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Maintenance
TX,90,DH1768 –19–06JUN91–1/2
REMOVING BATTERIES
1. Remove battery cover.
TX,90,DH1768 –19–06JUN91–2/2
T6570AD2 –UN–20OCT88
2. Disconnect negative (-) battery cable (A) first, then
positive (+) cable (B).
3. Remove nuts and washers (C) and hold down bracket.
4. Lift battery out of compartment.
TX,90,DH2266 –19–02OCT92–1/1
REPLACING FUSES
T7853AS –UN–08OCT92
IMPORTANT: Install fuses with correct amperage
rating to prevent electrical system
damage from overload.
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.
04T,90,J22 –19–28SEP92–1/1
FUSE (BLADE-TYPE) COLOR CODES
Amperage Rating Color
1 Black
3 Violet
4 Pink
5 Tan
7-1/2 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (White)
30 Light Green
90–15
PN=181
- 544G, 544G LL, and 1
- 544G TC Loaders 1
- 624G Loader 1
- 644G Loader 1
- (Serial No. 557739-) 1
- Introduction 2
- TX,DH2121 -19-08JUN96 5
- TX,DH2283 -19-02OCT92 6
- HELP!! HELP!! HELP!! HELP!! 7
- Contents 10
- T100127 –19–21FEB96 14
- RECOGNIZE SAFETY INFORMATION 15
- UNDERSTAND SIGNAL WORDS 15
- FOLLOW SAFETY INSTRUCTIONS 15
- TX,05,DH1525 –19–21JUN91–1/1 16
- TX,05,DH1573 –19–18MAR91–1/1 17
- TX,05,DH2478 –19–26SEP92–1/1 18
- T82,BHSA,CL –19–14MAR90–1/1 18
- USE HANDHOLDS AND STEPS 19
- PREVENT MACHINE RUNAWAY 19
- USE SEAT BELT PROPERLY 19
- MAINTAIN SEAT BELT 20
- SECONDARY EXITS 20
- TRAVEL SAFELY 21
- T6964AD –UN–20DEC88 21
- DRIVE MACHINE SAFELY 21
- T6582AS –UN–25OCT88 21
- OPERATE MACHINE WITH CAUTION 22
- T6642EF –UN–18OCT88 22
- OPERATING ON SLOPES 22
- T7050AB –UN–03AUG89 22
- CARRYING LOADS 23
- AVOID POWER LINES 23
- BEWARE OF EXHAUST FUMES 23
- KEEP RIDERS OFF MACHINE 24
- PREPARE FOR EMERGENCIES 24
- HANDLE STARTING FLUID SAFELY 25
- CLEAN TRASH FROM MACHINE 25
- PROTECT AGAINST FLYING DEBRIS 25
- WEAR PROTECTIVE CLOTHING 26
- PROTECT AGAINST NOISE 26
- USE SAFETY LIGHTS AND DEVICES 27
- N36564 –UN–10FEB89 27
- KEEP THE OPERATOR PROTECTIVE 28
- STRUCTURE (OPS) IN PLACE 28
- WARN OTHERS OF SERVICE WORK 28
- T7447AO –19–22APR91 28
- PRACTICE SAFE MAINTENANCE 29
- TS218 –UN–23AUG88 29
- SUPPORT MACHINE PROPERLY 30
- TS229 –UN–23AUG88 30
- DX,PAINT –19–03MAR93–1/1 31
- DX,TORCH –19–03MAR93–1/1 31
- AVOID HIGH-PRESSURE FLUIDS 32
- CLEAN THE MACHINE REGULARLY 32
- T6642EJ –UN–18OCT88 32
- SERVICE COOLING SYSTEM SAFELY 33
- STORE ATTACHMENTS SAFELY 33
- DISPOSE OF WASTE PROPERLY 33
- Safety Signs 34
- T7939AI –19–22MAR93 35
- T7773CV –UN–31AUG92 35
- A-Warning Decal 35
- T8417AD –19–09FEB95 36
- T7593AC –19–30AUG91 37
- T6976AE –UN–30JAN89 37
- T7939AK –19–22MAR93 38
- T8029AF –UN–15JUN93 38
- T7934AM –19–01FEB93 39
- T100703 –UN–22MAR96 39
- Left Side Shown 39
- T8029AR –19–16JUN93 40
- T8029AQ –UN–21JUN93 40
- T7829AT –19–17SEP92 41
- A-Warning Decal, If Equipped 41
- Right Side of Machine 41
- T7916AC –19–06JAN93 42
- T7773AZ –UN–10AUG92 42
- T7748CU –19–14OCT92 42
- T7773CA –UN–10AUG92 42
- T7829AQ –19–31AUG92 43
- T100702 –UN–22MAR96 43
- T7829AU –19–17SEP92 44
- T7839BB –UN–17SEP92 44
- Operator’s Station 45
- T8375AN –UN–02DEC94 46
- STOP INDICATOR AND ALARM 47
- T7673AM –UN–06JAN92 47
- T6201BL –UN–18OCT88 48
- DIGITAL DISPLAY 48
- T7747AT –UN–19MAY92 48
- FUEL GAUGE 49
- ENGINE OIL PRESSURE INDICATOR 50
- ALTERNATOR VOLTAGE INDICATOR 50
- ENGINE AIR FILTER RESTRICTION 50
- INDICATOR 50
- RIGHT TURN SIGNAL INDICATOR 52
- BRAKE OIL PRESSURE INDICATOR 52
- PARK BRAKE INDICATOR 52
- FASTEN SEAT BELT INDICATOR 53
- ETHER INJECTION INDICATOR 53
- LEFT TURN SIGNAL INDICATOR 54
- T7747AM –UN–19MAY92 55
- T7747AN –UN–19MAY92 55
- T7747AO –UN–19MAY92 56
- PARK BRAKE SWITCH 56
- NEUTRAL LOCK 57
- T7747BI –UN–19MAY92 57
- HORN BUTTON 57
- T7747BJ –UN–19MAY92 57
- TURN SIGNAL SWITCH 58
- VANDAL SHIELD—IF EQUIPPED 58
- WASHERS—IF EQUIPPED 59
- ADJUSTING STEERING WHEEL TILT 59
- OPENING SIDE WINDOW 59
- CAB DOOR RELEASE 60
- OPERATING LIGHTS 61
- HEATING AND AIR CONDITIONING 62
- CONTROLS 62
- ADJUSTING SUSPENSION SEAT 63
- SEAT BELT 64
- T8415AA –UN–09FEB95 64
- STORAGE COMPARTMENT 64
- T8029AK –UN–15JUN93 64
- Break-in 65
- AFTER THE FIRST 100 HOURS 66
- Pre-Start Inspection 67
- Operating the Engine 68
- T7747BU –UN–19MAY92 70
- WEATHER STARTING AID) 71
- COLD WEATHER WARM-UP 75
- STOPPING THE ENGINE 75
- Driving the Machine 77
- GENERAL DRIVING PRECAUTIONS 78
- SHIFTING THE TRANSMISSION 79
- TRAVEL SPEEDS 81
- STOPPING THE MACHINE 82
- PARKING THE MACHINE 83
- Operating the Machine 85
- TWO LEVER DESIGN 86
- QUICK SHIFT SWITCH 87
- T7773CE –UN–21AUG92 87
- PIN DISCONNECT SWITCH—544G TC 89
- BOOM DOWN SWITCH 89
- T7773AT –UN–30JUL92 90
- T100664 –UN–12MAR96 90
- T6601AI –UN–21OCT88 91
- ADJUSTING RETURN-TO-DIG 92
- T6599AD –UN–21OCT88 92
- GENERAL OPERATING TIPS 93
- T7208AV –UN–30JAN90 94
- USING THE LOADER BUCKET 94
- T7747BB –UN–19MAY92 94
- T7747BC –UN–19MAY92 95
- T7208AR –UN–30JAN90 95
- T7747BD –UN–19MAY92 95
- BACKDRAGGING 96
- T7747BG –UN–19MAY92 96
- BACKFILLING 96
- T6603AO –UN–20OCT88 96
- TRUCK LOADING 97
- T7511CN –UN–27JUN91 97
- TOWING PROCEDURE—ENGINE 100
- OPERATIONAL 100
- T6629AM –UN–20OCT88 100
- TOWING PROCEDURE—ENGINE NON 101
- Transporting 102
- LIFTING THE MACHINE 104
- T7477AV –UN–19MAR91 104
- Fuels and Lubricants 105
- FUEL TANK 107
- DIESEL ENGINE OIL 108
- T101239 –19–22MAY96 108
- T100663 –19–10MAY96 109
- T8358AI –19–27MAR95 110
- LUBRICANT STORAGE 111
- MIXING OF LUBRICANTS 111
- Periodic Maintenance 112
- LOCKING MACHINE FRAME 114
- BOOM LOCK 115
- SERVICE DOORS 115
- OPENING GRILLE DOOR 116
- MAINTENANCE AND REPAIR RECORD 117
- KEEPING SYSTEM 117
- T7511CO –UN–27JUN91 117
- OILSCAN 118
- *includes 544G LL and 544G TC 119
- Maintenance—As Required 121
- TIRE PRESSURES 122
- TX,55,JC1157 –19–03JUN96–1/1 123
- TX,55,JC1158 –19–03JUN96–1/1 124
- TX,55,JC1159 –19–03JUN96–1/1 125
- TX,55,DH2551 –19–16JUN93–1/1 125
- CLEAN OR REPLACE AIR CLEANER 126
- ELEMENTS 126
- T6119AF –UN–01NOV88 126
- T6119AG –UN–01NOV88 126
- CLEAN DUSTY PRIMARY ELEMENT 127
- INSPECT ELEMENT 128
- T90684 –UN–10NOV88 128
- CHECK AIR INLET COVER 129
- T6779BQ –UN–19OCT88 129
- INSPECT SERPENTINE BELT—644G 131
- T7405BG –UN–15NOV90 131
- DRAIN FUEL TANK 131
- T7773CN –UN–21AUG92 131
- (WATER SEPARATOR)—544G, 624G 132
- T8387AD –UN–17DEC94 133
- (WATER SEPARATOR)—644G 133
- T100696 –UN–22MAR96 133
- T8295AA –UN–10AUG94 134
- LUBRICATE PIVOTS 135
- CHECK ENGINE OIL LEVEL 135
- 544G Shown 136
- 624G Shown 136
- 644G Shown 136
- CHECK HYDRAULIC OIL LEVEL 137
- T7773CB –UN–10AUG92 138
- T8029AM –UN–15JUN93 138
- CHECK TRANSMISSION OIL LEVEL 139
- T7773CP –UN–21AUG92 139
- Maintenance—Every 100 Hours 140
- LUBRICATE BOOM, BUCKET, AND 141
- CYLINDER PIVOTS—544G TC 141
- T7829BH –UN–17SEP92 142
- Five Points 142
- CHECK CAB FRESH AIR FILTER—IF 144
- EQUIPPED 144
- T7829AC –UN–31AUG92 145
- Maintenance—Every 250 Hours 146
- CHANGE ENGINE OIL AND REPLACE 147
- T7853AI –UN–08OCT92 148
- CHECK RADIATOR COOLANT LEVEL 150
- T6642EK –UN–01NOV88 150
- Maintenance—Every 500 Hours 151
- AND TERMINALS 152
- TS203 –UN–23AUG88 152
- T6758AA –UN–21OCT88 154
- CHECK COOLANT 155
- T101279 –19–14MAY96 155
- TS281 –UN–23AUG88 155
- SEPARATOR) 156
- T100705 –UN–22MAR96 158
- REPLACE HYDRAULIC RESERVOIR 158
- BREATHER FILTER 158
- OIL LEVEL—IF EQUIPPED WITH 160
- DIFFERENTIAL LOCK AXLE 160
- Maintenance—Every 1000 Hours 161
- T7853AB –UN–06OCT92 162
- REPLACE AIR CLEANER ELEMENTS 163
- CHANGE TRANSMISSION OIL AND 165
- REPLACE FILTER 165
- T7853AA –UN–23SEP92 166
- T7853AC –UN–06OCT92 166
- CHECK PARK BRAKE 167
- T7773AG –UN–11JUN92 168
- ADJUST PARK BRAKE 168
- T7747BR –UN–19MAY92 168
- T100701 –UN–22MAR96 169
- LUBRICATE FRAME HINGE PIVOTS 170
- T100690 –UN–22MAR96 170
- Maintenance—Every 2000 Hours 171
- T6233AG –19–27JAN89 172
- T6233AH –19–27JAN89 172
- ADJUST ENGINE VALVE LASH 173
- (CLEARANCE)—644G 173
- T6105BF –UN–24FEB89 173
- T6233AI –19–27JAN89 174
- T6233AJ –19–27JAN89 174
- Maintenance—Every 3000 Hours 176
- FILTER(S)—IF EQUIPPED 177
- Maintenance 180
- T7829AN –UN–31AUG92 181
- 544G, 624G Shown 181
- T100709 –UN–22MAR96 181
- DIESEL ENGINE COOLANT 182
- FILLING THE COOLING SYSTEM 183
- TEST THE COOLANT FREEZE— 183
- PROTECTION LEVEL 183
- T85402 –UN–10NOV88 183
- DO NOT ADJUST INJECTION PUMP 184
- T6523BW1 –UN–20OCT88 185
- T7833AJ –UN–10SEP92 186
- BLEEDING FUEL SYSTEM—644G 187
- SERVICE BATTERIES CAREFULLY 189
- CHECKING ELECTROLYTE SPECIFIC 191
- USING BATTERY CHARGER 193
- TS204 –UN–23AUG88 193
- REPLACING BATTERIES 193
- REMOVING BATTERIES 194
- REPLACING FUSES 194
- FUSE (BLADE-TYPE) COLOR CODES 194
- RESETTING CIRCUIT BREAKERS 195
- REPLACING HALOGEN BULBS 195
- T6249AU –UN–19OCT88 196
- CHECKING NEUTRAL START SYSTEM 197
- BELT TENSION—IF EQUIPPED 199
- WELDING ON MACHINE 199
- INSPECTING PARK BRAKE PADS 200
- T7853AU –UN–08OCT92 201
- T6523BZ –UN–25OCT88 202
- T6138AZ –UN–25OCT88 202
- T8137AC –UN–03DEC93 202
- CHECKING BRAKE ACCUMULATOR 203
- T100704 –UN–22MAR96 203
- CHECKING RIDE CONTROL 204
- ACCUMULATOR—IF EQUIPPED 204
- BLEEDING BRAKES 205
- X9811 –UN–23AUG88 205
- T6522BR –UN–20OCT88 206
- CHECKING SECONDARY STEERING 207
- SYSTEM—IF EQUIPPED 207
- CLUTCH CUT-OFF ADJUSTMENT 207
- T7817AL –UN–08SEP92 208
- CYLINDERS, PUMPS OR MOTORS 208
- KEEP ROPS INSTALLED PROPERLY 209
- TS176 –UN–23AUG88 209
- *Torque tolerance is 212
- DX,TORQ1 –19–20JUL94–2/2 214
- CHECK OIL LINES AND FITTINGS 215
- T85401 –UN–24JAN89 215
- BOSS FITTINGS 216
- T6243AE –UN–18OCT88 216
- T6520AB –UN–18OCT88 217
- FACE O-RING SEAL FITTINGS 218
- T6243AD –UN–18OCT88 218
- T6890BB –UN–01MAR90 219
- 04T,90,K174 –19–01AUG94–2/2 221
- Operational Checkout 222
- – – –1/1 229
- T7825BB –UN–21AUG92 229
- T7825BD –UN–21AUG92 229
- T7825BE –UN–21AUG92 229
- LOOK: Machine MUST NOT move 231
- Troubleshooting 256
- ELECTRICAL SYSTEM 269
- HYDRAULIC SYSTEM 277
- Symptom Problem 283
- Solution 283
- POWER TRAIN 284
- SERVICE BRAKES 290
- DIFFERENTIAL AXLE 292
- DRIVELINE 294
- PARK BRAKE 295
- AIR CONDITIONING 296
- PREPARE MACHINE FOR STORAGE 297
- T47764 –UN–09NOV88 297
- T5813AM –UN–09FEB89 297
- MONTHLY STORAGE PROCEDURE 298
- T6191AA –UN–18OCT88 298
- T6181AU –UN–18OCT88 299
- Machine Numbers 300
- RECORD HYDRAULIC PUMP SERIAL 301
- Specifications 302
- 544G SPECIFICATIONS 304
- 544G LL SPECIFICATIONS 306
- T7829AX –UN–10SEP92 306
- 544G TC SPECIFICATIONS 310
- T7829AY –UN–21SEP92 310
- 624G SPECIFICATIONS 314
- T6603AC1 –UN–20OCT88 314
- 644G SPECIFICATIONS 318
- T6603AD1 –UN–20OCT88 318
- Crime Prevention Tips 322
- PARK INDOORS OUT OF SIGHT 323
- TS158 –UN–23MAR89 323
- WHEN PARKING OUTDOORS 323
- TS144 –UN–23AUG88 323
- REDUCE VANDALISM 324
- T7223BB –UN–22FEB90 324
- REPORT THEFTS IMMEDIATELY 324
- TS146 –UN–09JAN89 324
- Page Page 325
- Checklists 331
- PARTS CATALOG 333
- OPERATOR’S MANUAL 333
- TECHNICAL AND SERVICE MANUALS 333
- TX,LIT1 -19-08JUN96 334
- TS1643 -UN-12SEP95 335
- DX,IBC,4 -19-12SEP95 335
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