 6. Repeat steps previous steps five times. 7. Slowly raise the boom to full height. 8. Slowly lower the boom to ground. 9. Repeat previous steps three times. 10. Bucket Cylinder Position boom at half way height and roll bucket within two feet of full roll back position. 11. Position bucket within 1 foot of full dump. 12. Repeat previous steps five times. 13. Position bucket to full rollback position. 14. Position bucket to full dump.
Continued on next page
TM2136 (13DEC04)
31-3160-35
CED,OUOE024,240 –19–05DEC03–1/2
444J, 544J, 624J Loader 121304
PN=393
Hydraulic System 15. Repeat previous steps three times. 16. Adjust maximum system pressure to specifications. See Maximum System Pressure Test. (Group 9025-25.) 17. Install loader frame access cover.
CED,OUOE024,240 –19–05DEC03–2/2
31 3160 36
TM2136 (13DEC04)
31-3160-36
444J, 544J, 624J Loader 121304
PN=394
Hydraulic System
Hydraulic Reservoir Remove and Install 1. Release hydraulic pressure by holding pilot enable/boom down switch and moving hydraulic control lever to boom float. 2. Turn battery disconnect switch to OFF. 3. Remove hood. See Hood Remove and Install. (Group 1910.) 4. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 5. Remove cab side skirts. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
31 3160 37
6. Attach JT01748 lifting bracket to rear platform and remove mounting hardware. Remove rear platforms. 7. Remove wiring harness tie bands on bottom of reservoir. 8. Remove wiring harness clamps from reservoir. 9. Remove clamp from radiator surge tank from left rear of reservoir. 10. Remove engine air heater fuse and relay block hardware (444J, 544J) and tie band aside. 11. Open drain valve on side of filter head and drain hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities
Continued on next page
TM2136 (13DEC04)
31-3160-37
BT40170,000008F –19–20NOV03–1/3
444J, 544J, 624J Loader 121304
PN=395
Hydraulic System 12. Disconnect all hoses from bottom of reservoir (1). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.
NOTE: Muffler can be removed for easy access to hydraulic reservoir. 13. Install JT01748 lifting brackets to hood mounting holes (4) on reservoir using 19M7786 cap screws.
–UN–13NOV03
Specification Hydraulic Oil Reservoir—Weight ..................................................... 118 kg 260 lb
31 3160 38
T196309
NOTE: Tilt top of reservoir toward rear of machine as it is lifted from machine in order to clear cab. 14. Remove reservoir-to-frame cap screw (2). Hydraulic Oil Reservoir
NOTE: If reservoir shows signs of contamination, Perform Hydraulic Oil Clean-UP Procedure in this group.
1—Hydraulic Oil Reservoir 2—Hydraulic Oil Reservoir Mounting Cap Screw (4 used) 3—Fill Tube 4—Thread Holes for Hood Mounting Hardware 5—Spacer Washer
15. Replace parts as necessary.
NOTE: Be sure to align two spacer washers (5) on left side of reservoir between tank and frame. 16. Install reservoir (1). Install reservoir-to-frame cap screws (2) and tighten to specification. Specification Reservoir-to-Frame Cap Screw— Torque .......................................................................................... 350 N•m 255 lb-ft
17. Connect all hydraulic hoses to bottom of reservoir. 18. Connect engine air heater fuse and relay block (444J, 544J) to reservoir. 19. Install clamp for radiator surge tank to left rear of reservoir. 20. Use tie band to secure engine air heater wiring harness to bottom of reservoir.
Continued on next page
TM2136 (13DEC04)
31-3160-38
BT40170,000008F –19–20NOV03–2/3
444J, 544J, 624J Loader 121304
PN=396
Hydraulic System 21. Attach engine air heater wiring harness clamp to left rear side of reservoir. 22. Attach JT01748 lifting bracket to rear platform and install rear platforms. 23. Install cab side skirts. 24. Install engine side shields. 25. Install hood. 26. Fill hydraulic oil reservoir with recommended oil. See Hydraulic Reservoir Oil. (Operator’s Manual.) 27. Turn battery disconnect switch ON.
BT40170,000008F –19–20NOV03–3/3
TM2136 (13DEC04)
31-3160-39
444J, 544J, 624J Loader 121304
PN=397
31 3160 39
Hydraulic System
Pilot Control Valve Remove and Install CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before working in frame hinge area. 1. Install frame locking bar. 2. Stop engine. 3. Discharge ride control accumulator. See Ride Control Accumulator Hydraulic Discharge. (Group 9025-20.) 4. Discharge brake accumulators. Perform Brake Accumulator Precharge Test until brake accumulators are totally discharged. (Group 9025-25.) 5. Turn battery disconnect switch OFF. 31 3160 40
6. Remove pilot control trim panel. 7. Drain or apply vacuum to hydraulic reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 8. Open load center service door on right side of machine. 9. Remove all electrical connectors from pilot control valve(s).
Continued on next page
TM2136 (13DEC04)
31-3160-40
DW09104,00000CC –19–02DEC03–1/2
444J, 544J, 624J Loader 121304
PN=398
Hydraulic System NOTE: For machines equipped with single lever control and auxiliary hydraulics, remove pilot control console to gain access to STC connectors at auxiliary hydraulic valve. –UN–24NOV03
NOTE: STC tool supplied with vehicle and located in operator’s manual packet.
IMPORTANT: Do not twist control lever handle/knobs. Damage may occur to wires.
T196380A
10. Remove hydraulic hoses from pilot control valve(s) using JDG1385 STC tool. Cap and plug all openings.
Pilot Control Lines (Single Lever with Auxiliary Function Shown) 7—Pilot Control Valve 8—Pilot Control Valve Lines 9—Auxiliary Pilot Control Valve Lines
12. Install pilot controller(s) and connect lines. 13. Remove vacuum or fill hydraulic reservoir. 14. Operate machine and check for leaks at hydraulic connections.
31 3160 41
DW09104,00000CC –19–02DEC03–2/2
Pilot Control Valve Disassemble and Assemble Perform Pressure Reducing Valve Pressure Test. (Group 9025-25) before disassembling pilot control valve. 1. Perform Pilot Control Valve Remove and Install procedure in this group.
Continued on next page
TM2136 (13DEC04)
31-3160-41
DW09104,00000CD –19–02DEC03–1/5
444J, 544J, 624J Loader 121304
PN=399
Hydraulic System
T196147
–UN–13NOV03
31 3160 42
Continued on next page
TM2136 (13DEC04)
31-3160-42
DW09104,00000CD –19–02DEC03–2/5
444J, 544J, 624J Loader 121304
PN=400
Hydraulic System 1—Pilot Control Lever with Wiring Harness 2—Universal Joint
3—Solenoid 4—Guide 5—Push Pin
6—Pilot Control Spool Assembly
7—Boot 8—Pilot Control Valve
2.
Continued on next page
DW09104,00000CD –19–02DEC03–3/5
31 3160 43
TM2136 (13DEC04)
31-3160-43
444J, 544J, 624J Loader 121304
PN=401
Hydraulic System
T194881
–UN–24OCT03
31 3160 44
Continued on next page
TM2136 (13DEC04)
31-3160-44
DW09104,00000CD –19–02DEC03–4/5
444J, 544J, 624J Loader 121304
PN=402
Hydraulic System 1—Pilot Control Lever 2—Pilot Control Lever with Quickshift Switch
3—Armature 4—Solenoid 5—Adjustable Stop
6—Plate 9—Plate 10—Quickshift Switch
11—Boot 13—Pilot Control Valve
Disassemble and assemble parts as shown.
DW09104,00000CD –19–02DEC03–5/5
Pressure Reducing Valve Manifold Remove and Install 1. Turn engine off. Operate controls 20 times while holding pilot enable/boom down switch on to release hydraulic pressure.
31 3160 45
2. Apply vacuum to hydraulic oil reservoir.
Continued on next page
TM2136 (13DEC04)
31-3160-45
DW09104,00000B8 –19–20NOV03–1/2
444J, 544J, 624J Loader 121304
PN=403
Hydraulic System 3. Disconnect all electrical harnesses (3).
31 3160 46
T196112A
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
–UN–05NOV03
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. Pressure Reducing Valve Manifold 1—Pressure Reducing Manifold 2—Pressure Reducing Manifold Mounting Hardware (2 used) 3—Solenoid Electrical Harness (3 used)
4. Disconnect all hydraulic hoses and lines from manifold. Cap and plug openings. 5. Remove manifold mounting hardware (2) and remove manifold (1). 6. Replace parts as necessary. See Pressure Reducing Valve Manifold Disassemble and Assemble . 7. Install manifold (1). 8. Connect all hoses, lines, and electrical harnesses (3). 9. Fill hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 444J Drain and Refill Capacities 544J Drain and Refill Capacities 644J Drain and Refill Capacities 10. Adjust pilot control pressure. See Pressure Reducing Valve Pressure Test. (Group 9025-25.)
DW09104,00000B8 –19–20NOV03–2/2
TM2136 (13DEC04)
31-3160-46
444J, 544J, 624J Loader 121304
PN=404
Hydraulic System
Pressure Reducing Valve Manifold Disassemble and Assemble NOTE: Pressure reducing valve is not serviceable. If O-rings and orifice are OK, but pilot pressure cannot be adjusted within specification, replace pressure reducing valve. 1. Remove pressure reducing valve (2) from manifold (1). Inspect for dirty, worn, or damaged parts. 2. Remove orifice from inside pressure reducing manifold (1). Inspect for damage or plugged passage. 3. Replace orifice if damaged. 4. Install new O-rings and backup rings on pressure reducing valve and install parts in manifold. –UN–05NOV03
5. Remove pilot, differential lock, and boom down solenoids.
T196081A
6. Inspect for dirty, worn, or damaged parts. Check that spool inside solenoid valve moves freely. If spool does not move freely or if valve looks worn or damaged, replace complete solenoid assembly. Pressure Reducing Valve Manifold
7. Install solenoid valve using new O-rings and backup rings. 8. Install solenoid in manifold and tighten mounting hardware to specification. Specification Solenoid Valve Mounting Hardware—Torque ........................................................................... 7 N•m 62 lb-in.
1—Pressure Reducing Manifold 2—Pressure Reducing Valve 3—Pressure Reducing Valve Adjustment Screw 4—Pressure Reducing Valve Adjustment Locking Nut 5—Regulated Pressure Test Port 6—Pump Outlet Pressure Test Port
MX10672,000002A –19–20NOV03–1/1
TM2136 (13DEC04)
31-3160-47
444J, 544J, 624J Loader 121304
PN=405
31 3160 47
Hydraulic System
Ride Control Valve Remove and Install
X9811
–UN–23AUG88
CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the ride control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components. If ride control is operational, perform Ride Control Hydraulic Discharge. (Group 9025-25.) 31 3160 48
Continued on next page
TM2136 (13DEC04)
31-3160-48
TX,31,ME161 –19–25NOV03–1/3
444J, 544J, 624J Loader 121304
PN=406
Hydraulic System
31 3160 49
TM2136 (13DEC04)
31-3160-49
444J, 544J, 624J Loader 121304
PN=407
Hydraulic System
T157361
–UN–17JUL02
31 3160 50
Continued on next page
TM2136 (13DEC04)
31-3160-50
TX,31,ME161 –19–25NOV03–2/3
444J, 544J, 624J Loader 121304
PN=408
Hydraulic System 1—Label 2—Lock Nut 3—Washer 4—Screw 5—Clamp 6—Safety Sign 7—Screw 8—Ride Control Valve 9—O-Ring 10—Cover 11—Fitting
12—O-Ring 13—Elbow Fitting 14—O-Ring 15—Elbow Fitting 16—Elbow Fitting 17—O-Ring 18—Switch 19—O-Ring 20—Adapter 21—Adapter
22—Hydraulic Hose 23—O-Ring 24—Hydraulic Line 25—O-Ring 26—Hydraulic Hose 27—Hydraulic Line 28—Adapter 29—O-Ring 30—Hydraulic Hose 31—O-Ring
32—Adapter 33—O-Ring 34—Adapter 35—Accumulator 36—Hydraulic Hose 37—Relay 38—Rocker Switch (Included with kit but not standard on machine) 39—Wiring Harness
CAUTION: Present possible injury from crushing when removing ride control accumulator. Use appropriate lifting device. 2. Replace ride control parts as necessary. Specification Accumulator—Weight— Approximate ................................................................................ 40 kg 88 lb
31 3160 51
TX,31,ME161 –19–25NOV03–3/3
TM2136 (13DEC04)
31-3160-51
444J, 544J, 624J Loader 121304
PN=409
Hydraulic System
X9811
–UN–23AUG88
Ride Control Valve Disassemble and Assemble
T157009
–UN–09JUL02
31 3160 52
1—Ride Control Boom Solenoid (Y17) 2—Ride Control On/Off Solenoid (Y18)
3—Ride Control On/Off Solenoid (Y34) 4—Flow Control Valve
5—Flow Control Valve 6—Flow Control Valve
Continued on next page
TM2136 (13DEC04)
31-3160-52
7—Ride Control Manifold Valve
DW09104,00000C7 –19–25NOV03–1/2
444J, 544J, 624J Loader 121304
PN=410
Hydraulic System
CAUTION: Hydraulic oil may escape at pressure high enough to penetrate skin from components in the Ride Control solenoid circuit if components are removed without discharging the accumulator. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures. If ride control is NOT operational, the ride control accumulator must be discharged by releasing gas charge before starting repair of control valve or any of its components. If ride control is operational, perform Ride Control Hydraulic Discharge. (Group 9025-25.)
NOTE: Ride control components can be replaced while valve is on machine. Internal parts of solenoid and check valves are not serviceable. 1. Remove and inspect solenoids (1—3). Replace O-rings and backup rings as required. 2. Remove check valve and inspect. Replace O-rings and backup rings as required. 3. Install solenoids and tighten nut to specification. Specification Ride Control Solenoid Nut— Torque........................................................................................ 8 N•m 72 lb-in.
DW09104,00000C7 –19–25NOV03–2/2
Ride Control Accumulator Disassemble and Assemble 1. Perform Ride Control Accumulator Hydraulic Discharge procedure. (Group 9025-20.) 2. Perform Ride Control Valve Remove and Install in this group.
Continued on next page
TM2136 (13DEC04)
31-3160-53
DW09104,00000C8 –19–25NOV03–1/5
444J, 544J, 624J Loader 121304
PN=411
31 3160 53
Hydraulic System
CAUTION: Accumulator is gas charged and will cause end cap to blow out with deadly force if disassembly is attempted while charged. Do not disassemble ride control accumulator if not totally discharged.
NOTE: Loosen only the top special nut. The bottom "nut" is the accumulator gas valve. 3. Rotate cap (A) counterclockwise 2 1/2 turns to open gas valve and bleed off gas charge. Resistance may be felt at approximately 1 1/2 turns. 4. Remove gas valve (E).
NOTE: Both ends of accumulator are removed the same way. Piston can be removed from either end.
–UN–20NOV92
5. Remove end cap using spanner wrench and remove piston. A—Cap B—Accumulator Barrel C—Piston D—End Cap E—Gas Valve
T7893AJ
31 3160 54
Continued on next page
TM2136 (13DEC04)
31-3160-54
DW09104,00000C8 –19–25NOV03–2/5
444J, 544J, 624J Loader 121304
PN=412
Hydraulic System 6. Remove old seals from piston (E). 7. Install center O-ring (C) with split backup ring (B) on both sides of O-ring. 8. Install O-ring (D) in outer groove with wear ring (A) on top of O-ring. 9. Repeat procedure for opposite side of accumulator.
T7893AL
–UN–20NOV92
A—Wear Ring (2 used) B—Split Backup Ring (2 used) C—Special O-Ring Seal D—Inner O-Ring Seal (2 used) E—Piston
DW09104,00000C8 –19–25NOV03–3/5
10. Remove O-ring and backup ring. 11. Install backup ring (B) with flat surface to inside of groove. –UN–20NOV92
12. Install O-ring (C) next to curved surface of backup ring.
T7893AK
A—End Cap B—Backup Ring C—O-Ring
Continued on next page
TM2136 (13DEC04)
31-3160-55
DW09104,00000C8 –19–25NOV03–4/5
444J, 544J, 624J Loader 121304
PN=413
31 3160 55
Hydraulic System IMPORTANT: Put piston next to gas valve end to reduce amount of air in accumulator before charging. 13. Install piston (C) with hollow end toward gas valve in barrel (B). 14. Install end cap (D) and gas valve (E). Install other end cap if removed. 15. See Charge Ride Control Accumulator. (Group 9025-20.) 16. Install accumulator on machine. See Ride Control Valve Remove and Install in this group.
–UN–20NOV92 T7893AJ
31 3160 56
A—Cap B—Accumulator Barrel C—Piston D—End Cap E—Gas Valve
DW09104,00000C8 –19–25NOV03–5/5
Pin/Axle Disconnect Valve Remove and Install 1. Lower equipment to the ground. 2. Perform Ride Control Accumulator Hydraulic Discharge procedure. (Group 9025-20.) CAUTION: Prevent possible injury from compressed fluid. Discharge brake accumulators before working on Pin Disconnect/Axle Disconnect Valve. Brake accumulators supply pressure oil to pin disconnect valve when engine is off. 3. Perform Brake Accumulator Precharge Test (Group 9025-25) until brake accumulators are totally discharged. 4. Mark hoses and harness connectors for reference during assembly. Disconnect hoses and harness connectors.
Continued on next page
TM2136 (13DEC04)
31-3160-56
DW09104,00000C4 –19–20NOV03–1/2
444J, 544J, 624J Loader 121304
PN=414
Hydraulic System 5. Remove cap screws (B) and remove valve. 6. Replace O-rings, install valve and connect hoses and harness connectors.
T109182
–UN–18APR97
A—Lock Nut (2 used) B—Cap Screw (2 used) C—Solenoid Valve Manifold D—Axle Disconnect Solenoid E—O-Ring (6 used) F—Pin Disconnect Solenoid
DW09104,00000C4 –19–20NOV03–2/2
Pin Disconnect Valve Disassemble and Assemble
T109214B
2. Replace parts as needed. Replace O-rings and backup rings.
–UN–28APR97
1. Remove solenoid coil and spool. Inspect for damage or wear.
A—Nut B—Identification Plate C—Cover D—Coil E—Bottom Plate F—Spool G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring L—O-Ring M—Backup Ring
TX,31,RP3069 –19–25NOV03–1/1
TM2136 (13DEC04)
31-3160-57
444J, 544J, 624J Loader 121304
PN=415
31 3160 57
Hydraulic System
Axle Disconnect Valve Disassemble and Assemble
2. Replace parts as needed. Replace O-rings and backup rings.
T7751LI
C—Nut D—Identification Plate E—Coil F—Spool G—O-Ring H—Backup Ring I—O-Ring J—O-Ring K—Backup Ring
–UN–09NOV92
1. Remove solenoid coil and spool. Inspect for damage or wear.
31 3160 58
TX,31,RP3071 –19–25NOV03–1/1
TM2136 (13DEC04)
31-3160-58
444J, 544J, 624J Loader 121304
PN=416
Hydraulic System
Fan Pump Remove and Install
X9811
–UN–23AUG88
CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury may call the Deere & Company Medical Department in Moline, Illinois, or other knowledgeable medical source.
31 3160 59
1. Lower equipment to the ground. 2. Perform Ride Control Accumulator Hydraulic Discharge procedure. (Group 9025-20.) 3. Perform Brake Accumulator Precharge Test (Group 9025-25) until brake accumulators are totally discharged. 4. Turn battery disconnect switch OFF. 5. Drain or apply vacuum to reservoir.
Continued on next page
TM2136 (13DEC04)
31-3160-59
DW09104,00000C9 –19–01DEC03–1/2
444J, 544J, 624J Loader 121304
PN=417
Hydraulic System 6. Remove hoses (1 and 4). 7. Remove fan pump mounting hardware (2). 8. Remove fan pump. 9. Fan pump is not serviceable. Fan pump must be replaced as an assembly. 10. Install fan pump. 11. Install fan pump mounting hardware (2).
1—Fan Pump-to-Fan Motor Hydraulic Hose 2—Fan Pump Mounting Hardware 3—Fan Pump End Cap Hardware 4—Hydraulic Reservoir-to-Fan Pump Supply Hose
T196679A
31 3160 60
–UN–01DEC03
12. Install hoses (1 and 4).
DW09104,00000C9 –19–01DEC03–2/2
TM2136 (13DEC04)
31-3160-60
444J, 544J, 624J Loader 121304
PN=418
Section 9900
Dealer Fabricated Tools Contents Page
Group 0099—Dealer Fabricated Tools DFT1132 Hydraulic Pump Removal And Installation Tool . . . . . . . . . . . . . . . . . . . 9900-0099-1 DFT1149 Pre-Load Clutch Pack Compression Ring Tool . . . . . . . . . . . . . . . . . . . . . . . . 9900-0099-2
9900
TM2136 (13DEC04)
9900-1
444J, 544J, 624J Loader 121304
PN=1
Contents
9900
TM2136 (13DEC04)
9900-2
444J, 544J, 624J Loader 121304
PN=2
Group 0099
Dealer Fabricated Tools
T8366AC
–UN–10JUL95
DFT1132 Hydraulic Pump Removal And Installation Tool
A—1 in. Nut B—Pipe 2134 mm (7 ft) long
C—Pipe 457 mm (18 in.) long D—1 in. ID heavy Wall Steel Pipe
This tool is used to remove hydraulic motor from machine.
E—Pipe F—Weld
G—Pipe
• 1 in. ID piece heavy wall steel pipe 8 ft. x 6 in. long • Weld (E) to (G)
Material required:
CED,OUOE002,1681 –19–09DEC03–1/1
TM2136 (13DEC04)
9900-0099-1
444J, 544J, 624J Loader 121304
PN=421
9900 0099 1
Dealer Fabricated Tools
–UN–07MAY97
DFT1149 Pre-Load Clutch Pack Compression Ring Tool
T109434
9900 0099 2
The Clutch Pack Compression Ring Tool is used to compress the piston compression ring so snap ring can be removed.
Material is standard pipe (see dimensions above) with window cut out to allow for access when removing snap ring. TX,0399,ME296 –19–08MAY97–1/1
TM2136 (13DEC04)
9900-0099-2
444J, 544J, 624J Loader 121304
PN=422
Index Page
A A/C binary pressure switch Remove and install . . . . . . . . . . . . . . . .18-1830-29 Accumulator Brake, remove and install . . . . . . . . . . . .10-1060-3 Accumulator, ride control Disassemble and assemble . . . . . . . . .31-3160-53 Air cleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-1 Air conditioner system Purge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-13 Air conditioning Charge R134a system . . . . . . . . . . . . .18-1830-11 Cleaning procedures . . . . . . . . . . . . . . .18-1830-12 Component oil charge . . . . . . . . . . . . . . .18-1830-5 Compressor oil removal . . . . . . . . . . . . .18-1830-4 Compressor, remove and install . . . . . .18-1830-34 Condenser . . . . . . . . . . . . . . . . . . . . . .18-1830-25 Evacuate R134a system . . . . . . . . . . . . .18-1830-9 Expansion valve . . . . . . . . . . . . . . . . . .18-1830-20 Flush. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-14 Freeze control switch . . . . . . . . . . . . . .18-1830-20 Freeze control switch bench test. . . . . .18-1830-21 Heater control valve . . . . . . . . . . . . . . .18-1830-22 Heater control valve leak check . . . . . .18-1830-23 Heater/evaporator coil, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 Leak testing . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Main blower assembly. . . . . . . . . . . . . .18-1830-24 Module with heater/evaporator coil . . . .18-1830-16 Pressurizer motor assembly . . . . . . . . .18-1830-25 Receiver-dryer . . . . . . . . . . . . . . . . . . .18-1830-25 Recover R134a system. . . . . . . . . . . . . .18-1830-8 Refrigerant hoses and tubing inspection . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant R134a caution . . . . . . . . . . .18-1830-3 Air conditioning R134a component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 Air conditioning R134a compressor oil Removal . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Air conditioning R134a compressor oil charge Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Air conditioning R134a refrigerant Cautions . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9 Recover . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-8 Air conditioning, R134a refrigerant, recovery, recycling and charging Station installation . . . . . . . . . . . . . . . . . .18-1830-7 Air conditioning, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 TM2136 (13DEC04)
Page
Auxiliary valve section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-21 Auxiliary valve section and bucket section Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-20 Axle and differential Front, remove and install . . . . . . . . . . . .02-0200-1 Rear, install. . . . . . . . . . . . . . . . . . . . . .02-0200-12 Rear, remove . . . . . . . . . . . . . . . . . . . . .02-0200-6 Axle circulation system . . . . . . . . . . . . . . . .02-0260-2 Axle cooler Disassemble and assemble . . . . . . . . . .02-0260-5 Axle disconnect input shaft Cross-sectional view . . . . . . . . . . . . . . . .02-0250-2 Disassemble, inspect, and assemble . . .02-0250-3 Remove and install disconnect . . . . . . . .02-0250-3 Axle disconnect valve Disassemble and assemble . . . . . . . . .31-3160-58 Axle oil coolers Exploded view. . . . . . . . . . . . . . . . . . . . .02-0260-4 Axle oscillating supports Disassemble and assemble . . . . . . . . .02-0200-14
B Bell crank, powerllel Remove and install . . . . . . . . . . . . . . . .31-3140-16 Bellcrank, powerllel Remove and install . . . . . . . . . . . . . . . .31-3140-16 Blower assembly Remove and install . . . . . . . . . . . . . . . .18-1830-24 Boom circuit relief valve Disassemble and assemble . . . . . . . . .31-3160-31 Boom cylinder Loader start-up procedure. . . . . . . . . . .31-3160-35 Remove and install . . . . . . . . . . . . . . . .31-3160-31 Repair . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-34 Boom valve section Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-23 Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-24 Boom, powerllel loader Disassemble and assemble . . . . . . . . .31-3140-42 Brake Park, disassemble and assemble . . . . . .11-1111-4 Park, remove and install . . . . . . . . . . . . .11-1111-1 Brake accumulator Remove and install . . . . . . . . . . . . . . . . .10-1060-3
Index-1
444J, 544J, 624J Loader 121304
PN=1
Indx 1
Index
Indx 2
Page
Page
Brake assembly Remove and install . . . . . . . . . . . . . . . . .10-1011-1 Brake valve Remove and install . . . . . . . . . . . . . . . . .10-1060-1 Brakes Remove and install . . . . . . . . . . . . . . . . .10-1011-1 Bucket Remove and install . . . . . . . . . . . . . . . . .31-3102-1 Bucket bolt-on cutting edges Remove and install . . . . . . . . . . . . . . . . .31-3102-6 Bucket circuit relief valve Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-28 Bucket cylinder Remove and install . . . . . . . . . . . . . . . .31-3160-33 Repair . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-34 Bucket cylinder, powerllel Remove and install . . . . . . . . . . . . . . . .31-3140-22 Bucket link, powerllel Disassemble and assemble . . . . . . . . .31-3140-28 Bucket linkage seals and bushings Remove and install . . . . . . . . . . . . . . . . .31-3140-2 Bucket tilt linkage Remove and install . . . . . . . . . . . . . . . . .31-3140-1 Bucket tilt linkage, lower Disassemble and assemble . . . . . . . . . .31-3140-6 Bucket tilt linkage, upper Disassemble and assemble . . . . . . . . . .31-3140-4 Bucket valve section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-22 Bucket welded-on cutting edge Remove and install . . . . . . . . . . . . . . . . .31-3102-5 Bucket, powerllel Remove and install . . . . . . . . . . . . . . . . .31-3102-3 Bushings and seals, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Bushings, tool carrier boom Remove and install . . . . . . . . . . . . . . . .31-3140-10
Canopy Remove and Install . . . . . . . . . . . . . . . . .18-1800-1 Charging station, R134a refrigerant Recovery, recycling and charging . . . . . .18-1830-7 Circuit relief valve Disassemble and assemble . . . . . . . . .31-3160-27 Clutch Compressor . . . . . . . . . . . . . . . . . . . . .18-1830-36 Compressor, check hub clearance . . . .18-1830-37 Clutch pack KV and KR Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-23 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-20 Clutches, output and input shafts Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-12 Compressor Clutch hub clearance . . . . . . . . . . . . . .18-1830-37 Clutch, disassemble and assemble . . . .18-1830-36 Remove and install . . . . . . . . . . . . . . . .18-1830-34 Compressor, air conditioning, R134a oil Removal . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Compressor, R134a oil charge Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Compressor, R134a, component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-25 Control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-17 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Control valve, loader Remove and install (444J, 544J S.N. —594432) (624J) . . . . . . . . . . . . . . . . . . . . . . . .31-3160-10 Remove and install (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-14 Converter minimum pressure regulator valve Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-3 Converter relief valve Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-23 Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Converter, torque and housing Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-1 Cooling package Plenum Grille Remove and install . . . . . . . . . . . . .05-0510-9 Counterweights Remove and install . . . . . . . . . . . . . . . . .17-1749-1 Coupler, powerllel Disassemble and assemble . . . . . . . . .31-3140-38
C Cab Fresh air filter . . . . . . . . . . . . . . . . . . . .18-1830-30 Recirculating air filter . . . . . . . . . . . . . .18-1830-33 Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Cab door Adjust hold-open release . . . . . . . . . . . .18-1810-1 Cab door hold-open release Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 TM2136 (13DEC04)
Index-2
444J, 544J, 624J Loader 121304
PN=2
Index
Page
Page
Cutting edge Crack repair . . . . . . . . . . . . . . . . . . . . . .31-3102-8 Cutting edge, welded-on Remove and install . . . . . . . . . . . . . . . . .31-3102-5 Cutting edges, bucket bolt-on Remove and install . . . . . . . . . . . . . . . . .31-3102-6 Cylinder Boom, remove and install . . . . . . . . . . .31-3160-31 Bucket, remove and install . . . . . . . . . .31-3160-33 Repair . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-34 Cylinder, boom Loader start-up procedure. . . . . . . . . . .31-3160-35
Expansion valve Remove and install . . . . . . . . . . . . . . . .18-1830-20
D Dampener Install . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Dealer fabricated tool DFT1132 hydraulic pump removal tool . . . . . . . . . . . . . . . . . . . . . . . . . 9900-0099-1 DFT1149 Pre-Load Clutch Pack Compression Ring Tool . . . . . . . . . . . . . . . . . . . . . . . . . 9900-0099-2 Differential Front remove and install . . . . . . . . . . . . .02-0200-1 Install . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-12 Rear axle, install . . . . . . . . . . . . . . . . . .02-0200-12 Differential lock solenoid valve Remove and install . . . . . . . . . . . . . . . . .02-0260-1 Differential, rear Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-6 Disassemble and assemble Hydraulic pump . . . . . . . . . . . . . . . . . . . .31-3160-4 Drive shaft Remove and install . . . . . . . . . . . . . . . . .02-0225-2
E Element Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-3 Engine Remove and install . . . . . . . . . . . . . . . . .04-0400-3 Theory of operation. . . . . . . . . . . . . . . . .04-0400-1 Engine and loader frame Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Engine coolant heater Remove and install . . . . . . . . . . . . . . . . .05-0505-2 Engine side shields Remove and install . . . . . . . . . . . . . . . . .19-1910-2 Evaporator . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 TM2136 (13DEC04)
F Fan belt Remove and install . . . . . . . . . . . . . . . . .04-0400-1 Fan pump Remove and install . . . . . . . . . . . . . . . .31-3160-59 Filter Cab air recirculating . . . . . . . . . . . . . . .18-1830-33 Cab fresh air . . . . . . . . . . . . . . . . . . . . .18-1830-30 Fuel, remove and install . . . . . . . . . . . . .05-0560-5 Primary fuel, remove and install . . . . . . .05-0560-5 Fluid starting aid Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Frame Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Frame pivot bearing Lower, remove and install . . . . . . . . . . . .17-1740-8 Upper, remove and install . . . . . . . . . . . .17-1740-6 Freeze control switch Remove and install . . . . . . . . . . . . . . . .18-1830-20 Freeze control switch bench test . . . . . . .18-1830-21 Front axle and differential Remove and install . . . . . . . . . . . . . . . . .02-0200-1 Front axle guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Front wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-1
G Guard, front axle Ramove and install . . . . . . . . . . . . . . . . .17-1746-1 Guard, transmission bottom Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Guide links, powerllel Disassemble and assemble . . . . . . . . .31-3140-34
H Heater coil Remove and install . . . . . . . . . . . . . . . .18-1830-18 Heater control valve Remove and install . . . . . . . . . . . . . . . .18-1830-22
Index-3
444J, 544J, 624J Loader 121304
PN=3
Indx 3
Index
Page
Page
Heater control valve leak check . . . . . . . .18-1830-23 Hood Remove and install . . . . . . . . . . . . . . . . .19-1910-1 Hydraulic control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-17 Cross section view . . . . . . . . . . . . . . . .03-0360-12 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-6 Hydraulic fan pump Remove and install . . . . . . . . . . . . . . . .31-3160-59 Hydraulic oil cooler Remove and install hydraulic oil cooler . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-8 Hydraulic pump disassemble and assemble . . . . . . . . . . .31-3160-4 Remove and install . . . . . . . . . . . . . . . . .31-3160-1 Hydraulic reservoir remove and install. . . . . . . . . . . . . . . . .31-3160-37
Loader boom bushings and seals Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Loader boom, powerllel Disassemble and assemble . . . . . . . . .31-3140-42 Loader control valve Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-17 Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-18 Remove and install (444J, 544J S.N. —594432) (624J) . . . . . . . . . . . . . . . . . . . . . . . .31-3160-10 Remove and install (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-14 Loader hydraulic pump Remove and install . . . . . . . . . . . . . . . . .31-3160-1 Lower pivot bearing and seals Remove and install . . . . . . . . . . . . . . . . .17-1740-8
M Muffler Remove and install . . . . . . . . . . . . . . . . .05-0530-1
I
Indx 4
Inlet valve section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-25 Input and output clutches Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-12 Input shaft Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-32 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-32 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-6 Intercooler Remove and install . . . . . . . . . . . . . . . . .05-0510-1
L Leveling link, powerllel Disassemble and assemble . . . . . . . . .31-3140-12 Link, powerllel bucket Disassemble and assemble . . . . . . . . .31-3140-28 Link, powerllel leveling Disassemble and assemble . . . . . . . . .31-3140-12 Links, powerllel guide Disassemble and assemble . . . . . . . . .31-3140-34 Load sense relief valve Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-29 Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-30 TM2136 (13DEC04)
O Oil pipes and tube Replace . . . . . . . . . . . . . . . . . . . . . . . .03-0360-25 Oil, component, R134a air conditioning Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 Oscillating supports Disassemble and assemble . . . . . . . . .02-0200-14 Outlet valve section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-26 Output and input clutches Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-12 Output shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-6
P Park brake Assemble and disassemble. . . . . . . . . . .11-1111-4 Release solenoid valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-1 Remove and install . . . . . . . . . . . . . . . . .11-1111-1 Pilot control valve Disassemble and assemble . . . . . . . . .31-3160-41
Index-4
444J, 544J, 624J Loader 121304
PN=4
Index
Page
Page
Pilot controller valve, single lever Remove and install . . . . . . . . . . . . . . . .31-3160-40 Pin disconnect valve Disassemble and assemble . . . . . . . . .31-3160-57 Pin disconnect/axle disconnect Remove and install . . . . . . . . . . . . . . . .31-3160-56 Pivot bearing and seals Lower, remove and install . . . . . . . . . . . .17-1740-8 Upper, remove and install . . . . . . . . . . . .17-1740-6 Powerllel bell crank Remove and install . . . . . . . . . . . . . . . .31-3140-16 Powerllel Bucket Remove and install . . . . . . . . . . . . . . . . .31-3102-3 Powerllel bucket cylinder Remove and install . . . . . . . . . . . . . . . .31-3140-22 Powerllel bucket link Disassemble and assemble . . . . . . . . .31-3140-28 Powerllel coupler Disassemble and assemble . . . . . . . . .31-3140-38 Powerllel guide links Remove and install . . . . . . . . . . . . . . . .31-3140-34 Powerllel leveling link Disassemble and assemble . . . . . . . . .31-3140-12 Powerllel loader boom Disassemble and assemble . . . . . . . . .31-3140-42 Pressure reducing valve Disassemble and assemble . . . . . . . . .31-3160-47 Pressure reducing valve manifold Remove and install . . . . . . . . . . . . . . . .31-3160-45 Pressure switch A/C Binary . . . . . . . . . . . . . . . . . . . . . .18-1830-29 Pressurizer motor assembly Remove and install . . . . . . . . . . . . . . . .18-1830-25 Pump Disassemble and assemble . . . . . . . . . .31-3160-4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4 Pump, fan Remove and Install . . . . . . . . . . . . . . . .31-3160-59 Pump, hydraulic Remove and install . . . . . . . . . . . . . . . . .31-3160-1 Pump, transmission Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1
Refrigerant cautions, air conditioning R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Refrigerant, air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9 Recover . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-8 Refrigerant, R134a Recovery, recycling and charging . . . . . .18-1830-7 Refrigerant, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Relief valve Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-27 Remove and install. . . . . . . . . . . . . . . . . .18-1830-18 Ride control . . . . . . . . . . . . . . . . . . . . .31-3160-48 Repair Boom, bucket cylinder. . . . . . . . . . . . . .31-3160-34 Reservoir, hydraulic Remove and install . . . . . . . . . . . . . . . .31-3160-37 Ride control Remove and install . . . . . . . . . . . . . . . .31-3160-48 Ride control accumulator Disassemble and assemble . . . . . . . . .31-3160-53 Ride control valve Disassemble and assemble . . . . . . . . .31-3160-52 Roads Operating or traveling . . . . . . . . . . . . . .00-0001-11 ROPS Inpsect . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-12 Maintain . . . . . . . . . . . . . . . . . . . . . . . .00-0001-12 R134a compressor oil charge Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3
R Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-2 Rear wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-25 TM2136 (13DEC04)
S Safety Add cab guarding for special uses . . . . .00-0001-3 Avoid unauthorized machine modifications . . . . . . . . . . . . . . . . . . . .00-0001-2 Follow safety instructions . . . . . . . . . . . .00-0001-1 Inspect machine . . . . . . . . . . . . . . . . . . .00-0001-3 Operate only if qualified . . . . . . . . . . . . .00-0001-2 Recognize safety information . . . . . . . . .00-0001-1 Stay clear of moving parts . . . . . . . . . . .00-0001-3 Wear protective equipment . . . . . . . . . . .00-0001-2 Seals and bushings Bucket linkage, remove and install . . . . .31-3140-2 Seals and bushings, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-9 Seals, tool carrier boom Remove and install . . . . . . . . . . . . . . . .31-3140-10
Index-5
444J, 544J, 624J Loader 121304
PN=5
Indx 5
Index
Page
Page
Shields, engine side Remove and install . . . . . . . . . . . . . . . . .19-1910-2 Start aid solenoid Remove and install . . . . . . . . . . . . . . . . .05-0505-2 Start-up procedure Steering cylinder . . . . . . . . . . . . . . . . . . .09-0960-8 Starting aid, fluid Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Steering Valve, remove and install . . . . . . . . . . . .09-0960-1 Steering column Remove and install . . . . . . . . . . . . . . . . .09-0960-4 Steering cylinder Remove and install . . . . . . . . . . . . . . . . .09-0960-6 Steering valve Remove and install . . . . . . . . . . . . . . . . .09-0960-1 Structure Welding. . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1
Transmission pump Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1 Traveling On public roads. . . . . . . . . . . . . . . . . . .00-0001-11
T
Indx 6
Tilt linkage Bucket, remove and install . . . . . . . . . . .31-3140-1 Tire Install . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-4 Remove . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-2 Tool carrier Disassemble and assemble . . . . . . . . . .31-3140-8 Tool carrier boom bushings and seals Remove and install . . . . . . . . . . . . . . . .31-3140-10 Tool carrier lower tilt linkage Disassemble and assemble . . . . . . . . . .31-3140-6 Tool carrier upper tilt linkage Disassemble and assemble . . . . . . . . . .31-3140-4 Torque converter and housing Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-3 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-1 Torque converter relief valve Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Transmission Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Transmission bottom guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Transmission control valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-17 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-8 Transmission oil cooler Remove and Install . . . . . . . . . . . . . . . . .05-0510-9 TM2136 (13DEC04)
U Universal joint Remove and install . . . . . . . . . . . . . . . . .02-0225-2 Upper pivot bearing and seals Remove and install . . . . . . . . . . . . . . . . .17-1740-6
V Valve Minimum pressure regulator . . . . . . . . . .03-0360-3 Valve, auxiliary section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-21 Valve, auxiliary section and bucket section Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-20 Valve, axle disconnect Disassemble and assemble . . . . . . . . .31-3160-58 Valve, boom circuit relief Disassemble and assemble . . . . . . . . .31-3160-31 Valve, boom section Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-23 Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-24 Valve, brake Remove and install . . . . . . . . . . . . . . . . .10-1060-1 Valve, bucket circuit relief Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-28 Valve, bucket section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-22 Valve, circuit relief Disassemble and assemble . . . . . . . . .31-3160-27 Valve, inlet section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-25 Valve, load sense relief Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-29 Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-30
Index-6
444J, 544J, 624J Loader 121304
PN=6
Index
Page
Valve, loader control Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-17 Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-18 Remove and install (444J, 544J S.N. —594432) (624J) . . . . . . . . . . . . . . . . . . . . . . . .31-3160-10 Remove and install (444J, 544J S.N. 594433— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-14 Valve, outlet section Disassemble and assemble (444J, 544J S.N. 594433— ) . . . . . . . . . . . . . . . . . . . .31-3160-26 Valve, pilot controller, single lever Remove and install . . . . . . . . . . . . . . . .31-3160-40 Valve, pin disconnect Disassemble and assemble . . . . . . . . .31-3160-57 Valve, pin disconnect/axle disconnect Remove and install . . . . . . . . . . . . . . . .31-3160-56 Valve, pressure reducing Disassemble and assemble . . . . . . . . .31-3160-47 Remove and install . . . . . . . . . . . . . . . .31-3160-45 Valve, relief Disassemble and assemble (444J, 544J S.N. — 594432) (624J) . . . . . . . . . . . . . . . . .31-3160-27 Valve, ride control Disassemble and assemble . . . . . . . . .31-3160-52 Valve, steering Remove and install . . . . . . . . . . . . . . . . .09-0960-1 Valve, transmission control Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-6
Indx 7
W Wear plates Remove and install . . . . . . . . . . . . . . . . .31-3102-6 Welding Structure . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1 Wheel Remove and Install . . . . . . . . . . . . . . . . .01-0110-1 Windowpanes Remove and install . . . . . . . . . . . . . . . . .18-1810-1
TM2136 (13DEC04)
Index-7
444J, 544J, 624J Loader 121304
PN=7
Index
Indx 8
TM2136 (13DEC04)
Index-8
444J, 544J, 624J Loader 121304
PN=8