John Deere 544G 544G LL & 544G TC Loaders 624G Loader 644G Loader Official Operator's
John Deere 544G 544G LL & 544G TC Loaders 624G Loader 644G Loader Official Operator's
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Models And Serials :
Serial No. 557739-
CONTENTS :
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Engine Coolant Temperature Gauge . . . . . . . . . 10-5
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Transmission Oil Temperature Gauge . . . . . . . . 10-5
Engine Oil Pressure Indicator . . . . . . . . . . . . . . . 10-6
Alternator Voltage Indicator . . . . . . . . . . . . . . . . 10-6
Engine Air Filter Restriction Indicator . . . . . . . . . 10-6
Engine Coolant Level Indicator . . . . . . . . . . . . . . 10-7
Transmission Oil Pressure Indicator—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Hydraulic Oil Filter Restriction Indicator . . . . . . . 10-7
Right Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-8
Brake Oil Pressure Indicator. . . . . . . . . . . . . . . . 10-8
Park Brake Indicator. . . . . . . . . . . . . . . . . . . . . . 10-8
Fasten Seat Belt Indicator . . . . . . . . . . . . . . . . . 10-9
Ether Injection Indicator . . . . . . . . . . . . . . . . . . . 10-9
Steering Pressure Indicator—If Equipped . . . . . . 10-9
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-10
Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Front Axle Disconnect Lever—If Equipped . . . . 10-11
Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . 10-12
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . 10-14
Dome Light and Swivel Light—If Equipped . . . . 10-14
Vandal Shield—If Equipped . . . . . . . . . . . . . . . 10-14
Operating Windshield Wipers and
Washers—If Equipped . . . . . . . . . . . . . . . . . 10-15
Adjusting Steering Wheel Tilt . . . . . . . . . . . . . . 10-15
Opening Side Window . . . . . . . . . . . . . . . . . . . 10-15
Opening Sliding Side Window—If Equipped . . . 10-16
Cab Door Release . . . . . . . . . . . . . . . . . . . . . . 10-16
Operating Lights . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Adjusting Suspension Seat. . . . . . . . . . . . . . . . 10-19
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Storage Compartment . . . . . . . . . . . . . . . . . . . 10-20
Heating and Air Conditioning Controls . . . . . . . 10-18
Break-in
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . 15-1
Every 10 Hours or Daily . . . . . . . . . . . . . . . . . . . 15-1
After First 10 and First 50 Hours . . . . . . . . . . . . 15-2
After the First 100 Hours . . . . . . . . . . . . . . . . . . 15-2
Pre-Start Inspection
Inspect Machine Daily Before Starting . . . . . . . . 20-1
Operating the Engine
Check Instruments Before Starting . . . . . . . . . . . 25-1
Brake Pressure Indicator . . . . . . . . . . . . . . . . . . 25-1
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . 25-1
Starting Fluid—If Equipped (Cold Weather
Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Using Coolant Heater—If Equipped . . . . . . . . . . 25-5
Using Booster Batteries—12 Volt System. . . . . . 25-6
Check Instruments After Starting . . . . . . . . . . . . 25-7
Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-7
Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . . 25-8
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . 25-8
Driving the Machine
Driving on Public Roads . . . . . . . . . . . . . . . . . . . 30-1
General Driving Precautions . . . . . . . . . . . . . . . . 30-2
Front Axle Disconnect—If Equipped . . . . . . . . . . 30-2
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Shifting the Transmission . . . . . . . . . . . . . . . . . . 30-3
Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Ride Control Switch—If Equipped. . . . . . . . . . . . 30-6
Stopping the Machine. . . . . . . . . . . . . . . . . . . . . 30-6
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 30-7
Parking the Machine. . . . . . . . . . . . . . . . . . . . . . 30-7
Operating the Machine
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 . . . . . . . . . . 35-5
Secondary Steering—If Equipped. . . . . . . . . . . . 35-6
Differential Lock Pedal—If Equipped . . . . . . . . . 35-6
Adjusting Boom Height Kickout—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7
Adjusting Return-to-Dig . . . . . . . . . . . . . . . . . . . 35-8
General Operating Tips . . . . . . . . . . . . . . . . . . . 35-9
Excavating Banks or Stockpiles . . . . . . . . . . . . . 35-9
Using the Loader Bucket . . . . . . . . . . . . . . . . . 35-10
Backdragging . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12
Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12
Truck Loading . . . . . . . . . . . . . . . . . . . . . . . . . 35-13
Transporting
Transporting Precautions . . . . . . . . . . . . . . . . . . 40-1
Loading Machine on a Trailer . . . . . . . . . . . . . . . 40-1
Towing Procedure—Engine Operational . . . . . . . 40-3
Towing Procedure—Engine Non-
Operational. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . 40-7
Fuels and Lubricants
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . . 45-2
Handling and Storing Diesel Fuel . . . . . . . . . . . . 45-2
Do Not Use Galvanized Containers . . . . . . . . . . 45-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-3
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Transmission Oil, Hydraulic System Oil and
Differential Oil. . . . . . . . . . . . . . . . . . . . . . . . . 45-5
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-6
Alternative and Synthetic Lubricants . . . . . . . . . . 45-6
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 45-7
Periodic Maintenance
Service Your Machine at Specified Intervals. . . . 50-1
Check the Hour Meter Regularly . . . . . . . . . . . . 50-1
Use Correct Fuels and Lubricants . . . . . . . . . . . 50-1
Prepare Machine for Maintenance . . . . . . . . . . . 50-2
Locking Machine Frame . . . . . . . . . . . . . . . . . . . 50-3
Boom Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Opening Engine Side Shields and Service
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Opening Grille Door . . . . . . . . . . . . . . . . . . . . . . 50-5
Check Windshield Washer Fluid Level . . . . . . . . 50-5
Maintenance and Repair Record Keeping
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
OILSCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Maintenance Record Keeping. . . . . . . . . . . . . . . 50-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
Maintenance—As Required
Check Tire Pressure. . . . . . . . . . . . . . . . . . . . . . 55-1
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5
Tighten Wheel Retainer Cap Screws . . . . . . . . . 55-5
Clean or Replace Air Cleaner Elements . . . . . . . 55-6
Clean Dusty Primary Element. . . . . . . . . . . . . . . 55-7
Clean Oily or Sooty Primary Element . . . . . . . . . 55-7
Inspect Element . . . . . . . . . . . . . . . . . . . . . . . . . 55-8
Check Air Inlet Cover . . . . . . . . . . . . . . . . . . . . . 55-9
Check and Adjust Belt Tension—544G,
624G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10
Inspect Serpentine Belt—644G. . . . . . . . . . . . . 55-11
Drain Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 55-11
Drain and Clean Primary Fuel Filter (Water
Separator)—544G, 624G . . . . . . . . . . . . . . 55-12
Drain and Clean Primary Fuel Filter (Water
Separator)—644G . . . . . . . . . . . . . . . . . . . . 55-13
Check Cab Recirculating Air Filter . . . . . . . . . . 55-14
Maintenance—Every 10 Hours or Daily
Lubricate Pivots . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Clean Air Cleaner Dust Unloader Valve . . . . . . . 60-1
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . 60-1
Check Recovery Tank Coolant Level . . . . . . . . . 60-3
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . 60-3
Check Transmission Oil Level . . . . . . . . . . . . . . 60-5
Maintenance—Every 100 Hours
Lubricant Boom, Bucket, and Cylinder
Pivots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Lubricate Boom, Bucket, and Cylinder
Pivots—544G TC . . . . . . . . . . . . . . . . . . . . . . 70-2
Lubricate Oscillating Rear Axle. . . . . . . . . . . . . . 70-5
Check Cab Fresh Air Filter—If Equipped . . . . . . 70-5
Lubricate Steering Cylinder Pivots . . . . . . . . . . . 70-4
Maintenance—Every 250 Hours
Check Receiver Dryer Moisture Indicator . . . . . . 75-1
Change Engine Oil and Replace Filter . . . . . . . . 75-2
Check Radiator Coolant Level . . . . . . . . . . . . . . 75-5
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 . . . . . . . 80-7
Replace Final Fuel Filter—644G. . . . . . . . . . . . . 80-7
Replace Hydraulic System Return Filter . . . . . . . 80-7
Replace Hydraulic Reservoir Breather Filter . . . . 80-8
Check Front and Rear Differential Oil
Level—If Equipped with Standard Axle . . . . . 80-9
Check Front and Rear Differential Oil
Level—If Equipped with Differential Lock
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10
Maintenance—Every 1000 Hours
Lubricate Rear Driveline . . . . . . . . . . . . . . . . . . . 85-1
Check Engine Speeds . . . . . . . . . . . . . . . . . . . . 85-1
Adjust Engine Speed Control Linkage . . . . . . . . 85-2
Replace Air Cleaner Dust Unloader Valve . . . . . 85-3
Replace Air Cleaner Elements . . . . . . . . . . . . . . 85-3
Clean Engine Crankcase Vent Tube (A). . . . . . . 85-4
Change Transmission Oil and Replace
Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-5
Check Park Brake . . . . . . . . . . . . . . . . . . . . . . . 85-7
Adjust Park Brake. . . . . . . . . . . . . . . . . . . . . . . . 85-8
Lubricate Frame Hinge Pivots . . . . . . . . . . . . . 85-10
Maintenance—Every 2000 Hours
Measure and Adjust Engine Valve Lash
(Clearance)—544G, LL, TC, 624G . . . . . . . . 86-1
Adjust Engine Valve Lash (Clearance)—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-3
Lubricate Front Driveline Support Bearing . . . . . 86-5
Maintenance—Every 3000 Hours
Change Hydraulic System Oil . . . . . . . . . . . . . . . 87-1
Clean Hydraulic Suction Strainer . . . . . . . . . . . . 87-2
Replace Differential Lock Return Filter(s)—
If Equipped. . . . . . . . . . . . . . . . . . . . . . . . . . . 87-2
Change Front and Rear Differential Oil. . . . . . . . 87-3
Maintenance
Draining the Cooling System . . . . . . . . . . . . . . . 90-1
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . 90-3
Coolant drain intervals . . . . . . . . . . . . . . . . . . . . 90-3
Filling the Cooling System . . . . . . . . . . . . . . . . . 90-4
Test the Coolant Freeze—Protection Level . . . . 90-4
Do Not Service Injection Nozzles . . . . . . . . . . . . 90-5
Do Not Adjust Injection Pump. . . . . . . . . . . . . . . 90-5
Cleaning Fuel Tank Outlet Screen . . . . . . . . . . . 90-5
Bleeding Fuel System—544G, 624G . . . . . . . . . 90-7
Bleeding Fuel System—644G. . . . . . . . . . . . . . . 90-8
Adjusting Fuel Shut-Off Solenoid—644G . . . . . . 90-8
Precautions for Alternator and Regulator . . . . . . 90-9
Service Batteries Carefully . . . . . . . . . . . . . . . . 90-10
Checking Electrolyte Specific Gravity . . . . . . . . 90-12
Using Battery Charger . . . . . . . . . . . . . . . . . . . 90-14
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 90-14
Removing Batteries . . . . . . . . . . . . . . . . . . . . . 90-15
Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . 90-15
Fuse (Blade-Type) Color Codes . . . . . . . . . . . . 90-15
Resetting Circuit Breakers . . . . . . . . . . . . . . . . 90-16
Replacing Halogen Bulbs . . . . . . . . . . . . . . . . . 90-16
Changing Reverse Warning Alarm Volume. . . . 90-18
Checking Neutral Start System. . . . . . . . . . . . . 90-18
Adding Attachments/Accessories to RollOver
Protective Structure (ROPS) . . . . . . . . 90-19
Servicing Air Conditioning System . . . . . . . . . . 90-19
Checking and Adjusting Compressor Belt
Tension—If Equipped . . . . . . . . . . . . . . . . . . 90-20
Welding on Machine. . . . . . . . . . . . . . . . . . . . . 90-20
Inspecting Park Brake Pads . . . . . . . . . . . . . . . 90-21
External Service Brake Inspection . . . . . . . . . . 90-22
Checking Brake Accumulator . . . . . . . . . . . . . . 90-24
Checking Ride Control Accumulator—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Checking Secondary Steering System—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Clutch Cut-Off Adjustment . . . . . . . . . . . . . . . . 90-28
Do Not Service Control Valves, Cylinders,
Pumps or Motors . . . . . . . . . . . . . . . . . . . . . 90-29
Hardware Torque Specifications . . . . . . . . . . . . 90-30
Keep ROPS Installed Properly . . . . . . . . . . . . . 90-30
Metric Bolt and Cap Screw Torque Values . . . . 90-31
Additional Metric Cap Screw Torque Values. . . 90-33
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Check Oil Lines and Fittings. . . . . . . . . . . . . . . 90-36
Service Recommendations for O-Ring Boss
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
Service Recommendations for Flat Face O
Ring
Seal Fittings . . . . . . . . . . . . . . . . . . . . . 90-39
Service Recommendations for Metric Series
Four Bolt Flange Fitting . . . . . . . . . . . . . . . . 90-40
Service Recommendations for Inch Series
Four Bolt Flange Fittings . . . . . . . . . . . . . . . 90-41
Operational Checkout
Operational Checkout . . . . . . . . . . . . . . . . . . . . . 95-1
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 . . . . . . . . . . . . . . . . . . . . . . 95-4
Transmission Controls, Axle and Engine
Linkages, Neutral Start Switch, and
Reverse Warning Alarm Switch Checks . . . . . 95-4
Neutral Start And Reverse Warning Alarm
Circuit checks. . . . . . . . . . . . . . . . . . . . . . . . . 95-4
Engine Speed Control Linkage Check—
544G, 624G . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5
Engine Speed Control Linkage Check—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5
Engine Speed Control Linkage Check—
644G (Continued). . . . . . . . . . . . . . . . . . . . . . 95-5
Fuel Shut-off Solenoid Linkage Check—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-6
Front Axle Disconnect Check—If Equipped . . . . 95-6
Monitor Indicator and Gauge Checks
(Engine Running) . . . . . . . . . . . . . . . . . . . . . . 95-7
Monitor Display And Alternator Output
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-7
Monitor Indicator Circuit Bypass And Seat
Belt Indicator Check . . . . . . . . . . . . . . . . . . . . 95-9
Monitor Primary And Secondary Level
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-9
Transmission Temperature Gauge Check. . . . . 95-10
Brake System, Clutch Cut-Off, and
Differential Lock Checks. . . . . . . . . . . . . . . . 95-10
Park Brake Transmission Lockout Check . . . . . 95-10
Service Brake Pump Flow Check . . . . . . . . . . . 95-11
Service Brake Check . . . . . . . . . . . . . . . . . . . . 95-12
Brake Accumulator Precharge Check . . . . . . . . 95-12
Brake System Leakage Check . . . . . . . . . . . . . 95-13
Service Brake Pedal Check . . . . . . . . . . . . . . . 95-13
Service And Park Brake System Drag
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-13
Differential Lock Check. . . . . . . . . . . . . . . . . . . 95-14
Clutch Cut-Off Check . . . . . . . . . . . . . . . . . . . . 95-14
Driving Checks . . . . . . . . . . . . . . . . . . . . . . . . . 95-15
Transmission Noise Check . . . . . . . . . . . . . . . . 95-15
Automatic Shift and Speedometer Check . . . . . 95-16
Transmission Quickshift Check. . . . . . . . . . . . . 95-17
Transmission Pressure, Pump Flow, and
Leakage Check . . . . . . . . . . . . . . . . . . . . . . 95-17
Transmission Shift Modulation Check. . . . . . . . 95-18
Hydraulic System Checks. . . . . . . . . . . . . . . . . 95-18
Hydraulic System Warm-Up Procedure . . . . . . 95-18
Boom Down Solenoid Valve Check . . . . . . . . . 95-18
Control Valve Lift Check . . . . . . . . . . . . . . . . . . 95-19
Bucket Rollback Circuit Relief Valve Check . . . 95-19
Bucket Dump Circuit Relief Valve Pressure
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-19
Boom and Bucket Cylinder Drift . . . . . . . . . . . . 95-19
Boom Down Check Valve Leakage Check . . . . 95-20
Pilot Controller Check. . . . . . . . . . . . . . . . . . . . 95-20
Return-To-Dig Check . . . . . . . . . . . . . . . . . . . . 95-20
Boom Height Kickout Check—If Equipped . . . . 95-21
Pin Disconnect Cylinder Check (544G-TC
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Ride Control Accumulator Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Steering System Checks . . . . . . . . . . . . . . . . . 95-22
Steering Valve Check. . . . . . . . . . . . . . . . . . . . 95-22
Steering System Leakage Check . . . . . . . . . . . 95-22
Priority Valve Low Pressure Check. . . . . . . . . . 95-23
Priority Valve High Pressure Check . . . . . . . . . 95-23
Secondary Steering System Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-24
Secondary Steering System Primary Check
Valve Check. . . . . . . . . . . . . . . . . . . . . . . . . 95-24
Accessory Checks . . . . . . . . . . . . . . . . . . . . . . 95-25
Operating Lights Check . . . . . . . . . . . . . . . . . . 95-25
Work Light Check . . . . . . . . . . . . . . . . . . . . . . . 95-25
Brake Light Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Horn Circuit Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Windshield Washer and Wiper Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-27
Defroster Blower Check . . . . . . . . . . . . . . . . . . 95-27
Heater/Air Conditioner Blower Check . . . . . . . . 95-28
Heater Functional Check . . . . . . . . . . . . . . . . . 95-28
Air Conditioner Functional Check . . . . . . . . . . . 95-28
Start Aid System Check . . . . . . . . . . . . . . . . . . 95-29
Cab Component and Vandal Protection
Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Cab Door and Window Hold-Open Latch
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Cab Door Release Button. . . . . . . . . . . . . . . . . 95-30
Cab Door Lock Check . . . . . . . . . . . . . . . . . . . 95-30
Dome Light Check . . . . . . . . . . . . . . . . . . . . . . 95-30
Cab Window Latch Check . . . . . . . . . . . . . . . . 95-31
Cab Door Window Check . . . . . . . . . . . . . . . . . 95-31
Steering Column Adjustment Check . . . . . . . . . 95-31
Seat And Seat Belt Check . . . . . . . . . . . . . . . . 95-32
Toolbox Door Check. . . . . . . . . . . . . . . . . . . . . 95-32
Air Intake Filter Door Check . . . . . . . . . . . . . . . 95-33
Load Center Door Check . . . . . . . . . . . . . . . . . 95-33
Engine Side Panels Check . . . . . . . . . . . . . . . . 95-33
Radiator Cap Access Door Check . . . . . . . . . . 95-34
Frame Locking Bar Check . . . . . . . . . . . . . . . . 95-34
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 100-29
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . 100-35
Differential Axle . . . . . . . . . . . . . . . . . . . . . . . 100-37
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-39
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-40
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . 100-41
Storage
Prepare Machine for Storage . . . . . . . . . . . . . . 105-1
Monthly Storage Procedure . . . . . . . . . . . . . . . 105-2
Machine Numbers
Record Product Identification Number (PIN) . . . 110-1
Record Engine Serial Number—544G . . . . . . . 110-1
Record Engine Serial Number—624G . . . . . . . 110-1
Record Engine Serial Number—644G . . . . . . . 110-1
Record Transmission Serial Number . . . . . . . . 110-2
Record Hydraulic Pump Serial Number . . . . . . 110-2
Specifications
544G Specifications . . . . . . . . . . . . . . . . . . . . . 115-1
544G Specifications . . . . . . . . . . . . . . . . . . . . . 115-3
Drain and Refill Capacities—544G . . . . . . . . . . 115-5
544G LL Specifications. . . . . . . . . . . . . . . . . . . 115-5
544G LL Specifications. . . . . . . . . . . . . . . . . . . 115-7
Drain and Refill Capacities—544G LL . . . . . . . 115-9
544G TC Specifications . . . . . . . . . . . . . . . . . . 115-9
544G TC Specifications . . . . . . . . . . . . . . . . . 115-11
Drain and Refill Capacities—544G TC . . . . . . 115-13
624G Specifications . . . . . . . . . . . . . . . . . . . . 115-13
624G Specifications . . . . . . . . . . . . . . . . . . . . 115-15
Drain and Refill Capacities—624G . . . . . . . . . 115-17
644G Specifications . . . . . . . . . . . . . . . . . . . . 115-17
644G Specifications . . . . . . . . . . . . . . . . . . . . 115-19
Drain and Refill Capacities—644G . . . . . . . . . 115-20
Crime Prevention Tips . . . . . . . . . . . . . . . . . . 120-1
Index
John Deere 544G 544G LL & 544G TC Loaders 624G Loader 644G Loader Official Operator's
John Deere 544G 544G LL & 544G TC Loaders 624G Loader 644G Loader Official Operator's
The Best PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization !
Models And Serials :
Serial No. 557739-
CONTENTS :
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Engine Coolant Temperature Gauge . . . . . . . . . 10-5
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Transmission Oil Temperature Gauge . . . . . . . . 10-5
Engine Oil Pressure Indicator . . . . . . . . . . . . . . . 10-6
Alternator Voltage Indicator . . . . . . . . . . . . . . . . 10-6
Engine Air Filter Restriction Indicator . . . . . . . . . 10-6
Engine Coolant Level Indicator . . . . . . . . . . . . . . 10-7
Transmission Oil Pressure Indicator—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Hydraulic Oil Filter Restriction Indicator . . . . . . . 10-7
Right Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-8
Brake Oil Pressure Indicator. . . . . . . . . . . . . . . . 10-8
Park Brake Indicator. . . . . . . . . . . . . . . . . . . . . . 10-8
Fasten Seat Belt Indicator . . . . . . . . . . . . . . . . . 10-9
Ether Injection Indicator . . . . . . . . . . . . . . . . . . . 10-9
Steering Pressure Indicator—If Equipped . . . . . . 10-9
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-10
Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Front Axle Disconnect Lever—If Equipped . . . . 10-11
Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . 10-12
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . 10-14
Dome Light and Swivel Light—If Equipped . . . . 10-14
Vandal Shield—If Equipped . . . . . . . . . . . . . . . 10-14
Operating Windshield Wipers and
Washers—If Equipped . . . . . . . . . . . . . . . . . 10-15
Adjusting Steering Wheel Tilt . . . . . . . . . . . . . . 10-15
Opening Side Window . . . . . . . . . . . . . . . . . . . 10-15
Opening Sliding Side Window—If Equipped . . . 10-16
Cab Door Release . . . . . . . . . . . . . . . . . . . . . . 10-16
Operating Lights . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Adjusting Suspension Seat. . . . . . . . . . . . . . . . 10-19
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Storage Compartment . . . . . . . . . . . . . . . . . . . 10-20
Heating and Air Conditioning Controls . . . . . . . 10-18
Break-in
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . 15-1
Every 10 Hours or Daily . . . . . . . . . . . . . . . . . . . 15-1
After First 10 and First 50 Hours . . . . . . . . . . . . 15-2
After the First 100 Hours . . . . . . . . . . . . . . . . . . 15-2
Pre-Start Inspection
Inspect Machine Daily Before Starting . . . . . . . . 20-1
Operating the Engine
Check Instruments Before Starting . . . . . . . . . . . 25-1
Brake Pressure Indicator . . . . . . . . . . . . . . . . . . 25-1
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . 25-1
Starting Fluid—If Equipped (Cold Weather
Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Using Coolant Heater—If Equipped . . . . . . . . . . 25-5
Using Booster Batteries—12 Volt System. . . . . . 25-6
Check Instruments After Starting . . . . . . . . . . . . 25-7
Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-7
Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . . 25-8
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . 25-8
Driving the Machine
Driving on Public Roads . . . . . . . . . . . . . . . . . . . 30-1
General Driving Precautions . . . . . . . . . . . . . . . . 30-2
Front Axle Disconnect—If Equipped . . . . . . . . . . 30-2
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Shifting the Transmission . . . . . . . . . . . . . . . . . . 30-3
Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Ride Control Switch—If Equipped. . . . . . . . . . . . 30-6
Stopping the Machine. . . . . . . . . . . . . . . . . . . . . 30-6
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 30-7
Parking the Machine. . . . . . . . . . . . . . . . . . . . . . 30-7
Operating the Machine
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 . . . . . . . . . . 35-5
Secondary Steering—If Equipped. . . . . . . . . . . . 35-6
Differential Lock Pedal—If Equipped . . . . . . . . . 35-6
Adjusting Boom Height Kickout—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7
Adjusting Return-to-Dig . . . . . . . . . . . . . . . . . . . 35-8
General Operating Tips . . . . . . . . . . . . . . . . . . . 35-9
Excavating Banks or Stockpiles . . . . . . . . . . . . . 35-9
Using the Loader Bucket . . . . . . . . . . . . . . . . . 35-10
Backdragging . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12
Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12
Truck Loading . . . . . . . . . . . . . . . . . . . . . . . . . 35-13
Transporting
Transporting Precautions . . . . . . . . . . . . . . . . . . 40-1
Loading Machine on a Trailer . . . . . . . . . . . . . . . 40-1
Towing Procedure—Engine Operational . . . . . . . 40-3
Towing Procedure—Engine Non-
Operational. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . 40-7
Fuels and Lubricants
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . . 45-2
Handling and Storing Diesel Fuel . . . . . . . . . . . . 45-2
Do Not Use Galvanized Containers . . . . . . . . . . 45-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-3
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Transmission Oil, Hydraulic System Oil and
Differential Oil. . . . . . . . . . . . . . . . . . . . . . . . . 45-5
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-6
Alternative and Synthetic Lubricants . . . . . . . . . . 45-6
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 45-7
Periodic Maintenance
Service Your Machine at Specified Intervals. . . . 50-1
Check the Hour Meter Regularly . . . . . . . . . . . . 50-1
Use Correct Fuels and Lubricants . . . . . . . . . . . 50-1
Prepare Machine for Maintenance . . . . . . . . . . . 50-2
Locking Machine Frame . . . . . . . . . . . . . . . . . . . 50-3
Boom Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Opening Engine Side Shields and Service
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Opening Grille Door . . . . . . . . . . . . . . . . . . . . . . 50-5
Check Windshield Washer Fluid Level . . . . . . . . 50-5
Maintenance and Repair Record Keeping
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
OILSCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Maintenance Record Keeping. . . . . . . . . . . . . . . 50-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
Maintenance—As Required
Check Tire Pressure. . . . . . . . . . . . . . . . . . . . . . 55-1
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5
Tighten Wheel Retainer Cap Screws . . . . . . . . . 55-5
Clean or Replace Air Cleaner Elements . . . . . . . 55-6
Clean Dusty Primary Element. . . . . . . . . . . . . . . 55-7
Clean Oily or Sooty Primary Element . . . . . . . . . 55-7
Inspect Element . . . . . . . . . . . . . . . . . . . . . . . . . 55-8
Check Air Inlet Cover . . . . . . . . . . . . . . . . . . . . . 55-9
Check and Adjust Belt Tension—544G,
624G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10
Inspect Serpentine Belt—644G. . . . . . . . . . . . . 55-11
Drain Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 55-11
Drain and Clean Primary Fuel Filter (Water
Separator)—544G, 624G . . . . . . . . . . . . . . 55-12
Drain and Clean Primary Fuel Filter (Water
Separator)—644G . . . . . . . . . . . . . . . . . . . . 55-13
Check Cab Recirculating Air Filter . . . . . . . . . . 55-14
Maintenance—Every 10 Hours or Daily
Lubricate Pivots . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Clean Air Cleaner Dust Unloader Valve . . . . . . . 60-1
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . 60-1
Check Recovery Tank Coolant Level . . . . . . . . . 60-3
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . 60-3
Check Transmission Oil Level . . . . . . . . . . . . . . 60-5
Maintenance—Every 100 Hours
Lubricant Boom, Bucket, and Cylinder
Pivots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Lubricate Boom, Bucket, and Cylinder
Pivots—544G TC . . . . . . . . . . . . . . . . . . . . . . 70-2
Lubricate Oscillating Rear Axle. . . . . . . . . . . . . . 70-5
Check Cab Fresh Air Filter—If Equipped . . . . . . 70-5
Lubricate Steering Cylinder Pivots . . . . . . . . . . . 70-4
Maintenance—Every 250 Hours
Check Receiver Dryer Moisture Indicator . . . . . . 75-1
Change Engine Oil and Replace Filter . . . . . . . . 75-2
Check Radiator Coolant Level . . . . . . . . . . . . . . 75-5
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 . . . . . . . 80-7
Replace Final Fuel Filter—644G. . . . . . . . . . . . . 80-7
Replace Hydraulic System Return Filter . . . . . . . 80-7
Replace Hydraulic Reservoir Breather Filter . . . . 80-8
Check Front and Rear Differential Oil
Level—If Equipped with Standard Axle . . . . . 80-9
Check Front and Rear Differential Oil
Level—If Equipped with Differential Lock
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10
Maintenance—Every 1000 Hours
Lubricate Rear Driveline . . . . . . . . . . . . . . . . . . . 85-1
Check Engine Speeds . . . . . . . . . . . . . . . . . . . . 85-1
Adjust Engine Speed Control Linkage . . . . . . . . 85-2
Replace Air Cleaner Dust Unloader Valve . . . . . 85-3
Replace Air Cleaner Elements . . . . . . . . . . . . . . 85-3
Clean Engine Crankcase Vent Tube (A). . . . . . . 85-4
Change Transmission Oil and Replace
Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-5
Check Park Brake . . . . . . . . . . . . . . . . . . . . . . . 85-7
Adjust Park Brake. . . . . . . . . . . . . . . . . . . . . . . . 85-8
Lubricate Frame Hinge Pivots . . . . . . . . . . . . . 85-10
Maintenance—Every 2000 Hours
Measure and Adjust Engine Valve Lash
(Clearance)—544G, LL, TC, 624G . . . . . . . . 86-1
Adjust Engine Valve Lash (Clearance)—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-3
Lubricate Front Driveline Support Bearing . . . . . 86-5
Maintenance—Every 3000 Hours
Change Hydraulic System Oil . . . . . . . . . . . . . . . 87-1
Clean Hydraulic Suction Strainer . . . . . . . . . . . . 87-2
Replace Differential Lock Return Filter(s)—
If Equipped. . . . . . . . . . . . . . . . . . . . . . . . . . . 87-2
Change Front and Rear Differential Oil. . . . . . . . 87-3
Maintenance
Draining the Cooling System . . . . . . . . . . . . . . . 90-1
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . 90-3
Coolant drain intervals . . . . . . . . . . . . . . . . . . . . 90-3
Filling the Cooling System . . . . . . . . . . . . . . . . . 90-4
Test the Coolant Freeze—Protection Level . . . . 90-4
Do Not Service Injection Nozzles . . . . . . . . . . . . 90-5
Do Not Adjust Injection Pump. . . . . . . . . . . . . . . 90-5
Cleaning Fuel Tank Outlet Screen . . . . . . . . . . . 90-5
Bleeding Fuel System—544G, 624G . . . . . . . . . 90-7
Bleeding Fuel System—644G. . . . . . . . . . . . . . . 90-8
Adjusting Fuel Shut-Off Solenoid—644G . . . . . . 90-8
Precautions for Alternator and Regulator . . . . . . 90-9
Service Batteries Carefully . . . . . . . . . . . . . . . . 90-10
Checking Electrolyte Specific Gravity . . . . . . . . 90-12
Using Battery Charger . . . . . . . . . . . . . . . . . . . 90-14
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 90-14
Removing Batteries . . . . . . . . . . . . . . . . . . . . . 90-15
Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . 90-15
Fuse (Blade-Type) Color Codes . . . . . . . . . . . . 90-15
Resetting Circuit Breakers . . . . . . . . . . . . . . . . 90-16
Replacing Halogen Bulbs . . . . . . . . . . . . . . . . . 90-16
Changing Reverse Warning Alarm Volume. . . . 90-18
Checking Neutral Start System. . . . . . . . . . . . . 90-18
Adding Attachments/Accessories to RollOver
Protective Structure (ROPS) . . . . . . . . 90-19
Servicing Air Conditioning System . . . . . . . . . . 90-19
Checking and Adjusting Compressor Belt
Tension—If Equipped . . . . . . . . . . . . . . . . . . 90-20
Welding on Machine. . . . . . . . . . . . . . . . . . . . . 90-20
Inspecting Park Brake Pads . . . . . . . . . . . . . . . 90-21
External Service Brake Inspection . . . . . . . . . . 90-22
Checking Brake Accumulator . . . . . . . . . . . . . . 90-24
Checking Ride Control Accumulator—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Checking Secondary Steering System—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Clutch Cut-Off Adjustment . . . . . . . . . . . . . . . . 90-28
Do Not Service Control Valves, Cylinders,
Pumps or Motors . . . . . . . . . . . . . . . . . . . . . 90-29
Hardware Torque Specifications . . . . . . . . . . . . 90-30
Keep ROPS Installed Properly . . . . . . . . . . . . . 90-30
Metric Bolt and Cap Screw Torque Values . . . . 90-31
Additional Metric Cap Screw Torque Values. . . 90-33
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Check Oil Lines and Fittings. . . . . . . . . . . . . . . 90-36
Service Recommendations for O-Ring Boss
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
Service Recommendations for Flat Face O
Ring
Seal Fittings . . . . . . . . . . . . . . . . . . . . . 90-39
Service Recommendations for Metric Series
Four Bolt Flange Fitting . . . . . . . . . . . . . . . . 90-40
Service Recommendations for Inch Series
Four Bolt Flange Fittings . . . . . . . . . . . . . . . 90-41
Operational Checkout
Operational Checkout . . . . . . . . . . . . . . . . . . . . . 95-1
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 . . . . . . . . . . . . . . . . . . . . . . 95-4
Transmission Controls, Axle and Engine
Linkages, Neutral Start Switch, and
Reverse Warning Alarm Switch Checks . . . . . 95-4
Neutral Start And Reverse Warning Alarm
Circuit checks. . . . . . . . . . . . . . . . . . . . . . . . . 95-4
Engine Speed Control Linkage Check—
544G, 624G . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5
Engine Speed Control Linkage Check—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5
Engine Speed Control Linkage Check—
644G (Continued). . . . . . . . . . . . . . . . . . . . . . 95-5
Fuel Shut-off Solenoid Linkage Check—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-6
Front Axle Disconnect Check—If Equipped . . . . 95-6
Monitor Indicator and Gauge Checks
(Engine Running) . . . . . . . . . . . . . . . . . . . . . . 95-7
Monitor Display And Alternator Output
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-7
Monitor Indicator Circuit Bypass And Seat
Belt Indicator Check . . . . . . . . . . . . . . . . . . . . 95-9
Monitor Primary And Secondary Level
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-9
Transmission Temperature Gauge Check. . . . . 95-10
Brake System, Clutch Cut-Off, and
Differential Lock Checks. . . . . . . . . . . . . . . . 95-10
Park Brake Transmission Lockout Check . . . . . 95-10
Service Brake Pump Flow Check . . . . . . . . . . . 95-11
Service Brake Check . . . . . . . . . . . . . . . . . . . . 95-12
Brake Accumulator Precharge Check . . . . . . . . 95-12
Brake System Leakage Check . . . . . . . . . . . . . 95-13
Service Brake Pedal Check . . . . . . . . . . . . . . . 95-13
Service And Park Brake System Drag
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-13
Differential Lock Check. . . . . . . . . . . . . . . . . . . 95-14
Clutch Cut-Off Check . . . . . . . . . . . . . . . . . . . . 95-14
Driving Checks . . . . . . . . . . . . . . . . . . . . . . . . . 95-15
Transmission Noise Check . . . . . . . . . . . . . . . . 95-15
Automatic Shift and Speedometer Check . . . . . 95-16
Transmission Quickshift Check. . . . . . . . . . . . . 95-17
Transmission Pressure, Pump Flow, and
Leakage Check . . . . . . . . . . . . . . . . . . . . . . 95-17
Transmission Shift Modulation Check. . . . . . . . 95-18
Hydraulic System Checks. . . . . . . . . . . . . . . . . 95-18
Hydraulic System Warm-Up Procedure . . . . . . 95-18
Boom Down Solenoid Valve Check . . . . . . . . . 95-18
Control Valve Lift Check . . . . . . . . . . . . . . . . . . 95-19
Bucket Rollback Circuit Relief Valve Check . . . 95-19
Bucket Dump Circuit Relief Valve Pressure
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-19
Boom and Bucket Cylinder Drift . . . . . . . . . . . . 95-19
Boom Down Check Valve Leakage Check . . . . 95-20
Pilot Controller Check. . . . . . . . . . . . . . . . . . . . 95-20
Return-To-Dig Check . . . . . . . . . . . . . . . . . . . . 95-20
Boom Height Kickout Check—If Equipped . . . . 95-21
Pin Disconnect Cylinder Check (544G-TC
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Ride Control Accumulator Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Steering System Checks . . . . . . . . . . . . . . . . . 95-22
Steering Valve Check. . . . . . . . . . . . . . . . . . . . 95-22
Steering System Leakage Check . . . . . . . . . . . 95-22
Priority Valve Low Pressure Check. . . . . . . . . . 95-23
Priority Valve High Pressure Check . . . . . . . . . 95-23
Secondary Steering System Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-24
Secondary Steering System Primary Check
Valve Check. . . . . . . . . . . . . . . . . . . . . . . . . 95-24
Accessory Checks . . . . . . . . . . . . . . . . . . . . . . 95-25
Operating Lights Check . . . . . . . . . . . . . . . . . . 95-25
Work Light Check . . . . . . . . . . . . . . . . . . . . . . . 95-25
Brake Light Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Horn Circuit Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Windshield Washer and Wiper Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-27
Defroster Blower Check . . . . . . . . . . . . . . . . . . 95-27
Heater/Air Conditioner Blower Check . . . . . . . . 95-28
Heater Functional Check . . . . . . . . . . . . . . . . . 95-28
Air Conditioner Functional Check . . . . . . . . . . . 95-28
Start Aid System Check . . . . . . . . . . . . . . . . . . 95-29
Cab Component and Vandal Protection
Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Cab Door and Window Hold-Open Latch
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Cab Door Release Button. . . . . . . . . . . . . . . . . 95-30
Cab Door Lock Check . . . . . . . . . . . . . . . . . . . 95-30
Dome Light Check . . . . . . . . . . . . . . . . . . . . . . 95-30
Cab Window Latch Check . . . . . . . . . . . . . . . . 95-31
Cab Door Window Check . . . . . . . . . . . . . . . . . 95-31
Steering Column Adjustment Check . . . . . . . . . 95-31
Seat And Seat Belt Check . . . . . . . . . . . . . . . . 95-32
Toolbox Door Check. . . . . . . . . . . . . . . . . . . . . 95-32
Air Intake Filter Door Check . . . . . . . . . . . . . . . 95-33
Load Center Door Check . . . . . . . . . . . . . . . . . 95-33
Engine Side Panels Check . . . . . . . . . . . . . . . . 95-33
Radiator Cap Access Door Check . . . . . . . . . . 95-34
Frame Locking Bar Check . . . . . . . . . . . . . . . . 95-34
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 100-29
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . 100-35
Differential Axle . . . . . . . . . . . . . . . . . . . . . . . 100-37
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-39
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-40
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . 100-41
Storage
Prepare Machine for Storage . . . . . . . . . . . . . . 105-1
Monthly Storage Procedure . . . . . . . . . . . . . . . 105-2
Machine Numbers
Record Product Identification Number (PIN) . . . 110-1
Record Engine Serial Number—544G . . . . . . . 110-1
Record Engine Serial Number—624G . . . . . . . 110-1
Record Engine Serial Number—644G . . . . . . . 110-1
Record Transmission Serial Number . . . . . . . . 110-2
Record Hydraulic Pump Serial Number . . . . . . 110-2
Specifications
544G Specifications . . . . . . . . . . . . . . . . . . . . . 115-1
544G Specifications . . . . . . . . . . . . . . . . . . . . . 115-3
Drain and Refill Capacities—544G . . . . . . . . . . 115-5
544G LL Specifications. . . . . . . . . . . . . . . . . . . 115-5
544G LL Specifications. . . . . . . . . . . . . . . . . . . 115-7
Drain and Refill Capacities—544G LL . . . . . . . 115-9
544G TC Specifications . . . . . . . . . . . . . . . . . . 115-9
544G TC Specifications . . . . . . . . . . . . . . . . . 115-11
Drain and Refill Capacities—544G TC . . . . . . 115-13
624G Specifications . . . . . . . . . . . . . . . . . . . . 115-13
624G Specifications . . . . . . . . . . . . . . . . . . . . 115-15
Drain and Refill Capacities—624G . . . . . . . . . 115-17
644G Specifications . . . . . . . . . . . . . . . . . . . . 115-17
644G Specifications . . . . . . . . . . . . . . . . . . . . 115-19
Drain and Refill Capacities—644G . . . . . . . . . 115-20
Crime Prevention Tips . . . . . . . . . . . . . . . . . . 120-1
Index