544K 4WD Loader
Engine 6068HDW74
Repair
(Serial No. - 642664)
TECHNICAL MANUAL
544K 4WD Loader Repair
TM10689 24APR12 (ENGLISH)
For complete service information also see:
544K Loader Test Manual .................................. TM10688
544K Loader Operator's Manual ........................ OMT231639
PowerTech™ 4.5 L and 6.8 L Diesel
Engines—Base Engine ....................................... CTM104
PowerTech E™ 4.5 & 6.8L Diesel
Engines—Level 16 Electronic Fuel System
with Denso HPCR ................................................ CTM502
TeamMate™ IV 1200 and 1400 Series Inboard
Planetary Axles.................................................... CTM442
120 Series Hydraulic Cylinders .......................... CTM114319
125 Series Hydraulic Cylinders .......................... CTM109319
JDLink™ / ZXLink™ Machine Monitoring
System.................................................................. CTM10006
JDLink™ / ZXLink™ (MTG) Diagnosis and
Tests Manual ........................................................ CTM114519
Super Caddy Oil Cleanup Procedure................. CTM310
Specifications Manual......................................... SP458
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
, Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
DX,TMIFC -19-29SEP98-1/1
TM10689 (24APR12) 544K 4WD Loader
042412
PN=2
, Contents
Section 00—General Information Group 1800—Removal and Installation
Group 0001—Safety Information Group 1810—Operator Enclosure
Group 1821—Seat and Seat Belt
Section 01—Wheels Group 1830—Heating and Air Conditioning
Group 0110—Powered Wheels and Fasteners
Section 19—Sheet Metal and Styling
Section 02—Axles and Suspension Systems Group 1910—Hood or Engine Enclosure
Group 0200—Removal and Installation
Group 0225—Axle Shafts and U-Joints Section 31—Loader
Group 0250—Axle Shaft, Bearings, Reduction Gears Group 3102—Bucket
Group 0260—Hydraulic System Group 3140—Frames
Group 3160—Hydraulic System
Section 03—Transmission
Group 0300—Removal and Installation Section 99—Dealer Fabricated Tools
Group 0350—Gears, Shafts, Bearings and Power Shift Group 9900—Dealer Fabricated Tools
Clutch
Group 0360—Hydraulic System
Section 04—Engine
Group 0400—Removal and Installation
Section 05—Engine Auxiliary Systems
Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
Group 0520—Intake System
Group 0530—External Exhaust System
Group 0560—External Fuel Supply Systems
Section 07—Dampener Drive
Group 0752—Elements
Section 09—Steering System
Group 0960—Hydraulic System
Section 10—Service Brakes
Group 1011—Active Elements
Group 1060—Hydraulic System
Section 11—Park Brake
Group 1111—Active Elements
Group 1160—Hydraulic System
Section 17—Frame or Supporting Structure
Group 1740—Frame Installation
Group 1746—Frame Bottom Guards
Group 1749—Chassis Weights
Section 18—Operator’s Station
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 © 2012
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual
Previous Editions
Copyright © 2008, 2009,2010
TM10689 (24APR12) i 544K 4WD Loader
042412
PN=1
, Contents
TM10689 (24APR12) ii 544K 4WD Loader
042412
PN=2
Engine 6068HDW74
Repair
(Serial No. - 642664)
TECHNICAL MANUAL
544K 4WD Loader Repair
TM10689 24APR12 (ENGLISH)
For complete service information also see:
544K Loader Test Manual .................................. TM10688
544K Loader Operator's Manual ........................ OMT231639
PowerTech™ 4.5 L and 6.8 L Diesel
Engines—Base Engine ....................................... CTM104
PowerTech E™ 4.5 & 6.8L Diesel
Engines—Level 16 Electronic Fuel System
with Denso HPCR ................................................ CTM502
TeamMate™ IV 1200 and 1400 Series Inboard
Planetary Axles.................................................... CTM442
120 Series Hydraulic Cylinders .......................... CTM114319
125 Series Hydraulic Cylinders .......................... CTM109319
JDLink™ / ZXLink™ Machine Monitoring
System.................................................................. CTM10006
JDLink™ / ZXLink™ (MTG) Diagnosis and
Tests Manual ........................................................ CTM114519
Super Caddy Oil Cleanup Procedure................. CTM310
Specifications Manual......................................... SP458
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
, Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
DX,TMIFC -19-29SEP98-1/1
TM10689 (24APR12) 544K 4WD Loader
042412
PN=2
, Contents
Section 00—General Information Group 1800—Removal and Installation
Group 0001—Safety Information Group 1810—Operator Enclosure
Group 1821—Seat and Seat Belt
Section 01—Wheels Group 1830—Heating and Air Conditioning
Group 0110—Powered Wheels and Fasteners
Section 19—Sheet Metal and Styling
Section 02—Axles and Suspension Systems Group 1910—Hood or Engine Enclosure
Group 0200—Removal and Installation
Group 0225—Axle Shafts and U-Joints Section 31—Loader
Group 0250—Axle Shaft, Bearings, Reduction Gears Group 3102—Bucket
Group 0260—Hydraulic System Group 3140—Frames
Group 3160—Hydraulic System
Section 03—Transmission
Group 0300—Removal and Installation Section 99—Dealer Fabricated Tools
Group 0350—Gears, Shafts, Bearings and Power Shift Group 9900—Dealer Fabricated Tools
Clutch
Group 0360—Hydraulic System
Section 04—Engine
Group 0400—Removal and Installation
Section 05—Engine Auxiliary Systems
Group 0505—Cold Weather Starting Aids
Group 0510—Cooling System
Group 0520—Intake System
Group 0530—External Exhaust System
Group 0560—External Fuel Supply Systems
Section 07—Dampener Drive
Group 0752—Elements
Section 09—Steering System
Group 0960—Hydraulic System
Section 10—Service Brakes
Group 1011—Active Elements
Group 1060—Hydraulic System
Section 11—Park Brake
Group 1111—Active Elements
Group 1160—Hydraulic System
Section 17—Frame or Supporting Structure
Group 1740—Frame Installation
Group 1746—Frame Bottom Guards
Group 1749—Chassis Weights
Section 18—Operator’s Station
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 © 2012
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual
Previous Editions
Copyright © 2008, 2009,2010
TM10689 (24APR12) i 544K 4WD Loader
042412
PN=1
, Contents
TM10689 (24APR12) ii 544K 4WD Loader
042412
PN=2
