Worldwide Construction And Forestry Division 444J Manuel utilisateur

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

DX,TMIFC –19–29SEP98–1/1

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

TX,II,FAX –19–10JUL01–1/1

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: John Deere Dubuque Works

P.O. Box 538

Attn: Publications Supervisor, Dept. 303

Dubuque, IA 52004-0538

FAX NUMBER: 563-589-5800

Ideas, Comments (Please State Page Number):

OVERALL, how would you rate the quality of this publication? (Check one)

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12345678910

Company Name:

Technician Name:

Address:

Phone:

Fax No.:

Dealer Acct. No.:

THANK YOU!

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Introduction

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Contents

SECTION 17—Frame or Supporting Structure

SECTION 00—General Information Group 1740—Frame Installation

Group 0001—Safety Information Group 1746—Frame Bottom Guards

Group 1749—Chassis Weights

SECTION 01—Wheels

Group 0110—Powered Wheels and Fasteners

SECTION 18—Operator’s Station

Group 1800—Removal and Installation

SECTION 02—Axles and Suspension Systems Group 1810—Operator Enclosure

Group 0200—Removal and Installation Group 1830—Heating and Air Conditioning

Group 0225—Axle Shafts and U-Joints

Group 0250—Axle Shaft, Bearings, Reduction SECTION 19—Sheet Metal and Styling

Gears Group 1910—Hood or Engine Enclosure

Group 0260—Hydraulic System SECTION 31—Loader

Group 3102—Bucket

SECTION 03—Transmission Group 3140—Frames

Group 0300—Removal and Installation

Group 3160—Hydraulic System

Group 0350—Gears, Shafts, Bearings and Power

Shift Clutch SECTION 9900—Dealer Fabricated Tools

Group 0360—Hydraulic System Group 0099—Dealer Fabricated Tools

SECTION 04—Engine

Group 0400—Removal and Installation

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

SECTION 07—Dampener Drive

Group 0752—Elements

SECTION 09—Steering System

Group 0960—Hydraulic System

SECTION 10—Service Brakes

Group 1011—Active Elements

Group 1060—Hydraulic System

SECTION 11—Park Brake

Group 1111—Active Elements

Group 1160—Hydraulic System

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

the latest information available at the time of publication. The right is

reserved to make changes at any time without notice.



2004

DEERE & COMPANY

Moline, Illinois

A John Deere ILLUSTRUCTION



Manual

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Contents

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Contents

9900

INDX

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Contents

9900

INDX

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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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Contents

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