Specifications

Contents
Page Page
Maintenance—Every 500 Hours Cleaning Fuel Tank Outlet Screen . . . . . . . . . . . 90-5
Bleeding Fuel System—544G, 624G . . . . . . . . . 90-7Lubricant Front Driveline. . . . . . . . . . . . . . . . . . . 80-1
Check Air Intake Hoses . . . . . . . . . . . . . . . . . . . 80-1 Bleeding Fuel System—644G. . . . . . . . . . . . . . . 90-8
Adjusting Fuel Shut-Off Solenoid—644G . . . . . . 90-8Check Battery Electrolyte Level and
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-2 Precautions for Alternator and Regulator . . . . . . 90-9
Service Batteries Carefully . . . . . . . . . . . . . . . . 90-10Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
Replace Primary Fuel Filter (Water Checking Electrolyte Specific Gravity . . . . . . . . 90-12
Using Battery Charger . . . . . . . . . . . . . . . . . . . 90-14Separator) . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6
Replace Final Fuel Filter—544G, 624G . . . . . . . 80-7 Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 90-14
Removing Batteries . . . . . . . . . . . . . . . . . . . . . 90-15Replace Final Fuel Filter—644G. . . . . . . . . . . . . 80-7
Replace Hydraulic System Return Filter . . . . . . . 80-7 Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . 90-15
Fuse (Blade-Type) Color Codes . . . . . . . . . . . . 90-15Replace Hydraulic Reservoir Breather Filter . . . . 80-8
Check Front and Rear Differential Oil Resetting Circuit Breakers . . . . . . . . . . . . . . . . 90-16
Replacing Halogen Bulbs . . . . . . . . . . . . . . . . . 90-16Level—If Equipped with Standard Axle . . . . . 80-9
Check Front and Rear Differential Oil Changing Reverse Warning Alarm Volume. . . . 90-18
Checking Neutral Start System. . . . . . . . . . . . . 90-18Level—If Equipped with Differential Lock
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10 Adding Attachments/Accessories to Roll-
Over Protective Structure (ROPS) . . . . . . . . 90-19
Servicing Air Conditioning System . . . . . . . . . . 90-19
Maintenance—Every 1000 Hours
Checking and Adjusting Compressor Belt
Lubricate Rear Driveline. . . . . . . . . . . . . . . . . . . 85-1
Tension—If Equipped . . . . . . . . . . . . . . . . . . 90-20
Check Engine Speeds . . . . . . . . . . . . . . . . . . . . 85-1
Welding on Machine. . . . . . . . . . . . . . . . . . . . . 90-20
Adjust Engine Speed Control Linkage . . . . . . . . 85-2
Inspecting Park Brake Pads . . . . . . . . . . . . . . . 90-21
Replace Air Cleaner Dust Unloader Valve . . . . . 85-3
External Service Brake Inspection . . . . . . . . . . 90-22
Replace Air Cleaner Elements . . . . . . . . . . . . . . 85-3
Checking Brake Accumulator . . . . . . . . . . . . . . 90-24
Clean Engine Crankcase Vent Tube (A). . . . . . . 85-4
Checking Ride Control Accumulator—If
Change Transmission Oil and Replace
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-5
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Check Park Brake . . . . . . . . . . . . . . . . . . . . . . . 85-7
Checking Secondary Steering System—If
Adjust Park Brake. . . . . . . . . . . . . . . . . . . . . . . . 85-8
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Lubricate Frame Hinge Pivots . . . . . . . . . . . . . 85-10
Clutch Cut-Off Adjustment . . . . . . . . . . . . . . . . 90-28
Do Not Service Control Valves, Cylinders,
Maintenance—Every 2000 Hours
Pumps or Motors . . . . . . . . . . . . . . . . . . . . . 90-29
Measure and Adjust Engine Valve Lash
Hardware Torque Specifications . . . . . . . . . . . . 90-30
(Clearance)—544G, LL, TC, 624G . . . . . . . . 86-1
Keep ROPS Installed Properly . . . . . . . . . . . . . 90-30
Adjust Engine Valve Lash (Clearance)—
Metric Bolt and Cap Screw Torque Values . . . . 90-31
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-3
Additional Metric Cap Screw Torque Values. . . 90-33
Lubricate Front Driveline Support Bearing . . . . . 86-5
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Maintenance—Every 3000 Hours
Check Oil Lines and Fittings. . . . . . . . . . . . . . . 90-36
Change Hydraulic System Oil . . . . . . . . . . . . . . . 87-1
Service Recommendations for O-Ring Boss
Clean Hydraulic Suction Strainer . . . . . . . . . . . . 87-2
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
Replace Differential Lock Return Filter(s)—
Service Recommendations for Flat Face O-
If Equipped. . . . . . . . . . . . . . . . . . . . . . . . . . . 87-2
Ring Seal Fittings . . . . . . . . . . . . . . . . . . . . . 90-39
Change Front and Rear Differential Oil. . . . . . . . 87-3
Service Recommendations for Metric Series
Four Bolt Flange Fitting . . . . . . . . . . . . . . . . 90-40
Maintenance
Service Recommendations for Inch Series
Draining the Cooling System . . . . . . . . . . . . . . . 90-1
Four Bolt Flange Fittings . . . . . . . . . . . . . . . 90-41
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . 90-3
Coolant drain intervals . . . . . . . . . . . . . . . . . . . . 90-3
Operational CheckoutFilling the Cooling System . . . . . . . . . . . . . . . . . 90-4
Test the Coolant Freeze—Protection Level . . . . 90-4 Operational Checkout . . . . . . . . . . . . . . . . . . . . . 95-1
Do Not Service Injection Nozzles . . . . . . . . . . . . 90-5
Do Not Adjust Injection Pump. . . . . . . . . . . . . . . 90-5 Continued on next page
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