Description
544G, 544G LL, 544G TC, 624G, 644G 4WD Loader Operation and Test
OPERATION & TEST TECHNICAL MANUAL 544G, 544G LL, 544G TC, 624G, and 644G 4WD Loader TM1529 27JUN17
(ENGLISH)
For complete service information also see: 544G, 544G LL, 544G TC, 624G, and 644G Repair ...................................................................
TM1530
6059 and 6068 Engines .......................................
CTM8
6076 Engine..........................................................
CTM42
6081 Engine..........................................................
CTM86
Alternators and Starting Motors ........................
CTM77
1200 and 1400 Series Axles................................
CTM138519
Test and Service Specifications Manual ...........
SP458VOL2
Worldwide Construction And Forestry Division PRINTED 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. CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. 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. See DB1990 Service Publications Catalog to order an Operation and Test Technical Manual (TM). An Operation and Test manual includes the following sections:
• Section 9000 General Information • Section 9005 Operational Checkout Procedure • Section 9010 Engine • Section 9015 Electrical System • Section 9020 Power Train • Section 9025 Hydraulics • Section 9031 Air Conditioning
TX,INTR,TJ36 -19-27OCT97-1/1
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Introduction
John Deere Dealers IMPORTANT: Please Remove This Page and Route Through Your Service Department. This is a complete revision for TM1529, 544G, 544G LL, 544G TC, 624G, 644G Loader—Operation and Test. Listed below is a brief explanation of "what" was changed and "why" it was changed.
•
This manual was revised:
•
• To add general specifications for 644G (S.N. 557739—) • •
•
in Section 9000. To update CTM references to include CTM86 (8.1 L engine) in Section 9010. To add the following procedures in Section 9010: - Coolant overflow tube check - Pressure test radiator cap - Pressure test cooling system - Compression pressure test - Fuel supply pump pressure test To include changes to the following illustrations and procedures in Section 9015: - Fuse block illustration. - Theory of operation for sixth transmission control valve solenoid.
•
•
- Revise procedure to isolate whether problem in transmission control system is electrical or hydraulic. - Theory of operation and specifications for the 9-segment engine coolant temperature display used in 544G (S.N. 555000—) and 644G (S.N. 554491—). - 15 amp fuses changed to 10 amp circuit breakers in front and rear wiper circuit functional schematic. - Step 6 in calibrate tachometer —rpm changed to mph. To revise transmission shifting and modulation theory for 6-solenoid in section 9020. To add alternate method to adjust transmission sensor in Section 9020. To add note advising of possible F907 service code appearance on 544G (S.N. 548219—548955), 624G (S.N. 548398—548982), and 644G (S.N. 548303—548887) when performing the following procedures in Section 9020: - Transmission oil warm-up procedure. - Transmission system pressure, element leakage, and shift modulation test - Converter-in pressure test To add theory of operation and test procedures for new heavy duty pilot controller used on machines (S.N. 563543—) in Section 9025.
TX,1529,RP2584 -19-03FEB95-1/1
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Introduction SEND TO:
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Contents Section 9000—General Information Group Group Group Group
01—Safety Information 02—General Specifications 03—Torque Values 04—Fuels And Lubricants
Section 9005—Operational Checkout Procedure Group 10—Operational Checkout Procedure
Section 9010—Engine Operation And Tests Group 05—Theory Of Operation Group 10—System Operational Checks Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
Section 9015—Electrical System Group Group Group Group
05—System Information 10—System Diagrams 15—Sub-System Diagnostics 20—References
Section 9020—Power Train Operation And Tests Group 05—Theory Of Operation Group 10—System Operational Checks Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
Section 9025—Hydraulic System Operation And Tests Group 05—Theory Of Operation Group 10—System Operational Checks Group 15—Diagnostic Information Group 20—Adjustments Group 25—Test
Section 9031—Air Conditioning System Group 05—Theory Of Operation Group 10—System Operational Checks Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests
Original Instructions. 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. COPYRIGHT © 2017 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 1992, 1994, 1995, 1997, 2000, 2011, 2016
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Contents
Section 9000 General Information
Page Page
Group 01—Safety Information Handle Fluids Safely—Avoid Fires....................................................... 9000-01-1 Prevent Battery Explosions ....................... 9000-01-1 Prepare for Emergencies........................... 9000-01-1 Prevent Acid Burns.................................... 9000-01-2 Handle Chemical Products Safely.............. 9000-01-2 Avoid High-Pressure Fluids ....................... 9000-01-3 Park And Prepare For Service Safely..................................................... 9000-01-3 Park Machine Safely.................................. 9000-01-4 Support Machine Properly ......................... 9000-01-4 Wear Protective Clothing........................... 9000-01-4 Work in Clean Area ................................... 9000-01-5 Service Machines Safely ........................... 9000-01-5 Work In Ventilated Area............................. 9000-01-5 Illuminate Work Area Safely ...................... 9000-01-6 Replace Safety Signs ................................ 9000-01-6 Use Proper Lifting Equipment.................... 9000-01-6 Remove Paint Before Welding or Heating .................................................. 9000-01-7 Avoid Heating Near Pressurized Fluid Lines ............................................. 9000-01-7 Keep ROPS Installed Properly .................. 9000-01-7 Service Tires Safely................................... 9000-01-8 Avoid Harmful Asbestos Dust.................... 9000-01-8 Practice Safe Maintenance........................ 9000-01-9 Use Proper Tools ....................................... 9000-01-9 Decommissioning — Proper Recycling and Disposal of Fluids and Components ................................. 9000-01-10 Live With Safety....................................... 9000-01-10
Unified Inch Bolt and Screw Torque Values .................................................... 9000-03-4 Check Oil Lines And Fittings ..................... 9000-03-5 Service Recommendations for O-Ring Boss Fittings.............................. 9000-03-5 Service Recommendations For Flat Face O-Ring Seal Fittings .............. 9000-03-7 Service Recommendations for Metric Series Four Bolt Flange Fitting..................................................... 9000-03-8 Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................... 9000-03-9 Group 04—Fuels And Lubricants Fuel Specifications .................................... 9000-04-1 Storing Fuel ............................................... 9000-04-1 Do Not Use Galvanized Containers ............................................. 9000-04-1 Fuel Tank ................................................... 9000-04-1 Engine Oil .................................................. 9000-04-2 Hydraulic System Oil And Differential Oil ........................................ 9000-04-3 Transmission Oil........................................ 9000-04-4 Grease....................................................... 9000-04-5 Alternative and Synthetic Lubricants .............................................. 9000-04-5 Lubricant Storage ...................................... 9000-04-5 Mixing of Lubricants................................... 9000-04-6 Diesel Engine Coolant (engine with wet sleeve cylinder liners) ..................... 9000-04-6
Group 02—General Specifications 544G Specifications................................... 9000-02-1 544G Drain And Refill Capacities .............. 9000-02-3 544G LL Specifications.............................. 9000-02-4 544G LL Drain And Refill Capacities.............................................. 9000-02-7 544G TC Specifications............................. 9000-02-8 544G TC Drain And Refill Capacities............................................ 9000-02-10 624G Specifications................................. 9000-02-11 624G Drain And Refill Capacities ............ 9000-02-13 644G Specifications................................. 9000-02-14 644G Drain And Refill Capacities ............ 9000-02-16 Group 03—Torque Values Hardware Torque Specifications................ 9000-03-1 ROPS Torque Specifications ..................... 9000-03-1 Metric Bolt and Screw Torque Values .................................................... 9000-03-2 Additional Metric Cap Screw Torque Values ........................................ 9000-03-3 TM1529 (27JUN17)
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Group 01
Safety Information Handle Fluids Safely—Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards.
Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously.
TS227 —UN—15APR13
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
DX,FLAME -19-29SEP98-1/1
Prevent Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
TS204 —UN—15APR13
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
DX,SPARKS -19-03MAR93-1/1
Prepare for Emergencies Be prepared if a fire starts.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
TS291 —UN—15APR13
Keep a first aid kit and fire extinguisher handy.
DX,FIRE2 -19-03MAR93-1/1
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Safety Information
Prevent Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. 2. 3. 4. 5.
Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or dripping electrolyte. Use proper jump start procedure.
If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.
1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately.
TS203 —UN—23AUG88
If acid is swallowed:
DX,POISON -19-21APR93-1/1
Handle Chemical Products Safely
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.
TS1132 —UN—15APR13
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.) DX,MSDS,NA -19-03MAR93-1/1
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Safety Information
Avoid High-Pressure Fluids
X9811 —UN—23AUG88
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. 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 in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636. DX,FLUID -19-12OCT11-1/1
Park And Prepare For Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly. to the ground.
• Engage park brake. • Stop engine and remove key. • Install frame locking bar. • Attach a “Do Not Operate” tag in an obvious place in the operator's station.
Securely support machine or attachment before working under it.
T133332 —19—17APR13
• Park machine on a level surface and lower equipment
• 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.
devices that may slip out of place.
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 —UN—23AUG88
• Do not support machine with a single jack or other
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Safety Information
Park Machine Safely
• Lower all equipment to the ground. • Stop the engine and remove the key. • Disconnect the battery ground strap. • Hang a "DO NOT OPERATE" tag in operator station.
TS230 —UN—24MAY89
Before working on the machine:
DX,PARK -19-04JUN90-1/1
Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator's manual.
TS229 —UN—23AUG88
Support Machine Properly
DX,LOWER -19-24FEB00-1/1
Wear Protective Clothing
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.
TS206 —UN—15APR13
Wear close fitting clothing and safety equipment appropriate to the job.
DX,WEAR2 -19-03MAR93-1/1
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Safety Information
Work in Clean Area
• Clean work area and machine. • Make sure you have all necessary tools to do your job. • Have the right parts on hand. • Read all instructions thoroughly; do not attempt shortcuts.
T6642EJ —UN—18OCT88
Before starting a job:
DX,CLEAN -19-04JUN90-1/1
Service Machines Safely
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
TS228 —UN—23AUG88
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
DX,LOOSE -19-04JUN90-1/1
Work In Ventilated Area
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
TS220 —UN—15APR13
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.
DX,AIR -19-17FEB99-1/1
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Safety Information
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
TS223 —UN—23AUG88
Illuminate Work Area Safely
DX,LIGHT -19-04JUN90-1/1
Replace Safety Signs
TS201 —UN—15APR13
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
DX,SIGNS1 -19-04JUN90-1/1
Use Proper Lifting Equipment Lifting heavy components incorrectly can cause severe injury or machine damage.
TS226 —UN—23AUG88
Follow recommended procedure for removal and installation of components in the manual.
DX,LIFT -19-04JUN90-1/1
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Safety Information
Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 —UN—15APR13
Remove paint before heating:
• Remove paint a minimum of 100 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.
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
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.
TS953 —UN—15MAY90
Avoid Heating Near Pressurized Fluid Lines
DX,TORCH -19-10DEC04-1/1
Keep ROPS Installed Properly
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. A damaged ROPS should be replaced, not reused. The seat is part of the ROPS safety zone. Replace only with John Deere seat approved for your tractor.
TS212 —UN—23AUG88
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque.
Any alteration of the ROPS must be approved by the manufacturer. DX,ROPS3 -19-12OCT11-1/1
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Safety Information
Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. 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.
TS211 —UN—15APR13
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
DX,RIM -19-24AUG90-1/1
Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos.
TS220 —UN—15APR13
Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.
Keep bystanders away from the area.
DX,DUST -19-15MAR91-1/1
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Safety Information
Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet, and clothing away from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool. Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine. Falling while cleaning or working at height can cause serious injury. Use a ladder or platform to easily reach each location. Use sturdy and secure footholds and handholds.
TS218 —UN—23AUG88
On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine.
DX,SERV -19-28FEB17-1/1
Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.
TS779 —UN—08NOV89
Use power tools only to loosen threaded parts and fasteners.
DX,REPAIR -19-17FEB99-1/1
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Safety Information
Decommissioning — Proper Recycling and Disposal of Fluids and Components
TS1133 —UN—15APR13
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:
• Use appropriate tools and personal protective • •
• • • •
equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. Follow instructions for specialized components. Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. Do not pour waste fluids onto the ground, down a drain, or into any water source. Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid);
•
• •
filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste. DX,DRAIN -19-01JUN15-1/1
Live With Safety
TS231 —19—07OCT88
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
DX,LIVE -19-25SEP92-1/1
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Group 02
General Specifications
T6603AC —UN—20OCT88
544G Specifications
Machine Dimensions: A—Overall operating height (boom full raise)
4.83 m (15 ft 10 in.)
B—Bucket hinge height
3.72 m (12 ft 3 in.)
C—Dump height
2.84 m (9 ft 4 in.)
D—Dump reach
0.94 m (3 ft 1 in.)
E—Height to top of cab and canopy
3.17 m (10 ft 5 in.)
F—Overhang
1.63 m (5 ft 4 in.)
G—Wheelbase
2.90 m (9 ft 6 in.)
H—Ground clearance
373 mm (1 ft 3 in.)
I—Overall length
6.89 m (22 ft 7 in.)
Width over tires: 17. 5-25 tires
2.42 m (8 ft 0 in.)
20. 5-25 tires
2.46 m (8 ft 1 in.)
Machine Weights: Standard operating weight
10 262 kg (22,624 lb)
Counterweight weight: Continued on next page
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General Specifications Machine Weights: 1st optional counterweight
358 kg (790 lb)
2nd optional counterweight
434 kg (934 lb)
NOTE: Specifications And Design Subject To Change Without Notice. Wherever Applicable, Specifications Are In Accordance With SAE Standards. Except Where Otherwise Noted, Specifications
Are Based On A Machine Equipped With All Standard, 17.5—25, 12 Pr, L2 Tires, One Rear Counterweight, ROPS Cab, Full Fuel Tank, And 79 Kg (175 Lb) Operator.
Engine: John Deere 6059T
86 kW (115 hp)
Piston displacement
5.884 L (359 cu in.)
Air cleaner
Dual stage dry type with restriction indicator
Electrical system
12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F)
625 amps
Reserve capacity
160 min.
Torque Converter
Single phase, single stage
Transmission
Countershaft, power shift, automatic
Travel Speeds:
km/h
mph
Forward Speeds: 1
0 0—4.6 — 7. 4
2
0 0—7.7 — 1 2. 3
3
0 0—16.9 — 2 7. 2
4
0 0—23.8 — 3 8. 4 Reverse Speeds:
1
0 0—4.6 — 7. 4
2
0 0—7.7 — 1 2. 3
3
0 0—16.9 — 2 7. 2
NOTE: All Travel Speeds Are With 20.5—25 Tires. Brakes, Service: Power-actuated, 4-wheel, inboard-mounted, wet disk Foot-operated, by either pedal Left pedal also disconnects transmission (if selected by operator)
Continued on next page
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General Specifications Brakes, Service: External inspection Low brake pressure warning light and buzzer in monitor Brakes, Park: Spring applied, hydraulically released parking brake is attached to the output shaft Transmission disconnects with park brake applied Warning light in monitor—Dual-level Amber lights with transmission in neutral Red STOP indicator lights, and buzzer sounds with transmission in gear Steering: Turning radius (to centerline of outside tire)
4.95 m (16 ft 3 in.)
Rear axle oscillation
22 degrees, stop to stop
Tires: 15.5—25, 12 PR L2 17.5—25, 12 PR L2 17.5—25, 12 PR L3 20.5—25, 12 PR L2 20.5—25, 12 PR L3 17.5—25, Radial, One Star L2 Equivalent 17.5—25, Radial, One Star L3 Equivalent 20.5—25, Radial, One Star L2 Equivalent 20.5—25, Radial, One Star L3 Equivalent Maximum Lift Capacity With Standard Equipment: Maximum height
5 457 kg (12 031 lb)
Ground level
11 006 kg (24 264 lb) TX,115,DH2265 -19-16JUN93-3/3
544G Drain And Refill Capacities Metric
U.S.
Cooling system
23.5 L
25 qt
Fuel tank
218 L
57.6 gal
Engine crankcase and 19 L filter
20 qt
Transmission case and filter
9.5 L
10 qt
Front differential
19 L
20 qt
Rear differential
19 L
20 qt
Hydraulic reservoir
76 L
80 qt TX,I,DY278 -19-16APR96-1/1
TM1529 (27JUN17)
9000-02-3
544G, 624G, 644G Loader
062717
PN=21
General Specifications
T7829AX —UN—10SEP92
544G LL Specifications
Machine Dimensions: A—Coupler hinge height
3.72 m (12 ft 3 in.)
B—Ground to top of tine
3.53 m (11 ft 7 in.)
C—Height to top of cab and canopy
3.17 m (10 ft 5 in.)
D—Ground clearance
373 mm (1 ft 3 in.)
E—Wheelbase
2.90 m (9 ft 6 in.)
F—Overall length: with 1219 mm (48 in.) tine
7.52 m (24 ft 8 in.)
with 1372 mm (54 in.) tine
7.67 m (25 ft 2 in.)
with 1524 mm (60 in.) tine
7.82 m (25 ft 8 in.)
Width over tires: 17.5-25 tires
2.42 m (8 ft 0 in.)
20.5-25 tires
2.46 m (8 ft 1 in.)
23.1-26 tires
2.77 m (9 ft 1 in.)
Machine Weights: Standard operating weight: with 1219 mm (48 in.) tine
12 019 kg (2 6,497 lb)
Continued on next page
TM1529 (27JUN17)
9000-02-4
TX,115,DH2291 -19-16JUN93-1/3
544G, 624G, 644G Loader
062717
PN=22
General Specifications Machine Weights: with 1372 mm (54 in.) tine
12 038 kg (2 6,544 lb)
with 1524 mm (60 in.) tine
12 056 kg (2 6,583 lb)
NOTE: Specifications And Design Subject To Change Without Notice. Wherever Applicable, Specifications Are In Accordance With SAE Standards. Except Where Otherwise Noted, Specifications
Are Based On A Machine Equipped With All Standard, 17.5—25, 12 Pr, L3 Tires, Two Rear Counterweights, ROPS Cab, Full Fuel Tank, And 79 Kg (175 Lb) Operator.
Engine: John Deere 6059T
86 kW (115 hp)
Piston displacement
5.884 L (359 cu in.)
Air cleaner
Dual stage dry type with restriction indicator
Electrical system
12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F)
625 amps
Reserve capacity
160 min.
Torque Converter
Single phase, single stage
Transmission
Countershaft, power shift, automatic
Travel Speeds:
km/h
mph
Forward Speeds: 1
0 0—4.6 — 7. 4
2
0 0—7.7 — 1 2. 3
3
0 0—16.9 — 2 7. 2
4
0 0—23.8 — 3 8. 4 Reverse Speeds:
1
0 0—4.6 — 7. 4
2
0 0—7.7 — 1 2. 3
3
0 0—16.9 — 2 7. 2 Continued on next page
TM1529 (27JUN17)
9000-02-5
TX,115,DH2291 -19-16JUN93-2/3
544G, 624G, 644G Loader
062717
PN=23
General Specifications
NOTE: All Travel Speeds Are With 20.5—25 Tires. Brakes, Service: Power-actuated, 4-wheel, inboard-mounted, wet disk Foot-operated, by either pedal Left pedal also disconnects transmission (if selected by operator) External inspection Low brake pressure warning light and buzzer in monitor Brakes, Park: Spring applied, hydraulically released parking brake is attached to the output shaft Transmission disconnects with park brake applied Warning light in monitor—Dual-level Amber lights with transmission in neutral Red STOP indicator lights, and buzzer sounds with transmission in gear Steering: Turning radius (to centerline of outside tire)
4.95 m (16 ft 3 in.)
Rear axle oscillation
22 degrees, stop to stop
Tires: 17.5—25, 12 PR L2 17.5—25, 12 PR L3 17.5—25, Radial, One Star, L2 Equivalent 20.5—25, 12 PR L2 20.5—25, 12 PR L3 23.1—26, 10 PR LS-2 28 L—26, 14 PR LS-2 Maximum Lift Capacity: Maximum height: Fork level
4 649 kg (10,2 51 lb)
Fork 4 440 rolled kg (9 back ,789 lb) Ground level: Fork level
8 716 kg (19,2 15 lb)
Fork 11 rolled 748 back kg (25,9 00 lb) TX,115,DH2291 -19-16JUN93-3/3
TM1529 (27JUN17)
9000-02-6
544G, 624G, 644G Loader
062717
PN=24
General Specifications
544G LL Drain And Refill Capacities Metric
U.S.
Cooling system
23.5 L
25 qt
Fuel tank
218 L
57.6 gal
Engine crankcase and 19 L filter
20 qt
Transmission case and filter
9.5 L
10 qt
Front differential
19 L
20 qt
Rear differential
19 L
20 qt
Hydraulic reservoir
76 L
80 qt TX,I,DY279 -19-16APR96-1/1
TM1529 (27JUN17)
9000-02-7
544G, 624G, 644G Loader
062717
PN=25
General Specifications
T7829AY —UN—21SEP92
544G TC Specifications
Machine Dimensions: A—Overall operating height (boom full raise)
4.83 m (15 ft 10 in.)
B—Bucket hinge height
3.75 m (12 ft 4 in.)
C—Dump height
2.82 m (9 ft 3 in.)
D—Dump reach
1.06 m (3 ft 6 in.)
E—Height to top of cab and canopy
3.17 m (10 ft 5 in.)
F—Ground clearance
373 mm (1 ft 3 in.)
G—Wheelbase
2.90 m (9 ft 6 in.)
H—Overall length
7.10 m (23 ft 3 in.)
Width over tires 15. 5-25 tires
2.37 m (7 ft 9 in.)
17. 5-25 tires
2.42 m (8 ft 0 in.)
20. 5-25 tires
2.46 m (8 ft 1 in.)
NOTE: Specifications And Design Subject To Change Without Notice. Wherever Applicable, Specifications Are In Accordance With SAE Standards. Except Where Otherwise Noted, Specifications
Are Based On A Machine Equipped With All Standard, 17.5—25, 12 Pr, L2 Tires, Two Rear Counterweights, ROPS Cab, Full Fuel Tank, And 79 Kg (175 Lb) Operator.
Machine Weight: Standard operating weight with bucket
11 168 kg (24,621 lb) Continued on next page
TM1529 (27JUN17)
9000-02-8
TX,115,DH2294 -19-18JUN93-1/3
544G, 624G, 644G Loader
062717
PN=26
General Specifications Engine: John Deere 6059T
86 kW (115 hp)
Piston displacement
5.884 L (359 cu in.)
Air cleaner
Dual stage dry type with restriction indicator
Electrical system
12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F)
625 amps
Reserve capacity
160 min.
Torque Converter
Single phase, single stage
Transmission
Countershaft, power shift, automatic
Travel Speeds:
km/h
mph
Forward Speeds: 1
0 0—4.6 — 7. 4
2
0 0—7.7 — 1 2. 3
3
0 0—16.9 — 2 7. 2
4
0 0—23.8 — 3 8. 4
1
0 0—4.5 — 7. 2
2
0 0—7.6 — 1 2. 2
3
0 0—17.2 — 2 7. 7
Reverse Speeds:
NOTE: All Travel Speeds Are With 20.5—25 Tires. Brakes, Service: Power-actuated, 4-wheel, inboard-mounted, wet disk Foot-operated, by either pedal Left pedal also disconnects transmission (if selected by operator) External inspection Low brake pressure warning light and buzzer in monitor Brakes, Park: Spring applied, hydraulically released parking brake is attached to the output shaft Transmission disconnects with park brake applied Warning light in monitor—Dual-level
Continued on next page
TM1529 (27JUN17)
9000-02-9
TX,115,DH2294 -19-18JUN93-2/3
544G, 624G, 644G Loader
062717
PN=27
General Specifications Brakes, Park: Amber lights with transmission in neutral Red STOP indicator lights, and buzzer sounds with transmission in gear Steering: Turning radius (to centerline of outside tire)
4.95 m (16 ft 3 in.)
Rear axle oscillation
22 degrees, stop to stop
Tires: 15.5—25, 12 PR L2 17.5—25, 12 PR L2 17.5—25, 12 PR L3 17.5—25, Radial, One Star, L2 Equivalent 20.5—25, Radial, One Star, L2 Equivalent 20.5—25, 12 PR L2 20.5—25, 12 PR L3 20.5—25, 16 PR L3 Maximum Lift Capacity With Standard Equipment: Maximum height
5 154 kg (11,365 lb)
Ground level
9 086 kg (20,035 lb) TX,115,DH2294 -19-18JUN93-3/3
544G TC Drain And Refill Capacities Metric
U.S.
Cooling system
23.5 L
25 qt
Fuel tank
218 L
57.6 gal
Engine crankcase and 19 L filter
20 qt
Transmission case and filter
9.5 L
10 qt
Front differential
19 L
20 qt
Rear differential
19 L
20 qt
Hydraulic reservoir
76 L
80 qt TX,I,DY280 -19-16APR96-1/1
TM1529 (27JUN17)
9000-02-10
544G, 624G, 644G Loader
062717
PN=28
General Specifications
T6603AC1 —UN—20OCT88
624G Specifications
Machine Dimensions: A—Overall operating height (boom full raise)
5.06 m (16 ft 7 in.)
B—Bucket hinge height
3.89 m (12 ft 9 in.)
C—Dump height
2.94 m (9 ft 8 in.)
D—Dump reach
0.90 m (2 ft 11 in.)
E—Height to top of cab and canopy
3.30 m (10 ft 10 in.)
F—Overhang
1.94 m (6 ft 4.5 in.)
G—Wheelbase
3.03 m (9 ft 11 in.)
H—Ground clearance
430 mm (1 ft 5 in.)
I—Overall length
7.30 m (24 ft 0 in.)
Width over tires 17. 5-25 tires
2.55 m (8 ft 4 in.)
20. 5-25 tires
2.52 m (8 ft 3 in.)
Machine Weights: Standard Operating Weights
12 398kg (27 338 lb)
Counterweight weight: Continued on next page
TM1529 (27JUN17)
9000-02-11
TX,115,DH2268 -19-16JUN93-1/3
544G, 624G, 644G Loader
062717
PN=29
General Specifications Machine Weights: (1st optional counterweight)
429 kg (946 lb)
(2nd optional counterweight)
530 kg ( 1168 lb)
NOTE: Specifications And Design Subject To Change Without Notice. Wherever Applicable, Specifications Are In Accordance With SAE Standards. Except Where Otherwise Noted, Specifications
Are Based On A Machine Equipped With All Standard, 20.5—25, 12 Pr, L2 Tires, One Rear Counterweight, ROPS Cab, Full Fuel Tank, And 79 Kg (175 Lb) Operator.
Engine: John Deere 6068T
108 kW (145 hp)
Piston displacement
6.8 L (414 cu in.)
Air cleaner
Dual stage dry type with restriction indicator
Electrical system
12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F)
625 amps
Reserve capacity
160 min.
Torque Converter
Single phase, single stage
Transmission
Countershaft, power shift, automatic
Travel Speeds:
km/h
mph
Forward Speeds: 1
0 0—4.5 — 7. 3
2
0 0—7.2 — 11 .6
3
0 0—15.2 — 24 .5
4
0 0—23.0 — 37 .3 Reverse Speeds:
1
0 0—4.5 — 7. 3
2
0 0—7.2 — 11 .6
3
0 0—15.2 — 2 4. 5
Brakes, Service: Power-actuated, 4-wheel, inboard-mounted, wet disk Foot-operated, by either pedal Continued on next page
TM1529 (27JUN17)
9000-02-12
TX,115,DH2268 -19-16JUN93-2/3
544G, 624G, 644G Loader
062717
PN=30
General Specifications Brakes, Service: Left pedal also disconnects transmission (if selected by operator) External inspection Low brake pressure warning light and buzzer in monitor Brakes, Park: Spring applied, hydraulically released parking brake is attached to the output shaft Transmission disconnects with park brake applied Warning light in monitor—Dual-level Amber lights with transmission in neutral Red STOP indicator lights, and buzzer sounds with transmission in gear Steering: Turning radius (to centerline of outside tire
5.14 m (16 ft 11 in.)
Rear axle oscillates 26° total Tires: 17.5—25, 12 PR L2 17.5—25, 12 PR L3 17.5—25, Radial, One Star, L2 Equivalent 20.5—25, 12 PR L2 20.5—25, 12 PR L3 20.5—25, Radial, One Star, L2 Equivalent Maximum Lift Capacity With Standard Equipment: Maximum height
6 414 kg (14 140 lb)
Ground level
12 217 kg (26 939 lb) TX,115,DH2268 -19-16JUN93-3/3
624G Drain And Refill Capacities Metric
U.S.
Cooling system
24.6 L
26 qt
Fuel tank
249 L
66 gal
Engine crankcase and filter 19 L
20 qt
Transmission case and filter 11.4 L
12 qt
Front differential
28.4 L
30 qt
Rear differential
18 L
19 qt
Hydraulic reservoir
102 L
108 qt TX,I,DY281 -19-16APR96-1/1
TM1529 (27JUN17)
9000-02-13
544G, 624G, 644G Loader
062717
PN=31
General Specifications
T6603AD1 —UN—20OCT88
644G Specifications
Machine Dimensions: A—Overall operating height (boom full raise)
5.28 m (17 ft 4 in.)
B—Bucket hinge height
4.00 m (13 ft 2 in.)
C—Dump height
2.99 m (9 ft 10 in.)
D—Dump reach
1.01 m (3 ft 4 in.)
E—Height to top of cab and canopy
3.42 m (11 ft 3 in.)
F—Overhang
1.95 m (6 ft 5 in.)
G—Wheelbase
3.20 m (10 ft 6 in.)
H—Ground clearance
483 mm (1 ft 7 in.)
I—Overall length
7.65 m (25 ft 1 in.)
Width over tires: 20.5-25 tires
2.73 m (8 ft 11 in.)
20.5-R25 tires
2.74 m (9 ft 0 in.)
23.5-25 tires
2.77 m (9 ft 1 in.)
Machine Weights: Standard Operating Weights
15 666 kg (34 544 lb)
Counterweight weight: (1st optional counterweight)
413 kg (910 lb)
(2nd optional counterweight)
645 kg (1422 lb)
Continued on next page
TM1529 (27JUN17)
9000-02-14
TX,115,DH2270 -19-16JUN93-1/3
544G, 624G, 644G Loader
062717
PN=32
General Specifications NOTE: Specifications And Design Subject To Change Without Notice. Wherever Applicable, Specifications Are In Accordance With SAE Standards. Except Where Otherwise Noted, Specifications
Are Based On A Machine Equipped With All Standard, 23.5—25, 12 Pr, L2 Tires, One Rear Counterweight, ROPS Cab, Full Fuel Tank, And 79 Kg (175 Lb) Operator.
Engine: Machine S.N. —557738 John Deere 6076A
127 kW (170 hp)
Piston displacement
7.636 L (466 cu in.)
Air cleaner
Dual stage dry type with restriction indicator
Electrical system
12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F)
925 amps
Reserve capacity
160 min.
Machine S.N. 557739— John Deere 6081H
127 kW (170 hp)
Piston displacement
8.1 L (494 cu in.)
Air cleaner
Dual stage dry type with restriction indicator
Electrical system
12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F)
950 amps
Reserve capacity
160 min.
Transmission and Torque Converter: Transmission
Countershaft, powershift, automatic
Torque Converter
Single phase, planetary
Travel Speeds:
km/h
mph
1
0—7.0
0—4.4
2
0—11.2
0—7.0
3
0—22.0
0—13.7
4
0—34.6
0—21.5
1
0—7.0
0—4.4
2
0—10.2
0—7.0
3
0—22.0
0—13.7
Forward Speeds:
Reverse Speeds:
Brakes, Service: Power-actuated, 4-wheel, inboard-mounted, wet disk Foot-operated, by either pedal Left pedal also disconnects transmission (if selected by operator) External inspection Low brake pressure warning light and buzzer in monitor Brakes, Park: Expanding shoe on transmission output shaft, foot-operated Transmission disconnects with park brake applied Warning light in monitor—Dual-level Amber lights with transmission in neutral Red STOP indicator lights, and buzzer sounds with transmission in gear Steering: Turning radius (to centerline of outside tire).
5.46 m (17 ft 11 in.)
Rear axle oscillates 26° total Tires: 20.5—25, 12 PR L2 20.5—25, 16 PR L2 20.5—25, 16 PR L3 20.5—25, Radial, One Star, L2 equivalent Continued on next page
TM1529 (27JUN17)
9000-02-15
TX,115,DH2270 -19-16JUN93-2/3
544G, 624G, 644G Loader
062717
PN=33
General Specifications Tires: 20.5—25, Radial, One Star, L3 equivalent 23.5—25, 12 PR L2 23.5—25, 20 PR L3 23.5—25, Radial, One Star, L3 equivalent TX,115,DH2270 -19-16JUN93-3/3
644G Drain And Refill Capacities Metric
U.S.
Cooling system
28 L
29.5 qt
Fuel tank
284 L
75 gal
Engine crankcase and 24 L filter
25 qt
Transmission case and filter
14.2 L
15 qt
Front differential
28.4 L
30 qt
Rear differential
28.4 L
30 qt
Hydraulic reservoir
115 L
120 qt TX,I,DY282 -19-16APR96-1/1
TM1529 (27JUN17)
9000-02-16
544G, 624G, 644G Loader
062717
PN=34
Group 03
Torque Values Hardware Torque Specifications Check cap screws and nuts to be sure they are tight. If hardware is loose, tighten to torque shown on the following charts unless a special torque is specified. T82,SKMA,AT -19-01AUG94-1/1
ROPS Torque Specifications
TS176 —UN—23AUG88
CAUTION: Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque. 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. A damaged ROPS should be replaced, not reused. When installation of equipment on a machine necessitates loosening or removing ROPS, mounting bolts must be tightened to 620 ± 120 N·m (457 ± 88 lb-ft). Item
Measurement
Specification
ROPS Mounting Bolts
Torque
620 ± 120 N·m (457 ± 88 lb-ft) CED,OUTX782,581 -19-12AUG99-1/1
TM1529 (27JUN17)
9000-03-1
544G, 624G, 644G Loader
062717
PN=35
Torque Values
Metric Bolt and Screw Torque Values TS1670 —UN—01MAY03
Bolt or Screw Size M6 M8 M10
4.8
8.8
9.8
10.9
12.9
12.9
4.8
8.8
9.8
10.9
12.9
12.9
Class 4.8 Lubricateda
Class 8.8 or 9.8 Dryb
Lubricateda
Class 10.9
Dryb
Lubricateda
Class 12.9 Dryb
Lubricateda
Dryb
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
4.7
42
6
53
8.9
79
11.3
100
13
115
16.5
146
15.5
137
19.5
172
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
32
23.5
40
29.5
37
27.5
47
35
63
46
80
59
75
55
95
70
11.5
102
14.5
128
22
194
27.5
243
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
29
21
43
32
55
40
lb.-in.
23
204
N·m
lb.-ft.
M12
40
29.5
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14
63
46
80
59
120
88
150
110
175
130
220
165
205
150
260
190
M16
100
74
125
92
190
140
240
175
275
200
350
255
320
235
400
300
M18
135
100
170
125
265
195
330
245
375
275
475
350
440
325
560
410
M20
190
140
245
180
375
275
475
350
530
390
675
500
625
460
790
580
M22
265
195
330
245
510
375
650
480
725
535
920
680
850
625
1080
800
M24
330
245
425
315
650
480
820
600
920
680
1150
850
1080
800
1350
1000
M27
490
360
625
460
950
700
1200
885
1350
1000
1700
1250
1580
1160
2000
1475
M30
660
490
850
625
1290
950
1630
1200
1850
1350
2300
1700
2140
1580
2700
2000
M33
900
665
1150
850
1750
1300
2200
1625
2500
1850
3150
2325
2900
2150
3700
2730
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2770
4750
3500
Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For stainless steel fasteners or for nuts on U-bolts, see the tightening instructions for the specific application. Tighten plastic insert or crimped steel type lock nuts by turning the nut to the dry torque shown in the chart, unless different instructions are given for the specific application.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Replace fasteners with the same or higher property class. If higher property class fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.
a “Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20 and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. b “Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ2 -19-12JAN11-1/1
TM1529 (27JUN17)
9000-03-2
544G, 624G, 644G Loader
062717
PN=36
Torque Values
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening. Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart. METRIC CAP SCREW TORQUE VALUES
a
Nominal Dia 8
T-Bolt
H-Bolt
N·m
lb-ft
29
21
N·m
lb-ft
M-Bolt N·m
lb-ft
20
15
10
7
10
63
46
45
33
20
15
12
108
80
88
65
34
25
14
176
130
137
101
54
40
16
265
195
206
152
78
58
18
392
289
294
217
118
87
20
539
398
392
289
167
125
22
735
542
539
398
216
159
24
931
687
686
506
274
202
27
1372
1012
1029
759
392
289
30
1911
1410
1421
1049
539
398
33
2548
1890
1911
1410
735
542
36
3136
2314
2401
1772
931
687
T6873AB —UN—18OCT88
Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application.
T6873AC —UN—18OCT88
CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury.
T6873AA —UN—15APR13
Additional Metric Cap Screw Torque Values
a
Torque tolerance is ±10%. TX,9000,RR7443 -19-01AUG94-1/1
TM1529 (27JUN17)
9000-03-3
544G, 624G, 644G Loader
062717
PN=37
Torque Values
Unified Inch Bolt and Screw Torque Values TS1671 —UN—01MAY03
Bolt or Screw Size 1/4 5/16 3/8 7/16
SAE Grade 2a
SAE Grade 1 b
c
Lubricated
Lubricatedb
Dry
SAE Grade 5, 5.1 or 5.2
Dryc
Lubricatedb
Dryc
SAE Grade 8 or 8.2 Lubricatedb
Dryc
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
lb.-in.
N·m
3.7
33
4.7
42
6
53
7.5
66
9.5
84
12
106
13.5
120
17
150
N·m
lb.-ft.
N·m
lb.-ft.
28
20.5
35
26
7.7 13.5
68 120
22
194
N·m
lb.-ft.
9.8
86
12
106
15.5
137
17.5
155
22
194
27
240
N·m
lb.-ft.
N·m
lb.-ft.
N·m
lb.-ft.
28
20.5
35
26
44
32.5
lb.-in.
19.5
172
25
221
N·m
lb.-ft.
N·m
lb.-ft.
35
26
44
32.5
49
36
63
46
56
41
70
52
80
59
100
74
1/2
34
25
42
31
53
39
67
49
85
63
110
80
120
88
155
115
9/16
48
35.5
60
45
76
56
95
70
125
92
155
115
175
130
220
165
5/8
67
49
85
63
105
77
135
100
170
125
215
160
240
175
305
225
3/4
120
88
150
110
190
140
240
175
300
220
380
280
425
315
540
400
7/8
190
140
240
175
190
140
240
175
490
360
615
455
690
510
870
640
1
285
210
360
265
285
210
360
265
730
540
920
680
1030
760
1300
960
1-1/8
400
300
510
375
400
300
510
375
910
670
1150
850
1450
1075
1850
1350
1-1/4
570
420
725
535
570
420
725
535
1280
945
1630
1200
2050
1500
2600
1920
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2140
1580
2700
2000
3400
2500
1-1/2
990
730
1250
930
990
730
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
Torque values listed are for general use only, based on the strength of the bolt or screw. DO NOT use these values if a different torque value or tightening procedure is given for a specific application. For plastic insert or crimped steel type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Replace fasteners with the same or higher grade. If higher grade fasteners are used, tighten these to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. When possible, lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless different instructions are given for the specific application.
a Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. b “Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in. and larger fasteners with JDM F13C, F13F or F13J zinc flake coating. c “Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ1 -19-12JAN11-1/1
TM1529 (27JUN17)
9000-03-4
544G, 624G, 644G Loader
062717
PN=38
Torque Values
Check Oil Lines And Fittings
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. Check all oil lines, hoses, and fittings regularly for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching moving machine parts. If abrasion or wear occurs, replace immediately.
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.
Tubing with dents may cause the oil to overheat. If you find tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque chart. When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings. TX,90,DH1559 -19-01AUG94-1/1
Service Recommendations for O-Ring Boss Fittings Straight Fitting T6243AE —UN—15APR13
1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart.
Continued on next page
TM1529 (27JUN17)
9000-03-5
TX,I,DY265 -19-05APR96-1/2
544G, 624G, 644G Loader
062717
PN=39
Torque Values Angle Fitting
2. Turn fitting into threaded boss until back-up washer contacts face of boss. 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings. 4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.
T6520AB —UN—15APR13
1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size
N·m
lb-ft
3/8-24 UNF
8
6
7/16-20 UNF
12
9
1/2-20 UNF
16
12
9/16-18 UNF
24
18
3/4-16 UNF
46
34
7/8-14 UNF
62
46
1-1/16-12 UN
102
75
1-3/16-12 UN
122
90
1-5/16-12 UN
142
105
1-5/8-12 UN
190
140
1-7/8-12 UN
217
160
NOTE: Torque tolerance is ± 10%. TX,I,DY265 -19-05APR96-2/2
TM1529 (27JUN17)
9000-03-6
544G, 624G, 644G Loader
062717
PN=40
Torque Values
Service Recommendations For Flat Face O-Ring Seal Fittings 1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.
IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise.
2. Lubricate O-rings and install into grove using petroleum jelly to hold in place.
Tighten fittings to 50% of listed torque value if used in aluminum housing.
3. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.
FLAT FACE O-RING SEAL FITTING TORQUE* Nomial Tube O.D. mm in.
Thread Size
Bulkhead Nut
Swivel Nut
in.
N·m
lb-ft
N·m
lb-ft
6.35
0.250
9/16-18
16
12
12
9
9.52
0.375
11/16-16
24
18
24
18
12.70
0.500
13/16-16
50
37
46
34
15.88
0.625
1-14
69
51
62
46
19.05
0.750
1 3/16-12
102
75
102
75
22.22
0.875
1 3/16-12
102
75
102
75
25.40
1.000
1 7/16-12
142
105
142
105
31.75
1.250
1 11/16-12
190
140
190
140
38.10
1.500
2-12
217
160
217
160
*Torque tolerance is +15 -20% unless otherwise specified. Stud End O-ring Seal Torque for Straight and Adjustable Fittings* Thread Size
Straight Hex Size
Locknut Hex Size
Inch
Inch
Inch
Straight Fitting or Locknut Toque N·m
3/8-24
5/8
9/16
12
9
7/16-20
5/8
5/8
21
15 19
lb-ft
1/2-20
3/4
11/16
26
9/16-18
3/4
3/4
34
25
3/4-16
7/8
15/16
73
55
7/8-14
1 1/16
1 1/16
104
76
1 1/16-12
1 1/4
1 3/8
176
130
1 3/16-12
1 3/8
1 1/2
230
170
1 5/16-12
1 1/2
1 5/8
285
210
*Torque tolerance is +15 -20% unless otherwise specified. 04T,90,K67 -19-02MAR00-1/1
TM1529 (27JUN17)
9000-03-7
544G, 624G, 644G Loader
062717
PN=41
Torque Values
T6890BB —UN—15APR13
Service Recommendations for Metric Series Four Bolt Flange Fitting
Metric Series Four Bolt Flange Fitting A—Sealing Surface B—Split Flange
C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. TORQUE CHARTa
2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.
b
3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.
Thread
N·m
M6
12
lb·ft 9
M8
30
22
M10
57
42
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
a
Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. b Metric standard thread.
04T,90,K175 -19-29SEP99-1/1
TM1529 (27JUN17)
9000-03-8
544G, 624G, 644G Loader
062717
PN=42
Torque Values
T6890BB —UN—15APR13
Service Recommendations For Inch Series Four Bolt Flange Fittings
Flange Fittings A—Sealing Surface B—Split Flange
C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.
TORQUE CHART N·m
lb·ft
Nominal Flange Size
Cap Screw Size Min
Max
Min
Max
1/2
5/16-18 UNC
20
31
15
23
3/4
3/8-16 UNC
28
54
21
40
1
3/8-16 UNC
37
54
27
40
1-1/4
7/16-14 UNC
47
85
35
63
1-1/2
1/2-13 UNC
62
131
46
97
2
1/2-13 UNC
73
131
54
97
2-1/2
1/2-13 UNC
107
131
79
97
5/8-11 UNC
158
264
117
195
2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.
3 3-1/2
5/8-11 UNC
158
264
117
195
4
5/8-11 UNC
158
264
117
195
5
5/8-11 UNC
158
264
117
195
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. 04T,90,K174 -19-01AUG94-1/1
TM1529 (27JUN17)
9000-03-9
544G, 624G, 644G Loader
062717
PN=43
Torque Values
TM1529 (27JUN17)
9000-03-10
544G, 624G, 644G Loader
062717
PN=44
Group 04
Fuels And Lubricants Fuel Specifications Use ONLY clean, high-quality fuel.
For maximum filter life, sediment and water should not be more than 0.10 percent.
Use Grade No. 2-D fuel above 4°C (40°F). Use Grade No. 1-D fuel below 4°C (40°F). Use Grade No. 1-D fuel for all air temperatures at altitudes above 1500 m (5000 ft). IMPORTANT: Use fuel with less than 1.0 percent sulfur. If possible, use fuel with less than 0.5 percent sulfur.
The cetane number should be 40 minimum. If you operate your machine where air temperatures are normally low or where altitudes are high, you may need fuel with a higher cetane number. Cloud Point—For cold weather operation, cloud point should be 6°C (10°F) below lowest normal air temperature.
If fuel sulfur content exceeds 0.5 percent, change the engine oil at 1/2 the normal interval. TX,DH,54 -19-01AUG94-1/1
Storing Fuel If there is a very slow turnover of fuel in the fuel tank or supply tank, it may be necessary to add a fuel
conditioner to prevent water condensation. Contact your authorized dealer for proper service or maintenance recommendations. TX,45,DH2536 -19-03SEP92-1/1
Do Not Use Galvanized Containers IMPORTANT: Diesel fuel stored in galvanized containers reacts with zinc coating on the container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and fuel pumps. DO NOT USE a galvanized container to store diesel fuel.
Store fuel in:
• plastic containers. • aluminum containers. • specially coated steel containers made for diesel fuel. DO NOT USE brass-coated containers: brass is an alloy of copper and zinc. MX,FLBT,C -19-04JUN90-1/1
Fuel Tank CAUTION: Handle fuel carefully. If the engine is hot or running, DO NOT fill the fuel tank. DO NOT smoke while you fill fuel tank or work on fuel system.
To avoid condensation, fill the fuel tank at the end of each day’s operation. Shut off engine before filling.
Item
Measurement
Specification
544G, 544G LL, 544G TC Fuel Tank
Capacity
218 L (58 gal)
624G Fuel Tank
Capacity
249 L (66 gal)
644G Fuel Tank
Capacity
284 L (75 gal) TX,45,DH2188 -19-17AUG92-1/1
TM1529 (27JUN17)
9000-04-1
544G, 624G, 644G Loader
062717
PN=45
Fuels And Lubricants
T7396BK —19—19JUN91
Engine Oil
Depending upon the expected air temperature range between oil changes, use oil viscosity shown on the temperature chart above. Additives are not required nor recommended. John Deere engine oil filters are highly recommended because they are of known high quality and effectiveness. John Deere TORQ-GARD SUPREME PLUS 50® engine oil is recommended. It is a specifically balanced formulation to provide superior protection against oil thickening, carbon deposits, lacquer, and mechanical wear during high temperature operation. John Deere TORQ-GARD SUPREME® engine oil is also recommended.
• API Service Class CE or CD (1) • Military Spec MIL-L-2104D or MIL-L-2104C Most oil containers or specifications list several API Service Classes (such as SC, SG, CE, CC) met by the oil. For the oil you use, either CE or CD must be among the classes listed. NOTE: Oils meeting API Service Classes CE or CD are not always available in viscosity grades SAE 5W20, SAE 5W30, and Arctic Oils. For these viscosity grades only, the following oil specification may be used but the oil and filter change interval must be reduced to 125 hours.
If other oils are used, the required specification is:
• API Service Class CC (MIL-L-46152B) • Military Spec MIL-L-46167A (arctic oil)
TORQ-GARD SUPREME PLUS 50 is a trademark of Deere & Company. TORQ-GARD SUPREME is a trademark of Deere & Company TX,45,DH1532 -19-01AUG94-1/1
TM1529 (27JUN17)
9000-04-2
544G, 624G, 644G Loader
062717
PN=46
Fuels And Lubricants
T7646AB —19—19DEC91
Hydraulic System Oil And Differential Oil
Depending on the expected air temperature range between oil changes, use oil viscosity shown on the chart above.
You may also use oils which meet minimum John Deere standards, or other oils meeting John Deere Standard JDM J20A or J20C and J20B or J20D.
JOHN DEERE HY-GARD® TRANSMISSION AND HYDRAULIC OIL IS RECOMMENDED because it is specifically formulated to minimize brake chatter, and to provide maximum protection against mechanical wear.
Oils meeting MIL-L-46167A may be used as an arctic oil.
HY-GARD is a trademark of Deere & Company TX,45,DH2945 -19-21JUN93-1/1
TM1529 (27JUN17)
9000-04-3
544G, 624G, 644G Loader
062717
PN=47
Fuels And Lubricants
T7946AT —19—18FEB93
Transmission Oil
Depending on the expected air temperature range between oil changes, use oil viscosity shown on the chart above.
You may also use oils which meet minimum John Deere standards, or other oils meeting John Deere Standard JDM J20A or J20C and J20B or J20D.
JOHN DEERE HY-GARD® TRANSMISSION AND HYDRAULIC OIL IS RECOMMENDED because it is specifically formulated to minimize brake chatter, and to provide maximum protection against mechanical wear.
Oils meeting MIL-L-46167A may be used as an arctic oil.
HY-GARD is a trademark of Deere & Company TX,45,DH2706 -19-12MAR93-1/1
TM1529 (27JUN17)
9000-04-4
544G, 624G, 644G Loader
062717
PN=48
Fuels And Lubricants
T6722AA —19—27JAN89
Grease
Depending on the expected air temperature range, use grease shown on chart above.
• SAE Multipurpose Grease with Extreme Pressure
Greases recommended are:
• •
• John Deere Moly High Temperature/EP Grease (Preferred)
(EP) performance and containing 3 to 5 per cent molybdenum disulfide SAE multi-purpose EP Grease Grease meeting MIL-G-10924C specifications may be used as arctic grease.
NOTE: Greases containing greater than 5 per cent molybdenum disulfide are not recommended for the frame hinge pivots and driveline joints. TX,45,DH2964 -19-16JUN93-1/1
Alternative and Synthetic Lubricants Conditions in certain geographical areas may require lubricant recommendations different from those printed in this manual.
The temperature limits and service intervals shown in this manual apply to both conventional and synthetic lubricants.
Some John Deere brand coolants and lubricants may not be available in your location.
Re-refined base stock products may be used if the finished lubricant meets the performance requirements.
Consult your John Deere dealer to obtain information and recommendations. Synthetic lubricants may be used if they meet the performance requirements as shown in this manual. DX,ALTER -19-11APR11-1/1
Lubricant Storage Your equipment can operate at top efficiency only when clean lubricants are used. Use clean containers to handle all lubricants. Store lubricants and containers in an area protected from dust, moisture, and other contamination. Store containers on their side to avoid water and dirt accumulation.
Make certain that all containers are properly marked to identify their contents. Properly dispose of all old containers and any residual lubricant they may contain.
DX,LUBST -19-11APR11-1/1
TM1529 (27JUN17)
9000-04-5
544G, 624G, 644G Loader
062717
PN=49
Fuels And Lubricants
Mixing of Lubricants In general, avoid mixing different brands or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements.
Consult your John Deere dealer to obtain specific information and recommendations.
Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance. DX,LUBMIX -19-18MAR96-1/1
Diesel Engine Coolant (engine with wet sleeve cylinder liners)
• Coolant concentrate meeting ASTM D6210
Preferred Coolants
requirements in a 40—60% mixture of concentrate with quality water
The following pre-mix engine coolants are preferred:
• John Deere COOL-GARD™II • John Deere COOL-GARD II PG COOL-GARD II pre-mix coolant is available in several concentrations with different freeze protection limits as shown in the following table. COOL-GARD II pre-mix
Freeze Protection Limit
COOL-GARD II 20/80
-9 °C (16 °F)
COOL-GARD II 30/70
-16 °C (3 °F)
COOL-GARD II 50/50
-37 °C (-34 °F)
COOL-GARD II 55/45
-45 °C (-49 °F)
COOL-GARD II PG 60/40
-49 °C (-56 °F)
COOL-GARD II 60/40
-52 °C (-62 °F)
If coolant meeting one of these specifications is unavailable, use a coolant concentrate or pre-mix coolant that has a minimum of the following chemical and physical properties:
• Provides cylinder liner cavitation protection according to • •
either the John Deere Cavitation Test Method or a fleet study run at or above 60% load capacity Is formulated with a nitrite-free additive package Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion
Water Quality
Not all COOL-GARD II pre-mix products are available in all countries.
Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene glycol base engine coolant concentrate.
Use COOL-GARD II PG when a non-toxic coolant formulation is required.
Coolant Drain Intervals
Additional Recommended Coolants
Drain and flush the cooling system and refill with fresh coolant at the indicated interval, which varies with the coolant used.
The following engine coolant is also recommended:
• John Deere COOL-GARD II Concentrate in a 40—60%
When COOL-GARD II or COOL-GARD II PG is used, the drain interval is 6 years or 6000 hours of operation.
IMPORTANT: When mixing coolant concentrate with water, do not use less than 40% or greater than 60% concentration of coolant. Less than 40% gives inadequate additives for corrosion protection. Greater than 60% can result in coolant gelation and cooling system problems.
If a coolant other than COOL-GARD II or COOL-GARD II PG is used, reduce the drain interval to 2 years or 2000 hours of operation.
mixture of concentrate with quality water.
IMPORTANT: Do not use cooling system sealing additives or antifreeze that contains sealing additives.
Other Coolants Other ethylene glycol or propylene glycol base coolants may be used if they meet the following specification:
Do not mix ethylene glycol and propylene glycol base coolants. Do not use coolants that contain nitrites.
• Pre-mix coolant meeting ASTM D6210 requirements COOL-GARD is a trademark of Deere & Company DX,COOL3 -19-15MAY13-1/1
TM1529 (27JUN17)
9000-04-6
544G, 624G, 644G Loader
062717
PN=50
Contents
Section 9005 Operational Checkout Procedure
Page
Group 10—Operational Checkout Procedure Operational Checkout Record Sheet—544G, 624G, And 644G...................................................... 9005-10-1 Complete Machine Operational Checkout ............................................... 9005-10-3 Monitor Indicator And Gauge Checks—Engine Off..............................9005-10-4 Transmission Controls, Axle And Engine Linkages, Neutral Start Switch, And Reverse Warning Alarm Switch Checks.......................................9005-10-6 Monitor Indicator And Gauge Checks—Engine Running ...................9005-10-10 Brake System, Clutch Cut-Off, And Differential Lock Checks .....................9005-10-14 Driving Checks ........................................9005-10-21 Hydraulic System Checks........................9005-10-28 Steering System Checks .........................9005-10-34 Accessory Checks ...................................9005-10-38 Cab Component And Vandal Protection Checks ................................................9005-10-42
TM1529 (27JUN17)
9005-1
544G, 624G, 644G Loader
062717
PN=1
Contents
TM1529 (27JUN17)
9005-2
544G, 624G, 644G Loader
062717
PN=2
Group 10
Operational Checkout Procedure Operational Checkout Record Sheet—544G, 624G, And 644G DATE
OWNER HOURS
MODEL/SERIAL NO T6522CJ —UN—19OCT88
TECHNICIAN
Use this sheet to record Operational Checkout results. Bold face numbers in Group 9005-10 correspond to numbers on the record sheet. Perform the Operational Checks before installing any test equipment.
OK
NOT OK
1
Monitor Indicator And Gauge Checks (Engine Off)
2.
Hourmeter And Gauge Check
□
□
Battery Check
□
□
Monitor Indicator Circuit Check
□
□
Monitor Turn Signals and Warning Indicator Check
□
□
□
□
Neutral Start And Reverse Warning Alarm Circuit Checks □ □ Engine Speed Control Linkage Check
□
Fuel Shut-off Solenoid Linkage Check (644G)
□
□
Front Axle Disconnect Check (If Equipped)
□
□
Monitor Display and Alternator Output Checks
□
□
Monitor Bypass Circuit and Seat Belt Indicator Check
□
□
Monitor Primary and Secondary Level Check
□
□
Transmission Oil Warm-Up Procedure
□
□
Transmission Temperature Gauge Check
□
□
Transmission, Axle and Engine Linkages, Neutral Start Switch and Reverse Warning Alarm Switch Checks Transmission Control Lever and Neutral Lock Latch Checks
3.
□
Monitor Indicator and Gauge Checks (Engine Running)
OK
NOT OK
4.
Brake System, Clutch Cut-Off, and Differential Lock Checks
5.
COMMENTS
COMMENTS
Park Brake Capacity Check
□
□
Park Brake Transmission Lockout Check
□
□
Service Brake Pump Flow Check
□
□
Service Brake Capacity Check
□
□
Brake Accumulator Precharge Check
□
□
Brake System Leakage Check
□
□
Service Brake Pedal Check
□
□
Service and Park Brake System Drag Check
□
□
Differential Lock Check
□
□
Differential Lock Leakage Check
□
□
Clutch Cut-off Check
□
□
Driving Checks Transmission Oil Warm-Up Procedure
□
□
Transmission Noise Check
□
□
Automatic Shift and Speedometer Check
□
□
Transmission "Quick Shift" Check
□
□
Continued on next page
TM1529 (27JUN17)
9005-10-1
TX,9005,WW1260 -19-16SEP92-1/3
544G, 624G, 644G Loader
062717
PN=53
Operational Checkout Procedure 5.
Driving Checks Forward, Reverse and 4TH Speed Clutch Pack Drag Check
□
□
1ST, 2ND and 3RD Speed Clutch Pack Drag Check
□
□
Transmission Pressure, Pump Flow and Leakage Check □ □ Transmission Shift Modulation Check
□
□
Torque Converter Check
□
□
Engine Power Check
□
□
Hydraulic System Warm-up Procedure
□
□
Hydraulic Pump Performance Check
□
□
Pilot Control Valve Boom Float Check
□
□
Boom Down Solenoid Valve Check
□
□
Control Valve Lift Check Check
□
□
Bucket Rollback Circuit Relief
□
□
Valve Check
□
□
Ride Control Accumulator Check (If Equipped)
□
□
Boom Raise Circuit Relief Valve Check
□
□
Boom and Bucket Cylinder Drift Check
□
□
Boom Down Solenoid Valve Leakage Check
□
□
Pilot Controller Check
□
□
OK
NOT OK
6.
Hydraulic System Checks
COMMENTS
Bucket Dump Circuit Relief Valve: □ □ Low Pressure Check High □ □ Pressure Check
OK 7.
Low Check Pressure High Check Pressure
Return-To-Dig Check
□
□
Boom Height Kickout Check—If Equipped
□
□
Pin Disconnect Cylinder Check (544G-TC only)
□
□
Steering Valve Check
□
□
Steering System Leakage Check
□
□
NOT OK
COMMENTS
Steering System Checks
Priority Valve: □ □
□
□
Continued on next page
TM1529 (27JUN17)
9005-10-2
TX,9005,WW1260 -19-16SEP92-2/3
544G, 624G, 644G Loader
062717
PN=54
Operational Checkout Procedure
OK
NOT OK
COMMENTS □
□
Secondary Steering System Primary Check Valve Check □
□
Secondary Steering System Check—If Equipped 8.
9.
Accessory Checks Operating Lights Check
□
□
Work Light Check
□
□
Brake Light Check
□
□
Dome Light Check
□
□
Horn Circuit Check
□
□
Windshield Washer and Wiper Check
□
□
Defroster Blower Check
□
□
Heater/Air Conditioner Blower Check
□
□
Heater Functional Checks
□
□
Air Conditioner Functional Checks
□
□
Start Aid System Check
□
□
Cab Door Latch Check
□
□
Cab Door Hold-Open Latch Check
□
□
Cab Door Release Button Check
□
□
Cab Door Lock Check
□
□
Cab Components and Vandal Protection Checks
Cab Door Window Check
□
□
Cab Window Latch Check
□
□
Steering Column Adjustment Check
□
□
Seat and Seat Belt Check
□
□
Air Intake Filter Door Check
□
□
Engine Side Panels Check
□
□
Radiator Cap Access Door Check
□
□
Frame Locking Bar Check
□
□
Boom Lock Check
□
□
Service Decal Check
□
□ TX,9005,WW1260 -19-16SEP92-3/3
Complete Machine Operational Checkout This procedure is designed so technician can make a quick check of the operation of machine while sitting in operator’s seat. A location will be required which is level, has adequate space to complete the driving checks and to work the unit.
At the end of each check, if no problem is found (OK:), you will be instructed to go to next check. If problem is indicated (NOT OK:), you will be given repair required and group location or CTM number. If verification is needed, you will be given next best source of information:
The engine and all other major components must be at operating temperature for some checks.
Group 10 (System Operational Checks)
Complete the necessary visual checks (oil levels, oil condition, external leaks, loose hardware, loose linkage, etc.) prior to doing the checkout.
Group 20 (Adjustments)
No special tools or gauges are needed. Always start in the left column and read completely, following this sequence from left to right. Read each check completely before performing.
CTM (Component Technical Manual)
Group 15 (Diagnostic Information)
Group 25 (Tests)
Continued on next page
TM1529 (27JUN17)
9005-10-3
10T,9005,K118 -19-08JAN16-1/93
544G, 624G, 644G Loader
062717
PN=55
Operational Checkout Procedure
• 1
Monitor Indicator And Gauge Checks—Engine Off
10T,9005,K118 -19-08JAN16-2/93
Hourmeter And Gauge Check
T7773BC —UN—05AUG92
Key ON. Press SELECT button.
OK: Go to next check.
LOOK: Hourmeter reading must be displayed. The Engine Temperature, Fuel, and Transmission Temperature gauges must have single arrow pointing to correct reading. Backlighting of gauges must be ON.
NOT OK: Temperature gauge is solid, 9 arrows showing, circuit is open or shorted. Check Fault Codes in Electronic Monitor circuit see Group 9015-20.
NOTE: Hourmeter only displays in hours, not in tenths of hour.
NOT OK: Fuel gauge with one flashing arrow showing. Add fuel. After adding fuel, if one arrow still flashes, circuit is open or shorted. Check Fault Codes in Electronic Monitor circuit see Group 9015-20. 10T,9005,K118 -19-08JAN16-3/93
Battery Check
T8081AC —UN—05NOV93
Key OFF.
OK: Go to next check.
Press SELECT button and hold until battery volts are displayed.
NOT OK: See Monitor Display and Alternator Output Check in this group.
LOOK: Battery volts must read a minimum of 12.6 volts.
IF OK: Check and recharge batteries.
Continued on next page
TM1529 (27JUN17)
9005-10-4
10T,9005,K118 -19-08JAN16-4/93
544G, 624G, 644G Loader
062717
PN=56
Operational Checkout Procedure Monitor Indicator Circuit And Key Switch Check
T7773BA —UN—05AUG92
Apply brake pedal 10 times. Turn key switch to accessory position. LISTEN: Accessory relay must click. LOOK/LISTEN: All monitor indicators, functions and alarm must come ON after 1 second and remain ON for 5 seconds. After 5 seconds: LOOK: Hourmeter and gauges must display a reading and backlighting must be ON. LOOK/LISTEN: The following indicators must be ON: STOP light, Engine Oil Pressure, Engine Alternator Volts, Transmission Pressure, Steering Pressure (If equipped) and Brake Pressure. Turn key switch to ON. LISTEN: Accessory relay must click. LOOK/LISTEN: All monitor indicators and functions must come ON after 1 second and remain ON for 5 seconds. After 5 seconds: LOOK: Hourmeter and gauges must display a reading and backlighting must be ON.
OK: Go to next check
LOOK/LISTEN: The following indicators must be ON: STOP light, Engine Oil Pressure, NOT OK: Go to Electronic Engine Alternator Volts, Transmission Pressure, Steering Pressure (If equipped), Park Monitor circuit in Group Brake and Brake Pressure. 9015-15. Continued on next page
TM1529 (27JUN17)
9005-10-5
10T,9005,K118 -19-08JAN16-5/93
544G, 624G, 644G Loader
062717
PN=57
Operational Checkout Procedure Monitor Turn Signals And Hazard Warning Indicator Checks
T7747BK1 —UN—21AUG92
T7773BB —UN—21AUG92
T7773BO5 —UN—05AUG92
T6633AB2 —UN—18OCT88
T6564OL —UN—19OCT88
Key ON.
OK: Go to next check
Move turn signal switch left then right. Then press hazard warning switch ON.
NOT OK: Check Turn/Warn fuse.
LOOK: Left, right, and then both turn signal indicators (A and B) must be flashing. Front and rear lights must flash as indicated by monitor lights.
IF OK: Check bulbs and wiring. Go to Lighting Circuit in Group 9015-15. 10T,9005,K118 -19-08JAN16-6/93
• 2
Transmission Controls, Axle And Engine Linkages, Neutral Start Switch, And Reverse Warning Alarm Switch Checks
Continued on next page
TM1529 (27JUN17)
9005-10-6
10T,9005,K118 -19-08JAN16-7/93
544G, 624G, 644G Loader
062717
PN=58
Operational Checkout Procedure Transmission Control Lever And Neutral Lock Latch Checks
T7773BN —UN—05AUG92
Engine OFF. Put neutral lock in LOCKED position. Apply slight effort to move lever into forward (F) and reverse (R). LOOK: Neutral lock must stay engaged and lever must stay in neutral. Move neutral lock to UNLOCKED position. Move control lever to each position Forward, Neutral and Reverse. Then twist lever to shift into each gear 1st, 2nd, 3rd and (4)th. LOOK: Lever must align with gear indicator in each detented position.
OK: Go to next check
FEEL: Lever must move freely through all positions.
NOT OK: Repair lock or replace shift lever assembly. 10T,9005,K118 -19-08JAN16-8/93
Neutral Start And Reverse Warning Alarm Circuit Checks
T7773BI1 —UN—05AUG92
T7773BN2 —UN—05AUG92
Turn key switch to ON position and wait 5 seconds. With transmission control lever in reverse (R), forward (F), and neutral (N) positions, turn key switch to START.
OK: Go to next check.
LISTEN: Starting motor must run while lever is in neutral position only.
NOT OK: Check Neutral Start Fuse.
LISTEN: Reverse warning alarm must sound with lever in reverse.
IF OK: Go Starting Circuit in Group 9015-15.
Continued on next page
TM1529 (27JUN17)
9005-10-7
10T,9005,K118 -19-08JAN16-9/93
544G, 624G, 644G Loader
062717
PN=59
Operational Checkout Procedure Engine Speed Control Linkage Check—544G, 624G
T6564NL —UN—19OCT88
T6564NM —UN—19OCT88
Engine off. Right engine service door open. Check injection pump lever with accelerator pedal up. LOOK: Slow idle stop screw (A) must contact injection pump housing. Have someone fully depress accelerator pedal (or use a weight). Check injection pump lever position. LOOK: Long lever must slightly over-travel short lever (B).
OK: Go to next check.
FEEL: Accelerator pedal must contact stop bolt (C).
NOT OK: Adjust linkage. Go to Engine Speed Control Linkage , Slow and Fast Idle , Group 9010-20 10T,9005,K118 -19-08JAN16-10/93
Engine Speed Control Linkage Check—644G
T7827AE1 —UN—08SEP92
Release accelerator pedal. Push up on injection pump lever. LOOK: Lever must not move up.
OK: Go to next step in this check.
Have someone fully depress accelerator pedal or place a weight on pedal.
OK: Go to next check.
LOOK: Injection pump lever must be against fast idle stop.
NOT OK: Adjust speed control linkage. Go to Engine Speed Linkage Adjustment , Group 9010-20.
Continued on next page
TM1529 (27JUN17)
9005-10-8
10T,9005,K118 -19-08JAN16-11/93
544G, 624G, 644G Loader
062717
PN=60
Operational Checkout Procedure Fuel Shut-Off Solenoid Linkage Check—644G
T7827AE1 —UN—08SEP92
Open right engine side shield and inspect linkage. LOOK: Fuel shut-off cam must be tight against the lower stop. Start engine and engage park brake. Open right engine side shield and inspect linkage. OK: Go to next check.
T7827AF1 —UN—08SEP92
LOOK: Fuel shut-off cam must be tight against the upper stop.
NOT OK: Adjust fuel shut-off solenoid linkage. Go to Fuel Shut-Off Solenoid and Linkage Adjustment , Group 9010-20. 10T,9005,K118 -19-08JAN16-12/93
Front Axle Disconnect Check-If Equipped
T7747AN1 —UN—21AUG92
Move front axle disconnect lever (A) up to disconnect axle. Start engine. Lower boom to raise front wheels off ground. Release park brake. Move transmission control lever to reverse. Back drag with bucket. Observe front wheels. LOOK: Front wheels must not turn. Push lever down to reconnect axle. Observe front wheels when back dragging.
OK: Go to next check.
LOOK: Front wheels must turn.
NOT OK: Go to Front Axle Disconnect Linkage Adjustment , Group 9020-20. Continued on next page
TM1529 (27JUN17)
9005-10-9
10T,9005,K118 -19-08JAN16-13/93
544G, 624G, 644G Loader
062717
PN=61
Operational Checkout Procedure
• 3
Monitor Indicator And Gauge Checks—Engine Running
Continued on next page
TM1529 (27JUN17)
9005-10-10
10T,9005,K118 -19-08JAN16-14/93
544G, 624G, 644G Loader
062717
PN=62
Operational Checkout Procedure Monitor Display And Alternator Output Check
T7825BD —UN—21AUG92
1. Turn key switch to ON and wait 5 seconds. LOOK: Hourmeter reading must appear.
T7825BC —UN—21AUG92
2. Press SELECT button once. LOOK: Battery volts reading must be 12.3—13.8.
T7825BF1 —UN—24AUG92
3. Press SELECT button once. LOOK: Engine rpm must read 0. 4. Press SELECT button once. LOOK: MPH reading must be 0. 5. Press SELECT button once. LOOK: km/H reading must be 0.
OK: Go to next check. NOT OK: No monitor reading displayed, check monitor ACC fuse.
T7825BA —UN—21AUG92
6. Start engine and run at slow idle. Observe monitor display. LOOK: The following engine rpm readings must be displayed. 544G/624G: 825—875 rpm 644G:(S.N. —544523) 775—825 rpm, (S.N.544524—) 875—925 rpm
IF OK: Go to Electronic Monitor circuit in Group 9015-15. NOT OK: If engine speed are more than 100 rpm out of specifications, program monitor for correct machine model. Go to Programing Monitor in group 9015-20.
T7825BB —UN—21AUG92
7. Increase engine speed to fast idle and observe monitor display. Continued on next page
TM1529 (27JUN17)
9005-10-11
10T,9005,K118 -19-08JAN16-15/93
544G, 624G, 644G Loader
062717
PN=63
Operational Checkout Procedure LOOK: The following engine rpm readings must be displayed. 544G: 2350—2400 rpm NOT OK: If slow idle is 624G/644G: 2300—2350 rpm not to specifications, check speed control linkage. IF OK: Adjust Engine Slow Idle see group 9010-20.
T7825BD —UN—21AUG92
8. Press SELECT button until hourmeter symbol is displayed. LOOK: Hourmeter symbol must be flashing and hourmeter reading must be displayed. NOT OK: If fast idle is not to specifications, check speed control linkage. IF OK: Adjust Engine Fast Idle see group 9010-20.
T7825BE —UN—21AUG92
9. Reduce engine speed to slow idle and press SELECT button until battery voltage is displayed. LOOK: Battery voltage should be higher than in step 2 and should be approximately 13.6—14.5 volts.
Continued on next page
TM1529 (27JUN17)
9005-10-12
NOT OK: Check Alternator Circuit output see group 9015-15. 10T,9005,K118 -19-08JAN16-16/93
544G, 624G, 644G Loader
062717
PN=64
Operational Checkout Procedure Monitor Indicator Circuit Bypass And Seat Belt Indicator Check
T7773BH1 —UN—05AUG92
Depress service brake pedal 10 times. Lock transmission control lever in neutral. In a single motion, turn key and start engine. LOOK/LISTEN: Engine should start and bypass the bulb check mode.
T7747AH1 —UN—24AUG92
T7773BB —UN—21AUG92
LOOK: Seat belt indicator must go out after 5 seconds after engine starts. LOOK: Monitor must display engine rpm and gauges must indicate only one reading. Release park brake.
OK: Go to next check.
LOOK: Park brake indicator must go out.
NOT OK: Check for a malfunctioning component.
NOTE: It is normal for Engine Oil Pressure, Brake Pressure, and Transmission Pressure indicators to stay on 4 to 6 seconds after engine starts.
IF OK: Go to Electronic Monitor circuit in Group 9015-15.
Continued on next page
TM1529 (27JUN17)
9005-10-13
10T,9005,K118 -19-08JAN16-17/93
544G, 624G, 644G Loader
062717
PN=65
Operational Checkout Procedure Monitor Primary And Secondary Level Checks
T7747AG1 —UN—24AUG92
Engine running. Engage park brake LOOK: Park brake indicator must come ON. Move transmission control lever in forward. LOOK: Park brake indicator remain ON and STOP light must come ON and flash at one second intervals.
OK: Go to next check.
Engage park brake.
NOT OK: Go to Electronic Monitor circuit in Group 9015-15. 10T,9005,K118 -19-08JAN16-18/93
Transmission Temperature Gauge Check
T7773BO2 —UN—05AUG92
T7773BF —UN—05AUG92
Engine running. Release park brake. Move clutch cut-off switch to OFF position. Apply service brakes. Put transmission in 3rd forward gear.
OK: Go to next check.
Increase engine speed to fast idle for 30 seconds.
NOT OK: If gauge shows solid arrows, check connector at sender.
LOOK: Transmission temperature indicator arrow must move to the right.
IF OK: Check wiring, go to Transmission Temperature Circuit in group 9015-15. 10T,9005,K118 -19-08JAN16-19/93
• 4
Brake System, Clutch Cut-Off, And Differential Lock Checks
Continued on next page
TM1529 (27JUN17)
9005-10-14
10T,9005,K118 -19-08JAN16-20/93
544G, 624G, 644G Loader
062717
PN=66
Operational Checkout Procedure Park Brake Capacity Check
T8081AH —UN—05NOV93
T7773BM —UN—05AUG92
CAUTION: Seat belt must be worn while doing this check to prevent possible injury when machine stops suddenly. Start engine. Fasten seat belt. Press Monitor display until MPH reading is displayed. Release park brake and put transmission in 2nd gear forward. Drive machine at 3 MPH and switch park brake ON.
OK: Go to next check.
LOOK/FEEL: Machine must come to a stop within 2 meters (6 feet) when park brake is NOT OK: Inspect park engaged at 3 MPH. Transmission must shift to neutral. brake. Go to Group 9020-20. 10T,9005,K118 -19-08JAN16-21/93
Park Brake Transmission Lockout Check
T7773BM —UN—05AUG92
T7773BN —UN—05AUG92
Engine running. Turn park brake to ON. Place transmission in 1st forward. Slowly increase engine speed to fast idle.
OK: Go to next check.
LOOK: Unit must not move, STOP warning light must flash and alarm must sound.
NOT OK: Go to Transmission Control Circuit in Group 9015-15.
Continued on next page
TM1529 (27JUN17)
9005-10-15
10T,9005,K118 -19-08JAN16-22/93
544G, 624G, 644G Loader
062717
PN=67
Operational Checkout Procedure Service Brake Pump Flow Check
T7747AF1 —UN—24AUG92
T7773BQ3 —UN—21AUG92
NOTE: Hydraulic oil must be at operating temperature for the check. Engine OFF. Stop engine. Operate brake pedal approximately 15 times. Start engine and run at slow idle. Record number of seconds required for low brake pressure indicator light to go out.
OK: Go to next check.
LOOK: Indicator light must go out in less than 10 seconds from time engine starts.
NOT OK: Check for brake circuit leakage. Go to Brake Circuit Leakage in this group.
NOTE: Indicator will not come on for approximately 1 second after starting engine.
IF OK: Install a cap on line connected to inlet of pressure reducing valve and on the 544G TC, install a cap on the line connected to the inlet of the pin disconnect solenoid valve and repeat pump flow check. If time does not decrease, check for worn brake pump. Go to Brake Pump Flow Test , Group 9020-25.
Continued on next page
TM1529 (27JUN17)
9005-10-16
10T,9005,K118 -19-08JAN16-23/93
544G, 624G, 644G Loader
062717
PN=68
Operational Checkout Procedure Service Brake Capacity Check
T7773BO2 —UN—05AUG92
T7773BQ3 —UN—21AUG92
Engine running. Push Clutch Cut-off switch to OFF position. Fully apply service brakes, release park brake and put transmission in 2nd forward. Increase engine speed to fast idle. LOOK: Unit must not move or move at a very slow speed.
OK: Go to next check.
Repeat check three times to ensure accurate results.
NOT OK: Go to Low Brake Capacity , Group 9020-15.
Continued on next page
TM1529 (27JUN17)
9005-10-17
10T,9005,K118 -19-08JAN16-24/93
544G, 624G, 644G Loader
062717
PN=69
Operational Checkout Procedure Brake Accumulator Precharge Check
NOTE: The axles and hydraulic oil must be at operating temperature for this check. Start and run engine for 30 seconds. Stop engine and turn key switch to ON and wait 5 seconds. NOTE: Stop engine light will be on due to no engine oil pressure. Count the number of times the brake pedal can be fully depressed before the low brake pressure warning light comes on.
T7747AF1 —UN—24AUG92
LOOK: Warning light must NOT come before 3 applications. Start engine and operate at slow idle.
OK: Go to next check.
Observe monitor while applying brake pedal with maximum force.
NOT OK: Make sure brake pedal is not binding and keeping brakes partially engaged. Bleed brakes in Group 9020-20. Check brake system pressure in Group 9020-25.
LOOK/LISTEN: Brake pressure indicator must not come ON.
Continued on next page
TM1529 (27JUN17)
9005-10-18
NOT OK: If light comes on with engine running, accumulator has lost it’s charge. Inspect and recharge accumulator see Group 9020-20. 10T,9005,K118 -19-08JAN16-25/93
544G, 624G, 644G Loader
062717
PN=70
Operational Checkout Procedure Brake System Leakage Check
T7773BI1 —UN—05AUG92
T7747AF1 —UN—24AUG92
Start engine and wait 30 seconds. Stop engine. Wait 2 minutes. Turn key switch to ON and wait 5 seconds.
OK: Go to next check.
LOOK: Brake low pressure warning light must not come on within 2 minutes after stopping engine.
NOT OK: If brake leakage is indicated with brakes released, check leakage at accumulator inlet check valve and brake valve . If brake leakage is indicated with brakes applied, check for leakage at brake valve and brake pistons . Check individual component leakage in Group 9020-25. 10T,9005,K118 -19-08JAN16-26/93
Service Brake Pedal Check
Engine OFF. Slowly depress each brake pedal one at a time. Listen for a hissing noise that indicates oil is flowing to brake pistons.
OK: Go to next check.
FEEL/LISTEN: A hissing noise must be heard when pedal is depressed approximately NOT OK: Inspect for debris 6 mm (1/4 in.) under brake pedal. Inspect clutch cut-off linkage. Continued on next page
TM1529 (27JUN17)
9005-10-19
10T,9005,K118 -19-08JAN16-27/93
544G, 624G, 644G Loader
062717
PN=71
Operational Checkout Procedure Service And Park Brake System Drag Checks
T6522CH —UN—19OCT88
Engine running. Position unit on gradual slope. Lower bucket approximately 50 mm (2 in.) from ground. Release park and service brakes. LOOK: Unit must move or coast. NOTE: If unit does not move, check brake pedals to be sure they fully release when feet are removed from pedals. Drive unit at high speed for about 5 minutes. Brake drag is indicated if brake areas in differential case are too hot to touch by hand.
OK: Go to next check.
NOTE: Observe park brake. If disk is hot, park brake drag is indicated.
NOT OK: Adjust Park Brake , go to Group 9020-20. 10T,9005,K118 -19-08JAN16-28/93
Differential Lock Check
T7773BQ1 —UN—21AUG92
Park unit on a hard surface. Release brakes. Engage differential lock. Steer unit back and forth. LOOK: Front wheels must not turn in opposite direction.
OK: Go to next check.
NOTE: It is normal to get a "clunk" sound when you release pedal.
NOT OK: Go to Diagnose Malfunctions in Group 9020-15.
Continued on next page
TM1529 (27JUN17)
9005-10-20
10T,9005,K118 -19-08JAN16-29/93
544G, 624G, 644G Loader
062717
PN=72
Operational Checkout Procedure Differential Lock Leakage Check
T7747AF1 —UN—24AUG92
Stop engine. Depress brake pedal 10 times. Start and run engine at slow idle. Record the number of seconds for low brake pressure indicator to go out. Repeat check with differential lock applied.
OK: Go to next check.
LOOK: Time for indicator light to go out must not increase more than two seconds with NOT OK: Go to Differential differential lock applied. Lock Leakage Test in Group 9020-25. 10T,9005,K118 -19-08JAN16-30/93
Clutch Cut-Off Check
T7773BO2 —UN—05AUG92
T7773BQ2 —UN—21AUG92
Place clutch cut-off switch in ON position. Release park brake. Run engine at half speed in 1st forward. Firmly depress left brake pedal. FEEL: Transmission must disengage when left brake pedal is depressed.
OK: Go to next check.
NOTE: Clutch cut-off switch on left brake pedal can be adjusted to operator preference to match your loading needs.
NOT OK: Adjust clutch cut-off switch , see Group 9020-20. 10T,9005,K118 -19-08JAN16-31/93
• 5
Driving Checks
NOTE: Transmission oil must be at operating temperature for these checks. Continued on next page
TM1529 (27JUN17)
9005-10-21
10T,9005,K118 -19-08JAN16-32/93
544G, 624G, 644G Loader
062717
PN=73
Operational Checkout Procedure Transmission Oil Warm-Up Procedure
T7773BF —UN—05AUG92
Start engine, apply service brakes, and release park brake Push Clutch Cut-off switch to OFF position. Move transmission selector lever to 3rd speed. Move transmission control lever to forward "F" position. Increase engine speed to fast idle for 30 seconds. Move transmission control lever to neutral "N" position and run for 15 seconds. Repeat procedure until transmission temperature gauge arrow points to bar above dial. OK: Go to next check. 10T,9005,K118 -19-08JAN16-33/93
Transmission Noise Check
T7825BH —UN—21AUG92
T7773BN —UN—05AUG92
Engine running. Run engine at approximately 1600 rpm. Drive unit with transmission in each forward and reverse speed.
OK: Go to next check.
LISTEN: Transmission must not make excessive noise in any range. Engine rpm must not "lug down" as unit is shifted between gears.
NOT OK: Go to Transmission Makes Excessive Noise . Group 9020-15.
Continued on next page
TM1529 (27JUN17)
9005-10-22
10T,9005,K118 -19-08JAN16-34/93
544G, 624G, 644G Loader
062717
PN=74
Operational Checkout Procedure Automatic Shift And Speedometer Check
T7825BG —UN—21AUG92
Engine running. Press SELECT button on monitor until MPH or Km/H is displayed. Release park brake and shift to (4th) forward. Drive machine on level ground and slowly accelerate to fast idle speed and note speed when shifts are made until 4th gear. Reduce engine rpm to idle and note speed when transmission makes each downshift. LOOK: The transmission should shift at following speeds:
OK: Check completed.
544G Loader—Specification 2nd to 3rd Gear Shift—Speed.............................................................6 MPH (9.6 Km/H) 3rd to 4th Gear Shift—Speed.............................................................13 MPH (21 Km/H) 4th to 3rd Gear Shift—Speed.............................................................12 MPH (19 Km/H) 3rd to 2nd Gear Shift—Speed................................................................5 MPH (8 Km/H)
NOT OK: Monitor is programmed for wrong machine model. Go to Programming Monitor in group 9015-20.
624G Loader—Specification 2nd to 3rd Gear Shift—Speed.............................................................6 MPH (9.6 Km/H) 3rd to 4th Gear Shift—Speed.............................................................12 MPH (19 Km/H) 4th to 3rd Gear Shift—Speed.......................................................... 11 MPH (17.7 Km/H) 3rd to 2nd Gear Shift—Speed................................................................5 MPH (8 Km/H) 644G Loader—Specification 2nd to 3rd Gear Shift—Speed.............................................................6 MPH (9.6 Km/H) 3rd to 4th Gear Shift—Speed.......................................................... 11 MPH (17.7 Km/H) 4th to 3rd Gear Shift—Speed.............................................................10 MPH (16 Km/H) 3rd to 2nd Gear Shift—Speed................................................................5 MPH (8 Km/H) NOTE: In (4th) automatic the transmission starts out in 2nd gear, and when it downshifts it returns to 2nd.
Continued on next page
TM1529 (27JUN17)
9005-10-23
IF OK: If shift points are still wrong, the transmission controller does not match machine model. Install correct controller. Wrong controller will cause quick shifts or remain in 2nd gear in (4th) automatic mode. 10T,9005,K118 -19-08JAN16-35/93
544G, 624G, 644G Loader
062717
PN=75
Operational Checkout Procedure Transmission "Quick Shift" Check
T7825BH —UN—21AUG92
T7825BL1 —UN—31AUG92
Engine running. Release park brake and shift to 2nd forward. Drive machine at approximately 1600 rpm and press boom control lever switch once. LOOK/FEEL: Transmission must shift to and remain in 1st gear. Press boom control lever switch once. LOOK/FEEL: Transmission must shift back to 2nd gear. Shift to (4th) gear and press boom control lever switch once.
OK: Go to next check.
LOOK/FEEL: Transmission must not shift down.
NOT OK: Check connector at base of control valve.
NOTE: If boom lever switch is pressed twice, transmission will shift down then immediately back to 2nd. Transmission will also downshift/upshift from 3rd gear but will not work in any gear when in (4th) gear automatic mode.
IF OK: Go to Transmission Controller Circuit in group 9015-15.
Continued on next page
TM1529 (27JUN17)
9005-10-24
10T,9005,K118 -19-08JAN16-36/93
544G, 624G, 644G Loader
062717
PN=76
Operational Checkout Procedure Forward, Reverse And 4th Speed Clutch Pack Drag Check
T7773BN —UN—05AUG92
T7825BF —UN—21AUG92
IMPORTANT: Transmission must be warmed up for this check. Engine running. Park unit on level surface. Apply service brakes. Move transmission control lever to neutral. Move speed selector lever to 1st. Release park brake and service brakes. Run engine at slow idle. LOOK: Unit must not move in either direction.
OK: Go to next check.
NOTE: If unit moves forward, either the forward pack or the 4th speed pack is dragging. NOT OK: If unit moves, repair transmission . (See Group 0350.) 10T,9005,K118 -19-08JAN16-37/93
1st, 2nd, And 3rd Speed Clutch Pack Drag Check
Engine running. Stop unit on a level, hard-surfaced area. Run engine at slow idle. Release park and service brakes. Put transmission in 1st forward, 2nd forward, and then 3rd forward. Note machine movement. LOOK: Machine must roll ahead in each gear.
OK: Go to next check.
NOTE: If machine rolls ahead in one gear but not the other two, drag is indicated in that clutch pack.
NOT OK: Repair transmission , see Group 0350 in TM1530.
Continued on next page
TM1529 (27JUN17)
9005-10-25
10T,9005,K118 -19-08JAN16-38/93
544G, 624G, 644G Loader
062717
PN=77
Operational Checkout Procedure Transmission Pressure, Engine running. Pump Flow, And Leakage Check Run engine at slow idle. Release park brake. Shift transmission to reverse, then forward, and then to 1st, 2nd, and 3rd speeds. Wait 5 seconds after each shift and observe transmission pressure indicator light.
T7747AD1 —UN—24AUG92
LOOK: Indicator light must not come on.
OK: Go to next check.
NOTE: If light comes on in one gear only, leakage is indicated on that gear.
NOT OK: Do Transmission Leakage Test , System Pressure Test , or Pump Flow Test in Group 9020-25.
If light comes on in all gears, low pump flow or pressure is indicated.
10T,9005,K118 -19-08JAN16-39/93
Transmission Shift Modulation Check
T7825BB —UN—21AUG92
T7773BN —UN—05AUG92
Engine running. Run engine at fast idle speed (approximately 2350 rpm). Put transmission in 1st forward, shift several times from forward to reverse and reverse OK: Go to next check. to forward. Repeat check in 2nd gear. LOOK: Machine must slow down and change direction without excessive delay.
Continued on next page
TM1529 (27JUN17)
9005-10-26
NOT OK: Go to Transmission Shifts Too Slow , Group 9020-15. 10T,9005,K118 -19-08JAN16-40/93
544G, 624G, 644G Loader
062717
PN=78
Operational Checkout Procedure Torque Converter Check
T7773BF —UN—05AUG92
Engine running and park brake released. Apply service brakes. Move transmission selector lever to 3rd speed. Move transmission control lever to forward "F" position. Increase engine speed to fast idle and observe engine rpm in monitor display. Record lowest rpm reading. OK: Go to next check.
T7825BI —UN—21AUG92
LOOK: Torque converter stall rpm must be within following range: 544G 2125—2275 rpm 624G 2125—2225 rpm 644G 1950—2150 rpm
NOT OK: If stall rpm readings are outside range, problem may be engine power or torque converter. Go to Engine Power Test in group 9010-25.
Move transmission control lever to neutral "N" position and run for 15 seconds to cool oil. IF OK: If power is ok, go to Diagnose Transmission Malfunctions in group 9020-15. Continued on next page
TM1529 (27JUN17)
9005-10-27
10T,9005,K118 -19-08JAN16-41/93
544G, 624G, 644G Loader
062717
PN=79
Operational Checkout Procedure Engine Power Check
T7827AE1 —UN—08SEP92
Engine running. Apply service brakes. Roll bucket back against stops. Move transmission selector lever to 3rd speed. Move transmission control lever to forward "F" position. Increase engine speed to fast idle and stall torque converter, then hold bucket rollback function over relief. Observe engine rpm in monitor display. Record lowest rpm reading.
T7825BH —UN—21AUG92
LOOK: Combined Hydraulic/Torque Converter stall must be within the following range: Using No. 1 Fuel 544G 1300—1580 rpm 624G 1250—1580 rpm 644G 1350—1550 rpm Using No. 2 Fuel 544G 1400—1700 rpm 624G 1400—1700 rpm
OK: Go to next check.
644G 1450—1650 rpm
NOT OK: If stall rpm readings are outside range, do Hydraulic System Relief Test in group 9025-25.
Move transmission control lever to neutral "N" position and run for 15 seconds to cool oil. IF OK: Go to Engine Power Test in group 9010-25. 10T,9005,K118 -19-08JAN16-42/93
• 6
Hydraulic System Checks
10T,9005,K118 -19-08JAN16-43/93
Hydraulic System Warm-Up Procedure
Engine running. Run engine at fast idle. Hold a hydraulic function over relief to heat oil. Periodically cycle all hydraulic functions to distribute warm oil. Repeat procedure until oil is at operating temperature. FEEL: Hydraulic reservoir must be uncomfortable to hold your hand against (approximately 50°C [120°F]). Continued on next page
TM1529 (27JUN17)
9005-10-28
OK: Go to next check. 10T,9005,K118 -19-08JAN16-44/93
544G, 624G, 644G Loader
062717
PN=80
Operational Checkout Procedure Hydraulic Pump Performance Check
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-up Procedure in this group.) Run engine at fast idle. Turn steering wheel rapidly until frames are against stop. Hold approximately 22 N (5 lb force) pressure on steering wheel. With bucket flat on ground, actuate boom raise. Measure the time to raise boom to full height. LOOK: Boom must raise to full height in less than:
OK: Go to next check.
624G 8 seconds.
NOT OK: Do Steering System Leakage Check in this group.
544G/644G 9 seconds
IF OK: Do Main Hydraulic Pump Flow Test in Group 9025-25. 10T,9005,K118 -19-08JAN16-45/93
Pilot Control Valve Float Check
T6601AA —UN—19OCT88
T7827AI1 —UN—24AUG92
Run engine at slow idle and ride control OFF. With the bucket partially dumped, lower boom to raise front of machine. Push control lever to the float detent position and release lever.
OK: Go to next check.
LOOK: Front of machine must lower to the ground and valve must remain in float position when lever is released.
NOT OK: Do Pilot Control Valve Pressure Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
9005-10-29
10T,9005,K118 -19-08JAN16-46/93
544G, 624G, 644G Loader
062717
PN=81
Operational Checkout Procedure Boom Down Solenoid Valve Check
T7773BO1 —UN—05AUG92
Engine running. Raise boom to full height. Roll bucket back. Stop engine. Hold boom down button down. Move control lever to bucket dump position. Move control lever to boom lower position.
OK: Go to next check.
LOOK: Bucket must dump and boom must lower.
NOT OK: Do Boom Down Solenoid Check in Group 9015-00. 10T,9005,K118 -19-08JAN16-47/93
Control Valve Lift Check
T6601AA —UN—19OCT88
Run machine at slow idle. With bucket partially dumped, lower boom to raise front of machine. Slowly move boom control lever to boom lower position. Slowly move bucket control lever to bucket dump position.
OK: Go to next check.
LOOK: Boom must not raise before moving down. Bucket must not rollback before dumping.
NOT OK: Repair lift checks in control valve. See Group 3160 in TM1530. 10T,9005,K118 -19-08JAN16-48/93
Bucket Rollback Circuit Relief Valve Check
T6564OD —UN—19OCT88
Position bucket at a 45° angle against an immovable object. Engage transmission in third speed forward.
OK: Go to next check.
LOOK: Bucket angle must NOT change.
NOT OK: Do Loader System and Circuit Relief Valve Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
9005-10-30
10T,9005,K118 -19-08JAN16-49/93
544G, 624G, 644G Loader
062717
PN=82
Operational Checkout Procedure Bucket Dump Circuit Relief Valve Pressure Check
T6601AA —UN—19OCT88
Raise front of unit with bucket at 45° angle. Backdrag with bucket while observing bucket angle.
OK: Go to next check.
LOOK: Bucket must not rollback more than 5-8 degrees.
NOT OK: Do Loader System and Circuit Relief Valve Test in Group 9025-25. 10T,9005,K118 -19-08JAN16-50/93
Ride Control Accumulator Check (If Equipped)
T7010AO —UN—15MAR89
CAUTION: The boom will jump upward during this check, Make sure area around bucket is clear. Start engine. Push ride control switch to OFF position. Raise boom to maximum height and hold control lever over relief for 2 seconds. Lower boom and bucket to ground and stop engine.
OK: Go to next check.
Turn key switch to ON position.
NOT OK: Check Ride Control fuse.
Observe loader boom as ride control switch is switched to ON.
IF OK: Ride control accumulator has lost gas charge. See Ride Control Accumulator Hydraulic Discharge Procedure—If Equipped. (Group 9025-20.)
LOOK/FEEL: Boom must jump upward approximately 200 mm (8 in) as accumulator pressure is released.
IF OK: Check valve or solenoid valve in ride control manifold is stuck open. Inspect and repair.
Continued on next page
TM1529 (27JUN17)
9005-10-31
10T,9005,K118 -19-08JAN16-51/93
544G, 624G, 644G Loader
062717
PN=83
Operational Checkout Procedure Boom And Bucket Cylinder Drift
T6564NZ —UN—19OCT88
Raise bucket about 50 mm (2 in.) off ground with bucket level. Stop engine. Wait 1 minute. LOOK: Bucket must not touch ground.
OK: Go to next check.
NOTE: Use good judgement to determine if the amount of drift is objectionable for your loader application.
NOT OK: Go to Cylinder Leakage Check , Group 9025-10 to isolate cylinder or valve leakage. 10T,9005,K118 -19-08JAN16-52/93
Boom Down Check Valve Leakage Check
T7010AO —UN—15MAR89
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-up Procedure in this group.) Position bucket flat on ground. Run engine at slow idle for two minutes.
OK: Go to next check.
LOOK: Bucket must not drift up.
NOT OK: Replace boom lower check valve , see Group 3160 in TM1530. Continued on next page
TM1529 (27JUN17)
9005-10-32
10T,9005,K118 -19-08JAN16-53/93
544G, 624G, 644G Loader
062717
PN=84
Operational Checkout Procedure Pilot Controller Check
T7827AI2 —UN—24AUG92
T7827AD —UN—24AUG92
Stop engine. Turn key switch to OFF position. Move control lever to all positions and then release.
OK: Go to next check.
LOOK: Lever must return to neutral when released from all positions.
NOT OK: Repair pilot controllers. Go to Group 3160 in TM1530. 10T,9005,K118 -19-08JAN16-54/93
Return-To-Dig Check
T7827AI3 —UN—24AUG92
Run engine at slow idle. Position bucket fully dumped just above ground level. Move control lever to return-to-dig detent position and release.
OK: Go to next check.
LOOK: Bucket must rollback to the level position and control lever must return to neutral. NOT OK: Check fuse. NOTE: If bucket is in a rolled back position when key is turned ON, control lever must be returned to neutral manually if placed in the return-to-dig detent position. After bucket is dumped once, return-to-dig will work normally. Continued on next page
TM1529 (27JUN17)
9005-10-33
IF OK: Go to Return-to-Dig Circuit in Group 9015-15 10T,9005,K118 -19-08JAN16-55/93
544G, 624G, 644G Loader
062717
PN=85
Operational Checkout Procedure Boom Height Kickout Check—If Equipped
T7825BL —UN—24AUG92
Run engine at slow idle. Position bucket flat on ground.
OK: Go to next check.
Move control lever to boom raise detent position and release.
NOT OK: Check fuse.
LOOK: Boom must raise to the set height and stop. Control lever must return to neutral. IF OK: Go to Boom Height Kickout Circuit in Group 9015-15. 10T,9005,K118 -19-08JAN16-56/93
Pin Disconnect Cylinder Check (544G—TC Only)
Engine running. Run engine at slow idle. Lower boom to ground. Push and hold pin disconnect switch.
OK: Go to next check.
LOOK: Pin disconnect cylinder must retract both pins, while switch is depressed.
NOT OK: Hold a screwdriver blade against the end of the solenoid valve and check for magnetism with the switch pushed. See Pin Disconnect Circuit in Group 9015-15 if the problem is electrical. See Group 9025-15 if the problem is hydraulic . 10T,9005,K118 -19-08JAN16-57/93
• 7
Steering System Checks
10T,9005,K118 -19-08JAN16-58/93
Steering Valve Check
T6471AQ —UN—19OCT88
Run engine at slow idle. Turn steering wheel until frames are at maximum right (A) and then left (B) positions. LOOK: Frames must move smoothly in both directions. NOTE: It is normal for steering to drift away from steering stops when steering wheel is released. When steering wheel is stopped, frames must stop.
OK: Go to next check.
FEEL: Excessive effort must not be required to turn steering wheel.
NOT OK: Go to next check.
Continued on next page
TM1529 (27JUN17)
9005-10-34
10T,9005,K118 -19-08JAN16-59/93
544G, 624G, 644G Loader
062717
PN=86
Operational Checkout Procedure Steering System Leakage Check
T6601AC —UN—19OCT88
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.) Run engine at fast idle. Turn steering wheel rapidly until frames are against stops. Jerk wheel to stop, then hold approximately 22 N (5 lb force) pressure on steering wheel. Count steering wheel revolutions for 1 minute. Repeat test in opposite direction. LOOK: Steering wheel should rotate less than 5 rpm.
OK: Go to next check.
NOTE: Steering wheel may rotate faster than specification if oil is cold. Use good NOT OK: Do Steering judgement, excessive steering wheel rpm does not mean steering will be affected. System Leakage Test in Group 9025-25 to isolate A new valve may exceed specification. the leakage. 10T,9005,K118 -19-08JAN16-60/93
Priority Valve Low Pressure Check
Park machine on gravel surface. Run engine at fast idle. Hold brake pedal down. Steer machine to the right and left as far as possible.
OK: Go to next check.
LOOK: Machine must turn at least half way to the right and left stops.
NOT OK: Do Priority Valve Pressure Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
9005-10-35
10T,9005,K118 -19-08JAN16-61/93
544G, 624G, 644G Loader
062717
PN=87
Operational Checkout Procedure Priority Valve High Pressure Check
T7827AI3 —UN—24AUG92
T7825BJ —UN—21AUG92
Run engine at fast idle. Steer to steering stop and release wheel. Roll bucket back and hold over relief and observe engine rpm. Turn wheel to steering stop and hold, observe engine rpm.
OK: Go to next check.
LOOK: Steering stall engine rpm must be higher than hydraulic stall rpm.
NOT OK: Priority pressure is set too high. Do Priority Valve Pressure Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
9005-10-36
10T,9005,K118 -19-08JAN16-62/93
544G, 624G, 644G Loader
062717
PN=88
Operational Checkout Procedure Secondary Steering System Check—If Equipped
T7773BH1 —UN—05AUG92
IMPORTANT: Do not operate secondary steering pump for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur. Park unit on a hard level surface with steering straight ahead. Stop engine. Without starting engine, turn key to START position and release.
T6601AC —UN—19OCT88
Steer unit to right and left. OK: Go to next check.
T7747AJ1 —UN—24AUG92
LOOK: Unit must steer approximately half way to stops in both directions. Light in monitor must come ON and stay on until key is turned off.
NOT OK: If secondary steering pump and motor do not operate, do Secondary Steering and System Operational Checks in Group 9025-10. If secondary steering pump and motor operate but unit does not steer, do Secondary Steering Pump Relief Valve Pressure Test in Group 9025-25. 10T,9005,K118 -19-08JAN16-63/93
Secondary Steering System Primary Check Valve Check
Run engine at fast idle.
Turn steering wheel rapidly until frames are against stops. Hold approximately 22 N (5 lb force) pressure on steering wheel. Actuate a hydraulic function and hold over relief. Return control lever to neutral. FEEL: Steering wheel must not "kickback" as hydraulic function is released.
OK: Go to next check.
NOTE: Steering wheel "kickback" is normal on units without secondary steering.
NOT OK: Do Secondary Steering Manifold Block Primary Check Valve Leakage Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
9005-10-37
10T,9005,K118 -19-08JAN16-64/93
544G, 624G, 644G Loader
062717
PN=89
Operational Checkout Procedure
• 8
Accessory Checks
NOTE: Engine must be stopped and key switch must be ON for these checks 10T,9005,K118 -19-08JAN16-65/93
Operating Lights Check
T7773BO3 —UN—05AUG92
T6633AB —UN—18OCT88
T6637AA —UN—18OCT88
Push light switch to detent.
OK: Go to next check.
Note light operation.
NOT OK: Check fuse.
LOOK: Headlights (C), and taillights (D) must come on.
IF OK: Go to Lighting Circuit in group 9015-15. 10T,9005,K118 -19-08JAN16-66/93
Work Light Check
T7773BO4 —UN—05AUG92
T6633AB1 —UN—18OCT88
T6564OI —UN—19OCT88
Push work light switch to detent.
OK: Go to next check.
Note light operation.
NOT OK: Check fuse.
LOOK: Front work lights (C) and rear work lights (D) must come on. Headlights, taillights must remain on.
IF OK: Go to Lighting Circuit in group 9015-15.
Continued on next page
TM1529 (27JUN17)
9005-10-38
10T,9005,K118 -19-08JAN16-67/93
544G, 624G, 644G Loader
062717
PN=90
Operational Checkout Procedure Brake Light Check
T6633AB3 —UN—18OCT88
Depress brake pedal and observe brake lights (A).
OK: Go to next check.
LOOK: Brake lights must come on.
NOT OK: Check brake light fuse.
NOTE: Brake light switch is a pressure switch. If accumulator is empty, unit may need to be started for brake lights to come on.
IF OK: Go to Diagnose Malfunctions in Group 9015-15 10T,9005,K118 -19-08JAN16-68/93
OK: Go to next check.
Horn Circuit Check
T7747BJ1 —UN—21AUG92
Push horn button (A).
NOT OK: Check fuse
LISTEN: Horn must sound.
IF OK: Go to Horn Circuit in Group 9015-15. Continued on next page
TM1529 (27JUN17)
9005-10-39
10T,9005,K118 -19-08JAN16-69/93
544G, 624G, 644G Loader
062717
PN=91
Operational Checkout Procedure Windshield Washer And Wiper Check—If Equipped
T7773BO6 —UN—21AUG92
Turn front wiper switch knob clockwise to first detent and then to second position. LOOK: Front wiper must operate at slow speed with switch in first detent and fast speed with switch in second position. Push in front switch knob to turn front washer on. LOOK: Washer must spray water on windshield. Turn wiper off. LOOK: Front wiper must park at side of windshield. Push rear wiper switch down to first detent position. LOOK: Rear wiper must operate at one speed with switch in first detent. Push rear wiper switch past detent to turn rear washer on. LOOK: Washer must spray water on rear window.
OK: Go to next check.
Turn wiper off.
NOT OK: If wiper and washer do not work, check fuses.
LOOK: Rear wiper must park at side of rear window.
IF OK: Go to Diagnose Malfunctions in Group 9015-15. 10T,9005,K118 -19-08JAN16-70/93
Defroster Fan Switch Check
T7773BP2 —UN—05AUG92
Turn defroster fan switch knob to low, medium and high speeds.
NOT OK: Check fuse.
NOTE: Whenever defroster fan switch is turned to medium speed, both defroster fan motor and pressurizer fan motor will operate at medium speed.
IF OK: Go Defroster Pressurization Circuit in Group 9015-15.
Continued on next page
TM1529 (27JUN17)
OK: Go to next check.
FEEL/LISTEN: Defroster fan must have three speeds and OFF.
9005-10-40
10T,9005,K118 -19-08JAN16-71/93
544G, 624G, 644G Loader
062717
PN=92
Operational Checkout Procedure OK: Go to next check.
Heater/Air Conditioner Blower Check
T7773BP3 —UN—05AUG92
Turn blower switch knob to low, medium and high speeds.
NOT OK: Check fuse.
FEEL/LISTEN: Blower must have three speeds and OFF.
IF OK: Go to Heater/Pressurizer Circuit in Group 9015-15. 10T,9005,K118 -19-08JAN16-72/93
Heater Functional Check
T7773BP1 —UN—05AUG92
Open heater shut-off valve on water pump. Start engine. Run at fast idle. Wait 2 minutes. Turn heater control to maximum heat position.
OK: Go to next check.
FEEL: Air from ducts must be warm.
NOT OK: Go Heater/Pressurizer Circuit in Group 9015-15. 10T,9005,K118 -19-08JAN16-73/93
Air Conditioner Functional Check
T7773BP1 —UN—05AUG92
Start engine and run at fast idle. Turn air conditioner switch to maximum COOL setting.
OK: Go to next check.
Wait for any warm air in duct system to dissipate.
NOT OK: Check fuse.
FEEL: Air from ducts must be cool.
IF OK: Go to Air Conditioner Circuit in Group 9015-15. Continued on next page
TM1529 (27JUN17)
9005-10-41
10T,9005,K118 -19-08JAN16-74/93
544G, 624G, 644G Loader
062717
PN=93
Operational Checkout Procedure Start Aid System Check
T6564NO —19—22MAR89
T6477AP —UN—19OCT88
Start engine and run at slow idle.
OK: Go to next check.
Momentarily push start aid button.
NOT OK: Check for empty start aid can (A).
LISTEN: Engine speed must increase slightly.
IF OK: Check fuse. Replace.
LOOK: Light in monitor must come on when button is pushed.
NOT OK: If light does not come ON, go to Start Aid Circuit in Group 9015-15. 10T,9005,K118 -19-08JAN16-75/93
• 9
Cab Component And Vandal Protection Checks
10T,9005,K118 -19-08JAN16-76/93
Cab Door Latch Check
T6633AR —UN—18OCT88
T6564OZ —UN—19OCT88
Unlatch door. Inspect door seal. Close door.
OK: Go to next check.
LOOK: Door latch must work freely. No door movement must be felt. Door seal MUST NOT OK: Oil hinges. NOT be damaged. Adjust door latch. Continued on next page
TM1529 (27JUN17)
9005-10-42
10T,9005,K118 -19-08JAN16-77/93
544G, 624G, 644G Loader
062717
PN=94
Operational Checkout Procedure Cab Door And Window Hold-Open Latch Check
T6633AK —UN—18OCT88
T6633AN —UN—18OCT88
T6633AJ —UN—18OCT88
Push window and door to full open position. Release window and door by turning lever (D) clockwise.
OK: Go to next check.
LOOK: Pin (B) must fit into latch notch (A). Latch must retain door and window against NOT OK: Adjust rubber rubber stops (C). stop. Repair latch. 10T,9005,K118 -19-08JAN16-78/93
Cab Door Release Button
OK: Go to next check.
T7832AJ —UN—27AUG92
Press door release button.
NOT OK: If latch does not release, check fuse.
LOOK/LISTEN: Latch must click and release door.
IF OK: Go to Door Release Circuit in 9015-15. NOT OK: If door does not latch tightly, adjust latch assembly. 10T,9005,K118 -19-08JAN16-79/93
Cab Door Lock Check
T6564PB —UN—19OCT88
Lock cab door. LOOK: Cab door handle must not move.
OK: Go to next check.
FEEL: Lock must operate freely and key must not stick in lock.
NOT OK: Lubricate or repair lock.
Continued on next page
TM1529 (27JUN17)
9005-10-43
10T,9005,K118 -19-08JAN16-80/93
544G, 624G, 644G Loader
062717
PN=95
Operational Checkout Procedure Cab Window Latch Check
T6633AO —UN—18OCT88
Inspect window seals. Open right side cab window. Pull window closed. LOOK: Latch must hold window tightly closed. LOOK: Window seals must not have gaps between seals and window frames. Position latch outer notch over catch. Open latch.
OK: Go to next check.
LOOK: When window latch is in outer notch position, window must be held slightly open. NOT OK: Lubricate latch. Replace window seals if necessary. 10T,9005,K118 -19-08JAN16-81/93
Cab Door Window Check
T7409AQ —UN—27NOV90
Inspect window seals. Open sliding window to maximum open position and back to 1/2 open notch and release latches (A). Close sliding window. LOOK: Latches must hold window tightly closed, and hold in any notched position.
OK: Go to next check.
LOOK: Window seals must not have gaps between seals and window frames.
NOT OK: Oil latch. Replace window seals if necessary. 10T,9005,K118 -19-08JAN16-82/93
Dome Light Check
T7832AI —UN—24AUG92
Key OFF Move each dome light toggle switch to ON position.
OK: Go to next check.
LOOK: Dome lights must come on.
NOT OK: Check fuse and bulb.
Turn both switches OFF.
IF OK: Go to Dome Light Circuit in group 9015-15. Continued on next page
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Operational Checkout Procedure Steering Column Adjustment Check
T7773BQ —UN—05AUG92
Depress pedal (A) and move steering wheel column to all positions. Release pedal at each position.
OK: Go to next check.
LOOK: When pedal is released, steering column must lock securely in that position.
NOT OK: Check and adjust pedal linkage. 10T,9005,K118 -19-08JAN16-84/93
Seat And Seat Belt Check
T7747AP —UN—21AUG92
A—Weight Adjustment B—Backrest Depth Adjustment C—Armrest Adjustment D—Seat Belt E—Backrest Tilt Adjustment F— Fore-Aft Adjustment Standing over seat reach down and lift seat assembly to top of travel then let go. Lift seat slowly until latch CLICKS and release seat. Repeat for upper latch. LOOK/FEEL: Seat must have 3 positions and must latch in 2 upper positions. Inspect seat shell and suspension for cracks, broken welds or looseness. LOOK: Seat must be in safe condition. Check seat adjustment functions. LOOK: Seat must adjust freely and remain in locked position. Bounce on seat to check suspension operation. FEEL: Seat suspension must not bottom out and must support operator’s weight. Inspect seat belt for damage. LOOK: Seat belt must lock and not be damaged or worn.
OK: Go to next check.
FEEL: Seat belt must stay adjusted snugly and not slip in adjuster.
NOT OK: Replace any worn or broken parts. Lubricate moving parts of suspension and seat adjusters. Go to Group 1821 in TM1530.
Continued on next page
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Operational Checkout Procedure Toolbox Door And Operator Manual Check
Unlock and open toolbox door under seat in operators station. Close and lock door. LOOK: Door must open and close smoothly.
OK: Go to next check.
LOOK: Operators Manual must be on shelf inside toolbox.
NOT OK: Lubricate hinges. Lubricate or repair lock.
FEEL: Lock must operate freely and key must not stick in lock.
NOT OK: Order Operator Manual from service parts. 10T,9005,K118 -19-08JAN16-86/93
Air Intake Filter Door Check
T6633AW —UN—18OCT88
Unlock and open door on left side of operators station. Close and lock door. LOOK: Door must open and close smoothly.
OK: Go to next check.
FEEL: Lock must operate freely and key must not stick in lock.
NOT OK: Lubricate hinges. Lubricate or repair lock. 10T,9005,K118 -19-08JAN16-87/93
Load Center Door Check
T7832AK —UN—27AUG92
Unlock and open door on right side of operators station. Close and lock door. LOOK: Door must open and close smoothly.
OK: Go to next check.
FEEL: Lock must operate freely and key must not stick in lock.
NOT OK: Lubricate hinges. Lubricate or repair lock.
Continued on next page
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Operational Checkout Procedure Engine Side Panels Check
T6633AS —UN—18OCT88
Unlock and open side panel (A). Latch side panel in open position. Pull rear of panel up and slide out side panel (B). Install side panel (B). Close panel (A). LOOK: Panels must open and close smoothly. FEEL: Latch must operate freely and locking tab must be able to accept a padlock.
OK: Go to next check.
Repeat with other side.
NOT OK: Lubricate hinges. Repair latch. 10T,9005,K118 -19-08JAN16-89/93
Radiator Cap Access Door Check
T6633AY —UN—18OCT88
Open and close access door on top of grille housing.
OK: Go to next check.
LOOK: Door must move freely. Locking pin for padlock must not be bent.
NOT OK: Lubricate hinges. Repair door. 10T,9005,K118 -19-08JAN16-90/93
Frame Locking Bar Check
OK: Go to next check.
T7773CL —UN—21AUG92
LOOK: Red frame locking bar must be pinned (A) to engine frame below left cab step.
NOT OK: Order new parts and install new locking bar and pins. 10T,9005,K118 -19-08JAN16-91/93
Boom Lock Check
LOOK: Red boom lock must be bolted to front frame at hinge in vertical position.
OK: Go to next check. NOT OK: Order new parts and install new boom lock.
Continued on next page
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Operational Checkout Procedure Service Decal Check
T6633AV —UN—18OCT88
Check service decal (A) above left side battery compartment.
OK: Operational Checkout completed.
LOOK: Service decal must be legible.
NOT OK: Replace service decal. 10T,9005,K118 -19-08JAN16-93/93
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Section 9010 Engine Operation And Tests Contents Page Page
Group 05—Theory Of Operation Air Cleaner Operation................................ 9010-05-1 Fuel System Operation—544G And 624G .............................................. 9010-05-2 Fuel System Operation—644G ................. 9010-05-3 Group 10—System Operational Checks Engine Operational Checks....................... 9010-10-1 Cooling System Checks ............................9010-10-1 Air System Checks ....................................9010-10-5 Lubrication System Checks .......................9010-10-6 Fuel System Checks..................................9010-10-7 Engine Speed And Performance Checks ..................................................9010-10-7
Cooling System Pressure Test .................. 9010-25-3 Radiator Air Flow .......................................9010-25-4 Engine Power Test Using Engine Pulldown ................................................ 9010-25-6 Engine Power Test Using Turbocharger Boost Pressure................ 9010-25-7 Compression Pressure Test ...................... 9010-25-9 Air Intake System Leakage Test .............. 9010-25-10 Fuel Supply Pump Pressure Test ............ 9010-25-11 Fuel Line Leakage Test ........................... 9010-25-12
Group 15—Diagnostic Information Diagnose Engine Malfunctions .................. 9010-15-1 Coolant Requirements............................. 9010-15-12 Group 20—Adjustments JT05801 Clamp-On Electronic Tachometer Installation.......................... 9010-20-1 JT05800 Digital Thermometer Installation ............................................. 9010-20-1 Display Monitor Tachometer ...................... 9010-20-1 JT07158 TIME TRAC® Installation ............................................. 9010-20-2 Injection Pump Timing ............................... 9010-20-3 Fan Belt Tension Adjustment..................... 9010-20-4 Slow And Fast Idle Adjustment—544G, 624G ..................... 9010-20-5 Slow Idle Adjustment—644G..................... 9010-20-6 Fast Idle Adjustment—644G ..................... 9010-20-6 Speed Control Linkage Adjustment............................................. 9010-20-7 Fuel Shut-Off Solenoid Adjustment—644G ................................ 9010-20-8 Primary Fuel Filter, Drain Water—544G, 624G .............................. 9010-20-9 Primary Fuel Filter, Drain Water—644G......................................... 9010-20-9 Bleed The Fuel System—544G, 624G...................................................... 9010-20-9 Bleed The Fuel System—644G............... 9010-20-10 Group 25—Tests Display Monitor Tachometer ...................... 9010-25-1 Display Monitor Hydraulic Oil Temperature .......................................... 9010-25-1 Display Monitor Hydraulic Oil Pressure ................................................ 9010-25-1 Air Filter Restriction Indicator Switch Test ............................................ 9010-25-2 Radiator Cap Pressure Test ...................... 9010-25-2 TM1529 (27JUN17)
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Contents
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Group 05
Theory Of Operation
IT4370 —19—14MAR89
Air Cleaner Operation
Air enters the air cleaner inlet tube and is forced into a high-speed centrifugal motion by fins in the inlet tube. Most of the dust is centrifugally separated from the air (before it enters the filter elements) and is trapped in unloader valve (A). The air and remaining dust enters primary filter element (B). Dust that is deposited in the unloader valve (A) is removed through the rubber diaphragm at base of unloader valve. When engine is running, a pulsing action is created in the intake system by each intake stroke of the engine. This pulsing action causes rubber diaphragm to open and close, thus, emptying unloader valve. The safety element (C) retains the dust that would otherwise pass into the engine if primary element should rupture. The safety element prevents dust particles that passed by the primary element end seal from entering the engine whenever primary element is removed for service.
Only remove primary element for cleaning when the air restriction indicator light in the cab is lit. Change safety element yearly. However, if air cleaner primary element has been cleaned and air restriction indicator light in the cab continues to be lit, safety element must be changed. The air restriction indicator switch (D) is located on the outlet between air cleaner and turbocharger. The indicator monitors vacuum in the outlet. Whenever air cleaner element becomes excessively restricted and vacuum reaches approximately 635 mm (25 in.) water, the air restriction indicator switch closes turning on the indicator light in cab. The light will stay on until air cleaner elements are serviced. Continued operation of engine with restricted air cleaner elements can shorten engine life since excessive restriction increases carbon build up and increases engine temperature. TX,901005,B3 -19-12MAR93-1/1
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Theory Of Operation
T7799CF —19—31AUG92
Fuel System Operation—544G And 624G
The fuel supply pump (E) draws fuel from the vented fuel tank through the primary filter (H) and pressurizes the fuel, forcing it to flow through the final fuel filter (I) to fuel gallery in injection pump (A). Fuel supply pump output pressures will vary depending on load. The fuel injection pump then pumps the fuel through injection lines (B) to each injection nozzle (D). High pressure is required to open the nozzle valve. When
the nozzle valve opens, fuel is forced through orifices in the nozzle tip and atomizes as it enters the combustion chamber. Leakage past the nozzle valve is required for lubrication of the nozzle. Fuel that leaks past the valve flows into leak-off lines (C), and combines with excess fuel used for cooling and lubricating the injection pump. Fuel then flows back to fuel tank. 901005,MD194 -19-16SEP92-1/1
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Theory Of Operation
T7799CG —19—31AUG92
Fuel System Operation—644G
The fuel supply pump mounted on the injection pump, draws fuel from the vented fuel tank, through the primary fuel filter (E) and pressurizes the fuel, forcing it to flow through final fuel filter (F) to the fuel gallery (D) in the injection pump. Fuel supply pump output pressures will vary depending on load. The gallery is kept full by the fuel supply pump. Injection pump plungers further pressurize the fuel and delivery pipes (C) route the fuel to the nozzles (B). The high
pressure fuel opens the nozzle and the nozzle valve and forces fuel out small orifices in the nozzle tip. This atomizes the fuel as it enters the combustion chamber. There are two sources of excess fuel in the system. The fuel supply pump supplies more fuel to the injection pump than is required by the engine, and the nozzle requires excess fuel to lubricate the nozzle valve. A leak-off line (A) returns this excess fuel to the tank from both the pump and nozzles. 901005,MD195 -19-16SEP92-1/1
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Theory Of Operation
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Group 10
System Operational Checks Engine Operational Checks This procedure is designed so the mechanic can make a quick check of the engine using a minimum amount of diagnostic equipment. If you need additional information, read Theory of Operation, Group 9010-05.
If problem is indicated (NOT OK:), you will be given repair required and group location or CTM number. If verification is needed, you will be given next best source of information:
A location will be required which is level and has adequate space to complete the driving checks.
Group 10 (System Operational Checks)
The engine and all other major components must be at operating temperature for some checks.
Group 15 (Diagnostic Information) Group 20 (Adjustments) Group 25 (Tests)
Locate system check in the left column and read completely, following this sequence from left to right. Read each check completely before performing.
CTM (Component Technical Manual)
At the end of each check, if no problem is found (OK:), that check is complete or an additional check is needed. 10T,9010,MD222 -19-16SEP92-1/30
• 1
Cooling System Checks
10T,9010,MD222 -19-16SEP92-2/30
Radiator Outside Air Flow Check
Open grille to radiator. Inspect fins for mud and debris. Inspect radiator for bent or damaged fins.
OK: Check complete.
LOOK: Radiator must be free of mud, leaves, grass, and other debris.
NOT OK: Clean outside of radiator.
LOOK: Fins must be straight and not broken or cracked.
NOT OK: Straighten fins. Replace radiator if severely damaged. 10T,9010,MD222 -19-16SEP92-3/30
Radiator Cap Checks CAUTION: To avoid personal injury, DO NOT remove radiator cap unless engine is cool. When engine is hot and cap is removed, hot coolant or steam will spray out causing serious burns. Engine OFF. Open radiator access door. Remove and inspect cap. FEEL: The radiator cap must have a stop position and must be pushed down to turn and remove. LISTEN: If radiator is warmer than air temperature a "whoosh" must be heard when cap is turned to first stop. LOOK: Cap must have a good seal and gasket. The seal must turn freely and spring must not be corroded. LOOK: The vacuum release valve (in center of seal) must move freely and holes must not be clogged.
OK: Check complete.
NOTE: If vacuum release valve is clogged, the upper radiator hose may collapse when the engine is stopped and radiator is cooling.
NOT OK: Replace radiator cap.
Continued on next page
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System Operational Checks Coolant Level Checks
Engine OFF. Engine cold. CAUTION: To avoid personal injury. DO NOT remove cap unless engine is cool. Remove radiator cap. Inspect coolant level.
OK: Go to next check.
LOOK: With engine cold, coolant level must be at or above cold mark on coolant recovery bottle. Coolant level must be at base of radiator cap.
NOT OK: Fill radiator and recovery bottle to proper levels, then go to Coolant Overflow Tube Check in this group. 10T,9010,MD222 -19-16SEP92-5/30
Coolant Condition Check
Engine OFF. Engine cold. Inspect coolant condition.
OK: Go to next check.
LOOK: Coolant must not be oily, foamy, or rusty.
NOT OK: Check for faulty head gasket, cracked or loose head, or cracked engine block. Refer to CTM8, CTM42, or CTM86 for engine repair. 10T,9010,MD222 -19-16SEP92-6/30
Radiator Internal Core Check
T6488FZ —UN—19OCT88
CAUTION: DO NOT remove radiator cap unless engine is cool. Open radiator access door. Remove radiator cap. Drain coolant into a clean container until core tubes are visible. Inspect radiator core.
OK: Go to next check.
LOOK: Radiator core must be free of rust or corrosion and passages in core must NOT be clogged.
NOT OK: Remove and clean radiator or replace radiator. Refill cooling system with correct coolant. Go to Section I, Group IV.
Continued on next page
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System Operational Checks Radiator Bubble Check
T112163 —UN—10NOV97
Fill radiator to the top. Install radiator cap and tighten. Run engine until it is at normal operating temperature. Place overflow tube from radiator in a clear jar of water. Run engine at fast idle. Operate a hydraulic function over relief to load engine.
OK: Go to next check.
LOOK: No bubbles must be seen coming from overflow tube.
NOT OK: If there is a constant flow of bubbles, a cracked or loose cylinder head, or a faulty head gasket could be indicated. Go to CTM8, CTM42, or CTM86 for engine repair. 10T,9010,MD222 -19-16SEP92-8/30
Coolant Overflow Tube Check
T111234 —UN—26AUG97
Engine OFF. Engine cold. Install radiator cap. Drain coolant from engine block.
OK: Check complete.
LOOK: Coolant must be drawn from coolant recovery bottle.
NOT OK: Check coolant overflow tube and connections. Replace or repair as necessary. 10T,9010,MD222 -19-16SEP92-9/30
Hoses, Clamps, And Water Pump Checks
Inspect all radiator and heater hoses for cracks or leaks. Inspect all hose clamps for straightness and tightness. Inspect water pump for leaks. LOOK: Radiator and heater hoses must NOT be brittle, show signs of leaks, or rub on adjacent parts.
OK: Check complete.
NOTE: There must be a wire spiral in lower radiator hose.
NOT OK: Replace damaged hoses.
LOOK: All hose clamps must be tight and perpendicular to the hose. Crooked clamps can cause damage and leaks.
NOT OK: Straighten clamps.
LOOK: Water pump must NOT show signs of leaks.
NOT OK: Replace water pump.
Continued on next page
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System Operational Checks Fan Checks
T6488GB —UN—23AUG93
Inspect fan blades for damage. LOOK: Fan blades must not have any nicks or bends. Check fan for correct installation.
OK: Go to next check.
LOOK: Cupped portion of fan blades must be toward radiator.
NOT OK: If blades are bent, replace fan. If fan blades are nicked, repair.
NOTE: If fan is installed backwards, about 50% of its capacity is lost.
NOT OK: Remove and install fan correctly. 10T,9010,MD222 -19-16SEP92-11/30
Fan Shroud And Fan Guard Checks
T6488GC —UN—23AUG93
Check fan-to-fan shroud clearance. Inspect fan guard.
OK: Go to next check.
LOOK: Fan must be centered in fan shroud.
NOT OK: Center fan in fan shroud.
LOOK: Guard must NOT be bent or damaged, all mounting brackets must be intact and all hardware must be tight.
NOT OK: Repair or replace guard. Tighten hardware. 10T,9010,MD222 -19-16SEP92-12/30
Fan Belt Checks
T6488GD —UN—02SEP93
Inspect condition of belts. LOOK: There must NOT be any oil or grease on fan belt or pulley. Inside surface of belt must NOT have any cracks or contact bottom of pulley groove.
OK: Check complete.
Check fan belt for tightness.
NOT OK: Replace fan belt.
LOOK/FEEL: On 544G, 624G belt deflection must be 3/4 in. with 15 lb push. On 644G NOT OK: Adjust tightness belt deflection must be 3/4 in. with 20 lb push. of belt or replace belt. Go to Group 9010-20. Continued on next page
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System Operational Checks
• 2
Air System Checks
10T,9010,MD222 -19-16SEP92-14/30
Air Filter Restriction Indicator Switch Check
Run engine at slow idle. Slowly cover air intake tube.
OK: Check complete.
LOOK: Air restriction indicator light in monitor must come ON.
NOT OK: Replace air restriction indicator switch. 10T,9010,MD222 -19-16SEP92-15/30
Starting Aid Checks
T6477AP —UN—19OCT88
T6488GE —UN—23AUG93
Open engine side shield door. Check position of lower can holder (A). LOOK: If can is missing, lower holder must be upside down to seal opening in upper holder. Inspect plastic line from top of starting aid to air intake manifold. LOOK: There must NOT be any kinks or breaks in line and ends must be installed securely.
OK: Check complete.
Check for arrow on starting aid nozzle in air intake manifold.
NOT OK: Reposition lower holder.
NOTE: It may be necessary to scrape paint from nozzle.
NOT OK: Replace plastic line.
LOOK: Arrow must be pointed AGAINST air flow of air intake manifold.
NOT OK: Turn nozzle until arrow is in correct position—pointing AGAINST incoming air flow.
Continued on next page
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System Operational Checks Exhaust Smoke Check
NOTE: Engine must be at operating temperature before performing this check.
T6488GF —UN—19OCT88
Run engine at fast idle. Operate a hydraulic function over relief to load engine. Observe exhaust smoke. LOOK: Exhaust smoke must NOT be excessive or blue in color.
OK: Check complete.
NOTE: Excessive black smoke is caused by lack of sufficient air to the engine. Excessive white smoke when engine is cold, can be caused by a cold engine, dirty nozzles, or both. Excessive blue smoke can be caused by worn or damaged rings or cylinder liners.
NOT OK: See Engine Emits Excessive Black, Gray , or Blue Smoke in Diagnose Engine Malfunctioning, Group 9010-15.
644G only. Excessive black smoke and lack of power can also be caused by fuel restriction.
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• 3
Lubrication System Checks
10T,9010,MD222 -19-16SEP92-18/30
Oil Level Check
T6488GG —UN—29JUL99
T6488GH —19—23FEB89
Engine OFF. Remove dipstick and check oil level. LOOK: Oil must be between add and full marks (arrows). NOTE: If oil level is high, check for fuel in oil. Also, drain a small quantity of oil and check for anti-freeze. If oil level is low, check for oil leaks or oil seal problems in engine. Remove dipstick and check condition of oil.
OK: Check complete.
LOOK: Oil must NOT be milky, grainy, contain fuel or anti-freeze.
NOT OK: Add or replace oil. Go to Section I, Group IV.
Continued on next page
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System Operational Checks
• 4
Fuel System Checks
10T,9010,MD222 -19-16SEP92-20/30
Fuel Cap And Fuel Strainer
Remove fuel cap. NOTE: If air "hisses" from tank or enters tank when cap is removed, replace cap.
OK: Go to next check.
Inspect fuel cap seal.
NOT OK: Replace fuel cap.
Check fuel tank vent hose.
NOT OK: Replace fuel strainer. 10T,9010,MD222 -19-16SEP92-21/30
Inner Fuel Tank Check
Remove fuel cap. Use a flashlight and inspect bottom of fuel tank by shining light through the fuel. LOOK: There must NOT be debris in bottom of fuel tank that would restrict flow. NOTE: If excessive debris is found, remove fuel line from shut-off valve and observe flow. If flow is restricted, remove shut-off valve and clean fuel strainer in bottom of fuel tank.
OK: Go to next check.
IMPORTANT: Be careful not to damage fuel level float or low fuel sending component. Component may not operate if damaged.
NOT OK: Remove large pieces of debris through filler neck. 10T,9010,MD222 -19-16SEP92-22/30
Fuel Pump Check—544G, CRACK open bleed screw on fuel filter and operate hand primer on fuel pump. 624G Only Tighten bleed screw and again operate hand primer. LOOK: Fuel must come out of bleed screw when hand primer is operated.
OK: Go to next check.
FEEL: Resistance must be felt when fuel is being pumped but no resistance after system is pumped up.
NOT OK: Be certain fuel filter is clean. If not, replace filter and recheck fuel pump. 10T,9010,MD222 -19-16SEP92-23/30
Fuel System Check
Engine OFF. Disconnect fuel return hose from leak-off line. Connect a hose to leak-off line to route excess fuel into a container. Start engine and run at fast idle. Put engine under load by operating a hydraulic function over relief. Observe fuel flow from leak-off line. LOOK: Fuel must flow from leak-off line with engine at full load.
OK: Check complete.
NOTE: Fuel that flows from leak-off line is excess fuel not required by the engine.
NOT OK: Check for plugged fuel filters, plugged fuel tank cap vent, restricted lines, stuck injection pump overflow valve, or a bad fuel pump. Repair or replace as necessary. 10T,9010,MD222 -19-16SEP92-24/30
• 5
Engine Speed And Performance Checks
Continued on next page
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System Operational Checks Engine Speed Check
Start engine, run at slow idle, and record rpm. LOOK: Slow idle: 544G and 624G; 850 ± 25 rpm. 644G (S.N. —544523); 800 ± 25 rpm. 644G (S.N.544524—); 900 ± 25 rpm. Increase engine speed to fast idle and record rpm.
OK: Check complete.
LOOK: Fast idle: 544G; 2375 ± 25 rpm. 624G and 644G; 2325 ± 25 rpm.
NOT OK: If any of the engine rpm’s are not within specification, see Engine Speed Adjustments in Group 9010-20. 10T,9010,MD222 -19-16SEP92-26/30
Engine Power Check
NOTE: Pulldown specification will be inaccurate if test is made without thoroughly warming up the engine under load. Move accelerator pedal to fast idle position. Operate unit under full load until engine is thoroughly warmed up. Put transmission in 3rd forward. Apply service brakes. Increase engine speed to fast idle. Hold boom down over relief while the transmission is at torque converter stall.
OK: Check complete.
LOOK: Exhaust smoke should not be evident at approximately 2200 rpm (rated speed). NOT OK: If exhaust smoke is excessive, go to Engine Emits Excessive Black Smoke or Gray Exhaust Smoke , Group 9010-15. LOOK: Rpm must be within the following specifications: 544G; 1400—1650 rpm. 624G; 1400—1600 rpm. 644G; 1450—1650 rpm.
NOT OK: If engine speed decreases to less than specification, check system relief valve pressure setting.
NOTE: When using #1 fuel decrease engine rpm’s by 7%.
IF OK: Go to Engine Does Not Develop Full Power , Group 9010-15. 10T,9010,MD222 -19-16SEP92-27/30
Low Compression Check
NOTE: Install fuel shut-off fuse after this check. Remove fuel shut-off fuse from fuse panel. CRANK engine for 10 seconds. LISTEN: Air must not be heard leaking past valves. LISTEN: Starting motor must run at a constant speed.
OK: Check complete.
Install fuel shut-off fuse in fuse panel.
NOT OK: If starting motor runs at uneven speed, low compression is indicated on one or two cylinders. Go to Compression Pressure Test in Group 9010-25. 10T,9010,MD222 -19-16SEP92-28/30
Engine Blow-By Check
Run engine at fast idle and check blow-by tube. LOOK: Fumes should be barely visible at the blow-by tube at fast idle, no load.
OK: Check complete.
NOTE: Excessive blow-by indicates that piston rings and cylinder liners do not seal off the combustion chamber. This is a comparative check that requires some experience to determine excessive blow-by.
NOT OK: If blow-by is excessive. Go to Compression Pressure Test in Group 9010-25.
Continued on next page
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System Operational Checks Loose Or Worn Engine Parts
Run hydraulic system over relief to put engine under load.
OK: Check complete.
LISTEN: Knock or rattling noise must NOT be heard from engine.
NOT OK: Go to Abnormal Engine Noise , in Group 9010-15. 10T,9010,MD222 -19-16SEP92-30/30
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System Operational Checks
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Group 15
Diagnostic Information Diagnose Engine Malfunctions
Step 4. Adjustments and/or Tests (See Group 9010-20 and/or 9010-25.)
NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely more difficult to verify. Remember the following steps when troubleshooting a problem:
For 544G with 6059, see CTM8 for engine repair. For 624G with 6068, see CTM8 for engine repair.
Step 1. Operational Checkout Procedure (See Group 9005-10.)
For 644G with 6076, see CTM42 for engine repair. For 644G with 6081, see CTM86 for engine repair.
Step 2. Engine Operational Checkout Procedure (See Group 9010-10.) Step 3. Diagnose Malfunctions Charts (See Group 9010-15.) Symptom
Problem
Solution
Engine Will Not Start or Starts Hard Fuel tank empty
Check fuel quantity.
Fuel tank vent hose clogged
Loosen cap and listen for air rushing into tank. Clean or replace hose.
Water in fuel or water frozen in line
Drain water from fuel tank. Inspect fuel filter(s) for water. Change filter(s).
Fuel filter(s) clogged
Inspect and replace fuel filter(s).
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Air leak on suction side of fuel system Check and tighten connection. Check fuel lines for damage. Fuel shut-off solenoid linkage incorrectly adjusted—644G
Adjust so fuel shut-off lever is against run stop on injection pump.
Injection pump metering valve sticking—544G, 624G
Lightly tap injection pump housing. If engine now starts, repair metering valve. (See Local Injection Pump Service Center.)
Faulty electric shut-off—544G, 624G
Test solenoid. (See Group 9015-25.)
Fuel pump
Check fuel pump pressure. (See Group 9010-25.)
Slow cranking speed
Check batteries and connections.
Restricted air filter
Check air filter restriction indicator and air filters.
Incorrect injection pump timing
Check timing. (See Group 9010-20.)
Fuel drains from filters with engine stopped due to leakage in check valve—644G Injection nozzle(s)
Disconnect filter inlet line from check valve. Inspect for leakage.
Continued on next page
TM1529 (27JUN17)
9010-15-1
Remove and test nozzles. (See CTM8, CTM42, or CTM86.) TX,15,WW2202 -19-13JUN96-1/10
544G, 624G, 644G Loader
062717
PN=117
Diagnostic Information Symptom
Problem
Solution
Low compression or blown head gasket
Remove injection pump fuse. Crank engine and listen for air leaking past valves or an uneven starter speed. Start engine and observe blow-by from vent tube. Do Compression Pressure Test . (See Group 9010-25.)
Fuel injection pump
Remove and test pump. (See Local Fuel Injection Pump Service Center.)
Engine Surges or Stalls Frequently Fuel tank hose vent clogged
Loosen cap and listen for air rushing into tank. Clean or replace hose.
Fuel shut-off solenoid linkage incorrectly adjusted—644G
Adjust so fuel shut-off lever is against run stop on injection pump.
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Water in fuel or water frozen in line.
Inspect primary fuel filter for water. Change filter.
Fuel filter clogged
Replace filter.
Air leak on suction side of fuel system Check and tighten connections. Check fuel lines for damages. Fuel pump
Check fuel pump pressure. (See Group 9010-25.)
Fuel return line from injection pump to tank restricted
Disconnect fuel return line from injection pump. Connect a hose to pump and route fuel into a container. If engine now operates normally, return hose is restricted.
Plugged or malfunctioning overflow valve in injection pump.
Check for high fuel pressure. Do Fuel Pump Pressure Test . (See Group 9010-25.)
Restrictor fitting on top fitting in injection pump clogged Injection pump metering valve sticking—544G, 624G
Remove, inspect and clean.
Fuel injection pump out of time
Check injection pump timing. (See Group 9010-20.)
Engine overheating
Test cooling system. (See Group 9010-25.)
Incorrect slow idle or supplementary idling screw adjustment—644G
Check and adjust slow idle. (See Group 9010-20.)
Continued on next page
TM1529 (27JUN17)
Lightly tap injection pump housing. If engine now starts, repair metering valve. (See Local Fuel Injection Pump Service Center.)
9010-15-2
TX,15,WW2202 -19-13JUN96-2/10
544G, 624G, 644G Loader
062717
PN=118
Diagnostic Information Symptom
Problem
Solution
Incorrect valve clearance
Check and adjust valve clearance. (See Group 9010-20.)
Valves sticking or burned
Remove injection pump fuse. Crank engine and listen for air leaking past valves or an uneven starter speed. Do Compression Pressure Test . (See Group 9010-25.)
Worn or broken compression rings or Start engine and observe blow-by cylinder head gasket leaking from vent tube. Do Compression Pressure Test . (See Group 9010-25.)
Engine Misses
Injection nozzles
Remove and test nozzles. (See CTM8, CTM42, or CTM86.)
Injection pump
Remove and test fuel injection pump. (See Local Fuel Injection Pump Service Center.)
Air in fuel
Disconnect return hose from leak-off lines. Crank engine and check for air in fuel at leak-off lines. Tighten connections. Check fuel lines for damage.
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Fuel injection pump out of time
Time injection pump. (See Group 9010-20.)
Slow idle speed too low
Check slow idle speed. (See Group 9010-20.)
Fuel pump
Check fuel pump pressure. (See Group 9010-25.)
Engine overheats
Test cooling system. (See Group 9010-25.)
Incorrect valve clearance
Check and adjust valve clearance. (See Group 9010-20.)
Bent push rods
Inspect and replace. (See CTM8, CTM42, or CTM86.)
Valve sticking or burned
Remove injection pump fuse. Crank engine and listen for air leaking past valves or an uneven starter speed. Do Compression Pressure Test . (See Group 9010-25.)
Cylinder head gasket leaking
Do Compression Pressure Test . (See Group 9010-25.)
Continued on next page
TM1529 (27JUN17)
9010-15-3
TX,15,WW2202 -19-13JUN96-3/10
544G, 624G, 644G Loader
062717
PN=119
Diagnostic Information Symptom
Engine Does Not Develop Full Power
Problem
Solution
Worn or broken compression rings
Start engine and observe blow-by from vent tube. Do Compression Pressure Test . (See Group 9010-25.)
Injection nozzles
Test nozzles. (See CTM8, CTM42, or CTM86.)
Injection pump
Remove and test injection pump. (See Local Fuel Injection Pump Service Center.)
Fuel tank vent hose clogged
Loosen fuel cap and listen for air rushing into tank. Clean or replace hose.
Fuel shut-off solenoid linkage incorrectly adjusted—644G
Adjust so fuel shut-off lever is against run stop on injection pump.
Air intake system restricted
Check air filter elements and air filter restriction indicator switch. (See Group 9010-25.)
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Excess drag in transmission
Test transmission drag. (See Group 9020-10 or 9020-25.)
Excess drag in brakes
Check service and park brake drag. (See Group 9020-10 or 9020-25.)
Fast idle speed set too low
Check and adjust fast idle. (See Group 9010-20.)
Fuel filter(s) clogged
Change filter(s).
Fuel line restricted
Check for pinched or kinked lines or debris in lines. Route return line into separate container. If engine operation returns to normal, repair fuel return system lines.
Fuel pump malfunction
Do Fuel Pump Pressure Test . (See Group 9010-25.)
Fuel tank strainer clogged
Remove, inspect and clean.
Plugged or malfunctioning overflow valve in injection pump
Do Fuel Pump Pressure Test to check for high pressure. (See Group 9010-25.)
Remove, inspect and clean. Restrictor fitting on top fitting in injection pump clogged—544G, 624G
Continued on next page
TM1529 (27JUN17)
9010-15-4
TX,15,WW2202 -19-13JUN96-4/10
544G, 624G, 644G Loader
062717
PN=120
Diagnostic Information Symptom
Engine Emits Excessive Black or Gray Exhaust Smoke
Problem
Solution
Injection pump metering valve sticking—544G, 624G
Lightly tap injection pump housing. If engine now starts, repair metering valve. (See Local Fuel Injection Pump Service Center.)
Incorrect injection pump timing
Check timing. (See Group 9010-20.)
Air leak in intake manifold
Test air intake system for leaks. (See Group 9010-25.)
Incorrect valve clearance
Check and adjust valve clearance. (See Group 9010-20.)
Worn camshaft
Check valve lift. (See Group 9010-25.) Repair.
Turbocharger
Remove air intake hose and exhaust elbow. Leading edge of compressor vanes must be sharp and straight. Spin compressor wheel and listen for noisy bearings. Turbine and compressor wheels must not rub in housing.
Muffler restricted
Run engine without muffler. If engine operation is now normal, install a new muffler.
Low compression
Remove injection pump fuse. Crank engine and listen for air leaking past valves or an uneven starter speed. Start engine and observe blow-by from vent tube. Do Compression Pressure Test . (See Group 9010-25.)
Injection nozzles
Remove and test nozzles. (See CTM8, CTM42, or CTM86.)
Incorrect camshaft timing
Check timing. (See CTM8, CTM42, or CTM86.)
Injection pump
Remove and test pump. (See Local Fuel Injection Pump Service Center.)
Hydraulic pump
Remove and inspect pump.
Restricted air filter
Check air filter restriction indicator and air filters. Replace.
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Incorrect injection pump timing
Time injection pump. (See Group 9010-20.)
Continued on next page
TM1529 (27JUN17)
9010-15-5
TX,15,WW2202 -19-13JUN96-5/10
544G, 624G, 644G Loader
062717
PN=121
Diagnostic Information Symptom
Engine Emits Excessive Blue or White Smoke
Problem
Solution
Air leak between turbo and manifold
Test air intake system for leaks. (See Group 9010-25.)
Excessive fuel delivery
Remove and test fuel injection pump. (See Local Fuel Injection Pump Service Center.)
Injection nozzles
Remove and test nozzles. Check nozzle placement. (See CTM8, CTM42, or CTM86.)
Turbocharger
Remove air intake hose and exhaust elbow. Leaking edge of compressor vanes must be sharp and straight. Spin compressor wheel and listen for noisy bearings. Turbine and compressor wheels must not rub in housing.
Cranking speed too slow
Check batteries and connections.
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Injection pump out of time
Time injection pump. (See Group 9010-20.)
Engine running too cold
Check thermostats. (See CTM8, CTM42, or CTM86.)
Injection nozzles
Remove and test nozzles. (See CTM8, CTM42, or CTM86.)
Low compression
Remove fuel shut-off solenoid fuse. Crank engine and listen for air leaking past valves. Start engine and observe blow-by from vent tube. Do Compression Pressure Test . (See Group 9010-25.)
Excessive wear in liners and/or piston Inspect and repair. (See CTM8, rings stuck CTM42, or CTM86.)
Slow Acceleration
Worn valve guides
Inspect and repair. (See CTM8, CTM42, or CTM86.)
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Fuel injection pump
Remove and test fuel injection pump. (See Local Fuel Injection Pump Service Center.)
Injection nozzles
Remove and test nozzles. (See CTM8, CTM42, or CTM86.)
Continued on next page
TM1529 (27JUN17)
9010-15-6
TX,15,WW2202 -19-13JUN96-6/10
544G, 624G, 644G Loader
062717
PN=122
Diagnostic Information Symptom
Problem
Solution
Detonation
Starting aid solenoid stuck open
Inspect and repair.
Incorrect injection pump timing
Time injection pump. (See Group 9010-20.)
Incorrect injection pump advance
Repair advance. (See Local Fuel Injection Pump Service Center.)
Low or incorrect engine oil
Add correct oil.
Loose or worn dampener drive
Inspect and repair. (See CTM8, CTM42, or CTM86.)
Engine oil diluted with fuel
Inspect engine oil. Inspect fuel pump spindle, seal, and housing.
Incorrect fuel injection pump timing
Time injection pump. (See Group 9010-20.)
Turbocharger failure
Remove air intake hose and check compressor wheel clearance between housing and wheel. Spin compressor wheel and check for failed bearings. Repair turbocharger.
Excessive valve clearance
Adjust valve clearance. (See Group 9010-20.)
Bent push rods
Replace. (See CTM8, CTM42, or CTM86.)
Worn rocker arm shafts
Replace. (See CTM8, CTM42, or CTM86.)
Loose connecting rod caps
Inspect and tighten connecting rod cap screws. (See CTM8, CTM42, or CTM86.)
Loose main bearing caps
Inspect and tighten main bearing cap screws. (See CTM8, CTM42, or CTM86.)
Worn main bearing
Replace bearings. (See CTM8, CTM42, or CTM86.)
Worn connecting rod bearings
Replace bearings. (See CTM8, CTM42, or CTM86.)
Incorrect camshaft timing
Check camshaft timing. (See CTM8, CTM42, or CTM86.)
Scored piston
Replace. (See CTM8, CTM42, or CTM86.)
Abnormal Engine Noise
Continued on next page
TM1529 (27JUN17)
9010-15-7
TX,15,WW2202 -19-13JUN96-7/10
544G, 624G, 644G Loader
062717
PN=123
Diagnostic Information Symptom
Low Oil Pressure
High Oil Pressure
Engine Overheats
Problem
Solution
Worn piston pin bushings and pins
Replace pins and bushings. (See CTM8, CTM42, or CTM86.)
Low oil level
Add oil.
Wrong viscosity oil or oil diluted with diesel fuel
Change oil. On 644G, inspect fuel pump spindle, seal, and housing. On 544G, 624G inspect fuel pump diaphragm.
Oil pressure gauge or sensor
Test gauge and sensor. (See Group 9015-25.)
Oil pressure regulating valve
Replace or adjust regulating valve. (See CTM8, CTM42, or CTM86.)
Turbocharger shaft seal leaking
Inspect and repair. (See CTM8, CTM42, or CTM86.)
Plugged oil pump intake screen
Inspect and clean. (See CTM8, CTM42, or CTM86.)
Loose oil pump drive gear
Inspect and repair. (See CTM8, CTM42, or CTM86.)
Worn oil pump gear or housing
Remove, inspect and repair. (See CTM8, CTM42, or CTM86.)
Excessive main bearing clearance
Replace main bearings. (See CTM8, CTM42, or CTM86.)
Excessive connecting rod bearing clearance
Replace connecting rod bearings. (See CTM8, CTM42, or CTM86.)
Cracked cylinder block
Replace cylinder block. (See CTM8, CTM42, or CTM86.)
Piston cooling orifice missing
Inspect piston cooling orifices. (See CTM8, CTM42, or CTM86.)
Leakage at internal oil passage
Check all possible internal leakage paths. Repair. (See CTM8, CTM42, or CTM86.)
Wrong viscosity oil (too thick)
Check for antifreeze in oil. Change oil.
Oil pressure gauge or sender
Check gauge or sender
Oil pressure regulating valve
Repair or adjust regulating valve. (See CTM8, CTM42, or CTM86.)
Low coolant level
Fill cooling system and check for leaks.
Continued on next page
TM1529 (27JUN17)
9010-15-8
TX,15,WW2202 -19-13JUN96-8/10
544G, 624G, 644G Loader
062717
PN=124
Diagnostic Information Symptom
Problem
Solution
Charge air cooler restricted, 644G only Check air inlet for restriction Low engine oil level
Add oil.
Loose or broken fan belt
Tighten or replace belt.
Fan on backwards, damaged, or wrong fan installed
Check for correct fan installation. (See Group 9010-10.)
Radiator dirty, clogged, or fins damaged
Check air flow. (See Group 9010-25.) Clean radiator. Straighten fins.
Radiator shroud missing, damaged, or baffles missing Engine overloaded
Inspect. Repair or replace. Reduce load.
Incorrect grade of fuel
Drain fuel tank and add correct fuel.
Radiator cap
Replace cap.
Faulty gauge or sender
Test, repair, or replace. (See Group 9015-10.)
Incorrect injection pump timing
Time injection pump. (See Group 9010-20.)
Faulty thermostats (stuck)
Inspect thermostats. Replace thermostats. (See CTM8, CTM42, or CTM86.)
Thermostats missing
Install thermostats. (See CTM8, CTM42, or CTM86.)
Cooling system coated with lime deposits Excessive brake drag
Flush cooling system.
Excessive transmission drag
Check transmission drag. (See Group 9020-10 or 9020-25.)
Water pump
Repair. (See CTM8, CTM42, or CTM86.)
Excessive fuel delivery
Remove injection pump. Check for proper fuel delivery. Adjust. (See Local Fuel Injection Pump Service Center.)
Scored piston
Replace piston. (See CTM8, CTM42, or CTM86.)
Continued on next page
TM1529 (27JUN17)
9010-15-9
Check brake drag. (See Group 9020-10 or 9020-25.)
TX,15,WW2202 -19-13JUN96-9/10
544G, 624G, 644G Loader
062717
PN=125
Diagnostic Information Symptom
Engine Runs Cold
Oil in Coolant or Coolant in Oil
Excessive Fuel Consumption
Problem
Solution
Combustion leak into cooling system
Remove radiator cap. Start engine and check for bubbles in radiator.
Temperature gauge or sender
Test gauge and sender. (See Group 9015-25.)
Thermostat (stuck open)
Replace thermostat. (See CTM8, CTM42, or CTM86.)
Leaking heat exchanger
Air test and repair or replace.
Leaking cylinder head gasket
Replace gasket. (See CTM8, CTM42, or CTM86.)
Leaking cylinder liner packings
Replace packings. (See CTM8, CTM42, or CTM86.)
Cracked cylinder liner
Replace liner. (See CTM8, CTM42, or CTM86.)
Cracked cylinder block
Replace cylinder block. (See CTM8, CTM42, or CTM86.)
Air system restricted
Check filter restriction indicator and air filters. Replace.
Leakage in fuel system
Inspect and repair.
Incorrect grade of fuel
Drain and refill with correct fuel.
Charge air cooler restricted, 644G only Check air inlet for restriction Incorrect injection pump timing
Time injection pump. (See Group 9010-20.)
Faulty turbocharger
Remove air intake hose and exhaust elbow. Leaking edge of compressor vanes must be sharp and straight. Spin compressor wheel to check for rough bearings. Turbine and compressor wheels must not rub in housing.
Faulty injection nozzles
Test nozzles. Repair. (See CTM8, CTM42, or CTM86.)
Turbocharger Excessively Noisy or Bearings not lubricated Vibrates
Insufficient oil pressure. Check for restricted turbocharger oil line.
Air leak in engine, intake or exhaust manifold
Inspect and repair. (See Group 9010-25.)
TX,15,WW2202 -19-13JUN96-10/10
TM1529 (27JUN17)
9010-15-10
544G, 624G, 644G Loader
062717
PN=126
Diagnostic Information Symptom
Oil Dripping From Turbocharger Adapter
Excessive Drag in Turbocharger Rotating Members
Problem
Solution
Incorrect clearance between turbine wheel and turbine housing
Remove exhaust elbow and air inlet hose. Inspect and repair.
Broken blades on turbine
Remove exhaust elbow and air inlet hose. Inspect and repair.
Damaged or worn bearings and/or worn seals
Inspect compressor and turbine wheel for damaged blades. Check for proper engine service intervals or dirt entering engine.
Excessive crankcase pressure
Check for clogged vent tube. Clean.
Remove line. Inspect and clean. Carbon build-up in turbocharger oil return line where line passes exhaust manifold. Carbon build-up behind turbine wheel Inspect and clean. (See CTM8, CTM42, or CTM86.) caused by combustion deposits. Dirt build-up behind compressor wheel Inspect and repair. (See CTM8, caused by air intake leaks. CTM42, or CTM86.) Bearing seizure or dirty or worn bearings caused by excessive temperature, unbalanced wheel, dirty oil, oil starvation, or insufficient lubrication.
Check for clogged air filters.
TX,15,WW2202 -19-13JUN96-11/10
TM1529 (27JUN17)
9010-15-11
544G, 624G, 644G Loader
062717
PN=127
Diagnostic Information
Coolant Requirements Coolant solutions used in John Deere Engines must meet the following basic requirements: Provide for adequate heat transfer. Provide a corrosion-resistant environment within the cooling system. Prevent formation of scale or sludge deposits in the cooling system. Be compatible with cooling system hose and seal materials. Provide adequate freeze protection during cold weather operation and boil-over protection in hot weather. NOTE: In some areas outside United States and Canada, John Deere Engine Cooling Fluid is marketed for use in the engine cooling system. It protects the engine from corrosion and freezing down to -37°C (-35°F).
T6604AE —19—23FEB89
John Deere Engine Cooling Fluid is ready to use without dilution or mixing. Consult parts catalog and check for local availability. Where available, the cooling fluid is the preferred coolant to use. To meet the requirements, the coolant has to consist of high quality water, the correct type antifreeze, and adequate inhibitors. 1. Water Quality Preferred - Distilled or deionized Must be ethylene glycol type, contain not more than 0.1% anhydrous metasilicate, and meet General Motors Performance Specification GM1899M, or be formulated to Specification GM6038M or an equivalent.
Acceptable - Softened to 170 Parts Per Million (10 Grains per Gallon) Water Quality—Specification Chlorides—Maximum Concentration......................... 40 parts per million (2.5 grains per gallon) Sulfates—Maximum Concentration....................... 100 parts per million (5.8 grains per gallon) Total Dissolved Solids—Maximum Concentration........................ 340 parts per million (20 grains per gallon) Total Hardness—Maximum Concentration............... 170 parts per million (10 grains per gallon)
NOTE: Some types of ethylene glycol antifreeze commonly available on the open market are intended for automotive use. These products are often labeled for use in aluminum engines and usually contain more than 0.1% anhydrous metasilicate. Use of this type antifreeze can cause a gel-like deposit to form that reduces heat transfer and coolant flow. When wet, the gel becomes the same color as the coolant. When dry, it is a white, powdery deposit. Check container label or consult with antifreeze supplier before using. 2. Antifreeze
Solutions containing 50—67% antifreeze are recommended. Antifreeze solutions should be used year-round for freeze protection, boil-over protection, and stable environment for seals and hoses. Using antifreeze during warm weather is recommended. Never use methyl alcohol base antifreeze. Never use methoxy propanol antifreeze. Damage can occur to rubber seals on cylinder liners which are in contact with coolant. If engine is equipped with a coolant filter/conditioner, do not use a antifreeze containing methoxy propanol or stop leak additive. These products may clog the coolant filter. NOTE: John Deere RE23182 Inhibitor is a non-chromate inhibitor and is recommended for use in all applications not having a coolant filter. If engine is equipped with a John Deere Coolant Filter Conditioner, the correct inhibitors are contained in the filter. With both inhibitor systems, follow service recommendation printed on the container.
Continued on next page
TM1529 (27JUN17)
9010-15-12
TX,901015,SS1K -19-12MAR93-1/2
544G, 624G, 644G Loader
062717
PN=128
Diagnostic Information 3. Inhibitors
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.
Non-chromate inhibitors must be used. Do not use soluble oil. Always follow the supplier recommendations printed on the container. Over-inhibiting antifreeze solutions can cause silicate-dropout. When this happens, a gel-type deposit is created which retards heat transfer and coolant flow. NOTE: John Deere Liquid Coolant Conditioner does not protect against freezing. General Recommendations
Always maintain engine coolant at correct level. Coolant make-up should be mixed at same concentrations as original coolant, including inhibitors. In tropical areas where antifreeze or John Deere Cooling fluid is not available, use the liquid coolant conditioner (or coolant filter conditioner) with water meeting the water quality specifications.
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. TX,901015,SS1K -19-12MAR93-2/2
TM1529 (27JUN17)
9010-15-13
544G, 624G, 644G Loader
062717
PN=129
Diagnostic Information
TM1529 (27JUN17)
9010-15-14
544G, 624G, 644G Loader
062717
PN=130
Group 20
Adjustments JT05801 Clamp-On Electronic Tachometer Installation SERVICE EQUIPMENT AND TOOLS
A—Clamp-On Tachometer Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten only—DO NOT over tighten. B—Black Clip (-). Connect to main frame. C—Red Clip (+). Connect to transducer. D—Tachometer Readout. Install cable.
T6813AG —UN—28FEB89
Tachometer:
902025,AA75 -19-16SEP92-1/1
JT05800 Digital Thermometer Installation SERVICE EQUIPMENT AND TOOLS
A—Temperature Probe. Fasten to a bare metal line using tie band. Wrap with shop towel. B—Cable C—Digital Thermometer
T6808CE —UN—28FEB89
Digital Thermometer
902525,AA4 -19-14FEB95-1/1
Display Monitor Tachometer
T7817AG —UN—31AUG92
The display monitor tachometer is accurate enough for test work. If accuracy is questioned See Calibrate Tachometer in Group 9015-20.
TX,9020,UU1277 -19-16SEP92-1/1
TM1529 (27JUN17)
9010-20-1
544G, 624G, 644G Loader
062717
PN=131
Adjustments
JT07158 TIME TRAC® Installation ESSENTIAL TOOLS JT07158 TIME TRAC™ Kit T8010AL —UN—18MAY93
A-JT07155 9/16-in. In-Line SOI Sensor (Optional) B-JT07173 SOI Clamp Assembly E-JT07177 6 mm Clamp-On Transducer (Green) I-JDG793 Magnetic Pick-Up Adapter J-JT07171 Magnetic Pick-Up
Remove paint and thoroughly clean injection line. IMPORTANT: Install clamp-on transducer as close as possible to fuel injection nozzle.
T8010AM —UN—20MAY93
G—Ground H—Meter Connection I— Adapter J— Magnetic Probe K—Meter Connection
T8010AN —UN—18MAY93
A—SOI Sensor B—Transducer Clamp C—Ground D—Meter Connection E—Clamp-On Transducer F— Injection Line
TIME TRAC is a registered trademark of the Stanadyne Automotive Corp. TX,TIMETRAC,300 -19-21FEB95-1/1
TM1529 (27JUN17)
9010-20-2
544G, 624G, 644G Loader
062717
PN=132
Adjustments
Injection Pump Timing
544G Engine Model
6059T
544G Net HP
115 hp (86 kW)
624G Engine Model
6058T
624G Net HP
145 hp (108 kW)
644G (S.N. —005083) Engine Model
6076T
644G (S.N. —005083) Net HP
170 hp (127 kW)
644G (S.N. 005084—) Engine Model
8.1 L H
644G (S.N. 005084—) Net HP
174 hp (130 kW)
544G Rated RPM
2200
624G Rated RPM
2200
644G Rated RPM
2200
544G Dynamic Timing
15.0
624G Dynamic Timing
15.0
644G (S.N. —005083) Dynamic Timing
16.0
644G (S.N. 005084—) Dynamic Timing
4.0
RG6293 —UN—03NOV97
SPECIFICATIONS
A—Front Plate
B—Pump Flange
3. 544G/624G— run engine at fast idle as bucket rollback hydraulic function is metered over relief to pull engine down to rated speed, 2200 rpm. Specification 544G—Rated RPM.......................................................................... 2200 624G—Rated RPM.......................................................................... 2200
ESSENTIAL TOOLS
NOTE: If hydraulic stall does not pull engine down to 2200 rpm, stall torque converter with transmission in 3rd forward by holding right brake pedal before metering bucket over relief.
JT07158 TIME TRAC™ Kit
The JT07158 timing kit electronically indicates start of injection with respect to piston top dead center, and allows setting injection pump timing to provide optimum power, smoke and exhaust emissions. Timing engines with this tool improves consistency and helps control cylinder pressures which can be a factor in head gasket failures. 1. Install JT07158 TIME TRAC™. See procedure in this group. (Also found on JT07175 Quick Reference Sheet.) 2. Warm engine to operating temperature. Specification 544G—Engine Model..................................................................... 6059T Net HP ............................................................................. 115 hp (86 kW) 624G—Engine Model..................................................................... 6058T Net HP ...........................................................................145 hp (108 kW) 644G (S.N. —005083)—Engine Model.............................................................................................. 6076T Net HP ...........................................................................170 hp (127 kW) 644G (S.N. 005084—)—Engine Model.............................................................................................8.1 L H Net HP ...........................................................................174 hp (130 kW)
4. 644G— Operate engine at 2200 rpm. Specification 644G—Rated RPM.......................................................................... 2200
No load. 5. Record dynamic timing. 6. If timing is not to specification, follow procedure on JT07175 Quick Reference Sheet, CTM8 and CTM42. Specification 544G—Dynamic Timing.................................................................... 15.0 624G—Dynamic Timing.................................................................... 15.0 644G (S.N. —005083)—Dynamic Timing................................................................................................ 16.0 644G (S.N. 005084—)—Dynamic Timing.................................................................................................. 4.0
TIME TRAC is a registered trademark of the Stanadyne Automotive Corp. TX,544G,RP2585 -19-21FEB95-1/1
TM1529 (27JUN17)
9010-20-3
544G, 624G, 644G Loader
062717
PN=133
Adjustments
Fan Belt Tension Adjustment SPECIFICATIONS 544G, 624G Fan Belt Deflection
19 mm (0.75 in.) at 67 N (15 lb force) measured midway between fan and crankshaft pulleys
644G Fan Belt Deflection
19 mm (0.75 in.) at 90 N (20 lb force) measured midway between alternator and crankshaft pulleys
SERVICE EQUIPMENT AND TOOLS Belt Tension Gauge
NOTE: The following procedure is for 544G, 624G, and 644G (S.N. —557738) loaders. The 644G (S.N. 557739—) loader uses a serpentine belt with an automatic belt adjusting mechanism.
T6099AB —UN—27OCT88
1. Check fan belt tension using a belt tension gauge on belt closest to alternator. IMPORTANT: Apply pressure to alternator front housing only when adjusting belt tension. 2. Adjust belts to specification if necessary. Specification 544G, 624G Fan Belt—Deflection.................................................................................... 19 mm (0.75 in.) at 67 N (15 lb force) measured midway between fan and crankshaft pulleys 644G Fan Belt—Deflection..........................................................19 mm (0.75 in.) at 90 N (20 lb force) measured midway between alternator and crankshaft pulleys
Fan Belt Deflection Check
901020,MD221 -19-16SEP92-1/1
TM1529 (27JUN17)
9010-20-4
544G, 624G, 644G Loader
062717
PN=134
Adjustments
Slow And Fast Idle Adjustment—544G, 624G
Engine Speed Slow Idle
850 ± 25 rpm
544G Engine Speed Fast Idle
2375 ± 25 rpm
624G Engine Speed Fast Idle
2325 ± 25 rpm
T6522AG —UN—24OCT88
SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS Tachometer Sealing Wire Pliers
1. Connect tachometer. (See Tachometer Installation Procedure in this group.)
A—Lever Stop Screw B—Speed Control Cable C—Sealing Wire
2. Disconnect speed control cable (B) from injection pump lever. 3. Start engine. Run engine until it is at normal operating temperature. 4. Hold injection pump lever rearward (toward radiator). Read tachometer. 5. If slow idle is not to specification, adjust as follows: Specification Engine Speed—Slow Idle....................................................................................... 850 ± 25 rpm
D—Fast Idle Adjusting Screw E—Slow Idle Adjusting Screw
7. If fast idle is not to specifications, adjust as follows: Specification 544G Engine Speed—Fast Idle............................................................... 2375 ± 25 rpm 624G Engine Speed—Fast Idle............................................................... 2325 ± 25 rpm
a. Remove sealing wire (C).
a. Loosen lock nut and turn screw (A) out one or two turns to adjust slow idle. Tighten nut.
b. Loosen lock nut and turn screw (D) counterclockwise to increase rpm or clockwise to decrease rpm.
b. Loosen lock nut and turn screw (E) to adjust slow idle.
c. Tighten lock nut and install a new sealing wire using a seal wire pliers.
c. Loosen lock nut and turn screw (A) in until rpm starts to increase, then turn screw out one full turn. Tighten nuts.
8. Reconnect speed control cable to ball joint on pump lever.
6. Hold injection pump lever forward (away from radiator). Read tachometer. TX,9010,MD197 -19-16SEP92-1/1
TM1529 (27JUN17)
9010-20-5
544G, 624G, 644G Loader
062717
PN=135
Adjustments
Slow Idle Adjustment—644G
(S.N. —544523) Engine Speed Slow Idle
775—825 rpm
(S.N. 544524—) Engine Speed Slow Idle
875—925 rpm
T7827AF —UN—10SEP92
SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS JT05801 Tachometer
1. Connect JT05801 Tachometer as shown in this group. 2. Run engine until it is at normal operating temperature.
A—Fast Idle Stop B—Supplementary Idle Spring Adjustment Screw
3. Disconnect speed control cable from governor control lever.
C—Slow Idle Stop Screw
4. Push governor control lever up. Read tachometer. 5. If engine speed is not to specification, adjust slow idle as follows:
b. Loosen lock nut and turn slow idle stop screw (C) to adjust engine speed to 780 rpm. Tighten lock nut.
Specification (S.N. —544523) Engine Speed—Slow Idle.............................................................. 775—825 rpm (S.N. 544524—) Engine Speed—Slow Idle.............................................................. 875—925 rpm
c. Turn supplementary idle screw (B) until rpm increases 20 rpm. Tighten lock nut.
a. Loosen lock nut and turn out supplementary idle spring adjusting screw (B) three turns.
d. Accelerate rapidly to fast idle, then decelerate to slow idle. If engine surges, turn supplementary idle screw in to increase slow idle slightly to a maximum of 850 rpm. If surge continues, repair injection pump. 6. Connect speed control cable into bottom hole of control lever. TX,9010,MD196 -19-06JAN94-1/1
Fast Idle Adjustment—644G SPECIFICATIONS Engine Speed Fast Idle
2300—2350 rpm T7827AF —UN—10SEP92
SERVICE EQUIPMENT AND TOOLS JT05801 Tachometer
1. Connect JT05801 tachometer as shown in this group. 2. Run engine until it is at normal operating temperature. 3. Disconnect speed control cable from governor control lever. A—Fast Idle Stop B—Supplementary Idle Spring Adjustment Screw
4. Hold governor control lever against fast idle stop screw (A). Read tachometer. 5. If engine speed is not to specification, remove sealing wire.
Loosen lock nut and turn fast idle stop screw (A) to adjust fast idle to specifications, tighten lock nut.
Specification Engine Speed—Fast Idle................................................................................. 2300—2350 rpm
C—Slow Idle Stop Screw
6. Install sealing wire. 7. Connect speed control cable into bottom hole of control lever. TX,9010,MD198 -19-16SEP92-1/1
TM1529 (27JUN17)
9010-20-6
544G, 624G, 644G Loader
062717
PN=136
Adjustments
T7853AB —UN—06OCT92
Speed Control Linkage Adjustment
A—Swivel B—Cable
C—Lever D—Stop Screw
1. Adjust pedal angle to 32—35° from the base plate with the pedal released.
3. Depress accelerator pedal until injection pump lever is against fast idle stop and hold.
2. With accelerator pedal at slow idle, disconnect swivel (A) on speed control cable (B) and adjust until:
4. Adjust pedal stop screw (D) until it makes contact with the pedal. Release pedal.
544G and 624G—Injection pump lever (C) has 2—4 mm (0.08—0.16 in.) of override at the slow idle position. Connect cable to injection pump lever.
5. 544G and 624G—Shorten pedal stop screw until 2—4 mm (0.09—0.16 in.) override is obtained at the pump.
644G—Hole in injection pump lever just lines up with swivel at the slow idle position. Lengthen cable two turns. Connect to injection pump lever.
644G—Tighten lock nut.
TX,1020,MD199 -19-16SEP92-1/1
TM1529 (27JUN17)
9010-20-7
544G, 624G, 644G Loader
062717
PN=137
Adjustments
Fuel Shut-Off Solenoid Adjustment—644G 1. Turn key switch to START to "bump" starter, but not start engine, leave key switch in ON position. This will energize shut-off solenoid. 2. Loosen nut (C) and lengthen rod (B) until shut-off lever (E) moves away from stop (D). Solenoid bracket may need to be removed to rotate rod (B). 3. Shorten rod (B) until shut-off lever (E) touches stop (D), then shorten rod 2 more turns to preload spring (A). NOTE: Orient bend in rod so its lower end is closest to engine block. If rod is not oriented correctly, linkage will bind and not move freely.
5. If rod (B) is adjusted too short, engine may not shut off. If rod is adjusted too long, engine may not start easily or may not have full power. If adjustment cannot be made, shut-off lever (E) may be binding, solenoid mounting bracket may be bent or injection pump may be worn or have internal failures. D—Stop E—Shut-off lever
T8413AF —19—06FEB95
A—Spring B—Rod C—Nut
T8413AA —UN—06FEB95
4. Tighten nut (C) after final adjustment is made.
TX,9010,DU1527 -19-09FEB95-1/1
TM1529 (27JUN17)
9010-20-8
544G, 624G, 644G Loader
062717
PN=138
Adjustments
Primary Fuel Filter, Drain Water—544G, 624G 1. Place pan under primary filter (water separator) (C).
T7833AJ —UN—10SEP92
2. Open drain valve (D) on the bottom of primary filter and press pump (B) to remove water from fuel system. 3. When water is removed close drain valve. 4. Open drain valve (F) on bottom of final filter (G) and press pump (B) to remove water. 5. When water is removed close drain valve. A—Bleed Screw (Final Filter) B—Pump C—Primary Filter (Water Separator) D—Drain Valve (Primary Filter)
E—Bleed Screw (Primary Filter) F— Drain Valve (Final Filter) G—Final Filter
TX,9010,MD201 -19-16SEP92-1/1
Primary Fuel Filter, Drain Water—644G 1. Place pan under primary filter (water separator) (E).
T7799CJ —UN—10SEP92
2. Open drain valve (D) on the bottom of primary filter and press pump (B) to remove water from fuel system. 3. When water is removed close drain valve. A—Final Fuel Filter B—Pump C—Fuel Supply Line D—Drain Valve
E—Primary Filter (Water Separator) F— Bleed Screw G—Bleed Screw
TX,9010,MD202 -19-16SEP92-1/1
Bleed The Fuel System—544G, 624G 1. Place pan under filters (C and G).
T7833AJ —UN—10SEP92
2. Open bleed screw (A) and push pump (B) until fuel free of bubbles flows from around the bleed screw. 3. Close bleed screw. NOTE: If you run out of fuel and air is in the supply line to the injection pump continue next step. 4. Loosen fuel line at injection pump and push pump (B) until fuel free of bubbles flows from around connection. 5. Tighten fuel line. A—Bleed Screw (Final Filter) B—Pump C—Primary Filter (Water Separator) D—Drain Valve (Primary Filter)
E—Bleed Screw (Primary Filter) F— Drain Valve (Final Filter) G—Final Filter
TX,9010,MD203 -19-16SEP92-1/1
TM1529 (27JUN17)
9010-20-9
544G, 624G, 644G Loader
062717
PN=139
Adjustments
Bleed The Fuel System—644G 1. Place pan under primary filter (water separator) (E).
T7799CJ —UN—10SEP92
2. Open bleed screw (F) and push pump (B) until fuel free of bubbles flows from around the bleed screw. 3. Close bleed screw (F) and loosen bleed screw (G) from final fuel filter (A). 4. Push pump until only fuel flows from fuel bleed screw opening. NOTE: If you run out of fuel and air is in the supply line to the injection pump continue next step. 644G shown. 5. Loosen fuel line (C) at injection pump and push pump until fuel free of bubbles flows from connector. 6. Tighten fuel line.
A—Final Fuel Filter B—Pump C—Fuel Supply Line D—Drain Valve
E—Primary Filter (Water Separator) F— Bleed Screw G—Bleed Screw TX,9010,MD204 -19-16SEP92-1/1
TM1529 (27JUN17)
9010-20-10
544G, 624G, 644G Loader
062717
PN=140
Group 25
Tests Display Monitor Tachometer
T7817AG —UN—31AUG92
The display monitor tachometer is accurate enough for test work. If accuracy is questioned See Calibrate Tachometer in Group 9015-20.
TX,9020,UU1277 -19-16SEP92-1/1
NOTE: The monitor display will be used to indicate hydraulic oil temperature. The temperature sensor is located in the pressure return oil manifold block on the loader pump outlet. Return oil temperature is sensed. The display monitor hydraulic oil temperature should be used for test work. To display hydraulic temperature in Basic Display window of monitor, start engine:
T7817AG —UN—31AUG92
Display Monitor Hydraulic Oil Temperature
Press MENU to get Diagnostic Mode d displayed. Press SELECT to get d 01 displayed, then press NEXT until d 06 is displayed. Press SELECT then NEXT to get d 060, then press SELECT to activate hydraulic system oil temperature. TX,05,WW2225 -19-05AUG96-1/1
Display Monitor Hydraulic Oil Pressure
To display hydraulic temperature in Basic Display window of monitor, start engine: Press MENU to get Diagnostic Mode d displayed. Press SELECT to get d 01 displayed, then press NEXT until d 06 is displayed.
T7817AG —UN—31AUG92
NOTE: The monitor display can be used to indicate hydraulic oil pressure if machine is equipped with LPM optional transducer, installed in steering hydraulic pump.
Press SELECT then NEXT to get d 061, then press SELECT to activate hydraulic system oil pressure. TX,9010,TJ28 -19-29SEP97-1/1
TM1529 (27JUN17)
9010-25-1
544G, 624G, 644G Loader
062717
PN=141
Tests
Air Filter Restriction Indicator Switch Test SPECIFICATIONS Restriction Indicator Light Activation Vacuum Pressure
5.0—7.5 kPa (50—75 mbar) (20—30 in. water)
SERVICE EQUIPMENT AND TOOLS 0—15 kPa (0—150 mbar) (0—60 in. water) Vacuum Gauge 1/4” Tee Fitting 1/4” x 1/8” Reducer (2 Used) 1/8” Pipe Nipple
1. Remove pre-cleaner. 2. Connect gauge and indicator as shown. 3. Start engine and slowly cover the air cleaner inlet with a piece of cardboard.
T6522AI —UN—24OCT88
4. Yellow warning light and white air filter restriction indicator must come on. 5. If reading is not within specifications, install a new indicator switch. Specification Restriction Indicator Light Activation—Vacuum Pressure.............................................................................. 5.0—7.5 kPa (50—75 mbar) (20—30 in. water)
TX,901025,SS33 -19-30JUN87-1/1
Radiator Cap Pressure Test RG6557 —UN—20JAN93
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Stop 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. 1. Remove radiator cap and attach to D05104ST Pressure Pump as shown. 2. Pressurize cap to 50 kPa (0.0 bar) (7 psi). Gauge should hold pressure for 10 seconds within the normal range if cap is acceptable. If gauge does not hold pressure, replace radiator cap.
3. Remove the cap from pressure pump, turn it 180°, and retest cap. This will verify that the first measurement was accurate. 4. To pressure test cooling system, see procedure in this group. TX,9010,TJ8 -19-09SEP97-1/1
TM1529 (27JUN17)
9010-25-2
544G, 624G, 644G Loader
062717
PN=142
Tests
Cooling System Pressure Test
RG6558 —UN—20JAN93
CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Stop 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. NOTE: Engine should be warmed up to test overall cooling system. 1. Allow engine to cool, then carefully remove radiator cap.
4. With pressure applied, check all cooling system hose connections, radiator, and overall engine for leaks.
2. Fill radiator with coolant to the normal operating level. IMPORTANT: Do not apply excessive pressure to cooling system. Doing so may damage radiator and hoses. 3. Connect gauge and adapter to radiator filler neck. Pressurize cooling system to 50 kPa (0.5 bar) (7 psi) using D05104ST Pressure Pump.
If leakage is detected, correct as necessary and pressure test system again. If no leakage is detected, but the gauge indicated a drop in pressure, coolant may be leaking internally within the system or at the head gasket.
TX,9010,TJ9 -19-09SEP97-1/1
TM1529 (27JUN17)
9010-25-3
544G, 624G, 644G Loader
062717
PN=143
Tests
Radiator Air Flow Test SPECIFICATIONS Engine Speed
2400 + 25 - 0 rpm
Typical Test Reading Voltage
4.27 volts
ESSENTIAL TOOLS JT05529 Air Flowmeter SERVICE EQUIPMENT AND TOOLS Tachometer Heavy Duty Digital Multimeter Analog/Digital Multimeter
1. Apply parking brake, put transmission in neutral and lower equipment to the ground. Stop engine.
T6080AH —UN—01NOV88
2. Install tachometer. (See procedure in this group.) 3. Check that all sheet metal is in place. Close side shields. 4. Divide the surface of the grille into 16 equal squares. 5. Start engine and run at specification. Specification Engine—Speed............................................................2400 + 25 - 0 rpm
6. Connect air flowmeter to digital multimeter. Turn switch on multimeter to 20 volts A.C.
If readings are less than specifications remove oil cooler and clean external surfaces of both oil cooler and radiator. Install oil cooler and repeat test. If reading is still low, check for correct fan installation. Be sure sheet metal is in place.
7. Place air flowmeter in contact with grille. Arrow on meter must point in direction of air flow (away from unit). 8. Record voltage reading for each area.
NOTE: Air flow readings minus 20% is a number used as a guideline to determine when a partially plugged radiator and or cooler core may cause overheating.
9. Combined total of air flow test readings must be approximately at specifications. Specification Typical Test Reading—Voltage.....................................................................4.27 volts
Continued on next page
TM1529 (27JUN17)
9010-25-4
TX,9010,RB39 -19-14NOV97-1/2
544G, 624G, 644G Loader
062717
PN=144
T6500AK —19—21MAR89
Tests
• Divide the surface of the grille into 16 equal squares. • Park brake ON. • Transmission in Neutral and side shields closed. • Divide the surface of the grille into 16 equal squares. • Start engine. • Perform AIR FLOW TEST at fast idle. Observe correct • •
air flow direction and place air flowmeter in direct contract with grille. Record air flow in each square. Combine total of air flow test readings must be approximately at specifications.
T95955 —UN—25MAY89
Specification Typical Test Reading—Voltage.....................................................................4.27 volts
TX,9010,RB39 -19-14NOV97-2/2
TM1529 (27JUN17)
9010-25-5
544G, 624G, 644G Loader
062717
PN=145
Tests
Engine Power Test Using Engine Pulldown SPECIFICATIONS Transmission Oil Temperature
82 ± 6°C (180 ± 10°F)
Hydraulic Oil Temperature
65 ± 5°C (150 ± 10°F)
Engine Speed
Fast idle
Combined Torque Converter Stall and Bucket Rollback Over Relief, Number 1 Fuel: 544G (S.N. —553284) Engine Pulldown Speed
1300—1580 rpm
544G (S.N. 553285—) Engine Pulldown Speed
1350—1700 rpm
624G Engine Pulldown Speed
1250—1580 rpm
644G Engine Pulldown Speed
1350—1580 rpm
Combined Torque Converter Stall and Bucket Rollback Over Relief, Number 2 Fuel: 544G (S.N. —553284) Engine Pulldown Speed
1400—1700 rpm
544G (S.N. 553285—) Engine Pulldown Speed
1440—1800 rpm
624G Engine Pulldown Speed
1400—1700 rpm
644G Engine Pulldown Speed
1450—1700 rpm
SERVICE EQUIPMENT AND TOOLS JT05800 Digital Thermometer
Combined Torque Converter Stall And Bucket Rollback Over Relief, Number 1 Fuel:—Specification 544G (S.N. —553284) Engine—Pulldown Speed............................................................................ 1300—1580 rpm 544G (S.N. 553285—) Engine—Pulldown Speed............................................................................ 1350—1700 rpm 624G Engine—Pulldown Speed............................................................................ 1250—1580 rpm 644G Engine—Pulldown Speed............................................................................ 1350—1580 rpm Combined Torque Converter Stall And Bucket Rollback Over Relief, Number 2 Fuel:—Specification 544G (S.N. —553284) Engine—Pulldown Speed............................................................................ 1400—1700 rpm 544G (S.N. 553285—) Engine—Pulldown Speed............................................................................ 1440—1800 rpm 624G Engine—Pulldown Speed............................................................................ 1400—1700 rpm 644G Engine—Pulldown Speed............................................................................ 1450—1700 rpm
7. Perform the following checks:
JT05801 Clamp-On Electronic Tachometer
• If rpm is low, check for:
1. Fasten temperature sensor on main hydraulic pump to priority valve line. 2. Heat oil to specification. Specification Transmission Oil—Temperature.................................................. 82 ± 6°C (180 ± 10°F) Hydraulic Oil—Temperature.................................................. 65 ± 5°C (150 ± 10°F)
3. Apply brakes and put transmission in 3rd forward. 4. Operate engine at fast idle. Specification Engine—Speed...........................................................................Fast idle
5. Hold bucket rollback over relief. 6. Record lowest engine speed.
- Engine malfunction. (See Engine Does Not Develop Full Power in Group 9010-15.) - High hydraulic system pressure. (See Loader System and Circuit Relief Valve Test in group 9025-25.)
• If rpm is high, check for:
a. Low hydraulic system pressure. (See Loader System and Circuit Relief Valve Test in Group 9025-25.) b. Low transmission oil level or aerated oil. c. Transmission slippage or a failed torque converter freewheel clutch. d. High fuel delivery. (To remove injection pump, refer to the following CTMs: 544G with 6059 engine — use CTM8 624G with 6068 engine — use CTM8 644G with 6076 engine — use CTM42 644G with 6081 engine — use CTM86 TX,25,WW2239 -19-17AUG96-1/1
TM1529 (27JUN17)
9010-25-6
544G, 624G, 644G Loader
062717
PN=146
Tests
T7799CP —UN—10SEP92
Engine Power Test Using Turbocharger Boost Pressure
T7799CV —UN—11SEP92
644G
544G, 624G SPECIFICATIONS 544G Engine Using Number 2 41 kPa (0.41 bar) (6 psi) Fuel Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed
This procedure should be used ONLY as a guide to determine engine condition. Fuel temperature above 24°C (75°F) will reduce engine power approximately 1.5% per 10°C (18°F) and will lower turbo boost pressures.
624G Engine Using Number 2 69 kPa (0.7 bar) (10 psi) Fuel Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed
IMPORTANT: Gauge accuracy is very critical for this test. DO NOT make adjustments to injection pump fuel delivery on unit to raise or lower boost pressure.
644G Engine Using Number 2 90 kPa (0.9 bar) (13 psi) Fuel Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed
1. Install tachometer and gauge. See procedure in this group. Cap differential lock turbo boost line to axles.
544G Engine Using Number 1 35 kPa (0.35 bar) (5 psi) Fuel Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed 624G Engine Using Number 1 55 kPa (0.55 bar) (8 psi) Fuel Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed 644G Engine Using Number 21 76 kPa (0.76 bar) (11 psi) Fuel Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed SERVICE EQUIPMENT AND TOOLS JT05801 Tachometer Manifold Pressure Test Gauge Kit
NOTE: Maximum boost pressure is obtained by pulling engine down below rated speed, which will cause pressure to drop, then slowly releasing load and let engine slowly increase rpm. This cycle will have to be repeated a minimum of six times in succession to insure that maximum boost pressure is obtained. 2. Start engine and warm to normal operating temperature. Roll bucket back and hold over relief. (See Hydraulic Warm-up Procedure in this group.) IMPORTANT: Do not overheat hydraulic or transmission oil during this test, converter stalls will rapidly increase transmission temperature. Watch transmission temperature gauge on front dash, if it goes into red zone, stop test until transmission circulates and cools to safe zone. Continued on next page
TM1529 (27JUN17)
9010-25-7
TX,9010,TJ38 -19-27OCT97-1/2
544G, 624G, 644G Loader
062717
PN=147
Tests 3. With engine at operating temperature:
• Meter the bucket rollback hydraulic function over •
relief to apply load to engine to pull engine speed down to 100 rpm below rated speed (2200 rpm). Slowly release load, gauge reading should start raising, until gauge reaches it’s maximum reading then starts to decrease.
NOTE: If hydraulic stall does not pull engine down below rated speed, Put transmission in 3rd gear forward. Hold right brake pedal, release park brake, and increase engine speed to fast idle to stall torque converter. With transmission stalled do step 3. 4. Repeat Step 3 six times recording maximum reading each time. 5. Compare highest reading to specification. Specification 544G Engine Using Number 2 Fuel—Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed......................................... 41 kPa (0.41 bar) (6 psi) 624G Engine Using Number 2 Fuel—Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed......................................... 69 kPa (0.7 bar) (10 psi) 644G Engine Using Number 2 Fuel—Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed......................................... 90 kPa (0.9 bar) (13 psi)
544G Engine Using Number 1 Fuel—Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed......................................... 35 kPa (0.35 bar) (5 psi) 624G Engine Using Number 1 Fuel—Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed......................................... 55 kPa (0.55 bar) (8 psi) 644G Engine Using Number 21 Fuel—Minimum Turbocharger Boost Pressure at 2200 rpm With Muffler Installed........................................76 kPa (0.76 bar) (11 psi)
6. If boost pressure is low, remove muffler and recheck boost pressure. If pressure is still low, check for the following:
• Wrong fuel • Restricted air filter elements • Restricted fuel filter elements • Incorrect injection pump timing • Incorrect fast idle adjustment • Exhaust manifold leaks • Intake manifold leaks • Faulty fuel pump • Low compression pressure • Cam lobe wear (valve clearance) • Faulty fuel injection nozzles • Carbon build-up in turbocharger • Turbocharger compressor or turbine wheel rubbing housing
7. Remove gauge and install plug. TX,9010,TJ38 -19-27OCT97-2/2
TM1529 (27JUN17)
9010-25-8
544G, 624G, 644G Loader
062717
PN=148
Tests
Compression Pressure Test
544G Loader Minimum Compression Pressure
4210 kPa (24 bar) (350 psi)
624G Loader Minimum Compression Pressure
4210 kPa (24 bar) (350 psi)
644G Loader Minimum Compression Pressure
2380—2790 kPa (23.8—27.9 bar) (345—405 psi)
Maximum Compression Pressure Difference Between Cylinders
350 kPa (3.5 bar) (50 psi)
NOTE: Pressure listed is for 300 m (1000 ft) above sea level. Reduce specification by 3.6% for each additional 300 m (1000 ft) of altitude. SERVICE EQUIPMENT AND TOOLS Compression Test Set
1. Thoroughly clean area around injection nozzles. 2. Warm engine to normal operating temperature. 3. Stop engine. 4. Disconnect wire connectors from injection pump. 5. Remove fuel injection nozzles. 6. Install compression gauge.
T6099AF —UN—27OCT88
SPECIFICATIONS
9. If pressure readings are low, put oil on piston rings by injecting oil through the nozzle bores. Specification 544G Loader—Minimum Compression Pressure................................. 4210 kPa (24 bar) (350 psi) 624G Loader—Minimum Compression Pressure................................. 4210 kPa (24 bar) (350 psi) 644G Loader—Minimum Compression Pressure.................................................. 2380—2790 kPa (23.8—27.9 bar) (345—405 psi) Maximum Compression—Pressure Difference Between Cylinders......................................................... 350 kPa (3.5 bar) (50 psi)
IMPORTANT: Turning crankshaft more than seven revolutions can give incorrect pressure reading. 7. Turn crankshaft seven revolutions with starting motor.
• If pressure increases, worn or stuck rings are indicated.
• If pressure does not increase or increases very little, worn or stuck valves are indicated.
8. Record pressure readings. TX,9010,TJ10 -19-09SEP97-1/1
TM1529 (27JUN17)
9010-25-9
544G, 624G, 644G Loader
062717
PN=149
Tests
Air Intake System Leakage Test SPECIFICATIONS 14—21 kPa (0.14—0.21 bar) (2—3 psi) T5906AP —UN—23FEB89
Air Intake System Pressure
SERVICE EQUIPMENT AND TOOLS Manifold Pressure Test Gauge 1/4” NPT Fitting x 1/8” Hose Barb
IMPORTANT: If machine is equipped with turbo boost differential lock line, remove line and cap fitting. 1. Remove air cleaner cover and primary filter element.
T6099BE —UN—10NOV88
2. Put large plastic bag into and cover end of primary filter element as shown. Install primary filter element and cover. 3. Remove 1/8 in. plug from intake manifold. 4. Connect air pressure regulator to manifold using hose and fitting from manifold pressure tester. 5. Pressurize air intake system to 14—21 kPa (0.14—0.21 bar) (2—3 psi). Specification Air Intake System—Pressure.....................14—21 kPa (0.14—0.21 bar) (2—3 psi)
If intake system cannot be pressurized, turn engine slightly to close valves.
6. Spray soap solution over all connections from the air cleaner or turbocharger or air intake manifold and check for leaks. Correct all leaks. TX,9010,DU1529 -19-10SEP93-1/1
TM1529 (27JUN17)
9010-25-10
544G, 624G, 644G Loader
062717
PN=150
Tests
Fuel Supply Pump Pressure Test
Engine Speed
Slow idle
544G Loader Fuel Pressure
15—30 kPa (0.15—0.30 bar) (2—4 psi)
624G Loader Fuel Pressure
15—30 kPa (0.15—0.30 bar) (2—4 psi)
644G Loader Fuel Pressure
200—207 kPa (2.0—2.1 bar) (29—30 psi)
T108450 —UN—22APR97
SPECIFICATIONS
ESSENTIAL TOOLS 544G, 624G Shown
JT05487 (1/8 M NPT x 7/16-20 M 37°) Fitting (544G, 624G) (1/2 M ORB x 7/16-20 M 37°) Fitting (644G) SERVICE EQUIPMENT AND TOOLS
T108451 —UN—22APR97
Gauge 0—200 kPa (0—2 bar) (29—30 psi)
1. Make test connection at fuel filter base auxiliary outlet port (A). 2. Operate engine at slow idle. Specification Engine—Speed..........................................................................Slow idle 644G Shown
Record fuel pressure reading. 3. If fuel pressure is low, check for: Specification 544G Loader—Fuel Pressure.....................................15—30 kPa (0.15—0.30 bar) (2—4 psi) 624G Loader—Fuel Pressure.....................................15—30 kPa (0.15—0.30 bar) (2—4 psi) 644G Loader—Fuel Pressure.................................200—207 kPa (2.0—2.1 bar) (29—30 psi)
• Partially closed fuel tank shut-off valve. • Pinched or kinked fuel lines. • Injection pump overflow valve stuck open. • Fuel transfer pump malfunctioning. 4. To help isolate the cause of low pressure, connect a hose to transfer pump inlet and put the other end into a container of fuel. Repeat test:
• If fuel pressure increases to normal, the malfunction is between the tank and fuel transfer pump.
• If pressure is still low, the malfunction is in the fuel transfer pump or injection pump overflow valve.
5. If pressure is high, check for: Specification 544G Loader—Fuel Pressure.....................................15—30 kPa (0.15—0.30 bar) (2—4 psi) 624G Loader—Fuel Pressure.....................................15—30 kPa (0.15—0.30 bar) (2—4 psi) 644G Loader—Fuel Pressure.................................200—207 kPa (2.0—2.1 bar) (29—30 psi)
• Plugged fuel filters. • Restricted fuel return hose or leak-off lines. TX,9010,TJ11 -19-10SEP97-1/1
TM1529 (27JUN17)
9010-25-11
544G, 624G, 644G Loader
062717
PN=151
Tests
Fuel Line Leakage Test Connections may allow air to enter the fuel system without allowing fuel to leak out. Follow this procedure to find air leaks in the system. Disconnect fuel supply and fuel return lines at fuel tank. Drain all fuel from system, including fuel transfer pump, fuel injection pump, and fuel filter(s). Close end of fuel return line using a plug, cap, or a short length of hose, plug, and clamps. CAUTION: Never exceed 103 kPa (1 bar) (15 psi) to prevent damage to fuel system components.
Apply liquid soap and water solution to all joints and connections in the fuel system and inspect for leaks. Repair any leaks. Connect supply and return lines and prime system. Start machine and let run for approximately 10 minutes. NOTE: For engines with an in-line fuel injection pump, an internal leak path may allow air to enter the fuel system. If an internal pump leak is suspected, remove the pump and have a pressure test performed by an authorized repair station.
Pressurize the system to 69 kPa (0.7 bar) (10 psi) at the fuel supply line using a regulated pressure air source. TX,1025,MM,140 -19-07NOV94-1/1
TM1529 (27JUN17)
9010-25-12
544G, 624G, 644G Loader
062717
PN=152
Section 9015 Electrical System Contents Page Page
Group 05—System Information Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic................................................ 9015-05-1 Example Of Simple Electrical Test To Find Problem .................................... 9015-05-2 Visually Inspect Electrical System.............. 9015-05-4 Electrical Circuit Malfunctions.................... 9015-05-5 High Resistance Circuit ............................. 9015-05-6 Open Circuit............................................... 9015-05-7 Grounded Circuit ....................................... 9015-05-8 Shorted Circuit........................................... 9015-05-9 Multimeter................................................ 9015-05-10 Seven Step Electrical Test Procedure ............................................ 9015-05-11 Wiring Diagram And Schematic Information........................................... 9015-05-12 Reading A System Functional Schematic............................................ 9015-05-13 Reading A Wiring Diagram ...................... 9015-05-14 Electrical Schematic Symbols ................. 9015-05-15 Group 10—System Diagrams Component Identification Table ................. 9015-10-1 Fuse Block................................................. 9015-10-2 Wiring And Schematic Diagrams Legend................................................... 9015-10-3 System Functional Schematic Section Legend...................................... 9015-10-5 System Functional Schematic ................... 9015-10-6 Steering Column Harness (W2) Wiring Diagram.................................... 9015-10-15 Steering Column Harness (W2) Component Location ........................... 9015-10-16 Loader Frame Harness (W3) Wiring Diagram.................................... 9015-10-17 Loader Frame Harness (W3) Component Location ........................... 9015-10-19 Transmission Harness (W4) Wiring Diagram ............................................... 9015-10-21 Transmission Harness (W4) Component Location ........................... 9015-10-23 Load Center Harness (W5) Wiring Diagram (Page 1 of 4) ......................... 9015-10-25 Load Center Harness (W5) Wiring Diagram (Page 2 of 4) ......................... 9015-10-27 Load Center Harness (W5) Wiring Diagram (Page 3 of 4) ......................... 9015-10-29 Load Center Harness (W5) Wiring Diagram (Page 4 of 4) ......................... 9015-10-31
Load Center Harness (W5) Component Location ........................... 9015-10-33 Load Center Harness (W5) Component Location—Continued (Detail A) ......................................................... 9015-10-35 Load Center Harness (W5) Component Location—Continued (Detail B) ......................................................... 9015-10-37 Load Center Harness (W5) Component Location—Continued (Detail C)......................................................... 9015-10-38 Load Center Harness (W5) Component Location—Continued (Detail D)......................................................... 9015-10-39 Load Center Harness (W5) Component Location—Continued (Detail E) ......................................................... 9015-10-40 Canopy Work Lights Harness (W6) Wiring Diagram.................................... 9015-10-41 Canopy Work Lights Harness (W6) Component Location ........................... 9015-10-42 Cab Work Lights Harness (W7) Wiring Diagram.................................... 9015-10-43 Cab Work Lights Harness (W7) Component Location ........................... 9015-10-45 Left Panel Temperature Control Harness (W8) Wiring Diagram............. 9015-10-47 Left Panel Temperature Control Harness (W8) Component Location ............................................... 9015-10-49 Engine Frame Harness (W9) Wiring Diagram.................................... 9015-10-51 Engine Frame Harness (W9) Component Location ........................... 9015-10-53 Engine Harness (W10) Wiring Diagram ............................................... 9015-10-55 Engine Harness (W10) Component Location ............................................... 9015-10-57 Rear Frame Harness (W11) Wiring Diagram ............................................... 9015-10-59 Rear Frame Harness (W11) Component Location ........................... 9015-10-60 A/C Compressor Harness (W12) Wiring Diagram.................................... 9015-10-61 A/C Compressor Harness (W12) Component Location ........................... 9015-10-62 Continued on next page
TM1529 (27JUN17)
9015-1
544G, 624G, 644G Loader
062717
PN=1
Contents
Page
Page
Secondary Steering Harness (W13) Wiring Diagram ......................... 9015-10-63 Secondary Steering Harness (W13) Component Location................. 9015-10-64 Start Aid Lead (W14) Wiring Diagram ............................................... 9015-10-65 Start Aid Lead (W14) Component Location ............................................... 9015-10-66 Ride Control Harness (W15) Wiring Diagram ............................................... 9015-10-67 Ride Control Harness (W15) Component Location ........................... 9015-10-68 Pin Disconnect Harness (W16) Wiring Diagram.................................... 9015-10-69 Pin Disconnect Harness (W16) Component Location ........................... 9015-10-70
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Functional Schematic ............... 9015-15-19 Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Diagnostics............................... 9015-15-21 Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Diagnostic Procedures..........................................9015-15-17 Transmission Control Circuit Operational Information ....................... 9015-15-24 Transmission Control Circuit Theory Of Operation............................ 9015-15-25 Transmission Control Circuit Functional Schematic .......................... 9015-15-29 Jumper Wire For Display Monitor ............ 9015-15-31 Replace CPC, Large MATE-N-LOK and METRIMATE™ Pin Type Connectors .......................................... 9015-15-32 Pin Identification On Transmission Controller ............................................. 9015-15-33 Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic.............................................. 9015-15-34 Transmission Control Circuit Diagnostics .......................................... 9015-15-34 Transmission Control Circuit Diagnostic Procedures..........................................9015-15-28 Start Circuit Operational Information........................................... 9015-15-37 Start Circuit Theory Of Operation ............ 9015-15-37 Start Circuit Functional Schematic............................................ 9015-15-39 Start Circuit Diagnostics .......................... 9015-15-41 Start Circuit Diagnostic Procedures..........................................9015-15-33 Park Brake Circuit Operational Information........................................... 9015-15-43 Park Brake Circuit Theory Of Operation............................................. 9015-15-43 Park Brake Circuit Functional Schematic............................................ 9015-15-44 Park Brake Circuit Diagnostics ................ 9015-15-45 Park Brake Circuit Diagnostic Procedures..........................................9015-15-37 Secondary Steering Circuit Specifications ...................................... 9015-15-47 Secondary Steering Circuit Operational Information ....................... 9015-15-47 Secondary Steering Circuit Theory Of Operation ........................................ 9015-15-47 Secondary Steering Circuit Functional Schematic .......................... 9015-15-48 Secondary Steering Circuit Diagnostics .......................................... 9015-15-49
Group 15—Sub-System Diagnostics Special Or Essential Tools......................... 9015-15-1 Power Circuit Operational Information............................................. 9015-15-1 Power Circuit Theory Of Operation............................................... 9015-15-2 Power Circuit Functional Schematic.............................................. 9015-15-3 Power Circuit Diagnostics.......................... 9015-15-5 Power Circuit Diagnostic Procedures............................................9015-15-3 Charging Circuit Operational Information............................................. 9015-15-7 Charging Circuit Theory Of Operation............................................... 9015-15-7 Charging Circuit Functional Schematic.............................................. 9015-15-8 Charging Circuit Diagnostics ..................... 9015-15-9 Charging Circuit Diagnostic Procedures............................................9015-15-7 Start Aid And Fuel Control Circuit Operational Information ....................... 9015-15-11 Start Aid And Fuel Control Circuit Theory Of Operation............................ 9015-15-11 Start Aid And Fuel Control Circuit Functional Schematic .......................... 9015-15-12 Start Aid And Fuel Control Circuit Diagnostics .......................................... 9015-15-13 Start Aid And Fuel Control Circuit Diagnostic Procedures ........................9015-15-11 Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Specifications ........................... 9015-15-18 Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Operational Information............ 9015-15-18 Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Theory Of Operation................. 9015-15-18
Continued on next page
TM1529 (27JUN17)
9015-2
544G, 624G, 644G Loader 062717 PN=2
Contents
Page
Page
Secondary Steering Circuit Diagnostic Procedures..........................................9015-15-41 Differential Lock And Boom Down Circuit Operational Information............ 9015-15-51 Differential Lock And Boom Down Circuit Theory Of Operation................. 9015-15-51 Differential Lock And Boom Down Circuit Functional Schematic ............... 9015-15-52 Differential Lock And Boom Down Circuit Diagnostics............................... 9015-15-53 Differential Lock And Boom Down Circuit Diagnostic Procedures..........................................9015-15-45 Switch Inputs To Monitor Circuit Specifications ...................................... 9015-15-55 Switch Inputs To Monitor Circuit Operational Information ....................... 9015-15-55 Switch Inputs To Monitor Circuit Theory Of Operation............................ 9015-15-56 Switch Inputs To Monitor Circuit Functional Schematic .......................... 9015-15-57 Switch Inputs To Monitor Circuit Diagnostics .......................................... 9015-15-59 Switch Inputs To Monitor Circuit Diagnostic Procedures ........................9015-15-49 Electronic Monitor Signals Circuit Operational Information ....................... 9015-15-61 Electronic Monitor Signals Circuit Theory Of Operation............................ 9015-15-62 Electronic Monitor Signals Circuit Functional Schematic .......................... 9015-15-64 Electronic Monitor Signals Circuit Diagnostics .......................................... 9015-15-65 Electronic Monitor Signals Diagnostic Procedures..........................................9015-15-55 Electronic Monitor And Gauge Inputs Circuit Specifications ................ 9015-15-67 Electronic Monitor/Gauge Inputs Circuit Operational Information............ 9015-15-69 Electronic Monitor/Gauge Inputs Circuit Theory Of Operation................. 9015-15-69 Electronic Monitor/Gauge Inputs Circuit Functional Schematic ............... 9015-15-70 Electronic Monitor/Gauge Inputs Circuit Diagnostics............................... 9015-15-70 Electronic Monitor/Gauge Inputs Circuit Diagnostic Procedures ........................9015-15-61 Boom Height Kickout And Return-To-Dig Circuit Operational Information ....................... 9015-15-72 Boom Height Kickout And Return-To-Dig Circuit Theory Of Operation............................................. 9015-15-72 Boom Height Kickout And Return-To-Dig Circuit Functional Schematic............................................ 9015-15-73
Boom Height Kickout And Return-To-Dig Circuit Diagnostics .......................................... 9015-15-74 Boom Height Kickout And Return-To-Dig Circuit Diagnostic Procedures..........................................9015-15-64 Front And Rear Wiper Circuit Operational Information ....................... 9015-15-75 Front And Rear Wiper Circuit Theory Of Operation............................ 9015-15-76 Front And Rear Wiper Circuit Functional Schematic .......................... 9015-15-77 Front And Rear Wiper Circuit Diagnostics .......................................... 9015-15-78 Front And Rear Wiper Circuit Diagnostic Procedures ........................9015-15-68 Brake Light Circuit Specifications ............ 9015-15-80 Brake Light Circuit Operational Information........................................... 9015-15-80 Brake Light Circuit Theory Of Operation............................................. 9015-15-81 Brake Light Circuit Functional Schematic............................................ 9015-15-82 Brake Light Circuit Diagnostics................ 9015-15-83 Brake Light Circuit Diagnostic Procedures..........................................9015-15-73 Heater/Pressurizer Circuit Operational Information ....................... 9015-15-84 Heater/Pressurizer Circuit Theory Of Operation ........................................ 9015-15-84 Heater/Pressurizer Circuit Functional Schematic .......................... 9015-15-85 Heater/Pressurizer Circuit Diagnostics .......................................... 9015-15-86 Heater/Pressurizer Circuit Diagnostic Procedures..........................................9015-15-76 Air Conditioning Circuit Specifications ...................................... 9015-15-88 Air Conditioning Circuit Operational Information........................................... 9015-15-88 Air Conditioning Circuit Theory Of Operation............................................. 9015-15-88 Air Conditioning Circuit Functional Schematic............................................ 9015-15-89 Air Conditioning Circuit Diagnostics .......................................... 9015-15-90 Air Conditioning Circuit Diagnostic Procedures..........................................9015-15-80 Defroster Pressurization Circuit Operational Information ....................... 9015-15-93 Defroster Pressurization Circuit Theory Of Operation............................ 9015-15-93 Defroster Pressurization Circuit Functional Schematic .......................... 9015-15-94 Defroster Pressurization Circuit Diagnostics .......................................... 9015-15-95 Defroster Pressurization Circuit Diagnostic Procedures ........................9015-15-85 Continued on next page
TM1529 (27JUN17)
9015-3
544G, 624G, 644G Loader
062717
PN=3
Contents
Page
Page
Turn Signal And 4-Way Flasher Circuit Operational Information............ 9015-15-96 Turn Signal And 4-Way Flasher Circuit Theory Of Operation................. 9015-15-97 Turn Signal And 4-Way Flasher Circuit Functional Schematic ............... 9015-15-98 Turn Signal And 4-Way Flasher Circuit Diagnostics............................... 9015-15-99 Turn Signal And 4-Way Flasher Circuit Diagnostic Procedures ........................9015-15-89 Cab And Canopy Work Light Circuit Operational Information ..................... 9015-15-100 Cab And Canopy Work Light Circuit Theory Of Operation.......................... 9015-15-100 Cab And Canopy Work Light Circuit Functional Schematic ........................ 9015-15-101 Cab And Canopy Work Light Circuit Diagnostics ........................................ 9015-15-102 Cab And Canopy Work Light Circuit Diagnostic Procedures ........................9015-15-92 Drive Light/Dome Light Circuit Operational Information ..................... 9015-15-103 Drive Light/Dome Light Circuit Theory Of Operation.......................... 9015-15-103 Drive Light/Dome Light Circuit Functional Schematic ........................ 9015-15-104 Drive Light/Dome Light Circuit Diagnostics ........................................ 9015-15-105 Drive Light/Dome Light Circuit Diagnostic Procedures ........................9015-15-95 Door Release/Radio/Horn/Rotary Beacon Circuit Operational Information......................................... 9015-15-108 Door Release/Radio/Horn/Rotary Beacon Circuit Theory Of Operation........................................... 9015-15-108 Door Release/Radio/Horn/Rotary Beacon Circuit Functional Schematic.......................................... 9015-15-109 Door Release/Radio/Horn/Rotary Beacon Circuit Diagnostics................ 9015-15-110 Door Release/Radio/Horn/Rotary Beacon Circuit Diagnostic Procedures........................................9015-15-100 Pin Disconnect/Ride Control/Spare Circuit Operational Information.......... 9015-15-112 Pin Disconnect/Ride Control/Spare Circuit Theory Of Operation............... 9015-15-113 Pin Disconnect/Ride Control/Spare Circuit Functional Schematic ............. 9015-15-114 Pin Disconnect/Ride Control/Spare Circuit Diagnostics............................. 9015-15-115 Pin Disconnect/Ride Control/Spare Circuit Diagnostic Procedures ...............9015-15-105
Check Electrolyte Level and Terminals ..9015-20-3 Procedure For Testing Batteries ................ 9015-20-4 Using Booster Batteries—12 Volt System................................................... 9015-20-5 Starter Operation ....................................... 9015-20-6 Alternator Operation—95 Amp Or 135 Amp Bosch ..................................... 9015-20-8 Accessing Monitor Service Code Display................................................... 9015-20-9 Monitor Service Code Interpretation ....................................... 9015-20-11 Program Monitor Display To Match Machine ............................................... 9015-20-11 Calibrate Tachometer .............................. 9015-20-13 Transmission Electrical Circuit Test Procedure ............................................ 9015-20-16 Jumper Wire For Display Monitor ............ 9015-20-18 Replace CPC, Large MATE-N-LOK and METRIMATE™ Pin Type Connectors .......................................... 9015-20-19 Transmission Sensor Adjustment............ 9015-20-20 Disconnecting Tab Retainer Connectors .......................................... 9015-20-21 Secondary Steering Controller Bench Test........................................... 9015-20-21
Group 20—References Battery Specifications ................................ 9015-20-1 Battery Operation ...................................... 9015-20-1 Diagnose Battery Malfunctions.................. 9015-20-2 Batteries TM1529 (27JUN17)
9015-4
544G, 624G, 644G Loader
062717
PN=4
Group 05
System Information Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic
3. Put transmission control lever in 1st forward. 4. Remove solenoid cover.
NOTE: When not sure if problem is electrical or hydraulic, perform the following procedure.
NOTE: To check solenoid voltage, put voltmeter probes across the two terminals of each solenoid connector.
1. Remove clutch cutoff (CCO) and park brake diodes (located next to transmission controller). This will allow the transmission control system to energize the solenoids with the engine off and the park brake engaged.
5. Check voltage at solenoids M2, M3, and M4.
2. Turn key to ON position. DO NOT start engine.
6. Put transmission control lever in 1st reverse. 7. Check voltage at solenoid M1. 8. If voltage is correct for all solenoids, problem is hydraulic. TX,9015,TJ44 -19-21NOV97-1/1
TM1529 (27JUN17)
9015-05-1
544G, 624G, 644G Loader
062717
PN=157
System Information
T8399AA —19—16FEB95
Example Of Simple Electrical Test To Find Problem
Continued on next page
TM1529 (27JUN17)
9015-05-2
TX,9015,DU1531 -19-19JAN95-1/2
544G, 624G, 644G Loader
062717
PN=158
T8399AB —19—27JAN95
System Information
TX,9015,DU1531 -19-19JAN95-2/2
TM1529 (27JUN17)
9015-05-3
544G, 624G, 644G Loader
062717
PN=159
System Information
Visually Inspect Electrical System
burned insulation. Put your hand on the alternator. Heat in these parts when the unit has not been operated for some time is a sure clue to charging circuit problems.
Make the following visual electrical inspection prior to starting the tractor after receiving customer complaint: 1. Look for bare wires that could ground a component or short across to another component. 2. Look for missing or worn conduit. This could indicate a wire problem. 3. Look for loose or broken connectors and wires. 4. Inspect batteries for:
7. If your visual inspection does not indicate the possible malfunction, but your inspection does indicate that the machine can be run, turn the key switch to the IGN position. Try out the accessory circuits, indicator lights, gauge lights, etc. How does each of these components work? Look for sparks or smoke which might indicate shorts. 8. Start machine. Check all gauges for good operation and check to see if system is charging or discharging.
• Corroded terminals • Loose terminals or battery posts • Dirty condition • Damp condition • Cracked case • Proper electrolyte level
9. In general, look for anything unusual. Many electrical failures cannot be detected even if the machine is started. Therefore, a systematic and complete inspection of the electrical system is necessary.
5. Check alternator belt tension. 6. After machine has been shut down for five minutes inspect for overheated parts. They will often smell like TX,901505,QQ369 -19-12JAN95-1/1
TM1529 (27JUN17)
9015-05-4
544G, 624G, 644G Loader
062717
PN=160
System Information
T7713AD —19—27FEB92
Electrical Circuit Malfunctions
A—Battery B—Fuse
C—Switch D—Light
E—Ground
• After the component.
Malfunctions
Component malfunctions can easily be confused with circuit malfunctions. Therefore, care must be exercised when isolating the cause of a problem.
1. There are four common circuit malfunctions.
• High-Resistance Circuit • Open Circuit • Grounded Circuit • Shorted Circuit 2. Three sections in a simple circuit where these malfunctions can occur;
• Before the controlling switch (C). • Between the controlling switch and before the
Example: Light does not operate or is dim when switch is turned ON, until switch connector is disconnected and reconnected. Reason: High resistance caused by a dirty switch connector, caused a voltage drop which prevented the proper amount of current from flowing to the light.
component, light (D).
TX,9015,DY283 -19-17APR96-1/1
TM1529 (27JUN17)
9015-05-5
544G, 624G, 644G Loader
062717
PN=161
System Information
T7713AG —19—26FEB92
High Resistance Circuit
A—Battery B—Fuse C—Switch D—Switch Terminal
E—High Resistance F— Harness Connector
G—Light Terminal H—Light I— Ground
A high resistance circuit can result in slow, dim or no component operation.
If less than battery voltage is measured, check again closer to switch.
Examples: Loose, corroded, dirty or oily terminals. Wire size too small. Strands broken inside the wire. Poor ground connection to frame.
If battery voltage is measured, check closer to ground to locate point of voltage drop. The example shows high resistance (E) between switch and harness connector.
To locate the cause of high resistance:
Repair circuit as required. In the example, strands were broken inside the wire, replace that section of wire.
With switch (C) ON, check for battery voltage between switch and ground (I) at an easily accessible location, like harness connector (F).
Repeat check-out procedure after repair. TX,901505,RP968 -19-12JAN95-1/1
TM1529 (27JUN17)
9015-05-6
544G, 624G, 644G Loader
062717
PN=162
System Information
T7713AF —19—27FEB92
Open Circuit
A—Battery B—Fuse C—Switch D—Switch Terminal
E—Harness Connector F— Open Circuit
G—Light Terminal H—Light I— Ground
An open circuit will result in no components operating. Fuse may or may not be blown.
If battery voltage is measured, inspect connector pins. If pins are OK check for voltage at light terminal (G).
Example: Broken wire, disconnected component terminal, pins inside a connector not making contact, blown fuse, open circuit breaker, failed switch or component, or a disconnected ground wire.
In the example, zero voltage will be measured at light terminal, indicating a broken wire between harness connector and light terminal.
To locate an open circuit:
If battery voltage had been measured, the next check for voltage would be at ground connection (I).
Check fuse. If blown, replace and operate circuit. If fuse blows a second time, continue check. With switch (C) ON check for battery voltage at switch terminal (D). If no voltage is measured, check switch, fuse and wiring to battery.
Normal measured voltage at a ground connection should be 0.0 to 0.5 volts. If battery voltage is measured, poor connection to frame or broken wire is indicated. When problem is located, repair as needed then repeat last check.
If battery voltage is measured, check for voltage closer to ground at harness connector (E). If no voltage is measured, wire may be broken between switch and connector. TX,901505,RP964 -19-12JAN95-1/1
TM1529 (27JUN17)
9015-05-7
544G, 624G, 644G Loader
062717
PN=163
System Information
T7713AE —19—27FEB92
Grounded Circuit
A—Battery B—Fuse C—Fuse Terminal D—Switch
E—Switch Terminal F— Harness Connector G—Harness Connector
H—Grounded Circuit I— Light (Component) Terminal
J— Light K—Ground
If no component operates, the fuse is blown and replacement fuses blow immediately or the circuit breaker is open and reopens when reset, a grounded circuit exists. (Example: power wire contacting frame or other metal component). A wire may be pinched or insulation may be worn from a wire.
If continuity to ground does not exist, disconnect ground (K) from frame. Measure continuity to ground at harness connector (G). This checks harness from harness connector to ground terminal. In the example continuity to ground will exist because circuit is grounded (wire is pinched) at (H).
To isolate the location of a grounded circuit:
If continuity exists, disconnect circuit at light terminal (I) and measure continuity to ground on light terminal. This checks harness from light to ground terminal. In the example continuity will not exist, indicating a grounded circuit between the light and harness connector (G).
If circuit is grounded between battery and fuse, wire will be burned and circuit will be open, fuse will not be blown. If fuse is blown, remove fuse from circuit, disconnect circuit near its center, such as harness connector (F), turn switch (D) ON, check for continuity to ground at harness connector (F). This will check harness from harness connector to fuse.
Repeat check-out procedure after repair.
If continuity to ground is measured, there is a pinched or bare wire between fuse (C) and harness connector (F). TX,901505,RP969 -19-12JAN95-1/1
TM1529 (27JUN17)
9015-05-8
544G, 624G, 644G Loader
062717
PN=164
System Information
T7713AH —19—27FEB92
Shorted Circuit
A—Battery B—Fuse C—Fuse D—Switch E—Switch Terminal
F— Switch G—Harness Connector H—Shorted Circuit
I— Harness Connector J— Light K—Light Terminal
A shorted circuit causes components in separate circuits to operate when a switch in either circuit is turned ON. (Example: two harnesses rubbing together until insulation is worn through allowing bare wires to touch.) Components can also become shorted. However, shorted components will usually blow the fuse. To locate a shorted circuit: Turn Switch (F) ON then OFF, turn switch (D) ON then OFF, both lights (J and L) will be ON when either switch (D or F) is ON. Turn switch (F) ON. Both lights (J and L) will be ON, only light (L) should be ON.
L— Light M—Ground N—Ground
Disconnect circuit at convenient places like harness connectors (G), (I) and light terminal (K) until light (J) goes OFF. The short circuit will be between the last two places the circuit was disconnected. In the example, it is between harness connectors (G and I). Light (J) will go OFF when harness connector (I) is disconnected. Inspect harness between connectors (G and I). Repair or replace wires and harnesses as needed. Install tie bands and clamps on harnesses as required to prevent future failures. Repeat check-out procedure after repair.
Disconnect wire from switch of component that should not be ON. In the example, disconnect wire from terminal (E) at switch (D). Light (J) remains ON. TX,901505,RP970 -19-12JAN95-1/1
TM1529 (27JUN17)
9015-05-9
544G, 624G, 644G Loader
062717
PN=165
System Information
Multimeter The multimeter is an autoranging digital display that allows very accurate readings to be taken. F— Current AC (Alternating Current) G—Current DC (Direct Current) H—Voltage, Resistance, Diode/Continuity (Red Lead Input) I— Ground (Black Lead Input) J— Current/Amps (Red Lead Input)
T8074AA —19—03SEP93
A—Display B—Voltage AC (Alternating Current) C—Voltage DC (Direct Current) D—Resistance E—Diode Test/Continuity
TX,901505,QQ374 -19-12JAN95-1/1
TM1529 (27JUN17)
9015-05-10
544G, 624G, 644G Loader
062717
PN=166
System Information
T7719AA —19—05MAR92
Seven Step Electrical Test Procedure
A—Battery Ground B—Battery C—Battery Side Of Fuse Or Circuit Breaker
D—Fuse Or Circuit Breaker E—Component Side Of Fuse Or Circuit Breaker
F— Switch G—Battery Side Of Component Terminal H—Light (Component)
I— Ground Side Of Component Terminal J— Component Ground
Step 1—Switch ON Check battery side of circuit breaker (C) for battery voltage
Battery voltage normal. Go to Step 2. Low voltage, repair high resistance. Open circuit from battery.
Step 2—Switch OFF Check component side of circuit breaker for battery voltage
Battery voltage normal. Go to Step 4. Low voltage, repair high resistance. No voltage. Go to Step 3.
Step 3—Switch OFF Check component side of circuit breaker for continuity to ground
Continuity to ground. Repair grounded circuit at or before switch. No continuity to ground, replace circuit breaker.
Step 4—Switch ON Check component side of circuit breaker for battery voltage
Battery voltage normal. Go to Step 6. Low voltage, repair high resistance. No voltage. Go to Step 5.
Step 5
a
Disconnect wire at battery side of component (G). Switch ON. Check wire at (G) for battery voltage
Battery voltage, repair component. No voltage, repair grounded or open circuit at or after switch.
Step 6—Switch ON Check lead to component at (G) for battery voltage
Battery voltage normal. Go to Step 7. Low voltage, repair high resistance in circuit between fuse and component. No voltage, repair high resistance or open circuit between fuse and component.
Continued on next page
TM1529 (27JUN17)
9015-05-11
TX,9015,QQ1697 -19-12JAN95-1/2
544G, 624G, 644G Loader
062717
PN=167
System Information Step 7—Switch ON No voltage, good continuity to ground. Repair component. Voltage, poor continuity to ground. Repair high resistance or open ground circuit.
Check ground wire of component at (I) for voltage
a
A multimeter will not apply a load to the circuit at step 5. The multimeter result is tested as a voltage condition in the result column. TX,9015,QQ1697 -19-12JAN95-2/2
Wiring Diagram And Schematic Information System Functional Schematic Diagram- The System Functional Schematic is a schematic diagram of the complete machine. All harnesses are identified by letter/number designation and description (W1 Engine Harness, W2 Dash Harness Etc.). Each wire is identified by number and/or color (G01 BLK, R02 Red, RED/WHT, BLU/GRN Etc.). All components are identified by letter/number designation, description and are represented by a schematic symbol. Component letter/number designation, (K1 Start Relay, S1 Key Switch, B9 Horn, Etc.) will indicate that component throughout the manual. The System Functional Schematic Diagram is divided into Sections. Each section contains one or more electrical circuits. Each section is indicated by a number and circuit (SE1 CHARGING CIRCUIT, SE2 STARTING CIRCUIT etc.). Wiring Diagram- The Wiring Diagram shows each wiring harness, wire color, wire destination, harness connectors and schematic symbols for each electrical component
connected to that harness. Harnesses are identified by the same letter/number designation and description used in the System Functional Schematic Diagram (W1 Engine Harness, W2 Dash Harness Etc.). Each component schematic symbol will be identified by the same letter/number designation used in the System Functional Schematic Diagram. Harness connectors will be identified by a letter/number designation and description (X1 CAB HARNESS TO ENGINE HARNESS CONNECTOR, X3 DASH HARNESS TO HEATER BLOWER HARNESS CONNECTOR Etc.). Component Location Diagram- The Component Location Diagram is a pictorial view by harness showing location of all electrical components, connectors, harness main ground locations and harness band and clamp location. Each component will be identified by the same identification letter/number and description used in the System Functional Schematic Diagram. TX,901505,RP548 -19-06JUL94-1/1
TM1529 (27JUN17)
9015-05-12
544G, 624G, 644G Loader
062717
PN=168
System Information
T7502CE —19—29MAY91
Reading A System Functional Schematic
A—Power Wires B—Continuity Chart C—Component Schematic Symbol
D—Component Identification Code E—Component Name
The System Functional Schematic is made up of sections which contain one or more Subsystem Functional Schematic laid out side by side in a logical sequence of related functions. Each Subsystem is a major group of components like starting components or charging components (H). Sections are named to reflect that group of components (G). The System Functional Schematic is formatted with power supply wires (A) shown across the top of the drawing and ground wires (F) across the bottom. The diagram contains no harness or connector information.
F— Ground Wires G—Circuit Name H—Section Number
identification code (D). A continuity chart (B) is included for each multi-terminal switch. The same names and identification letter codes are used on all machine drawings—the System Functional Schematic, System Wiring and Harness Diagram, and the System Component Location Drawing. Components and connectors can easily be cross-referenced from one drawing to another. See Group -10 for Component Identification Legend .
Each electrical component is shown by a schematic symbol (C), the component name (E), and a component TX,9015,RP751 -19-12APR94-1/1
TM1529 (27JUN17)
9015-05-13
544G, 624G, 644G Loader
062717
PN=169
System Information
T7713AI —19—17MAR92
Reading A Wiring Diagram
A—Harness Connector Letter/Number Identification B—Component Letter/Number Identification C—Component Connector Pin Number or Letter
D—Component Connector E—Wire Number and/or Color F— Component(s) Identification Number/Letter Wire is Routed To G—Harness Identification Letter/Number and Description
Each harness on the machine is drawn showing components, connectors and wires. Harnesses (G) are identified by a letter/number designation and description, (W3 PARK BRAKE HARNESS Etc.). Each component (B) is represented by a schematic symbol and is identified by the same letter/number designation and description used in the System Functional Schematic. Components with integral connectors (D) have pin number/letters indicated (C). Wires from harness to components are identified by letter/number designation (E). Component identification letter/number (F) indicates component wire is routed to.
H—Wiring Harness I— Component(s) Identification Number/Letter Wire is Routed To J— Wire Number and/or Color K—Harness Connector Pin Number or Letter
BRAKE HARNESS TO DASH HARNESS CONNECTOR Etc.). Harness connector description indicates which harnesses connect together. Connector pin numbers or letters (K) are indicated as they are marked on the connector. Wires attached to each connector pin are identified by number and/or color designation (J). Component identification number/letter (I) indicates destination of each wire. Harness, harness connector and component identification letter/numbers and description are the same as used on the System Functional Schematic.
Main harness connectors (A) are identified by a letter/number designation and description, (X2 PARK TX,9015,RP971 -19-12JAN95-1/1
TM1529 (27JUN17)
9015-05-14
544G, 624G, 644G Loader
062717
PN=170
System Information
T120028 —19—03FEB99
Electrical Schematic Symbols
Continued on next page
TM1529 (27JUN17)
9015-05-15
TX,901505,RP983 -19-26OCT93-1/4
544G, 624G, 644G Loader
062717
PN=171
T120029 —19—03FEB99
System Information
Continued on next page
TM1529 (27JUN17)
9015-05-16
TX,901505,RP983 -19-26OCT93-2/4
544G, 624G, 644G Loader
062717
PN=172
T120030 —19—03FEB99
System Information
Continued on next page
TM1529 (27JUN17)
9015-05-17
TX,901505,RP983 -19-26OCT93-3/4
544G, 624G, 644G Loader
062717
PN=173
T120031 —19—22MAR99
System Information
TX,901505,RP983 -19-26OCT93-4/4
TM1529 (27JUN17)
9015-05-18
544G, 624G, 644G Loader
062717
PN=174
Group 10
System Diagrams Component Identification Table Each component (electrical device) and main connector will have and identification letter assigned to it. A number
is added to the letter to separate and indicate the total components within that letter group.
Identification Letter
Type
Examples
A
System, subassembly, parts group
Control units, trigger boxes, two-way radios, logic module, FNR logic module
B
Transducer for conversion of non-electrical variables to electrical and vice versa
Speed sensors, pressure sensors, pressure switches horns, sensors, pickups, limit-value sensors, pulse generators, loudspeakers, inductive pickups, probes, air-flow sensors, oil-pressure switches, temperature sensors, ignition-voltage pickups
C
Condenser, capacitor
Condensers and capacitors, general
D
Binary device, memory
Digital devices, integrated circuits, pulse counters, magnetic tape recorders
E
Various devices and equipment
Heating devices, air conditioners, light, headlights, spark plugs, ignition distributors
F
Protection device
Release mechanisms, polarity protection devices, fuses, current protection circuits
G
Power supply, generator
Batteries, generators, alternators, charging units
H
Monitor, alarm, signalling device
Audible alarms, indicator lights, turn-signal lights, brake lights, alarms, warning lights, buzzers
K
Relay
Battery relays, turn-signal relays, solenoid switches, starting relays, warning flashers
L
Inductor
Choke coils, coils, windings
M
Motor
Blower motors, fan motors, starter motors
N
Regulator, amplifier
Regulators (electronic or electromechanical), voltage stabilizers
P
Measuring instrument
Ammeter, diagnostic connectors, tachometers, fuel gauge, pressure gauges, measuring points, test points, speedometers
R
Resistor
Flame glow plugs, sheathed-element flame glow plugs, glow plugs, heating resistors, NTC resistors, PTC resistors, potentiometers, regulating resistors
Identification Letter
Type
Examples
S
Switch
Switches and pushbuttons, general key switch, light switch, horn switch, flasher switch
T
Transformer
Ignition coil, ignition transformer
U
Modulator, converter
DC transformers
V
Semiconductor, electron tubes
Transistors, diodes, electron tubes, thyristors, zener diodes
W
Transmission path, conductor,
Antennas, shielding components, shielded conductors,
antenna
cable harnesses, conductors, ground conductors
X
Terminal, plug, plug and socket
connection
electrical line couplers, line connectors, sockets, plugs, terminals, plug-and-socket connections
Y
Electrically actuated mechanical
device
valves, electromagnetic clutches and brakes, air valves, fuel pumps, solenoids, switching valves, start valves, locking systems
Z
Electrical filter
Terminal studs, electrical connections, connectors
Permanent magnets, (solenoid-operated) injection
Interference suppression filters TX,901505,QQ381 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-10-1
544G, 624G, 644G Loader
062717
PN=175
System Diagrams
T111397 —19—19SEP97
Fuse Block
IMPORTANT: Use fuses and circuit breakers with the correct amperage rating to prevent electrical system damage caused by circuit overload.
The fuse block is located in the air conditioning and heater panel, behind the pilot controllers at right side of cab. It is accessed through panel door from outside of cab. TX,9015,DU1534 -19-10SEP93-1/1
TM1529 (27JUN17)
9015-10-2
544G, 624G, 644G Loader
062717
PN=176
System Diagrams
Wiring And Schematic Diagrams Legend NOTE: A1—Transmission Controller (SE5,W5)
• A1 indicates component identification number. • Transmission Controller indicates component name.
• SE5 indicates section number of system functional schematic where component is located.
• W5 indicates harness wiring diagram and
harness component location drawings where component is located.
(SE4,W5)
K1—Accessory Relay (SE2,W5)
• K1 indicates component identification number. • Accessory Relay indicates component name. • SE2 indicates section number of system functional schematic where component is located.
• W5 indicates harness wiring diagram and
(SE13,W5)
W1—Antenna (Cab machines only) (SE23,W7)
(SE16,W5)
• W1 indicates component identification number. • Antenna indicates component name. • SE23 indicates section number of system
• F18—A/C Condenser Motor Circuit Breaker (20 Amp) (SE17,W5)
functional schematic where component is located. W7 indicates harness wiring diagram and harness component location drawings where component is located.
(SE21,W5)
• F22—Drive and Cab Work Light Switch Fuse (5 Amp) • F23—Drive Light Circuit Breaker (20 Amp) (SE22,W5) • F24—Unswitched Radio, Dome Light and Door Release Circuit Breaker (10 Amp) (SE22,W5)
brake is on) (SE4,W9)
• B2—Magnetic Pickup (SE5,W4) • B3—Secondary Steering Pressure Switch (SE8,W5) • B5—Hydraulic Oil Filter Restriction Switch (Closed when restricted) (SE10,W9)
• B6—Air Filter Restriction Switch (Closed when restricted) (SE10,W10)
• B7—Service Brake Pressure Switch (Closed when pressure low) (SE10,W5)
• B8—Engine Oil Pressure Switch (Closed when pressure low) (SE10,W10)
• B9—Transmission Oil Pressure Switch (Closed when pressure low) (SE10,W4)
• B10—Engine Coolant Level Switch (In radiator) (Closed when level low) (SE10,W9)
• B11—Transmission Oil Temperature Sender (SE12,W4) • B12—Engine Coolant Temperature Sender (SE12,W10) • B13—Fuel Level Sender (SE12,W9) • B14—Brake Light Pressure Switch (SE15,W5) • B15—Freeze Control Temperature Cycling Switch (Opens when freezing) (SE17,W8)
• B16—A/C Low Pressure Switch (Opens when pressure • B17—A/C High Pressure Switch (Opens when pressure above maximum) (SE17,W12)
• F19—Defroster Fan Fuse (20 Amp) (SE18,W5) • F20—Flasher Fuse (15 Amp) (SE19,W5) • F21—Cab Work Light Circuit Breaker (25 Amp) (SE21,W5)
• A1—Transmission Controller (SE5,W5) • A2—Secondary Steering Controller (SE8,W5) • A3—Pilot Controller (SE13,W5) • A4—Radio (Cab machines only) (SE23,W7) • B1—Park Brake Pressure Switch (Closed when park
below minimum) (SE17,W8)
• F6—Neutral Start Fuse (5 Amp) (SE6,W5) • F7—Secondary Steering Fuse (5 Amp) (SE8,W5) • F8—Differential Lock Fuse (5 Amp) (SE9,W5) • F9—Boom Down Fuse (5 Amp) (SE9,W5) • F10—Unswitched Monitor Fuse (5 Amp) (SE10,W5) • F11—Switched Monitor Fuse (5 Amp) (SE10,W5) • F12—Return-to-Dig and Breakout Fuse (5 Amp) • F13—Front Wiper Circuit Breaker (10 Amp) (SE14,W5) • F14—Rear Wiper Circuit Breaker (10 Amp) (SE14,W5) • F15—Brake Light Fuse (15 Amp) (SE15,W5) • F16—Heater/Pressurizer Fan Fuse (30 Amp)
harness component location drawings where component is located.
•
• B18—Speaker (Cab machines only) (SE23,W7) • B19—Hi Note Horn (SE23,W3) • B20—Low Note Horn (SE23,W3) • F1—Alternator Excitation Fuse (10 Amp) (SE2,W5) • F2—Start Aid Fuse (10 Amp) (SE3,W5) • F3—Fuel Shutoff Fuse (5 Amp) (SE3,W5) • F4—Transmission Controller Fuse (5 Amp) (SE4,W5) • F5—Park Brake and Backup Alarm Fuse (5 Amp)
• F25—Switched Radio Fuse (5 Amp) (SE23,W5) • F26—Horn Fuse (15 Amp) (SE23,W5) • F27—Rotary Beacon Fuse (10 Amp) (SE24,W5) • F28—Spare (SE24,W5) • F29—Pin Disconnect Fuse (5 Amp) (SE24,W5) • F30—Ride Control Fuse (5 Amp) (SE24,W5) • F31—Fuse Block (W5) • G1—Battery (SE1,W10) • G2—Emergency Starting Terminal (SE1,W10) • G3—Alternator (95 Amp-12 Volt) (SE2,W10) • G4—Alternator (135 Amp-12 Volt) (SE2,W10) • H1—Backup Alarm (SE4,W9) • H2—Display Monitor (SE11,W5) • H3—Monitor Alarm (SE12,W5) • H4—Right Brake Light (SE15,W11) • H5—Left Brake Light (SE15,W11) • H6—Left Front Turn Signal Light (SE20,W3) • H7—Left Rear Turn Signal Light (SE20,W11) • H8—Right Front Turn Signal Light (SE20,W3) • H9—Right Rear Turn Signal Light (SE20,W11) • H10—Left Front Work Light (SE21,W6,W7) • H11—Right Front Work Light (SE21,W6,W7) • H12—Left Rear Work Light (SE21,W6,W7) • H13—Right Rear Work Light (SE21,W6,W7) • H14—Left Front Drive Light (SE22,W3) • H15—Right Front Drive Light (SE22,W3)
Continued on next page
TM1529 (27JUN17)
9015-10-3
TX,9015,DU1669 -19-12OCT93-1/3
544G, 624G, 644G Loader
062717
PN=177
System Diagrams
• H16—Left Tail Light (SE22,W11) • H17—Right Tail Light (SE22,W11) • H18—License Plate Light (Optional) (SE22,W11) • H19—Dome Light (Cab machines only) (SE22,W7) • H20—Map Light (Cab machines only) (SE22,W7) • H21—Rotary Beacon Light (If equipped) (SE24,W6,W7) • K1—Accessory Relay (SE2,W5) • K2—Accessory Relay (SE2,W5) • K3—Backup Alarm Relay (SE4,W5) • K4—Neutral Start Circuit Relay (SE6,W5) • K5—Neutral Start Circuit Relay (SE6,W5) • K6—Start Relay (SE6,W5) • K7—Park Brake Reset Relay (SE7,W5) • K8—Brake Light Relay (SE15,W5) • K9—Defroster Pressurization Relay (SE16,W5) • K10—A/C Condenser Motor Relay (SE17,W5) • K11—Flasher (SE19,W5) • K12—Cab Work Light Relay (SE21,W5) • K13—Drive Light Relay (SE22,W5) • K14—Ride Control Reset Relay (SE24,W15) • M1—Starter Motor (SE1,W10) • M2—Secondary Steering Pump Motor (SE8,W13) • M3—Front Wiper Motor (SE14,W5) • M4—Front Washer Pump Motor (SE14,W10) • M5—Rear Wiper Motor (SE14,W8) • M6—Rear Washer Pump Motor (SE14,W10) • M7—Pressurizer Fan Motor (SE16,W8) • M8—Condenser Motor (SE17,W5) • M9—Condenser Motor (SE17,W5) • M10—Defroster Fan Motor (SE18,W5) • R1—Heater/Pressurizer Resistor (SE16,W8) • R2—Defroster Resistor (SE18,W8) • S1—Key Switch (SE1,W5) • S2—Manual Battery Disconnect (Optional) (SE1,W9,W10)
• S3—Start Aid Push Button Switch (SE3,W5) • S4—Quickshift Switch (SE4,W5) • S5—Clutch Cutoff Pedal Switch (SE4,W5) • S6—Clutch Cutoff Enable Switch (SE4,W5) • S7—Shifter Switch (SE5,W5) • S8—Park Brake Switch (SE7,W5) • S9—Differential Lock Pedal Switch (SE9,W5) • S10—Boom Down Switch (SE9,W5) • S11—Boom Height Kickout Switch (SE13,W3) • S12—Return-to-Dig Switch (SE13,W3) • S13—Front Wiper/Washer Switch (SE14,W5) • S14—Rear Wiper/Washer Switch (SE14,W5) • S15—A/C Shutoff Switch (SE17,W8) • S16—Heater/Pressurizer Fan Switch (SE16,W8) • S17—Defroster Fan Switch (SE18,W8) • S18—Turn Signal Switch (SE19,W2) • S19—4-Way Flasher Switch (SE19,W5) • S20—Cab Work Light Switch (SE21,W5) • S21—Drive Light Switch (SE22,W5) • S22—Dome Light Switch (Cab machines only) (SE22,W7)
• V1—Alternator Excitation Diode (5 Amp) (SE2,W10) • V2—Load Dump Suppression Zener Diode (Limits peak voltage of system) (SE2,W5)
• V3—Reverse Voltage Protection Diode (5 Amp) (SE2,W5)
• V4—Start Aid Diode (1 Amp) (SE3,W10) • V5—Engine Fuel Shutoff Hold-In Diode (1 Amp) (SE3,W10)
• V6—Park Brake Clutch Cutoff Diode (5 Amp) (SE4,W5) • V7—Clutch Cutoff Diode (5 Amp) (SE4,W5) • V8—Start Relay Coil Suppression Diode (1 Amp) (SE6,W5)
• V9—Engine Starter Coil Suppression Diode (5 Amp) (SE6,W5)
• V10—Park Brake Diode (5 Amp) (SE7,W5) • V11—Park Brake Release Diode (1 Amp) (SE7,W9) • V12—Differential Lock Diode (1 Amp) (SE9,W9) • V13—Boom Down Diode (1 Amp) (SE9,W9) • V14—A/C Clutch Diode (1 Amp) (SE17,W10) • V15—4-Way Flasher Diode (5 Amp) (SE20,W5) • V16—4-Way Flasher Diode (5 Amp) (SE20,W5) • V17—Door Release Diode (Cab machines only) (1 Amp) (SE23,W7)
• V18—Pin Disconnect Diode (1 Amp) (SE24,W16) • V19—Ride Control Diode (1 Amp) (SE24,W15) • V20—Fuel Shutoff Pull-In Diode (5 Amp) (644G) (SE3,W10)
• W1—Antenna (Cab machines only) (SE23,W7) • W2—Steering Column Harness • W3—Loader Frame Harness • W4—Transmission Harness • W5—Load Center Harness • W6—Canopy Work Lights Harness • W7—Cab Work Lights Harness • W8—Left Panel Temperature Control Harness • W9—Engine Frame Harness • W10—Engine Harness • W11—Rear Frame Harness • W12—A/C Compressor Harness • W13—Secondary Steering Harness • W14—Start Aid Lead • W15—Engine Frame Ground for EMI • W16—Cab Leg Ground • W17—Front Console Ground • W18—Front of Cab Ground • W19—Right Rear Cab Leg Ground • W20—Right Rear Cab Leg Ground (Transmission Controller)
• W21—Cab Ground (Transmission Controller Case) • W22—Cab Leg Ground • W23—Cab Leg Ground • W24—Canopy Roof Ground • W25—Cab Roof Ground • W26—Left Panel Temperature Control Ground • W27—Right Side Engine Frame Ground • W28—Engine Frame Ground From Starter Motor • W29—Engine Frame in Battery Box ground • W30—Engine Ground From A/C Compressor Clutch • X1—Steering Column Harness to Load Center Harness
• S23—Map Light Switch (Cab machines only) (SE22,W7) • S24—Door Release Switch (SE23,W8) • S25—Horn (Push button switch) (SE23,W2) Connector • S26—Rotary Beacon Switch (SE24,W5) • S27—Pin Disconnect Switch (SE24,W16) • X2—Load Frame Harness to Load Center Harness Connector • S28—Ride Control Switch (SE24,W15) Continued on next page TX,9015,DU1669 -19-12OCT93-2/3 TM1529 (27JUN17)
9015-10-4
544G, 624G, 644G Loader
062717
PN=178
System Diagrams
• X3—Load Frame Harness to Load Center Harness
• X24—Engine Harness to Secondary Steering Harness
•
• X25—Engine Harness to Start Aid Lead • X26—Ride Control Harness to Loader Frame Harness
• • • • • • • • • • • • • • • • • • •
Connector X4—Transmission Harness to Load Center Harness Connector X5—Transmission Harness to Load Center Harness Connector X6—Canopy/Cab Work Lights Harness to Load Center Harness Connector X7—Rotary Beacon to Load Center Harness Connector X8—Left Panel Temperature Control Harness to Load Center Harness Connector X9—Left Panel Temperature Control Harness to Load Center Harness Connector X10—Engine Frame Harness to Load Center Harness Connector X11—Engine Frame Harness to Load Center Harness Connector X12—Engine Frame Harness to Load Center Harness Connector X13—Engine Frame Harness to Load Center Harness Connector X14—Engine Frame Harness to Load Center Harness Connector X15—Engine Frame Harness to Load Center Harness Connector X16—Engine Frame Harness to Load Center Harness Connector X17—Engine Frame Harness to Engine Harness Connector X18—Engine Frame Harness to Engine Harness Connector X19—Engine Frame Harness to Rear Frame Harness Connector X20—Engine Frame Harness to Engine Harness Connector X21—Engine Frame Harness to Engine Harness Connector X22—Engine Frame Harness to Engine Harness Connector X23—Engine Harness to A/C Compressor Harness Connector
Connector
Connector
• X27—Ride Control Harness to Load Center Harness Connector
• X28—Ride Control Harness to Load Center Harness Connector
• X29—Pin Disconnect Harness to Load Center Harness Connector
• X30—Transmission Harness to Load Cntr Harness Connector*
• Y1—Start Aid Solenoid (SE3,W14) • Y2—Fuel Shutoff Solenoid (For 544/624) (SE3,W10) • Y3—Fuel Shutoff Solenoid (For 644) (SE3,W10) • Y4—Transmission Control Valve Solenoid (M1) (SE5,W4)
• Y5—Transmission Control Valve Solenoid (M2) (SE5,W4)
• Y6—Transmission Control Valve Solenoid (M3) (SE5,W4)
• Y7—Transmission Control Valve Solenoid (M4) (SE5,W4)
• Y8—Transmission Control Valve Solenoid (M5) (SE5,W4)
• Y9—Park Brake Release Solenoid (SE7,W9) • Y10—Differential Lock Solenoid (SE9,W9) • Y11—Boom Down Solenoid (SE9,W9) • Y12—A/C Compressor Clutch (SE17,W12) • Y13—Door Release Solenoid (Cab machines only) (SE23,W7)
• Y14—Pin Disconnect Solenoid (If equipped) (SE24,W16)
• Y15—Ride Control Solenoid (If equipped) (SE24,W15) • 1Y16—Ride Control Solenoid (SE24,W15) • Y17—Transmission Control Valve Solenoid (M6) (SE5,W4)
1
544G (S.N. 548219—), 624G (S.N. 548398—), 644G (S.N. 548303—). TX,9015,DU1669 -19-12OCT93-3/3
System Functional Schematic Section Legend
• SE1—Battery/Ignition Power Circuit (12 Volt System) • SE2—Alternator and Accessory Power Circuit • SE3—Start Aid and Fuel Control Circuit • SE4—Park Brake Sensing/Clutch Cutoff/Kickdown/Backup Alarm Circuit
• SE5—Transmission Control Circuit • SE6—Start Circuit • SE7—Park Brake Circuit • SE8—Secondary Steering Circuit • SE9—Differential Lock and Boom Down Circuit • SE10—Switch Inputs to Monitor Circuits • SE11—Electronic Monitor Signal Circuits
• SE12—Electronic Monitor/Gauge Input Circuits • SE13—Boom Height Kickout and Return-to-Dig Circuit • SE14—Front and Rear Wiper Circuit • SE15—Brake and Light Circuit • SE16—Heater/Pressurizer Circuit • SE17—Air Conditioner Circuit • SE18—Defroster Pressurization Circuit • SE19—Turn Signal and 4-Way Flasher Circuit • SE20—Turn Signal and 4-Way Flasher Circuit • SE21—Cab Work Light Circuit • SE22—Drive Light/Dome Light Circuit • SE23—Door Release/Radio/Horn/Rotary Beacon Circuit
• SE24—Pin Disconnect/Ride Control/Spare Circuit TX,9015,TJ16 -19-17SEP97-1/1
TM1529 (27JUN17)
9015-10-5
544G, 624G, 644G Loader
062717
PN=179
System Diagrams
T8393AB —19—27JAN95
System Functional Schematic
Continued on next page
TM1529 (27JUN17)
9015-10-6
TX,9015,TJ15 -19-13APR11-1/9
544G, 624G, 644G Loader
062717
PN=180
TM1529 (27JUN17)
T8396AD —19—13APR11
9015-10-7
Continued on next page
System Diagrams
062717
PN=181
544G, 624G, 644G Loader
Battery/Ign, Alternator/Acc, Start Aid/Fuel Ctrl
TX,9015,TJ15 -19-13APR11-2/9
T8396AE —19—13APR11
Continued on next page
TM1529 (27JUN17)
9015-10-8
System Diagrams
062717
PN=182
544G, 624G, 644G Loader
TX,9015,TJ15 -19-13APR11-3/9
TM1529 (27JUN17)
T8396AH —19—08OCT97
9015-10-9
Continued on next page
System Diagrams
062717
PN=183
544G, 624G, 644G Loader
TX,9015,TJ15 -19-13APR11-4/9
T8396AI —19—13APR11
Continued on next page
TM1529 (27JUN17)
9015-10-10
System Diagrams
062717
PN=184
544G, 624G, 644G Loader
TX,9015,TJ15 -19-13APR11-5/9
TM1529 (27JUN17)
T8396AJ —19—13APR11
9015-10-11
Continued on next page
System Diagrams
062717
PN=185
544G, 624G, 644G Loader
TX,9015,TJ15 -19-13APR11-6/9
T8396AK —19—13APR11
Continued on next page
TM1529 (27JUN17)
9015-10-12
System Diagrams
062717
PN=186
544G, 624G, 644G Loader
TX,9015,TJ15 -19-13APR11-7/9
TM1529 (27JUN17)
T8396AL —19—13APR11
9015-10-13
Continued on next page
System Diagrams
062717
PN=187
544G, 624G, 644G Loader
TX,9015,TJ15 -19-13APR11-8/9
T8396AS —19—13APR11
TM1529 (27JUN17)
9015-10-14
System Diagrams
062717
PN=188
544G, 624G, 644G Loader
TX,9015,TJ15 -19-13APR11-9/9
System Diagrams
T8093BB —UN—06DEC93
Steering Column Harness (W2) Wiring Diagram
TX,901510,DU511 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-15
544G, 624G, 644G Loader
062717
PN=189
System Diagrams
T7751BE —19—11SEP92
Steering Column Harness (W2) Component Location
TX,901510,DU512 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-10-16
544G, 624G, 644G Loader
062717
PN=190
TM1529 (27JUN17)
T8397AB —19—13APR11
9015-10-17
Loader Frame Harness (W3) Wiring Diagram
System Diagrams
062717
PN=191
544G, 624G, 644G Loader
TX,9015,DU1577 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-18
544G, 624G, 644G Loader
062717
PN=192
System Diagrams
T8093BD —19—11NOV93
Loader Frame Harness (W3) Component Location
TX,9015,DU1578 -19-07JAN94-1/1
TM1529 (27JUN17)
9015-10-19
544G, 624G, 644G Loader
062717
PN=193
System Diagrams
TM1529 (27JUN17)
9015-10-20
544G, 624G, 644G Loader
062717
PN=194
TM1529 (27JUN17)
T8397AC —19—13APR11
Transmission Harness (W4) Wiring Diagram
9015-10-21
System Diagrams
062717
PN=195
544G, 624G, 644G Loader
TX,9015,DU1706 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-22
544G, 624G, 644G Loader
062717
PN=196
TM1529 (27JUN17)
T8397AD —19—13APR11
9015-10-23
Transmission Harness (W4) Component Location
System Diagrams
062717
PN=197
544G, 624G, 644G Loader
TX,9015,DU1718 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-24
544G, 624G, 644G Loader
062717
PN=198
System Diagrams
TM1529 (27JUN17)
T8397AE —19—08OCT97
9015-10-25
Load Center Harness (W5) Wiring Diagram (Page 1 of 4)
062717
PN=199
544G, 624G, 644G Loader
TX,901510,DU517 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-26
544G, 624G, 644G Loader 062717 PN=200
System Diagrams
TM1529 (27JUN17)
T8397AF —19—13APR11
9015-10-27
Load Center Harness (W5) Wiring Diagram (Page 2 of 4)
062717
PN=201
544G, 624G, 644G Loader
TX,901510,DU642 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-28
544G, 624G, 644G Loader 062717 PN=202
System Diagrams
TM1529 (27JUN17)
T8093BG —19—13APR11
9015-10-29
Load Center Harness (W5) Wiring Diagram (Page 3 of 4)
062717
PN=203
544G, 624G, 644G Loader
TX,901510,DU643 -19-23SEP93-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-30
544G, 624G, 644G Loader 062717 PN=204
TM1529 (27JUN17)
T8397AG —19—13APR11
9015-10-31
Load Center Harness (W5) Wiring Diagram (Page 4 of 4)
System Diagrams
062717
PN=205
544G, 624G, 644G Loader
TX,901510,DU644 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-32
544G, 624G, 644G Loader
062717
PN=206
System Diagrams
T8127AE —UN—06DEC93
Load Center Harness (W5) Component Location
TX,9015,DU1719 -19-07JAN94-1/1
TM1529 (27JUN17)
9015-10-33
544G, 624G, 644G Loader
062717
PN=207
System Diagrams
TM1529 (27JUN17)
9015-10-34
544G, 624G, 644G Loader
062717
PN=208
TM1529 (27JUN17)
T8127AF —19—13APR11
9015-10-35
Load Center Harness (W5) Component Location—Continued (Detail A)
System Diagrams
062717
PN=209
544G, 624G, 644G Loader
TX,9015,DU1600 -19-10NOV93-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-36
544G, 624G, 644G Loader
062717
PN=210
System Diagrams
T8397AH —19—27JAN95
Load Center Harness (W5) Component Location—Continued (Detail B)
TX,901510,DU781 -19-23JAN95-1/1
TM1529 (27JUN17)
9015-10-37
544G, 624G, 644G Loader
062717
PN=211
System Diagrams
T8089AI —UN—05NOV93
Load Center Harness (W5) Component Location—Continued (Detail C)
TX,9015,DU1601 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-38
544G, 624G, 644G Loader
062717
PN=212
System Diagrams
T8397AI —19—30JAN95
Load Center Harness (W5) Component Location—Continued (Detail D)
TX,901510,DU783 -19-23JAN95-1/1
TM1529 (27JUN17)
9015-10-39
544G, 624G, 644G Loader
062717
PN=213
System Diagrams
T111396 —19—19SEP97
Load Center Harness (W5) Component Location—Continued (Detail E)
Detail E TX,901510,DU805 -19-02NOV92-1/1
TM1529 (27JUN17)
9015-10-40
544G, 624G, 644G Loader
062717
PN=214
System Diagrams
T8127AG —UN—06DEC93
Canopy Work Lights Harness (W6) Wiring Diagram
TX,9015,DU1707 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-41
544G, 624G, 644G Loader
062717
PN=215
System Diagrams
T8127AH —UN—06DEC93
Canopy Work Lights Harness (W6) Component Location
TX,9015,DU1720 -19-07JAN94-1/1
TM1529 (27JUN17)
9015-10-42
544G, 624G, 644G Loader
062717
PN=216
TM1529 (27JUN17)
T8093BJ —19—13APR11
9015-10-43
Cab Work Lights Harness (W7) Wiring Diagram
System Diagrams
062717
PN=217
544G, 624G, 644G Loader
TX,901510,DU521 -19-23SEP93-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-44
544G, 624G, 644G Loader
062717
PN=218
System Diagrams
T8127AI —UN—06DEC93
Cab Work Lights Harness (W7) Component Location
TX,9015,DU1721 -19-07JAN94-1/1
TM1529 (27JUN17)
9015-10-45
544G, 624G, 644G Loader
062717
PN=219
System Diagrams
TM1529 (27JUN17)
9015-10-46
544G, 624G, 644G Loader
062717
PN=220
TM1529 (27JUN17)
T8093BK —19—13APR11
9015-10-47
Left Panel Temperature Control Harness (W8) Wiring Diagram
System Diagrams
062717
PN=221
544G, 624G, 644G Loader
TX,901510,DU523 -19-23SEP93-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-48
544G, 624G, 644G Loader
062717
PN=222
TM1529 (27JUN17)
T7551BK —19—18NOV97
9015-10-49
Left Panel Temperature Control Harness (W8) Component Location
System Diagrams
062717
PN=223
544G, 624G, 644G Loader
TX,901510,DU524 -19-16SEP92-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-50
544G, 624G, 644G Loader
062717
PN=224
System Diagrams
TM1529 (27JUN17)
T8397AJ —19—13APR11
9015-10-51
Engine Frame Harness (W9) Wiring Diagram
062717
PN=225
544G, 624G, 644G Loader
TX,901510,DU525 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-52
544G, 624G, 644G Loader 062717 PN=226
System Diagrams
TM1529 (27JUN17)
T8387AC —19—04NOV97
9015-10-53
Engine Frame Harness (W9) Component Location
062717
PN=227
544G, 624G, 644G Loader
TX,9015,DU1722 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-54
544G, 624G, 644G Loader 062717 PN=228
TM1529 (27JUN17)
T8397AK —19—13APR11
Engine Harness (W10) Wiring Diagram
9015-10-55
System Diagrams
062717
PN=229
544G, 624G, 644G Loader
TX,901510,DU527 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-56
544G, 624G, 644G Loader 062717 PN=230
TM1529 (27JUN17)
T8387AF —19—13APR11
Engine Harness (W10) Component Location
9015-10-57
System Diagrams
062717
PN=231
544G, 624G, 644G Loader
TX,9015,DU1723 -19-23JAN95-1/1
System Diagrams
TM1529 (27JUN17)
9015-10-58
544G, 624G, 644G Loader
062717
PN=232
System Diagrams
T8127AL —UN—06DEC93
Rear Frame Harness (W11) Wiring Diagram
TX,9015,DU1708 -19-07JAN94-1/1
TM1529 (27JUN17)
9015-10-59
544G, 624G, 644G Loader
062717
PN=233
System Diagrams
T7751BR —19—11SEP92
Rear Frame Harness (W11) Component Location
TX,901510,DU530 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-10-60
544G, 624G, 644G Loader
062717
PN=234
System Diagrams
T8127AM —UN—06DEC93
A/C Compressor Harness (W12) Wiring Diagram
TX,9015,DU1709 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-61
544G, 624G, 644G Loader
062717
PN=235
System Diagrams
T8127AN —UN—06DEC93
A/C Compressor Harness (W12) Component Location
TX,9015,DU1724 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-62
544G, 624G, 644G Loader
062717
PN=236
System Diagrams
T7751BT —19—14SEP92
Secondary Steering Harness (W13) Wiring Diagram
TX,901510,DU533 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-10-63
544G, 624G, 644G Loader
062717
PN=237
System Diagrams
T8127AO —UN—06DEC93
Secondary Steering Harness (W13) Component Location
TX,9015,DU1725 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-64
544G, 624G, 644G Loader
062717
PN=238
System Diagrams
T8127AP —UN—06DEC93
Start Aid Lead (W14) Wiring Diagram
TX,9015,DU1710 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-65
544G, 624G, 644G Loader
062717
PN=239
System Diagrams
T7751BW —19—11SEP92
Start Aid Lead (W14) Component Location
TX,901510,DU536 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-10-66
544G, 624G, 644G Loader
062717
PN=240
System Diagrams
T8127AQ —UN—06DEC93
Ride Control Harness (W15) Wiring Diagram
TX,9015,DU1711 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-67
544G, 624G, 644G Loader
062717
PN=241
System Diagrams
T7751GR —19—11SEP92
Ride Control Harness (W15) Component Location
TX,901510,DU808 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-10-68
544G, 624G, 644G Loader
062717
PN=242
System Diagrams
T8127AR —UN—06DEC93
Pin Disconnect Harness (W16) Wiring Diagram
TX,9015,DU1712 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-10-69
544G, 624G, 644G Loader
062717
PN=243
System Diagrams
T7751GS —19—11SEP92
Pin Disconnect Harness (W16) Component Location
TX,901510,DU810 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-10-70
544G, 624G, 644G Loader
062717
PN=244
Group 15
Sub-System Diagnostics RW18164 —UN—20APR90
Special Or Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD ™Catalog or in the European Microfiche Tool Catalog (MTC). Remove contacts from electrical connectors. SERVICEGARD is a trademark of Deere & Company
DX,TOOLS -19-05JUN91-1/2
T8414AA —UN—06FEB85
Remove contacts from electrical connectors.
DX,TOOLS -19-05JUN91-2/2
Power Circuit Operational Information Battery power must continue through the key switch for the power circuit to operate. An optional battery disconnect (S2) is located in the positive cable between the batteries and the starter motor. It is located along the engine frame, inside the right engine access door.
This terminal provides a convenient positive connection to emergency start the loader or to connect an external charger to the batteries. Unswitched power is provided to the display monitor directly from the batteries through the unswitched monitor fuse (F10).
An emergency starting terminal (G2) is located along the engine frame, inside the right engine access door. TX,901515,DU537 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-1
544G, 624G, 644G Loader
062717
PN=245
Sub-System Diagnostics
Power Circuit Theory Of Operation The power circuit includes batteries and main current paths to primary distribution points.
With accessory relay K1 energized, the following fuses receive power:
A manual battery disconnect is located between the battery red cable and the starter motor. When the switch is turned off, power is not supplied to any electrical circuits on the machine.
• Differential Lock Fuse • Return-to-Dig and Breakout [Boom Height Kickout] Fuse • Heater/Pressurizer Fan Fuse • Switched Radio Fuse • Rotary Beacon Fuse • Spare Fuse • Pin Disconnect Fuse • Ride Control Fuse
When the key switch is in the OFF position, voltage is from the batteries, to the key switch and the Unswitched Monitor fuse. When the key switch is in the ON or START position, power flows from the IGN terminal of the key switch, to the following:
With accessory relay K2 energized, the following fuses receive power:
• Switched Monitor Fuse • Defroster Fan Fuse • Horn Fuse
• Start Aid Fuse • Fuel Shutoff Fuse • Transmission Controller Fuse • Park Brake and Backup Alarm Fuse • Secondary Steering Fuse
With accessory relay K3 energized, the following fuses receive power:
When the key switch is in the START position, power flows from the ST terminal of the key switch, to the Neutral Start fuse. When the key switch is in the ACC or ON position, power flows from the ACC terminal of the key switch and energizes the coils of accessory relays K1, K2, and K3. Accessory relays K1, K2, and K3 must be energized for all other systems to operate.
• Front Wiper Fuse • Rear Wiper Fuse • Brake Light Fuse • Flasher Fuse • Drive and Cab Work Light Switch Fuse NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,9015,DU1579 -19-02NOV94-1/1
TM1529 (27JUN17)
9015-15-2
544G, 624G, 644G Loader
062717
PN=246
Power Circuit Functional Schematic
TM1529 (27JUN17)
T8093BO —19—13APR11
9015-15-3
Sub-System Diagnostics
062717
PN=247
544G, 624G, 644G Loader
TX,9015,TJ47 -19-21NOV97-1/1
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-4
544G, 624G, 644G Loader
062717
PN=248
Sub-System Diagnostics
Power Circuit Diagnostics TX,9015,TJ46 -19-21NOV97-1/7
Power Circuit Diagnostic Procedures TX,9015,TJ46 -19-21NOV97-2/7
Battery State Of Charge
YES: Clean battery cable terminals. Repeat test.
CAUTION: Engine may crank during this check.
If lights still get dim, test battery. If battery charge is low, recharge or replace battery. Move any light switch to ON position. Turn key switch to START position. Do lights go out or get very dim while cranking engine?
NO: Battery charge is good. Go to next check. TX,9015,TJ46 -19-21NOV97-3/7
Accessory Relay (K1)
Key switch ON. With harness connected, check voltage at differential lock fuse, switched radio fuse, rotary beacon fuse, spare fuse, pin disconnect fuse, and ride control fuse.
YES: Relay is good.
Are 12 volts measured at each fuse?
NO: Check wiring harness between accessory relay (K1) and circuit fuse. Go to next step in this check.
T7287BH —UN—16AUG90
Disconnect harness from relay. Connect battery voltage to terminal where J01 tan wire was attached. Ground terminal where G03 black wire was attached. Check for continuity between the two remaining terminals.
YES: Relay is good.
Is continuity measured?
NO: Replace accessory relay. Continued on next page
TM1529 (27JUN17)
9015-15-5
TX,9015,TJ46 -19-21NOV97-4/7
544G, 624G, 644G Loader
062717
PN=249
Sub-System Diagnostics Accessory Relay (K2)
Key switch ON. With harness connected, check voltage at switched monitor fuse, defroster fan fuse, and horn fuse.
YES: Relay is good.
Are 12 volts measured at each fuse?
NO: Check wiring harness between accessory relay (K2) and circuit fuse. Go to next step in this check.
T7287BH —UN—16AUG90
Disconnect harness from relay. Connect battery voltage to terminal where J01 tan wire was attached. Ground terminal where G03 black wire was attached. Check for continuity between the two remaining terminals.
YES: Relay is good.
Is continuity measured?
NO: Replace accessory relay. TX,9015,TJ46 -19-21NOV97-5/7
Accessory Relay (K3)
Key switch ON. With harness connected, check voltage at return-to-dig and breakout fuse, front wiper fuse, rear wiper fuse, brake light fuse, heater/pressurizer fan fuse, flasher fuse, and drive light and cab work light fuse.
YES: Relay is good.
Are 12 volts measured at each fuse?
NO: Check wiring harness between accessory relay (K3) and circuit fuse.
T7287BH —UN—16AUG90
Disconnect harness from relay. Connect battery voltage to terminal where J01 tan wire was attached. Ground terminal where G03 black wire was attached. Check for continuity between the two remaining terminals.
YES: Relay is good.
Is continuity measured?
NO: Replace accessory relay. TX,9015,TJ46 -19-21NOV97-6/7
Key Switch
Key switch ON. (Engine will start or crank, but monitor and other circuits will not operate.) With harness connected, check for voltage at coils of accessory relays (J01 tan wire).
YES: Switch is good.
Are 12 volts measured?
NO: Check wiring harness between key switch and accessory relays (K1, K2, and K3). If voltage is still not present, key switch is failed. Replace key switch. TX,9015,TJ46 -19-21NOV97-7/7
TM1529 (27JUN17)
9015-15-6
544G, 624G, 644G Loader
062717
PN=250
Sub-System Diagnostics
Charging Circuit Operational Information The following conditions must be met for the charging circuit to function:
• Key switch to the ON position • Engine running TX,901515,DU553 -19-16SEP92-1/1
Charging Circuit Theory Of Operation The charging circuit consists of the batteries, a 95 amp or 135 amp Bosch alternator, an alternator excitation diode, key switch, and indicator on the display monitor. The alternator provides power to all machine circuits and charges the batteries when the engine is running. The alternator B+ terminal is connected to battery voltage at all times. The alternator D+ terminal gets power from the ACC terminal of the key switch. With the key switch in the ON position and the engine running, current flows from the W terminal of the alternator to the display monitor. The display monitor will indicate the voltage output of the alternator.
When the key switch is in the ON position and the engine is not running, or the alternator has failed, the Engine Alt Volts indicator on the display monitor will come on. The alternator excitation diode will prevent current from feeding back from the alternator in the event the alternator circuitry is improperly connected, or there is a major failure of the alternator. A load dump suppression Zener diode is installed to limit the peak voltage of the system. The breakdown voltage is between 28 and 32 volts, depending on current draw. This prevents damage to electronic components. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,9015,DU1714 -19-10NOV93-1/1
TM1529 (27JUN17)
9015-15-7
544G, 624G, 644G Loader
062717
PN=251
Sub-System Diagnostics
T8093BP —19—11NOV93
Charging Circuit Functional Schematic
TX,9015,DU1581 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-8
544G, 624G, 644G Loader
062717
PN=252
Sub-System Diagnostics
Charging Circuit Diagnostics TX,9015,TJ48 -19-21NOV97-1/7
• 1
Charging Circuit Diagnostic Procedures
TX,9015,TJ48 -19-21NOV97-2/7
Battery State Of Charge CAUTION: Engine may crank during this check.
YES: Clean battery cable terminals. Repeat test. If lights still get dim, test battery. If battery charge is low, recharge or replace battery.
Move any light switch to ON position. Turn key to START. Do lights go out or get very dim while cranking engine?
NO: Battery charge is good. Go to next check. TX,9015,TJ48 -19-21NOV97-3/7
Alternator Check—95 And 135 Amp Bosch
T7835AT —19—23SEP92
Key switch ON. Engine running. Park brake ON. Using a multimeter, check for DC voltage at terminals (D+) and (B+). Is 14 DC volts measured? Using a multimeter, check for AC voltage at terminal (W).
YES: Alternator is good.
Is 7.5—7.6 AC volts measured? Does voltage increase with rpm?
NO: Alternator is failed. Repair or replace.
Continued on next page
TM1529 (27JUN17)
9015-15-9
TX,9015,TJ48 -19-21NOV97-4/7
544G, 624G, 644G Loader
062717
PN=253
Sub-System Diagnostics Load Dump Suppression Zener Diode
T8102AE —UN—08NOV93
Remove diode from connector. Connect an ohmmeter to diode terminals. Measure continuity. Is continuity measured?
YES: If continuity is measured in both checks, diode has failed in a shorted mode. Replace.
Reverse ohmmeter probes.
NO: If continuity is NOT measured in either check, diode has failed in an open mode. Replace.
Is continuity measured?
NO: If continuity is measured in one check and not the other, diode is OK. TX,9015,TJ48 -19-21NOV97-5/7
Alternator Excitation Diode
T7287CA —UN—20AUG90
Remove diode from connector. Connect an ohmmeter to diode terminals. Measure continuity. Is continuity measured?
YES: If continuity is measured in both checks, diode has failed in a shorted mode. Replace.
Reverse ohmmeter probes.
NO: If continuity is NOT measured in either check, diode has failed in an open mode. Replace.
Is continuity measured?
NO: If continuity is measured in one check and not the other, diode is OK. Continued on next page
TM1529 (27JUN17)
9015-15-10
TX,9015,TJ48 -19-21NOV97-6/7
544G, 624G, 644G Loader
062717
PN=254
Sub-System Diagnostics Reverse Voltage Protection Diode
T7287CA —UN—20AUG90
Remove diode from connector. Connect an ohmmeter to diode terminals. Measure continuity. Is continuity measured?
YES: If continuity is measured in both checks, diode has failed in a shorted mode. Replace.
Reverse ohmmeter probes.
NO: If continuity is NOT measured in either check, diode has failed in an open mode. Replace.
Is continuity measured?
NO: If continuity is measured in one check and not the other, diode is OK. TX,9015,TJ48 -19-21NOV97-7/7
Start Aid And Fuel Control Circuit Operational Information The following conditions must exist for start aid and fuel control circuits to function:
• Key switch to IGN or ST position • Start aid pushbutton switch pressed • Start aid solenoid energized • Fuel shutoff solenoid energized TX,901515,DU566 -19-16SEP92-1/1
Start Aid And Fuel Control Circuit Theory Of Operation Power flows from key switch IGN or ST terminal to start aid fuse, and to fuel shutoff fuse. When start aid pushbutton switch is pushed, the start aid solenoid is energized. This allows ether injection into the fuel system. The start aid diode is installed to limit the voltage spike back to the start aid pushbutton switch when the button is released.
shutoff solenoid is energized when power flows through the fuel shutoff fuse. On 644 machines, the starter motor coil wire (E03 white or E08 white) must be powered to allow the fuel shutoff solenoid to operate. The engine fuel shutoff diode is installed to limit the voltage spike back to the key switch when the switch is being turned OFF. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
The fuel shutoff solenoid must be energized to allow fuel to the injector pump. On 544 and 624 machines, the fuel TX,901515,DU567 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-11
544G, 624G, 644G Loader
062717
PN=255
Sub-System Diagnostics
T8399AH —19—27JAN95
Start Aid And Fuel Control Circuit Functional Schematic
TX,901515,DU568 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-12
544G, 624G, 644G Loader
062717
PN=256
Sub-System Diagnostics
Start Aid And Fuel Control Circuit Diagnostics TX,9015,TJ49 -19-21NOV97-1/8
• 1
Start Aid And Fuel Control Circuit Diagnostic Procedures
Power for this circuit comes from the 10 amp Start Aid Fuse, and the 5 amp Fuel Shutoff Fuse. TX,9015,TJ49 -19-21NOV97-2/8
Fluid Starting Aid Canister CAUTION: Adding fluid starting aid to a hot engine is not recommended. Check fluid starting aid canister.
YES: Go to next check.
Does canister contain fluid starting aid?
NO: Replace fluid starting aid canister. TX,9015,TJ49 -19-21NOV97-3/8
Start Aid Switch
T7751DR —19—26AUG92
Key switch to ON position. With harness connected, check voltage at terminal with P03 red wire.
YES: Go to next step in this check.
Are 12 volts measured?
NO: Check wiring harness between fuse and start aid switch.
T7751DS —19—26AUG92
Disconnect harness from start aid switch. With start aid button pushed, check for continuity between terminals with P03 red wire and E06 white wire.
YES: Start aid switch is good. Go to next check.
Is continuity measured?
NO: Replace start aid switch. Continued on next page
TM1529 (27JUN17)
9015-15-13
TX,9015,TJ49 -19-21NOV97-4/8
544G, 624G, 644G Loader
062717
PN=257
Sub-System Diagnostics Start Aid Solenoid
T7751DT —19—26AUG92
CAUTION: Remove start aid fluid canister from holder to prevent injecting starting fluid into engine. Key switch OFF. Disconnect harness from solenoid. Connect battery voltage to terminal with E06 white wire. Ground terminal with G18 black wire.
YES: Start aid solenoid is good. Check wiring harness.
Does solenoid "click"?
NO: Replace start aid solenoid. Continued on next page
TM1529 (27JUN17)
9015-15-14
TX,9015,TJ49 -19-21NOV97-5/8
544G, 624G, 644G Loader
062717
PN=258
Sub-System Diagnostics Display Monitor
T8102AG —UN—08NOV93
(Fluid start aid functions, but start aid indicator on monitor does not light.) Key switch to OFF position. Unplug display monitor. Disconnect harness from start aid solenoid. Check for continuity between terminals with E06 white wire.
YES: Check lamp in display monitor. If lamp is good, go to next step in this check.
Is continuity measured?
NO: Check wiring harness between start aid solenoid and display monitor.
T7751EU —19—31AUG92
Key switch to ON position. Unplug display monitor. Press start aid pushbutton switch. With harness connected, check voltage at terminal 19 with wire E06 white.
YES: Replace display monitor.
Are 12 volts measured?
NO: Check wiring harness between display monitor and start aid solenoid. Continued on next page
TM1529 (27JUN17)
9015-15-15
TX,9015,TJ49 -19-21NOV97-6/8
544G, 624G, 644G Loader
062717
PN=259
Sub-System Diagnostics Fuel Shutoff Solenoid—544G, 624G
T6785AG —UN—18OCT88
Connect battery voltage to terminal with E04 white wire. Does solenoid "click"? Remove voltage from terminal.
YES: Solenoid is good. Check wiring harness between fuse and solenoid.
Does solenoid "click" again?
NO: Replace fuel shutoff solenoid. Continued on next page
TM1529 (27JUN17)
9015-15-16
TX,9015,TJ49 -19-21NOV97-7/8
544G, 624G, 644G Loader
062717
PN=260
Sub-System Diagnostics Fuel Shutoff Solenoid—644G
T7751EV —UN—31AUG92
Disconnect harness from fuel shutoff solenoid. Check for continuity between terminal with E03 white wire or E08 white wire coil of starter motor.
YES: Go to next step in this check.
Is continuity measured?
NO: Check wiring harness between fuel shutoff solenoid and starter motor.
T7751EW —UN—31AUG92
Connect battery voltage to terminals with E03 white wire or E08 white wire and E04 white wire.
YES: Go to next step in this check.
Does solenoid "click"?
NO: Replace fuel shutoff solenoid.
T7751EX —UN—31AUG92
Connect battery voltage to terminals with E03 white wire or E08 white wire and E04 white wire. Solenoid should "click". Remove voltage from terminal with E03 white wire or E08 white wire.
YES: Replace fuel shutoff solenoid.
Does solenoid "click" again?
NO: Solenoid is good. Check wiring harness between fuel shutoff solenoid and fuse. TX,9015,TJ49 -19-21NOV97-8/8
TM1529 (27JUN17)
9015-15-17
544G, 624G, 644G Loader
062717
PN=261
Sub-System Diagnostics
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Specifications Specification Park Brake Switch (Normally Closed)—Opening Pressure........................................................................ 6896—8274 kPa (68.0—81.6 bar) (1000—1200 psi) TX,9015,DU1615 -19-12OCT93-1/1
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Operational Information
Pins 1, 12, and 22 of the transmission controller must receive power for the park brake, clutch cutoff, quickshift, and backup alarm circuit to function.
The park brake sensing, clutch cutoff, quickshift, and backup alarm circuit works in conjunction with the transmission controller.
The backup alarm is a solid state audible alarm. The alarm will sound when the key switch is ON and the shifter switch is in the reverse position. TX,9015,DU1616 -19-12OCT93-1/1
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Theory Of Operation The park brake pressure switch is a normally closed switch.
transmission controller. If the gear selection is 1F, 2F, 1R, or 2R, the transmission will go to neutral.
When the park brake pressure switch is closed (park brake is on), the transmission will go to neutral. This circuit functions in any gear selection. The park brake pressure switch does not directly indicate the status of the park brake switch.
The clutch cutoff diode is installed to prevent power from feeding back into T06 blue wire.
The clutch cutoff enable switch is a normally open switch. When the clutch cutoff enable switch is on and the left brake pedal is pushed, the transmission will go to neutral. This circuit functions only when gear selection is 1st or 2nd. The output, pin 12 of the transmission controller, is powered when the gear selection is 1F, 2F, 1R, or 2R. The clutch cutoff enable switch receives power from pin 12 of the transmission controller, to enable the clutch cutoff pedal switch to control the transmission. The clutch cutoff pedal switch is a normally open switch that is held open when the clutch cutoff pedal is NOT pushed. When the clutch cutoff pedal is pushed, clutch cutoff pedal switch closes, and power is supplied to pin 22 of the
The quickshift switch is a normally open switch. It provides an input signal to the transmission controller. When the quickshift switch is pushed and the gear selection is 2F, 3F, 2R, or 3R, the transmission will downshift to 1F or 1R. When the quickshift switch is pushed again, the transmission will upshift to the gear selected on the shifter switch. The backup alarm is powered through the backup alarm relay. When the shifter switch is in the reverse position, the backup alarm relay is energized. This will allow power to go from the park brake and backup alarm fuse, to the backup alarm. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,9015,DU1617 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-18
544G, 624G, 644G Loader
062717
PN=262
TM1529 (27JUN17)
T8399AI —19—13APR11
9015-15-19
062717
PN=263
544G, 624G, 644G Loader
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Functional Schematic
Sub-System Diagnostics
TX,9015,TJ45 -19-21NOV97-1/1
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-20
544G, 624G, 644G Loader
062717
PN=264
Sub-System Diagnostics
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Diagnostics TX,9015,DU1618 -19-02FEB95-1/10
• 1
Park Brake Sensing/Clutch Cutoff/Quickshift/Backup Alarm Circuit Diagnostic Procedures
Power for this circuit comes from the Transmission Controller fuse and the Park Brake and Backup Alarm fuse. CAUTION: Stop engine and turn key switch only to the ON position when performing diagnostic procedures on the transmission and the park brake electrical circuits. Machine movement can occur if the key switch is turned to the start or ignition position. CAUTION: It is important to have someone in the cab at all times when checking the transmission and park brake electrical circuits with the engine running. TX,9015,DU1618 -19-02FEB95-2/10
Park Brake Pressure Switch
T7199EE —UN—02OCT90
Disconnect harness from park brake pressure switch. Check for continuity between terminals with P15 red wire and T05 blue wire. Is continuity measured? Start engine.
YES: Park brake pressure switch is good. Check wiring harness.
Is continuity not measured?
NO: Replace park brake pressure switch. Continued on next page
TM1529 (27JUN17)
9015-15-21
TX,9015,DU1618 -19-02FEB95-3/10
544G, 624G, 644G Loader
062717
PN=265
Sub-System Diagnostics Transmission Controller
T8102AH —UN—08NOV93
Unplug clutch cutoff diode. Key switch to ON position. Select 1F, 2F, 1R, or 2R on shifter switch. Check for voltage at T06 blue wire leading to pin 12 on transmission controller.
YES: Transmission controller is good. Go to next check.
Are 12 volts measured?
NO: Check T06 blue wire. If wire is good, replace transmission controller. TX,9015,DU1618 -19-02FEB95-4/10
Clutch Cutoff Enable Switch
T7751EZ —UN—31AUG92
Disconnect harness from clutch cutoff enable switch. Check for continuity between terminals with T02 blue wire and T03 blue wire with switch in ON position. Is continuity measured? Place switch in OFF position.
YES: Switch is good. Check wiring harness.
Is continuity not measured?
NO: Replace clutch cutoff enable switch. Continued on next page
TM1529 (27JUN17)
9015-15-22
TX,9015,DU1618 -19-02FEB95-5/10
544G, 624G, 644G Loader
062717
PN=266
Sub-System Diagnostics Clutch Cutoff Pedal Switch
T7751DU —UN—26AUG92
Disconnect harness from clutch cutoff pedal switch. Check for continuity between terminals with T03 blue wire and T25 blue wire with pedal depressed. Is continuity measured? Release pedal.
YES: Switch is good. Check wiring harness.
Is continuity not measured?
NO: Replace clutch cutoff pedal switch. TX,9015,DU1618 -19-02FEB95-6/10
Quickshift Switch
T8102AI —UN—08NOV93
Disconnect harness from quickshift switch. Check for continuity between terminals with P15 red wire and T04 blue wire, with quickshift switch depressed. Is continuity measured? Release switch.
YES: Switch is good. Check wiring harness.
Is continuity not measured?
NO: Replace quickshift switch. TX,9015,DU1618 -19-02FEB95-7/10
Shifter Switch
T7751FA —UN—08SEP92
Disconnect harness from shifter switch. Place shifter switch in reverse position. Check for continuity between terminal A red wire and terminal C pink wire.
YES: Shifter switch is good. Check wiring harness.
Is continuity measured?
NO: Replace shifter switch. Continued on next page
TM1529 (27JUN17)
9015-15-23
TX,9015,DU1618 -19-02FEB95-8/10
544G, 624G, 644G Loader
062717
PN=267
Sub-System Diagnostics Backup Alarm Relay
T7287BH —UN—16AUG90
Key switch in OFF position. Disconnect harness from backup alarm relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace backup alarm relay. TX,9015,DU1618 -19-02FEB95-9/10
Backup Alarm
T7199BZ —UN—16AUG90
Disconnect harness from backup alarm. Connect battery voltage to backup alarm positive (+) terminal. Connect jumper wire from backup alarm negative (-) terminal to ground.
YES: Backup alarm is good. Check wiring harness.
Does backup alarm sound?
NO: Replace backup alarm. TX,9015,DU1618 -19-02FEB95-10/10
Transmission Control Circuit Operational Information
signals into the controller will activate the transmission control valve solenoids.
The transmission can operate in four forward gear ranges and three reverse gear ranges.
NOTE: Shifter switch must be in NEUTRAL position to allow for engine to start.
The shifter switch tells the transmission the desired gear of operation.
The following conditions must exist for the transmission to go into gear:
Selecting 1, 2, 3, or 4 speed range is controlled by rotating the end of the shift lever. The switches in the shift lever create a 3-bit code for each of the gear ranges.
• Engine running • Park brake released • Clutch cutoff circuit not engaged (clutch cutoff enable
The transmission controller is a microcomputer based electronic controller to shift the transmission. The input
• Shifter switch moved to desired gear
switch off or left brake pedal not pressed)
TX,901515,DU595 -19-10NOV93-1/1
TM1529 (27JUN17)
9015-15-24
544G, 624G, 644G Loader
062717
PN=268
Sub-System Diagnostics
Transmission Control Circuit Theory Of Operation The transmission controller is powered when the key switch is in the ON or START position. The transmission controller runs a diagnostic check for about six seconds upon initial start up. If the shifter switch is not in the neutral position for six seconds after the key switch is turned on, it will not allow the machine to shift into gear. The shifter switch must be moved back to neutral and then to the desired gear before the machine will move.
by the magnetic pickup. If the machine is moving faster than 20% higher than the next higher gear at wide open throttle, then the transmission will not downshift.
When the shifter switch is moved to forward, neutral, or reverse, an input signal is sent to the transmission controller. The transmission controller will then activate the appropriate solenoids in the transmission control valve for the desired movement. (Refer to the Transmission Controller Input and Output signal designation tables.)
With the machine coasting in neutral, the transmission controller will not allow the transmission to engage too low of a gear to cause engine overspeed. The gear appropriate for the ground speed will be engaged, and then the transmission will downshift to the selected gear. If the machine is coasting in neutral at a speed greater than fourth gear wide open throttle, only fourth gear will engage. If the machine is in fourth gear and going downhill, it will automatically shift up to fourth gear as ground speed dictates, regardless of engine speed.
When the transmission is operating, five solenoids in the transmission control valve provide pilot operation for five hydraulic valve spools. The five hydraulic valve spools control six clutches in the transmission.
If the machine is operating faster than 20% greater than wide open throttle in the gear engaged, a downshift or reversal will not be permitted. Only an upshift will be permitted.
On following machines, transmission control valve contains six solenoids:
The transmission controller has three basic modes of operation. They are as follows:
• 544G (S.N. 548219—) • 624G (S.N. 548398—) • 644G (S.N. 548303—)
1. Manual Mode: the shifter switch is in 1st, 2nd, or 3rd gear. The following rules apply: a. When shifting from neutral to 1st, 2nd, or 3rd forward or reverse, the selected gear will be immediately engaged.
The additional sixth solenoid in the transmission control valve allows transmission system pressure oil to fill the piston cavity before the shift modulation starts. This causes less delay between gear shifts since the piston cavity can be filled faster when using oil at a higher pressure.
b. When shifting from 1st to 3rd in the same direction, the transmission controller will shift from 1st to 2nd, and then to 3rd. c. Quickshift will function only when 2nd or 3rd gear is selected.
If the transmission controller detects an invalid combination of energized solenoids, all solenoids will de-energize causing the machine to go in to neutral.
2. Automatic Mode: the shifter switch is in 4th gear. The machine will automatically select 2nd, 3rd, or 4th gear according to the machine ground speed as indicated by the magnetic pickup. 1st gear will not be engaged if 4th gear (automatic) is selected. The following rules apply:
When there is input from the clutch cutoff circuit (12 volts to pin 22 of the transmission controller), the transmission will be in neutral. When the transmission is operating, the magnetic pickup detects gear teeth motion of the transmission and sends a signal to the transmission controller. This signal is proportional to the output speed of the transmission and proportional to the wheel speed.
a. When shifting from neutral to 4th forward gear (automatic), the transmission controller will engage the gear appropriate for the ground speed. b. The transmission will shift based on ground speed. If the machine is accelerated in the gear engaged, then the transmission will upshift. If the machine is decelerated in the gear engaged, then the transmission will downshift.
The transmission controller operates as follows: When reversing in 1F or 2F, the transmission will immediately shift to 1R or 2R.
NOTE: If machine is in fourth gear and going downhill, it will automatically shift up to fourth gear as ground speed dictates, regardless of engine speed.
When reversing in 3F or 4F and the ground speed is more than 20% above second gear wide open throttle, the transmission will be downshifted to second, then reversed, and then upshifted to third or fourth in the opposite direction. If the ground speed is below second gear wide open throttle, the transmission will reverse without downshifting first.
c. Reversals will be controlled by checking the ground speed from the magnetic pickup, against the allowed reversal speed set in the transmission controller.
The transmission controller will limit downshifting of the transmission if the machine is moving too fast as indicated Continued on next page
TM1529 (27JUN17)
9015-15-25
TX,9015,TJ40 -19-30OCT97-1/3
544G, 624G, 644G Loader
062717
PN=269
Sub-System Diagnostics
• 644G (S.N. —548302) It is possible for service code to register without failure of magnetic pickup if transmission is shifted to forward and reverse, then back to forward again while machine is stationary. Under this condition, the transmission controller would sense the direction changes being made, but there would be no speed signal from speed sensor, since machine is not moving. If this happens, clear the code and verify if it comes back again during machine operation.
d. If 2nd gear is engaged and a reversal is selected, the reversal will occur immediately unless a 3rd to 2nd automatic shift has started. The transmission controller will then complete the automatic downshift and then do the reversal. e. If 3rd gear is engaged and a reversal is selected, the ground speed will determine if a downshift is required. If the ground speed is below the reversing speed, the reversal will occur immediately unless a 2nd to 3rd or 4th to 3rd shift has started. The transmission controller will then complete the 4th to 3rd downshift, and then do a 3rd gear reversal. If the ground speed is above the reversing speed, the transmission will do a 3rd to 2nd downshift to slow the machine, and then do a 2nd gear reversal. f. If 4th gear is engaged and a reversal is selected, the transmission will downshift to 3rd to slow the machine. Then, the above rule (2e.) applies. 3. Fault Mode: the transmission controller has determined a service condition. The following rules apply:
After the above serial numbers, the transmission controller was reprogrammed so it would not send the F907 (failed speed sensor) service code to the display monitor. This was done because the F907 service code had caused some confusion to the users. The M05 purple wire, which sent the service code signal to the monitor, was also deleted. At the same time, a change needed to be made to display monitor programming (pin 22 of monitor connector), because an open circuit on M05 wire will cause the F907 service code to register. The change to the display monitor was not made at the same time, so F907 service code appears on following machines:
• 544G (S.N. 548219—548955) • 624G (S.N. 548398—548982) • 644G (S.N. 548303—548887)
a. If an invalid combination of transmission solenoids has been detected, all the solenoids will turn off and the transmission will go to neutral. b. If an invalid combination of shifter switch signals has been detected, all the solenoids will turn off and the transmission will go to neutral. c. If a failure of the magnetic pickup has been detected, the transmission controller will not allow the transmission to operate above 2nd gear. The display monitor will then display a service code on following machines:
On these machines, if the speedometer works or the transmission still shifts into 3rd or 4th gear, the speed sensor is working normally, and the erroneous service code reading should be ignored. To eliminate erroneous F907 service codes, make a jumper wire harness. See Jumper Wire Harness for Display Monitor , this group. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
• 544G (S.N. —548218) • 624G (S.N. —548397)
TABLE 1-INPUTS TO THE TRANSMISSION CONTROLLER Pin
Wire
Signal Description
1, 2, 19
P15 red
Power to the controller
23
T20 blue
Forward signal from shifter switch
29
E02 white
Neutral signal from shifter switch
5
T21 blue
Reverse signal from shifter switch
26
T22 blue
1-2-3-4 shift code signal (bit B1) from shifter switch
8
T23 blue
1-2-3-4 shift code signal (bit B2) from shifter switch
25
T24 blue
1-2-3-4 shift code signal (bit B3) from shifter switch
24
T04 blue
Quickshift signal from quickshift switch
22
T25 blue
Clutch cutoff signal (go to neutral) from clutch cutoff switches and from park brake pressure switch
27
T12 blue
Wheel speed signal from magnetic pickup
17
T11 blue
Wheel speed signal ground
18, 35
G06 black
Controller ground TABLE 2-OUTPUTS FROM TRANSMISSION CONTROLLER
Pin
Wire
Signal Description
33
T14 blue
Transmission control valve solenoid Y4
15
T15 blue
Transmission control valve solenoid Y5 Continued on next page
TM1529 (27JUN17)
9015-15-26
TX,9015,TJ40 -19-30OCT97-2/3
544G, 624G, 644G Loader
062717
PN=270
Sub-System Diagnostics TABLE 2-OUTPUTS FROM TRANSMISSION CONTROLLER Pin
Wire
Signal Description
32
T16 blue
Transmission control valve solenoid Y6
14
T17 blue
Transmission control valve solenoid Y7
31
T13 blue
Transmission control valve solenoid Y8
34
T18 blue
Ground for transmission control valve solenoids
12
T06 blue
Clutch cutoff enable signal to the clutch cutoff switches. Transmission controller turns on this signal when the transmission is in 1st or 2nd gear.
11
M03 purple
Wheel speed signal to display monitor pin 18. This signal is one half the frequency received on the magnetic pickup.
13
M05 purple
a
30
T26 blue
b
Wheel speed magnetic pickup fault signal to the display monitor pin 22. Transmission control valve solenoid Y17.
a
544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302) 544G (S.N. 548219—), 624G (S.N. 548398— ), 644G (S.N. 548303—)
b
TX,9015,TJ40 -19-30OCT97-3/3
TM1529 (27JUN17)
9015-15-27
544G, 624G, 644G Loader
062717
PN=271
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-28
544G, 624G, 644G Loader
062717
PN=272
TM1529 (27JUN17)
T8399AM —19—24OCT97
9015-15-29
Transmission Control Circuit Functional Schematic
Sub-System Diagnostics
062717
PN=273
544G, 624G, 644G Loader
TX,901515,DU598 -19-02FEB95-1/1
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-30
544G, 624G, 644G Loader
062717
PN=274
Sub-System Diagnostics
T8404BD —19—02FEB95
Jumper Wire For Display Monitor
On 544G (S.N. 548219—), 624G (S.N. 548398—) and 644G (S.N. 548303—), the transmission controller was reprogrammed so it would not send the F907 (failed speed sensor) service code to the display monitor. This was done because the F907 service code had caused some confusion to the users. The M05 purple wire, which sent the service code signal to the monitor, was also deleted. At the same time, a change needed to be made to display monitor programming (pin 22 of monitor connector), because an open circuit on M05 wire will cause the F907 service code to register. The change to the display monitor was not made at the same time, so F907 service code appears on following machines:
• 544G (S.N. 548219—548955) • 624G (S.N. 548398—548982) • 644G (S.N. 548303—548887) On these machines the F907 service code is an erroneous reading and can be ignored. If the speedometer works and the transmission will shift into 3rd and 4th gear, the speed sensor is working normally.
To eliminate erroneous F907 service code, make a jumper wire using approximately 660 mm (26 in.) of 16 gauge wire, one U46662 Terminal and R77465 Socket Contact as shown. Insert U46662 Terminal into open connection (A) in backside of key switch connector. NOTE: After the transmission controller change was made, there were a few machines produced with M05 wire in the harness. If M05 wire is in display monitor connector at pin 22 location (B), remove wire using JDG140 AMP Socket Extractor or JDG364 Weatherpack Socket Extractor. Tape the wire back to the harness. Insert R77465 Socket Contact of jumper wire harness into display monitor connector at pin 22 location (B). Use four to six tie bands to secure jumper wire to harness and bundle between key switch and display monitor.
TX,1515,MM2404 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-31
544G, 624G, 644G Loader
062717
PN=275
Sub-System Diagnostics
Replace CPC, Large MATE-N-LOK and METRIMATE™ Pin Type Connectors 1. Select correct size Extraction Tool (JDG140 or JDG143) for contact to be removed. NOTE: Allow tool push rod (C) to back out during insertion. 2. Insert tool sleeve (A) over contact until it bottoms. 3. Rotate tool handle (B) to assure release of contact locking lances. 4. Hold tool sleeve firmly seated in connector and press push rod button (D) to remove contact from connector. 5. Spread contact locking lances and insert wire in correct terminal of new connector. 6. Transfer remaining wires to correct terminal of new connector. C—Tool Push Rod D—Push Rod Button TS113 —UN—23AUG88
A—Tool Sleeve B—Tool Handle
CPC, MATE-N-LOK, and METRIMATE are trademarks of AMP Inc. DX,ECONN,F -19-04JUN90-1/1
TM1529 (27JUN17)
9015-15-32
544G, 624G, 644G Loader
062717
PN=276
Sub-System Diagnostics
T8400AE —19—27JAN95
Pin Identification On Transmission Controller
TX,9015,MM1539 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-33
544G, 624G, 644G Loader
062717
PN=277
Sub-System Diagnostics
Procedure To Isolate Whether Problem In Transmission Control System Is Electrical Or Hydraulic
3. Put transmission control lever in 1st forward. 4. Remove solenoid cover.
NOTE: When not sure if problem is electrical or hydraulic, perform the following procedure.
NOTE: To check solenoid voltage, put voltmeter probes across the two terminals of each solenoid connector.
1. Remove clutch cutoff (CCO) and park brake diodes (located next to transmission controller). This will allow the transmission control system to energize the solenoids with the engine off and the park brake engaged.
5. Check voltage at solenoids M2, M3, and M4.
2. Turn key to ON position. DO NOT start engine.
6. Put transmission control lever in 1st reverse. 7. Check voltage at solenoid M1. 8. If voltage is correct for all solenoids, problem is hydraulic. TX,9015,TJ42 -19-21NOV97-1/1
Transmission Control Circuit Diagnostics TX,9015,TJ50 -19-21NOV97-1/5
• 1
Transmission Control Circuit Diagnostic Procedures
CAUTION: Stop engine and turn key switch only to the ON position when performing diagnostic procedures on the transmission and the park brake electrical circuits. Machine movement can occur if the key switch is turned to the start position. CAUTION: It is important to have someone in the cab at all times when checking the transmission and park brake electrical circuits with the engine running. Power for this circuit comes from the Transmission Controller fuse. NOTE: See Transmission Electrical Circuit Test Procedure in Group 9015-20 for additional checks at the Transmission Controller connector. Continued on next page
TM1529 (27JUN17)
9015-15-34
TX,9015,TJ50 -19-21NOV97-2/5
544G, 624G, 644G Loader
062717
PN=278
Sub-System Diagnostics Transmission Controller
Perform Driving Check in Operational Checkout Procedure. (See Group 9005—10.) Does transmission go into gear?
YES: Transmission controller is good.
Does the transmission upshift and downshift, in forward and reverse, as specified?
NO: Move shifter switch to neutral. Go to next step in this check.
T7751FB —19—31AUG92
Unplug transmission controller. Key switch to ON position. Check for voltage at pins 1, 2, and 19 of transmission controller connector.
YES: Go to next step in this check.
Are 12 volts measured?
NO: Check wiring harness.
T7751FC —UN—31AUG92
Unplug transmission controller. Key switch to OFF position. Check for continuity between pins 18 and 35 to ground.
YES: Transmission controller is good. Go to next check.
Is continuity measured?
NO: Check wiring harness between transmission controller and ground. TX,9015,TJ50 -19-21NOV97-3/5
Clutch Cutoff Pedal Switch
Clutch cutoff enable switch to ON position. Start engine. Park brake OFF. Depress clutch pedal. Transmission in gear.
YES: Replace clutch cutoff pedal switch.
Does machine move?
NO: Check wiring harness. Go to next check. Continued on next page
TM1529 (27JUN17)
9015-15-35
TX,9015,TJ50 -19-21NOV97-4/5
544G, 624G, 644G Loader
062717
PN=279
Sub-System Diagnostics Transmission Solenoid
T8401AA —UN—06FEB95
Key switch to OFF position. Disconnect harness from transmission controller and transmission control valve. Check for continuity between transmission controller connector terminals:
• 14 and 34. • 15 and 34. • 31 and 34. • 32 and 34. • 33 and 34. • 130 and 34.
YES: Go to next step in this check.
Is resistance the same in all checks?
NO: Check wiring harness between transmission controller and transmission control valve. Change solenoid.
T7751FE —UN—31AUG92
Disconnect harness from transmission solenoid. Apply battery voltage to solenoids Y4 (T14 blu wire), Y5 (T15 blu wire), Y6 (T16 blu wire), Y7 (T17 blu wire), and Y8 (T13 blu wire). Do solenoids "click"? For 2machines with six-solenoid transmission voltage to solenoid Y17 (T26 blue wire). Does solenoid click?
control valve, apply battery YES: Transmission solenoid is good. Check wiring harness. NO: Replace transmission solenoid.
1
544G (S.N.548219— ), 624G (S.N. 548398—), 644G (S.N. 548303—). 544G (S.N. 548219—), 624G (S.N. 548398— ), 644G (S.N. 548303—).
2
TX,9015,TJ50 -19-21NOV97-5/5
TM1529 (27JUN17)
9015-15-36
544G, 624G, 644G Loader
062717
PN=280
Sub-System Diagnostics
Start Circuit Operational Information The following conditions must exist for the start circuit to function:
• Shifter switch in NEUTRAL position • Neutral start circuit relay energized • Start relay energized
• Key switch in START position TX,901515,DU607 -19-16SEP92-1/1
Start Circuit Theory Of Operation When the key switch is in the START position and the shifter switch is in the NEUTRAL position, battery power flows through the neutral start circuit relay and energizes the start relay. When the start relay is energized, battery power goes to the starter motor coil through wire E03 white. The coil in the starter motor is energized and direct battery power is then sent to the starter motor and the starter motor operates.
The start relay coil suppression diode is installed to limit the voltage spike back to the neutral start circuit relay contacts when the relay is opening. The engine starter coil suppression diode is installed to limit the voltage spike back to the start relay contacts when the relay is opening. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,901515,DU608 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-37
544G, 624G, 644G Loader
062717
PN=281
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-38
544G, 624G, 644G Loader
062717
PN=282
Start Circuit Functional Schematic
TM1529 (27JUN17)
T8399AG —19—13APR11
9015-15-39
Sub-System Diagnostics
062717
PN=283
544G, 624G, 644G Loader
TX,9015,DU1588 -19-02FEB95-1/1
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-40
544G, 624G, 644G Loader
062717
PN=284
Sub-System Diagnostics
Start Circuit Diagnostics TX,9015,TJ51 -19-21NOV97-1/7
• 1
Start Circuit Diagnostic Procedures
Power for this circuit comes from the Neutral Start fuse. TX,9015,TJ51 -19-21NOV97-2/7
Key Switch
T7199BO —UN—17SEP90
Remove neutral start fuse. Remove start aid fuse. Remove Fuel shutoff fuse. Remove transmission controller fuse. Remove park brake and backup alarm fuse. Remove secondary steering fuse. Key switch to START position. With harness connected, check voltage at IGN and START terminals.
YES: Key switch is good. Go to next check.
Are 12 volts measured at each terminal?
NO: Replace key switch. TX,9015,TJ51 -19-21NOV97-3/7
Shifter Switch
T7751FF —UN—08SEP92
Key switch to ON position. Shifter switch in NEUTRAL position. With harness connected, check voltage at terminal with E02 white wire.
YES: Shifter switch is good.
Are 12 volts measured?
NO: Check wiring harness. If wiring harness is good, replace shifter switch. Go to next check. Continued on next page
TM1529 (27JUN17)
9015-15-41
TX,9015,TJ51 -19-21NOV97-4/7
544G, 624G, 644G Loader
062717
PN=285
Sub-System Diagnostics Neutral Start Circuit Relay
T7287BH —UN—16AUG90
Key switch in OFF position. Disconnect harness from neutral start circuit relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Check for continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace neutral start circuit relay. TX,9015,TJ51 -19-21NOV97-5/7
Start Relay
T7287BK —19—16AUG90
Key switch to OFF position. Disconnect harness from relay. Connect battery voltage to terminal with E07 white wire. Ground terminal with G06 black wire. Does relay "click"? Check for continuity between terminals with B02 red wire and E03 white wire.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace start relay. TX,9015,TJ51 -19-21NOV97-6/7
Starter Motor
T6534BJ —UN—07JAN97
CAUTION: Starter motor will crank engine if metal strap is NOT disconnected. Disconnect metal strap from starter motor terminal. Connect a heavy gauge wire from battery positive cable to starter motor terminal.
YES: Starter motor is good. Check wiring harness.
Does starter motor turn, but NOT crank engine?
NO: Repair or replace starter motor. TX,9015,TJ51 -19-21NOV97-7/7
TM1529 (27JUN17)
9015-15-42
544G, 624G, 644G Loader
062717
PN=286
Sub-System Diagnostics
Park Brake Circuit Operational Information The park brake is a spring-applied, hydraulically-released brake. The park brake is applied when any of the following conditions exist:
• Key switch in OFF or START position • A bypass start at the starter motor is attempted • Low hydraulic supply pressure to the service brakes and the park brake (Not an electrically controlled function.)
The park brake is released only when the park brake reset relay and the park brake release solenoid are energized.
• Park brake switch is ON TX,901515,DU617 -19-16SEP92-1/1
Park Brake Circuit Theory Of Operation The park brake reset relay must be energized for the park brake circuit to operate. The park brake reset relay is energized when the following sequence is followed:
• • •
Key switch to ON position Starter motor not being powered Park brake switch to ON position
• Park brake switch to ON position • Key switch to OFF position • Starter motor operating The park brake roll away protection diode is installed to prevent feedback of voltage from the starter motor. The park brake release solenoid protection diode is installed to limit the voltage spike back to the park brake switch contacts as the switch is opening.
The park brake is applied at this point. When the park brake reset relay is energized and the park brake switch is in the OFF position, the park brake release solenoid will be energized and allows hydraulic release of the park brake.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
When the park brake release solenoid de-energizes, the park brake will apply. The park brake release solenoid will de-energize when any of the following conditions exist: TX,901515,DU618 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-43
544G, 624G, 644G Loader
062717
PN=287
Sub-System Diagnostics
T8399AO —19—27JAN95
Park Brake Circuit Functional Schematic
TX,9015,DU1614 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-44
544G, 624G, 644G Loader
062717
PN=288
Sub-System Diagnostics
Park Brake Circuit Diagnostics TX,9015,TJ52 -19-21NOV97-1/6
• 1
Park Brake Circuit Diagnostic Procedures
Power for this circuit comes from the Park Brake and Backup Alarm fuse. CAUTION: Stop engine and turn key switch only to the ON position when performing diagnostic procedures on the transmission and the park brake electrical circuits. Machine movement can occur if the key switch is turned to the start or ignition position. CAUTION: It is important to have someone in the cab at all times when checking the transmission and park brake electrical circuits with the engine running. TX,9015,TJ52 -19-21NOV97-2/6
Park Brake Switch
T7751FG —UN—31AUG92
Disconnect harness from park brake switch. Park brake switch in OFF position. Check for continuity between terminals with J06 tan wire and J07 tan wire. Is continuity measured? Park brake in ON position. Check for continuity between terminals with J06 tan wire and P24 red wire.
YES: Park brake switch is good. Go to next check.
Is continuity measured?
NO: Replace park brake switch. Continued on next page
TM1529 (27JUN17)
9015-15-45
TX,9015,TJ52 -19-21NOV97-3/6
544G, 624G, 644G Loader
062717
PN=289
Sub-System Diagnostics Park Brake Reset Relay
T7287BH —UN—16AUG90
Key switch to OFF position. Disconnect harness from relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace park brake reset relay. TX,9015,TJ52 -19-21NOV97-4/6
Park Brake Release Solenoid
T7199CT —UN—16AUG90
Key switch to OFF position. Disconnect harness from park brake release solenoid. Connect battery voltage to terminal with J07 tan wire. Ground terminal with G15 black wire.
YES: Solenoid is good. Check wiring harness.
Does solenoid "click"?
NO: Replace park brake release solenoid. TX,9015,TJ52 -19-21NOV97-5/6
Park Brake Clutch Cutoff Diode
T7751GC —UN—31AUG92
Key switch to OFF position. Disconnect harness from park brake diode. Connect jumper wire to E03 white wire and J05 tan wire.
YES: Replace park brake clutch cutoff diode.
Does park brake function?
NO: Check wiring harness. TX,9015,TJ52 -19-21NOV97-6/6
TM1529 (27JUN17)
9015-15-46
544G, 624G, 644G Loader
062717
PN=290
Sub-System Diagnostics
Secondary Steering Circuit Specifications The secondary steering pressure switch closes at less than 240 kPa (2.4 bar) (35 psi) differential pressure between circuits P and LS. TX,9015,DU1590 -19-12OCT93-1/1
Secondary Steering Circuit Operational Information
The secondary steering controller controls the secondary steering pump motor.
The secondary steering circuit will function any time the steering pressure is low, after an engine start. TX,901515,DU624 -19-16SEP92-1/1
Secondary Steering Circuit Theory Of Operation The secondary steering pressure switch is held open hydraulically. When the steering pressure is low, the secondary steering pressure switch will close. This will ground the secondary steering controller.
energize a relay in the pump motor. Battery power is then sent to the pump motor through wire B09 red, and the pump motor will operate. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
The secondary steering controller will now activate the secondary steering pump motor. Wire H03 green will TX,901515,DU625 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-47
544G, 624G, 644G Loader
062717
PN=291
Sub-System Diagnostics
T7751CL —19—14SEP92
Secondary Steering Circuit Functional Schematic
TX,901515,DU626 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-48
544G, 624G, 644G Loader
062717
PN=292
Sub-System Diagnostics
Secondary Steering Circuit Diagnostics TX,9015,TJ53 -19-21NOV97-1/5
• 1
Secondary Steering Circuit Diagnostic Procedures
Power for this circuit comes from the Secondary Steering fuse. TX,9015,TJ53 -19-21NOV97-2/5
Secondary Steering Pressure Switch
T7199EE —UN—02OCT90
Key switch to OFF position. Disconnect harness from secondary steering pressure switch. Measure continuity between terminals with H04 green wire and R01 black wire. Is continuity measured? Start engine.
YES: Switch is good. Go to next check.
Is continuity not measured?
NO: Replace secondary steering pressure switch. Continued on next page
TM1529 (27JUN17)
9015-15-49
TX,9015,TJ53 -19-21NOV97-3/5
544G, 624G, 644G Loader
062717
PN=293
Sub-System Diagnostics Secondary Steering Controller
T7751DX —19—26AUG92
Key switch to OFF position. Disconnect harness from secondary steering controller. Check for continuity between terminal with G06 black wire and right rear cab leg ground. YES: Go to next step in this check. Is continuity measured?
NO: Check wiring harness between secondary steering controller and right rear cab leg ground.
T8102AK —UN—08NOV93
Disconnect harness from secondary steering pressure switch. Connect jumper wire to terminal H04 green and R01 black wires. Start engine. Check for voltage at terminal with H03 green wire.
YES: Secondary steering controller is good.
Are 12 volts measured?
NO: Check wiring harness. If wiring harness is good, replace secondary steering controller. Continued on next page
TM1529 (27JUN17)
9015-15-50
TX,9015,TJ53 -19-21NOV97-4/5
544G, 624G, 644G Loader
062717
PN=294
Sub-System Diagnostics Secondary Steering Pump Motor
T7751DZ —19—26AUG92
Disconnect harness from secondary steering pump motor. Apply battery voltage to terminals with H03 green wire and B09 red wire. Ground terminal with G20 black wire.
YES: Pump motor is good. Check wiring harness.
Does pump motor run?
NO: Replace secondary steering pump motor. TX,9015,TJ53 -19-21NOV97-5/5
Differential Lock And Boom Down Circuit Operational Information The differential lock circuit functions only while the differential lock pedal is pressed. The hydraulic differential lock engages when the differential lock solenoid is energized.
The boom down switch is functional only when the key switch is in the OFF position. The operator can lower the boom by using the boom down hydraulic control lever when the boom down switch is closed. TX,901515,DU633 -19-16SEP92-1/1
Differential Lock And Boom Down Circuit Theory Of Operation The differential lock pedal switch is a normally open switch, which is held open when the differential lock pedal is NOT pressed. When the differential lock pedal is pressed, the differential lock pedal switch closes and power is sent to the differential lock solenoid. With the solenoid energized, the differential lock will engage. When the differential lock pedal is released, the differential lock pedal switch will open, and the differential lock solenoid will de-energize. The differential lock will now disengage.
The differential lock diode is installed to limit the voltage spike back to the differential lock pedal switch contacts when the switch opens. When the key switch is in the OFF or ON position, the boom down switch can be held ON. This will energize the boom down solenoid and the boom control lever can be moved to boom down, and the boom will lower. The boom down diode is installed to limit the voltage spike back to the boom down switch contacts when the switch opens. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,9015,DU1591 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-51
544G, 624G, 644G Loader
062717
PN=295
Sub-System Diagnostics
T8399AJ —19—27JAN95
Differential Lock And Boom Down Circuit Functional Schematic
TX,901515,DU635 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-52
544G, 624G, 644G Loader
062717
PN=296
Sub-System Diagnostics
Differential Lock And Boom Down Circuit Diagnostics TX,9015,TJ54 -19-21NOV97-1/6
• 1
Differential Lock And Boom Down Circuit Diagnostic Procedures
Power for this circuit comes from the Differential Lock fuse and the Boom Down fuse. TX,9015,TJ54 -19-21NOV97-2/6
Differential Lock Pedal Switch
T8102AL —UN—08NOV93
Disconnect harness from differential lock pedal switch. Press switch to activated position. Check for continuity between terminals with P19 red wire and T01 blue wire. Is continuity measured? Release switch.
YES: Switch is good. Go to next check.
Is continuity not measured?
NO: Replace differential lock pedal switch. TX,9015,TJ54 -19-21NOV97-3/6
Differential Lock Solenoid
T8102AM —UN—08NOV93
Disconnect harness from differential lock solenoid. Apply battery power to terminal with T01 blue wire. Ground terminal with G15 black wire. YES: Solenoid is good. Check wiring harness. Does solenoid "click"?
NO: Replace differential lock solenoid. Continued on next page
TM1529 (27JUN17)
9015-15-53
TX,9015,TJ54 -19-21NOV97-4/6
544G, 624G, 644G Loader
062717
PN=297
Sub-System Diagnostics Boom Down Switch
T7751EZ —UN—31AUG92
Disconnect harness from boom down switch. Check continuity between terminals with P20 red wire and H05 green wire with switch in ON position. Is continuity measured? Place switch in OFF position.
YES: Boom down switch is good. Check wiring harness.
Is continuity not measured?
NO: Replace boom down switch. TX,9015,TJ54 -19-21NOV97-5/6
Boom Down Solenoid
T8102AM —UN—08NOV93
Disconnect harness from boom down solenoid. Apply battery voltage to terminal with H05 green wire. Ground terminal with G15 black wire.
YES: Solenoid is good. Check wiring harness.
Does solenoid "click"?
NO: Replace boom down solenoid. TX,9015,TJ54 -19-21NOV97-6/6
TM1529 (27JUN17)
9015-15-54
544G, 624G, 644G Loader
062717
PN=298
Sub-System Diagnostics
Switch Inputs To Monitor Circuit Specifications Item
Measurement
Specification
Engine Coolant Level Switch (Normally Open)
Closing Level
With coolant level 25 mm (1.0 in.) low in top tank of radiator
Transmission Oil Pressure Switch (Normally Closed)
Opening Pressure
993—1213 kPa (10—12 bar) (144—176 psi)
Hydraulic Oil Filter Restriction Switch (Normally Open)
Closing Pressure
345 ± 35 kPa (3.5 ± 0.4 bar) (50 ± 5 psi)
Air Filter Restriction Switch (Normally Open)
Closes on Increasing Vacuum at
4.98—7.48 kPa (20—30 in. H Vacuum
Engine Oil Pressure Switch (Normally Closed)
Opening Pressure
37—72 kPa (0.4—0.7 bar) (5.5—10.5 psi)
Service Brake Pressure Switch (Normally Closed)
Opening Pressure
6896—8274 kPa (68.0—81.6 bar) (1000—1200 psi)
Park Brake Pressure Switch (Normally Closed)
Opening Pressure
6896—8274 kPa (68.0—81.6 bar) (1000—1200 psi)
2
O)
TX,9015,DU1592 -19-12OCT93-1/1
Switch Inputs To Monitor Circuit Operational Information The hydraulic oil filter restriction switch detects a plugged hydraulic oil filter. An indication on the display monitor will appear when the hydraulic oil filter is plugged. The air filter restriction switch detects a plugged air filter. An indication on the display monitor will appear when the air filter is plugged. The service brake pressure switch detects low supply pressure to the service brakes. An indication on the display monitor will appear when the supply pressure to the service brakes is low.
The engine oil pressure switch detects low engine oil pressure. An indication on the display monitor will appear when the engine oil pressure is low. The transmission oil pressure switch detects low transmission oil pressure. An indication on the display monitor will appear when the transmission oil pressure is low. The engine coolant level switch detects low engine coolant level. An indication on the display monitor will appear when the engine coolant level is low. Power to pin 24 and pin 37 on the display module must exist for this circuit to function. TX,901515,DU645 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-55
544G, 624G, 644G Loader
062717
PN=299
Sub-System Diagnostics
Switch Inputs To Monitor Circuit Theory Of Operation When the hydraulic oil filter restriction switch detects a plugged hydraulic oil filter, it will close. This will ground the switch and an indication will appear on the display monitor. When the air filter restriction switch detects a plugged air filter, it will close. This will ground the switch and an indication will appear on the display monitor. When the service brake pressure switch detects low supply pressure to the service brakes, it will close. This will ground the switch and an indication will appear on the display module. When the engine oil pressure switch detects low engine oil pressure, it will close. This will ground the switch and an indication will appear on the display module.
When the engine coolant level switch detects low engine coolant, it will close. This will ground the switch and an indication will appear on the display module. The unswitched monitor fuse is for power to the display monitor unswitched power signal. This signal provides the connection for battery voltage display on the display monitor. The unswitched power also allows the display monitor to display the machine hours while the key switch is in the OFF position, by pressing the select button on the display monitor. The switched monitor fuse is for power to the display monitor when the key switch is in the ON position. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
When the transmission oil pressure switch detects low transmission oil pressure, it will close. This will ground the switch and an indication will appear on the display module. TX,901515,DU646 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-56
544G, 624G, 644G Loader
062717
PN=300
TM1529 (27JUN17)
T7751CR —19—13APR11
9015-15-57
Switch Inputs To Monitor Circuit Functional Schematic
Sub-System Diagnostics
062717
PN=301
544G, 624G, 644G Loader
TX,90515,DU650 -19-16SEP92-1/1
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-58
544G, 624G, 644G Loader
062717
PN=302
Sub-System Diagnostics
Switch Inputs To Monitor Circuit Diagnostics TX,9015,TJ55 -19-21NOV97-1/9
• 1
Switch Inputs To Monitor Circuit Diagnostic Procedures
Power for this circuit comes from the Unswitched Monitor fuse and the Switched Monitor fuse. NOTE: Checks are performed with the key in OFF position. Tests are done with components on the machine and wire connectors disconnected. TX,9015,TJ55 -19-21NOV97-2/9
Hydraulic Oil Filter Restriction Switch
T7287BQ —UN—20AUG90
Disconnect harness from hydraulic oil filter restriction switch. Check for continuity between switch terminal and ground.
YES: Replace hydraulic oil filter restriction switch.
Is continuity measured?
NO: Switch is good. Check wiring harness. TX,9015,TJ55 -19-21NOV97-3/9
Air Filter Restriction Switch
T7751EC —19—26AUG92
Disconnect harness from air filter restriction switch. Check for continuity between terminal with M01 purple wire and ground.
YES: Replace air filter restriction switch.
Is continuity measured?
NO: Switch is good. Check wiring harness. Continued on next page
TM1529 (27JUN17)
9015-15-59
TX,9015,TJ55 -19-21NOV97-4/9
544G, 624G, 644G Loader
062717
PN=303
Sub-System Diagnostics Service Brake Pressure Switch
T7199EE —UN—02OCT90
Discharge brake accumulator by depressing brake pedal 15 times, before doing this check. Disconnect harness from service brake pressure switch. Check for continuity between terminal with N03 yellow wire and ground.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace service brake pressure switch. TX,9015,TJ55 -19-21NOV97-5/9
Engine Oil Pressure Switch
T7199DZ —19—26SEP90
Disconnect harness from engine on pressure switch. Check for continuity between switch terminal and ground.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace engine oil pressure switch. TX,9015,TJ55 -19-21NOV97-6/9
Transmission Oil Pressure Switch
T7199EE —UN—02OCT90
Disconnect harness from transmission oil pressure switch. Check for continuity between terminal with N04 yellow wire and ground.
YES: Replace transmission oil pressure switch.
Is continuity measured?
NO: Switch is good. Check wiring harness. Continued on next page
TM1529 (27JUN17)
9015-15-60
TX,9015,TJ55 -19-21NOV97-7/9
544G, 624G, 644G Loader
062717
PN=304
Sub-System Diagnostics Engine Coolant Level Switch
T7199EE —UN—02OCT90
CAUTION: To avoid personal injury, DO NOT remove radiator cap unless engine is cool. When engine is hot and cap is removed, hot coolant or steam will spray out causing serious burns. NOTE: Radiator coolant level must be to the base of the filler neck to do test. Adjust coolant level as required. Inspect coolant level. Disconnect harness from engine coolant level switch. Check for continuity between terminal with Y02 yellow wire and ground.
YES: Replace engine coolant level switch.
Is continuity measured?
NO: Switch is good. Check wiring harness. TX,9015,TJ55 -19-21NOV97-8/9
Park Brake Pressure Switch
T7199EE —UN—02OCT90
Disconnect harness from park brake pressure switch. Check for continuity between terminal with P15 red wire and T05 blue wire. Is continuity measured? Start engine. Release park brake.
YES: Switch is good. Check wiring harness.
Is continuity not measured?
NO: Replace park brake pressure switch. TX,9015,TJ55 -19-21NOV97-9/9
Electronic Monitor Signals Circuit Operational Information
monitor controls only the lights and displays on the front of the unit. It does not cause any machine operation to occur.
The display monitor is a microcomputer controlled display unit to indicate the status of machine functions. The
Power to pin 24 and pin 37, on the display module, must exist for this circuit to function. TX,901515,DU659 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-61
544G, 624G, 644G Loader
062717
PN=305
Sub-System Diagnostics
Electronic Monitor Signals Circuit Theory Of Operation NOTE: See Group 9015-20 for the following additional electronic monitor circuit information:
• • • • •
• For 544G (S.N. —554999) and 644G (S.N.
Access Monitor Fault Code Display Monitor Service Code Interpretation Calibrate Tachometer Program Monitor Display to Match Machine Jumper Wire for Display Monitor
•
—554490), the first level warning triggers at 99°C (210°F). For 544G (S.N. 555000—) and 644G (S.N. 554491—), the first level warning triggers at 103°C (218°F).
2. The ninth segment of the 9-segment display lights up and triggers the red light warning:
Power to the display module is supplied by wire P08 red to pin 37 and wire P17 red to pin 24.
• For 544G (S.N. —554999) and 644G (S.N.
The display module is grounded from pin 36.
•
When the key switch is in the OFF position, power from wire P17 red allows the machine hours to be displayed, when the SELECT button is pressed. Volts will be displayed if held for 4 seconds.
—554490), the red light warning triggers at 103°C (217°F). For 544G (S.N. 555000—) and 644G (S.N. 554491—), the red light warning triggers at 110°C (230°F).
The fuel gauge is a 9-segment, analog-looking gauge that is controlled by the signal received from the fuel level sender.
When the key switch is in the ON position, power is supplied to the display monitor from wire P08 red. The display monitor has three modes of operation. They are as follows: 1. Key OFF Mode: with the key switch in the OFF position, the display monitor will display machine hours only, when the SELECT button is pressed. Volts will be displayed if held for 4 seconds. 2. Bulb Check Mode: with the key switch in the ON position and the engine not running, the display monitor will go into the bulb check mode. All the indicator lights and displays on the display monitor will light and the monitor alarm will sound for five seconds. This provides time, for the operator, to see that all display elements are functional.
The transmission oil temperature gauge is a 9-segment, analog-looking gauge that is controlled by the signal received from the transmission oil temperature sender. IMPORTANT: When a critical warning is being displayed, the stop light will flash and the monitor alarm will sound. The machine should be stopped immediately or serious damage could result. When less critical warnings are being displayed, the caution light will be on. The machine should be serviced as soon as possible. The engine oil pressure light will be on when the engine oil pressure is too low, closing the engine oil pressure switch.
3. Engine Running Mode: the display monitor determines that the engine is running when there is engine oil pressure or frequency from the alternator. The display monitor will display the status of the machine.
The engine alternator volts light will be on when the battery/alternator voltage is below 11.5 volts at monitor connector terminal 37.
The SELECT button, displays, and indicator lights function as follows:
The engine air filter light will be on when the air filter is clogged, closing the air filter restriction switch.
With the key switch in the OFF position, pressing and holding the SELECT button will display engine running hours. With the engine running and pressing the SELECT button each time, the display monitor will indicate RPM, MPH, Km/h, Hours, or Volts. The SELECT button can also be used to enter calibration modes of the display monitor.
The coolant level light will be on when the engine coolant level is too low, closing the engine coolant level switch. The transmission oil pressure light will be on when the transmission oil pressure is too low, closing the transmission oil pressure switch. The left turn arrow light will be on when the left turn signal or 4-way flasher is on.
The digital display is used to display RPM, MPH, Km/h, Hours, Volts, service codes, and calibration information.
The steering pressure light will be on when the steering pressure is too low, closing the secondary steering pressure switch. (This light will be on only during the bulb check mode if the secondary steering option is not installed on the machine.)
The engine coolant temperature gauge is a 9-segment, analog-looking gauge that is controlled by the signal received from the engine coolant temperature sender. It has two levels of warning: 1. The eighth segment of the 9-segment display lights up and triggers the first level warning:
The fluid injection light will be on when the start aid pushbutton switch is pressed. This is the only light that operates during engine cranking.
Continued on next page
TM1529 (27JUN17)
9015-15-62
TX,9015,DU1593 -19-02FEB95-1/2
544G, 624G, 644G Loader
062717
PN=306
Sub-System Diagnostics
The fasten seat belt light will be on for five seconds after the display monitor is powered, reminding the operator to fasten the seat belt. The park brake light will be on when the park brake is applied, closing the park brake pressure switch. The brake pressure light will be on when the service brake supply pressure is too low, closing the service brake pressure switch. The right turn arrow light will be on when the right turn signal or 4-way flasher is on.
Voltage will vary from about 7.5 to 7.6 VAC as engine speed increases. The hourmeter is an internal part of the display monitor. The display monitor determines if the engine is running by comparing two input signals — a signal from the engine oil pressure switch (oil pressure is present) and a signal from terminal “W” on the alternator. If both signals are present, the hourmeter will operate. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
The tachometer will operate when voltage from alternator W terminal is present on monitor connector terminal 17. TX,9015,DU1593 -19-02FEB95-2/2
TM1529 (27JUN17)
9015-15-63
544G, 624G, 644G Loader
062717
PN=307
Sub-System Diagnostics
T7751CS —19—14SEP92
Electronic Monitor Signals Circuit Functional Schematic
TX,901515,DU661 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-64
544G, 624G, 644G Loader
062717
PN=308
Sub-System Diagnostics
Electronic Monitor Signals Circuit Diagnostics TX,9015,TJ56 -19-21NOV97-1/4
• 1
Electronic Monitor Signals Diagnostic Procedures
Power for this circuit comes from the Unswitched Monitor fuse and the Switched Monitor fuse. If display monitor does not appear to be working, perform the following checks. TX,9015,TJ56 -19-21NOV97-2/4
Display Monitor
T7751FI —19—31AUG92
Unplug harness from display monitor. Key switch to OFF position. Check for voltage at pin 24. Are 12 volts measured? Key switch to ON position. Check for voltage at pin 37.
YES: Go to next check.
Are 12 volts measured?
NO: Check wiring harness. Continued on next page
TM1529 (27JUN17)
9015-15-65
TX,9015,TJ56 -19-21NOV97-3/4
544G, 624G, 644G Loader
062717
PN=309
Sub-System Diagnostics Alternator Check—95 And 135 Amp Bosch
T7835AT —19—23SEP92
Key switch ON. Engine running. Park brake ON. Using a multimeter, check for DC voltage at terminals (D+) and (B+). Is 14 DC volts measured? Using a multimeter, check for AC voltage at terminal (W).
YES: Alternator is good.
Is 7.5—7.6 AC volts measured? Does voltage increase with rpm?
NO: Alternator is failed. Repair or replace. TX,9015,TJ56 -19-21NOV97-4/4
TM1529 (27JUN17)
9015-15-66
544G, 624G, 644G Loader
062717
PN=310
Sub-System Diagnostics
Electronic Monitor And Gauge Inputs Circuit Specifications Specification 544G, 624G Fuel Level Sender—Resistance Value at Full.....................................................................170—190 ohms Resistance Value at 1/2 ....................................................95—105 ohms Resistance Value at Empty ...................................................................................8—12 ohms Transmission Oil Temperature Sender—Resistance at 15.5°C (60°F)......................................................................... 4441 ohms Resistance at 85°C (185°F) .................................................................................... 283 ohms Resistance at 90.5°C (195°F) .................................................................................... 231 ohms Resistance at 98.9°C (210°F) .................................................................................... 192 ohms Resistance at 104°C (220°F) .................................................................................. 1523 ohms Item
Engine Coolant Temperature Sender—Resistance at 15.5°C (60°F)......................................................................... 4441 ohms Resistance at 85°C (185°F) .................................................................................... 283 ohms Resistance at 90.5°C (195°F) .................................................................................... 231 ohms Resistance at 98.9°C (210°F) .................................................................................... 192 ohms Resistance at 104°C (220°F) .................................................................................... 153 ohms
Measurement
Specification
(S.N. —549966) Engine
Temperature
-17.8—48.9°C (0—120°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
-17.8—76.7°C (0—170°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
-17.8—67.8°C (0—154°F)
Segment 1 Engine Temperature Gauge Indication
Segment 2 Engine Temperature Gauge Indication (S.N. —549966) Engine
Temperature
49.4—60°C (121—140°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
77.2—83.9°C (171—183°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
68.4—81.7°C (155—179°F)
Segment 3 Engine Temperature Gauge Indication (S.N. —549966) Engine
Temperature
60.5—71°C (141—160°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
84.4—87.8°C (184—190°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
82.3—89.0°C (180—192°F)
Segment 4 Engine Temperature Gauge Indication (S.N. —549966) Engine
Temperature
71.6—82.2°C (161—180°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
88.3—91.7°C (191—197°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
89.5—92.3°C (193—198°F)
Continued on next page
TM1529 (27JUN17)
9015-15-67
TX,9015,DU1596 -19-02FEB95-1/2
544G, 624G, 644G Loader
062717
PN=311
Sub-System Diagnostics Item
Measurement
Specification
(S.N. —549966) Engine
Temperature
82.8—90.5°C (181—195°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
92.2—95.6°C (198—204°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
92.9—96.2°C (199—205°F)
Segment 5 Engine Temperature Gauge Indication
Segment 6 Engine Temperature Gauge Indication (S.N. —549966) Engine
Temperature
91—96°C (196—205°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
96.1—99.4°C (205—211°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
96.7—100.1°C (206—212°F)
Segment 7 Engine Temperature Gauge Indication (S.N. —549966) Engine
Temperature
96.6—98.9°C (206—210°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
100.1—103.4°C (212—218°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
100.1—102.9°C (212—217°F)
Segment 8 Engine Temperature Gauge Indication (S.N. —549966) Engine
Temperature
99.4—102.9°C (211—217°F)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
103.9—107.2°C (219—225°F)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
103.4—109.5°C (218—229°F)
Segment 9 Engine Temperature Gauge Indication (S.N. —549966) Engine
Temperature
103.4°C or higher (218°F or higher)
(S.N. 549967—) (Komar No. 505364) Engine
Temperature
107.8°C or higher (226°F or higher)
544G (S.N. 555000—), 644G (S.N. Temperature 554491—) Engine
110.1°C or higher (230°F or higher)
Item
Measurement
Specification
Segment 1 Gauge Indication
Transmission Temperature
-17.8—60°C (0—140°F)
Segment 2 Gauge Indication
Transmission Temperature
60.5—76.7°C (141—170°F)
Segment 3 Gauge Indication
Transmission Temperature
77.2—87.8°C (171—190°F)
Segment 4 Gauge Indication
Transmission Temperature
88.3—98.9°C (191—210°F)
Segment 5 Gauge Indication
Transmission Temperature
99.4—110°C (211—230°F)
Segment 6 Gauge Indication
Transmission Temperature
110.5—118.3°C (231—245°F)
Segment 7 Gauge Indication
Transmission Temperature
118.9—126.6°C (246—260°F)
Segment 8 Gauge Indication
Transmission Temperature
127.2—132.2°C (261—270°F) TX,9015,DU1596 -19-02FEB95-2/2
TM1529 (27JUN17)
9015-15-68
544G, 624G, 644G Loader
062717
PN=312
Sub-System Diagnostics Item
Measurement
Specification
Segment 9 Gauge Indication
Transmission Temperature
132.7°C or higher (271°F or higher) TX,9015,DU1596 -19-02FEB95-3/2
Electronic Monitor/Gauge Inputs Circuit Operational Information The transmission oil temperature sender, engine coolant temperature sender, and fuel level sender are resistive devices that change resistance as changes occur.
The monitor alarm is an audible alarm controlled by the display monitor. It will alert the operator to a critical condition indicated on the display monitor. Power to pin 24 and pin 37 must exist for this circuit to function. TX,901515,DU665 -19-16SEP92-1/1
Electronic Monitor/Gauge Inputs Circuit Theory Of Operation When the transmission oil temperature rises, the resistance in the transmission oil temperature sender will decrease. This will allow a signal to be sent to the transmission oil temperature gauge LCD display. If the temperature is too high, the transmission oil temperature warning light, stop warning, and the monitor alarm will activate.
high, the engine coolant temperature warning light, stop warning, and the monitor alarm will activate.
When the engine coolant temperature rises, the resistance in the engine coolant temperature sender will decrease. This will allow a signal to be sent to the engine coolant temperature gauge LCD display. If the temperature is too
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
When the fuel level is low, the resistance in the fuel level sender will decrease. This will allow a signal to be sent to the fuel level gauge LCD display. If the fuel level is too low, the lowest segment of the gauge display will flash.
TX,901515,DU666 -19-15DEC93-1/1
TM1529 (27JUN17)
9015-15-69
544G, 624G, 644G Loader
062717
PN=313
Sub-System Diagnostics
T8399AK —19—02FEB95
Electronic Monitor/Gauge Inputs Circuit Functional Schematic
TX,901515,DU667 -19-02FEB95-1/1
Electronic Monitor/Gauge Inputs Circuit Diagnostics Continued on next page
TM1529 (27JUN17)
9015-15-70
TX,9015,TJ57 -19-21NOV97-1/5
544G, 624G, 644G Loader
062717
PN=314
Sub-System Diagnostics
• 1
Electronic Monitor/Gauge Inputs Circuit Diagnostic Procedures
Power for this circuit comes from the Unswitched Monitor fuse and the Switched Monitor fuse. TX,9015,TJ57 -19-21NOV97-2/5
Transmission Oil Temperature Sender
T8102AN —UN—08NOV93
Key switch to OFF position. Disconnect harness from transmission oil temperature sender. Check for continuity between terminal with X01 yellow wire and R05 black wire.
YES: Replace transmission oil temperature sender.
Is continuity measured?
NO: Check wiring harness between transmission oil temperature sender and display monitor. TX,9015,TJ57 -19-21NOV97-3/5
Engine Coolant Temperature Sender
T8102AN —UN—08NOV93
Key switch to OFF position. Disconnect harness from engine coolant temperature sender. Check for continuity between terminal with X02 yellow wire and R02 black wire.
YES: Replace engine coolant temperature sender.
Is continuity measured?
NO: Check wiring harness between engine coolant temperature sender and display monitor. Continued on next page
TM1529 (27JUN17)
9015-15-71
TX,9015,TJ57 -19-21NOV97-4/5
544G, 624G, 644G Loader
062717
PN=315
Sub-System Diagnostics Fuel Level Sender
T8102AO —UN—08NOV93
Key switch to OFF position. Disconnect harness from fuel level sender. Check resistance between terminal with Y01 yellow wire and R03 black wire.
• EMPTY TANK — 10 ± 2 ohms Specification 544G, 624G Fuel Level Sender—Resistance Value at Empty................................................................................... 10 ± 2 ohms
• HALF TANK — 100 ± 5 ohms Specification 544G, 624G Fuel Level Sender—Resistance Value at 1/2...................................................................................... 100 ± 5 ohms
• FULL TANK — 180 ± 10 ohms Specification 544G, 624G Fuel Level Sender—Resistance Value at Full................................................................................... 180 ± 10 ohms Does resistance measure between 8 and 190 ohms?
YES: Fuel level sender is good. Check wiring harness between fuel level sender and display monitor. NO: Replace fuel level sender. TX,9015,TJ57 -19-21NOV97-5/5
Boom Height Kickout And Return-To-Dig Circuit Operational Information
the pilot controller are solenoids to engage the float, boom height kickout, and return-to-dig detents.
The pilot controller is a manually-operated, hydraulic valve that controls the boom and bucket motions. Inside
The key switch must be in the ON position for this circuit to function. TX,9015,DU1597 -19-12OCT93-1/1
Boom Height Kickout And Return-To-Dig Circuit Theory Of Operation
spring return to center position, and the boom will stop in the boom height kickout position.
The float detent coil is powered when the pilot controller lever is pushed fully forward. The boom will lower to the float position, and the detent coil will hold the lever in that position until the lever is pulled back.
The return-to-dig switch opens when the bucket is moved below the dig position. The dig position is determined by the location of the return-to-dig magnet.
The boom height kickout switch opens when the boom is raised above the boom height kickout position. The boom height kickout position is determined by the location of the boom height kickout magnet. The boom height kickout detent coil is powered when the boom is below the boom height kickout position. If the pilot controller lever is pulled fully to the boom up position, the boom height kickout detent will hold the lever in that position. The boom will raise until the boom height kickout switch aligns with the boom height kickout magnet. Then the boom height kickout switch will open, the boom height kickout detent coil will de-energize, the pilot controller will
The return-to-dig detent coil is powered when the bucket is below the dig position. If the pilot controller lever is pulled fully to the bucket dump position, the return-to-dig detent will hold the lever in that position. The bucket will move until the return-to-dig switch aligns with the return-to-dig magnet. Then the return-to-dig switch will open, the return-to-dig detent coil will de-energize, the pilot controller will spring return to center position, and the bucket will stop in the dig position. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,9015,DU1598 -19-12OCT93-1/1
TM1529 (27JUN17)
9015-15-72
544G, 624G, 644G Loader
062717
PN=316
Sub-System Diagnostics
T8093BS —19—11NOV93
Boom Height Kickout And Return-To-Dig Circuit Functional Schematic
TX,9015,DU1599 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-73
544G, 624G, 644G Loader
062717
PN=317
Sub-System Diagnostics
Boom Height Kickout And Return-To-Dig Circuit Diagnostics TX,9015,TJ58 -19-21NOV97-1/7
• 1
Boom Height Kickout And Return-To-Dig Circuit Diagnostic Procedures
Power for this circuit comes from the Return-to-Dig and Boom Height Kickout fuse. TX,9015,TJ58 -19-21NOV97-2/7
Float Detent Coil
T8102AP —UN—08NOV93
Disconnect harness from pilot controller. Apply battery voltage to terminal with P11 red wire. Ground terminal with G07 black wire. Move pilot lever to float detent position. Remove voltage.
YES: Float detent coil is good.
Does pilot lever stay in float detent position until voltage is removed, and then return to neutral?
NO: Replace pilot controller. TX,9015,TJ58 -19-21NOV97-3/7
Boom Height Kickout Detent Coil
T8102AQ —UN—08NOV93
Disconnect harness from pilot controller. Apply battery voltage to terminal with P11 red wire. Ground terminal with H07 green wire. Move pilot lever to boom height kickout detent position. Remove voltage.
YES: Boom height kickout detent coil is good.
Does pilot lever stay in boom height kickout detent position until voltage is removed, and then return to neutral?
NO: Replace pilot controller.
Continued on next page
TM1529 (27JUN17)
9015-15-74
TX,9015,TJ58 -19-21NOV97-4/7
544G, 624G, 644G Loader
062717
PN=318
Sub-System Diagnostics Boom Height Kickout Switch
T6989AN —UN—15MAR89
Disconnect harness from boom height kickout switch. Check for continuity between terminals with H07 green wire and G12 black wire.
YES: Replace boom height kickout switch.
Is continuity measured?
NO: Switch is good. Check wiring harness. TX,9015,TJ58 -19-21NOV97-5/7
Return-To-Dig Detent Coil
T8102AR —UN—08NOV93
Disconnect harness from pilot controller. Apply battery voltage to terminal with P11 red wire. Ground terminal with H06 green wire. Move pilot lever to return-to-dig detent position. Remove voltage.
YES: Return-to-dig detent coil is good.
Does pilot lever stay in return-to-dig detent position until voltage is removed, and then return to neutral?
NO: Replace pilot controller. TX,9015,TJ58 -19-21NOV97-6/7
Return-To-Dig Switch
T6989AN —UN—15MAR89
Disconnect harness from return-to-dig switch. Check for continuity between terminals with H06 green wire and G12 black wire.
YES: Replace return-to-dig switch.
Is continuity measured?
NO: Switch is good. Check wiring harness. TX,9015,TJ58 -19-21NOV97-7/7
Front And Rear Wiper Circuit Operational Information
• Key switch in ON or ACC position • Front and rear wiper/washer switches ON
The following conditions must exist for the front and rear wiper circuit to function: TX,901515,DU681 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-75
544G, 624G, 644G Loader
062717
PN=319
Sub-System Diagnostics
Front And Rear Wiper Circuit Theory Of Operation The front wiper/washer switch is a rotary and push button switch. The rotary motion selects the front wiper speed of OFF, LOW, or HIGH. Pushing on the rotary knob closes the washer switch to operate the front washer pump motor. The front washer pump motor will stop when the knob is released. The front wiper motor drives the front wiper arm. The front washer pump motor pumps washer fluid to the front windshield.
LOW in the middle position. The third position closes the washer switch to operate the rear washer pump motor. When the rocker is released, it will spring return to the LOW position and the rear washer pump motor will stop. The rear wiper motor drives the rear wiper arm. The rear washer pump motor pumps washer fluid to the rear windshield. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
The rear wiper/washer switch is a three position rocker switch. The switch selects OFF in the first position and TX,901515,DU682 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-76
544G, 624G, 644G Loader
062717
PN=320
Sub-System Diagnostics
T111395 —19—19SEP97
Front And Rear Wiper Circuit Functional Schematic
TX,901515,DU683 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-15-77
544G, 624G, 644G Loader
062717
PN=321
Sub-System Diagnostics
Front And Rear Wiper Circuit Diagnostics TX,9015,TJ59 -19-21NOV97-1/9
• 1
Front And Rear Wiper Circuit Diagnostic Procedures
Power for this circuit comes from the Front Wiper fuse and the Rear Wiper fuse. TX,9015,TJ59 -19-21NOV97-2/9
Front Wiper/Washer Switch
T8102AS —UN—08NOV93
Disconnect harness from front wiper/washer switch. Wiper/washer switch in LOW position. Check for continuity between terminals with P18 red wire and A03 orange wire. Is continuity measured? Wiper/washer switch in HIGH position. Check for continuity between terminals with P18 red wire and A04 orange wire. Is continuity measured? Wiper/washer switch in WASH position. Check for continuity between terminals with P18 red wire and A09 orange wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace front wiper/washer switch. TX,9015,TJ59 -19-21NOV97-3/9
Front Wiper Motor—Low Speed
T8102AT —UN—08NOV93
Disconnect harness from front wiper motor. Connect battery voltage to terminals with A03 orange wire and A02 orange wire. Does motor run in LOW speed? Remove voltage from terminal with A03 orange wire.
YES: Go to next check.
Does motor run until blade reaches PARK position?
NO: Replace front wiper motor.
Continued on next page
TM1529 (27JUN17)
9015-15-78
TX,9015,TJ59 -19-21NOV97-4/9
544G, 624G, 644G Loader
062717
PN=322
Sub-System Diagnostics Front Wiper Motor—High Speed
T8102AT —UN—08NOV93
Disconnect harness from front wiper motor. Connect battery voltage to terminals with A04 orange wire and A02 orange wire. Does motor run in HIGH speed? Remove voltage from terminal with A04 orange wire.
YES: Front wiper motor is good. Check wiring harness.
Does motor run until blade reaches PARK position?
NO: Replace front wiper motor. TX,9015,TJ59 -19-21NOV97-5/9
Front Washer Pump Motor
T7751EI —19—26AUG92
Disconnect harness from front washer pump motor. Connect battery voltage to terminal with A09 orange wire. Ground terminal with G18 black wire.
YES: Front washer pump motor is good. Check wiring harness.
Does motor run and operate the pump?
NO: Replace front washer pump motor. TX,9015,TJ59 -19-21NOV97-6/9
Rear Wiper/Washer Switch
T8102AU —UN—08NOV93
Disconnect harness from rear wiper/washer switch. Wiper/washer switch in LOW position. Check for continuity between terminals with P09 red wire and A07 orange wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace rear wiper/washer switch. Continued on next page
TM1529 (27JUN17)
9015-15-79
TX,9015,TJ59 -19-21NOV97-7/9
544G, 624G, 644G Loader
062717
PN=323
Sub-System Diagnostics Rear Wiper Motor
T8102AV —UN—08NOV93
Disconnect harness from rear wiper motor. Connect battery voltage to terminals with P09 red wire and A07 orange wire. Does motor run in LOW speed? Remove voltage from terminal with A07 orange wire.
YES: Rear wiper motor is good. Check wiring harness.
Does motor run until blade reaches PARK position?
NO: Replace rear wiper motor. TX,9015,TJ59 -19-21NOV97-8/9
Rear Washer Pump Motor
T7751EK —19—26AUG92
Disconnect harness from rear washer pump motor. Connect battery voltage to terminal with A10 orange wire. Ground terminal with G18 black wire.
YES: Rear washer pump motor is good. Check wiring harness.
Does motor run and operate the pump?
NO: Replace rear washer pump motor. TX,9015,TJ59 -19-21NOV97-9/9
Brake Light Circuit Specifications Specification Brake Light Pressure Switch (Normally Open)—Closing Pressure...............................140—690 kPa (4.0—6.8 bar) (60—100 psi) TX,9015,HH868 -19-17FEB95-1/1
Brake Light Circuit Operational Information The following conditions must exist for the brake and light circuit to function:
• Key switch to ON position • Brake light pressure switch activated • Brake light relay energized TX,901515,DU693 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-80
544G, 624G, 644G Loader
062717
PN=324
Sub-System Diagnostics
Brake Light Circuit Theory Of Operation The brake light relay is activated by the brake light pressure switch. When the brakes are applied, the brake light pressure switch will close. This will allow the brake light relay to
energize. Power is then sent to the left and right brake lights and they will come on. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,901515,DU694 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-81
544G, 624G, 644G Loader
062717
PN=325
Sub-System Diagnostics
T7751CW —19—14SEP92
Brake Light Circuit Functional Schematic
TX,901515,DU695 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-82
544G, 624G, 644G Loader
062717
PN=326
Sub-System Diagnostics
Brake Light Circuit Diagnostics TX,9015,TJ60 -19-21NOV97-1/6
• 1
Brake Light Circuit Diagnostic Procedures
Power for this circuit comes from the Brake Light fuse. TX,9015,TJ60 -19-21NOV97-2/6
Brake Light Pressure Switch
T8102AW —UN—08NOV93
Disconnect harness from brake light pressure switch. Check for continuity between terminals with P23 red wire and L17 brown wire. Is continuity measured? Start engine. Depress brake pedal.
YES: Replace brake light pressure switch.
Is continuity not measured?
NO: Switch is good. Check wiring harness. TX,9015,TJ60 -19-21NOV97-3/6
Brake Light Relay
T7287BH —UN—16AUG90
Key switch to OFF position. Disconnect harness from brake light relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace brake light relay. Continued on next page
TM1529 (27JUN17)
9015-15-83
TX,9015,TJ60 -19-21NOV97-4/6
544G, 624G, 644G Loader
062717
PN=327
Sub-System Diagnostics Left Brake Light
T7751EL —UN—26AUG92
Disconnect harness from left brake light. Connect battery voltage to terminal with L07 brown wire. Ground terminal with G14 black wire.
YES: Brake light is good. Check wiring harness.
Does brake light come on?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ60 -19-21NOV97-5/6
Right Brake Light
T7751EL —UN—26AUG92
Disconnect harness from right brake light. Connect battery voltage to terminal with L07 brown wire. Ground terminal with G14 black wire.
YES: Brake light is good. Check wiring harness.
Does brake light come on?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ60 -19-21NOV97-6/6
Heater/Pressurizer Circuit Operational Information
• Key switch to ON position • Defroster pressurization relay energized
The following conditions must exist for the heater/pressurizer circuit to function: TX,901515,DU701 -19-16SEP92-1/1
Heater/Pressurizer Circuit Theory Of Operation
pressurization relay will energize, and the pressurizer fan motor will operate at medium speed.
The heater/pressurizer fan switch is a four position rotary switch to select OFF, LOW, MEDIUM, or HIGH fan speed.
The defroster pressurization relay is energized when the defroster fan motor is on. The pressurizer fan motor will also be on. This is to balance the air flow in the ducts.
The pressurizer fan resistor limits the current to the pressurizer fan motor to control the speed of the fan. The pressurizer fan motor drives the pressurizer fan. Note that when the defroster fan motor is on, the defroster
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,901515,DU702 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-84
544G, 624G, 644G Loader
062717
PN=328
Sub-System Diagnostics
T7812BH —19—09SEP97
Heater/Pressurizer Circuit Functional Schematic
TX,901515,DU703 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-85
544G, 624G, 644G Loader
062717
PN=329
Sub-System Diagnostics
Heater/Pressurizer Circuit Diagnostics TX,9015,TJ61 -19-21NOV97-1/6
• 1
Heater/Pressurizer Circuit Diagnostic Procedures
Power for this circuit comes from the Heater/Pressurizer Fan fuse. TX,9015,TJ61 -19-21NOV97-2/6
Heater/Pressurizer Fan Switch
T7751FK —UN—31AUG92
Disconnect harness from heater/pressurizer fan switch. Heater/pressurizer fan switch to OFF position. Check for continuity between B switch terminal and remaining terminals.
YES: Replace heater/pressurizer fan switch.
Is continuity measured at any terminal?
NO: Go to next step in this check.
T7751FK —UN—31AUG92
Heater/pressurizer fan switch to LOW position. Check for continuity between switch terminals B, L and C. Is continuity measured? Heater/pressurizer fan switch to MEDIUM position. Check for continuity between switch terminals B, M and C. Is continuity measured? Heater/pressurizer fan switch to HIGH position. Check for continuity between switch terminals B, H and C.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace heater/pressurizer fan switch. Continued on next page
TM1529 (27JUN17)
9015-15-86
TX,9015,TJ61 -19-21NOV97-3/6
544G, 624G, 644G Loader
062717
PN=330
Sub-System Diagnostics Resistor
T7751FM —UN—31AUG92
Disconnect harness from resistor. Check for continuity between terminals with A17 orange wire and A18 orange wire. Is continuity measured? Check for continuity between terminals with A16 orange wire and A18 orange wire.
YES: Resistor is good. Check wiring harness.
Is continuity measured?
NO: Replace resistor. TX,9015,TJ61 -19-21NOV97-4/6
Pressurizer Fan Motor
T7751FN —UN—31AUG92
Disconnect harness from pressurizer fan motor. Apply battery voltage to terminal with A18 orange wire. Ground terminal with G08 black wire.
YES: Motor is good. Check wiring harness.
Does motor run?
NO: Replace pressurizer fan motor. TX,9015,TJ61 -19-21NOV97-5/6
Defroster Pressurization Relay
T7287BH —UN—16AUG90
Key switch to OFF position. Disconnect harness from defroster pressurization relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace defroster pressurization relay. TX,9015,TJ61 -19-21NOV97-6/6
TM1529 (27JUN17)
9015-15-87
544G, 624G, 644G Loader
062717
PN=331
Sub-System Diagnostics
Air Conditioning Circuit Specifications Specification A/C Freeze Control Temperature Cycling Switch (Normally Closed)—Opening Temperature............................................... -2°C—0.3°C 29.5°F—32.5°F A/C Low Pressure Switch (Normally Open)—Opens on Decreasing Pressure............220 ± 20 kPa (2.2 ± 0.2 bar) (32 ± 3 psi) Closes on Increasing Pressure .................................276 ± 20 kPa (2.76 ± 0.2 bar) (40 ± 3 psi)
NOTE: Low pressure switch is normally open when removed from machine. When installed the switch becomes closed because of normal system pressure. Specification A/C High Pressure Switch (Normally Closed)—Opens on Increasing Pressure..............2410 ± 100 kPa (24.1 ± bar) (350 ± 15 psi) Closes on Decreasing Pressure ........................... 1390 ± 100 kPa (13.91 ± 1 bar) (220 ± 15 psi) TX,9015,HH869 -19-02FEB95-1/1
• Heater/pressurizer fan switch to HIGH, MEDIUM or
Air Conditioning Circuit Operational Information
LOW position
The following conditions must exist for the air conditioner circuit to function:
• Key switch to ON position
• A/C shutoff switch closed • Freeze control temperature cycling switch closed • A/C low pressure switch closed • A/C high pressure switch closed TX,9015,DU1658 -19-10NOV93-1/1
Air Conditioning Circuit Theory Of Operation The A/C shutoff switch is a rocker switch to enable the air conditioning system to operate.
The A/C condenser motor relay is energized at the same time as the A/C compressor clutch. This will allow power to the condenser motors.
The A/C freeze control temperature cycling switch opens when the air conditioning system freezes.
The A/C condenser motors drive the condenser motor fans. This forces air past the condenser coils.
The A/C low pressure switch opens when there is insufficient charge of freon in the system.
The A/C condenser motor circuit breakers provide overload protection for the A/C Condenser motors. After an overload, these circuit breakers will automatically reset when they cool.
The A/C high pressure switch opens when the refrigerant pressure reaches the high limit. The compressor will be shut off since sufficient pressure has been attained. The A/C clutch diode limits the voltage spike back to all A/C switch contacts as the relay opens.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,901515,DU711 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-88
544G, 624G, 644G Loader
062717
PN=332
Sub-System Diagnostics
T8102AX —UN—08NOV93
Air Conditioning Circuit Functional Schematic
TX,901515,DU712 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-89
544G, 624G, 644G Loader
062717
PN=333
Sub-System Diagnostics
Air Conditioning Circuit Diagnostics TX,9015,TJ62 -19-21NOV97-1/10
• 1
Air Conditioning Circuit Diagnostic Procedures
Power for this circuit comes from the Heater/Pressurizer Fan fuse. TX,9015,TJ62 -19-21NOV97-2/10
Heater/Pressurizer Fan Switch
T7751FK —UN—31AUG92
Heater/pressurizer fan switch to LOW position. Check for continuity between switch terminals B, L and C. Is continuity measured? Heater/pressurizer fan switch to MEDIUM position. Check for continuity between switch terminals B, M and C. Is continuity measured? Heater/pressurizer fan switch to HIGH position. Check for continuity between switch terminals B, H and C.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace heater/pressurizer fan switch. TX,9015,TJ62 -19-21NOV97-3/10
A/C Shutoff Switch
T7751GF —UN—31AUG92
Disconnect harness from A/C shutoff switch. Check for continuity between terminals with A23 orange wire and A24 orange wire.
YES: Replace A/C shutoff switch.
Is continuity measured?
NO: Switch is good. Go to next check. Continued on next page
TM1529 (27JUN17)
9015-15-90
TX,9015,TJ62 -19-21NOV97-4/10
544G, 624G, 644G Loader
062717
PN=334
Sub-System Diagnostics Freeze Control Temperature Cycling Switch
T7751GG —UN—31AUG92
Disconnect harness from freeze control temperature cycling switch. Check for continuity between terminals with A24 orange wire and A25 orange wire.
YES: Switch is good. Go to next check.
Is continuity measured?
NO: Replace freeze control temperature cycling switch. TX,9015,TJ62 -19-21NOV97-5/10
Air Conditioner Low Pressure Switch Check
T8093AB —UN—05OCT93
Disconnect harness from switch.
YES: Replace switch.
Check for continuity between connector terminals for A07 orange wires. Is continuity measured?
NO: Go to next step in this check.
Remove switch from system. (A valve under switch prevents refrigerant from escaping when the switch is removed.) Measure continuity across switch terminals.
YES: Switch is good. Check wiring harness.
Does ohmmeter read open?
NO: Go to Low Pressure Switch Test , Group 9031-25. Continued on next page
TM1529 (27JUN17)
9015-15-91
TX,9015,TJ62 -19-21NOV97-6/10
544G, 624G, 644G Loader
062717
PN=335
Sub-System Diagnostics Air Conditioner High Pressure Switch Check
T8093AD —UN—05OCT93
Disconnect harness from switch. Measure continuity across switch terminals.
YES: Go to next step in this check.
Does ohmmeter read continuity?
NO: Replace switch.
Remove switch from system. (A valve under the switch prevents freon from escaping when the switch is removed.) Measure continuity across switch terminals.
YES: Switch is good. Check wiring harness.
Does ohmmeter read continuity?
NO: System pressure is too high. Go to Air Conditioning Operating Pressure Diagnostic Chart , Group 9031-25. TX,9015,TJ62 -19-21NOV97-7/10
A/C Compressor Clutch
T7751GJ —UN—31AUG92
Disconnect harness from A/C compressor clutch. Connect battery voltage to terminal with A11 orange wire.
YES: A/C compressor clutch is good. Check wiring harness.
Does A/C compressor clutch "click"?
NO: Replace A/C compressor clutch. Continued on next page
TM1529 (27JUN17)
9015-15-92
TX,9015,TJ62 -19-21NOV97-8/10
544G, 624G, 644G Loader
062717
PN=336
Sub-System Diagnostics A/C Condenser Motor Relay
T7287BH —UN—16AUG90
Key switch to OFF position. Disconnect harness from A/C condenser motor relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace A/C condenser motor relay. TX,9015,TJ62 -19-21NOV97-9/10
Condenser Motor
T7751GL —UN—31AUG92
Disconnect harness from condenser motor. Connect battery voltage to P13 red wire or P14 red wire. Ground terminal with black wire. YES: Condenser motor is good. Check wiring harness. Does condenser motor run?
NO: Replace condenser motor. TX,9015,TJ62 -19-21NOV97-10/10
Defroster Pressurization Circuit Operational Information
• Key switch to ON position • Defroster fan switch to LOW, MEDIUM, or HIGH position
The following conditions must exist for the defroster pressurization circuit to function: TX,901515,DU715 -19-16SEP92-1/1
Defroster Pressurization Circuit Theory Of Operation
pressurization relay will energize, and the pressurizer fan motor will operate at medium speed.
The defroster fan switch is a four position rotary switch to select OFF, LOW, MEDIUM, or HIGH fan speed.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
The defroster fan resistor limits the current to the defroster fan motor to control the speed of the fan. The defroster fan motor drives the defroster fan. Note that when the defroster fan motor is on, the defroster
TX,901515,DU716 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-93
544G, 624G, 644G Loader
062717
PN=337
Sub-System Diagnostics
T7812BG —19—09SEP97
Defroster Pressurization Circuit Functional Schematic
TX,901515,DU717 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-94
544G, 624G, 644G Loader
062717
PN=338
Sub-System Diagnostics
Defroster Pressurization Circuit Diagnostics TX,9015,TJ63 -19-21NOV97-1/5
• 1
Defroster Pressurization Circuit Diagnostic Procedures
Power for this circuit comes from the Defroster Fan fuse. TX,9015,TJ63 -19-21NOV97-2/5
Defroster Fan Switch
T7751FP —UN—31AUG92
Disconnect harness from defroster fan switch. Defroster fan switch to OFF position. Check for continuity between terminal with P27 red wire and remaining terminals.
YES: Replace defroster fan switch.
Is continuity measured at any terminal?
NO: Go to next step in this check.
T7751FK —UN—31AUG92
Defroster fan switch to LOW position. Check for continuity between switch terminals B, L and C. Is continuity measured? Defroster fan switch to MEDIUM position. Check for continuity between switch terminals B, M and C. Is continuity measured? Defroster fan switch to HIGH position. Check for continuity between switch terminals B, H and C.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace defroster fan switch. Continued on next page
TM1529 (27JUN17)
9015-15-95
TX,9015,TJ63 -19-21NOV97-3/5
544G, 624G, 644G Loader
062717
PN=339
Sub-System Diagnostics Resistor
T7751FM —UN—31AUG92
Disconnect harness from resistor. Check for continuity between terminals with A14 orange wire and A15 orange wire. Is continuity measured? Check for continuity between terminals with A13 orange wire and A15 orange wire.
YES: Resistor is good. Check wiring harness.
Is continuity measured?
NO: Replace resistor. TX,9015,TJ63 -19-21NOV97-4/5
Defroster Fan Motor
T8399AC —UN—27JAN95
Disconnect harness from defroster fan motor. Apply battery voltage to terminal with A15 orange wire. Ground terminal with G13 black wire.
YES: Motor is good. Check wiring harness.
Does motor run?
NO: Replace defroster fan motor. TX,9015,TJ63 -19-21NOV97-5/5
Turn Signal And 4-Way Flasher Circuit Operational Information The key switch must be to the ON position for the turn signal and 4-way flasher circuit to function. TX,901515,DU724 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-96
544G, 624G, 644G Loader
062717
PN=340
Sub-System Diagnostics
Turn Signal And 4-Way Flasher Circuit Theory Of Operation The turn signal and 4-way flasher circuit controls the turn signal lights. When the turn signal switch is selected left, the left turn signal lights will flash, and the right turn signal lights will be off. When the turn signal switch is selected right, the right turn signal lights will flash, and the left turn signal lights will be off.
The turn signal switch is a double pole switch. One set of contacts in the switch connects the flasher signal to the right or left turn signal lights. The other set of contacts in the switch connects the steady signal from the 4-way flasher switch to the lights on the opposite side when the 4-way flasher switch is on. The 4-way flasher switch is a double pole switch.
When the 4-way flasher switch is turned on and the turn signal switch is off, the left and right turn signal lights will flash together (4-way flashing).
One set of contacts in the switch connects the flasher signal to the left and right turn signal lights through the 4-way flasher diodes.
If the 4-way flasher is on, and the turn signal switch is selected left, then the left turn signal lights will flash and the right turn signal lights will be on steady. When the turn signal switch is turned off, the 4-way flashing will resume.
The other set of contacts in the switch connects the steady signal to the turn signal switch. Thus, when the turn signal switch is turned on while the 4-way flasher switch is on, the lights on the opposite side of the turn direction will be on steady.
If the 4-way flasher is on, and the turn signal switch is selected right, then the right turn signal lights will flash and the left turn signal lights will be on steady. When the turn signal switch is turned off, the 4-way flashing will resume. The flasher switches the power to make the turn signal lights flash.
The 4-way flasher diodes are installed to keep the signals from feeding back to the flasher. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10. TX,901515,DU725 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-97
544G, 624G, 644G Loader
062717
PN=341
Sub-System Diagnostics
T8102AY —UN—08NOV93
Turn Signal And 4-Way Flasher Circuit Functional Schematic
TX,901515,DU726 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-98
544G, 624G, 644G Loader
062717
PN=342
Sub-System Diagnostics
Turn Signal And 4-Way Flasher Circuit Diagnostics TX,9015,TJ64 -19-21NOV97-1/6
• 1
Turn Signal And 4-Way Flasher Circuit Diagnostic Procedures
Power for this circuit comes from the Flasher fuse. TX,9015,TJ64 -19-21NOV97-2/6
Flasher
T8102AZ —UN—08NOV93
Remove flasher. Key switch to ON position. Check for voltage between terminal with P02 red wire and G03 black wire.
YES: Replace flasher.
Are 12 volts measured?
NO: Check wiring harness. TX,9015,TJ64 -19-21NOV97-3/6
Turn Signal Switch
T7751FT —UN—31AUG92
Disconnect harness from turn signal switch. Turn signal switch turned RIGHT. Check for continuity between terminals with L03 brown wire and L01 brown wire, and L09 brown wire and L02 brown wire. Is continuity measured? Turn signal switch turned LEFT. Check for continuity between terminals with L03 brown wire and L02 brown wire, and L09 brown wire and L01 brown wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace turn signal switch. Continued on next page
TM1529 (27JUN17)
9015-15-99
TX,9015,TJ64 -19-21NOV97-4/6
544G, 624G, 644G Loader
062717
PN=343
Sub-System Diagnostics 4-Way Flasher Switch
T7751FU —UN—31AUG92
Disconnect harness from 4-way flasher switch. 4-way flasher switch to ON position. Check for continuity between terminals with L03 brown wire and L08 brown wire. Is continuity measured? Check for continuity between terminals with P02 red wire and L09 brown wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace 4-way flasher switch. TX,9015,TJ64 -19-21NOV97-5/6
Turn Signal Light
T7751EN —UN—26AUG92
Disconnect harness from turn signal light. Connect battery voltage to terminal with L01 brown wire or L02 brown wire. Ground terminal with G12 black wire or G14 black wire.
YES: Turn signal light is good. Check wiring harness.
Does turn signal light function?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ64 -19-21NOV97-6/6
Cab And Canopy Work Light Circuit Operational Information
The following conditions must exist for the cab and canopy work light circuit to function:
The cab work lights are mounted on the upper corners of the cab or canopy.
• Key switch to ON position • Cab work light switch closed TX,901515,DU732 -19-16SEP92-1/1
Cab And Canopy Work Light Circuit Theory Of Operation When the cab work light switch is closed, the cab work light relay will energize. Power will then go to the front and rear work lights.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
The cab work light circuit breaker provides overload protection for the cab work lights. After an overload, the circuit breaker will automatically reset when it cools down. TX,901515,DU733 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-100
544G, 624G, 644G Loader
062717
PN=344
Sub-System Diagnostics
T8102BA —UN—08NOV93
Cab And Canopy Work Light Circuit Functional Schematic
TX,901515,DU734 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-101
544G, 624G, 644G Loader
062717
PN=345
Sub-System Diagnostics
Cab And Canopy Work Light Circuit Diagnostics TX,9015,TJ65 -19-21NOV97-1/5
• 1
Cab And Canopy Work Light Circuit Diagnostic Procedures
Power for this circuit comes from the Cab Work Light circuit breaker and the Drive and Cab Work Light Switch fuse. TX,9015,TJ65 -19-21NOV97-2/5
Cab Work Light Switch
T7751FV —UN—31AUG92
Disconnect harness from cab work light switch. Cab work light switch to ON position. Check for continuity between terminals with P04 red wire and L05 brown wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace cab work light switch. TX,9015,TJ65 -19-21NOV97-3/5
Cab Work Light Relay
T7287BH —UN—16AUG90
Key switch to OFF position. Disconnect harness from cab work light relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace cab work light relay. Continued on next page
TM1529 (27JUN17)
9015-15-102
TX,9015,TJ65 -19-21NOV97-4/5
544G, 624G, 644G Loader
062717
PN=346
Sub-System Diagnostics Work Light
T7751EP —19—26AUG92
Disconnect harness from work light. Connect battery voltage to terminal with L06 brown wire. Ground terminal with G09 black wire.
YES: Work light is good. Check wiring harness.
Does work light function?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ65 -19-21NOV97-5/5
Drive Light/Dome Light Circuit Operational Information The following conditions must exist for the drive light/dome light circuit to function:
• Key switch to ON position • Drive light switch closed • Dome light switch closed • Map light switch closed TX,901515,DU739 -19-16SEP92-1/1
Drive Light/Dome Light Circuit Theory Of Operation When the drive light switch is closed, the drive light relay will energize. Power will then go to the left and right front drive lights, left and right tail lights, and the license plate light.
The unswitched radio, dome light, and door release circuit breaker provides overload protection for the dome light and map light. After an overload, the circuit breaker will automatically reset when it cools down.
When the dome light switch is closed, power will go to the dome light.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
When the map light switch is closed, power will go to the map light. The drive light circuit breaker provides overload protection for the drive lights and the tail lights. After an overload, the circuit breaker will automatically reset when it cools down.
TX,901515,DU740 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-103
544G, 624G, 644G Loader
062717
PN=347
Sub-System Diagnostics
T8102BB —UN—08NOV93
Drive Light/Dome Light Circuit Functional Schematic
TX,901515,DU741 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-104
544G, 624G, 644G Loader
062717
PN=348
Sub-System Diagnostics
Drive Light/Dome Light Circuit Diagnostics TX,9015,TJ66 -19-21NOV97-1/11
• 1
Drive Light/Dome Light Circuit Diagnostic Procedures
Power for this circuit comes from the Drive and Cab Work Light Switch fuse, the Drive Light circuit breaker, and the Unswitched Radio, Dome Light, and Door Release circuit breaker. TX,9015,TJ66 -19-21NOV97-2/11
Drive Light Switch
T7751FW —UN—31AUG92
Disconnect harness from drive light switch. Drive light switch to ON position. Check for continuity between terminals with P04 red wire and L14 brown wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace drive light switch. TX,9015,TJ66 -19-21NOV97-3/11
Drive Light Relay
T7287BH —UN—16AUG90
Key switch to OFF position. Disconnect harness from drive light relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace drive light relay. Continued on next page
TM1529 (27JUN17)
9015-15-105
TX,9015,TJ66 -19-21NOV97-4/11
544G, 624G, 644G Loader
062717
PN=349
Sub-System Diagnostics Front Drive Light
T7751EP —19—26AUG92
Disconnect harness from drive light. Connect battery voltage to terminal with L04 brown wire. Ground terminal with G12 black wire.
YES: Drive light is good. Check wiring harness.
Does drive light function?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ66 -19-21NOV97-5/11
Tail Light
T7751ER —UN—26AUG92
Disconnect harness from tail light. Connect battery voltage to terminal with L04 brown wire. Ground terminal with G14 black wire.
YES: Tail light is good. Check wiring harness.
Does tail light function?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ66 -19-21NOV97-6/11
License Plate Light (If Equipped)
T7751FX —UN—08SEP92
Disconnect harness from license plate light. Connect battery voltage to terminal with L04 brown wire. Ground terminal with G14 black wire.
YES: License plate light is good. Check wiring harness.
Does license plate light function?
NO: Replace bulb. If bulb is good, replace light. Continued on next page
TM1529 (27JUN17)
9015-15-106
TX,9015,TJ66 -19-21NOV97-7/11
544G, 624G, 644G Loader
062717
PN=350
Sub-System Diagnostics Dome Light Switch
T6622BB —UN—09DEC88
Disconnect harness from dome light switch. Dome light switch to ON position. Check for continuity between terminals with P25 red wire and G09 black wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace dome light switch. TX,9015,TJ66 -19-21NOV97-8/11
Map Light Switch
T6622BB —UN—09DEC88
Disconnect harness from map light switch. Map light switch to ON position. Check for continuity between terminals with P25 red wire and G09 black wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace map light switch. TX,9015,TJ66 -19-21NOV97-9/11
Dome Light
T6534DZ —UN—19OCT88
Disconnect harness from dome light. Connect battery voltage to terminal with P25 red wire. Ground terminal with G09 black wire.
YES: Dome light is good. Check wiring harness.
Does dome light function?
NO: Replace bulb. If bulb is good, replace light. Continued on next page
TM1529 (27JUN17)
9015-15-107
TX,9015,TJ66 -19-21NOV97-10/11
544G, 624G, 644G Loader
062717
PN=351
Sub-System Diagnostics Map Light
T6534DZ —UN—19OCT88
Disconnect harness from map light. Connect battery voltage to terminal with P25 red wire. Ground terminal with G09 black wire.
YES: Map light is good. Check wiring harness.
Does map light function?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ66 -19-21NOV97-11/11
Door Release/Radio/Horn/Rotary Beacon Circuit Operational Information The following conditions must exist for the door release/radio/horn/rotary beacon circuit to function:
• Key switch to ON position • Door release switch closed • Horn (pushbutton) switch closed • Rotary beacon switch closed TX,901515,DU752 -19-16SEP92-1/1
Door Release/Radio/Horn/Rotary Beacon Circuit Theory Of Operation
When the rotary beacon switch is closed, power from L15 brown wire will activate the rotary beacon light.
With the key switch in the ON position and the door release switch closed, the door release solenoid will energize. This will unlatch the door hold-back.
The door release diode is installed to limit the voltage spike back to the door release switch contacts when the relay is opening.
With the key switch in the ON position, power from P25 red wire and P21 red wire will allow operation of the radio.
NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
When the horn (pushbutton) switch is closed, power from P01 red wire will activate the HI and LOW note horns.
TX,901515,DU753 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-108
544G, 624G, 644G Loader
062717
PN=352
Sub-System Diagnostics
T8102BC —UN—08NOV93
Door Release/Radio/Horn/Rotary Beacon Circuit Functional Schematic
TX,901515,DU754 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-109
544G, 624G, 644G Loader
062717
PN=353
Sub-System Diagnostics
Door Release/Radio/Horn/Rotary Beacon Circuit Diagnostics TX,9015,TJ67 -19-21NOV97-1/9
• 1
Door Release/Radio/Horn/Rotary Beacon Circuit Diagnostic Procedures
Power for this circuit comes from the Unswitched Radio, Dome Light, and Door Release circuit breaker, Switched Radio fuse, Horn fuse, and Rotary Beacon fuse. TX,9015,TJ67 -19-21NOV97-2/9
Door Release Switch
T7751FY —UN—31AUG92
Disconnect harness from door release switch. Door release switch to ON position. Check for continuity between terminals with A22 orange wire and G08 black wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace door release switch. TX,9015,TJ67 -19-21NOV97-3/9
Door Release Solenoid
T7199BV —UN—16AUG90
Key switch to OFF position. Disconnect harness from door release solenoid. Connect battery voltage to terminal with P25 red wire. Ground terminal with A22 orange wire.
YES: Solenoid is good. Check wiring harness.
Does solenoid "click"?
NO: Replace door release solenoid. Continued on next page
TM1529 (27JUN17)
9015-15-110
TX,9015,TJ67 -19-21NOV97-4/9
544G, 624G, 644G Loader
062717
PN=354
Sub-System Diagnostics Radio (If Equipped)
T7751FZ —UN—31AUG92
Key switch to ON position. Radio to ON position. Check voltage at terminal with P21 red wire.
YES: Radio is good. Check wires to speaker(s) and wiring harness between radio and right rear cab leg ground.
Are 12 volts measured?
NO: Check wiring harness between circuit breaker and radio. If harness is good, replace radio. TX,9015,TJ67 -19-21NOV97-5/9
Horn (Pushbutton) Switch
T7199CY —UN—16AUG90
Disconnect harness from horn switch. Horn switch pressed. Check for continuity between terminals with A01 orange wire and G13 black wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace horn (pushbutton) switch. TX,9015,TJ67 -19-21NOV97-6/9
Horn
T6573AO —UN—23AUG93
Key switch to OFF position. Disconnect harness from horn. Connect battery voltage to terminal with P01 red wire. Ground terminal with A01 orange wire.
YES: Horn is good. Check wiring harness.
Does horn sound?
NO: Replace horn. Continued on next page
TM1529 (27JUN17)
9015-15-111
TX,9015,TJ67 -19-21NOV97-7/9
544G, 624G, 644G Loader
062717
PN=355
Sub-System Diagnostics Rotary Beacon Switch (If Equipped)
T7751EZ —UN—31AUG92
Disconnect harness from rotary beacon switch. Rotary beacon switch to ON position. Check for continuity between terminals with P16 red wire and L15 brown wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace rotary beacon switch. TX,9015,TJ67 -19-21NOV97-8/9
Rotary Beacon Light (If Equipped)
T7199DF —UN—16AUG90
Disconnect harness from rotary beacon light. Connect battery voltage to terminal with L15 brown wire. Ground rotary beacon light.
YES: Rotary beacon light is good. Check wiring harness.
Does rotary beacon light function?
NO: Replace bulb. If bulb is good, replace light. TX,9015,TJ67 -19-21NOV97-9/9
Pin Disconnect/Ride Control/Spare Circuit Operational Information The following conditions must exist for the pin disconnect/ride control/spare circuit to function:
• Pin disconnect switch closed • Pin disconnect solenoid energized • Ride control switch to ON position • Ride control reset relay energized • Ride control solenoids energized
• Key switch to ON position TX,901515,DU763 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-112
544G, 624G, 644G Loader
062717
PN=356
Sub-System Diagnostics
Pin Disconnect/Ride Control/Spare Circuit Theory Of Operation When the pin disconnect switch is closed, power from H08 green wire will energize the pin disconnect solenoid. This will allow the pins to move. The pin disconnect diode is installed to limit the voltage spike back to the pin disconnect switch contacts as the switch is opening. The ride control circuit will function only when the ride control reset relay is energized. When the key switch is in the ON position, the ride control solenoids will not energize until the ride control switch is moved to the ON position. If the key switch was turned to the OFF position with the ride control switch in the ON position, the ride control switch must be toggled from ON to OFF and back to ON when the key switch is turned to the ON position again.
The ride control diode is installed to limit the voltage spike back to the ride control switch contacts as the switch is opening. The ride control solenoids actuate the ride control hydraulic valves. When the solenoids are energized, oil from the head of the boom lift cylinders will flow to and from the ride control accumulator. This will help smooth the machine ride by counteracting the machine bounce with a small amount of boom motion. The spare fuse is for additional circuits which may be added. It is recommended that this circuit not exceed 20 amps. NOTE: For component identification code description, see Wiring and Schematic Diagrams Legend , Group 9015-10.
TX,901515,DU764 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-15-113
544G, 624G, 644G Loader
062717
PN=357
Sub-System Diagnostics
T8102BD —UN—08NOV93
Pin Disconnect/Ride Control/Spare Circuit Functional Schematic
TX,901515,DU765 -19-16DEC93-1/1
TM1529 (27JUN17)
9015-15-114
544G, 624G, 644G Loader
062717
PN=358
Sub-System Diagnostics
Pin Disconnect/Ride Control/Spare Circuit Diagnostics TX,9015,TJ68 -19-21NOV97-1/7
• 1
Pin Disconnect/Ride Control/Spare Circuit Diagnostic Procedures
Power for this circuit comes from the Pin Disconnect fuse and the Ride Control fuse. TX,9015,TJ68 -19-21NOV97-2/7
Pin Disconnect Switch
T6534BK —UN—19OCT88
Disconnect harness from pin disconnect switch. Pin disconnect switch to ON position. Check for continuity between terminals with P29 red wire and H08 green wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace pin disconnect switch. TX,9015,TJ68 -19-21NOV97-3/7
Pin Disconnect Solenoid
T6989AR —UN—15MAR89
Key switch to OFF position. Disconnect harness from pin disconnect solenoid. Connect battery voltage to terminal with H08 green wire. Ground terminal with G05 black wire.
YES: Solenoid is good. Check wiring harness.
Does solenoid "click"?
NO: Replace pin disconnect solenoid. Continued on next page
TM1529 (27JUN17)
9015-15-115
TX,9015,TJ68 -19-21NOV97-4/7
544G, 624G, 644G Loader
062717
PN=359
Sub-System Diagnostics Ride Control Reset Relay
T7287BH —UN—16AUG90
Key switch to OFF position. Disconnect harness from ride control reset relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click"? Measure continuity between terminals #30 and #87.
YES: Relay is good. Check wiring harness.
Is continuity measured?
NO: Replace ride control reset relay. TX,9015,TJ68 -19-21NOV97-5/7
Ride Control Switch
T7751GB —UN—31AUG92
Disconnect harness from ride control switch. Ride control switch to OFF position. Check for continuity between terminals with P30 red wire and J08 tan wire. Is continuity measured? Check for continuity between terminals with H09 green wire and G01 black wire. Is continuity measured? Ride control switch to ON position. Check for continuity between terminals with J08 tan wire, H09 green wire, and G01 black wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace ride control switch. Continued on next page
TM1529 (27JUN17)
9015-15-116
TX,9015,TJ68 -19-21NOV97-6/7
544G, 624G, 644G Loader
062717
PN=360
Sub-System Diagnostics Ride Control Solenoid
T7199BV —UN—16AUG90
Key switch to OFF position. Disconnect harness from ride control solenoid. Connect battery voltage to terminal with H09 green wire. Ground terminal with G12 black wire.
YES: Solenoid is good. Check wiring harness.
Does solenoid "click"?
NO: Replace ride control solenoid. TX,9015,TJ68 -19-21NOV97-7/7
TM1529 (27JUN17)
9015-15-117
544G, 624G, 644G Loader
062717
PN=361
Sub-System Diagnostics
TM1529 (27JUN17)
9015-15-118
544G, 624G, 644G Loader
062717
PN=362
Group 20
References Battery Specifications Specification Battery—Voltage......................................................................... 12 Volts Reserve Capacity ..............................................160 minutes at 25 amps BCI Group Size.................................................................................... 27 Fully Charged Electrolyte Specific Gravity...................................................................1.265—1.280
544G, 624G Battery—Cold Cranking Power................................................................ 625 amps at -18°C (0°F) 644G Battery—Cold Cranking Power................................................. 925 amps at -18°C (0°F)
TX,901505,HH756 -19-16SEP92-1/1
Battery Operation A battery is a device for converting chemical energy to electrical energy. It is not a storage tank for electricity, but stores electrical energy in chemical form. Because of the constant chemical to electrical change (self-discharge, discharge, or charge), the battery has a limited life. Proper care (cleaning, adding water, charging) will extend the life of the battery. The battery is made up of positive plates, negative plates, separators, plate straps, and chemical solution (electrolyte). The electrolyte is a solution of sulfuric acid and water. Sulfuric acid is not lost during overcharging; therefore, if the liquid solution is low, only water should be added. In a fully charged battery, the positive plate is lead peroxide (PBQ2), the negative plate is "spongy" lead (Pb), and the electrolyte solution is about 1.270 times heavier than water. The amount that the solution is heavier than water is called specific gravity. All batteries will self discharge at a rate of .001 specific gravity point per 24 hour period at a constant 85 °F. The discharge rate increases as temperature increases and decreases as temperature decreases. If the machine
is not used for a period of time, the batteries must be maintained or stored in a cool place. Wipe batteries with a damp cloth. If terminals are corroded, use a stiff brush and wash with an ammonia solution. After washing, flush battery and compartment with clear water. Keep caps in place when cleaning and charging. Batteries should be maintained at an open circuit voltage of 12.40 volts or greater. To determine open circuit voltage use the following chart. Check Open Circuit Voltage For State Of Charge NOTE: Stabilize voltage by turning on high beams 15 Amp load for 15 seconds. STABILIZED OPEN CIRCUIT VOLTAGE
PERCENT CHARGED
12.6 Volts or More
100%
12.4
75%
12.2
50%
12.0
25%
11.7 or less
0%
TX,9015,DY253 -19-16MAR93-1/1
TM1529 (27JUN17)
9015-20-1
544G, 624G, 644G Loader
062717
PN=363
References
Diagnose Battery Malfunctions Symptom
Problem
Solution
Battery Using Too Much Water
Shorted battery cell
Check battery state of charge. (See Procedure for Testing Batteries .)
High ambient temperature
Add distilled water.
Cracked battery case
Check battery hold down clamps. Replace battery.
Regulator
Do Alternator Output Check . (See Charging Circuit Operational Checks.)
Cracked Battery Case
Low Battery Output
Battery hold down clamp too tight, too Install new battery. Install hold down loose or missing clamps correctly. Frozen battery
Keep electrolyte at correct level and battery fully charged during cold weather.
Low water level
See Battery Using Too Much Water and Cracked Battery Case symptoms.
Dirty or wet battery top, causing discharge Corroded or loose battery cable ends
Clean battery top. Recharge battery.
Broken or loose battery posts
Wiggle posts by hand. If posts are loose or will turn, replace battery.
Loose fan/alternator belt or worn pulleys
Inspect belt or pulley. Adjust or replace as necessary.
Clean and tighten cable end clamps. Recharge battery.
TX,901505,QQ365 -19-06JUL94-1/1
TM1529 (27JUN17)
9015-20-2
544G, 624G, 644G Loader
062717
PN=364
References
Check Battery Electrolyte Level And Terminals CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Always remove grounded (-) battery clamp first and replace it last. Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by:
TS203 —UN—23AUG88
• Filling batteries in a well-ventilated area. • Wearing eye protection and rubber gloves. • Avoiding breathing fumes when electrolyte is added.
• Avoiding spilling or dripping electrolyte • Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 10—15 minutes. Get medical attention immediately. If acid is swallowed:
3. Get medical attention immediately. 1. Remove hold-down clamps. 2. Remove battery covers.
1. Drink large amounts of water or milk. 2. Then drink milk of magnesia, beaten eggs, or vegetable oil. Continued on next page
TM1529 (27JUN17)
9015-20-3
TX,9015,RB38 -19-14NOV97-1/2
544G, 624G, 644G Loader
062717
PN=365
References
IMPORTANT: During freezing weather, batteries must be charged after water is added to prevent battery freezing. Charge battery using a battery charger or by running the engine.
A—Battery Post B—Fill Tube
T6996DB —UN—10FEB89
3. Fill each cell to within specified range with distilled water. DO NOT overfill. C—Electrolyte Level Range
T6996DA —UN—10FEB89
Single Level Fill Tube Application
Dual Level Fill Tube Application TX,9015,RB38 -19-14NOV97-2/2
Procedure For Testing Batteries
2. Record specific gravity reading for each cell.
Visual Check 1. Check for damage such as cracked or broken case and electrolyte leakage. If damage is seen, replace battery. 2. Check electrolyte level. (See procedure in this group.) If low, add distilled water to specified level and charge battery. 3. Check terminals for corrosion. If corroded, clean using a wire brush or battery post cleaner such as JT05838 Battery Post/Clamp Cleaner.
3. If high and low readings vary LESS than 0.050 and average specific gravity is between 1.225 and 1.280, battery is fully charged. Go to LOAD TEST. 4. If high and low readings vary LESS than 0.050 and average specific gravity is LESS than 1.225, charge battery and repeat test. If average specific gravity is still LESS than 1.225, replace battery. 5. If high and low readings vary MORE than 0.050, charge battery and repeat test. If high and low readings still vary MORE than 0.050, replace battery. Load Test 1. Check battery capacity with a load tester such as JT05832 Battery Load Tester. Follow tester manufacturer’s instructions for proper load test procedures.
4. Check posts for looseness. If posts are loose, replace battery. Hydrometer Test
2. If battery fails load test, replace.
1. Check specific gravity with a hydrometer or battery tester such as JT05460 Coolant/Battery Tester. TX,9015,DY277 -19-16APR96-1/1
TM1529 (27JUN17)
9015-20-4
544G, 624G, 644G Loader
062717
PN=366
References
Using Booster Batteries—12 Volt System Before boost starting, machine must be properly shut down and secured to prevent unexpected machine movement when engine starts. CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Make sure the batteries are charged in a well ventilated area. IMPORTANT: The machine electrical system is a 12 volt negative (-) ground. Use only 12 volt booster batteries. Connect booster batteries as shown for your battery application. Make last connection to frame. B—Booster Batteries
T6508AE1 —UN—24OCT91
A—Machine Batteries
T6713AI1 —UN—24OCT91
Single Battery Application
Two Battery Application TX,901505,QQ364 -19-06JUL94-1/1
TM1529 (27JUN17)
9015-20-5
544G, 624G, 644G Loader
062717
PN=367
References
Starter Operation IMPORTANT: Never operate starter longer than 30 seconds. Allow at least 2 minutes for cooling and battery recovery before operating again. Overheating caused by excessive operation will seriously damage starter.
T6463AB —UN—07NOV88
When wire (A) from start relay is energized, current flows to ground through both pull-in winding (C) and hold-in winding (D). Current through windings engages solenoid plunger (E), which closes main contact (F). When main contacts close, both ends of pull-in winding have same voltage, so current through pull-in winding stops. Current continues through hold-in winding, keeping solenoid engaged and main contacts closed. With main contacts closed, current flows from battery cable (B) to starter. Four heavy field windings (G) carry current to commutator brushes (H). A—Wire From Relay B—Cable From Battery C—Pull-In Winding D—Hold-In Winding E—Solenoid Plunger F— Main Contacts
Light shunt windings (J) are wrapped together with two of the heavy field windings. Shunt windings are connected to solenoid switch terminal and directly to ground. They provide additional low speed torque to assist engine rotation and prevent overspeed of starter. From field windings, current flows to ground through armature windings (I), making contact through commutator brushes.
G—Field Windings H—Commutator Brushes I— Armature J— Shunt Winding K—Starter Solenoid L— Starter
arranged so that magnetic fields constantly repel each other, causing the armature to rotate.
Strong magnetic fields are set up by current flow through field windings and armature windings. Windings are Continued on next page
TM1529 (27JUN17)
9015-20-6
901505,PP3 -19-12MAR93-1/2
544G, 624G, 644G Loader
062717
PN=368
R25228 —UN—14NOV88
References
1— Snap Ring 2— Drive End Housing 3— Shift Lever 4— Plunger 5— Shunt Field Terminal 6— Solenoid Assembly
13— Field Windings 14— Armature 15— Pole Shoe 16— Oil Seal 17— Bushing 18— Felt 19— Brake Washer
7— Field Connector 8— End Frame Cover 9— Brush 10— Bushing 11— Thrust Washer 12— Commutator
When solenoid (6) engages, it pulls shift lever (3). Shift lever pushes overrunning clutch drive (21) to engage pinion in starter gear on flywheel. As armature (14) turns, it cranks engine. When engine starts, overrunning clutch spins freely on shaft to prevent over-speeding of armature by flywheel. When key switch is released, current to solenoid hold-in windings shuts off. Current can feed through both pull-in and hold-in windings from main contacts, but direction of
20— Wear Pads 21— Overrunning Clutch 22— Pinion Stop 23— Bushing
current is reversed in pull-in winding. The two windings cancel each other, and solenoid is released. A spring pushes solenoid back to disengaged position. This opens main contacts and shuts off current to field windings and armature. Shift lever retracts overrunning clutch drive, disengaging pinion from flywheel. Brake washer (19) slows armature to a stop. 901505,PP3 -19-12MAR93-2/2
TM1529 (27JUN17)
9015-20-7
544G, 624G, 644G Loader
062717
PN=369
References
T7751GM —19—14SEP92
Alternator Operation—95 Amp Or 135 Amp Bosch
This stage is necessary because the residual magnetism in the iron core of the excitation winding is not sufficient for building up the magnetic field and thus to generate the desired voltage.
initiated by the residual magnetism (remanence) in the iron core of the excitation winding. When the engine turns the alternator, during initial start-up, the residual magnetism, aided by pre- excitation, induces a slight voltage in the stator winding. This voltage causes a slight current flow from the stator winding to the excitation winding, strengthening the magnetic field in the excitation winding. This, in turn, will increase the stator voltage. This will occur continuously until the alternator is fully excited and the generator voltage is reached.
Excitation stage - throughout the entire operating time of the alternator, a magnetic field in the excitation winding of the rotor induces the desired voltage in the three-phase winding of the stator. Some current from the stator is rectified by the exciter diodes and is supplied to the carbon brushes and collector rings of the excitation winding. The current is then passed through the regulator, through the negative diodes, and back to the three-phase winding of the stator.
Generator stage - the alternating current induced in the stator winding is rectified by the negative diodes and delivered to the battery and current- consuming accessories. The currents in the stator winding are constantly changing magnitude and direction. However, current flowing to the battery and accessories always maintains the same direction. This is because no matter what position the rotor is in, all the diodes are simultaneously involved in the process of rectification.
There are three basic stages for proper operation of the Bosch alternator. They are as follows: Pre-excitation stage - when the key switch is turned to the ON position, battery current flows to the excitation winding, through the regulator, then to ground.
When the alternator is operating, no external power source is needed for self- excitation. Self-excitation is TX,901520,DV800 -19-16SEP92-1/1
TM1529 (27JUN17)
9015-20-8
544G, 624G, 644G Loader
062717
PN=370
References
Accessing Monitor Service Code Display
T7812BO —19—26AUG92
Depress SELECT switch, hold for 4 seconds and release switch before 5 seconds have elapsed. Repeat this procedure 3 times in a row and the word DIAG should show in the display after the third time. When DIAG shows in the display, press and release SELECT switch immediately. Service codes should display at this time. NOTE: When the SELECT button is held down, the symbol in the display window will change every 4 seconds. Use this to determine length of time to hold SELECT switch down. The MPH display symbol is only being used as an example in following step by step procedure. Any one of the five display symbols can be shown. 1. With engine OFF, turn key to ACC position.
2. Push SELECT button twice on display monitor until RPM symbol shows in window. TX,9015,DU1538 -19-02FEB95-1/6
T7812BQ —19—26AUG92
3. Press and hold SELECT button until km/h shows in window; then release SELECT button within one second.
TX,9015,DU1538 -19-02FEB95-2/6
T7812BS —19—26AUG92
4. Press and hold SELECT button until battery voltage symbol is shown in display window; then release button within one second.
Continued on next page
TM1529 (27JUN17)
9015-20-9
TX,9015,DU1538 -19-02FEB95-3/6
544G, 624G, 644G Loader
062717
PN=371
References
T7812BP —19—08SEP92
5. Press and hold select button until MPH symbol appears in window; then release button within one second.
TX,9015,DU1538 -19-02FEB95-4/6
T7812BT —19—26AUG92
IMPORTANT: If the display shows PROG, 644, 624, or 544 when trying to access the service codes, immediately turn the key to OFF position and start the procedure over again from Step 1. Pressing SELECT button while in this mode could install the wrong diagnostic information. 6. Display window will immediately show DIAG.
TX,9015,DU1538 -19-02FEB95-5/6
7. Press and immediately release select button within first 5 seconds. If you wait more than 5 seconds to press select button, turn key off, and start procedure over again at Step 1. T7812BU —19—26AUG92
If there are no service codes (faults), F900 will be displayed. If there is one service code, it will be displayed until it is deleted. If there is more than one service code, each service code will be displayed in sequence for five seconds each, starting with most recent service code showing first. Service codes will remain in memory until they are deleted by technician. To delete a service code, press the SELECT button while the code is displayed.
To exit the diagnostic mode, turn key to OFF position. TX,9015,DU1538 -19-02FEB95-6/6
TM1529 (27JUN17)
9015-20-10
544G, 624G, 644G Loader
062717
PN=372
References
Monitor Service Code Interpretation The service code number is indicated by an F9 plus two other digits.
The last two digits of the service code number would indicate failures as follows:
The letter F means that a fault has occurred. The number 9 means the fault has been diagnosed by the monitor and will be displayed as a service code. CODE
DESCRIPTION
F900
No service codes stored
F901
Fuel level sender circuit shorted to ground
F902
Fuel level circuit open circuited
F903
Transmission oil temperature sensor circuit shorted to ground
F904
Transmission oil temperature sensor circuit open circuit
F905
Coolant temperature sensor circuit shorted to ground
F906
Coolant temperature sensor circuit is open circuit
F907
a
F998
Hour meter failed (memory has failed; monitor must be replaced) (this message cannot be deleted)
F999
Indicator hour meter has accumulated more than 20,000 hours. (maximum allowable is 19,999; sets back to 0 after that) (this message cannot be deleted)
Wheel speed magnetic pick up fault (signal received from transmission controller)
a
For 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302), see Jumper Wire For Display Monitor in this group for additional information.
Possible causes in order of probability for circuit shorted to ground:
Possible causes in order of probability for open circuit: 1. Either one of two wires from sensor broken.
1. High side touching ground.
2. Bad connection.
2. Sensor is bad or shorted.
3. Sensor is bad.
3. Two wires from sensor touching each other.
4. Bad monitor.
4. Bad monitor. 5. Bad Connection anywhere.
TX,9015,MM1523 -19-12JUL00-1/1
Program Monitor Display To Match Machine 1. With engine OFF, turn key to ACC position.
T7812BO —19—26AUG92
2. Push SELECT button twice on display monitor until RPM symbol shows in window.
Continued on next page
TM1529 (27JUN17)
9015-20-11
TX,9015,DU1539 -19-02FEB95-1/6
544G, 624G, 644G Loader
062717
PN=373
References
T7812BQ —19—26AUG92
3. Press and hold SELECT button until km/h shows in window; then release SELECT button within one second.
TX,9015,DU1539 -19-02FEB95-2/6
T7812BS —19—26AUG92
4. Press and hold SELECT button until battery voltage symbol is shown in display window; then release button within one second.
TX,9015,DU1539 -19-02FEB95-3/6
T7812BP —19—08SEP92
5. Press and hold SELECT button until MPH symbol appears in window; then release button within one second.
Continued on next page
TM1529 (27JUN17)
9015-20-12
TX,9015,DU1539 -19-02FEB95-4/6
544G, 624G, 644G Loader
062717
PN=374
References
T7812BT —19—26AUG92
6. When the DIAG appears in display window, DO NOT press SELECT button again, and it will automatically go to PROG. PROG will display for 3 seconds.
TX,9015,DU1539 -19-02FEB95-5/6
7. Machine models will be displayed only once in following order: 644, 624, 544. When correct machine model appears in display, press SELECT button. This will program correct tire size, fuel tank capacity, and engine rpm. T7812BW —19—10NOV94
IMPORTANT: Tachometer must be recalibrated after this programming to make it accurate for running tests. 8. Calibrate tachometer. See procedure in this group.
TX,9015,DU1539 -19-02FEB95-6/6
Calibrate Tachometer 1. Install calibration tachometer on engine so that it is visible to an operator sitting in the seat. T7812BO —19—26AUG92
2. Start engine and keep running during calibration procedure. 3. RPM symbol should be displayed in window. If not, push SELECT button until RPM symbol shows.
Continued on next page
TM1529 (27JUN17)
9015-20-13
TX,9015,MM1524 -19-02FEB95-1/5
544G, 624G, 644G Loader
062717
PN=375
References
T7812BQ —19—26AUG92
4. Press and hold SELECT button until km/h shows in window; then release SELECT button within one second.
TX,9015,MM1524 -19-02FEB95-2/5
T7812BS —19—26AUG92
5. Press and hold SELECT button until battery voltage symbol is shown in display window; then release button within one second.
TX,9015,MM1524 -19-02FEB95-3/5
T7812BP —19—08SEP92
6. Press and hold SELECT button until MPH symbol appears in window; then release within one second.
Continued on next page
TM1529 (27JUN17)
9015-20-14
TX,9015,MM1524 -19-02FEB95-4/5
544G, 624G, 644G Loader
062717
PN=376
References
7. The display window will show ECAL.
8. Turn key to OFF position (stop engine), then restart engine. 9. After monitor tachometer has been calibrated, check slow and fast idle engine speeds against the calibration tachometer. If there is more than 10 rpm difference, repeat this calibration procedure.
T7812BV —19—26AUG92
Run engine until speed reaches 2000 rpm on calibration tachometer. While holding speed at 2000 rpm, push SELECT button. This will calibrate the monitor tachometer.
TX,9015,MM1524 -19-02FEB95-5/5
TM1529 (27JUN17)
9015-20-15
544G, 624G, 644G Loader
062717
PN=377
References
T8400AE —19—27JAN95
Transmission Electrical Circuit Test Procedure
All of the following checks are made at the transmission controller connector (shown above).
3. Pins 5, 23 and 29 are powered by the forward and reverse switches.
1. Pins 1, 2 and 19 must have power when the key is turned to ON position. 2. Pin 22 is powered by the clutch cut-off (CCO) switch and park brake pressure switch. Whenever either of these two switches are closed, pin 22 is powered to put the transmission in neutral. When testing the electrical system, the two diodes banded to the harness next to the transmission control box can be removed. This prevents the park brake pressure switch from supplying power to pin 22 when the engine is off and the electrical system can be tested without starting the engine.
Pin 29 must have voltage with the FNR lever in neutral. If it does not have voltage in neutral, the transmission controller will not energize the shift solenoids when the lever is moved to forward or reverse. This is to assure that the transmission would not engage if the engine neutral start system were bypassed and the engine was started in gear. Pin 5 must have voltage with the FNR lever in reverse only. Pin 23 must have voltage when the shift lever is in forward only.
Continued on next page
TM1529 (27JUN17)
9015-20-16
TX,1520,MM2405 -19-02FEB95-1/2
544G, 624G, 644G Loader
062717
PN=378
References
NOTE: The transmission controller is programmed so that the forward, neutral, and reverse switches must make contact within 70 milliseconds after the previous switch opens. If it does not, the control box will not send power to the solenoids. 4. Voltage is supplied to pin 24 to operate the quickshift feature on the hydraulic control lever. 5. A combination of power to pins 8, 25 and 26 give the controller a signal to select the proper gear and provide the automatic mode. See the continuity chart for the shifter switch (S7) on the transmission control circuit functional schematic in Group 9015-15 for the combination of power to these pins for each gear. NOTE: Power to pins 8 and 26 will select all four gears. Power to pin 25 gives the transmission automatic operation. If power to pin 25 is lost, the transmission will operate as a four speed manual transmission. 6. Pins 17 and 27 connect the transmission speed sensor to the transmission controller. If the speed sensor signal is lost, the transmission will only operate in 1st and 2nd gear. If 3rd or 4th are selected, the transmission will remain in 2nd. NOTE: With a failed speed sensor, each time the transmission is shifted out of neutral, the transmission will start in the highest gear available and downshift at 1.5 second intervals to either 1st or 2nd, depending on switch position. This is to prevent damage if operator is coasting down a hill and then puts the transmission in gear. 7. Pin 11 sends the transmission speed sensor signal to the monitor to operate the speedometer.
only to make the clutch cut-off function in 1st and 2nd and not in 3rd and 4th. 9. Pin 13 sends a signal to the monitor to enter fault code F907 if the transmission speed sensor circuit fails on following machines: 544G (S.N. —548218), 624G (S.N. —548397) and 644G (S.N. —548302). See Jumper Wire for Display Monitor in this group for additional information on possible erroneous fault code F907 readings. NOTE: If the operator holds the unit stationary and shifts between forward and reverse several times, the transmission controller will detect that shifts are being made without a signal from the speed sensor and also register an F907 fault code in the monitor. 10. Pins 14, 15, 31, 32, and 33 are the pins that supply voltage to the solenoids in the five solenoid control valve. On machines 544G (S.N.548219— ), 624G (S.N.548398—) and 644G (S.N.548303—), pin 30 supplies voltage to the sixth solenoid of the six solenoid control valve. Pin 34 is the ground circuit for all solenoids. The transmission controller checks the resistance through the solenoid circuit on each start-up and if one solenoid is out of specification, the controller will cut off voltage to all solenoids. To check solenoids, check resistance between each of the solenoid power pins and the ground pin (34) and make sure they are similar. 11. Pins 18 and 35 are controller ground circuits. NOTE: The braided ground strap connected to the controller case is to eliminate radio interference and does not provide a ground circuit for the controller.
8. Pin 12 sends voltage out to operate the clutch cut-off circuit. This voltage is supplied in 1st and 2nd gear TX,1520,MM2405 -19-02FEB95-2/2
TM1529 (27JUN17)
9015-20-17
544G, 624G, 644G Loader
062717
PN=379
References
T8404BD —19—02FEB95
Jumper Wire For Display Monitor
On 544G (S.N. 548219—), 624G (S.N. 548398—) and 644G (S.N. 548303—), the transmission controller was reprogrammed so it would not send the F907 (failed speed sensor) service code to the display monitor. This was done because the F907 service code had caused some confusion to the users. The M05 purple wire, which sent the service code signal to the monitor, was also deleted. At the same time, a change needed to be made to display monitor programming (pin 22 of monitor connector), because an open circuit on M05 wire will cause the F907 service code to register. The change to the display monitor was not made at the same time, so F907 service code appears on following machines:
• 544G (S.N. 548219—548955) • 624G (S.N. 548398—548982) • 644G (S.N. 548303—548887) On these machines the F907 service code is an erroneous reading and can be ignored. If the speedometer works and the transmission will shift into 3rd and 4th gear, the speed sensor is working normally.
To eliminate erroneous F907 service code, make a jumper wire using approximately 660 mm (26 in.) of 16 gauge wire, one U46662 Terminal and R77465 Socket Contact as shown. Insert U46662 Terminal into open connection (A) in backside of key switch connector. NOTE: After the transmission controller change was made, there were a few machines produced with M05 wire in the harness. If M05 wire is in display monitor connector at pin 22 location (B), remove wire using JDG140 AMP Socket Extractor or JDG364 Weatherpack Socket Extractor. Tape the wire back to the harness. Insert R77465 Socket Contact of jumper wire harness into display monitor connector at pin 22 location (B). Use four to six tie bands to secure jumper wire to harness and bundle between key switch and display monitor.
TX,1515,MM2404 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-20-18
544G, 624G, 644G Loader
062717
PN=380
References
Replace CPC, Large MATE-N-LOK and METRIMATE™ Pin Type Connectors 1. Select correct size Extraction Tool (JDG140 or JDG143) for contact to be removed. NOTE: Allow tool push rod (C) to back out during insertion. 2. Insert tool sleeve (A) over contact until it bottoms. 3. Rotate tool handle (B) to assure release of contact locking lances. 4. Hold tool sleeve firmly seated in connector and press push rod button (D) to remove contact from connector. 5. Spread contact locking lances and insert wire in correct terminal of new connector. 6. Transfer remaining wires to correct terminal of new connector. C—Tool Push Rod D—Push Rod Button TS113 —UN—23AUG88
A—Tool Sleeve B—Tool Handle
CPC, MATE-N-LOK, and METRIMATE are trademarks of AMP Inc. DX,ECONN,F -19-04JUN90-1/1
TM1529 (27JUN17)
9015-20-19
544G, 624G, 644G Loader
062717
PN=381
References
Transmission Sensor Adjustment NOTE: The 544G and 624G transmission sensor is on the right side of the machine. The 644G sensor is on the left side of the machine. 1. Engine off. 2. Lower equipment to the ground. 3. Install frame locking bar. 4. Remove transmission side shield (if equipped). 5. Block wheels. 6. Disconnect wire connector from sensor. 7. Scribe a mark on the sensor and transmission case. Remove sensor.
T8249AA —UN—01JUN94
8. Loosen park brake adjusting screw to release park brake, see Adjust Park Brake in this Group (Step 6). Using a pry bar on the driveshaft, center gear tooth in hole. 9. Adjust sensor by performing one of the following methods:
• Conventional method
a. Measure distance from tooth to outside hole of transmission (A). Record measurement. b. Measure distance of sensor (B). Record measurement. c. Subtract measurements (A from B) and add 0.5—0.8 mm (0.020—0.030 in.) to determine shim pack.
a. Remove shims from sensor. b. Install sensor to original position as marked. c. Continue to turn sensor until sensor bottoms out against gear tooth. Sensor should turn an additional 1/3—1/2 turn past original position. d. If original sensor position allows sensor to turn more than or less than specified, add or remove shims as necessary.
EXAMPLE: ( 26.28 mm (1.035 in.) Sensor Measurement B) — ( 24.34 mm (0.958 in.) Tooth Measurement A)
10. Apply pipe sealant with TEFLON® to threads of sensor. Install sensor.
2.04 mm (0.080 in.)
11. Install transmission side shield (if equipped). Add 0.5—to 0.8 mm (0.020—0.030 in.) to 2.04 mm (0.080 in.) to get shim pack required.
12. Adjust park brake. (See procedure in this group.)
• Alternative method: TEFLON is a trademark of Du Pont Co. TX,9020,SS2205 -19-02FEB95-1/1
TM1529 (27JUN17)
9015-20-20
544G, 624G, 644G Loader
062717
PN=382
References
Disconnecting Tab Retainer Connectors 1. Push retainer tab (A).
T7535AE —UN—22MAY91
2. Hold tab (A) and pull connector halves apart. (Do not pull wires).
TX,901520,DV801 -19-16SEP92-1/1
Secondary Steering Controller Bench Test
The switch closes on decreasing pressure before 69 kPa (0.69 bar) (10 psi), activating the steering controller timer. Three to five seconds after the timer is activated, voltage is sent to the secondary steering pump motor. To test the controller, disconnect harness from controller. Connect 12 volts to pin B in four-pin connector. Connect a 12 V test bulb to ground and pin C. Ground pin D. Light will be OFF.
T7349DQ —UN—05SEP90
The controller provides voltage to secondary steering pump motor when steering pressure is below the secondary steering switch setting.
TX,9015,MM667 -19-16SEP92-1/2
Connect a wire to pins A and B in two-pin connector.
Remove wire between pins A and B of two-pin connector. Test bulb must go out as wire is removed.
T7349DR —19—27AUG90
Momentarily connect 12 volts to pin A of four-pin connector. Three to five seconds after voltage is removed from pin A, the test bulb must come on. If test bulb fails to come on, replace controller.
TX,9015,MM667 -19-16SEP92-2/2
TM1529 (27JUN17)
9015-20-21
544G, 624G, 644G Loader
062717
PN=383
References
TM1529 (27JUN17)
9015-20-22
544G, 624G, 644G Loader
062717
PN=384
Section 9020 Power Train Operation And Tests
Contents Page
Page
Group 05—Theory Of Operation Clutch Engagement and Solenoid Activation Charts ................................... 9020-05-1 Power Train Component Overview................................................ 9020-05-2 Drive Dampener ........................................ 9020-05-2 Torque Converter Operation ...................... 9020-05-4 Transmission Operation—Neutral.......................................................... 9020-05-6 Transmission Operation—1st Gear Forward ................................................. 9020-05-8 Transmission Operation—2nd Gear Forward ...................................... 9020-05-10 Transmission Operation—3rd Gear Forward ............................................... 9020-05-12 Transmission Operation—4th Gear Forward ............................................... 9020-05-14 Transmission Operation—1st Gear Reverse ............................................... 9020-05-16 Transmission Operation—2nd Gear Reverse ...................................... 9020-05-18 Transmission Operation—3rd Gear Reverse ............................................... 9020-05-20 Clutch Operation...................................... 9020-05-22 Transmission Hydraulic Components ........................................ 9020-05-23 Transmission Hydraulic System .............. 9020-05-24 Transmission Pump Operation ................ 9020-05-26 Transmission Control Valve Components (5-Solenoid Valve)................................................... 9020-05-28 Modulation Components And Shift Time (5-Solenoid Valve) ...................... 9020-05-30 Completed Shift—First Speed Forward (5-Solenoid)........................... 9020-05-32 Shift Modulation Starts For 2nd, 3rd, Or 4th (5-Solenoid)....................... 9020-05-34 Shift Modulation For 2nd, 3rd, And 4th (5-Solenoid) ................................... 9020-05-36 Completed Shift Modulation For 2nd, 3rd, Or 4th (5-Solenoid)............... 9020-05-38 Transmission Clutch Engagement And Solenoids Activated (5-Solenoid) ......................................... 9020-05-40 Third Speed Neutral (5-Solenoid)............ 9020-05-42 First Speed—Forward (5-Solenoid) ......................................... 9020-05-44 Second Speed—Forward (5-Solenoid) ......................................... 9020-05-46 Third Speed—Forward (5-Solenoid) ......................................... 9020-05-48
Fourth Speed—Forward (5-Solenoid) ......................................... 9020-05-49 First Speed—Reverse (5-Solenoid) ......................................... 9020-05-50 Second Speed—Reverse (5-Solenoid) ......................................... 9020-05-52 Third Speed—Reverse (5-Solenoid) ......................................... 9020-05-54 Thermal Bypass Valve Operation ............ 9020-05-56 Transmission Control Valve Components (6-Solenoid Valve)................................................... 9020-05-58 Modulation Components And Shift Time (6-Solenoid Valve) ...................... 9020-05-60 Control Valve In Neutral (6-Solenoid) ......................................... 9020-05-62 Transmission Clutch Engagement And Solenoids Activated (6-Solenoid) ......................................... 9020-05-64 Shift Modulation (6-Solenoid) .................. 9020-05-66 First Speed—Forward (6-Solenoid) ......................................... 9020-05-68 Second Speed—Forward (6-Solenoid) ......................................... 9020-05-70 Third Speed—Forward (6-Solenoid) ......................................... 9020-05-72 Fourth Speed—Forward (6-Solenoid) ......................................... 9020-05-74 First Speed—Reverse (6-Solenoid) ......................................... 9020-05-76 Second Speed—Reverse (6-Solenoid) ......................................... 9020-05-78 Third Speed—Reverse (6-Solenoid) ......................................... 9020-05-80 TeamMate™ II Axle Operation ................ 9020-05-82 John Deere TeamMate™ II Axles............ 9020-05-83 Differential Lock Operation ...................... 9020-05-84 Hydraulic Differential Lock Air Boost System ...................................... 9020-05-85 Turbocharger Boost For Differential Lock ..................................................... 9020-05-86 Axle Shaft And Housing........................... 9020-05-87 Axle Disconnect Operation ...................... 9020-05-88 Brake Hydraulic System Operation............................................. 9020-05-89 Brake Pump Operation ............................ 9020-05-90 Brake Pump Pressure Compensator—At Standby.................. 9020-05-91 Pressure Compensator—Pump Going Into Stroke................................. 9020-05-92 Brake Accumulator Operation ................. 9020-05-93 Continued on next page
TM1529 (27JUN17)
9020-1
544G, 624G, 644G Loader
062717
PN=1
Contents
Page
Page
Wet Chambered Brake Valve Operation............................................. 9020-05-94 Park Brake Operation .............................. 9020-05-96 Pressure Reducing Valve—Differential Lock Off, Park Brake On ..................................... 9020-05-98 Pressure Reducing Valve—Differential Lock On, Park Brake Off ................................... 9020-05-100 Hydraulic Tank Operation ...................... 9020-05-102
Display Monitor Tachometer ...................... 9020-25-1 Transmission Oil Warm-Up Procedure .............................................. 9020-25-2 Brake, Differential Lock, And Hydraulic System Oil Warm-Up Procedure .............................................. 9020-25-2 Transmission Pump Flow Test................... 9020-25-3 Transmission System Pressure, Element Leakage, And Shift Modulation Test ..................................... 9020-25-5 Transmission Lube Pressure Test.............. 9020-25-7 Converter Relief Pressure Test.................. 9020-25-8 Converter-In Pressure Test...................... 9020-25-10 Converter-Out Pressure Test................... 9020-25-12 Converter-Out Flow Test.......................... 9020-25-13 Transmission Oil Cooler Backflush Procedure ............................................ 9020-25-14 Transmission Oil Cooler Restriction Test ...................................................... 9020-25-15 Pressure Reducing Valve Manifold Leakage Test ....................................... 9020-25-16 Transmission Oil Cooler Thermal Bypass Valve Test ............................... 9020-25-17 Transmission Oil Cooler Bypass Valve Pressure Test ............................. 9020-25-18 Torque Converter Stall Speed Test ...................................................... 9020-25-19 Brake Pump Flow Test............................. 9020-25-20 Brake Pump Standby Pressure Test ...................................................... 9020-25-21 Brake Accumulator Precharge Test ...................................................... 9020-25-22 Brake Valve Pressure Test ...................... 9020-25-24 Brake Valve Leakage Test ....................... 9020-25-26 Brake Accumulator Inlet Check Valve Leakage Test ............................. 9020-25-27 Park Brake Pressure Test........................ 9020-25-28 Differential Lock Pressure Test................ 9020-25-29 Differential Lock Leakage Test ................ 9020-25-30 Axle Bearing Adjustment Check .............. 9020-25-31 No-Spin Differential Test.......................... 9020-25-31
Group 10—System Operational Checks Power Train Operational Checks............... 9020-10-1 Brake System, Clutch Cut-Off, Differential Lock And Front Axle Disconnect Checks ...............................9020-10-1 Transmission Checks ................................9020-10-8 Group 15—Diagnostic Information Procedure To Isolate Whether Transmission Control System Problem Is Electrical Or Hydraulic................................................ 9020-15-1 Diagnose Transmission System Malfunctions .......................................... 9020-15-2 Diagnose Service Brake Malfunctions ........................................ 9020-15-10 Diagnose Differential/Axle Malfunctions ........................................ 9020-15-12 Diagnose Drive Line Malfunctions............ 9020-15-15 Diagnose Park Brake Malfunctions ........................................ 9020-15-16 Hydraulic Circuit Symbols........................ 9020-15-17 Brake, Differential Lock, And Boom Lower Circuit Schematic...................... 9020-15-18 Power Train And Brakes System Component Location Diagram............. 9020-15-19 First Forward Schematic.......................... 9020-15-21 Group 20—Adjustments Front Axle Disconnect Adjustment............................................. 9020-20-1 Clutch Cut-Off Adjustment......................... 9020-20-2 Adjust Park Brake (S.N. 788774—).............................................. 9020-20-3 External Service Brake Inspection .............................................. 9020-20-4 Hydraulic Brake Bleeding Procedure .............................................. 9020-20-5 Charge Brake Accumulator ....................... 9020-20-6 Brake Pump And Differential Lock System Oil Clean-Up Procedure Using Portable Filter Caddy................... 9020-20-7 Transmission Sensor Adjustment.............. 9020-20-7 Group 25—Tests JT05801 Clamp-On Electronic Tachometer Installation.......................... 9020-25-1 JT05800 Digital Thermometer Installation ............................................. 9020-25-1 TM1529 (27JUN17)
9020-2
544G, 624G, 644G Loader
062717
PN=2
Group 05
Theory Of Operation
T8089AB —UN—05NOV93
Clutch Engagement and Solenoid Activation Charts
TX,9020,TJ17 -19-19SEP97-1/1
TM1529 (27JUN17)
9020-05-1
544G, 624G, 644G Loader
062717
PN=387
Theory Of Operation
Power Train Component Overview NOTE: See Power Train and Brakes System Component Location (Park Brakes Switch Off) drawing in Group 9020-15 for location of components. The power train consists of the following components:
• Drive dampener • Transmission • Front and rear drive shafts • Front and rear axles Engine power is transmitted to the transmission through the drive dampener. The drive dampener helps to remove torque spikes from the power train. The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft-type powershift transmission. A disk-type park brake is located on the front of the transmission housing.
The transmission outputs through universal joints to two drive shaft assemblies. The front drive shaft is a telescoping shaft which drives the front axle. The front axle is mounted directly to the loader frame. The front axle may be equipped with either a standard differential, optional hydraulic differential lock or an optional NO-SPIN differential. A mechanical front axle disconnect option is also available. The rear axle is mounted on an oscillating pivot. The rear axle will be equipped with either a standard differential or an optional NO-SPIN differential. Machines with differential lock axles use turbocharger boost pressure to regulate the level of oil in the differential housing. This boost pressure forces return oil through a filter and into the hydraulic reservoir. TX,9020,HH777 -19-16SEP92-1/1
T7799CE —19—26AUG92
Drive Dampener
The drive dampener is located between the engine and the input shaft to the transmission. The drive dampener absorbs torque spikes encountered during machine operation.
transmission. The dampener (B) is a solid rubber ring bonded to the inner sleeve and pressed into the outer sleeve. The drive dampener is serviced as an assembly.
The outer sleeve (A) is bolted to the engine flywheel. The inner sleeve (C) is bolted to the input shaft to the TX,9020,HH778 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-05-2
544G, 624G, 644G Loader
062717
PN=388
Theory Of Operation
TM1529 (27JUN17)
9020-05-3
544G, 624G, 644G Loader
062717
PN=389
Theory Of Operation
Torque Converter Operation
D IMPELLER STATOR C E
DRIVE GEAR
TURBINE B F
H A
INPUT YOKE
I
J
CONVERTER HOUSING
GROUND SLEEVE
G
IMPELLER SHAFT
TRANSMISSION PUMP
TURBINE SHAFT
POWER DIRECT FROM ENGINE
T7799BV
K
TORQUE CONVERTER COMPONENTS
The torque converter splines to the transmission pump assembly. The transmission pump assembly is mounted into the transmission housing as a unit. Continued on next page TM1529 (27JUN17)
9020-05-4
T7799BV —19—09FEB98
POWER FROM CONVERTER
TX,9020,HH779 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=390
Theory Of Operation
The input yoke (A) is driven by the engine through the drive dampener. The input yoke is connected by a plate to the torque converter impeller (D) and impeller shaft (F). The impeller shaft rotates the gears inside of the transmission pump (G). The coupling on the right end of the impeller shaft drives the main hydraulic pump. As the impeller rotates, the impeller vanes force oil to flow against the turbine (B) vanes. The turbine rotates the same direction as the impeller. The turbine is splined to the turbine shaft (I), which rotates the drive gear (E)
to transfer torque to the transmission countershafts and clutches. Maximum output torque is produced by the torque converter at stall, where the impeller is spinning at maximum speed and the turbine is stationary. Due to the curvature of the turbine vanes, a stator (C) is used to redirect the oil flow from the inside diameter of the turbine vanes back to the impeller. The single-phase stator splines to a stationary ground sleeve (H) mounted to the transmission pump manifold. The transmission pump manifold bolts to the transmission pump housing. TX,9020,HH779 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-05-5
544G, 624G, 644G Loader
062717
PN=391
Theory Of Operation
Transmission Operation—Neutral DRIVE C GEAR
FIRST D SPEED CLUTCH FORWARD CLUTCH B HUB
REVERSE CLUTCH A HUB
E MAIN PRESSURE
G
T6567NB —19—15SEP97
F RETURN PRESSURE
NEUTRAL
T6567NB
The torque converter supplies torque to the drive gear (C) which meshes with a gear on the forward clutch hub (B) and the reverse clutch hub (A). In neutral, both the TM1529 (27JUN17)
forward and reverse clutches are disengaged, allowing the respective hubs to freewheel. Continued on next page
9020-05-6
TX,902005,D40 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=392
Theory Of Operation
This view shows the transmission in first speed. Main pressure oil is routed through a passage in the countershaft to engage the first speed clutch (D). The clutch piston is moved to the right, compressing the clutch
plates and disks which lock the first speed gear hub to the clutch drum. With only one clutch engaged, the vehicle will not move. TX,902005,D40 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-7
544G, 624G, 644G Loader
062717
PN=393
Theory Of Operation
Transmission Operation—1st Gear Forward DRIVE A GEAR
FIRST B SPEED CLUTCH
FIRST C SPEED HUB
FORWARD CLUTCH H HUB FORWARD G CLUTCH
THIRD D SPEED HUB SECOND SPEED F HUB
I MAIN PRESSURE
K
OUTPUT E GEAR T6567NC —19—15SEP97
J RETURN PRESSURE
1ST FORWARD
T6567NC
With the transmission in first forward, the forward clutch (G) and the first speed clutch (B) are engaged. The torque
converter supplies torque to the drive gear (A) which meshes with the gear on the forward clutch hub (H).
Continued on next page
TM1529 (27JUN17)
9020-05-8
TX,902005,D42 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=394
Theory Of Operation
Main pressure oil is routed through drilled passages in the top countershaft to the forward and first speed clutches. This causes the pistons to move, compressing the plates and disks causing both clutches to rotate as a unit through the upper clutch drum.
The gear on the first speed hub (C) meshes with a gear on the second speed hub (F). The second speed hub gear meshes with a gear on the third speed hub (D), transferring torque to the output gear (E) which drives the output shafts. TX,902005,D42 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-9
544G, 624G, 644G Loader
062717
PN=395
Theory Of Operation
Transmission Operation—2nd Gear Forward DRIVE A GEAR
B
FORWARD CLUTCH
SECOND C SPEED HUB
FORWARD CLUTCH G HUB
THIRD D SPEED HUB
SECOND SPEED F CLUTCH
H MAIN PRESSURE
J
OUTPUT E GEAR
T6567ND —19—15SEP97
I RETURN PRESSURE
2ND FORWARD
T6567ND
With the transmission in second forward, the forward clutch (B) and second speed clutch (F) are engaged. The
torque converter supplies torque to the drive gear (A) which meshes with a gear on the forward clutch hub (G).
Continued on next page
TM1529 (27JUN17)
9020-05-10
TX,902005,D44 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=396
Theory Of Operation
Main pressure oil is routed through a drilled passage in the top countershaft. This causes the forward clutch piston to move to the left and compress the plates and disks which lock the forward clutch hub to its drum (upper drum). The clutch drums have gear teeth machined on their outside diameter. The upper and lower drums are in constant mesh with the center drum. Main pressure oil is also routed through a drilled passage in the center countershaft. This causes the piston in the
second speed clutch to move to the right, compressing the plates and disks which lock the second speed clutch to its drum (center drum). Torque is transferred from the forward clutch hub through the upper drum to the center drum which rotates the second speed hub (C). The gear on the second speed hub meshes with the gear on the third speed hub (D) which transfers torque to the output gear (E). The output gear rotates the output shafts. TX,902005,D44 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-11
544G, 624G, 644G Loader
062717
PN=397
Theory Of Operation
Transmission Operation—3rd Gear Forward DRIVE A GEAR
B
FORWARD CLUTCH
C
REVERSE/SECOND SPEED DRUM
FORWARD CLUTCH G HUB
THIRD D SPEED HUB
THIRD SPEED F CLUTCH
I RETURN PRESSURE
J
OUTPUT E GEAR T6567NE —19—15SEP97
H MAIN PRESSURE
3RD FORWARD
T6567NE
With the transmission in third forward, the forward clutch (B) and third speed clutch (F) are engaged. The torque
converter supplies torque to the drive gear (A) which meshes with a gear on the forward clutch hub (G). Continued on next page
TM1529 (27JUN17)
9020-05-12
TX,902005,D46 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=398
Theory Of Operation
Main pressure oil is routed through a drilled passage in the top countershaft. This causes the piston in the forward clutch to move to the left, compressing the plates and disks. This locks the forward clutch hub to the upper drum which has gear teeth machined into its outside diameter. The upper drum meshes with the gear teeth on the reverse and second speed drum (C). The gear teeth on the reverse and second speed drum mesh with gear teeth on the lower drum, causing it to rotate.
Main pressure oil is routed through a drilled passage in the lower countershaft. This causes the piston in the third speed clutch to move to the right, compressing the plates and disks. With the third speed clutch engaged, the lower drum rotates the third speed hub (D) which meshes with the output gear (E). The output gear rotates the drive shafts.
TX,902005,D46 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-13
544G, 624G, 644G Loader
062717
PN=399
Theory Of Operation
Transmission Operation—4th Gear Forward DRIVE A GEAR
FORWARD CLUTCH H HUB THIRD B SPEED CLUTCH
IDLER G GEAR
THIRD C SPEED HUB
FOURTH SPEED F HUB FOURTH SPEED E CLUTCH
J RETURN PRESSURE
K
OUTPUT D GEAR T6567NF —19—15SEP97
I MAIN PRESSURE
4TH FORWARD
T6567NF
Continued on next page
TM1529 (27JUN17)
9020-05-14
TX,902005,D48 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=400
Theory Of Operation With the transmission in fourth gear forward, the third and fourth speed clutches (B and E) are engaged. The torque converter supplies torque to the drive gear (A) which meshes with the gear on the forward clutch hub (H). With the clutches and countershafts assembled in the transmission housing, the forward clutch hub gear meshes with the fourth speed hub (F) through an idler gear (G).
clutches. This causes both clutch pistons to move to the left and right respectively, compressing the plates and disks. The fourth speed hub will rotate the third speed hub (C) through the lower drum which rotates the output gear (D). The output gear rotates the drive shafts.
Main pressure oil is routed through the drilled passages in the lower countershaft to the fourth and third speed TX,902005,D48 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-15
544G, 624G, 644G Loader
062717
PN=401
Theory Of Operation
Transmission Operation—1st Gear Reverse DRIVE A GEAR
FIRST B SPEED CLUTCH FIRST C SPEED HUB SECOND D SPEED HUB
REVERSE CLUTCH H HUB
THIRD E SPEED HUB REVERSE G CLUTCH
J RETURN PRESSURE
T6567NG
K
OUTPUT F GEAR
1ST REVERSE
T6567NG —19—15SEP97
I MAIN PRESSURE
drive gear meshes with the gear on the reverse clutch With the transmission in first gear reverse, the reverse hub (H). clutch (G) and first speed clutch (B) are engaged. The torque converter supplies torque to the drive gear (A). TheContinued on next page TX,902005,D50 -19-30JUL87-1/2 TM1529 (27JUN17)
9020-05-16
544G, 624G, 644G Loader
062717
PN=402
Theory Of Operation
Main pressure oil is routed through a drilled passage in the center countershaft. This causes the piston in the reverse clutch to move to the left, compressing the plates and disks. The reverse clutch rotates the center clutch drum. The center clutch drum has teeth machined into its outside diameter. These teeth mesh with the teeth on the outside diameter of the upper clutch drum.
speed clutch to move to the right, compressing the plates and disks. The upper drum rotates the first speed hub (C). The gear on the first speed hub meshes with the gear on the second speed hub (D). The second speed hub meshes with the gear on the third speed hub (E) which rotates the output gear (F). The output gear rotates the drive shafts.
Main pressure oil is routed through a drilled passage in the upper countershaft. This causes the piston in the first TX,902005,D50 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-17
544G, 624G, 644G Loader
062717
PN=403
Theory Of Operation
Transmission Operation—2nd Gear Reverse DRIVE A GEAR
SECOND B SPEED CLUTCH REVERSE CLUTCH G HUB SECOND C SPEED HUB
REVERSE F CLUTCH
THIRD D SPEED HUB
H MAIN PRESSURE
OUTPUT E GEAR
T6567NH
J
T6567NH —19—15SEP97
I RETURN PRESSURE
2ND REVERSE
With the transmission in second gear reverse, the reverse clutch (F) and second speed clutch (B) are engaged. The
torque converter supplies torque to the drive gear (A) which meshes with the reverse clutch hub (G).
Continued on next page
TM1529 (27JUN17)
9020-05-18
TX,902005,D52 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=404
Theory Of Operation
Main pressure oil is routed through drilled passages in the center countershaft. This causes the pistons in the reverse and second speed clutches to move to the left and right respectively, compressing the plates and disks, causing both clutches to rotate as a unit through the center drum.
The gear on the second speed hub (C) meshes with the gear on the third speed hub (D) which rotates the output gear (E). The output gear rotates the drive shafts.
TX,902005,D52 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-19
544G, 624G, 644G Loader
062717
PN=405
Theory Of Operation
Transmission Operation—3rd Gear Reverse DRIVE A GEAR
REVERSE CLUTCH F HUB THIRD B SPEED HUB REVERSE E CLUTCH THIRD SPEED D CLUTCH
H RETURN PRESSURE
T6567NI
I
OUTPUT C GEAR T6567NI —19—15SEP97
G MAIN PRESSURE
3RD REVERSE
With the transmission in third speed reverse, the reverse clutch (E) and third speed clutch (D) are engaged. The
torque converter supplies torque through the drive gear (A) which meshes with the reverse gear hub (F). Continued on next page
TM1529 (27JUN17)
9020-05-20
TX,902005,D54 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=406
Theory Of Operation
Main pressure oil is routed through a drilled passage in the center countershaft to the reverse clutch piston. This causes the piston to move to the left, compressing the plates and disks. The reverse clutch hub (F) rotates the center clutch drum which has gear teeth machined on its outside diameter. The center clutch drum gear teeth mesh with gear teeth on the lower clutch drum outside diameter, causing it to rotate.
Main pressure oil is routed through a drilled passage in the lower countershaft to the third speed clutch piston. This causes the piston to move to the right, compressing the plates and disks. The lower clutch drum rotates the third speed hub (B) gear which meshes with the output gear (C). The output gear rotates the drive shafts.
TX,902005,D54 -19-30JUL87-2/2
TM1529 (27JUN17)
9020-05-21
544G, 624G, 644G Loader
062717
PN=407
Theory Of Operation
Clutch Operation
B
F BACKING PLATE
D DRUM
GEAR HUB
G
E RETURN SPRING
BLEED C BALLS
GEAR HUB
A LUBE PASSAGE H COUNTERSHAFT
N LUBE ORIFICE
I
M SHIMS L
SEAL RING
J PISTON
PLATES AND DISKS
K SEPARATOR
CLUTCH ASSEMBLY
T7799BW —19—15JAN98
O
TXC7799BW
Continued on next page
TM1529 (27JUN17)
9020-05-22
TX,9020,HH780 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=408
Theory Of Operation The clutch assembly consists of two clutch packs inside of a common drum (D). The drum has external gear teeth machined on its outside diameter. The clutch assembly rotates on a stationary countershaft (H) bolted to the transmission housing. The countershaft has two drilled passages which route main pressure oil to move the pistons (J). Main pressure oil is sealed between the separator (K) and the countershaft by seal rings (L). Lube oil is supplied to the clutches through passage (A). Clutch lube flow is controlled by orifices (N) pressed into the countershaft. When the clutch is engaged, main pressure oil is routed to the inner area of the piston, moving it against the plates and disks (I). The plates and disks compress against the backing plate (F), locking the gear hub (G) to the drum. When the clutch is disengaged, main pressure oil is routed to return, causing the coil return spring (E) to move the piston back against the separator. This allows the plates and disks to slip, disengaging the gear hub from the drum.
To prevent partial clutch pack engagement, the clutch drum rotation forces the bleed balls (C) off their vertical seats allowing the oil trapped in the piston cavity to escape out the drain hole. If this oil remained behind the clutch piston, the centrifugal force of the rotating drum would force the oil to the outside edge of the piston cavity, moving the piston outward to partially engage the clutch. When the clutch is pressurized, the bleed balls seat to prevent oil leakage out of the piston cavity. IMPORTANT: The clutch assemblies have a clearance dimension between the plates and disks when installed. The gear hub has a protrusion measurement. Shims (M) are used to control the end play of the clutch assemblies when they are installed into the transmission housing. Consult the repair section of the technical manual for the correct measurement procedures.
TX,9020,HH780 -19-16SEP92-2/2
Transmission Hydraulic Components NOTE: See Power Train and Brakes System Component Location (Park Brakes Switch Off) drawing in Group 9020-15 for location of components. The components of the transmission hydraulic system are:
• Transmission pump • Transmission filter • Transmission control valve • Thermal bypass valve • Oil cooler The transmission housing serves as a reservoir for the transmission hydraulic system. The transmission pump
is located inside of the transmission. The transmission pump flow passes through the filter element and to the transmission control valve. The transmission control valve contains the control circuit used to engage the transmission clutches. Flow not needed to actuate the clutches flows through the converter and is routed out of the transmission housing to the thermal bypass valve. The thermal bypass valve directs cold oil back to the transmission as lube oil. When the transmission oil reaches a preset temperature, the thermal bypass valve opens to allow oil flow through the transmission oil cooler before returning to lube. TX,9020,HH781 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-05-23
544G, 624G, 644G Loader
062717
PN=409
Theory Of Operation
Transmission Hydraulic System
FILTER E F PUMP D HOUSING
B MANIFOLD
CONVERTER C RELIEF VALVE
A CONVERTER
G TRANSMISSION PRESSURE SWITCH
FROM L COOLER J TO COOLER
K CONVERTER MINIMUM PRESSURE REGULATOR
H CONTROL VALVE
I SUCTION TUBE
M MAIN PRESSURE O LUBE/COOLER PRESSURE P RETURN PRESSURE
TXC7799AB
Q
TRANSMISSION HYDRAULIC SYSTEM
The transmission hydraulic system is grouped into three circuits: TM1529 (27JUN17)
• Control Circuit • Converter/Cooler Circuit Continued on next page
9020-05-24
T7799AB —19—15JAN98
N CONVERTER PRESSURE
TX,9020,HH782 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=410
Theory Of Operation
• Lube Circuit The transmission housing (D) serves as the reservoir for the transmission hydraulic system. Inlet oil flows through a suction screen located in the suction tube (I) where it flows into the transmission housing to the pump manifold (B). The inlet oil flows through the manifold to the inlet of the transmission pump (F). Outlet oil from the transmission pump flows into the transmission housing where it is routed to the transmission filter (E). The transmission filter is a spin-on filter element with an internal bypass valve. Filtered pump outlet oil flows back into the transmission housing where it is routed to the transmission control circuit. The transmission control circuit is in the transmission control valve (H). The transmission control valve has a pressure regulating valve which establishes transmission main pressure. Transmission main pressure is used to engage the speed and direction clutches. Return flow
from the transmission control valve flows back into the transmission housing (dotted line). Excess flow from the control circuit supplies the converter circuit and is routed back into the transmission where it flows to the manifold. A direct-acting converter relief valve (C) is used to control the maximum pressure in the converter circuit. The manifold routes oil into and out of the torque converter (A). Converter outlet flow passes through the minimum pressure regulator (K). The minimum pressure regulator is a relief valve which prevents cavitation in the converter circuit. During normal operation, the minimum pressure regulator remains open. Converter outlet oil flows to the oil cooler through passage (J). The return flow from the oil cooler enters passage (L) where it supplies the lube circuit. Lube circuit flow fills a passage in the transmission housing. The housing passage supplies lube flow to the three countershaft assemblies. TX,9020,HH782 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-05-25
544G, 624G, 644G Loader
062717
PN=411
Theory Of Operation
Transmission Pump Operation B
B OUTLET
A
C INNER GEAR INLET A
F OUTLET FLOW E OUTER GEAR T6567OC
H
G INLET FLOW
TRANSMISSION PUMP
The transmission pump is a fixed displacement, internal gear-type pump. The transmission pump is driven at engine speed off the impeller drive from the torque converter. During operation, the inner gear (C), which is splined to the impeller shaft, rotates counterclockwise. The teeth of the inner gear mesh with the teeth of the outer gear (E), causing it to rotate in the same direction. As the gears
T6567OC —19—26AUG97
D SEPARATOR
come out of mesh by the inlet (A), a void is created. This causes inlet oil to be drawn into the areas between the gear teeth. As the gear teeth contact the separator (D), oil is trapped between the gear teeth and carried around to the outlet (B). As the gear teeth re-mesh, the space between the gears decreases, forcing oil out the pump outlet. TX,902005,D61 -19-30JUL87-1/1
TM1529 (27JUN17)
9020-05-26
544G, 624G, 644G Loader
062717
PN=412
Theory Of Operation
TM1529 (27JUN17)
9020-05-27
544G, 624G, 644G Loader
062717
PN=413
Theory Of Operation
T7799BI —19—26AUG92
Transmission Control Valve Components (5-Solenoid Valve)
Continued on next page
TM1529 (27JUN17)
9020-05-28
TX,9020,HH784 -19-13JAN95-1/2
544G, 624G, 644G Loader
062717
PN=414
Theory Of Operation NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302).
• M3 solenoid valve engages forward shift valve (J). • M4 solenoid valve engages first, second shift valve (A). • M5 solenoid valve engages fourth shift valve (L).
The transmission control valve assembly regulates the hydraulic control circuit of the transmission. The control valve receives electrical signals from the main controller to energize the solenoids which direct oil to move the shift valves. When the shift valves move, oil pressure drops to start modulation and fill the oncoming clutch pack.
The pressure regulating valve supplies a regulated pressure oil through a plate orifice to the modulation valve (E). The modulation valve is a spring-loaded valve which controls the speed of clutch engagement during a shift.
There are four gaskets and three plates between the transmission control valve (P) and the housing. Two plates are used to orifice oil to valves. The middle plate (duct plate) is used to route oil from the solenoids to the valves and then through the hoses to transmission shafts. The main valve contains pressure regulating valves, solenoid valves, shift valves, and valves for modulation. The pressure regulating valve (D) is a spring-loaded spool valve which regulates main pressure oil by controlling flow into the control circuit. Excess oil from the control circuit flows to the torque converter. Main pressure oil flows to the solenoid pressure regulating valve (B). The regulating valve provides a constant oil pressure to the solenoids and is not affected by modulation. The five solenoid valves (M) direct oil to the shift valves to provide machine direction and speed selection.
• M1 solenoid valve engages reverse shift valve (N). • M2 solenoid valve engages first shift valve (M).
When the first speed clutch is engaged, oil routed to the clutch pack also flows to the pilot valve (F). The pilot valve, which is a spring-loaded shuttle valve, moves and blocks passage to the two-stage piston (G). The two-stage piston is a stepping piston used to preload the modulation valve springs to start clutch modulation at a higher pressure. In first speed, modulation starts at a lower pressure to result in a less aggressive shift. In all other speeds, main pressure flows through the pilot valve to the two-stage piston and preloads the modulation valve resulting in a higher starting pressure. As modulation ends, the reset valve (K), which is a spring-loaded spool valve, moves and opens a direct path through the modulation valve for fast clutch engagement. Two clutches have to be engaged for the machine to move. One from the directional clutch packs either forward, reverse, or fourth. One from the speed clutch packs either first, second, or third. Check valves (C and I) are used to prevent flow between a directional shift and a speed shift. These check valves prevent a drop in clutch pack pressure in the engaged clutch. TX,9020,HH784 -19-13JAN95-2/2
TM1529 (27JUN17)
9020-05-29
544G, 624G, 644G Loader
062717
PN=415
Theory Of Operation
T7799AI —19—26AUG92
Modulation Components And Shift Time (5-Solenoid Valve)
Continued on next page
TM1529 (27JUN17)
9020-05-30
TX,9020,HH786 -19-13JAN95-1/2
544G, 624G, 644G Loader
062717
PN=416
Theory Of Operation NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). Several components are used in the transmission control valve to control shift modulation. They are:
• Pilot valve (B) • Two stage piston (E) • Vent valve (G) • Reset valve (H) These components work in conjunction with the modulation valve (I) to control the pressure increase on the clutches when the transmission is shifted.
two stage piston preloads the modulation valve. In 2nd, 3rd and 4th speeds, oil flows through the pilot valve to move the two stage piston against the pin (C) and preload modulation valve. When the modulation valve is pressurized, clutch modulation starts at a higher pressure. The vent valve routes pressure oil to the modulation valve and opens the passage to return during the last part of modulation. The reset valve opens a direct passage to the modulation valve for the final fill to the clutch pack. As the modulation ends, the reset valve moves, and routes main pressure oil to the clutch pack for final engagement.
The pilot valve is controlled by the first speed clutch. The pilot valve controls flow to the two stage piston. The TX,9020,HH786 -19-13JAN95-2/2
TM1529 (27JUN17)
9020-05-31
544G, 624G, 644G Loader
062717
PN=417
Theory Of Operation
Completed Shift—First Speed Forward (5-Solenoid) MONITOR TRANSMISSION PRESSURE LIGHT
SOLENOID PRESSURE REGULATING VALVE
PILOT VALVE
VENT VALVE RESET VALVE
2 STAGE PISTON
MODULATION VALVE S MAIN PRESSURE OIL T SOLENOID PRESSURE OIL
PRESSURE REGULATING VALVE
U CONVERTER PRESSURE OIL V RETURN PRESSURE OIL
FIRST AND A SECOND SHIFT VALVES B ORIFICE
SOLENOID PRESTART Q REGULATING VALVE
PRESSURE C REGULATING VALVE D MODULATION VALVE E
M4
M3
SOLENOID VALVES R
PILOT VALVE TO 1ST F SPEED CLUTCH PACK G SPACER
M5
2 STAGE H PISTON M2 I PIN J ORIFICE K
FIRST O SHIFT VALVE TXC7799AE
W
P
CHECK VALVES
L TO FORWARD CLUTCH PACK FORWARD M SHIFT VALVE
COMPLETED SHIFT FIRST SPEED FORWARD
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
N RESET VALVE
Continued on next page
9020-05-32
VENT VALVE
T7799AE —19—15JAN98
M1
TX,9020,HH788 -19-13JAN95-1/2
544G, 624G, 644G Loader
062717
PN=418
Theory Of Operation
When the transmission is in first speed forward and at full main pressure, the control valve modulation components are positioned as shown.
amount of oil to the speed clutch packs. The check valves allow modulated pressure oil to the oncoming clutch pack and prevent a pressure drop to the engaged clutch pack.
The control circuit oil flow is regulated by the pressure regulating valve (C) and the solenoid pressure regulating valve (Q). The pressure regulating valve controls main pressure oil (S) and the solenoid pressure regulating valve controls the solenoid pressure oil (T). Converter pressure oil (U) is excess pressure oil from the pressure regulating valve.
For forward to be engaged, main pressure oil from the check valve is routed through the forward shift valve to the forward clutch pack (L).
During first speed forward operation, solenoid valves (R) M2, M3, and M4 are activated. The activated solenoids route solenoid pressure oil (T) to move the shift valves:
• M4 shifts first and second shift valve (A). • M2 shifts first shift valve (O). • M3 shifts forward shift valve (M).
For first speed to be engaged, main pressure oil is routed through first, second shift valve and through first shift valve to first speed clutch pack (F). As the main pressure oil flows to first speed clutch pack, the pilot valve (E) is shifted to block main pressure oil flow to the two stage piston (H). The two stage piston relieves preload on modulation valve (D). The modulation valve will then start modulation for a directional shift at a lower pressure for a less aggressive shift.
The shift valves receive main pressure oil through orifice (B) and through check valves (P). The orifice allows a small TX,9020,HH788 -19-13JAN95-2/2
TM1529 (27JUN17)
9020-05-33
544G, 624G, 644G Loader
062717
PN=419
Theory Of Operation
Shift Modulation Starts For 2nd, 3rd, Or 4th (5-Solenoid) MONITOR TRANSMISSION PRESSURE LIGHT
SOLENOID PRESSURE REGULATING VALVE
PILOT VALVE
VENT VALVE RESET VALVE
2 STAGE PISTON
MODULATION VALVE L MAIN PRESSURE OIL M SOLENOID PRESSURE OIL N CONVERTER PRESSURE OIL O MODULATION PRESSURE OIL
PRESSURE REGULATING VALVE
P RETURN PRESSURE OIL
A ORIFICE
PRESSURE B REGULATING VALVE C
MODULATION VALVE
D
PILOT VALVE E 2 STAGE PISTON
F PIN
G SPACER H ORIFICE
K
TXC7799AH
Q
J
RESET VALVE
SHIFT MODULATION STARTS 2ND, 3RD OR 4TH
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
CHECK VALVE
Continued on next page
9020-05-34
VENT VALVE T7799AH —19—15JAN98
I
TX,9020,HH792 -19-17JAN95-1/2
544G, 624G, 644G Loader
062717
PN=420
Theory Of Operation
When a shift is made, a momentary pressure drop occurs as the new clutch pack is being engaged. The check valves (K) prevents a drop in pressure to the engaged clutch pack. The decreased pressure causes the reset valve (J) spring to shift the valve and to open a passage to return. Main pressure oil (L) is routed to the modulation valve (C) and is routed through the pilot valve (D) to the two stage piston (E) to preload the modulation valve. The modulation valve spring shifts the valve and meters
modulation pressure oil (O). The modulation pressure oil flows to the reset valve (J), the check valves (K), the orifice (H), and the vent valve (I). The reset valve spring tension holds the valve from moving until the end of modulation. The check valves are a spring held ball, which holds engaged clutch pack pressure. The orifice (H) screws into the aluminum control valve housing and supplies oil to the vent valve. The vent valve will be the first valve to shift as modulation begins. TX,9020,HH792 -19-17JAN95-2/2
TM1529 (27JUN17)
9020-05-35
544G, 624G, 644G Loader
062717
PN=421
Theory Of Operation
Shift Modulation For 2nd, 3rd, And 4th (5-Solenoid) MONITOR TRANSMISSION PRESSURE LIGHT
SOLENOID PRESSURE REGULATING VALVE
PILOT VALVE VENT VALVE RESET VALVE
2 STAGE PISTON
MODULATION VALVE
L MAIN PRESSURE OIL M SOLENOID PRESSURE OIL N CONVERTER PRESSURE OIL O MODULATION PRESSURE OIL (HIGH) P MODULATION PRESSURE OIL (LOW) Q RETURN PRESSURE OIL
PRESSURE REGULATING VALVE
A ORIFICE
PRESSURE B REGULATING VALVE MODULATION C VALVE D
PILOT VALVE E 2 STAGE PISTON
F PIN
G SPACER H ORIFICE
K TXC7799AG
R
J
RESET VALVE
SHIFT MODULATION FOR 2ND, 3RD, 4TH
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
CHECK VALVE
Continued on next page
9020-05-36
VENT VALVE T7799AG —19—15JAN98
I
TX,9020,HH794 -19-17JAN95-1/2
544G, 624G, 644G Loader
062717
PN=422
Theory Of Operation
As the oncoming clutch is filling, the modulation pressure oil (O) increases and moves the modulation valve (C) to the right against the springs in the valve. The movement in the modulation valve meters the engagement oil supplied to the clutches. While the modulation pressure oil (P) increases, oil flows to the check valves (K) and the orifice (H). The check valve directs oil to the oncoming clutch pack. The orifice (H) causes a time delay for the oncoming clutch pack to fill and provides a passage to shift the vent valve (I). When the vent valve is shifted, modulation pressure oil (P) flows to the modulation valve chamber. The pressure in the chamber compresses the modulation valve (C) against the modulation pressure oil (O) on the left side of the valve.
for main pressure oil (L) flow. While the valve continues to move, a passage is opened to fill the center of the modulation valve. The center of the modulation valve routes pressure oil to the spring side of the vent valve. The vent valve shifts and dumps the chamber side of the modulation valve. As modulation ends, main pressure oil shifts the reset valve for final clutch pack fill. The total time for modulation is approximately 1.2 seconds for both speed shifts and directional shifts. The combined action of the modulation valve, the orifice, the vent valve and the reset valve controls the rate of clutch slippage during a shift.
As the pressure increases in the chamber and moves the modulation valve to the left, a larger passage is opened TX,9020,HH794 -19-17JAN95-2/2
TM1529 (27JUN17)
9020-05-37
544G, 624G, 644G Loader
062717
PN=423
Theory Of Operation
Completed Shift Modulation For 2nd, 3rd, Or 4th (5-Solenoid) MONITOR TRANSMISSION PRESSURE LIGHT
SOLENOID PRESSURE REGULATING VALVE
PILOT VALVE
VENT VALVE RESET VALVE
2 STAGE PISTON
MODULATION VALVE L MAIN PRESSURE OIL M SOLENOID PRESSURE OIL N CONVERTER PRESSURE OIL
PRESSURE REGULATING VALVE
O RETURN PRESSURE OIL
A ORIFICE
PRESSURE B REGULATING VALVE MODULATION C VALVE D
M4
PILOT VALVE E 2 STAGE PISTON
M3
F PIN
M5
M2
G SPACER H ORIFICE I
K
TXC7799AF
P
J
RESET VALVE
COMPLETED SHIFT MODULATION FOR 2ND, 3RD, OR 4TH
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
CHECK VALVE
VENT VALVE
Continued on next page
9020-05-38
T7799AF —19—15JAN98
M1
TX,9020,HH790 -19-17JAN95-1/2
544G, 624G, 644G Loader
062717
PN=424
Theory Of Operation
When the transmission is in second, third, or fourth speeds, modulation starts at a higher pressure for a more aggressive shift. Main pressure oil (L) flows through the pilot valve (D) to the two stage piston (E). The two stage piston moves the pin (F) to preload the modulation valve
(C). The preload on the modulation valve spring increases pressure for modulation to start. Modulation for a shift in all speeds is the same except for pilot valve movement in first speed. TX,9020,HH790 -19-17JAN95-2/2
TM1529 (27JUN17)
9020-05-39
544G, 624G, 644G Loader
062717
PN=425
Theory Of Operation
T8089AB —UN—05NOV93
Transmission Clutch Engagement And Solenoids Activated (5-Solenoid)
pack is on the directional side of the transmission and meshes with an idler gear and forward gear.
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). The transmission has four forward speeds and three reverse speeds. For the machine to move, at least two clutch packs have to be engaged. One range clutch pack either forward, reverse, or 4th. One speed clutch pack either 1st, 2nd, or 3rd. In fourth forward, fourth speed clutch pack and third speed clutch pack have to be engaged for the machine to move. Fourth speed clutch
When the shift lever is moved, the shifter switch sends a signal to the transmission controller. The transmission controller is a microprocessor, it sends voltage to correct solenoids so they can energize and direct oil to engage the clutch packs. For the machine to move the following signals have to be transmitted:
• Engine running.
Continued on next page
TM1529 (27JUN17)
9020-05-40
TX,9020,DU1541 -19-18JAN95-1/2
544G, 624G, 644G Loader
062717
PN=426
Theory Of Operation
• Park brake released. • Clutch cutoff not engaged. • Shifter lever moved from neutral to forward or reverse. When the shifter lever is moved, the controller energizes the appropriate solenoid.
• M1 solenoid engages reverse shift valve.
• M2 solenoid engages first shift valve. • M3 solenoid engages forward shift valve. • M4 solenoid engages first, second shift valve. • M5 solenoid engages fourth shift valve. For transmission controller modes, see Transmission Control Circuit Theory of Operation in Section 9015-15. TX,9020,DU1541 -19-18JAN95-2/2
TM1529 (27JUN17)
9020-05-41
544G, 624G, 644G Loader
062717
PN=427
Theory Of Operation
Third Speed Neutral (5-Solenoid) SOLENOID VALVE (M5)
SOLENOID ACTIVATED
SPEED
FORWARD
REVERSE
1
1
2
3
4
2
4TH SHIFT VALVE
4TH SPEED CLUTCH
3
M1
FORWARD RANGE CLUTCH
SOLENOID VALVE (M3)
M2 M3
FORWARD SHIFT VALVE
M4 M5
REVERSE RANGE CLUTCH
SOLENOID VALVE (M1)
REVERSE SHIFT VALVE
FROM MODULATION VALVE CHECK VALVES FROM TRANSMISSION PUMP SOLENOID VALVE (M4)
1ST, 2ND SHIFT VALVE
SOLENOID VALVE (M2)
PILOT VALVE
TXC7799BM
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
MAIN PRESSURE OIL SOLENOID PRESSURE OIL RETURN PRESSURE OIL
Continued on next page
9020-05-42
3RD SPEED CLUTCH 2ND SPEED CLUTCH 1ST SPEED CLUTCH
T7799BM —19—20JAN98
1ST SHIFT VALVE
TX,9020,HH800 -19-17JAN95-1/2
544G, 624G, 644G Loader
062717
PN=428
Theory Of Operation
When the shifter is in third speed neutral, the controller sends the transmission control valve solenoids, NO signal. In third neutral, all the valves are in their normal position and no solenoids are activated, so third speed clutch pack is automatically engaged. The normal position of 1st, 2nd shift valve and 1st shift valve allows main pressure oil to flow through the shift valves to 3rd speed clutch. With all of the solenoid in their normal position, the solenoids will be open to return. With all of the valves in their normal position, only 3rd speed clutch receives main pressure oil. All the other clutch packs are open to return.
Keeping one clutch pack engaged in neutral: Prevents transmission from chattering or rolling. Allows a single modulated smooth shift to move the machine. The 1st, 2nd shift valve only moves in first speed or second speed and is normally open to 1st shift valve. The 1st shift valve only moves in first speed and is normally open to 3rd speed clutch.
TX,9020,HH800 -19-17JAN95-2/2
TM1529 (27JUN17)
9020-05-43
544G, 624G, 644G Loader
062717
PN=429
Theory Of Operation
First Speed—Forward (5-Solenoid) SOLENOID ACTIVATED FORWARD SPEED
1
2
3
4
REVERSE 1
2
4TH SHIFT VALVE
SOLENOID VALVE (M5)
4TH SPEED CLUTCH
3
M1 FORWARD RANGE CLUTCH
M2 M3 M4
FORWARD SHIFT VALVE
M5 SOLENOID VALVE (M3)
REVERSE RANGE CLUTCH
SOLENOID VALVE (M1)
REVERSE SHIFT VALVE
FROM MODULATION VALVE CHECK VALVES FROM TRANSMISSION PUMP
SOLENOID VALVE (M4) 1ST, 2ND SHIFT VALVE
SOLENOID VALVE (M2)
PILOT VALVE
TXC7799BL
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
MAIN PRESSURE OIL SOLENOID PRESSURE OIL RETURN PRESSURE OIL
Continued on next page
9020-05-44
3RD SPEED CLUTCH 2ND SPEED CLUTCH 1ST SPEED CLUTCH
T7799BL —19—20JAN98
1ST SHIFT VALVE
TX,9020,HH802 -19-17JAN95-1/2
544G, 624G, 644G Loader
062717
PN=430
Theory Of Operation
In first speed forward, three solenoids are activated. Forward solenoid is M3 and will always be activated whenever the shifter is in forward. In first speed, M4 solenoid is activated to shift 1st, 2nd shift valve and M2 solenoid is activated to shift 1st shift valve. When the valves are shifted, main pressure oil flows to the
forward range clutch and the 1st speed clutch allowing the machine to move. Main pressure oil also flows from 1st speed clutch to shift pilot valve. The shifted pilot valve blocks main pressure oil to the two stage piston and opens the return passage for the preloaded modulation valve pressure. TX,9020,HH802 -19-17JAN95-2/2
TM1529 (27JUN17)
9020-05-45
544G, 624G, 644G Loader
062717
PN=431
Theory Of Operation
Second Speed—Forward (5-Solenoid)
SOLENOID ACTIVATED FORWARD SPEED
1
2
3
4
4TH SHIFT VALVE
SOLENOID VALVE (M5)
4TH SPEED CLUTCH
REVERSE 1
2
3
M1
SOLENOID VALVE (M3)
M2
FORWARD RANGE CLUTCH
M3
FORWARD SHIFT VALVE
M4 M5
REVERSE RANGE CLUTCH
SOLENOID VALVE (M1)
REVERSE SHIFT VALVE
FROM MODULATION VALVE CHECK VALVES FROM TRANSMISSION PUMP SOLENOID VALVE (M4)
1ST, 2ND SHIFT VALVE
SOLENOID VALVE (M2)
PILOT VALVE
TXC7799BN
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
MAIN PRESSURE OIL SOLENOID PRESSURE OIL RETURN PRESSURE OIL
Continued on next page
9020-05-46
3RD SPEED CLUTCH 2ND SPEED CLUTCH 1ST SPEED CLUTCH
T7799BN —19—20JAN98
1ST SHIFT VALVE
TX,9020,HH804 -19-18JAN95-1/2
544G, 624G, 644G Loader
062717
PN=432
Theory Of Operation
In second speed forward, the solenoid for forward, M3 is activated and the solenoid M4 is activated to shift 1st, 2nd shift valve. The forward range clutch is engaged by the solenoid valve M3 shifting and allowing solenoid pressure oil to shift the forward shift valve. The forward shift valve moves and opens a passage for main pressure oil to flow to clutch pack.
The second clutch is engaged with the solenoid pressure oil from the activated solenoid, shifting the 1st, 2nd shift valve. The movement of the 1st, 2nd shift valve directs main pressure oil to flow through the valve and through the 1st shift valve. The 1st shift valve is normally open to 2nd speed clutch allowing the main pressure to engage second speed clutch. TX,9020,HH804 -19-18JAN95-2/2
TM1529 (27JUN17)
9020-05-47
544G, 624G, 644G Loader
062717
PN=433
Theory Of Operation
Third Speed—Forward (5-Solenoid)
FORWARD SPEED
1
2
3
4
4TH SHIFT VALVE
SOLENOID VALVE (M5)
SOLENOID ACTIVATED
4TH SPEED CLUTCH
REVERSE 1
2
3
M1
FORWARD RANGE CLUTCH
SOLENOID VALVE (M3)
M2 M3
FORWARD SHIFT VALVE
M4 M5
REVERSE RANGE CLUTCH
SOLENOID VALVE (M1)
REVERSE SHIFT VALVE
FROM MODULATION VALVE CHECK VALVES FROM TRANSMISSION PUMP SOLENOID VALVE (M4)
1ST, 2ND SHIFT VALVE
SOLENOID VALVE (M2)
PILOT VALVE
TXC7799BP
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
MAIN PRESSURE OIL SOLENOID PRESSURE OIL RETURN PRESSURE OIL
Continued on next page
9020-05-48
3RD SPEED CLUTCH 2ND SPEED CLUTCH 1ST SPEED CLUTCH
T7799BP —19—20JAN98
1ST SHIFT VALVE
TX,9020,HH806 -19-18JAN95-1/2
544G, 624G, 644G Loader
062717
PN=434
Theory Of Operation
In third speed forward, the only solenoid activated is the forward solenoid M3. Main pressure flows through the forward shift valve to engage the forward clutch. The 3rd speed clutch is normally engaged when the shift
valves are in their normal position. Main pressure oil flows through 1st, 2nd shift valve and through 1st shift valve to engage third speed clutch. TX,9020,HH806 -19-18JAN95-2/2
Fourth Speed—Forward (5-Solenoid)
The controller activates M5 solenoid valve and sends solenoid pressure oil to the 4th shift valve. The 4th shift valve moves and opens the passage for main pressure oil to engage the 4th speed clutch.
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). When the machine is in fourth speed forward, the third and fourth speed clutch packs are engaged. 3rd speed clutch pack is normally engaged, so the only solenoid to be activated will be M5 solenoid or fourth speed solenoid.
3rd speed clutch is engaged by main pressure oil flowing through 1st, 2nd shift valve and 1st shift valve. These valves are in their normal position. TX,9020,HH808 -19-18JAN95-1/1
TM1529 (27JUN17)
9020-05-49
544G, 624G, 644G Loader
062717
PN=435
Theory Of Operation
First Speed—Reverse (5-Solenoid) SOLENOID ACTIVATED FORWARD SPEED
1
2
3
4
4TH SHIFT VALVE
SOLENOID VALVE (M5)
4TH SPEED CLUTCH
REVERSE 1
2
3
M1
FORWARD RANGE CLUTCH FORWARD SHIFT VALVE
SOLENOID VALVE (M3)
M2 M3 M4 M5
SOLENOID VALVE (M1)
REVERSE RANGE CLUTCH REVERSE SHIFT VALVE
FROM MODULATION VALVE CHECK VALVES FROM TRANSMISSION PUMP SOLENOID VALVE (M4)
1ST, 2ND SHIFT VALVE
SOLENOID VALVE (M2)
PILOT VALVE
TXC7799BS
MAIN PRESSURE OIL SOLENOID PRESSURE OIL RETURN PRESSURE OIL
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
Continued on next page
9020-05-50
3RD SPEED CLUTCH 2ND SPEED CLUTCH 1ST SPEED CLUTCH
T7799BS —19—20JAN98
1ST SHIFT VALVE
TX,9020,HH810 -19-18JAN95-1/2
544G, 624G, 644G Loader
062717
PN=436
Theory Of Operation
First speed reverse is like first forward except the reverse solenoid M1 is activated instead of the forward solenoid M3. When the machine is shifted into first reverse, the controller activates:
• M1 solenoid to shift reverse shift valve. • M4 solenoid to shift 1st, 2nd shift valve. • M2 solenoid to shift 1st shift valve. When M1 solenoid is energized, the solenoid opens a passage for solenoid pressure oil to pressurize the reverse shift valve. The pressure oil moves the reverse shift valve and the main pressure oil engages the reverse clutch pack.
For first speed to be energized, the controller activates M4 and M2 solenoids. The activated solenoid allows solenoid pressure oil to pressurize 1st, 2nd shift valve and 1st shift valve. The pressurized valves open a passage for main pressure oil to engage 1st speed clutch. In normal operation, only one solenoid will change. The shift could be a shuttle shift from 1st forward to 1st reverse or a downshift from 2nd speed to 1st speed. Usually only one solenoid changes. If a shuttle shift and a downshift occur, modulation will start over with the second shift. TX,9020,HH810 -19-18JAN95-2/2
TM1529 (27JUN17)
9020-05-51
544G, 624G, 644G Loader
062717
PN=437
Theory Of Operation
Second Speed—Reverse (5-Solenoid)
FORWARD SPEED
1
2
3
4
4TH SHIFT VALVE
SOLENOID VALVE (M5)
SOLENOID ACTIVATED
4TH SPEED CLUTCH
REVERSE 1
2
3
M1
FORWARD RANGE CLUTCH FORWARD SHIFT VALVE
SOLENOID VALVE (M3)
M2 M3 M4 M5
SOLENOID VALVE (M1)
REVERSE RANGE CLUTCH REVERSE SHIFT VALVE
FROM MODULATION VALVE CHECK VALVES FROM TRANSMISSION PUMP
SOLENOID VALVE (M2)
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
1ST SHIFT VALVE 3RD SPEED CLUTCH 2ND SPEED CLUTCH 1ST SPEED CLUTCH
PILOT VALVE
TXC7799BT
1ST, 2ND SHIFT VALVE
MAIN PRESSURE OIL SOLENOID PRESSURE OIL RETURN PRESSURE OIL
Continued on next page
9020-05-52
T7799BT —19—20JAN98
SOLENOID VALVE (M4)
TX,9020,HH812 -19-18JAN95-1/2
544G, 624G, 644G Loader
062717
PN=438
Theory Of Operation
When the machine is shuttle shifted from second speed forward to second speed reverse, the reverse solenoid M1 is activated and the forward solenoid M3 is deactivated. The solenoid allows solenoid pressure oil to shift the shift valves and main pressure oil flows to the reverse clutch. The forward clutch is open to return. When the machine is downshifted from third speed to second speed, the controller signals M4 solenoid to shift 1st, 2nd shift valve. The shifted valve opens the passage
for main pressure oil to engage 2nd speed clutch and opens the passage for 3rd speed clutch to empty to return. If the machine is upshifted from 1st speed to 2nd speed, the controller signals M2 solenoid to deactivate. The deactivated solenoid opens the passage to return to drain solenoid pressure oil to 1st shift valve. The shifted valve opens a passage for main pressure oil to engage 2nd speed clutch and opens the passage for 1st speed clutch to empty to return. TX,9020,HH812 -19-18JAN95-2/2
TM1529 (27JUN17)
9020-05-53
544G, 624G, 644G Loader
062717
PN=439
Theory Of Operation
Third Speed—Reverse (5-Solenoid) SOLENOID ACTIVATED FORWARD SPEED
1
2
3
4
REVERSE 1
2
4TH SHIFT VALVE
SOLENOID VALVE (M5)
4TH SPEED CLUTCH
3
M1
FORWARD RANGE CLUTCH FORWARD SHIFT VALVE
SOLENOID VALVE (M3)
M2 M3 M4 M5
SOLENOID VALVE (M1)
REVERSE RANGE CLUTCH REVERSE SHIFT VALVE
FROM MODULATION VALVE CHECK VALVES FROM TRANSMISSION PUMP
SOLENOID VALVE (M4)
1ST, 2ND SHIFT VALVE
SOLENOID VALVE (M2)
PILOT VALVE
TXC7799BU
NOTE: Five solenoid valves are used on: 544G (S.N. —548218), 624G (S.N. —548397), 644G (S.N. —548302). TM1529 (27JUN17)
MAIN PRESSURE OIL SOLENOID PRESSURE OIL RETURN PRESSURE OIL
Continued on next page
9020-05-54
3RD SPEED CLUTCH 2ND SPEED CLUTCH 1ST SPEED CLUTCH
T7799BU —19—20JAN98
1ST SHIFT VALVE
TX,9020,HH814 -19-18JAN95-1/2
544G, 624G, 644G Loader
062717
PN=440
Theory Of Operation
For third speed reverse, M1 solenoid is the only solenoid activated. M1 solenoid opens the passage for solenoid pressure oil to shift the reverse shift valve. The shifted valve allows main pressure oil to engage the reverse range clutch.
If the machine is shuttle shifted from 3rd forward to 3rd reverse, the transmission controller will monitor the ground speed and determine if a downshift or a reversal will occur. At high speeds the machine will downshift to 2nd forward to 2nd reverse and then to 3rd reverse.
To engage 3rd speed clutch, main pressure oil flows through 1st, 2nd shift valve and 1st shift valve. TX,9020,HH814 -19-18JAN95-2/2
TM1529 (27JUN17)
9020-05-55
544G, 624G, 644G Loader
062717
PN=441
Theory Of Operation
Thermal Bypass Valve Operation C D H
A
E
C TO LUBE
C
G
F
D
FROM COOLER
D
SEAT B
H SPRING
VALVE A
FROM CONVERTER
E
I BYPASS
THERMOSTAT G
TXC7799BX
F TO COOLER
M
F K LUBE/CONVERTER-OUT FLOW
THERMAL BYPASS VALVE
The thermal bypass valve is used to maintain the transmission oil temperature at a level which provides optimum torque converter performance. TM1529 (27JUN17)
J COOLING
T7799BX —19—20JAN98
E
L TO COOLER (VALVE CLOSED) FLOW
The valve contains a standard automotive-type thermostat element connected to a hollow valve spool. Continued on next page
9020-05-56
TX,9020,HH816 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=442
Theory Of Operation
The valve is designed to bypass the transmission oil cooler at low temperatures. Converter outlet flow enters passage (E) and flows through the valve (A) to lube (C).
oil cooler. The thermostat will go to the full open position, forcing the valve closed against the seat (B). The spring loaded seat will act as a relief valve in the event cooler flow is blocked.
At higher temperatures, the thermostat (G) begins to open, allowing flow out of passage (F) to the transmission TX,9020,HH816 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-05-57
544G, 624G, 644G Loader
062717
PN=443
Theory Of Operation
T8347AF —19—04JAN95
Transmission Control Valve Components (6-Solenoid Valve)
Continued on next page
TM1529 (27JUN17)
9020-05-58
TX,9020,RP2555 -19-13JAN95-1/2
544G, 624G, 644G Loader
062717
PN=444
Theory Of Operation NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—).
• M2 solenoid valve engages first shift valve (M). • M3 solenoid valve engages forward shift valve (J). • M4 solenoid valve engages first and second shift valve
The transmission control valve assembly regulates the hydraulic control circuit of the transmission. The control valve receives electrical signals from the main controller to energize the solenoids which direct oil to move the shift valves. When the shift valves move, oil pressure drops to start modulation and fill the oncoming clutch pack.
• M5 solenoid valve engages fourth shift valve (L). • M6 solenoid valve reduces time between shifts
(A).
There are four gaskets and three plates between the transmission control valve (P) and the housing. Two plates are used to orifice oil to valves. The middle plate (duct plate) is used to route oil from the solenoids to the valves and then through the hoses to transmission shafts. The main valve contains pressure regulating valves, solenoid valves, shift valves, valves for modulation (hydraulic reset valve and M6 solenoid). The pressure regulating valve (D) is a spring-loaded spool valve which regulates main pressure oil by controlling flow into the control circuit. Excess oil from the control circuit flows to the torque converter. Main pressure oil flows to the solenoid pressure regulating valve (B). The regulating valve provides a constant oil pressure to the solenoids and is not affected by modulation. The five solenoid valves (O) direct oil to the shift valves to provide machine direction and speed selection.
• M1 solenoid valve engages reverse shift valve (N).
The pressure regulating valve supplies a regulated pressure oil through a plate orifice to the modulation valve (F). The modulation valve is a spring-loaded valve which controls the speed of clutch engagement during a shift. The M6 solenoid is always energized, except during clutch modulation. It holds the modulation valve in full open position to allow maximum oil fill to each clutch. When the clutch pack piston is moved to “ready to begin engagement”, the M6 solenoid de-energizes to allow the modulation circuit to raise clutch pressure to the regulated rate. After full clutch engagement, the M6 solenoid is energized until another shift is required. As modulation ends, the reset valve (I), which is a spring-loaded spool valve, moves and opens a direct path through the modulation valve for the sequence to begin again. Two clutches have to be engaged for the machine to move. One from the directional clutch packs either forward, reverse, or fourth. One from the speed clutch packs either first, second, or third. Check valves (C and H) are used to prevent flow between a directional shift and a speed shift. These check valves prevent a drop in clutch pack pressure in the engaged clutch. TX,9020,RP2555 -19-13JAN95-2/2
TM1529 (27JUN17)
9020-05-59
544G, 624G, 644G Loader
062717
PN=445
Theory Of Operation
T8394AE —19—12JAN95
Modulation Components And Shift Time (6-Solenoid Valve)
Continued on next page
TM1529 (27JUN17)
9020-05-60
TX,9020,RP2560 -19-13JAN95-1/2
544G, 624G, 644G Loader
062717
PN=446
Theory Of Operation NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). Several components are used in the transmission control valve to control shift modulation. They are:
• M6 Solenoid Valve (E) • Modulation Valve (F) • Vent Valve (G) • Reset Valve (I) These components work together to control the rate of pressure increase in the clutch packs when the transmission is shifted.
When M6 solenoid valve is de-energized, the reset valve connects the center of the modulation valve to tank, and the vent valve applies pressure oil to the end of the modulation piston, causing it to regulate the pressure rise of the oil going into the on-coming clutch. M6 solenoid valve is energized after the shift is made. When M6 solenoid valve re-energizes, the reset valve directs pressure oil to the center of the modulation valve and the vent valve opens the end of the modulation valve to tank, causing it to move to the non-modulating (full open) position ready for the next shift to be made.
TX,9020,RP2560 -19-13JAN95-2/2
TM1529 (27JUN17)
9020-05-61
544G, 624G, 644G Loader
062717
PN=447
Theory Of Operation
Control Valve In Neutral (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 CLUTCH K3 CLUTCH
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5 K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH M1 KR REVERSE RANGE CLUTCH
ENERGIZED M6
PRESSURE CHECK VALVE
CONVERTER PRESSURE REGULATOR
VENT VALVE RESET VALVE
M4 MODULATION VALVE PRESSURE REGULATING VALVE
CONVERTER
TRANSMISSION FILTER
OIL COOLER LUBRICATION
TRANSMISSION PUMP
XJ1236906
OIL SUMP
M2
1ST, 2ND SHIFT VALVE 1ST SHIFT VALVE K3 3RD SPEED CLUTCH K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
XJ1236906 —UN—05APR17
CONVERTER OUTLET TEMPERATURE
Control Valve in Neutral
NOTE: Six Solenoid valves are used on 544G (S.N. 548219— ), 624G (S.N. 548398— ), and 644G (S.N. 548303— ).
When the transmission is in neutral, the control valve components are positioned as shown.
Continued on next page
TM1529 (27JUN17)
9020-05-62
TX,9020,RP2563 -19-06APR17-1/2
544G, 624G, 644G Loader
062717
PN=448
Theory Of Operation
Main pressure oil is controlled by the regulating valve. Solenoid pressure oil is controlled by the reduction valve. Converter pressure oil is excess from the regulating valve.
When the vent valve is shifted, it opens the small end of the modulation valve to tank, further ensuring the modulation valve cannot modulate oil flow.
With the engine running, M6 is energized, main pressure oil flows to the reset valve and vent valve, shifting their spools.
With solenoid valves M2 and M4 de-energized, third speed clutch, K3, is pressurized. One range clutch and one speed clutch must be pressurized for the machine to move.
When the reset valve is shifted, it allows main pressure to the center of the modulation valve, moving it to the non-modulating position. TX,9020,RP2563 -19-06APR17-2/2
TM1529 (27JUN17)
9020-05-63
544G, 624G, 644G Loader
062717
PN=449
Theory Of Operation
T8403AA —19—25JAN95
Transmission Clutch Engagement And Solenoids Activated (6-Solenoid)
Continued on next page
TM1529 (27JUN17)
9020-05-64
TX,9020,RP2566 -19-02FEB95-1/2
544G, 624G, 644G Loader
062717
PN=450
Theory Of Operation NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). The transmission has four forward speeds and three reverse speeds. For the machine to move, at least two clutch packs have to be engaged. One range clutch pack either forward, reverse, or 4th. One speed clutch pack either 1st, 2nd, or 3rd. In fourth forward, fourth speed clutch pack and third speed clutch pack have to be engaged for the machine to move. Fourth speed clutch pack is on the directional side of the transmission and meshes with an idler gear and forward gear. When the shift lever is moved, the shifter switch sends a signal to the transmission controller. The transmission controller is a microprocessor, it sends voltage to correct solenoids so they can energize and direct oil to engage the clutch packs.
• Engine running. • Park brake released. • Clutch cutoff not engaged. • Shifter lever moved from neutral to forward or reverse. When the shifter lever is moved, the controller energizes the appropriate solenoid.
• M1 solenoid engages reverse shift valve. • M2 solenoid engages first shift valve. • M3 solenoid engages forward shift valve. • M4 solenoid engages first, second shift valve. • M5 solenoid engages fourth shift valve. • M6 solenoid reduces time between shifts. For transmission controller modes, see Transmission Control Circuit Theory of Operation in Section 9015-15.
For the machine to move the following signals have to be transmitted: TX,9020,RP2566 -19-02FEB95-2/2
TM1529 (27JUN17)
9020-05-65
544G, 624G, 644G Loader
062717
PN=451
Theory Of Operation
Shift Modulation (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 CLUTCH KV K3 CLUTCH K1
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5
K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF
M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH
M1
KR REVERSE RANGE CLUTCH
M6
PRESSURE CHECK VALVE
VENT VALVE
CONVERTER PRESSURE REGULATOR
RESET VALVE
M4
MODULATION VALVE PRESSURE REGULATING VALVE
CONVERTER OIL COOLER
K3 3RD SPEED CLUTCH
TRANSMISSION PUMP
K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). TM1529 (27JUN17)
1ST SHIFT VALVE
TRANSMISSION FILTER
LUBRICATION
TXC8398AF
M2
1ST, 2ND SHIFT VALVE
Continued on next page
9020-05-66
T8398AF —19—15JAN98
CONVERTER OUTLET TEMPERATURE
TX,9020,RP2569 -19-21FEB95-1/2
544G, 624G, 644G Loader
062717
PN=452
Theory Of Operation
When shifting from neutral to first speed forward, M6 solenoid is energized. M6 remains energized a short time after the shift lever is moved to forward, then is de-energized. When M6 is energized, it directs pressure oil to reset valve and vent valve. The reset valve shifts, allowing main pressure oil to the center of the modulation valve. The vent valve is also shifted, connecting the small end of the modulation valve to tank. The modulation valve shifts to the non-modulation position and main pressure oil flows through it to the on-coming clutch, in this case the forward range clutch, starting to fill the clutch rapidly. The
transmission controller has also energized M3 Forward Range Clutch Solenoid, M4 First and Second Shift Valve Solenoid and M2 First Shift Valve Solenoid. A short time later, the transmission controller de-energizes M6 solenoid, moving the modulation valve into the modulating position to finish filling the clutch pack and complete the shift. After the shift is complete, transmission controller energizes M6 again and transmission control valve is ready for another shift. Each time a shift is made, this sequence repeats.
TX,9020,RP2569 -19-21FEB95-2/2
TM1529 (27JUN17)
9020-05-67
544G, 624G, 644G Loader
062717
PN=453
Theory Of Operation
First Speed—Forward (6-Solenoid) MAIN PRESSURE OIL
FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 CLUTCH KV CLUTCH K1
MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5
K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF
M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
M1
M6
VENT VALVE RESET VALVE
PRESSURE REGULATING VALVE
CONVERTER
TRANSMISSION FILTER
OIL COOLER LUBRICATION
TRANSMISSION PUMP
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—).
Continued on next page
9020-05-68
M4
1ST, 2ND SHIFT VALVE
M2
1ST SHIFT VALVE K3 3RD SPEED CLUTCH K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
T8398AG —19—15JAN98
MODULATION VALVE
TM1529 (27JUN17)
KR REVERSE RANGE CLUTCH PRESSURE CHECK VALVE
CONVERTER PRESSURE REGULATOR CONVERTER OUTLET TEMPERATURE
TXC8398AG
KV FORWARD RANGE CLUTCH
TX,9020,RP2570 -19-21FEB95-1/2
544G, 624G, 644G Loader
062717
PN=454
Theory Of Operation
In first speed forward, M3 forward range clutch solenoid is energized. Solenoid pressure oil flows through M3 to shift the forward clutch valve. Main pressure oil flows to the forward range clutch and engages it.
M4 1st, 2nd shift valve solenoid and M2 1st shift valve solenoid are energized. Main pressure oil flows through both valves to engage first speed clutch. TX,9020,RP2570 -19-21FEB95-2/2
TM1529 (27JUN17)
9020-05-69
544G, 624G, 644G Loader
062717
PN=455
Theory Of Operation
Second Speed—Forward (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 K4 CLUTCH K3 CLUTCH
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5 K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF
M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH M1 KR REVERSE RANGE CLUTCH
M6
PRESSURE CHECK VALVE
VENT VALVE
CONVERTER PRESSURE REGULATOR
RESET VALVE
M4
MODULATION VALVE PRESSURE REGULATING VALVE
CONVERTER OIL COOLER
K3 3RD SPEED CLUTCH
TRANSMISSION PUMP
K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). TM1529 (27JUN17)
1ST SHIFT VALVE
TRANSMISSION FILTER
LUBRICATION
TXC8398AH
M2
1ST, 2ND SHIFT VALVE
Continued on next page
9020-05-70
T8398AH —19—15JAN98
CONVERTER OUTLET TEMPERATURE
TX,9020,RP2572 -19-22FEB95-1/2
544G, 624G, 644G Loader
062717
PN=456
Theory Of Operation
In second speed forward, M3 forward range clutch solenoid is energized. Solenoid pressure oil flows through M3 to shift the forward clutch valve. Main pressure oil flows through forward clutch valve to engage the forward clutch pack.
M4 1st, 2nd shift valve solenoid is energized. Main pressure oil flows through 1st, 2nd shift valve and 1st shift valve to 2nd speed clutch pack to engage it.
TX,9020,RP2572 -19-22FEB95-2/2
TM1529 (27JUN17)
9020-05-71
544G, 624G, 644G Loader
062717
PN=457
Theory Of Operation
Third Speed—Forward (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 KV CLUTCH K3 CLUTCH
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5
K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF
M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH
M1 KR REVERSE RANGE CLUTCH
M6
PRESSURE CHECK VALVE
VENT VALVE
CONVERTER PRESSURE REGULATOR
RESET VALVE
M4 MODULATION VALVE PRESSURE REGULATING VALVE
CONVERTER
TRANSMISSION FILTER
OIL COOLER LUBRICATION
TRANSMISSION PUMP
TXC8398AI
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). TM1529 (27JUN17)
Continued on next page
9020-05-72
M2
1ST, 2ND SHIFT VALVE 1ST SHIFT VALVE K3 3RD SPEED CLUTCH K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
T8398AI —19—15JAN98
CONVERTER OUTLET TEMPERATURE
TX,9020,RP2574 -19-21FEB95-1/2
544G, 624G, 644G Loader
062717
PN=458
Theory Of Operation
In third speed forward, M3 forward range clutch solenoid is energized. Solenoid pressure oil flows through M3 to shift the forward clutch valve. Main pressure oil flows through forward clutch valve to engage the forward clutch pack.
M4 1st, 2nd shift valve solenoid and M2 1st shift valve solenoids are de-energized, allowing main pressure oil to flow through them to 3rd speed clutch pack to engage it. TX,9020,RP2574 -19-21FEB95-2/2
TM1529 (27JUN17)
9020-05-73
544G, 624G, 644G Loader
062717
PN=459
Theory Of Operation
Fourth Speed—Forward (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 K4 CLUTCH K3 CLUTCH
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5
K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF
M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH M1
KR REVERSE RANGE CLUTCH
M6
PRESSURE CHECK VALVE
VENT VALVE
CONVERTER PRESSURE REGULATOR
RESET VALVE
M4 MODULATION VALVE PRESSURE REGULATING VALVE
CONVERTER
TRANSMISSION FILTER
OIL COOLER LUBRICATION
TRANSMISSION PUMP
TXC8398AJ
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). TM1529 (27JUN17)
Continued on next page
9020-05-74
M2
1ST, 2ND SHIFT VALVE 1ST SHIFT VALVE K3 3RD SPEED CLUTCH K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
T8398AJ —19—15JAN98
CONVERTER OUTLET TEMPERATURE
TX,9020,RP2576 -19-21FEB95-1/2
544G, 624G, 644G Loader
062717
PN=460
Theory Of Operation
In fourth speed forward, M5 fourth speed clutch solenoid is energized. Solenoid pressure oil flows through M5 to shift the fourth speed clutch valve. Main pressure oil flows through fourth speed clutch valve to engage the fourth speed clutch pack. Fourth speed is the only speed that doesn’t have a range clutch engaged.
M4 1st, 2nd shift valve solenoid and M2 1st shift valve solenoid are de-energized, allowing main pressure oil to flow through them to engage the third speed clutch pack. The combination of third speed clutch and fourth speed clutch result in fourth speed forward. TX,9020,RP2576 -19-21FEB95-2/2
TM1529 (27JUN17)
9020-05-75
544G, 624G, 644G Loader
062717
PN=461
Theory Of Operation
First Speed—Reverse (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 KR CLUTCH K1 CLUTCH
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5
K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF
M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH
M1
KR REVERSE RANGE CLUTCH
M6
PRESSURE CHECK VALVE
VENT VALVE
CONVERTER PRESSURE REGULATOR
RESET VALVE
CONVERTER OUTLET TEMPERATURE
M4 MODULATION VALVE
CONVERTER
TRANSMISSION FILTER
OIL COOLER LUBRICATION
TRANSMISSION PUMP
TXC8398AK
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). TM1529 (27JUN17)
Continued on next page
9020-05-76
M2 1ST SHIFT VALVE K3 3RD SPEED CLUTCH K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
T8398AK —19—15JAN98
PRESSURE REGULATING VALVE
1ST, 2ND SHIFT VALVE
TX,9020,RP2578 -19-21FEB95-1/2
544G, 624G, 644G Loader
062717
PN=462
Theory Of Operation
In first speed reverse, M1 reverse range clutch solenoid is energized. Solenoid pressure oil flows through M1 to shift the reverse range clutch valve. Main pressure oil flows through the reverse range clutch valve to engage the reverse clutch pack.
M4 1st, 2nd shift valve solenoid and M2 1st shift valve solenoid are energized, allowing main pressure oil to flow through them to engage the first speed clutch pack.
TX,9020,RP2578 -19-21FEB95-2/2
TM1529 (27JUN17)
9020-05-77
544G, 624G, 644G Loader
062717
PN=463
Theory Of Operation
Second Speed—Reverse (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 CLUTCH KR CLUTCH K2
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5
K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH
M1
KR REVERSE RANGE CLUTCH
M6 PRESSURE CHECK VALVE
VENT VALVE RESET VALVE M4
CONVERTER PRESSURE REGULATOR
MODULATION VALVE PRESSURE REGULATING VALVE
CONVERTER
TRANSMISSION FILTER
OIL COOLER LUBRICATION
TRANSMISSION PUMP
TXC8398AL
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). TM1529 (27JUN17)
Continued on next page
9020-05-78
M2
1ST, 2ND SHIFT VALVE 1ST SHIFT VALVE K3 3RD SPEED CLUTCH K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
T8398AL —19—15JAN98
CONVERTER OUTLET TEMPERATURE
TX,9020,RP2580 -19-21FEB95-1/2
544G, 624G, 644G Loader
062717
PN=464
Theory Of Operation
In second speed reverse, M1 reverse range clutch solenoid is energized. Solenoid pressure oil flows through M1 to shift the reverse range clutch valve. Main pressure oil flows through the reverse range clutch valve to engage the reverse clutch pack.
M4 1st, 2nd shift valve solenoid is energized, allowing main pressure oil to flow through it to engage the second speed clutch pack.
TX,9020,RP2580 -19-21FEB95-2/2
TM1529 (27JUN17)
9020-05-79
544G, 624G, 644G Loader
062717
PN=465
Theory Of Operation
Third Speed—Reverse (6-Solenoid) FORWARD REVERSE NEUTRAL SPEED 1 2 3 4 1 2 3 M1 M2 M3 M4 M5 M6 CLUTCH KR CLUTCH K3
MAIN PRESSURE OIL MODULATION PRESSURE OIL SOLENOID PRESSURE OIL CONVERTER PRESSURE OIL RETURN OIL LUBRICATION OIL M5
K4 4TH SPEED CLUTCH
= SOLENOID ON = SOLENOID ON/THEN OFF M3 SOLENOID PRESSURE REGULATING VALVE
REGULATED MAIN PRESSURE
KV FORWARD RANGE CLUTCH
M1
KR REVERSE RANGE CLUTCH
M6 PRESSURE CHECK VALVE
VENT VALVE RESET VALVE M4
CONVERTER PRESSURE REGULATOR
MODULATION VALVE PRESSURE REGULATING VALVE
CONVERTER
TRANSMISSION FILTER
OIL COOLER LUBRICATION
TRANSMISSION PUMP
TXC8398AM
OIL SUMP
NOTE: Six Solenoid valves are used on 544G (S.N.548219—), 624G (S.N.548398—) 644G (S.N.548303—). TM1529 (27JUN17)
Continued on next page
9020-05-80
M2
1ST, 2ND SHIFT VALVE 1ST SHIFT VALVE K3 3RD SPEED CLUTCH K2 2ND SPEED CLUTCH K1 1ST SPEED CLUTCH
T8398AM —19—15JAN98
CONVERTER OUTLET TEMPERATURE
TX,9020,RP2582 -19-21FEB95-1/2
544G, 624G, 644G Loader
062717
PN=466
Theory Of Operation
In third speed reverse, M1 reverse range clutch solenoid is energized. Solenoid pressure oil flows through M1 to shift the reverse range clutch valve. Main pressure oil flows through the reverse range clutch valve to engage the reverse clutch pack.
M4 1st, 2nd shift valve solenoid and M2 1st shift valve solenoid are energized, allowing main pressure oil to flow through it to engage the second speed clutch pack.
TX,9020,RP2582 -19-21FEB95-2/2
TM1529 (27JUN17)
9020-05-81
544G, 624G, 644G Loader
062717
PN=467
Theory Of Operation
TeamMate™ II Axle Operation Access to the differential assembly (L) is through the front cover/input quill (D). The spiral pinion (C) is housed in the front cover. The differential case houses the annular brake pistons (F) which work against the brake disks (G) and backing plate (H). The brake piston is sealed by O-rings on both the ID and OD of the piston and is held static by dowel pins. The brake disk has friction material bonded to both sides of it. The backing plate is on the ring gear side of the final drive and is held stationary by six dowel pins.
The oscillating supports (A) are located on the rear axle and are sealed and grease lubricated by a remote grease bank. The front axle is bolted to a fixed position on the frame. The final drive assemblies (I) have been improved with thicker planetary thrust washers and dual path roller bearings to reduce axial thrusting of the planet pinions. The axle inner bearing (J) and the axle outer bearing (K) are lubricated by oil from the differential case.
TeamMate is a trademark of Deere & Company TX,9020,HH818 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-05-82
544G, 624G, 644G Loader
062717
PN=468
Theory Of Operation
T7799AK —19—10APR95
John Deere TeamMate™ II Axles
TeamMate is a trademark of Deere & Company TX,9020,DY267 -19-08APR96-1/1
TM1529 (27JUN17)
9020-05-83
544G, 624G, 644G Loader
062717
PN=469
Theory Of Operation
Differential Lock Operation
PISTON B
PINION JOURNAL C D SEAL RINGS E INLET
CLUTCH PACK A
F SUN PINION SHAFT G THRUST WASHER
SUN F PINION SHAFT
H BEARING QUILL
I
ENGAGEMENT PRESSURE
TXC7799AL CV
DIFFERENTIAL LOCK OPERATION
Continued on next page
TM1529 (27JUN17)
9020-05-84
T7799AL —19—17NOV98
J LUBRICATION OIL
TX,9020,HH819 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=470
Theory Of Operation When the operator pushes the differential lock pedal, the pedal activities a switch. The switch energizes the differential lock solenoid on the pressure reducing valve. When the differential lock solenoid is energized, pressure oil flows to the inlet (E) and through the cross-drilled passages to the piston (B). Seal rings (D) seal between the stationary quill and the rotating differential housing. The
pressurized oil compresses the piston against the clutch pack (A). The compressed clutch pack locks the axles (F) together causing both axles to rotate at the same speed. Oil that leaks into the differential housing around the seal rings is forced back to the reservoir by turbocharger air pressure. TX,9020,HH819 -19-16SEP92-2/2
T7799AJ —19—31AUG92
Hydraulic Differential Lock Air Boost System
The hydraulic differential lock air boost system (D) allows hydraulic differential lock oil to seep into the differential case and uses turbocharger air pressure to force access oil from the axle to the reservoir. When the differential lock is used, oil will seep through the cast iron sealing rings into the differential case. Oil level stability is accomplished by pressurizing the differential case with air from the engine turbocharger and a return line to the reservoir. The
pressurized air (C) flows into the top of the case through line (A). A return line (B) connects the two vertical lines that extend from the top of the differential case down to the center of the axle. If the oil level is below the end of the lines, air flows through the axle housing and is vented at the reservoir. If the oil level is above the ends of the lines, the pressurized air forces the oil back to the reservoir. TX,9020,HH821 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-05-85
544G, 624G, 644G Loader
062717
PN=471
Theory Of Operation
T8089AC —UN—05NOV93
Turbocharger Boost For Differential Lock
Continued on next page
TM1529 (27JUN17)
9020-05-86
TX,9020,DU1542 -19-16DEC93-1/2
544G, 624G, 644G Loader
062717
PN=472
Theory Of Operation Air from the turbocharger (A) is supplied to the front axle (H) through a fitting that screws into the engine intake manifold. The turbocharged air pressure flow pressurizes air to the axle and forces access differential lock oil from the axle to the reservoir. The access differential lock oil returns through hose (G) to the filter in the reservoir. The return oil filter is located inside the tank and is serviced by removing filler cap cover cap screws in reservoir. If machine is equipped with dual differential locks, the
reservoir will have two return filters. Pressurized air from the axle is vented at the reservoir. The differential lock solenoid (D) located in the pressure reducing valve manifold (E) supplies the differential lock with pilot pressure oil. The rear axle differential lock (if equipped) uses a similar system but return to reservoir is through port (B). TX,9020,DU1542 -19-16DEC93-2/2
T7799AM —19—26AUG92
Axle Shaft And Housing
The outboard portion of the axle shaft (C) is lubricated with oil from the differential housing. The structure of the axle housing (D) retains oil for the outboard bearing (B) even on a slope. The seal (A) in the housing is in two
parts: the inner presses into the axle housing and the outer goes over the axle shaft and rotates with the axle. If something would rap around the axle like a piece of wire, the seal will rotate with it. TX,9020,HH824 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-05-87
544G, 624G, 644G Loader
062717
PN=473
Theory Of Operation
T8142BI —UN—29DEC93
Axle Disconnect Operation
The optional axle disconnect is located on the input quill of the front axle. When the front axle is connected to the drive line, the input yoke (B) drives the bevel pinion (C)
through the collar (A). When the front axle is disconnected, mechanical linkage shifts the yoke (D) which moves the collar to disconnect the bevel pinion from the input yoke. TX,9020,DU1733 -19-07JAN94-1/1
TM1529 (27JUN17)
9020-05-88
544G, 624G, 644G Loader
062717
PN=474
Theory Of Operation
Brake Hydraulic System Operation NOTE: See Power Train and Brakes System Component Location (Park Brakes Switch Off) drawing in Group 9020-15 for location of components. The brakes are operated by a pressure compensated, closed center hydraulic system. Flow is supplied by a variable displacement, axial piston brake pump. A low pressure pilot control system is also supplied by the brake pump. The pilot control system supplies the hydraulic system pilot controller and hydraulic differential lock functions. Brake System The variable displacement brake pump supplies flow to the pressure reducing valve for park brake circuit and pilot pressure circuits. It the flows to a accumulator. The accumulator has a gas precharge and an inlet check valve to maintain a pressurized volume of oil for reserve brake applications. Oil through the accumulator flows to the brake valves. The brake valves are a closed center design each operated by a separate pedal. The brake valve outlets go to a check valve manifold. If either valve is actuated, both brakes are applied. If either brake line is cut, the remaining axle will still function.
The front and rear brakes operate simultaneously with only one brake pedal depressed. The left brake pedal linkage is connected to a switch which operates the clutch cut-off function. The differential contains annulor brake piston and double sided disk. Brake pump flow also goes to the pressure reducing valve manifold (A). The pressure reducing valve manifold contains the following components:
• Pressure Reducing Valve • Differential Lock Solenoid Valve • Boom Lower Solenoid Valve • Park Brake Solenoid Valve The pressure reducing valve reduces brake system operating pressure to differential lock and pilot system pressure. The differential lock solenoid valve is energized by a two-position switch located on the floor of the operator’s compartment. The boom lower solenoid valve is part of the loader hydraulic system.
TX,9020,DU1543 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-05-89
544G, 624G, 644G Loader
062717
PN=475
Theory Of Operation
Brake Pump Operation
B PISTON C SWASHPLATE ASSEMBLY
CYLINDER A BLOCK
D CONTROL PISTON PIN E SWASHPLATE BEARING F SHAFT SEAL
I PISTON RETAINER
BEARING J
TX1213459
M
TX1213459 —UN—29MAR16
G DRIVE SHAFT H BALL GUIDE K STANDBY PRESURE OIL L RETURN OIL
BRAKE PUMP OPERATION Brake Pump Operation
The main hydraulic pump (M) is an axial piston, variable displacement pump. The pump mounts to the front of the transmission auxiliary drive case and the drive shaft (G) splines into the external pump drive. The drive shaft is supported by a ball bearing on the spline end and bearing sleeve in the valve plate end cap.
(I) backed by a spring -loaded ball guide (H) holds the piston slippers against the swashplate (C). The cylinder block is supported by a Bearing (J). The swashplate rides on a bearing (E) and is moved by a pin (D) that moves with the pressure compensator control piston.
With the engine running, the drive shaft drives the cylinder block (A) and 9 pistons assemblies (B). A piston retainer TX,9020,HH826 -19-29MAR16-1/1
TM1529 (27JUN17)
9020-05-90
544G, 624G, 644G Loader
062717
PN=476
Theory Of Operation
Brake Pump Pressure Compensator—At Standby C SWASHPLATE CONTROL D PISTON PIN
B PISTON STOP
E CONTROL PISTON
F PRESSURE COMPENSATOR SPOOL
A PRESSURE ADJUSTMENT ASSEMBLY
H CONTROL PLUG K
TXC7799CB
T7799CB —19—20JAN98
G PUMP PRESSURE SENSING PASSAGE I STANDBY PRESSURE OIL J RETURN OIL
BRAKE PUMP PRESSURE COMPENSATOR — AT STANDBY
When the engine is running and no hydraulic functions are activated, the brake pump is at standby pressure (K). Pressure oil from the pump pressure passage (G) works on the end of the pressure compensator spool (F). At standby pressure, the spool moves opening a passage to
the control piston (E). The control piston moves against its stop (B) and the piston pin (D) moves the pump swashplate (C) to neutral. The pressure compensator is screw adjustable (A). TX,9020,DU1544 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-05-91
544G, 624G, 644G Loader
062717
PN=477
Theory Of Operation
Pressure Compensator—Pump Going Into Stroke D SWASHPLATE
ORIFICE C
CONTROL E PISTON PIN
PISTON B STOP
PRESSURE ADJUSTMENT ASSEMBLY A
CONTROL F PISTON
G PRESSURE COMPENSATOR SPOOL
T7799CC —19—20JAN98
H PUMP PRESSURE SENSING PASSAGE I STANDBY PRESSURE OIL J RETURN OIL K TXC7799CC
BRAKE PUMP PRESSURE COMPENSATOR — GOING INTO STROKE
When a hydraulic function is used, the pressure in the pump sensing passage (H) drops and the pressure compensator spool (G) moves to the right blocking the passage to the control piston (F). Oil that was holding the control piston and pump swashplate (D) in neutral vents through an orifice (C) in the control piston to return. The
control piston spring moves the piston to the right and the pin (E) swashes the pump. Depending on the pressure required in the hydraulic work circuits, the control piston and swashplate will move just enough for the pump to supply the required oil. TX,9020,HH828 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-05-92
544G, 624G, 644G Loader
062717
PN=478
Theory Of Operation
T7597AD —19—26SEP91
Brake Accumulator Operation
The accumulator is used to store pressurized oil for reserve brake application. The top of the accumulator is charged with dry nitrogen gas through valve (B). When the hydraulic system pressure exceeds the charge pressure, oil flows through the inlet (E) and inlet check valve (A). The piston (C) moves upward until gas pressure is equal to hydraulic circuit pressure.
If pump flow stops, the inlet check valve will close against inlet fitting which is machined to provide a check valve seat, keeping the accumulator charged. The accumulator will remain pressurized until the brakes are applied. The volume of the accumulator will allow several brake applications in the event of a loss of brake pump flow. TX,9025,HH263 -19-31OCT91-1/1
TM1529 (27JUN17)
9020-05-93
544G, 624G, 644G Loader
062717
PN=479
Theory Of Operation
Wet Chambered Brake Valve Operation B
C
A
B INLET
C RETURN
A WORKPORTS
SPOOL E
D PLUNGER
GUIDE F
H SPRING G ORIFICE L
B
J
C
INLET PRESSURE
M METERED PRESSURE
T8077AQ —19—13JAN98
N RETURN PRESSURE
I
A K
WET CHAMBERED BRAKE VALVE
T8077AQ
The brake valve is a closed center, manually operated spool-type valve. Two valves are used. Each valve is plumbed in parallel to the front and rear brake lines. The
brake valve outlets go to a check valve manifold. If either valve is actuated, both brakes are applied. If either brake line is cut, the remaining axle brake will still function.
Continued on next page
TM1529 (27JUN17)
9020-05-94
TX,9020,HH831 -19-22SEP93-1/2
544G, 624G, 644G Loader
062717
PN=480
Theory Of Operation
Brake pressure oil from the accumulator enters the inlet (B). When the valve is in neutral, oil in the work ports is routed to return through passage (C). When the brakes are partially engaged, the brake pedal pushes the plunger (D) against a spring which contacts the guide (F). The spool has a metering notch which begins to trap the work port oil from the return passage. As the brake pedal is further depressed, the plunger (D) compresses the spring against the guide (F) which moves the spool (E) further to the left. As the spool moves to the left, the return passage (C) is blocked. A metering notch on the spool starts to open, allowing brake pressure oil from the inlet (B) to the work ports (A). The brakes in the front and rear axles begin to engage.
When the brakes are fully engaged, the spool is moved to the far left position against the spring (H). Full inlet flow at regulated pressure is available to the work ports to engage the brakes. The brake valve regulates brake application pressure based on brake pedal travel. When the inlet is opened to pressurize the work ports, the orifice (G) allows work port pressure on the left end of the spool. The work port pressure plus spring force on the left end of the spool balance against the compressed spring force on the right end of the spool. This meters the inlet pressure oil to prevent aggressive braking or brake lock-up.
TX,9020,HH831 -19-22SEP93-2/2
TM1529 (27JUN17)
9020-05-95
544G, 624G, 644G Loader
062717
PN=481
Theory Of Operation
Park Brake Operation B SEALS
A DUST SEAL
C PISTON
D PARK BRAKE ADJUSTING SCREW
PARK J BRAKE PADS TXC7792AE
E LOCK NUT
J PARK BRAKE PADS I SHAFT M
F COVER T7792AE —19—20JAN98
PARK BRAKE K DISK
H SPRING WASHERS G SNAP RING L BRAKE PUMP PRESSURE
PARK BRAKE OPERATION
The parking brake (M) is spring applied and hydraulically released. When the park brake is applied or machine is shut off, spring pressure applies parking brake. The spring washers (H) force the piston (C) against pads (J) which contact parking brake disk (K) on the transmission output shaft. The park brake pads (J) hold the disk from turning and the machine from moving. When parking brake switch is pushed to the OFF position, the switch energizes the park brake solenoid on the pressure reducing valve. The solenoid routes brake pump pressure oil (L) to the piston (C). The piston moves against the spring washers (H) and releases the force from the shaft (I) on the brake pads (J). As the pads are released, the parking brake disk (K) is free to turn.
To release the parking brake: 1. The switch has to be pushed to the OFF position. 2. When the machine is shut off with the switch in the OFF position, the switch has to be cycled from OFF to ON to OFF after the machine has been started. The parking brake can be manually released to move the machine. Remove cover (F), loosen lock nut (E), and turn parking brake adjusting screw (D) out. To re-engage park brake, turn adjusting screw in. Adjust park brake per procedure in Group 20.
TX,9020,DU1546 -19-06FEB95-1/1
TM1529 (27JUN17)
9020-05-96
544G, 624G, 644G Loader
062717
PN=482
Theory Of Operation
TM1529 (27JUN17)
9020-05-97
544G, 624G, 644G Loader
062717
PN=483
Theory Of Operation
Pressure Reducing Valve—Differential Lock Off, Park Brake On C O
M I
G K
P
J
DIFFERENTIAL LOCK SOLENOID VALVE D
H F
E PARK BRAKE SOLENOID VALVE
L R B
PILOT ORIFICE C
TO RETURN B
PRESSURE REDUCING VALVE A
F TO BRAKE VALVE
R DIFFERENTIAL LOCK RETURN CHECK VALVE PARK G BRAKE ORIFICE
P TEST PORT N TEST PORT O FROM BOOM CIRCUIT
L TO AXLE
M TO PILOT CONTROLLER(S)
TXC8067AA
The pressure reducing valve manifold contains several components which are part of either the power train
S
BRAKE PRESSURE OIL
T
PILOT PRESSURE OIL
U
RETURN PRESSURE OIL
V
TRAPPED OIL
hydraulic system or the pilot control system. These components are: Continued on next page
TM1529 (27JUN17)
K CHECK VALVE
I PARK BRAKE SWITCH J TO PARK BRAKE T8067AA —19—20JAN98
Q BOOM DOWN SOLENOID VALVE
H INLET
9020-05-98
TX,9020,HH850 -19-22SEP93-1/2
544G, 624G, 644G Loader
062717
PN=484
Theory Of Operation
• Park Brake Solenoid Valve (E) • Differential Lock Solenoid Valve (D) • Pressure Reducing Valve (A) • Boom Lower Solenoid Valve (Q) Brake pump flow enters the inlet (H) where it flows directly to the park brake solenoid valve. The park brake circuit uses brake circuit pressure to release the park brake calipers when the solenoid is energized. Park brake orifice (G) creates a warm-up circuit for park brake circuit to improve cold weather operation of park brake. Check valve (K) seals pressure oil in brake circuit in event of loss of brake pump pressure when engine is running. When brake pump pressure is lost check valve (K) closes and allows operator to modulate to application of park brake to bring machine to a gradual stop rather than a abrupt stop.
Brake pump oil also flows through the de-energized boom lower solenoid valve to the pressure reducing valve. The pressure reducing valve is shown in the neutral position, blocking brake pump flow. When brake pump flow is blocked, the brake pump destrokes if the brakes are in neutral. The pressure reducing valve regulates brake pump flow to maintain pilot circuit pressure. Pilot circuit pressure is available through orifice (C) to the inlet of the differential lock solenoid valve (D) and to the pilot controllers through passage (M). If the pilot controllers are actuated, the pressure in passage (M) will drop, causing the spool to shift to the right. Brake pump flow will be metered through the pressure reducing valve sleeve to passage (M) to maintain pilot circuit pressure. TX,9020,HH850 -19-22SEP93-2/2
TM1529 (27JUN17)
9020-05-99
544G, 624G, 644G Loader
062717
PN=485
Theory Of Operation
Pressure Reducing Valve—Differential Lock On, Park Brake Off C O
M I
G K
P
J
DIFFERENTIAL LOCK SOLENOID VALVE D
H F
E PARK BRAKE SOLENOID VALVE
L R B TO RETURN B
PRESSURE REDUCING VALVE A
PILOT ORIFICE C
F TO BRAKE VALVE
R DIFFERENTIAL LOCK RETURN CHECK VALVE PARK G BRAKE ORIFICE
P TEST PORT
H INLET
N TEST PORT O FROM BOOM CIRCUIT
L TO AXLE
M TO PILOT CONTROLLER(S)
TXC8075AB
K CHECK VALVE
I PARK BRAKE SWITCH J TO PARK BRAKE
S
BRAKE PRESSURE OIL
T
PILOT PRESSURE OIL
U
RETURN PRESSURE OIL
V
TRAPPED OIL
T8075AB —19—15JAN98
Q BOOM DOWN SOLENOID VALVE
When the differential lock solenoid valve (D) is energized, Passage (L) routes flow to the differential clutch(es) to engage the differential lock. the spool shifts up in the sleeve. Pilot circuit flow enters the sleeve and flows through the spool to passage (L). Continued on next page TX,9020,HH851 -19-22SEP93-1/2 TM1529 (27JUN17)
9020-05-100
544G, 624G, 644G Loader
062717
PN=486
Theory Of Operation
The pressure reducing valve spool (A) will meter brake pump flow at pilot circuit pressure until the differential lock solenoid is de-energized. When the solenoid is de-energized, pilot circuit flow is blocked and return oil from passage (L) is routed to return oil passages. If a pressure spike is encountered in either the differential lock or the pilot circuit, the pilot poppet in the pressure
reducing valve will open. The pressure reducing valve spool will shift to the left, blocking brake pump flow. With the spool shifted far enough to the left, the excess pressure in the pilot circuit will be bled to return. The differential lock return check valve (R) prevents oil from reservoir return from draining into the differentials, which are at a lower point on machine. TX,9020,HH851 -19-22SEP93-2/2
TM1529 (27JUN17)
9020-05-101
544G, 624G, 644G Loader
062717
PN=487
Theory Of Operation
T7799AD —19—31AUG92
Hydraulic Tank Operation
TX,9020,HH829 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-05-102
544G, 624G, 644G Loader
062717
PN=488
Group 10
System Operational Checks Power Train Operational Checks This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read Theory of Operation, Group 9020-05 and CTM4 or CTM8.
If problem is indicated (NOT OK:), you will be given repair required and group location or CTM number. If verification is needed, you will be given next best source of information: Group 10 (System Operational Checks)
A location will be required which is level and has adequate space to complete the checks.
Group 15 (Diagnostic Information)
The engine and all other major components must be at operating temperature for some checks.
Group 20 (Adjustments)
Locate system check in the left column and read completely, following this sequence from left to right. Read each check completely before performing.
CTM (Component Technical Manual)
Group 25 (Tests)
At the end of each check, if no problem is found (OK:), that check is complete or an additional check is needed. 10T,9020,K86 -19-29JUN94-1/25
• 1
Brake System, Clutch Cut-Off, Differential Lock And Front Axle Disconnect Checks
10T,9020,K86 -19-29JUN94-2/25
Front Axle Disconnect Check-If Equipped
T7747AN1 —UN—21AUG92
Move front axle disconnect lever (A) up to disconnect axle. Start engine. Lower boom to raise front wheels off ground. Move transmission control lever to reverse. Back drag with bucket. Observe front wheels. LOOK: Front wheels must not turn. Push lever down to reconnect axle. Observe front wheels when back dragging.
OK: Check completed.
LOOK: Front wheels must turn.
NOT OK: Go to Front Axle Disconnect Linkage Adjustment , Group 9020-20. Continued on next page
TM1529 (27JUN17)
9020-10-1
10T,9020,K86 -19-29JUN94-3/25
544G, 624G, 644G Loader
062717
PN=489
System Operational Checks Park Brake Capacity Check
T8081AH —UN—05NOV93
T7773BM —UN—05AUG92
CAUTION: Seat belt must be worn while doing this check to prevent possible injury when machine stops suddenly. Start engine. Fasten seat belt. Press Monitor display until MPH reading is displayed. Release park brake and put transmission in 2nd gear forward. Drive machine at 3 MPH and switch park brake ON.
OK: Check completed.
LOOK/FEEL: Machine must come to a stop within 2 meters (6 feet) when park brake is NOT OK: Inspect park engaged at 3 MPH. Transmission must shift to neutral. brake. Go to Group 9020-20. 10T,9020,K86 -19-29JUN94-4/25
Park Brake Transmission Lockout Check
T7773BM —UN—05AUG92
T7773BN —UN—05AUG92
Engine running. Turn park brake to ON. Place transmission in 1st forward. Slowly increase engine speed to fast idle.
OK: Check completed.
LOOK: Unit must not move.
NOT OK: Go to Transmission Control Circuit in Group 9015-15. Continued on next page
TM1529 (27JUN17)
9020-10-2
10T,9020,K86 -19-29JUN94-5/25
544G, 624G, 644G Loader
062717
PN=490
System Operational Checks Service Brake Pump Flow Check
T7747AF1 —UN—24AUG92
T7773BQ3 —UN—21AUG92
NOTE: Hydraulic oil must be at operating temperature for the check. Engine OFF. Stop engine. Operate brake pedal approximately 15 times. Start engine and run at slow idle. Record number of seconds required for low brake pressure indicator light to go out.
OK: Check completed.
LOOK: Indicator light must go out in less than 6 seconds from time engine starts.
NOT OK: Check for brake circuit leakage. Go to Brake System Leakage Check .
NOTE: Indicator will not come on for approximately 1 second after starting engine.
IF OK: Install a cap on line connected to inlet of pressure reducing valve and on the 544G TC, install a cap on the line connected to the inlet of the pin disconnect solenoid valve and repeat pump flow check. If time does not decrease, check for worn brake pump. Go to Brake Pump Flow Test , Group 9020-25.
Continued on next page
TM1529 (27JUN17)
9020-10-3
10T,9020,K86 -19-29JUN94-6/25
544G, 624G, 644G Loader
062717
PN=491
System Operational Checks Service Brake Capacity Check
T7773BO2 —UN—05AUG92
T7773BQ3 —UN—21AUG92
Engine running. Turn Clutch Disconnect switch OFF. Apply service brakes, release park brake and put transmission in 2nd forward. Increase engine speed to fast idle.
OK: Check completed.
LOOK: Unit may not move or move at a very slow speed.
NOT OK: Check Brake Pressure in Group 9020-25.
Repeat check three times to ensure accurate results.
IF OK: Inspect brake disk , see Group 9020-20
Continued on next page
TM1529 (27JUN17)
9020-10-4
10T,9020,K86 -19-29JUN94-7/25
544G, 624G, 644G Loader
062717
PN=492
System Operational Checks Brake Accumulator Precharge Check
NOTE: The axles and hydraulic oil must be at operating temperature for this check. Start and run engine for 30 seconds. Stop engine and turn key switch to ON and wait 5 seconds. NOTE: Stop engine light will be on due to no engine oil pressure. Count the number of times the brake pedal can be fully depressed before the low brake pressure warning light comes on.
T7747AF1 —UN—24AUG92
LOOK: Warning light must come on in 1—5 applications. Start engine and operate at slow idle.
OK: Check completed.
Observe monitor while applying brake pedal with maximum force.
NOT OK: Make sure brake pedal is not binding and keeping brakes partially engaged. Bleed brakes in Group 9020-20. Check brake system pressure in Group 9020-25.
LOOK/LISTEN: Brake pressure indicator must not come ON.
Continued on next page
TM1529 (27JUN17)
9020-10-5
NOT OK: If light comes on with engine running, accumulator has lost it’s charge. Inspect and recharge accumulator see Group 9020-20. 10T,9020,K86 -19-29JUN94-8/25
544G, 624G, 644G Loader
062717
PN=493
System Operational Checks Brake System Leakage Check
T7773BI1 —UN—05AUG92
T7747AF1 —UN—24AUG92
Start engine and wait 30 seconds. Stop engine. Wait 2 minutes. Turn key switch to ON and wait 5 seconds.
OK: Check completed.
LOOK: Brake low pressure warning light must not come on within 2 minutes after stopping engine.
NOT OK: If brake leakage is indicated with brakes released, check leakage at accumulator inlet check valve and brake valve . If brake leakage is indicated with brakes applied, check for leakage at brake valve and brake pistons . Check individual component leakage in Group 9020-25. 10T,9020,K86 -19-29JUN94-9/25
Service Brake Pedal Check
Slowly depress brake pedal. Listen for a hissing noise that indicates oil is flowing to brake pistons.
OK: Check completed.
LISTEN/FEEL: A hissing noise must be heard when pedal is depressed.
NOT OK: Inspect for debris under brake pedal. Inspect clutch cut-off linkage.
Continued on next page
TM1529 (27JUN17)
9020-10-6
10T,9020,K86 -19-29JUN94-10/25
544G, 624G, 644G Loader
062717
PN=494
System Operational Checks Service And Park Brake System Drag Checks
T6522CH —UN—19OCT88
Engine running. Position unit on gradual slope. Lower bucket approximately 50 mm (2 in.) from ground. Release park and service brakes. LOOK: Unit must move or coast.
OK: Check completed.
NOTE: If unit does not move, check brake pedals to be sure they fully release when feet are removed from pedals.
NOT OK: Adjust Park Brake , go to Group 9020-20.
Drive unit at high speed for about 5 minutes. Brake drag is indicated if brake areas in differential case are hot.
NOT OK: Check floor mat interference to pedal or debris build-up.
NOTE: Observe park brake. If disk is hot, park brake drag is indicated.
IF OK: Check for brake pressure when brake is released. Go to Brake Pressure Test on group 9020-25. 10T,9020,K86 -19-29JUN94-11/25
Differential Lock Check
T7773BQ1 —UN—21AUG92
Park unit on a hard surface. Release brakes. Engage differential lock. Steer unit back and forth. LOOK: Front wheels must not turn in opposite direction.
OK: Check completed.
NOTE: It is normal to get a "clunk" sound when you release pedal.
NOT OK: Go to Diagnose Malfunctions in Group 9020-15.
Continued on next page
TM1529 (27JUN17)
9020-10-7
10T,9020,K86 -19-29JUN94-12/25
544G, 624G, 644G Loader
062717
PN=495
System Operational Checks Differential Lock Leakage Check
T7747AF1 —UN—24AUG92
Stop engine. Depress brake pedal 10 times. Start and run engine at slow idle. Record the number of seconds for low brake pressure indicator to go out. Repeat check with differential lock applied.
OK: Check completed.
LOOK: Time for indicator light to go out must not increase more than two seconds with NOT OK: Do Differential differential lock applied. Lock Leakage Test in Group 9020-25. 10T,9020,K86 -19-29JUN94-13/25
Clutch Cut-Off Check
T7773BO2 —UN—05AUG92
T7773BQ2 —UN—21AUG92
Place clutch cut-off switch in ON position. Release park brake. Run engine at half speed in 1st forward. Firmly depress left brake pedal. FEEL: Transmission must disengage when left brake pedal is depressed.
OK: Check completed.
NOTE: Clutch cut-off switch on left brake pedal can be adjusted to operator preference to match your loading needs.
NOT OK: Adjust clutch cut-off switch , see Group 9020-20. 10T,9020,K86 -19-29JUN94-14/25
• 2
Transmission Checks
NOTE: Transmission oil must be at operating temperature for these checks. Continued on next page
TM1529 (27JUN17)
9020-10-8
10T,9020,K86 -19-29JUN94-15/25
544G, 624G, 644G Loader
062717
PN=496
System Operational Checks Transmission Oil Warm-Up Procedure
T7773BF —UN—05AUG92
NOTE: For machines 544G (S.N. 548219—548955), 624G (S.N. 548398—548982), 644G (S.N 548303—548887), an “F907” service code may appear on the monitor when performing the transmission oil warm-up procedure. (See Jumper Wire for Display Monitor in Section 9015-20 for more information.) Start engine. Apply service brakes. Release park brake. Move transmission selector lever to 3rd speed. Move transmission control lever to forward "F" position. Increase engine speed to fast idle for 30 seconds. Move transmission control lever to neutral "N" position and run for 15 seconds. Repeat procedure until transmission temperature gauge arrow points to bar above dial. OK: Check completed. 10T,9020,K86 -19-29JUN94-16/25
Transmission Selector Lever And Neutral Lock Latch Checks
Engine off.
Move selector lever to each position. LOOK: Lever must align with gear indicator in each detented position. NOTE: Indicator position changes slightly as steering column is tilted. FEEL: Lever must move freely through all positions. OK: Check completed.
T7773BN —UN—05AUG92
Engage neutral lock. Apply slight effort to move lever into forward (F) and reverse (R). LOOK: Neutral lock must stay engaged.
Continued on next page
TM1529 (27JUN17)
9020-10-9
NOT OK: Repair lock or replace switch. 10T,9020,K86 -19-29JUN94-17/25
544G, 624G, 644G Loader
062717
PN=497
System Operational Checks Transmission Noise Check
T7825BH —UN—21AUG92
T7773BN —UN—05AUG92
Engine running. Run engine at approximately 1600 rpm. Drive unit with transmission in each forward and reverse speed.
OK: Check completed.
LISTEN: Transmission must not make excessive noise in any range. Engine rpm must not "lug down" as unit is shifted between gears.
NOT OK: Go to Transmission Makes Excessive Noise . Group 9020-15.
Continued on next page
TM1529 (27JUN17)
9020-10-10
10T,9020,K86 -19-29JUN94-18/25
544G, 624G, 644G Loader
062717
PN=498
System Operational Checks Automatic Shift And Speedometer Check
T7825BG —UN—21AUG92
Engine running. Press SELECT button on monitor until MPH or Km/H is displayed. Release park brake and shift to (4th) forward. Drive machine on level ground and slowly accelerate to fast idle speed and note speed when shifts are made until 4th gear. Reduce engine rpm to idle and note speed when transmission makes each downshift. LOOK: The transmission should shift at following speeds:
OK: Check completed.
544G Loader—Specification 2nd to 3rd Gear Shift—Speed.............................................................6 MPH (9.6 Km/H) 3rd to 4th Gear Shift—Speed.............................................................13 MPH (21 Km/H) 4th to 3rd Gear Shift—Speed.............................................................12 MPH (19 Km/H) 3rd to 2nd Gear Shift—Speed................................................................5 MPH (8 Km/H)
NOT OK: Monitor is programmed for wrong machine model. Go to Programming Monitor in group 9015-20.
624G Loader—Specification 2nd to 3rd Gear Shift—Speed.............................................................6 MPH (9.6 Km/H) 3rd to 4th Gear Shift—Speed.............................................................12 MPH (19 Km/H) 4th to 3rd Gear Shift—Speed.......................................................... 11 MPH (17.7 Km/H) 3rd to 2nd Gear Shift—Speed................................................................5 MPH (8 Km/H) 644G Loader—Specification 2nd to 3rd Gear Shift—Speed.............................................................6 MPH (9.6 Km/H) 3rd to 4th Gear Shift—Speed.......................................................... 11 MPH (17.7 Km/H) 4th to 3rd Gear Shift—Speed.............................................................10 MPH (16 Km/H) 3rd to 2nd Gear Shift—Speed................................................................5 MPH (8 Km/H) NOTE: In (4th) automatic the transmission starts out in 2nd gear, and when it downshifts it returns to 2nd.
Continued on next page
TM1529 (27JUN17)
9020-10-11
IF OK: If shift points are still wrong, the transmission controller does not match machine model. Install correct controller. Wrong controller will cause quick shifts or remain in 2nd gear in (4th) automatic mode. 10T,9020,K86 -19-29JUN94-19/25
544G, 624G, 644G Loader
062717
PN=499
System Operational Checks Transmission "Quick Shift" Check
T7825BH —UN—21AUG92
T7825BL1 —UN—31AUG92
Engine running. Release park brake and shift to 2nd forward. Drive machine at approximately 1600 rpm and press boom control lever switch once. LOOK/FEEL: Transmission must shift to and remain in 1st gear. Press boom control lever switch once. LOOK/FEEL: Transmission must shift back to 2nd gear. Shift to (4th) gear and press boom control lever switch once.
OK: Check completed.
LOOK/FEEL: Transmission must not shift down.
NOT OK: Check connector at base of control valve.
NOTE: If boom lever switch is pressed twice, transmission will shift down then immediately back to 2nd. Transmission will also downshift/upshift from 3rd gear but will not work in any gear when in (4th) gear automatic mode.
IF OK: Go to Transmission Controller Circuit in group 9015-15.
Continued on next page
TM1529 (27JUN17)
9020-10-12
10T,9020,K86 -19-29JUN94-20/25
544G, 624G, 644G Loader
062717
PN=500
System Operational Checks Forward, Reverse And 4th Speed Clutch Pack Drag Check
T7773BN —UN—05AUG92
T7825BF —UN—21AUG92
IMPORTANT: Transmission must be warmed up for this check. Engine running. Park unit on level surface. Apply service brakes. Move transmission control lever to neutral. Move speed selector lever to 1st. Release park brake and service brakes. Run engine at slow idle. LOOK: Unit must not move in either direction.
OK: Check completed.
NOTE: If unit moves forward, either the forward pack or the 4th speed pack is dragging. NOT OK: If unit moves, repair transmission (See Group 0350). 10T,9020,K86 -19-29JUN94-21/25
1st, 2nd, And 3rd Speed Clutch Pack Drag Check
Engine running. Stop unit on a level, hard-surfaced area. Run engine at slow idle. Release park and service brakes. Put transmission in 1st forward, 2nd forward, and then 3rd forward. Note machine movement. LOOK: Machine must roll ahead in each gear.
OK: Check completed.
NOTE: If machine rolls ahead in one gear but not the other two, drag is indicated in that clutch pack.
NOT OK: Repair transmission , see Group 0350 in TM1530.
Continued on next page
TM1529 (27JUN17)
9020-10-13
10T,9020,K86 -19-29JUN94-22/25
544G, 624G, 644G Loader
062717
PN=501
System Operational Checks Transmission Pressure, Engine running. Pump Flow, And Leakage Check Run engine at slow idle. Release park brake. Shift transmission to reverse, then forward, and then to 1st, 2nd, and 3rd speeds. Wait 5 seconds after each shift and observe transmission pressure indicator light.
T7747AD1 —UN—24AUG92
LOOK: Indicator light must not come on.
OK: Check completed.
NOTE: If light comes on in one gear only, leakage is indicated on that gear.
NOT OK: Do Transmission Leakage Test , System Pressure Test , or Pump Flow Test in Group 9020-25.
If light comes on in all gears, low pump flow or pressure is indicated.
10T,9020,K86 -19-29JUN94-23/25
Transmission Shift Modulation Check
T7825BB —UN—21AUG92
T7773BN —UN—05AUG92
Engine running. Run engine at fast idle (approximately 2350 rpm). Put transmission in 1st forward, shift several times from forward to reverse and reverse OK: Check completed. to forward. Repeat check in 2nd gear. LOOK: Machine must slow down and change direction without excessive delay.
Continued on next page
TM1529 (27JUN17)
9020-10-14
NOT OK: Go to Transmission Shifts Too Slow , Group 9020-15. 10T,9020,K86 -19-29JUN94-24/25
544G, 624G, 644G Loader
062717
PN=502
System Operational Checks Torque Converter Check
T7825BI —UN—21AUG92
T7773BF —UN—05AUG92
Engine running and park brake released. Apply service brakes. Move transmission selector lever to 3rd speed. Move transmission control lever to forward "F" position. Increase engine speed to fast idle and observe engine rpm in monitor display. Record lowest rpm reading.
OK: Check completed.
LOOK: Torque converter stall rpm must be within following range: 544G 2125—2275 rpm 624G 2125—2225 rpm 644G 1950—2150 rpm
NOT OK: If stall rpm readings are outside range, problem may be engine power or torque converter. Go to Engine Power Test in group 9010-25.
Move transmission control lever to neutral "N" position and run for 15 seconds to cool oil. IF OK: If power is ok, go to Diagnose Transmission Malfunctions in group 9020-15. 10T,9020,K86 -19-29JUN94-25/25
TM1529 (27JUN17)
9020-10-15
544G, 624G, 644G Loader
062717
PN=503
System Operational Checks
TM1529 (27JUN17)
9020-10-16
544G, 624G, 644G Loader
062717
PN=504
Group 15
Diagnostic Information Procedure To Isolate Whether Transmission Control System Problem Is Electrical Or Hydraulic NOTE: When not sure if problem is electrical or hydraulic, perform the following procedure. 1. Remove clutch cutoff (CCO) and park brake diodes (located next to transmission control box). This will allow the transmission control system to energize the solenoids with the engine off and the park brake engaged. 2. Turn key to ON position. DO NOT start engine.
3. Put transmission in 1st forward. 4. Remove solenoid cover. 5. Check voltage at solenoids M2, M3, and M4. NOTE: To check solenoid voltage, put voltmeter probes across the two terminals of each solenoid connector. 6. Put transmission in 1st reverse. 7. Check voltage at solenoid M1. 8. If voltage is correct for all solenoids, problem is hydraulic. TX,9020,TJ43 -19-21NOV97-1/1
TM1529 (27JUN17)
9020-15-1
544G, 624G, 644G Loader
062717
PN=505
Diagnostic Information
Diagnose Transmission System Malfunctions NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem:
Step 2. Power Train Operational Checkout Procedure (See Group 9020-10.) Step 3. Diagnose Malfunctions Charts (See Group 9020-15.) Step 4. Tests and/or Adjustments (See Group 9020-20 and/or 9020-25.)
Step 1. Operational Check Out Procedure (See Group 9005-10.) Symptom
Problem
Solution
Transmission Slippage
Low oil level
Add oil. (See Section I, Group IV.)
Wrong oil grade
Change oil. (See Section I, Group IV.)
Restricted Transmission pump suction Remove and clean screen. (See screen Group 0360.)
Machine Will Not Move
Leak in transmission control valve or gasket
Remove valve and inspect gaskets. (See Group 0360.)
Low transmission pump flow due to worn pump
Do Transmission Pump Flow Test . (See Group 9020-25.)
Weak or broken pressure regulating valve spring
Do Transmission System Pressure Test . (See Group 9020-25.)
Malfunctioning reset valve
Remove and inspect reset valve. (See Group 0360.)
Malfunctioning check valve
Remove and inspect check valve. (See Group 0360.)
Applied park brake
Check park brake fuse. (See 9015-00.) Check continuity to park brake switch. (See 9015-00.)
No power to transmission controller
Check transmission controller fuse. (See 9015-00.) If fuse blows repeatedly, especially when operating loader boom or bucket, check transmission downshift switch wires in loader control handle for shorts. Repair or replace as necessary. Band wires to prevent wires from rubbing on edges or kinking as lever is moved
Malfunctioning park brake solenoid valve
Continued on next page
TM1529 (27JUN17)
9020-15-2
Remove and inspect park brake solenoid valve. (See Group 0360.) Check for power to solenoid valve. (See Group 9015-00.)
TX,9020,DU1552 -19-10NOV93-1/7
544G, 624G, 644G Loader
062717
PN=506
Diagnostic Information Symptom
Machine Does Not Engage in Low Gear
Machine Will Not Shift Correctly
Problem
Solution
Restricted modulation orifice
Remove orifice and check for contamination and/or plugging. (See Group 0360.) (Do Not remove valve housing for this purpose.)
Excessive leakage in transmission element
Do Transmission Element Leakage Test Using System Pressure . (See Group 9020-25.)
Worn clutch disks
Repair transmission. (See Group 0350.)
Low or no transmission pressure
See Transmission Pressure Is Low in this group.
Service brakes will not release
Do Brake Pedal Operational Check . Do Service and Park Brake System Drag Checks . (See Group 9020-10.)
Failed torque converter
Do Torque Converter Stall Test . (See Group 9020-25.) If engine pulldown is normal, torque converter is good.
Broken shafts or gears
Drain transmission to determine if large pieces of metal contamination are present.
Broken drive shafts
Inspect drive shafts and universal joints for external damage. Repair.
Broken ring or pinion gear
If drive shafts rotate with transmission in gear but machine does not move, a differential failure is indicated. Repair.
Malfunctioning transmission control solenoid valve
Check solenoid valve. (See Group 9015-00.)
Stuck spool in transmission control valve
Remove and inspect transmission control valve spools. (See Group 0360.)
Stuck modulation valve
Remove end cover to inspect modulation spool. Replace if necessary. (See control valve , Group 0360.)
Transmission shifts fast in fourth gear Wrong transmission controller for automatic machine model number. Install correct controller. Transmission will not shift out of second in automatic mode
Continued on next page
TM1529 (27JUN17)
9020-15-3
Wrong transmission controller for machine model number. Install correct controller.
TX,9020,DU1552 -19-10NOV93-2/7
544G, 624G, 644G Loader
062717
PN=507
Diagnostic Information Symptom
Problem
Solution
Transmission Shifts Too Slow
Low oil level (aeration of oil)
Add oil.
Low transmission pressure
Do Transmission System Pressure Test . (See Group 9020-25.)
Restricted transmission pump suction Remove and clean screen. (See screen Group 0360.)
Transmission Shifts Too Fast
Low transmission pump flow
Do Transmission Pump Flow Test . (See Group 9020-25.)
Excessive transmission element leakage
Do Transmission Element Leakage Test Using System Pressure . (See Group 9020-25.)
Stuck modulation valve
Remove end cover to inspect modulation spool. Replace if necessary.
Restricted modulation orifice
Remove orifice and inspect for contamination and/or plugging. (See Group 0360.)
Malfunctioning two stage piston
Remove and inspect two stage piston. (See Group 0360.)
Restricted oil passages between control valve and transmission elements Control valve cap screws overtightened
Remove control valve and inspect oil passages. (See Group 0360.)
System pressure too high
Do Transmission System Pressure Test. (See Group 9020-25.)
Stuck modulation valve
Remove and inspect modulation valve. Replace if necessary. Also remove end cover to inspect modulation spool and control valve housing. Replace if necessary. (See Group 0360.)
Malfunctioning two stage piston
Remove and inspect two stage piston. (See Group 0360.)
Stuck or missing check valves
Inspect transmission control valve. (See Group 0360.)
Loosen cap screws and torque. (See Group 0360.)
Missing O-ring from end of modulation Remove orifice and inspect port for O-ring. (See Group 0360.) orifice Broken piston return spring
Continued on next page
TM1529 (27JUN17)
9020-15-4
Disassemble and inspect clutch. (See Group 0360.)
TX,9020,DU1552 -19-10NOV93-3/7
544G, 624G, 644G Loader
062717
PN=508
Diagnostic Information Symptom
Problem
Solution
Machine "Creeps" in Neutral
Warped disks and plates in transmission
Check transmission. (See Group 0350.)
Machine Runs Only in 2nd Gear
Wrong transmission controller
Check if transmission controller has been changed.
Machine Will Intermittently Go to Neutral When Making a Direction Change
Contamination in FNR lever forward or reverse microswitch.
Check all input signals to the transmission controller connector. Measure resistance (at transmission controller connector) of all shift solenoid coils. (See Transmission Control Circuit Diagnostic Procedures in Group 9015-15.) If all items check ok, replace shift switch.
Machine Will Not Shift to 3rd or 4th Transmission speed sensor failure Gear; 1st and 2nd Gear Operate Normally; Speedometer Does Not Operate
Transmission Pressure Is Low (All Gears)
Low oil level
Check transmission oil level and refill if necessary.
Failed transmission pressure switch
Verify transmission system pressure. Do Transmission System Pressure Test . (See Group 9020-25.)
Plugged suction strainer
Transmission pump may be noisy if transmission suction screen is clogged. Drain transmission. Remove and clean suction screen. (See Group 0360.) Also, check condition of transmission filter.
Stuck transmission pressure regulating valve or broken spring
Remove transmission pressure regulating valve. Inspect for damage. (See transmission control valve in Group 0360.)
Failed control valve gasket
Inspect transmission control valve for external leakage. Remove control valve. Inspect or replace gasket. (See Group 0360.)
Stuck modulation valve
Remove end cover to inspect modulation spool and check torque on cap screws retaining control valve to transmission. Torque over 20 N·m (15 lb-ft) may cause modulation valve to stick. Replace if necessary.
Failed transmission pump
Do pump flow test. (See Group 9020-20.)
Continued on next page
TM1529 (27JUN17)
Check monitor for an F907 service code. Check continuity of wires between the transmission controller and speed sensor. If wires check ok, replace speed sensor.
9020-15-5
TX,9020,DU1552 -19-10NOV93-4/7
544G, 624G, 644G Loader
062717
PN=509
Diagnostic Information Symptom
Problem
Solution
Transmission System Pressure Is Low (One or Two Gears)
Failed transmission control valve gasket
Inspect transmission control valve for external leakage. Remove control valve. Inspect or replace gasket. (See Group 0360.)
Leakage in clutch piston or seal ring
Disassemble and repair.
High oil level
Transmission overfilled or hydraulic pump seal leaking.
Low oil level
Add oil. (See Section I, Group IV.)
Wrong oil grade
Change oil. (See Section I, Group IV.)
Park brake dragging
Check for heat in park brake area.
Pinched, restricted or leaking lube lines Machine operated in too high gear range
Check cooler lines.
Malfunction in temperature gauge or sender
Install temperature sensor to verify temperature. Do Tachometer/Temperature Reader Installation Procedure . (See Group 9020-25.)
Restricted air flow through oil cooler or radiator
Do Radiator Air Flow Test . (See Group 9010-25.)
Failed oil cooler bypass valve (in thermal bypass valve)
Disassemble and inspect. (See Group 0360.)
Failed thermal bypass valve
Remove thermal bypass valve and check to see if machine still overheats. Do Transmission Oil Cooler Thermal Bypass Valve Test . (See Group 9020-25.)
Internally restricted oil cooler
Do Oil Cooler Restriction Test . (See Group 9020-25.)
Leakage in transmission hydraulic system
Do Transmission System Pressure, Element Leakage, and Shift Modulation Test . (See Group 9020-25.)
Malfunction in converter relief valve
Do converter out pressure test. (See Group 9020-25.)
Low transmission pump output
Do Transmission Pump Flow Test . (See Group 9020-25.)
Transmission Hydraulic System Overheats
Continued on next page
TM1529 (27JUN17)
9020-15-6
Operate machine in correct gear range.
TX,9020,DU1552 -19-10NOV93-5/7
544G, 624G, 644G Loader
062717
PN=510
Diagnostic Information Symptom
Problem
Solution
Excessive Transmission Noise (Under Load or No Load)
Too low engine slow idle
Check engine slow idle speed. (See Group 9010-20.)
Worn parts or damaged in transmission
Remove transmission suction screen. Inspect for metal particles. Repair as necessary. (See Group 0360.)
Warped drive line between engine and Inspect drive line. (See Group 0325.) torque converter Low or no lube Do Converter-Out and Lube Pressure Test. (See Group 9010-25.) Do Transmission Pump Flow Test . (See Group 9010-25.) Incorrect type of oil
Change oil. (See Section I, Group IV.)
High oil level
Transmission overfilled or hydraulic pump seal leaking.
Low oil level
Add oil. (See Section I, Group IV.)
Air leak on suction side of pump
Check oil pickup tube on side of transmission.
Oil Ejected from Dipstick
Plugged breather
Inspect breather on top of transmission. Replace.
Machine Vibrates
Aerated oil
Add oil. (See Section I, Group IV.)
Low engine speed
Check engine speed. (See Group 9010-20.)
Foaming Oil
Failed universal joints on transmission Check universal joints. (See Group drive shaft or differential drive shafts 0225.) Machine Lacks Power and Acceleration
Engine fast idle speed set too low
Check fast idle adjustment. (See Group 9010-20.)
Incorrect transmission oil
Change oil. (See Section I, Group IV.)
Aerated oil
Add oil. (See Section I, Group IV.)
Low transmission pressure
Do Transmission System Pressure Test . (See Group 9020-25.)
Warped transmission clutch
Do Transmission Clutch Drag Checks . (See Group 9020-10.)
Torn transmission control valve gasket Inspect gasket. (See Group 0360.) Brake drag
Do Brake Drag Check . (See Group 9020-10.)
Continued on next page
TM1529 (27JUN17)
9020-15-7
TX,9020,DU1552 -19-10NOV93-6/7
544G, 624G, 644G Loader
062717
PN=511
Diagnostic Information Symptom
Torque Converter Stall RPM Too High
Torque Converter Stall RPM Too Low
Problem
Solution
Failed torque converter
Do Torque Converter Stall Speed Test . (See Group 9020-25.)
Low engine power
Do Engine Power Test . (See Group 9010-25.)
Aerated oil
Put clear hose on thermal bypass outlet port. Run machine to check for bubbles in oil.
Stuck open converter relief valve
Do Converter-Out Pressure Test . (See Group 9020-25.)
Leakage in torque converter seal
Do Converter-Out Pressure Test . (See Group 9020-25.)
Torque converter not transferring power (bent fins, broken stator)
Replace torque converter. (See Group 0350.)
Low engine power
Do engine power test. (See Group 9010-25.)
Mechanical malfunction
Remove and inspect torque converter. (See Group 0350.)
Low oil level Transmission Pressure Light Comes On When Shifting from FWD to REV (All Other Gears OK) Cold oil
Transmission Pressure Light Comes On for Each Shift
Add oil. (See Section I, Group IV.)
Warm oil to specification. (See Group 9020-25.)
Leak in reverse pack
Do Transmission Pressure, Pump Flow, and Leakage Check . (See Group 9020-10.)
Cold oil
Warm oil to specification. (See Group 9020-25.)
No time delay in monitor
Do Monitor Check . (See Group 9005-10.)
Restriction in modulation orifice
Remove orifice and inspect for restriction and/or plugging. (See Group 0360.)
Stuck modulation valve
Remove and inspect. (See Group 0360.)
Low transmission pressure
Do Transmission System Pressure Test . (See Group 9020-25.)
Leak in transmission pressure circuit
Do Converter Out Pressure Test . (See Group 9020-25.) TX,9020,DU1552 -19-10NOV93-7/7
TM1529 (27JUN17)
9020-15-8
544G, 624G, 644G Loader
062717
PN=512
Diagnostic Information Symptom
Problem
Solution
Failed transmission pump
Do Transmission Pump Flow Test . (See Group 9020-25.)
Clogged filter
Inspect filter. Replace. TX,9020,DU1552 -19-10NOV93-8/7
TM1529 (27JUN17)
9020-15-9
544G, 624G, 644G Loader
062717
PN=513
Diagnostic Information
Diagnose Service Brake Malfunctions Symptom
Problem
Solution
Poor or No Brakes
Brake accumulator charge low
Do Brake Accumulator Check . (See Group 9020-10.)
Brake pump standby pressure low
Do Brake Pump Standby Pressure Test . (See Group 9020-25.)
Brake pressure low
Do Brake Valve Pressure Test . (See Group 9020-25.)
Air in system
Bleed brakes. (See Group 9020-20.)
Worn brake surface material
Inspect brake surface material. (See Group 9020-20.)
Leakage in brake valve
Do Brake Valve Leakage Test . (See Group 9020-25.)
Leakage in brake piston seal
On non-differential lock axles check for an overfilled differential. On differential lock axles remove differential check plug. Apply brakes and check for leakage from check plug. NOTE: It is normal for the oil level to be slightly above the check plug.
Internal restriction in circuit
Aggressive Brakes
Remove lines and components. (See Group 1060.)
Clutch cut-off switch out of adjustment Adjust switch. (See Group 9020-20.) Brake valve malfunction
Disassemble and inspect. (See Group 1060.)
Low oil level
Check oil level.
Brake pedal not returning properly
Inspect floor mat and pedal.
Debris holding valve partially open in brake valve
Do Brake Valve Pressure Test . (See Group 9020-25.)
Warped brake disk
Inspect brake disk. (See Group 9020-20.)
Stuck brake piston
Repair. (See CTM138519.)
Brakes Lock Up
Brake valve malfunction
Clean or replace brake valve.
Brakes Chatter
Air in brake system
Do brake bleed procedure. (See Group 9020-20.)
Brakes Drag
Continued on next page
TM1529 (27JUN17)
9020-15-10
TX,2015,UU1235 -19-15FEB16-1/2
544G, 624G, 644G Loader
062717
PN=514
Diagnostic Information Symptom
Problem
Solution
Worn brake surface material
Inspect brake surface material. (See Group 9020-20.)
Wrong oil in differential
Drain. Refill. (See Section I, Group IV.)
Hissing Noise When Brake Pedal Is Leakage in brake valve, or brake Held With Engine Stopped piston
Do Brake System Leakage Test . (See Group 9020-25.)
Brake Pressure Warning Light Will Malfunction in brake low pressure Not Go Out or Stays On Excessively warning switch Long After Start-Up Brake accumulator pressure too low
Replace switch. (See Group 1674.)
Recharge Accumulator. (See Group 9020-20.)
Low brake pump standby pressure setting
Do Brake Pump Standby Pressure Test . (See Group 9020-25.)
Leakage in pressure reducing manifold block
Do Pressure Reducing Valve Manifold Leakage Test . (See Group 9020-25.)
Leakage in differential lock circuit
Do Differential Lock Leakage Test . (See Group 9020-25.)
Leakage in brake system
Do brake system components leakage tests. (See Group 9020-25.)
Leakage in pin disconnect solenoid valve or cylinders. (544G TC only)
Do leakage tests. (See Group 9020-25.)
Worn brake pump
Do Brake Pump Flow Test . (See Group 9020-25.)
Leakage in park brake solenoid
Do Park Brake Pressure Test . (See Group 9020-25.) TX,2015,UU1235 -19-15FEB16-2/2
TM1529 (27JUN17)
9020-15-11
544G, 624G, 644G Loader
062717
PN=515
Diagnostic Information
Diagnose Differential/Axle Malfunctions Symptom
Problem
Solution
No Differential Lock Operation
Malfunction in electrical circuit
With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. Do Differential Lock Operational Checks . (See Group 9015-00.)
Differential Lock Slips or Chatters When Engaged
Differential Lock Will Not Release
Stuck differential lock solenoid valve
With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. Remove and inspect valve. (See Group 0260.)
Malfunction in pressure reducing valve or setting low
Do Differential Lock Pressure Test . (See Group 9020-25.)
Excessive leakage in differential lock sealing ring
Do Differential Lock Leakage Test . (See Group 9020-25.)
Stuck differential lock piston
Disassemble, inspect, repair. (See Group 0260.)
Excessive wear on differential lock disks and plates
Disassemble, inspect, repair. (See Group 0210.)
Malfunction or setting low on pressure Do Differential Lock Pressure Test . (See Group 9020-25.) Remove and reducing valve inspect regulating valve. Excessive leakage differential lock sealing ring
Do Differential Lock Leakage Test . (See Group 9020-25.)
Failed seals on differential lock solenoid valve or regulating valve
Remove and inspect seals. (See Group 0260.)
Stuck differential lock piston
Disassemble, inspect and repair. (See Group 0260.)
Excessive wear of differential lock disks and plates
Disassemble, inspect, and repair. (See Group 0210.)
Warped differential lock disks and plates
Disassemble, inspect, and repair. (See Group 0210.)
Stuck differential lock piston
Disassemble, inspect, and repair. (See Group 0260.)
Stuck foot switch
Inspect.
Continued on next page
TM1529 (27JUN17)
9020-15-12
TX,9020,UU1237 -19-16SEP92-1/3
544G, 624G, 644G Loader
062717
PN=516
Diagnostic Information Symptom
Problem
Solution
Malfunction in electrical circuit
With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. Do Differential Lock Operational Checks . (See Group 9025-00.)
Stuck differential lock solenoid valve
With engine stopped and key switch on, activate differential lock and listen for a click from solenoid valve. Remove and inspect valve. (See Group 0260.)
Stuck differential lock piston
Disassemble, inspect, repair. (See Group 0260.)
Warped differential lock disks and plates
Disassemble, inspect, repair. (See Group 0210.)
Leak in brake piston seals
Remove differential check plugs and check leakage from check plug with brakes applied.
Incorrect breather tube
Replace tube with one that has a vee notch in end of tube.
Malfunctioning turbo boost/return circuit Low engine power or failed turbo charger
Inspect turbo boost and return hoses
Reservoir differential filter plugged
Remove filter from inside reservoir and inspect for debris.
Differential Low on Oil
External leakage
Inspect axle and differential for leaks.
Excessive Differential and/or Axle Noise
Low oil level in differential
Check oil. Remove drain plug and inspect for metal particles in differential case. Disassemble and determine cause. (See Group 0210.)
Dragging brakes
Do brake check. (See Group 9020-10.)
Engaged differential lock
Release lock.
Differential Overfilled With Oil on Non-Differential Lock Axles
Differential Overfilled With Oil on Differential Lock Axles
Check turbo boost. (See Engine Power Test Using Turbocharger Boost Pressure in Group 9010-25.)
If circuit remains pressurized, check if foot switch is sticking. Remove and inspect. Check solenoid valve for sticking. Remove and inspect valve. (See Group 0260.)
Continued on next page
TM1529 (27JUN17)
9020-15-13
TX,9020,UU1237 -19-16SEP92-2/3
544G, 624G, 644G Loader
062717
PN=517
Diagnostic Information Symptom
Problem
Solution
Failed pinion bearing
Remove and inspect pinion. Check to ensure pinion housing was indexed. (See Group 0250.)
Incorrect gear mesh pattern between ring and pinion gear
Remove pinion gear housing and inspect ring and pinion gear. (See Group 0250.)
Failed differential pinion gears and/or Remove differential housing drain plug and inspect for metal particles. cross shafts Disassemble and inspect. (See Group 0250.)
Oil Seeping from Outer Axle Seal
Axle Overheats
Failed axle bearing
Do Axle Bearing Adjustment Check . (See Group 9020-25.)
Mechanical failure in axle planetary
Remove differential. Inspect, repair. (See Group 0210.)
Excessive end play in axle
Do Axle Bearing Adjustment Check . (See Group 9020-25.)
Worn outer bearing and/or cup
Disassemble and inspect outer axle bearing, cup, spacer, and seal. Replace, if necessary. (See Group 0225.)
Overfilled differential
Check differential oil return system for excessive internal restriction. (See Group 0210.)
Low differential oil
Add oil. (See Section I, Group IV.)
Overfilled differential
See Differential Overfills with Oil in this Group.
Brake drag
See Brakes Drag in this group. TX,9020,UU1237 -19-16SEP92-3/3
TM1529 (27JUN17)
9020-15-14
544G, 624G, 644G Loader
062717
PN=518
Diagnostic Information
Diagnose Drive Line Malfunctions Symptom
Problem
Solution
Excessive Drive Line Vibration or Noise
Yokes not in line on drive shafts
Inspect. Align drive shaft yokes. (See Group 0325.)
Worn front drive line support bearing
Inspect, repair.
Bent drive shaft
Inspect all drive shafts. Replace. (See Group 0325.)
Loose yoke retaining nuts (drive shafts Inspect. Replace. (See Group 0325.) wobble at high speed) Rear axle oscillating support Inspect, repair. Lack of lubrication
Lubricate with proper grade of grease. (See Section I, Group IV.) TX,9020,UU1238 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-15-15
544G, 624G, 644G Loader
062717
PN=519
Diagnostic Information
Diagnose Park Brake Malfunctions Symptom
Problem
Solution
Brake Will Not Hold
Pads not adjusted correctly
Adjust Park Brake. (See Group 9020-20.)
Malfunctioning park brake solenoid
Inspect and replace
Worn brake disk and/or brake pads
Disassemble, inspect, repair. (See Group 1111.)
Brake piston hangs up in bore
Remove and inspect. Repair. (See Group 1111.)
Pads out of adjustment
Adjust Park Brake. (See Group 9020-20.)
Brake not released
Release park brake.
Brake Disk Overheats
Disassemble, inspect brake. Repair if necessary. (See Group 1111.) Park Brake Indicator in Monitor Does Not Come On When Brake Applied
Faulty wiring or switch
Inspect for loose or broken lines between brake indicator switch and indicator on dash. Inspect for a faulty indicator on dash. Replace if necessary. (See Group 9015-00.)
Brake Will Not Apply
Pads out of adjustment
Adjust Park Brake. (See Group 9020-20.)
Malfunctioning wiring, switch, or solenoid
Check electric circuit. (See Group 9015-00.)
Restriction between pressure reducing Remove hose and inspect. Replace. valve manifold and brake TX,9020,UU1239 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-15-16
544G, 624G, 644G Loader
062717
PN=520
Diagnostic Information
TS700 —19—28SEP89
Hydraulic Circuit Symbols
DX,HYSYM -19-24AUG90-1/1
TM1529 (27JUN17)
9020-15-17
544G, 624G, 644G Loader
062717
PN=521
Diagnostic Information
Brake, Differential Lock, And Boom Lower Circuit Schematic HIGH PRESSURE MEDIUM PRESSURE PRESSURE FREE OIL (RETURN-TOBOOM RESERVOIR)
PRESSURE REDUCING VALVE
PILOT CONTROLLERS PARK BRAKE SWITCH
INLET TEST
"SAHR" PARK BRAKE
DIFFERENTIAL LOCK (OPTIONAL)
BRAKE PUMP
PRESSURE REDUCING VALVE MANIFOLD
CLUTCH CUT-OFF SWITCH
P
FILTER RETURN
BRAKE VALVES
FRONT BRAKES
BRAKE ACCUMULATOR
BRAKE LIGHTS
P BRAKE ACCULULATOR PRESSURE SWITCH
BRAKE SHUTTLE VALVE
T7799BH
BRAKE, DIFFERENTIAL LOCK, AND BOOM LOWER CIRCUIT SCHEMATIC
T7799BH —19—09FEB98
REAR BRAKES
Brake, Diff Lock And Boom Lower Circuit JW40272,00000CC -19-13APR11-1/1
TM1529 (27JUN17)
9020-15-18
544G, 624G, 644G Loader
062717
PN=522
TRANSMISSION OIL COOLER
BRAKE HOSE
HYDRAULIC RESERVOIR
TRANSMISSION CONTROL VALVE BRAKE PUMP
9020-15-19
062717
PN=523
544G, 624G, 644G Loader
BRAKE HOSE
BRAKE ACCUMULATOR
BRAKE LIGHT SWITCH BRAKE SHUTTLE VALVE
BRAKE ACCUMULATOR LOW PRESSURE SWITCH
DIFFERENTIAL LOCK PRESSURE PORT BRAKE VALVES
PRESSURE REDUCING VALVE MANIFOLD
PARK BRAKE SWITCH
BRAKE PRESSURE HOSE
Power Train, Brakes System Components
BRAKE PRESSURE TEST PORT DIFFERENTIAL LOCK, PARK BRAKE AND PILOT CIRCUIT PRESSURE TEST PORT
PARK BRAKE
BRAKE PUMP PRESSURE REDUCING VALVE
POWER TRAIN AND BRAKES SYSTEM COMPONENT LOCATION (PARK BRAKE SWITCH OFF)
TM1529 (27JUN17)
TXC7774BK
TRANSMISSION PRESSURE SWITCH
TRANSMISSION FILTER
TRANSMISSION
TRANSMISSION OIL THERMAL BYPASS VALVE
T7774BK —19—15JAN98
Power Train And Brakes System Component Location Diagram
Diagnostic Information
HIGH PRESSURE
JW40272,00000CD -19-13APR11-1/1
BRAKE DISK INSPECTION PLUGS
BRAKE BLEED SCREWS
PRESSURE FREE (RETURN-TO-RESERVOIR)
LUBE PRESSURE
LOW PRESSURE
Diagnostic Information
TM1529 (27JUN17)
9020-15-20
544G, 624G, 644G Loader
062717
PN=524
4
TM1529 (27JUN17)
SOLENOID PRESSURE REGULATING VALVE
9020-15-21
TO LUBE
CONVERTER RELIEF VALVE
TORQUE CONVERTER
3
OIL COOLER
2
COOLER RELIEF BYPASS VALVE
THERMAL RELIEF BYPASS VALVE
CONVERTER MINIMUM PRESSURE REGULATOR
TXC7799BK
3
1
2
1
CONVERTER OUTLET TEMPERATURE
M5
M4
M3
M2
M1
SPEED
REVERSE
FORWARD
SOLENOID ACTIVATED
First Forward Schematic
T7799BK —19—15JAN98
Diagnostic Information
TRANSMISSION OIL SUMP
FILTER BYPASS
PN=525
062717
First Forward Schematic
FIRST FORWARD
VENT VALVE
RESET VALVE
HYDRAULIC PUMP
FILTER
MODULATION VALVE
544G, 624G, 644G Loader
PRESSURE REGULATING VALVE
P
MONITOR TRANSMISSION PRESSURE LIGHT
REVERSE SHIFT VALVE
REVERSE RANGE CLUTCH
FORWARD SHIFT VALVE
FORWARD RANGE CLUTCH
4TH SPEED CLUTCH
JW40272,00000CE -19-13APR11-1/1
RETURN PRESSURE OIL PRESSURE FREE OIL CONVERTER PRESSURE OIL
1ST SPEED CLUTCH
2ND SPEED CLUTCH
3RD SPEED CLUTCH
1ST SHIFT VALVE
1ST, 2ND SHIFT VALVE
4TH SHIFT VALVE
SOLENOID PRESSURE OIL
SOLENOID VALVE (M2)
CHECK VALVES
SOLENOID VALVE (M4)
SOLENOID VALVE (M1)
MAIN PRESSURE OIL
2 STAGE PISTON
PILOT VALVE
SOLENOID VALVE (M3)
SOLENOID VALVE (M5)
Diagnostic Information
TM1529 (27JUN17)
9020-15-22
544G, 624G, 644G Loader
062717
PN=526
Group 20
Adjustments Front Axle Disconnect Adjustment
T8142BH —UN—29DEC93
Adjust cable (C) so that axle disconnect is engaged when lever is in lower position (A). Axle disconnect must be disengaged in position (B).
TX,9020,DU1734 -19-15DEC93-1/1
TM1529 (27JUN17)
9020-20-1
544G, 624G, 644G Loader
062717
PN=527
Adjustments
Clutch Cut-Off Adjustment The clutch cut-off switch assembly (C) is easily adjustable to suit operators preference. Adjusting it can increase or decrease the braking action prior to disconnecting the transmission. 1. Loosen nut (A). 2. Rotate switch assembly (C) to desired gap (D) between lever (B) and bottom of pedal. NOTE: Increasing gap (D) increases the amount of braking applied prior to disengaging the transmission. 3. Tighten nut (A).
T7817AL —UN—08SEP92
4. Operate machine with clutch cut-off ON to check if adjustment is to operators preference for his work application. Adjust as required.
TX,9020,DY268 -19-08APR96-1/1
TM1529 (27JUN17)
9020-20-2
544G, 624G, 644G Loader
062717
PN=528
Adjustments
T8089AD —UN—05NOV93
Adjust Park Brake (S.N. 788774—)
A—Dust Seal B—Seals C—Piston D—Parking Brake Adjusting Screw
E—Lock Nut F— Cover G—Snap Ring H—Spring Washers
I— Shaft J— Brake Pad Assembly Thickness K—Parking Brake Disk
Specification Brake Pad Assembly—Minimum Thickness....................................................................... 9 mm (0.354 in.) Maximum Padto-Disk—Running Clearance................................................................... 4.76 mm (0.187 in) Minimum Padto-Disk—Running Clearance.........................................................................0.5 mm (0.020)
L— Cap Screw
4. Stop engine, this will engage park brake. 5. Place blocks in front and behind tires. NOTE: If this is the initial installation of new park brake pads, install the four mounting screws but do not tighten them. 6. Remove 3 park brake adjustment cover cap screws (L) and cover (F). Loosen the lock nut (E). 7. Tighten park brake adjustment screw (D) to 100 N·m (75 lb-ft).
1. Park machine on level surface. 2. Lower bucket to ground. 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.
8. If a new brake assembly is being installed tighten brake assembly for mounting cap screws to 70 N·m (50 lb-ft). 9. Turn park brake adjustment screw counterclockwise 1/2 turn (180°) 10. Hold adjusting screw (D) and tighten locknut (E). 11. Install cover and tighten cap screws (L).
3. Install frame locking bar. TX,9020,DY269 -19-08APR96-1/1
TM1529 (27JUN17)
9020-20-3
544G, 624G, 644G Loader
062717
PN=529
Adjustments
External Service Brake Inspection
Do first inspection at 5000 hours followed by 1000 hours inspection intervals after the first 5000 hours inspection. If the service brakes are subjected to severe duty, inspect more frequently. 1. Remove brake inspection port plug (A).
T6523BZ —UN—07MAY08
CAUTION: Prevent possible injury from hot spraying oil. Slowly loosen plug to relieve any air pressure.
TX,90,JC263 -19-29NOV94-1/2
2. Inspect the brake linings (A) on brake disk.
T8137AC —UN—03DEC93
4. If further inspection of brake elements or replacement of brake linings is necessary, see your authorized dealer.
T6138AZ —UN—07MAY08
3. Remove axle housing and replace brake disc if oil grooves (B) on facing material are no longer visible.
TX,90,JC263 -19-29NOV94-2/2
TM1529 (27JUN17)
9020-20-4
544G, 624G, 644G Loader
062717
PN=530
Adjustments
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.
X9811 —UN—23AUG88
Hydraulic Brake Bleeding Procedure
NOTE: Two people are required to bleed brake system oil, one to operate brake valve and other to open and close bleed screws. 1. Install frame locking bar. Engage park brake. 2. Put a clear plastic tube on bleed screw (B) to route flow to hydraulic reservoir filler tube (A) or container. 3. Start engine and run at slow idle.
NOTE: If bubbles continue for more than 3 minutes, stop bleeding procedure. Check for and correct problem, then continue. 5. Open one bleed screw on differential and axle assembly until hydraulic oil starts to flow. Close bleed screw when oil is free of air. Release brake pedal. 6. Repeat steps 2—5 for each bleed screw (two bleed screws on each differential).
T7011AB —UN—21MAR89
4. Push and hold brake pedal down until brake bleeding procedure is complete.
7. Check hydraulic oil level. TX,2020,EE26 -19-07SEP94-1/1
TM1529 (27JUN17)
9020-20-5
544G, 624G, 644G Loader
062717
PN=531
Adjustments
Charge Brake Accumulator SPECIFICATIONS Oil Temperature
40°C (104°F)
Brake Accumulator Charge Pressure
3450 ± 249 kPa (34.5 ± 2.4 bar) (500 ± 35 psi)
ESSENTIAL TOOLS JT01735 Gas Cock
IMPORTANT: Charge accumulator using only dry nitrogen. Dry nitrogen does not mix with oil and is non-combustible. Specification Oil—Temperature................................................................ 40°C (104°F)
T7594AA —UN—10SEP91
It will not cause oxidation or condensation inside accumulator and is not harmful to piston seal. DO NOT use air or any combustible gas as these can cause oxidation and condensation. Oxidation and condensation are harmful to piston seal and accumulator. 1. If accumulator is to be charged on machine and has some nitrogen pressure left, depress brake pedal at one second intervals 20 times to drain oil from accumulator. 2. Remove cover and cap from bottom of accumulator. 3. Turn handle on gas cock fully counterclockwise. Attach gas cock, hose, and regulator to accumulator.
T7594AB —UN—10SEP91
NOTE: Loosen only the top special nut. The bottom "nut" is actually the accumulator gas valve. 4. Loosen special nut (A) (counterclockwise) two and 1/2 turns to open gas valve in accumulator. (Resistance may be felt at approximately one and 1/2 turns.) 5. Slowly open regulator valve to pressurize accumulator to specification. Specification Brake Accumulator—Charge Pressure....... 3450 ± 249 kPa (34.5 ± 2.4 bar) (500 ± 35 psi)
6. If accumulator is being charged on machine and has no nitrogen pressure, depress brake pedal at one second intervals 20 times to drain oil from accumulator. 7. After the accumulator is charged, close regulator valve and tighten special nut (A) clockwise.
9. Slowly loosen the connector at pressure regulator valve to release pressure from hose. 10. Remove gas cock, hose and regulator from accumulator. Install cap. 11. Install cap and cover on bottom of accumulator.
8. Close the control on the nitrogen tank. TX,9020,DU1556 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-20-6
544G, 624G, 644G Loader
062717
PN=532
Adjustments
Brake Pump And Differential Lock System Oil Clean-Up Procedure Using Portable Filter Caddy For oil clean-up procedure, see Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy , Group 9025-20. TX,902020,HH37 -19-16SEP92-1/1
Transmission Sensor Adjustment NOTE: The 544G and 624G transmission sensor is on the right side of the machine. The 644G sensor is on the left side of the machine. 1. Engine off. 2. Lower equipment to the ground. 3. Install frame locking bar. 4. Remove transmission side shield (if equipped). 5. Block wheels. 6. Disconnect wire connector from sensor. 7. Scribe a mark on the sensor and transmission case. Remove sensor.
T8249AA —UN—01JUN94
8. Loosen park brake adjusting screw to release park brake, see Adjust Park Brake in this Group (Step 6). Using a pry bar on the driveshaft, center gear tooth in hole. 9. Adjust sensor by performing one of the following methods:
• Conventional method
a. Measure distance from tooth to outside hole of transmission (A). Record measurement. b. Measure distance of sensor (B). Record measurement. c. Subtract measurements (A from B) and add 0.5—0.8 mm (0.020—0.030 in.) to determine shim pack.
b. Install sensor to original position as marked. c. Continue to turn sensor until sensor bottoms out against gear tooth. Sensor should turn an additional 1/3—1/2 turn past original position. d. If original sensor position allows sensor to turn more than or less than specified, add or remove shims as necessary.
EXAMPLE: (B) — (A)
26.28 mm (1.035 in.) Sensor Measurement 24.34 mm (0.958 in.) Tooth Measurement 2.04 mm (0.080 in.)
Add 0.5—to 0.8 mm (0.020—0.030 in.) to 2.04 mm (0.080 in.) to get shim pack required.
• Alternative method:
10. Apply pipe sealant with TEFLON® to threads of sensor. Install sensor. 11. Install transmission side shield (if equipped). 12. Adjust park brake, see procedure in this Group.
a. Remove shims from sensor.
TEFLON is a trademark of Du Pont Co. TX,9020,SS2205 -19-02FEB95-1/1
TM1529 (27JUN17)
9020-20-7
544G, 624G, 644G Loader
062717
PN=533
Adjustments
TM1529 (27JUN17)
9020-20-8
544G, 624G, 644G Loader
062717
PN=534
Group 25
Tests JT05801 Clamp-On Electronic Tachometer Installation SERVICE EQUIPMENT AND TOOLS
A—Clamp-On Tachometer Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten only—DO NOT over tighten. B—Black Clip (-). Connect to main frame. C—Red Clip (+). Connect to transducer. D—Tachometer Readout. Install cable.
T6813AG —UN—28FEB89
Tachometer:
902025,AA75 -19-16SEP92-1/1
JT05800 Digital Thermometer Installation SERVICE EQUIPMENT AND TOOLS
A—Temperature Probe. Fasten to a bare metal line using tie band. Wrap with shop towel. B—Cable C—Digital Thermometer
T6808CE —UN—28FEB89
Digital Thermometer
902525,AA4 -19-14FEB95-1/1
Display Monitor Tachometer
T7817AG —UN—31AUG92
The display monitor tachometer is accurate enough for test work. If accuracy is questioned see Calibrate Tachometer in Group 9015-20.
TX,9020,UU1277 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-1
544G, 624G, 644G Loader
062717
PN=535
Tests
Transmission Oil Warm-Up Procedure NOTE: For machines 544G (S.N. 548219—548955), 624G (S.N. 548398—548982), 644G (S.N. 548303—548887), an “F907” service code may appear on the monitor when performing the transmission oil warm-up procedure. This code may appear because the transmission controller is programmed to compare an input signal from the gear selector with a signal from the speed sensor. If the controller senses gear selector movement (step 4), but does not receive a signal from the speed sensor (because of step 3), then “F907” code will appear. Delete the “F907” code when procedure is completed. (See Jumper Wire for Display Monitor in Group 9015-20 for more information.)
1. Install tachometer/temperature reader. (See Tachometer/Temperature Reader Installation in this group.) 2. Release park brake. 3. Apply service brakes. 4. Shift to third gear forward. 5. Run engine at fast idle until test specification is met or for 30 seconds (whichever comes first). 6. Reduce speed, shift to neutral and run for 15 seconds. 7. Repeat steps 3—5 until oil is to test specification. TX,9020,UU1278 -19-16SEP92-1/1
Brake, Differential Lock, And Hydraulic System Oil Warm-Up Procedure 1. Install tachometer/temperature reader. (See Tachometer/Temperature Reader Installation Procedure in this group.)
5. Drive machine with differential lock on and make frequent stops to heat axles.
2. Run engine speed at fast idle.
6. Heat oil to test specification.
3. Hold bucket rollback function over relief to heat oil. 4. Periodically cycle all hydraulic functions to distribute warm oil. TX,9020,UU1279 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-2
544G, 624G, 644G Loader
062717
PN=536
Tests
T7801AH —UN—26AUG92
Transmission Pump Flow Test
SPECIFICATIONS Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
2000 rpm
544G New Pump Minimum Flow Rate
57 L/min (15 gpm)
544G Used Pump Minimum Flow Rate
42 L/min (11 gpm)
624G New Pump Minimum Flow Rate
64 L/min 22 gpm)
624G Used Pump Minimum Flow Rate
64 L/min (17 gpm)
644G New Pump Minimum Flow Rate
83 L/min 22 gpm)
644G Used Pump Minimum Flow Rate
64 L/min (17 gpm)
ESSENTIAL TOOLS JDG596 Filter Adapter (A)
1. Make test connections as shown. IMPORTANT: Before starting engine, check that flowmeter loading valve is open. Pump can be damaged if engine is started with loading valve closed. 2. Connect tachometer/temperature reader. (See Tachometer/Temperature Reader Installation Procedure in this group.) 3. Heat transmission oil up to test specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Transmission Oil Warm-Up Procedure , this group.) 4. Run engine at test specification. Specification Engine—Speed......................................................................... 2000 rpm
SERVICE EQUIPMENT AND TOOLS
Measure flow. Flowmeter loading valve must be open.
Flowmeter Tachometer/Temperature Reader
Continued on next page
TM1529 (27JUN17)
9020-25-3
TX,9020,UU1217 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=537
Tests
Low transmission pump flow can be caused by: Specification 544G New Pump—Minimum Flow Rate............................................................................. 57 L/min (15 gpm) 544G Used Pump—Minimum Flow Rate............................................................................. 42 L/min (11 gpm) 624G New Pump—Minimum Flow Rate.............................................................................. 64 L/min 22 gpm) 624G Used Pump—Minimum Flow Rate............................................................................. 64 L/min (17 gpm)
644G New Pump—Minimum Flow Rate.............................................................................. 83 L/min 22 gpm) 644G Used Pump—Minimum Flow Rate............................................................................. 64 L/min (17 gpm)
• Low oil level in transmission. • Cold transmission oil. • Plugged suction screen. • Air leak in pump suction tube. • Pump mounting cap screws loose. • Worn transmission pump. TX,9020,UU1217 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-25-4
544G, 624G, 644G Loader
062717
PN=538
Tests
T7801AI —UN—26AUG92
Transmission System Pressure, Element Leakage, And Shift Modulation Test
SPECIFICATIONS Transmission Temperature
65 ± 5°C (150 ± 10°F)
Transmission System Pressure at 1500 RPM
1600—1800 kPa (16—18 bar) (230—260 psi)
Transmission System Minimum Pressure at Slow Idle (Element Leakage Check ONLY)
1200 kPa (12 bar) (175 psi)
Transmission System Maximum Pressure Difference Between Gears (Element Leakage)
100 kPa (1 bar) (15 psi)
1st Gear Approximate Forward-to-Reverse Shift Modulation Time
1.2 seconds
2nd Gear Approximate Forward-to-Reverse Shift Modulation Time
1.0 seconds
2. Connect tachometer/temperature reader. (See Tachometer/Temperature Reader Installation in this group.) 3. Heat transmission oil to test specification. Specification Transmission—Temperature........................................................................ 65 ± 5°C (150 ± 10°F)
(See Transmission Oil Warm-Up Procedure in this Group.) 4. Check system pressure as follows: Specification Transmission System—Pressure at 1500 RPM.............................................................................1600—1800 kPa (16—18 bar) (230—260 psi)
ESSENTIAL TOOLS JT01608 (1/8 x 7/16 F 37°) Quick Coupler (A) (7/16 M 37° x M10 ORB) (Parker No. 4-M 10 x 1 F80X-S) Connector (B)
• Run engine at 1500 rpm. • Record pressure. If pressure is low, move transmission speed lever to several different gears in both forward and reverse. If pressure increases to specifications in any gear, leakage is indicated in the element circuits that were low in step 4.
SERVICE EQUIPMENT AND TOOLS Gauge 0—2000 kPa (0—20 bar) (0—300 psi) Tachometer/Temperature Reader
If pressure is low in all gears:
1. Remove transmission pressure switch (C) and make test connections as shown.
• Check modulation orifice for contamination or plugging.
Continued on next page
TM1529 (27JUN17)
9020-25-5
TX,9020,UU1218 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=539
Tests
• Check pressure regulating valve and associated •
Compare main pressure difference between 1st forward and reverse. Pressure difference must not exceed specification.
passages for debris or contamination. Inspect for broken pressure regulating spring or stuck or damaged spool. Inspect control valve and gaskets for leakage.
Compare main pressure difference between 3rd Neutral and 3rd Forward. Pressure difference must not exceed specification.
If pressure is still low, adjust pressure regulating valve by adding shims between the pressure regulating valve spool and spring to increase pressure. NOTE: For machines 544G (S.N. 548219—548955), 624G (S.N. 548398—548982), 644G (S.N. 548303—548887), an “F907” service code may appear on the monitor when performing the transmission oil warm-up procedure. This code may appear because the transmission controller is programmed to compare an input signal from the gear selector with a signal from the speed sensor. If the controller senses gear selector movement, but does not receive a signal from the speed sensor, then “F907” code will appear. Delete the “F907” code when procedure is completed. (See Jumper Wire for Display Monitor in Group 9015-20 for more information.)
If pressure difference between gears is greater than specification, element leakage is indicated in that gear. To isolate leakage, cap hose to clutch shaft for element with leakage and repeat test. If leakage is still indicated, inspect control valve and gasket for leakage . (See Group 0360.) If leakage is not indicated, check for worn clutch shaft or piston seals . (See Group 0350.) If system pressure is below the minimum specification at slow idle in all gears, but normal at 1500 rpm, a sticking regulating valve, low pump flow, or control valve gasket leakage is indicated. 6. Check shift modulation as follows:
• Shift from forward to reverse. • Measure the time from when the shift lever is moved
5. Check element leakage as follows: Specification Transmission System—Minimum Pressure at Slow Idle (Element Leakage Check ONLY)........................................................... 1200 kPa (12 bar) (175 psi) Maximum Pressure Difference Between Gears (Element Leakage)............................................................ 100 kPa (1 bar) (15 psi)
until system pressure is at specification.
Specification 1st Gear Approximate Forward-toReverse—Shift Modulation Time....................................................................1.2 seconds 2nd Gear Approximate Forward-toReverse—Shift Modulation Time....................................................................1.0 seconds
• Release park brake. • Turn clutch disconnect switch off. • Apply service brakes. • Run engine at slow idle.
If pressure is not within specification, remove control valve and check modulation spool, modulation piston, two-stage piston, pilot valve and vent valve for malfunction.
Compare main pressure difference between 1st Neutral, 2nd Neutral and 3rd Neutral. Pressure difference must not exceed specification. TX,9020,UU1218 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-25-6
544G, 624G, 644G Loader
062717
PN=540
Tests
T6738AJ —UN—19OCT88
Transmission Lube Pressure Test
(See Transmission Oil Warm-Up Procedure in this group.)
SPECIFICATIONS Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
544G Lube Pressure
41—90 kPa (0.4—9 bar) (6—13 psi)
624G, 644G Lube Pressure
103—241 kPa (1—2.4 bar) (15—35 psi)
4. Run engine at test specification. Specification Engine—Speed...........................................................................Fast idle
Low lube pressure can be caused by: Specification 544G—Lube Pressure.....................41—90 kPa (0.4—9 bar) (6—13 psi) 624G, 644G—Lube Pressure....................................103—241 kPa (1—2.4 bar) (15—35 psi)
ESSENTIAL TOOLS JT03103 (7/16 M 37° x 1-1/16 F 37°) Adapter (A) JT05687 (-6 F ORFS x 1-1/16 M 37°) Adapter (B)
• Hose
S8H1278 (-6 M ORFS x -6 M ORFS) (Parker No. 6 HLO-S) Union (C) SERVICE EQUIPMENT AND TOOLS
• •
Gauge 0—414 kPa (0—4 bar) (0—60 psi)
•
Tachometer/Temperature Reader
1. Make test connections as shown.
•
2. Connect temperature reader. (See Temperature Reader Installation Procedure in this group.) 3. Heat transmission oil to test specification.
pinched or restricted. Check converter-out-to-thermal bypass inlet hose and oil cooler-to-lube inlet hose. Suction screen plugged. Remove and inspect. Converter relief valve stuck open. Do Converter Relief Pressure Test in this group. Thermal bypass valve restriction. Disassemble and inspect components. Transmission pump worn. Do Transmission Pump Flow Test in this group.
High lube pressure can be caused by plugged thermal bypass valve-to-transmission line or lube passage in transmission.
Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F) TX,9020,UU1254 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-7
544G, 624G, 644G Loader
062717
PN=541
Tests
T7801AJ —UN—26AUG92
Converter Relief Pressure Test
SPECIFICATIONS Oil Temperature
Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Converter Pressure Relief Valve Pressure Setting
850—1050 kPa (8.5—10.5 bar) (125—155 psi)
(See Transmission Oil Warm-Up Procedure in this group.) 2. Disconnect converter out hose at tee, install cap on tee, install gauge on hose.
ESSENTIAL TOOLS 38H1418 (-12 ORFS) (Parker No. 12 FNL-S) Cap (A)
3. Connect temperature reader. (See Temperature Reader Installation Procedure in this group.)
38H1272 (-12 M ORFS x -12 M ORFS) (Parker No. 12 HLO-S) Union (B)
4. Run engine at specification. Specification Engine—Speed..........................................................................Slow idle
JT05590 (-12 F ORFS x 1-1/16 M 37°) Adapter (C) JT03103 (1-1/16 F 37° x 7/17 M 37°) Adapter (D)
5. Read pressure gauge.
SERVICE EQUIPMENT AND TOOLS
Low converter relief valve pressure can be caused by: Gauge 0—2000 kPa (0—20 bar) (0—300 psi)
Specification Converter Pressure Relief Valve—Pressure Setting............................................................................. 850—1050 kPa (8.5—10.5 bar) (125—155 psi)
Temperature Reader
Do this test only if machine fails Converter-Out Pressure Test . IMPORTANT: DO NOT heat up transmission with cooler flow dead headed to gauge, transmission damage could occur from overheating due of lack of lubrication to the clutch packs.
• Transmission control valve or gasket leakage. Remove and inspect. (See Group 0360.)
• Torque converter leakage. Disassemble and inspect. (See Group 0350.)
1. Heat transmission oil to test specifications. Continued on next page
TM1529 (27JUN17)
9020-25-8
TX,9020,UU1219 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=542
Tests
• Converter relief valve stuck open or spring broken
or weak. Remove transmission pump and inspect. (See Group 0350.) TX,9020,UU1219 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-25-9
544G, 624G, 644G Loader
062717
PN=543
Tests
T7801AK —UN—26AUG92
Converter-In Pressure Test
appear on the monitor when performing the transmission oil warm-up procedure. This code may appear because the transmission controller is programmed to compare an input signal from the gear selector with a signal from the speed sensor. If the controller senses gear selector movement, but does not receive a signal from the speed sensor, then “F907” code will appear. Delete the “F907” code when procedure is completed. (See Jumper Wire for Display Monitor in Group 9015-20 for more information.)
SPECIFICATIONS Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
Torque converter stall
Minimum Converter-In Pressure
172 kPa (1.72 bar) (25 psi)
ESSENTIAL TOOLS (7/16 M 37° x M 10 x 1) (Parker No. 4-M 10 x 1 F80X-S) Connector SERVICE EQUIPMENT AND TOOLS
4. Apply brakes.
Gauge 0—1000 kPa (0—10 bar) (0—150 psi) Temperature Reader
1. Remove transmission control valve test plug and make test connection as shown.
5. Put transmission in 3rd forward. Measure converter-in pressure at specification. Specification Engine—Speed......................................................Torque converter stall
2. Connect temperature reader. (See Temperature Reader Installation Procedure in this group.)
Low converter-in pressure can be caused by:
3. Heat transmission oil up to test specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
Specification Minimum ConverterIn—Pressure................................................. 172 kPa (1.72 bar) (25 psi)
(See Transmission Oil Warm-Up Procedure in this group.)
• Plugged suction screen. •
NOTE: For machines 544G (S.N. 548219—548955), 624G (S.N. 548398—548982), 644G (S.N. 548303—548887), an “F907” service code may
•
Remove and inspect suction screen. Transmission pump worn. Do Transmission Pump Flow Test in this group. Control valve or valve gasket leakage. Remove and inspect.
Continued on next page
TM1529 (27JUN17)
9020-25-10
TX,2025,UU1220 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=544
Tests
• Converter relief valve set too low, stuck open,
or spring broken or weak. Do Converter Relief Pressure Test in this group.
• Torque converter leakage. Disassemble and inspect. TX,2025,UU1220 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-25-11
544G, 624G, 644G Loader
062717
PN=545
Tests
T7801AL —UN—26AUG92
Converter-Out Pressure Test
SPECIFICATIONS
4. Measure converter-out pressure at specification.
Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
Converter-Out Pressure
483—690 kPa (5—7 bar) (70—100 psi)
Specification Engine—Speed...........................................................................Fast idle ConverterOut—Pressure............................483—690 kPa (5—7 bar) (70—100 psi)
Low converter-out pressure can be caused by:
ESSENTIAL TOOLS
• Plugged suction screen. JT05491 (7/16 M 37° x M 14 x 1.5) Connector
•
SERVICE EQUIPMENT AND TOOLS
• Gauge 0—2069 kPa (0—21 bar) (0—300 psi)
• •
Temperature Reader
1. Remove transmission temperature sender and make test connection as shown. 2. Connect temperature reader. (See Temperature Reader Installation Procedure in this group.)
High converter-out pressure can be caused by:
• Pinched
3. Heat transmission oil up to test specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
Remove and inspect suction screen. Transmission pump worn. Do Transmission Pump Flow Test in this group. Control valve or valve gasket leakage. Remove and inspect. Torque converter leakage. Disassemble and inspect. Converter relief valve set too low, stuck open, or spring broken or weak. Do Converter Relief Pressure Test in this group.
•
or restricted hose. Check converter-out-to-thermal bypass inlet and return hoses. Thermal bypass valve restriction. Disassemble and inspect components.
(See Transmission Oil Warm-Up Procedure in this group.) TX,9020,UU1221 -19-30JAN95-1/1
TM1529 (27JUN17)
9020-25-12
544G, 624G, 644G Loader
062717
PN=546
Tests
T7801AM —UN—26AUG92
Converter-Out Flow Test
(See Transmission Oil Warm-Up Procedure in this group.)
SPECIFICATIONS Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
2000 rpm
544G Minimum Converter-Out Flow Rate
26.5 L/min (7 gpm)
624G, 644G Minimum Converter-Out Flow Rate
43.5 L/min (11.5 gpm)
NOTE: Normal new machine minimum flows will be approximately double the minimum specification. 4. Measure converter-out flow at test specification. Specification Engine—Speed......................................................................... 2000 rpm 544G Minimum Converter-Out—Flow Rate............................................................................ 26.5 L/min (7 gpm) 624G, 644G Minimum Converter-Out—Flow Rate....................................................................... 43.5 L/min (11.5 gpm)
ESSENTIAL TOOLS 38H1272 (-12 M ORFS x -12 M ORFS) (Parker No. 12 HLO-S) Union (A) JT05690 (-12 F ORFS x 1-1/16 M 37°) Adapter (B) SERVICE EQUIPMENT AND TOOLS
If converter-out flow is low, check the following:
• Clutch piston or seal ring leakage.
Gauge 0—2069 kPa (0—21 bar) (0—300 psi) Flowmeter Tachometer/Temperature Reader
• • • • •
1. Make test connections as shown. 2. Connect temperature reader. (See Temperature Reader Installation Procedure in this group.) 3. Heat transmission oil to test specification.
•
Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
•
Move transmission speed selector lever to a different position and repeat test. Low oil level in transmission. Cold transmission oil. Plugged suction screen. Air leak in pump suction tube. Plugged thermal bypass valve or lube passage. (See Lube Pressure Test in this group.) Low transmission pump flow. (Do Pump Flow Test in this group.) Transmission control valve gasket leakage. Remove and inspect gasket. (See Group 0360.)
Continued on next page
TM1529 (27JUN17)
9020-25-13
TX,9020,UU1222 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=547
Tests
• Converter relief valve stuck open or spring weak or
• Torque converter leakage. Disassemble and inspect.
broken. (Do Converter Relief Pressure Test in this group.)
(See Group 0350.)
TX,9020,UU1222 -19-16SEP92-2/2
T6834AV —UN—19OCT88
Transmission Oil Cooler Backflush Procedure
ESSENTIAL TOOLS
2. Put a 20 L (5 gal) container under cooler inlet (A). 3. Connect converter-out line (D) to cooler outlet line (E).
38H1418 (-12 ORFS) (Parker No. 12 FNL-S) Cap
1. Disconnect and cap thermal relief valve-to-cooler outlet (B), thermal relief valve-to-converter-out inlet (F), and thermal relief valve-to-cooler inlet (C).
4. Run engine to backflush cooler with converter-out pressure. TX,902025,AA77 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-14
544G, 624G, 644G Loader
062717
PN=548
Tests
T8089AE —UN—05NOV93
Transmission Oil Cooler Restriction Test
NOTE: If internally restricted oil cooler is suspected, oil cooler can be backflushed in less time than it takes to test for restriction. (See Oil Cooler Backflush Procedure in this group.) SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS Gauge 0—2069 kPa (0—21 bar) (0—300 psi) (2 used) Temperature Reader
1. Make test connections as shown. Connect cooler inlet (H) and converter-out (G) to a tee and cap ports (A).
Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
Inlet and Outlet Maximum Pressure Differential
276 kPa (2.8 bar) (40 psi)
2. Connect temperature reader. (See Temperature Reader Installation in this group.) 3. Heat transmission oil to test specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F) Engine—Speed...........................................................................Fast idle
ESSENTIAL TOOLS JT01608 (1/8 x 7/16 F 37°) Quick Coupler (B)
(See Transmission Oil Warm-Up Procedure in this group.)
JT03103 (7/16 M 37° x 1-1/16 F 37°) Adapter (C) JT05690 (1-1/16 M37° x 12 M ORFS) Adapter (D) 38H1033 (-12 M ORFS x -12 M ORFS x -12 F ORFS) (Parker No. 12 R6LO-S) Tee (E) 38H1272 (-12 M ORFS x -12 M ORFS) Union (F) 38H1418 (-12 ORFS) (Parker No. 12 FNL-S) Cap (2 used) NA Converter Out Hose NA Cooler Inlet Hose
4. Read pressure on inlet and outlet sides of oil cooler. If difference is greater than specification, switch gauges to verify gauge accuracy. Specification Inlet and Outlet—Maximum Pressure Differential........................................ 276 kPa (2.8 bar) (40 psi)
If gauges are correct, then backflush oil cooler. (See procedure in this group.) TX,9020,DU1558 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-25-15
544G, 624G, 644G Loader
062717
PN=549
Tests
T6522AY —UN—19OCT88
Pressure Reducing Valve Manifold Leakage Test
SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
4. Run engine at specification. Specification Engine—Speed..........................................................................Slow idle
Pressure Reducing Valve Manifold 225 ml/min (7.85 oz/min) Leakage With Park Brake Released
5. Measure flow from valve. 6. Release park brake and measure flow from valve;
Pressure Reducing Valve Manifold 3785 ml/min (128 oz/min) Leakage With Park Brake Applied
Specification Pressure Reducing Valve Manifold—Leakage With Park Brake Released........................................225 ml/min (7.85 oz/min)
ESSENTIAL TOOLS JT03028 (7/16 M ORB) Plug
1. With differential lock ON. 2. With differential lock OFF.
SERVICE EQUIPMENT AND TOOLS
7. Apply park brake and measure flow from valve; Temperature Reader
Specification Pressure Reducing Valve Manifold—Leakage With Park Brake Applied...........................................3785 ml/min (128 oz/min)
Measuring Container Stop Watch
1. Connect temperature reader. (See Temperature Reader Installation in this group.)
1. With differential lock ON. 2. With differential lock OFF.
2. Heat oil to test specification. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Disconnect pressure regulating manifold-to-reservoir return line. Install plug in line.
NOTE: Flow from pressure reducing valve is much greater with park brake applied because the warm-up orifice allows flow through park brake lines and hoses to warm the park brake system during cold weather operation.
Continued on next page
TM1529 (27JUN17)
9020-25-16
TX,9020,UU1255 -19-30JAN95-1/2
544G, 624G, 644G Loader
062717
PN=550
Tests
If flow from valve is exceeds specification, pressure reducing valve or seals may be damaged. If flow changes when differential lock is turned ON then OFF, differential
lock solenoid valve or seals may be damaged. Replace as necessary. TX,9020,UU1255 -19-30JAN95-2/2
T7801AO —UN—26AUG92
Transmission Oil Cooler Thermal Bypass Valve Test
SPECIFICATIONS
2. Start engine.
Thermal Bypass Valve Starts to Open Temperature
82 ± 3°C (180 ± 5°F)
3. Put transmission in 3rd forward.
Thermal Bypass Valve Full Open Temperature
96°C (205°F)
4. Increase engine speed to fast idle. 5. Observe temperature at which flowmeter reading starts to increase.
ESSENTIAL TOOLS 38H1272 (-12 F ORFS x -12 M ORFS) (Parker No. 12 HLO-S) Union (A) JT05690 (-12 F ORFS x -1-1/16 M 37°) Adapter (2 used) (B) JT03051 (1-1/16 F 37° x 1-1/16 F 37°) Coupler (C) SERVICE EQUIPMENT AND TOOLS Flowmeter Temperature Reader
1. Make test connections as shown.
If valves does not start operating at test specification, replace valve. Specification Thermal Bypass Valve Starts to Open—Temperature................................................ 82 ± 3°C (180 ± 5°F) Thermal Bypass Valve Full Open—Temperature............................................................ 96°C (205°F)
Repeat test. TX,9020,UU1223 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-17
544G, 624G, 644G Loader
062717
PN=551
Tests
T7817AF —UN—31AUG92
Transmission Oil Cooler Bypass Valve Pressure Test
NOTE: If an oil cooler bypass valve malfunction is suspected, the thermal bypass valve can be removed to inspect relief valve in less time than it takes to perform a test.
1. Make test connections. 2. Heat transmission oil to specification. Specification Oil—Temperature............................................... 93—99°C (200—210°F)
SPECIFICATIONS
(See procedure in this group.) Oil Temperature
93—99°C (200—210°F)
Cooler Bypass Pressure Differential
214—269 kPa (2.1—2.7 bar) (31—39 psi)
Engine Speed
Slow idle
3. Observe pressure gauges during warm-up. Pressure differential should start out low and then when thermal bypass valve opens, pressure differential will increase. Specification Cooler Bypass—Pressure Differential......................214—269 kPa (2.1—2.7 bar) (31—39 psi)
ESSENTIAL TOOLS JT03103 (7/16 M37° x 1-1/16 F 37°) Adapter (2 used) (A)
When oil temperature is at specification, put transmission in neutral and run engine at specification.
JT05690 (1-1/16 M 37° x 12 M ORFS) Adapter (B) JT05687 (-6 F ORFS x 1-1/16 M 37°) Adapter (C) 38H1278 (-6 M ORFS x 6 M ORFS) (Parker No. 12 FNL-S) Union (D) 38H1418 (-12 F ORFS) (Parker No. 12 FNL-S) Cap (E) SERVICE EQUIPMENT AND TOOLS Gauge 0—700 kPa (0—7 bar) (0—100 psi)
Specification Engine—Speed..........................................................................Slow idle
If pressure is low, a failed cooler bypass valve or thermal bypass valve is indicated. Disassemble and inspect valve. (See Group 0360.)
Hydraulic Switch Box Temperature Reader TX,9020,UU1256 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-18
544G, 624G, 644G Loader
062717
PN=552
Tests
Torque Converter Stall Speed Test SPECIFICATIONS
4. Run engine at fast idle with transmission in 3rd forward.
Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
Specification Engine—Speed...........................................................................Fast idle
544G Using No. 2 Fuel Torque Converter Stall Speed
2125—2275
5. Engine speed must be at specification.
624G Using No. 2 Fuel Torque Converter Stall Speed
2125—2250
644G Using No. 2 Fuel Torque Converter Stall Speed
1950—2150
Specification 544G Using No. 2 Fuel—Torque Converter Stall Speed............................................................................2125—2275 624G Using No. 2 Fuel—Torque Converter Stall Speed............................................................................2125—2250 644G Using No. 2 Fuel—Torque Converter Stall Speed............................................................................1950—2150
SERVICE EQUIPMENT AND TOOLS Temperature Reader
NOTE: Decrease rpm specification by 7% if using No. 1 fuel. 1. Connect temperature reader. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Temperature Reader Installation Procedure in this group.) 2. Turn clutch cut-off switch OFF. 3. Apply service brakes.
If engine rpm is excessively low, engine horsepower or an incorrect torque converter is indicated. Do Engine Power Test . (See Group 9010-25.) Replace torque converter. (See Group 0350.) If engine rpm is excessively high, clutch slippage or incorrect torque converter is indicated. Remove and inspect torque converter. (See Group 0350.) If engine is overpowered. Do Engine Power Test . (See Group 9010-25). TX,9020,UU1257 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-19
544G, 624G, 644G Loader
062717
PN=553
Tests
T7801AN —UN—26AUG92
Brake Pump Flow Test
SPECIFICATIONS
4. Install cap on brake line. 5. Connect flowmeter inlet to brake pump outlet.
Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
2000 rpm
Brake Pump Flow Test Pressure
13 790 kPa (138 bar) (2000 psi)
Minimum Brake Pump Flow Rate
23 L/min (6 gpm)
6. Route flowmeter outlet to hydraulic reservoir fill tube. 7. Run engine at test specification. Specification Engine—Speed......................................................................... 2000 rpm
ESSENTIAL TOOLS
8. Close flowmeter loading valve until pressure is at test specification.
38H1415 (-6 F ORFS) (Parker No. 6 FNL-S) Cap JT05687 (1 1/16 M 37° X -6 F ORFS) Adapter
Specification Brake Pump Flow Test—Pressure...................................... 13 790 kPa (138 bar) (2000 psi)
SERVICE EQUIPMENT AND TOOLS Tachometer/Temperature Reader
9. Read flowmeter.
Flowmeter
1. Connect tachometer/temperature reader. (See Tachometer/Temperature Reader Installation Procedure in this group.)
Specification Minimum Brake Pump—Flow Rate......................................................... 23 L/min (6 gpm)
2. Heat brake oil to specification.
If flow is less than test specification, see Brake Pump Standby Pressure Test in this group.
Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
If standby pressure is to specification, remove and repair pump . (See Group 1060 in TM1530.)
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Disconnect brake pump outlet-to-brake accumulator inlet line. Cap inlet line (B). TX,9020,DU1559 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-25-20
544G, 624G, 644G Loader
062717
PN=554
Tests
T8089AF —UN—05NOV93
Brake Pump Standby Pressure Test
(See Hydraulic Oil Warm-Up Procedure in this group.)
SPECIFICATIONS Oil Temperature
3. Make test connections to brake pressure outer fitting test port.
65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
Brake Pump Standby Pressure
16 550 ± 345 kPa (165 ± 3.5 bar) (2400 ± 50 psi)
1/2 Turn of Adjustment Screw Pressure Change
1800 kPa (18 bar) (250 psi)
4. Start engine. Specification Engine—Speed...........................................................................Fast idle
5. Wait for brake pump standby pressure to reach maximum.
ESSENTIAL TOOLS JT01608 (1/8 X 7/16 M 37°) Quick Coupler (A) JT03011 (7/16 M 37° X 7/16 M ORB) (Parker No. 0101-8-12) Connector (B) SERVICE EQUIPMENT AND TOOLS
Specification Brake Pump Standby—Pressure...................................................... 16 550 ± 345 kPa (165 ± 3.5 bar) (2400 ± 50 psi)
6. If brake pressure does not meet specification, regulate with adjustment screw (C) on brake pump.
Temperature Reader Gauge 0—34 475 kPa (0—345 bar) (0—5000 psi)
1. Connect temperature reader. (See Temperature Reader Installation in this group.)
Specification 1/2 Turn of Adjustment Screw—Pressure Change......................................................... 1800 kPa (18 bar) (250 psi)
If brake pressure still does not meet specification, see Brake Pump Flow Test in this group.
2. Heat brake oil up to test specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
TX,9020,DU1560 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-25-21
544G, 624G, 644G Loader
062717
PN=555
Tests
T7817AI —UN—08SEP92
Brake Accumulator Precharge Test
SPECIFICATIONS
If ANY fluid is injected into skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.
Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
0 rpm
Brake Accumulator Precharge Pressure
3448 ± 241 kPa (34.5 ± 2.4 bar) (500 ± 35 psi)
1. If accumulator is to be charged on machine and has some nitrogen pressure left, apply either brake pedal 15 times at one second intervals.
ESSENTIAL TOOLS
NOTE: Oil can be heard flowing through brake valve for approximately five applications. After the hissing noise stops, the accumulator is still pressurized and requires more applications to fully relieve oil pressure.
JT01608 (1/8 x 7/16 M 37°) Quick Coupler (A) JT03103 (7/16 M 37° x 1-1/16 F 37°) Adapter (B) JT05687 (-6 F ORFS x 1-1/16 M 37°) Adapter (C) 38H1030 (-6 M ORFS x -6 M ORFS x -6 F ORFS) (Parker No. 6 R6LO-S) Tee (D)
Gauge 0—34 475 kPa (0—345 bar) (0—5000 psi)
2. Loosen hose fitting at brake valve inlet 1 turn. Move hose from side to side to bleed of any remaining oil pressure. Disconnect hose and install test fittings.
Temperature Reader
3. Heat brake oil to test specifications.
SERVICE EQUIPMENT AND TOOLS
CAUTION: Escaping fluid under pressure can penetrate skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.
Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 4. Run engine until pressure exceeds precharge test specifications on pressure gauge. Stop engine. Specification Engine—Speed............................................................................... 0 rpm
Continued on next page
TM1529 (27JUN17)
9020-25-22
TX,2025,UU1226 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=556
Tests Point of rapid decrease is brake accumulator precharge pressure.
5. Slowly operate brake valve and observe pressure gauge. Pressure must decrease slowly to brake accumulator precharge pressure specifications, then decrease rapidly to zero. Specification Brake Accumulator Precharge—Pressure........ 3448 ± 241 kPa (34.5 ± 2.4 bar) (500 ± 35 psi)
If brake accumulator precharge is not to specification, charge accumulator . (See Group 9020-20.) 6. Pump brake until gauge pressure is at zero before removing test fittings. TX,2025,UU1226 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-25-23
544G, 624G, 644G Loader
062717
PN=557
Tests
T7801AQ —UN—26AUG92
Brake Valve Pressure Test
SPECIFICATIONS
2. Apply either brake pedal 15 times at one second intervals.
Oil Temperature
65 ± 6°C (150 ± 10°F)
Maximum Brake Valve Pressure With Brakes Applied
3950—5000 kPa (40—50 bar) (575—725 psi)
Maximum Brake Valve Pressure With Brakes Released
0 kPa (0 bar) (0 psi)
CAUTION: Escaping fluid under pressure can penetrate skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.
ESSENTIAL TOOLS JT01608 (1/8 X 7/16 M 37°) Quick Coupler (A) JT03103 (7/16 M 37° X 1-1/16 F 37°) Adapter (B)
If ANY fluid is injected into skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.
JT05687 (-6 F ORFS x 1-1/16 M 37°) Adapter (C) 38H1030 (-6 M ORFS X -6 M ORFS X -6 F ORFS) (Parker No. 6 R6LO-S) Tee (D) SERVICE EQUIPMENT AND TOOLS
NOTE: Oil can be heard flowing through brake valve for approximately five applications. After the hissing noise stops, the accumulator is still pressurized and requires more applications to fully relieve oil pressure.
Temperature Reader Gauge 0—34 475 kPa (0—345 bar) (0—5000 psi)
1. Heat brake oil to test specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
3. Make test connections to outlet of brake valve.
(See Hydraulic Oil Warm-Up Procedure in this group.)
Continued on next page
TM1529 (27JUN17)
9020-25-24
TX,2025,UU1227 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=558
Tests
If brake valve regulated pressure is not to specification, check brake pump standby pressure in this group. Replace brake valve. (See Group 1060.)
4. Start engine. Depress brake pedal. Read outlet brake pressure on gauge. Pressure must be to specification. Specification Maximum Brake Valve—Pressure With Brakes Applied......................................................................3950—5000 kPa (40—50 bar) (575—725 psi) Pressure With Brakes Released ................................................................. 0 kPa (0 bar) (0 psi)
5. Remove test fittings. If oil is lost from hose bleed brakes. (See Hydraulic Brake Bleeding Procedure in Group 9020-20.)
TX,2025,UU1227 -19-16SEP92-2/2
TM1529 (27JUN17)
9020-25-25
544G, 624G, 644G Loader
062717
PN=559
Tests
T7801AS —UN—26AUG92
Brake Valve Leakage Test
(See Hydraulic Oil Warm-Up Procedure this group.)
SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Maximum Brake Valve Leakage Flow Rate With Brakes Released
14 ml/min (1/2 oz/min)
Maximum Brake Valve Leakage Flow Rate With Brakes Applied
22 ml/min (3/4 oz/min)
2. Stop engine. DO NOT depress brake pedal to discharge accumulator. 3. Disconnect each brake valve return line. Install plugs in lines. 4. Measure leakage from brake valve return ports.
ESSENTIAL TOOLS
If leakage is greater than specification, replace brake valve .
38H1146 (-6 M ORFS) (Parker No. 6 PNLO-S) Plug
Specification Maximum Brake Valve Leakage—Flow Rate With Brakes Released...........................................14 ml/min (1/2 oz/min) Flow Rate With Brakes Applied..................................................................22 ml/min (3/4 oz/min)
SERVICE EQUIPMENT AND TOOLS Temperature Reader Measuring Container Stop Watch
(See Group 1060.)
1. Heat brake oil to test specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
TX,9020,DU1561 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-25-26
544G, 624G, 644G Loader
062717
PN=560
Tests
T7801AT —UN—26AUG92
Brake Accumulator Inlet Check Valve Leakage Test
Removing inlet fitting from base inlet port will cause high pressure oil to be released out accumulator inlet port.
SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Maximum Brake Accumulator Inlet 1 mL/min (0.034 oz/min) (16 drops Check Valve Leakage per min)
Escaping fluid under pressure can penetrate skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use your hand.
ESSENTIAL TOOLS 38H1146 (-6 M ORFS) Plug SERVICE EQUIPMENT AND TOOLS Temperature Reader
If ANY fluid is injected into skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result.
Measuring Container Stop Watch
1. Heat hydraulic oil up to test specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure this group.) 2. Stop engine. DO NOT depress brake pedal to discharge accumulator. CAUTION: Accumulator inlet check valve is located between inlet fitting and base inlet port. Only remove inlet line from inlet fitting.
3. Disconnect inlet line from accumulator inlet fitting and plug line. 4. Measure leakage. If leakage is greater than specification, repair accumulator . Specification Maximum Brake Accumulator Inlet Check Valve—Leakage.................. 1 mL/min (0.034 oz/min) (16 drops per min)
(See Group 1060.) TX,2025,UU1229 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-27
544G, 624G, 644G Loader
062717
PN=561
Tests
Park Brake Pressure Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Park Brake Pressure With Park Brake Switch “OFF”
16 200 kPa ± 345 kPa (162 ± 3.5 bar) (2350 ± 50 psi)
ESSENTIAL TOOLS 38H1029 (-4 M ORFS x -4 F ORFS x -4 M ORFS) Tee SERVICE EQUIPMENT AND TOOLS Temperature Reader Gauge 20 500 kPa (205 bar) (3000 psi)
1. Connect temperature reader. (See Temperature Reader Installation Procedure in this group.) T7817AH —UN—31AUG92
2. Connect gauge and fittings. 3. Heat hydraulic oil up to specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-up Procedure in Group 9025-25.) 4. Park brake switch in "OFF" position. 5. Read park brake pressure.
7. Read park brake pressure.
Specification Engine—Speed..........................................................................Slow idle Park Brake—Pressure With Park Brake Switch “OFF”..................................................................... 16 200 kPa ± 345 kPa (162 ± 3.5 bar) (2350 ± 50 psi)
8. If pressure is too high or low, Do Brake Pump Pressure Test in this group. If pressure does not drop to 0 when park brake is ON remove and inspect park brake solenoid valve.
6. Park brake switch in "ON" position. TX,2025,UU1287 -19-17SEP93-1/1
TM1529 (27JUN17)
9020-25-28
544G, 624G, 644G Loader
062717
PN=562
Tests
T7817AJ —UN—08SEP92
Differential Lock Pressure Test
SPECIFICATIONS
3. Heat hydraulic system oil to test specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
Differential Lock Pressure
4102—4516 kPa (41—45 bar) (595—655 psi)
ESSENTIAL TOOLS
(See Hydraulic Oil Warm-Up Procedure in this group.) 4. Actuate differential lock. 5. Shift transmission to neutral. Run engine at specification.
JT03455 (7/16-20 M JIC x -4 F ORFS) Adapter
Specification Engine—Speed...........................................................................Fast idle
38H1414 (-4) (Parker No. 4FNL-S) Cap SERVICE EQUIPMENT AND TOOLS
Pressure must reach test specifications.
Gauge 0—6900 kPa (0—69 bar) (0—1000 psi) Temperature Reader
NOTE: The differential lock uses pressure oil from the pilot control circuit. 1. Connect test gauge and fitting to pressure reducing valve-to-differential lock line. Cap axle differential lock line at hinge plate. 2. Connect temperature reader. (See Temperature Reader Installation Procedure in this group.)
Specification Differential Lock—Pressure.....................................................................4102—4516 kPa (41—45 bar) (595—655 psi)
If pressure is not to specification, do Pressure Reducing Valve Test in Group 9025-25. If pilot pressure is to specification and differential lock is not working properly, do Differential Lock Leakage Test in this group. TX,2025,UU1230 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-29
544G, 624G, 644G Loader
062717
PN=563
Tests
T7817AK —UN—08SEP92
Differential Lock Leakage Test
SPECIFICATIONS
Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Minimum Differential Lock Pressure
3965 kPa (40 bar) (575 psi)
(See Differential Oil Warm-Up Procedure this group.)
ESSENTIAL TOOLS
2. Install gauge into tee (A) connecting line from pressure reducing valve-to-differential lock line (B). 3. Apply differential lock and read gauge.
38H1029 (-4 M ORFS x -4 F ORFS x -4 M ORFS) (Parker No. 4R6LO-S) Tee
If pressure is below minimum, do Differential Lock Pressure Test in this Group. Specification Engine—Speed..........................................................................Slow idle Minimum Differential Lock—Pressure............................................ 3965 kPa (40 bar) (575 psi)
SERVICE EQUIPMENT AND TOOLS Measuring Container Stop Watch
If Differential Lock Pressure Test is correct repair differential lock sealing rings . (See Group 0210.)
Tachometer/Temperature Reader
NOTE: An 550 kPa (5.5 bar) (80 psi) drop in pressure equals a 1 gpm leak in differential lock circuit.
NOTE: For dual differential locks, perform same test for both axles.
1. Heat differential oil to test specifications. TX,2025,UU1231 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-30
544G, 624G, 644G Loader
062717
PN=564
Tests
Axle Bearing Adjustment Check SPECIFICATIONS Maximum Axle Shaft Movement
0.38 mm (0.015 in.)
T6103AZ —UN—07MAY08
SERVICE EQUIPMENT AND TOOLS Magnetic Base Dial Indicator
1. Clean axle housing to bare metal where dial indicator base touches. 2. Install dial indicator as close to end of axle housing as possible. Dial indicator probe must contact axle flange. Dial indicator can be installed on bottom of axle housing. IMPORTANT: Depress brake pedal so axle does not turn when machine is raised.
If recorded measurement is above specification, remove differential and axle assembly.
3. Carefully raise machine until wheel on side being checked is off ground.
Specification Maximum Axle Shaft—Movement...................................................... 0.38 mm (0.015 in.)
4. Depress brake pedal. Turn dial indicator to "zero". Lower machine to ground. Make a record of dial indicator measurement. Repeat check to make sure measurement is accurate.
(See procedure in Group 0200.) Disassemble and inspect planetary to axle shaft cap screw, bronze thrust washer, bearings, outer seal. (See repair procedures in Groups 0210 and 0250.)
If recorded measurement does not repeat, check to make sure magnetic base of dial indicator is positioned correctly. TX,9020,UU1292 -19-30JAN95-1/1
No-Spin Differential Test the left wheel must be held firmly against the stop or the right wheel will not disengage freely.)
1. Raise the front wheels from the floor using the loader bucket or a floor jack. 2. Rotate both wheels in a forward direction as far as possible (normally, both wheels will stop after rotating a few inches).
6. Repeat steps 2—5 starting with the left wheel. If either wheel does not rotate or "cam" freely in both directions, the NO-SPIN differential must be removed for inspection.
3. Hold the left wheel forward (against the stop), and rotate the right wheel rearward. The left wheel must be held firmly against the stop or the right wheel will not disengage freely. 4. Rotate both wheels rearward as far as possible. Again both wheels will be stopped after rotating only a few inches. 5. Hold the left wheel in the rearward position (against the stop) and rotate the right wheel forward. (Again,
If a definite sound other than regular indexing or clicking sound is present when rotating one wheel, the NO-SPIN differential is not functioning properly and should be removed for inspection. 7. Drive the loader in a tight right and left circle on concrete. Tire scuffing on the inside tire is normal but little or no scuffing must occur on the outside tire. 902025,G24 -19-16SEP92-1/1
TM1529 (27JUN17)
9020-25-31
544G, 624G, 644G Loader
062717
PN=565
Tests
TM1529 (27JUN17)
9020-25-32
544G, 624G, 644G Loader
062717
PN=566
Section 9025 Hydraulic System Operation And Tests Contents Page Page
Group 05—Theory Of Operation Main Hydraulic Pump Operation................ 9025-05-1 Steering System Components Operation............................................... 9025-05-2 Steering Circuit Operation—Right Turn ....................................................... 9025-05-4 Priority Valve Operation............................. 9025-05-6 Steering Valve Operation......................... 9025-05-10 Steering Cylinder Operation .................... 9025-05-11 Secondary Steering System Operation............................................. 9025-05-11 Secondary Steering Inlet Manifold Operation............................................. 9025-05-12 Loader Hydraulic System Operation............................................. 9025-05-13 Pressure Reducing Valve—Secondary Boom Lower Operation............................................. 9025-05-14 Pilot Controller Operation (Serial Number —563542) .............................. 9025-05-15 Pilot Controller—Boom Float (Serial Number 563543—)................... 9025-05-18 Pilot Controller—Bucket Rollback (Serial Number 563543— ).................. 9025-05-20 Boom Section Operation ......................... 9025-05-22 Bucket And Boom Section Pilot Orifice Check Valve ............................. 9025-05-23 Bucket Section Operation—544G, 624G, And 644G.................................. 9025-05-24 Bucket Section Operation—544G TC And 544G LL.................................. 9025-05-26 Auxiliary Section Operation ..................... 9025-05-28 System Relief Valve Operation................ 9025-05-29 Circuit Relief Valve Operation.................. 9025-05-30 Anti-Cavitation Valve Operation............... 9025-05-32 Loader Cylinder Information .................... 9025-05-33 Return Filter Operation ............................ 9025-05-34 Hydraulic Reservoir Operation ................ 9025-05-35 Pin Disconnect Circuit Operation—544G TC........................... 9025-05-36 Ride Control Operation—In "On" Position................................................ 9025-05-38 Ride Control Operation—In "Off" Position................................................ 9025-05-39 Group 10—System Operational Checks Hydraulic Operational Checks ................... 9025-10-1 Hydraulic System Checks..........................9025-10-1 Steering System Checks .........................9025-10-10
Group 15—Diagnostic Information Diagnose Hydraulic System Malfunctions .......................................... 9025-15-1 Hydraulic Circuit Symbols.......................... 9025-15-8 Main Hydraulic System Component Location ................................................. 9025-15-9 Main Hydraulic System Schematic............................................ 9025-15-11 Hydraulic System Component Location-544G TC & 544G LL ............. 9025-15-13 Group 20—Adjustments Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy................... 9025-20-1 Boom Height Kickout Adjustment .............. 9025-20-2 Return-To-Dig Adjustment ......................... 9025-20-2 Ride Control Accumulator Discharge Procedure—If Equipped ............................................... 9025-20-3 Ride Control Accumulator Gas Charge Procedure—If Equipped ............................................... 9025-20-4 Ride Control Accumulator Draining Procedure .............................................. 9025-20-6 Group 25—Test JT05801 Clamp-On Electronic Tachometer Installation.......................... 9025-25-1 JT05800 Digital Thermometer Installation ............................................. 9025-25-1 Display Monitor Tachometer ...................... 9025-25-1 Hydraulic Oil Warm-Up Procedure .............................................. 9025-25-1 Main Hydraulic Pump Flow Test ................ 9025-25-2 Loader System And Circuit Relief Valve Pressure Test ............................... 9025-25-3 Hydraulic System Restriction Test.............. 9025-25-5 Loader Cylinder Drift Test .......................... 9025-25-6 Boom And Bucket Cylinder Leakage Test ......................................... 9025-25-7 Hydraulic Oil Cooler Restriction Test ........................................................ 9025-25-8 Steering Valve Leakage Test ..................... 9025-25-9 Steering Valve Drift Test .......................... 9025-25-10 Priority Valve Pressure Test..................... 9025-25-11 Priority Valve "LS" Port Flow Test............ 9025-25-12 Priority Valve Relief Cartridge Leakage Test ....................................... 9025-25-13 Secondary Steering Pump Relief Valve Pressure Test ............................. 9025-25-14 Continued on next page
TM1529 (27JUN17)
9025-1
544G, 624G, 644G Loader
062717
PN=1
Contents
Page
Secondary Steering Manifold Primary Check Valve Leakage Test ...................................................... 9025-25-15 Secondary Steering Manifold Secondary Check Valve Leakage Test ....................................... 9025-25-16 Pilot Control Valve Pressure Test (Serial Number —563542)................... 9025-25-17 Pilot Control Valve Pressure Test (Serial Number 563543—)................... 9025-25-20 Pressure Reducing Valve Pressure Test ...................................................... 9025-25-23 Cycle Time Test ....................................... 9025-25-24 Hydraulic Oil Filter Inspection Procedure ............................................ 9025-25-25 Pin Disconnect Solenoid Valve Leakage Test ....................................... 9025-25-25 Pin Disconnect Cylinder Leakage Test ...................................................... 9025-25-26
TM1529 (27JUN17)
9025-2
544G, 624G, 644G Loader
062717
PN=2
Group 05
Theory Of Operation Main Hydraulic Pump Operation
INNER SEAL A
C
HOUSING B
F
PORT PLATE D
OUTER E SEAL
DRIVE GEAR
PRESSURE PLATE CHANNEL G SEAL
I
H
IDLER J GEAR K FLANGE PLATE T6567PH
F
PRESSURE PLATE
N
MAIN HYDRAULIC PUMP
H INLET
B HOUSING L OUTLET PRESSURE M INLET PRESSURE
The main hydraulic pump is a fixed displacement, external gear-type pump. The pump is driven at engine speed by the transmission. The pump shafts are supported by bushings in the port plate (C) and flange plate (K). A pressure plate (F) is located between the gear faces and the port and flange plates. As the drive gear (D) turns the idler gear (J), the gear teeth come out of mesh. Oil flows from the reservoir through the inlet (H) into the cavity between the gear teeth. As the gears continue to rotate, the oil becomes trapped between the gear teeth and the housing (B). The trapped oil is then carried to the pump outlet (I). Oil is forced out the outlet to supply the hydraulic functions. As the gears re-mesh,
T6567PH —19—15OCT97
I OUTLET
they form a seal to prevent oil from flowing between the gears and back to the inlet. The pump uses outlet pressure oil to load the pressure plates against the gear faces. This controls internal leakage to maintain pump displacement. Outlet pressure fills the area bounded by the channel seal (G) to force the pressure plate against the high pressure area of the gear faces. Pump shaft lubrication is achieved by routing outlet pressure oil into the area between the gear shafts and the bushings. The oil is collected at the end of the shafts in the hollow areas in the port and flange plates and routed back to return. TX,902505,D25 -19-29JUL87-1/1
TM1529 (27JUN17)
9025-05-1
544G, 624G, 644G Loader
062717
PN=569
Theory Of Operation
Steering System Components Operation NOTE: See Main Hydraulic System Component Location drawing in Group 9025-15 for location of components.
steered, the steering valve routes flow to the steering cylinders to articulate the machine.
The main hydraulic system consists of a fixed-displacement pump supplying a closed center steering system and an open center loader system. The components of the steering system are:
• Steering valve • Priority valve • Steering cylinders The main hydraulic pump draws oil through a suction screen from the reservoir. Outlet flow from the pump flows to the priority valve. The priority valve supplies flow, on demand, to the steering valve. When the machine is
When the machine is not being steered, or if pump flow is greater than steering flow, the priority valve supplies flow to the loader system. An optional secondary steering system is used to provide momentary steering flow in the event of a flow loss in the main hydraulic system. The secondary steering pump and motor is a small gear pump driven by an electric motor. The secondary steering inlet manifold is a valve connected to the steering valve inlet. The manifold contains two check valves which isolate secondary steering flow and a pressure switch which controls operation of the secondary steering motor. TX,9025,HH836 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-05-2
544G, 624G, 644G Loader
062717
PN=570
Theory Of Operation
TM1529 (27JUN17)
9025-05-3
544G, 624G, 644G Loader
062717
PN=571
Theory Of Operation
Steering Circuit Operation—Right Turn INLET A
PRIORITY B VALVE
R-PORT J
EF-PORT I C
STEERING VALVE
LS-PORT H
F RIGHT CYLINDER
A INLET PRESSURE B STEERING PRESSURE
E LEFT CYLINDER
C RETURN PRESSURE T7800BA
O
STEERING CIRCUIT (RIGHT TURN)
Continued on next page
TM1529 (27JUN17)
9025-05-4
T7800BA —19—09FEB98
D LEFT WORK PORT
RIGHT WORK PORT G
TX,9025,HH837 -19-06JAN94-1/2
544G, 624G, 644G Loader
062717
PN=572
Theory Of Operation Pump flow enters the priority valve (B) at the inlet (A) and flows past the spool to the steering valve (C). The right end of the priority valve spool has a pilot orifice. The pilot orifice supplies steering inlet pressure oil to the right end of the priority valve spool. The inlet pressure oil loads the spool against the spring on the left end of the spool plus load-sensing pressure from the LS-port (H). As long as the difference between load-sensing and inlet pressure is less than the spring force, the priority valve routes oil to the steering valve. Oil in the steering valve flows through the sleeve and spool assembly to the gerotor, then back through the sleeve and spool and out through the right work port (G). The LS-port on the steering valve supplies load-sensing flow to the priority valve. The priority valve contains an orifice to meter the load-sensing flow as the machine is being steered. Load-sensing flow plus spring force work with the orificed flow to the steering valve. Together they
keep the priority valve spool shifted to the right against the pilot oil on the right end of the spool. The steering flow is then routed to the two double-acting steering cylinders (F and E). Return flow from the steering cylinders is routed back through the left work port (D) to the steering valve. From there it flows through the sleeve and spool and back to the return filter. When steering is stopped, the LS-port is opened to return through the steering valve. LS-port flow through the steering valve is also used as a warm-up circuit for the steering valve. Pressure to the steering valve is kept just high enough to overcome spring force and move the priority valve spool to the left. With the spool shifted to the left, pump flow is routed to the loader system through the EF-port (I). TX,9025,HH837 -19-06JAN94-2/2
TM1529 (27JUN17)
9025-05-5
544G, 624G, 644G Loader
062717
PN=573
Theory Of Operation
Priority Valve Operation
SPRING B
D P-PORT
ORIFICE C
E SPOOL
J RELIEF PRESSURE K STEERING CIRCUIT PRESSURE L RETURN PRESSURE
R-PORT A
B
E D
G EF-PORT F CF-PORT H LS-PORT I LOADER ACTUATED T6567OF
G
H
F C
M
PRIORITY VALVE (NEUTRAL)
The priority valve is a pressure control valve that maintains priority pressure to the closed center steering valve. With the steering valve in neutral, flow through it is blocked and all flow through the priority valve is directed out the EF-port (G) to the loader control valve. With the engine off, the spool (E) is pushed to the right by the spring (B). The passage to the EF-port is blocked while the passage to the CF-port (F) is open. When the machine is first started, all pump flow is routed to the steering valve which blocks the flow. With the flow blocked, the pressure increases. Steering inlet pressure is supplied through the pilot orifice to the right end of the spool. This causes the priority valve spool to shift to the left against the spring and open the EF-port. As long as the steering valve is in neutral, just enough pressure is maintained at the steering valve to keep the priority valve spool shifted to the left.
The operating pressure in the loader system has no effect on the operation of the priority valve. With the loader actuated in relief (I), the priority valve will not shift until the machine is steered. Flow through the priority valve spool passes from the CF-port through the orifice (C) and into the LS-port (H). It flows through the steering valve LS passage which is routed to return when the steering valve is in neutral. This provides a warm-up circuit for the steering valve to prevent binding of the steering valve due to oil temperature extremes. The priority valve has a test port located on the side of the valve section to test P-Port pressure.
Continued on next page
TM1529 (27JUN17)
T6567OF —19—09OCT97
A
9025-05-6
TX,9025,HH844 -19-16SEP92-1/3
544G, 624G, 644G Loader
062717
PN=574
Theory Of Operation
ORIFICE C
P-PORT D
E SPOOL
SPRING B
J STEERING INLET PRESSURE K STEERING WORK PORT PRESSURE L RETURN PRESSURE
R-PORT A E
B
D
G EF-PORT
A
F
H G
H LS-PORT T6567OG
I FULL STEER RATE
T6567OG —19—09OCT97
F CF-PORT
C M
PRIORITY VALVE (MID-TURN)
When the machine is steered, load-sensing pressure from the steering valve flows through the orificed LS-port (H) in the priority valve. Load-sensing pressure plus spring (B) force move the spool to the right against the pilot pressure on the right end of the spool. This restricts flow to the loader through the EF-port (G) while the CF-port (F) is opened to the steering valve. The load-sensing circuit is a control circuit that routes steering work port pressure to the spring side of the priority valve spool. It allows the priority valve spool to sense the pressure that is required to steer the unit under varying conditions.
valve. When steering at the full steer rate (I), the orifice opens to an unrestricted passage. At low engine speed, the spool will shift to the full right position, directing all flow to the steering valve. At fast idle, the steering system can use about one-half of the pump flow. Therefore, the excess oil flows to the loader control valve. The load-sensing circuit receives the majority of its flow from the load-sensing orifice in the steering valve. Some flow is also supplied from the CF-port through orifice (C) in the priority valve spool.
During normal steering conditions, oil is metered into the load-sensing circuit through an orifice in the steering Continued on next page
TM1529 (27JUN17)
9025-05-7
TX,9025,HH844 -19-16SEP92-2/3
544G, 624G, 644G Loader
062717
PN=575
Theory Of Operation
D P-PORT POPPET B
E SPOOL
C SPRING
R-PORT A
C
E
I SCREEN
D
A
J STEERING RELIEF PRESSURE
F
H B
K REDUCED PRESSURE
T6567OH —19—09OCT97
H F LS-PORT G CF-PORT EF-PORT
G
I
L RETURN PRESSURE T6567OH
M
PRIORITY VALVE (STEERING CYLINDER BOTTOMED)
When the machine is steered to a full turn, the frames bottom against the steering stops. To limit steering system pressure, a relief system is built into the priority valve assembly. When the frames bottom, the pressure in the steering cylinders increases. This pressure is sensed at the LS-port (H). When the pressure in the LS-port increases enough to push poppet (B) off its seat, oil in the load sensing circuit flows to return through the R-port (A). Load-sensing pressure is limited to the pressure setting of the relief valve.
Pressure to the steering valve (pilot pressure), which is sensed at the right end of the priority valve spool (E), continues to increase until it can move the spool to the left against the load-sensing pressure plus spring force. At this time, all oil flows out of the EF-port (G) to the loader control valve. If the loader is being operated while steering, the loader function will slow until the machine reaches the steering stops. At that time, the loader cycle speed will increase until the machine is steered again. TX,9025,HH844 -19-16SEP92-3/3
TM1529 (27JUN17)
9025-05-8
544G, 624G, 644G Loader
062717
PN=576
Theory Of Operation
TM1529 (27JUN17)
9025-05-9
544G, 624G, 644G Loader
062717
PN=577
Theory Of Operation
Steering Valve Operation A NEUTRAL B
STEERING CYLINDERS
C ANTI-CAVITATION VALVES D
LOAD SENSE PORT TO PRIORITY VALVE E GEROTOR
T7799CK
L WORK PRESSURE OIL
G RETURN
O
T7799CK —19—09FEB98
J STEERING SHAFT
K SYSTEM PRESSURE OIL
G RETURN H I SLEEVE SPOOL
F FROM PRIORITY VALVE
M TRAPPED OIL N RETURN PRESSURE OIL
STEERING VALVE OPERATION
The steering valve (O) consists of a spool (I) inside a sleeve (H) within a housing. When steering wheel is not moving, the valve is in the neutral (A) position. In neutral, the spool and sleeve are aligned so that oil flow through the valve is blocked. The steering cylinders (B) are held stationary by trapped oil in the left and right work ports. When the steering valve is turned to the right, the spool rotates relative to the sleeve, and opens passages which allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor (E) causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the valve where it is directed out the right work port to the respective ends of the steering cylinders. A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces a small leak into the pressure side of the steering valve. Its purpose is to dampen the initial pressure surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is closed off.
Return oil flows back in through the left work port through the spool and sleeve assembly to return. The load-sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load-sensing circuit between the steering valve and the priority valve through the LS-port. When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve, until the sleeve stops the flow to the gerotor. At this point, the valve is back in the neutral position and will remain there until the steering wheel is moved again. The valve has a variable steering rate which is proportional to the speed the steering wheel is rotated. A variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes approximately seven turns (variable orifice small) stop-to-stop versus three turns (variable orifice large) when turning the steering wheel quickly. Four anti-cavitation balls are located inside the spool. (Not shown.) TX,9025,HH839 -19-15DEC92-1/1
TM1529 (27JUN17)
9025-05-10
544G, 624G, 644G Loader
062717
PN=578
Theory Of Operation
T6567OQ —19—22MAR89
Steering Cylinder Operation
The steering cylinders use a snap ring (D) and threaded retainer (E) to retain the rod guide (H) to the barrel (K). The piston (L) is fastened to the rod (G) by a nut (A).
seals against the barrel with an O-ring. The rod is sealed against the rod guide with a lip-type inner seal (J) and a U-cup outer seal (I).
The piston uses a single wear ring (B) with a cap seal (C) to seal between the piston and barrel. The rod guide TX,902505,D31 -19-30JUL87-1/1
Secondary Steering System Operation NOTE: See Main Hydraulic System Component Location drawing in Group 9025-15 for location of components. The secondary steering system provides flow in the event of a loss of main pump flow. The key switch provides a power source to the controller. The controller contains the electronic circuitry to control the operation of the secondary steering system. When the machine is started, the start switch button is depressed, sending a signal to the controller that the machine is in use.
If main pump flow is lost, the decrease in system pressure closes a pressure switch in the inlet manifold. The closed pressure switch signals the controller to energize the relay. The relay energizes the pump and motor which provides flow through the inlet manifold. The dash mounted indicator is also energized, indicating the system is operating. Two check valves in the inlet manifold isolate the secondary steering pump flow from the rest of the system.
TX,9025,HH840 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-05-11
544G, 624G, 644G Loader
062717
PN=579
Theory Of Operation
Secondary Steering Inlet Manifold Operation
J E G B C
K
SWITCH E PISTON D
LEVER H
J
LS-PORT I SECONDARY CHECK VALVE J
I MAGNET G
SPRING C ORIFICE B A INLET
F
K
OUTLET F
L STEERING PRESSURE
T6567OL —19—07NOV97
PRIMARY CHECK VALVE K
M LS PRESSURE O
INLET MANIFOLD
N RETURN PRESSURE
T6567OL
is higher than load-sensing pressure. This pressure difference keeps the switch (E) in the open position.
The secondary steering inlet manifold isolates the main steering system and provides a signal to the controller to warn of low steering pressure. During normal steering operation, pump flow enters from the priority valve through the inlet (A), unseats the primary check valve (K), and flows to the steering valve through the outlet (F). Inlet pressure is sensed on top of the piston (D) through the orifice (B) to move the piston down against the spring (C) and load-sensing pressure. With the main hydraulic pump supplying flow, the steering inlet pressure
If main pump flow is lost, the primary check valve seats. The pilot pressure in the priority valve drops, causing the priority valve spool to move to the full steering position. The pressure through the orifice drops, causing the spring, plus load-sensing pressure through the LS-port (I), to move the piston up. The magnet (G) pulls the lever (H), which closes the switch.
Continued on next page
TM1529 (27JUN17)
9025-05-12
TX,9025,DU1562 -19-17SEP93-1/2
544G, 624G, 644G Loader
062717
PN=580
Theory Of Operation
When the switch closes, the controller energizes the secondary steering relay. The relay energizes the secondary steering motor which drives the pump. Pump
flow unseats the secondary check valve (J) providing temporary steering flow. TX,9025,DU1562 -19-17SEP93-2/2
Loader Hydraulic System Operation
• Auxiliary (optional) • Outlet
NOTE: See Main Hydraulic System Component Location drawing in Group 9025-15 for location of components. The loader hydraulic system is a pilot-operated, open center system which is supplied with flow from the fixed displacement main hydraulic pump. The pilot control system is a low pressure, closed center hydraulic system which is supplied with flow from a pressure compensated, variable displacement brake pump. The loader system components are:
• Loader control valve • Bucket cylinder • Boom cylinders • Pilot controller(s) The pilot control system consists of the pressure reducing valve manifold. Flow from the main hydraulic pump not used by the steering system leaves the priority valve EF-port. It flows to the inlet port plate of a stack-type loader control valve. The loader control valve sections are (from rear to front):
• Inlet • Boom • Bucket
The loader control valve is a tandem version spool-type, open center valve which routes flow to the boom, bucket or auxiliary cylinders (not shown) when the respective spools are shifted. Flow from the brake pump is routed to the pressure reducing valve manifold where the brake pump outlet pressure is reduced to pilot circuit pressure. The pressure reducing valve manifold supplies flow to the pilot controllers. The pilot controllers route flow to either end of each spool valve section in the loader control valve to control spool stroke. A hose from the boom head end hydraulic line runs back to the pressure reducing valve manifold. It supplies a secondary pressure source to operate the pilot control system so the boom can be lowered if the engine is off. The return circuit for the main hydraulic system consists of the return filter and the oil cooler. The return filter uses a spin-on filter element which attaches to a filter housing. The bypass valve is located in the housing with a switch indicating when the filter is restricted. A portion of the filtered return oil is routed out a tee fitting to the oil cooler. The cooler is an oil-to-air heat exchanger. Oil from the filter and cooler returns to the nonpressurized reservoir. TX,9025,HH841 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-05-13
544G, 624G, 644G Loader
062717
PN=581
Theory Of Operation
Pressure Reducing Valve—Secondary Boom Lower Operation C O
M I
G K
P
J
DIFFERENTIAL LOCK SOLENOID VALVE D
H F
E PARK BRAKE SOLENOID VALVE
L R B
TO RETURN B
PRESSURE REDUCING VALVE A
PILOT ORIFICE C
F TO BRAKE VALVE
R DIFFERENTIAL LOCK RETURN CHECK VALVE PARK G BRAKE ORIFICE
P TEST PORT
I PARK BRAKE SWITCH
N TEST PORT O FROM BOOM CIRCUIT
L TO AXLE
M TO PILOT CONTROLLER(S)
J TO PARK BRAKE
S PILOT PRESSURE OIL T RETURN PRESSURE OIL U TRAPPED OIL
TXC7799CM
The secondary boom lower circuit is a solenoid operated circuit which allows the boom to lower with the engine off.
It uses trapped oil in the head end of the boom cylinders as a flow source when the engine is off.
Continued on next page
TM1529 (27JUN17)
K CHECK VALVE
T7799CM —19—15JAN98
Q BOOM DOWN SOLENOID VALVE
H INLET
9025-05-14
TX,9025,HH842 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=582
Theory Of Operation
With the key off and the engine not running, the boom lower solenoid (Q) electromagnet energizes. The spool is pulled to the left allowing trapped oil to flow through the sleeve to the pressure reducing valve (A). The pressure
reducing valve meters the flow to the pilot controller(s) to maintain pilot pressure at controller(s) so main control valve spool can be moved to lower boom or tip bucket. TX,9025,HH842 -19-16SEP92-2/2
Pilot Controller Operation (Serial Number —563542) M DETENT PLATE
C
A CONTROL LEVER B BOOM RAISE DETENT
L BOOM FLOAT DETENT
F
D
PUSH K PLATE SPRING J GUIDE
E G RETURN SPRING
"T" PORT C
SPOOL H
E "P" PORT T6567PC —19—05NOV97
MAIN I SPRING
D "C" PORT
"A" PORT F "A" PORT F
T6567PC
D "C" PORT E "P" PORT Q
N END VIEW
P RETURN PRESSURE
PILOT CONTROLLER — BOOM FLOAT
The pilot controller is an assembly of four, two-position, two-way, lever-operated valves. The standard controller has a single lever which moves fore and aft as well as side to side. A dual lever controller is available as an option where each lever moves fore and aft. In neutral, the return spring (G) holds the spool assembly closed, blocking flow from the P-port (E) to the C-port (D). During operation, pilot pressure oil from the pressure reducing valve enters the controller housing at the P-port. With the control lever pushed forward (boom float), the push plate (K) moves a pin which contacts the spring retainer (J). The upper spring retainer (J) compresses the main spring (I) which moves the spool (H) down, allowing flow out the A-port (F). The spool will meter flow until the upper spring retainer contacts the lower spring retainer. The spool is shown in full open position.
The boom float function uses an electromagnetic detent. When the control lever is moved forward to the float position, a groove in the detent plate (M) passes over the boom float detent pin (L). The pin is held upward by the electromagnet with enough force to hold the detent plate but, can be manually disengaged by pulling back on the control lever. The boom raise function uses an optional electromagnetic detent. The operation of this detent is identical to the boom float detent. The end view (N) shows the work port location of the four-function pilot controller. When the valves are in neutral, the flow is blocked from the P-port to the work ports (F and D). The work ports are opened to return through the T-port (C). The spring area in the pilot controller housing is connected to the T-port on the bottom of the valve.
Continued on next page
TM1529 (27JUN17)
O PILOT PRESSURE
9025-05-15
TX,902505,D38 -19-30JUL87-1/2
544G, 624G, 644G Loader
062717
PN=583
Theory Of Operation
CONTROL A LEVER
RETURN-TO- L DIG DETENT SPRING GUIDES
C
B DETENT PLATE
D
G PUSH PLATE K J
E
F
"T" PORT C D "B" PORT
MAIN L SPRING "D" PORT F
E "P" PORT "D" PORT F SPOOL H M METERING T6567PD
T6567PD —19—05NOV97
N END VIEW D "B" PORT E "P" PORT
O PILOT PRESSURE P RETURN PRESSURE
Q PILOT CONTROLLER — BUCKET ROLLBACK
The pilot controller is shown in the bucket rollback position during return-to-dig operation. With the control lever (A) partially held in the return-to-dig position, the push plate (G) contacts a pin which contacts the upper spring guide (K). The upper spring guide compresses the main spring (I) against the lower spring guide (J) which moves the spool (H) into a metering (M) position. The pressure in the pilot controller work port controls the amount of stroke of the function spool in the loader control valve. As the control lever is moved further from neutral, the main spring compression is greater. The controller work port pressure acts on the bottom of the spool against the main spring compression to regulate the pressure delivered to the function spool.
The optional return-to-dig is controlled by a bucket mounted linkage which controls a switch. When the bucket is dumped, the switch is closed and the return-to-dig detent (L) is energized. With the control lever moved to the full left position, the groove on the detent plate (B) passes over the pin in the return-to-dig detent (L). The energized magnet, along with the spring, hold the pin in the upward position. The detent will release when the bucket reaches the pre-set position and the detent switch on the bucket linkage opens. The detent can also be manually released by moving the control lever to the right. The optional two-function controller is designed and operated the same as the four-function controller.
TX,902505,D38 -19-30JUL87-2/2
TM1529 (27JUN17)
9025-05-16
544G, 624G, 644G Loader
062717
PN=584
Theory Of Operation
TM1529 (27JUN17)
9025-05-17
544G, 624G, 644G Loader
062717
PN=585
Theory Of Operation
Pilot Controller—Boom Float (Serial Number 563543—) CONTROL LEVER A
PULL PLATE N
B PUSH BAR
ELECTRIC COIL M C PLUNGER
D SPRING GUIDE MECHANIC FEEL POSITION L
E METERING SPRING F RETURN SPRING G SPOOL ASSEMBLY
C
O PILOT PRESSURE OIL P PRESSURE FREE OIL (RETURN)
T
C
P
K
J
I
"A" PORT
"P" PORT
B
P
"C" PORT D
T101974
A—Control Lever B—Push Bar C—Plunger D—Spring Guide E—Metering Spring F— Return Spring
Q
PILOT CONTROLLER - BOOM FLOAT
G—Spool Assembly H—End View I— “C” Port J— “P” Port K—“A” Port L— Mechanical Feel Position
M—Electric Coil N—Pull Plate O—Pilot Pressure Oil P—Pressure Free Oil (Return) Continued on next page
TM1529 (27JUN17)
9025-05-18
A
H END VIEW
T101974 —19—14JAN98
A
Q—Pilot Controller—Bucket Rollback
TX,9025,TJ25 -19-26SEP97-1/2
544G, 624G, 644G Loader
062717
PN=586
Theory Of Operation The pilot controller is an assembly of four, two-position, two-way, lever-operated valves. The standard controller has a single lever which moves fore and aft as well as side to side. A dual lever controller is available as an option where each lever moves fore and aft. In neutral, return spring (F) holds spool assembly (G) closed, blocking flow from “P” port (J) to “C” port (I). During operation, pilot pressure oil (O) from the pressure reducing valve enters the pilot controller housing at “P” port. With control lever (A) pushed forward, push bar (B) pushes plunger (C) down which contacts spring guide (D). The spring guide compresses both return spring (F) and metering spring (E). This moves spool assembly (G) down into a metering position, allowing oil to flow out “A” port (K). With the spool assembly moved down all the way, full pilot pressure will be available to shift the boom control valve spool. Approximately 500 psi is needed to shift the boom spool to the float position. The boom float function uses an electromagnetic detent. When the control lever is moved forward to the float position, pull plate (N) comes in contact with electric coil (M). The pull plate is held downward by the electromagnet
with enough force to hold the control lever in the float position, but it can be manually disengaged by pulling back on the control lever. An optional return to carry feature is also available. With return to carry activated and the pilot controller in the float position, the boom will float down until it reaches a present height. The magnetic detent will release when the boom reaches the preset position and the return to carry switch on the boom opens. The boom lower function of the pilot controller also contains a mechanical feel position (L). The operator will feel a slight resistance in the pilot controller when going from boom lower to float. The boom raise function also uses an electromagnetic detent. The operation of this detent is identical to the boom float detent. The end view (H) shows the work port location of the single-lever four-function pilot controller. When the valves are in neutral, the flow is blocked from the “P” port to the work ports. The work ports are opened to return through the spring area in the pilot controller which is connected to the “T” port on the bottom of the valve. TX,9025,TJ25 -19-26SEP97-2/2
TM1529 (27JUN17)
9025-05-19
544G, 624G, 644G Loader
062717
PN=587
Theory Of Operation
Pilot Controller—Bucket Rollback (Serial Number 563543— ) A CONTROL LEVER
PULL PLATE L
PUSH BAR K
ELECTRIC COIL J
B PLUNGER
SPRING GUIDE I C METERING SPRING RETURN SPRING H
D SPOOL ASSEMBLY
D
B
P
M PILOT PRESSURE OIL
A—Control Lever B—Plunger C—Metering Spring D—Spool Assembly E—“B” Port
O
F
E
"D" PORT
"P" PORT
"B" PORT
PILOT CONTROLLER - BUCKET ROLLBACK
F— “P” Port G—“D” Port H—Return Spring I— Spring Guide J— Electric Coil
K—Push Bar L— Pull Plate M—Pilot Pressure Oil N—Pressure Free Oil (Return)
The pilot controller is shown in the bucket rollback position during return to dig operation. Continued on next page TM1529 (27JUN17)
N PRESSURE FREE OIL (RETURN) T101922 —19—14JAN98
T101922
G
9025-05-20
O—Pilot Controller—Bucket Rollback
TX,9025,TJ24 -19-26SEP97-1/2
544G, 624G, 644G Loader
062717
PN=588
Theory Of Operation
With control lever (A) partially held in the return-to-dig position, push bar (K) pushes plunger (B) down which contacts spring guide (I). The spring guide compresses both return spring (H) and metering spring (C) which moves spool assembly (D) down, into a metering position, allowing oil to flow out “D” port (G). The pressure in the pilot controller work port controls the amount of stroke of the function spool in the loader control valve. As the control lever is moved further from neutral, the compression of the metering spring (C) is greater. The controller work port pressure acts on the bottom of spool assembly (D) which pushes up on the metering spring to regulate the pressure delivered to the bucket control valve spool.
The return-to-dig function is controlled by a bucket mounted linkage which controls a switch. When the bucket is dumped, the switch closes and the return-to-dig detent is energized. When the control lever is moved to the full left position, pull plate (L) comes in contact with electric coil (J). The pull plate is held downward by the electromagnet with enough force to hold the control lever in the bucket rollback position. The detent will release when the bucket reaches the pre-set position and the switch on the bucket linkage opens. The detent can also be manually released by moving the control lever to the right. The optional two-lever controller is designed and operated the same as the single lever controller. TX,9025,TJ24 -19-26SEP97-2/2
TM1529 (27JUN17)
9025-05-21
544G, 624G, 644G Loader
062717
PN=589
Theory Of Operation
Boom Section Operation D B
C
G M
A
F
K ANTI-CAVITATION VALVE B
L
J
H
BOOM LOWER WORK PORT C
BOOM RAISE WORK PORT D PLUG E
FROM PILOT CONTROLLER A
TO PILOT CONTROLLER F
G K NEUTRAL PASSAGE
L SPOOL
I J LIFT CHECK
H RETURN PASSAGE
CENTERING SPRINGS
POWER PASSAGE (BLOCKED FROM BUCKET SECTION)
N OPERATING PRESSURE TXC7799CU
P
BOOM SECTION — BOOM LOWER
O RETURN PRESSURE
T7799CU —19—15JAN98
M BOOST SPRING
of the valve housing. The boom lower work port (C) is The boom section of the loader control valve is an open center, four-position, four-way spool-type valve. The work equipped with an anti-cavitation valve (B) while the boom raise work port (D) is equipped with a plug. ports from the pilot controller connect to the end caps Continued on next page TX,9025,HH863 -19-16SEP92-1/2 TM1529 (27JUN17)
9025-05-22
544G, 624G, 644G Loader
062717
PN=590
Theory Of Operation
Pump flow from the inlet port plate enters the neutral passage (K). In neutral, oil flows around the boom spool (L) lands to the boom section. When the boom lower function is operated, pilot pressure oil enters passage (A) in the end cap and shifts the boom spool to the right against the centering springs (G). The greater the pilot pressure, the farther the boom spool will shift. A small amount of pilot circuit leakage is allowed between the boom spool and the return passage (H) as pilot circuit warm-up oil. When the boom spool shifts, the neutral passage is blocked, causing the pressure to increase in the power passage (I) and unseat the lift check (J). Pressure oil then flows around the spool lands and out of the boom lower work port. The boom lower work port is connected to the rod-end of the boom cylinders. As the cylinders retract,
return oil in the head end of the cylinders flows back through the boom raise work port, around the spool lands and to return through the return passage (H). When the valve is moved to the float position, both work ports are connected to the return passage (H). The tandem valve functions become evident when bucket rollback and boom lower are both activate. Priority is given to the bucket section. Pilot pressure shifts the boom spool and allows oil to return to the tank through the boom head end port. This allows the boom to lower as bucket rollback is occurring, but not before the bucket has returned to level position first. This will also cause the loader raise function to stop while bucket rollback is held over relief.
TX,9025,HH863 -19-16SEP92-2/2
T7688AG —19—12FEB92
Bucket And Boom Section Pilot Orifice Check Valve
Orifice check valve is installed in control valve pilot cap of bucket and boom section. The O-ring (D) end is installed in control valve pilot cap. This orifice (A) dampens the control valve spool movement to stop unwanted bucket
or boom movement when the pilot controller lever is centering itself. It also stops unwanted bucket or boom correction in other direction as the lever kicks out of bucket return-to-dig, or boom height kickout function. TX,9025,DU1563 -19-17SEP93-1/1
TM1529 (27JUN17)
9025-05-23
544G, 624G, 644G Loader
062717
PN=591
Theory Of Operation
Bucket Section Operation—544G, 624G, And 644G D
C
B E
K
G F
A
H
J I
BUCKET DUMP WORK PORT C
BUCKET ROLLBACK WORK PORT D
CIRCUIT RELIEF B VALVE
E CIRCUIT RELIEF VALVE TO PILOT CONTROLLER F
A FROM SPOOL L PILOT CONTROLLER
G CENTERING SPRINGS I NEUTRAL PASSAGE J LIFT CHECK
H RETURN PASSAGE M OPERATING PRESSURE N RETURN PRESSURE
T6567PA
O
BUCKET SECTION – BUCKET DUMP
Continued on next page
TM1529 (27JUN17)
9025-05-24
T6567PA —19—09OCT97
POWER K PASSAGE
TX,9025,HH846 -19-10NOV93-1/2
544G, 624G, 644G Loader
062717
PN=592
Theory Of Operation The bucket section of the loader control valve is an open center, three-position, four-way spool-type valve. The work ports of the pilot controller are connected to the end caps of the valve housing. The bucket dump work port (C) is equipped with a pilot-operated circuit relief valve with an anti-cavitation feature. The bucket rollback work port (D) is also equipped with a pilot-operated circuit relief valve with an anti-cavitation feature. Pump flow from the inlet port plate enters the neutral passage (I). In neutral, oil flows around the bucket spool (L) lands to the auxiliary section (if equipped) or to the outlet port plate. When the bucket dump function is engaged, pilot pressure oil from the pilot controller enters the end cap through passage (A) to shift the bucket spool to the right against the centering springs (G). The greater
the pilot pressure value, the farther the bucket spool will shift to the right. A small amount of pilot circuit leakage is allowed between the bucket spool and the return passage (H) as pilot circuit warm-up oil. With the bucket spool shifted, the neutral passage (I) is blocked causing the pressure to increase in the power passage (K) which unseats the lift check (J). The oil flows through the metering notches in the bucket spool to the rod end of the bucket cylinder through the bucket dump work port (C). As the bucket cylinder retracts, return oil flows from the head end of the cylinder back through the bucket rollback work port (D), across the bucket spool metering notches into the return passage. The metering notches control the oil flow across the bucket spool lands to regulate the function speed. TX,9025,HH846 -19-10NOV93-2/2
TM1529 (27JUN17)
9025-05-25
544G, 624G, 644G Loader
062717
PN=593
Theory Of Operation
Bucket Section Operation—544G TC And 544G LL D
C
B E G F
A
H
J I
BUCKET ROLLBACK WORK PORT D
BUCKET DUMP WORK PORT C CIRCUIT RELIEF VALVE B
E CIRCUIT RELIEF VALVE TO PILOT CONTROLLER F
A FROM PILOT CONTROLLER
G CENTERING SPRINGS
L SPOOL J LIFT CHECK
I NEUTRAL PASSAGE
H RETURN PASSAGE M OPERATING PRESSURE N RETURN PRESSURE
TXC7004AI
O
BUCKET SECTION – REGENERATIVE DUMP
The bucket section of the loader control valve is an open center, four-position, four-way spool-type valve. The work
ports of the pilot controller are connected to the end caps of the valve housing. The bucket dump work port (C) is
Continued on next page
TM1529 (27JUN17)
T7004AI —19—15JAN98
POWER K PASSAGE
9025-05-26
TX,9025,HH847 -19-10NOV93-1/2
544G, 624G, 644G Loader
062717
PN=594
Theory Of Operation equipped with a pilot-operated circuit relief valve with an anti-cavitation feature. The bucket rollback work port (D) is also equipped with a pilot-operated circuit relief valve with an anti-cavitation feature. Pump flow from the inlet port plate enters the neutral passage (I). In neutral, oil flows around the bucket spool (L) lands to the auxiliary section (if equipped) or to the outlet port plate. When the bucket dump function is engaged, pilot pressure oil from the pilot controller enters the end cap through passage (A) to shift the bucket spool to the right against the centering springs (G). The greater the pilot pressure value, the farther the bucket spool will shift to the right. With the bucket spool shifted, the neutral passage (I) is blocked causing the pressure to increase in the power passage (K) which unseats the lift check (J). The oil flows through the metering notches in the bucket spool to the
head end of the bucket cylinder through the bucket dump work port (C). As the bucket cylinder extends, return oil flows from the rod end of the cylinder back through the bucket rollback work port (D), across the bucket spool metering notches into the return passage. The metering notches control the oil flow across the bucket spool lands to regulate the function speed. When the spool is moved to the regenerative dump position, both ends of the cylinder are connected to the power passage. This pressurizes both ends of the cylinder with equal pressure. Since the head end of the piston has a larger area than the rod end, a greater force is exerted to extend the cylinder. As the cylinder extends, the return oil from the rod end flows back to the valve, combines with the oil from the pump, and flows out to the head end of the cylinder. This provides a faster bucket dump cycle time but reduces the cylinder force. TX,9025,HH847 -19-10NOV93-2/2
TM1529 (27JUN17)
9025-05-27
544G, 624G, 644G Loader
062717
PN=595
Theory Of Operation
Auxiliary Section Operation
D
C
E G F
A
H
L
I K
"A" WORK PORT C
"B" WORK PORT D CIRCUIT E RELIEF VALVE
CIRCUIT RELIEF B VALVE
TO PILOT CONTROLLER F
A FROM SPOOL L PILOT CONTROLLER I LIFT CHECK J POWER PASSAGE
H RETURN PASSAGE
M OPERATING PRESSURE N RETURN PRESSURE
T6567PB
O
AUXILIARY SECTION – FUNCTION OPERATING
The auxiliary section is an open center, three position, four-way spool-type valve. The work ports of the
pilot controller are connected to the end caps of the valve housing. The "A" and "B" work ports (C and D) Continued on next page
TM1529 (27JUN17)
T6567PB —19—09OCT97
NEUTRAL K PASSAGE
G CENTERING SPRINGS
9025-05-28
TX,902505,D44 -19-21MAR89-1/2
544G, 624G, 644G Loader
062717
PN=596
Theory Of Operation are equipped with pilot operated circuit reliefs with anti-cavitation (B and E). Pump flow from the inlet port plate enters the neutral passage (K). In neutral, oil flows around the auxiliary spool (L) lands to the outlet port plate. When the "A" work port is pressurized, pilot pressure oil from the pilot controller enters the end cap through passage (A) to shift the auxiliary spool to the right against the centering springs (G). The greater the pilot pressure valve, the farther the auxiliary spool will shift to the right. A small amount of pilot circuit leakage is allowed between the auxiliary spool and the return passage (H) as pilot circuit warm-up oil.
With the auxiliary spool shifted, the neutral passage is blocked, causing the pressure to increase in the power passage (J), which unseats the lift check (I). The oil flows through the metering notches in the auxiliary spool to the function cylinder(s) through the "A" work port. Return oil flows back in through the "B" work port, across the auxiliary spool metering notches and into the return passage. The metering notches control the oil flow across the auxiliary spool lands to regulate function speed.
TX,902505,D44 -19-21MAR89-2/2
System Relief Valve Operation RETURN B
E SNUBBER
C FLOATING SEAT
B
INLET A
POPPET F
D NORMAL OPERATION B RETURN
G PLUNGER
H SPRING
A
I ADJUSTER B
K RELIEF PRESSURE
J RELIEF OPERATION
L OPERATING PRESSURE
T6567OT —19—09OCT97
INLET A
A
M RETURN PRESSURE T6567OT
N
SYSTEM RELIEF VALVE
The loader hydraulic system uses a direct-acting system relief valve located in the inlet port plate of the loader control valve assembly. During normal operation (D), loader circuit pressures are below the relief pressure of the system relief valve. The floating seat (C) and snubber (E) remain seated against the poppet (F), sealing inlet (A) oil from the return (B) passage.
During relief operation (J), loader circuit pressures exceed the system relief setting. Relief pressure oil in the inlet forces the snubber and floating seat open against the spring (H). The plunger remains stationary where it maintains a volume of oil on the right of the snubber orifice. The snubber orifice dampens the movement of the floating seat. The relief pressure is adjusted by the position of the adjuster (I). TX,902505,D46 -19-21MAR89-1/1
TM1529 (27JUN17)
9025-05-29
544G, 624G, 644G Loader
062717
PN=597
Theory Of Operation
Circuit Relief Valve Operation
B RETURN B
A D
WORKPORT A G POPPET D B RETURN
C SEAT
H NORMAL OPERATION
E
WORKPORT
WORKPORT
A
B
A
B RETURN
A
G PILOT POPPET
F PIN I
D POPPET J RELIEF OPERATION
PILOT OPERATION
T6567OU —19—09OCT97
K RELIEF PRESSURE L OPERATING PRESSURE M RETURN PRESSURE N T6567OU
CIRCUIT RELIEF VALVE (WITH ANTI-CAVITATION)
The bucket rollback and dump, and both auxiliary work ports of the loader control valve use a pilot-operated circuit relief with an anti-cavitation feature.
Grooves cut into the pin, bleed oil on the right side of poppet D) to return through passage (E).
During normal operation (H), the poppet (D) is positioned against the seat (C) to seal the work port (A) oil from the return (B) passage.
During relief operation (J), oil on the right side of the poppet is drained to return causing pressure in the work port to overcome the poppet spring force. Relief pressure oil flows from the work port to return across the poppet.
As the circuit pressures approach the relief pressure setting, the pin (F) forces the pilot poppet (G) off its seat. Continued on next page
TM1529 (27JUN17)
9025-05-30
TX,9025,HH854 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=598
Theory Of Operation
B RETURN
WORKPORT A
B
A
B
A
C POPPET F NORMAL OPERATION
B RETURN
WORKPORT A
D PIN
E SPRING
T6567OV —19—26AUG97
G ANTI-CAVITATION OPERATION H RETURN PRESSURE G
CIRCUIT RELIEF VALVE (WITH ANTI-CAVITATION)
I LOW PRESSURE
T6567OV
If the work port pressure in the circuit drops below return pressure, the anti-cavitation feature of the circuit relief valve operates. During normal operation (F), the poppet (C) remains closed against its seat causing the work port (A) to be sealed from the return (B) passage.
If cavitation occurs, the oil pressure in the work port and in the spring (E) area of the poppet drops below return pressure. Return pressure oil works against the shoulder of the poppet to force it open against the spring.
TX,9025,HH854 -19-16SEP92-2/2
TM1529 (27JUN17)
9025-05-31
544G, 624G, 644G Loader
062717
PN=599
Theory Of Operation
Anti-Cavitation Valve Operation RETURN A
D POPPET A
WORK PORT B
SEAT C
B G NORMAL OPERATION RETURN A
E SPRING A
POPPET F
B
B
J RETURN PRESSURE H ANTI-CAVITATION OPERATION
K LOW PRESSURE T6567OX
T6567OX —19—09OCT97
I OPERATING PRESSURE
L
ANTI-CAVITATION VALVE
The boom section of the loader control valve uses an anti-cavitation valve in the boom lower work port. The anti-cavitation prevents cylinder cavitation when the pump flow cannot match the boom down speed. During normal operation (G), the popper (D) is held against the seat (C) by spring force plus oil pressure acting on the back side of the poppet. With the poppet seated, the work port (B) is sealed from the return (A) passage.
When the boom is lowered faster than the pump can supply flow, the work port pressure drops below the return pressure. With the work port pressure below return pressure, the return pressure works against the shoulder of the poppet (F), causing it to open against the spring (E). Return pressure oil flows into the work port to prevent cylinder cavitation. TX,902505,D51 -19-21MAR89-1/1
TM1529 (27JUN17)
9025-05-32
544G, 624G, 644G Loader
062717
PN=600
Theory Of Operation
T7799CS —19—08SEP92
Loader Cylinder Information
The boom and bucket cylinders are a 180 series metric design. They use a bolt-on rod guide. The piston (J) threads on to rod (L) and is retained by key (A). The piston seals against barrel (K) with a center mounted cap seal (C). Two wear rings (J) are located on each side of the cap seal.
The rod guide seals against the barrel with an O-ring. The rod guide seals against the rod with a lip-type inner seal (D) and a U-cup outer seal (E). A wiper seal (E) cleans the rod when it is retracted. TX,9025,HH848 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-05-33
544G, 624G, 644G Loader
062717
PN=601
Theory Of Operation
Return Filter Operation INLET A
A HOUSING B PISTON G VALVE C
I
A
C
K
D SPRING
SPRING F J J TO COOLER
H TERMINAL I ELEMENT
T6567OK —19—26AUG97
K L RESTRICTED FLOW
K OUTLET O RETURN FILTER T6567OK
The hydraulic return filter removes contaminants from the hydraulic system oil. The filter housing contains a bypass valve and a filter restriction switch. Under normal operation, return flow from the steering, loader and priority valve enters the inlet (A), flows through the filter element (I), up through the filter cannister and out the outlet (K). If the pressure differential between the inlet and outlet increases past a set level due to cold oil or a partially restricted filter element, inlet pressure in the housing (B) increases, moving the piston (C) down against spring (D) force and outlet pressure. The piston contacts the terminal (H), completing a circuit which causes the filter restriction indicator light to glow.
M SEMI-RESTRICTED FLOW N RETURN FLOW
As the filter element becomes plugged, the pressure differential between the inlet and outlet increases. Inlet pressure is sensed on one side of the valve (G) which opens against spring (F) force and outlet pressure. The return oil then bypasses the filter while the restriction indicator light glows. Under normal operation, the restriction indicator light will glow when operating the hydraulic functions with cold oil. However, if the restriction indicator light continues to glow after the oil reaches operating temperature, the return filter is being bypassed. Extended operation in the bypass mode will cause damage to the hydraulic system.
TX,902505,D53 -19-30JUL87-1/1
TM1529 (27JUN17)
9025-05-34
544G, 624G, 644G Loader
062717
PN=602
Theory Of Operation
T7799AD —19—31AUG92
Hydraulic Reservoir Operation
TX,9020,HH829 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-05-35
544G, 624G, 644G Loader
062717
PN=603
Theory Of Operation
Pin Disconnect Circuit Operation—544G TC
ROD END G TUBE
H PIN
WORK A PORT
F PISTON B WORK PORT
F PISTON
H PIN
C SOLENOID VALVE BODY
PRESSURE E PORT
T7799CN —19—15JAN98
D RETURN PORT
I INLET PRESSURE OIL J RETURN PRESSURE OIL
TXC7799CN
Brake pump pressure oil enters the solenoid valve through the pressure port (E). When the solenoid is not energized, pressure oil flows out work port (B) to the center of the cylinder holding the pins in the extended position. The cylinder rod ends are joined by tube (G) to return through work port (A).
When the pin disconnect switch is depressed, the solenoid coil is energized, and the spool moves to the left. This allows pressure oil to flow out work port (A) to the rod ends of the cylinder, retracting the pins (H). Return oil then flows into work port (B) and out return port (D). TX,9025,HH849 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-05-36
544G, 624G, 644G Loader
062717
PN=604
Theory Of Operation
TM1529 (27JUN17)
9025-05-37
544G, 624G, 644G Loader
062717
PN=605
Theory Of Operation
Ride Control Operation—In "On" Position HEAD END C SOLENOID
ROD END SOLENOID B TO BOOM CYLINDER A ROD END
G
D
C
F
D ORIFICE
E
E TO ACCUMULATOR
H A
I PRESSURE OIL F CHECK VALVE
J TRAPPED OIL K RETURN OIL T7832AM1
A—Rod End of Boom Cylinder B—Rod End Solenoid C—Head End Solenoid
G TO BOOM CYLINDER HEAD END
TO CONTROL H VALVE RETURN D—Orifice E—To Accumulator F— Check Valve G—To Boom Cylinder Head End
NOTE: Ride control must be reactivated each time the key switch is turned OFF. When the machine is shut off with the switch in the ON position the switch has to be cycled from the ON to OFF to ON position to become activated. The ride control system consists of a solenoid valve (C) which allows flow to and from the boom cylinder head end into a gas charged piston type accumulator (E). Solenoid valve (B) also connects the cylinder rod end to return oil hose of main control valve. When traveling over rough terrain at high speed with loaded or empty bucket, the bucket produces a pitching motion, which is common to wheel loader. Ride control allows the boom cylinder head end oil (J) to move into an accumulator and the oil coming out of accumulator is orificed to reduce rebounding. This cushion action reduces pitching motion and improves machine ride and reduces tire flexing.
H—To Control Valve Return I— Pressure Oil J— Trapped Oil
T7832AM1 —19—14NOV97
B
K—Return Oil
The components of the ride control system are:
• Ride Control Valve (located inside loader frame) • Ride Control Accumulator • ON/OFF Switch (located on right dash) • Relay (located under right dash on fuse block) In the ON position, pressure spikes from the boom cylinder head end flow freely into the accumulator. When pressure in the accumulator exceeds the boom cylinder head end, flow is then orificed (D) from the accumulator back into the head end. In the ON position the rod end of the boom cylinder (A) is open to return. Ride control can be left engaged during bucket loading, but may be turned OFF if more rigid operation is desired. Boom cannot be powered down with ride control ON. Oil going to the boom cylinder rod end is bypassed to return through the ride control solenoid.
The solenoid (B) of boom cylinder rod end is open to pull in or push out return oil (K) as required. TX,9025,HH1015 -19-03FEB95-1/1
TM1529 (27JUN17)
9025-05-38
544G, 624G, 644G Loader
062717
PN=606
Theory Of Operation
Ride Control Operation—In "Off" Position HEAD END C SOLENOID
ROD END SOLENOID B
D
TO BOOM CYLINDER A ROD END
G C
F
D ORIFICE
E
H
E TO ACCUMULATOR
A
I PRESSURE OIL F CHECK VALVE
J TRAPPED OIL K RETURN OIL T7832AL1
A—Rod End of Boom Cylinder B—Rod End Solenoid C—Head End Solenoid
G TO BOOM CYLINDER HEAD END
TO CONTROL H VALVE RETURN D—Orifice E—To Accumulator F— Check Valve G—To Boom Cylinder Head End
In the OFF position, normal loader functions occur except, pressure spikes in trapped oil circuit (J) will be absorbed in the accumulator (E). The accumulator will store oil pressure at a level equal to the highest boom circuit pressure.
H—To Control Valve Return I— Pressure Oil J— Trapped Oil
T7832AL1 —19—14NOV97
B
K—Return Oil
This circuit can be bled off by turning the ride control switch from OFF to ON with key ON then pressing boom lower switch with hydraulic lever in float position.
The solenoid valve (C) and check valve (F) allow higher pressure oil to enter accumulator circuit but prevents it from returning. TX,9025,HH1016 -19-03FEB95-1/1
TM1529 (27JUN17)
9025-05-39
544G, 624G, 644G Loader
062717
PN=607
Theory Of Operation
TM1529 (27JUN17)
9025-05-40
544G, 624G, 644G Loader
062717
PN=608
Group 10
System Operational Checks Hydraulic Operational Checks This procedure is designed so the mechanic can make a quick check of the hydraulic system using a minimum amount of diagnostic equipment. If you need additional information, read Theory of Operation, Group 9025-05.
If problem is indicated (NOT OK), you will be given repair required and Group location or CTM number. If verification is needed, you will be given next best source of information:
A location will be required which is level and has adequate space to complete the checks.
Group 10 (System Operational Checks)
The engine and all other major components must be at operating temperature for some checks. Locate system check in the left column and read completely, following this sequence from left to right. Read each check completely before performing.
Group 15 (Diagnostic Information) Group 20 (Adjustments) Group 25 (Tests) Component Technical Manual (CTM)
At the end of each check, if no problem is found (OK:), that check is complete or an additional check is needed. 27T,9025,K86 -19-03MAR93-1/26
• 1
Hydraulic System Checks
IMPORTANT: Hydraulic oil must be at operating temperature for these checks. 27T,9025,K86 -19-03MAR93-2/26
Hydraulic System Warm-Up Procedure
Run engine at fast idle. Hold a hydraulic function over relief to heat oil. Periodically cycle all hydraulic functions to distribute warm oil. Repeat procedure until oil is at operating temperature. FEEL: Hydraulic reservoir must be uncomfortable to hold your hand against [approximately 50°C (120°F)].
OK: Check complete.
27T,9025,K86 -19-03MAR93-3/26
Hydraulic Pump Performance Check
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.) Run engine at fast idle.
OK: Check complete.
Turn steering wheel rapidly until frames are against stop. Hold approximately 22 N (5 lb force) pressure on steering wheel.
NOT OK: Go to Priority Valve High Pressure Check .
With bucket flat on ground, actuate boom raise. Time how long it takes to raise boom to full height.
IF OK: Do Steering System Leakage Check in this group.
LOOK: Boom must raise to full height in less than: 544G/644G—9 seconds 624G—8 seconds
IF OK: Do Main Hydraulic Pump Flow Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
9025-10-1
27T,9025,K86 -19-03MAR93-4/26
544G, 624G, 644G Loader
062717
PN=609
System Operational Checks Control Valve Lift Check
T6601AA —UN—19OCT88
Run machine at slow idle. Ride control OFF (if equipped). With bucket partially dumped, lower boom to raise front of machine. Slowly move boom control lever to boom lower position. Slowly move bucket control lever to bucket dump position. LOOK: Boom must not raise before moving down.
OK: Check complete.
Bucket must not rollback before dumping.
NOT OK: Repair lift checks in loader control valve. (See Group 3160). 27T,9025,K86 -19-03MAR93-5/26
Bucket Rollback Circuit Relief Valve Check
T6564OD —UN—19OCT88
Position bucket at a 45° angle against an immovable object. Engage transmission in 3rd speed forward.
OK: Check complete.
LOOK: Bucket angle must NOT change more than 4° to 8°.
NOT OK: Do Loader System and Circuit Relief Valve Test in Group 9025-25. 27T,9025,K86 -19-03MAR93-6/26
Bucket Dump Circuit Relief Valve Low Pressure Check
T6601AA —UN—19OCT88
Raise front of unit which bucket at 45° angle. Backdrag with bucket while observing bucket angle.
OK: Go to next check.
LOOK: Bucket must not rollback.
NOT OK: Do Loader System and Circuit Relief Valve Test in Group 9025-25. Continued on next page
TM1529 (27JUN17)
9025-10-2
27T,9025,K86 -19-03MAR93-7/26
544G, 624G, 644G Loader
062717
PN=610
System Operational Checks Pilot Control Valve Float Check
T6601AA —UN—19OCT88
T7827AI1 —UN—24AUG92
Run engine at slow idle. With the bucket partially dumped, lower boom to raise front of unit. Push control lever to the float detent position and release lever.
OK: Check complete.
LOOK: Front of unit must lower to the ground and valve must remain in float position when lever is released.
NOT OK: Do Pilot Control Valve Pressure Test in Group 9025-25. 27T,9025,K86 -19-03MAR93-8/26
Boom Cylinder Drift Check
T6601AB —UN—19OCT88
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.) Raise bucket about 1 m (3 ft) above ground with bucket level. Stop engine. Place a piece of tape on cylinder rod at least 51 mm (2 in.) from rod guide. Measure cylinder rod drift for 1 minute. LOOK: For 544G and 624G, cylinder must drift less than 3 mm (0.12 in.) in one minute. OK: Check complete. For 644G, cylinder must drift less than 2 mm (0.08 in.) Continued on next page
TM1529 (27JUN17)
9025-10-3
NOT OK: Go to next check. 27T,9025,K86 -19-03MAR93-9/26
544G, 624G, 644G Loader
062717
PN=611
System Operational Checks Boom Cylinder Leakage Check
T6601AM —UN—19OCT88
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this Group.) Dump bucket until teeth or cutting edge is perpendicular to the ground. Raise boom until cutting edge is about 1 m (3 ft) above ground. Stop engine. Measure drift from tooth or cutting edge to ground for 1 minute. Wait 10 minutes. Measure drift from tooth or cutting edge to ground for 1 minute.
OK: Drift is approximately the same between first and second measurement. Repair loader control valve or circuit relief valve.
LOOK: Compare the drift rate between the first measurement and the second measurement.
NOT OK: If drift is considerably less on second measurement, repair cylinder. 27T,9025,K86 -19-03MAR93-10/26
Bucket Cylinder Drift Check
T6601AB —UN—19OCT88
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.) Raise bucket about 305 mm (1 ft) off ground with bucket level. Stop engine. Place a piece of tape on cylinder rod at least 51 mm (2 in.) from rod guide. Measure cylinder rod drift for 1 minute. LOOK: For 544G and 624G, cylinder must drift less than 7 mm (0.27 in.) in one minute. OK: Check complete. For 644G, cylinder must drift less than 6 mm (0.236 in.). Continued on next page
TM1529 (27JUN17)
9025-10-4
NOT OK: Go to next check. 27T,9025,K86 -19-03MAR93-11/26
544G, 624G, 644G Loader
062717
PN=612
System Operational Checks Bucket Cylinder Leakage Check
T6552AC —UN—19OCT88
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.) Raise bucket about 1 m (3 ft) off ground with bucket level. Stop engine. Place a support under boom. Measure drift from tooth or cutting edge to ground for 1 minute. Wait 10 minutes. Measure drift from tooth or cutting edge to ground for 1 minute.
OK: Drift is approximately the same between first and second measurement. Repair loader control valve or circuit relief valve . Go to Group 3160.
LOOK: Compare the drift rates between the first measurement and the second measurement.
NOT OK: Drift is considerably less on second measurement. Repair cylinder. Go to Group 3160. 27T,9025,K86 -19-03MAR93-12/26
Boom Lower Solenoid Valve Check
T7773BO1 —UN—05AUG92
Engine running. Raise boom to full height. Roll bucket back. Stop engine. Hold boom down button down. Move control lever to bucket dump position. Move control lever to boom lower position.
OK: Check complete.
LOOK: Bucket must dump and boom must lower.
NOT OK: Do Boom Down Solenoid Check in Group 9015-00.
Continued on next page
TM1529 (27JUN17)
9025-10-5
27T,9025,K86 -19-03MAR93-13/26
544G, 624G, 644G Loader
062717
PN=613
System Operational Checks Boom Lower Check Valve Leakage Check
T6601AB —UN—19OCT88
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.) Put bucket level and position about 1.2 m (4 ft) above ground. Place a piece of tape on cylinder rod at least 51 mm (2 in.) from rod guide. Run engine at slow idle.
OK: Check complete.
LOOK: Bucket must not drift up.
NOT OK: Replace boom lower check valve. 27T,9025,K86 -19-03MAR93-14/26
Pilot Controller Check
T7827AI2 —UN—24AUG92
T7827AD —UN—24AUG92
Stop engine. Turn key switch to OFF position. Move control lever to all positions and then release.
OK: Check complete.
LOOK: Lever must return to neutral when released from all positions.
NOT OK: Repair pilot control valve. Go to Group 3160.
Continued on next page
TM1529 (27JUN17)
9025-10-6
27T,9025,K86 -19-03MAR93-15/26
544G, 624G, 644G Loader
062717
PN=614
System Operational Checks Return-To-Dig Check
T7827AI3 —UN—24AUG92
Run engine at slow idle. Position bucket fully dumped just above ground level. Move control lever to return-to-dig detent position and release. LOOK: Bucket must rollback to the level position and control lever must return to neutral. OK: Check complete. NOTE: If bucket is in a rolled back position when key is turned ON, control lever must be returned to neutral manually if placed in the return-to-dig detent position. After bucket is dumped once, return-to-dig will work normally.
NOT OK: Do Return-to-Dig Checks in Group 9015-00. 27T,9025,K86 -19-03MAR93-16/26
Boom Height Kickout Check—If Equipped
T7825BL —UN—24AUG92
Run engine at slow idle. Position bucket flat on ground. Move control lever to boom raise detent position and release.
OK: Check complete.
LOOK: Boom must raise to the set height and stop. Control lever must return to neutral. NOT OK: Do Boom Height Kickout Check in Group 9015-00. Continued on next page
TM1529 (27JUN17)
9025-10-7
27T,9025,K86 -19-03MAR93-17/26
544G, 624G, 644G Loader
062717
PN=615
System Operational Checks Pin Disconnect Cylinder Check (544G—TC Only)
T7773BO2 —UN—05AUG92
Run engine at slow idle. Lower boom to ground. Push and hold pin disconnect switch.
OK: Check complete.
LOOK: Pin disconnect cylinder must retract both pins, while switch is depressed.
NOT OK: Hold a screwdriver blade against the end of the solenoid valve and check for magnetism with the switch pushed. See Pin Disconnect Circuit in Group Section 9015-15 if the problem is electrical. See Group 9025-15 if the problem is hydraulic .
Continued on next page
TM1529 (27JUN17)
9025-10-8
27T,9025,K86 -19-03MAR93-18/26
544G, 624G, 644G Loader
062717
PN=616
System Operational Checks Cycle Time Check
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.)
OK: Check complete.
544G LL And 544G TC Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time..............................................................6.2 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.........................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time....................................................................2.1 seconds Bucket Rollback (Boom at Full Height)—Maximum Cycle Time....................................................................2.7 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.......................................................................2.5 seconds Number of Turns ............................................................................................. 3.75 turns 544G Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time..............................................................6.2 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.........................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time....................................................................1.6 seconds Bucket Rollback (Boom at Full Height)—Maximum Cycle Time....................................................................2.5 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.......................................................................2.5 seconds Number of Turns ............................................................................................. 3.75 turns 624G Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time..............................................................6.2 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.........................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time....................................................................1.8 seconds Bucket Rollback (Boom at Full Height)—Maximum Cycle Time....................................................................2.5 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.......................................................................2.5 seconds Number of Turns ............................................................................................. 3.75 turns 644G Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time..............................................................6.4 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.........................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time....................................................................2.0 seconds Bucket Rollback (Boom at Full Height)—Maximum Cycle Time....................................................................3.0 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.......................................................................2.5 seconds Number of Turns ............................................................................................. 3.75 turns NOT OK: Go to Slow Hydraulic Functions in Group 9025-15. Continued on next page
TM1529 (27JUN17)
9025-10-9
27T,9025,K86 -19-03MAR93-19/26
544G, 624G, 644G Loader
062717
PN=617
System Operational Checks
• 2
Steering System Checks
27T,9025,K86 -19-03MAR93-20/26
Steering Valve Check
T6471AQ —UN—19OCT88
Run engine at slow idle. Turn steering wheel until frames are at maximum right (A) and then left (B) positions. LOOK: Frames must move smoothly in both directions. When steering wheel is stopped, frames must stop. FEEL: Excessive effort must not be required to turn steering wheel.
OK: Check complete.
NOTE: It is normal for steering to drift from stops when steering wheel is released.
NOT OK: Go to next check. 27T,9025,K86 -19-03MAR93-21/26
Steering System Leakage Check
T6601AC —UN—19OCT88
Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-Up Procedure in this group.) Run engine at fast idle. Turn steering wheel rapidly until frames are against stops. Jerk wheel to stop, then hold approximately 22 N (5 lb force) pressure on steering wheel. Count steering wheel revolutions for 1 minute. Repeat test in opposite direction. LOOK: Steering wheel should rotate less than 5 rpm.
OK: Check complete.
NOTE: Steering wheel may rotate faster than specification, if oil is cold. Use good NOT OK: Do Steering judgment; excessive steering wheel rpm does not mean steering will be affected. System Leakage Test in Group 9025-25 to isolate A new valve may exceed specification. the leakage. 27T,9025,K86 -19-03MAR93-22/26
Priority Valve Low Pressure Check
Park machine on gravel surface. Run engine at fast idle. Hold brake pedal down. Steer machine to the right and left as far as possible.
OK: Go to next check.
LOOK: Machine must turn at least half way to the right and left stops.
NOT OK: Do Priority Valve Pressure Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
9025-10-10
27T,9025,K86 -19-03MAR93-23/26
544G, 624G, 644G Loader
062717
PN=618
System Operational Checks Priority Valve High Pressure Check
T7827AI3 —UN—24AUG92
T7825BJ —UN—21AUG92
Run engine at fast idle. Steer to steering stop and release wheel. Roll bucket back and hold over relief and observe engine rpm. Turn wheel to steering stop and hold, observe engine rpm.
OK: Check complete.
LOOK: Steering stall engine rpm must be higher than hydraulic stall rpm.
NOT OK: Priority pressure is set too high. Do Priority Valve Pressure Test in Group 9025-25. 27T,9025,K86 -19-03MAR93-24/26
Secondary Steering System Check (If Equipped)
T6601AC —UN—19OCT88
IMPORTANT: Do not operate secondary steering pump for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur. Park unit on a hard level surface with steering straight ahead. Stop engine. Being careful not to start the engine, turn key to start position and release. Steer unit to right and left. LOOK: Unit must steer approximately half way to stops in both directions.
OK: Check complete.
IMPORTANT: DO NOT operate secondary steering pump for more than 15 seconds NOT OK: If secondary with the steering in neutral or damage to the pump and motor can occur. steering pump and motor do not operate, do Secondary Steering and System Operational Checks in Group 9015-00. If secondary steering pump and motor operate but unit does not steer, do Secondary Steering Pump Relief Valve Pressure Test in Group 9025-25. Continued on next page
TM1529 (27JUN17)
9025-10-11
27T,9025,K86 -19-03MAR93-25/26
544G, 624G, 644G Loader
062717
PN=619
System Operational Checks Secondary Steering System Primary Check Valve Check
Run engine at fast idle.
Turn steering wheel rapidly until frames are against stops. Hold approximately 22 N (5 lb force) pressure on steering wheel. Actuate a hydraulic function and hold over relief. Return control lever to neutral. FEEL: Steering wheel must not "kickback" as hydraulic function is released.
OK: Check complete.
NOTE: Steering wheel "kickback" is normal on units without secondary steering.
NOT OK: Do Secondary Steering Manifold Block Primary Check Valve Leakage Test in Group 9025-25. 27T,9025,K86 -19-03MAR93-26/26
TM1529 (27JUN17)
9025-10-12
544G, 624G, 644G Loader
062717
PN=620
Group 15
Diagnostic Information Diagnose Hydraulic System Malfunctions
• Step 2. Hydraulic System Operational Checkout
NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem:
• Step 3. •
Procedure (See Group 9025-10.) Diagnose Malfunctions Charts (See Group 9025-15.) Step 4. Tests and/or Adjustments (See Group 9025-20 and/or 9025-25.)
• Step 1.
Operational Check Out Procedure (See Group 9005-10.)
Symptom
Problem
Solution
Noisy Hydraulic Pump
Low oil supply or wrong viscosity
Fill reservoir with recommended oil. (See Section I, Group IV.)
Plugged or pinched suction line
Clean or replace line.
Air in oil
Check for foamy oil. Tighten connections. Replace O-rings and/or lines.
Plugged suction strainer
Inspect and clean strainer in reservoir.
Loose or missing hydraulic line clamps Tighten or replace clamps.
Slow Hydraulic Functions
Hydraulic lines in contact with frame
Inspect and repair.
Worn or damaged pump
Do Hydraulic Pump Performance Check in Group 9025-10. Do Hydraulic Pump Flow Test in Group 9025-25.
Cold oil
Warm oil up.
Slow engine speed
Adjust engine speed control linkage. Check fast idle speed in Group 9010-20.
Suction line air leak
Check for foamy oil.
Low oil supply
Add recommended oil. (See Section I, Group IV.)
Wrong oil viscosity
Use recommended oil. (See Section I, Group IV.)
Oil leaking past cylinders or control valve Blocked or damaged line
Check cylinder drift in Group 9025-10. Inspect lines.
Faulty or misadjusted pressure reducing valve
Do Pressure Reducing Valve Pressure Test in Group 9025-25.
Faulty pilot control valve
Do Pilot Control Valve Pressure Test in Group 9025-25.
Binding loader control valve spool
Inspect valve. (See Group 3160.)
Continued on next page
TM1529 (27JUN17)
9025-15-1
TX,9025,DU1569 -19-17SEP93-1/7
544G, 624G, 644G Loader
062717
PN=621
Diagnostic Information Symptom
Problem
Solution
Leaking secondary steering secondary Do Secondary Steering Manifold Block check valve Secondary Check Valve Leakage Test in Group 9025-25. Leaking steering valve
No Steering or Hydraulic Functions Low oil level
Do Steering Valve Neutral Leakage Test in Group 9025-25. Add recommended oil. (See Section I, Group IV.)
Plugged suction strainer
Clean strainer in reservoir.
Failed hydraulic pump
Remove and inspect return filter for metal pump particles.
Failed main hydraulic pump dampener Do Main Hydraulic Pump Flow Test in drive Group 9025-25.
No Hydraulic Functions Steering Normal
Boom Float Function Does Not Work
One Hydraulic Function Does Not Work
Failed main hydraulic pump drive
Remove main hydraulic pump and inspect drive gear. (See Group 3160.)
Shorted boom lower solenoid valve ground wire or wrong ground wire connected to solenoid. Boom lower solenoid valve stuck in actuated position
Disconnect wires from solenoid valve and check operation of hydraulics. Remove and inspect solenoid valve. (See Group 3160.)
Faulty or misadjusted pressure reducing valve.
Do Pressure Reducing Valve Pressure Test in Group 9025-25.
Stuck open system relief valve
Replace relief valve. (See Group 3160.)
Low pilot control pressure
Do Pressure Reducing Valve Pressure Test in Group 9025-25.
Faulty pilot control valve
Do Pilot Control Valve Pressure Test in Group 9025-25.
Loader control valve spool binding in bore
Inspect and repair valve. (See Group 3160.)
Faulty pilot control valve
Do Pilot Control Valve Pressure Test in Group 9025-25.
Stuck open circuit relief valve
Replace valve. (See Group 3160.)
Oil leaking past cylinder packings
Do Boom, Bucket, and Clam Cylinder Leakage Test in Group 9025-25.
Blockage in oil lines or valve
Inspect lines for damage. Disconnect and inspect lines for internal blockage.
Continued on next page
TM1529 (27JUN17)
9025-15-2
TX,9025,DU1569 -19-17SEP93-2/7
544G, 624G, 644G Loader
062717
PN=622
Diagnostic Information Symptom
Low Hydraulic Power
Function Drifts Down
Boom Drifts Up
Problem
Solution
Loader control valve spool stuck in bore
Inspect and repair valve. (See Group 3160.)
Leakage within work circuit
Do Cylinder Drift Check in Group 9025-25.
Low system relief valve setting
Do Loader System and Circuit Relief Valve Pressure Test in Group 9025-25.
Low circuit relief valve setting
Do Loader System and Circuit Relief Valve Pressure Test in Group 9025-25.
Faulty or misadjusted pressure reducing valve
Do Pressure Reducing Valve Pressure Test in Group 9025-25.
Leaking system relief valve
Remove and inspect valve. (See Group 3160.)
Worn hydraulic pump
Do Hydraulic Pump Performance Check in Group 9025-10.
Faulty pilot control valve
Do Pilot Control Valve Pressure Test in Group 9025-25.
Leaking cylinders
Do Cylinder Leakage Checks in Group 9025-10.
Leaking seals in circuit relief valve or valve stuck open
Inspect seals. Replace relief valve. (See Group 3160.)
Leaking loader control valve
Repair or replace valve section. (See Group 3160.)
Leakage in boom down solenoid valve Remove and inspect boom lower solenoid valve. (See Group 3160.) or O-rings
Boom Down Does Not Work (Engine Boom down button not pushed Off) Stuck solenoid valve
Oil Overheats
Inspect. (See Group 3160.)
Electrical malfunction
See Section 9015.
Low oil viscosity in hot weather
Use recommended oil. (See Section I, Group IV.)
Excessive load
Reduce load.
Holding hydraulic system over relief
Reduce load.
Leakage in work circuit
Do Boom, Bucket, and Clam Cylinder Leakage Test in Group 9025-25.
Plugged fins in oil cooler
Inspect and clean oil cooler.
Continued on next page
TM1529 (27JUN17)
Push button.
9025-15-3
TX,9025,DU1569 -19-17SEP93-3/7
544G, 624G, 644G Loader
062717
PN=623
Diagnostic Information Symptom
Problem
Solution
Internally plugged oil cooler
Do Hydraulic Oil Cooler Restriction Test in Group 9025-25.
Incorrect system or circuit relief valve Do Loader System and Circuit Relief setting Valve Pressure Test in Group 9025-25. Restriction in oil lines or loader valve
Inspect for dented or kinked lines. Do Hydraulic System Restriction Test in Group 9025-25.
Pinched or restricted priority valve "LS" line
Run engine at slow idle. Steer machine back and forth. If engine load decreases while steering, a restricted "LS" line or priority valve malfunction is indicated. Do Priority Valve "LS" Port Flow Test in Group 9025-25.
Malfunctioning priority valve
Do Hydraulic System Restriction Test in Group 9025-25.
Leaking system relief valve
Remove and inspect valve and seals. (See Group 3160.)
Worn hydraulic pump (internal leakage)
Do Hydraulic Pump Performance Check in Group 9025-10.
Function Drops Before Raising When Valve Is Activated
Stuck open lift check
Do Control Valve Lift Check in Group 9025-10.
Hydraulic Oil Foams
Low oil level
Add recommended oil. (See Section I, Group IV.)
Wrong oil
Change to recommended oil. (See Section I, Group IV.)
Water in oil
Change oil. (See Section I, Group IV.)
Loose or faulty suction lines (air leak in system) Leaking plunger seals
Tighten or install new lines.
Electrical circuit failure
Hold a screwdriver against end of pin disconnect solenoid valve and check for magnetism with switch pushed. See Section 9015 if problem is electrical .
Solenoid valve failure
Remove and inspect
Cold oil
Warm the hydraulic oil.
Boom/Bucket Controller Leaking
Pin Disconnect Cylinders Will Not Retract
Slow or Hard Steering
Continued on next page
TM1529 (27JUN17)
9025-15-4
Remove, inspect and replace plunger seals. (See Group 3160.)
TX,9025,DU1569 -19-17SEP93-4/7
544G, 624G, 644G Loader
062717
PN=624
Diagnostic Information Symptom
No Steering
Problem
Solution
Low priority valve pressure setting
Do Priority Valve Pressure Test in Group 9025-25. Clean or replace cartridge in bottom of priority valve. (See Group 0960.)
Worn hydraulic pump
Do Hydraulic Pump Performance Check in Group 9025-10.
Sticking priority valve spool
Remove and inspect. (See Group 0960.)
Broken priority valve spring
Remove and inspect. (See Group 0960.)
Pinched or restricted "LS" line
Inspect line. Do Priority Valve "LS" Port Flow Test in Group 9025-25.
Secondary steering check valve leakage
Do Secondary Steering Secondary Check Valve Leakage Test in Group 9025-25.
Stuck priority valve spool
Remove and inspect priority valve spool. (See Group 0960.)
Broken priority valve spring
Remove and inspect spring. (See Group 0960.)
Relief valve in priority valve stuck open Do Priority Valve Relief Cartridge Leakage Test in Group 9025-25. Constant Steering to Maintain Straight Travel
Air in system
Check for foamy oil.
Leakage in steering system
Do Steering System Leakage Check in Group 9025-10.
Worn steering valve
Do Steering System Leakage Check in Group 9025-10. Do Steering Valve Neutral Leakage Test in Group 9025-25.
Slow Steering Wheel Movement Will Leakage in steering system Not Cause Any Frame Movement
Steering Wheel Turns With No Resistance and Causes No Frame Movement
Worn steering valve gerotor
Do Steering Leakage Check in Group 9025-10.
Broken steering column or splined coupling
Remove and inspect. (See Group 0960.)
Lack of oil in steering valve
Start engine and check steering operation.
Leakage in steering system
Do Steering System Leakage Test in Group 9025-25.
Continued on next page
TM1529 (27JUN17)
Do Steering System Leakage Check in Group 9025-10.
9025-15-5
TX,9025,DU1569 -19-17SEP93-5/7
544G, 624G, 644G Loader
062717
PN=625
Diagnostic Information Symptom
Erratic Steering
Spongy or Soft Steering
Free Play at Steering Wheel
Steering Valve Binding or Steering Wheel Does Not Immediately Return to Neutral When Released
Steering Valve Locks Up
Problem
Solution
Sticking steering inlet manifold primary check valve (machines with secondary steering only)
Remove and inspect. (See Group 0930.) Replace secondary steering inlet manifold if necessary.
Steering valve malfunction
Remove and inspect. (See Group 0960.)
Air in oil
Check for foamy oil.
Low oil level
Add recommended oil. (See Section I, Group IV.)
Sticking priority valve spool
Remove and inspect spool. (See Group 0960.)
Loose cylinder piston
Remove rod to inspect piston. (See Group 0960.)
Damaged steering valve
Remove and inspect. (See Group 0960.)
Air in oil
Check for foamy oil.
Low oil level
Add recommended oil. (See Section I, Group IV.)
Loose steering wheel nut
Tighten. (See Group 0960.)
Worn or damaged splines on steering Inspect. (See Group 0960.) column or valve Binding in steering column or Inspect. (See Group 0960.) misalignment of column High return pressure
Check for a pinched or damaged return line.
Contamination in steering valve
Inspect hydraulic filter for contamination. Repair cause of contamination. Flush hydraulic system.
Large particles of contamination in steering valve
Inspect hydraulic filter for contamination. (See Group 9025-25.) Repair cause of contamination. Flush hydraulic system. (See Group 9025-20.)
Thermal shock
1
Do Priority Valve "LS" Port Flow Test . (See Group 9025-25.) This oil flow provides a warm-up flow to steering valve when not using the steering.
Worn or damaged steering valve
Repair or replace valve. (See Group 0960.)
Continued on next page
TM1529 (27JUN17)
9025-15-6
TX,9025,DU1569 -19-17SEP93-6/7
544G, 624G, 644G Loader
062717
PN=626
Diagnostic Information Symptom
Problem
Solution
Abrupt Steering Wheel Oscillation
Improperly timed gerotor gear in steering valve Lines connected to wrong port
Time gerotor gear. (See Group 0960.)
Steering Wheel Turns by Itself
Reconnect lines. (See Hydraulic System Component Location Drawing in this group.) Do Priority Valve Pressure Test in Group 9025-25.
Vibration in Steering System or Hoses Jump
High priority valve setting
Machine Turns in Opposite Direction
Lines to cylinders connected to wrong Connect lines to correct ports. ports at steering valve. (See Hydraulic System Component Location Drawing in this group.)
Machine Turns When Steering Valve Is in Neutral
Leakage in steering valve
Do Steering Valve Neutral Leakage Test in Group 9025-25.
Steering Wheel Kickback
Failed check valve in secondary steering manifold block
On machines without secondary steering, if both steering and loader are held over relief at the same time and then the loader lever is released, steering wheel kickback is normal. On machines with secondary steering, a failed check valve is indicated. Do Secondary Steering Primary Check Valve Leakage Test in Group 9025-25.
Jerky Steering
LS port
Inspect orifice.
orifice missing Orifice in top end of priority valve spool missing. Secondary Steering Motor Will Not Electrical malfunction. Run
Secondary Steering Pump Runs But Will Not Steer Machine
Disassemble and inspect. Do Operational Check in Group 9015-00.
Seized pump
Remove and inspect. (See Group 0930.)
Stuck open secondary steering manifold block primary check valve
Do Secondary Steering Manifold Block Primary Check Valve Leakage Test in Group 9025-25.
Low relief valve setting
Do Secondary Steering Relief Valve Pressure Test in Group 9025-25.
Failed pump or pump coupling
Replace. (See Group 0930.)
1
Thermal shock is caused by a large temperature differential [approximately 30°C (50°F)] between the steering valve and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority valve spool is plugged, the steering valve may bind up when the steering is operated if the hydraulic oil is hot enough. TX,9025,DU1569 -19-17SEP93-7/7
TM1529 (27JUN17)
9025-15-7
544G, 624G, 644G Loader
062717
PN=627
Diagnostic Information
TS700 —19—28SEP89
Hydraulic Circuit Symbols
JW40272,00000D4 -19-13APR11-1/1
TM1529 (27JUN17)
9025-15-8
544G, 624G, 644G Loader
062717
PN=628
TM1529 (27JUN17)
TXC7774BL
LOADER CONTROL VALVE
SYSTEM RELIEF VALVE
9025-15-9
SECONDARY STEERING VALVE BLOCK (IF EQUIPPED)
BUCKET CYLINDER
SINGLE FUNCTION PILOT CONTROL VALVES (OPTIONAL) (SHOWN WITH AUXILIARY SECTION)
BOOM CYLINDERS
T7774BL —19—15JAN98
Main Hydraulic System Component Location
Diagnostic Information
STEERING VALVE
DUAL FUNCTION PILOT CONTROL VALVE
P
062717
PN=629
544G, 624G, 644G Loader
STEERING CYLINDERS
PARK BRAKE SOLENOID RESERVOIR VENT FILTER
PILOT CONTROL OIL
TRAPPED OIL
RETURN TO RESERVOIR OR PRESSURE FREE OIL
LOW PRESSURE OIL
MEDIUM PRESSURE OIL
HIGH PRESSURE OIL
MAIN HYDRAULIC PUMP
PRESSURE REDUCING VALVE MANIFOLD
RESERVOIR SUCTION SCREEN
SECONDARY STEERING PUMP (IF EQUIPPED)
RETURN FILTER
HYDRAULIC RESERVOIR
OIL COOLER
JW40272,00000D0 -19-13APR11-1/1
MAIN HYDRAULIC SYSTEM COMPONENT LOCATION
PRIORITY VALVE
BRAKE PUMP
DIFFERENTIAL LOCK SOLENOID
Main Hydraulic System Component Location
PP
PRESSURE REDUCING VALVE BOOM DOWN SOLENOID
Diagnostic Information
TM1529 (27JUN17)
9025-15-10
544G, 624G, 644G Loader
062717
PN=630
TM1529 (27JUN17)
TXC8077BD
BRAKE PUMP
BRAKE ACCUMULATOR
BRAKE VALVE
CLUTCH CUT OFF
STEERING
DIFF. LOCK
"SAHR" PARKING BRAKE
REG.PRESS.TEST PARK BRAKE SWITCH
ORIFICE CHECKS IN PILOT CAPS AND BOOM (4 USED)
062717
PN=631
544G, 624G, 644G Loader
Main Hydraulic System Schematic
MAIN HYDRAULIC SYSTEM SCHEMATIC
BRAKE LIGHTS PRESSURE SWITCH
REAR BRAKES
9025-15-11
BRAKE VALVE
BRAKE SHUTTLE VALVE
FRONT BRAKES
PRESS. REDUCING VALVE MANIFOLD
STEERING VALVE
TEST PORT
INLET TEST -PP-
PIN DISCONNECT CYLINDER (TOOL CARRIER ONLY)
SEC.STEER VALVE (OPTIONAL)
SEC.STEER PUMP (OPTIONAL)
BRAKE ACCUMULATOR SWITCH
PRIORITY VALVE
MAIN PUMP
SCREEN
LOADER SUMP
COOLER
RETURN FILTER
TEST PORT
Main Hydraulic System Schematic
T8077BD —19—15JAN98
Diagnostic Information
JW40272,00000D1 -19-13APR11-1/1
RETURN TO RESERVOIR OR PRESSURE FREE OIL
LOW PRESSURE OIL
TRAPPED OIL PILOT CONTROL OIL
HIGH PRESSURE OIL
PILOT CONTROLS
OPTIONAL
LOADER CONTROL VALVE
AUXILIARY
MEDIUM PRESSURE OIL
INLET TEST
OPTIONAL
BUCKET
BOOM
Diagnostic Information
TM1529 (27JUN17)
9025-15-12
544G, 624G, 644G Loader
062717
PN=632
TM1529 (27JUN17)
TXC7774BN
T7774BN —19—20JAN98
PIN DISCONNECT CYLINDER (544G TC ONLY)
TILT CYLINDER
9025-15-13
LIFT CYLINDERS
PIN DISCONNECT VALVE (544G TC ONLY)
Hydraulic System Component Location-544G TC & 544G LL
Diagnostic Information
TO RETURN
RETURN TO RESERVOIR OR PRESSURE FREE OIL
TRAPPED OIL
PILOT CONTROL OIL
HIGH PRESSURE OIL
PRIORITY VALVE
PRESSURE REDUCING VALVE MANIFOLD
062717
PN=633
JW40272,00000D2 -19-13APR11-1/1
HYDRAULIC SYSTEM COMPONENT LOCATION — 544G TC AND 544G LL
TILT VALVE
AUXILIARY VALVE
Hydraulic System Component Location-544G TC & 544G LL
LIFT VALVE
544G, 624G, 644G Loader
BRAKE PUMP
TO PILOT CONTROLLER
Diagnostic Information
TM1529 (27JUN17)
9025-15-14
544G, 624G, 644G Loader
062717
PN=634
Group 20
Adjustments Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy SERVICE EQUIPMENT AND TOOLS
Operate filter caddy approximately 7 minutes (544G) or 10 minutes (624G and 644G) so oil in reservoir is circulated through filter a minimum of four times.
Portable Filter Caddy Two 3658 mm (12 ft) x 3/4 in. ID 100R1 Hoses with 3/4 M NPT Ends
Leave filter caddy operating for the next steps.
Quick Disconnect Fittings JT03297 (1-1/16 M ORB x 3/4 M NPT) Connector Discharge Wand
IMPORTANT: Brake system uses oil from hydraulic reservoir. Flush all lines in the brake, pilot, differential lock, and clutch cut-off system. Disassemble and clean pressure reducing valve and pilot controller. Remove and clean pilot caps from main control valve. Brake components may fail if brake system is not cleaned after hydraulic reservoir contamination.
NOTE: Filtering time for reservoir is 0.089 minute x number of liters (0.33 minute x number of gallons). Reservoir capacity is 76 L (20 gal) on 544G, and 108 L (28.5 gal) on 624G and 644G. 6. Start the engine and run it at fast idle. IMPORTANT: For the most effective results, cleaning procedure must start with the smallest capacity circuit then proceed to the next largest capacity circuit.
1. If hydraulic system is contaminated due to a major component failure, remove and disassemble steering cylinders to clean debris from cylinders.
7. Operate all functions, one at a time, through a complete cycle in the following order: clam, steering, bucket, and boom. Also include all auxiliary hydraulic functions.
2. Install a new return filter element. Clean filter housing before installing new element.
Repeat procedure until the total system capacity has circulated through filter caddy seven times, approximately 21 minutes (544G), 28 minutes (624G), or 30 minutes (644G). Each function must go through a minimum of three complete cycles for a thorough cleaning of oil.
IMPORTANT: To prevent cavitation of filter caddy pump, the minimum ID of connector is 1/2 in. NOTE: For a failure that creates a lot of debris, remove access cover from reservoir. Drain reservoir and connect filter caddy suction line to drain port. Add a minimum of 19 L (5 gal) of oil to reservoir. Operate filter caddy and wash out the reservoir. 3. To minimize oil loss, pull a vacuum in reservoir using a vacuum pump. Connect filter caddy suction line to drain port at bottom of reservoir using connector and quick disconnect fitting. Check to be sure debris has not closed drain port. 4. Put filter caddy discharge line into reservoir filler hole so end is as far away from drain port as possible to obtain a thorough cleaning of oil.
NOTE: Filtering time for complete hydraulic system is 0.158 minute x number of liters (0.6 minute x number of gallons). Complete hydraulic system capacity is 133 L (35 gal) on 544G, 180 L (48 gal) on 624G, and 189 L (50 gal) on 644G. Filtering time for machines with auxiliary hydraulic functions must be increased because system capacity is larger. 8. Stop the engine. Remove the filter caddy. 9. Install a new return filter element. 10. Check oil level in reservoir; add oil if necessary. (See Fuels and Lubricants in Section I, Group IV.)
5. Start the filter caddy. Check to be sure oil is flowing through the filters. TX,9025,UU1289 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-20-1
544G, 624G, 644G Loader
062717
PN=635
Adjustments
Boom Height Kickout Adjustment NOTE: If boom is in the raised position when key is turned on, control lever must returned to neutral manually if placed in the boom raise detent position. After boom is lowered once, the boom height kickout will work normally. 1. Raise boom to full height and back to ground level to reset switch. 2. Move loader control lever to boom raise detent position and release. 3. After loader control lever returns to neutral, make a mark (D) on the magnet and boom height kickout switch. 4. Position the boom in the desired boom height kickout position. Stop engine.
T6601AI —UN—21OCT88
5. Loosen cap screws (B) and slide bracket to align marks on magnet and boom kickout switch. 6. Loosen cap screws (C) and adjust clearance (A) between magnet and boom height kickout switch to 9 ± 3 mm (0.35 ± 0.12 in.). 7. Raise boom to full height and back to ground level to reset switch. Check boom height kickout for correct adjustment. A—Magnet-to-Switch Clearance B—Cap Screws
C—Cap Screws D—Alignment Marks
TX,2520,ZZ,29 -19-16SEP92-1/1
Return-To-Dig Adjustment
T6599AD —UN—21OCT88
NOTE: If bucket is in a rolled back position when key is turned on, control lever must be returned to neutral manually if placed in the return-to-dig detent position. After bucket is dumped once, return-to-dig will work normally. 1. Raise boom. Cycle bucket from full rollback to dump, to reset the switch. 2. Move loader control lever to return-to-dig detent position and release. 3. After control lever returns to neutral, make a mark (B) on magnet and return-to-dig switch.
A—Magnet-to-Switch Clearance B—Alignment Marks
4. Position the boom and bucket in the desired return-to-dig position. Stop engine. 5. Loosen cap screws (D) and slide bar to align marks on magnet and return-to-dig switch. Apply medium strength thread lock and sealer to cap screws. 6. Remove cap screws (C), apply medium strength thread lock and sealer and adjust clearance (A) between
C—Cap Screws D—Cap Screws
magnet and return-to-dig switch to 9 ± 3 mm (0.35 ± 0.12 in.). Torque cap screws to 121 N·m (89 lb-ft). 7. Raise boom. Cycle bucket from full rollback to dump. Check return-to-dig for correct adjustment. TX,9025,DU1570 -19-31JAN95-1/1
TM1529 (27JUN17)
9025-20-2
544G, 624G, 644G Loader
062717
PN=636
Adjustments
Ride Control Accumulator Discharge Procedure—If Equipped 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. T7895BD —UN—10MAY93
1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Install frame locking bar. 3. Turn key switch to ON position to provide ignition power. Do not start engine. CAUTION: Prevent possible injury and machine damage from unexpected machine movement. Perform procedure in an open area clear of bystanders and obstructions. Boom may move upward when ride control is turned on.
Ride Control Assembly A—Accumulator B—Valve-to-Accumulator Line C—Accumulator 90° Fitting D—Valve E—90° Swivel Fittings (3 used) F— Boom Head End Line G—Tee Swivel Fitting
NOTE: Ride control accumulator can only be discharged when ride control is on. 4. Press ride control switch to ON position to turn on ride control. 5. Press and hold boom down switch and perform the following steps: a. Lower boom to ground.
H—90° Swivel Adaptors for Pilot Hoses (2 or 3 used) I— Ride Control Valve-toControl Valve Return Line J— Return Line to Reservoir K—Boom Rod End Line L— Boom Head End Line-to-Ride Control Valve Line M—Boom Rod End Line-to-Ride Control Valve Line N—Ride Control Mounting Bracket
b. Engage boom float for 5 seconds. or wait until flow lessens before loosening line fitting (C) further. Repair or replace accumulator solenoid as necessary.
c. Move all other hydraulic control levers to relieve hydraulic pressure. CAUTION: Oil will flow out of accumulator solenoid if solenoid does not move by use of switch. If ride control solenoid has failed, accumulator gas charge or oil from accumulator line fitting must be released to prevent pressurized oil flow. 6. Slowly loosen line fitting (C) in 1/4 turn increments until oil flows.
8. When oil flows steadily, ride control accumulator is discharged. 9. Tighten line fitting (C). 10. Turn key switch to OFF position to turn off ignition power. 11. Remove frame locking bar.
7. If oil sprays or flows rapidly, ride control accumulator is still charged. Either release accumulator gas charge, BS13840,000044B -19-26JAN16-1/1
TM1529 (27JUN17)
9025-20-3
544G, 624G, 644G Loader
062717
PN=637
Adjustments
Ride Control Accumulator Gas Charge Procedure—If Equipped SPECIFICATIONS Ride Control Accumulator Gas Charge Pressure
with appropriate supporting device before working on or around machine. 5. Raise boom and install boom lock. See Boom Lock. (Operator’s Manual.)
1720—2210 kPa 17.2—22.1 bar 250—320 psi
6. Remove cover and cap from top of accumulator.
Nitrogen Tank Pressure Regulator
7. Turn handle of JT01735 Gas Cock from JT05420 Nitrogen Accumulator Charging Kit fully counterclockwise (out).
JT05420 Nitrogen Accumulator Charging Kit
8. Attach gas cock to charging valve.
SERVICE EQUIPMENT AND TOOLS Dry Nitrogen Tank
JT01735 Gas Cock
Perform this procedure to verify that gas pressure in ride control accumulator is within specification and to charge accumulator as necessary. 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 9000-01.) 2. Stop engine and relieve hydraulic system pressure. See Ride Control Accumulator Discharge Procedure—If Equipped. (Group 9025-20.) IMPORTANT: All hydraulic pressure must be relieved from accumulators and ride control circuit before attempting to charge accumulators.
IMPORTANT: Charge accumulator using only dry nitrogen. Dry nitrogen does not mix with oil and is non-combustible. Dry nitrogen does not cause oxidation or condensation inside accumulator and is not harmful to piston seal. Do not use air or any combustible gas as these gases can cause oxidation and condensation. Oxidation and condensation are harmful to piston seal and accumulator. 9. Attach hose from nitrogen tank pressure regulator to gas cock. 10. Verify that bleed valve on regulator is closed. 11. Verify that all fittings are tight.
3. Verify that ride control accumulator is discharged. 4. Disconnect boom attachment.
12. Inspect for oil in gas side of ride control accumulator. Drain oil as necessary. See Ride Control Accumulator Draining Procedure—If Equipped. (Group 9025-20.)
CAUTION: Prevent possible crushing injury from falling boom. Always support raised boom
Continued on next page
TM1529 (27JUN17)
9025-20-4
MP01188,00000E7 -19-21JAN16-1/2
544G, 624G, 644G Loader
062717
PN=638
T7594AB —UN—10SEP91
Adjustments
T7594AA —UN—10SEP91
Cross Section of Charging Valve
Special Nut A—Special Nut
CAUTION: Loosen only top special nut. The bottom "nut" is actually accumulator charging valve fitting. Do not loosen bottom fitting. Loose fitting under pressure can cause injury. 13. Loosen special nut (A) (counterclockwise) 2-1/2 turns to open charging valve. (Resistance may be felt at approximately 1-1/2 turns.) 14. Turn regulator valve handle counterclockwise (out) until loose. 15. Open nitrogen tank valve. NOTE: If ambient temperature is cooler than 20°C (70°F), pressure reading may require a few minutes to stabilize. 16. Slowly turn regulator valve handle clockwise (in) to pressurize accumulator to specification. Specification Ride Control Accumulator Gas—Charge Pressure................................................. 1720—2210 kPa 17.2—22.1 bar 250—320 psi
17. If ride control accumulator cannot be charged to specification, replace accumulator. See Ride Control Accumulator Remove and Install—If Equipped. (Group 3160.) 18. Tighten special nut (A) until snug to close charging valve. 19. Turn handle on gas cock fully counterclockwise (out). 20. Close nitrogen tank valve. 21. Turn regulator valve handle counterclockwise (out) until loose. 22. Slowly loosen gas cock from charging valve to release pressure from hose. 23. Remove gas cock from charging valve. 24. Install cap on charging valve. 25. Raise boom and remove boom lock. 26. Remove frame locking bar. 27. Install boom attachment. MP01188,00000E7 -19-21JAN16-2/2
TM1529 (27JUN17)
9025-20-5
544G, 624G, 644G Loader
062717
PN=639
Adjustments
Ride Control Accumulator Draining Procedure SERVICE EQUIPMENT AND TOOLS JT05420 Nitrogen Accumulator Charging Kit
1. Discharge ride control accumulator (1). See Ride Control Accumulator Discharge Procedure. (Group 9025-20.) 2. Remove ride control accumulator. 3. Remove charging valve cap (2). TX1099353A —UN—10OCT11
4. Connect JT05420 Nitrogen Accumulator Charging Kit to charging valve (3). 5. Slowly bleed down pressure from accumulator. 6. Slowly remove charging valve (3) from accumulator. 7. Drain oil into suitable container. Dispose of waste properly. 8. Install charging valve (3) with new O-ring (4).
Charging Valve Cap
9. Install ride control accumulator. 10. Charge ride control accumulator. See Ride Control Accumulator Gas Charge Procedure. (Group 9025-20.) 11. Install charging valve cap. 12. Remove frame locking bar. 3— Charging Valve 4— O-Ring
XJ1185255 —UN—13FEB15
1— Ride Control Accumulator 2— Charging Valve Cap
Charging Valve Core DD00738,00002E1 -19-25FEB16-1/1
TM1529 (27JUN17)
9025-20-6
544G, 624G, 644G Loader
062717
PN=640
Group 25
Test JT05801 Clamp-On Electronic Tachometer Installation SERVICE EQUIPMENT AND TOOLS
T6813AG —UN—28FEB89
Tachometer: A—Clamp-On Tachometer Remove paint using emery cloth and connect to a straight section of injection line within 100 mm (4 in.) of pump. Finger tighten only—DO NOT over tighten. B—Black Clip (-). Connect to main frame. C—Red Clip (+). Connect to transducer. D—Tachometer Readout. Install cable.
902025,AA75 -19-16SEP92-1/1
JT05800 Digital Thermometer Installation SERVICE EQUIPMENT AND TOOLS Digital Thermometer T6808CE —UN—28FEB89
A—Temperature Probe. Fasten to a bare metal line using tie band. Wrap with shop towel. B—Cable C—Digital Thermometer
902525,AA4 -19-14FEB95-1/1
Display Monitor Tachometer
T7817AG —UN—31AUG92
The display monitor tachometer is accurate enough for test work. If accuracy is questioned, see Calibrate Tachometer in Group 9015-20.
TX,9020,UU1277 -19-16SEP92-1/1
Hydraulic Oil Warm-Up Procedure 1. Install temperature reader. (See Temperature Reader Installation Procedure in this group).
4. Periodically cycle all hydraulic functions to distribute warm oil.
2. Run engine at fast idle.
5. Heat oil to test specification.
3. Hold a hydraulic function over relief to heat the oil. TX,9025,UU1290 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-1
544G, 624G, 644G Loader
062717
PN=641
Test
Main Hydraulic Pump Flow Test SPECIFICATIONS Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
2000 rpm
Main Hydraulic Pump Flow Test Pressure
13 790 kPa (138 bar) (2000 psi)
544G Minimum Pump Flow Rate
129 L/min (34 gpm)
624G Minimum Pump Flow Rate
170 L/min (45 gpm)
644G Minimum Pump Flow Rate
189 L/min (50 gpm)
ESSENTIAL TOOLS JT05692 (-20 F ORFS x 1-5/16 M 37°) Fitting (3 used) (A) 38H1282 (-20 M ORFS x -20 M ORFS) Fitting (B) 38H1034 (-20 F ORFS x -20 M ORFS x -20 M ORFS) Tee (C) JT03251 (1-5/16 F 37° x 7/16 M 37°) Fitting (D)
T6536AE —19—21APR89
SERVICE EQUIPMENT AND TOOLS Flowmeter Gauge 0—35 000 kPa (0—350 bar) (0—5000 psi) Temperature Reader
1. Make test connections. 2. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 3. Heat hydraulic oil to specifications.
6. Read flowmeter.
Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 4. Run engine at test specifications. Specification Engine—Speed......................................................................... 2000 rpm
5. Close flowmeter loading valve to increase pressure to test specifications.
7. If flow is below specifications, check hydraulic reservoir suction screen for restriction before removing pump. Specification 544G Minimum Pump—Flow Rate..................................................... 129 L/min (34 gpm) 624G Minimum Pump—Flow Rate..................................................... 170 L/min (45 gpm) 644G Minimum Pump—Flow Rate..................................................... 189 L/min (50 gpm)
Specification Main Hydraulic Pump Flow Test—Pressure............................. 13 790 kPa (138 bar) (2000 psi) TX,2525,UU1204 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-2
544G, 624G, 644G Loader
062717
PN=642
Test
Loader System And Circuit Relief Valve Pressure Test
65 ± 5°C (150 ± 10°F)
544G, 624G, 644G System Relief Valve Test Engine Speed
Fast idle
544G System Relief Valve Relief Pressure
19 000 + 1379-0 kPa (190 + 14-0 bar) (2750 + 200-0 psi)
544G System Relief Valve Approximate Pressure Change Per 1/8 Turn Adjustment
690 kPa (6.9 bar) (100 psi)
624G System Relief Valve Relief Pressure
19 300 + 1379-0 kPa (193 + 14-0 bar) (2800 + 200-0 psi)
624G System Relief Valve Approximate Pressure Change Per 1/8 Turn Adjustment
690 kPa (6.9 bar) (100 psi)
644G System Relief Valve Relief Pressure
20 689 + 1 034-0 kPa (207 + 10-0 bar) (3000 + 150-0 psi)
644G System Relief Valve Approximate Pressure Change Per 1/8 Turn Adjustment
690 kPa (6.9 bar) (100 psi)
Bucket Rollback Relief Valve Test Engine Speed
Slow idle
Bucket Dump Relief Valve Test Engine Speed
Slow idle
Auxiliary Relief Valve Test Engine Speed
Slow idle
Bucket Rollback Relief Valve Relief Pressure
22 409 + 1379-0 kPa (224 + 14-0 bar) (3250 + 200-0 psi)
Bucket Dump Relief Valve Relief Pressure
22 409 + 1379-0 kPa (224 + 14-0 bar) (3250 + 200-0 psi)
Auxiliary Relief Valve Relief Pressure
22 409 + 1379-0 kPa (224 + 14-0 bar) (3250 + 200-0 psi)
Bucket Rollback Relief Valve Approximate Pressure Change Per 1/8 Turn Adjustment
2 069 kPa (20.7 bar) (300 psi)
Bucket Dump Relief Valve Approximate Pressure Change Per 1/8 Turn Adjustment
2 069 kPa (20.7 bar) (300 psi)
T7817AB —UN—26AUG92
Oil Temperature
T7817AC —UN—26AUG92
SPECIFICATIONS
Auxiliary Relief Valve Approximate 1 379 kPa (13.8 bar) (200 psi) Pressure Change Per 1/8 Turn Adjustment ESSENTIAL TOOLS
A—Test Port B—Auxiliary Relief (2 used) C—Bucket Rollback Relief D—Boom Raise Plug
JT03111 (7/16 M 37° x 9/16 M ORB) Fitting
E—Boom Lower AntiCavitation Plug F— Bucket Dump Relief G—System Relief Valve
SERVICE EQUIPMENT AND TOOLS Gauge 0—35 000 kPa (0—350 bar) (0—5000 psi)
3. Heat hydraulic oil to specifications.
Temperature Reader
1. Install fitting and pressure gauge to test port in priority valve.
Specification Oil—Temperature.................................................. 65 ± 5°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.)
2. Install temperature reader. (See Temperature Reader Installation Procedure in this group.)
Continued on next page
TM1529 (27JUN17)
9025-25-3
TX,9025,DU1571 -19-17SEP93-1/2
544G, 624G, 644G Loader
062717
PN=643
Test
4. To check the system relief (G), run engine at fast idle. Specification 544G, 624G, 644G System Relief Valve Test—Engine Speed....................................................................Fast idle
Bucket Dump Relief Valve—Test Engine Speed.........................................................................................Slow idle Auxiliary Relief Valve—Test Engine Speed.........................................................................................Slow idle
Lower boom to bottomed position. Slowly activate boom down function while watching pressure gauge. If pressure is not to specification, loosen lock nut on system relief valve (G) and adjust to specification. Specification 544G System Relief Valve—Relief Pressure...................................19 000 + 1379-0 kPa (190 + 14-0 bar) (2750 + 200-0 psi) Approximate Pressure Change Per 1/8 Turn Adjustment.................................................... 690 kPa (6.9 bar) (100 psi) 624G System Relief Valve—Relief Pressure...................................19 300 + 1379-0 kPa (193 + 14-0 bar) (2800 + 200-0 psi) Approximate Pressure Change Per 1/8 Turn Adjustment.................................................... 690 kPa (6.9 bar) (100 psi) 644G System Relief Valve—Relief Pressure..................................20 689 + 1 034-0 kPa (207 + 10-0 bar) (3000 + 150-0 psi) Approximate Pressure Change Per 1/8 Turn Adjustment.................................................... 690 kPa (6.9 bar) (100 psi)
IMPORTANT: DO NOT adjust the system relief valve above 24 132 kPa (241 bar) (3500 psi). Damage to the pump will result from excessive pressure settings. 5. To check the bucket dump, bucket rollback, or auxiliary valve relief setting, adjust the system relief valve to 24 132 kPa (241 bar) (3500 psi). Run engine to maintain 850 rpm when hydraulic function is activated over relief. Specification Bucket Rollback Relief Valve—Test Engine Speed.........................................................................................Slow idle
Activate the function to be checked with the cylinder bottomed. Read the pressure gauge. If pressure is not to specification cycle relief valve over relief 10 times to flush. Specification Bucket Rollback Relief Valve—Relief Pressure...................................22 409 + 1379-0 kPa (224 + 14-0 bar) (3250 + 200-0 psi) Bucket Dump Relief Valve—Relief Pressure...................................22 409 + 1379-0 kPa (224 + 14-0 bar) (3250 + 200-0 psi) Auxiliary Relief Valve—Relief Pressure...................................22 409 + 1379-0 kPa (224 + 14-0 bar) (3250 + 200-0 psi)
Read pressure gauge again. Turn screw to adjust valve to specification. Specification Bucket Rollback Relief Valve—Approximate Pressure Change Per 1/8 Turn Adjustment....................................... 2 069 kPa (20.7 bar) (300 psi) Bucket Dump Relief Valve—Approximate Pressure Change Per 1/8 Turn Adjustment....................................... 2 069 kPa (20.7 bar) (300 psi) Auxiliary Relief Valve—Approximate Pressure Change Per 1/8 Turn Adjustment....................................... 1 379 kPa (13.8 bar) (200 psi)
IMPORTANT: Do Not work machine with system relief adjusted above specification or structural damage may occur. 6. Adjust system relief valve to specification.
TX,9025,DU1571 -19-17SEP93-2/2
TM1529 (27JUN17)
9025-25-4
544G, 624G, 644G Loader
062717
PN=644
Test
Hydraulic System Restriction Test SPECIFICATIONS 65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
Maximum Hydraulic System Pressure at Loader Control Valve
1725 kPa (17 bar) (250 psi)
Maximum Hydraulic System Pressure at Steering Valve
1965 kPa (20 bar) (285 psi)
T6569AD —UN—21OCT88
Oil Temperature
ESSENTIAL TOOLS JT05488 (7/16 M 37° x 7/16 M ORB) (Parker No. 0503-4-4) Fitting JT03111 (7/16 M 37° x 9/16 M ORB) Fitting SERVICE EQUIPMENT AND TOOLS
T6569AC —UN—21OCT88
Gauge 0—7000 kPa (0—70 bar) (0—1000 psi) (2 used)
This test will check for restrictions in the hydraulic system which can cause overheating of hydraulic oil. 1. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 2. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Connect fitting (A) and gauge to steering valve. 4. Connect fitting (B) and gauge to loader control valve. IMPORTANT: Do Not operate steering or loader functions or test gauge may be damaged. 5. Run engine at specification and read pressure gauges. Specification Engine—Speed...........................................................................Fast idle
If pressure is more than specification at the loader control valve, check for a kinked, dented or obstructed hydraulic line.
Specification Maximum Hydraulic System—Pressure at Loader Control Valve.................................... 1725 kPa (17 bar) (250 psi)
Check loader control valve for a binding spool. If pressure is more than specification at the steering valve, inspect priority valve for a stuck spool. Specification Maximum Hydraulic System—Pressure at Steering Valve.............................................. 1965 kPa (20 bar) (285 psi)
Make sure orifice plugs are installed in ends of priority valve spool. Check for plugged orifice in priority valve "LS" port. TX,2525,UU1207 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-5
544G, 624G, 644G Loader
062717
PN=645
Test
Loader Cylinder Drift Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 10°F)
Maximum Allowable Cylinder Drift 51 mm/min. (2.00 in./min.) With Engine OFF (Overall Drift Down Measured at Bucket Cutting Edge) 544G, 624G Boom Cylinder Drift
3 mm/min. (0.12 in./min.)
644G Boom Cylinder Drift
2 mm/min. (0.08 in./min.) 7 mm/min. (0.28 in./min.)
644G Bucket Cylinder Drift
6 mm/min. (0.24 in./min.)
Maximum Allowable Boom Cylinder Drift Up With Engine ON (Boom Lower Solenoid Valve Leakage Check)
6 mm (0.24 in.) in 2 minutes T6203AT —UN—21OCT88
544G, 624G Bucket Cylinder Drift
SERVICE EQUIPMENT AND TOOLS Temperature Reader Stop Watch
1. Fasten temperature probe to port of cylinder being tested. Cover probe with a shop towel. 2. Heat hydraulic oil to specifications. T6222AN —UN—26OCT88
Specification Oil—Temperature..................................................... 40 ± 6°C (100 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Stop engine. 4. To check boom and bucket overall drift rate, measure drift down at tooth tip (A) for 1 minute. Specification Maximum Allowable Cylinder—Drift With Engine OFF (Overall Drift Down Measured at Bucket Cutting Edge)..................................... 51 mm/min. (2.00 in./min.)
If drift rate is excessive, measure individual cylinder drift with a dial indicator to determine which circuit is leaking. Specification 544G, 624G Boom Cylinder—Drift.................................................. 3 mm/min. 644G Boom Cylinder—Drift.................................................. 2 mm/min. 544G, 624G Bucket Cylinder—Drift.................................................. 7 mm/min. 644G Bucket Cylinder—Drift.................................................. 6 mm/min.
(0.12 in./min.) (0.08 in./min.) (0.28 in./min.) (0.24 in./min.)
5. If drift is excessive for any cylinder, do Cylinder Leakage Check in Group 9025-10 to determine if leakage is in the cylinder or control valve. NOTE: Boom lower solenoid valve leakage can cause boom to drift up with engine running. Stop engine. Install and zero dial indicator. Start engine. If cylinder drifts up more than specification, remove solenoid valve and check seals. Specification Maximum Allowable Boom Cylinder—Drift Up With Engine ON (Boom Lower Solenoid Valve Leakage Check).......................................... 6 mm (0.24 in.) in 2 minutes TX,2525,UU1208 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-6
544G, 624G, 644G Loader
062717
PN=646
Test
Boom And Bucket Cylinder Leakage Test SPECIFICATIONS 40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Maximum Boom and Bucket Cylinder Leakage
15 mL/min. (1/2 oz/min.)
T6222AL —UN—26OCT88
Oil Temperature
ESSENTIAL TOOLS 38H1150 (-16 ORFS) (Parker No. 16 PNLO-S) Plug (544G Boom Head End) 38H1149 (-12 ORFS) (Parker No. 12 PLNO-S) Plug (544G Boom Rod End) 38H1150 (-16 ORFS) (Parker No. 16 PNLO-S) Plug (624G Boom) (2 used) 38H1151 (-20 ORFS) (Parker No. 20 PNLO-S) Plug (644G Boom Head End)
3. Fully extend the cylinder to be tested. If testing the boom cylinders, restrain boom in the fully raised position using a hoist or a stand.
38H1150 (-16 ORFS) (Parker No. 16 PNLO-S) Plug (544G Bucket) (2 used)
NOTE: Check cylinders for leakage in the fully extended position only. In the retracted position the piston contacts the end of the cylinder and seals off piston seal leakage.
38H1151 (-20 ORFS) (Parker No. 20 PLNO-S) Plug (624G Bucket) (2 used)
4. Remove and plug cylinder rod end hose or line.
38H1151 (-20 ORFS) (Parker No. 20 PLNO-S) Plug (644G Bucket) (2 used)
5. Run engine at slow idle.
38H1150 (-16 ORFS) (Parker No. 16 PNLO-S) Plug (644G Boom Rod End)
Specification Engine—Speed..........................................................................Slow idle
SERVICE EQUIPMENT AND TOOLS
Activate control lever to extend cylinder for 1 minute over relief while measuring leakage from open port.
Temperature Reader Stop Watch Measuring Container
1. Fasten temperature sensor to head end port of cylinder to be tested. Cover sensor with a shop towel. 2. Heat hydraulic oil to specification. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
If leakage is within specification, excessive cylinder drift is caused by leakage in the loader control valve or circuit relief valve. Specification Maximum Boom and Bucket Cylinder—Leakage............................................ 15 mL/min. (1/2 oz/min.)
(See Hydraulic Oil Warm-Up Procedure in this group.) CAUTION: Never work under raised equipment unless it is supported with a hoist or support stands. TX,2525,ZZ,37 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-7
544G, 624G, 644G Loader
062717
PN=647
Test
Hydraulic Oil Cooler Restriction Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Fast idle
544G Minimum Cooler Flow Rate
9.1 L/min (2.4 gpm)
624G Minimum Cooler Flow Rate
10.8 L/min (2.8 gpm)
644G Minimum Cooler Flow Rate
13.2 L/min (3.5 gpm)
ESSENTIAL TOOLS 38H1418 (-12 F ORFS) (Parker No. 12 FNL-S) Cap SERVICE EQUIPMENT AND TOOLS Temperature Reader Measuring Container Stop Watch
T7801AC —UN—26AUG92
1. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 2. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in the group.) 3. Disconnect hose (B) at reservoir. Install cap (A). NOTE: Hydraulic flows on new machines will be approximately twice specification. 4. Run engine at specification and measure oil flow for 1/2 minute. Specification Engine—Speed...........................................................................Fast idle
Specification 544G Minimum Cooler—Flow Rate.................................................... 9.1 L/min (2.4 gpm) 624G Minimum Cooler—Flow Rate.................................................. 10.8 L/min (2.8 gpm) 644G Minimum Cooler—Flow Rate.................................................. 13.2 L/min (3.5 gpm)
5. If oil flow is below specification, check hoses for obstructions.
Clean or replace oil cooler. TX,9025,UU1209 -19-06SEP94-1/1
TM1529 (27JUN17)
9025-25-8
544G, 624G, 644G Loader
062717
PN=648
Test
Steering Valve Leakage Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Fast idle
Maximum Steering Valve Leakage 7.5 L/min. (2 gpm) ESSENTIAL TOOLS 38H1419 (-16 F ORFS) (Parker No. 16 FNL-S) Cap SERVICE EQUIPMENT AND TOOLS Temperature Reader Measuring Container (Approximately 5 Gallon) Stop Watch
1. Install frame locking bar to prevent machine from turning. T6536AB —UN—21OCT88
2. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 3. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 4. Disconnect return hose (A) from fitting (B). Install cap on fitting (B). If leakage is greater than specifications, repair or replace steering valve .
5. Run engine at specifications. Specification Engine—Speed...........................................................................Fast idle
Rotate steering wheel against locking bar applying 11 N·m (8 lb-ft) to steering shaft to turn valve. Measure oil flow from return hose for 1 minute.
Specification Maximum Steering Valve—Leakage..........................................................7.5 L/min. (2 gpm)
(See Group 0960.) TX,9025,DU1731 -19-02DEC93-1/1
TM1529 (27JUN17)
9025-25-9
544G, 624G, 644G Loader
062717
PN=649
Test
Steering Valve Drift Test
Oil Temperature
65 ± 6°C (150 ± 10°F)
544G Minimum Steering Cylinder Collapse Cycle Time
40 seconds
624G Minimum Steering Cylinder Collapse Cycle Time
55 seconds
644G Minimum Steering Cylinder Collapse Cycle Time
70 seconds
T6569AE —UN—21OCT88
SPECIFICATIONS
ESSENTIAL TOOLS 38H1031 (-8 M x -8 F x -8 M ORFS) (Parker No. 8R6LO-S) Tee (544G) JT03457 (7/16-20 M x -8 F ORFS) Adaptor (544G) 38H1032 (-10 M x -10 F x -10 M ORFS) (Parker No. 10R6LO-S) Tee (624G, 644G)
NOTE: Do test with hands off of steering wheel if wheel rotates, then move wheel back and forth slightly to center wheel.
JT03458 (7/16-20 M x -10 F ORFS) Adaptor (624G, 644G)
5. Release park brake. Put machine in 2nd gear forward and apply power to maintain 3450 kPa (34.5 bar) (500 psi) pressure reading on gauge. Measure time it takes until equipment frame hits the engine frame stop.
SERVICE EQUIPMENT AND TOOLS Temperature Reader Gauge 20 000 kPa (200 bar) (3000 psi)
If time is greater than specifications, steering drift is normal.
Stop Watch
1. Install temperature reader on hydraulic line to priority valve. Install tee in head end of steering cylinder and attach gauge. Remove the steering stop from this side of the machine. 2. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) Steer machine back and forth to make sure steering cylinders contain heated oil. 3. Align machine so outside bucket corner is against a immovable object such as a loading dock. Engage park brake.
Specification 544G Minimum Steering Cylinder Collapse—Cycle Time........................................................................................40 seconds 624G Minimum Steering Cylinder Collapse—Cycle Time........................................................................................55 seconds 644G Minimum Steering Cylinder Collapse—Cycle Time........................................................................................70 seconds
If time is less than specifications, do Steering Cylinder Leakage in this group before repairing or replacing the steering valve . (See Group 0960.) 6. Remove test equipment and install steering stop.
4. Turn steering wheel, approximately 3/4 revolution, until dimension (A) measures 235 mm (9.25 in.) on cylinder with gauge on it. TX,2525,WW1490 -19-31JAN95-1/1
TM1529 (27JUN17)
9025-25-10
544G, 624G, 644G Loader
062717
PN=650
Test
Priority Valve Pressure Test SPECIFICATIONS Oil Temperature
65 ± 6°C (150 ± 10°F)
Engine Speed
Fast idle
Priority Valve Relief Pressure
16 900—18 270 kPa (169—182 bar) (2450—2650 psi)
1/2 Turn of Adjusting Screw Approximate Pressure Change
3792 kPa (37 bar) (550 psi)
ESSENTIAL TOOLS JT05488 (7/16 M 37° x 7/16 M ORB) (Parker No. 0503-4-4) Fitting SERVICE EQUIPMENT AND TOOLS Gauge 0—35 000 kPa (0—350 bar) (0—5000 psi) Temperature Reader
T7817AB —UN—26AUG92
1. Connect test fitting and gauge to test port on priority valve. 2. Install temperature reader. (See installation procedure in this group.) 3. Install frame locking bar. 4. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 5. Run engine at specification and turn steering wheel rapidly hold approximately 22 N (5 lb force) pressure on wheel with frames locked. Specification Engine—Speed...........................................................................Fast idle
NOTE: If steering wheel is turned slowly, it will continue to with the frames locked. This will give an incorrect pressure reading. If steering wheel continues to turn rapidly with the frames locked, steering system leakage is indicated. 6. Read pressure gauge. This is the priority valve relief pressure.
Specification Priority Valve—Relief Pressure.................................................................. 16 900—18 270 kPa (169—182 bar) (2450—2650 psi)
7. If pressure is not to specification, remove elbow and connector from bottom of priority valve. Turn adjusting screw in relief cartridge using a hex-head wrench to adjust pressure. Specification 1/2 Turn of Adjusting Screw—Approximate Pressure Change......................................... 3792 kPa (37 bar) (550 psi)
If pressure cannot be adjusted to specification, disassemble and inspect priority valve . (See Group 0960.) TX,2525,UU1213 -19-03DEC92-1/1
TM1529 (27JUN17)
9025-25-11
544G, 624G, 644G Loader
062717
PN=651
Test
Priority Valve "LS" Port Flow Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Approximate Priority Valve "LS" Port Flow Rate
750 mL/min (0.2 gpm)
ESSENTIAL TOOLS 38H1146 (-6 M ORFS) (Parker No. 6 PNLO-S) Plug SERVICE EQUIPMENT AND TOOLS Temperature Reader Measuring Container Stop Watch
T7801AB —UN—26AUG92
Priority valve "LS" port flow test will check for a plugged or missing orifice in the bottom of the priority valve spool. A plugged orifice will block warm-up flow to the steering valve which can cause thermal shock. (See Group 9025-15 for an explanation of thermal shock .) A missing orifice can cause the pump to be loaded to high pressure at all times causing overheating. 1. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 2. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Disconnect line from "LS" port and install plug (A). 4. Connect line (B) to priority valve.
If flow is low, low steering system neutral pressure or a plugged orifice in bottom priority valve spool is indicated. Specification Approximate Priority Valve "LS" Port—Flow Rate....................................................................... 750 mL/min (0.2 gpm)
If flow is high, remove priority valve spool and inspect for a missing orifice . (See Group 0960.)
5. Start engine and run at specification. Specification Engine—Speed..........................................................................Slow idle
Do Hydraulic System Restriction Test in this group.
6. Measure flow from "LS" port for 1 minute. TX,2525,UU1214 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-12
544G, 624G, 644G Loader
062717
PN=652
Test
Priority Valve Relief Cartridge Leakage Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Fast idle
Maximum Priority Valve Relief Cartridge Leakage
1 m/L (16 drops per min.)
ESSENTIAL TOOLS 38H1145 (-4 M ORFS) (Parker No. 4 PNLO-S) Plug SERVICE EQUIPMENT AND TOOLS Temperature Reader Measuring Container Stop Watch
T7801AA —UN—26AUG92
1. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 2. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Disconnect line from "R" port on priority valve. Install plug (A) in line. 4. Start engine and run at specification. Specification Engine—Speed...........................................................................Fast idle
5. Measure oil leakage from "R" port. If leakage is more than specification, disassemble and inspect cartridge for damage or debris .
Specification Maximum Priority Valve Relief Cartridge—Leakage.........................................1 m/L (16 drops per min.)
(See Group 0960.) TX,9025,UU1232 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-13
544G, 624G, 644G Loader
062717
PN=653
Test
Secondary Steering Pump Relief Valve Pressure Test SPECIFICATIONS 65 ± 6°C (150 ± 10°F)
Engine Speed
Stopped
Secondary Steering Pump Relief Valve Pressure
3450—4480 kPa (35—45 bar) (500—650 psi)
T6569AD —UN—21OCT88
Oil Temperature
ESSENTIAL TOOLS JT05488 (7/16 M 37° x 7/16 M ORB) (Parker No. 0503-4-4) Fitting SERVICE EQUIPMENT AND TOOLS Temperature Reader Gauge 0—7000 kPa (0—70 bar) (0—1000 psi)
1. Install temperature reader. (See procedure in this group.) 2. Heat hydraulic oil to specification. Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Connect fitting (A) and gauge to steering valve. IMPORTANT: DO NOT operate secondary steering pump and motor for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur. T6569AL —UN—21OCT88
4. Being careful not to start the engine, turn key switch to START position and release. Specification Engine—Speed...........................................................................Stopped
This will activate the secondary steering pump. Read pressure gauge. If pressure is not to specification, remove cover (B) and turn adjusting screw to adjust pressure. Specification Secondary Steering Pump Relief Valve—Pressure....................................................................3450—4480 kPa (35—45 bar) (500—650 psi)
• Do Secondary Steering Valve Primary Check Valve Leakage Test in this group.
• Do Steering Valve Leakage Test in this group. • Replace secondary steering pump. (See Group 0930.)
If pressure is low and cannot be adjusted to specifications: TX,9025,UU1233 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-14
544G, 624G, 644G Loader
062717
PN=654
Test
Secondary Steering Manifold Primary Check Valve Leakage Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Stopped
Maximum Secondary Steering Manifold Primary Check Valve Leakage
No steady stream of oil
ESSENTIAL TOOLS 38H1417 (-10 F ORFS) (Parker No. 10 FNL-S) Cap (544G) 38H1418 (-12 F ORFS) (Parker No. 12 FNL-S) Cap (624G, 644G) SERVICE EQUIPMENT AND TOOLS Temperature Reader
T6569AI —UN—21OCT88
Primary check valve leakage will allow oil to flow from the secondary steering circuit into the main hydraulic system during secondary steering operation. This leakage can cause slow secondary steering. 1. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 2. Heat hydraulic oil to specification. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
This will activate the secondary steering pump.
(See Hydraulic Oil Warm-Up Procedure in this group.) 3. Disconnect line (B) from priority valve. Install cap (A) to priority valve fitting. IMPORTANT: DO NOT operate secondary steering pump and motor for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur. 4. Being careful not to start engine, turn key switch to START and release.
5. Observe leakage from hose (B). If leakage is more than specification, replace manifold block . Specification Maximum Secondary Steering Manifold Primary Check Valve—Leakage.................................................. No steady stream of oil
(See Group 0930).
Specification Engine—Speed...........................................................................Stopped TX,2525,UU1234 -19-17SEP93-1/1
TM1529 (27JUN17)
9025-25-15
544G, 624G, 644G Loader
062717
PN=655
Test
Secondary Steering Manifold Secondary Check Valve Leakage Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Maximum Secondary Steering Manifold Secondary Check Valve Leakage
No steady stream of oil
ESSENTIAL TOOLS 38H1147 (-8 M ORFS) (Parker No. 8 PNLO-S) Plug SERVICE EQUIPMENT AND TOOLS Temperature Reader
T6569AJ —UN—21OCT88
Secondary check valve leakage will allow oil to flow from the main hydraulic system to the reservoir through the secondary steering pump. This leakage can cause slow cycle times. 1. Install temperature reader. (See procedure in this group.) 2. Heat hydraulic oil to specification. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) If leakage is more than specification, clean or replace check valve .
3. Stop engine. 4. Remove line from check valve (A) on secondary steering valve. 5. Install plug (B) to line. 6. Run engine at specification. Specification Engine—Speed..........................................................................Slow idle
Specification Maximum Secondary Steering Manifold Secondary Check Valve—Leakage.................................................. No steady stream of oil
(See Group 0930.)
7. Observe leakage from check valve (A). TX,9025,UU1235 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-16
544G, 624G, 644G Loader
062717
PN=656
Test
Pilot Control Valve Pressure Test (Serial Number —563542) SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Pilot Controller Begins Metering at 3/4—1 in. Lever Travel Distance Pilot Control Valve Pressure in Boom Float Detent
4137—4480 kPa (41—45 bar) (600—650 psi)
Boom Power Down Pressure at Feel Position
2275—2620 kPa (22.7—26.2 bar) (330—380 psi)
Boom Raise Pressure at Feel Position
2034—2710 kPa (20.4—27.1 bar) (295—393 psi)
544G LL, 544G TC Bucket 2034—2710 kPa (20.4—27.1 bar) Rollback Pressure at Feel Position (295—393 psi) 544G, 624G, 644G Bucket 2034—2710 kPa (20.4—27.1 bar) Rollback Pressure at Feel Position (295—393 psi) 544G LL, 544G TC Bucket Dump Pressure at Feel Position
2034—2710 kPa (20.4—27.1 bar) (295—393 psi)
NOTE: As the control lever is moved from neutral, the pilot pressure will suddenly jump up to approximately 90 psi at 3/4—1 in. lever travel. The pressure should then increase smoothly to the specification at the FEEL position (or 3/4 lever travel), then jump up to 600—650 psi as the lever is moved into detent.
T7011AK —UN—21MAR89
Bucket Dump (544G, 624G, 644G) Pressure must increase smoothly to 2034—2710 kPa (20.4—27.1 and Auxiliary Valve Pressure at bar) (295—393 psi) at 3/4 Feel Position lever travel, then increase to 4140—4480 kPa (41.4—44.8 bar) (600—650 psi) as the lever is moved past 80—90% travel
NOTE: The FEEL position is when lever is moved to feel the ramp of the detent before lever passes into detent position. 1. Lower boom to ground.
ESSENTIAL TOOLS
2. Connect test fittings and gauge to the pilot pressure port of function to be checked.
JT03103 (1-1/16 F 37° x 7/16 M 37°) Adapter JT05687 (-6 F ORFS x 1-1/16 M 37°) Adapter
3. Install temperature reader. (See Temperature Reader Installation Procedure in this group.)
SERVICE EQUIPMENT AND TOOLS
4. Heat hydraulic oil to specification.
Gauge 0—6895 kPa (0—69 bar)
This test will determine if adequate pilot pressure is available to move the loader control valve spools.
Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.)
Continued on next page
TM1529 (27JUN17)
9025-25-17
TX,9025,DU1572 -19-02DEC93-1/3
544G, 624G, 644G Loader
062717
PN=657
Test
5. Run engine at specification. Specification Engine—Speed..........................................................................Slow idle
Activate function to be checked and record pressure reading. Specification Pilot Controller Begins Metering at—Lever Travel Distance..........................................................................3/4—1 in. Pilot Control Valve—Pressure in Boom Float Detent...........................................................................4137—4480 kPa (41—45 bar) (600—650 psi) Boom Power Down—Pressure at Feel Position.......................................................................... 2275—2620 kPa (22.7—26.2 bar) (330—380 psi) Boom Raise—Pressure at Feel Position.............................................................. 2034—2710 kPa (20.4—27.1 bar) (295—393 psi) 544G LL, 544G TC Bucket Rollback—Pressure at Feel Position.................................................................. 2034—2710 kPa (20.4—27.1 bar) (295—393 psi)
544G, 624G, 644G Bucket Rollback—Pressure at Feel Position.................................................................. 2034—2710 kPa (20.4—27.1 bar) (295—393 psi) 544G LL, 544G TC Bucket Dump—Pressure at Feel Position.............................................................. 2034—2710 kPa (20.4—27.1 bar) (295—393 psi) Bucket Dump (544G, 624G, 644G) and Auxiliary Valve—Pressure at Feel Position............................................ Pressure must increase smoothly to 2034—2710 kPa (20.4—27.1 bar) (295—393 psi) at 3/4 lever travel, then increase to 4140—4480 kPa (41.4—44.8 bar) (600—650 psi) as the lever is moved past 80—90% travel
NOTE: If boom raise or bucket rollback FEEL positions are not operating due to boom or bucket position, plug boom float detent wires into return-to-dig solenoid or boom height kickout solenoid. This will provide a feel position on the control lever.
Continued on next page
TM1529 (27JUN17)
9025-25-18
TX,9025,DU1572 -19-02DEC93-2/3
544G, 624G, 644G Loader
062717
PN=658
T6740AC —UN—21OCT88
Test
A—Spool Positioning Shims
B—Spool Metering Shims
C—Pilot Controller
If pressure is not to specification at the boom float detent, check for a worn detent plate or detent pins. If parts are not worn, loosen screws on upper portion of controller and shift upper sections forward before tightening screws. Lever travel to begin metering can also be reduced to minimum specification to raise pressure in detent position.
To adjust lever travel specification to begin metering, add or remove spool positioning shims (A).
If pressure is still not to specification, do Pressure Reducing Valve Pressure Test in this group.
Shims are available in following sizes:
If pressure reducing valve pressure is to specification, add or remove shims to reach correct pilot pressure as follows:
To adjust pressure to specification for feel positions and pressure at 3/4 lever travel, add or remove spool metering shims (B).
• 0.004 in. • 0.007 in. • 0.015 in. TX,9025,DU1572 -19-02DEC93-3/3
TM1529 (27JUN17)
9025-25-19
544G, 624G, 644G Loader
062717
PN=659
Test
Pilot Control Valve Pressure Test (Serial Number 563543—) SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Pilot Controller Begins Metering at 3/8—5/8 in. Lever Travel Distance (Measured at Top End of Lever) 4137—4480 kPa (41—45 bar) (600—650 psi)
Boom Pressure at Feel Position
As the control lever is moved from neutral, the pilot pressure will suddenly jump up to approximately 90 psi at 3/8—5/8 in. lever travel. The pressure should then increase smoothly to the specification at the FEEL position (or 75% lever travel), then jump up to 600—650 psi as the lever is moved into detent.
Boom Power Down Pressure
1860—2082 kPa (19—21 bar) (270—302 psi)
Boom Raise Pressure
1882—2227 kPa (19—22 bar) (273—323 psi)
Bucket Rollback Pressure
2110—2455 kPa (21—25 bar) (306—356 psi)
Bucket Dump and Auxiliary Valve Pressure
Pressure must increase smoothly to 2110—2455 kPa (21—25 bar) (306—356 psi) at 3/4 lever travel, then increase to 4140—4480 kPa (41.4—44.8 bar) 600—650 psi) as the lever is moved past 80—90% travel.
T107155 —19—19FEB97
Boom Pressure in Float Detent
Continued on next page
TM1529 (27JUN17)
9025-25-20
TX,9025,TJ26 -19-26SEP97-1/3
544G, 624G, 644G Loader
062717
PN=660
Test ESSENTIAL TOOLS 38H1415 (11/16 - 16 F ORFS) Cap (A) 38H1278 (11/16 - 18 M 37° x 11/16 -18 M ORFS) Union (B) JT03456 (7/16 -20 M 37° x 11/16 -16 F ORFS) Adapter (C) SERVICE EQUIPMENT AND TOOLS Gauge 0—6895 kPa (0—69 bar) (0—1000 psi)
This test will determine if adequate pilot pressure is available to move the loader control valve spools. NOTE: The FEEL position is when the lever is moved to feel the ramp of the detent before lever passes into detent position. 1. Lower boom to ground. 2. Connect test fittings and gauge to the pilot pressure port of function to be checked control valve. 3. Use monitor display unit. 4. Heat hydraulic oil to specification. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 5. Operate engine at specification. Specification Engine—Speed..........................................................................Slow idle
Activate function to be checked and record pressure reading.
Specification Pilot Controller Begins Metering at—Lever Travel Distance (Measured at Top End of Lever).....................................................................................3/8—5/8 in. Boom—Pressure in Float Detent....................................................................................4137—4480 kPa (41—45 bar) (600—650 psi) Pressure at Feel Position................................. As the control lever is moved from neutral, the pilot pressure will suddenly jump up to approximately 90 psi at 3/8—5/8 in. lever travel. The pressure should then increase smoothly to the specification at the FEEL position (or 75% lever travel), then jump up to 600—650 psi as the lever is moved into detent. Boom Power Down—Pressure...................................................................1860—2082 kPa (19—21 bar) (270—302 psi) Boom Raise—Pressure.........................................................1882—2227 kPa (19—22 bar) (273—323 psi) Bucket Rollback—Pressure................................... 2110—2455 kPa (21—25 bar) (306—356 psi) Bucket Dump and Auxiliary Valve—Pressure.................................. Pressure must increase smoothly to 2110—2455 kPa (21—25 bar) (306—356 psi) at 3/4 lever travel, then increase to 4140—4480 kPa (41.4—44.8 bar) 600—650 psi) as the lever is moved past 80—90% travel.
6. If pressure is not to specification, do Pressure Reducing Valve Pressure Test . 7. If pressure reducing valve pressure is to specification, but pilot control pressure is not to specification, check for loose or worn ball and socket assembly. Continued on next page
TM1529 (27JUN17)
9025-25-21
TX,9025,TJ26 -19-26SEP97-2/3
544G, 624G, 644G Loader
062717
PN=661
T105535 —UN—03DEC96
Test
8. If pressure reducing valve is to specification, add or remove 1shims to reach the correct pilot pressure as follows:
• To adjust pressure to specification for feel positions
and pressure at 3/4 lever travel, add or remove spool metering shims (B).
• To adjust lever travel specification to begin metering, add or remove spool position shims (A).
1
Shims are available in 0.004, 0.007, and 0.015 in. thicknesses. TX,9025,TJ26 -19-26SEP97-3/3
TM1529 (27JUN17)
9025-25-22
544G, 624G, 644G Loader
062717
PN=662
Test
Pressure Reducing Valve Pressure Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Pressure Reducing Valve Pilot Pressure Setting
4140—4480 kPa (41.4—44.8 bar) (600—650 psi)
ESSENTIAL TOOLS JT03111 (7/16 M 37° x 9/16 M ORB) Connector SERVICE EQUIPMENT AND TOOLS Gauge 0—6895 kPa (0—69 bar) (0—1000 psi)
The pressure reducing valve regulates pressure to the pilot control circuit and differential lock.
T8127AU —UN—20MAY94
1. Connect test fitting and gauge to test port (A), marked REG TEST on the pressure reducing valve. 2. Install temperature reader. (See Temperature Reader Installation Procedure in this group.) 3. Heat hydraulic oil to specifications. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
(See Hydraulic Oil Warm-Up Procedure in this group.) 4. Run engine at specification with park brake on service brakes Not applied, differential lock off and pilot controller in neutral and read pressure gauge. Specification Engine—Speed..........................................................................Slow idle
This reading is the pressure reducing valve pilot pressure. 5. If pressure is not within specifications, replace valve (C).
A—Test Port B—Cap
C—Valve
Specification Pressure Reducing Valve—Pilot Pressure Setting........................................................................... 4140—4480 kPa (41.4—44.8 bar) (600—650 psi)
The valve is staked and should not be adjusted. TX,9025,DU1573 -19-02NOV94-1/1
TM1529 (27JUN17)
9025-25-23
544G, 624G, 644G Loader
062717
PN=663
Test
Cycle Time Test Specification Oil—Temperature.................................................. 65 ± 6°C (150 ± 10°F) Engine—Speed...........................................................................Fast idle 544G LL And 544G TC Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time.......................................................................................6.2 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.......................................................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time.............................................................................2.1 seconds Bucket Rollback (Boom at Full Height)—Maximum Cycle Time.............................................................................2.7 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.............................................................................2.5 seconds Number of Turns...................................................................... 3.75 turns 544G Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time.......................................................................................6.2 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.......................................................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time.............................................................................1.6 seconds Bucket Rollback (Boom at Full Height)—Maximum Cycle Time.............................................................................2.5 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.............................................................................2.5 seconds Number of Turns...................................................................... 3.75 turns 624G Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time.......................................................................................6.2 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.......................................................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time.............................................................................1.8 seconds
Bucket Rollback (Boom at Full Height)—Maximum Cycle Time.............................................................................2.5 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.............................................................................2.5 seconds Number of Turns...................................................................... 3.75 turns 644G Loader—Specification Boom Raise (Bucket Flat on Ground to Full Height)—Maximum Cycle Time.......................................................................................6.4 seconds Boom Lower (Float; Full Height to Ground Level)—Maximum Cycle Time.......................................................................................3.8 seconds Bucket Dump (Boom at Full Height)—Maximum Cycle Time.............................................................................2.0 seconds Bucket Rollback (Boom at Full Height)—Maximum Cycle Time.............................................................................3.0 seconds Steering (Frame Stop to Frame Stop)—Maximum Cycle Time.............................................................................2.5 seconds Number of Turns...................................................................... 3.75 turns Hydraulic Pump Performance—Specification 544G LL, 544G TC Boom Raise (Bucket Flat on Ground to Full Height While Holding Steering Over Relief)—Maximum Cycle Time.............................................................................9.0 seconds 544G Boom Raise (Bucket Flat on Ground to Full Height While Holding Steering Over Relief)—Maximum Cycle Time.......................................................................................9.0 seconds 624G Boom Raise (Bucket Flat on Ground to Full Height While Holding Steering Over Relief)—Maximum Cycle Time.......................................................................................8.0 seconds 644G Boom Raise (Bucket Flat on Ground to Full Height While Holding Steering Over Relief)—Maximum Cycle Time.......................................................................................9.0 seconds
TX,2525,UU1284 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-24
544G, 624G, 644G Loader
062717
PN=664
Test
Hydraulic Oil Filter Inspection Procedure 1. Remove filter. 2. Pour oil out of filter to inspect for water contamination. T6238AK —UN—13MAR89
3. Use an oil filter cutting tool to cut top off filter. 4. Remove element and inspect for metal particles and debris in bottom of filter can. 5. Excessive amounts of brass and steel particles can indicate a failed hydraulic pump or a pump failure in process. A rubber type of material can indicate cylinder packing failure.
TX,902525,EE25 -19-16SEP92-1/1
Pin Disconnect Solenoid Valve Leakage Test SPECIFICATIONS Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle
Maximum Pin Disconnect Solenoid 460 mL/min (15.5 oz/min) Valve Leakage ESSENTIAL TOOLS 38H1414 (-4 F ORFS) (Parker No. 4FNL-S) Cap SERVICE EQUIPMENT AND TOOLS Temperature Reader Measuring Container Stop Watch
T7812CG —UN—26AUG92
1. Fasten temperature sensor to inlet fitting of solenoid valve. 2. Heat hydraulic oil by holding a function over relief. Cycle pin disconnect cylinders until temperature is at specification. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
3. Extend pin disconnect cylinder. 4. Stop engine. 5. Disconnect line. Install cap (A).
8. If leakage is excessive, replace seals or valve .
6. Start engine.
Specification Maximum Pin Disconnect Solenoid Valve—Leakage.............................................. 460 mL/min (15.5 oz/min)
Specification Engine—Speed..........................................................................Slow idle
DO NOT push pin disconnect switch.
(See Group 3160.)
7. Check leakage for 1 minute. TX,2525,UU1285 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-25
544G, 624G, 644G Loader
062717
PN=665
Test
Pin Disconnect Cylinder Leakage Test
Oil Temperature
40 ± 6°C (100 ± 10°F)
Engine Speed
Slow idle T7812CF —UN—26AUG92
SPECIFICATIONS
Maximum Pin Disconnect Cylinder 15 mL/min (1/2 oz/min) Leakage ESSENTIAL TOOLS 38H1414 (-4 F ORFS) (Parker No. 4FNL-S) Cap SERVICE EQUIPMENT AND TOOLS Temperature Reader
5. Disconnect line. Install cap (A).
Measuring Container
6. Start engine.
Stop Watch
1. Fasten temperature sensor to fitting of cylinder to be tested. 2. Heat hydraulic oil by holding a function over relief. Cycle pin disconnect cylinders until temperature is at specification. Specification Oil—Temperature.................................................. 40 ± 6°C (100 ± 10°F)
3. Extend pin disconnect cylinder.
Specification Engine—Speed..........................................................................Slow idle
DO NOT push pin disconnect switch. 7. Check leakage for 1 minute. 8. If leakage is excessive, repair or replace cylinder . Specification Maximum Pin Disconnect Cylinder—Leakage.............................................. 15 mL/min (1/2 oz/min)
(See Group 3160.)
4. Stop engine.
TX,2525,UU1286 -19-16SEP92-1/1
TM1529 (27JUN17)
9025-25-26
544G, 624G, 644G Loader
062717
PN=666
Section 9031 Air Conditioning System Contents Page Page
Group 05—Theory Of Operation Proper Refrigerant Handling...................... 9031-05-1 R12 And R134a Refrigerant Cautions ................................................ 9031-05-1 Refrigerant Theory Of Operation ............... 9031-05-2 Air Conditioner Circuit Operational Information............................................. 9031-05-3 Air Conditioning Circuit Theory Of Operation............................................... 9031-05-3 Air Conditioning Circuit Schematic.............................................. 9031-05-4 Defroster Pressurization Circuit Operational Information ......................... 9031-05-6 Defroster Pressurization Circuit Operation............................................... 9031-05-7 Heater/Pressurizer Circuit Operational Information ....................... 9031-05-10 Heater/Pressurizer Circuit Theory Of Operation ........................................ 9031-05-11 Receiver/Dryer Operation........................ 9031-05-13 Expansion Valve Operation ..................... 9031-05-14 Compressor Relief Valve Operation............................................. 9031-05-14 Temperature Control................................ 9031-05-15 Group 10—System Operational Checks Air Conditioning Operational Checks................................................... 9031-10-1 Visual Inspection Of Components .....................................................9031-10-1 System Operating Checks.........................9031-10-3 System Performance Checks ....................9031-10-5 Air Conditioner Electrical Circuit Checks ..................................................9031-10-6
R134a Compressor Oil Information............................................. 9031-20-7 R134a Compressor Oil Charge Check .................................................... 9031-20-7 R134a Compressor Oil Removal............... 9031-20-8 R134a Component Oil Charge .................. 9031-20-8 R134a Refrigerant Recovery/Recycling And Charging Station Installation Procedures ............................................ 9031-20-9 R134a Refrigerant Recovery ................... 9031-20-10 Evacuate R134a System ......................... 9031-20-11 Charge R134a System ............................ 9031-20-12 Check And Adjust Compressor Belt Tension ................................................ 9031-20-13 Group 25—Tests Special Or Essential Tools......................... 9031-25-1 Proper Refrigerant Handling...................... 9031-25-1 R12 And R134a Refrigerant Cautions ................................................ 9031-25-1 R12 Air Conditioning System Test.............. 9031-25-2 R134a Air Conditioning System Test ........................................................ 9031-25-3 Operating Pressure Diagnostic Chart...................................................... 9031-25-5 Pressure Diagnostic Chart......................... 9031-25-7 Low Pressure Switch Test ......................... 9031-25-8 High Pressure Switch Test......................... 9031-25-9 Clutch Cycle Switch................................... 9031-25-9 Leak Testing ............................................ 9031-25-10 Refrigerant Hoses And Tubing Inspection ............................................ 9031-25-10
Group 15—Diagnostic Information Diagnose Air Conditioning Electrical Malfunctions........................... 9031-15-1 Air Conditioning Component Location Drawing................................... 9031-15-3 Group 20—Adjustments Special Or Essential Tools......................... 9031-20-1 Proper Refrigerant Handling...................... 9031-20-1 R12 And R134a Refrigerant Cautions ................................................ 9031-20-1 R12 Component Oil Charge ...................... 9031-20-2 R12 Refrigerant Evacuation And Charging Station Installation Procedure .............................................. 9031-20-3 Recover R12 System................................. 9031-20-4 Evacuate R12 System ............................... 9031-20-5 Charge R12 System .................................. 9031-20-6
TM1529 (27JUN17)
9031-1
544G, 624G, 644G Loader
062717
PN=1
Contents
TM1529 (27JUN17)
9031-2
544G, 624G, 644G Loader
062717
PN=2
Group 05
Theory Of Operation Proper Refrigerant Handling The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings, components or refrigerant oils intended for use with R12 refrigerant.
Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants.
TX,9031,QQ2009 -19-19AUG94-1/1
R12 And R134a Refrigerant Cautions 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. 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. 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 develop high pressure which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. 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. (R12 ONLY) Refrigerant exposed to high temperature forms phosgene gas. Inhaling toxic phosgene gas may result in serious illness or death. Phosgene gas has an odor like new mown hay or green corn. If you inhale phosgene gas, go to a physician or hospital immediately for treatment. TX,9031,QQ2010 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-05-1
544G, 624G, 644G Loader
062717
PN=669
Theory Of Operation
Refrigerant Theory Of Operation The compressor draws low pressure gas from the evaporator and compresses it into high pressure gas. Increasing the pressure of refrigerant causes its boiling point to rise to a temperature higher than the outside air temperature. As the high pressure gas flows through the condenser, the condenser fans draw air through the condenser core which cools the refrigerant. Cooling the refrigerant causes it to condense and leave the condenser as a high pressure liquid. The high pressure liquid flows into the receiver/dryer where moisture and contaminants are removed. The receiver/dryer is also a reservoir that stores excess refrigerant. A sight glass is mounted above the receiver/dryer. Bubbles can be seen in the sight glass when the system refrigerant is low.
If too much refrigerant is flowing into evaporator, the liquid refrigerant will still be evaporating as it leaves the evaporator, causing a low temperature at the evaporator outlet. The low temperature causes the expansion valve variable orifice to decrease in size, restricting refrigerant flow. If the evaporator outlet temperature is too warm, the orifice will increase in size, allowing more refrigerant into evaporator. If the evaporator temperature becomes to low and freezes, the air conditioning freeze control temperature switch will open and interrupt current flow to the compressor clutch coil, stopping system operation.
T8408AA —19—03FEB95
The refrigerant flows from the receiver/dryer to the expansion valve. The expansion valve is one of the dividing lines between the high side and low side of the air conditioning system. At this point in the system, the high pressure/high temperature liquid refrigerant is sprayed into the evaporator where it changes and becomes a gas.
The valve diaphragm is activated by sensing temperature and pressure within the valve body. The internal bulb senses the evaporator outlet or discharge temperature and pressure of the refrigerant as it passes through the valve back to the low pressure or suction side of the compressor. See Expansion Valve Operation in this group for additional information on theory of operation.
A—Low Pressure Switch B—Receiver Dryer C—High Pressure Liquid
D—Condenser Fans E—Condenser F— High Pressure Gas
G—Compressor H—Low Pressure Gas I— Evaporator J— Expansion Valve
K—High Pressure Switch
TX,9031,DU1676 -19-04NOV93-1/1
TM1529 (27JUN17)
9031-05-2
544G, 624G, 644G Loader
062717
PN=670
Theory Of Operation
• Heater/pressurizer fan switch to HIGH, MEDIUM or
Air Conditioner Circuit Operational Information
LOW position
The following conditions must exist for the air conditioner circuit to function:
• Key switch to ON position
• A/C shutoff switch closed • Freeze control temperature cycling switch closed • A/C low pressure switch closed • A/C high pressure switch closed TX,9015,DU1658 -19-10NOV93-1/1
Air Conditioning Circuit Theory Of Operation With the engine running, heater/pressurizer fan switch on, air conditioning shutoff switch on, and the freeze control temperature cycling switch, high pressure switch and low pressure switch in closed position, the compressor clutch is engaged and the compressor operates. Refrigerant in a gaseous state enters the compressor and is compressed into a high pressure, high temperature gas. As the air conditioning compressor clutch is energized, current flows from the accessory relay through the air conditioning motor relay and through the two 20 amp circuit breakers, to energize the condenser motors. The air conditioning freeze control temperature cycling switch prevents evaporator freeze-up. The switch is closed during normal operation, allowing current to flow to the low pressure switch, high pressure switch and compressor clutch coil to ground, engaging compressor clutch. If temperature in evaporator goes below specified range, temperature switch opens, de-energizing
compressor clutch until evaporator temperature is within specification. Temperature switch then closes, energizing compressor clutch. The air conditioning low pressure switch is a pressure switch that opens when there is insufficient charge of the refrigerant in the system. This is to protect the compressor from operating without refrigerant. The switch opens to stop current flow to the compressor clutch coil, preventing compressor engagement. The air conditioning high pressure switch is a pressure switch that opens when the refrigerant pressure reaches the high limit. If a malfunction or line restriction causes pressure to increase above switch setting, the switch will open, stopping current flow to the compressor clutch coil. The air conditioning compressor clutch coil suppression diode limits the voltage spike across the switch contacts when any of the air conditioning switches are open. TX,9031,DU1678 -19-04NOV93-1/1
TM1529 (27JUN17)
9031-05-3
544G, 624G, 644G Loader
062717
PN=671
Theory Of Operation
T8118AE —UN—04JAN94
Air Conditioning Circuit Schematic
Continued on next page
TM1529 (27JUN17)
9031-05-4
TX,9031,DU1680 -19-05JAN94-1/2
544G, 624G, 644G Loader
062717
PN=672
Theory Of Operation B15— Freeze Control Temperature Cycling Switch B16— Low Pressure Switch B17— High Pressure Switch F16— 30 A Heater/Pressurizer Fan Fuse F17— 20 A Condenser Motor Circuit Breaker
F18— 20 A Condenser Motor Circuit Breaker F19— 20 A Defroster Fan Fuse K9—Defroster Pressurization Relay K10— Condenser Motor Relay M7—Pressurizer Fan Motor
M8—Condenser Motor M9—Condenser Motor M10— Defroster Fan Motor R1—Resistor R2—Resistor S15— Air Conditioning Shutoff Switch S16— Heater/Pressurizer Fan Switch
NOTE: B15—Freeze Control Temperature Cycling Switch
S17— Defroster Fan Switch V14— Air Conditioning Clutch 1 A Diode Y12— Compressor Clutch
• B15 indicates component identification number listed on schematic diagrams.
TX,9031,DU1680 -19-05JAN94-2/2
TM1529 (27JUN17)
9031-05-5
544G, 624G, 644G Loader
062717
PN=673
Theory Of Operation
Defroster Pressurization Circuit Operational Information
• Key switch to ON position • Defroster fan switch to LOW, MEDIUM, or HIGH position
The following conditions must exist for the defroster pressurization circuit to function: TX,901515,DU715 -19-16SEP92-1/1
TM1529 (27JUN17)
9031-05-6
544G, 624G, 644G Loader
062717
PN=674
Theory Of Operation
Defroster Pressurization Circuit Operation Current flows from 20 amp defroster fan fuse to the four-position rotary defroster fan switch. When switch is turned on, current flows to the defroster fan resistor to
operate the defroster fan motor. The defroster fan resistor limits the current to the defroster fan motor to control the speed of the fan.
Continued on next page
TM1529 (27JUN17)
9031-05-7
TX,9031,MM1469 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=675
T7812BG —19—09SEP97
Theory Of Operation
TX,9031,MM1469 -19-16SEP92-2/2
TM1529 (27JUN17)
9031-05-8
544G, 624G, 644G Loader
062717
PN=676
Theory Of Operation
TM1529 (27JUN17)
9031-05-9
544G, 624G, 644G Loader
062717
PN=677
Theory Of Operation
Heater/Pressurizer Circuit Operational Information
• Key switch to ON position • Defroster pressurization relay energized
The following conditions must exist for the heater/pressurizer circuit to function: TX,901515,DU701 -19-16SEP92-1/1
TM1529 (27JUN17)
9031-05-10
544G, 624G, 644G Loader
062717
PN=678
Theory Of Operation
Heater/Pressurizer Circuit Theory Of Operation
fan. The pressurizer fan resistor limits the current to the pressurizer fan motor to control the speed of the fan.
Current flows from the 20 amp heater/pressurizer fan fuse to the four-position rotary heater/pressurizer fan switch. When the switch is turned on, current flows to the pressurizer fan motor, which drives the pressurizer
The defroster pressurization relay is energized when the defroster fan motor is on, and the pressurizer fan motor is also on. This balances the air flow in the ducts.
Continued on next page
TM1529 (27JUN17)
9031-05-11
TX,9031,MM1470 -19-04NOV93-1/2
544G, 624G, 644G Loader
062717
PN=679
T7812BH —19—09SEP97
Theory Of Operation
TX,9031,MM1470 -19-04NOV93-2/2
TM1529 (27JUN17)
9031-05-12
544G, 624G, 644G Loader
062717
PN=680
Theory Of Operation
Receiver/Dryer Operation The receiver/dryer is a reservoir to store excess liquid refrigerant in the system. Excess refrigerant is required for two reasons: Outside air temperature and humidity have an effect on the minimum quantity of refrigerant required in the system for the air conditioner to operate at maximum efficiency. The higher the temperature and humidity, the more refrigerant required in the system. More refrigerant is required due to the expansion valve opening farther allowing more refrigerant into the low pressure side of the system. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls. Extra refrigerant stored in the system allows for a longer period of time before additional refrigerant is needed.
T8104AE —UN—19OCT93
The receiver/dryer also contains two filters (E) and desiccant (F) between the filters. The filters remove solid materials which could be generated by a compressor failure, debris left in the system due to improper service procedures, or particles caused by corrosion of metal parts due to moisture and acids in the system (also caused by improper service procedures).
A sight glass is located in receiver/dryer to condenser line. Remove plug in service door to view sight glass through the door. If the refrigerant level is low, a steady stream of gas bubbles will be present in the liquid flowing from the receiver/dryer. These gas bubbles in the sight glass indicate that the system needs charging. Bubbles may be present when the compressor clutch first engages but must disappear after a few seconds. If the sight glass is clear, the system either has a sufficient charge or is completely discharged.
T8104AF —UN—10JAN94
Desiccant is used to absorb moisture. If too much moisture gets into the system, the desiccant may not be able to absorb it all. When moisture is combined with refrigerant oil, a sludge is formed. This sludge does not permit moving parts to be adequately lubricated. When moisture is combined with refrigerant, hydrofluoric and hydrochloric acids are formed. These acids are very corrosive to metal surfaces and leakage will eventually develop. If the air conditioning system is left open for a period of time or if the plugs are removed from the receiver/dryer, the desiccant will also absorb moisture from the air. The receiver/dryer contains a color moisture indicator. (Blue) indicates dryer is dry. (Pink) indicates moisture in the desiccant. Evacuating the system will not remove moisture from the desiccant. You must replace the receiver/dryer.
A—Inlet Port B—Sight Glass (Not Used, This Application) C—Outlet Port D—Pickup Tube E—Filter
F— Desiccant G—Strainer H—Spring I— Receiver/Dryer J— Wet/Dry Indicator
TX,9031,MM2407 -19-26JAN95-1/1
TM1529 (27JUN17)
9031-05-13
544G, 624G, 644G Loader
062717
PN=681
Theory Of Operation
T7828AY —19—24SEP92
Expansion Valve Operation
A—Valve Diaphragm B—Sealed Sensing Bulb C—Outlet to Compressor
D—Operating Pin E—Inlet Flow F— Metering Orifice G—Valve Spring
H—Ball Seat I— Outlet to Evaporator J— Discharge from Evaporator
The expansion valve is used to regulate the amount of refrigerant flowing into the evaporator. At this point in the system, the high pressure/high temperature liquid is sprayed into the evaporator where it changes state and becomes a gas. The valve diaphragm (A) is activated by sensing temperature and pressure within the valve body. The sealed sensing bulb (B) senses the evaporator outlet (I) or discharge temperature and pressure of the refrigerant as it passes through the valve back to the low pressure or suction side of the compressor.
K—Internal Equalization Passage
The metering orifice (F) and ball seat area (H) in the expansion valve is relatively small. The rapidly expanding refrigerant passing through this area can cause any moisture in the system to freeze at this point and block refrigerant flow. Other contaminants in the system can also cause a valve to malfunction. If expansion valve malfunctions, it must be replaced. Expansion valve is not repairable.
TX,9031,QQ2012 -19-17JUN94-1/1
Compressor Relief Valve Operation The compressor relief valve is a direct-acting, pressure-limiting valve. If a malfunction in the system occurs that would cause high pressure, such as a restricted line. On R12 systems, the valve will open at 3100 ± 380 kPa (31 ± 3.8 bar) (450 ± 55 psi). On R314A systems, the valve will open at 3795 ± 345 kPa (38 ±
3.5 bar) (550 ± 50 psi). The valve will remain open until pressure drops to below the valve setting. If the relief valve opens, a loud popping noise will be heard. Some oil may also be lost from the system. Correct any condition that would cause the valve to open. TX,9031,DU1681 -19-04NOV93-1/1
TM1529 (27JUN17)
9031-05-14
544G, 624G, 644G Loader
062717
PN=682
Theory Of Operation
Temperature Control Temperature control is adjusted by the position of the heater temperature switch in the cab. This switch is mechanically connected to the water valve at the base of the heater core. Turning the heater temperature switch towards maximum and/or towards off opens and closes the water valve controlling engine coolant flow through
the heater core, thus controlling the temperature inside the cab. In certain conditions when the air conditioning switch is turned on and the blower switch is in low position, the cab temperature may still be too cool. It may be necessary to blend heat with cooling to get a comfortable cab temperature. TX,903105,QQ775 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-05-15
544G, 624G, 644G Loader
062717
PN=683
Theory Of Operation
TM1529 (27JUN17)
9031-05-16
544G, 624G, 644G Loader
062717
PN=684
Group 10
System Operational Checks Air Conditioning Operational Checks This procedure is designed so the mechanic can make a quick check of the system using a minimum amount of diagnostic equipment. If you need additional information, read Theory of Operation (Group 9031-05).
additional checks or repair information will be given. The TM Group or CTM number required for repair will be given. If verification is needed, you will be given next best source of information:
The engine or other major components must be at operating temperature for some checks.
Group: 10 (System Operational Checks) Group: 15 (Diagnostic Information)
Locate system check in the left column and read completely, following this sequence from left to right. Read each check completely before performing.
Group: 20 (Adjustments)
At the end of each check, if no problem is found, that check is complete. When a problem is indicated,
CTM (Component Technical Manual)
Group: 25 (Tests)
TX,9031,QQ1862 -19-17JUN94-1/40
• 1
Visual Inspection Of Components
TX,9031,QQ1862 -19-17JUN94-2/40
All Lines And Hoses
Engine OFF. Inspect all lines and hoses. Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts or "weather checked"? Are hose and line connections clean NOT showing signs of leakage, such as oil or dust YES: Check complete. accumulation at fittings? All hose and line clamps must be in place and tight. Clamps must have rubber inserts or cushions in place to prevent clamps from crushing or wearing into hoses or lines.
Continued on next page
TM1529 (27JUN17)
9031-10-1
NO: Reposition hoses or lines and tighten or replace clamps. Tighten fittings or replace O-rings in fittings. Replace hoses or lines as required. TX,9031,QQ1862 -19-17JUN94-3/40
544G, 624G, 644G Loader
062717
PN=685
System Operational Checks Air Conditioner Compressor Check
T6488GD —UN—02SEP93
Engine OFF. Inspect compressor. Is compressor drive belt tight? Specification is 19 mm (0.75 in.) deflection with 90 N (20 lb force) midway between pulleys. Is belt in good condition, NOT frayed, worn or glazed? Is compressor belt pulley in good condition, NOT worn or grooved? Are compressor mounting brackets in good condition, NOT bent or broken? Are compressor mounting bracket cap screws tight? Is compressor pulley aligned with engine pulleys, NOT worn or grooved?
YES: Check complete.
Are electrical connections to compressor clutch clean and tight? Is wiring to compressor NO: Repair or replace in good condition? components as required. TX,9031,QQ1862 -19-17JUN94-4/40
Condenser Check
Engine OFF. Inspect condenser cores. Is condenser core free of dirt or debris? Does condenser show signs of leakage, dust accumulation or oily areas? Are condenser fins straight, NOT bent or damaged? Inspect engine fan.
YES: Check complete.
Are fan blades in good condition, NOT worn, bent, broken or missing?
NO: Clean, repair or replace condenser core. Replace engine fan. TX,9031,QQ1862 -19-17JUN94-5/40
Evaporator Core Check
Engine OFF. Inspect core. Are fins straight?
YES: Check complete.
Is evaporator core free of dirt and debris?
NO: Repair, replace or clean evaporator. TX,9031,QQ1862 -19-17JUN94-6/40
Freeze Control Switch Sensing Tube Check
Engine OFF. Inspect freeze control switch sensing tube.
YES: Check complete.
Is sensing tube straight, NOT kinked or broken?
NO: If sensing tube is kinked, replace freeze control switch.
Is sensing tube inserted into evaporator core and secured in place?
NO: If tube is positioned in evaporator incorrectly, re-route.
Continued on next page
TM1529 (27JUN17)
9031-10-2
TX,9031,QQ1862 -19-17JUN94-7/40
544G, 624G, 644G Loader
062717
PN=686
System Operational Checks Heater Shut-Off Valve Check
Engine OFF. Close heater shut-off valve located on engine. Run engine at operating temperature. Operate heater fan on high speed. Move heater temperature control to HOT. Does heater valve move freely through operating range? Run blower fan on high speed. Does hot air come through heater outlets? Move heater temperature control to COLD.
YES: Check complete.
Is cooler air coming from heater outlets?
NO: If air coming from heater outlets is hot or warm all the time, replace shut-off valve. TX,9031,QQ1862 -19-17JUN94-8/40
Cab Door And Window Seals Check
Open and close door and windows. Inspect seals. Do door and windows contact seals evenly?
YES: Check complete.
Are seals in position and in good condition?
NO: Adjust door and windows to close against seals properly. Replace seals as necessary. TX,9031,QQ1862 -19-17JUN94-9/40
• 2
System Operating Checks
TX,9031,QQ1862 -19-17JUN94-10/40
Defroster Fan Motor Check
Engine OFF. Key switch ON. Turn defroster fan switch to LOW, MEDIUM and HIGH. Does fan have three speeds?
YES: Check complete.
Does air exit from ducts?
NO: See Circuit Checks in Group 9031. Check wiring harness. TX,9031,QQ1862 -19-17JUN94-11/40
Heater/Pressurizer Motor Check
Engine OFF. Key switch ON. Turn heater/pressurizer fan switch to LOW, MEDIUM and HIGH. Does fan have three speeds?
YES: Check complete.
Does air exit from ducts?
NO: See Circuit Checks in Group 9031. Check wiring harness. Continued on next page
TM1529 (27JUN17)
9031-10-3
TX,9031,QQ1862 -19-17JUN94-12/40
544G, 624G, 644G Loader
062717
PN=687
System Operational Checks Defroster/ Pressurization Relay Check
Engine OFF. Key switch ON. Turn defroster fan switch from OFF to MEDIUM speed.
YES: Check complete.
Does relay "click" as switch is turned from OFF to MEDIUM?
NO: See Circuit Checks in Group 9031. Check wiring harness. TX,9031,QQ1862 -19-17JUN94-13/40
Air Conditioner Condenser Motor Relay Check
Engine OFF.
Key switch ON. Turn heater/pressurizer fan switch to LOW position. Turn air conditioning shutoff switch to ON position. Does condenser motor relay "click?"
YES: Check complete.
Does condenser motor "click?"
NO: See Circuit Checks in Group 9031. Check wiring harness. TX,9031,QQ1862 -19-17JUN94-14/40
Air Conditioning Shutoff Switch Check
Engine OFF. Heater/pressurizer fan switch on LOW. Air conditioning shutoff switch OFF.
YES: Check complete.
Turn air conditioning shutoff switch to ON. Do switch contacts close with a "click" as switch is turned on?
NO: If switch does not "click" as specified, switch is failed. Replace. TX,9031,QQ1862 -19-17JUN94-15/40
Low Pressure Switch Check
Engine OFF. Key switch ON. Heater/pressurizer fan switch on LOW. Air conditioning shutoff switch ON. Disconnect low pressure switch wiring leads. Does compressor clutch solenoid "click" when wiring leads are disconnected? Reconnect low pressure switch wiring leads to harness.
YES: Check complete.
Does compressor clutch solenoid "click" as wiring leads are reconnected?
NO: If compressor clutch solenoid does not click as specified, low pressure switch is failed. Replace low pressure switch.
Continued on next page
TM1529 (27JUN17)
9031-10-4
TX,9031,QQ1862 -19-17JUN94-16/40
544G, 624G, 644G Loader
062717
PN=688
System Operational Checks High Pressure Switch Check
Engine OFF. Key switch ON. Heater/pressurizer fan switch on LOW. Air conditioning shutoff switch ON. Disconnect high pressure switch wiring leads. Reconnect high pressure switch wiring leads to harness.
YES: Check complete.
Does compressor clutch solenoid "click" when wiring leads are disconnected?
NO: If compressor clutch solenoid does not "click" as specified, high pressure switch is failed. Replace high pressure switch. TX,9031,QQ1862 -19-17JUN94-17/40
Low And High Pressure Valve Schrader Valve Check
Engine OFF.
Remove low and high pressure switches from line. (Schrader valves are located under pressure switch to prevent system from discharging when switch is removed.)
YES: Discharge air conditioning system and replace Schrader valve. (See Recover and Recycle Refrigerant Group 9031.)
Does refrigerant leak from Schrader valve?
NO: Check complete. TX,9031,QQ1862 -19-17JUN94-18/40
Compressor Clutch Check
Engine OFF. Key switch ON. Heater/pressurizer fan switch on LOW. Turn air conditioner shutoff switch to ON.
YES: Check complete.
Does compressor clutch "click" as switch is pushed?
NO: Replace compressor clutch. TX,9031,QQ1862 -19-17JUN94-19/40
• 3
System Performance Checks
Continued on next page
TM1529 (27JUN17)
9031-10-5
TX,9031,QQ1862 -19-17JUN94-20/40
544G, 624G, 644G Loader
062717
PN=689
System Operational Checks System Performance Check
NOTE: Perform Visual Inspection and Operating Checks in this group prior to evaluating air conditioning system performance. Open load center door located below cab right window. Inspect wet/dry indicator on receiver/dryer. If indicator shows blue, continue checks. If indicator shows pink, replace receiver/dryer. Turn heater/pressurizer fan switch to HIGH position. Push air conditioner shutoff switch to ON. Move heater control to COLD position, and close heater shut-off valve. Start engine and run at fast idle for 5 minutes. Measure air temperature at condenser inlet. Measure air temperature at air ducts in cab. If condenser inlet air (ambient) temperature is below 27°C (80°F), duct air temperature must be below 13°C (55°F).
YES: Operation is satisfactory. System Operational Checkout is complete.
If condenser inlet air temperature is above 27°C (80°F), duct air temperature must be 14—17°C (25—30°F) below condenser inlet air temperature.
NO: Go to next check. TX,9031,QQ1862 -19-17JUN94-21/40
Receiver/Dryer Check
Position controls as in System Performance Check. After starting engine, pull plug on load center door located below cab right window and observe inline sight glass.
YES: Check complete.
Bubbles may be present when compressor clutch engages but must disappear after a few seconds.
NO: Go to Recharge System in Group 9031-20. TX,9031,QQ1862 -19-17JUN94-22/40
Evaporator Check
Remove seat and covers over evaporator. Is ice forming on evaporator core? Is fan motor failing or fan blades damaged? Is freeze control temperature cycling switch sensing tube properly positioned? Is heater temperature control misadjusted or damaged? Is evaporator core plugged with dirt?
YES: Repair as needed.
Is evaporator drain tube plugged or damaged?
NO: Go to Expansion Valve Bench Test in Group 1830. TX,9031,QQ1862 -19-17JUN94-23/40
Evaporator Housing Drain Check
Remove bottom guard from underside of cab. Is water dripping on cab floor? Is drain tube plugged, cracked or misrouted? Is evaporator housing or drain tray broken?
YES: Repair or replace as needed.
Is drain tube connected to drain?
NO: Air Conditioning Operation Checkout complete. TX,9031,QQ1862 -19-17JUN94-24/40
• 4
Air Conditioner Electrical Circuit Checks
This circuit is protected by a 20 amp Defroster fan fuse and a 30 amp Heater/pressurizer fan fuse. Continued on next page
TM1529 (27JUN17)
9031-10-6
TX,9031,QQ1862 -19-17JUN94-25/40
544G, 624G, 644G Loader
062717
PN=690
System Operational Checks Air Conditioner Compressor Check
Engine OFF. Inspect compressor. Is compressor drive belt tight? Is belt in good condition? Is belt tightening strap straight? Is compressor belt pulley in good condition (NOT grooved)? Are compressor to bracket and bracket to engine mounting cap screws tight? Is compressor pulley aligned with engine pulley? Is engine dampener pulley in good condition (not grooved)?
YES: Go to next check.
Are electrical connections to compressor clutch clean and tight? Is wiring to compressor NO: Repair or replace in good condition? components as required. TX,9031,QQ1862 -19-17JUN94-26/40
Air Conditioner Shutoff Switch Check
T7751GF —UN—31AUG92
Disconnect harness from switch. Check for continuity between terminals with A23 orange wire and A24 orange wire.
YES: Replace switch.
Is continuity measured?
NO: Switch is good. Go to next check. TX,9031,QQ1862 -19-17JUN94-27/40
Freeze Control Temperature Cycling Switch Check
T7751GG —UN—31AUG92
Disconnect harness from freeze control temperature cycling switch. Check for continuity between terminals with A24 orange wire and A25 orange wire.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace switch. Continued on next page
TM1529 (27JUN17)
9031-10-7
TX,9031,QQ1862 -19-17JUN94-28/40
544G, 624G, 644G Loader
062717
PN=691
System Operational Checks Air Conditioning Low Pressure Switch Check
T7199EE —UN—02OCT90
Disconnect harness from switch. Check for continuity between terminals with A25 orange wire and A12 orange wire.
YES: Replace low pressure switch.
Does ohmmeter read continuity?
NO: Switch is good. Go to next step in this check.
Remove switch from system. (A valve under the switch prevents freon from escaping when the switch is removed.) Measure continuity across switch terminals.
YES: Switch is good. Check wiring harness.
Does ohmmeter read open?
NO: Go to Low Pressure Switch Test , Group 9031-25. TX,9031,QQ1862 -19-17JUN94-29/40
Air Conditioner High Pressure Switch Check
T7199EE —UN—02OCT90
Disconnect harness from switch. Measure continuity across switch terminals.
YES: Switch is good. Check wiring harness.
Does ohmmeter read continuity?
NO: Replace high pressure switch.
Remove switch from system. (A valve under the switch prevents freon from escaping when the switch is removed.) Measure continuity across switch terminals.
YES: Switch is good. Check wiring harness.
Does ohmmeter read continuity?
NO: System pressure is too high. Go to Air Conditioning Operating Pressure Diagnostic Chart , Group 9031-25. Continued on next page
TM1529 (27JUN17)
9031-10-8
TX,9031,QQ1862 -19-17JUN94-30/40
544G, 624G, 644G Loader
062717
PN=692
System Operational Checks Compressor Clutch Coil Check
T7751GJ —UN—31AUG92
Disconnect harness from clutch. Connect battery voltage to clutch terminal that had A11 orange wire.
YES: Clutch is good. Check wiring harness.
Does clutch coil "click?"
NO: Replace clutch coil. TX,9031,QQ1862 -19-17JUN94-31/40
Air Conditioner Condenser Motor Relay Check
T7287BH —UN—16AUG90
Disconnect harness from relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click?" Measure continuity between terminals #30 and #87.
YES: Relay is OK. Check wiring harness.
Is continuity measured?
NO: Replace relay. TX,9031,QQ1862 -19-17JUN94-32/40
Condenser Fan Motor Check
T7751GL —UN—31AUG92
NOTE: Each condenser fan motor has a circuit breaker. The air conditioning system will operate with one condenser fan, but will be inefficient. Disconnect harness from fan motor. Connect battery voltage to motor terminal that had P13 red wire or P14 red wire. Ground black wire terminal.
YES: Check wiring harness.
Does condenser fan motor operate?
NO: Replace fan motor. Continued on next page
TM1529 (27JUN17)
9031-10-9
TX,9031,QQ1862 -19-17JUN94-33/40
544G, 624G, 644G Loader
062717
PN=693
System Operational Checks Defroster Fan Switch Check
T7751FP —UN—31AUG92
Disconnect harness from switch. Defroster fan switch to OFF position. Check for continuity between terminal with P27 red wire and remaining terminals.
YES: Replace defroster fan switch.
Is continuity measured at any terminal?
NO: Go to next step in this check.
T7751FK —UN—31AUG92
Defroster fan switch to LOW position. Check for continuity between switch terminals B, L and C. Is continuity measured? Defroster fan switch to MEDIUM position. Check for continuity between switch terminals B, M and C. Is continuity measured? Defroster fan switch to HIGH position. Check for continuity between switch terminals B, H and C.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace defroster fan switch. TX,9031,QQ1862 -19-17JUN94-34/40
Defroster Fan Resistor Check
T6534CR —UN—19OCT88
Measure ohms between terminals 3 and 1. Does ohmmeter read about 1.0 ohms? Measure ohms between terminals 3 and 2.
YES: Resistor is OK. Check wiring harness.
Does ohmmeter read about 0.5 ohms?
NO: Replace resistor. Continued on next page
TM1529 (27JUN17)
9031-10-10
TX,9031,QQ1862 -19-17JUN94-35/40
544G, 624G, 644G Loader
062717
PN=694
System Operational Checks Defroster Fan Motor Check
T8399AC —UN—27JAN95
Disconnect harness from fan motor. Connect battery voltage to motor terminal that had orange wire. Ground black wire terminal.
YES: Motor is good. Check wiring harness.
Does defroster fan motor operate?
NO: Replace fan motor. Continued on next page
TM1529 (27JUN17)
9031-10-11
TX,9031,QQ1862 -19-17JUN94-36/40
544G, 624G, 644G Loader
062717
PN=695
System Operational Checks Heater/Pressurizer Fan Switch Check
T7751FK —UN—31AUG92
Disconnect harness from switch. Heater/pressurizer fan switch to OFF position. Check for continuity between B switch terminal and remaining terminals.
YES: Replace heater/pressurizer fan switch.
Is continuity measured at any terminal?
NO: Go to next step in this check.
T7751FK —UN—31AUG92
Heater/pressurizer fan switch to LOW position. Check for continuity between switch terminals B, L and C. Is continuity measured? Heater/pressurizer fan switch to MEDIUM position. Check for continuity between switch terminals B, M and C. Is continuity measured? Heater/pressurizer fan switch to HIGH position. Check for continuity between switch terminals B, H and C.
YES: Switch is good. Check wiring harness.
Is continuity measured?
NO: Replace heater/pressurizer fan switch. Continued on next page
TM1529 (27JUN17)
9031-10-12
TX,9031,QQ1862 -19-17JUN94-37/40
544G, 624G, 644G Loader
062717
PN=696
System Operational Checks Heater/Pressurizer Fan Resistor Check
T6534CR —UN—19OCT88
Measure ohms between terminals 3 and 1. Does ohmmeter read about 1.0 ohms? Measure ohms between terminals 3 and 2.
YES: Check wiring harness.
Does ohmmeter read about 0.5 ohms?
NO: Replace resistor. TX,9031,QQ1862 -19-17JUN94-38/40
Defroster Pressurization Relay Check
T6534CC —UN—02SEP93
Disconnect harness from relay. Connect battery voltage to terminal #86. Ground terminal #85. Does relay "click?" Measure continuity between terminals #30 and #87.
YES: Check wiring harness.
Is continuity measured?
NO: Replace relay. TX,9031,QQ1862 -19-17JUN94-39/40
Pressurizer Fan Motor Check
T7812BJ —UN—21AUG92
Disconnect harness from fan motor. Connect battery voltage to motor terminal that had orange wire. Ground black wire terminal.
YES: Check wiring harness.
Does fan motor operate?
NO: Replace fan motor. TX,9031,QQ1862 -19-17JUN94-40/40
TM1529 (27JUN17)
9031-10-13
544G, 624G, 644G Loader
062717
PN=697
System Operational Checks
TM1529 (27JUN17)
9031-10-14
544G, 624G, 644G Loader
062717
PN=698
Group 15
Diagnostic Information Diagnose Air Conditioning Electrical Malfunctions
Step 2. Diagnose Malfunctions Chart for possible problems of symptoms.
NOTE: Diagnose malfunction charts are arranged from most probable and simplest to verify, to least likely, more difficult to verify. Remember the following steps when troubleshooting a problem:
Step 3. Electrical Operational Checkout to verify problem. Step 4. Tests
Step 1. Operational Checkout to verify symptom. Symptom
Problem
Solution
Air Conditioning System Does Not Operate
30 amp Heater/pressurizer fan fuse or Replace fuse. 20 amp Defroster fan fuse Heater/pressurizer fan switch See Heater/Pressurizer Fan Switch Check , Group 9031-10. Air conditioner shutoff switch
See Air Conditioner Shutoff Switch Check , Group 9031-10.
Freeze control temperature cycling switch
See Freeze Control Temperature Cycling Switch Check , Group 9031-10.
Air conditioner low pressure switch
See Air Conditioner Low Pressure Switch Check , Group 9031-10.
Air conditioner high pressure switch
See Air Conditioner High Pressure Switch Check , Group 9031-10.
Compressor clutch coil
See Compressor Clutch Coil Check , Group 9031-10.
Air conditioner condenser motor relay See Air Conditioner Condenser Motor Relay Check , Group 9031-10. 20 amp Air conditioner condenser motor circuit breaker Condenser motor
Wiring harness
Replace fuse.
Defroster fan switch
See Defroster Fan Switch Check , Group 9031-10.
Defroster fan resistor
See Defroster Fan Resistor Check , Group 9031-10.
Defroster fan motor
See Defroster Fan Motor Check , Group 9031-10.
30 amp Heater/pressurizer fan fuse
Replace fuse.
Continued on next page
TM1529 (27JUN17)
See Condenser Motor Check , Group 9031-10. Check wiring harness.
Defroster System Does Not Operate 20 amp Defroster fan fuse
Heater/Pressurizer System Does Not Work
Replace circuit breaker
9031-15-1
TX,9031,MM1513 -19-16SEP92-1/2
544G, 624G, 644G Loader
062717
PN=699
Diagnostic Information Symptom
Problem
Solution
Heater/pressurizer fan switch
See Heater/Pressurizer Fan Switch Check , Group 9031-10.
Pressurizer fan motor
See Pressurizer Fan Motor Check , Group 9031-10.
Wiring harness
Check wiring harness. TX,9031,MM1513 -19-16SEP92-2/2
TM1529 (27JUN17)
9031-15-2
544G, 624G, 644G Loader
062717
PN=700
TM1529 (27JUN17)
T8118AF —19—13APR11
9031-15-3
Air Conditioning Component Location Drawing
Diagnostic Information
062717
PN=701
544G, 624G, 644G Loader
TX,9031,DU1687 -19-16DEC93-1/1
Diagnostic Information
TM1529 (27JUN17)
9031-15-4
544G, 624G, 644G Loader
062717
PN=702
Group 20
Adjustments T8389AF —UN—03JAN95
Special Or Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD ™Catalog or in the European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company DX,TOOLS -19-05JUN91-1/3
Schrader Valve Tool............................................. JD02130 To replace Schrader valve in compressor manifold on R134a A/C Systems. To replace Schrader valve
in ports where high and low pressure switches are located in R134a A/C Systems.
DX,TOOLS -19-05JUN91-2/3
To replace Schrader valve in compressor manifold on R134a A/C Systems.
To replace Schrader valve in ports where high and low pressure switches are located in R134a A/C Systems. DX,TOOLS -19-05JUN91-3/3
Proper Refrigerant Handling The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings, components
or refrigerant oils intended for use with R12 refrigerant. Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants. TX,9031,QQ2009 -19-19AUG94-1/1
R12 And R134a Refrigerant Cautions 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. 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. 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 develop high pressure which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. 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. (R12 ONLY) Refrigerant exposed to high temperature forms phosgene gas. Inhaling toxic phosgene gas may result in serious illness or death. Phosgene gas has an odor like new mown hay or green corn. If you inhale phosgene gas, go to a physician or hospital immediately for treatment. TX,9031,QQ2010 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-20-1
544G, 624G, 644G Loader
062717
PN=703
Adjustments
R12 Component Oil Charge IMPORTANT: The compressor takes a special 525 viscosity oil R49856 that has "special additives" which give better compressor life. If complete system was flushed to remove contamination, the full charge of oil 326 mL (11 fl oz) must be added to the system. NOTE: Dispose oil drained from compressor in accordance with Federal, State and Local regulations. Do not reuse oil drained from the system. Always add NEW oil to the system. 1. Remove compressor. Drain the oil from the suction port and record amount of oil. 2. If 90—240 mL (3—8 fl oz) was drained from the original compressor, add 180 mL (6 fl oz) of new oil back into the compressor. 3. If more than 240 mL (8 fl oz) was drained from the original compressor, add 180 mL (6 fl oz) of new oil back into the compressor. Replace receiver/dryer to remove excess oil from the system. 4. If less than 90 mL (3 fl oz) was drained from the original compressor, flush all components of the system. Replace the receiver/dryer and add 330 mL (11 fl oz) of new oil back into the system.
5. When installing a compressor that has been disassembled and reassembled with no oil charge, add an extra 30 mL (1 fl oz) to the amounts specified in steps 2, 3 or 4. 6. When installing a new or remanufactured compressor, drain the oil. Replace with new oil per steps 2, 3 or 4. 7. If components of the system were drained and flushed, add 330 mL (11 fl oz) to the compressor. 8. After adding proper amount of oil, rotate the compressor shaft four or five times to insure proper lubrication of the compressor seal. IMPORTANT: DO NOT add any more oil than necessary or maximum cooling will be reduced. 9. When servicing individual components, determine the oil charge needed using following chart: Component
Oil Charge
Condenser
59 mL (2 fl oz)
Evaporator
118 mL (4 fl oz)
Receiver/Dryer
15 mL (0.4 fl oz)
TX,9031,QQ2081 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-20-2
544G, 624G, 644G Loader
062717
PN=704
Adjustments
R12 Refrigerant Evacuation And Charging Station Installation Procedure E—Yellow Hose F— Recovery/Recycling Station G—Low Pressure Test Port H—High Pressure Relief Valve
T7938AJ —UN—25FEB93
A—High Pressure Switch B—Red Hose (High Pressure) C—Blue Hose (Low Pressure) D—Gauge Assembly
TX,9031,QQ2014 -19-17JUN94-1/3
R12 Refrigerant Charging and Evacuation Station ..................................................................JT02023
To service the air conditioning system. TX,9031,QQ2014 -19-17JUN94-2/3
CAUTION: Do not remove high pressure relief valve (H). 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. 1. Close both high and low pressure valves on gauge assembly (D).
2. Remove cap from low pressure test port (G). 3. Connect (C) low pressure hose blue from refrigerant recovery, recycling station (F) to low pressure test port (G) on compressor. 4. Remove high pressure switch (A) and connect high pressure red hose (B) from refrigerant charging and evacuation station. 5. Follow the manufactures instructions when using the refrigerant evacuation and charging station. TX,9031,QQ2014 -19-17JUN94-3/3
TM1529 (27JUN17)
9031-20-3
544G, 624G, 644G Loader
062717
PN=705
Adjustments
Recover R12 System E—Yellow Hose F— Recovery/Recycling Station G—Low Pressure Test Port H—High Pressure Relief Valve
T7938AI —UN—25FEB93
A—High Pressure Switch B—Red Hose (High Pressure) C—Blue Hose (Low Pressure) D—Gauge Assembly
TX,9031,QQ2016 -19-17JUN94-1/3
R12 Refrigerant Recovery and Recycling Station ..................................................................JT02020
To service the air conditioning system. TX,9031,QQ2016 -19-17JUN94-2/3
JT02020 recovery and recycling station can be substituted for the JT02021 station.
CAUTION: Do not remove high pressure relief valve (H). 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.
1. Connect refrigerant recovery and recycling station. (See installation procedure in this group.) 2. Follow the manufactures instructions when using the refrigerant recovery and recycling station.
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. TX,9031,QQ2016 -19-17JUN94-3/3
TM1529 (27JUN17)
9031-20-4
544G, 624G, 644G Loader
062717
PN=706
Adjustments
Evacuate R12 System E—Yellow Hose F— Recovery/Recycling Station G—Low Pressure Test Port H—High Pressure Relief Valve
T7938AJ —UN—25FEB93
A—High Pressure Switch B—Red Hose (High Pressure) C—Blue Hose (Low Pressure) D—Gauge Assembly
TX,9031,QQ2017 -19-17JUN94-1/3
R12 Refrigerant Charging and Evacuation Station ..................................................................JT02023
To service air conditioning system.
Continued on next page
TM1529 (27JUN17)
9031-20-5
TX,9031,QQ2017 -19-17JUN94-2/3
544G, 624G, 644G Loader
062717
PN=707
Adjustments
4. Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.
CAUTION: Do not remove high pressure relief valve (H). Air conditioning system will discharge rapidly causing possible injury.
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test the system for leaks. (See Leak Testing , 9031-25). Correct any leaks.
IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off. 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.
Do not run compressor while evacuating. 1. Connect refrigerant charging and evacuation station. (See installation procedure in this group.)
7. Repair leak. 8. Start to evacuate.
2. Open low and high pressure valves on refrigerant charging and evacuation station.
9. Open low-side and high-side valves.
3. Follow the manufactures instructions and evacuate the system.
10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached.
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.
11. Close low-side and high-side valves. Stop evacuation. 12. Charge the system. (See procedure in this group.) TX,9031,QQ2017 -19-17JUN94-3/3
Charge R12 System E—Yellow Hose F— Charging and Evacuation Station G—Low Side Test Port H—High Pressure Relief Valve
T7938AJ —UN—25FEB93
A—High Pressure Switch B—Red Hose (High Pressure) C—Blue Hose (Low Pressure) D—Gauge Assembly
Continued on next page
TM1529 (27JUN17)
9031-20-6
TX,9031,DU1727 -19-22NOV93-1/3
544G, 624G, 644G Loader
062717
PN=708
Adjustments
R12 Refrigerant Charging and Evacuation Station ..................................................................JT02023
To service air conditioning system. TX,9031,DU1727 -19-22NOV93-2/3
CAUTION: Do not remove high pressure relief valve (H). 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. 1. Connect refrigerant charging and evacuation station. (See installation procedure in this group.) 2. Evacuate the system. (See Evacuate Air Conditioning System in this group.)
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. 3. Follow the manufacturers’ instructions and charge the system. 4. Add refrigerant until system is charged with 2.3 Kg (5 lbs). 5. Do air conditioner checks and tests in Groups 9031-10 and 9031-25. TX,9031,DU1727 -19-22NOV93-3/3
R134a Compressor Oil Information 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.
A new compressor from parts depot contains 230 ± 20 mL (7.7 ± .7 fl oz) of new oil. The oil level visible through the suction port normally is below the drive shaft. The normal operating oil level of a compressor removed from operation is 30—45 mL (1.0—1.5 fl oz). This level cannot be seen through the suction port of the compressor. TX,9031,QQ2365 -19-19APR94-1/1
R134a Compressor Oil Charge Check Remove compressor if R134a leakage was detected and repaired. See Remove and Install Compressor in Repair Manual. Drain oil from the compressor and record the amount. See Compressor Oil Removal procedure in this group. NOTE: Drain oil and save if this is a new compressor. 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: 1. Remove and discard the receiver/dryer.
3. Flush the complete system with air conditioning flushing solvent. 4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil. 5. Install a new receiver/dryer. 6. Install required amount of TY22025 refrigerant oil in the compressor. (See R134a Component Oil Charge in this group.) 7. Connect all components, evacuate and charge the system.
2. Remove, clean, but do not disassemble the valve. TX,9031,QQ2366 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-20-7
544G, 624G, 644G Loader
062717
PN=709
Adjustments
R134a Compressor Oil Removal
4. Record measured oil and discard oil properly.
1. Remove compressor from machine. See Remove and Install Compressor in Repair Manual.
5. Install new oil. See R134a Component Oil Charge in this Group.
2. Remove inlet/outlet manifold from compressor, and clutch dust cover.
6. Install compressor. See Remove and Install Compressor in Repair Manual.
3. Drain oil into graduated container while rotating compressor shaft. TX,9015,QQ2299 -19-17JUN94-1/1
R134a Component Oil Charge
• Used compressor removed from operation and oil
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 Determining 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 100 mL (3.4 fl oz) of new oil. Used compressor removed from operation, oil drained, and flushed requires 330 ± 20 mL (11.1 ± .7 fl oz) of new oil.
•
drained, (See Compressor Oil Removal 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
130 mL (4.4 fl oz)
Condenser
65 mL (2.2 fl oz)
Receiver/Dryer
30 mL (1.0 fl oz)
Hoses
60 mL (2.0 fl oz)
NOTE: Hoses = 3 mL per 30 cm (0.1 fl oz per ft) Approximate total length equals 600 cm (20 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 amount of oil for each component that was serviced.
• New compressor from parts depot, drain and return
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.
45 mL (1.5 fl oz) of oil to the compressor. (See Compressor Oil Removal procedure in this group)
TX,9015,QQ2300 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-20-8
544G, 624G, 644G Loader
062717
PN=710
Adjustments
R134a Refrigerant Recovery/Recycling And Charging Station Installation Procedures D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging Station
T8118AG —UN—06DEC93
A—High Pressure Hose Charge Port Cap B—Red Hose C—Blue Hose
TX,9031,DU1693 -19-26JAN95-1/3
HFC134a Deluxe Recovery/Recycling and Charging Station ..................................................................JT02045
To service air conditioning system. TX,9031,DU1693 -19-26JAN95-2/3
CAUTION: Do not remove high pressure relief valve (D). Air conditioning station 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. NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station.
2. Remove cap from low-side charge port. 3. Connect blue hose (C) from refrigerant recovery/recycling and charging station (E) to low-side test port. 4. Remove cap (A) from charge port on high pressure hose and connect red hose (B). 5. Follow the manufacturers’ instructions when using the refrigerant recovery/recycling and charging station.
1. Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (E). TX,9031,DU1693 -19-26JAN95-3/3
TM1529 (27JUN17)
9031-20-9
544G, 624G, 644G Loader
062717
PN=711
Adjustments
R134a Refrigerant Recovery D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging Station
T8118AG —UN—06DEC93
A—High Pressure Hose Charge Port Cap B—Red Hose C—Blue Hose
TX,9031,DU1694 -19-26JAN95-1/3
HFC134a Deluxe Recovery/Recycling and Charging Station ..................................................................JT02045
To service air conditioning system. TX,9031,DU1694 -19-26JAN95-2/3
CAUTION: Do not remove high pressure relief valve (D). 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.
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.) 2. Follow the manufacturers’ instructions when using the refrigerant recovery/recycling and charging station.
NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. TX,9031,DU1694 -19-26JAN95-3/3
TM1529 (27JUN17)
9031-20-10
544G, 624G, 644G Loader
062717
PN=712
Adjustments
Evacuate R134a System D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging Station
T8118AG —UN—06DEC93
A—High Pressure Hose Charge Port Cap B—Red Hose C—Blue Hose
TX,9031,DU1695 -19-26JAN95-1/3
HFC134a Deluxe Recovery/Recycling and Charging Station ..................................................................JT02045
To service air conditioning system.
Continued on next page
TM1529 (27JUN17)
9031-20-11
TX,9031,DU1695 -19-26JAN95-2/3
544G, 624G, 644G Loader
062717
PN=713
Adjustments
4. Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.
CAUTION: Do not remove high pressure relief valve (D). Air conditioning system will discharge rapidly causing possible injury.
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test the system for leaks. (See Leak Testing , 9031-25). Correct any leaks.
IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils.
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off. 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.
Do not run compressor while evacuating. NOTE: JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station.
7. Repair leak. 8. Start to evacuate.
1. Connect refrigerant recovery/recycling and charging station. (See installation procedure in this group.)
9. Open low-side and high-side valves.
2. Open low-side and high-side valves on refrigerant recovery/recycling and charging station.
10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached.
3. Follow the manufacturers’ instructions and evacuate the system.
11. Close low-side and high-side valves. Stop evacuation. 12. Charge the system. (See procedure in this group.)
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. TX,9031,DU1695 -19-26JAN95-3/3
Charge R134a System D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging Station
T8118AG —UN—06DEC93
A—High Pressure Hose Charge Port Cap B—Red Hose C—Blue Hose
Continued on next page
TM1529 (27JUN17)
9031-20-12
TX,9031,DU1696 -19-26JAN95-1/3
544G, 624G, 644G Loader
062717
PN=714
Adjustments
HFC134a Deluxe Recovery/Recycling and Charging Station ..................................................................JT02045
To service air conditioning system. TX,9031,DU1696 -19-26JAN95-2/3
CAUTION: Do not remove high pressure relief valve (D). 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. NOTE: JT02047 and JT02050 recovery and charging stations can be substituted for the JT02045 station. 1. Connect refrigerant recovery/recycling and charging station. (See installation procedure in this group.) 2. Evacuate the system. (See Evacuate R134a System in this group.)
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. 3. Follow the manufacturers’ instructions and charge the system. 4. Add refrigerant until system is charged with 2.3 Kg (5 lbs). 5. Do air conditioner checks and tests in Groups 9031-10 and 9031-25. TX,9031,DU1696 -19-26JAN95-3/3
Check And Adjust Compressor Belt Tension SERVICE EQUIPMENT AND TOOLS
2. Belt must deflect 19 mm (0.75 in.) at 90 N (20 lb force). If not, allow belt to cool for 8—10 minutes.
Belt Tension Gauge
IMPORTANT: NEVER over tighten belt. Over tightening may cause belt cord damage and excessive load on bearings. 1. Run engine for five minutes. Stop the engine, then immediately check tension using a belt tension gauge. Measure strand tension or deflection at a point halfway between pulleys.
IMPORTANT: Force to adjust belt must be applied to front of compressor housing only to prevent damage to compressor. 3. Loosen compressor mounting cap screws. Apply force to front of compressor housing to tighten belt. Tighten cap screws. 4. Repeat Steps 1 and 2 to check belts. TX,1830,QQ1112 -19-16SEP92-1/1
TM1529 (27JUN17)
9031-20-13
544G, 624G, 644G Loader
062717
PN=715
Adjustments
TM1529 (27JUN17)
9031-20-14
544G, 624G, 644G Loader
062717
PN=716
Group 25
Tests T8389AF —UN—03JAN95
Special Or Essential Tools NOTE: Order tools according to information given in the U.S. SERVICEGARD ™Catalog or in the European Microfiche Tool Catalog (MTC).
SERVICEGARD is a trademark of Deere & Company DX,TOOLS -19-05JUN91-1/3
Schrader Valve Tool............................................. JD02130 To replace Schrader valve in compressor manifold on R134a A/C Systems. To replace Schrader valve
in ports where high and low pressure switches are located in R134a A/C Systems. DX,TOOLS -19-05JUN91-2/3
To replace Schrader valve in compressor manifold on R134a A/C Systems.
To replace Schrader valve in ports where high and low pressure switches are located in R134a A/C Systems. DX,TOOLS -19-05JUN91-3/3
Proper Refrigerant Handling The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings, components
or refrigerant oils intended for use with R12 refrigerant. Recovery, recycling and charging stations for R12 and R134a refrigerants MUST NOT be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants. TX,9031,QQ2009 -19-19AUG94-1/1
R12 And R134a Refrigerant Cautions 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. 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. 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 develop high pressure which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. 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. (R12 ONLY) Refrigerant exposed to high temperature forms phosgene gas. Inhaling toxic phosgene gas may result in serious illness or death. Phosgene gas has an odor like new mown hay or green corn. If you inhale phosgene gas, go to a physician or hospital immediately for treatment. TX,9031,QQ2010 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-25-1
544G, 624G, 644G Loader
062717
PN=717
Tests
R12 Air Conditioning System Test SPECIFICATIONS Condenser Inlet Air Temperature
Low Side Pressure
High Side Pressure
°C
(°F)
kPa
(bar)
(psi)
kPa
(bar)
(psi)
15
(60)
7—76
(0.07—0.76)
(1—11)
690—900
(6.9—9.0)
(100—130)
21
(70)
10—86
(0.1—0.86)
(1.5—12.5)
865—1070
(8.6—10.7)
(125—155)
27
(80)
7—117
(0.07—1.17)
(1—17)
965—1175
(9.7—11.7)
(140—170)
32
(90)
21—124
(0.21—1.24)
(3—18)
1105—1310
(11.0—13.1)
(160—190)
38
(100)
38—145
(0.38—1.45)
(5.5—21)
1310—1520
(13.1—15.2)
(190—220)
43
(110)
62—165
(0.62—1.65)
(9—24)
1550—1760
(15.5—17.6)
(225—255)
SERVICE EQUIPMENT AND TOOLS JT02023 R12 Refrigerant Charging and Evacuation Station
IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Connect refrigerant charging and evacuation station. (See installation procedure in this group.) 2. Start engine and run at fast idle. 3. Turn temperature control switch to the maximum cooling position. 4. Turn blower switch to high speed. 5. Check sight glass in receiver/dryer to condenser line. Remove plug in service door to view sight glass through door. T7938AJ —UN—25FEB93
6. Run machine for at least 5 minutes. 7. Measure air temperature at condenser air inlet and at air ducts in air conditioning unit. If condenser inlet air temperature is below 27°C (80°F), duct air temperature must be below 13°C (55°F). If condenser inlet air temperature is above 27°C (80°F), duct air temperature must be at least 14°C (25°F) below condenser inlet air temperature. 8. Observe low-side pressure (C) and high-side pressure (B) on gauges. 9. Compare pressure readings to the pressure shown in specifications.
A—High Pressure Switch B—Red Hose (High Pressure) C—Blue Hose (Low Pressure) D—Gauge Assembly
E—Yellow Hose F— Charging and Evacuation Station G—Low-Side Test Port H—High Pressure Relief Valve
Use the Operating Pressure Diagnostic Chart in this group to diagnose the malfunction. TX,9031,DU1699 -19-26JAN95-1/1
TM1529 (27JUN17)
9031-25-2
544G, 624G, 644G Loader
062717
PN=718
Tests
R134a Air Conditioning System Test SPECIFICATIONS Engine Speed
2200 rpm
Temperature Control Switch Position
Maximum cooling
Blower Switch Position
High Speed
Ambient Temperature
Air Duct Temperature
Low Pressure Gauge
High Pressure Gauge
16°C (60°F)
13°C (55°F)
7—165 kPa
630—1095 kPa
(0.07—1.6 bar)
(6—11 bar)
21°C (70°F)
27°C (80°F)
32°C (90°F)
38°C (100°F)
43°C (110°F)
16°C (60°F)
18°C (65°F)
21°C (70°F)
27°C (80°F)
29°C (85°F)
(1—24 psi)
(90—160 psi)
7—180 kPa
785—1225 kPa
(0.07—1.8 bar)
(7.6—12 bar)
(1—26 psi)
(110—175 psi)
7—205 kPa
955—1410 kPa
(0.07—2.1 bar)
(9.6—14.1 bar)
(1—30 psi)
(140—205 psi)
7—240 kPa
1145—1645 kPa
(0.07—2.4 bar)
(11.4—16.5 bar)
(1—35 psi)
(165—240 psi)
7—280 kPa
1355—1935 kPa
(0.07—2.7 bar)
(13.4—19.3 bar)
(1—40 psi)
(195—280 psi)
7—330 kPa
1580—2275 kPa
(0.07—3.3 bar)
(15.8—22.7 bar)
(1—48 psi)
(230—330 psi)
ESSENTIAL TOOLS
6. Turn blower switch to high speed. Specification Blower Switch—Position......................................................................................... High Speed
JT02045 R134a Refrigerant Recovery/Recycling and Charging Station
IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings, components or refrigerant oils intended for R12 refrigerant.
7. Check sight glass in receiver/dryer to condenser line. Remove plug in service door to view sight glass through door.
1. Connect refrigerant recovery, recycling and charging station. (See installation procedure in this group.)
8. Run unit for at least 5 minutes.
2. Close both low and high pressure valves on refrigerant recovery, recycling and charging station. 3. Open cab doors and windows. 4. Start engine and run at rated engine speed. Specification Engine—Speed......................................................................... 2200 rpm
5. Turn temperature control switch to the maximum cooling position.
9. Measure air temperature at condenser air inlet and at air ducts in air conditioning unit. 10. Compare air duct temperature reading to the temperatures shown in the specifications. 11. Observe low-side pressure (C) and high-side pressure (B) on gauges. 12. Compare pressure readings to the pressure shown in specifications. Use the Operating Pressure Diagnostic Chart in this group to diagnose the malfunction.
Specification Temperature Control Switch—Position.......................................................... Maximum cooling
Continued on next page
TM1529 (27JUN17)
9031-25-3
TX,9031,QQ2358 -19-19AUG94-1/2
544G, 624G, 644G Loader
062717
PN=719
T8118AG —UN—06DEC93
Tests
A—High Pressure Hose Charge Port Cap B—Red Hose (High Pressure) C—Blue Hose (Low Pressure)
D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging System
TX,9031,QQ2358 -19-19AUG94-2/2
TM1529 (27JUN17)
9031-25-4
544G, 624G, 644G Loader
062717
PN=720
Tests
Operating Pressure Diagnostic Chart Low Side Pressure
High Side Pressure
Sight Glass
Problem
Solution
Low
Low
Clear
Loss of refrigerant
Leak in system. Do leak test. Repair leak. Add refrigerant.
Low
Low or Normal
Bubbles
Loss of refrigerant
Normal migration through hoses. Add refrigerant. Leak in system. Do leak test. Repair leak. Add refrigerant in this group. Normal migration through hoses. Add refrigerant in this group.
Low
Low or Normal
Clear
Restriction in system: • Between compressor and condenser. • Inside condenser. • Between condenser and receiver/dryer. • Inside receiver/dryer
Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.
Blower motor running too slow.
Check for motor shaft binding or defective electrical connections.
Evaporator core dirty or air flow through evaporator Clean evaporator and straighten fins. restricted. Expansion valve malfunction
Replace expansion valve.
Restriction in system: • Between receiver/dryer and expansion valve. • Between expansion valve and evaporator. • Between evaporator and compressor.
Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.
Low Side Pressure
High Side Pressure
Sight Glass
Problem
Solution
Low
Low or Normal
Clear
Moisture in system.
Remove refrigerant using recovery operation, evacuate and charge the system. (See procedure in Group 9031-20).
Low
High
Clear or Bubbles
Restriction in system: • Between compressor and condenser. • Inside condenser. • Between condenser and receiver/dryer. • Inside receiver/dryer. • Between receiver/dryer and expansion valve.
Inspect for bent, kinked or dented lines. Feel lines for temperature change. Remove refrigerant using recovery method. Inspect and clean each component.
Normal
Normal
Clear
Heater valve not closing.
Close heater shut-off valve on engine block or clamp heater hoses shut.
Expansion valve malfunction
Replace expansion valve.
Moisture in system (intermittent cooling below 27°C Remove refrigerant using recovery method, [80°F] ambient.) evacuate and charge the system. (See procedure in Group 9031-20.) Normal
Normal
Occasional Bubbles
Leak in system. Do leak test. Repair leak. Add refrigerant.
Loss of refrigerant
Normal migration through hoses. Add refrigerant in this group. Remove refrigerant using recovery operation, evacuate and charge the system (See procedure in Group 9031-20.)
Air in system.
Continued on next page
TM1529 (27JUN17)
9031-25-5
TX,9031,DU1700 -19-04NOV93-1/2
544G, 624G, 644G Loader
062717
PN=721
Tests Low Side Pressure
High Side Pressure
Sight Glass
Problem
Solution
Normal
High
Clear
Restricted air flow through condenser or radiator.
Inspect for debris. Straighten fins. Do Radiator Air Flow Test. (See procedure in Group 9010-25.)
Overcharge of refrigerant.
Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove refrigerant from low-side of system using recovery operation until bubbles appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant through low-side valve.
Expansion valve malfunction.
Replace expansion valve.
Restriction in system: • Between compressor and condenser. • Inside condenser. • Between condenser and receiver/dryer. • Inside receiver/dryer.
Inspect for bent, kinked, or dented lines. Feel lines for temperature change. Remove refrigerant using recovery method. Inspect and clean each component.
Normal
High
Bubbles
Restriction in system: • Between compressor and condenser. • Inside condenser. • Between condenser and receiver/dryer. • Inside receiver/dryer.
Inspect for bent, kinked, dented, or pinched lines. Feel lines for temperature change. Discharge system. Inspect and backflush each component.
High
Low
Clear
Compressor belt loose.
Tighten belt.
Compressor clutch slipping
Check for battery voltage at compressor clutch with clutch engaged. Clean electrical connections or replace relay. Inspect and repair clutch.
Low Side Pressure
High Side Pressure
Sight Glass
Problem
Solution
High
Low
Clear
Compressor failure.
Test compressor efficiency. (See procedure in Group 1830 of Repair Technical Manual.)
High
Normal
Clear
Expansion valve malfunction.
Replace expansion valve.
High
High
Clear
Restricted air flow through condenser or radiator.
Inspect for debris. Straighten fins. Do Radiator Air Flow Test. (See procedure in Group 9010-25.)
Expansion valve malfunction
Replace expansion valve.
Overcharge of refrigerant.
Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove refrigerant from low-side of system using refrigerant recovery method until bubbles appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant through low-side valve.
Restriction in system: • Between compressor and condenser. • Inside condenser. • Between condenser and receiver/dryer. •Inside receiver/dryer.
Inspect for bent, kinked, dented, or pinched lines. Feel lines for temperature change. Remove refrigerant using recovery method. Inspect and clean each component.
Air in system.
Remove refrigerant using recovery method. Evacuate and charge the system (See procedure in Group 9031-20). Inspect for bent, kinked, dented, or pinched lines. Feel lines for temperature change. Remove refrigerant using recovery method. Inspect and clean each component.
High
High
Bubbles
Restriction in system: • Between compressor and condenser. • Inside condenser. • Between condenser and receiver/dryer. • Inside receiver/dryer.
TX,9031,DU1700 -19-04NOV93-2/2
TM1529 (27JUN17)
9031-25-6
544G, 624G, 644G Loader
062717
PN=722
Tests
T6609AB —19—28FEB89
Pressure Diagnostic Chart
TX,9031,QQ2145 -19-25FEB94-1/1
TM1529 (27JUN17)
9031-25-7
544G, 624G, 644G Loader
062717
PN=723
Tests
Low Pressure Switch Test
Air Conditioning Low Pressure Switch Opens on Decreasing Pressure
220 ± 20 kPa (2.2 ± 0.2 bar) (32 ± 3 psi)
Air Conditioning Low Pressure Switch Closes on Increasing Pressure
276 ± 20 kPa (2.76 ± 0.2 bar) (40 ± 3 psi)
T88001 —UN—08NOV88
SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS Volt-Ohm-Amp Meter
NOTE: Low pressure switch is normally open when removed from machine. When installed, the switch becomes closed because of normal system pressure. 1. Perform the following:
• Turn key switch to ON position. Do not start engine. • Turn blower switch to ON position. • Turn temperature control switch to the maximum cooling position.
2. Disconnect and connect low pressure switch at harness connector. Compressor clutch must engage and disengage (click). NOTE: The line that attaches the low pressure switch has a valve to prevent discharging the air conditioning system when switch is removed.
Compressor clutch must not engage (click). 4. The actual pressure setting of switch can be checked by connecting it to a pressure source such as a regulated air supply or hydraulic hand pump. Specification Air Conditioning Low Pressure Switch—Opens on Decreasing Pressure............220 ± 20 kPa (2.2 ± 0.2 bar) (32 ± 3 psi) Closes on Increasing Pressure .................................276 ± 20 kPa (2.76 ± 0.2 bar) (40 ± 3 psi)
5. Switch must not have continuity between terminals (A and C) until pressure increases to switch closing pressure specification. Slowly release pressure. Switch must have continuity until pressure decreases to switch opening pressure specification.
3. Disconnect harness from switch and remove switch from line. Connect low pressure switch to harness. TX,903125,QQ731 -19-17JUN94-1/1
TM1529 (27JUN17)
9031-25-8
544G, 624G, 644G Loader
062717
PN=724
Tests
High Pressure Switch Test
High Pressure Switch (Normally Closed) Opens on Increasing Pressure
2410 ± 100 kPa (24.1 ± 1 bar) (350 ± 15 psi)
High Pressure Switch (Normally Closed) Closes on Decreasing Pressure
1516 ± 100 kPa (13.91 ± 1 bar) (220 ± 15 psi)
T88002 —UN—08NOV88
SPECIFICATIONS
SERVICE EQUIPMENT AND TOOLS Volt-Ohm-Amp Meter Air Conditioning Gauge Set
NOTE: The high pressure switch has a valve under it to prevent discharging the air conditioning system when switch is removed. 1. Remove high pressure switch. 2. Connect a portable pressure source, such as a hydraulic hand pump, to high pressure switch. 3. Switch must have continuity between terminals (A and C) until pressure increases to switch opening pressure specification. Specification High Pressure Switch (Normally Closed)—Opens on Increasing Pressure...........2410 ± 100 kPa (24.1 ± 1 bar) (350 ± 15 psi)
4. Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure specification. Specification High Pressure Switch (Normally Closed)—Closes on Decreasing Pressure......... 1516 ± 100 kPa (13.91 ± 1 bar) (220 ± 15 psi)
5. The switch can also be checked when installed in air conditioning system, however, pressure is slow to increase to test specification. Connect an air conditioning gauge set to service fittings at compressor. Cover condenser with paper or plastic to stop air flow. Operate air conditioner on maximum cooling. Note high-side pressure when high pressure switch opens and then closes. TX,903125,QQ774 -19-26JAN95-1/1
Clutch Cycle Switch
Specification Clutch Cycle Switch (Normally Closed)—Opens as Temperature Drops.............................................................. -0.5°C (31°F)
SPECIFICATIONS Clutch Cycle Switch (Normally Closed) Opens as Temperature Drops
-0.5°C (31°F)
Clutch Cycle Switch (Normally Closed) Closes as Temperature Rises
4°C (39°F)
4. Remove switch from freezer. Put sensing tube into a glass of warm water. Switch must close, and continuity must be read.
1. Remove clutch cycle switch from evaporator.
Specification Clutch Cycle Switch (Normally Closed)—Closes as Temperature Rises.................................................................. 4°C (39°F)
2. Connect ohmmeter to switch terminals. Switch must be closed at room temperature.
5. If switch does not open and close during testing, install new switch.
SERVICE EQUIPMENT AND TOOLS Multimeter
3. Put switch into a freezer (assure freezer temperature is below -0.5°C (31°F). Switch must open, and continuity must not be read. TX,9031,QQ777 -19-05AUG94-1/1
TM1529 (27JUN17)
9031-25-9
544G, 624G, 644G Loader
062717
PN=725
Tests
Leak Testing 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. 2. A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.
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. 4. Some refrigerant manufacturers add dye to refrigerant to aid in leak detection. TX,9031,QQ1881 -19-19AUG94-1/1
Refrigerant Hoses And Tubing Inspection 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 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.
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. IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.
To assist in making leak-proof joints in R12 systems, use a small amount of clean 525 viscosity refrigerant oil on all hose and tube connections. Dip O-rings in 525 oil before assembling.
DO NOT use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J2064 requirements.
TX,9031,DU1705 -19-23JUN17-1/1
TM1529 (27JUN17)
9031-25-10
544G, 624G, 644G Loader
062717
PN=726
Index Page Page
A Accumulator Brake Inlet check valve leakage test .................. 9020-25-27 Precharge test .......................................... 9020-25-22 Charge brake ................................................. 9020-20-6 Air conditioning Charge system (R12) .......................................................... 9031-20-6 (R134A) .................................................... 9031-20-12 Clutch cycle switch test.................................. 9031-25-9 Component location drawing ......................... 9031-15-3 Component oil charge (R12) .......................................................... 9031-20-2 (R134a) ...................................................... 9031-20-8 Compressor Belt tension adjust .................................... 9031-20-13 Oil (R134a) Check charge.......................................... 9031-20-7 Information.............................................. 9031-20-7 Removal.................................................. 9031-20-8 Relief valve operation............................... 9031-05-14 Diagnostic information ................................... 9031-15-1 Diagnostic procedures ................................. 9015-15-90 Electrical circuit Checks ....................................................... 9031-10-6 Operational information .............................. 9031-05-3 Schematic................................................... 9031-05-4 Theory of operation .................................... 9031-05-3 Evacuate system (R12) .......................................................... 9031-20-5 (R134A) .................................................... 9031-20-11 Expansion valve........................................... 9031-05-14 Functional schematic ................................... 9015-15-89 Harness (W12) Component location ................................. 9015-10-62 Wiring diagram ......................................... 9015-10-61 High pressure switch test............................... 9031-25-9 Hoses and tubing inspection........................ 9031-25-10 Leak testing.................................................. 9031-25-10 Low pressure switch test................................ 9031-25-8 Operational checks ........................................ 9031-10-1 Operational information................................ 9015-15-88 Pressure diagnostic chart ........9031-25-5, 9031-25-7 Receiver/dryer operation.............................. 9031-05-13 Recover refrigerant (R12) .......................................................... 9031-20-4 (R134a) .................................................... 9031-20-10 Refrigerant Handling ................ 9031-05-1, 9031-20-1, 9031-25-1 (R12/R134a) caution ............9031-05-1, 9031-20-1, 9031-25-1 Theory of operation .................................... 9031-05-2 Specifications............................................... 9015-15-88 Station installation (R12) .......................................................... 9031-20-3
(R134A) ...................................................... 9031-20-9 System test (R12) .......................................................... 9031-25-2 (R134a) ...................................................... 9031-25-3 Temperature control ..................................... 9031-05-15 Theory of operation...................................... 9015-15-88 Air flow Radiator ......................................................... 9010-25-4 Alternator operation 95 amp or 135 amp Bosch............................. 9015-20-8 Auxiliary section operation............................... 9025-05-28 Axle Bearing adjustment check............................ 9020-25-31 Diagnose malfunctions................................. 9020-15-12 Disconnect operation ................................... 9020-05-88 Front disconnect adjustment.......................... 9020-20-1 Shaft and housing information ..................... 9020-05-87 Teammate II ................................................. 9020-05-83
B Backup alarm circuit Diagnostic procedures ................................. 9015-15-21 Functional schematic ................................... 9015-15-19 Operational information................................ 9015-15-18 Specifications............................................... 9015-15-18 Theory of operation...................................... 9015-15-18 Battery Booster........................................................... 9015-20-5 Electrolyte level.............................................. 9015-20-3 Malfunctions................................................... 9015-20-2 Operation ....................................................... 9015-20-1 Specification................................................... 9015-20-1 Testing............................................................ 9015-20-4 Beacon, rotary Diagnostic procedures ............................... 9015-15-110 Functional schematic ................................. 9015-15-109 Operational information.............................. 9015-15-108 Theory of operation.................................... 9015-15-108 Bolt and screw torque values Metric ............................................................. 9000-03-2 Unified inch .................................................... 9000-03-4 Boom Anti-cavitation valve operation ..................... 9025-05-32 Cycle time test ............................................. 9025-25-24 Cylinder leakage test ..................................... 9025-25-7 Down circuit Diagnostic procedures.............................. 9015-15-53 Functional schematic................................ 9015-15-52 Operational information ............................ 9015-15-51 Theory of operation .................................. 9015-15-51 Height kickout circuit Adjustment ................................................. 9025-20-2 Diagnostic procedures.............................. 9015-15-74 Functional schematic................................ 9015-15-73 Operational information ............................ 9015-15-72 Theory of operation .................................. 9015-15-72 Continued on next page
TM1529 (27JUN17)
Index-1
544G, 624G, 644G Loader
062717
PN=1
Index
Page
Page
Loader control valve Boom section-tandem spool operation................................................. 9025-05-22 Bucket and boom section Pilot orifice check valve operation ............................................. 9025-05-23 Brake, park Adjust (SN 788774-) ...................................... 9020-20-3 Diagnose malfunctions................................. 9020-15-16 Electrical circuit Diagnostic procedures.............................. 9015-15-45 Functional schematic................................ 9015-15-44 Operational information ............................ 9015-15-43 Theory of operation .................................. 9015-15-43 Hydraulic system operation.......................... 9020-05-96 Pressure test................................................ 9020-25-28 Sensing circuit Diagnostic procedures.............................. 9015-15-21 Functional schematic................................ 9015-15-19 Operational information ............................ 9015-15-18 Pressure switch specifications ................. 9015-15-18 Theory of operation .................................. 9015-15-18 Brake, service Accumulator Inlet check valve leakage test .................. 9020-25-27 Operation.................................................. 9020-05-93 Precharge test .......................................... 9020-25-22 Bleeding procedure........................................ 9020-20-5 Charge accumulator....................................... 9020-20-6 Diagnose malfunctions................................. 9020-15-10 External inspection......................................... 9020-20-4 Hydraulic system operation.......................... 9020-05-89 Light circuit Diagnostic procedures.............................. 9015-15-83 Operational information ............................ 9015-15-80 Schematic................................................. 9015-15-82 Specifications ........................................... 9015-15-80 Theory of operation .................................. 9015-15-81 Pump Flow test ................................................... 9020-25-20 Operation.................................................. 9020-05-90 Pressure compensator, at standby ................................................... 9020-05-91 Pressure compensator, going stroke...................................................... 9020-05-92 Standby pressure test .............................. 9020-25-21 Valve Leakage test............................................. 9020-25-26 Pressure test ............................................ 9020-25-24 Wet chambered operation ........................ 9020-05-94 Bucket Circuit relief valve operation......................... 9025-05-30 Cycle time test ............................................. 9025-25-24 Cylinder leakage test ..................................... 9025-25-7 Loader control valve Bucket and boom section Pilot orifice check valve operation ............................................. 9025-05-23
Bucket section operation 544G TC and 544G LL ......................... 9025-05-26 544G, 624G, and 644G ........................ 9025-05-24 Bypass valve Operation ..................................................... 9020-05-56 Pressure test................................................ 9020-25-18
C Cab work lights Diagnostic procedures ............................... 9015-15-102 Functional schematic ................................. 9015-15-101 Harness (W7) Component location ................................. 9015-10-45 Wiring diagram ......................................... 9015-10-43 Operational information.............................. 9015-15-100 Theory of operation.................................... 9015-15-100 Canopy work lights Diagnostic procedures ............................... 9015-15-102 Functional schematic ................................. 9015-15-101 Harness (W6) Component location ................................. 9015-10-42 Wiring diagram ......................................... 9015-10-41 Operational information.............................. 9015-15-100 Theory of operation.................................... 9015-15-100 Capacities, machine 544G .............................................................. 9000-02-3 544G LL ......................................................... 9000-02-7 544G TC ...................................................... 9000-02-10 624G ............................................................ 9000-02-13 644G ............................................................ 9000-02-16 Charging circuit Alternator operation ....................................... 9015-20-8 Diagnostic procedures ................................... 9015-15-9 Functional schematic ..................................... 9015-15-8 Operational information.................................. 9015-15-7 Theory of operation........................................ 9015-15-7 Clutch Control valve (5-solenoid) Engagement and solenoid activated ................................................... 9020-05-1 Cutoff circuit Switch adjustment ...................................... 9020-20-2 Operation ..................................................... 9020-05-22 Clutch cutoff circuit Diagnostic procedures ................................. 9015-15-21 Functional schematic ................................... 9015-15-19 Operational information................................ 9015-15-18 Specifications............................................... 9015-15-18 Theory of operation...................................... 9015-15-18 Component location A/C compressor harness (W12)................... 9015-10-62 Air conditioning .............................................. 9031-15-3 Cab work lights harness (W7)...................... 9015-10-45 Canopy work lights harness (W6) ................ 9015-10-42 Engine frame harness (W9) ......................... 9015-10-53 Engine harness (W10) ................................. 9015-10-57 Hydraulic system.......................................... 9025-15-13 Continued on next page
TM1529 (27JUN17)
Index-2
544G, 624G, 644G Loader
062717
PN=2
Index
Page
Page
Left panel temp cntrl harness (W8).............. 9015-10-49 Load center harness (W5) ........................... 9015-10-33 Loader frame harness (W3) ......................... 9015-10-19 Main hydraulic system ................................... 9025-15-9 Pin disconnect harness (W16) ..................... 9015-10-70 Rear frame harness (W11)........................... 9015-10-60 Ride control harness (W15) ......................... 9015-10-68 Secondary steering harness (W13) ............. 9015-10-64 Start aid lead (W14) ..................................... 9015-10-66 Steering column harness (W2) .................... 9015-10-16 Transmission harness (W4) ......................... 9015-10-23 Component location diagram Power train and brakes ................................ 9020-15-19 Compressor, A/C Belt tension adjust........................................ 9031-20-13 Relief valve operation .................................. 9031-05-14 Connectors, tab retainer Disconnecting .............................................. 9015-20-21 Converter In pressure test ............................................ 9020-25-10 Operation ....................................................... 9020-05-4 Out flow test ................................................. 9020-25-13 Out pressure test ......................................... 9020-25-12 Relief pressure............................................... 9020-25-8 Stall speed test ............................................ 9020-25-19 Coolant Diesel engine Engine with wet sleeve cylinder liners ......................................................... 9000-04-6 Coolant, engine Requirements............................................... 9010-15-12 Cooling system Checks ........................................................... 9010-10-1 Pressure test.................................................. 9010-25-3 Radiator cap pressure test............................. 9010-25-2 Cylinder, hydraulic Boom and bucket ......................................... 9025-05-33 boom and bucket leakage test ....................... 9025-25-7 Loader drift test .............................................. 9025-25-6
Theory of operation .................................. 9015-15-51 No-spin test.................................................. 9020-25-31 Oil specification.............................................. 9000-04-3 Digital thermometer installation ...9010-20-1, 9020-25-1, 9025-25-1 Dome light circuit Diagnostic procedures ............................... 9015-15-105 Functional schematic ................................. 9015-15-104 Operational information.............................. 9015-15-103 Theory of operation.................................... 9015-15-103 Door release circuit Diagnostic procedures ............................... 9015-15-110 Functional schematic ................................. 9015-15-109 Operational information.............................. 9015-15-108 Theory of operation.................................... 9015-15-108 Drive dampener ................................................. 9020-05-2 Drive light circuit Diagnostic procedures ............................... 9015-15-105 Functional schematic ................................. 9015-15-104 Operational information.............................. 9015-15-103 Theory of operation.................................... 9015-15-103 Driveline Diagnose malfunctions................................. 9020-15-15
D Defroster pressurization circuit Diagnostic procedures ................................. 9015-15-95 Functional schematic ................................... 9015-15-94 Operational information..........9015-15-93, 9031-05-6 Theory of operation....................9015-15-93, 9031-05-7 Differential Diagnose malfunctions................................. 9020-15-12 Lock circuit Air boost system....................................... 9020-05-85 Diagnostic procedures.............................. 9015-15-53 Functional schematic................................ 9015-15-52 Leakage test............................................. 9020-25-30 Operation.................................................. 9020-05-84 Operational information ............................ 9015-15-51 Pressure test ............................................ 9020-25-29
E Electrical Schematic symbols ...................................... 9015-05-15 Electrical system Battery specification....................................... 9015-20-1 Circuit malfunctions........................................ 9015-05-5 Component identification ............................... 9015-10-1 Functional schematic section legend .......................................................... 9015-10-5 Functional schematics ................................... 9015-10-6 Fuse block Identification ................................ 9015-10-2 Grounded circuit............................................. 9015-05-8 High resistance circuit.................................... 9015-05-6 Inspection....................................................... 9015-05-4 Isolate problem; electrical or hydraulic....................................................... 9015-05-1 Open circuit.................................................... 9015-05-7 Shorted circuit ................................................ 9015-05-9 System functional schematic reading ....................................................... 9015-05-13 Test equipment............................................. 9015-05-10 Test procedure ............................................. 9015-05-11 Wiring and schematic diagrams legend .......................................................... 9015-10-3 Wiring diagram information .......................... 9015-05-12 Wiring diagram, reading............................... 9015-05-14 Engine Air cleaner operation...................................... 9010-05-1 Air filter Restriction indicator switch test .................. 9010-25-2 Air intake system leakage test ..................... 9010-25-10 Air system checks .......................................... 9010-10-5 Continued on next page
TM1529 (27JUN17)
Index-3
544G, 624G, 644G Loader
062717
PN=3
Index
Page
Page
Bleed fuel system 544G and 624G.......................................... 9010-20-9 644G......................................................... 9010-20-10 Compression test ........................................... 9010-25-9 Coolant requirements................................... 9010-15-12 Cooling system pressure test......................... 9010-25-3 Diagnose malfunctions................................... 9010-15-1 Fan belt tension adjustment........................... 9010-20-4 Fuel line leakage test ................................... 9010-25-12 Fuel shut-off solenoid adjustment .................. 9010-20-8 Fuel supply pump pressure test................... 9010-25-11 Fuel system operation 544G and 624G.......................................... 9010-05-2 644G........................................................... 9010-05-3 Harness (W10) Component location ................................. 9015-10-57 Wiring diagram ......................................... 9015-10-55 Harness (W9), frame Component location ................................. 9015-10-53 Wiring diagram ......................................... 9015-10-51 Idle adjustment Fast 544G and 624G ...................................... 9010-20-5 644G ....................................................... 9010-20-6 Slow 544G and 624G ...................................... 9010-20-5 644G ....................................................... 9010-20-6 Injection pump timing ..................................... 9010-20-3 Oil specification.............................................. 9000-04-2 Operational checks ........................................ 9010-10-1 Performance checks ...................................... 9010-10-7 Power test Using engine pulldown ............................... 9010-25-6 Using turbocharger boost pressure.................................................... 9010-25-7 Primary fuel filter, drain water 544G and 624G.......................................... 9010-20-9 644G........................................................... 9010-20-9 Radiator cap pressure test............................. 9010-25-2 Speed checks ................................................ 9010-10-7 Speed control linkage adjustment.................. 9010-20-7 Start aid Lead (W14) component location .............. 9015-10-66 Lead (W14) wiring diagram ...................... 9015-10-65 Start aid and fuel control circuit Diagnostic procedures.............................. 9015-15-13 Functional schematic................................ 9015-15-12 Operational information ............................ 9015-15-11 Theory of operation .................................. 9015-15-11
Theory of operation...................................... 9015-15-97 Front axle Disconnect adjustment................................... 9020-20-1 Front wiper circuit Diagnostic procedures ................................. 9015-15-78 Functional schematic ................................... 9015-15-77 Operational information................................ 9015-15-75 Theory of operation...................................... 9015-15-76 Fuel Specifications................................................. 9000-04-1 Storage .......................................................... 9000-04-1 Tank capacity ................................................. 9000-04-1 Fuel system Bleed system 544G and 624G.......................................... 9010-20-9 644G......................................................... 9010-20-10 Checks ........................................................... 9010-10-7 Control circuit Diagnostic procedures.............................. 9015-15-13 Functional schematic................................ 9015-15-12 Operational information ............................ 9015-15-11 Theory of operation .................................. 9015-15-11 Line leakage test.......................................... 9010-25-12 Operation 544G and 624G.......................................... 9010-05-2 644G........................................................... 9010-05-3 Primary fuel filter, drain water 544G and 624G.......................................... 9010-20-9 644G........................................................... 9010-20-9 Shut-off solenoid adjustment (644G) .......................................................... 9010-20-8 Supply pump pressure test .......................... 9010-25-11
F Fan belt Tension adjustment ........................................ 9010-20-4 Flasher, 4-way Diagnostic procedures ................................. 9015-15-99 Functional schematic ................................... 9015-15-98 Operational information................................ 9015-15-96
G Gauge inputs, electronic monitor Diagnostic procedures ................................. 9015-15-71 Functional schematic ................................... 9015-15-70 Operational information................................ 9015-15-69 Theory of operation...................................... 9015-15-69 Grease Specification................................................... 9000-04-5
H Hardware Torque specifications ..................................... 9000-03-1 Hardware torque values Metric ............................................................. 9000-03-2 Unified inch .................................................... 9000-03-4 Heater/pressurizer circuit Diagnostic procedures ................................. 9015-15-86 Functional schematic ................................... 9015-15-85 Operational information..........9015-15-84, 9031-05-10 Theory of operation.................. 9015-15-84, 9031-05-11
Continued on next page
TM1529 (27JUN17)
Index-4
544G, 624G, 644G Loader
062717
PN=4
Index
Page
Page
Horn circuit Diagnostic procedures ............................... 9015-15-110 Functional schematic ................................. 9015-15-109 Operational information.............................. 9015-15-108 Theory of operation.................................... 9015-15-108 Hydraulic Oil specification.............................................. 9000-04-3 Ride control accumulator draining procedure ..................................................... 9025-20-6 Ride control accumulator gas charge procedure ..................................................... 9025-20-4 Hydraulic system Auxiliary section operation ........................... 9025-05-28 Diagnose malfunctions................................... 9025-15-1 Main pump flow test ....................................... 9025-25-2 Main pump operation ..................................... 9025-05-1 Oil filter inspection procedure ...................... 9025-25-25 Oil warm-up procedure ................9020-25-2, 9025-25-1 Operational checks ........................................ 9025-10-1 Pin disconnect circuit operation 544G TC................................................... 9025-05-36 Reservoir operation................9020-05-102, 9025-05-35 Restriction test ............................................... 9025-25-5 Return filter operation .................................. 9025-05-34 ride control operation In OFF position......................................... 9025-05-39 Ride control operation In ON position........................................... 9025-05-38 Hydraulics Circuit symbols...........................9020-15-17, 9025-15-8
Circuit relief valve operation......................... 9025-05-30 Circuit relief valve pressure test..................... 9025-25-3 Control valve Boom and bucket section pilot orifice check valve............................................. 9025-05-23 Boom section-tandem spool operation................................................. 9025-05-22 Bucket section operation 544G TC and 544G LL ......................... 9025-05-26 544G, 624G, and 644G ........................ 9025-05-24 Cylinder drift test ............................................ 9025-25-6 Frame harness (W3) Component location ................................. 9015-10-19 Wiring diagram ......................................... 9015-10-17 Pilot control valve Pressure test (SN --563542) ....................................... 9025-25-17 (SN 563543--) ....................................... 9025-25-20 Pilot controller operation (SN --563542)........................................... 9025-05-15 (SN 563543--) Boom float............................................. 9025-05-18 Bucket rollback ..................................... 9025-05-20 Pin disconnect Harness (W16) component location ................................................... 9015-10-70 Harness (W16) wiring diagram................. 9015-10-69 Pin disconnect leakage test Cylinder .................................................... 9025-25-26 Solenoid valve .......................................... 9025-25-25 Pressure reducing valve Secondary boom lower operation................................................. 9025-05-14 System operation ......................................... 9025-05-13 System relief valve operation....................... 9025-05-29 Loader hydraulic system Cycle time test ............................................. 9025-25-24 Lower circuit schematic Brake differential and boom ......................... 9020-15-18 Lubricant Mixing............................................................. 9000-04-6 Lubricant Storage Storage, Lubricant.......................................... 9000-04-5 Lubricants, Safety Safety, Lubricants .......................................... 9000-04-5 Lubrication system checks ................................ 9010-10-6
I Idle adjustment Fast 544G and 624G.......................................... 9010-20-5 644G........................................................... 9010-20-6 Slow 544G and 624G.......................................... 9010-20-5 644G........................................................... 9010-20-6 Injection pump Timing ............................................................ 9010-20-3
L Lights, drive and dome Diagnostic procedures ............................... 9015-15-105 Functional schematic ................................. 9015-15-104 Operational information.............................. 9015-15-103 Theory of operation.................................... 9015-15-103 Load center harness (W5) Component location ..................................... 9015-10-33 Wiring diagram............................................. 9015-10-25 Loader Anti-cavitation valve operation ..................... 9025-05-32 Boom and bucket hydraulic cylinders Information ............................................... 9025-05-33
M Main hydraulic pump Flow test......................................................... 9025-25-2 Operation ....................................................... 9025-05-1 Metric bolt and screw torque values .................. 9000-03-2 Mixing lubricants................................................ 9000-04-6 Monitor Fault code display Accessing ................................................... 9015-20-9 Interpretation ............................................ 9015-20-11 Continued on next page
TM1529 (27JUN17)
Index-5
544G, 624G, 644G Loader
062717
PN=5
Index
Page
Page
Gauge inputs Diagnostic procedures.............................. 9015-15-71 Functional schematic................................ 9015-15-70 Operational information ............................ 9015-15-69 Specifications ........................................... 9015-15-67 Theory of operation .................................. 9015-15-69 Input signals Diagnostic procedures.............................. 9015-15-65 Functional schematic................................ 9015-15-64 Operational information ............................ 9015-15-61 Theory of operation .................................. 9015-15-62 Jumper wire .............................9015-15-31, 9015-20-18 Program ....................................................... 9015-20-11 Switch inputs Diagnostic procedures.............................. 9015-15-59 Functional schematic................................ 9015-15-57 Operational information ............................ 9015-15-55 Specifications ........................................... 9015-15-55 Theory of operation .................................. 9015-15-56
N No-spin differential test.................................... 9020-25-31
O O-ring boss fittings............................................. 9000-03-5 Oil Clean-up procedure ....................................... 9025-20-1 Brake pump and differential lock ................ 9020-20-7 Filter inspection procedure........................... 9025-25-25 Lines and fittings ............................................ 9000-03-5 Specification differential ................................. 9000-04-3 Specification engine....................................... 9000-04-2 Specification hydraulic system....................... 9000-04-3 Specification transmission ............................. 9000-04-4 Warm-up procedure ....................................... 9025-25-1 Brake, diff lock and hydraulic system ...................................................... 9020-25-2 Transmission .............................................. 9020-25-2 Oil cooler Backflush procedure .................................... 9020-25-14 Restriction test ...........................9020-25-15, 9025-25-8 Oil lines and fittings ........................................... 9000-03-5 Operational checkout Cab component............................................ 9005-10-42 Driving checks.............................................. 9005-10-21 Hydraulic system checks ............................. 9005-10-28 Machine, complete......................................... 9005-10-3 Monitor indicator and gauge ....9005-10-4, 9005-10-10 Record sheet.................................................. 9005-10-1 Steering system checks ............................... 9005-10-34 Vandal protection ......................................... 9005-10-42
P Park brake Adjust (SN 788774-) ...................................... 9020-20-3 Diagnose malfunctions................................. 9020-15-16 Electrical circuit Diagnostic procedures.............................. 9015-15-45 Functional schematic................................ 9015-15-44 Operational information ............................ 9015-15-43 Theory of operation .................................. 9015-15-43 Pressure test................................................ 9020-25-28 Sensing circuit Diagnostic procedures.............................. 9015-15-21 Functional schematic................................ 9015-15-19 Operational information ............................ 9015-15-18 Pressure switch specifications ................. 9015-15-18 Theory of operation .................................. 9015-15-18 Pilot control valve Pressure test (SN --563542)........................................... 9025-25-17 (SN 563543--)........................................... 9025-25-20 Pilot controller operation (SN --563542) .............................................. 9025-05-15 (SN 563543--) Boom Float ............................................... 9025-05-18 Bucket rollback ......................................... 9025-05-20 Pin disconnect Electrical circuit Diagnostic procedures............................ 9015-15-115 Functional schematic.............................. 9015-15-114 Harness (W16) Component location.............................. 9015-10-70 Wiring diagram...................................... 9015-10-69 Operational information .......................... 9015-15-112 Theory of operation ................................ 9015-15-113 Leakage test Cylinder .................................................... 9025-25-26 Solenoid valve .......................................... 9025-25-25 Power circuit Diagnostic procedures ................................... 9015-15-5 Functional schematic ..................................... 9015-15-3 Operational information.................................. 9015-15-1 Theory of operation........................................ 9015-15-2 Power train Component overview ..................................... 9020-05-2 Operational checks ........................................ 9020-10-1 Pressure reducing valve Diff lock OFF; park brake ON....................... 9020-05-98 Diff lock ON; park brake OFF..................... 9020-05-100 Manifold leakage test ................................... 9020-25-16 Pressure test................................................ 9025-25-23 Secondary boom lower operation ................ 9025-05-14 Priority valve LS port flow test ........................................... 9025-25-12 Operation ....................................................... 9025-05-6 Pressure test................................................ 9025-25-11 Relief cartridge leakage test ........................ 9025-25-13 Continued on next page
TM1529 (27JUN17)
Index-6
544G, 624G, 644G Loader
062717
PN=6
Index
Page
Q Quickshift circuit Diagnostic procedures ................................. 9015-15-21 Functional schematic ................................... 9015-15-19 Operational information................................ 9015-15-18 Specifications............................................... 9015-15-18 Theory of operation...................................... 9015-15-18
R Radiator Air flow test .................................................... 9010-25-4 Cap pressure test........................................... 9010-25-2 Cooling system pressure test......................... 9010-25-3 Radio circuit Diagnostic procedures ............................... 9015-15-110 Functional schematic ................................. 9015-15-109 Operational information.............................. 9015-15-108 Theory of operation.................................... 9015-15-108 Rear frame Harness (W11) component location....................................................... 9015-10-60 Harness (W11) wiring diagram..................... 9015-10-59 Rear wiper circuit Diagnostic procedures ................................. 9015-15-78 Functional schematic ................................... 9015-15-77 Operational information................................ 9015-15-75 Theory of operation...................................... 9015-15-76 Receiver/dryer Operation ..................................................... 9031-05-13 Refrigerant Proper handling.............................................. 9031-25-1 (R12/R134a) caution...................................... 9031-25-1 Recover (R12) system ................................... 9031-20-4 Recover (R134A) system............................. 9031-20-10 Theory of operation........................................ 9031-05-2 Return-to-dig circuit Adjustment ..................................................... 9025-20-2 Diagnostic procedures ................................. 9015-15-74 Functional schematic ................................... 9015-15-73 Operational information................................ 9015-15-72 Theory of operation...................................... 9015-15-72 Ride control Accumulator gas charge procedure .............................................................. 9025-20-4 Accumulator gas discharge procedure ..................................................... 9025-20-4 Accumulator hydraulic discharge ................... 9025-20-3 Electrical circuit Diagnostic procedures............................ 9015-15-115 Functional schematic.............................. 9015-15-114 Harness (W15) Component location.............................. 9015-10-68 Wiring diagram...................................... 9015-10-67 Operational information .......................... 9015-15-112 Theory of operation ................................ 9015-15-113
Page
Operation In OFF position......................................... 9025-05-39 In ON position........................................... 9025-05-38 Ride control accumulator Draining procedure ........................................ 9025-20-6 Gas charge procedure ................................... 9025-20-4 Gas discharge procedure............................... 9025-20-4 Roll-over protective structure Torque specifications ..................................... 9000-03-1 Rotary beacon circuit Diagnostic procedures ............................... 9015-15-110 Functional schematic ................................. 9015-15-109 Operational information.............................. 9015-15-108 Theory of operation.................................... 9015-15-108
S Safety Safe maintenance, practice ........................... 9000-01-9 Safety, Avoid High-Pressure Fluids Avoid High-Pressure Fluids ........................... 9000-01-3 Safety, ROPS ROPS, Keep Installed Propertly..................... 9000-01-7 Schematic First foward .................................................. 9020-15-21 Main hydraulic system ................................. 9025-15-11 Schematics Electrical Air conditioning circuit ........9015-15-89, 9031-05-4 Backup alarm circuit ................................. 9015-15-19 Boom down circuit .................................... 9015-15-52 Boom height kickout circuit....................... 9015-15-73 Brake light circuit ...................................... 9015-15-82 Clutch cutoff circuit ................................... 9015-15-19 Differential lock circuit .............................. 9015-15-52 Functional................................................... 9015-10-6 Monitor circuit Signal inputs ......................................... 9015-15-64 Switch inputs......................................... 9015-15-57 Monitor gauge inputs................................ 9015-15-70 Park brake circuit...................................... 9015-15-44 Park brake sensing circuit ........................ 9015-15-19 Power circuit............................................... 9015-15-3 Quickshift circuit ....................................... 9015-15-19 Return-to-dig circuit .................................. 9015-15-73 Secondary steering circuit ........................ 9015-15-48 Section legend............................................ 9015-10-5 Start aid and fuel control circuit ................ 9015-15-12 Transmission control circuit ...................... 9015-15-29 Wiring diagram legend ............................... 9015-10-3 Service Safely park and prepare................................. 9000-01-3 Signal, turn Diagnostic procedures ................................. 9015-15-99 Functional schematic ................................... 9015-15-98 Operational information................................ 9015-15-96 Theory of operation...................................... 9015-15-97 Continued on next page
TM1529 (27JUN17)
Index-7
544G, 624G, 644G Loader
062717
PN=7
Index
Page
Page
Spare circuit Diagnostic procedures ............................... 9015-15-115 Functional schematic ................................. 9015-15-114 Operational information.............................. 9015-15-112 Theory of operation.................................... 9015-15-113 Specification Differential oil ................................................. 9000-04-3 Engine oil ....................................................... 9000-04-2 Grease ........................................................... 9000-04-5 Hydraulic oil ................................................... 9000-04-3 Transmission oil ............................................. 9000-04-4 Specifications Air conditioning ............................................ 9015-15-88 Battery............................................................ 9015-20-1 Brake lights .................................................. 9015-15-80 Clutch cutoff/quickshift/backup alarm .......................................................... 9015-15-18 Hardware torque ............................................ 9000-03-1 Machine 544G........................................................... 9000-02-1 544G LL...................................................... 9000-02-4 544G TC..................................................... 9000-02-8 624G......................................................... 9000-02-11 644G......................................................... 9000-02-14 Park brake sensing circuit............................ 9015-15-18 Start aid Diagnostic procedures ................................. 9015-15-13 Functional schematic ................................... 9015-15-12 Lead (W14) Component location ................................. 9015-10-66 Wiring diagram ......................................... 9015-10-65 Operational information................................ 9015-15-11 Theory of operation...................................... 9015-15-11 Start circuit Diagnostic procedures ................................. 9015-15-41 Functional schematic ................................... 9015-15-39 Operational information................................ 9015-15-37 Theory of operation...................................... 9015-15-37 Steering system (primary) Column harness (W2) Component location ................................. 9015-10-16 Wiring diagram ......................................... 9015-10-15 Components operation................................... 9025-05-2 Cycle time test ............................................. 9025-25-24 Cylinder operation........................................ 9025-05-11 Priority valve LS port flow test........................................ 9025-25-12 Pressure test ............................................ 9025-25-11 Relief cartridge leakage test..................... 9025-25-13 Priority valve operation .................................. 9025-05-6 Right turn operation ....................................... 9025-05-4 Valve Drift test .................................................... 9025-25-10 Neutral leakage test ................................... 9025-25-9 Valve operation ............................................ 9025-05-10 Steering system (secondary) Diagnostic procedures ................................. 9015-15-49 Functional schematic ................................... 9015-15-48
Harness (W13) Component location ................................. 9015-10-64 Wiring diagram ......................................... 9015-10-63 Manifold Check valve leakage test ......................... 9025-25-16 Primary check valve leakage test.......................................................... 9025-25-15 Operation ..................................................... 9025-05-11 Operational information................................ 9015-15-47 Pump relief valve pressure test.................... 9025-25-14 Steering inlet manifold operation ................. 9025-05-12 Steering switch specification........................ 9015-15-47 Theory of operation...................................... 9015-15-47
T Tab retainer connectors Disconnecting .............................................. 9015-20-21 Tachometer Calibrate....................................................... 9015-20-13 Install electronic clamp-on .......9010-20-1, 9020-25-1, 9025-25-1 Teammate II axle ............................................. 9020-05-83 Temperature control, left panel Harness (W8) component location............... 9015-10-49 Harness (W8) wiring diagram ...................... 9015-10-47 Thermal bypass valve test............................... 9020-25-17 Thermometer, digital Install......................... 9010-20-1, 9020-25-1, 9025-25-1 Time Trac™ Injection pump timing ..................................... 9010-20-3 Installation...................................................... 9010-20-2 Torque charts Metric ............................................................. 9000-03-2 Unified inch .................................................... 9000-03-4 Torque converter In pressure test ............................................ 9020-25-10 Operation ....................................................... 9020-05-4 Out flow test ................................................. 9020-25-13 Out pressure test ......................................... 9020-25-12 Relief pressure test ........................................ 9020-25-8 Stall speed test ............................................ 9020-25-19 Torque specifications Hardware ....................................................... 9000-03-1 Roll-over protective structure ......................... 9000-03-1 Torque value Flat face O-ring seal fitting ............................. 9000-03-7 Inch SAE four bolt flange fitting...................... 9000-03-9 Metric cap screw ............................................ 9000-03-3 Metric four bolt flange fitting........................... 9000-03-8 O-Ring boss fitting ......................................... 9000-03-5 Transmission Oil specification.............................................. 9000-04-4 Transmission, electrical Control circuit Diagnostic procedures.............................. 9015-15-34 Functional schematic................................ 9015-15-29 Operational information ............................ 9015-15-24 Continued on next page
TM1529 (27JUN17)
Index-8
544G, 624G, 644G Loader
062717
PN=8
Index
Page
Page
Theory of operation .................................. 9015-15-25 Controller pin identification........................... 9015-15-33 Electrical test procedure .............................. 9015-20-16 Harness (W4) Component location ................................. 9015-10-23 Wiring diagram ......................................... 9015-10-21 Isolate problem; electrical or hydraulic..................................................... 9015-15-34 Sensor adjustment .....................9015-20-20, 9020-20-7 Transmission, hydraulic Components................................................. 9020-05-23 Control valve (5-Solenoid) Clutch engaged & solenoids activated ................................................. 9020-05-40 Completed shift ........................................ 9020-05-32 Completed shift modulation...................... 9020-05-38 Components ............................................. 9020-05-28 First speed-forward .................................. 9020-05-44 First speed-reverse .................................. 9020-05-50 Fourth speed-forward ............................... 9020-05-49 Modulation Components .......................... 9020-05-30 Second speed-forward ............................. 9020-05-46 Second speed-reverse ............................. 9020-05-52 Shift modulation for 2nd,3rd,4th ............... 9020-05-36 Shift modulation starts (2nd,3rd,4th) ........................................... 9020-05-34 Shift times................................................. 9020-05-30 Third speed-forward ................................. 9020-05-48 Third speed-neutral .................................. 9020-05-42 Third speed-reverse ................................. 9020-05-54 Control valve (6-Solenoid) Clutch engaged & solenoids activated ................................................. 9020-05-64 Components ............................................. 9020-05-58 First speed-forward .................................. 9020-05-68 First speed-reverse .................................. 9020-05-76 Fourth speed-forward ............................... 9020-05-74 In neutral .................................................. 9020-05-62 Modulation components ........................... 9020-05-60 Second speed-forward ............................. 9020-05-70 Second speed-reverse ............................. 9020-05-78 Shift modulation........................................ 9020-05-66 Shift times................................................. 9020-05-60 Third speed-forward ................................. 9020-05-72 Third speed-reverse ................................. 9020-05-80 Diagnose malfunctions................................... 9020-15-2 Element leakage test ..................................... 9020-25-5 Isolate problem; electrical or hydraulic....................................................... 9020-15-1 Lube pressure test ......................................... 9020-25-7
Oil cooler Backflush procedure................................. 9020-25-14 Bypass valve pressure test ...................... 9020-25-18 Restriction test.......................................... 9020-25-15 Thermal bypass valve test........................ 9020-25-17 Oil warm-up procedure .................................. 9020-25-2 Pump flow test ............................................... 9020-25-3 Shift modulation test ...................................... 9020-25-5 System pressure test ..................................... 9020-25-5 Thermal bypass valve operation .................. 9020-05-56 Turn signal and 4-way flasher circuit Diagnostic procedures ................................. 9015-15-99 Functional schematic ................................... 9015-15-98 Operational information................................ 9015-15-96 Theory of operation...................................... 9015-15-97
TM1529 (27JUN17)
U Unified inch bolt and screw torque values .............................................................. 9000-03-4
W Wiper circuit Diagnostic procedures ................................. 9015-15-78 Functional schematic ................................... 9015-15-77 Operational information................................ 9015-15-75 Theory of operation...................................... 9015-15-76 Wiring diagram A/C compressor harness (W12)................... 9015-10-61 Cab work lights harness (W7)...................... 9015-10-43 Canopy work lights harness (W6) ................ 9015-10-41 Engine frame harness (W9) ......................... 9015-10-51 Engine harness (W10) ................................. 9015-10-55 Left panel temp cntrl harness (W8).............. 9015-10-47 Load center harness (W5) ........................... 9015-10-25 Loader frame harness (W3) ......................... 9015-10-17 Pin disconnect harness (W16) ..................... 9015-10-69 Rear frame harness (W11)........................... 9015-10-59 Ride control harness (W15) ......................... 9015-10-67 Secondary steering harness (W13) ............. 9015-10-63 Start aid lead (W14) ..................................... 9015-10-65 Steering column harness (W2) .................... 9015-10-15 Transmission harness (W4) ......................... 9015-10-21 Work lights, cab and canopy Diagnostic procedures ............................... 9015-15-102 Functional schematic ................................. 9015-15-101 Operational information.............................. 9015-15-100 Theory of operation.................................... 9015-15-100
Index-9
544G, 624G, 644G Loader
062717
PN=9
Index
TM1529 (27JUN17)
Index-10
544G, 624G, 644G Loader
062717
PN=10
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