John Deere 544G, 544G LL, 544G TC, 624G and 644G Loader Repair Technical Manual (TM1530)

John Deere 544G, 544G LL, 544G TC, 624G and 644G Loader Repair Technical Manual (TM1530 07APR98)

This in-depth factory repair manual provides advanced technical service data, disassembly and reassembly procedures, torque specifications, and component-level diagnostics for the John Deere 544G, 544G LL, 544G TC, 624G, and 644G Loaders. Engineered for professional service technicians, this publication enables precision-level servicing of mechanical, hydraulic, electrical, and structural subsystems across all model variants.

Model Covers:

John Deere 544G, 544G LL, 544G TC Loaders
John Deere 624G Loader
John Deere 644G Loader

File Format: PDF

Size: 8.28 MB

No. of pages: 580

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Included Sections:

General Specifications & Service Safety

• Comprehensive model-specific capacities and torque specs
• Hydraulic fitting torque values and sealing best practices
• Technical safety protocols for high-pressure fluids, batteries, welding, and ROPS

Transmission and Powertrain Systems

• Complete teardown and rebuild procedures for transmission, clutch packs, and torque converter
• Flow, pressure, stall speed, and modulation tests with troubleshooting paths
• Detailed drive shaft, U-joint, axle shaft and bearing maintenance guides

Hydraulic System Service

• Main pump overhaul, loader valve service, boom/bucket cylinder rebuilds
• Ride control, pilot valve control (joystick & lever) disassembly/bench testing
• Relief, anti-cavitation and orifice check valve diagnostics

Engine and Auxiliary System

• Component-level procedures for engine removal, fuel injection, turbocharger, and water pump service
• Speed control linkage adjustments and fuel shut-off solenoid calibration
• Cold weather starting aids, coolant system maintenance, air intake leak testing

Brake and Steering Systems

• Service brake disassembly, valve overhaul, accumulator charging and bleeding
• Park brake hydraulic circuit diagnostics and mechanical pad adjustments
• Steering valve and cylinder rebuilds, priority valve disassembly and testing

Electrical and HVAC Systems

• Component replacement: switches, sensors, pressure valves, connectors
• Alternator, starter motor, battery circuit testing and connector retermination
• Compressor, evaporator, and receiver/dryer R12/R134a servicing with volumetric and leak testing

Cab, Frame, Loader, and Fabricated Tool Support

• Welding repairs, bearing/seal replacement in pivot assemblies
• Cab disassembly, wiper/washer service, seat belt inspection
• Loader frame and linkage component service including tool carrier mechanisms
• Dealer-fabricated tools list with part numbers and applications

For complete service information, also see:

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

This John Deere Repair Technical Manual is a vital resource for authorized service centers and advanced technicians requiring precise service workflows, torque data, and system-level rebuild guidance for mid-size loaders in the G-series lineup.