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Maintenance
TX,90,DY323 –19– 2MAY96–2/2
T6520AB –UN–18OCT88
ANGLE FITTING
1. Back-off lock nut (A) and back-up washer (B)
completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index
(maximum of one turn).
4. Hold fitting head-end with a wrench and tighten
locknut and back-up washer to proper torque value.
NOTE: Do not allow hoses to twist when tightening
fittings.
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
NOTE: Torque tolerance is
±
10%.
90–38
PN=204
- 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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