John Deere. MODEL: 5448 Loader Volume 1 of 2 JD-S-TM1094

John Deere MODEL: 5448 Loader Volume 1 of 2 THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF JOHN DEERE OR IT'S SUCCESSORS. JOHN DEERE AND IT'S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. JD-S-TM1094

JOHN DEERE JD544B LOADER TECHNICAL MANUAL JOHN DEERE JD544B LOADER TM1094 (01JAN80) I JOHN DEERE DUBUQUE WORKS TM1094

Loader - JD544-B TM-1094 (Jan-80) 1 JDS44-B LOADER CONTENTS Section 10 - GENERAL Group 5 Specifications Group 10 Predelivery, Delivery, and Services Group 15 Lubrication After-Sale Section 20 - ENGINE Group 5 Engine Removal and Installation Group 10 Basic Engine Group 15 Engine Lubrication System Group 20 Engine Cooling System Group 25 Fuel System Group 30 Speed Control Linkage (Refer to Section 70) Group 35 Air Intake System Group 40 Specifications and Special Tools Section 30 - ELECTRICAL SYSTEM Group 5 Batteries Group 10 Charging System Group 15 Delco-Remy Starting System Group 20 John Deere Starting System Group 25 Miscellaneous Electrical Components Group 26 Heating and Air Conditioning Systems Group 30 Specifications and Special Tools Section 40 - POWER TRAIN Group 5 Drive Shafts Group 10 Damper Assembly Group 15 Transmission Group 20 Final Drives Group 25 Differential Group 30 Specifications and Special Tools Technical Manual TM-1094 (Jan-aD) Section 50 - HYDRAULIC SYSTEM Group 5 Transmission Pump Group 10 Transm iss ion Control Valve Group 15 Steering and Brake Pump Group 20 Steering Valve Group 25 Brake System Group 30 Loader Pump Group 35 Loader Control Valve Group 40 Cylinders Group 45 Miscellaneous Hydraulic Components Group 47 Backhoe Swing Cylinder Group 49 Backhoe Control Valve Group 50 Specifications and Special Tools Section 60 - MISCELLANEOUS COMPONENTS Group 5 Loader and Engine Frames Group 10 Loader Boom and Buckets Group 15 Seats Group 20 Canopy and Cab Group 21 Backhoe Group 25 Specifications and Special Tools Section 70 - SYSTEM TESTING Group 5 General Information - Seven Basic Steps of Testing and Diagnosis Group 10 Engine Group 15 Electrical System Group 16 Heating and Air Conditioning Systems Group 20 Power Train Group 25 Hydraulic System Group 26 Hydraulic System (Analyzer) Group 30 Miscellaneous Components Group 35 Specifications and Special Tools INDEX The specifications and design information contained in this manual were correct at the time this machine was manufactured. It is John Deere's policy to continually improve and update our machines. Therefore, the specifications and deisgn information are subject to change without notice. Wherever applicable, specifications and design information are in accordance with SAE and ICED standards. Litho in U.S.A.

Loader - JD544-8 TM-1094 (Jan-BO) General Information 10 General Specifications 5-1 CONTENTS OF THIS SECTION Section 10 GENERAL GROUP 5 - SPECIFICATIONS General Machine Specifications... 5-1 GROUP 10 - PREDELIVERY, DELIVERY, AND AFTER SALE SERVICES Temporary Machine Storage............... 10-1 Predelivery Serivce... 10-1 Del ivery Service......................... 1 0-15 After Sale Inspection... 10-15 GROUP 15 - LUBRICATION General Information... 15-1 Loader Periodic Service Chart............. 15-1 Engine Lubricating Oil... 15-2 Transmission, Steering, and Brake Oils..... 15-2 Loader Hydraulic Oil...................... 15-2 Greases................................. 15-2 Group 5 GENERAL MACHINE SPECIFICATIONS (Specifications and design are subject to change without notice. Wherever applicable, specifications are in accordance with ICED and SAE Standards. Except where otherwise noted, specifications are based on a machine equipped with all standard equipment and 17.5-25, 12-ply loader-tread tires with 1180 Ibs (535.2 kg) CaCI 2 solution in rear tires, ROPS cab, side counterweights, full fuel tank, and 175 lb. (79.4 kg) operator.) Power (at 2,200 engine rpm): SAE Gross... 115 (85.8 kw*) Net... 105 (78.3 kw) 106.5 PS *Net engine flywheel horsepower is for. an engine equipped with fan, air cleaner, water pump, lubricating oil pump, fuel pump, alternator, and muffler. The gross engine power is without fan. Flywheel power ratings are under SAE standard conditions of 500-ft. (150 m) altitude and B5 F (29 C) temperature and DIN 70 020 conditions (non-corrected). No derating is required up to 10,000 feet (3000 m) altitude. **In the International System of Units (Sf), power is expressed in kilowatts (kw). Engine: John Deere turbocharged diesel, vertical 6- cylinder, 4-stroke cycle. Bore and stroke... 4.19 x 5 in. (106.5 x 127 mm) Piston displacement... 414 cu. in. (6784 cm 3 ) Compression ratio... 16.2 to 1 Maximum torque @ 1,400 rpm... 325 Ib-ft (44.9 kg-m) NACC or AMA (U.S. Tax) horsepower..., 42 Lubrication... Pressure system with full-flow filter Cooling... Pressurized with thermostat and fixed by-pass Fan... " Blower Aspirated air cleaner with restriction indicator... Dry Electrical system... 12-volt (12 v) with alternator Batteries (2)... Reserve capacity: 420 minutes each battery Torque Converter: Type..., Twin-turbine Torque Multiplication... 5.15 to 1 Transmission... " Power Shift planetary Forward Speeds: mph 1... 0-3 2... 3-7.7 3... 0-11.2 4... 11.2-25 Reverse Speeds: 1... 0.4 2... 4-10 km/h 0-4.8 4.8-12 0-18 18.40 0-6.4 6.4-16 Note: Shift from 1st to 2nd and 3rd to 4th is automatic. Differentials: Front..., No-Spin Rear.................................. Standard Drive Axles... Inboard-mounted planetary gears to each wheel. Front axle fixed. Rear axle oscillates 22- degree total (13.5 inches [343 mm] vertical travel at center of tire). Litho in U.S.A.

Loader - J0544-8 TM-1094 (Jan-BO) CONTENTS Engine 20 Engine Removal and Installation 5-1 Section 20 ENGINE GROUP 5 - ENGINE REMOVAL AND INSTALLATION Removal... 5-3 Installation... 5-4 GROUP 10 - BASIC ENGINE General Information... 1 0-1 Cylinder Head and Valves Valve Lift Check... 10-1 Removal... 10-2 Repair... 10-2 Assem bly... 1 0-4 Installation... 10-4 Camshaft Removal... 10-6 Repair... 1 0-6 Installation... 10-7 Cylinder Block, Liners, Pistons and Rods Removal... 10-8 Repair... 1 0-8 Installation... 10-11 Crankshaft, Main Bearings, and Flywheel Removal... 10-13 Repair... 10-13 Installation... 10-15 Timing Gear Train Removal... 1 0-19 Repair... 10-19 Installation... 10-20 GROUP 15 - ENGINE LUBRICATION SYSTEM General Information... 15-1 Oil Pump Removal.............................. 15-1 Repair... '.'............. 15-2 Installation............................. 15-2 Oil Pressure Regulating Valve Removal.............................. 15-2 Repair................................ 15-3 Installation... " 15-3 Oil Filters and Housing Removal... " 15-3 Repair................................ 15-3 Installation.... "..................... 15-3 Oil Cooler Removal... " 15-4 Repair.,...,... 15-4 Installation...,... " 15-4 GROUP 20 - ENGINE COOLING SYSTEM General Information... 20-1 Radiator Removal... 20-1 Repair... 20-1 Installation... 20-1 Water Pump Removal... 20-1 Repair... 20-1 Installation... 20-3 GROUP 25 - FUEL SYSTEM General Information... 25-1 Fuel Tank Removal... 25-1 Repair... 25-1 Installation... 25-2 Fuel Filter Removal...,... 25-2 Repair... 25-3 Installation... 25-3 Fuel Transfer Pump Removal... 25-3 Repair... 25-3 Installation... 25-3 Fuel Injection Pump Removal... 25-4 Repair... 25-5 (Refer to SM-2045 "Testing and Servicing Fuel Injection Pumps and Nozzles") Installation and Timing... 25-5 Bleeding... 25-6 Fuel Injection Nozzles Removal... 25-6 Repair... 25-7 (Refer to SM-2045 "Testing and Servicing Fuel Injection Pumps and Nozzles") Installation... 25-7 GROUP 30 - SPEED CONTROL LINKAGE General Information... 30-1 Contents continued on next page Litho in U. S.A.

20 Engine 5-2 Engine Removal and Installation Loader - JOS44-8 TM-1094 (Jan-80) CONTENTS-Continued GROUP 35 - AIR INTAKE SYSTEM GROUP 40 - SPECIFICATIONS AND General Information... 35-1 SPECIAL TOOLS Air Cleaner Engine Removal and Installation... 40-1 Removal...,.. 35-1 Basic Engine... 40-3 Repair... 35-2 Engine Lubrication System... 40-19 Installation... 35-2 Engine Cooling System... 40-21 Turbocharger Fuel System... 40-24 Removal... 35-2 Speed Control Linkage... 40-26 Testing... 35-3 Air Intake System... 40-26 Repair... 35-4 Installation... 35-7 Intake Manifold Removal...,... 35-8 Repair... 35-8 Installation... 35-8 Litho in U.S.A.

Loader - JOS44-B TM-1094 (Jan-80) Engine Basic Engine 20 10-19 TIMING GEAR TRAIN Removal To service gear train and related parts, with the exception of the crankshaft, engine normally need not be removed. If engine must be removed, see Group 5 of this section. 4. Remove oil pump (Group 15). 5. Remove fuel injection pump and drive gear (see Group 25). 6. Remove camshaft. Repair For gear inspection and repair, refer to the section and group in the manual which covers the assemblies which the gears drive. The camshaft and crankshaft must be removed from the engine to replace their gears. Checking Gear Train Backlash If gear train noise is noted at the time of disassembly it usually indicates excessive gear lash or damaged gear teeth. During disassembly measure gear train backlash. Specified timing gear train backlash is as follows: 1-Camshaft Gear 2-Upper Idler Gear 3-lnjection Pump Gear Fig. 25-Gear Train 4-0il Pump Gear 5-Lower Idler Gear 6-Crankshaft Gear Whenever an engine is being completely reconditioned or the crankshaft is being removed, the engine front plate with gear assemblies should be removed from the engine using the following steps: 1. Remove timing gear cover. 2. Remove hex. nuts from the oil pump, drive gears and cap screws from upper and lower idler gears. 3. Remove upper and lower idler gears from engine front plate. Attach a puller to oil pump gear and pull gear from shaft. NEVER PRY GEAR FROM SHAFT. Gear Backlash Crankshaft to upper idler... 0.0027 to 0.0116 in. [0.0686 to 0.2946 mm] Upper idler tocamshaft... 0.0028 to 0.0135 in. [0.0711 to 0.3429 mm] Upper idler to injection pump... O.0028 to 0.0135 in. [0.0711 to 0.3429] Crankshaft to lower idler... 0.0027 to 0.0137 in [0.0686 to 0.3480 mm] Lower idler to oil pump... 0.0016 to 0.0147 in. [0.0406 to 0.3734 mm] Idler Gears Be sure that the oil hole in the upper shaft is open. Measure inside diameter of bushing (1.7520 inches to 1.7530 inches [44.5008 to 44.5262 mm]) and outside diameter of shaft (1.7495 inches to 1.7505 inches [44.4373 to 44.4627 mm]) to determine oil clearance. If bushing replacement is required, press in new bushing to flush with either side of gear using JD252 Driver. Litho in U.S.A.

Loader - JDS44-B TM-1094 (Jan-BO) Electrical System 30 Batteries 5-1 Section 30 ELECTRICAL SYSTEM CONTENTS OF THIS SECTION GROUP 5 - BATTERIES General Information... 5-2 Precautions... 5-2 Removal... 5-2 Inspection... 5-3 Testing... 5-3 Charging the Battery... 5-5 Installation... 5-6 GROUP 10 - CHARGING SYSTEM Delco Remy Alternator General Information... 10-1 Removal... 10-1 Repair... 10-2 Assembly... 10-6 Test After Assembly... 10-6 Installation...............................10-7 Motorola Alternator General Information... 10-8 Removal... 10-9 Repair... 10-9 Test After Assembly... 10-22 Installation.............................. 10-22 GROUP 15 - DELCO-REMY STARTING SYSTEM General Information... 15-1 Removal... 15-2 Testing and Diagnosis.................... 15-3 Repair... 15-4 Assembly... "... 15-7 Installation..., 15-10 GROUP 20 - JOHN DEERE STARTING SYSTEM General Information... 20-1 Removal... 20-2 Testing and Diagnosis... 20-2 Repair... 20-3 Assembly... 20-8 Installation...,... 20-9 GROUP 25 - MISCELLANEOUS ELECTRICAL COMPONENTS General Information... 25-1 Removal... 25-6 Installation... 25-6 Reverse Warning Alarm Removal... 25-7 Repair................................ 25-7 Installation............................. 25-7 GROUP 26 - HEATING AND AIR CONDITIONING Heating System General Information '"... 26-1 Removal... 26-1 Repair................................ 26-1 Installation... 26-2 Air Conditioning System Compressor... 26-3 Condenser, Receiver-Dryer and Evaporator Condenser... 26-19 Receiver-Dryer... 26-20 Evaporator......................... 26-21 Regulatory Controls Expansion Valve... 26-23 Thermostatic Temperature Control Switch........................... 26-24 Compressor Relief Valve... 26-25 High Pressure Switch... 26-26 Thermal Fuse and Superheat Shut-Off Switch... 26-27 Pressurizer Motor................... 26-28 GROUP 30 - SPECIFICATIONS AND SPECIAL TOOLS Batteries... 30-1 Charging System... 30-2 Delco-Remy Starting System... 30-6 John Deere Starting System... 30-9 Miscellaneous Electrical Components... 30-14 Air Conditioning System.................. 30-15 Litho in U. S.A.

Loader - JDS44-8 TM-1094 (Jan-BO) Electrical System 30 Heating and Air Conditioning 26-9 Engage tabs on compressor shaft seal assembly (2, Fig. 14) with locking tangs on the AC-415 (part of D-05276ST) Seal Installation and Removal Tool (1). Press down on tool and twist clockwise to engage shaft seal. Remove shaft seal assembly by pulling straight out from shaft (Fig. 14). Remove the ceramic seal seat O-ring (1, Fig. 15) from inside of compressor neck by using the AC-412 (part of D-05276ST) O-Ring Removal Tool. Installation NOTE: Never reuse old seals. Always install new seals. Be sure interior of compressor neck is clean before reassembling parts. 1-Ceramic Seal Seat Removal Tool (D-05284ST) 2-Ceramic Seal Seat Fig. 13-Removing Shaft Seal Seat 1-Seal Seat O-Ring 2-Washers Fig. 15-lnstalling Seal Seat O-Ring 1-Seal Removal Tool (AC-415j Fig. 14-Removing Shaft Seal Assembly 2-Shaft Seal Assembly Remove ceramic seal seat (2, Fig. 13) using D- 05284ST Removal Tool (1). Coat seal seat O-ring (1, Fig. 15) with clean compressor oil and place over shaft of AC-460 Tool between the two washers (2). Pull O-ring tight and hold against tool as in Fig. 15. Insert tool into compressor neck and push down firmly with a rocking motion to allow O-ring to snap into the bottom groove. Litho in U. S.A.

Loader - JDS44-8 TM-1094 (Jan-BO) CONTENTS OF THIS SECTION Power Train 40 Drive Shafts 5-1 Section 40 POWER TRAIN GROUP 5 - DRIVE SHAFTS General Information... 5-2 Removal... 5-2 Repair... 5-2 Installation... 5-4 GROUP 10 - DAMPER ASSEMBLY General Information... 1 0-1 Removal... 1 0-1 Repair... 10-1 Installation... 10-2 GROUP 15 - TRANSMISSION General Information... 15-1 Removal... 15-3 Disassembly of Transmission Into Subassemblies... 15-4 Removal of Exterior Components... 15-4 Removal of Input Components... 15-4 Removal of Converter Components... 15-5 Removal of Front Cover, Range Gearing, and Clutches... 15-8 Removal of Output Components and Transfer Driven Gear... 15-11 Rebuild of Subassemblies... 15-15 Assembly of Transmission from Subassemblies... 15-28 Output Components and Transfer Driven Gear.......................... 15-28 Reverse - Range Clutch and Planetary......................... 15-31 Low - Range Clutch and Planetary......................... 15-32 Transfer Drive Gear, High Range Clutch, and Front Cover... 15-33 Turbine Gearing and Oil Suction Tube... 15-35 Converter Housing and Converter Components... 15-36 Exterior Components.................. 15-37 Installation... 15-38 Mechanical Parking Brake... 15-38 GROUP 20 - FINAL DRIVES General Information... 20-1 Removal... 20-1 Rear Axle... 20-1 Front Differential and Axle... 20-1 Repair... 20-2 Installation... 20-5 Bleeding Brakes... 20-5 GROUP 25 - DIFFERENTIAL General Information... 25-1 Removal Rear Differential... 25-1 Front Differential... 25-1 Repair Differential Drive and Bearings... 25-2 Spiral Bevel Pinion Shaft Disassembly... 25-2 Differential Case Replacement... 25-2 Differential Case Cover Replacement... 25-2 No Spin Differential... 25-9 Disassembly... 25-10 Assembly... 25-11 Installation... 25-12 Bleeding Brakes... 25-12 GROUP 30 - SPECIFICATIONS AND SPECIAL TOOLS Drive Shafts............................. 30-1 Damper Assembly... " 30-2 Transmission... 30-3 Final Drives... 30-12 Differential... 30-13 Litho in U.S.A.

Loader - JOS44-8 TM-1094 (Jan-80) Hydraulic System 50 Transmission Pump 5-1 GROUP 5 - TRANSMISSION PUMP General Information... 5-3 Removal... 5-3 Repair... 5-3 Installation... 5-3 GROUP 10 - TRANSMISSION CONTROL VALVE General Information... 10-1 Removal... 10-3 Repair... 10-3 Installation............................... 10-5 Shift Lever and Linkage................... 10-5 GROUP 15 - STEERING AND BRAKE PUMP General Information... 15-1 Removal... 15-2 Repair..................... 15-2 Installation... 15-6 GROUP 20 - STEERING VALVE Steering Valve Serial No. ( -247599) General Information..,................. 20-1 Removal.............................. 20-4 Repair................................ 20-4 Adjustment........................... 20-10 Bench Testing Steering Valve... 20-11 Installation............................ 20-14 Bleeding... 20-15 Steering Valve Serial No. (247600- ) General Information... 20-16 Removal............................. 20-19 Repair... 20-20 Adjustment..., 20-28 Installation... 20-31 Steering Cylinders (247600- )... 20-32 General Information... 20-32 Removal............................. 20-32 Repair............................... 20-32 Installation... '...................... 20-34 Section 50 HYDRAULIC SYSTEM CONTENTS OF THIS SECTION GROUP 25 - BRAKE SYSTEM Brake Valve Serial No. ( -248384) General Information... " 25-1 Removal.............................. 25-3 Repair... " 25-3 Adjustment............................ 25-4 Installation... 25-4 Brake Valve Serial No. (248385- ) General Information... 25-5 Removal... 25-6 Repair................................ 25-6 Installation... 25-7 Clutch Control Valve General Information..., 25-8 Removal... " 25-8 Repair...'... " 25-8 Installation... " 25-8 GROUP 30 - LOADER PUMP General Information... 30-1 Removal... 30-2 Repair... 30-~ Installation... " 30-5 GROUP 35 - LOADER CONTROL VALVE General Information... 35-1 Removal... 35-5 Repair... 35-5 Installation...,... 35-11 GROUP 40 - CYLINDERS General Information... 40-1 Removal... 40-1 Repair... 40-2 Installation... 40-9 Contents continued on next page Litho in U.S.A.

50 Hydraulic System 5-2 Transmission Pump Loader - JOS44-8 TM-1094 (Jan-BO) GROUP 45 - MISCELLANEOUS HYDRAULIC COMPONENTS Reservoir and Filters General Information... 45-1 Removal............................ 45-1 Repair................................ 45-2 Installation............................. 45-3 Transmission Oil Filter Removal.............................. 45-5 Repair................................ 45-5 Oil Cooler General Information... 45-6 Removal.............................. 45-6 Repair................................ 45-6 Accumulators General Information.................. 45-7 Removal..................... 45-7 Repair................................ 45-7 Assembly... 45-9 Installation... 45-9 Pre-Charging Accumulator... 45-9 Emergency Steering Accumulator... "... 45-10 Removal..................... 45-1 0 Repair............................... 45-1 0 Pre charging... 45-11 Installation... 45-12 Emergency Steering Low Pressure Warning Switch... 45-13 General Information... 45-13 Repair... '..... 45-13 GROUP 50 - SPECIFICATIONS AND SPECIAL TOOLS Transmission Pump... 50-1 Transmission Control Valve... 50-1 Steering and Brake Pump..., 50-2 Steering Valve Serial No. ( -247599). 50-8 Steering Valve Serial No. (247600- ) 50-13 Brake System............................ 50-18 Loader Pump........................... 50-19 Loader Control Valve... " 50-19 Cylinders... 50-21 Miscellaneous Hydraulic Components... 50-32 Backhoe Control Valve... 50-35 A CAUTION: Escaping fluid under pressure... can have sufficient force to penetrate the skin, causing serious personal injury. Before disconnecting lines, be sure to relieve all pressure. Before applying pressure to system, be sure all connections are tight and that lines, pipes and hoses are not damaged. Fluid escaping from a very small hole can be almost invisible. Use a pi~ce of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately. GROUP 47 - BACKHOE SWING CYLINDER General Information... 47-1 Removal... "... 47-2 Repair... 47-2 Installation... 47-4 GROUP 49 - BACKHOE CONTROL VALVE General Information... 49-1 Removal... 49-3 Repair... 49-3 Installation............................... 49-5 Quick-Disconnect Couplers................ 49-6 Relief Valves... 49-6 Litho in U.S.A.

Loader - JOS44-8 TM-1094 (Nov-78) Miscellaneous Components 60 Loader and Engine Frames 5-1 Section 60 MISCELLANEOUS COMPONENTS CONTENTS OF THIS SECTION GROUP 5 - LOADER AND ENGINE FRAMES General Information... 5-2 Removal... 5-2 Repair... 5-3 Installation... 5-5 GROUP 10 - LOADER BOOM AND BUCKETS General Information... '"... 10-1 Removal... 1 0-1 Repair Boom and Linkage... 10-2 Buckets............................... 10-3 Special Welding Instructions............ 10-5 Replacing Bucket Tooth Shank... 10-8 Lumber Fork..................... 10-9 Installation... 10-8 GROUP 15 - SEAT General Information... 15-1 Removal... 15-1 Repair... 15-1 Installation... 15-2 GROUP 20 - CANOPY AND CAB General Information... 20-1 Removal...,... 20-1 Repair Canopy and Cab Frame... 20-1 Windshield Wipers... 20-5 Defroster... 20-7 Installation... 20-8 GROUP 21 - BACKHOE General Information... 21-1 Removal... 21-1 Repair... 21-1 Installation... 21-5 GROUP 25 - SPECIFICATIONS AND SPECIAL TOOLS Loader and Engine Frames... 25-1 Boom and Buckets... 25-2 Canopy and Cabs... 25-3 Litho in U.S.A.

Loader - JDS44-8 TM-1094 (Nov-78) CONTENTS OF THIS SECTION System Testing 70 General Information 5-1 Section 70 SYSTEM TESTING GROUP 5 - GENERAL INFORMATION - SEVEN BASIC STEPS OF DIAGNOSIS AND TESTING... 5-2 GROUP 10 - ENGINE General Information... 10-1 Diagnosing Malfunctions... 10-3 Visual Inspection... 10-6 Testing and Adjustments... 10-8 GROUP 15 - ELECTRICAL SYSTEM General Information... 15-1 Visual Inspection... 15-7 Diagnosing Malfunctions... 15-8 Testing and Adjustments... 15-26 GROUP 16 - HEATING AND AIR CONDITIONING Heating System General Information... 16-1 Diagnosis and Testing... 16-2 Air Conditioning System General Information... 16-3 Diagnosis and Testing... 16-5 Diagnosing Malfunctions... 16-6 Safety Precautions... 16-9 System Service... 16-1 0 GROUP 25 - HYDRAULIC SYSTEM General Information... 25-1 Diagnosing Malfunctions... 25-14 Visual Inspection... 25-24 Testing and Adjustment..... 25-24 GROUP 26 - HYDRAULIC SYSTEM (ANALYZER) General Information... 26-1 Pretest Inspection and Operational Checks....................... 26-3 Pretest Check Sheet...................... 26-4 Symptom Index.......................... 26-5 Loader Hydraulic System Tests............ 26-8 Steering and Brake System Tests... 26-15 List of Parts for Tests.................... 26-31 GROUP 30 - MISCELLANEOUS COMPONENTS Adjustment... 30-1 GROUP 35 - SPECIFICATIONS AND SPECIAL TOOLS Engine... " 35-1 Electrical System......................... 35-6 Hydraulic System......................... 35-8 Hydraulic System (Analyzer)... 35-13 GROUP 20 - POWER TRAIN General Information... 20-1 Diagnosing Malfunctions... 20-7 Visual Inspection... 20-9 Testing and Adjustments... 20-10 Litho in U. S.A.

Loader - JD544-B TM-1094 (Jan-80) Index 1 ALPHABETICAL INDEX A Accumulator, brake... ; 50-45-7 Accumulator, emergency steering... ".. 50-45-10 After-sale inspection... " 10-10-15 Air cleaner.............................. 20-35-1 Air conditioning system................... 30-26-3 Air conditioning system testing... 70.;16-3 Diagnosing malfunctions... 70-16-6 Precautions... 70-16-9 System service....................... 70-16-10 Visual checks..., 70-16-5 Air intake system..., 20-35-1 Alternator (Delco-Remy)... :............ 30-10-1 Alternator (Motorola)..................... 30-10-8 Analyzer testing......................... 70-26-1 Axle,' front... 40-20-1 Axle, rear............................... 40-20-1 B Backhoe... 60-20-1 Backhoe control linkage..., 50-49-7 Backhoe control valve..., 50-49-1 Backhoe quick-disconnect couplers... 50-49-6 Backhoe relief valve... 50-49-6 Backhoe swing cylinder... "..,... 50-47-1 Batteries... 30-5-2 Bearings, main... " 20-10-13 Bleeding brakes... 40-20-5,40-25-12, 50-25-4 Bleeding fuel injection pump..., 20-25-6 Bleeding power steering valve... 50-20-10 Boom... "... 60-10-2 Boom cylinder (Serial No. -xxxxx).............. 50-40-6 (Serial No. xxxxx- )... 50-40-6 Boom raise switch....................... 30-25-4 Brake accumulator... 50-45-7 Brake, parking... '".. 40-15-38 Brake valve (Serial No. -248384)... 50-25-1 (Serial No. 248385~ )..., 50-25-5 Break-in, engine... " 20-40-11 Bucket... :... 60-10-3 Bucket cutting edge repair..., 60-10-5 Bucket teeth... ~.................. 60-10-3 C Camshaft............................... 20-10-6 Canopy and.cabs........................ 60-20-1 Charging system... 30-10-1 Checking and adding compressor oil... 30-26-14 Cigar lighter............................. 30-25-2 Circuit breakers... 30-25-3 Clutch coil and housing, compressor..,.. 30~26-13 Clutch control valve... " 50-25-8 Compressor... :... " 30-26-3 Compressor hub and drive plate assembly. 30-26-6 Compressor pulley and bearings... "... 30-26-12 Compressor servicing................... 30-26-15 Compressor shaft seal... " 30-26-8 Condenser...,... '"...,. "... 30-26-19 Connecting rods........................ 20-10-10 Crankshaft............................. 20-1 0-13 Cylinder block........................... 20-10-8 Cylinder, boom (Serial No. -xxxxx)... " 50-40-6 (Serial No. xxxxx- )... 50-40-6 Cylinder head........................... 20-10-1 Cylinder liners... "... 20-10-8 Cylinder, steering (Serial No. -247599)... 50-40-1 (Serial No. 247600- )... 50-40-6 Cylinders, hydraulic... " 50-40-1 D Damper assembly... 40-10-1 Deglazing cylinder liners... 20-10-10 Delivery service..................... 10-10-15 Diagnosis and testing... 70-5-2 Differential, no-spin... " 40-25-7 Differential, standard... " 40-25-1 Drive shafts... 40-5-2 E Electrical system testing... " 70-15-1 Block diagram... 70-15-13 Component location... 70-15-12 Inspection... 70-15-7 Malfunctions.......................... 70-15-8 Operation............................. 70-15-1 Precautions........................... 70-15-6 Schematic diagram... 70-15-14 Tests... 70-15-31 Wiring routes... 70-15-22 Emergency steering accumulator... 50-45-10 Emergency steering low pressure warning system.............................. 50-45-13 Engine break-in..................... 20-40-11 Engine components... " 20-10-1 Engine cooling system................... 20-20-1 Engine frame... 60-5-2 Engine fuel system... 20-25-1 Engine lubricating system... 20-15-1 Engine oil pressure adjustment... 70-10-9 Litho in U. S.A.

2 Index Loader - JOS44-8 TM-1094 (Jan-BO) Engine oil pressure check...,. 70-10-8 Engine oil pressure gauge................ 30-25-2 Engine oil pump... 20-15-1 Engine removal, installation... 20-5-3 Engine speed control linkage... 20-30-1 Engine testing........................... 70-10-1 Component locations... 70-10-1 Malfunctions... 70-10-3 Speed control linkage adjustment..., 70-10-12 Tests and adjustments... 70-10-8 Visual inspection...................... 70-10-6 Engine water temperature gauge... 30-25-3 Evaporator... 30-26-21 Expansion valve..., 30-26-23 F Filter, engine fuel... 20-25-2 Final drives... 40-20-1 Flywheel... 20-10-42 Frames... 60-5-2 Fuel filter, engine... 20-25-2 Fuel gauge... 30-25-1 Fuel injection nozzles... 20-25-6 Fuel injection pump...................... 20-25-4 Fuel system............................. 20-25-1 Fuel tank............................... 20-25-1 Fuel transfer pump... 20-25-3 Fuses.................................. 30-25-3 G Gauges and switches... " 30-25-1 General after-sale inspection... 10-10-15 Gear train, engine... 20-10-19 Gear train, timing... 20-10-20 General predelivery inspection............ 10-10-1 General specifications... 10-5-1 H Heating system.......................... 30-26-1 Heating system testing... 70-16-1 High pressure switch..., 30-26-26 Horns.................................. 30-25-2 Hour meter... 30-25-1 Hydraulic accumulator... 50-45-7 Hydraulic cylinders....................... 50-40-1 Hydraulic filter indicator light... 30-25-2 Hydraulic low pressure warning switch... 50-45-8 Hydraulic oil cooler... 50-45-6 Hydraulic oil filters... 50-45-2 Hydraulic pump (loader)... 50-30-1 Hydraulic pump (power steering and brakes) 50-15-1 Hydraulic rese rvoir....................... 50-45-1 Hydraulic system (analyzer) testing... 70-26-1 Hydraulic system pretest check sheet... 70-26-4 Loader hydraulic system tests... 70-26-8 Operational checks.................... 70-26-3 Parts list for tests... 70-26-31 Pretest inspection... 70-26-3 Steering and brake system tests... 70-26-15 Symptom index... 70-26-5 Transmission tests... 70-26-21 Hydraulic system testing... 70-25-1 Component location... 70-25-3 Diagnosing malfunctions... 70-25-14 Operations... 70-25-1 Testing and adjustments..., 70-25-23 Visual inspection..., 70-25-23 Injection nozzles, fuel... 20-25-6 Injection pump, fuel... 20-25-4 Inspection, after-sale... 10-10-15 Instrument panels... 30-25-5 Intake manifold... 20-35-8 K Key switch... 30-25-1 L Leak testing compressor... 30-26-16 Light switch... 30-25-2 Loader boom and buckets................ 60-10-1 Loader control valve... 50-35-1 Loader frame... 60-5-2 Low pressure warning switch... 50-45-8 Lubricants... 10-15-2 Lubrication chart......................... 10-15-1 Lubrication system, engine... 20-15-1 Lumber fork... 60-10-9 M Main bearings..., 20-10-31 Malfunctions: Air conditioning system... 70-16-6 Batteries... 70-15-8 Brake system..., 70-25-22 Charging circuit... 70-15-7 Clutch control valve... 70-25-28 Damper assembly... 70-20-7 Differential............................ 70-20-9 Drive shafts........................... 70-20-7 Engine............................... 70-10-3 Final drives... 70-20-8 Fuel pump, electric... 70-15-8 Litho in U. S.A.

Loader - JDS44-8 TM-1094 (Jan-80) Index 3 Malfunctions - Continued Gauges and switches.................. 70-15-8 Hydraulic pump (loader)............... 70-25-15 Hydraulic pump (steering and brakes).. 70-25-19 Lights................................ 70-15-9 Loader functions... 70-25-16 Loader pump... 70-25-15 Starting circuit... 70-15-6 Steering and brake hydraulic pump... 70-25-17 Steering and brake system............ 70-25-15 Steering valve (Serial No. -247599)... 70-25-17 (Serial No. 247600- )... 70-25-18 Manifold, intake... 20-35-8 Motor, pressurizer... 30-26-28 N Neutral start switch...................... 30-25-1 No-spin differential... 40-25-9 Nozzles, fuel injection... 20-25-6 o Oil cooler, engine... 20-15-4 Oil cooler, hydraulic... 50-45-6 Oil filter, transmission... 50-45-3 Oil filters, engine... 20-15-3 Oil filters, hydraulic... 50-45-2 Oil pressure adjustment... 70-10-9 Oil pressure control valve... 20-15-2 Oil pump, engine... 20-15-1 Oil pump, transmission... 50-5-3 p Parking brake... 40-15-37 Parking brake light....................... 30-25-1 Periodic service chart... 10-15-1 Piston rings............................. 20-10-9 Pistons................................. 20-10-8 Power train testing....................... 70-20-1 Components location... 70-20-1 Inspection... 70-20-9 Malfunctions.......................... 70-20-7 Pre-charging accumulator... 50-45-9 Tests and adjustments... 70-20-10 Torque paths... 70-20-3 Predelivery service... 10-10-1 Pressurizer motor... ;'... 30-26-28 Pump, fuel injection... 20-25-4 Pump, fuel transfer... 20-25-3 Pump, hydraulic (loader)... 50-30-1 Pump, hydraulic (power steering and brakes)... 50-15-1 Pump, oil, engine... 20-15-1 Pump, oil, transmission... 50-5-3 Pump, torque converter... 40-15-18 Pump, water... 20-20-2 R Radiator... 20-20-1 Receiver-dryer... 30-26-20 Reservoir, hydraulic... 50-45-1 Return-to-dig switch (Serial No. -243965)... 30-25-4 (Serial No. 243966- )... 30-25-5 Reverse warning alarm... 30-25-7 Rings, piston............................ 20-10-9 Rocker arm assembly... 20-10-2 Rolling torque, upper pivot.... 60-5-5 S Safety cautions... 3-8 Seat... 60-15-1 Seat adjustment......................... 70-30-1 Service, delivery... 10-10-15 Service, predelivery... 10-10-1 Special tools: Air conditioning system... 30-30-15 Air conditioning system testing... 70-35-19 Air intake system..................... 20-40-27 Batteries.:... 30-30-1 Charging system...................... 30-30-5 Cylinders............................ 50-50-27 Electrical system testing... 70-35-9 Engine, basic... 20-40-12 Engine cooling system... 20-40-23 Engine removal and installation... 20-40-2 Engine testing... 70-35-3 Fuel system... 20-40-25 Heating system testing................ 70-35-19 Hydraulic components... 50-50-25 Hydraulic pump (steering and brakes)... 50-50-6 Hydraulic system (analyzer) testing... 70-35-20 Hydraulic system testing.............. 70-35-15 Miscellaneous hydraulic components... 50-50-35 Starting motor, Delco-Remy... 30-30-8 Starting motor, John Deere... 30-30-12 Steering and brake pump... 50-50-6 Steering valve... 50-50-17 Transmission... 40-30-8 Specifications: Air conditioning system... 30-30-13 Air conditioning system testing... 70-35-11 Air intake system... 20-40-26 Backhoe control valve........ 50-50-35 Batteries... 30-30-1 Brake system (Serial No. -248384)... 50-50-23 (Serial No. 248385- )......... 50-50-23 Litho in U. S.A.

4 Index Loader - JOS44-8 TM-1094 (Jan-BO) Specifications - Continued Canopy and cabs... 60-25-3 Cylinders..., 50-50-21 Damper assembly... 40-30-2 Delco-Remy charging system... 30-30-2 Differential... 40-30-13 Drive shafts... 40~30-1 Electrical system testing... 70-35-6 Engine, basic... 20-40-3 Engine, break-in... 20-40-11 Engine cooling system... 20-40-25 Engine frame... 60-25-1 Engine lubrication system... 20-40-19 Engine removal and installation... 20-40-1 Engine testing... 70-35-1 Final drives... 40-30-12 Frames............................... 60-25-1 Fuel system... 20-40-24 General... 10-5-1 Heating system testing... 70-35-10 Hydraulic components... 50-50-28 Hydraulic cylinders... 50-50-21 Hydraulic pump (loader)... 50-50-19 Hydraulic pump (power steering and brakes)... 50-50-2 Hydraulic system (analyzer) testing... 70-35-17 Hydraulic system testing... 70-35-12 Lights............................... 30-30-14 Loader boom and buckets.............. 60-25-2 Loader control valve.................. 50-50-19 Loader frame... 60-25-1 Loader pump... 50-50-19 Miscellaneous electrical equipment... 30-30-14 Miscellaneous hydraulic components... 50-50-32 Motorola charging system... 30-30-2 Pump drive assembly... 50-50-5 Speed control linkage... 20-40-26 Starting motor, Delco-Remy... 30-30-6 Starting motor, John Deere... 30-30-9 Steering and brake pump... 50-50-3 Steering valve (Serial No. -247599)... 50-50-8 (Serial No. 247600- )... " 50-50-13 Transmission... 40-30-3 Transm iss ion control valve..., 50-50-1 Transmission pump... 50-50-1 Speed control linkage... " 70-10-12 Start switch... 30-25-1 Starting aid... 30-25-4 Starting aid switch... 30-25-2 Starting motor (Delco-Remy)... 30-15-1 Starting motor (John Deere)... 30-20-1 Steering accumulator..., 50-45-10 Steering cylinder (Serial No. -247599)... 50-40-1 (Serial No. 247600- )... 50-20-32 Steering valve (Serial No. -247599)... 50-20-1 (Serial No. 247600- )... 50-20-16 Storage, temporary... 10-10-1 Superheat shut-off switch... 30-26-27 Switch, emergency steering low pressure warning... 50-45-13 Switch, superheat shut-off... 30-26-27 T Temporary storage... 10-10-1 Thermal fuse... 30-26-27 Thermostatic temperature control switch...,................... 30-26-24 Thermostats... 20-20-3 Timing gear train..., 20-10-19 Transmission... 40-15-1 Transm iss ion control valve... 50-10-1 Transmission oil filter... 50-45-5 Transmission pump... 50-5-3 Turbocharger............................ 20-35-2 Turn signal switch... 30-25-3 v Valve, brake (Serial No. -248384)... 50-25-1 (Serial No. 248385- )... 50-25-5 Valve, clutch control... 50-25-8 Valve guides... 20-10-3 Valve lift check... 20-10-1 Valve, loader control... 50-35-1 Valve seat inserts... 20-10-3 Valve springs... 20-10-2 Valve, steering (Serial No. -247599)..., 50-20-1 (Serial No. 247600- )... 50-20-16 Valve, tappet clearance adjustment...., 20-10-4 Valve, transmission... ' 50-10-1 Valve, engine..., 20-10-1 Voltmeter..., 30-25-3 W Water pump... 20-20-1 Windshield wiper adjustment...., 70-30-1 Wiring diagrams..., 70-15-14 Litho in U.S.A.

Loader - JOS44-8 TM-1094 (Nov-78) Steering low pressure warning switch............................... 50-45-13 Steering valve (Serial No. -247599)... 50-20-1-50-20-15 Adjustment... 50-20-10-50-20-11 Bench testing steering valve. 50-20-11-50-20-14 Bleeding............................. 50.:.20-15 Components... 50-20-5-50-20-8 Oil flow... 50-20-1-50-20-4 Synchronization... 50-20-4 Storage, temporary...................... 10-10-1 Steering valve (Serial No. 247600- ).50-20-17-50-20-29 Adjustment... 50-20-25-50-20-26 Components... 50-20-21-50-20-22 Oil flow... 50-20-17-50-20-20 Steering cylinders... 50-20-27-50-20-29 Components... 50-20-28-50-20-29 Superheat shut off switch... 30-26-26-30-26-27 Switch, emergency steering low pressure warning..................... 50-45-13 T Temporary storage... 1 0-1 0-1 Thermal fuse... 30-26-26-30-26-27 Thermostatic temperature control switch... 20-26-23-20-26-24 Timing gear train... 20-10-19-20-10:20 Transmission (twin turbine torque converter)... 40-15-1-40-15-40 Assembly... 40-15-28-40-15-37 Cleaning and insp~ction............... 40-15-15 Components... 40-15-1 Disassembly...,... 40-15-4-40-15-14 Installation... " 40-15-38 Output shaft... 40-15-28-40-15-29 Parking brake... 40-15-38-40-15-40 Rebuild... 40-15-15-40-15-27 Removal... 40-15-3 Torque converter housing.. 40-15-18-40-15-19, 40-15-36 Torque converter pump... 40-15-18 Transmission housing... 40-15-26-40-15-27 Turbine gears and clutch... 40-15-19-40-15-26, 40-15-29-40-15-37 Turbines... '...,... 40-15-17 Transmission control valve... 50-10-1-50-10-6 Components... 50-10-4 Oil flow...,... 50-10-1 Shift lever and linkage... 50-10-5-50-10-Ef Transmission oil filter... 50-45-5 Transmission pump... 50-5-3 Turbocharger... 20-35-2-20-35-8 Tests... 20-35-3-20-35-4 Turn signal switch... 30-25-3 v Index 5 Valve, brake (Serial No. -248384)... 50-25-1-50-25-4 Valve, brake (Serial No. 248385- )... 50-25-5-50-25-7 Valve guides............................ 20-10-3 Valve lift check... 20-10-1 Valve, loader control... 50-35-1-50-35-11 Valve, oil pressure regulating............. 20-15-2 Valve seat inserts..., 20-10-3 Valve springs...,... 20-10-2 Valve, steering (Serial No. -247599)... 50-20-1-50-20-15 Valve, steering (Serial No. 247600- ).50-20-17-50-20-29 Valve tappet clearance adjustment.... 20-10-4-20-10-5 Valve, transmission... 50-10-1-50-10-6 Valves, engine... 20-10-1-20-10-5 Voltmeter...,.............. 30-25-3 W Water pump... 20-20-1-20-20-3 Windshield wiper adjustment... 70-30-1 Wiring diagrams... 70-15-14-70-15-20 Litho in U. S.A.