John Deere 544G 544G LL & 544G TC Loaders 624G Loader 644G Loader  Official Operator's

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This manual contains information and data to this model. Has specs, diagrams, and actual real photo illustrations, These technical manual is as good as it gets for Diagnosing, Repairing, and Maintenancing John Deere machinery. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need... or all manual. 

Models And Serials :

Serial No. 557739-

CONTENTS : 

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-1
Operator’s Station
Gauges, Indicators, Switches, and
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Stop Indicator and Alarm . . . . . . . . . . . . . . . . . . 10-3
Service Required Indicator (Yellow) . . . . . . . . . . 10-4
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Engine Coolant Temperature Gauge . . . . . . . . . 10-5
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Transmission Oil Temperature Gauge . . . . . . . . 10-5
Engine Oil Pressure Indicator . . . . . . . . . . . . . . . 10-6
Alternator Voltage Indicator . . . . . . . . . . . . . . . . 10-6
Engine Air Filter Restriction Indicator . . . . . . . . . 10-6
Engine Coolant Level Indicator . . . . . . . . . . . . . . 10-7
Transmission Oil Pressure Indicator—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Hydraulic Oil Filter Restriction Indicator . . . . . . . 10-7
Right Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-8
Brake Oil Pressure Indicator. . . . . . . . . . . . . . . . 10-8
Park Brake Indicator. . . . . . . . . . . . . . . . . . . . . . 10-8
Fasten Seat Belt Indicator . . . . . . . . . . . . . . . . . 10-9
Ether Injection Indicator . . . . . . . . . . . . . . . . . . . 10-9
Steering Pressure Indicator—If Equipped . . . . . . 10-9
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-10
Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Front Axle Disconnect Lever—If Equipped . . . . 10-11
Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . 10-12
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . 10-14
Dome Light and Swivel Light—If Equipped . . . . 10-14
Vandal Shield—If Equipped . . . . . . . . . . . . . . . 10-14
Operating Windshield Wipers and
Washers—If Equipped . . . . . . . . . . . . . . . . . 10-15
Adjusting Steering Wheel Tilt . . . . . . . . . . . . . . 10-15
Opening Side Window . . . . . . . . . . . . . . . . . . . 10-15
Opening Sliding Side Window—If Equipped . . . 10-16
Cab Door Release . . . . . . . . . . . . . . . . . . . . . . 10-16
Operating Lights . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Adjusting Suspension Seat. . . . . . . . . . . . . . . . 10-19
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Storage Compartment . . . . . . . . . . . . . . . . . . . 10-20
Heating and Air Conditioning Controls . . . . . . . 10-18
Break-in
Engine Break-In Oil . . . . . . . . . . . . . . . . . . . . . . 15-1
Every 10 Hours or Daily . . . . . . . . . . . . . . . . . . . 15-1
After First 10 and First 50 Hours . . . . . . . . . . . . 15-2
After the First 100 Hours . . . . . . . . . . . . . . . . . . 15-2
Pre-Start Inspection
Inspect Machine Daily Before Starting . . . . . . . . 20-1
Operating the Engine
Check Instruments Before Starting . . . . . . . . . . . 25-1
Brake Pressure Indicator . . . . . . . . . . . . . . . . . . 25-1
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . 25-1
Starting Fluid—If Equipped (Cold Weather
Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Using Coolant Heater—If Equipped . . . . . . . . . . 25-5
Using Booster Batteries—12 Volt System. . . . . . 25-6
Check Instruments After Starting . . . . . . . . . . . . 25-7
Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-7
Cold Weather Warm-Up . . . . . . . . . . . . . . . . . . . 25-8
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . 25-8
Driving the Machine
Driving on Public Roads . . . . . . . . . . . . . . . . . . . 30-1
General Driving Precautions . . . . . . . . . . . . . . . . 30-2
Front Axle Disconnect—If Equipped . . . . . . . . . . 30-2
Neutral Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Shifting the Transmission . . . . . . . . . . . . . . . . . . 30-3
Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Ride Control Switch—If Equipped. . . . . . . . . . . . 30-6
Stopping the Machine. . . . . . . . . . . . . . . . . . . . . 30-6
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 30-7
Parking the Machine. . . . . . . . . . . . . . . . . . . . . . 30-7
Operating the Machine
Boom and Bucket Control Lever—One
Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
Boom and Bucket Control Lever—Two
Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Quick Shift Switch . . . . . . . . . . . . . . . . . . . . . . . 35-3
Quick Coupler Operation—544G TC . . . . . . . . . 35-4
Pin Disconnect Switch—544G TC . . . . . . . . . . . 35-5
Boom Down Switch . . . . . . . . . . . . . . . . . . . . . . 35-5
Clutch Cut-Off Switch—If Equipped . . . . . . . . . . 35-5
Secondary Steering—If Equipped. . . . . . . . . . . . 35-6
Differential Lock Pedal—If Equipped . . . . . . . . . 35-6
Adjusting Boom Height Kickout—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-7
Adjusting Return-to-Dig . . . . . . . . . . . . . . . . . . . 35-8
General Operating Tips . . . . . . . . . . . . . . . . . . . 35-9
Excavating Banks or Stockpiles . . . . . . . . . . . . . 35-9
Using the Loader Bucket . . . . . . . . . . . . . . . . . 35-10
Backdragging . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12
Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12
Truck Loading . . . . . . . . . . . . . . . . . . . . . . . . . 35-13
Transporting
Transporting Precautions . . . . . . . . . . . . . . . . . . 40-1
Loading Machine on a Trailer . . . . . . . . . . . . . . . 40-1
Towing Procedure—Engine Operational . . . . . . . 40-3
Towing Procedure—Engine Non-
Operational. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . 40-7
Fuels and Lubricants
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Low Sulfur Diesel Fuel Conditioner. . . . . . . . . . . 45-2
Handling and Storing Diesel Fuel . . . . . . . . . . . . 45-2
Do Not Use Galvanized Containers . . . . . . . . . . 45-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-3
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Transmission Oil, Hydraulic System Oil and
Differential Oil. . . . . . . . . . . . . . . . . . . . . . . . . 45-5
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-6
Alternative and Synthetic Lubricants . . . . . . . . . . 45-6
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . . . . 45-7
Periodic Maintenance
Service Your Machine at Specified Intervals. . . . 50-1
Check the Hour Meter Regularly . . . . . . . . . . . . 50-1
Use Correct Fuels and Lubricants . . . . . . . . . . . 50-1
Prepare Machine for Maintenance . . . . . . . . . . . 50-2
Locking Machine Frame . . . . . . . . . . . . . . . . . . . 50-3
Boom Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Opening Engine Side Shields and Service
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-4
Opening Grille Door . . . . . . . . . . . . . . . . . . . . . . 50-5
Check Windshield Washer Fluid Level . . . . . . . . 50-5
Maintenance and Repair Record Keeping
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
OILSCAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Maintenance Record Keeping. . . . . . . . . . . . . . . 50-8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-9
Maintenance—As Required
Check Tire Pressure. . . . . . . . . . . . . . . . . . . . . . 55-1
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . 55-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-5
Tighten Wheel Retainer Cap Screws . . . . . . . . . 55-5
Clean or Replace Air Cleaner Elements . . . . . . . 55-6
Clean Dusty Primary Element. . . . . . . . . . . . . . . 55-7
Clean Oily or Sooty Primary Element . . . . . . . . . 55-7
Inspect Element . . . . . . . . . . . . . . . . . . . . . . . . . 55-8
Check Air Inlet Cover . . . . . . . . . . . . . . . . . . . . . 55-9
Check and Adjust Belt Tension—544G,
624G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10
Inspect Serpentine Belt—644G. . . . . . . . . . . . . 55-11
Drain Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . 55-11
Drain and Clean Primary Fuel Filter (Water
Separator)—544G, 624G . . . . . . . . . . . . . . 55-12
Drain and Clean Primary Fuel Filter (Water
Separator)—644G . . . . . . . . . . . . . . . . . . . . 55-13
Check Cab Recirculating Air Filter . . . . . . . . . . 55-14
Maintenance—Every 10 Hours or Daily
Lubricate Pivots . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Clean Air Cleaner Dust Unloader Valve . . . . . . . 60-1
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . 60-1
Check Recovery Tank Coolant Level . . . . . . . . . 60-3
Check Hydraulic Oil Level . . . . . . . . . . . . . . . . . 60-3
Check Transmission Oil Level . . . . . . . . . . . . . . 60-5
Maintenance—Every 100 Hours
Lubricant Boom, Bucket, and Cylinder
Pivots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Lubricate Boom, Bucket, and Cylinder
Pivots—544G TC . . . . . . . . . . . . . . . . . . . . . . 70-2
Lubricate Oscillating Rear Axle. . . . . . . . . . . . . . 70-5
Check Cab Fresh Air Filter—If Equipped . . . . . . 70-5
Lubricate Steering Cylinder Pivots . . . . . . . . . . . 70-4
Maintenance—Every 250 Hours
Check Receiver Dryer Moisture Indicator . . . . . . 75-1
Change Engine Oil and Replace Filter . . . . . . . . 75-2
Check Radiator Coolant Level . . . . . . . . . . . . . . 75-5
Maintenance—Every 500 Hours
Lubricant Front Driveline. . . . . . . . . . . . . . . . . . . 80-1
Check Air Intake Hoses . . . . . . . . . . . . . . . . . . . 80-1
Check Battery Electrolyte Level and
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-2
Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
Replace Primary Fuel Filter (Water
Separator) . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6
Replace Final Fuel Filter—544G, 624G . . . . . . . 80-7
Replace Final Fuel Filter—644G. . . . . . . . . . . . . 80-7
Replace Hydraulic System Return Filter . . . . . . . 80-7
Replace Hydraulic Reservoir Breather Filter . . . . 80-8
Check Front and Rear Differential Oil
Level—If Equipped with Standard Axle . . . . . 80-9
Check Front and Rear Differential Oil
Level—If Equipped with Differential Lock
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10
Maintenance—Every 1000 Hours
Lubricate Rear Driveline . . . . . . . . . . . . . . . . . . . 85-1
Check Engine Speeds . . . . . . . . . . . . . . . . . . . . 85-1
Adjust Engine Speed Control Linkage . . . . . . . . 85-2
Replace Air Cleaner Dust Unloader Valve . . . . . 85-3
Replace Air Cleaner Elements . . . . . . . . . . . . . . 85-3
Clean Engine Crankcase Vent Tube (A). . . . . . . 85-4
Change Transmission Oil and Replace
Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-5
Check Park Brake . . . . . . . . . . . . . . . . . . . . . . . 85-7
Adjust Park Brake. . . . . . . . . . . . . . . . . . . . . . . . 85-8
Lubricate Frame Hinge Pivots . . . . . . . . . . . . . 85-10
Maintenance—Every 2000 Hours
Measure and Adjust Engine Valve Lash
(Clearance)—544G, LL, TC, 624G . . . . . . . . 86-1
Adjust Engine Valve Lash (Clearance)—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86-3
Lubricate Front Driveline Support Bearing . . . . . 86-5
Maintenance—Every 3000 Hours
Change Hydraulic System Oil . . . . . . . . . . . . . . . 87-1
Clean Hydraulic Suction Strainer . . . . . . . . . . . . 87-2
Replace Differential Lock Return Filter(s)—
If Equipped. . . . . . . . . . . . . . . . . . . . . . . . . . . 87-2
Change Front and Rear Differential Oil. . . . . . . . 87-3
Maintenance
Draining the Cooling System . . . . . . . . . . . . . . . 90-1
Diesel Engine Coolant . . . . . . . . . . . . . . . . . . . . 90-3
Coolant drain intervals . . . . . . . . . . . . . . . . . . . . 90-3
Filling the Cooling System . . . . . . . . . . . . . . . . . 90-4
Test the Coolant Freeze—Protection Level . . . . 90-4
Do Not Service Injection Nozzles . . . . . . . . . . . . 90-5
Do Not Adjust Injection Pump. . . . . . . . . . . . . . . 90-5
Cleaning Fuel Tank Outlet Screen . . . . . . . . . . . 90-5
Bleeding Fuel System—544G, 624G . . . . . . . . . 90-7
Bleeding Fuel System—644G. . . . . . . . . . . . . . . 90-8
Adjusting Fuel Shut-Off Solenoid—644G . . . . . . 90-8
Precautions for Alternator and Regulator . . . . . . 90-9
Service Batteries Carefully . . . . . . . . . . . . . . . . 90-10
Checking Electrolyte Specific Gravity . . . . . . . . 90-12
Using Battery Charger . . . . . . . . . . . . . . . . . . . 90-14
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . 90-14
Removing Batteries . . . . . . . . . . . . . . . . . . . . . 90-15
Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . 90-15
Fuse (Blade-Type) Color Codes . . . . . . . . . . . . 90-15
Resetting Circuit Breakers . . . . . . . . . . . . . . . . 90-16
Replacing Halogen Bulbs . . . . . . . . . . . . . . . . . 90-16
Changing Reverse Warning Alarm Volume. . . . 90-18
Checking Neutral Start System. . . . . . . . . . . . . 90-18
Adding Attachments/Accessories to RollOver
Protective Structure (ROPS) . . . . . . . . 90-19
Servicing Air Conditioning System . . . . . . . . . . 90-19
Checking and Adjusting Compressor Belt
Tension—If Equipped . . . . . . . . . . . . . . . . . . 90-20
Welding on Machine. . . . . . . . . . . . . . . . . . . . . 90-20
Inspecting Park Brake Pads . . . . . . . . . . . . . . . 90-21
External Service Brake Inspection . . . . . . . . . . 90-22
Checking Brake Accumulator . . . . . . . . . . . . . . 90-24
Checking Ride Control Accumulator—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Checking Secondary Steering System—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Clutch Cut-Off Adjustment . . . . . . . . . . . . . . . . 90-28
Do Not Service Control Valves, Cylinders,
Pumps or Motors . . . . . . . . . . . . . . . . . . . . . 90-29
Hardware Torque Specifications . . . . . . . . . . . . 90-30
Keep ROPS Installed Properly . . . . . . . . . . . . . 90-30
Metric Bolt and Cap Screw Torque Values . . . . 90-31
Additional Metric Cap Screw Torque Values. . . 90-33
Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Check Oil Lines and Fittings. . . . . . . . . . . . . . . 90-36
Service Recommendations for O-Ring Boss
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
Service Recommendations for Flat Face O
Ring
Seal Fittings . . . . . . . . . . . . . . . . . . . . . 90-39
Service Recommendations for Metric Series
Four Bolt Flange Fitting . . . . . . . . . . . . . . . . 90-40
Service Recommendations for Inch Series
Four Bolt Flange Fittings . . . . . . . . . . . . . . . 90-41
Operational Checkout
Operational Checkout . . . . . . . . . . . . . . . . . . . . . 95-1
Monitor Indicator and Gauge Checks—
Engine Off . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2
Hourmeter And Gauge Check . . . . . . . . . . . . . . 95-2
Battery Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 95-2
Monitor Indicator Circuit And Key Switch
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-3
Monitor Turn Signals And Hazard Warning
Indicator Checks . . . . . . . . . . . . . . . . . . . . . . 95-4
Transmission Controls, Axle and Engine
Linkages, Neutral Start Switch, and
Reverse Warning Alarm Switch Checks . . . . . 95-4
Neutral Start And Reverse Warning Alarm
Circuit checks. . . . . . . . . . . . . . . . . . . . . . . . . 95-4
Engine Speed Control Linkage Check—
544G, 624G . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5
Engine Speed Control Linkage Check—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5
Engine Speed Control Linkage Check—
644G (Continued). . . . . . . . . . . . . . . . . . . . . . 95-5
Fuel Shut-off Solenoid Linkage Check—
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-6
Front Axle Disconnect Check—If Equipped . . . . 95-6
Monitor Indicator and Gauge Checks
(Engine Running) . . . . . . . . . . . . . . . . . . . . . . 95-7
Monitor Display And Alternator Output
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-7
Monitor Indicator Circuit Bypass And Seat
Belt Indicator Check . . . . . . . . . . . . . . . . . . . . 95-9
Monitor Primary And Secondary Level
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-9
Transmission Temperature Gauge Check. . . . . 95-10
Brake System, Clutch Cut-Off, and
Differential Lock Checks. . . . . . . . . . . . . . . . 95-10
Park Brake Transmission Lockout Check . . . . . 95-10
Service Brake Pump Flow Check . . . . . . . . . . . 95-11
Service Brake Check . . . . . . . . . . . . . . . . . . . . 95-12
Brake Accumulator Precharge Check . . . . . . . . 95-12
Brake System Leakage Check . . . . . . . . . . . . . 95-13
Service Brake Pedal Check . . . . . . . . . . . . . . . 95-13
Service And Park Brake System Drag
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-13
Differential Lock Check. . . . . . . . . . . . . . . . . . . 95-14
Clutch Cut-Off Check . . . . . . . . . . . . . . . . . . . . 95-14
Driving Checks . . . . . . . . . . . . . . . . . . . . . . . . . 95-15
Transmission Noise Check . . . . . . . . . . . . . . . . 95-15
Automatic Shift and Speedometer Check . . . . . 95-16
Transmission Quickshift Check. . . . . . . . . . . . . 95-17
Transmission Pressure, Pump Flow, and
Leakage Check . . . . . . . . . . . . . . . . . . . . . . 95-17
Transmission Shift Modulation Check. . . . . . . . 95-18
Hydraulic System Checks. . . . . . . . . . . . . . . . . 95-18
Hydraulic System Warm-Up Procedure . . . . . . 95-18
Boom Down Solenoid Valve Check . . . . . . . . . 95-18
Control Valve Lift Check . . . . . . . . . . . . . . . . . . 95-19
Bucket Rollback Circuit Relief Valve Check . . . 95-19
Bucket Dump Circuit Relief Valve Pressure
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-19
Boom and Bucket Cylinder Drift . . . . . . . . . . . . 95-19
Boom Down Check Valve Leakage Check . . . . 95-20
Pilot Controller Check. . . . . . . . . . . . . . . . . . . . 95-20
Return-To-Dig Check . . . . . . . . . . . . . . . . . . . . 95-20
Boom Height Kickout Check—If Equipped . . . . 95-21
Pin Disconnect Cylinder Check (544G-TC
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Ride Control Accumulator Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-21
Steering System Checks . . . . . . . . . . . . . . . . . 95-22
Steering Valve Check. . . . . . . . . . . . . . . . . . . . 95-22
Steering System Leakage Check . . . . . . . . . . . 95-22
Priority Valve Low Pressure Check. . . . . . . . . . 95-23
Priority Valve High Pressure Check . . . . . . . . . 95-23
Secondary Steering System Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-24
Secondary Steering System Primary Check
Valve Check. . . . . . . . . . . . . . . . . . . . . . . . . 95-24
Accessory Checks . . . . . . . . . . . . . . . . . . . . . . 95-25
Operating Lights Check . . . . . . . . . . . . . . . . . . 95-25
Work Light Check . . . . . . . . . . . . . . . . . . . . . . . 95-25
Brake Light Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Horn Circuit Check . . . . . . . . . . . . . . . . . . . . . . 95-26
Windshield Washer and Wiper Check—If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-27
Defroster Blower Check . . . . . . . . . . . . . . . . . . 95-27
Heater/Air Conditioner Blower Check . . . . . . . . 95-28
Heater Functional Check . . . . . . . . . . . . . . . . . 95-28
Air Conditioner Functional Check . . . . . . . . . . . 95-28
Start Aid System Check . . . . . . . . . . . . . . . . . . 95-29
Cab Component and Vandal Protection
Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Cab Door and Window Hold-Open Latch
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-29
Cab Door Release Button. . . . . . . . . . . . . . . . . 95-30
Cab Door Lock Check . . . . . . . . . . . . . . . . . . . 95-30
Dome Light Check . . . . . . . . . . . . . . . . . . . . . . 95-30
Cab Window Latch Check . . . . . . . . . . . . . . . . 95-31
Cab Door Window Check . . . . . . . . . . . . . . . . . 95-31
Steering Column Adjustment Check . . . . . . . . . 95-31
Seat And Seat Belt Check . . . . . . . . . . . . . . . . 95-32
Toolbox Door Check. . . . . . . . . . . . . . . . . . . . . 95-32
Air Intake Filter Door Check . . . . . . . . . . . . . . . 95-33
Load Center Door Check . . . . . . . . . . . . . . . . . 95-33
Engine Side Panels Check . . . . . . . . . . . . . . . . 95-33
Radiator Cap Access Door Check . . . . . . . . . . 95-34
Frame Locking Bar Check . . . . . . . . . . . . . . . . 95-34
Boom Lock Check . . . . . . . . . . . . . . . . . . . . . . 95-34
Service Decal Check . . . . . . . . . . . . . . . . . . . . 95-34
Troubleshooting
Using Troubleshooting Charts . . . . . . . . . . . . . 100-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . 100-14
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . 100-22
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . 100-29
Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . 100-35
Differential Axle . . . . . . . . . . . . . . . . . . . . . . . 100-37
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-39
Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-40
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . 100-41
Storage
Prepare Machine for Storage . . . . . . . . . . . . . . 105-1
Monthly Storage Procedure . . . . . . . . . . . . . . . 105-2
Machine Numbers
Record Product Identification Number (PIN) . . . 110-1
Record Engine Serial Number—544G . . . . . . . 110-1
Record Engine Serial Number—624G . . . . . . . 110-1
Record Engine Serial Number—644G . . . . . . . 110-1
Record Transmission Serial Number . . . . . . . . 110-2
Record Hydraulic Pump Serial Number . . . . . . 110-2
Specifications
544G Specifications . . . . . . . . . . . . . . . . . . . . . 115-1
544G Specifications . . . . . . . . . . . . . . . . . . . . . 115-3
Drain and Refill Capacities—544G . . . . . . . . . . 115-5
544G LL Specifications. . . . . . . . . . . . . . . . . . . 115-5
544G LL Specifications. . . . . . . . . . . . . . . . . . . 115-7
Drain and Refill Capacities—544G LL . . . . . . . 115-9
544G TC Specifications . . . . . . . . . . . . . . . . . . 115-9
544G TC Specifications . . . . . . . . . . . . . . . . . 115-11
Drain and Refill Capacities—544G TC . . . . . . 115-13
624G Specifications . . . . . . . . . . . . . . . . . . . . 115-13
624G Specifications . . . . . . . . . . . . . . . . . . . . 115-15
Drain and Refill Capacities—624G . . . . . . . . . 115-17
644G Specifications . . . . . . . . . . . . . . . . . . . . 115-17
644G Specifications . . . . . . . . . . . . . . . . . . . . 115-19
Drain and Refill Capacities—644G . . . . . . . . . 115-20
Crime Prevention Tips . . . . . . . . . . . . . . . . . . 120-1
Index

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