D C O 544G, 544G LL, and 544G TC Loaders 624G Loader 644G Loader (Serial No. 557739-) OPERATORS MANUAL 544G, 544G LL, and 544G TC Loaders 624G Loader 644G Loader (Serial No. 557739-) English John Deere Dubuque Works OMT159816 Issue G6 (Mark old manual OMT154907 L4 for machines up to Serial No. 557738) LITHO IN U.S.A.
T7773CX -UN-08SEP92 Introduction READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage. This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.) THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it. MEASUREMENTS in this manual are given in both metric and customary U.S.
T100255 -19-14FEB96 Introduction TX,DY549 -19-08JUN96 170696 PN=6
Introduction 170696 PN=7
TX,DH2121 -19-08JUN96 PN=8 170696 T7773CZ -UN-08SEP92 T7773CY -UN-08SEP92
TX,DH2283 -19-02OCT92 PN=9 170696 T7799CZ -UN-06OCT92 T7799CY -UN-06OCT92
HELP!! HELP!! HELP!! HELP!! We need your help to continually improve our Operator’s Manuals. Please FAX or mail your comments, ideas and improvements on this comment sheet. SEND TO: John Deere Dubuque Works P.O. Box 538 Dubuque, Iowa 52004-0538 Dept.
170696 PN=11
Contents Page Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1 Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-1 Operator’s Station Gauges, Indicators, Switches, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Stop Indicator and Alarm . . . . . . . . . . . . . . . . . . 10-3 Service Required Indicator (Yellow) . . . . . . . . . . 10-4 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Page Page Boom and Bucket Control Lever—One Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Boom and Bucket Control Lever—Two Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-2 Quick Shift Switch . . . . . . . . . . . . . . . . . . . . . . . 35-3 Quick Coupler Operation—544G TC . . . . . . . . . 35-4 Pin Disconnect Switch—544G TC . . . . . . . . . . . 35-5 Boom Down Switch . . . . . . . . . . . . . . . . . . . . . . 35-5 Clutch Cut-Off Switch—If Equipped . .
Contents Page Page Maintenance—Every 500 Hours Lubricant Front Driveline. . . . . . . . . . . . . . . . . . . 80-1 Check Air Intake Hoses . . . . . . . . . . . . . . . . . . . 80-1 Check Battery Electrolyte Level and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-2 Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5 Replace Primary Fuel Filter (Water Separator) . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6 Replace Final Fuel Filter—544G, 624G . . . .
Contents Page Page Monitor Indicator and Gauge Checks— Engine Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2 Hourmeter And Gauge Check . . . . . . . . . . . . . . 95-2 Battery Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2 Monitor Indicator Circuit And Key Switch Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-3 Monitor Turn Signals And Hazard Warning Indicator Checks . . . . . . . . . . . . . . . . . . . . . .
Contents Page Boom Lock Check . . . . . . . . . . . . . . . . . . . . . . 95-34 Service Decal Check . . . . . . . . . . . . . . . . . . . . 95-34 Troubleshooting Using Troubleshooting Charts . . . . . . . . . . . . . 100-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-2 Electrical System . . . . . . . . . . . . . . . . . . . . . . 100-14 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 100-22 Power Train . . . . . . . . . . . . . . . . . . . . . . . . . .
TX,05,JC1054 –19–22JAN96–1/1 T100127 –19–21FEB96 Safety 05–1 PN=1
Safety RECOGNIZE SAFETY INFORMATION –UN–07DEC88 This is the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. T81389 Follow recommended precautions and safe operating practices. DX,ALERT –19–03MAR93–1/1 UNDERSTAND SIGNAL WORDS TS187 DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
Safety AVOID INJURY FROM ROLLOVER ACCIDENTS -------------------------------WEAR YOUR SEAT BELT -------------------------------DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE—SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT -------------------------------MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE To avoid rollovers: Be careful when operating on a slope. Carry tools and loads close to the ground to aid visibility and lower center of gravity. Reduce speed before turning or swinging load.
T7241AY AVOID INJURY FROM BACKOVER ACCIDENTS -----------------------------------BEFORE MOVING MACHINE, BE SURE ALL PERSONS ARE CLEAR OF AREA -----------------------------------ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE -----------------------------------WHEN USING A SIGNAL PERSON, KEEP PERSON IN VIEW AT ALL TIMES.
T7241AZ AVOID INJURY FROM ROLLAWAY ACCIDENTS -----------------------------------TO PREVENT ROLLAWAY, ALWAYS MAKE SURE MACHINE IS PROPERLY SECURED BEFORE LEAVING OPERATOR’S SEAT -----------------------------------DEATH OR SERIOUS INJURY MAY RESULT IF YOU ATTEMPT TO MOUNT OR STOP A MOVING MACHINE ------------------------------------ –UN–21FEB90 Safety To avoid rollaways: Select level ground when possible to park machine.
Safety USE HANDHOLDS AND STEPS When you get on and off the machine, always maintain a three point contact with the steps and handrails, and face the machine. Do not use the steering wheel or any controls as handholds. T6981AN Never jump on or off the machine. Never mount or dismount a moving machine. –UN–15JUN89 Falling is one of the major causes of personal injury. Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.
Safety MAINTAIN SEAT BELT It is important to use the seat belt on ROPS equipped machines to minimize the chance of injury from an accident such as an overturn. Keep the seat belt in good condition. The complete seat belt assembly should be replaced after three years of usage, regardless of appearance. Between replacement intervals: Carefully examine buckle, webbing, and attaching hardware. Be sure that the retractor, if equipped, locks to prevent belt extension after latching buckle.
Safety TRAVEL SAFELY Know the location of bystanders before moving the machine. Use a signal person when moving the machine in congested areas. Coordinate hand signals before starting the machine. T6964AD –UN–20DEC88 Always keep the reverse warning alarm in working condition. It warns people when the machine starts to move in reverse. TX,05,DH496 –19–02AUG89–1/1 DRIVE MACHINE SAFELY Walk around machine to clear all persons from area of operation and machine movement.
Safety OPERATE MACHINE WITH CAUTION Never lower a loaded bucket with the boom and bucket control lever in the float position. Increase the power gradually when pulling a heavy load or when driving out of a ditch or excavation. T6642EF Keep loading area smooth. –UN–18OCT88 Check location of cables, gas lines, and water mains before digging. TX,05,DH1932 –19–06JUN91–1/1 OPERATING ON SLOPES Avoid sideslope travel whenever possible. Drive up slope in forward and down in reverse.
Safety CARRYING LOADS Do not start, stop, or turn quickly when transporting a load. Do not change forward or reverse directions quickly when carrying a load. T7050AA Handle only those loads which are properly arranged. Do not overload. –UN–03AUG89 Carry loader bucket as low as possible for better stability and visibility. TX,05,RR,172 –19–03JUN92–1/1 AVOID POWER LINES T6642EG Never move any part of the machine or load closer to electric line than 3 m (10 ft) plus twice the line insulator length.
Safety KEEP RIDERS OFF MACHINE Only allow the operator on the machine. Keep riders off. TS290 –UN–23AUG88 Riders on machine are subject to injury such as being struck by foreign objects and being thrown off of the machine. Riders also obstruct the operator’s view resulting in the machine being operated in an unsafe manner. DX,RIDER –19–03MAR93–1/1 HANDLE FUEL SAFELY—AVOID FIRES Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel.
Safety HANDLE STARTING FLUID SAFELY Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables. T6464AV Remove container from machine if engine does not need starting fluid. –UN–18OCT88 Starting fluid is highly flammable. To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location. Do not incinerate or puncture a starting fluid container.
Safety WEAR PROTECTIVE CLOTHING TS206 Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. –UN–23AUG88 Wear close fitting clothing and safety equipment appropriate to the job. DX,WEAR2 –19–03MAR93–1/1 PROTECT AGAINST NOISE TS207 Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
Safety USE SAFETY LIGHTS AND DEVICES –UN–10FEB89 Operators of machines that travel below normal highway speeds should take special precautions to avoid collision with other vehicles. Install and use all safety lights and devices necessary to assure safe operation and local compliance. Keep these safety items in good condition. Replace missing or damaged parts immediately.
Safety KEEP THE OPERATOR PROTECTIVE STRUCTURE (OPS) IN PLACE It is important to keep the operator protective structure (OPS) in place (doors, screens, windows, windshield, etc.) to minimize hazards from whipping or intruding objects. To maintain OPS protection, replace damaged parts immediately. Replace 3–piece hard-coated polycarbonate windshield with only Lexan Margard 5000 or equivalent.
Safety PRACTICE SAFE MAINTENANCE If maintenance procedure must be performed with engine running, DO NOT leave machine unattended. Securely support any machine elements that must be raised for service work. Understand service procedure before doing work. Keep area clean and dry. Never lubricate or service machine while it is moving. Keep hands, feet, and clothing from power-driven parts. Before servicing machine and before leaving the operator’s seat: 1. Park machine on a level surface. 3.
Safety 8. Allow engine to cool. 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. Disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine. TX,05,DH2122 –19–31JUL92–2/2 SUPPORT MACHINE PROPERLY TS229 Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.
Safety REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust. –UN–23AUG88 Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: • 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.
Safety AVOID HIGH-PRESSURE FLUIDS Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. X9811 Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. –UN–23AUG88 Escaping fluid under pressure can penetrate the skin causing serious injury. If an accident occurs, see a doctor immediately.
Safety SERVICE COOLING SYSTEM SAFELY TS281 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. –UN–23AUG88 Explosive release of fluids from pressurized cooling system can cause serious burns. DX,RCAP –19–04JUN90–1/1 STORE ATTACHMENTS SAFELY TS219 Securely store attachments and implements to prevent falling. Keep playing children and bystanders away from storage area.
T7967AK –19–22MAR93 T7829AA –UN–31AUG92 Safety Signs TX,06,JC1102 –19–18MAR96–1/12 06–1 PN=21
T7773CV –UN–31AUG92 Safety Signs T7939AI –19–22MAR93 A-Warning Decal TX,06,JC1102 –19–18MAR96–2/12 06–2 PN=22
T100704 T8417AD –19–09FEB95 –UN–22MAR96 Safety Signs TX,06,JC1102 –19–18MAR96–3/12 06–3 PN=23
T6976AE –UN–30JAN89 T7593AC –19–30AUG91 Safety Signs TX,06,JC1102 –19–18MAR96–4/12 06–4 PN=24
–UN–15JUN93 T8029AF T7939AK –19–22MAR93 Safety Signs TX,06,JC1102 –19–18MAR96–5/12 06–5 PN=25
T7934AM –19–01FEB93 Safety Signs T100703 –UN–22MAR96 A-Warning Decal Left Side Shown TX,06,JC1102 –19–18MAR96–6/12 06–6 PN=26
T8029AQ –UN–21JUN93 T8029AR –19–16JUN93 Safety Signs TX,06,JC1102 –19–18MAR96–7/12 06–7 PN=27
T7829AT –19–17SEP92 T7853AF –UN–08OCT92 Safety Signs T8029AH –UN–15JUN93 A-Warning Decal, If Equipped Right Side of Machine TX,06,JC1102 –19–18MAR96–8/12 06–8 PN=28
T7773AZ T7916AC –19–06JAN93 –UN–10AUG92 Safety Signs –UN–10AUG92 T7773CA T7748CU –19–14OCT92 TX,06,JC1102 –19–18MAR96–9/12 TX,06,JC1102 –19–18MAR96–10/12 06–9 PN=29
T100702 T7829AQ –19–31AUG92 –UN–22MAR96 Safety Signs TX,06,JC1102 –19–18MAR96–11/12 06–10 PN=30
T101279 –19–14MAY96 T7829AU –19–17SEP92 T7839BB –UN–17SEP92 Safety Signs Located on top of radiator cap TX,06,JC1102 –19–18MAR96–12/12 06–11 PN=31
Operator’s Station T7773AP –UN–11JUN92 GAUGES, INDICATORS, SWITCHES, AND ACCESSORIES A—SELECT Switch B—Digital Display C—Engine Coolant Temperature Gauge D—Fuel Gauge E—Transmission Oil Temperature Gauge F—Hydraulic Oil Filter Restriction Indicator G—Transmission Oil Pressure Indicator—If Equipped H—Engine Coolant Level Indicator I—Engine Air Filter Restriction Indicator J—Engine Alternator Voltage Indicator K—Engine Oil Pressure Indicator L—STOP Indicator M—Service Required Indicator N—Left Turn Sign
T8375AN –UN–02DEC94 Operator’s Station A—Front Wiper Switch B—Drive Light Switch C—Work Light Switch D—Clutch Cut-off Switch E—Warning Light Switch F—Boom Down Switch G—Rear Wiper Switch H—Air Conditioner Control Switch—If Equipped I—Pin Disconnect Switch— 544G TC J—Ride Control Switch—If Equipped K—Blower Knob L—Air Conditioner Defroster Blower Knob M—Temperature Control Knob TX,10,JC1046 –19–16JAN96–2/2 10–2 PN=33
Operator’s Station Ö CAUTION: Prevent possible injury, or machine damage. If STOP indicator light flashes and alarm sounds, stop immediately and investigate cause of problem. The STOP indicator light flashes and alarm sounds when: T7673AM Engine oil pressure is low. STOP ENGINE IMMEDIATELY. –UN–06JAN92 STOP INDICATOR AND ALARM Engine coolant temperature is excessively high. Stop machine and allow engine to cool. Shut off engine and take corrective action. Engine coolant level is low.
Operator’s Station SERVICE REQUIRED INDICATOR (YELLOW) –UN–18OCT88 If service required indicator lights, a problem is developing. It is not necessary to stop the engine immediately, but the cause should be investigated as soon as possible. The service required indicator lights when: T6201BL • Alternator voltage is low. • Engine air filter is restricted. • Hydraulic oil filter is restricted. NOTE: Cold oil may cause hydraulic oil filter restriction indicator to light temporarily.
Operator’s Station ENGINE COOLANT TEMPERATURE GAUGE T7747AU All the arrows will flash, STOP indicator light will flash, and audible alarm will sound when temperature reaches above 110°C (230°F). If all 9 arrows are ON but not flashing, system has a malfunction. Stop machine and allow engine to cool. Shut off engine and take corrective action. –UN–19MAY92 The first arrow will flash until engine temperature warms to 38°C (100°F).
Operator’s Station Indicator light will light, STOP indicator will flash, and alarm will sound when engine oil pressure is low. Stop machine. STOP ENGINE IMMEDIATELY. NOTE: Cold oil or extreme off level operation may cause indicator to light. T7747AA IMPORTANT: Prevent possible engine damage. If engine oil pressure indicator light comes on while operating, stop machine. STOP ENGINE IMMEDIATELY.
Operator’s Station ENGINE COOLANT LEVEL INDICATOR T7747AC Indicator light will light, STOP indicator light will flash, and alarm will sound when engine coolant level is low. Stop machine and allow engine to cool. Shut off engine and take corrective action. –UN–19MAY92 IMPORTANT: Prevent machine damage. Low coolant will result in engine or radiator damage. TX,10,DH2152 –19–02OCT92–1/1 T7747AD Indicator light will light and STOP indicator light will light when transmission oil pressure is low.
Operator’s Station RIGHT TURN SIGNAL INDICATOR T6201BK –UN–18OCT88 Indicator light will light when right turn signal switch is engaged. TX,DH,39 –19–12APR93–1/1 BRAKE OIL PRESSURE INDICATOR Indicator light will light, STOP indicator light will flash, and alarm will sound when brake oil pressure is low, or brake accumulator has lost its charge. Stop machine immediately and engage park brake. Take corrective action. –UN–19MAY92 CAUTION: Prevent possible injury or machine damage.
Operator’s Station FASTEN SEAT BELT INDICATOR T7747AH –UN–19MAY92 Indicator light will light for the first 5 seconds after the engine is started to warn the operator to fasten seat belt. TX,10,DH2344 –19–31JUL92–1/1 ETHER INJECTION INDICATOR T7747AI –UN–19MAY92 Indicator light will light when the ether injection button is pressed by the operator.
Operator’s Station LEFT TURN SIGNAL INDICATOR T6201BG –UN–18OCT88 Indicator light will light when left turn signal switch is engaged.
T7747AM –UN–19MAY92 Operator’s Station A—Transmission Control Lever TX,10,DH2133 –19–31JUL92–3/3 T7747AN –UN–19MAY92 FRONT AXLE DISCONNECT LEVER—IF EQUIPPED A—Front Axle Disconnect Lever TX,10,DH2137 –19–31JUL92–1/1 10–11 PN=42
Operator’s Station T7747AO –UN–19MAY92 PEDALS A—Accelerator Pedal B—Right Brake Pedal C—Steering Column Tilt Pedal D—Left Brake/Clutch Cut-off Pedal E—Differential Lock Pedal—If Equipped TX,10,DH2136 –19–07OCT92–1/1 T7773AG –UN–11JUN92 PARK BRAKE SWITCH A—Park Brake Switch TX,10,DH2285 –19–18SEP92–1/1 10–12 PN=43
Operator’s Station T7747BI –UN–19MAY92 NEUTRAL LOCK A—Neutral Lock TX,10,DH2138 –19–02OCT92–1/1 T7747BJ –UN–19MAY92 HORN BUTTON A—Horn Button TX,10,DH2279 –19–18SEP92–1/1 10–13 PN=44
Operator’s Station T7747BK –UN–19MAY92 TURN SIGNAL SWITCH A—Turn Signal Switch TX,10,DH2280 –19–31JUL92–1/1 DOME LIGHT AND SWIVEL LIGHT—IF EQUIPPED Push switch (A) to light dome light. T7773AU –UN–10AUG92 Push switch (B) to light swivel light. A—Dome Light B—Swivel Light TX,10,DH2139 –19–31JUL92–1/1 VANDAL SHIELD—IF EQUIPPED T7853AG –UN–08OCT92 A vandal shield (A) is available for canopy equipped machines. Shield covers the side instrument panel and locks with the ignition key.
Operator’s Station OPERATING WINDSHIELD WIPERS AND WASHERS—IF EQUIPPED –UN–02DEC94 Turn front windshield wiper knob (A) clockwise to first position for low speed. Turn windshield wiper knob clockwise to second position for high speed. Push windshield wiper knob in to wash window. T8375AO Press rear windshield wiper switch (B) to operate rear wiper.
Operator’s Station OPENING SLIDING SIDE WINDOW—IF EQUIPPED T6603AQ1 –UN–20OCT88 Squeeze latch tabs (A) together and slide window down to desired position. Release tabs. 02T,10,MM27 –19–31JUL92–1/1 CAB DOOR RELEASE T8029AI –UN–15JUN93 Push lever (A) to release cab door. TX,10,DH2960 –19–16JUN93–1/2 T8029AJ –UN–15JUN93 Push button (B) to release opened cab door from inside the cab or on the ground.
Operator’s Station OPERATING LIGHTS Press light switch (A). Lights (E and I) will come on. –UN–02DEC94 Press light switch (B). Lights (D and G) will come on. T8373BD Press turn signal switch to left or right position. One turn indicator light on monitor, if equipped, will be on. One front amber light (F) and one rear amber light (H) will be flashing. T7773AY –UN–10AUG92 T7773AX –UN–10AUG92 Press hazard light switch (C). Both front amber lights (F) and both rear amber lights (H) will be flashing.
Operator’s Station HEATING AND AIR CONDITIONING CONTROLS NOTE: Open valve (E) before operating heater. –UN–02DEC94 Turn temperature control knob (A) clockwise to increase temperature. T8373AY Turn defroster blower knob (B) clockwise to increase blower speed. (Knob also turns on heater blower.) Blower has three speeds. IMPORTANT: Before you start air conditioner first time in the season, check filters and condenser. Clean them if necessary. Check refrigerant level. (See Maintenance chapter.
Operator’s Station ADJUSTING SUSPENSION SEAT Ö CAUTION: You can lose control of machine and be injured if seat is loose. Be sure seat is properly locked in position before operating the machine. • Suspension seat is equipped with a weight adjustment feature of 50—130 kg (110—285 lb). Turn knob (F) to adjust seat to weight of the operator. Weight is displayed in window (E). Turn knob clockwise for a heavier operator and counterclockwise for a lighter operator. • Turn knob (A) to make lumbar adjustment.
Operator’s Station T8415AA –UN–09FEB95 SEAT BELT Seat belt and mounting hardware must be inspected for wear or damage before operating the machine. Replace the belt or mounting hardware if worn or damaged. Replace the complete seat belt assembly every three years regardless of appearance. A date label, to determine the age of the belt, is attached to each belt.
Break-in ENGINE BREAK-IN OIL New engines are filled at the factory with John Deere ENGINE BREAK-IN OIL. During the break-in period, add John Deere ENGINE BREAK-IN OIL as needed to maintain the specified oil level. Change the oil and filter after the first 100 hours of operation of a new or rebuilt engine. After engine overhaul, fill the engine with John Deere ENGINE BREAK-IN OIL.
Break-in AFTER FIRST 10 AND FIRST 50 HOURS Tighten wheel retainer cap screws to 542 N•m (400 lb-ft). TX,15,DH1828 –19–16JUN93–1/1 AFTER THE FIRST 100 HOURS 1. Check hardware torque. (See Hardware Torque Specifications in Maintenance chapter.) 2. Perform 100 hours service. (See Maintenance—Every 100 Hours chapter.) 3. Change engine oil and filter. (See Maintenance— Every 250 Hours chapter.) 4. Change hydraulic reservoir return filter. (See Maintenance—Every 500 Hours chapter.) 5.
Pre-Start Inspection INSPECT MACHINE DAILY BEFORE STARTING Do periodic service checks in the Maintenance—Every 10 Hours or Daily chapter. A-Check wheels (front and rear) for loose or missing hardware. B-Clean operator’s station. C-Check air inlet cover. D-Clean radiator. E-Check fuel level. F-Check tires (front and rear). ELECTRICAL SYSTEM: Check for worn or frayed wires and loose or corroded connections. BOOM, BUCKET, SHEET METAL: Check for bent, broken, loose, or missing parts.
Operating the Engine CHECK INSTRUMENTS BEFORE STARTING Turn key switch clockwise to ON position. All indicator lights must light. If any indicator light fails to light, the bulb may be burned out. If bulb is not burned out, but indicator light still fails to light, see your authorized dealer.
Operating the Engine T7747BR –UN–19MAY92 3. Move transmission control lever (A) to neutral "N". Engage neutral lock (B).
Operating the Engine 4. Hold accelerator pedal (C) down 1/3 of the way to the floor. T7747BU IMPORTANT: Never operate starter motor for more than 20 seconds at a time. If engine fails to start after two or three tries, return key switch to STOP position. Wait for about 2 minutes, then try again. –UN–19MAY92 5. Turn key switch to ON position. Push horn button to sound horn. After a false start, DO NOT turn key switch until engine stops or starter may be damaged.
Operating the Engine STARTING FLUID—IF EQUIPPED (COLD WEATHER STARTING AID) CAUTION: Prevent possible injury from exploding container. Starting fluid is highly flammable. Keep container away from heat, sparks, and open flame. Contents are pressurized. DO NOT puncture or incinerate container. Remove container from machine if engine does not need starting fluid. TS281 Ö –UN–23AUG88 USE STARTING FLUID IMPORTANT: Prevent damage to engine.
Operating the Engine REPLACING STARTING AID CAN T7747BT 2. After one or two revolutions of engine crankshaft, press starting aid button (A) at short intervals. Crank engine for 20 seconds maximum, then allow 2 minutes between cranking periods. –UN–19MAY92 IMPORTANT: Excess starting fluid could damage engine; press starting aid button only when engine is cold and cranking. Starting aid fluid is being injected into engine as long as you press button. 1.
Operating the Engine 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. Ö 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 12volt negative (-) ground. Use only 12volt booster batteries.
Operating the Engine CHECK INSTRUMENTS AFTER STARTING Ö CAUTION: Prevent possible injury, or machine damage. If STOP indicator light does not go out within 10 seconds after starting engine, STOP THE ENGINE. Find and correct the cause. Cold oil may cause hydraulic oil filter restriction indicator light to come on temporarily. Turn signal and park brake lights will come on if the function is engaged. Engine coolant temperature gauge will flash until temperature reaches 38°C (100°F).
Operating the Engine COLD WEATHER WARM-UP IMPORTANT: If hydraulic oil is cold, hydraulic functions move slowly. Do not attempt normal loader operation until hydraulic functions move at close-to-normal cycle times. 1. Run engine at 1/2 speed for 5 minutes. 2. Cycle boom and bucket functions until functions move at normal speed. TX,DH,40 –19–17JUN91–1/1 STOPPING THE ENGINE IMPORTANT: Prevent possible engine damage. If engine stops when operating under load, remove load. Restart engine immediately.
Operating the Engine CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park brake to hold machine. 4. Engage park brake. T7747BR Ö –UN–19MAY92 3. Move transmission control lever (A) to neutral "N". Engage neutral lock (B). IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 5.
Driving the Machine DRIVING ON PUBLIC ROADS Before driving on public roads, check state and local laws that may apply to tractors, self-propelled machines, and towed equipment. Additional lights, mirrors, SMV emblems, or reflectors may be required. TX,30,DH2123 –19–31JUL92–1/2 T6458AN1 –UN–25OCT88 For best visibility and stability, raise bucket approximately 406 mm (16 in.) (A) and tilt it back completely.
Driving the Machine GENERAL DRIVING PRECAUTIONS Ö CAUTION: Riders on machine are subject to injury. Never allow riders on the machine.
Driving the Machine Pull up lever (A) to disconnect front axle. T7747AN –UN–19MAY92 Push down lever to connect front axle. TX,30,DH2169 –19–31JUL92–2/2 Ö CAUTION: Prevent possible injury from unexpected machine movement. Always move transmission control lever to neutral "N", and engage neutral lock before starting or dismounting. T7747BI Move neutral lock (A) to the locked position to engage neutral lock. Move lock to the unlocked position to disengage neutral lock.
Driving the Machine When transmission control lever is positioned in 4th gear, transmission is in "automatic" mode. In "automatic" mode, transmission starts out in 2nd gear, then shifts to 3rd and 4th gear as speed increases. It will also automatically downshift from 4th to 3rd to 2nd gear as speed decreases. T7747AM Change speed of machine by moving transmission control lever to desired gear. Machine has four forward gears and three reverse gears.
Driving the Machine TRAVEL SPEEDS NOTE: Km/h and mph will only display in full increments on digital display. 544G, LL, TC: Forward Speeds km/h mph Reverse Speeds km/h mph 1 0—7.4 0—4.6 1 0—7.4 0—4.6 2 0—12.3 0—7.7 2 0—12.3 0—7.7 3 0—27.2 0—16.9 3 0—27.2 0—16.9 4 0—38.4 0—23.8 624G: Forward Speeds km/h mph Reverse Speeds km/h mph 1 0—7.3 0—4.5 1 0—7.3 0—4.5 2 0—11.6 0—7.2 2 0—11.6 0—7.2 3 0—24.5 0—15.2 3 0—24.5 0—15.2 4 0—37.3 0—23.
Driving the Machine CAUTION: Prevent possible injury from unexpected boom movement. The bucket may "jump up" when ride control switch is turned ON. Turn ride control switch ON to improve machine ride and reduce tire flexing when traveling over rough terrain at a high speed with loaded bucket. If engine is stopped with ride control switch in ON position, ride control is automatically disengaged. Start the engine, press switch to OFF and then back to ON to engage ride control.
Driving the Machine Ö CAUTION: Prevent possible injury or death from machine runaway. Before disengaging park brake, be sure engine is running and service brakes are operational. T7773AG NOTE: Transmission clutches are disengaged when park brake is applied. –UN–11JUN92 PARK BRAKE SWITCH Press park brake switch (A) to ON position to engage park brake. Press park brake switch to OFF position to disengage park brake.
Driving the Machine CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park brake to hold machine. 4. Engage park brake. T7747BR Ö –UN–19MAY92 3. Move transmission control lever (A) to neutral "N". Engage neutral lock (B). IMPORTANT: Turbocharger may be damaged if engine is not properly shut down. 5.
Operating the Machine BOOM AND BUCKET CONTROL LEVER— ONE LEVER DESIGN –UN–11JUN92 Move control lever forward (A) to lower boom, or rearward (D) to raise boom. T7773AC NOTE: Boom down switch (I) must be pushed while moving control lever forward to lower boom with engine stopped. Move control lever left (F) to roll back bucket, or right (C) to dump bucket. 544G LL and 544G TC will also have a fast dump bucket position (H).
Operating the Machine BOOM AND BUCKET CONTROL LEVER— TWO LEVER DESIGN –UN–11JUN92 Move left control lever forward (A) to dump bucket, or rearward (B) to roll back bucket. 544G LL and 544G TC will also have a fast dump bucket position (H). T7773AE NOTE: Boom down switch (I) must be pushed while moving control lever forward to lower boom with engine stopped. Move right control lever forward (E) to lower boom or rearward (F) to raise boom.
Operating the Machine QUICK SHIFT SWITCH T7773CE Press down on switch to downshift from 2nd gear to 1st gear when transmission control lever is positioned in 2nd gear. Press again to return to 2nd gear. –UN–21AUG92 Press down on switch (A) to downshift from 3rd gear to 2nd gear when transmission control lever is positioned in 3rd gear. Press again to return to 3rd gear. Quick shift will not function in 4th gear.
Operating the Machine QUICK COUPLER OPERATION—544G TC Move control lever left (D) to tilt coupler rearward. Move it right (C) to tilt coupler forward. T7773AF NOTE: Boom down switch must be pushed while moving control lever forward to lower boom with engine stopped. –UN–11JUN92 Move control lever forward (A) to lower boom, or rearward (B) to raise boom. 1. Align equipment to be used so hooks fit over coupler and eyelet is centered.
Operating the Machine PIN DISCONNECT SWITCH—544G TC Use the pin disconnect switch (A) when adding or changing equipment. –UN–02DEC94 Hold down switch to retract pins on coupler. T8373AW Release switch to extend and lock pins in place. TX,35,DH2287 –19–29NOV94–1/1 BOOM DOWN SWITCH T8373AX –UN–02DEC94 Push boom down switch (A) while moving control lever forward to lower boom with the engine stopped. TX,35,DH2179 –19–29NOV94–1/1 CAUTION: Prevent possible injury from unexpected machine movement.
Operating the Machine Steering pressure indicator light (A) will light, STOP indicator light (B) will flash, and audible alarm will sound when secondary steering system is activated. The light indicates low hydraulic pressure resulting from mechanical malfunction, such as loss of engine power. An electrically driven pump will actuate to provide steering T7773AT IMPORTANT: Prevent possible damage to secondary steering system.
Operating the Machine ADJUSTING BOOM HEIGHT KICKOUT—IF EQUIPPED 1. Start engine. 2. Move control lever to boom raise detent position and release. TX,35,DH2183 –19–31JUL92–1/2 3. After control lever returns to neutral, make a mark (D) on the magnet and the boom height kickout switch. 4. Position the boom in the desired boom height kickout position. Stop engine. 5. Loosen cap screws (B) and slide bracket to align marks on magnet and boom kickout switch. 6.
Operating the Machine ADJUSTING RETURN-TO-DIG 1. Start engine. 2. Move control lever to return-to-dig detent position and release. TX,35,DH2184 –19–02OCT92–1/2 NOTE: On 544G LL and 544G TC, the return-to-dig switch and magnet are located below the cylinder. –UN–21OCT88 3. After control lever returns to neutral, make a mark (B) on magnet and return-to-dig switch. T6599AD 4. Position the boom and bucket in the desired return-todig position. Stop engine. 5.
Operating the Machine GENERAL OPERATING TIPS Carry loaded bucket low to the ground for a better view and to improve machine stability. Keep the bottom of the bucket parallel to the ground when dozing. DO NOT doze with the bucket in dump position. Use bucket teeth when digging in hard material. When bucket digs in, decreasing traction, roll bucket back slightly. In float position, the bucket will follow the contour of the ground. Use float position to back drag.
Operating the Machine Work bank or stockpile with machine at a 90° angle to the bank or stockpile. T7208AV 1. Position bucket on the ground in return-to-dig position. –UN–30JAN90 Normally, a bank or stockpile is excavated from the bottom and then up the side. Work the face of the bank or stockpile evenly to prevent outcroppings and overhangs. 2. Move transmission control lever to 1st or 2nd gear depending on ground conditions. In loose material, use 2nd gear for better traction.
Operating the Machine T7747BC –UN–19MAY92 4. Raise and curl bucket to hold load. TX,35,JC1049 –19–17JAN96–2/4 T7208AR –UN–30JAN90 EXCAVATING ON THE LEVEL: Position bucket at a slightly downward angle on ground (use bucket teeth for this type of digging). TX,35,JC1049 –19–17JAN96–3/4 USING BOOM IN FLOAT POSITION: Place the boom in float position and bucket in return-to-dig position to prevent gouging the surface, as in cleaning concrete and snow removal.
Operating the Machine T7747BG Leveling and grading can be done with the boom in the float position by backdragging the loader bucket while traveling in reverse. (Float position allows the bucket to follow contour of the ground.) –UN–19MAY92 BACKDRAGGING TX,35,DH2278 –19–31JUL92–1/1 BACKFILLING 1. Use loader bucket as a dozer. As bucket approaches the trench, material being pushed will fall into the trench. Reverse direction and reposition loader to maintain a 90° angle to the trench line.
Operating the Machine TRUCK LOADING The most efficient technique for truck loading is the "V" method. 2. Run engine near fast idle to penetrate material. 3. Increase engine speed to fast idle and crowd into the pile. T7511CN –UN–27JUN91 1. Level bucket and lower to the ground. 4. As engine rpm starts to decrease, pull loader control lever back and to the left. 5. Feather hydraulics to obtain a smooth combination of bucket rollback and boom lift. 6.
Transporting TRANSPORTING PRECAUTIONS If machine is transported, check route for road width and overhead clearance. Check any bridges for weight limits. (See Specifications chapter.) TX,40,FF3416 –19–27MAY93–1/1 LOADING MACHINE ON A TRAILER 3. Fasten seat belt before starting engine. Ö CAUTION: Position the machine so that its centerline is over the centerline of the truck bed. NEVER steer the machine while on the ramp.
Transporting CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park brake to hold machine. 7. Engage park brake. T7747BR Ö –UN–19MAY92 6. Move transmission control lever (A) to neutral "N". Engage neutral lock (B). 8. Connect frame locking bar. 9. Turn key switch to STOP. 10.
Transporting CAUTION: Use flashing warning lights and turn signals when towing this equipment on public roads unless prohibited by state or local regulations. An implement safety lighting kit is available from your John Deere dealer. Keep safety items in good condition. Replace missing or damaged items. IMPORTANT: Engine cannot be started by towing because machine is equipped with a torque converter.
Transporting 4. Move transmission control lever to neutral. Engage neutral lock. 5. Raise boom, and support so bucket is off ground. 6. Stop engine. TX,40,DH2288 –19–12MAY93–2/2 TOWING PROCEDURE—ENGINE NONOPERATIONAL Ö CAUTION: Prevent possible injury from unexpected machine movement. Always install frame locking bar, and block wheels to hold machine when working on park brake. 1. Install frame locking bar. Put blocks at front and rear of tires.
Transporting 2. Manually release park brake: Remove (3) screws and remove sheet metal cover from brake. Loosen lock nut (A). 3. Back out adjustment screw (B) to release park brake. 4. Remove blocks. Slowly tow machine. Ö CAUTION: Prevent possible injury from unexpected machine movement. Always apply park brake to hold machine if drive shafts are connected. 5. When towing is completed, adjust park brake to hold machine. (See Adjust Park Brake in Maintenance— Every 1000 Hours chapter.) 6.
Transporting 10. Connect a rigid tow bar to drawbar pin (A) of machine being towed. NOTE: Frame locking bar is installed to prevent weaving as machine is towed. 13. Move transmission control lever to neutral. Engage neutral lock. T6629AM 12. Install frame locking bar. –UN–20OCT88 11. Start engine. 14. Raise boom, and support so bucket is off ground. 15. Stop engine. 16. Put blocks at front and rear of tires. Ö CAUTION: Machine may roll when park brake is released.
Transporting LIFTING THE MACHINE Ö CAUTION: Prevent possible injury from unexpected machine movement. Clear all bystanders from lifting area. Select correct lifting cable strength for weight of machine. Test lift by raising machine 0.3 m (1 ft) off the ground.
Fuels and Lubricants DIESEL FUEL Consult your local fuel distributor for properties of the diesel fuel available in your area. gram load level as measured by the BOCLE scuffing test. In general, diesel fuels are blended to satisfy the low temperature requirements of the geographical area in which they are marketed. • Sulfur content: 1. Sulfur content should not exceed 0.5% Sulfur content less than 0.05% is preferred. Diesel fuels specified to EN 590 or ASTM D975 are recommended. 2.
Fuels and Lubricants LOW SULFUR DIESEL FUEL CONDITIONER When possible, use existing fuel formulations for engines used off-highway. This fuel will not require any additives to provide good performance and engine reliability. However, many local fuel distributors will not carry both low and regular sulfur diesel fuels. If the local fuel distributor will supply only low sulfur fuel, order and use John Deere TY22030 Diesel Fuel Conditioner.
Fuels and Lubricants 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.
Fuels and Lubricants T101239 –19–22MAY96 DIESEL ENGINE OIL • John Deere UNI-GARD Use oil viscosity based on the expected air temperature range during the period between oil changes. • API Service Classification CG-4 The following oil is preferred: • API Service Classification CF-4 • John Deere PLUS-50 • ACEA Specification E3 If John Deere PLUS-50 engine oil and a John Deere oil filter are used, the service interval for oil and filter changes may be extended by 50 hours.
Fuels and Lubricants T100663 –19–10MAY96 TRANSMISSION OIL, HYDRAULIC SYSTEM OIL AND DIFFERENTIAL OIL Use oil viscosity based on the expected air temperature range during the period between oil changes.
Fuels and Lubricants T8358AI –19–27MAR95 GREASE Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval.
Fuels and Lubricants LUBRICANT STORAGE Your equipment can operate at top efficiency only if clean lubricants are used. Make certain that all containers are properly marked to identify their contents. Use clean containers to handle all lubricants. Properly dispose of all old containers and any residual lubricant they may contain. 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.
Periodic Maintenance SERVICE YOUR MACHINE AT SPECIFIED INTERVALS T100700 Service items at multiples of the original requirement. For example, at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily. –UN–22MAR96 Lubricate, make service checks and adjustments at intervals shown on the periodic maintenance chart (A) and on the following pages.
Periodic Maintenance PREPARE MACHINE FOR MAINTENANCE Before performing maintenance procedures given in the following chapters, and before leaving the operator’s seat, park the machine as described below unless another position is specified in the procedure. 1. Park machine on a level surface. 2. Lower bucket to ground. TX,50,DH2194 –19–29NOV94–1/2 Ö CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving.
Periodic Maintenance LOCKING MACHINE FRAME Ö CAUTION: Prevent possible injury from unexpected machine movement. Connect frame locking bar to both frames before you work in frame pivot area. 1. Align machine frames. TX,50,DH2199 –19–17AUG92–1/2 2. Remove pin (A), and move locking bar forward. T7773CL –UN–21AUG92 3. Install pin through holes in machine frame (B) and end of locking bar.
Periodic Maintenance BOOM LOCK CAUTION: Always install boom lock before working on or around this machine with the boom raised. –UN–17SEP92 Ö Empty bucket and place in dump position before installing boom lock. T7839BB 1. Raise boom. Empty bucket and place in dump position before installing boom lock. 2. Remove boom lock from side of machine by turning lock lever counterclockwise. –UN–22MAR96 3. Install boom lock on boom cylinder with lock lever facing to the outside of machine.
Periodic Maintenance OPENING GRILLE DOOR Push down on latch (A) to open grille door. T7773CD –UN–10AUG92 T6785CD –UN–19OCT88 Rotate stop (B) 180° to hold door open. TX,50,DH2198 –19–31JUL92–1/1 CHECK WINDSHIELD WASHER FLUID LEVEL Check fluid in windshield washer bottle (A). T7829AD –UN–31AUG92 During winter season, use all season windshield washer fluid which will not freeze.
Periodic Maintenance MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM The checklist on the following page summarizes scheduled maintenance, and parts and oil required at each maintenance interval. Use the checklist to: • Remind you to perform machine maintenance at specified intervals to minimize downtime. • Calculate cost of machine operation and ownership allowing you to make better job estimates. • Place yourself in a stronger position at trade-in time.
Periodic Maintenance OILSCAN Oil samples should be taken from each system prior to its recommended oil change interval. T6829AB –UN–18OCT88 T6828AB OILSCAN kits are available from your dealer. –UN–15JUN89 OILSCAN is a John Deere oil sampling program to help you monitor machine performance and identify potential problems before they cause serious damage.
Periodic Maintenance MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM SERVICE INTERVALS Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.
Periodic Maintenance MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM Model: ❒ 544G ❒ 544G LL PIN/Serial Number: ❒ 544G TC ❒ 624G Delivery Date: ❒ 644G Customer: Hour Meter Reading: Oil Sampling Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form. Maintenance recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply.
Maintenance—As Required CHECK TIRE PRESSURE Ö CAUTION: Explosive separation of a tire and rim parts can cause serious injury or death. Always maintain the correct tire pressure. DO NOT inflate tires above the recommended pressure. Inspect tires and wheels daily. DO NOT operate with low pressure, cuts, bubbles, damaged rims, or missing lug bolts. TS211 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.
Maintenance—As Required 4. Turn on air supply. Stand to front or rear of tire when you add air to tire. 5. After tire is at correct pressure, shut off air supply. Release chuck. (See following Tire Pressure chart.) 6. Inspect tire for damage. TX,55,FF2820 –19–25OCT94–2/2 TIRE PRESSURES 544G, 544G TC Operating Pressure* Tire Size Type Ply Rating kPa bar psi 14 x 24 G2 10 300 3.8 55 15.5 x 25 L2 12 380 3.8 55 15.5R x 25 L2 or L3 Equiv (1) Star **Front 415 4.1 60 **Rear 205 2.
Maintenance—As Required 544G LL Operating Pressure* Tire Size Type Ply Rating kPa bar psi 17.5 x 25 L2 12 345 3.4 50 17.5 x 25 L3 12 345 3.4 50 17.5R x 25 L2 or L3 Equiv (1) Star **Front 345 3.4 50 **Rear 170 1.7 25 Rear, alternate 275 2.8 40 20.5 x 25 L2 12 275 2.8 40 20.5 x 25 L3 12 275 2.8 40 20.5 x 25 L3 16 345 3.4 50 23.1 x 26 LS-2 10 140 1.4 20 28L x 26 LS-2 14 170 1.7 25 *Shipping pressure may vary from operating pressure.
Maintenance—As Required 624G Ply Tire Size Type Operating Pressure* Rating kPa bar psi 14 x 24 G2 10 380 3.8 55 17.5 x 25 L3 12 345 3.4 50 17.5 x 25 L2 12 345 3.4 50 17.5 R25 L2 or L3 Equiv (1) Star **Front 450 4.5 65 **Rear 205 2.0 30 Rear, alternate 310 3.1 45 20.5 x 25 L3 12 275 2.8 40 20.5 x 25 L3 16 345 3.4 50 20.5 x 25 L2 12 275 2.8 40 20.5R x 25 L2 or L3 Equiv (1) Star **Front 310 3.1 45 **Rear 170 1.7 25 Rear, alternate 275 2.
Maintenance—As Required 644G Ply Tire Size Type Operating Pressure* Rating kPa bar psi 16.0 X 24 G2 12 380 3.8 55 20.5 X 25 L2 12 275 2.8 40 20.5 x 25 L2 16 345 3.4 50 20.5 x 25 L3 16 345 3.4 50 20.5R x 25 L2 or L3 Equiv (I) Star **Front 415 4.1 60 **Rear 205 2.0 30 Rear, alternate 310 3.1 45 23.5 x 25 L2 12 240 2.4 35 23.5 x 25 L3 16 310 3.1 45 23.5 x 25 L3 20 380 3.8 55 23.5R x 25 L2 or L3 Equiv (1) Star **Front 275 2.8 40 **Rear 205 2.
Maintenance—As Required CLEAN OR REPLACE AIR CLEANER ELEMENTS 1. Open left service door. 2. Loosen wing nut to remove cover. TX,55,DH2226 –19–31JUL92–1/3 T6119AF –UN–01NOV88 3. Remove wing nut and primary element (A). TX,55,DH2226 –19–31JUL92–2/3 T6119AG –UN–01NOV88 4. Remove wing nut from 544G, LL, TC, and 644G, or hex nut from 624G, and remove secondary element (B).
Maintenance—As Required Ö CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. T47764 1. Tap element with the palm of your hand, NOT ON A HARD SURFACE. –UN–09NOV88 CLEAN DUSTY PRIMARY ELEMENT 2.
Maintenance—As Required INSPECT ELEMENT IMPORTANT: A damaged or dirty element may cause engine damage. • If the element shows damage. • If element will not clean. • After 1000 hours service or annually. T90684 –UN–10NOV88 Install a new primary element: Install a new secondary element: • If the primary element is damaged and needs to be replaced. • If the element is visibly dirty. • After 1000 hours service or annually. DO NOT clean a secondary element.
Maintenance—As Required CHECK AIR INLET COVER 1. Loosen clamp and slide strap (B) down stack. CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. T6779BQ Ö –UN–19OCT88 2. Remove air inlet cover (A). 3.
Maintenance—As Required CHECK AND ADJUST BELT TENSION—544G, 624G 1. Check belt regularly for wear. Replace if necessary. –UN–18OCT88 2. Check belt tension of belt closest to fan midway between pulleys. 544G, LL, TC, 624G: right side of engine. 644G: left side of engine. T6603AK SPECIFICATIONS 544G, LL, TC, 624G: Force: 67 N (15 lb) Deflection: 19 mm (0.75 in.) 544G, 624G Shown 3. If deflection is not within specifications, loosen alternator mounting cap screws. –UN–30NOV94 4.
Maintenance—As Required INSPECT SERPENTINE BELT—644G 1. Check belt regularly for wear, especially for cracks at the bottom of grooves and for frayed edges. 2. If necessary, replace belt. 3. Place the drive of a 1/2 in. drive ratchet in square hole. Turn ratchet counterclockwise to pull tension adjuster assembly away from belt, releasing belt tension. 4. Hold tension adjuster assembly away from belt while removing old belt and installing new belt. 5.
Maintenance—As Required DRAIN AND CLEAN PRIMARY FUEL FILTER (WATER SEPARATOR)—544G, 624G 1. Open left side shield to access primary fuel filter (water separator). TX,55,JC283 –19–16MAY95–1/3 2. Put container under drain valves (D and F). –UN–10SEP92 3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base. T8387AE –UN–17DEC94 T7833AJ 4.
Maintenance—As Required 5. Remove fuel inlet line (A) and fuel drain plug (C). 6. Flush any debris from filter base (B). –UN–17DEC94 7. Install fuel inlet drain plug and fuel inlet line. 8. Assemble primer assembly and install onto fuel filter base. T8387AD 9. Install filter element to fuel filter base. 10. Close side shield. 11. Dispose of waste properly. TX,55,JC283 –19–16MAY95–3/3 DRAIN AND CLEAN PRIMARY FUEL FILTER (WATER SEPARATOR)—644G 1. Open left side shield to access primary fuel filter (F).
Maintenance—As Required CHECK CAB RECIRCULATING AIR FILTER 2. Remove filter. Ö CAUTION: Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment, including eye protection. T8295AA 1. Loosen two thumbscrews (A) holding grille. Remove grille. –UN–10AUG94 NOTE: The cab recirculating air filter is located behind the seat. 3.
Maintenance—Every 10 Hours or Daily LUBRICATE PIVOTS Lubricate working tool pivots every 10 hours or daily when operating in deep mud, water, or snow. TX,60,DH2560 –19–02OCT92–1/1 IMPORTANT: A missing, damaged, or hardened dust unloader valve will make the dust cup precleaner ineffective, causing very short element life. Valve should suck closed above 1/3 engine speed. T7773CQ Squeeze dust valve (A) to remove dust from the air cleaner.
Maintenance—Every 10 Hours or Daily 3. 544G, 624G: Make sure dipstick (A) is fully seated. 4. 544G, 624G: Remove dipstick to check oil level. –UN–31AUG92 644G: Tighten filler cap (B) to fully seat. Remove filler cap to check oil level. AFTER THE ENGINE HAS BEEN RUN: Allow the oil to drain into the oil pan for 10 minutes before checking the oil level. Ten minutes after shutdown the engine oil level must be above the ADD mark.
Maintenance—Every 10 Hours or Daily CHECK RECOVERY TANK COOLANT LEVEL Ö CAUTION: Prevent possible injury from hot spraying water. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. Release all pressure before you remove cap. T8385AE If coolant is below the COLD mark, add coolant to the recovery tank. –UN–15DEC94 With the engine cold, coolant level must be between HOT and COLD marks on the recovery tank.
Maintenance—Every 10 Hours or Daily T7773CB –UN–10AUG92 3. When oil is cold, oil level must be in FULL range on sight glass (A). TX,60,DH2213 –19–16JUN93–2/3 4. If necessary, add oil to filler cap (B). (See Fuels and Lubricants chapter.) T8029AM –UN–15JUN93 5. Install filler cap.
Maintenance—Every 10 Hours or Daily CHECK TRANSMISSION OIL LEVEL IMPORTANT: Prevent possible transmission damage. DO NOT operate engine when transmission oil level is low. 1. Before starting engine, check oil level on dipstick (A). If oil is to upper mark when oil is cold, there is sufficient oil to start the engine. 2. If necessary, add oil to filler tube. (See Fuels and Lubricants chapter.) 3. Install dipstick. –UN–21AUG92 4. Start engine. T7773CP 5. Engage service brakes.
Maintenance—Every 100 Hours LUBRICANT BOOM, BUCKET, AND CYLINDER PIVOTS Ö CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. Lower bucket flat on ground. Lubricate following 13 points until grease escapes around seals. (See Fuels and Lubricants chapter.) T6523CP1 –UN–20OCT88 Lubricate every 10 hours or daily when operating in deep mud, water, or snow.
Maintenance—Every 100 Hours LUBRICATE BOOM, BUCKET, AND CYLINDER PIVOTS—544G TC CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. –UN–17SEP92 Ö Lower equipment to ground. T7829BF Lubricate following 17 points until grease escapes around seals. (See Fuels and Lubricants chapter.
Maintenance—Every 100 Hours T7829BH –UN–17SEP92 Lubricate every 10 hours or daily when operating in deep mud, water, or snow.
Maintenance—Every 100 Hours LUBRICATE STEERING CYLINDER PIVOTS CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. –UN–22MAR96 Ö T100694 Lubricate each point with three shots of grease. (See Fuels and Lubricants chapter.
Maintenance—Every 100 Hours LUBRICATE OSCILLATING REAR AXLE CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. –UN–22MAR96 Ö T100693 Lubricate each point with 10 shots of grease. (See Fuels and Lubricants chapter.) Grease daily when operating in deep mud, water, or snow.
Maintenance—Every 100 Hours NOTE: If operating in dusty conditions, cab fresh air filter should be checked and cleaned as required. Ö CAUTION: Prevent possible injury from flying chips if compressed air is more than 210 kPa (2.1 bar) (30 psi). Reduce compressed air to less than 210 kPa (2.1 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection. T7829AC 3.
Maintenance—Every 250 Hours 1. Remove rubber plug (A) on right front panel. T8372BH IMPORTANT: Prevent possible compressor damage. If receiver dryer moisture eye color indicates "WET" (yellow), dryer is saturated and should be changed within the next 100 machine hours to prevent further buildup of moisture in the refrigerant. –UN–30NOV94 CHECK RECEIVER DRYER MOISTURE INDICATOR TX,75,JC260 –19–16MAY95–1/2 3.
Maintenance—Every 250 Hours CHANGE ENGINE OIL AND REPLACE FILTER IMPORTANT: If fuel sulphur content exceeds 0.5 percent, change engine oil at 1/2 the normal interval. NOTE: If engine has not run 250 hours before the season changes, change oil. 1. Run engine to warm oil. 2. Park machine on a level surface. 3. Lower bucket to ground. 4. Move transmission control lever to neutral "N". Engage neutral lock. Ö CAUTION: Prevent possible injury from unexpected machine movement.
Maintenance—Every 250 Hours T7853AI –UN–08OCT92 7. Install hose on drain valve (A). Turn valve counterclockwise with a 1/4 in. hex key wrench. Allow oil to drain into a container. Dispose of waste oil properly.
Maintenance—Every 250 Hours 8. Turn filter (A) counterclockwise to remove. 9. Clean mounting surface. Apply thin film of oil to gasket of new filter. –UN–31AUG92 10. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface. T7829AH 11. Tighten 1/2—3/4 turn more. 12. Tighten drain valve. 544G Shown 13. Remove filler cap (B). 14. Fill engine with oil. (See Fuels and Lubricants chapter.
Maintenance—Every 250 Hours 20. Check for any leakage at filter. Tighten filter only enough to stop leakage. TX,75,JC1109 –19–18MAR96–4/4 CAUTION: Prevent possible injury from hot spraying water. DO NOT remove radiator filler cap unless engine is cool. Then turn cap slowly to the stop. Release air to relieve all pressure before you remove cap. 1. Slowly remove cap. Coolant level must be at bottom of the filler neck.
Maintenance—Every 500 Hours LUBRICANT FRONT DRIVELINE CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. –UN–08OCT92 Ö T7853AJ NOTE: To prevent plug loss, lubricate the machine when it is fully articulated or half articulated and NOT in the straight position. Lubricate until grease escapes around vent holes in drive shaft end. (See Fuels and Lubricants chapter.) One Point NOTE: Grease daily when operating in deep mud, water, or snow.
Maintenance—Every 500 Hours 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.
Maintenance—Every 500 Hours • Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts). • Get medical attention immediately. 1. Remove battery box cover. TX,75,DH1574 –19–28APR93–2/4 –UN–10FEB89 IMPORTANT: If water is added to batteries during freezing weather, batteries must be charged after water is added to prevent batteries from freezing. Charge battery using a battery charger or by running the engine. Ö T6996DB 2. Fill each cell to within specified range with distilled water.
Maintenance—Every 500 Hours 4. Clean battery terminals (A) and clamps with a stiff brush. –UN–21OCT88 5. Apply lubricating grease (B) around battery terminal base only. T6758AA 6. Install and tighten clamps, grounded clamp last.
Maintenance—Every 500 Hours CAUTION: Prevent possible injury from hot spraying water. DO NOT remove radiator cap unless the engine is cool. Then loosen cap slowly to the stop. Release all pressure before removing cap. 1. Turn cap slowly to the stop to release pressure. Then remove cap. NOTE: A coolant strip test, available from your dealer, provides a simple, effective way to check freeze point and molybdate/nitrite levels.
Maintenance—Every 500 Hours REPLACE PRIMARY FUEL FILTER (WATER SEPARATOR) –UN–31AUG92 1. Turn filter assembly (A) counterclockwise to remove. Allow sediment to drain into a container. Dispose of waste properly. 3. Rotate retaining ring around filter element counterclockwise 1/4 turn. Lifting ring as it is rotated helps get it past retaining detent. Ring should drop down and release filter from base. T7829AR 2. Turn sediment bowl (B) counterclockwise to remove from filter assembly.
Maintenance—Every 500 Hours REPLACE FINAL FUEL FILTER—544G, 624G –UN–31AUG92 1. Turn filter assembly (A) counterclockwise to remove. Allow sediment to drain into a container. Dispose of waste properly. 2. Clean filter base. T7829AS 3. Install new filter. (Follow instructions on filter.) 4. Bleed fuel system. (See Bleeding Fuel System in Maintenance chapter.) 544G Shown TX,80,DH2506 –19–02OCT92–1/1 REPLACE FINAL FUEL FILTER—644G 1. Loosen clamps (A) to remove filter (B). –UN–01MAY89 2.
Maintenance—Every 500 Hours 2. Turn filter (A) counterclockwise to remove. 3. Clean mounting surface. Apply thin film of oil to gasket of new filter. 4. Install new filter. Tighten filter 3/4—1 full turn after seal contacts mounting base. 5. Fully loosen filter element. Repeat step 4. 6. Start engine. Check for leaks around the filter base. Tighten filter only enough to stop leaks. T100705 –UN–22MAR96 7. Stop engine. Check oil level.
Maintenance—Every 500 Hours 1. Turn filter (A) counterclockwise to remove. T7829BE –UN–17SEP92 2. Install new filter. T100708 –UN–22MAR96 544G Shown 644G Shown TX,80,JC1112 –19–18MAR96–2/2 CHECK FRONT AND REAR DIFFERENTIAL OIL LEVEL—IF EQUIPPED WITH STANDARD AXLE –UN–08OCT92 NOTE: Each differential housing has three sumps. Fill center housing slowly to let oil drain into all sumps. 2. Oil must be to bottom of opening. T7853AK 1. Loosen plugs (A).
Maintenance—Every 500 Hours CHECK FRONT AND REAR DIFFERENTIAL OIL LEVEL—IF EQUIPPED WITH DIFFERENTIAL LOCK AXLE CAUTION: Prevent possible injury from hot spraying oil. Slowly loosen plugs to relieve any air pressure. –UN–08OCT92 Ö 2. Start engine. T7853AK 1. Remove plugs (A). Oil must be to bottom of opening. If not, install plugs. Front Differential Shown 3. Hold down differential lock pedal for 1 minute with engine running at slow idle. 4. Stop engine. –UN–20OCT88 5. Slowly remove plugs.
Maintenance—Every 1000 Hours LUBRICATE REAR DRIVELINE CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. –UN–11JUN91 Ö T7516BG NOTE: To prevent plug loss, lubricate the machine when it is fully articulated or half articulated and NOT in the straight position. Lubricate until grease escapes around vent holes in drive shaft end. (See Fuels and Lubricants chapter.) One Point NOTE: Grease daily when operating in deep mud, water, or snow.
Maintenance—Every 1000 Hours T7853AB –UN–06OCT92 ADJUST ENGINE SPEED CONTROL LINKAGE A—Swivel B—Cable C—Lever 1. With accelerator pedal at slow idle, disconnect swivel (A) on speed control cable (B) and adjust until: D—Stop Screw 2. Depress accelerator pedal until injection pump lever is against fast idle stop and hold. 3. Adjust pedal stop screw (D) until it makes contact with the pedal. Release pedal. 544G, LL, TC, and 624G: Injection pump lever (C) has 2—4 mm (0.08—0.16 in.
Maintenance—Every 1000 Hours REPLACE AIR CLEANER DUST UNLOADER VALVE –UN–21AUG92 NOTE: A missing, damaged, or hardened dust valve will cause the air filter elements to be ineffective. T7773CQ Replace dust valve (A). 624G Shown TX,85,DH2246 –19–26AUG92–1/1 REPLACE AIR CLEANER ELEMENTS 1. Remove cover. TX,85,DH2245 –19–31JUL92–1/3 T6119AF –UN–01NOV88 2. Remove wing nut to remove primary element (A). TX,85,DH2245 –19–31JUL92–2/3 3.
Maintenance—Every 1000 Hours T7829AK –UN–31AUG92 CLEAN ENGINE CRANKCASE VENT TUBE (A) T7829AL –UN–31AUG92 544G Shown T100691 –UN–22MAR96 624G Shown 644G Shown TX,85,DH2230 –19–02OCT92–1/1 85–4 PN=151
Maintenance—Every 1000 Hours CHANGE TRANSMISSION OIL AND REPLACE FILTER 1. Operate machine under load until transmission oil reaches normal operating temperature. 2. Park machine on a level surface. 3. Lower bucket to ground. 4. Move transmission control lever to neutral "N". Engage neutral lock. Ö CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving.
Maintenance—Every 1000 Hours T7853AA –UN–23SEP92 9. Remove plug (A), located inside hole in bottom guard, to drain oil. Allow oil to drain into a container. Dispose of waste oil properly. TX,85,JC1057 –19–24JAN96–2/4 11. Clean mounting surface. Apply thin film of oil to gasket of new filter. T7853AC 12. Install new filter. Turn filter clockwise by hand until gasket touches mounting surface. –UN–06OCT92 10. Remove right panel under cab to gain access to transmission filter (A).
Maintenance—Every 1000 Hours 15. Remove transmission dipstick (A). 16. Fill transmission with oil. (See Fuels and Lubricants chapter.) SPECIFICATIONS Includes filter change 544G, LL, TC, 9.5 L (10 qt) 624G 11 L (12 qt) 644G 14 L (15 qt) 17. Start engine and run for 2 minutes. –UN–21AUG92 18. Move transmission control lever to neutral "N", and engage neutral lock. T7773CP 19. Check oil level. Oil must be between marks on dipstick. 20. Check for leaks around the filter base.
Maintenance—Every 1000 Hours 5. Drive machine at 5 mph and move park brake switch to ON. Machine must stop within 2 m (6 ft), and transmission must shift to neutral. T7773AG 6. If necessary, adjust park brake. –UN–11JUN92 4. Move park brake switch (A) to OFF, and move transmission control lever to 2nd gear forward. TX,85,DH2561 –19–09OCT92–2/2 ADJUST PARK BRAKE 1. Park machine on a level surface. 2. Lower bucket to ground.
Maintenance—Every 1000 Hours 7. Remove screws and remove sheet metal cover from brake. Loosen lock nut (A). 8. Loosen the 4 mounting capscrews that hold the park brake to the mounting bracket. 9. Tighten adjustment screw (B) to 100 N•m (75 lb-ft). 10. Tighten the 4 mounting capscrews to 70 N•m (50 lbft). 11. Back the adjustment screw off 180° (1/2 turn). (This will give approximately 0.5 mm (.02 in.) pad to disk clearance with park brake released and engine running.) 12.
Maintenance—Every 1000 Hours LUBRICATE FRAME HINGE PIVOTS Ö CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. T100690 –UN–22MAR96 Lubricate each point with three shots of grease. (See Fuels and Lubricants chapter.
Maintenance—Every 2000 Hours MEASURE AND ADJUST ENGINE VALVE LASH (CLEARANCE)—544G, LL, TC, 624G 1. Remove precleaner or air intake cover, hood, air cleaner bracket with air cleaner intake manifold, and engine crankcase vent tube. 2. Plug all openings. 3. Check crankcase ventilation tube for restriction. Clean with solvent or diesel fuel. 4. Remove rocker arm cover. TX,85,DH2239 –19–31JUL92–1/5 5. Install JDE-81-1 Flywheel Turning Tool (A). T6129AJ 7. Try to move both pushrods at number one cylinder.
Maintenance—Every 2000 Hours 9. Remove turning tool and timing pin. 544G, LL, TC, 624G VALVE CLEARANCE SPECIFICATIONS 0.36 mm (0.014 in.) Exhaust Valve (E) 0.46 mm (0.018 in.) T6233AG –19–27JAN89 Intake Valves (I) TX,85,DH2239 –19–31JUL92–4/5 0.36 mm (0.014 in.) Exhaust Valve (E) 0.46 mm (0.018 in.) 10. Clean cylinder head and rocker arm cover mating surfaces. 11. Install rocker arm cover gasket. Do not use sealant on the gasket. 12. Install rocker arm cover. Tighten screws to 10.8 N•m (96 lb-in.
Maintenance—Every 2000 Hours ADJUST ENGINE VALVE LASH (CLEARANCE)—644G 1. Remove precleaner, hood, air cleaner support with starting aid and air cleaner, engine crankcase vent tube. 2. Plug all openings. 3. Check crankcase ventilation tube for restriction. Clean with solvent or diesel fuel. 4. Remove rocker arm cover. 5. Remove plugs. Install JDE-81-I Flywheel Turning Tool (A) and JDE-81-4 Timing Pin (B). 6. Rotate flywheel until timing pin fits into hole in flywheel. 7.
Maintenance—Every 2000 Hours 12. Remove flywheel turning tool and timing pin. Install plugs. 644G VALVE CLEARANCE SPECIFICATIONS 0.38 mm (0.015 in.) Exhaust Valve (E) 0.71 mm (0.028 in.) T6233AI –19–27JAN89 Intake Valves (I) TX,86,JC1142 –19–23MAY96–3/4 Intake Valves (I) 0.38 mm (0.015 in.) Exhaust Valve (E) 0.71 mm (0.028 in.) 13. Clean cylinder head and rocker arm cover mating surfaces. Apply gasket cement to rocker arm cover. T6233AJ 14. Install rocker arm cover. Tighten cap screws to 10.
Maintenance—Every 2000 Hours LUBRICATE FRONT DRIVELINE SUPPORT BEARING CAUTION: Prevent possible injury from unexpected machine movement. Install frame locking bar before lubricating. –UN–23AUG89 Ö T7114AS Lubricate until grease escapes around seal. (See Fuels and Lubricants chapter.) NOTE: Grease every 250 hours if operating in deep mud or water.
Maintenance—Every 3000 Hours CHANGE HYDRAULIC SYSTEM OIL T8029AN –UN–15JUN93 1. Remove hydraulic reservoir filler cap (A). TX,86,JC281 –19–16MAY95–1/3 2. Install hose on hydraulic reservoir drain valve (B). Loosen valve with a 1/4 in. hex key wrench. Allow oil to drain into a container. Dispose of waste oil properly. –UN–15DEC94 3. Flush reservoir with diesel fuel. 4. Tighten drain valve. T8385AF 5. Fill reservoir. (See Fuels and Lubricants chapter.) SPECIFICATIONS 544G, LL, TC Approx.
Maintenance—Every 3000 Hours CLEAN HYDRAULIC SUCTION STRAINER 1. Remove hydraulic reservoir filler cap (A). –UN–15JUN93 2. Remove cap screws and cover (B). T8029AO 3. Inspect gasket and replace if necessary. TX,86,DH2963 –19–16JUN93–1/1 REPLACE DIFFERENTIAL LOCK RETURN FILTER(S)—IF EQUIPPED 1. Remove hydraulic reservoir filler cap (A). –UN–15JUN93 2. Remove cap screws and cover (B). T8029AO 3. Inspect gasket and replace if necessary. TX,86,DH2250 –19–16JUN93–1/2 4.
Maintenance—Every 3000 Hours CHANGE FRONT AND REAR DIFFERENTIAL OIL –UN–08OCT92 1. Remove drain plug (A). Allow oil to drain into a container. Dispose of waste oil properly. NOTE: It is normal for differential lock axles to be filled approximately 1—2 L (1—2 qt) above level plug. Approx. 19 L (20 qt) 624G Front Approx. 28 L (30 qt) 624G Rear Approx. 19 L (20 qt) 644G Front and Rear, each Approx.
Maintenance—Every 3000 Hours T7853AR –UN–08OCT92 5. Open left service door. Remove fill plug (A) from rear differential. TX,87,JC1058 –19–24JAN96–4/5 NOTE: Each differential housing has three sumps. Fill center housing slowly so oil drains into all sumps. –UN–08OCT92 6. Add oil slowly until it appears in the bottom of the check level plugs (A). (See Fuels and Lubricants chapter.) T7853AK 7. Install fill plugs.
Maintenance DRAINING THE COOLING SYSTEM CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns TS281 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. –UN–23AUG88 Ö 1. Check hoses (A) for cracks and leaks. Replace, if necessary. 2. Tighten clamps. T6523CC –UN–20OCT88 3.
Maintenance T7829AN –UN–31AUG92 6. 544G, 624G: Remove plug (A) to drain engine block. Allow coolant to drain into a container. Dispose of used coolant properly. 544G, 624G Shown TX,90,JC1114 –19–18MAR96–3/4 644G: Turn draincock (B) counterclockwise to drain engine block. Allow coolant to drain into a container. Dispose of used coolant properly. T100709 –UN–22MAR96 7. Disconnect hose from recovery tank to drain the tank.
Maintenance DIESEL ENGINE COOLANT The engine cooling system is filled to provide yearround protection against corrosion and cylinder liner pitting, and winter freeze protection to -37°C (-34°F). The following engine coolant is preferred for service: • John Deere PREDILUTED ANTIFREEZE/SUMMER COOLANT The following engine coolant is also recommended: • John Deere ANTIFREEZE/SUMMER COOLANT CONCENTRATE in a 40 to 60 percent mixture of concentrate and quality water.
Maintenance FILLING THE COOLING SYSTEM SPECIFICATIONS 544G Cooling system capacity Approx. 24 L (25 qt) 624G Cooling system capacity Approx. 25 L (26 qt) 644G Cooling system capacity Approx. 28.5 L (30 qt) IMPORTANT: After filling radiator, operate engine to purge air from the engine block. When air is purged, the coolant level sensor in the radiator will turn warning alarm on, STOP indicator will flash, and engine coolant indicator will light. Shut off engine and add coolant immediately.
Maintenance DO NOT SERVICE INJECTION NOZZLES IMPORTANT: Do not service or remove injection nozzles. The service life of the injection nozzles may be shortened by: • Overheating • Improper operation • Poor quality fuel • Excessive idling If injection nozzles are not working correctly or are dirty, the engine will not run normally. (See your authorized dealer for service.
Maintenance 1. Connect hose to fuel tank draincock (B). 2. Remove fuel tank cap. 4. Disconnect fuel hose. Remove hose clamp (A). T6523BW1 5. Remove fitting to remove screen from inside fuel tank. –UN–20OCT88 3. Drain fuel from tank. 6. Remove debris from screen with clean solvent or diesel fuel, or install a new screen. 7. Flush debris out of fuel tank. 8. Clean fitting threads and threads in fuel tank with clean and cure primer. 9.
Maintenance BLEEDING FUEL SYSTEM—544G, 624G 1. Place container under filters (C and G). –UN–10SEP92 2. Loosen bleed screw (E). 3. Pump hand primer (B) until bleed screw (E) has solid stream of fuel. T7833AJ 4. Open bleed screw (A). Pump hand primer until bleed screw has solid stream of fuel coming from it. Tighten bleed screw on final fuel filter.
Maintenance BLEEDING FUEL SYSTEM—644G 1. Place container under primary fuel filter (F). 2. Loosen bleed screw (C), and push pump (D) until fuel free of bubbles flows from around bleed screw. 3. Tighten bleed screw. T100696 –UN–22MAR96 4. Loosen bleed screw (B) from final fuel filter (A), and push pump (D) until fuel free of bubbles flows from around bleed screw.
Maintenance PRECAUTIONS FOR ALTERNATOR AND REGULATOR When batteries are connected, follow these rules: 1. Disconnect negative (-) battery cable when you work on or near alternator or regulator. 2. DO NOT TRY TO POLARIZE ALTERNATOR OR REGULATOR. 3. Be sure alternator wires are correctly connected BEFORE you connect batteries. 6. Connect batteries or a booster battery in the correct polarity (positive [+] to positive [+] and negative [-] to negative [-]). 7.
Maintenance SERVICE BATTERIES CAREFULLY Always remove grounded (-) battery clamp first and replace it last. TS204 Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. –UN–23AUG88 CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Sulfuric acid in battery electrolyte is poisonous.
Maintenance • Get medical attention immediately. If electrolyte spills on the floor, use one of the following mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in 4 L (1 gal) water. IMPORTANT: Electrolyte can damage paint and metal surfaces of your machine. Do not overfill the battery cells.
Maintenance CHECKING ELECTROLYTE SPECIFIC GRAVITY Always remove grounded (-) battery clamp first and replace it last. TS204 Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. –UN–23AUG88 CAUTION: Battery gas can explode. Keep sparks and flames away from batteries. Use a flashlight to check battery electrolyte level. Sulfuric acid in battery electrolyte is poisonous.
Maintenance • Drink large amounts of water or milk, but do not exceed 1.9 L (2 quarts). • Get medical attention immediately. Check the specific gravity of electrolyte in each battery cell. 04T,90,FF20 –19–12MAY93–2/3 A fully charged battery will have a corrected specific gravity reading of 1.260. If the reading is below 1.200, charge the battery. T85402 NOTE: In tropical areas, use 1.225 for the full charge reading. In cold areas, use 1.280 for the fullcharge reading.
Maintenance CAUTION: Prevent possible injury from exploding battery. Do not charge a battery if the battery is frozen or it may explode. Warm battery to 16°C (60°F). Disconnect battery ground (—) clamp before you charge batteries in the machine to prevent damage to electrical components. IMPORTANT: Do not use a battery charger as a booster if a battery has a 1.150 specific gravity reading or lower. Turn off charger before connecting or disconnecting it.
Maintenance REMOVING BATTERIES 1. Remove battery cover. TX,90,DH1768 –19–06JUN91–1/2 2. Disconnect negative (-) battery cable (A) first, then positive (+) cable (B). 3. Remove nuts and washers (C) and hold down bracket. T6570AD2 –UN–20OCT88 4. Lift battery out of compartment. TX,90,DH1768 –19–06JUN91–2/2 REPLACING FUSES –UN–08OCT92 IMPORTANT: Install fuses with correct amperage rating to prevent electrical system damage from overload.
Maintenance RESETTING CIRCUIT BREAKERS Air conditioning system contains two circuit breakers. If circuit breakers open because of a short circuit or overloading, air conditioner will shut off. Turn off air conditioning switch. Wait a couple of minutes before restarting, to allow a cooling off period. Circuit breaker will reset itself. If circuit breaker opens repeatedly, see your John Deere dealer.
Maintenance 1. Remove four screws (H) to remove bezel (G) and lens (F). –UN–19OCT88 2. Disconnect wiring lead and release retainer clip to remove bulb (D). 3. To disconnect ground wiring lead, push tab up, then pull connector from terminal. T6249AU IMPORTANT: Do not touch the halogen bulb with bare hands. Oil and moisture may cause premature bulb failure. Clean bulb using a soft, oil-free cloth and alcohol. 4. Install new bulb so square notch is aligned with square tab on reflector back. 5.
Maintenance IMPORTANT: The reverse warning alarm is set on high volume at the factory. It may be necessary to adjust the volume to meet local regulations. T7853AT NOTE: Alarm removed from machine for clarity of photograph. –UN–08OCT92 CHANGING REVERSE WARNING ALARM VOLUME To change alarm volume, move switch (A) to desired position. TX,90,DH2566 –19–03FEB95–1/1 CHECKING NEUTRAL START SYSTEM Ö CAUTION: Avoid possible injury or death.
Maintenance ADDING ATTACHMENTS/ACCESSORIES TO ROLL-OVER PROTECTIVE STRUCTURE (ROPS) Do not add attachments or accessories to the ROPS without contacting your John Deere dealer for information. Improper attachment may impair the protection offered by the ROPS. 04T,90,K117 –19–16MAR88–1/1 SERVICING AIR CONDITIONING SYSTEM 1. Check and adjust compressor belt tension. 2. Check compressor clutch engagement. 3. Check evaporator core for clogging. 4. Check air intake filters for clogging. 5.
Maintenance CHECKING AND ADJUSTING COMPRESSOR BELT TENSION—IF EQUIPPED 1. A force of 111 N (25 lb force) halfway between pulleys must move belt 13 mm (0.5 in.). 2. To adjust tension, loosen mounting cap screws. 3. Apply force to FRONT compressor housing only (near the belt) until tension is correct. 4. Tighten cap screws.
Maintenance INSPECTING PARK BRAKE PADS 1. Park machine on a level surface. 2. Lower bucket to ground. TX,90,DH2348 –19–19MAY93–1/3 CAUTION: Prevent possible injury from unexpected machine movement. Never rely on transmission control lever alone to keep machine from moving. Machine can unexpectedly roll or move under power, resulting in death or serious injury. Always engage park brake to hold machine. 4. Install frame locking bar. T7747BR Ö –UN–19MAY92 3.
Maintenance T7853AU –UN–08OCT92 6. Check the combined thickness of backing plates, brake pads (C), (2nd pad not shown) and disk (D). If thickness of backing plates, pads, and disk is less than 29.0 mm (1.20 in.) or if grooves are worn off pads, replace pads. New backing plates, pads and disk measure 35.0 mm (1.40 in). (See your authorized dealer.) TX,90,DH2348 –19–19MAY93–3/3 EXTERNAL SERVICE BRAKE INSPECTION Ö CAUTION: Prevent possible injury from hot spraying oil.
Maintenance T6523BZ –UN–25OCT88 1. Remove brake inspection port plug (A). TX,90,JC263 –19–29NOV94–2/4 T6138AZ –UN–25OCT88 2. Inspect the brake linings (A) on brake disk. TX,90,JC263 –19–29NOV94–3/4 3. Remove axle housing and replace brake disc if oil grooves (B) on facing material are no longer visible. T8137AC –UN–03DEC93 4. If further inspection of brake elements or replacement of brake linings is necessary, see your authorized dealer.
Maintenance CHECKING BRAKE ACCUMULATOR 1. Start engine. 2. Run engine for 1 minute at slow idle. TX,90,JC1116 –19–18MAR96–1/2 3. Quickly apply brake pedal as hard as possible, and hold down. If brake low pressure indicator light comes on, brake accumulator (A) pressure is low. T100704 –UN–22MAR96 4. Replace brake accumulator.
Maintenance CAUTION: The boom will jump upward during this check. Make sure area around bucket is clear. 1. Start engine. 2. Push ride control switch to OFF position. 3. Raise boom to maximum height and hold control lever over relief for 2 seconds. T7829AV Ö –UN–08SEP92 CHECKING RIDE CONTROL ACCUMULATOR—IF EQUIPPED 4. Lower boom and bucket to ground and stop engine. TX,90,DH2560 –19–12MAY93–1/2 T7853AV 6. If ride control accumulator has lost gas charge, go to your authorized dealer.
Maintenance 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.
Maintenance 4. Put a clear plastic tube on bleed screw (B) to route flow to hydraulic reservoir filler tube (A) or to a container. 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. 6. Repeat steps 2—4 for each bleed screw (two bleed screws on each differential). 7. Release brake pedal and stop engine. T6522BR –UN–20OCT88 8. Check hydraulic oil level. (See Maintenance—Every 10 Hours or Daily chapter.
Maintenance CHECKING SECONDARY STEERING SYSTEM—IF EQUIPPED 1. Park machine on a level surface. 2. Shut off engine. Release brakes. 3. Momentarily turn key switch to START but DO NOT start the engine. Release key to ON. 4. The secondary steering motor must be heard running. Secondary steering indicator must light and alarm must sound. 5. Turn steering wheel; Machine should turn partway. Machine will not turn fully when machine is stopped. 6. Start engine.
Maintenance 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 operator’s preference for his work application. Adjust as required.
Maintenance 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 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. A damaged ROPS should be replaced, not reused.
Maintenance TS1163 –19–04MAR91 METRIC BOLT AND CAP SCREW TORQUE VALUES Class 4.8 Size Lubricated a N•m lb-ft M6 4.8 M8 12 M10 M12 Class 8.8 or 9.8 Dry a a Lubricated N•m lb-ft 4.5 9 11 22 29 21 50 37 Class 10.9 Dry a a Lubricated N•m lb-ft 6.5 11 16 28 43 32 55 75 55 95 Class 12.9 Dry N•m lb-ft N•m 8.5 13 9.5 17 20 32 24 40 40 63 47 80 70 110 80 140 a Lubricateda lb-ft Drya N•m lb-ft N•m lb-ft N•m lb-ft 3.5 6 8.
Maintenance DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class. Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original.
Maintenance 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. T6873AA CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. T-Bolt –UN–18OCT88 Ö –UN–18OCT88 ADDITIONAL METRIC CAP SCREW TORQUE VALUES Shear bolts are designed to fail under predetermined loads.
Maintenance TS1162 –19–04MAR91 UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES Grade 2b Grade 1 Size Lubricated a Dry a a Lubricated N•m lb-ft N•m lb-ft Grade 5, 5.1, or 5.2 Dry a Lubricateds N•m lb-ft N•m lb-ft N•m a lb-ft Dry N•m Grade 8 or 8.2 a Lubricateda lb-ft N•m lb-ft Drya N•m lb-ft 1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5 5/16 7.7 5.
Maintenance a 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. ”Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated without any lubrication. Make sure fasteners threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.
Maintenance 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 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.
Maintenance SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS 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. T6243AE 1. Inspect O-ring boss seat for dirt or defects.
Maintenance ANGLE FITTING 3. Turn fitting head-end counterclockwise to proper index (maximum of one turn). 4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value. T6520AB 2. Turn fitting into threaded boss until back-up washer contacts face of boss. –UN–18OCT88 1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting. NOTE: Do not allow hoses to twist when tightening fittings.
Maintenance SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS –UN–18OCT88 1. Inspect the fitting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring. It must be free of damage or defects. T6243AD 3. Lubricate O-rings and install into groove using petroleum jelly to hold in place. 4. Push O-ring into the groove with plenty of petroleum jelly so O-ring is not displaced during assembly. 5.
Maintenance T6890BB –UN–01MAR90 SERVICE RECOMMENDATIONS FOR METRIC SERIES FOUR BOLT FLANGE FITTING A—Sealing Surface B—Split Flange C—Pinched O-Ring 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. D—Single Piece Flange DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. TORQUE CHART* 2.
Maintenance T6890BB –UN–01MAR90 SERVICE RECOMMENDATIONS FOR INCH SERIES FOUR BOLT FLANGE FITTINGS A—Sealing Surface B—Split Flange C—Pinched O-Ring 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. D—Single Piece Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5.
Maintenance TORQUE CHART* N•m Nominal Flange Size lb-ft Cap Screw Size Min Max Min 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 3 5/8-11 UNC 158 264 117 195 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 *Tolerance ± 10%.
Operational Checkout OPERATIONAL CHECKOUT Use this procedure to check all systems and functions on the machine. It is designed so you can make a quick check of the operation of the machine while doing a walk around inspection and performing specific checks from the operator’s seat. Should you experience a problem with your machine, you will find helpful diagnostic information in this checkout that will pinpoint the cause.
Operational Checkout ' MONITOR INDICATOR AND GAUGE CHECKS—ENGINE OFF – – –1/1 HOURMETER AND GAUGE CHECK OK: Go to next check NOT OK: Temperature gauge is solid, 9 arrows showing, circuit is open or shorted. Go to your authorized dealer. Key switch OFF. T7773BC –UN–05AUG92 Press SELECT button. 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.
Operational Checkout MONITOR INDICATOR CIRCUIT AND KEY SWITCH CHECK OK: Go to next check NOT OK: Check monitor ACC fuse. NOT OK: If brake pressure stays off after 10 pumps, see Brake Accumulator Precharge check. IF OK: Go to your authorized dealer. T7773BA –UN–05AUG92 Apply brake pedal 10 times. Turn key switch to accessory position. LISTEN: Accessory relay must click. LOOK & LISTEN: All monitor indicators and functions, including the alarm, must come ON after 1 second and remain ON for 5 seconds.
Operational Checkout MONITOR TURN SIGNALS AND HAZARD WARNING INDICATOR CHECKS OK: Go to next check NOT OK: Check fuse. IF OK: Check bulbs and wiring. Go to your authorized dealer. T7773BB –UN–21AUG92 T6564OL –UN–19OCT88 T6633AB2 –UN–18OCT88 Move turn signal switch left, then right. Move hazard warning switch to ON. LOOK: Left, right, and then both turn signal indicators must be flashing. Front and rear lights (A and B) must flash as indicated by monitor lights.
Operational Checkout ENGINE SPEED CONTROL LINKAGE CHECK—544G, 624G OK: Go to next check NOT OK: Adjust linkage. See Adjust Engine Speed Control Linkage in Maintenance—Every 1000 Hours chapter. Engine OFF. Right engine service door open. T6564NL –UN–19OCT88 T6564NM –UN–19OCT88 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.
Operational Checkout FUEL SHUT-OFF SOLENOID LINKAGE CHECK—644G Open right engine side shield and inspect linkage. OK: Go to next check LOOK: Fuel shut-off cam must be tight against the lower stop. NOT OK: Adjust fuel shut-off solenoid linkage. See Adjusting Fuel ShutOff Solenoid in Maintenance chapter. Start engine and engage park brake. Open right engine side shield and inspect linkage. T8030AN –UN–21JUN93 LOOK: Fuel shut-off cam must be tight against the upper stop.
Operational Checkout ) MONITOR INDICATOR AND GAUGE CHECKS (ENGINE RUNNING) – – –1/1 MONITOR DISPLAY AND ALTERNATOR OUTPUT CHECK Turn key switch to on and wait 5 seconds. LOOK: Hourmeter reading must appear. T7825BD –UN–21AUG92 Press SELECT button once. LOOK: Battery volts reading must be 12.3—13.8. T7825BC –UN–21AUG92 Press SELECT button once. LOOK: Engine rpm must read 0. Press SELECT button once. LOOK: MPH reading must be 0. T7825BF1 –UN–24AUG92 Press SELECT button once.
Operational Checkout Increase engine speed to fast idle andobserve monitor display. OK: Go to next check LOOK: The following engine rpm readings must be displayed. 544G: 2350—2400 rpm 624G/644G: 2300—2350 rpm NOT OK: No monitor reading displayed. Check ACC fuse to monitor. Press SELECT button until hourmeter icon is displayed. IF OK: Go to your authorized dealer. LOOK: Hourmeter icon must be flashing and hourmeter reading must be displayed. NOT OK: Check speed control linkage.
Operational Checkout MONITOR INDICATOR CIRCUIT BYPASS AND SEAT BELT INDICATOR CHECK In a single motion, turn key and start engine. OK: Go to next check LOOK & LISTEN: Engine should start and bypass the bulb check mode. NOT OK: Check for an unhooked wiring connecter. Depress service brake pedal 10 times. Lock transmission control lever in neutral "N". IF OK: Go to your authorized dealer.
Operational Checkout TRANSMISSION TEMPERATURE GAUGE CHECK OK: Go to next check. NOT OK: If gauge shows solid arrows, check connector at sender. Engine running. IF OK: Go to your authorized dealer. T7773BO2 –UN–05AUG92 T7773BF –UN–05AUG92 Release park brake. Move clutch cut-off switch to the ON position. Apply service brakes. Move transmission control lever to 3rd gear forward. Increase engine speed to fast idle for 30 seconds. LOOK: Transmission temperature indicator arrow must move to the right.
Operational Checkout SERVICE BRAKE PUMP FLOW CHECK OK: Go to next check NOT OK: Check for brake circuit leakage. Go to your authorized dealer. NOTE: Hydraulic oil must be at operating temperature for this check. Engine OFF. T7747AF1 –UN–24AUG92 T7773BQ3 –UN–21AUG92 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.
Operational Checkout SERVICE BRAKE CHECK OK: Go to next check Engine running. NOT OK: Go to your authorized dealer. T7773BO2 –UN–05AUG92 T7773BQ3 –UN–21AUG92 Move clutch disconnect switch to OFF. Apply service brakes, release park brake, and move transmission control lever to 2nd gear forward. Increase engine speed to fast idle. LOOK: Machine MUST NOT move or move at a very slow speed. Repeat check three times to ensure accurate results.
Operational Checkout BRAKE SYSTEM LEAKAGE CHECK OK: Go to next check NOT OK: Go to your authorized dealer. 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. LOOK: Brake low pressure warning light MUST NOT come ON within 2 minutes after stopping engine. – – –1/1 SERVICE BRAKE PEDAL CHECK Slowly depress each brake pedal one at a time.
Operational Checkout DIFFERENTIAL LOCK CHECK Park machine on a hard surface. OK: Go to next check Release brakes. NOT OK: See Differential Axle in Troubleshooting chapter. Engage differential lock. Steer machine back and forth. LOOK: Front wheels MUST NOT turn in opposite direction. NOTE: It is normal to get a "clunk" sound when you release pedal. T7773BQ1 –UN–21AUG92 – – –1/1 CLUTCH CUT-OFF CHECK OK: Go to next check NOT OK: Adjust clutch cut-off switch.
Operational Checkout + DRIVING CHECKS NOTE: Transmission oil must be at operating temperature for these checks. – – –1/1 OK: Go to next check TRANSMISSION NOISE CHECK NOT OK: Go to Transmission Makes Excessive Noise in Troubleshooting chapter. Engine running. T7825BH –UN–21AUG92 T7773BN –UN–05AUG92 Run engine at approximately 1600 rpm. Drive machine with transmission in each forward and reverse gear. LISTEN: Transmission MUST NOT make excessive noise in any range.
Operational Checkout AUTOMATIC SHIFT AND SPEEDOMETER CHECK Press SELECT button on monitor until MPH or Km/H is displayed. Engine running. Release park brake and move transmission control lever to 4th gear forward. T7825BG –UN–21AUG92 Drive machine on level ground and slowly accelerate to fast idle speed. Note speed when shifts are made until 4th gear. Reduce engine rpm to idle and note speed when transmission makes each downshift. OK: Go to next check.
Operational Checkout TRANSMISSION QUICKSHIFT CHECK Release park brake and move transmission control lever to 2nd gear forward. Engine running. Drive machine at approximately 1600 rpm and press boom control lever switch once. LOOK & FEEL: Transmission must shift to 1st gear. T7825BL1 –UN–31AUG92 OK: Go to next check. NOT OK: Check connector at base of control valve. IF OK: Go to your authorized dealer. Press boom control lever switch once. LOOK & FEEL: Transmission must shift back to 2nd gear.
Operational Checkout TRANSMISSION SHIFT MODULATION CHECK OK: Go to next check NOT OK: See Machine Shifts Too Fast in Troubleshooting chapter. Engine running. T7825BH –UN–21AUG92 T7773BN –UN–05AUG92 Run engine at approximately 1600 rpm. Move transmission control lever to 1st gear forward. Shift several times from forward to reverse and reverse to forward. Repeat check in 2nd gear. LOOK: Machine must slow down and change direction without excessive delay.
Operational Checkout CONTROL VALVE LIFT CHECK With bucket partially dumped, lower boom to raise front of machine. Run engine at slow idle. Slowly move boom control lever to boom lower position. Slowly move bucket control lever to bucket dump position. T6601AA –UN–19OCT88 OK: Go to next check. NOT OK: Repair lift checks in loader control valve. Go to your authorized dealer. LOOK: Boom MUST NOT raise before moving down. Bucket MUST NOT rollback before dumping.
Operational Checkout BOOM DOWN CHECK VALVE LEAKAGE CHECK Position bucket flat on ground. OK: Go to next check Run engine at slow idle for 2 minutes. Heat hydraulic oil to operating temperature. (See Hydraulic System Warm-up Procedure in this group.) LOOK: Bucket MUST NOT drift up. NOT OK: Replace boom lower check valve. Go to your authorized dealer. T7010AO –UN–15MAR89 – – –1/1 PILOT CONTROLLER CHECK OK: Go to next check. NOT OK: Repair pilot controllers. Go to your authorized dealer.
Operational Checkout BOOM HEIGHT KICKOUT CHECK—IF EQUIPPED 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: See Adjusting Boom Height Kickout in Operating the Machine chapter. T7825BL –UN–24AUG92 – – –1/1 PIN DISCONNECT CYLINDER CHECK (544G-TC ONLY) Run engine at slow idle.
Operational Checkout - STEERING SYSTEM CHECKS – – –1/1 STEERING VALVE CHECK Run engine at slow idle. OK: Go to next check. Turn steering wheel until frames are at maximum right (A) and then left (B) positions. NOT OK: Go to next check. LOOK: Frames must move smoothly in both directions. T6471AQ –UN–19OCT88 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.
Operational Checkout PRIORITY VALVE LOW PRESSURE CHECK Park machine on a hard surface. Hold brake pedal down. OK: Go to next check. Steer machine to the right and left as far as possible. NOT OK: Adjust priority valve pressure. Go to your authorized dealer. LOOK: machine must turn at least 1/2 way to the right and left stops. Run engine at fast idle. – – –1/1 PRIORITY VALVE HIGH PRESSURE CHECK OK: Go to next check. NOT OK: Priority pressure is set too high. Go to your authorized dealer.
Operational Checkout SECONDARY STEERING SYSTEM CHECK—IF EQUIPPED 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. OK: Go to next check. NOT OK: If secondary steering pump and motor do not operate, go to your authorized dealer. T7773BH1 –UN–05AUG92 T6601AC –UN–19OCT88 Park machine on a hard level surface with bucket off of ground and steering straight ahead. Stop engine.
Operational Checkout . ACCESSORY CHECKS NOTE: Engine must be stopped and key switch must be ON for these checks – – –1/1 OPERATING LIGHTS CHECK OK: Go to next check NOT OK: Check fuse. IF OK: Go to your authorized dealer. T7773BO3 –UN–05AUG92 T6633AB –UN–18OCT88 T6637AA –UN–18OCT88 Push light switch. Note light operation. LOOK: Headlights (C), and taillights (D) must come on. – – –1/1 WORK LIGHT CHECK OK: Go to next check NOT OK: Check fuse. IF OK: Check bulbs and replace as required.
Operational Checkout BRAKE LIGHT CHECK 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, engine may need to be started for brake lights to come on. IF OK: Check bulbs, replace as required. Go to your authorized dealer. T6633AB3 –UN–18OCT88 – – –1/1 HORN CIRCUIT CHECK Push horn button (A). OK: Go to next check LISTEN: Horn must sound.
Operational Checkout WINDSHIELD WASHER AND WIPER CHECK—IF EQUIPPED Turn front wiper switch knob clockwise to first detent, 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 knob in to turn front washer on. T7773AN –UN–05AUG92 OK: Go to next check. NOT OK: If wiper and washer do not work, check fuses. IF OK: Check wiring. Go to your authorized dealer. LOOK: Washer must spray water on windshield.
Operational Checkout HEATER/AIR CONDITIONER BLOWER CHECK Turn blower switch knob to low, medium and high speeds. OK: Go to next check NOT OK: Check fuse. FEEL & LISTEN: Blower must have three speeds and OFF. IF OK: Go to your authorized dealer. T7773BP3 –UN–05AUG92 – – –1/1 HEATER FUNCTIONAL CHECK Open heater shut-off valve on water pump. OK: Go to next check Start engine. Run at fast idle. NOT OK: Go to your authorized dealer. Wait 2 minutes.
Operational Checkout START AID SYSTEM CHECK OK: Go to next check. NOT OK: Check for empty start aid can (A). IF OK: Check fuse. Replace. T7747AI1 –UN–14SEP92 NOT OK: If light does not come ON, go to your authorized dealer. T6477AP –UN–19OCT88 Start engine and run at slow idle. Momentarily push start aid button. LISTEN: Engine speed must increase slightly. LOOK: Light in monitor must come ON when button is pushed.
Operational Checkout CAB DOOR RELEASE BUTTON Press door release button. OK: Go to next check LOOK & LISTEN: Latch must click and release door. NOT OK: If latch does not release, check fuse. IF OK: Go to your authorized dealer. NOT OK: If door does not latch tightly, adjust latch assembly. T7832AJ –UN–27AUG92 – – –1/1 CAB DOOR LOCK CHECK Lock cab door. OK: Go to next check. LOOK: Cab door handle MUST NOT move. NOT OK: Lubricate or repair lock.
Operational Checkout CAB WINDOW LATCH CHECK Inspect window seals. OK: Go to next check Open right side cab window. Pull window closed. NOT OK: Lubricate latch. Replace window seals if necessary. LOOK: Latch must hold window tightly closed. LOOK: Window seals MUST NOT have gaps between seals and window frames. T6633AO –UN–18OCT88 Position latch outer notch (A) over catch. Open latch. LOOK: When window latch is in outer notch position, window must be held slightly open.
Operational Checkout SEAT AND SEAT BELT CHECK IMPORTANT: Replace the complete seat belt assembly every three years regardless of appearance. A date label, to determine the age of the belt, is attached to each seat belt. 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.
Operational Checkout AIR INTAKE FILTER DOOR CHECK Unlock and open door on left side of operator’s station. OK: Go to next check. Close and lock door. NOT OK: Lubricate hinges. Lubricate or repair lock. LOOK: Door must open and close smoothly. FEEL: Lock must operate freely and key MUST NOT stick in lock. T6633AW –UN–18OCT88 – – –1/1 LOAD CENTER DOOR CHECK Unlock and open door on right side of operator’s station. OK: Go to next check. Close and lock door. NOT OK: Lubricate hinges.
Operational Checkout RADIATOR CAP ACCESS DOOR CHECK 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. T6633AY –UN–18OCT88 – – –1/1 LOOK: Red frame locking bar must be pinned to engine frame below left side cab step. FRAME LOCKING BAR CHECK OK: Go to next check. NOT OK: Order new parts and install new locking bar and pins.
Troubleshooting USING TROUBLESHOOTING CHARTS NOTE: Troubleshooting charts are arranged from the simplest to verify, to least likely, more difficult to verify. When diagnosing a problem, use all possible means to isolate the problem to a single component or system. Use the following steps to diagnose problems: Step 1. Operational Checkout Procedure. Step 2. Troubleshooting charts. Step 3. Adjustments. Step 4. See your authorized dealer.
Troubleshooting ENGINE 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 shut-off fuse. Replace fuse. Fuel filter(s) clogged. Inspect and replace fuel filter(s). Incorrect grade of fuel.
Troubleshooting Symptom Engine Surges Or Stalls Frequently Problem Solution Injection nozzle(s). See your authorized dealer. Low compression or blown head gasket. 544G, LL, TC, 624G—Remove fuel shut-off fuse. Crank engine and listen for air leaking past valves or an uneven starter speed. Start engine and observe blow-by from vent tube. See your authorized dealer. Fuel injection pump. See your authorized dealer. Fuel tank vent hose clogged. Loosen cap and listen for air rushing into tank.
Troubleshooting Symptom Engine Misses Problem Solution 544G, LL, TC, 624G—Injection pump metering valve sticking. Lightly tap injection pump housing. If engine starts, see your authorized dealer. Fuel injection pump out of time. See your authorized dealer. Engine overheating. See your authorized dealer. 644G—Incorrect slow idle, or supplementary idling screw adjustment. Check and adjust slow idle. See your authorized dealer. Incorrect valve clearance. Check and adjust valve clearance.
Troubleshooting Symptom Engine Does Not Develop Full Power Problem Solution Slow idle speed too low. Check slow idle speed. (See Maintenance—Every 1000 Hours chapter.) See your authorized dealer. Fuel pump. See your authorized dealer. Engine overheats. See your authorized dealer. Incorrect valve clearance. Check and adjust valve clearance. (See Maintenance—Every 1000 hours chapter.) Bent push rods. See your authorized dealer. Valve sticking or burned. Remove fuel shut-off fuse.
Troubleshooting Symptom Problem Solution Excess drag in transmission. See your authorized dealer. Excess drag in brakes. Check service and park brake drag. See your authorized dealer. Fast idle speed set too low. Check and adjust fast idle. See your authorized dealer. 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.
Troubleshooting Symptom Engine Emits Excessive Black Or Gray Exhaust Smoke Problem Solution 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 fuel shut-off fuse.
Troubleshooting Symptom Engine Emits Excessive Blue Or White Smoke Slow Acceleration. Detonation Problem Solution 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. Cranking speed too low. Check batteries and connections. Incorrect grade of fuel. Drain fuel tank and add correct fuel. (See Fuel and Lubricants chapter.
Troubleshooting Symptom Problem Solution Abnormal Engine Noise Low or incorrect engine oil. Add correct oil. Loose or worn dampener drive. See your authorized dealer. Engine oil diluted with fuel. Inspect engine oil. Inspect fuel pump spindle, seal, and housing. Clean and use or replace. Incorrect fuel injection pump timing. See your authorized dealer. Turbocharger. See your authorized dealer. Excessive valve clearance. Adjust valve clearance. (See Maintenance—Every 1000 Hours chapter.
Troubleshooting Symptom High Oil Pressure Engine Overheats Problem Solution Oil pressure gauge or sensor. See your authorized dealer. Oil pressure regulating valve. See your authorized dealer. Turbocharger shaft seal leaking. See your authorized dealer. Clogged oil pump intake screen. See your authorized dealer. Loose oil pump drive gear. See your authorized dealer. Worn oil pump gear or housing. See your authorized dealer. Excessive main bearing clearance. See your authorized dealer.
Troubleshooting Symptom Engine Runs Cold Oil In Coolant Or Coolant In Oil Problem Solution Radiator shroud missing, damaged, or baffles missing. Inspect. Repair or replace. Engine overloaded. Reduce load. Incorrect grade of fuel. Drain fuel tank and add correct fuel. Radiator cap. Replace cap. Faulty gauge or sender. See your authorized dealer. Incorrect injection pump timing. See your authorized dealer. Faulty thermostats (stuck). See your authorized dealer. Thermostats missing.
Troubleshooting Symptom Excessive Fuel Consumption Turbocharger Excessively Noisy Or Vibrates Oil Dripping From Turbocharger Adapter Problem Solution Cracked cylinder liner. See your authorized dealer. Cracked cylinder block. See your authorized dealer. Air system restricted. Check filter restriction indicator and air filters. Replace. (See Maintenance—As Required chapter.) Leakage in fuel system. Inspect and repair. Incorrect grade of fuel. Drain and refill with correct fuel.
Troubleshooting Symptom Excessive Drag In Turbocharger Rotating Members Problem Solution Carbon build-up in turbocharger oil return line where line passes exhaust manifold. Remove line. Inspect and clean. Carbon build-up behind turbine wheel caused by combustion deposits. See your authorized dealer. Dirt build-up behind compressor wheel caused by air intake leaks. See your authorized dealer.
Troubleshooting ELECTRICAL SYSTEM Symptom Problem Solution Nothing Works Power circuit components. See your authorized dealer. Battery undercharged or dead. See your authorized dealer. Battery cables making poor connections. Clean cable connections at battery and starter solenoid. Neutral start fuse. Replace fuse. Battery undercharged or dead. See your authorized dealer. Battery cables making poor connections. Clean connections at battery, starter, and ground to frame. Start relay.
Troubleshooting Symptom Problem Solution Starting Motor Turns, But Engine Will Not Crank Starter pinion not engaging flywheel ring gear. See your authorized dealer. Starter pinion or flywheel gear teeth broken. See your authorized dealer. Starter solenoid stuck. See your authorized dealer. Starter not disengaging. See your authorized dealer. Starter relay stuck. See your authorized dealer. Key switch. See your authorized dealer. Wiring harness shorted. See your authorized dealer.
Troubleshooting Symptom Problem Solution Starter Solenoid Chatters Poor connections at batteries or starter. Clean connections. Low battery charge. Recharge or replace batteries. Starter solenoid "hold-in" windings open. See your authorized dealer. Fuel shut-off solenoid. See your authorized dealer. Key switch. See your authorized dealer. Wiring harness. See your authorized dealer. Empty start aid can. Replace start aid can. Start aid switch. See your authorized dealer.
Troubleshooting Symptom Hour Meter Does Not Work Fuel Gauge Displays One Flashing Arrow Transmission Temperature Gauge Displays Nine (9) Arrows No Display Monitor Functions Individual Light In Monitor Panel Is Inoperative (Not During Bulb Check) Individual Light In Monitor Panel Is Inoperative (During Normal Operation And Bulb Check) Problem Solution Alternator. See your authorized dealer. Display monitor. See your authorized dealer. Key switch. See your authorized dealer. Hour meter.
Troubleshooting Symptom Problem Solution Horn Inoperative Fuse. Replace fuse. Horn. See your authorized dealer. Horn switch. See your authorized dealer. Wiring harness. See your authorized dealer. Fuse. Replace fuse. Reverse alarm. See your authorized dealer. Reverse alarm switch. See your authorized dealer. Wiring harness. See your authorized dealer. Fuse. Replace fuse. Proximity switch. See your authorized dealer. Solenoid. See your authorized dealer. Accessory relay.
Troubleshooting Symptom Problem Solution Defrost Fan Motor Does Not Work In All Speeds Fan motor switch. See your authorized dealer. Fan motor resistor. See your authorized dealer. Wiring harness. See your authorized dealer. Fuse. Replace fuse. Fan motor switch. See your authorized dealer. Fan motor resistor. See your authorized dealer. Wiring harness. See your authorized dealer. Fuse. Replace fuse. Light switch. See your authorized dealer. Cab work light relay.
Troubleshooting Symptom Brake Lights Do Not Operate Differential Lock Does Not Work Secondary Steering Does Not Operate Secondary Steering Indicator Light Does Not Operate Problem Solution Turn signal switch. See your authorized dealer. Wiring harness. See your authorized dealer. Fuse. Replace fuse. Brake light switch. See your authorized dealer. Wiring harness. See your authorized dealer. Key switch. See your authorized dealer. Accessory relay. See your authorized dealer. Fuse.
Troubleshooting Symptom Problem Solution Indicator light bulb. Replace bulb. Secondary steering light relay. See your authorized dealer. Wiring harness. See your authorized dealer.
Troubleshooting HYDRAULIC SYSTEM Symptom Problem Solution Noisy Hydraulic Pump Low oil supply or wrong viscosity. Fill reservoir with proper oil. Suction line clogged or pinched. Clean or replace line. Air in oil. Check for foamy oil. Tighten connections. Replace O-rings and/ or lines. Clogged suction strainer. Inspect and clean strainer in reservoir. Loose or missing hydraulic line clamps. Tighten or replace clamps. Hydraulic lines in contact with frame. Inspect and repair.
Troubleshooting Symptom No Steering Or Hydraulic Functions No Hydraulic Functions, Steering Normal Boom Float Function Does Not Work Boom Down Does Not Work— Engine Off One Hydraulic Function Does Not Work Problem Solution Binding loader control valve spool. See your authorized dealer. Secondary steering check valve leaking. See your authorized dealer. Steering valve leaking. See your authorized dealer. Low oil level. Check oil level. Clogged suction strainer. Clean strainer in reservoir.
Troubleshooting Symptom Problem Solution Circuit relief valve. See your authorized dealer. Oil leaking past cylinder packings. See your authorized dealer. Blockage in oil lines or valve. See your authorized dealer. Loader control valve spool stuck in bore. See your authorized dealer. Leakage within work circuit. See your authorized dealer. Low system relief valve setting. See your authorized dealer. Low circuit relief valve setting. See your authorized dealer.
Troubleshooting Symptom Problem Solution Oil cooler clogged internally. See your authorized dealer. Incorrect system or circuit relief valve setting. See your authorized dealer. Restriction in oil lines or loader valve. See your authorized dealer. Pinched or restricted priority valve "LS" line. See your authorized dealer. Priority valve. See your authorized dealer. Leaking system relief valve. See your authorized dealer. Worn hydraulic pump (internal leakage). See your authorized dealer.
Troubleshooting Symptom No Steering Constant Steering To Maintain Straight Travel Slow Steering Wheel Movement Will Not Cause Any Frame Movement Steering Wheel Can Be Turned With Frames Against Steering Stop Steering Wheel Turns With No Resistance And Causes No Frame Movement Erratic Steering Problem Solution Secondary steering check valve leakage. See your authorized dealer. Stuck priority valve spool. See your authorized dealer. Broken priority valve spring. See your authorized dealer.
Troubleshooting Symptom 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 Low oil level. Add oil. Sticking priority valve spool. See your authorized dealer. Loose cylinder piston. See your authorized dealer. Damaged steering valve. See your authorized dealer. Air in oil. Check for foamy oil. Low oil level. Add oil. Loose steering wheel nut. Tighten.
Troubleshooting Symptom Problem Solution Abrupt Steering Wheel Oscillation Gerotor gear in steering valve not properly timed. See your authorized dealer. Steering Wheel Turns By Itself Lines connected to wrong port. Reconnect lines. Vibration In Steering System Or Hoses Jump High priority valve setting. See your authorized dealer. Low crossover relief valve pressure setting. See your authorized dealer.
Troubleshooting POWER TRAIN Symptom Problem Solution Transmission Slippage Low oil level. Check and add oil. Wrong oil grade. Check oil grade. (See Fuels and Lubricants chapter.) Weak or broken pressure regulating valve spring. See your authorized dealer. Transmission pump suction screen restricted. See your authorized dealer. Low transmission pump flow due to worn pump. See your authorized dealer. Transmission control valve or gasket leakage. See your authorized dealer.
Troubleshooting Symptom Machine Does Not Engage In Low Gear Transmission Will Not Shift Correctly Transmission Pressure Is Low (All Gears) Problem Solution Broken ring or pinion gear. See your authorized dealer. Transmission control solenoid valve. See your authorized dealer. Stuck spool in transmission control valve. See your authorized dealer. Stuck modulation valve. See your authorized dealer. Transmission shifts fast in 4th gear automatic.
Troubleshooting Symptom Problem Solution Transmission System Pressure Is Low (One Or Two Gears) Transmission control valve gasket. Inspect transmission control valve for external leakage. Remove control valve. Inspect and replace gasket, if necessary. Clutch piston or seal ring leakage. See your authorized dealer. Low oil level (aeration of oil). Check and add oil. (See Maintenance—Every 10 Hours or Daily chapter.) Low transmission pressure. See your authorized dealer.
Troubleshooting Symptom Problem Solution Machine "Creeps" In Neutral Warped disks and plates in transmission. See your authorized dealer. Transmission Hydraulic System Overheats High oil level. Check and adjust. Low oil level. Check and correct. (See Fuels and Lubricants Chapter.) Wrong oil grade. Check oil grade. (See Fuels and Lubricants Chapter.) Park brake engaged. Release park brake. Lube lines pinched, restricted, or leaking. Check cooler lines.
Troubleshooting Symptom Foaming Oil Machine Vibrates Machine Lacks Power And Acceleration Problem Solution Parts worn or damaged in transmission. Remove transmission suction screen. Inspect for metal particles. Repair or replace as necessary. Low or no lube. See your authorized dealer. Incorrect type of oil. Change oil. High oil level. Drain some oil. Low oil level. Add oil. Air leak on suction side of pump. Check oil pickup tube on side of transmission. Aerated oil. Check and add oil.
Troubleshooting Symptom Problem Solution Torque Converter Stall RPM Too High Aerated oil. See your authorized dealer. Converter relief valve stuck open. See your authorized dealer. Torque converter seal leakage. See your authorized dealer. Torque converter not transferring power (bent fins, broken stator). See your authorized dealer. Low engine power. See your authorized dealer. Mechanical malfunction. See your authorized dealer. Low oil level. Add oil. Cold oil. Warm oil.
Troubleshooting SERVICE BRAKES Symptom Problem Solution Poor Or No Brakes Brake accumulator charge low. See your authorized dealer. Brake pump standby pressure low. See your authorized dealer. Low brake pressure. See your authorized dealer. Air in system. Bleed brakes. (See Bleeding Brakes in Maintenance chapter.) Worn brake pads. Inspect brake pads. Brake valve leakage. See your authorized dealer. Brake piston seal leakage. Check for an overfilled differential.
Troubleshooting Symptom Problem Solution Brakes Lock Up Air in brake system. Bleed brakes. (See Bleeding Brakes in Maintenance chapter.) Brake valve. See your authorized dealer. Air in brake system. Bleed brakes. (See Bleeding Brakes in Maintenance chapter.) Worn brake pads. Inspect brake pads. (See Inspecting Brake Pads in Maintenance chapter.) Wrong oil in differential. Drain. Refill. (See Fuels and Lubricants chapter.) Loose brake pads. See your authorized dealer.
Troubleshooting DIFFERENTIAL AXLE Symptom Problem Solution No Differential Lock Operation Electrical circuit. See your authorized dealer. Differential lock solenoid valves stuck. See your authorized dealer. Pressure reducing valve malfunction or setting low. See your authorized dealer. Excessive differential lock sealing ring leakage. See your authorized dealer. Seals on differential lock solenoid valve or regulating valve. Remove and inspect seals. Differential lock piston stuck in bore.
Troubleshooting Symptom Problem Solution Electrical circuit. See your authorized dealer. Differential lock solenoid valve stuck. See your authorized dealer. Differential lock piston stuck in bore. See your authorized dealer. Warped differential lock disks and plates. See your authorized dealer. Leak in brake piston seals. See your authorized dealer. Incorrect breather tube. See your authorized dealer. Not operating engine at full load.
Troubleshooting Symptom Axle Overheats Problem Solution Worn outer bearing and/or cup. See your authorized dealer. Differential overfilled with oil. See your authorized dealer. Low or high differential oil. See your authorized dealer. Turbo boost return circuit. Release differential lock pedal and operate engine at full load. Brakes drag. See your authorized dealer.
Troubleshooting PARK BRAKE Symptom Problem Solution Brake Will Not Hold Not adjusted correctly. Adjust park brake. (See Adjust Park Brake in Maintenance—Every 1000 Hours chapter.) Park brake solenoid. See your authorized dealer. Brake disk and/or brake pads worn. See your authorized dealer. Brake piston. See your authorized dealer. Brake pads out of adjustment. Adjust park brake. (See Adjust Park Brake in Maintenance—Every 1000 Hours chapter.) Brake not released. Release park brake.
Troubleshooting AIR CONDITIONING Symptom Problem Solution Air Conditioning System Does Not Operate Accessory relay #2. See your authorized dealer. Fuse. Replace fuse. Fan motor switch. See your authorized dealer. Fan motor resistor. See your authorized dealer. Fan motor. See your authorized dealer. Wiring harness. See your authorized dealer. Temperature control switch. See your authorized dealer. Low pressure switch. See your authorized dealer. High pressure switch.
Storage 1. Repair worn or damaged parts. Install new parts, if necessary, to avoid needless delays later. T47764 2. Loosen alternator and fan belts. –UN–09NOV88 PREPARE MACHINE FOR STORAGE 3. Clean primary air cleaner element. 4. Wash the machine. [Use low pressure wash operations (less than 1379 kpa (13.8 bar) (200 psi)) until 30 days after receipt of machine.] Paint areas to prevent rust. Replace decals, where needed. T5813AM IMPORTANT: High pressure washing [greater than 1379 kpa (13.
Storage IMPORTANT: Prevent possible machine damage from unauthorized persons operating machine. Attach a "DO NOT OPERATE" tag to steering wheel. 10. Place a "DO NOT OPERATE" tag on the steering wheel. 11. Remove keys and lock all covers and doors. T7447AO –19–22APR91 LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation. TX,105,FF1190 –19–03AUG92–3/3 MONTHLY STORAGE PROCEDURE 1. Drain water and sediment from fuel tank when air temperature is above freezing. 2.
3. Check all fluid levels. If low, check for leaks and add oil as required. T6181AU IMPORTANT: Prevent possible engine damage. During cold temperatures, check fluidity of engine oil on dipstick. If the oil appears waxy and/or jelly-like rather than liquid, DO NOT attempt to start engine. Use external heat source to warm the crankcase until oil appears fluid. –UN–18OCT88 Storage 4. Check belts. 5. Check condition of all hoses and connections. 6. Check electrolyte level. Charge and install battery. 7.
Machine Numbers RECORD PRODUCT IDENTIFICATION NUMBER (PIN) Purchase Date T7829BJ –UN–21SEP92 NOTE: Record all 13 characters of the Product Identification Number.
Machine Numbers RECORD TRANSMISSION SERIAL NUMBER Transmission Serial Number Located on right side of transmission case, near lower right corner of case.
Specifications T6603AC –UN–20OCT88 544G SPECIFICATIONS TX,115,DH2265 –19–16JUN93–1/2 115–1 PN=289
Specifications 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.
Specifications 544G 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, 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 (S.N. 553285— ) 89 kW (120 hp) Piston displacement 5.884 L (359 cu in.
Specifications 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
Specifications DRAIN AND REFILL CAPACITIES—544G Metric U.S. Cooling system 23.5 L 25 qt Fuel tank 218 L 58 gal Engine crankcase and filter 19 L 20 qt Transmission case and filter 9.
Specifications 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.
Specifications 544G LL 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, 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 (S.N. 553285— ) 89 kW (120 hp) Piston displacement 5.884 L (359 cu in.
Specifications 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
Specifications DRAIN AND REFILL CAPACITIES—544G LL Metric U.S. Cooling system 23.5 L 25 qt Fuel tank 218 L 58 gal Engine crankcase and filter 19 L 20 qt Transmission case and filter 9.
Specifications 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.
Specifications 544G TC 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, 17.5— 25, 12 PR, L2 tires, two rear counterweights, ROPS cab, full fuel tank, and 79 kg (175 lb) operator. Engine: John Deere 6059T (S.N. 553285— ) 89 kW (120 hp) Piston displacement 5.884 L (359 cu in.
Specifications 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
Specifications DRAIN AND REFILL CAPACITIES—544G TC Metric U.S. Cooling system 23.5 L 25 qt Fuel tank 218 L 58 gal Engine crankcase and filter 19 L 20 qt Transmission case and filter 9.
Specifications 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.
Specifications 624G 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, 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.
Specifications 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
Specifications DRAIN AND REFILL CAPACITIES—624G 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.
Specifications 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.
Specifications 644G 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: John Deere 6081 127 kW (170 hp) Piston displacement 8.1 L (494 cu in.
Specifications 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 transm
Crime Prevention Tips HELP PREVENT CRIME TS140 –19–07OCT88 You can help take a bite out of crime by properly documenting ownership and discouraging theft. DX,CRPRV,A –19–03MAR93–1/1 RECORD IDENTIFICATION NUMBERS TS156 2. Record the Product Identification Number (PIN) of the unit and also individual component identification numbers for engines, axles, pumps, etc. Include the PIN numbers on all documentation, such as insurance, financial, and warranty papers. –UN–23MAR89 1.
Crime Prevention Tips PARK INDOORS OUT OF SIGHT Make machines hard to move: • Park large equipment in front of exits. • Remove battery when unit is in storage. • Lock cab doors, windows, and vandal-proof devices. TS158 –UN–23MAR89 • Lower equipment to the ground. Remove key. • Lock building. DX,CRPRV,J –19–04JUN90–1/1 WHEN PARKING OUTDOORS Make machines hard to move: • Park in a well-lighted, fenced area. –UN–23AUG88 • Lower all equipment to the ground. • Remove ignition key.
Crime Prevention Tips REDUCE VANDALISM 3. Regularly verify that identification plates have not been removed. If they have, notify law enforcement agency. Order duplicate plates from your dealer. T7223BB 2. Participate in a neighborhood watch program. Take written notes of suspicious vehicles or persons and report your findings to law enforcement agency. –UN–22FEB90 1. Install vandal-proof devices. TX,120,DH1093 –19–16SEP92–1/1 REPORT THEFTS IMMEDIATELY 1.
Index Page A Accessory Operational checkout . . . . . . . . . . . . . . . . . . 95-25 Accumulator Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-24 Acid burns . . . . . . . . . . . . . . . . . . 80-2, 90-12, 90-14 Adjustment Belt tension. . . . . . . . . . . . . . . . . . . . .55-10, 55-11 Boom height control . . . . . . . . . . . . . . . . . . . . 35-7 Clutch cut-off. . . . . . . . . . . . . . . . . . . . . . . . . 90-28 Compressor belt tension . . . . . . . . . . . . . . . .
Index Page Page Cooling Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1 System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29 Operational checkout . . . . . . . . . . . . . . . . . . . 95-4 Serial number . . . . . . . . . . . . . . . . . . . . . . . . 110-1 Speed control linkage adjust . . . . . . . . . . . . . . 85-2 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index Page Page Transmission oil temperature . . . . . . . . .10-1, 10-5 Grease Boom and cylinder pivots-544G . . . . . . . . . . . 70-2 Boom and cylinder pivots . . . . . . . . . . . . . . . . 70-1 Extreme pressure and multipurpose . . . . . . . . 45-6 Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 85-10 Front driveline support bearing . . . . . . . . . . . . 86-5 Front driveline . . . . . . . . . . . . . . . . . . . . . . . . . 80-1 Oscillating rear axle . . . . . . . . . . . . . . . . . .
Index Page Page Front driveline . . . . . . . . . . . . . . . . . . . . . . . . . 80-1 Oscillating rear axle . . . . . . . . . . . . . . . . . . . . 70-5 Rear driveline . . . . . . . . . . . . . . . . . . . . . . . . . 85-1 Steering cylinder pivots . . . . . . . . . . . . . . . . . . 70-4 Operational checkout Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-25 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-4 Brake . . . . . . . . . . . . . . . . . . . . . . . .
Index Page Page Receiver dryer Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1 Recovery tank Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9 Return-to-dig Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-8 Reverse Warning alarm . . . . . . . . . . . . . . . . . . . . . . . 90-18 Ride control Accumulator . . . . . . . . . . . . . . . . . . . . . . . . .
Index Page Hydraulic system. . . . . . . . . . . . . . . . . . . . . 100-22 Park brake . . . . . . . . . . . . . . . . . . . . . . . . . 100-40 Power train . . . . . . . . . . . . . . . . . . . . . . . . . 100-29 Service brake . . . . . . . . . . . . . . . . . . . . . . . 100-35 Truck loading . . . . . . . . . . . . . . . . . . . . . . . . . . 35-13 U Unloader valve Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1 V Valve Air cleaner dust unloader Control . . . . . . . . . . . . .
Checklists MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM SERVICE INTERVALS Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.
Checklists MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM Model: ❒ 544G ❒ 544G LL PIN/Serial Number: ❒ 544G TC ❒ 624G Delivery Date: ❒ 644G Customer: Hour Meter Reading: Oil Sampling Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form. Maintenance recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply.
John Deere Service Literature Available PARTS CATALOG TS189 -UN-17JAN89 The parts catalog lists service parts available for your machine with exploded view illustrations to help you identify the correct parts. It is also useful in assembling and disassembling. DX,PARTS -19-03MAR93 DX,INDOM -19-17SEP92 OPERATOR’S MANUAL -UN-02DEC88 The operator’s manual provides safety, operating, maintenance, and service information about John Deere machines.
John Deere Service Literature Available Name John Deere Distribution Service Center Service Publications Department P.O. Box 186, Moline, IL. 61266-0186 Address To order, fill out this form and mail it to the address above. Check forCity prices with your John Deere dealer or call 1-800-522-7448. You may State also place credit card orders by calling this number. Make checks payable to Deere & Co. Service Publications. Allow three weeks for delivery. No COD orders. Do not send cash or stamps.
John Deere Service Keeps You On The Job TS1643 -UN-12SEP95 JOHN DEERE IS AT YOUR SERVICE WHEN YOU NEED IT Division 1—Calgary John Deere Industrial Equipment Co. 6715 8th Street NE, Suite 218 Calgary, AB T2E 7H7 Canada 403-531-5731; fax: 403-531-5739 Division 2—Denver John Deere Industrial Equipment Co. 6101 Stapleton North Drive, Suite A Denver, CO 80216 303-336-1204; fax: 303-336-1208 Division 3—Dallas John Deere Industrial Equipment Co. P.O.
