LDR 04 - 644G - English PDF
LDR 04 - 644G - English PDF
LDR 04 - 644G - English PDF
O
544G TC Loaders
C
624G Loader
D
644G Loader
(Serial No. 557739-)
OPERATORS MANUAL
544G, 544G LL, and 544G TC Loaders 624G Loader
644G Loader (Serial No. 557739-)
G 6
O M T 1 5 9 8 1 6
LITHO IN U.S.A.
ENGLISH
Introduction
-UN-08SEP92
T7773CX
READ THIS MANUAL carefully to learn how to numbers when you order parts. File the identification
operate and service your machine correctly. Failure to numbers in a secure place off the machine.
do so could result in personal injury or equipment
damage. This manual and safety signs on your WARRANTY is provided as part of John Deere’s
machine may also be available in other languages. support program for customers who operate and
(See your John Deere dealer to order.) maintain their equipment as described in this manual.
The warranty is explained on the warranty certificate
THIS MANUAL SHOULD BE CONSIDERED a which you should have received from your dealer.
permanent part of your machine and should remain
with the machine when you sell it. This warranty provides you the assurance that John
Deere will back its products where defects appear
MEASUREMENTS in this manual are given in both within the warranty period. In some circumstances,
metric and customary U.S. unit equivalents. Use only John Deere also provides field improvements, often
correct replacement parts and fasteners. Metric and without charge to the customer, even if the product is
inch fasteners may require a specific metric or inch out of warranty. Should the equipment be abused, or
wrench. modified to change its performance beyond the
original factory specifications, the warranty will
RIGHT-HAND AND LEFT-HAND sides are determined become void and field improvements may be denied.
by facing in the direction of forward travel. Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
WRITE PRODUCT IDENTIFICATION NUMBERS
(P.I.N.) in the Machine Numbers section. Accurately THE TIRE MANUFACTURER’S warranty supplied
record all the numbers to help in tracing the machine with your machine may not apply outside the U.S.
should it be stolen. Your dealer also needs these
TX,DH2120 -19-13DEC95
170696
PN=5
Introduction
-19-14FEB96
T100255
TX,DY549 -19-08JUN96
170696
PN=6
Introduction
170696
PN=7
T7773CZ -UN-08SEP92 T7773CY -UN-08SEP92
TX,DH2121
-19-08JUN96
PN=8
170696
T7799CZ -UN-06OCT92 T7799CY -UN-06OCT92
TX,DH2283
-19-02OCT92
PN=9
170696
HELP!! HELP!! HELP!! HELP!!
OVERALL, how would you rate the quality of “ALL” Operator’s Manuals provided to you? (Check one)
Company Name
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FAX No.
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TX,FAX,JC544G -19-08JUN96
170696
PN=10
170696
PN=11
Contents
Page Page
Operator’s Station
Gauges, Indicators, Switches, and Break-in
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Engine Break-In Oil . . . . . . . . . . . .. .. .. .. .. . 15-1
Stop Indicator and Alarm . . . . . . . . . . . . . . . . . . 10-3 Every 10 Hours or Daily . . . . . . . . .. .. .. .. .. . 15-1
Service Required Indicator (Yellow) . . . . . . . . . . 10-4 After First 10 and First 50 Hours . .. .. .. .. .. . 15-2
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 After the First 100 Hours . . . . . . . .. .. .. .. .. . 15-2
Engine Coolant Temperature Gauge . . . . . . . . . 10-5
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Pre-Start Inspection
Transmission Oil Temperature Gauge . . . . . . . . 10-5 Inspect Machine Daily Before Starting . . . . . . . . 20-1
Engine Oil Pressure Indicator . . . . . . . . . . . . . . . 10-6
Alternator Voltage Indicator . . . . . . . . . . . . . . . . 10-6 Operating the Engine
Engine Air Filter Restriction Indicator . . . . . . . . . 10-6 Check Instruments Before Starting . . . . . . . . . . . 25-1
Engine Coolant Level Indicator . . . . . . . . . . . . . . 10-7 Brake Pressure Indicator . . . . . . . . . . . . . . . . . . 25-1
Transmission Oil Pressure Indicator—If Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . 25-1
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Starting Fluid—If Equipped (Cold Weather
Hydraulic Oil Filter Restriction Indicator . . . . . . . 10-7 Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Right Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-8 Using Coolant Heater—If Equipped . . . . . . . . . . 25-5
Brake Oil Pressure Indicator. . . . . . . . . . . . . . . . 10-8 Using Booster Batteries—12 Volt System. . . . . . 25-6
Park Brake Indicator. . . . . . . . . . . . . . . . . . . . . . 10-8 Check Instruments After Starting . . . . . . . . . . . . 25-7
Fasten Seat Belt Indicator . . . . . . . . . . . . . . . . . 10-9 Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-7
Ether Injection Indicator . . . . . . . . . . . . . . . . . . . 10-9 Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . . 25-8
Steering Pressure Indicator—If Equipped . . . . . . 10-9 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . 25-8
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-10
Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Front Axle Disconnect Lever—If Equipped . . . . 10-11 Driving the Machine
Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Driving on Public Roads . . . . . . . . . . .. .. .. .. . 30-1
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . 10-12 General Driving Precautions . . . . . . . .. .. .. .. . 30-2
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Front Axle Disconnect—If Equipped . .. .. .. .. . 30-2
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Neutral Lock . . . . . . . . . . . . . . . . . . . .. .. .. .. . 30-3
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . 10-14 Shifting the Transmission . . . . . . . . . .. .. .. .. . 30-3
Dome Light and Swivel Light—If Equipped . . . . 10-14 Travel Speeds . . . . . . . . . . . . . . . . . .. .. .. .. . 30-5
Vandal Shield—If Equipped . . . . . . . . . . . . . . . 10-14 Ride Control Switch—If Equipped. . . .. .. .. .. . 30-6
Operating Windshield Wipers and Stopping the Machine. . . . . . . . . . . . .. .. .. .. . 30-6
Washers—If Equipped . . . . . . . . . . . . . . . . . 10-15 Park Brake Switch . . . . . . . . . . . . . . .. .. .. .. . 30-7
Adjusting Steering Wheel Tilt . . . . . . . . . . . . . . 10-15 Parking the Machine. . . . . . . . . . . . . .. .. .. .. . 30-7
Opening Side Window . . . . . . . . . . . . . . . . . . . 10-15
Opening Sliding Side Window—If Equipped . . . 10-16 Operating the Machine
Cab Door Release . . . . . . . . . . . . . . . . . . . . . . 10-16
Operating Lights . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Continued on next page
COPYRIGHT 1996
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRATION Manual
i 040596
PN=1
Contents
Page Page
Boom and Bucket Control Lever—One Check Windshield Washer Fluid Level . . . . . . . . 50-5
Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-1 Maintenance and Repair Record Keeping
Boom and Bucket Control Lever—Two System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-2 OILSCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Quick Shift Switch . . . . . . . . . . . . . . . . . . . . . . . 35-3 Maintenance Record Keeping. . . . . . . . . . . . . . . 50-8
Quick Coupler Operation—544G TC . . . . . . . . . 35-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
Pin Disconnect Switch—544G TC . . . . . . . . . . . 35-5
Boom Down Switch . . . . . . . . . . . . . . . . . . . . . . 35-5 Maintenance—As Required
Clutch Cut-Off Switch—If Equipped . . . . . . . . . . 35-5 Check Tire Pressure. . . . . . . . . . . . . . . . . . . . . . 55-1
Secondary Steering—If Equipped. . . . . . . . . . . . 35-6 Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
Differential Lock Pedal—If Equipped . . . . . . . . . 35-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3
Adjusting Boom Height Kickout—If . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5
Adjusting Return-to-Dig . . . . . . . . . . . . . . . . . . . 35-8 Tighten Wheel Retainer Cap Screws . . . . . . . . . 55-5
General Operating Tips . . . . . . . . . . . . . . . . . . . 35-9 Clean or Replace Air Cleaner Elements . . . . . . . 55-6
Excavating Banks or Stockpiles . . . . . . . . . . . . . 35-9 Clean Dusty Primary Element. . . . . . . . . . . . . . . 55-7
Using the Loader Bucket . . . . . . . . . . . . . . . . . 35-10 Clean Oily or Sooty Primary Element . . . . . . . . . 55-7
Backdragging . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12 Inspect Element . . . . . . . . . . . . . . . . . . . . . . . . . 55-8
Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12 Check Air Inlet Cover . . . . . . . . . . . . . . . . . . . . . 55-9
Truck Loading . . . . . . . . . . . . . . . . . . . . . . . . . 35-13 Check and Adjust Belt Tension—544G,
624G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10
Transporting Inspect Serpentine Belt—644G. . . . . . . . . . . . . 55-11
Transporting Precautions . . . . . . . . . . . . . . . . . . 40-1 Drain Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 55-11
Loading Machine on a Trailer . . . . . . . . . . . . . . . 40-1 Drain and Clean Primary Fuel Filter (Water
Towing Procedure—Engine Operational . . . . . . . 40-3 Separator)—544G, 624G . . . . . . . . . . . . . . 55-12
Towing Procedure—Engine Non- Drain and Clean Primary Fuel Filter (Water
Operational. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4 Separator)—644G . . . . . . . . . . . . . . . . . . . . 55-13
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . 40-7 Check Cab Recirculating Air Filter . . . . . . . . . . 55-14
ii
PN=2
Contents
Page Page
iii
PN=3
Contents
Page Page
Monitor Indicator and Gauge Checks— Control Valve Lift Check . . . . . . . . . . . . . . . . . . 95-19
Engine Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2 Bucket Rollback Circuit Relief Valve Check . . . 95-19
Hourmeter And Gauge Check . . . . . . . . . . . . . . 95-2 Bucket Dump Circuit Relief Valve Pressure
Battery Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2 Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-19
Monitor Indicator Circuit And Key Switch Boom and Bucket Cylinder Drift . . . . . . . . . . . . 95-19
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-3 Boom Down Check Valve Leakage Check . . . . 95-20
Monitor Turn Signals And Hazard Warning Pilot Controller Check. . . . . . . . . . . . . . . . . . . . 95-20
Indicator Checks . . . . . . . . . . . . . . . . . . . . . . 95-4 Return-To-Dig Check . . . . . . . . . . . . . . . . . . . . 95-20
Transmission Controls, Axle and Engine Boom Height Kickout Check—If Equipped . . . . 95-21
Linkages, Neutral Start Switch, and Pin Disconnect Cylinder Check (544G-TC
Reverse Warning Alarm Switch Checks . . . . . 95-4 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Neutral Start And Reverse Warning Alarm Ride Control Accumulator Check—If
Circuit checks . . . . . . . . . . . . . . . . . . . . . . . . . 95-4 Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Engine Speed Control Linkage Check— Steering System Checks . . . . . . . . . . . . . . . . . 95-22
544G, 624G . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5 Steering Valve Check. . . . . . . . . . . . . . . . . . . . 95-22
Engine Speed Control Linkage Check— Steering System Leakage Check . . . . . . . . . . . 95-22
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5 Priority Valve Low Pressure Check. . . . . . . . . . 95-23
Engine Speed Control Linkage Check— Priority Valve High Pressure Check . . . . . . . . . 95-23
644G (Continued). . . . . . . . . . . . . . . . . . . . . . 95-5 Secondary Steering System Check—If
Fuel Shut-off Solenoid Linkage Check— Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-24
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-6 Secondary Steering System Primary Check
Front Axle Disconnect Check—If Equipped . . . . 95-6 Valve Check. . . . . . . . . . . . . . . . . . . . . . . . . 95-24
Monitor Indicator and Gauge Checks Accessory Checks . . . . . . . . . . . . . . . . . . . . . . 95-25
(Engine Running) . . . . . . . . . . . . . . . . . . . . . . 95-7 Operating Lights Check . . . . . . . . . . . . . . . . . . 95-25
Monitor Display And Alternator Output Work Light Check . . . . . . . . . . . . . . . . . . . . . . . 95-25
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-7 Brake Light Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Monitor Indicator Circuit Bypass And Seat Horn Circuit Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Belt Indicator Check . . . . . . . . . . . . . . . . . . . . 95-9 Windshield Washer and Wiper Check—If
Monitor Primary And Secondary Level Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-27
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-9 Defroster Blower Check . . . . . . . . . . . . . . . . . . 95-27
Transmission Temperature Gauge Check. . . . . 95-10 Heater/Air Conditioner Blower Check . . . . . . . . 95-28
Brake System, Clutch Cut-Off, and Heater Functional Check . . . . . . . . . . . . . . . . . 95-28
Differential Lock Checks. . . . . . . . . . . . . . . . 95-10 Air Conditioner Functional Check . . . . . . . . . . . 95-28
Park Brake Transmission Lockout Check . . . . . 95-10 Start Aid System Check . . . . . . . . . . . . . . . . . . 95-29
Service Brake Pump Flow Check . . . . . . . . . . . 95-11 Cab Component and Vandal Protection
Service Brake Check . . . . . . . . . . . . . . . . . . . . 95-12 Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Brake Accumulator Precharge Check . . . . . . . . 95-12 Cab Door and Window Hold-Open Latch
Brake System Leakage Check . . . . . . . . . . . . . 95-13 Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Service Brake Pedal Check . . . . . . . . . . . . . . . 95-13 Cab Door Release Button. . . . . . . . . . . . . . . . . 95-30
Service And Park Brake System Drag Cab Door Lock Check . . . . . . . . . . . . . . . . . . . 95-30
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-13 Dome Light Check . . . . . . . . . . . . . . . . . . . . . . 95-30
Differential Lock Check. . . . . . . . . . . . . . . . . . . 95-14 Cab Window Latch Check . . . . . . . . . . . . . . . . 95-31
Clutch Cut-Off Check . . . . . . . . . . . . . . . . . . . . 95-14 Cab Door Window Check . . . . . . . . . . . . . . . . . 95-31
Driving Checks . . . . . . . . . . . . . . . . . . . . . . . . . 95-15 Steering Column Adjustment Check . . . . . . . . . 95-31
Transmission Noise Check . . . . . . . . . . . . . . . . 95-15 Seat And Seat Belt Check . . . . . . . . . . . . . . . . 95-32
Automatic Shift and Speedometer Check . . . . . 95-16 Toolbox Door Check. . . . . . . . . . . . . . . . . . . . . 95-32
Transmission Quickshift Check. . . . . . . . . . . . . 95-17 Air Intake Filter Door Check . . . . . . . . . . . . . . . 95-33
Transmission Pressure, Pump Flow, and Load Center Door Check . . . . . . . . . . . . . . . . . 95-33
Leakage Check . . . . . . . . . . . . . . . . . . . . . . 95-17 Engine Side Panels Check . . . . . . . . . . . . . . . . 95-33
Transmission Shift Modulation Check. . . . . . . . 95-18 Radiator Cap Access Door Check . . . . . . . . . . 95-34
Hydraulic System Checks. . . . . . . . . . . . . . . . . 95-18 Frame Locking Bar Check . . . . . . . . . . . . . . . . 95-34
Hydraulic System Warm-Up Procedure . . . . . . 95-18
Boom Down Solenoid Valve Check . . . . . . . . . 95-18 Continued on next page
iv
PN=4
Contents
Page
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
Index
v
PN=5
Safety
–19–21FEB96
T100127
TX,05,JC1054 –19–22JAN96–1/1
05–1
PN=1
Safety
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT –19–03MAR93–1/1
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1
–UN–23AUG88
available from your John Deere dealer.
TS201
instruction.
DX,READ –19–03MAR93–1/1
05–2
PN=2
Safety
To avoid rollovers:
–19–22FEB90
stable.
T7242EA
Reduce speed before turning or swinging load.
TX,05,DH1525 –19–21JUN91–1/1
05–3
PN=3
Safety
–UN–21FEB90
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE HORN
OR OTHER SIGNAL TO WARN
T7241AY
BYSTANDERS BEFORE MOVING MACHINE
------------------------------------
WHEN USING A SIGNAL PERSON, KEEP
PERSON IN VIEW AT ALL TIMES. BE SURE
SIGNAL PERSON IS CLEAR BEFORE
BACKING UP
TX,05,DH1573 –19–18MAR91–1/1
05–4
PN=4
Safety
–UN–21FEB90
------------------------------------
DEATH OR SERIOUS INJURY MAY RESULT
IF YOU ATTEMPT TO MOUNT OR STOP A
T7241AZ
MOVING MACHINE
------------------------------------
To avoid rollaways:
TX,05,DH2478 –19–26SEP92–1/1
INSPECT MACHINE
T82,BHSA,CL –19–14MAR90–1/1
05–5
PN=5
Safety
–UN–15JUN89
the machine. Do not use the steering wheel or any
controls as handholds.
T6981AN
dismount a moving machine.
TX,05,DH553 –19–18MAR91–1/1
–UN–20OCT88
Never start engine while standing on ground. Start engine
only from operator’s seat with transmission control lever
locked in neutral and park brake engaged.
T6642EB
TX,05,DH2281 –19–06OCT92–1/1
TX,05,JC1044 –19–12JAN96–1/1
05–6
PN=6
Safety
TX,05,JC242 –19–03MAR95–1/1
SECONDARY EXITS
TX,05,JC1051 –19–18JAN96–1/1
05–7
PN=7
Safety
TRAVEL SAFELY
–UN–20DEC88
condition. It warns people when the machine starts to
move in reverse.
T6964AD
congested areas. Coordinate hand signals before starting
the machine.
TX,05,DH496 –19–02AUG89–1/1
–UN–25OCT88
Drive carefully in congested areas, over rough ground,
near ditches for excavations, and on slopes or curves.
T6582AS
Keep machine in gear when going down hills.
TX,05,DH1931 –19–21JUN91–1/1
05–8
PN=8
Safety
–UN–18OCT88
Never lower a loaded bucket with the boom and bucket
control lever in the float position.
T6642EF
Increase the power gradually when pulling a heavy load or
when driving out of a ditch or excavation.
TX,05,DH1932 –19–06JUN91–1/1
OPERATING ON SLOPES
–UN–03AUG89
T7050AB
TX,05,RR,171 –19–27APR89–1/1
05–9
PN=9
Safety
CARRYING LOADS
–UN–03AUG89
not overload.
T7050AA
Do not change forward or reverse directions quickly when
carrying a load.
TX,05,RR,172 –19–03JUN92–1/1
–UN–20JUN89
electric line than 3 m (10 ft) plus twice the line insulator
length.
T6642EG
02T,05,J18 –19–06JUN91–1/1
TX,DH,2 –19–09FEB89–1/1
05–10
PN=10
Safety
–UN–23AUG88
resulting in the machine being operated in an unsafe
manner.
TS290
DX,RIDER –19–03MAR93–1/1
–UN–23AUG88
outdoors.
TS202
DX,FIRE1 –19–03MAR93–1/1
DX,FIRE2 –19–03MAR93–1/1
05–11
PN=11
Safety
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
–UN–18OCT88
Remove container from machine if engine does not need
starting fluid.
T6464AV
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and
store in a cool, protected location.
TX,05,FF2281 –19–22FEB91–1/1
–UN–18OCT88
immediately after engine is stopped. BE ON GUARD
FOR FIRES DURING THIS PERIOD.
T6669AG
engine compartment.
02T,05,J33 –19–14MAR90–1/1
02T,05,J45 –19–30MAY90–1/1
05–12
PN=12
Safety
–UN–23AUG88
while operating machine.
TS206
DX,WEAR2 –19–03MAR93–1/1
–UN–23AUG88
uncomfortable loud noises.
TS207
DX,NOISE –19–03MAR93–1/1
–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques. TS1132
TX,05,DH2500 –19–02OCT92–1/1
05–13
PN=13
Safety
–UN–10FEB89
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.
N36564
Install and use all safety lights and devices necessary to
assure safe operation and local compliance. Keep these A—Lights
safety items in good condition. Replace missing or B—Slow Moving Vehicle Emblem
damaged parts immediately. C—Reflector Tape
D—Reflectors
TX,05,DH1729 –19–26JAN91–1/1
TX,05,DH1846 –19–14MAY91–1/1
05–14
PN=14
Safety
TX,05,JC1068 –19–21FEB96–1/1
–19–22APR91
T7447AO
TX,05,DH1820 –19–14MAY91–1/1
05–15
PN=15
Safety
–UN–23AUG88
3. Move transmission control lever to neutral "N".
Engage neutral lock.
TS218
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.
TX,05,DH2122 –19–31JUL92–1/2
05–16
PN=16
Safety
TX,05,DH2122 –19–31JUL92–2/2
–UN–23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
TS229
DX,LOWER –19–04JUN90–1/1
05–17
PN=17
Safety
–UN–23AUG88
by welding, soldering, or using a torch.
TS220
Remove paint before welding or heating:
DX,PAINT –19–03MAR93–1/1
–UN–15MAY90
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
TS953
DX,TORCH –19–03MAR93–1/1
05–18
PN=18
Safety
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
X9811
and body from high pressure fluids.
DX,FLUID –19–03MAR93–1/1
–UN–18OCT88
(200 psi)] can damage freshly painted finishes. Paint
should be allowed to air dry for 30 days minimum after
receipt of machine before cleaning with high pressure.
Use low pressure wash operations until 30 days have
elapsed. T6642EJ
TX,05,FF2787 –19–27JUL94–1/1
05–19
PN=19
Safety
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP –19–04JUN90–1/1
–UN–23AUG88
storage area.
TS219
DX,STORE –19–03MAR93–1/1
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.
TX,05,DH2502 –19–26AUG92–1/1
05–20
PN=20
Safety Signs
–UN–31AUG92
T7829AA
–19–22MAR93
T7967AK
TX,06,JC1102 –19–18MAR96–1/12
06–1
PN=21
Safety Signs
–UN–31AUG92
T7773CV
A-Warning Decal
–19–22MAR93
T7939AI
TX,06,JC1102 –19–18MAR96–2/12
06–2
PN=22
Safety Signs
–UN–22MAR96
T100704
–19–09FEB95
T8417AD
TX,06,JC1102 –19–18MAR96–3/12
06–3
PN=23
Safety Signs
–19–30AUG91
T7593AC
–UN–30JAN89
T6976AE
TX,06,JC1102 –19–18MAR96–4/12
06–4
PN=24
Safety Signs
–19–22MAR93
–UN–15JUN93
T7939AK
T8029AF
TX,06,JC1102 –19–18MAR96–5/12
06–5
PN=25
Safety Signs
–19–01FEB93
T7934AM
A-Warning Decal
–UN–22MAR96
T100703
TX,06,JC1102 –19–18MAR96–6/12
06–6
PN=26
Safety Signs
–19–16JUN93
T8029AR
–UN–21JUN93
T8029AQ
TX,06,JC1102 –19–18MAR96–7/12
06–7
PN=27
Safety Signs
–UN–08OCT92
T7853AF
–19–17SEP92
T7829AT
–UN–15JUN93
T8029AH
Right Side of Machine
TX,06,JC1102 –19–18MAR96–8/12
06–8
PN=28
Safety Signs
–UN–10AUG92
T7773AZ
–19–06JAN93
T7916AC
TX,06,JC1102 –19–18MAR96–9/12
–UN–10AUG92
–19–14OCT92
T7748CU
T7773CA
TX,06,JC1102 –19–18MAR96–10/12
06–9
PN=29
Safety Signs
–UN–22MAR96
T100702
–19–31AUG92
T7829AQ
TX,06,JC1102 –19–18MAR96–11/12
06–10
PN=30
Safety Signs
–UN–17SEP92
T7839BB
–19–17SEP92
T7829AU
–19–14MAY96
T101279
TX,06,JC1102 –19–18MAR96–12/12
06–11
PN=31
Operator’s Station
GAUGES, INDICATORS, SWITCHES, AND ACCESSORIES
–UN–11JUN92
T7773AP
A—SELECT Switch H—Engine Coolant Level N—Left Turn Signal S—Brake Pressure
B—Digital Display Indicator Indicator Indicator
C—Engine Coolant I—Engine Air Filter O—Steering Pressure T—Right Turn Signal
Temperature Gauge Restriction Indicator Indicator—If Equipped Indicator
D—Fuel Gauge J—Engine Alternator With Secondary
E—Transmission Oil Voltage Indicator Steering
Temperature Gauge K—Engine Oil Pressure P—Ether Injection Indicator
F—Hydraulic Oil Filter Indicator Q—Fasten Seat Belt
Restriction Indicator L—STOP Indicator Indicator
G—Transmission Oil M—Service Required R—Park Brake Indicator
Pressure Indicator—If Indicator
Equipped
TX,10,JC1046 –19–16JAN96–1/2
10–1
PN=32
Operator’s Station
–UN–02DEC94
T8375AN
A—Front Wiper Switch G—Rear Wiper Switch J—Ride Control Switch—If M—Temperature Control
B—Drive Light Switch H—Air Conditioner Control Equipped Knob
C—Work Light Switch Switch—If Equipped K—Blower Knob
D—Clutch Cut-off Switch I—Pin Disconnect Switch— L—Air Conditioner
E—Warning Light Switch 544G TC Defroster Blower Knob
F—Boom Down Switch
TX,10,JC1046 –19–16JAN96–2/2
10–2
PN=33
Operator’s Station
–UN–06JAN92
The STOP indicator light flashes and alarm sounds when:
T7673AM
IMMEDIATELY.
TX,10,DH2165 –19–02OCT92–1/1
10–3
PN=34
Operator’s Station
–UN–18OCT88
The service required indicator lights when:
T6201BL
• Engine air filter is restricted.
TX,10,DH2282 –19–12MAY93–1/1
DIGITAL DISPLAY
Engine running:
–UN–19MAY92
tachometer, to the speedometer (in mph), to the
speedometer (in km/h), to the hourmeter, to the voltmeter,
and then back to the tachometer. If the switch is pressed
continuously, the information will sequence every 4
seconds. T7747AT
TX,10,DH2347 –19–19MAY93–1/1
10–4
PN=35
Operator’s Station
All the arrows will flash, STOP indicator light will flash,
–UN–19MAY92
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
T7747AU
action.
TX,10,JC1063 –19–14FEB96–1/1
FUEL GAUGE
–UN–19MAY92
condensation in fuel tank.
T7747AV
TX,10,DH2164 –19–29NOV94–1/1
All arrows will flash, STOP indicator light will flash, and –UN–19MAY92
audible alarm will sound when temperature reaches
above 133°C (271°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
T7747AW
action.
TX,10,JC245 –19–29NOV94–1/1
10–5
PN=36
Operator’s Station
–UN–19MAY92
Indicator light will light, STOP indicator will flash, and
alarm will sound when engine oil pressure is low. Stop
machine. STOP ENGINE IMMEDIATELY.
T7747AA
NOTE: Cold oil or extreme off level operation may cause
indicator to light.
TX,10,DH2153 –19–29NOV94–1/1
–UN–18OCT88
T6201BD
TX,10,DH2549 –19–02OCT92–1/1
TX,10,DH2154 –19–08FEB93–1/1
10–6
PN=37
Operator’s Station
–UN–19MAY92
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.
T7747AC
TX,10,DH2152 –19–02OCT92–1/1
Indicator light will light and STOP indicator light will light
when transmission oil pressure is low. Stop machine and
allow engine to cool. Shut off engine and take corrective
–UN–19MAY92
action.
T7747AD
TX,10,JC1048 –19–16JAN96–1/1
–UN–19MAY92
occurs.
T7747AE
NOTE: Cold oil may cause hydraulic oil filter restriction
indicator light to light until oil is warm.
TX,10,DH2158 –19–13SEP94–1/1
10–7
PN=38
Operator’s Station
–UN–18OCT88
T6201BK
TX,DH,39 –19–12APR93–1/1
–UN–19MAY92
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
T7747AF
action.
TX,10,DH2157 –19–05OCT92–1/1
TX,10,DH2156 –19–05OCT92–1/1
10–8
PN=39
Operator’s Station
Indicator light will light for the first 5 seconds after the
engine is started to warn the operator to fasten seat belt.
–UN–19MAY92
T7747AH
TX,10,DH2344 –19–31JUL92–1/1
–UN–19MAY92
T7747AI
TX,10,DH2345 –19–31JUL92–1/1
–UN–19MAY92
indicator light and alarm come on while
operating. THE SECONDARY STEERING
SYSTEM IS NOT INTENDED FOR
CONTINUOUS USE.
T7747AJ
Indicator light will light, STOP indicator light will flash and
alarm will sound when secondary steering system is
activated. Stop machine immediately and take corrective
action. The secondary steering system is not intended for
continuous use.
TX,10,DH2159 –19–02OCT92–1/1
10–9
PN=40
Operator’s Station
–UN–18OCT88
T6201BG
TX,DH,38 –19–12APR93–1/1
LEVERS
–UN–11JUN92
T7747BO
A—Loader Control Lever—One
Lever Design
TX,10,DH2133 –19–31JUL92–1/3
–UN–11JUN92
T7747BN
TX,10,DH2133 –19–31JUL92–2/3
10–10
PN=41
Operator’s Station
–UN–19MAY92
T7747AM
A—Transmission Control Lever
TX,10,DH2133 –19–31JUL92–3/3
–UN–19MAY92
T7747AN
A—Front Axle Disconnect Lever
TX,10,DH2137 –19–31JUL92–1/1
10–11
PN=42
Operator’s Station
PEDALS
–UN–19MAY92
T7747AO
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
–UN–11JUN92
T7773AG
TX,10,DH2285 –19–18SEP92–1/1
10–12
PN=43
Operator’s Station
NEUTRAL LOCK
–UN–19MAY92
T7747BI
A—Neutral Lock
TX,10,DH2138 –19–02OCT92–1/1
HORN BUTTON
–UN–19MAY92
T7747BJ
A—Horn Button
TX,10,DH2279 –19–18SEP92–1/1
10–13
PN=44
Operator’s Station
–UN–19MAY92
T7747BK
A—Turn Signal Switch
TX,10,DH2280 –19–31JUL92–1/1
–UN–10AUG92
T7773AU
A—Dome Light
B—Swivel Light
TX,10,DH2139 –19–31JUL92–1/1
TX,10,DH2140 –19–02OCT92–1/1
10–14
PN=45
Operator’s Station
–UN–02DEC94
Push windshield wiper knob in to wash window.
T8375AO
wiper.
TX,10,JC271 –19–29NOV94–1/1
–UN–19MAY92
T7747BH
TX,10,DH2143 –19–31JUL92–1/1
TX,10,JC1052 –19–18JAN96–1/1
10–15
PN=46
Operator’s Station
–UN–20OCT88
T6603AQ1
02T,10,MM27 –19–31JUL92–1/1
–UN–15JUN93
T8029AI
TX,10,DH2960 –19–16JUN93–1/2
–UN–15JUN93
T8029AJ
TX,10,DH2960 –19–16JUN93–2/2
10–16
PN=47
Operator’s Station
OPERATING LIGHTS
–UN–02DEC94
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.
T8373BD
Press hazard light switch (C). Both front amber lights (F)
and both rear amber lights (H) will be flashing.
–UN–10AUG92
T7773AX
–UN–10AUG92
T7773AY
A—Operating Light Switch
B—Work Light Switch
C—Hazard Light Switch
D—Front Work Lights—If Equipped
E—Headlights
F—Turn Signals/Hazard Lights
G—Rear Work Lights—If Equipped
H—Turn Signals/Hazard Lights
I—Tail Lights/Brake Lights
TX,10,DH2144 –19–29NOV94–1/1
10–17
PN=48
Operator’s Station
–UN–02DEC94
temperature.
T8373AY
has three speeds.
Press air conditioning switch (D) and turn blower knob (C)
clockwise to increase blower speed in rear vents to
operate air conditioning. Blower has three speeds.
–UN–22MAR96
T100706
544G Shown
TX,10,JC1103 –19–18MAR96–1/1
10–18
PN=49
Operator’s Station
–UN–31AUG92
knob counterclockwise to lower tilt of armrest.
T7829AP
adjustment. Release lever to lock in place.
Ö CAUTION: Seat can move rapidly and may C—Backrest Tilt Adjustment Knob
D—Fore-Aft Adjustment Lever
cause an injury. DO NOT put your full weight on
E—Window
seat while adjusting height. F—Weight Adjustment Knob
TX,10,JC246 –19–29NOV94–1/2
TX,10,JC246 –19–29NOV94–2/2
10–19
PN=50
Operator’s Station
SEAT BELT
–UN–09FEB95
T8415AA
Seat belt and mounting hardware must be inspected Replace the complete seat belt assembly every three
for wear or damage before operating the machine. years regardless of appearance. A date label, to
Replace the belt or mounting hardware if worn or determine the age of the belt, is attached to each belt.
damaged.
MODTX10DH3548 –19–07FEB95–1/1
STORAGE COMPARTMENT
–UN–15JUN93
T8029AK
TX,10,DH2961 –19–18JUN93–1/1
10–20
PN=51
Break-in
ENGINE BREAK-IN OIL
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
• CCMC Specification D4
TX,15,JC1131 –19–21MAY96–1/1
TX,15,DH1800 –19–06JUN91–1/1
15–1
PN=52
Break-in
TX,15,DH1828 –19–16JUN93–1/1
TX,15,DH2147 –19–16JUN93–1/1
15–2
PN=53
Pre-Start Inspection
INSPECT MACHINE DAILY BEFORE
STARTING
D-Clean radiator.
–UN–02DEC94
each other or other parts.
T8374AB
PROTECTIVE DEVICES: Check guards, shields, ROPS,
covers, seat belt.
TX,20,JC273 –19–29NOV94–1/1
20–1
PN=54
Operating the Engine
CHECK INSTRUMENTS BEFORE STARTING
TX,25,DH2148 –19–22JUN93–1/1
–UN–30JUL92
authorized dealer.
T7739AJ
TX,25,DH2149 –19–22JUN93–1/1
–UN–11JAN89
circuitry is bypassed.
TX,25,DH2284 –19–31JUL92–1/3
25–1
PN=55
Operating the Engine
–UN–19MAY92
T7747BR
TX,25,DH2284 –19–31JUL92–2/3
25–2
PN=56
Operating the Engine
–UN–19MAY92
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.
T7747BU
Wait for about 2 minutes, then try again.
TX,25,DH2284 –19–31JUL92–3/3
25–3
PN=57
Operating the Engine
–UN–23AUG88
exploding container. Starting fluid is highly
flammable. Keep container away from heat,
sparks, and open flame. Contents are
pressurized. DO NOT puncture or incinerate
TS281
container. Remove container from machine if
engine does not need starting fluid.
TX,25,JC1155 –19–03JUN96–1/2
25–4
PN=58
Operating the Engine
–UN–19MAY92
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.
T7747BT
REPLACING STARTING AID CAN
–UN–01AUG91
4. Turn container clockwise in starting aid base (C) to
install starting aid can.
T7527EF
OPERATING MACHINE WITHOUT STARTING AID CAN
INSTALLED
TX,25,JC1155 –19–03JUN96–2/2
T82,25,C53 –19–03DEC91–1/1
25–5
PN=59
Operating the Engine
–UN–24OCT91
1. Turn battery disconnect switch OFF, if equipped.
T6508AE1
3. Turn battery disconnect switch ON, if equipped.
–UN–24OCT91
T6713AI1
TX,25,DH2166 –19–12SEP92–1/1
25–6
PN=60
Operating the Engine
TX,25,DH2550 –19–12MAY93–1/1
WARM-UP
TX,25,JC247 –19–29NOV94–1/1
25–7
PN=61
Operating the Engine
TX,DH,40 –19–17JUN91–1/1
TX,25,DH2168 –19–16JUN93–1/2
25–8
PN=62
Operating the Engine
–UN–19MAY92
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.
T7747BR
4. Engage park brake.
TX,25,DH2168 –19–16JUN93–2/2
25–9
PN=63
Driving the Machine
DRIVING ON PUBLIC ROADS
TX,30,DH2123 –19–31JUL92–1/2
–UN–25OCT88
T6458AN1
TX,30,DH2123 –19–31JUL92–2/2
30–1
PN=64
Driving the Machine
02T,30,C47 –19–31JUL92–1/1
TX,30,DH2169 –19–31JUL92–1/2
30–2
PN=65
Driving the Machine
–UN–19MAY92
T7747AN
TX,30,DH2169 –19–31JUL92–2/2
NEUTRAL LOCK
–UN–19MAY92
dismounting.
T7747BI
disengage neutral lock.
TX,30,DH2170 –19–02OCT92–1/1
TX,30,JC248 –19–29NOV94–1/2
30–3
PN=66
Driving the Machine
–UN–19MAY92
give same travel speed as 3rd gear reverse. Select a
gear suitable to operating and road conditions.
T7747AM
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.
TX,30,JC248 –19–29NOV94–2/2
30–4
PN=67
Driving the Machine
TRAVEL SPEEDS
TX,30,DH2172 –19–02OCT92–1/1
30–5
PN=68
Driving the Machine
–UN–08SEP92
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.
T7829AV
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. Switch will be backlit when engaged
(ON).
3. Stop engine.
TX,30,DH2505 –19–16JUN93–1/1
TX,30,DH2173 –19–31JUL92–1/1
30–6
PN=69
Driving the Machine
–UN–11JUN92
NOTE: Transmission clutches are disengaged when park
brake is applied.
T7773AG
Press park brake switch (A) to ON position to engage
park brake.
TX,30,DH2174 –19–06OCT92–1/1
TX,30,DH2176 –19–16JUN93–1/2
30–7
PN=70
Driving the Machine
–UN–19MAY92
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.
T7747BR
4. Engage park brake.
TX,30,DH2176 –19–16JUN93–2/2
30–8
PN=71
Operating the Machine
BOOM AND BUCKET CONTROL LEVER—
ONE LEVER DESIGN
–UN–11JUN92
NOTE: Boom down switch (I) must be pushed while
moving control lever forward to lower boom with
engine stopped.
T7773AC
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).
–UN–02DEC94
Return-to-Dig (lever in full left detent position [G]): Bucket
will return to set dig position.
T8373BA
Lever will remain in this position until boom is at a pre-set
height, then will return to neutral automatically.
TX,35,DH2177 –19–29NOV94–1/1
35–1
PN=72
Operating the Machine
–UN–11JUN92
NOTE: Boom down switch (I) must be pushed while
moving control lever forward to lower boom with
engine stopped.
T7773AE
Move right control lever forward (E) to lower boom or
rearward (F) to raise boom.
–UN–02DEC94
Return-to-Dig (left lever in full rearward detent position
[C]): Bucket will return to set dig position.
T8373BA
position [G]): Lever will remain in this position until boom
is at a pre-set height, then will return to neutral
automatically.
A—Dump bucket
B—Rollback Bucket
C—Return-to-Dig
D—Float
E—Lower Boom
F—Raise Boom
G—Boom Height Kickout
H—Fast Bucket Dump
I—Boom Down Switch
TX,35,DH2178 –19–29NOV94–1/1
35–2
PN=73
Operating the Machine
–UN–21AUG92
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.
T7773CE
Quick shift will not function in 4th gear.
TX,35,DH2490 –19–08OCT92–1/1
35–3
PN=74
Operating the Machine
–UN–11JUN92
control lever forward to lower boom with engine
stopped.
T7773AF
right (C) to tilt coupler forward.
–UN–02DEC94
Release switch to lock pins in place.
T8373AV
raise boom and tilt coupler rearward move lever
between positions (B and D).
A—Lower Boom
B—Raise Boom
C—Tilt Forward
D—Tilt Rearward
E—Pin Disconnect Switch
–UN–29MAR89
T6975AF
TX,35,DH2286 –19–29NOV94–1/1
35–4
PN=75
Operating the Machine
–UN–02DEC94
Release switch to extend and lock pins in place.
T8373AW
TX,35,DH2287 –19–29NOV94–1/1
–UN–02DEC94
T8373AX
TX,35,DH2179 –19–29NOV94–1/1
–UN–02DEC94
brake. This will prevent the machine from
rolling downhill during transmission re-
engagement cycle.
T8373AZ
The clutch cut-off switch (A) must be in clutch disengaged
position before left brake pedal (B) can be used to
disengage transmission clutches. Move switch up to
clutch disengaged position.
TX,35,DH2180 –19–29NOV94–1/1
35–5
PN=76
Operating the Machine
–UN–30JUL92
on while operating. THE SECONDARY
STEERING SYSTEM IS NOT INTENDED
FOR CONTINUOUS USE.
T7773AT
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
TX,35,DH2181 –19–02OCT92–1/1
TX,35,DH2182 –19–02OCT92–1/1
35–6
PN=77
Operating the Machine
1. Start engine.
TX,35,DH2183 –19–31JUL92–1/2
–UN–21OCT88
T6601AI
A—Clearance
B—Cap Screws
C—Cap Screws
D—Mark
TX,35,DH2183 –19–31JUL92–2/2
35–7
PN=78
Operating the Machine
ADJUSTING RETURN-TO-DIG
1. Start engine.
TX,35,DH2184 –19–02OCT92–1/2
–UN–21OCT88
4. Position the boom and bucket in the desired return-to-
dig position. Stop engine.
T6599AD
5. Loosen cap screws (D) and slide bar to align marks
on magnet and return-to-dig switch.
TX,35,DH2184 –19–02OCT92–2/2
35–8
PN=79
Operating the Machine
Clean and level the work area while waiting for truck.
TX,DH,49 –19–06JUN91–1/1
–UN–19MAY92
Remove any overhang before starting to dig at the base
of a bank or stockpile. This can be done with the bucket.
T7747BE
TX,35,DH2276 –19–02OCT92–1/3
TX,35,DH2276 –19–02OCT92–2/3
35–9
PN=80
Operating the Machine
–UN–30JAN90
bank or stockpile.
T7208AV
2. Move transmission control lever to 1st or 2nd gear
depending on ground conditions.
TX,35,DH2276 –19–02OCT92–3/3
–UN–19MAY92
machine is on-the-go.
TX,35,JC1049 –19–17JAN96–1/4
35–10
PN=81
Operating the Machine
–UN–19MAY92
T7747BC
TX,35,JC1049 –19–17JAN96–2/4
–UN–30JAN90
T7208AR
TX,35,JC1049 –19–17JAN96–3/4
–UN–19MAY92
DOZING: With bucket parallel to ground, remove as little
dirt as possible from the top surface. Let dirt spill from
partially dumped bucket to fill in low spots.
T7747BD
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. Also use float position to avoid mixing
surface material with stockpile material.
TX,35,JC1049 –19–17JAN96–4/4
35–11
PN=82
Operating the Machine
BACKDRAGGING
–UN–19MAY92
T7747BG
TX,35,DH2278 –19–31JUL92–1/1
BACKFILLING
–UN–20OCT88
to the bellcrank linkage. When dozing,
keep bucket bottom parallel to the
ground.
T6603AO
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.
TX,35,JC1064 –19–14FEB96–1/1
35–12
PN=83
Operating the Machine
TRUCK LOADING
–UN–27JUN91
2. Run engine near fast idle to penetrate material.
T7511CN
pile.
02T,35,J8 –19–25JUN91–1/1
35–13
PN=84
Transporting
TRANSPORTING PRECAUTIONS
TX,40,FF3416 –19–27MAY93–1/1
–UN–17AUG94
enough, have a low angle, and correct height.
T8301AK
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. If changing direction is required on the
ramp, unload the machine from the ramp,
reposition the machine on the ground, then try
loading again.
TX,40,JC274 –19–29NOV94–1/2
40–1
PN=85
Transporting
–UN–19MAY92
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.
T7747BR
7. Engage park brake.
TX,40,JC274 –19–29NOV94–2/2
40–2
PN=86
Transporting
TOWING PROCEDURE—ENGINE
OPERATIONAL
–UN–20OCT88
regulations. An implement safety lighting kit is
available from your John Deere dealer. Keep
safety items in good condition. Replace missing
or damaged items.
T6629AM
IMPORTANT: Engine cannot be started by towing
because machine is equipped with a
torque converter.
2. Start engine.
TX,40,DH2288 –19–12MAY93–1/2
40–3
PN=87
Transporting
6. Stop engine.
TX,40,DH2288 –19–12MAY93–2/2
TX,40,JC1101 –19–18MAR96–1/4
40–4
PN=88
Transporting
–UN–22MAR96
are disconnected. Use blocks at front and rear
of tires to prevent machine from rolling.
T100701
644G Show
TX,40,JC1101 –19–18MAR96–2/4
TX,40,JC1101 –19–18MAR96–3/4
40–5
PN=89
Transporting
–UN–20OCT88
NOTE: Frame locking bar is installed to prevent weaving
as machine is towed.
T6629AM
13. Move transmission control lever to neutral. Engage
neutral lock.
TX,40,JC1101 –19–18MAR96–4/4
40–6
PN=90
Transporting
SPECIFICATIONS
Approximate machine weight 10 262 kg (22,624 lb)
(544G)
Approximate machine weight (LL) 10 377 kg (22,881 lb)
Approximate machine weight 10 466 kg (23,078 lb)
(TC)
Approximate machine weight 12 398 kg (27,338 lb)
(624G)
Approximate machine weight 15 666 kg (34,538 lb)
(644G)
–UN–19MAR91
1. Attach cables (A) to machine so cables do not rub
machine.
T7477AV
as it is lifted.
TX,40,DH2187 –19–12SEP92–1/1
40–7
PN=91
Fuels and Lubricants
DIESEL FUEL
Consult your local fuel distributor for properties of the gram load level as measured by the BOCLE scuffing
diesel fuel available in your area. test.
In general, diesel fuels are blended to satisfy the low • Sulfur content:
temperature requirements of the geographical area in
which they are marketed. 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. If diesel fuel with sulfur content greater than
0.5% sulfur content is used, reduce the service
In all cases, the fuel shall meet the following interval for engine oil and filter by 50%
properties:
3. DO NOT use diesel fuel with sulfur content
• Cetane Number 40 minimum. Cetane number greater than 1.0%
greater than 50 is preferred, especially for
temperatures below -20°C (-4°F) or elevations Bio-diesel fuels with properties and meeting DIN 51606
above 1500 m (5000 ft). or equivalent specifications may be used.
• Cold Filter Plugging Point (CFPP) below the DO NOT mix used engine oil or any other type of
expected low temperature OR Cloud Point at least lubricant with diesel fuel.
5°C (9°F) below the expected low temperature
TX,45,JC1132 –19–22MAY96–1/1
45–1
PN=92
Fuels and Lubricants
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere TY22030 Diesel Fuel
Conditioner. It provides lubricating properties along with
other useful benefits, such as cetane improver, anti-
oxidant, fuel stabilizer, corrosion inhibitor and others.
TY22030 is specifically for use with low sulfur fuels.
Nearly all other diesel fuel conditioners only improve cold
weather flow and stabilize long-term fuel storage. They do
not contain the lubrication additives needed by rotary fuel
injection pumps.
TX,45,DH3124 –19–20OCT93–1/1
TX,45,JC1156 –19–03JUN96–1/1
45–2
PN=93
Fuels and Lubricants
• plastic containers.
• aluminum containers.
MX,FLBT,C –19–04JUN90–1/1
FUEL TANK
TX,45,DH2188 –19–17AUG92–1/1
45–3
PN=94
Fuels and Lubricants
–19–22MAY96
T101239
Use oil viscosity based on the expected air • John Deere UNI-GARD
temperature range during the period between oil
changes. • API Service Classification CG-4
If John Deere PLUS-50 engine oil and a John Deere • ACEA specification E2
oil filter are used, the service interval for oil and filter
changes may be extended by 50 hours. • CCMC Specification D5
Other oils may be used if they meet one or more of If diesel fuel with sulfur content greater than 0.5% is
the following: used, reduce the service interval by 50%.
TX,45,JC1133 –19–22MAY96–1/1
45–4
PN=95
Fuels and Lubricants
–19–10MAY96
T100663
Use oil viscosity based on the expected air • John Deere Standard JDM J20D
temperature range during the period between oil
changes. • John Deere Standard JDM J27A
The following oils are preferred: Use the following oil when a biodegradable fluid is
required:
• JOHN DEERE HY-GARD
• John DeereBIO-HY-GARD 1
• John Deere Low Viscosity HY-GARD
1
BIO-HY-GARD meets or exceeds the minimum
The following oil is also recommended: biodegradability of 80% within 21 days according to
CEC-L-33–T-82 test method.BIO-HY-GARD should
• John Deere UNI-GARD not be mixed with mineral oils because this reduces
the biodegradability and makes proper oil recycling
Other oils may be used if they meet one of the impossible.
following:
TX,45,JC1050 –19–18JAN96–1/1
45–5
PN=96
Fuels and Lubricants
GREASE
–19–27MAR95
T8358AI
Use grease based on NLGI consistency numbers and • John Deere HIGH TEMPERATURE EP GREASE
the expected air temperature range during the service
interval. • John Deere GREASE-GARD
The following greases are preferred: Other greases may be used if they meet one of the
following:
• John Deere MOLY HIGH TEMPERATURE EP
GREASE • NLGI Performance Classification GC-LB
TX,45,JC1134 –19–22MAY96–1/1
Conditions in certain geographical areas may require The temperature limits and service intervals shown in
lubricant recommendations different from those this manual apply to both conventional and synthetic
printed in this manual. Some John Deere lubricants oils.
may not be available in your location. Consult your
John Deere dealer to obtain information and Re-refined base stock products may be used if the
recommendations. finished lubricant meets the performance
requirements.
Synthetic lubricants may be used if they meet the
performance requirements listed in this manual.
DX,ALTER –19–01FEB94–1/1
45–6
PN=97
Fuels and Lubricants
LUBRICANT STORAGE
Your equipment can operate at top efficiency only if Make certain that all containers are properly marked to
clean lubricants are used. 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.
TX,45,JC1135 –19–22MAY96–1/1
MIXING OF LUBRICANTS
TX,45,JC1136 –19–22MAY96–1/1
45–7
PN=98
Periodic Maintenance
SERVICE YOUR MACHINE AT SPECIFIED
INTERVALS
–UN–22MAR96
example, at 500 hours also service those items (if
applicable) listed under 250 hours, 100 hours, 50 hours
and 10 hours or daily.
T100700
TX,50,JC1104 –19–18MAR96–1/1
–UN–19MAY92
Intervals on the periodic maintenance chart are for
operating in normal conditions. If you operate your
machine in severe conditions, you should service it at
SHORTER INTERVALS.
T7747AT
TX,50,DH2193 –19–02OCT92–1/1
TX,50,DH1964 –19–03JAN92–1/1
50–1
PN=99
Periodic Maintenance
TX,50,DH2194 –19–29NOV94–1/2
–UN–19MAY92
Ö CAUTION: Prevent possible injury from
unexpected machine movement. Never rely on
transmission control lever alone to keep
T7747BR
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.
–UN–02DEC94
unattended.
T8375AM
TX,50,DH2194 –19–29NOV94–2/2
50–2
PN=100
Periodic Maintenance
TX,50,DH2199 –19–17AUG92–1/2
–UN–21AUG92
T7773CL
624G Shown
–UN–21AUG92
T7773CM
TX,50,DH2199 –19–17AUG92–2/2
50–3
PN=101
Periodic Maintenance
BOOM LOCK
–UN–17SEP92
Empty bucket and place in dump position
before installing boom lock.
T7839BB
before installing boom lock.
–UN–22MAR96
4. Tighten boom lock lever.
T100699
644G Shown
TX,50,JC255 –19–29NOV94–1/1
–UN–21AUG92
3. To open lower side shield, remove cotter pin and
washers from engine service door. Open door to its full
extent. Pull lower side shield outward.
T7773CJ
–UN–22MAR96
T100697
TX,50,JC269 –19–29NOV94–1/1
50–4
PN=102
Periodic Maintenance
–UN–19OCT88
T6785CD
–UN–10AUG92
T7773CD
TX,50,DH2198 –19–31JUL92–1/1
–UN–31AUG92
T7829AD
544G Shown
TX,50,DH2200 –19–26AUG92–1/1
50–5
PN=103
Periodic Maintenance
–UN–27JUN91
list and record date and hour meter reading. Use the
second (perforated) copy of this form (immediately
preceding the Service Literature order form inside the
back cover).
T7511CO
Do not tear out or mark on Checklist in the Periodic
Maintenance chapter; keep it to make extra copies.
TX,50,FF2898 –19–09JUL93–1/1
50–6
PN=104
Periodic Maintenance
OILSCAN
–UN–15JUN89
Oil samples should be taken from each system prior to its
recommended oil change interval.
T6828AB
–UN–18OCT88
T6829AB
TX,50,JC1061 –19–12FEB96–1/1
50–7
PN=105
Periodic Maintenance
50–8
PN=106
Periodic Maintenance
TX,50,JC1160 –19–03JUN96–1/1
50–9
PN=107
Maintenance—As Required
CHECK TIRE PRESSURE
–UN–23AUG88
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. Use a safety cage if
TS211
available.
–UN–21OCT88
have the proper equipment and experience to
perform the job. Have it done by your
authorized dealer or a qualified repair service.
T87502
Check tire pressure with an accurate gauge having 7.0
kPa (0.07 bar) (1 psi) graduations.
TX,55,FF2820 –19–25OCT94–1/2
55–1
PN=108
Maintenance—As Required
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 2.0 30
Rear, alternate 310 3.1 45
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
20.5R x 25 L2 or L3 Equiv (1) Star **Front 205 2.0 30
**Rear 170 1.7 25
Rear, alternate 205 2.0 30
23.1 x 26 LS-2 10 140 1.4 20
28L x 26 LS-2 14 170 1.7 25
TX,55,JC248 –19–29NOV94–1/1
55–2
PN=109
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
TX,55,JC1157 –19–03JUN96–1/1
55–3
PN=110
Maintenance—As Required
624G
Ply Operating Pressure*
Tire Size Type 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 2.8 40
23.1 x 26 LS-2 10 140 1.4 20
28L x 26 LS-2 14 170 1.7 25
TX,55,JC1158 –19–03JUN96–1/1
55–4
PN=111
Maintenance—As Required
644G
Ply Operating Pressure*
Tire Size Type 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 2.0 30
Rear, alternate 240 2.4 35
28L x 26 LS-2 14 170 1.7 25
TX,55,JC1159 –19–03JUN96–1/1
TX,55,DH2551 –19–16JUN93–1/1
55–5
PN=112
Maintenance—As Required
TX,55,DH2226 –19–31JUL92–1/3
–UN–01NOV88
T6119AF
TX,55,DH2226 –19–31JUL92–2/3
–UN–01NOV88
T6119AG
TX,55,DH2226 –19–31JUL92–3/3
55–6
PN=113
Maintenance—As Required
–UN–09NOV88
HARD SURFACE.
T47764
(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.
03T,55,MM11 –19–18NOV92–1/1
–UN–10NOV88
1. Wash element in warm water and John Deere R36757
Filter Element Cleaner or equivalent non-sudsing
detergent.
T90673
2. Flush with clean water. Use water pressure under 280
kPa (2.8 bar) (40 psi).
03T,55,C19 –19–24JUL91–1/1
55–7
PN=114
Maintenance—As Required
INSPECT ELEMENT
–UN–10NOV88
• If the element shows damage.
T90684
• After 1000 hours service or annually.
03T,55,C67 –19–24JUL91–1/1
55–8
PN=115
Maintenance—As Required
–UN–19OCT88
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
T6779BQ
for cleaning purposes. Clear area of
bystanders, guard against flying chips, and
wear personal protection equipment including
eye protection.
TX,55,DH2206 –19–31JUL92–1/1
55–9
PN=116
Maintenance—As Required
–UN–18OCT88
between pulleys. 544G, LL, TC, 624G: right side of
engine. 644G: left side of engine.
SPECIFICATIONS
T6603AK
544G, LL, TC, 624G:
Force: 67 N (15 lb) Deflection: 19 mm (0.75 in.)
544G, 624G Shown
–UN–30NOV94
5. Tighten cap screws to 57 N•m (40 lb-ft).
T8372BK
544G Shown
A—Alternator Pulley
B—Fan Pulley
C—Crankshaft Pulley
D—Straight Edge
E—Belt Deflection Gauge
F—Cap Screws
TX,55,JC1138 –19–22MAY96–1/1
55–10
PN=117
Maintenance—As Required
–UN–15NOV90
T7405BG
TX,55,JC1118 –19–20MAR96–1/1
TX,55,DH2491 –19–16MAY95–1/2
4. Tighten petcock.
TX,55,DH2491 –19–16MAY95–2/2
55–11
PN=118
Maintenance—As Required
TX,55,JC283 –19–16MAY95–1/3
–UN–10SEP92
4. Remove hand primer (B) from fuel filter base.
Disassemble hand primer assembly and clean out any
debris.
T7833AJ
–UN–17DEC94
T8387AE
TX,55,JC283 –19–16MAY95–2/3
55–12
PN=119
Maintenance—As Required
5. Remove fuel inlet line (A) and fuel drain plug (C).
–UN–17DEC94
8. Assemble primer assembly and install onto fuel filter
base.
T8387AD
10. Close side shield.
TX,55,JC283 –19–16MAY95–3/3
–UN–22MAR96
T100696
TX,55,JC1105 –19–18MAR96–1/1
55–13
PN=120
Maintenance—As Required
–UN–10AUG94
grille.
2. Remove filter.
T8295AA
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.
5. Tighten thumbscrews.
TX,55,JC1122 –19–16APR96–1/1
55–14
PN=121
Maintenance—Every 10 Hours or Daily
LUBRICATE PIVOTS
–UN–21AUG92
short element life. Valve should suck
closed above 1/3 engine speed.
T7773CQ
cleaner.
TX,60,DH2210 –19–17AUG92–1/1
TX,60,JC1106 –19–18MAR96–1/2
60–1
PN=122
Maintenance—Every 10 Hours or Daily
–UN–31AUG92
BEFORE THE ENGINE IS STARTED: The engine is
full when oil level is in the cross hatched area. It is
acceptable to run the engine when the oil level is
T7829AE
above the ADD mark.
AFTER THE ENGINE HAS BEEN RUN: Allow the oil 544G Shown
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.
–UN–31AUG92
T7829AF
624G Shown
–UN–22MAR96
T100695
644G Shown
TX,60,JC1106 –19–18MAR96–2/2
60–2
PN=123
Maintenance—Every 10 Hours or Daily
–UN–15DEC94
recovery tank.
T8385AE
cap unless engine is cool. Then turn cap slowly
to the stop. Release all pressure before you
remove cap.
–UN–18OCT88
If recovery tank is full and radiator is low, check for leaks
in radiator cap and hose connections between radiator
and coolant recovery tank.
T6274AQ
TX,60,JC280 –19–16MAY95–1/1
TX,60,DH2213 –19–16JUN93–1/3
60–3
PN=124
Maintenance—Every 10 Hours or Daily
–UN–10AUG92
T7773CB
TX,60,DH2213 –19–16JUN93–2/3
–UN–15JUN93
T8029AM
TX,60,DH2213 –19–16JUN93–3/3
60–4
PN=125
Maintenance—Every 10 Hours or Daily
3. Install dipstick.
4. Start engine.
–UN–21AUG92
5. Engage service brakes. Move clutch cut-off switch up,
to disengaged position.
T7773CP
6. Release park brake.
11. Check oil level with engine at slow idle. Oil must be
between marks on dipstick.
TX,60,DH2214 –19–02OCT92–1/1
60–5
PN=126
Maintenance—Every 100 Hours
LUBRICANT BOOM, BUCKET, AND
CYLINDER PIVOTS
–UN–20OCT88
T6523CP1
Six Points, 544G Shown
–UN–21JUN93
T8029AS
Four Points, 544G Shown
–UN–25OCT88
T6570AR1
70–1
PN=127
Maintenance—Every 100 Hours
–UN–17SEP92
Lower equipment to ground.
T7829BF
seals. (See Fuels and Lubricants chapter.)
Four Points, Right Side Shown
–UN–17SEP92
T7829BG
Eight Points
TX,70,DH2290 –19–02OCT92–1/2
70–2
PN=128
Maintenance—Every 100 Hours
–UN–17SEP92
T7829BH
Five Points
TX,70,DH2290 –19–02OCT92–2/2
70–3
PN=129
Maintenance—Every 100 Hours
–UN–22MAR96
Lubricate each point with three shots of grease. (See
Fuels and Lubricants chapter.)
T100694
Four Points, 644G Left Side Shown
–UN–25OCT88
T6597AB1
A—Right Steering Cylinder (Head
End)
B—Left Steering Cylinder (Head
End)
TX,70,JC1107 –19–18MAR96–1/1
70–4
PN=130
Maintenance—Every 100 Hours
–UN–22MAR96
Lubricate each point with 10 shots of grease. (See Fuels
and Lubricants chapter.) Grease daily when operating in
deep mud, water, or snow.
T100693
Two Points, 644G Shown
–UN–25OCT88
T6597AB
A—Rear Axle Front Oscillating
Pivot
B—Rear Axle Rear Oscillating Pivot
TX,70,JC1108 –19–18MAR96–1/1
TX,70,JC1056 –19–24JAN96–1/2
70–5
PN=131
Maintenance—Every 100 Hours
–UN–31AUG92
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
T7829AC
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.
TX,70,JC1056 –19–24JAN96–2/2
70–6
PN=132
Maintenance—Every 250 Hours
CHECK RECEIVER DRYER MOISTURE
INDICATOR
–UN–30NOV94
saturated and should be changed
within the next 100 machine hours to
prevent further buildup of moisture in
the refrigerant.
T8372BH
1. Remove rubber plug (A) on right front panel.
TX,75,JC260 –19–16MAY95–1/2
–UN–30NOV94
4. Install plug.
T8372BG
TX,75,JC260 –19–16MAY95–2/2
75–1
PN=133
Maintenance—Every 250 Hours
NOTE: If engine has not run 250 hours before the season
changes, change oil.
TX,75,JC1109 –19–18MAR96–1/4
75–2
PN=134
Maintenance—Every 250 Hours
–UN–08OCT92
T7853AI
624G Shown
TX,75,JC1109 –19–18MAR96–2/4
75–3
PN=135
Maintenance—Every 250 Hours
–UN–31AUG92
gasket touches mounting surface.
T7829AH
12. Tighten drain valve.
SPECIFICATION
Includes filter change:
544G, LL, TC, 624G 19 L (20 qt)
–UN–31AUG92
644G 24 L (25 qt)
T7829AI
IMPORTANT: Before starting engine after a filter
change, crank engine for 10 seconds 624G Shown
without starting to refill filter and
prelubricate turbocharger.
–UN–22MAR96
engine immediately and find cause.
19. Stop the engine. Check oil level. The engine is full
when oil level is in the cross hatched area on the
T100692
dipstick.
644G Shown
TX,75,JC1109 –19–18MAR96–3/4
75–4
PN=136
Maintenance—Every 250 Hours
TX,75,JC1109 –19–18MAR96–4/4
–UN–01NOV88
before you remove cap.
T6642EK
NOTE: If radiator coolant level is low, check for leaks on
radiator cap, and hose connections between
radiator and coolant recovery tank.
TX,75,DH3501 –19–29NOV94–1/1
75–5
PN=137
Maintenance—Every 500 Hours
LUBRICANT FRONT DRIVELINE
–UN–08OCT92
NOTE: To prevent plug loss, lubricate the machine when
it is fully articulated or half articulated and NOT in
the straight position.
T7853AJ
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.
TX,80,JC1139 –19–23MAY96–1/1
–UN–17SEP92
T7829BD
544G Shown
–UN–22MAR96
T100707
644G Shown
TX,80,JC1110 –19–18MAR96–1/1
80–1
PN=138
Maintenance—Every 500 Hours
–UN–23AUG88
• Filling batteries in a well-ventilated area.
TS203
• Avoiding breathing fumes when electrolyte is
added.
If acid is swallowed:
TX,75,DH1574 –19–28APR93–1/4
80–2
PN=139
Maintenance—Every 500 Hours
TX,75,DH1574 –19–28APR93–2/4
–UN–10FEB89
2. Fill each cell to within specified range with distilled
water. DO NOT overfill.
T6996DB
Ö CAUTION: Prevent possible injury. ALWAYS
remove grounded (-) battery clamp first and
replace it last.
–UN–10FEB89
T6996DA
A—Battery Post
B—Fill Tube
C—Electrolyte Level Range
TX,75,DH1574 –19–28APR93–3/4
80–3
PN=140
Maintenance—Every 500 Hours
–UN–21OCT88
6. Install and tighten clamps, grounded clamp last.
T6758AA
TX,75,DH1574 –19–28APR93–4/4
80–4
PN=141
Maintenance—Every 500 Hours
CHECK COOLANT
–19–14MAY96
removing cap.
T101279
NOTE: A coolant strip test, available from your dealer,
provides a simple, effective way to check freeze
point and molybdate/nitrite levels. These results
can be compared to the SCA chart to determine
the amount of coolant conditioner in your system.
–UN–23AUG88
coolant from the radiator to allow room for the
conditioner.
SPECIFICATIONS
TS281
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)
TX,80,JC1140 –19–23MAY96–1/1
80–5
PN=142
Maintenance—Every 500 Hours
–UN–31AUG92
2. Turn sediment bowl (B) counterclockwise to remove
from filter assembly.
T7829AR
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 624G Shown
down and release filter from base.
–UN–17DEC94
T8387AE
TX,80,JC427 –19–18JAN96–1/2
–UN–17DEC94
8. Assemble primer assembly and install onto new fuel
filter base.
TX,80,JC427 –19–18JAN96–2/2
80–6
PN=143
Maintenance—Every 500 Hours
–UN–31AUG92
2. Clean filter base.
T7829AS
4. Bleed fuel system. (See Bleeding Fuel System in
Maintenance chapter.)
544G Shown
TX,80,DH2506 –19–02OCT92–1/1
–UN–01MAY89
3. Install new filter. Tighten clamps.
T7034AH
TX,80,DH2225 –19–29AUG92–1/1
80–7
PN=144
Maintenance—Every 500 Hours
–UN–22MAR96
T100705
644G Shown
TX,80,JC1111 –19–18MAR96–2/2
TX,80,JC1112 –19–18MAR96–1/2
80–8
PN=145
Maintenance—Every 500 Hours
–UN–17SEP92
T7829BE
544G Shown
–UN–22MAR96
T100708
644G Shown
TX,80,JC1112 –19–18MAR96–2/2
–UN–08OCT92
sumps.
T7853AK
2. Oil must be to bottom of opening.
Front Differential Shown
80–9
PN=146
Maintenance—Every 500 Hours
–UN–08OCT92
air pressure.
T7853AK
2. Start engine.
Front Differential Shown
4. Stop engine.
–UN–20OCT88
opening. If not, install plugs and repeat steps 2—4 until
oil seeps from opening.
T6570AC2
and Lubricants chapter.)
TX,80,DH2965 –19–23JUN93–1/1
80–10
PN=147
Maintenance—Every 1000 Hours
LUBRICATE REAR DRIVELINE
–UN–11JUN91
NOTE: To prevent plug loss, lubricate the machine when
it is fully articulated or half articulated and NOT in
the straight position.
T7516BG
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.
TX,85,DH2477 –19–31JUL92–1/1
SPECIFICATIONS
544G, LL, TC 624G 644G
SLOW IDLE 825—875 rpm 825—875 rpm 775—825 rpm
(S.N. -544523)
875—925 rpm
(S.N. 544524- )
FAST IDLE 2350—2400 2300—2350 2300—2350
rpm rpm rpm
TX,85,JC254 –19–29NOV94–1/1
85–1
PN=148
Maintenance—Every 1000 Hours
–UN–06OCT92
T7853AB
A—Swivel B—Cable C—Lever D—Stop Screw
1. With accelerator pedal at slow idle, disconnect 2. Depress accelerator pedal until injection pump
swivel (A) on speed control cable (B) and adjust lever is against fast idle stop and hold.
until:
3. Adjust pedal stop screw (D) until it makes contact
544G, LL, TC, and 624G: Injection pump lever (C) with the pedal. Release pedal.
has 2—4 mm (0.08—0.16 in.) of override at the
slow idle position. Connect cable to injection pump 4. 544G, LL, TC, and 624G: Shorten pedal stop
lever. screw until 2—4 mm (0.09—0.16 in.) override is
obtained at the pump.
644G: Hole in injection pump lever just lines up with
swivel at the slow idle position. Lengthen cable two 644G: Tighten lock nut.
turns. Connect to injection pump lever.
TX,85,DH2229 –19–02OCT92–1/1
85–2
PN=149
Maintenance—Every 1000 Hours
–UN–21AUG92
Replace dust valve (A).
T7773CQ
624G Shown
TX,85,DH2246 –19–26AUG92–1/1
1. Remove cover.
TX,85,DH2245 –19–31JUL92–1/3
–UN–01NOV88
T6119AF
TX,85,DH2245 –19–31JUL92–2/3
is centered in canister.
6. Install cover.
T6119AG
TX,85,DH2245 –19–31JUL92–3/3
85–3
PN=150
Maintenance—Every 1000 Hours
–UN–31AUG92
T7829AK
544G Shown
–UN–31AUG92
T7829AL
624G Shown
–UN–22MAR96
T100691
644G Shown
TX,85,DH2230 –19–02OCT92–1/1
85–4
PN=151
Maintenance—Every 1000 Hours
TX,85,JC1057 –19–24JAN96–1/4
85–5
PN=152
Maintenance—Every 1000 Hours
–UN–23SEP92
T7853AA
TX,85,JC1057 –19–24JAN96–2/4
–UN–06OCT92
12. Install new filter. Turn filter clockwise by hand until
gasket touches mounting surface.
TX,85,JC1057 –19–24JAN96–3/4
85–6
PN=153
Maintenance—Every 1000 Hours
SPECIFICATIONS
Includes filter change
544G, LL, TC, 9.5 L (10 qt)
624G 11 L (12 qt)
644G 14 L (15 qt)
–UN–21AUG92
19. Check oil level. Oil must be between marks on
dipstick.
T7773CP
20. Check for leaks around the filter base. Tighten filter
only enough to stop leaks.
624G Shown
TEFLON is a trademark of the DuPont Company.
TX,85,JC1057 –19–24JAN96–4/4
1. Start engine.
TX,85,DH2561 –19–09OCT92–1/2
85–7
PN=154
Maintenance—Every 1000 Hours
–UN–11JUN92
6. If necessary, adjust park brake.
T7773AG
TX,85,DH2561 –19–09OCT92–2/2
TX,85,JC1141 –19–23MAY96–1/3
–UN–19MAY92
Machine can unexpectedly roll or move under
power, resulting in death or serious injury.
Always block wheels to hold machine when
working on park brake.
T7747BR
4. Install frame locking bar.
TX,85,JC1141 –19–23MAY96–2/3
85–8
PN=155
Maintenance—Every 1000 Hours
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.)
–UN–22MAR96
T100701
TX,85,JC1141 –19–23MAY96–3/3
85–9
PN=156
Maintenance—Every 1000 Hours
–UN–22MAR96
T100690
644G Shown
TX,85,JC1113 –19–18MAR96–1/1
85–10
PN=157
Maintenance—Every 2000 Hours
MEASURE AND ADJUST ENGINE VALVE
LASH (CLEARANCE)—544G, LL, TC, 624G
TX,85,DH2239 –19–31JUL92–1/5
–UN–27OCT88
both are loose, proceed with adjustment per chart on
No. 1 TDC. If both pushrods at number six are loose,
proceed with adjustment per chart on No. 6 TDC.
T6129AJ
TX,85,DH2239 –19–31JUL92–2/5
TX,85,DH2239 –19–31JUL92–3/5
86–1
PN=158
Maintenance—Every 2000 Hours
–19–27JAN89
T6233AG
TX,85,DH2239 –19–31JUL92–4/5
–19–27JAN89
11. Install rocker arm cover gasket. Do not use sealant
on the gasket.
T6233AH
12. Install rocker arm cover. Tighten screws to 10.8 N•m
(96 lb-in.). Do not overtighten cap screws.
TX,85,DH2239 –19–31JUL92–5/5
86–2
PN=159
Maintenance—Every 2000 Hours
TX,86,JC1142 –19–23MAY96–1/4
TX,86,JC1142 –19–23MAY96–2/4
86–3
PN=160
Maintenance—Every 2000 Hours
–19–27JAN89
T6233AI
TX,86,JC1142 –19–23MAY96–3/4
–19–27JAN89
14. Install rocker arm cover. Tighten cap screws to 10.8
N•m (96 lb-in).
T6233AJ
15. Install parts.
TX,86,JC1142 –19–23MAY96–4/4
86–4
PN=161
Maintenance—Every 2000 Hours
–UN–23AUG89
Lubricate until grease escapes around seal. (See Fuels
and Lubricants chapter.)
T7114AS
NOTE: Grease every 250 hours if operating in deep mud
or water.
One Point
TX,86,JC1143 –19–23MAY96–1/1
86–5
PN=162
Maintenance—Every 3000 Hours
CHANGE HYDRAULIC SYSTEM OIL
–UN–15JUN93
T8029AN
TX,86,JC281 –19–16MAY95–1/3
–UN–15DEC94
4. Tighten drain valve.
T8385AF
SPECIFICATIONS
544G, LL, TC Approx. 76 L (80 qt)
624G Approx. 102 L (108 qt)
644G Approx. 115 L (122 qt)
TX,86,JC281 –19–16MAY95–2/3
TX,86,JC281 –19–16MAY95–3/3
87–1
PN=163
Maintenance—Every 3000 Hours
–UN–15JUN93
3. Inspect gasket and replace if necessary.
T8029AO
TX,86,DH2963 –19–16JUN93–1/1
–UN–15JUN93
3. Inspect gasket and replace if necessary.
T8029AO
TX,86,DH2250 –19–16JUN93–1/2
–UN–21SEP92
until tight.
T7829BI
TX,86,DH2250 –19–16JUN93–2/2
87–2
PN=164
Maintenance—Every 3000 Hours
–UN–08OCT92
NOTE: It is normal for differential lock axles to be filled
approximately 1—2 L (1—2 qt) above level plug.
SPECIFICATIONS
T7853AO
544G Front and Rear, each Approx. 19 L (20 qt)
624G Front Approx. 28 L (30 qt)
Front Differential Shown
624G Rear Approx. 19 L (20 qt)
644G Front and Rear, each Approx. 28 L (30 qt)
–UN–08OCT92
T7853AP
Rear Differential Shown
TX,87,JC1058 –19–24JAN96–1/5
–UN–20OCT88
T6523CY
TX,87,JC1058 –19–24JAN96–2/5
TX,87,JC1058 –19–24JAN96–3/5
87–3
PN=165
Maintenance—Every 3000 Hours
5. Open left service door. Remove fill plug (A) from rear
differential.
–UN–08OCT92
T7853AR
TX,87,JC1058 –19–24JAN96–4/5
–UN–08OCT92
7. Install fill plugs.
T7853AK
Front Differential Shown
–UN–20OCT88
T6570AC2
Rear Differential Shown
TX,87,JC1058 –19–24JAN96–5/5
87–4
PN=166
Maintenance
DRAINING THE COOLING SYSTEM
–UN–23AUG88
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
TS281
1. Check hoses (A) for cracks and leaks. Replace, if
necessary.
2. Tighten clamps.
–UN–20OCT88
T6523CC
TX,90,JC1114 –19–18MAR96–1/4
TX,90,JC1114 –19–18MAR96–2/4
90–1
PN=167
Maintenance
–UN–31AUG92
T7829AN
544G, 624G Shown
TX,90,JC1114 –19–18MAR96–3/4
–UN–22MAR96
T100709
644G Shown
TX,90,JC1114 –19–18MAR96–4/4
90–2
PN=168
Maintenance
The engine cooling system is filled to provide year- duty diesel engines, for protection against corrosion
round protection against corrosion and cylinder liner and cylinder liner erosion and pitting.
pitting, and winter freeze protection to -37°C (-34°F).
A 50 percent mixture of ethylene glycol engine coolant
The following engine coolant is preferred for service: in water provides freeze protection to -37°C (-34°F). If
protection at lower temperatures is required, consult
• John Deere PREDILUTED ANTIFREEZE/SUMMER your John Deere dealer for recommendations.
COOLANT
Water quality is important to the performance of the
The following engine coolant is also recommended: cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
• John Deere ANTIFREEZE/SUMMER COOLANT base engine coolant concentrate.
CONCENTRATE in a 40 to 60 percent mixture of
concentrate and quality water. IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
Other low silicate ethylene glycol base coolants for sealing additives.
heavy-duty diesel engines may be used if they meet
one of the following specifications: COOLANT DRAIN INTERVALS
• ASTM D5345 (prediluted coolant) Drain and flush the cooling system and refill with fresh
coolant every 24 months or 2000 hours of operation.
• ASTM D4985 (coolant concentrate) in a 40 to 60
percent mixture of concentrate with quality water When John Deere PREDILUTED ANTIFREEZE/
SUMMER COOLANT is used, the service interval may
Coolants meetings these specifications require use of be extended to 36 months or 3000 hours of operation.
supplemental coolant additives, formulated for heavy-
TX,90,JC1144 –19–23MAY96–1/1
90–3
PN=169
Maintenance
TX,90,JC1145 –19–23MAY96–1/1
TX,90,JC1117 –19–18MAR96–1/1
90–4
PN=170
Maintenance
• Overheating
• Improper operation
• Excessive idling
T82,SKMA,A –19–28JUL94–1/1
IMPORTANT: Never steam clean or pour cold Adjusting the injection pump in any way not approved
water on an injection pump while by the manufacturer will end the warranty. (See your
the engine is running, or while copy of the John Deere warranty on this machine.)
injection pump is still warm. To do
so may cause seizure of pump. Do not attempt to service an injection pump that is not
operating correctly. (See your authorized injection
Clean trash regularly from injection pump service center.)
pump.
TX,DH,236 –19–06JUN91–1/1
TX,90,DH2259 –19–12MAY93–1/2
90–5
PN=171
Maintenance
–UN–20OCT88
4. Disconnect fuel hose. Remove hose clamp (A).
T6523BW1
6. Remove debris from screen with clean solvent or
diesel fuel, or install a new screen.
TX,90,DH2259 –19–12MAY93–2/2
90–6
PN=172
Maintenance
–UN–10SEP92
3. Pump hand primer (B) until bleed screw (E) has solid
stream of fuel.
T7833AJ
screw has solid stream of fuel coming from it. Tighten
bleed screw on final fuel filter.
TX,90,JC285 –19–16MAY95–1/1
90–7
PN=173
Maintenance
2. Loosen bleed screw (C), and push pump (D) until fuel
free of bubbles flows from around bleed screw.
4. Loosen bleed screw (B) from final fuel filter (A), and
push pump (D) until fuel free of bubbles flows from
around bleed screw.
–UN–22MAR96
T100696
A—Final Fuel Filter
B—Bleed Screw
C—Bleed Screw
D—Pump
E—Fuel Supply Line
F—Primary Fuel Filter
G—Drain Valve
TX,90,JC1115 –19–18MAR96–1/1
TX,90,DH2534 –19–16JUN93–1/1
90–8
PN=174
Maintenance
When batteries are connected, follow these rules: 6. Connect batteries or a booster battery in the
correct polarity (positive [+] to positive [+] and
1. Disconnect negative (-) battery cable when you negative [-] to negative [-]).
work on or near alternator or regulator.
7. Do not disconnect the batteries when engine is
2. DO NOT TRY TO POLARIZE ALTERNATOR OR running and alternator is charging.
REGULATOR.
8. Disconnect battery cables before you connect
3. Be sure alternator wires are correctly connected battery charger to the batteries. If machine has
BEFORE you connect batteries. more than one battery, each battery must be
charged separately.
4. Do not ground alternator output terminal.
04T,90,C151 –19–20JUL92–1/1
90–9
PN=175
Maintenance
–UN–23AUG88
object across the posts. Use a voltmeter or
hydrometer.
TS204
and replace it last.
–UN–23AUG88
• Apply baking soda or lime to help neutralize
the acid.
TS203
• Flush your eyes with water for 15—30
minutes. Get medical attention immediately.
If acid is swallowed:
TX,90,DH1018 –19–30APR94–1/2
90–10
PN=176
Maintenance
TX,90,DH1018 –19–30APR94–2/2
90–11
PN=177
Maintenance
–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
TS204
Always remove grounded (-) battery clamp first
and replace it last.
–UN–23AUG88
• Flush your skin with water.
TS203
• Flush your eyes with water for 15—30
minutes. Get medical attention immediately.
If acid is swallowed:
04T,90,FF20 –19–12MAY93–1/3
90–12
PN=178
Maintenance
04T,90,FF20 –19–12MAY93–2/3
–UN–10NOV88
charge the battery.
T85402
charge reading.
04T,90,FF20 –19–12MAY93–3/3
90–13
PN=179
Maintenance
–UN–23AUG88
in the machine to prevent damage to electrical
components.
TS204
booster if a battery has a 1.150 specific
gravity reading or lower. Turn off
charger before connecting or
disconnecting it.
TX,FF,121 –19–15MAR93–1/1
REPLACING BATTERIES
544G, 624G:
625 cold cranking amps at -18°C (0°F)
160 minutes reserve capacity at 25 amps
644G:
950 cold cranking amps at -18°C (0°F)
180 minutes reserve capacity at 25 amps
TX,90,JC1146 –19–23MAY96–1/1
90–14
PN=180
Maintenance
REMOVING BATTERIES
TX,90,DH1768 –19–06JUN91–1/2
–UN–20OCT88
T6570AD2
TX,90,DH1768 –19–06JUN91–2/2
REPLACING FUSES
–UN–08OCT92
The fuse box (A) is in the electrical load center on the
right side (outside) of the cab. Both fuses and circuit
breakers are located in the load center.
T7853AS
TX,90,DH2266 –19–02OCT92–1/1
04T,90,J22 –19–28SEP92–1/1
90–15
PN=181
Maintenance
04T,90,C155 –19–06JUN91–1/1
–UN–17APR89
installed.
T5894AG1
Before disassembling, remember how bezel and lens are
installed with respect to mounting stud.
–UN–20OCT88
T5894AI1
TX,90,RR,1725 –19–11MAR94–1/2
90–16
PN=182
Maintenance
–UN–19OCT88
3. To disconnect ground wiring lead, push tab up, then
pull connector from terminal.
T6249AU
bare hands. Oil and moisture may
cause premature bulb failure. Clean
bulb using a soft, oil-free cloth and
alcohol. A—Flange Nut
B—Lock Washer
C—Housing
4. Install new bulb so square notch is aligned with square D—Bulb
tab on reflector back. E—Gasket
F—Lens
5. Install retainer clip into locking tabs on reflector back. G—Bezel
H—Screw
TX,90,RR,1725 –19–11MAR94–2/2
90–17
PN=183
Maintenance
–UN–08OCT92
local regulations.
T7853AT
To change alarm volume, move switch (A) to desired
position.
TX,90,DH2566 –19–03FEB95–1/1
TX,90,DH2556 –19–02OCT92–1/1
90–18
PN=184
Maintenance
ADDING ATTACHMENTS/ACCESSORIES TO
ROLL-OVER PROTECTIVE STRUCTURE
(ROPS)
04T,90,K117 –19–16MAR88–1/1
TX,90,DH2539 –19–12MAY93–1/2
TX,90,DH2539 –19–12MAY93–2/2
90–19
PN=185
Maintenance
TX,90,DH1756 –19–31JUL92–1/1
WELDING ON MACHINE
TX,90,JC1060 –19–25JAN96–1/1
90–20
PN=186
Maintenance
TX,90,DH2348 –19–19MAY93–1/3
–UN–19MAY92
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.
T7747BR
4. Install frame locking bar.
5. Stop engine.
TX,90,DH2348 –19–19MAY93–2/3
90–21
PN=187
Maintenance
–UN–08OCT92
T7853AU
TX,90,DH2348 –19–19MAY93–3/3
TX,90,JC263 –19–29NOV94–1/4
90–22
PN=188
Maintenance
–UN–25OCT88
T6523BZ
TX,90,JC263 –19–29NOV94–2/4
–UN–25OCT88
T6138AZ
TX,90,JC263 –19–29NOV94–3/4
–UN–03DEC93
T8137AC
TX,90,JC263 –19–29NOV94–4/4
90–23
PN=189
Maintenance
1. Start engine.
TX,90,JC1116 –19–18MAR96–1/2
–UN–22MAR96
T100704
TX,90,JC1116 –19–18MAR96–2/2
90–24
PN=190
Maintenance
–UN–08SEP92
1. Start engine.
T7829AV
3. Raise boom to maximum height and hold control lever
over relief for 2 seconds.
TX,90,DH2560 –19–12MAY93–1/2
–UN–08OCT92
your authorized dealer.
T7853AV
TX,90,DH2560 –19–12MAY93–2/2
90–25
PN=191
Maintenance
BLEEDING BRAKES
–UN–23AUG88
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
X9811
hand.
TX,DH,114 –19–06JUN91–1/2
90–26
PN=192
Maintenance
–UN–20OCT88
T6522BR
TX,DH,114 –19–06JUN91–2/2
90–27
PN=193
Maintenance
TX,DH,115 –19–06JUN91–1/1
TX,90,DH2541 –19–02OCT92–1/2
90–28
PN=194
Maintenance
–UN–08SEP92
T7817AL
A—Nut
B—Lever
C—Switch Assembly
D—Gap
TX,90,DH2541 –19–02OCT92–2/2
TX,90,DH2537 –19–03SEP92–1/1
90–29
PN=195
Maintenance
T82,SKMA,AT –19–01AUG94–1/1
–UN–23AUG88
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
TS176
be replaced, not reused.
04T,90,MM8 –19–25JUN91–1/1
90–30
PN=196
Maintenance
–19–04MAR91
TS1163
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
a a a a a a
Size Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Drya
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft
M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5
M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35
M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70
M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 190
M16 100 73 125 92 190 140 240 175 275 200 350 255 320 240 400 300
M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410
M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580
M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800
M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000
M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500
M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
DX,TORQ2 –19–20JUL94–1/2
90–31
PN=197
Maintenance
DO NOT use these values if a different torque value or properly start thread engagement. This will prevent
tightening procedure is given for a specific application. them from failing when tightening.
Torque values listed are for general use only. Check
tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to
approximately 50 percent of the dry torque shown in
Shear bolts are designed to fail under predetermined the chart, applied to the nut, not to the bolt head.
loads. Always replace shear bolts with identical Tighten toothed or serrated-type lock nuts to the full
property class. torque value.
a
Fasteners should be replaced with the same or higher ”Lubricated” means coated with a lubricant such as
property class. If higher property class fasteners are engine oil, or fasteners with phosphate and oil
used, these should only be tightened to the strength coatings. “Dry” means plane or zinc plated without
of the original. any lubrication.
DX,TORQ2 –19–20JUL94–2/2
90–32
PN=198
Maintenance
–UN–18OCT88
Ö CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly.
They may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if T-Bolt
a different torque value or tightening procedure is listed
for a specific application.
–UN–18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
H-Bolt
Make sure fastener threads are clean and you properly
start thread engagement. This will prevent them from
failing when tightening.
–UN–18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
METRIC CAP SCREW TORQUE VALUES
Nominal T-Bolt H-Bolt M-Bolt
Dia N•m lb-ft N•m lb-ft N•m lb-ft M-Bolt
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
04T,90,M170 –19–01AUG94–1/2
90–33
PN=199
Maintenance
–19–04MAR91
TS1162
Grade 1 Grade 2b Grade 5, 5.1, or 5.2 Grade 8 or 8.2
a a a a a a
Size Lubricated Dry Lubricated Dry Lubricateds Dry Lubricateda Drya
N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft 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 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26
3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46
7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75
1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115
9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160
5/8 67 50 85 62 105 78 135 100 170 125 215 160 240 175 300 225
3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400
7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650
1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975
1-1/8 400 300 510 375 400 300 510 375 900 675 1150 850 1450 1075 1850 1350
1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
DX,TORQ1 –19–20JUL94–1/2
90–34
PN=200
Maintenance
a
Fasteners should be replaced with the same or higher ”Lubricated” means coated with a lubricant such as
grade. If higher grade fasteners are used, these engine oil, or fasteners with phosphate and oil
should only be tightened to the strength of the coatings. “Dry” means plain or zinc plated without any
original. lubrication.
b
Make sure fasteners threads are clean and that you Grade 2 applies for hex cap screws (not hex bolts)
properly start thread engagement. This will prevent up to 152 mm (6 in.) long. Grade 1 applies for hex cap
them from failing when tightening. screws over 152 mm (6 in.) long and for all other
types of bolts and screws of any length.
Tighten plastic insert or crimped steel-type lock nuts to
approximately 50 percent of the dry torque shown in
the chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
DX,TORQ1 –19–20JUL94–2/2
90–35
PN=201
Maintenance
–UN–23AUG88
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
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. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
–UN–24JAN89
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
T85401
immediately.
TX,90,DH1559 –19–01AUG94–1/1
90–36
PN=202
Maintenance
STRAIGHT FITTING
–UN–18OCT88
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.
T6243AE
3. Tighten fitting to torque value shown on chart.
90–37
PN=203
Maintenance
ANGLE FITTING
–UN–18OCT88
contacts face of boss.
T6520AB
4. Hold fitting head-end with a wrench and tighten
locknut and back-up washer to proper torque value.
TORQUE VALUE
Thread Size N•m lb-ft
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
90–38
PN=204
Maintenance
–UN–18OCT88
2. Inspect the O-ring. It must be free of damage or
defects.
T6243AD
petroleum jelly to hold in place.
04T,90,K67 –19–01AUG94–1/2
90–39
PN=205
Maintenance
–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches DO NOT use air wrenches. DO NOT tighten one
cause leaks. Roughness causes seal wear. cap screw fully before tightening the others. DO
Out-of-flat causes seal extrusion. If defects NOT over tighten.
cannot be polished out, replace component.
TORQUE CHART*
2. Install the correct O-ring (and backup washer if Thread** N•m lb-ft
required) into groove using petroleum jelly to M6 12 9
hold it in place. M8 30 22
M10 57 42
3. Split flange: Loosely assemble split flange (B)
halves. Make sure split is centrally located and M12 95 70
perpendicular to the port. Hand tighten cap M14 157 116
screws to hold parts in place. Do not pinch O- M16 217 160
ring (C). M18 334 246
M20 421 318
4. Single piece flange (D): Place hydraulic line in
center of flange and install four cap screws.
*Tolerance ±10%. The torques given are enough
Flange must be centrally located on port. Hand
for the given size connection with the
tighten cap screws to hold flange in place. Do
recommended working pressure. Increasing cap
not pinch O-ring.
screw torque beyond these amounts will result in
flange and cap screw bending and connection
5. After components are properly positioned and
failures.
cap screws are hand tightened, tighten one cap
screw, then tighten the diagonally opposite cap
**Metric standard thread.
screw. Tighten two remaining cap screws.
Tighten all cap screws as specified in the chart
below.
04T,90,K175 –19–01AUG94–1/1
90–40
PN=206
Maintenance
–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches must be centrally located on port. Hand tighten
cause leaks. Roughness causes seal wear. cap screws to hold flange in place. Do not pinch
Out-of-flat causes seal extrusion. If defects O-ring.
cannot be polished out, replace component.
5. Tighten one cap screw, then tighten the
2. Install O-ring (and backup washer if required) diagonally opposite cap screw. Tighten two
into groove using petroleum jelly to hold it in remaining cap screws. Tighten all cap screws
place. as specified in the chart below.
3. Split flange: Loosely assemble split flange (B) DO NOT use air wrenches. DO NOT tighten one
halves. Make sure split is centrally located and cap screw fully before tightening the others. DO
perpendicular to port. Hand tighten cap screws NOT over tighten.
to hold parts in place. Do not pinch O-ring (C).
90–41
PN=207
Maintenance
TORQUE CHART*
N•m lb-ft
Nominal Flange Cap Screw Size
Size Min Max Min Max
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%. The torques given are enough Increasing cap screw torque beyond this maximum
for the given size connection with the will result in flange and cap screw bending and
recommended working pressure. Torques can be connection failures.
increased to the maximum shown for each cap
screw size if desired.
04T,90,K174 –19–01AUG94–2/2
90–42
PN=208
Operational Checkout
OPERATIONAL CHECKOUT
TX,95,DH2538 –19–03SEP92–1/1
95–1
PN=209
Operational Checkout
– – –1/1
– – –1/1
BATTERY CHECK Press SELECT button and hold until battery volts are OK: Go to next check.
displayed.
Key switch OFF. NOT OK: See Monitor
LOOK: Battery volts must read a minimum of 12.3 volts. Display and Alternator
Output Check in this
group.
– – –1/1
95–2
PN=210
Operational Checkout
IF OK: Go to your
authorized dealer.
T7773BA –UN–05AUG92
LOOK & LISTEN: All monitor indicators and functions, including the alarm, must come
ON after 1 second and remain ON for 5 seconds.
After 5 seconds:
LOOK: Hourmeter and gauges must display a reading and backlighting must be ON.
LOOK & LISTEN: The following indicators must be ON: STOP, Engine Oil Pressure,
Engine Alternator Volts, Transmission Pressure, Steering Pressure (If equipped) and
Brake Pressure.
All monitor indicators and functions must come ON after 1 second and remain ON for
5 seconds.
After 5 seconds:
LOOK: Hourmeter and gauges must display a reading and backlighting must be ON.
LOOK & LISTEN: The following indicators must be ON: STOP, Engine Oil Pressure,
Engine Alternator Volts, Transmission Pressure, Steering Pressure (If equipped), Park
Brake and Brake Pressure.
– – –1/1
95–3
PN=211
Operational Checkout
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.
– – –1/1
( TRANSMISSION CONTROLS, AXLE AND ENGINE LINKAGES, NEUTRAL START SWITCH, AND REVERSE
WARNING ALARM SWITCH CHECKS
– – –1/1
NEUTRAL START AND Turn key switch to ON position and wait 5 seconds. OK: Go to next check
REVERSE WARNING
ALARM CIRCUIT With transmission control lever in reverse "R", forward NOT OK: Check fuse.
CHECKS "F", and neutral "N" positions, turn key switch to START
. IF OK: Go to your
authorized dealer.
LISTEN: Starting motor must run while lever is in neutral
"N" position only.
T7773BI1 –UN–05AUG92
LISTEN: Reverse warning alarm must sound with lever
in reverse "R".
– – –1/1
95–4
PN=212
Operational Checkout
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.
– – –1/1
T8030AN –UN–21JUN93
– – –1/1
ENGINE SPEED Have someone fully depress accelerator pedal (or use a weight). OK: Go to next check.
CONTROL LINKAGE
CHECK—644G LOOK: Injection pump lever must be against fast idle stop. NOT OK: Adjust speed
(CONTINUED) control linkage. See
Adjust Engine Speed
Control Linkage in
Maintenance—Every
1000 Hours chapter.
– – –1/1
95–5
PN=213
Operational Checkout
FUEL SHUT-OFF Open right engine side shield and inspect linkage. OK: Go to next check
SOLENOID LINKAGE
CHECK—644G LOOK: Fuel shut-off cam must be tight against the lower NOT OK: Adjust fuel
stop. shut-off solenoid linkage.
See Adjusting Fuel Shut-
Start engine and engage park brake. Off Solenoid in
Maintenance chapter.
Open right engine side shield and inspect linkage.
T8030AN –UN–21JUN93
LOOK: Fuel shut-off cam must be tight against the upper
stop.
– – –1/1
FRONT AXLE Move front axle disconnect lever (A) up, to disconnect OK: Go to next check.
DISCONNECT CHECK— axle.
IF EQUIPPED NOT OK: Inspect cable
Start engine. linkage to axle, repair as
required.
Lower boom to raise front wheels off ground.
IF OK: Go to your
Move transmission control lever to reverse “R”. authorized dealer.
T7747AN1 –UN–21AUG92
Back drag with bucket.
– – –1/1
95–6
PN=214
Operational Checkout
– – –1/1
T7825BD –UN–21AUG92
T7825BC –UN–21AUG92
T8368BP –UN–02JAN94
– – –1/1
95–7
PN=215
Operational Checkout
– – –1/1
95–8
PN=216
Operational Checkout
MONITOR INDICATOR In a single motion, turn key and start engine. OK: Go to next check
CIRCUIT BYPASS AND
SEAT BELT INDICATOR LOOK & LISTEN: Engine should start and bypass the NOT OK: Check for an
CHECK bulb check mode. unhooked wiring
connecter.
Depress service brake
pedal 10 times. IF OK: Go to your
authorized dealer.
Lock transmission control T7773BH1 –UN–05AUG92
lever in neutral "N".
LOOK: Seat belt indicator must go out after 5 seconds after engine starts.
LOOK: Monitor must display engine rpm and gauges must indicate only one reading.
NOTE: It is normal for Engine Oil Pressure, Brake Pressure, and Transmission
Pressure indicators to stay on 4—6 seconds after engine starts.
– – –1/1
– – –1/1
95–9
PN=217
Operational Checkout
IF OK: Go to your
authorized dealer.
T7773BO2 –UN–05AUG92 T7773BF –UN–05AUG92
– – –1/1
– – –1/1
– – –1/1
95–10
PN=218
Operational Checkout
T7773BQ3 –UN–21AUG92
Stop engine.
Record number of seconds required for low brake pressure indicator light to go out.
LOOK: Indicator light must go out in less than 10 seconds from time engine starts.
NOTE: Indicator light will not come on for approximately 1 second after starting
engine.
– – –1/1
95–11
PN=219
Operational Checkout
T7773BO2 –UN–05AUG92
T7773BQ3 –UN–21AUG92
Apply service brakes, release park brake, and move transmission control lever to 2nd
gear forward.
– – –1/1
BRAKE ACCUMULATOR Start engine and run engine for 30 seconds. OK: Go to next check
PRECHARGE CHECK
Stop engine. Turn key switch to ON and wait 5 seconds. NOT OK: Make sure
NOTE: The axles and brake pedal is not binding
hydraulic oil must be at NOTE: STOP indicator light will be on due to no engine oil pressure. and keeping brakes
operating temperature for partially engaged.
this check. Count the number of times the brake pedal can be fully depressed before the low
brake pressure warning light comes ON. IF OK: Bleed brakes.
See Bleeding Brakes in
LOOK: Warning light must come ON in 1—5 Maintenance chapter.
applications.
NOT OK: If light comes
Start engine and operate at slow idle. ON with engine running,
accumulator not charged.
Observe monitor while applying brake pedal with Go to your authorized
maximum force. dealer.
T7747AF1 –UN–24AUG92
LOOK & LISTEN: Brake pressure indicator MUST NOT
come ON.
– – –1/1
95–12
PN=220
Operational Checkout
Stop engine.
Wait 2 minutes.
LOOK: Brake low pressure warning light MUST NOT come ON within 2 minutes after
stopping engine.
– – –1/1
SERVICE BRAKE PEDAL Slowly depress each brake pedal one at a time. OK: Go to next check
CHECK
Listen for a hissing noise that indicates oil is flowing to brake pistons. NOT OK: Inspect for
Engine OFF. debris under brake pedal.
LISTEN & FEEL: A hissing noise must be heard when pedal is depressed Inspect clutch cut-off
approximately 6 mm (1/4 in.) linkage.
– – –1/1
SERVICE AND PARK Position machine on a gradual slope. OK: Go to next check
BRAKE SYSTEM DRAG
CHECKS Lower bucket approximately 50 mm (2 in.) from ground. NOT OK: Adjust park
brake. See Adjusting Park
Engine running. Release park and service brakes. Brake in Maintenance
chapter.
LOOK: Machine must move or coast.
T6522CH –UN–19OCT88
NOTE: If machine does not move, check brake pedals to
be sure they fully release when feet are removed from
pedals.
– – –1/1
95–13
PN=221
Operational Checkout
T7773BQ1 –UN–21AUG92
– – –1/1
T7773BO2 –UN–05AUG92
T7773BQ2 –UN–21AUG92
NOTE: Clutch cut-off switch on left brake pedal can be adjusted to operator
preference to match your loading needs.
– – –1/1
95–14
PN=222
Operational Checkout
+ DRIVING CHECKS
– – –1/1
Engine rpm MUST NOT "lug down" as transmission is shifted between gears.
– – –1/1
95–15
PN=223
Operational Checkout
AUTOMATIC SHIFT AND Press SELECT button on monitor until MPH or Km/H is OK: Go to next check.
SPEEDOMETER CHECK displayed.
NOT OK: Monitor is
Engine running. Release park brake and move transmission control lever programmed for wrong
to 4th gear forward. machine model. Go to
your authorized dealer.
Drive machine on level ground and slowly accelerate to
fast idle speed. Note speed when shifts are made until NOT OK: Transmission
T7825BG –UN–21AUG92
4th gear. Reduce engine rpm to idle and note speed controller does not match
when transmission makes each downshift. machine model. Go to
your authorized dealer.
LOOK: Transmission should shift at following speeds:
– – –1/1
95–16
PN=224
Operational Checkout
TRANSMISSION Release park brake and move transmission control lever OK: Go to next check.
QUICKSHIFT CHECK to 2nd gear forward.
NOT OK: Check
Engine running. Drive machine at approximately 1600 rpm and press connector at base of
boom control lever switch once. control valve.
LOOK & FEEL: Transmission must shift to 1st gear. IF OK: Go to your
authorized dealer.
T7825BL1 –UN–31AUG92
Press boom control lever switch once.
– – –1/1
Wait 5 seconds after each shift and observe transmission pressure indicator light.
T7747AD1 –UN–24AUG92
– – –1/1
95–17
PN=225
Operational Checkout
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.
– – –1/1
– – –1/1
– – –1/1
BOOM DOWN SOLENOID Raise boom to full height. Roll bucket back. OK: Go to next check
VALVE CHECK
Stop engine. NOT OK: Check fuse.
Engine running.
Hold boom down switch down. IF OK: Go to your
authorized dealer.
Move control lever to bucket dump position.
– – –1/1
95–18
PN=226
Operational Checkout
CONTROL VALVE LIFT With bucket partially dumped, lower boom to raise front OK: Go to next check.
CHECK of machine.
NOT OK: Repair lift
Run engine at slow idle. Slowly move boom control lever to boom lower position. checks in loader control
valve. Go to your
Slowly move bucket control lever to bucket dump authorized dealer.
position.
T6601AA –UN–19OCT88
LOOK: Boom MUST NOT raise before moving down.
Bucket MUST NOT rollback before dumping.
– – –1/1
BUCKET ROLLBACK Position bucket at a 45° angle against an immovable OK: Go to next check.
CIRCUIT RELIEF VALVE object.
CHECK NOT OK: Check loader
Move transmission control lever to 3rd gear forward. system and circuit relief
valve pressures. Go to
LOOK: Bucket angle MUST NOT change. your authorized dealer.
T6564OD –UN–19OCT88
– – –1/1
BUCKET DUMP CIRCUIT Raise front of machine with bucket at 45° angle. OK: Go to next check.
RELIEF VALVE
PRESSURE CHECK Backdrag with bucket while observing bucket angle. NOT OK: Check loader
system and circuit relief
LOOK: Bucket MUST NOT rollback. valve pressure. Go to
your authorized dealer.
T6601AA –UN–19OCT88
– – –1/1
BOOM AND BUCKET Raise bucket about 50 mm (2 in.) off ground with bucket OK: Go to next check.
CYLINDER DRIFT level.
NOT OK: Go to your
Stop engine. Wait 1 minute. authorized dealer.
– – –1/1
95–19
PN=227
Operational Checkout
BOOM DOWN CHECK Position bucket flat on ground. OK: Go to next check
VALVE LEAKAGE
CHECK Run engine at slow idle for 2 minutes. NOT OK: Replace boom
lower check valve. Go to
Heat hydraulic oil to LOOK: Bucket MUST NOT drift up. your authorized dealer.
operating temperature.
(See Hydraulic System
Warm-up Procedure in
this group.) T7010AO –UN–15MAR89
– – –1/1
LOOK: Lever must return to neutral when released from all positions.
– – –1/1
RETURN-TO-DIG CHECK Position bucket fully dumped just above ground level. OK: Go to next check
Run engine at slow idle. Move control lever to return-to-dig detent position and NOT OK: Check fuse.
release.
IF OK: Adjust switch.
LOOK: Bucket must rollback to the level position and See Adjusting Return-To-
control lever must return to neutral. Dig in Operating the
Machine chapter.
T7827AI3 –UN–24AUG92
NOTE: If bucket is in a rolled back position when key
switch is turned ON, control lever must be returned to
neutral manually if placed in the return-to-dig detent
position. After bucket is dumped once, return-to-dig will
work normally.
– – –1/1
95–20
PN=228
Operational Checkout
BOOM HEIGHT KICKOUT Position bucket flat on ground. OK: Go to next check
CHECK—IF EQUIPPED
Move control lever to boom raise detent position and NOT OK: Check fuse.
Run engine at slow idle. release.
IF OK: See Adjusting
LOOK: Boom must raise to the set height and stop. Boom Height Kickout in
Control lever must return to neutral. Operating the Machine
chapter.
T7825BL –UN–24AUG92
– – –1/1
If the problem is
electrical, check fuse.
IF OK: Go to your
authorized dealer.
If the problem is
hydraulic, go to your
authorized dealer.
– – –1/1
– – –1/1
95–21
PN=229
Operational Checkout
– – –1/1
– – –1/1
STEERING SYSTEM Turn steering wheel rapidly until frames are against OK: Go to next check.
LEAKAGE CHECK stops. Hold approximately 22 N (5 lb force) pressure on
steering wheel. NOT OK: Go to your
Heat hydraulic oil to authorized dealer.
operating temperature. Count steering wheel revolutions for 1 minute. Repeat
(See Hydraulic System test in opposite direction.
Warm-Up Procedure in
this group.) LOOK: Steering wheel must rotate less than 5 rpm.
T6601AC –UN–19OCT88
Run engine at fast idle. NOTE: Use good judgement; excessive steering wheel
rpm does not mean steering will be affected.
Note: Cold oil may give
increased RPM’s during
this check.
– – –1/1
95–22
PN=230
Operational Checkout
PRIORITY VALVE LOW Hold brake pedal down. OK: Go to next check.
PRESSURE CHECK
Steer machine to the right and left as far as possible. NOT OK: Adjust priority
Park machine on a hard valve pressure. Go to
surface. LOOK: machine must turn at least 1/2 way to the right and left stops. your authorized dealer.
– – –1/1
Roll bucket back and hold over relief and observe engine rpm.
LOOK: Steering stall engine rpm must be higher than hydraulic stall rpm.
– – –1/1
95–23
PN=231
Operational Checkout
Without starting engine, turn key switch to START position and release.
T7747AJ1 –UN–24AUG92
– – –1/1
SECONDARY STEERING Turn steering wheel rapidly until frames are against stops. Hold approximately 22 N (5 OK: Go to next check
SYSTEM PRIMARY lb force) pressure on steering wheel.
CHECK VALVE CHECK NOT OK: Go to your
Actuate a hydraulic function and hold over relief. Return control lever to neutral. authorized dealer.
Run engine at fast idle.
FEEL: Steering wheel MUST NOT "kick back" as hydraulic function is released.
– – –1/1
95–24
PN=232
Operational Checkout
. ACCESSORY CHECKS
NOTE: Engine must be stopped and key switch must be ON for these checks
– – –1/1
IF OK: Go to your
authorized dealer.
– – –1/1
LOOK: Front work lights (C) and rear work lights (D) must come on.
– – –1/1
95–25
PN=233
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 IF OK: Check bulbs,
for brake lights to come on. 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
T7747BJ1 –UN–21AUG92
– – –1/1
95–26
PN=234
Operational Checkout
WINDSHIELD WASHER Turn front wiper switch knob clockwise to first detent, OK: Go to next check.
AND WIPER CHECK—IF then to second position.
EQUIPPED NOT OK: If wiper and
LOOK: Front wiper must operate at slow speed with washer do not work,
switch in first detent, and fast speed with switch in check fuses.
second position.
IF OK: Check wiring. Go
Push knob in to turn front washer on. to your authorized dealer.
T7773AN –UN–05AUG92
LOOK: Washer must spray water on windshield.
– – –1/1
DEFROSTER BLOWER Turn defroster blower switch knob to low, medium and OK: Go to next check
CHECK high speeds. (Heater blower will also come on
automatically.) NOT OK: Check fuse.
FEEL & LISTEN: Blower must have three speeds and IF OK: Go to your
OFF. authorized dealer.
T7773BP2 –UN–05AUG92
– – –1/1
95–27
PN=235
Operational Checkout
HEATER/AIR Turn blower switch knob to low, medium and high OK: Go to next check
CONDITIONER BLOWER speeds.
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 Open heater shut-off valve on water pump. OK: Go to next check
CHECK
Start engine. Run at fast idle. NOT OK: Go to your
authorized dealer.
Wait 2 minutes.
– – –1/1
AIR CONDITIONER Start engine and run at fast idle. OK: Go to next check
FUNCTIONAL CHECK
Turn air conditioner switch to maximum COOL setting. NOT OK: Check fuse.
Wait for any warm air in duct system to dissipate. IF OK: Go to your
authorized dealer.
FEEL: Air from ducts must be cool.
T7773BP1 –UN–05AUG92
– – –1/1
95–28
PN=236
Operational Checkout
– – –1/1
– – –1/1
LOOK: Pin (B) must fit into latch notch (A). Latch must retain door and window
against rubber stops (C).
– – –1/1
95–29
PN=237
Operational Checkout
CAB DOOR RELEASE Press door release button. OK: Go to next check
BUTTON
LOOK & LISTEN: Latch must click and release door. NOT OK: If latch does
not release, check fuse.
IF OK: Go to your
authorized dealer.
T7832AJ –UN–27AUG92
NOT OK: If door does
not latch tightly, adjust
latch assembly.
– – –1/1
T6564PB –UN–19OCT88
– – –1/1
DOME LIGHT CHECK Move each dome light toggle switch to ON position. OK: Go to next check.
Key switch OFF. LOOK: Dome lights must come on. NOT OK: Check fuse
and bulb.
Turn both switches OFF.
T7832AI –UN–24AUG92
– – –1/1
95–30
PN=238
Operational Checkout
Open latch.
– – –1/1
– – –1/1
STEERING COLUMN Depress pedal (A) and move steering wheel column to OK: Go to next check.
ADJUSTMENT CHECK all positions.
NOT OK: Check and
Release pedal at each position. adjust pedal linkage.
T7773BQ –UN–05AUG92
– – –1/1
95–31
PN=239
Operational Checkout
SEAT AND SEAT BELT Standing over seat reach down and lift seat assembly to OK: Go to next check
CHECK top of travel then let go. Lift seat slowly until latch "
clicks", and release seat. Repeat for upper latch. NOT OK: Replace any
IMPORTANT: Replace the worn or broken parts.
complete seat belt LOOK & FEEL: Seat must have 3 positions and must Lubricate moving parts of
assembly every three latch in 2 upper positions. suspension and seat
years regardless of adjusters. Go to your
appearance. A date label, Inspect seat shell and suspension for cracks, broken authorized dealer.
to determine the age of T7747AP –UN–21AUG92
welds or looseness.
the belt, is attached to
each seat belt. LOOK: Seat must be in safe condition.
FEEL: Seat belt must stay adjusted snugly and not slip
in adjuster.
– – –1/1
TOOLBOX DOOR CHECK Unlock and open toolbox door under seat in operator’s station. OK: Go to next check.
FEEL: Lock must operate freely and key MUST NOT stick in lock.
– – –1/1
95–32
PN=240
Operational Checkout
AIR INTAKE FILTER Unlock and open door on left side of operator’s station. OK: Go to next check.
DOOR CHECK
Close and lock door. NOT OK: Lubricate
hinges. Lubricate or
LOOK: Door must open and close smoothly. repair lock.
– – –1/1
LOAD CENTER DOOR Unlock and open door on right side of operator’s station. OK: Go to next check.
CHECK
Close and lock door. NOT OK: Lubricate
hinges. Lubricate or
LOOK: Door must open and close smoothly. repair lock.
– – –1/1
ENGINE SIDE PANELS Unlock and open side panel (A). OK: Go to next check.
CHECK
Latch side panel in open position. NOT OK: Lubricate
hinges. Repair latch.
Pull rear of panel up and slide out side panel (B).
– – –1/1
95–33
PN=241
Operational Checkout
RADIATOR CAP ACCESS Open and close access door on top of grille housing. OK: Go to next check.
DOOR CHECK
LOOK: Door must move freely. Locking pin for padlock NOT OK: Lubricate
MUST NOT be bent. hinges. Repair door.
T6633AY –UN–18OCT88
– – –1/1
FRAME LOCKING BAR LOOK: Red frame locking bar must be pinned to engine OK: Go to next check.
CHECK frame below left side cab step.
NOT OK: Order new
parts and install new
locking bar and pins.
T7799CX –UN–23SEP92
– – –1/1
BOOM LOCK CHECK LOOK: Red boom lock must be fastened to front frame at hinge in vertical position. OK: Go to next check.
– – –1/1
SERVICE DECAL CHECK Check service decal (A) above left side battery OK: Operational
compartment. Checkout completed.
T8385AC –UN–15DEC94
– – –1/1
95–34
PN=242
Troubleshooting
USING TROUBLESHOOTING CHARTS
Step 3. Adjustments.
TX,FF,105 –19–15JUL94–1/1
100–1
PN=243
Troubleshooting
ENGINE
Engine Will Not Start Or Starts Fuel tank empty. Check fuel quantity.
Hard
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).
Incorrect grade of fuel. Drain fuel tank and add correct fuel.
644G—Fuel drains from filter(s) with Disconnect filter inlet line from check
engine stopped, due to leakage in valve. Inspect for leakage.
check valve.
100–2
PN=244
Troubleshooting
Engine Surges Or Stalls Fuel tank vent hose clogged. Loosen cap and listen for air rushing
Frequently into tank. Clean or replace hose.
Incorrect grade of fuel. Drain fuel tank and add correct fuel.
Water in fuel or water frozen in line. Drain water from fuel tank trap.
Inspect fuel filter(s) for water.
Change filter(s).
Fuel return line from injection pump Disconnect fuel return line from
to tank restricted. injection pump. Connect a hose to
pump and route fuel into a container.
If engine runs normally, return hose
is restricted.
100–3
PN=245
Troubleshooting
Incorrect grade of fuel. Drain fuel tank and add correct fuel.
100–4
PN=246
Troubleshooting
Slow idle speed too low. Check slow idle speed. (See
Maintenance—Every 1000 Hours
chapter.) See your authorized
dealer.
Engine Does Not Develop Full Fuel tank vent hose clogged. Loosen fuel cap and listen for air
Power rushing into tank. Clean or replace
hose.
Fuel shut-off solenoid lever not Adjust solenoid. (See Adjusting Fuel
against stop on injection pump. Shut-Off Solenoid in Maintenance
chapter.)
Air intake system restricted. Check air filter elements and air filter
restriction indicator switch. (See
Maintenance—As Required chapter.)
Incorrect grade of fuel. Drain fuel tank and add correct fuel.
(See Fuels and Lubricants chapter.)
100–5
PN=247
Troubleshooting
Fast idle speed set too low. Check and adjust fast idle. See your
authorized dealer.
100–6
PN=248
Troubleshooting
Engine Emits Excessive Black Or Restricted air filter. Check air filter restriction indicator
Gray Exhaust Smoke and air filter(s). (See Maintenance—
As Required chapter.) Replace.
Incorrect grade of fuel. Drain fuel tank and add correct fuel.
(See Fuels and Lubricants chapter.)
Air leak between turbo and manifold. See your authorized dealer.
100–7
PN=249
Troubleshooting
Engine Emits Excessive Blue Or Cranking speed too low. Check batteries and connections.
White Smoke
Incorrect grade of fuel. Drain fuel tank and add correct fuel.
(See Fuel and Lubricants chapter.)
Slow Acceleration. Incorrect grade of fuel. Drain fuel tank and add correct fuel.
Detonation Starting aid solenoid stuck open. See your authorized dealer.
100–8
PN=250
Troubleshooting
Abnormal Engine Noise Low or incorrect engine oil. Add correct oil.
Engine oil diluted with fuel. Inspect engine oil. Inspect fuel pump
spindle, seal, and housing. Clean
and use or replace.
Worn piston pin bushings and pins. See your authorized dealer.
Wrong viscosity oil or oil diluted with Change oil. 644G—inspect fuel
diesel fuel. pump spindle, seal, and housing.
544G, LL, TC, 624G,—inspect fuel
pump diaphragm. Clean and use or
replace.
100–9
PN=251
Troubleshooting
High Oil Pressure Wrong viscosity oil (too thick). Check for antifreeze in oil. Change
oil.
Engine Overheats Low coolant level. Fill cooling system and check for
leaks.
100–10
PN=252
Troubleshooting
Incorrect grade of fuel. Drain fuel tank and add correct fuel.
Engine Runs Cold Temperature gauge or sender. See your authorized dealer.
Oil In Coolant Or Coolant In Oil Leaking heat exchanger. See your authorized dealer.
100–11
PN=253
Troubleshooting
Excessive Fuel Consumption Air system restricted. Check filter restriction indicator and
air filters. Replace. (See
Maintenance—As Required chapter.)
Turbocharger Excessively Noisy Bearings not lubricated. Insufficient oil pressure. Check for
Or Vibrates restricted turbocharger oil line.
Incorrect clearance between turbine Remove exhaust elbow and air inlet
wheel and turbine housing. hose. Inspect and repair.
Oil Dripping From Turbocharger Damaged or worn bearings and/or Inspect compressor and turbine
Adapter worn seals. wheel for damaged blades. Check
for proper engine service intervals or
dirt entering engine.
100–12
PN=254
Troubleshooting
Excessive Drag In Turbocharger Carbon build-up behind turbine See your authorized dealer.
Rotating Members wheel caused by combustion
deposits.
TX,100,DH2481 –19–02OCT92–12/12
100–13
PN=255
Troubleshooting
ELECTRICAL SYSTEM
Starter Will Not Crank Engine Battery undercharged or dead. See your authorized dealer.
100–14
PN=256
Troubleshooting
Starting Motor Turns, But Engine Starter pinion not engaging flywheel See your authorized dealer.
Will Not Crank ring gear.
Starting Motor Continues To Run Starter solenoid stuck. See your authorized dealer.
After Engine Starts
Starter not disengaging. See your authorized dealer.
Battery Using Too Much Water Battery being overcharged. See your authorized dealer.
Low Battery Output Low water level. (See "Battery Using Too Much
Water" and "Cracked Battery Case"
in this group.)
Dirty or wet battery top, causing Clean battery and wipe dry.
discharge.
Corroded or loose battery cable Clean and tighten cable end clamps.
ends. Recharge battery. If unit has two
batteries, recharge separately.
100–15
PN=257
Troubleshooting
Engine Cranks But Does Not Fuel shut-off solenoid. See your authorized dealer.
Start
Key switch. See your authorized dealer.
Start Aid Does Not Work Empty start aid can. Replace start aid can.
Charging Indicator Light Loose or glazed alternator belt. Check belt. Replace if glazed,
Remains ON tighten if loose.
100–16
PN=258
Troubleshooting
Hour Meter Does Not Work Key switch. See your authorized dealer.
Fuel Gauge Displays One Fuel gauge. See your authorized dealer.
Flashing Arrow
Fuel gauge sender. See your authorized dealer.
Individual Light In Monitor Panel Sending unit for that function. See your authorized dealer.
Is Inoperative (Not During Bulb
Check)
Wiring harness. See your authorized dealer.
100–17
PN=259
Troubleshooting
100–18
PN=260
Troubleshooting
Defrost Fan Motor Does Not Fan motor switch. See your authorized dealer.
Work In All Speeds
Fan motor resistor. See your authorized dealer.
Turn Signals Do Not Operate Accessory relay. See your authorized dealer.
100–19
PN=261
Troubleshooting
Differential Lock Does Not Work Key switch. See your authorized dealer.
Secondary Steering Does Not Key switch. See your authorized dealer.
Operate
Fuse. Replace fuse.
Secondary Steering Indicator Secondary steering controller. See your authorized dealer.
Light Does Not Operate
100–20
PN=262
Troubleshooting
TX,100,DH2482 –19–02OCT92–8/8
100–21
PN=263
Troubleshooting
HYDRAULIC SYSTEM
Noisy Hydraulic Pump Low oil supply or wrong viscosity. Fill reservoir with proper oil.
100–22
PN=264
Troubleshooting
No Hydraulic Functions, Steering Boom lower solenoid valve ground See your authorized dealer.
Normal wire shorted or wrong ground wire
connected to solenoid.
Boom Float Function Does Not Pilot control pressure low. See your authorized dealer.
Work
Loader control valve spool binding in See your authorized dealer.
bore.
Boom Down Does Not Work— Boom down switch not pushed. Push switch.
Engine Off
Electrical problem See your authorized dealer.
One Hydraulic Function Does Not Pilot control valve. See your authorized dealer.
Work
100–23
PN=265
Troubleshooting
Low Hydraulic Power Leakage within work circuit. See your authorized dealer.
Boom Drifts Up Leakage in boom lower solenoid See your authorized dealer.
valve, or O-rings.
Oil Overheats Low oil viscosity in hot weather. Use recommended oil. (See Fuels
and Lubricants chapter.)
100–24
PN=266
Troubleshooting
Function Drops Before Raising Stuck open lift check. See your authorized dealer.
When Valve Is Activated
Hydraulic Oil Foams Low oil level. Fill to correct level. (See
Maintenance—Every 10 Hours or
Daily chapter.)
Loose or faulty suction lines (air leak Tighten or install new lines.
in system).
100–25
PN=267
Troubleshooting
Slow Steering Wheel Movement Leakage in steering system. See your authorized dealer.
Will Not Cause Any Frame
Movement
Worn steering valve gerotor. See your authorized dealer.
Steering Wheel Can Be Turned Leakage in steering system. See your authorized dealer.
With Frames Against Steering
Stop
Low crossover relief valve pressure See your authorized dealer.
setting.
Steering Wheel Turns With No Broken steering column or splined See your authorized dealer.
Resistance And Causes No coupling.
Frame Movement
Lack of oil in steering valve. Start engine and check steering
operation.
100–26
PN=268
Troubleshooting
Steering Valve Binding Or Binding in steering column or See your authorized dealer.
Steering Wheel Does Not misalignment of column.
Immediately Return To Neutral
When Released
High return pressure. Check for a pinched or damaged
return line.
Steering Valve Locks Up Large particles of contamination in Inspect hydraulic filter for
steering valve. contamination. Repair cause of
contamination. Flush hydraulic
system. (See Maintenance—Every
3000 Hours chapter.)
100–27
PN=269
Troubleshooting
Abrupt Steering Wheel Gerotor gear in steering valve not See your authorized dealer.
Oscillation properly timed.
Steering Wheel Turns By Itself Lines connected to wrong port. Reconnect lines.
Vibration In Steering System Or High priority valve setting. See your authorized dealer.
Hoses Jump
Machine Turns In Opposite Lines to cylinders connected to See your authorized dealer.
Direction wrong ports at steering valve or
crossover relief valve.
Machine Turns When Steering Steering valve leakage. See your authorized dealer.
Valve Is In Neutral
Steering Wheel Kickback Failed check valve in secondary See your authorized dealer.
steering manifold block.
Secondary Steering Motor Will Electrical problem. See your authorized dealer.
Not Run
Secondary Steering Pump Runs Secondary steering manifold block See your authorized dealer.
But Will Not Steer Machine primary check valve stuck open.
*Thermal shock is caused by a large temperature differential (approximately 30°C (50°F)) between the steering valve
and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority
valve spool is clogged, the steering valve may bind up when the steering is operated if the hydraulic oil is hot
enough.
TX,100,DH2483 –19–09SEP92–7/7
100–28
PN=270
Troubleshooting
POWER TRAIN
Machine Will Not Move Applied park brake. See your authorized dealer.
100–29
PN=271
Troubleshooting
Machine Does Not Engage In Transmission control solenoid valve. See your authorized dealer.
Low Gear
Stuck spool in transmission control See your authorized dealer.
valve.
Transmission Will Not Shift Transmission shifts fast in 4th gear Wrong transmission controller for
Correctly automatic. machine model number. See your
authorized dealer.
Transmission will not shift out of 2nd Wrong transmission controller for
gear in automatic mode. machine model number. See your
authorized dealer.
Transmission Pressure Is Low Low oil level. Check transmission oil level and refill
(All Gears) if necessary.
100–30
PN=272
Troubleshooting
Transmission System Pressure Is Transmission control valve gasket. Inspect transmission control valve for
Low (One Or Two Gears) external leakage. Remove control
valve. Inspect and replace gasket, if
necessary.
Transmission Shifts Too Slow Low oil level (aeration of oil). Check and add oil. (See
Maintenance—Every 10 Hours or
Daily chapter.)
Transmission Shifts Too Fast System pressure too high. See your authorized dealer.
100–31
PN=273
Troubleshooting
Machine "Creeps" In Neutral Warped disks and plates in See your authorized dealer.
transmission.
Air flow through oil cooler or radiator See your authorized dealer.
restricted.
Oil cooler thermal relief bypass valve See your authorized dealer.
stuck.
Excessive Transmission Noise Engine low idle too low. Adjust. (See Adjust Engine Speed
(Under Load Or No Load) Linkage in Maintenance—Every
1000 Hours chapter.)
100–32
PN=274
Troubleshooting
Air leak on suction side of pump. Check oil pickup tube on side of
transmission.
Machine Lacks Power And Engine fast idle speed set too low. Check fast idle adjustment. (See
Acceleration Adjust Engine Speed Linkage in
Maintenance—Every 1000 Hours
chapter.)
100–33
PN=275
Troubleshooting
Torque Converter Stall RPM Too Aerated oil. See your authorized dealer.
High
Converter relief valve stuck open. See your authorized dealer.
Torque Converter Stall RPM Too Low engine power. See your authorized dealer.
Low
Mechanical malfunction. See your authorized dealer.
TX,100,DH2484 –19–27OCT92–6/6
100–34
PN=276
Troubleshooting
SERVICE BRAKES
Poor Or No Brakes Brake accumulator charge low. See your authorized dealer.
Aggressive Brakes Clutch cut-off switch out of Adjust switch. (See Adjusting Clutch
adjustment. Cut-Off Switch in Maintenance
chapter.)
100–35
PN=277
Troubleshooting
Brakes Lock Up Air in brake system. Bleed brakes. (See Bleeding Brakes
in Maintenance chapter.)
Brakes Chatter Air in brake system. Bleed brakes. (See Bleeding Brakes
in Maintenance chapter.)
Hissing Noise When Brake Pedal Brake valve, or brake piston See your authorized dealer.
Is Depressed With Engine leakage.
Stopped
Brake Pressure Warning Light Brake pressure warning switch. See your authorized dealer.
Will Not Go Out
TX,100,DH2485 –19–18SEP92–2/2
100–36
PN=278
Troubleshooting
DIFFERENTIAL AXLE
Differential Lock Slips Or Pressure reducing valve malfunction See your authorized dealer.
Chatters When Engaged or setting low.
100–37
PN=279
Troubleshooting
Differential Overfilled With Oil On Leak in brake piston seals. See your authorized dealer.
Standard Axles
Incorrect breather tube. See your authorized dealer.
Differential Overfilled With Oil On Not operating engine at full load. Release differential lock pedal and
Differential Lock Axles operate engine at full load.
Clogged reservoir differential filter. Remove filter and check for debris.
Excessive Differential And/Or Low oil level in differential. See your authorized dealer.
Axle Noise
Gear mesh pattern between ring and See your authorized dealer.
pinion gear incorrect.
Oil Seeping From Outer Axle Excessive axle end play. See your authorized dealer.
Seal
100–38
PN=280
Troubleshooting
Axle Overheats Low or high differential oil. See your authorized dealer.
TX,100,DH2486 –19–07OCT92–3/3
DRIVELINE
Excessive Driveline Vibration Or Yokes not in line on drive shafts. Inspect. Align drive shaft yokes.
Noise
Worn rear driveline support bearing. See your authorized dealer.
TX,100,DH2487 –19–09SEP92–1/1
100–39
PN=281
Troubleshooting
PARK BRAKE
Brake Will Not Hold Not adjusted correctly. Adjust park brake. (See Adjust Park
Brake in Maintenance—Every 1000
Hours chapter.)
Brake disk and/or brake pads worn. See your authorized dealer.
Brake Disk Overheats Brake pads out of adjustment. Adjust park brake. (See Adjust Park
Brake in Maintenance—Every 1000
Hours chapter.)
Park Brake Indicator In Monitor Wiring or switch. See your authorized dealer.
Does Not Come On When Brake
Applied
Brake Will Not Apply Pads out of adjustment. Adjust park brake. (See Adjust Park
Brake in Maintenance—Every 1000
Hours chapter.)
TX,100,DH2488 –19–02OCT92–1/1
100–40
PN=282
Troubleshooting
AIR CONDITIONING
Air Conditioning System Does Accessory relay #2. See your authorized dealer.
Not Operate
Fuse. Replace fuse.
TX,100,DH2489 –19–09SEP92–1/1
100–41
PN=283
Storage
PREPARE MACHINE FOR STORAGE
–UN–09NOV88
necessary, to avoid needless delays later.
T47764
3. Clean primary air cleaner element.
TX,105,FF1190 –19–03AUG92–1/3
–UN–09FEB89
high pressure. Use low pressure wash
operations until 30 days have elapsed.
T5813AM
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.
TX,105,FF1190 –19–03AUG92–2/3
105–1
PN=284
Storage
–19–22APR91
T7447AO
TX,105,FF1190 –19–03AUG92–3/3
–UN–18OCT88
1. Drain water and sediment from fuel tank when air
temperature is above freezing.
TX,105,FF,400 –19–06SEP94–1/2
105–2
PN=285
Storage
–UN–18OCT88
warm the crankcase until oil appears
fluid.
T6181AU
add oil as required.
4. Check belts.
TX,105,FF,400 –19–06SEP94–2/2
105–3
PN=286
Machine Numbers
RECORD PRODUCT IDENTIFICATION
NUMBER (PIN)
Purchase Date
–UN–21SEP92
Identification Number.
T7829BJ
TX,110,DH2545 –19–11DEC92–1/1
–UN–21SEP92
T7829BK
TX,110,DH2272 –19–02OCT92–1/1
–UN–08OCT92
T7853AW
TX,110,DH2273 –19–07OCT92–1/1
TX,110,DH2274 –19–02OCT92–1/1
110–1
PN=287
Machine Numbers
05T,120,MM9 –19–06JUN91–1/1
TX,110,DH2546 –19–16SEP92–1/1
110–2
PN=288
Specifications
544G SPECIFICATIONS
–UN–20OCT88
T6603AC
TX,115,DH2265 –19–16JUN93–1/2
115–1
PN=289
Specifications
TX,115,DH2265 –19–16JUN93–2/2
115–2
PN=290
Specifications
544G SPECIFICATIONS
Engine:
John Deere 6059T (S.N. 553285— ) 89 kW (120 hp)
Piston displacement 5.884 L (359 cu in.)
Air cleaner Dual stage dry type with restriction indicator
Electrical system 12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F) 625 amps
Reserve capacity 160 min.
Torque Converter Single phase, single stage
Transmission Countershaft, power shift, automatic
Travel Speeds:
Forward Speeds: km/h mph
1 0—7.4 0—4.6
2 0—12.3 0—7.7
3 0—27.2 0—16.9
4 0—38.4 0—23.8
Reverse Speeds: km/h mph
1 0—7.4 0—4.6
2 0—12.3 0—7.7
3 0—27.2 0—16.9
TX,115,DH2267 –19–08DEC95–1/2
115–3
PN=291
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 buzzer sounds with transmission in gear
Steering:
Turning radius (to centerline of outside tire) 4.95 m (16 ft 3 in.)
Rear axle oscillation 22 degrees, stop to stop
Tires
15.5—25, 12 PR L2
17.5—25, 12 PR L2
17.5—25, 12 PR L3
20.5—25, 12 PR L2
20.5—25, 12 PR L3
17.5—25, Radial, One Star L2 Equivalent
17.5—25, Radial, One Star L3 Equivalent
20.5—25, Radial, One Star L2 Equivalent
20.5—25, Radial, One Star L3 Equivalent
Maximum Lift Capacity With Standard Equipment
Maximum height 5 457 kg (12,031 lb)
Ground level 11 006 kg (24,264 lb)
TX,115,DH2267 –19–08DEC95–2/2
115–4
PN=292
Specifications
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 9.5 L 10 qt
Front differential 18 L 19 qt
Rear differential 18 L 19 qt
Hydraulic reservoir 76 L 80 qt
TX,115,JC1149 –19–23MAY96–1/1
544G LL SPECIFICATIONS
–UN–10SEP92
T7829AX
TX,115,DH2291 –19–16JUN93–1/2
115–5
PN=293
Specifications
TX,115,DH2291 –19–16JUN93–2/2
115–6
PN=294
Specifications
544G LL SPECIFICATIONS
Engine:
John Deere 6059T (S.N. 553285— ) 89 kW (120 hp)
Piston displacement 5.884 L (359 cu in.)
Air cleaner Dual stage dry type with restriction indicator
Electrical system 12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F) 625 amps
Reserve capacity 160 min.
Torque Converter Single phase, single stage
Transmission Countershaft, power shift, automatic
Travel Speeds:
Forward Speeds: km/h mph
1 0—7.4 0—4.6
2 0—12.3 0—7.7
3 0—27.2 0—16.9
4 0—38.4 0—23.8
Reverse Speeds: km/h mph
1 0—7.4 0—4.6
2 0—12.3 0—7.7
3 0—27.2 0—16.9
TX,115,JC1147 –19–23MAY96–1/2
115–7
PN=295
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 buzzer sounds with transmission in gear
Steering:
Turning radius (to centerline of outside tire) 4.95 m (16 ft 3 in.)
Rear axle oscillation 22 degrees, stop to stop
Tires:
17.5—25, 12 PR L2
17.5—25, 12 PR L3
17.5—25, Radial, One Star, L2 Equivalent
20.5—25, 12 PR L2
20.5—25, 12 PR L3
23.1—26, 10 PR LS-2
28 L—26, 14 PR LS-2
Maximum Lift Capacity
Maximum height
Fork level 4 649 kg (10,251 lb)
Fork rolled back 4 440 kg ( 9,789 lb)
Ground level
Fork level 8 716 kg (19,215 lb)
Fork rolled back 11 748 kg (25,900 lb)
TX,115,JC1147 –19–23MAY96–2/2
115–8
PN=296
Specifications
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 9.5 L 10 qt
Front differential 18 L 19 qt
Rear differential 18 L 19 qt
Hydraulic reservoir 76 L 80 qt
TX,115,JC1148 –19–23MAY96–1/1
544G TC SPECIFICATIONS
–UN–21SEP92
T7829AY
TX,115,DH2294 –19–18JUN93–1/2
115–9
PN=297
Specifications
TX,115,DH2294 –19–18JUN93–2/2
115–10
PN=298
Specifications
544G TC SPECIFICATIONS
Engine:
John Deere 6059T (S.N. 553285— ) 89 kW (120 hp)
Piston displacement 5.884 L (359 cu in.)
Air cleaner Dual stage dry type with restriction indicator
Electrical system 12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F) 625 amps
Reserve capacity 160 min.
Torque Converter Single phase, single stage
Transmission Countershaft, power shift, automatic
Travel Speeds:
Forward Speeds: km/h mph
1 0—7.4 0—4.6
2 0—12.3 0—7.7
3 0—27.2 0—16.9
4 0—38.4 0—23.8
Reverse Speeds: km/h mph
1 0—7.2 0—4.5
2 0—12.2 0—7.6
3 0—27.7 0—17.2
TX,115,DH2295 –19–08DEC95–1/2
115–11
PN=299
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 buzzer sounds with transmission in gear
Steering:
Turning radius (to centerline of outside tire) 4.95 m (16 ft 3 in.)
Rear axle oscillation 22 degrees, stop to stop
Tires:
15.5—25, 12 PR L2
17.5—25, 12 PR L2
17.5—25, 12 PR L3
17.5—25, Radial, One Star, L2 Equivalent
20.5—25, Radial, One Star, L2 Equivalent
20.5—25, 12 PR L2
20.5—25, 12 PR L3
20.5—25, 16 PR L3
Maximum Lift Capacity With Standard Equipment
Maximum height 5 154 kg (11,365 lb)
Ground level 9 086 kg (20,035 lb)
TX,115,DH2295 –19–08DEC95–2/2
115–12
PN=300
Specifications
Metric U.S.
Cooling system 23.5 L 25 qt
Fuel tank 218 L 58 gal
Engine crankcase and 19 L 20 qt
filter
Transmission case and 9.5 L 10 qt
filter
Front differential 18 L 19 qt
Rear differential 18 L 19 qt
Hydraulic reservoir 76 L 80 qt
TX,115,JC1153 –19–23MAY96–1/1
624G SPECIFICATIONS
–UN–20OCT88
T6603AC1
TX,115,DH2268 –19–16JUN93–1/2
115–13
PN=301
Specifications
TX,115,DH2268 –19–16JUN93–2/2
115–14
PN=302
Specifications
624G SPECIFICATIONS
Engine:
John Deere 6068T 108 kW (145 hp)
Piston displacement 6.8 L (414 cu in.)
Air cleaner Dual stage dry type with restriction indicator
Electrical system 12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F) 625 amps
Reserve capacity 160 min.
Torque Converter Single phase, single stage
Transmission Countershaft, power shift, automatic
Travel Speeds:
Forward Speeds: km/h mph
1 0—7.3 0—4.5
2 0—11.6 0—7.2
3 0—24.5 0—15.2
4 0—37.3 0—23.0
Reverse Speeds: km/h mph
1 0—7.3 0—4.5
2 0—11.6 0—7.2
3 0—24.5 0—15.2
TX,115,DH2269 –19–02OCT92–1/2
115–15
PN=303
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 buzzer sounds with transmission in gear
Steering:
Turning radius (to centerline of outside tire 5.14 m (16 ft 11 in.)
Rear axle oscillates 26° total
Tires:
17.5—25, 12 PR L2
17.5—25, 12 PR L3
17.5—25, Radial, One Star, L2 Equivalent
20.5—25, 12 PR L2
20.5—25, 12 PR L3
20.5—25, Radial, One Star, L2 Equivalent
Maximum Lift Capacity With Standard Equipment
Maximum height 6 414 kg (14,140 lb)
Ground level 12 217 kg (26,939 lb)
TX,115,DH2269 –19–02OCT92–2/2
115–16
PN=304
Specifications
Metric U.S.
Cooling system 24.6 L 26 qt
Fuel tank 249 L 66 gal
Engine crankcase and 19 L 20 qt
filter
Transmission case and 11.4 L 12 qt
filter
Front differential 28.4 L 30 qt
Rear differential 18 L 19 qt
Hydraulic reservoir 102 L 108 qt
644G SPECIFICATIONS
–UN–20OCT88
T6603AD1
TX,115,DH2270 –19–16JUN93–1/2
115–17
PN=305
Specifications
TX,115,DH2270 –19–16JUN93–2/2
115–18
PN=306
Specifications
644G SPECIFICATIONS
Engine:
John Deere 6081 127 kW (170 hp)
Piston displacement 8.1 L (494 cu in.)
Air cleaner Dual stage dry type with restriction indicator
Electrical system 12-volt battery with 95-amp alternator
Cold cranking capacity at -18°C (0°F) 950 amps
Reserve capacity 160 min.
Torque Converter single phase, planetary
Transmission Countershaft, power shift, automatic
Travel Speeds:
Forward Speeds: km/h mph
1 0—7.0 0—4.4
2 0—11.2 0—7.0
3 0—22.0 0—13.7
4 0—34.6 0—21.5
Reverse Speeds: km/h mph
1 0—7.0 0—4.4
2 0—11.2 0—7.0
3 0—22.0 0—13.7
TX,115,DH2271 –19–16JUN93–1/2
115–19
PN=307
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 transmission in gear
Steering:
Turning radius (to centerline of outside tire) 5.46 m (17 ft 11 in.)
Rear axle oscillates 26° total
Tires:
20.5—25, 12 PR L2
20.5—25, 16 PR L2
20.5—25, 16 PR L3
20.5—25, Radial, One Star, L2 equivalent
20.5—25, Radial, One Star, L3 equivalent
23.5—25, 12 PR L2
23.5—25, 20 PR L3
23.5—25, Radial, One Star, L3 equivalent
TX,115,DH2271 –19–16JUN93–2/2
Metric U.S.
Cooling system 28 L 29.5 qt
Fuel tank 284 L 75 gal
Engine crankcase and 24 L 25 qt
filter
Transmission case and 14.2 L 15 qt
filter
Front differential 28.4 L 30 qt
Rear differential 28.4 L 30 qt
Hydraulic reservoir 115 L 120 qt
115–20
PN=308
Crime Prevention Tips
HELP PREVENT CRIME
–19–07OCT88
TS140
DX,CRPRV,A –19–03MAR93–1/1
–UN–23MAR89
numbers for engines, axles, pumps, etc. Include
the PIN numbers on all documentation, such as
insurance, financial, and warranty papers.
TS156
DX,CRPRV,H –19–04JUN90–1/1
–UN–23MAR89
3. Keep your documented identification numbers,
color photographs, and inventory in a safe, secure
location. TS157
DX,CRPRV,I –19–04JUN90–1/1
120–1
PN=309
Crime Prevention Tips
–UN–23MAR89
• Remove battery when unit is in storage.
TS158
• Lock building.
DX,CRPRV,J –19–04JUN90–1/1
–UN–23AUG88
• Remove ignition key.
TS144
• Lock cab doors, windows, and vandal-proof devices.
DX,CRPRV,K –19–04JUN90–1/1
120–2
PN=310
Crime Prevention Tips
REDUCE VANDALISM
–UN–22FEB90
report your findings to law enforcement agency.
T7223BB
agency. Order duplicate plates from your dealer.
TX,120,DH1093 –19–16SEP92–1/1
DX,CRPRV,G –19–03MAR93–1/1
120–3
PN=311
Index
Page Page
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-10
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-2
A
Belt
Tension adjust . . . . . . . . . . . . . . . . . .55-10, 55-11
Accessory
Bleed
Operational checkout . . . . . . . . . . . . . . . . . . 95-25
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Accumulator
Fuel system . . . . . . . . . . . . . . . . . . . . . .90-7, 90-8
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-24
Boom
Acid burns . . . . . . . . . . . . . . . . . . 80-2, 90-12, 90-14
Control lever-544G TC . . . . . . . . . . . . . . . . . . 35-4
Adjustment
Control lever-one lever design . . . . . . . . . . . . 35-1
Belt tension. . . . . . . . . . . . . . . . . . . . .55-10, 55-11
Control lever-two lever design . . . . . . . . . . . . . 35-2
Boom height control . . . . . . . . . . . . . . . . . . . . 35-7
Down switch . . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Clutch cut-off. . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Height control adjust . . . . . . . . . . . . . . . . . . . . 35-7
Compressor belt tension . . . . . . . . . . . . . . . . 90-20
Booster battery . . . . . . . . . . . . . . . . . . . . . . . . . . 25-6
Engine speed control linkage . . . . . . . . . . . . . 85-2
Brake
Engine valve lash-544G, 624G . . . . . . . . . . . . 86-1
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . 90-24
Engine valve lash-644G . . . . . . . . . . . . . . . . . 86-3
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-8
Oil pressure indicator . . . . . . . . . . . . . . .10-8, 25-1
Return-to-dig . . . . . . . . . . . . . . . . . . . . . . . . . . 35-8
Operational checkout . . . . . . . . . . . . . . . . . . 95-10
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Break-in
Steering wheel tilt . . . . . . . . . . . . . . . . . . . . . 10-15
Air 10 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Cleaner elements clean . . . . . . . . . . . . . . . . . 55-6 100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Cleaner elements replace . . . . . . . . . . . . . . . . 85-3 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Cleaner unloader valve . . . . . . . . . . . . . . . . . . 60-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Conditioning control . . . . . . . . . . . . . . . . . . . 10-18 Bucket
Conditioning service . . . . . . . . . . . . . . . . . . . 90-19 Control lever-one lever design . . . . . . . . . . . . 35-1
Conditioning troubleshooting . . . . . . . . . . . . 100-41 Control lever-two lever design . . . . . . . . . . . . . 35-2
Filter restriction indicator . . . . . . . . . . . . . . . . . 10-6
Inlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-9
Intake hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Alarm C
Reverse warning . . . . . . . . . . . . . . . . . . . . . . 90-18
Stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Cab
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9 Fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . . 70-5
Voltage indicator . . . . . . . . . . . . . . . . . . . . . . . 10-6 Operational checkout . . . . . . . . . . . . . . . . . . 95-29
Antifreeze test . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4 Recirculating air filter . . . . . . . . . . . . . . . . . . 55-14
Axle Circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . 90-16
Operational checkout . . . . . . . . . . . . . . . . . . . 95-4
Clutch
Cut-off adjust . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Cut-off operational checkout . . . . . . . . . . . . . 95-10
B Cut-off switch . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Compressor
Backdragging . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12 Belt tension adjust . . . . . . . . . . . . . . . . . . . . 90-20
Battery Coolant, engine . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
Acid burns. . . . . . . . . . . . . . . . . 80-2, 90-12, 90-14 Coolant
Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-6 Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14 Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-5
Electrolyte level check. . . . . . . . . . . . . . . . . . . 80-2 Level radiator . . . . . . . . . . . . . . . . . . . . . . . . . 75-5
Explosion . . . . . . . . . . . . . . . . . 80-2, 90-12, 90-14 Level recovery tank. . . . . . . . . . . . . . . . . . . . . 60-3
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Index-1 040596
PN=1
Index
Page Page
Index-2
PN=2
Index
Page Page
Index-3
PN=3
Index
Page Page
P
N Park brake
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-8
Neutral Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-7
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13, 30-3 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Start operational checkout. . . . . . . . . . . . . . . . 95-4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Start system check . . . . . . . . . . . . . . . . . . . . 90-18 Switch . . . . . . . . . . . . . . . . . . . . . . . . . .10-12, 30-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 100-40
Pedal
Differential lock . . . . . . . . . . . . . . . . . . . . . . . . 35-6
O Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Pin disconnect
O-ring boss fittings . . . . . . . . . . . . . . . . . . . . . . 90-37 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Oil lines and fittings . . . . . . . . . . . . . . . . . . . . . 90-36 Power train
Oil Troubleshooting . . . . . . . . . . . . . . . . . . . . . 100-29
Change differential . . . . . . . . . . . . . . . . . . . . . 87-3 Product Identification Number. . . . . . . . . . . . . . 110-1
Change engine . . . . . . . . . . . . . . . . . . . . . . . . 75-2 Pump
Change hydraulic . . . . . . . . . . . . . . . . . . . . . . 87-1 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
Change transmission . . . . . . . . . . . . . . . . . . . 85-5
Level differential . . . . . . . . . . . . . . . . . .80-9, 80-10
Level engine . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1 Q
Level hydraulic system . . . . . . . . . . . . . . . . . . 60-3
Level transmission . . . . . . . . . . . . . . . . . . . . . 60-5 Quick shift
Lines and fittings. . . . . . . . . . . . . . . . . . . . . . 90-36 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3
Specification differential . . . . . . . . . . . . . . . . . 45-5
Specification hydraulic system . . . . . . . . . . . . 45-5
Oilscan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7 R
Operating
Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Radiator
Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9 Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 75-5
Index-4
PN=4
Index
Page Page
STOP T
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Tire
Seat Pressure check . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Torque value
Secondary steering Flat face O-ring seal fitting . . . . . . . . . . . . . . 90-39
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28 Inch SAE four bolt flange fitting. . . . . . . . . . . 90-41
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6 Metric cap screw . . . . . . . . . . . . . . . . . . . . . . 90-33
Serial number Metric four bolt flange fitting . . . . . . . . . . . . . 90-40
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-1 O-Ring boss fitting . . . . . . . . . . . . . . . . . . . . 90-37
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . 110-2 Wheel retaining cap screw . . . . . . . . . . . . . . . 55-5
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 110-2 Torque values
Service Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Brake troubleshooting . . . . . . . . . . . . . . . . . 100-35 Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
Interval . . . . . . . . . . . . . . . . . . . 50-1, 55-1, SLIT-1 Roll-over protective structure. . . . . . . . . . . . . 90-30
Required indicator. . . . . . . . . . . . . . . . . . . . . . 10-4 Towing procedure. . . . . . . . . . . . . . . . . . . . . . . . 40-3
Specification Transmission
Battery electrolyte . . . . . . . . . . . . . . . . . . . . . 90-12 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-5
Differential oil . . . . . . . . . . . . . . . . . . . . . . . . . 45-5 Oil filter change. . . . . . . . . . . . . . . . . . . . . . . . 85-5
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . 45-5 Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5
Speed Oil pressure indicator . . . . . . . . . . . . . . . . . . . 10-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-1 Oil temperature gauge . . . . . . . . . . . . . . . . . . 10-5
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5 Operational checkout . . . . . . . . . . . . . . . . . . . 95-4
Starting Serial number . . . . . . . . . . . . . . . . . . . . . . . . 110-2
The engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1 Travel speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Steering Troubleshooting
Pressure indicator . . . . . . . . . . . . . . . . . . . . . . 10-9 Air conditioning . . . . . . . . . . . . . . . . . . . . . . 100-41
System, operational checkout . . . . . . . . . . . . 95-22 Differential axle . . . . . . . . . . . . . . . . . . . . . . 100-37
Wheel tilt adjust . . . . . . . . . . . . . . . . . . . . . . 10-15 Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-39
Stopping Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-2
Index-5
PN=5
Index
Page
Unloader valve
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Valve
Air cleaner dust unloader .. .. .. .. .. . . . . . . 60-1
Control . . . . . . . . . . . . . . .. .. .. .. .. . . . . . 90-29
Dust unloader . . . . . . . . . .. .. .. .. .. . . . . . . 85-3
Lash adjust . . . . . . . . . . . .. .. .. .. .. . .86-1, 86-3
Vandal
Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Vent tube
Engine crankcase . . . . . . . . . . . . . . . . . . . . . . 85-4
Warm-up
Engine, cold weather . . . . . . . . . . . . . . . . . . . 25-8
Warning alarm
Operational checkout . . . . . . . . . . . . . . . . . . . 95-4
Washer
Windshield fluid level . . . . . . . . . . . . . . . . . . . 50-5
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-20
Wheel
Cap screw torque . . . . . . . . . . . . . . . . . . . . . . 55-5
Window
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Sliding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Windshield
Washer fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Wiper and washer. . . . . . . . . . . . . . . . . . . . . 10-15
Wiper
Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Index-6
PN=6
Checklists
CLIS–1
PN=312
Checklists
TX,50,JC1160 –19–03JUN96–1/1
CLIS–2
PN=313
John Deere Service Literature Available
PARTS CATALOG
-UN-17JAN89
and disassembling.
TS189
DX,PARTS -19-03MAR93
OPERATOR’S MANUAL
-UN-02DEC88
An extra copy of the operator’s manual is available. The
operator’s manual and safety signs on your machine
may also be available in other languages. (See your
John Deere dealer to order.)
TS191
DX,INDOM -19-17SEP92
-UN-17JAN89
and disassembly procedures, hydraulic oil flows, and
wiring diagrams.
TS224
DX,TM -19-03MAR93
DX,FOS -19-04JUN90
170696
PN=12
John Deere Service Literature Available
170696
PN=13
John Deere Service Keeps You On The Job
JOHN DEERE IS AT YOUR SERVICE WHEN YOU NEED IT
-UN-12SEP95
TS1643
Division 1—Calgary Division 4—Moline Division 8—Atlanta
John Deere Industrial Equipment Co. John Deere Industrial Equipment Co. John Deere Industrial Equipment Co.
6715 8th Street NE, Suite 218 400 19th Street 1201 Roberts Blvd., Suite 230
Calgary, AB T2E 7H7 Canada Moline, IL 61265 Kennesaw, GA 30144
403-531-5731; fax: 403-531-5739 309-765-3316; fax: 309-765-3357 404-423-2400; fax: 404-423-2411
Division 2—Denver Division 5—Grimsby a—John Deere Intercontinental Limited
John Deere Industrial Equipment Co. John Deere Industrial Equipment Co. Overseas Industrial Division
6101 Stapleton North Drive, Suite A P.O. Box 999 P.O. Box 2000
Denver, CO 80216 Grimsby, ON L3M 4S9 Canada Moline, IL 61265 U.S.A.
303-336-1204; fax: 303-336-1208 905-945-7389; fax: 905-945-7470 309-765-3316; fax: 309-765-3279
Division 3—Dallas Division 6—Baltimore
John Deere Industrial Equipment Co. John Deere Industrial Equipment Co.
P.O. Box 999 72 Loveton Circle, Suite 101
Lewisville, TX 75029-2610 Sparks, MD 21152
214-355-4513; fax: 214-355-4508 410-785-4118; fax: 410-785-4145
170696
PN=14