Moffat 500 TC Dokumentacja Strona 1

544G, 544G LL, and544G TC Loaders624G Loader644G Loader(Serial No. 557739-)OPERATORS MANUAL544G, 544G LL, and 544G TC Loaders 624G Loader644G Loader (

ContentsPage PageBoom and Bucket Control Lever—One Check Windshield Washer Fluid Level . . . . . . . . 50-5Maintenance and Repair Record KeepingLever

TransportingTX,40,DH2288 –19–12MAY93–1/2TOWING PROCEDURE—ENGINEOPERATIONALT6629AM –UN–20OCT88ÖCAUTION: Use flashing warning lights and turnsignals whe

TransportingTX,40,DH2288 –19–12MAY93–2/24. Move transmission control lever to neutral. Engageneutral lock.5. Raise boom, and support so bucket is off

TransportingTX,40,JC1101 –19–18MAR96–2/4T100701 –UN–22MAR96644G Show2. Manually release park brake: Remove (3) screws andremove sheet metal cover from

TransportingTX,40,JC1101 –19–18MAR96–4/4T6629AM –UN–20OCT8810. Connect a rigid tow bar to drawbar pin (A) of machinebeing towed.11. Start engine.12. I

TransportingTX,40,DH2187 –19–12SEP92–1/1LIFTING THE MACHINET7477AV –UN–19MAR91ÖCAUTION: Prevent possible injury fromunexpected machine movement. Clear

Fuels and LubricantsTX,45,JC1132 –19–22MAY96–1/1DIESEL FUELConsult your local fuel distributor for properties of thediesel fuel available in your area

Fuels and LubricantsTX,45,DH3124 –19–20OCT93–1/1LOW SULFUR DIESEL FUEL CONDITIONERWhen possible, use existing fuel formulations for enginesused off-hi

Fuels and LubricantsMX,FLBT,C –19–04JUN90–1/1DO NOT USE GALVANIZED CONTAINERSIMPORTANT: Diesel fuel stored in galvanizedcontainers reacts with zinc co

Fuels and LubricantsTX,45,JC1133 –19–22MAY96–1/1DIESEL ENGINE OILT101239 –19–22MAY96Use oil viscosity based on the expected airtemperature range durin

Fuels and LubricantsTX,45,JC1050 –19–18JAN96–1/1TRANSMISSION OIL, HYDRAULIC SYSTEM OIL AND DIFFERENTIAL OILT100663 –19–10MAY96Use oil viscosity based

ContentsPage PageMaintenance—Every 500 Hours Cleaning Fuel Tank Outlet Screen . . . . . . . . . . . 90-5Bleeding Fuel System—544G, 624G . . . . . . .

Fuels and LubricantsTX,45,JC1134 –19–22MAY96–1/1GREASET8358AI –19–27MAR95Use grease based on NLGI consistency numbers andthe expected air temperature

Fuels and LubricantsTX,45,JC1135 –19–22MAY96–1/1LUBRICANT STORAGEYour equipment can operate at top efficiency only ifclean lubricants are used.Use cle

Periodic MaintenanceTX,50,JC1104 –19–18MAR96–1/1SERVICE YOUR MACHINE AT SPECIFIEDINTERVALST100700 –UN–22MAR96Lubricate, make service checks and adjust

Periodic MaintenanceTX,50,DH2194 –19–29NOV94–1/2PREPARE MACHINE FOR MAINTENANCEBefore performing maintenance procedures given in thefollowing chapters

Periodic MaintenanceTX,50,DH2199 –19–17AUG92–1/2LOCKING MACHINE FRAMEÖCAUTION: Prevent possible injury fromunexpected machine movement. Connect framel

Periodic MaintenanceTX,50,JC255 –19–29NOV94–1/1BOOM LOCKT7839BB –UN–17SEP92T100699 –UN–22MAR96644G ShownÖCAUTION: Always install boom lock beforeworki

Periodic MaintenanceTX,50,DH2198 –19–31JUL92–1/1OPENING GRILLE DOORT6785CD –UN–19OCT88T7773CD –UN–10AUG92Push down on latch (A) to open grille door.Ro

Periodic MaintenanceTX,50,FF2898 –19–09JUL93–1/1MAINTENANCE AND REPAIR RECORDKEEPING SYSTEMT7511CO –UN–27JUN91The checklist on the following page summ

Periodic MaintenanceTX,50,JC1061 –19–12FEB96–1/1OILSCANT6828AB –UN–15JUN89T6829AB –UN–18OCT88OILSCAN is a John Deere oil sampling program to helpyou

Periodic MaintenanceTX,50,JC1137 –19–22MAY96–1/1MAINTENANCE AND REPAIR RECORD KEEPING SYSTEMSERVICE INTERVALSService your machine at intervals shown o

ContentsPage PageMonitor Indicator and Gauge Checks— Control Valve Lift Check. . . . . . . . . . . . . . . . . . 95-19Bucket Rollback Circuit Relief V

Periodic MaintenanceTX,50,JC1160 –19–03JUN96–1/1MAINTENANCE AND REPAIR RECORD KEEPING SYSTEMModel: ❒ 544G ❒ 544G LL ❒ 544G TC ❒ 624G ❒ 644G Customer:P

Maintenance—As RequiredTX,55,FF2820 –19–25OCT94–1/2CHECK TIRE PRESSURETS211 –UN–23AUG88T87502 –UN–21OCT88ÖCAUTION: Explosive separation of a tire andr

Maintenance—As RequiredTX,55,FF2820 –19–25OCT94–2/24. Turn on air supply. Stand to front or rear of tire whenyou add air to tire.5. After tire is at c

Maintenance—As RequiredTX,55,JC1157 –19–03JUN96–1/1544G LLOperating Pressure*Tire Size Type Ply Rating kPa bar psi17.5 x 25 L2 12 345 3.4 5017.5 x 25

Maintenance—As RequiredTX,55,JC1158 –19–03JUN96–1/1624GPly Operating Pressure*Tire Size Type Rating kPa bar psi14 x 24 G2 10 380 3.8 5517.5 x 25 L3 12

Maintenance—As RequiredTX,55,JC1159 –19–03JUN96–1/1644GPly Operating Pressure*Tire Size Type Rating kPa bar psi16.0 X 24 G2 12 380 3.8 5520.5 X 25 L2

Maintenance—As RequiredTX,55,DH2226 –19–31JUL92–1/3CLEAN OR REPLACE AIR CLEANERELEMENTS1. Open left service door.2. Loosen wing nut to remove cover.TX

Maintenance—As Required03T,55,MM11 –19–18NOV92–1/1CLEAN DUSTY PRIMARY ELEMENTT47764 –UN–09NOV881. Tap element with the palm of your hand, NOT ON AHARD

Maintenance—As Required03T,55,C67 –19–24JUL91–1/1INSPECT ELEMENTT90684 –UN–10NOV88IMPORTANT: A damaged or dirty element may causeengine damage.Install

Maintenance—As RequiredTX,55,DH2206 –19–31JUL92–1/1CHECK AIR INLET COVERT6779BQ –UN–19OCT881. Loosen clamp and slide strap (B) down stack.2. Remove ai

ContentsPageBoom Lock Check . . . . . . . . . . . . . . . . . . . . . . 95-34Service Decal Check . . . . . . . . . . . . . . . . . . . . 95-34Troubles

Maintenance—As RequiredTX,55,JC1138 –19–22MAY96–1/1CHECK AND ADJUST BELT TENSION—544G,624GT6603AK –UN–18OCT88544G, 624G ShownT8372BK –UN–30NOV94544G S

Maintenance—As RequiredTX,55,JC1118 –19–20MAR96–1/1INSPECT SERPENTINE BELT—644GT7405BG –UN–15NOV901. Check belt regularly for wear, especially for cra

Maintenance—As RequiredTX,55,JC283 –19–16MAY95–1/3DRAIN AND CLEAN PRIMARY FUEL FILTER(WATER SEPARATOR)—544G, 624G1. Open left side shield to access pr

Maintenance—As RequiredTX,55,JC283 –19–16MAY95–3/3T8387AD –UN–17DEC945. Remove fuel inlet line (A) and fuel drain plug (C).6. Flush any debris from fi

Maintenance—As RequiredTX,55,JC1122 –19–16APR96–1/1CHECK CAB RECIRCULATING AIR FILTERT8295AA –UN–10AUG94NOTE: The cab recirculating air filter is loca

Maintenance—Every 10 Hours or DailyTX,60,DH2560 –19–02OCT92–1/1LUBRICATE PIVOTSLubricate working tool pivots every 10 hours or daily whenoperating in

Maintenance—Every 10 Hours or DailyTX,60,JC1106 –19–18MAR96–2/2T7829AE –UN–31AUG92544G ShownT7829AF –UN–31AUG92624G ShownT100695 –UN–22MAR96644G Shown

Maintenance—Every 10 Hours or DailyTX,60,JC280 –19–16MAY95–1/1CHECK RECOVERY TANK COOLANT LEVELT8385AE –UN–15DEC94T6274AQ –UN–18OCT88With the engine c

Maintenance—Every 10 Hours or DailyTX,60,DH2213 –19–16JUN93–2/3T7773CB –UN–10AUG923. When oil is cold, oil level must be in FULL range onsight glass (

Maintenance—Every 10 Hours or DailyTX,60,DH2214 –19–02OCT92–1/1CHECK TRANSMISSION OIL LEVELT7773CP –UN–21AUG92624G ShownIMPORTANT: Prevent possible tr

SafetyTX,05,JC1054 –19–22JAN96–1/1T100127 –19–21FEB9605–1PN=1

Maintenance—Every 100 HoursTX,70,DH2215 –19–16JUN93–1/1LUBRICANT BOOM, BUCKET, ANDCYLINDER PIVOTST6523CP1 –UN–20OCT88Six Points, 544G ShownT8029AS –UN

Maintenance—Every 100 HoursTX,70,DH2290 –19–02OCT92–1/2LUBRICATE BOOM, BUCKET, ANDCYLINDER PIVOTS—544G TCT7829BF –UN–17SEP92Four Points, Right Side Sh

Maintenance—Every 100 HoursTX,70,DH2290 –19–02OCT92–2/2T7829BH –UN–17SEP92Five PointsLubricate every 10 hours or daily when operating in deepmud, wate

Maintenance—Every 100 HoursTX,70,JC1107 –19–18MAR96–1/1LUBRICATE STEERING CYLINDER PIVOTST100694 –UN–22MAR96Four Points, 644G Left Side ShownT6597AB1

Maintenance—Every 100 HoursTX,70,JC1108 –19–18MAR96–1/1LUBRICATE OSCILLATING REAR AXLET100693 –UN–22MAR96Two Points, 644G ShownT6597AB –UN–25OCT88A—Re

Maintenance—Every 100 HoursTX,70,JC1056 –19–24JAN96–2/2T7829AC –UN–31AUG92NOTE: If operating in dusty conditions, cab fresh air filtershould be checke

Maintenance—Every 250 HoursTX,75,JC260 –19–16MAY95–1/2CHECK RECEIVER DRYER MOISTUREINDICATORT8372BH –UN–30NOV94IMPORTANT: Prevent possible compressor

Maintenance—Every 250 HoursTX,75,JC1109 –19–18MAR96–1/4CHANGE ENGINE OIL AND REPLACEFILTERIMPORTANT: If fuel sulphur content exceeds 0.5percent, chang

Maintenance—Every 250 HoursTX,75,JC1109 –19–18MAR96–2/4T7853AI –UN–08OCT92624G Shown7. Install hose on drain valve (A). Turn valvecounterclockwise wit

Maintenance—Every 250 HoursTX,75,JC1109 –19–18MAR96–3/4T7829AH –UN–31AUG92544G ShownT7829AI –UN–31AUG92624G ShownT100692 –UN–22MAR96644G Shown8. Turn

SafetyDX,ALERT –19–03MAR93–1/1RECOGNIZE SAFETY INFORMATIONT81389 –UN–07DEC88This is the safety-alert symbol. When you see this symbolon your machine o

Maintenance—Every 250 HoursTX,75,JC1109 –19–18MAR96–4/420. Check for any leakage at filter. Tighten filter onlyenough to stop leakage.TX,75,DH3501 –19

Maintenance—Every 500 HoursTX,80,JC1139 –19–23MAY96–1/1LUBRICANT FRONT DRIVELINET7853AJ –UN–08OCT92One PointÖCAUTION: Prevent possible injury fromunex

Maintenance—Every 500 HoursTX,75,DH1574 –19–28APR93–1/4CHECK BATTERY ELECTROLYTE LEVELAND TERMINALSTS203 –UN–23AUG88ÖCAUTION: Battery gas can explode.

Maintenance—Every 500 HoursTX,75,DH1574 –19–28APR93–2/4• Drink large amounts of water or milk, but donot exceed 1.9 L (2 quarts).• Get medical attenti

Maintenance—Every 500 HoursTX,75,DH1574 –19–28APR93–4/4T6758AA –UN–21OCT884. Clean battery terminals (A) and clamps with a stiffbrush.5. Apply lubrica

Maintenance—Every 500 HoursTX,80,JC1140 –19–23MAY96–1/1CHECK COOLANTT101279 –19–14MAY96TS281 –UN–23AUG88ÖCAUTION: Prevent possible injury from hotspra

Maintenance—Every 500 HoursTX,80,JC427 –19–18JAN96–1/2REPLACE PRIMARY FUEL FILTER (WATERSEPARATOR)T7829AR –UN–31AUG92624G ShownT8387AE –UN–17DEC941. T

Maintenance—Every 500 HoursTX,80,DH2506 –19–02OCT92–1/1REPLACE FINAL FUEL FILTER—544G, 624GT7829AS –UN–31AUG92544G Shown1. Turn filter assembly (A) co

Maintenance—Every 500 HoursTX,80,JC1111 –19–18MAR96–2/2T100705 –UN–22MAR96644G Shown2. Turn filter (A) counterclockwise to remove.3. Clean mounting su

Maintenance—Every 500 HoursTX,80,JC1112 –19–18MAR96–2/2T7829BE –UN–17SEP92544G ShownT100708 –UN–22MAR96644G Shown1. Turn filter (A) counterclockwise t

SafetyTX,05,DH1525 –19–21JUN91–1/1AVOID INJURY FROM ROLLOVERACCIDENTS--------------------------------WEAR YOUR SEAT BELT------------------------------

Maintenance—Every 500 HoursTX,80,DH2965 –19–23JUN93–1/1CHECK FRONT AND REAR DIFFERENTIALOIL LEVEL—IF EQUIPPED WITHDIFFERENTIAL LOCK AXLET7853AK –UN–08

Maintenance—Every 1000 HoursTX,85,DH2477 –19–31JUL92–1/1LUBRICATE REAR DRIVELINET7516BG –UN–11JUN91One PointÖCAUTION: Prevent possible injury fromunex

Maintenance—Every 1000 HoursTX,85,DH2229 –19–02OCT92–1/1ADJUST ENGINE SPEED CONTROL LINKAGET7853AB –UN–06OCT92A—Swivel B—Cable C—Lever D—Stop Screw1.

Maintenance—Every 1000 HoursTX,85,DH2246 –19–26AUG92–1/1REPLACE AIR CLEANER DUST UNLOADERVALVET7773CQ –UN–21AUG92624G ShownNOTE: A missing, damaged, o

Maintenance—Every 1000 HoursTX,85,DH2230 –19–02OCT92–1/1CLEAN ENGINE CRANKCASE VENT TUBE(A)T7829AK –UN–31AUG92544G ShownT7829AL –UN–31AUG92624G ShownT

Maintenance—Every 1000 HoursTX,85,JC1057 –19–24JAN96–1/4CHANGE TRANSMISSION OIL ANDREPLACE FILTER1. Operate machine under load until transmission oilr

Maintenance—Every 1000 HoursTX,85,JC1057 –19–24JAN96–2/4T7853AA –UN–23SEP929. Remove plug (A), located inside hole in bottom guard,to drain oil. Allow

Maintenance—Every 1000 HoursTX,85,JC1057 –19–24JAN96–4/4T7773CP –UN–21AUG92624G Shown15. Remove transmission dipstick (A).16. Fill transmission with o

Maintenance—Every 1000 HoursTX,85,DH2561 –19–09OCT92–2/2T7773AG –UN–11JUN924. Move park brake switch (A) to OFF, and movetransmission control lever to

Maintenance—Every 1000 HoursTX,85,JC1141 –19–23MAY96–3/3T100701 –UN–22MAR967. Remove screws and remove sheet metal cover frombrake. Loosen lock nut (A

SafetyTX,05,DH1573 –19–18MAR91–1/1AVOID INJURY FROM BACKOVERACCIDENTS------------------------------------BEFORE MOVING MACHINE, BE SURE ALLPERSONS ARE

Maintenance—Every 1000 HoursTX,85,JC1113 –19–18MAR96–1/1LUBRICATE FRAME HINGE PIVOTST100690 –UN–22MAR96644G ShownÖCAUTION: Prevent possible injury fro

Maintenance—Every 2000 HoursTX,85,DH2239 –19–31JUL92–1/5MEASURE AND ADJUST ENGINE VALVELASH (CLEARANCE)—544G, LL, TC, 624G1. Remove precleaner or air

Maintenance—Every 2000 HoursTX,85,DH2239 –19–31JUL92–4/5T6233AG –19–27JAN899. Remove turning tool and timing pin.544G, LL, TC, 624G VALVE CLEARANCE SP

Maintenance—Every 2000 HoursTX,86,JC1142 –19–23MAY96–1/4ADJUST ENGINE VALVE LASH(CLEARANCE)—644G1. Remove precleaner, hood, air cleaner support withst

Maintenance—Every 2000 HoursTX,86,JC1142 –19–23MAY96–3/4T6233AI –19–27JAN8912. Remove flywheel turning tool and timing pin. Installplugs.644G VALVE CL

Maintenance—Every 2000 HoursTX,86,JC1143 –19–23MAY96–1/1LUBRICATE FRONT DRIVELINE SUPPORTBEARINGT7114AS –UN–23AUG89One PointÖCAUTION: Prevent possible

Maintenance—Every 3000 HoursTX,86,JC281 –19–16MAY95–1/3CHANGE HYDRAULIC SYSTEM OILT8029AN –UN–15JUN931. Remove hydraulic reservoir filler cap (A).TX,8

Maintenance—Every 3000 HoursTX,86,DH2963 –19–16JUN93–1/1CLEAN HYDRAULIC SUCTION STRAINERT8029AO –UN–15JUN931. Remove hydraulic reservoir filler cap (A

Maintenance—Every 3000 HoursTX,87,JC1058 –19–24JAN96–1/5CHANGE FRONT AND REAR DIFFERENTIALOILT7853AO –UN–08OCT92Front Differential ShownT7853AP –UN–08

Maintenance—Every 3000 HoursTX,87,JC1058 –19–24JAN96–4/5T7853AR –UN–08OCT925. Open left service door. Remove fill plug (A) from reardifferential.TX,87

SafetyTX,05,DH2478 –19–26SEP92–1/1AVOID INJURY FROM ROLLAWAYACCIDENTS------------------------------------TO PREVENT ROLLAWAY, ALWAYS MAKESURE MACHINE

MaintenanceTX,90,JC1114 –19–18MAR96–1/4DRAINING THE COOLING SYSTEMTS281 –UN–23AUG88T6523CC –UN–20OCT88ÖCAUTION: Explosive release of fluids frompressu

MaintenanceTX,90,JC1114 –19–18MAR96–3/4T7829AN –UN–31AUG92544G, 624G Shown6. 544G, 624G: Remove plug (A) to drain engine block.Allow coolant to drain

MaintenanceTX,90,JC1144 –19–23MAY96–1/1DIESEL ENGINE COOLANTThe engine cooling system is filled to provide year-round protection against corrosion and

MaintenanceTX,90,JC1145 –19–23MAY96–1/1FILLING THE COOLING SYSTEMSPECIFICATIONS544G Cooling system capacity Approx. 24 L (25 qt)624G Cooling system ca

MaintenanceT82,SKMA,A –19–28JUL94–1/1DO NOT SERVICE INJECTION NOZZLESIMPORTANT: Do not service or remove injectionnozzles. The service life of the inj

MaintenanceTX,90,DH2259 –19–12MAY93–2/2T6523BW1 –UN–20OCT881. Connect hose to fuel tank draincock (B).2. Remove fuel tank cap.3. Drain fuel from tank.

MaintenanceTX,90,JC285 –19–16MAY95–1/1BLEEDING FUEL SYSTEM—544G, 624GT7833AJ –UN–10SEP92A—Bleed Screw (Final Fuel Filter)B—Hand PrimerC—Primary Fuel F

MaintenanceTX,90,JC1115 –19–18MAR96–1/1BLEEDING FUEL SYSTEM—644GT100696 –UN–22MAR96A—Final Fuel FilterB—Bleed ScrewC—Bleed ScrewD—PumpE—Fuel Supply Li

Maintenance04T,90,C151 –19–20JUL92–1/1PRECAUTIONS FOR ALTERNATOR AND REGULATORWhen batteries are connected, follow these rules:1. Disconnect negative

MaintenanceTX,90,DH1018 –19–30APR94–1/2SERVICE BATTERIES CAREFULLYTS204 –UN–23AUG88TS203 –UN–23AUG88ÖCAUTION: Battery gas can explode. Keepsparks and

SafetyTX,05,DH553 –19–18MAR91–1/1USE HANDHOLDS AND STEPST6981AN –UN–15JUN89Falling is one of the major causes of personal injury.When you get on and o

MaintenanceTX,90,DH1018 –19–30APR94–2/2• Get medical attention immediately.If electrolyte spills on the floor, use one of the followingmixtures to neu

Maintenance04T,90,FF20 –19–12MAY93–1/3CHECKING ELECTROLYTE SPECIFICGRAVITYTS204 –UN–23AUG88TS203 –UN–23AUG88ÖCAUTION: Battery gas can explode. Keepspa

Maintenance04T,90,FF20 –19–12MAY93–2/3• Drink large amounts of water or milk, but donot exceed 1.9 L (2 quarts).• Get medical attention immediately.Ch

MaintenanceTX,FF,121 –19–15MAR93–1/1USING BATTERY CHARGERTS204 –UN–23AUG88ÖCAUTION: Prevent possible injury fromexploding battery. Do not charge a bat

MaintenanceTX,90,DH1768 –19–06JUN91–1/2REMOVING BATTERIES1. Remove battery cover.TX,90,DH1768 –19–06JUN91–2/2T6570AD2 –UN–20OCT882. Disconnect negativ

Maintenance04T,90,C155 –19–06JUN91–1/1RESETTING CIRCUIT BREAKERSAir conditioning system contains two circuit breakers. Ifcircuit breakers open because

MaintenanceTX,90,RR,1725 –19–11MAR94–2/2T6249AU –UN–19OCT88A—Flange NutB—Lock WasherC—HousingD—BulbE—GasketF—LensG—BezelH—Screw1. Remove four screws (

MaintenanceTX,90,DH2566 –19–03FEB95–1/1CHANGING REVERSE WARNING ALARMVOLUMET7853AT –UN–08OCT92IMPORTANT: The reverse warning alarm is set onhigh volum

Maintenance04T,90,K117 –19–16MAR88–1/1ADDING ATTACHMENTS/ACCESSORIES TOROLL-OVER PROTECTIVE STRUCTURE(ROPS)Do not add attachments or accessories to th

MaintenanceTX,90,DH1756 –19–31JUL92–1/1CHECKING AND ADJUSTING COMPRESSORBELT TENSION—IF EQUIPPED1. A force of 111 N (25 lb force) halfway between pull

READ THIS MANUAL carefully to learn how tooperate and service your machine correctly. Failure todo so could result in personal injury or equipmentdama

SafetyTX,05,JC242 –19–03MAR95–1/1MAINTAIN SEAT BELTIt is important to use the seat belt on ROPS equippedmachines to minimize the chance of injury from

MaintenanceTX,90,DH2348 –19–19MAY93–1/3INSPECTING PARK BRAKE PADS1. Park machine on a level surface.2. Lower bucket to ground.TX,90,DH2348 –19–19MAY93

MaintenanceTX,90,DH2348 –19–19MAY93–3/3T7853AU –UN–08OCT926. Check the combined thickness of backing plates, brakepads (C), (2nd pad not shown) and di

MaintenanceTX,90,JC263 –19–29NOV94–2/4T6523BZ –UN–25OCT881. Remove brake inspection port plug (A).TX,90,JC263 –19–29NOV94–3/4T6138AZ –UN–25OCT882. Ins

MaintenanceTX,90,JC1116 –19–18MAR96–1/2CHECKING BRAKE ACCUMULATOR1. Start engine.2. Run engine for 1 minute at slow idle.TX,90,JC1116 –19–18MAR96–2/2T

MaintenanceTX,90,DH2560 –19–12MAY93–1/2CHECKING RIDE CONTROLACCUMULATOR—IF EQUIPPEDT7829AV –UN–08SEP92ÖCAUTION: The boom will jump upward duringthis c

MaintenanceTX,DH,114 –19–06JUN91–1/2BLEEDING BRAKESX9811 –UN–23AUG88ÖCAUTION: Escaping fluid under pressure canpenetrate skin causing serious injury.

MaintenanceTX,DH,114 –19–06JUN91–2/2T6522BR –UN–20OCT884. Put a clear plastic tube on bleed screw (B) to routeflow to hydraulic reservoir filler tube

MaintenanceTX,DH,115 –19–06JUN91–1/1CHECKING SECONDARY STEERINGSYSTEM—IF EQUIPPED1. Park machine on a level surface.2. Shut off engine. Release brakes

MaintenanceTX,90,DH2541 –19–02OCT92–2/2T7817AL –UN–08SEP92A—NutB—LeverC—Switch AssemblyD—Gap1. Loosen nut (A).2. Rotate switch assembly (C) to desired

MaintenanceT82,SKMA,AT –19–01AUG94–1/1HARDWARE TORQUE SPECIFICATIONSCheck cap screws and nuts to be sure they are tight. Ifhardware is loose, tighten

SafetyTX,05,DH496 –19–02AUG89–1/1TRAVEL SAFELYT6964AD –UN–20DEC88Know the location of bystanders before moving themachine.Always keep the reverse warn

MaintenanceDX,TORQ2 –19–20JUL94–1/2METRIC BOLT AND CAP SCREW TORQUE VALUESTS1163 –19–04MAR91Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9Size Lubri

MaintenanceDX,TORQ2 –19–20JUL94–2/2DO NOT use these values if a different torque value ortightening procedure is given for a specific application.Torq

Maintenance04T,90,M170 –19–01AUG94–1/2ADDITIONAL METRIC CAP SCREW TORQUEVALUEST6873AA –UN–18OCT88T-BoltT6873AB –UN–18OCT88H-BoltT6873AC –UN–18OCT88M-B

MaintenanceDX,TORQ1 –19–20JUL94–1/2UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUESTS1162 –19–04MAR91Grade 1 Grade 2bGrade 5, 5.1, or 5.2 Grade 8 or 8.2S

MaintenanceDX,TORQ1 –19–20JUL94–2/2Fasteners should be replaced with the same or highergrade. If higher grade fasteners are used, theseshould only be

MaintenanceTX,90,DH1559 –19–01AUG94–1/1CHECK OIL LINES AND FITTINGSX9811 –UN–23AUG88T85401 –UN–24JAN89ÖCAUTION: Escaping fluid under pressure canpenet

MaintenanceTX,90,DY323 –19– 2MAY96–1/2SERVICE RECOMMENDATIONS FOR O-RINGBOSS FITTINGST6243AE –UN–18OCT88STRAIGHT FITTING1. Inspect O-ring boss seat fo

MaintenanceTX,90,DY323 –19– 2MAY96–2/2T6520AB –UN–18OCT88ANGLE FITTING1. Back-off lock nut (A) and back-up washer (B)completely to head-end (C) of fit

Maintenance04T,90,K67 –19–01AUG94–1/2SERVICE RECOMMENDATIONS FOR FLATFACE O-RING SEAL FITTINGST6243AD –UN–18OCT881. Inspect the fitting sealing surfac

Maintenance04T,90,K175 –19–01AUG94–1/1SERVICE RECOMMENDATIONS FOR METRIC SERIES FOUR BOLT FLANGE FITTINGT6890BB –UN–01MAR90A—Sealing Surface B—Split F

SafetyTX,05,DH1932 –19–06JUN91–1/1OPERATE MACHINE WITH CAUTIONT6642EF –UN–18OCT88Check location of cables, gas lines, and water mainsbefore digging.Ke

Maintenance04T,90,K174 –19–01AUG94–1/2SERVICE RECOMMENDATIONS FOR INCH SERIES FOUR BOLT FLANGE FITTINGST6890BB –UN–01MAR90A—Sealing Surface B—Split Fl

Maintenance04T,90,K174 –19–01AUG94–2/2TORQUE CHART*N•m lb-ftNominal Flange Cap Screw SizeSize Min Max Min Max1/2 5/16-18 UNC 20 31 15 233/4 3/8-16 UNC

Operational CheckoutTX,95,DH2538 –19–03SEP92–1/1OPERATIONAL CHECKOUTUse this procedure to check all systems and functionson the machine. It is designe

Operational Checkout– – –1/1'MONITOR INDICATOR AND GAUGE CHECKS—ENGINE OFF– – –1/1HOURMETER ANDGAUGE CHECKKey switch OFF.T7773BC –UN–05AUG92Press

Operational Checkout– – –1/1MONITOR INDICATORCIRCUIT AND KEYSWITCH CHECKT7773BA –UN–05AUG92Apply brake pedal 10 times.Turn key switch to accessory pos

Operational Checkout– – –1/1MONITOR TURNSIGNALS AND HAZARDWARNING INDICATORCHECKST7773BB –UN–21AUG92 T6564OL –UN–19OCT88T6633AB2 –UN–18OCT88Move turn

Operational Checkout– – –1/1ENGINE SPEEDCONTROL LINKAGECHECK—544G, 624GEngine OFF.Right engine service dooropen.T6564NL –UN–19OCT88 T6564NM –UN–19OCT8

Operational Checkout– – –1/1FUEL SHUT-OFFSOLENOID LINKAGECHECK—644GT8030AN –UN–21JUN93Open right engine side shield and inspect linkage.LOOK: Fuel shu

Operational Checkout– – –1/1)MONITOR INDICATOR AND GAUGE CHECKS (ENGINE RUNNING)– – –1/1MONITOR DISPLAY ANDALTERNATOR OUTPUTCHECKT7825BD –UN–21AUG92Tu

Operational Checkout– – –1/1T7825BB –UN–21AUG92Increase engine speed to fast idleandobserve monitor display.LOOK: The following engine rpm readingsmus

SafetyTX,05,RR,172 –19–03JUN92–1/1CARRYING LOADST7050AA –UN–03AUG89Carry loader bucket as low as possible for better stabilityand visibility.Handle on

Operational Checkout– – –1/1MONITOR INDICATORCIRCUIT BYPASS ANDSEAT BELT INDICATORCHECKDepress service brakepedal 10 times.Lock transmission controlle

Operational Checkout– – –1/1TRANSMISSIONTEMPERATURE GAUGECHECKEngine running.T7773BO2 –UN–05AUG92 T7773BF –UN–05AUG92Release park brake.Move clutch cu

Operational Checkout– – –1/1SERVICE BRAKE PUMPFLOW CHECKNOTE: Hydraulic oil mustbe at operatingtemperature for thischeck.Engine OFF.T7773BQ3 –UN–21AUG

Operational Checkout– – –1/1SERVICE BRAKE CHECKEngine running.T7773BQ3 –UN–21AUG92T7773BO2 –UN–05AUG92Move clutch disconnect switch to OFF.Apply servi

Operational Checkout– – –1/1BRAKE SYSTEMLEAKAGE CHECKT7773BI1 –UN–05AUG92 T7747AF1 –UN–24AUG92Start engine and wait 30 seconds.Stop engine.Wait 2 minu

Operational Checkout– – –1/1DIFFERENTIAL LOCKCHECKT7773BQ1 –UN–21AUG92Park machine on a hard surface.Release brakes.Engage differential lock.Steer mac

Operational Checkout– – –1/1+DRIVING CHECKSNOTE: Transmission oil must be at operating temperature for these checks.– – –1/1TRANSMISSION NOISECHECKEng

Operational Checkout– – –1/1AUTOMATIC SHIFT ANDSPEEDOMETER CHECKEngine running.T7825BG –UN–21AUG92Press SELECT button on monitor until MPH or Km/H isd

Operational Checkout– – –1/1TRANSMISSIONQUICKSHIFT CHECKEngine running.T7825BL1 –UN–31AUG92Release park brake and move transmission control leverto 2n

Operational Checkout– – –1/1TRANSMISSION SHIFTMODULATION CHECKEngine running.T7825BH –UN–21AUG92 T7773BN –UN–05AUG92Run engine at approximately 1600 r

SafetyDX,RIDER –19–03MAR93–1/1KEEP RIDERS OFF MACHINETS290 –UN–23AUG88Only allow the operator on the machine. Keep riders off.Riders on machine are su

Operational Checkout– – –1/1CONTROL VALVE LIFTCHECKRun engine at slow idle.T6601AA –UN–19OCT88With bucket partially dumped, lower boom to raise fronto

Operational Checkout– – –1/1BOOM DOWN CHECKVALVE LEAKAGECHECKHeat hydraulic oil tooperating temperature.(See Hydraulic SystemWarm-up Procedure inthis

Operational Checkout– – –1/1BOOM HEIGHT KICKOUTCHECK—IF EQUIPPEDRun engine at slow idle.T7825BL –UN–24AUG92Position bucket flat on ground.Move control

Operational Checkout– – –1/1-STEERING SYSTEM CHECKS– – –1/1STEERING VALVECHECKT6471AQ –UN–19OCT88Run engine at slow idle.Turn steering wheel until fra

Operational Checkout– – –1/1PRIORITY VALVE LOWPRESSURE CHECKPark machine on a hardsurface.Run engine at fast idle.Hold brake pedal down.Steer machine

Operational Checkout– – –1/1SECONDARY STEERINGSYSTEM CHECK—IFEQUIPPEDIMPORTANT: DO NOToperate secondary steeringpump for more than 15seconds with the

Operational Checkout– – –1/1.ACCESSORY CHECKSNOTE: Engine must be stopped and key switch must be ON for these checks– – –1/1OPERATING LIGHTSCHECKT7773

Operational Checkout– – –1/1BRAKE LIGHT CHECKT6633AB3 –UN–18OCT88Depress brake pedal and observe brake lights (A).LOOK: Brake lights must come on.NOTE

Operational Checkout– – –1/1WINDSHIELD WASHERAND WIPER CHECK—IFEQUIPPEDT7773AN –UN–05AUG92Turn front wiper switch knob clockwise to first detent,then

Operational Checkout– – –1/1HEATER/AIRCONDITIONER BLOWERCHECKT7773BP3 –UN–05AUG92Turn blower switch knob to low, medium and highspeeds.FEEL & LIST

SafetyTX,05,FF2281 –19–22FEB91–1/1HANDLE STARTING FLUID SAFELYT6464AV –UN–18OCT88Starting fluid is highly flammable.Keep all sparks and flame away whe

Operational Checkout– – –1/1START AID SYSTEMCHECKT7747AI1 –UN–14SEP92 T6477AP –UN–19OCT88Start engine and run at slow idle.Momentarily push start aid

Operational Checkout– – –1/1CAB DOOR RELEASEBUTTONT7832AJ –UN–27AUG92Press door release button.LOOK & LISTEN: Latch must click and release door.OK

Operational Checkout– – –1/1CAB WINDOW LATCHCHECKT6633AO –UN–18OCT88Inspect window seals.Open right side cab window. Pull window closed.LOOK: Latch mu

Operational Checkout– – –1/1SEAT AND SEAT BELTCHECKIMPORTANT: Replace thecomplete seat beltassembly every threeyears regardless ofappearance. A date l

Operational Checkout– – –1/1AIR INTAKE FILTERDOOR CHECKT6633AW –UN–18OCT88Unlock and open door on left side of operator’s station.Close and lock door.

Operational Checkout– – –1/1RADIATOR CAP ACCESSDOOR CHECKT6633AY –UN–18OCT88Open and close access door on top of grille housing.LOOK: Door must move f

TroubleshootingTX,FF,105 –19–15JUL94–1/1USING TROUBLESHOOTING CHARTSNOTE: Troubleshooting charts are arranged from thesimplest to verify, to least lik

TroubleshootingTX,100,DH2481 –19–02OCT92–1/12ENGINESymptom ProblemSolutionEngine Will Not Start Or Starts Fuel tank empty. Check fuel quantity.HardFue

TroubleshootingTX,100,DH2481 –19–02OCT92–2/12Symptom ProblemSolutionInjection nozzle(s). See your authorized dealer.Low compression or blown head 544G

TroubleshootingTX,100,DH2481 –19–02OCT92–3/12Symptom ProblemSolution544G, LL, TC, 624G—Injection Lightly tap injection pump housing. Ifpump metering v

SafetyDX,WEAR2 –19–03MAR93–1/1WEAR PROTECTIVE CLOTHINGTS206 –UN–23AUG88Wear close fitting clothing and safety equipmentappropriate to the job.Operatin

TroubleshootingTX,100,DH2481 –19–02OCT92–4/12Symptom ProblemSolutionSlow idle speed too low. Check slow idle speed. (SeeMaintenance—Every 1000 Hoursch

TroubleshootingTX,100,DH2481 –19–02OCT92–5/12Symptom ProblemSolutionExcess drag in transmission. See your authorized dealer.Excess drag in brakes. Che

TroubleshootingTX,100,DH2481 –19–02OCT92–6/12Symptom ProblemSolutionTurbocharger. Remove air intake hose and exhaustelbow. Leading edge of compressorv

TroubleshootingTX,100,DH2481 –19–02OCT92–7/12Symptom ProblemSolutionTurbocharger. Remove air intake hose and exhaustelbow. Leading edge of compressorv

TroubleshootingTX,100,DH2481 –19–02OCT92–8/12Symptom ProblemSolutionAbnormal Engine Noise Low or incorrect engine oil. Add correct oil.Loose or worn d

TroubleshootingTX,100,DH2481 –19–02OCT92–9/12Symptom ProblemSolutionOil pressure gauge or sensor. See your authorized dealer.Oil pressure regulating v

TroubleshootingTX,100,DH2481 –19–02OCT92–10/12Symptom ProblemSolutionRadiator shroud missing, damaged, Inspect. Repair or replace.or baffles missing.E

TroubleshootingTX,100,DH2481 –19–02OCT92–11/12Symptom ProblemSolutionCracked cylinder liner. See your authorized dealer.Cracked cylinder block. See yo

TroubleshootingTX,100,DH2481 –19–02OCT92–12/12Symptom ProblemSolutionCarbon build-up in turbocharger oil Remove line. Inspect and clean.return line wh

TroubleshootingTX,100,DH2482 –19–02OCT92–1/8ELECTRICAL SYSTEMSymptom ProblemSolutionNothing Works Power circuit components. See your authorized dealer

SafetyTX,05,DH1729 –19–26JAN91–1/1USE SAFETY LIGHTS AND DEVICESN36564 –UN–10FEB89A—LightsB—Slow Moving Vehicle EmblemC—Reflector TapeD—ReflectorsOpera

TroubleshootingTX,100,DH2482 –19–02OCT92–2/8Symptom ProblemSolutionStarting Motor Turns, But Engine Starter pinion not engaging flywheel See your auth

TroubleshootingTX,100,DH2482 –19–02OCT92–3/8Symptom ProblemSolutionStarter Solenoid Chatters Poor connections at batteries or Clean connections.starte

TroubleshootingTX,100,DH2482 –19–02OCT92–4/8Symptom ProblemSolutionAlternator. See your authorized dealer.Display monitor. See your authorized dealer.

TroubleshootingTX,100,DH2482 –19–02OCT92–5/8Symptom ProblemSolutionHorn Inoperative Fuse. Replace fuse.Horn. See your authorized dealer.Horn switch. S

TroubleshootingTX,100,DH2482 –19–02OCT92–6/8Symptom ProblemSolutionDefrost Fan Motor Does Not Fan motor switch. See your authorized dealer.Work In All

TroubleshootingTX,100,DH2482 –19–02OCT92–7/8Symptom ProblemSolutionTurn signal switch. See your authorized dealer.Wiring harness. See your authorized

TroubleshootingTX,100,DH2482 –19–02OCT92–8/8Symptom ProblemSolutionIndicator light bulb. Replace bulb.Secondary steering light relay. See your authori

TroubleshootingTX,100,DH2483 –19–09SEP92–1/7HYDRAULIC SYSTEMSymptom ProblemSolutionNoisy Hydraulic Pump Low oil supply or wrong viscosity. Fill reserv

TroubleshootingTX,100,DH2483 –19–09SEP92–2/7Symptom ProblemSolutionBinding loader control valve spool. See your authorized dealer.Secondary steering c

TroubleshootingTX,100,DH2483 –19–09SEP92–3/7Symptom ProblemSolutionCircuit relief valve. See your authorized dealer.Oil leaking past cylinder packings

SafetyTX,05,JC1068 –19–21FEB96–1/1KEEP THE OPERATOR PROTECTIVESTRUCTURE (OPS) IN PLACEIt is important to keep the operator protective structure(OPS) i

TroubleshootingTX,100,DH2483 –19–09SEP92–4/7Symptom ProblemSolutionOil cooler clogged internally. See your authorized dealer.Incorrect system or circu

TroubleshootingTX,100,DH2483 –19–09SEP92–5/7Symptom ProblemSolutionSecondary steering check valve See your authorized dealer.leakage.No Steering Stuck

TroubleshootingTX,100,DH2483 –19–09SEP92–6/7Symptom ProblemSolutionLow oil level. Add oil.Sticking priority valve spool. See your authorized dealer.Lo

TroubleshootingTX,100,DH2483 –19–09SEP92–7/7Symptom ProblemSolutionAbrupt Steering Wheel Gerotor gear in steering valve not See your authorized dealer

TroubleshootingTX,100,DH2484 –19–27OCT92–1/6POWER TRAINSymptom ProblemSolutionTransmission Slippage Low oil level. Check and add oil.Wrong oil grade.

TroubleshootingTX,100,DH2484 –19–27OCT92–2/6Symptom ProblemSolutionBroken ring or pinion gear. See your authorized dealer.Machine Does Not Engage In T

TroubleshootingTX,100,DH2484 –19–27OCT92–3/6Symptom ProblemSolutionTransmission System Pressure Is Transmission control valve gasket. Inspect transmis

TroubleshootingTX,100,DH2484 –19–27OCT92–4/6Symptom ProblemSolutionMachine "Creeps" In Neutral Warped disks and plates in See your authorize

TroubleshootingTX,100,DH2484 –19–27OCT92–5/6Symptom ProblemSolutionParts worn or damaged in Remove transmission suctiontransmission. screen. Inspect f

TroubleshootingTX,100,DH2484 –19–27OCT92–6/6Symptom ProblemSolutionTorque Converter Stall RPM Too Aerated oil. See your authorized dealer.HighConverte

SafetyTX,05,DH2122 –19–31JUL92–1/2PRACTICE SAFE MAINTENANCETS218 –UN–23AUG88If maintenance procedure must be performed with enginerunning, DO NOT leav

TroubleshootingTX,100,DH2485 –19–18SEP92–1/2SERVICE BRAKESSymptom ProblemSolutionPoor Or No Brakes Brake accumulator charge low. See your authorized d

TroubleshootingTX,100,DH2485 –19–18SEP92–2/2Symptom ProblemSolutionBrakes Lock Up Air in brake system. Bleed brakes. (See Bleeding Brakesin Maintenanc

TroubleshootingTX,100,DH2486 –19–07OCT92–1/3DIFFERENTIAL AXLESymptom ProblemSolutionNo Differential Lock Operation Electrical circuit. See your author

TroubleshootingTX,100,DH2486 –19–07OCT92–2/3Symptom ProblemSolutionElectrical circuit. See your authorized dealer.Differential lock solenoid valve stu

TroubleshootingTX,100,DH2486 –19–07OCT92–3/3Symptom ProblemSolutionWorn outer bearing and/or cup. See your authorized dealer.Differential overfilled w

TroubleshootingTX,100,DH2488 –19–02OCT92–1/1PARK BRAKESymptom ProblemSolutionBrake Will Not Hold Not adjusted correctly. Adjust park brake. (See Adjus

TroubleshootingTX,100,DH2489 –19–09SEP92–1/1AIR CONDITIONINGSymptom ProblemSolutionAir Conditioning System Does Accessory relay #2. See your authorize

StorageTX,105,FF1190 –19–03AUG92–1/3PREPARE MACHINE FOR STORAGET47764 –UN–09NOV881. Repair worn or damaged parts. Install new parts, ifnecessary, to a

StorageTX,105,FF1190 –19–03AUG92–3/3T7447AO –19–22APR91IMPORTANT: Prevent possible machine damage fromunauthorized persons operatingmachine. Attach a

StorageTX,105,FF,400 –19–06SEP94–2/2T6181AU –UN–18OCT88IMPORTANT: Prevent possible engine damage.During cold temperatures, checkfluidity of engine oil

T100255 -19-14FEB96TX,DY549 -19-08JUN96Introduction170696PN=6

SafetyTX,05,DH2122 –19–31JUL92–2/28. Allow engine to cool.Keep all parts in good condition and properly installed.Fix damage immediately. Replace worn

Machine NumbersTX,110,DH2545 –19–11DEC92–1/1RECORD PRODUCT IDENTIFICATIONNUMBER (PIN)T7829BJ –UN–21SEP92Purchase DateNOTE: Record all 13 characters of

Machine Numbers05T,120,MM9 –19–06JUN91–1/1RECORD TRANSMISSION SERIAL NUMBERTransmission Serial NumberLocated on right side of transmission case, near

SpecificationsTX,115,DH2265 –19–16JUN93–1/2544G SPECIFICATIONST6603AC –UN–20OCT88115–1PN=289

SpecificationsTX,115,DH2265 –19–16JUN93–2/2A—Overall operating height (boom full raise) 4.83 m (15 ft 10 in.)B—Bucket hinge height 3.72 m (12 ft 3 in.

SpecificationsTX,115,DH2267 –19–08DEC95–1/2544G SPECIFICATIONSNOTE: Specifications and design subject to changewithout notice. Wherever applicable, sp

SpecificationsTX,115,DH2267 –19–08DEC95–2/2Brakes, Service:Power-actuated, 4-wheel, inboard-mounted, wet diskFoot-operated, by either pedalLeft pedal

SpecificationsTX,115,JC1149 –19–23MAY96–1/1DRAIN AND REFILL CAPACITIES—544GMetric U.S.Cooling system 23.5 L 25 qtFuel tank 218 L 58 galEngine crankcas

SpecificationsTX,115,DH2291 –19–16JUN93–2/2A—Coupler hinge height 3.72 m (12 ft 3 in.)B—Ground to top of tine 3.53 m (11 ft 7 in.)C—Height to top of c

SpecificationsTX,115,JC1147 –19–23MAY96–1/2544G LL SPECIFICATIONSNOTE: Specifications and design subject to changewithout notice. Wherever applicable,

SpecificationsTX,115,JC1147 –19–23MAY96–2/2Brakes, Service:Power-actuated, 4-wheel, inboard-mounted, wet diskFoot-operated, by either pedalLeft pedal

SafetyDX,PAINT –19–03MAR93–1/1REMOVE PAINT BEFORE WELDING ORHEATINGTS220 –UN–23AUG88Avoid potentially toxic fumes and dust.Hazardous fumes can be gene

SpecificationsTX,115,JC1148 –19–23MAY96–1/1DRAIN AND REFILL CAPACITIES—544G LLMetric U.S.Cooling system 23.5 L 25 qtFuel tank 218 L 58 galEngine crank

SpecificationsTX,115,DH2294 –19–18JUN93–2/2A—Overall operating height (boom full raise) 4.83 m (15 ft 10 in.)B—Bucket hinge height 3.75 m (12 ft 4 in.

SpecificationsTX,115,DH2295 –19–08DEC95–1/2544G TC SPECIFICATIONSNOTE: Specifications and design subject to changewithout notice. Wherever applicable,

SpecificationsTX,115,DH2295 –19–08DEC95–2/2Brakes, Service:Power-actuated, 4-wheel, inboard-mounted, wet diskFoot-operated, by either pedalLeft pedal

SpecificationsTX,115,JC1153 –19–23MAY96–1/1DRAIN AND REFILL CAPACITIES—544G TCMetric U.S.Cooling system 23.5 L 25 qtFuel tank 218 L 58 galEngine crank

SpecificationsTX,115,DH2268 –19–16JUN93–2/2A—Overall operating height (boom full raise) 5.06 m (16 ft 7 in.)B—Bucket hinge height 3.89 m (12 ft 9 in.)

SpecificationsTX,115,DH2269 –19–02OCT92–1/2624G SPECIFICATIONSNOTE: Specifications and design subject to changewithout notice. Wherever applicable, sp

SpecificationsTX,115,DH2269 –19–02OCT92–2/2Brakes, Service:Power-actuated, 4-wheel, inboard-mounted, wet diskFoot-operated, by either pedalLeft pedal

SpecificationsTX,115,DY327 –19– 2MAY96–1/1DRAIN AND REFILL CAPACITIES—624GMetric U.S.Cooling system 24.6 L 26 qtFuel tank 249 L 66 galEngine crankcase

SpecificationsTX,115,DH2270 –19–16JUN93–2/2A—Overall operating height (boom full raise) 5.28 m (17 ft 4 in.)B—Bucket hinge height 4.00 m (13 ft 2 in.)

SafetyDX,FLUID –19–03MAR93–1/1AVOID HIGH-PRESSURE FLUIDSX9811 –UN–23AUG88Escaping fluid under pressure can penetrate the skincausing serious injury.Av

SpecificationsTX,115,DH2271 –19–16JUN93–1/2644G SPECIFICATIONSNOTE: Specifications and design subject to changewithout notice. Wherever applicable, sp

SpecificationsTX,115,DH2271 –19–16JUN93–2/2Brakes, Service:Power-actuated, 4-wheel, inboard-mounted, wet diskFoot-operated, by either pedalLeft pedal

Crime Prevention TipsDX,CRPRV,A –19–03MAR93–1/1HELP PREVENT CRIMETS140 –19–07OCT88You can help take a bite out of crime by properlydocumenting ownersh

Crime Prevention TipsDX,CRPRV,J –19–04JUN90–1/1PARK INDOORS OUT OF SIGHTTS158 –UN–23MAR89Make machines hard to move:• Park large equipment in front of

Crime Prevention TipsTX,120,DH1093 –19–16SEP92–1/1REDUCE VANDALISMT7223BB –UN–22FEB901. Install vandal-proof devices.2. Participate in a neighborhood

IndexPage PageReplacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IndexPage PageCooling Operational checkout . . . . . . . . . . . . . . . . . . . 95-4Serial number . . . . . . . . . . . . . . . . . . . . . . . . 110

IndexPage PageTransmission oil temperature . . . . . . . . .10-1, 10-5 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Operatio

IndexPage PageFront driveline . . . . . . . . . . . . . . . . . . . . . . . . . 80-1 Operational checkoutAccessory . . . . . . . . . . . . . . . . . .

IndexPage PageReceiver dryer The machine . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6StorageIndicator . . . . . . . . . . . . . . . . . .

SafetyDX,RCAP –19–04JUN90–1/1SERVICE COOLING SYSTEM SAFELYTS281 –UN–23AUG88Explosive release of fluids from pressurized coolingsystem can cause seriou

IndexPageHydraulic system. . . . . . . . . . . . . . . . . . . . . 100-22Park brake . . . . . . . . . . . . . . . . . . . . . . . . . 100-40Power trai

ChecklistsTX,50,JC1137 –19–22MAY96–1/1MAINTENANCE AND REPAIR RECORD KEEPING SYSTEMSERVICE INTERVALSService your machine at intervals shown on this cha

ChecklistsTX,50,JC1160 –19–03JUN96–1/1MAINTENANCE AND REPAIR RECORD KEEPING SYSTEMModel: ❒ 544G ❒ 544G LL ❒ 544G TC ❒ 624G ❒ 644G Customer:PIN/Serial

PARTS CATALOGThe parts catalog lists service parts available for yourmachine with exploded view illustrations to help youidentify the correct parts. I

Title Order Number Price Each x Quantity = Total544G, LL, TC, 624G, 644G LoaderParts Catalog—544G, LL, TC, 624G PC-2364 x =Parts Catalog—644G PC-2365

JOHN DEERE IS AT YOUR SERVICE WHEN YOU NEED ITDivision 1—Calgary Division 4—Moline Division 8—AtlantaJohn Deere Industrial Equipment Co. John Deere In

Safety SignsTX,06,JC1102 –19–18MAR96–1/12T7967AK –19–22MAR93T7829AA –UN–31AUG9206–1PN=21

Safety SignsTX,06,JC1102 –19–18MAR96–2/12T7939AI –19–22MAR93T7773CV –UN–31AUG92A-Warning Decal06–2PN=22

Safety SignsTX,06,JC1102 –19–18MAR96–3/12T8417AD –19–09FEB95T100704 –UN–22MAR9606–3PN=23

Safety SignsTX,06,JC1102 –19–18MAR96–4/12T7593AC –19–30AUG91T6976AE –UN–30JAN8906–4PN=24

Safety SignsTX,06,JC1102 –19–18MAR96–5/12T7939AK –19–22MAR93T8029AF –UN–15JUN9306–5PN=25

Safety SignsTX,06,JC1102 –19–18MAR96–6/12T7934AM –19–01FEB93A-Warning DecalT100703 –UN–22MAR96Left Side Shown06–6PN=26

Introduction170696PN=7

Safety SignsTX,06,JC1102 –19–18MAR96–7/12T8029AR –19–16JUN93T8029AQ –UN–21JUN9306–7PN=27

Safety SignsTX,06,JC1102 –19–18MAR96–8/12T7829AT –19–17SEP92A-Warning Decal, If EquippedT7853AF –UN–08OCT92T8029AH –UN–15JUN93Right Side of Machine06–

Safety SignsTX,06,JC1102 –19–18MAR96–9/12T7916AC –19–06JAN93T7773AZ –UN–10AUG92TX,06,JC1102 –19–18MAR96–10/12T7748CU –19–14OCT92T7773CA –UN–10AUG9206–

Safety SignsTX,06,JC1102 –19–18MAR96–11/12T7829AQ –19–31AUG92T100702 –UN–22MAR9606–10PN=30

Safety SignsTX,06,JC1102 –19–18MAR96–12/12T7829AU –19–17SEP92T7839BB –UN–17SEP92T101279 –19–14MAY96Located on top of radiator cap06–11PN=31

Operator’s StationTX,10,JC1046 –19–16JAN96–1/2GAUGES, INDICATORS, SWITCHES, AND ACCESSORIEST7773AP –UN–11JUN92A—SELECT Switch H—Engine Coolant Level N

Operator’s StationTX,10,JC1046 –19–16JAN96–2/2T8375AN –UN–02DEC94A—Front Wiper Switch G—Rear Wiper Switch J—Ride Control Switch—If M—Temperature Contr

Operator’s StationTX,10,DH2165 –19–02OCT92–1/1STOP INDICATOR AND ALARMT7673AM –UN–06JAN92ÖCAUTION: Prevent possible injury, or machinedamage. If STOP

Operator’s StationTX,10,DH2282 –19–12MAY93–1/1SERVICE REQUIRED INDICATOR (YELLOW)T6201BL –UN–18OCT88If service required indicator lights, a problem is

Operator’s StationTX,10,JC1063 –19–14FEB96–1/1ENGINE COOLANT TEMPERATURE GAUGET7747AU –UN–19MAY92The first arrow will flash until engine temperature w

T7773CY -UN-08SEP92T7773CZ -UN-08SEP92TX,DH2121 -19-08JUN96170696PN=8

Operator’s StationTX,10,DH2153 –19–29NOV94–1/1ENGINE OIL PRESSURE INDICATORT7747AA –UN–19MAY92IMPORTANT: Prevent possible engine damage. Ifengine oil

Operator’s StationTX,10,DH2152 –19–02OCT92–1/1ENGINE COOLANT LEVEL INDICATORT7747AC –UN–19MAY92IMPORTANT: Prevent machine damage. Low coolantwill resu

Operator’s StationTX,DH,39 –19–12APR93–1/1RIGHT TURN SIGNAL INDICATORT6201BK –UN–18OCT88Indicator light will light when right turn signal switch iseng

Operator’s StationTX,10,DH2344 –19–31JUL92–1/1FASTEN SEAT BELT INDICATORT7747AH –UN–19MAY92Indicator light will light for the first 5 seconds after th

Operator’s StationTX,DH,38 –19–12APR93–1/1LEFT TURN SIGNAL INDICATORT6201BG –UN–18OCT88Indicator light will light when left turn signal switch isengag

Operator’s StationTX,10,DH2133 –19–31JUL92–3/3T7747AM –UN–19MAY92A—Transmission Control LeverTX,10,DH2137 –19–31JUL92–1/1FRONT AXLE DISCONNECT LEVER—I

Operator’s StationTX,10,DH2136 –19–07OCT92–1/1PEDALST7747AO –UN–19MAY92A—Accelerator PedalB—Right Brake PedalC—Steering Column Tilt PedalD—Left Brake/

Operator’s StationTX,10,DH2138 –19–02OCT92–1/1NEUTRAL LOCKT7747BI –UN–19MAY92A—Neutral LockTX,10,DH2279 –19–18SEP92–1/1HORN BUTTONT7747BJ –UN–19MAY92A

Operator’s StationTX,10,DH2280 –19–31JUL92–1/1TURN SIGNAL SWITCHT7747BK –UN–19MAY92A—Turn Signal SwitchTX,10,DH2139 –19–31JUL92–1/1DOME LIGHT AND SWIV

Operator’s StationTX,10,JC271 –19–29NOV94–1/1OPERATING WINDSHIELD WIPERS ANDWASHERS—IF EQUIPPEDT8375AO –UN–02DEC94A—Front Wiper and Washer SwitchB—Rea

T7799CY -UN-06OCT92T7799CZ -UN-06OCT92TX,DH2283 -19-02OCT92170696PN=9

Operator’s Station02T,10,MM27 –19–31JUL92–1/1OPENING SLIDING SIDE WINDOW—IFEQUIPPEDT6603AQ1 –UN–20OCT88Squeeze latch tabs (A) together and slide windo

Operator’s StationTX,10,DH2144 –19–29NOV94–1/1OPERATING LIGHTST8373BD –UN–02DEC94T7773AX –UN–10AUG92T7773AY –UN–10AUG92A—Operating Light SwitchB—Work

Operator’s StationTX,10,JC1103 –19–18MAR96–1/1HEATING AND AIR CONDITIONINGCONTROLST8373AY –UN–02DEC94T100706 –UN–22MAR96544G ShownA—Temperature Contro

Operator’s StationTX,10,JC246 –19–29NOV94–1/2ADJUSTING SUSPENSION SEATT7829AP –UN–31AUG92A—Lumbar Depth Adjustment KnobB—Armrest Tilt Adjustment KnobC

Operator’s StationMODTX10DH3548 –19–07FEB95–1/1SEAT BELTT8415AA –UN–09FEB95Seat belt and mounting hardware must be inspectedfor wear or damage before

Break-inTX,15,JC1131 –19–21MAY96–1/1ENGINE BREAK-IN OILNew engines are filled at the factory with John DeereENGINE BREAK-IN OIL. During the break-in p

Break-inTX,15,DH1828 –19–16JUN93–1/1AFTER FIRST 10 AND FIRST 50 HOURSTighten wheel retainer cap screws to 542 N•m (400 lb-ft).TX,15,DH2147 –19–16JUN93

Pre-Start InspectionTX,20,JC273 –19–29NOV94–1/1INSPECT MACHINE DAILY BEFORESTARTINGT8374AB –UN–02DEC94Do periodic service checks in the Maintenance—Ev

Operating the EngineTX,25,DH2148 –19–22JUN93–1/1CHECK INSTRUMENTS BEFORE STARTINGTurn key switch clockwise to ON position.All indicator lights must li

Operating the EngineTX,25,DH2284 –19–31JUL92–2/3T7747BR –UN–19MAY923. Move transmission control lever (A) to neutral "N".Engage neutral lock

HELP!! HELP!! HELP!! HELP!!We need your help to continually improve our Operator’sManuals. Please FAX or mail your comments, ideas andimprovements on

Operating the EngineTX,25,DH2284 –19–31JUL92–3/3T7747BU –UN–19MAY924. Hold accelerator pedal (C) down 1/3 of the way to thefloor.5. Turn key switch to

Operating the EngineTX,25,JC1155 –19–03JUN96–1/2STARTING FLUID—IF EQUIPPED (COLDWEATHER STARTING AID)TS281 –UN–23AUG88USE STARTING FLUIDÖCAUTION: Prev

Operating the EngineTX,25,JC1155 –19–03JUN96–2/2T7747BT –UN–19MAY92T7527EF –UN–01AUG91IMPORTANT: Excess starting fluid could damageengine; press start

Operating the EngineTX,25,DH2166 –19–12SEP92–1/1USING BOOSTER BATTERIES—12 VOLTSYSTEMT6508AE1 –UN–24OCT91T6713AI1 –UN–24OCT91Before boost starting, ma

Operating the EngineTX,25,DH2550 –19–12MAY93–1/1CHECK INSTRUMENTS AFTER STARTINGÖCAUTION: Prevent possible injury, or machinedamage. If STOP indicator

Operating the EngineTX,DH,40 –19–17JUN91–1/1COLD WEATHER WARM-UPIMPORTANT: If hydraulic oil is cold, hydraulicfunctions move slowly. Do not attemptnor

Operating the EngineTX,25,DH2168 –19–16JUN93–2/2T7747BR –UN–19MAY923. Move transmission control lever (A) to neutral "N".Engage neutral lock

Driving the MachineTX,30,DH2123 –19–31JUL92–1/2DRIVING ON PUBLIC ROADSBefore driving on public roads, check state and local lawsthat may apply to trac

Driving the Machine02T,30,C47 –19–31JUL92–1/1GENERAL DRIVING PRECAUTIONSÖCAUTION: Riders on machine are subject toinjury. Never allow riders on the ma

Driving the MachineTX,30,DH2169 –19–31JUL92–2/2T7747AN –UN–19MAY92Pull up lever (A) to disconnect front axle.Push down lever to connect front axle.TX,

170696PN=11

Driving the MachineTX,30,JC248 –19–29NOV94–2/2T7747AM –UN–19MAY92Change direction of machine by moving transmissioncontrol lever (A) to forward "

Driving the MachineTX,30,DH2172 –19–02OCT92–1/1TRAVEL SPEEDSNOTE: Km/h and mph will only display in fullincrements on digital display.544G, LL, TC:For

Driving the MachineTX,30,DH2505 –19–16JUN93–1/1RIDE CONTROL SWITCH—IF EQUIPPEDT7829AV –UN–08SEP92ÖCAUTION: Prevent possible injury fromunexpected boom

Driving the MachineTX,30,DH2174 –19–06OCT92–1/1PARK BRAKE SWITCHT7773AG –UN–11JUN92ÖCAUTION: Prevent possible injury or death frommachine runaway. Bef

Driving the MachineTX,30,DH2176 –19–16JUN93–2/2T7747BR –UN–19MAY923. Move transmission control lever (A) to neutral "N".Engage neutral lock

Operating the MachineTX,35,DH2177 –19–29NOV94–1/1BOOM AND BUCKET CONTROL LEVER—ONE LEVER DESIGNT7773AC –UN–11JUN92T8373BA –UN–02DEC94A—Lower BoomB—Flo

Operating the MachineTX,35,DH2178 –19–29NOV94–1/1BOOM AND BUCKET CONTROL LEVER—TWO LEVER DESIGNT7773AE –UN–11JUN92T8373BA –UN–02DEC94A—Dump bucketB—Ro

Operating the MachineTX,35,DH2490 –19–08OCT92–1/1QUICK SHIFT SWITCHT7773CE –UN–21AUG92Press down on switch (A) to downshift from 3rd gear to2nd gear w

Operating the MachineTX,35,DH2286 –19–29NOV94–1/1QUICK COUPLER OPERATION—544G TCT7773AF –UN–11JUN92T8373AV –UN–02DEC94T6975AF –UN–29MAR89Move control

Operating the MachineTX,35,DH2287 –19–29NOV94–1/1PIN DISCONNECT SWITCH—544G TCT8373AW –UN–02DEC94Use the pin disconnect switch (A) when adding orchang

ContentsPage PageHeating and Air Conditioning Controls . . . . . . . 10-18Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1A

Operating the MachineTX,35,DH2181 –19–02OCT92–1/1SECONDARY STEERING—IF EQUIPPEDT7773AT –UN–30JUL92IMPORTANT: Prevent possible damage to secondarysteer

Operating the MachineTX,35,DH2183 –19–31JUL92–1/2ADJUSTING BOOM HEIGHT KICKOUT—IFEQUIPPED1. Start engine.2. Move control lever to boom raise detent po

Operating the MachineTX,35,DH2184 –19–02OCT92–1/2ADJUSTING RETURN-TO-DIG1. Start engine.2. Move control lever to return-to-dig detent position andrele

Operating the MachineTX,DH,49 –19–06JUN91–1/1GENERAL OPERATING TIPSCarry loaded bucket low to the ground for a better viewand to improve machine stabi

Operating the MachineTX,35,DH2276 –19–02OCT92–3/3T7208AV –UN–30JAN90Normally, a bank or stockpile is excavated from thebottom and then up the side. Wo

Operating the MachineTX,35,JC1049 –19–17JAN96–2/4T7747BC –UN–19MAY924. Raise and curl bucket to hold load.TX,35,JC1049 –19–17JAN96–3/4T7208AR –UN–30JA

Operating the MachineTX,35,DH2278 –19–31JUL92–1/1BACKDRAGGINGT7747BG –UN–19MAY92Leveling and grading can be done with the boom in thefloat position by

Operating the Machine02T,35,J8 –19–25JUN91–1/1TRUCK LOADINGT7511CN –UN–27JUN91The most efficient technique for truck loading is the "V"metho

TransportingTX,40,FF3416 –19–27MAY93–1/1TRANSPORTING PRECAUTIONSIf machine is transported, check route for road width andoverhead clearance. Check any

TransportingTX,40,JC274 –19–29NOV94–2/2T7747BR –UN–19MAY926. Move transmission control lever (A) to neutral "N".Engage neutral lock (B).ÖCAU