OPERATORS MANUAL - 544G - English

D
544G, 544G LL, and

544G TC Loaders
624G Loader
644G Loader
(Serial No. 557739-)
OPERATORS MANUAL
544G, 544G LL, and 544G TC Loaders 624G Loader
644G Loader (Serial No. 557739-)
English
John Deere Dubuque Works

OMT159816 Issue G6
(Mark old manual OMT154907 L4 for
machines up to Serial No. 557738)
LITHO IN U.S.A.
ENGLISH
O M T 1 5 9 8 1 6
G 6
OMT159816 Issue G6
T7773CX
-UN-08SEP92
Introduction
READ THIS MANUAL carefully to learn how to

operate and service your machine correctly. Failure to
do so could result in personal injury or equipment
damage. This manual and safety signs on your
machine may also be available in other languages.
(See your John Deere dealer to order.)
THIS MANUAL SHOULD BE CONSIDERED a
permanent part of your machine and should remain
with the machine when you sell it.
MEASUREMENTS in this manual are given in both
metric and customary U.S. unit equivalents. Use only
correct replacement parts and fasteners. Metric and
inch fasteners may require a specific metric or inch
wrench.
RIGHT-HAND AND LEFT-HAND sides are determined
by facing in the direction of forward travel.
WRITE PRODUCT IDENTIFICATION NUMBERS
(P.I.N.) in the Machine Numbers section. Accurately
record all the numbers to help in tracing the machine
should it be stolen. Your dealer also needs these
numbers when you order parts. File the identification

numbers in a secure place off the machine.
WARRANTY is provided as part of John Deeres
support program for customers who operate and
maintain their equipment as described in this manual.
The warranty is explained on the warranty certificate
which you should have received from your dealer.
This warranty provides you the assurance that John
Deere will back its products where defects appear
within the warranty period. In some circumstances,
John Deere also provides field improvements, often
without charge to the customer, even if the product is
out of warranty. Should the equipment be abused, or
modified to change its performance beyond the
original factory specifications, the warranty will
become void and field improvements may be denied.
Setting fuel delivery above specifications or otherwise
overpowering machines will result in such action.
THE TIRE MANUFACTURERS warranty supplied
with your machine may not apply outside the U.S.
CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects and other reproductive harm.
TX,DH2120
-19-13DEC95
170696
PN=5
T100255
-19-14FEB96
Introduction
TX,DY549
-19-08JUN96
170696
PN=6
Introduction
170696
PN=7
TX,DH2121
-19-08JUN96
PN=8
170696
T7773CZ
-UN-08SEP92
T7773CY
-UN-08SEP92
TX,DH2283
-19-02OCT92
PN=9
170696
T7799CZ
-UN-06OCT92
T7799CY
-UN-06OCT92
HELP!!
HELP!!
HELP!!
HELP!!
We need your help to continually improve our Operators

Manuals. Please FAX or mail your comments, ideas and
improvements on this comment sheet.
SEND TO: John Deere Dubuque Works

P.O. Box 538
Dubuque, Iowa 52004-0538
Dept. 304
Attn: Publications Supervisor
FAX NUMBER: 319-589-5800
OMT159816 544G, 624G and 644G Loader Operators
Manual
Ideas, Comments, (Please state Page Number):
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TX,FAX,JC544G -19-08JUN96
170696
PN=10
170696
PN=11
Contents
Page
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-1
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . 06-1
Operators 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 IndicatorIf
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 IndicatorIf Equipped . . . . . . 10-9
Left Turn Signal Indicator . . . . . . . . . . . . . . . . . 10-10
Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Front Axle Disconnect LeverIf 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 LightIf Equipped . . . . 10-14
Vandal ShieldIf Equipped . . . . . . . . . . . . . . . 10-14
Operating Windshield Wipers and
WashersIf Equipped . . . . . . . . . . . . . . . . . 10-15
Adjusting Steering Wheel Tilt . . . . . . . . . . . . . . 10-15
Opening Side Window . . . . . . . . . . . . . . . . . . . 10-15
Opening Sliding Side WindowIf Equipped . . . 10-16
Cab Door Release . . . . . . . . . . . . . . . . . . . . . . 10-16
Operating Lights . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Heating and Air Conditioning Controls . . . . . . .

Adjusting Suspension Seat . . . . . . . . . . . . . . . .
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage Compartment . . . . . . . . . . . . . . . . . . .
10-18
10-19
10-20
10-20
Break-in
Engine Break-In Oil . . . . . . . . . . .
Every 10 Hours or Daily . . . . . . . .
After First 10 and First 50 Hours .
After the First 100 Hours . . . . . . .
. 15-1
. 15-1
. 15-2
. 15-2
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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 FluidIf Equipped (Cold Weather
Starting Aid) . . . . . . . . . . . . . . . . . . . . . . . . . . 25-4
Using Coolant HeaterIf Equipped . . . . . . . . . . 25-5
Using Booster Batteries12 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 . . . . . . . . . .
General Driving Precautions . . . . . . .
Front Axle DisconnectIf Equipped .
Neutral Lock . . . . . . . . . . . . . . . . . . .
Shifting the Transmission . . . . . . . . .
Travel Speeds . . . . . . . . . . . . . . . . .
Ride Control SwitchIf Equipped. . .
Stopping the Machine. . . . . . . . . . . .
Park Brake Switch . . . . . . . . . . . . . .
Parking the Machine. . . . . . . . . . . . .
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. 30-1
. 30-2
. 30-2
. 30-3
. 30-3
. 30-5
. 30-6
. 30-6
. 30-7
. 30-7
Operating the Machine

Continued on next page
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT 1996
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRATION Manual
040596
PN=1
Contents
Page
Page
Boom and Bucket Control LeverOne

Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-1
Boom and Bucket Control LeverTwo
Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . 35-2
Quick Shift Switch . . . . . . . . . . . . . . . . . . . . . . . 35-3
Quick Coupler Operation544G TC . . . . . . . . . 35-4
Pin Disconnect Switch544G TC . . . . . . . . . . . 35-5
Boom Down Switch . . . . . . . . . . . . . . . . . . . . . . 35-5
Clutch Cut-Off SwitchIf Equipped . . . . . . . . . . 35-5
Secondary SteeringIf Equipped. . . . . . . . . . . . 35-6
Differential Lock PedalIf Equipped . . . . . . . . . 35-6
Adjusting Boom Height KickoutIf
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
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
MaintenanceAs 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 Tension544G,
624G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-10
Inspect Serpentine Belt644G. . . . . . . . . . . . . 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
Transporting
Transporting Precautions . . . . . . . . . . . . . . . . . . 40-1
Loading Machine on a Trailer . . . . . . . . . . . . . . . 40-1
Towing ProcedureEngine Operational . . . . . . . 40-3
Towing ProcedureEngine NonOperational. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
Lifting the Machine . . . . . . . . . . . . . . . . . . . . . . . 40-7
Fuels and Lubricants
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Sulfur Diesel Fuel Conditioner. . . . . . . . .
Handling and Storing Diesel Fuel . . . . . . . . . .
Do Not Use Galvanized Containers . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Engine Oil . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil, Hydraulic System Oil and
Differential Oil. . . . . . . . . . . . . . . . . . . . . . .
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternative and Synthetic Lubricants . . . . . . . .
Lubricant Storage . . . . . . . . . . . . . . . . . . . . . .
Mixing of Lubricants . . . . . . . . . . . . . . . . . . . .
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45-1
45-2
45-2
45-3
45-3
45-4
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45-5
45-6
45-6
45-7
45-7
MaintenanceEvery 10 Hours or Daily

Lubricate Pivots . . . . . . . . . . . . . . . . . . . .
Clean Air Cleaner Dust Unloader Valve . .
Check Engine Oil Level . . . . . . . . . . . . . .
Check Recovery Tank Coolant Level . . . .
Check Hydraulic Oil Level . . . . . . . . . . . .
Check Transmission Oil Level . . . . . . . . .
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. 60-1
. 60-1
. 60-1
. 60-3
. 60-3
. 60-5
MaintenanceEvery 100 Hours

Lubricant Boom, Bucket, and Cylinder
Pivots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Lubricate Boom, Bucket, and Cylinder
Pivots544G TC . . . . . . . . . . . . . . . . . . . . . . 70-2
Lubricate Steering Cylinder Pivots . . . . . . . . . . . 70-4
Lubricate Oscillating Rear Axle. . . . . . . . . . . . . . 70-5
Check Cab Fresh Air FilterIf Equipped . . . . . . 70-5
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 Receiver Dryer Moisture Indicator . . . . . . 75-1
Change Engine Oil and Replace Filter . . . . . . . . 75-2
Check Radiator Coolant Level . . . . . . . . . . . . . . 75-5
ii
PN=2
Contents
Page
Page

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 Filter544G, 624G . . . . . . . 80-7
Replace Final Fuel Filter644G. . . . . . . . . . . . . 80-7
Replace Hydraulic System Return Filter . . . . . . . 80-7
Replace Hydraulic Reservoir Breather Filter . . . . 80-8
Check Front and Rear Differential Oil
LevelIf Equipped with Standard Axle . . . . . 80-9
Check Front and Rear Differential Oil
LevelIf Equipped with Differential Lock
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10
Cleaning Fuel Tank Outlet Screen . . . . . . . . . . . 90-5

Bleeding Fuel System544G, 624G . . . . . . . . . 90-7
Bleeding Fuel System644G. . . . . . . . . . . . . . . 90-8
Adjusting Fuel Shut-Off Solenoid644G . . . . . . 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
TensionIf 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 AccumulatorIf
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Bleeding Brakes . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Checking Secondary Steering SystemIf
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 ORing 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

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
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
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 FreezeProtection Level . . . . 90-4
Do Not Service Injection Nozzles . . . . . . . . . . . . 90-5
Do Not Adjust Injection Pump. . . . . . . . . . . . . . . 90-5
Operational Checkout
Operational Checkout . . . . . . . . . . . . . . . . . . . . . 95-1
iii
PN=3
Contents
Page
Page
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
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-5
644G (Continued). . . . . . . . . . . . . . . . . . . . . . 95-5
Fuel Shut-off Solenoid Linkage Check
644G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-6
Front Axle Disconnect CheckIf 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 . . . . . . . . . . . . . . . . . .

Bucket Rollback Circuit Relief Valve Check . . .
Bucket Dump Circuit Relief Valve Pressure
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom and Bucket Cylinder Drift . . . . . . . . . . . .
Boom Down Check Valve Leakage Check . . . .
Pilot Controller Check. . . . . . . . . . . . . . . . . . . .
Return-To-Dig Check . . . . . . . . . . . . . . . . . . . .
Boom Height Kickout CheckIf Equipped . . . .
Pin Disconnect Cylinder Check (544G-TC
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ride Control Accumulator CheckIf
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering System Checks . . . . . . . . . . . . . . . . .
Steering Valve Check. . . . . . . . . . . . . . . . . . . .
Steering System Leakage Check . . . . . . . . . . .
Priority Valve Low Pressure Check. . . . . . . . . .
Priority Valve High Pressure Check . . . . . . . . .
Secondary Steering System CheckIf
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Steering System Primary Check
Valve Check. . . . . . . . . . . . . . . . . . . . . . . . .
Accessory Checks . . . . . . . . . . . . . . . . . . . . . .
Operating Lights Check . . . . . . . . . . . . . . . . . .
Work Light Check . . . . . . . . . . . . . . . . . . . . . . .
Brake Light Check . . . . . . . . . . . . . . . . . . . . . .
Horn Circuit Check . . . . . . . . . . . . . . . . . . . . . .
Windshield Washer and Wiper CheckIf
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . .
Defroster Blower Check . . . . . . . . . . . . . . . . . .
Heater/Air Conditioner Blower Check . . . . . . . .
Heater Functional Check . . . . . . . . . . . . . . . . .
Air Conditioner Functional Check . . . . . . . . . . .
Start Aid System Check . . . . . . . . . . . . . . . . . .
Cab Component and Vandal Protection
Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Door and Window Hold-Open Latch
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Door Release Button. . . . . . . . . . . . . . . . .
Cab Door Lock Check . . . . . . . . . . . . . . . . . . .
Dome Light Check . . . . . . . . . . . . . . . . . . . . . .
Cab Window Latch Check . . . . . . . . . . . . . . . .
Cab Door Window Check . . . . . . . . . . . . . . . . .
Steering Column Adjustment Check . . . . . . . . .
Seat And Seat Belt Check . . . . . . . . . . . . . . . .
Toolbox Door Check. . . . . . . . . . . . . . . . . . . . .
Air Intake Filter Door Check . . . . . . . . . . . . . . .
Load Center Door Check . . . . . . . . . . . . . . . . .
Engine Side Panels Check . . . . . . . . . . . . . . . .
Radiator Cap Access Door Check . . . . . . . . . .
Frame Locking Bar Check . . . . . . . . . . . . . . . .
95-19
95-19
95-19
95-19
95-20
95-20
95-20
95-21
95-21
95-21
95-22
95-22
95-22
95-23
95-23
95-24
95-24
95-25
95-25
95-25
95-26
95-26
95-27
95-27
95-28
95-28
95-28
95-29
95-29
95-29
95-30
95-30
95-30
95-31
95-31
95-31
95-32
95-32
95-33
95-33
95-33
95-34
95-34
iv
PN=4
Contents
Page
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) . . .
Record Engine Serial Number544G . . . . . . .
Record Transmission Serial Number . . . . . . . .
Record Hydraulic Pump Serial Number . . . . . .
Specifications
544G Specifications . . . . . . . . . . . . . .
Drain and Refill Capacities544G . . .
544G LL Specifications. . . . . . . . . . . .
544G LL Specifications. . . . . . . . . . . .
Drain and Refill Capacities544G LL
544G TC Specifications . . . . . . . . . . .
544G TC Specifications . . . . . . . . . . .
Drain and Refill Capacities544G TC
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
110-1
110-1
110-1
110-1
110-2
110-2
. 115-1
. 115-3
. 115-5
. 115-5
. 115-7
. 115-9
. 115-9
115-11
115-13
115-13
115-15
115-17
115-17
115-19
115-20
Crime Prevention Tips . . . . . . . . . . . . . . . . . . 120-1

Index
v
PN=5
TX,05,JC1054 1922JAN961/1
T100127
1921FEB96
Safety
051
PN=1
Safety
RECOGNIZE SAFETY INFORMATION
UN07DEC88
This is the safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.
T81389
Follow recommended precautions and safe operating

practices.
DX,ALERT
1903MAR931/1
UNDERSTAND SIGNAL WORDS
TS187
DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
1930SEP88
A signal wordDANGER, WARNING, or CAUTIONis

used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DX,SIGNAL 1903MAR931/1
Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
TS201
Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without
instruction.
UN23AUG88
FOLLOW SAFETY INSTRUCTIONS
Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair
the function and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your John Deere dealer.
DX,READ 1903MAR931/1
052
PN=2
Safety
AVOID INJURY FROM ROLLOVER

ACCIDENTS
-------------------------------WEAR YOUR SEAT BELT
-------------------------------DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINESERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
-------------------------------MACHINE WILL TIP OVER FASTER THAN
YOU CAN JUMP FREE
To avoid rollovers:
Be careful when operating on a slope.
Carry tools and loads close to the ground to aid visibility

and lower center of gravity.
Reduce speed before turning or swinging load.
T7242EA
Balance loads so weight is evenly distributed and load is

stable.
1922FEB90
Avoid sharp turns.
Know capacity of machine. Do not overload.

Be careful when operating at the edge of an excavation,
trench, or drop-off, and loading or unloading from a
trailer.
Read and understand the operating instructions in this
operators manual.
TX,05,DH1525 1921JUN911/1
053
PN=3
T7241AY
AVOID INJURY FROM BACKOVER

ACCIDENTS
-----------------------------------BEFORE MOVING MACHINE, BE SURE ALL
PERSONS ARE CLEAR OF AREA
-----------------------------------ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE HORN
OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE
-----------------------------------WHEN USING A SIGNAL PERSON, KEEP
PERSON IN VIEW AT ALL TIMES. BE SURE
SIGNAL PERSON IS CLEAR BEFORE
BACKING UP
UN21FEB90
Safety
To avoid backover accidents:

Always look around before you back up. Be sure that
everyone is in the clear.
Keep bystanders away from pivot area of an articulated
machine.
Keep reverse warning alarm in working condition, if
equipped.
Use a signal person when backing up if view is
obstructed. Always keep signal person in view.
Learn the meaning of all flags, signs, and markings used
on the job, and who has the responsibility for signaling.
Keep windows, mirrors, and lights clean and in good
condition.
Dust, heavy rain, fog, etc., can reduce visibility. As
visibility decreases, reduce speed and use proper
lighting.
operators manual.
TX,05,DH1573 1918MAR911/1
054
PN=4
T7241AZ
AVOID INJURY FROM ROLLAWAY

ACCIDENTS
-----------------------------------TO PREVENT ROLLAWAY, ALWAYS MAKE
SURE MACHINE IS PROPERLY SECURED
BEFORE LEAVING OPERATORS SEAT
-----------------------------------DEATH OR SERIOUS INJURY MAY RESULT
IF YOU ATTEMPT TO MOUNT OR STOP A
MOVING MACHINE
------------------------------------
UN21FEB90
Safety
To avoid rollaways:
Select level ground when possible to park machine.
Move transmission control lever to neutral "N", engage
neutral lock, and engage park brake.
Lower all equipment to ground.
Stop the engine.
Block all wheels if you must park on a grade. Position
machine to prevent rolling.
Park a reasonable distance from other machines.
operators manual.
TX,05,DH2478 1926SEP921/1
INSPECT MACHINE
T6607AQ
UN18OCT88
Inspect your machine carefully each day by walking

around it before you start it. (See Pre-Start Inspection
Chapter.)
T82,BHSA,CL 1914MAR901/1
055
PN=5
Safety
USE HANDHOLDS AND STEPS
When you get on and off the machine, always maintain a

three point contact with the steps and handrails, and face
the machine. Do not use the steering wheel or any
controls as handholds.
T6981AN
Never jump on or off the machine. Never mount or

dismount a moving machine.
UN15JUN89
Falling is one of the major causes of personal injury.
Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.
TX,05,DH553 1918MAR911/1
PREVENT MACHINE RUNAWAY
Never start engine while standing on ground. Start engine

only from operators seat with transmission control lever
locked in neutral and park brake engaged.
T6642EB
DO NOT start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.
UN20OCT88
Avoid possible injury or death from a runaway machine.
TX,05,DH2281 1906OCT921/1
USE SEAT BELT PROPERLY

Overturns may occur if proper operating instructions are
not followed.
TS175
UN23AUG88
Use your seat belt.
TX,05,JC1044 1912JAN961/1
056
PN=6
Safety
MAINTAIN SEAT BELT

It is important to use the seat belt on ROPS equipped
machines to minimize the chance of injury from an
accident such as an overturn. Keep the seat belt in good
condition.
The complete seat belt assembly should be replaced
after three years of usage, regardless of appearance.
Between replacement intervals:
Carefully examine buckle, webbing, and attaching
hardware.
Be sure that the retractor, if equipped, locks to prevent
belt extension after latching buckle.
Be sure that attaching hardware is in place. Tighten, if
necessary.
Replace the seat belt if it does not operate properly, or if it
is damaged, worn, or deteriorated.
TX,05,JC242 1903MAR951/1
SECONDARY EXITS
Machines equipped with cabs are equipped with
secondary exits. For additional secondary exit
information, see Windows in Operators Station, chapter
10 of this manual.
TX,05,JC1051 1918JAN961/1
057
PN=7
Safety
TRAVEL SAFELY
Know the location of bystanders before moving the
machine.
Use a signal person when moving the machine in

congested areas. Coordinate hand signals before starting
the machine.
T6964AD
UN20DEC88
Always keep the reverse warning alarm in working

condition. It warns people when the machine starts to
move in reverse.
TX,05,DH496 1902AUG891/1
DRIVE MACHINE SAFELY

Walk around machine to clear all persons from area of
operation and machine movement.
UN25OCT88
Always check area to rear before shifting to reverse.
T6582AS
Drive carefully in congested areas, over rough ground,

near ditches for excavations, and on slopes or curves.
Keep machine in gear when going down hills.
Use accessory lights and devices to warn operators of
other vehicles.
TX,05,DH1931 1921JUN911/1
058
PN=8
Safety
OPERATE MACHINE WITH CAUTION
Never lower a loaded bucket with the boom and bucket

control lever in the float position.
Increase the power gradually when pulling a heavy load or
when driving out of a ditch or excavation.
T6642EF
Keep loading area smooth.
UN18OCT88
Check location of cables, gas lines, and water mains

before digging.
TX,05,DH1932 1906JUN911/1
OPERATING ON SLOPES
Avoid sideslope travel whenever possible. Drive up slope
in forward and down in reverse. The danger of tipping is
always present.
In steep slope operation, do not allow engine to
overspeed. Select low gear speed before starting down
slope.
T7050AB
UN03AUG89
The grade of the slope you should attempt will be limited

by such factors as ground condition, and load being
handled.
TX,05,RR,171 1927APR891/1
059
PN=9
Safety
CARRYING LOADS
Do not start, stop, or turn quickly when transporting a

load.
Do not change forward or reverse directions quickly when
carrying a load.
T7050AA
Handle only those loads which are properly arranged. Do

not overload.
UN03AUG89
Carry loader bucket as low as possible for better stability

and visibility.
TX,05,RR,172 1903JUN921/1
AVOID POWER LINES
T6642EG
Never move any part of the machine or load closer to

electric line than 3 m (10 ft) plus twice the line insulator
length.
UN20JUN89
Serious injury or death can result from contact with

electric lines.
02T,05,J18 1906JUN911/1
BEWARE OF EXHAUST FUMES
T6458AO
If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
UN18OCT88
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
TX,DH,2 1909FEB891/1
0510
PN=10
Safety
KEEP RIDERS OFF MACHINE

Only allow the operator on the machine. Keep riders off.
TS290
UN23AUG88
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off of the
machine. Riders also obstruct the operators view
resulting in the machine being operated in an unsafe
manner.
DX,RIDER 1903MAR931/1
HANDLE FUEL SAFELYAVOID FIRES
Prevent fires by keeping machine clean of accumulated

trash, grease, and debris. Always clean up spilled fuel.
TS202
Always stop engine before refueling machine. Fill fuel tank

outdoors.
UN23AUG88
Handle fuel with care: it is highly flammable. Do not refuel

the machine while smoking or when near open flame or
sparks.
DX,FIRE1 1903MAR931/1
PREPARE FOR EMERGENCIES

Be prepared if a fire starts.
TS291
Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.
UN23AUG88
Keep a first aid kit and fire extinguisher handy.
DX,FIRE2 1903MAR931/1
0511
PN=11
Safety
HANDLE STARTING FLUID SAFELY
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
T6464AV
Remove container from machine if engine does not need

starting fluid.
UN18OCT88
Starting fluid is highly flammable.
To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and
store in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
TX,05,FF2281 1922FEB911/1
CLEAN TRASH FROM MACHINE

Keep engine compartment, radiator, batteries, hydraulic
lines, fuel tank, and operators station clean.
Open access door(s) to cool the engine faster, and clean

engine compartment.
T6669AG
UN18OCT88
Temperature in engine compartment may go up

immediately after engine is stopped. BE ON GUARD
FOR FIRES DURING THIS PERIOD.
02T,05,J33 1914MAR901/1
PROTECT AGAINST FLYING DEBRIS
T6642DK
UN18OCT88
When you drive connecting pins in or out, guard against

injury from flying pieces of metal or debris; wear goggles
or safety glasses.
02T,05,J45 1930MAY901/1
0512
PN=12
Safety
WEAR PROTECTIVE CLOTHING
TS206
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.
UN23AUG88
Wear close fitting clothing and safety equipment

appropriate to the job.
DX,WEAR2 1903MAR931/1
PROTECT AGAINST NOISE
TS207
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
UN23AUG88
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
DX,NOISE 1903MAR931/1
HANDLE CHEMICAL PRODUCTS SAFELY
TS1132
A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
UN26NOV90
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.
Check the MSDS before you start any job using a

hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
See your authorized dealer for MSDSs on chemical
products used with your machine.
TX,05,DH2500 1902OCT921/1
0513
PN=13
Safety
USE SAFETY LIGHTS AND DEVICES
UN10FEB89
Operators of machines that travel below normal highway

speeds should take special precautions to avoid collision
with other vehicles.
Install and use all safety lights and devices necessary to

assure safe operation and local compliance. Keep these
safety items in good condition. Replace missing or
damaged parts immediately.
N36564
Before driving on public roads, check state and local laws

that may apply to tractors, self-propelled machines, and
towed equipment. Additional lights, mirrors, SMV
emblems, or reflectors may be required.
ALights
BSlow Moving Vehicle Emblem
CReflector Tape
DReflectors
TX,05,DH1729 1926JAN911/1
KEEP ROPS INSTALLED PROPERLY

A damaged roll-over protective structure (ROPS) should
be replaced, not reused.
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting.
If ROPS was loosened or removed for any reason, inspect
it carefully before operating the machine again.
To maintain the ROPS:
Replace missing hardware using correct grade
hardware.
Check hardware torque.
Check isolation mounts for damage, looseness or
wear; replace them if necessary.
Check ROPS for cracks or physical damage.
TX,05,DH1846 1914MAY911/1
0514
PN=14
Safety
KEEP THE OPERATOR PROTECTIVE

STRUCTURE (OPS) IN PLACE
It is important to keep the operator protective structure
(OPS) in place (doors, screens, windows, windshield,
etc.) to minimize hazards from whipping or intruding
objects. To maintain OPS protection, replace damaged
parts immediately.
Replace 3piece hard-coated polycarbonate windshield
with only Lexan Margard 5000 or equivalent.
The protection offered by OPS will be impaired if OPS is
subjected to structural damage, is involved in an overturn
incident, or is altered by welding, bending, drilling, or
cutting. Damaged OPS components should be replaced,
not reused.
Keep all bolts and attaching hardware tight.
TX,05,JC1068 1921FEB961/1
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious injury.
T7447AO
1922APR91
Before performing any work on the machine, attach a "DO

NOT OPERATE" tag to the steering wheel.
TX,05,DH1820 1914MAY911/1
0515
PN=15
Safety
PRACTICE SAFE MAINTENANCE

If maintenance procedure must be performed with engine
running, DO NOT leave machine unattended.
Securely support any machine elements that must be
raised for service work.
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate or service machine while it is moving.
Keep hands, feet, and clothing from power-driven parts.
Before servicing machine and before leaving the
operators seat:
1. Park machine on a level surface.
3. Move transmission control lever to neutral "N".

Engage neutral lock.
CAUTION: Prevent possible injury from

unexpected machine movement. Never rely on
transmission control lever alone to keep
machine from moving. Machine can
unexpectedly roll or move under power,
resulting in death or serious injury. Always
engage park brake to hold machine.
TS218
UN23AUG88
2. Lower all equipment to ground.
4. Engage park brake.

5. Install the frame locking bar before working in the
frame hinge pivot area.
6. Turn key switch to STOP.
7. Turn battery disconnect switch OFF, if equipped.
TX,05,DH2122 1931JUL921/2
0516
PN=16
Safety
8. Allow engine to cool.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
Disconnect battery ground cable (-) before making
adjustments on electrical systems or welding on
machine.
TX,05,DH2122 1931JUL922/2
SUPPORT MACHINE PROPERLY
TS229
Do not support the machine on cinder blocks, hollow tiles,

or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
UN23AUG88
Always lower the attachment or implement to the ground

before you work on the machine. If you must work on a
lifted machine or attachment, securely support the
machine or attachment.
DX,LOWER 1904JUN901/1
0517
PN=17
Safety
REMOVE PAINT BEFORE WELDING OR

HEATING
Avoid potentially toxic fumes and dust.
UN23AUG88
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
TS220
Do all work outside or in a well ventilated area. Dispose of

paint and solvent properly.
Remove paint before welding or heating:
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper
with soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
DX,PAINT 1903MAR931/1
AVOID HEATING NEAR PRESSURIZED FLUID

LINES
TS953
UN15MAY90
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
accidentally cut when heat goes beyond the immediate
flame area.
DX,TORCH
1903MAR931/1
0518
PN=18
Safety
AVOID HIGH-PRESSURE FLUIDS
Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.
X9811
Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
UN23AUG88
Escaping fluid under pressure can penetrate the skin

causing serious injury.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable
medical source. Such information is available from
Deere & Company Medical Department in Moline, Illinois,
U.S.A.
DX,FLUID 1903MAR931/1
CLEAN THE MACHINE REGULARLY
T6642EJ
High pressure washing [greater than 1379 kpa (13.8 bar)

(200 psi)] can damage freshly painted finishes. Paint
should be allowed to air dry for 30 days minimum after
receipt of machine before cleaning with high pressure.
Use low pressure wash operations until 30 days have
elapsed.
UN18OCT88
Remove any grease, oil, fuel, or debris build-up to avoid

possible injury or machine damage.
Do not spray oil cooler fins at an angle. Fins may bend.
TX,05,FF2787 1927JUL941/1
0519
PN=19
Safety
SERVICE COOLING SYSTEM SAFELY
TS281
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
UN23AUG88
Explosive release of fluids from pressurized cooling

system can cause serious burns.
DX,RCAP 1904JUN901/1
STORE ATTACHMENTS SAFELY
TS219
Securely store attachments and implements to prevent

falling. Keep playing children and bystanders away from
storage area.
UN23AUG88
Stored attachments such as dual wheels, cage wheels,

and loaders can fall and cause serious injury or death.
DX,STORE 1903MAR931/1
DISPOSE OF WASTE PROPERLY
Do not pour waste onto the ground, down a drain, or into

any water source.
TS1133
Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
UN26NOV90
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with your machine include such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
Air conditioning refrigerants escaping into the air can

damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
TX,05,DH2502 1926AUG921/1
0520
PN=20
T7967AK
1922MAR93
T7829AA
UN31AUG92
Safety Signs
TX,06,JC1102 1918MAR961/12
061
PN=21
T7773CV
UN31AUG92
Safety Signs
T7939AI
1922MAR93
A-Warning Decal
TX,06,JC1102 1918MAR962/12
062
PN=22
T100704
T8417AD
1909FEB95
UN22MAR96
Safety Signs
TX,06,JC1102 1918MAR963/12
063
PN=23
T6976AE
UN30JAN89
T7593AC
1930AUG91
Safety Signs
TX,06,JC1102 1918MAR964/12
064
PN=24
UN15JUN93
T8029AF
T7939AK
1922MAR93
Safety Signs
TX,06,JC1102 1918MAR965/12
065
PN=25
T7934AM
1901FEB93
Safety Signs
T100703
UN22MAR96
A-Warning Decal
Left Side Shown
TX,06,JC1102 1918MAR966/12
066
PN=26
T8029AQ
UN21JUN93
T8029AR
1916JUN93
Safety Signs
TX,06,JC1102 1918MAR967/12
067
PN=27
T7829AT
1917SEP92
T7853AF
UN08OCT92
Safety Signs
T8029AH
UN15JUN93
A-Warning Decal, If Equipped
Right Side of Machine

TX,06,JC1102 1918MAR968/12
068
PN=28
T7773AZ
T7916AC
1906JAN93
UN10AUG92
Safety Signs
UN10AUG92
T7773CA
T7748CU
1914OCT92
TX,06,JC1102 1918MAR969/12
TX,06,JC1102 1918MAR9610/12
069
PN=29
T100702
T7829AQ
1931AUG92
UN22MAR96
Safety Signs
TX,06,JC1102 1918MAR9611/12
0610
PN=30
T101279
1914MAY96
T7829AU
1917SEP92
T7839BB
UN17SEP92
Safety Signs
Located on top of radiator cap
TX,06,JC1102 1918MAR9612/12
0611
PN=31
Operators Station
T7773AP
UN11JUN92
GAUGES, INDICATORS, SWITCHES, AND ACCESSORIES
ASELECT Switch
BDigital Display
CEngine Coolant
Temperature Gauge
DFuel Gauge
ETransmission Oil
Temperature Gauge
FHydraulic Oil Filter
Restriction Indicator
GTransmission Oil
Pressure IndicatorIf
Equipped
HEngine Coolant Level

Indicator
IEngine Air Filter
Restriction Indicator
JEngine Alternator
Voltage Indicator
KEngine Oil Pressure
Indicator
LSTOP Indicator
MService Required
Indicator
NLeft Turn Signal

Indicator
OSteering Pressure
IndicatorIf Equipped
With Secondary
Steering
PEther Injection Indicator
QFasten Seat Belt
Indicator
RPark Brake Indicator
SBrake Pressure
Indicator
TRight Turn Signal
Indicator
TX,10,JC1046 1916JAN961/2
101
PN=32
T8375AN
UN02DEC94
Operators Station
AFront Wiper Switch

BDrive Light Switch
CWork Light Switch
DClutch Cut-off Switch
EWarning Light Switch
FBoom Down Switch
GRear Wiper Switch

HAir Conditioner Control
SwitchIf Equipped
IPin Disconnect Switch
544G TC
JRide Control SwitchIf

Equipped
KBlower Knob
LAir Conditioner
Defroster Blower Knob
MTemperature Control
Knob
TX,10,JC1046 1916JAN962/2
102
PN=33
Operators Station
CAUTION: Prevent possible injury, or machine

damage. If STOP indicator light flashes and
alarm sounds, stop immediately and investigate
cause of problem.
The STOP indicator light flashes and alarm sounds when:
T7673AM
Engine oil pressure is low. STOP ENGINE

IMMEDIATELY.
UN06JAN92
STOP INDICATOR AND ALARM
Engine coolant temperature is excessively high. Stop

machine and allow engine to cool. Shut off engine and
take corrective action.
Engine coolant level is low. Stop machine and allow
engine to cool. Shut off engine and take corrective action.
Transmission oil temperature is excessively high. Stop
machine and take corrective action.
Transmission oil pressure is low. Stop machine and take
corrective action.
Transmission is shifted into gear with park brake engaged.
Disengage park brake.
Brake pressure is low. Stop machine and take corrective
action.
Steering system pressure is low, and secondary steering
is activated. Stop machine and take corrective action.
If indicators do not function correctly, see Troubleshooting
chapter.
TX,10,DH2165 1902OCT921/1
103
PN=34
Operators Station
SERVICE REQUIRED INDICATOR (YELLOW)
UN18OCT88
If service required indicator lights, a problem is

developing. It is not necessary to stop the engine
immediately, but the cause should be investigated as
soon as possible.
The service required indicator lights when:
T6201BL
Alternator voltage is low.

Engine air filter is restricted.
Hydraulic oil filter is restricted.
NOTE: Cold oil may cause hydraulic oil filter restriction

indicator to light temporarily.
TX,10,DH2282 1912MAY931/1
DIGITAL DISPLAY
T7747AT
Press the SELECT switch to change information on the

digital display. Information sequences from the
tachometer, to the speedometer (in mph), to the
speedometer (in km/h), to the hourmeter, to the voltmeter,
and then back to the tachometer. If the switch is pressed
continuously, the information will sequence every 4
seconds.
UN19MAY92
Engine running:
Engine not running, key switch in OFF position:

Press the SELECT switch to show hour meter information,
engine coolant temperature information, fuel tank level
information, and transmission oil temperature information
on the digital display. If switch is held down for more than
4 seconds, the hourmeter will change to display battery
voltage.
TX,10,DH2347 1919MAY931/1
104
PN=35
Operators Station
ENGINE COOLANT TEMPERATURE GAUGE
T7747AU
All the arrows will flash, STOP indicator light will flash,
and audible alarm will sound when temperature reaches
above 110C (230F). If all 9 arrows are ON but not
flashing, system has a malfunction. Stop machine and
allow engine to cool. Shut off engine and take corrective
action.
UN19MAY92
The first arrow will flash until engine temperature warms

to 38C (100F).
TX,10,JC1063 1914FEB961/1
FUEL GAUGE
First arrow will flash if fuel is low or system has a
malfunction.
T7747AV
UN19MAY92
Always fill fuel tank at the end of the day to eliminate

condensation in fuel tank.
TX,10,DH2164 1929NOV941/1
TRANSMISSION OIL TEMPERATURE GAUGE
T7747AW
All arrows will flash, STOP indicator light will flash, and
audible alarm will sound when temperature reaches
above 133C (271F), If all 9 arrows are ON but not
flashing, system has a malfunction. Stop machine and
action.
UN19MAY92
Audible alarm will sound once when temperature first

reaches 127-132C (260-270F).
TX,10,JC245 1929NOV941/1
105
PN=36
Operators Station
Indicator light will light, STOP indicator will flash, and

alarm will sound when engine oil pressure is low. Stop
machine. STOP ENGINE IMMEDIATELY.
NOTE: Cold oil or extreme off level operation may cause

indicator to light.
T7747AA
IMPORTANT: Prevent possible engine damage. If

engine oil pressure indicator light
comes on while operating, stop
machine. STOP ENGINE IMMEDIATELY.
UN19MAY92
ENGINE OIL PRESSURE INDICATOR
TX,10,DH2153 1929NOV941/1
ALTERNATOR VOLTAGE INDICATOR
T6201BD
UN18OCT88
Indicator light will light and service required indicator light

will light when alternator output is low. Check battery
charge by selecting battery voltage on digital display.
TX,10,DH2549 1902OCT921/1
T7747AB
Indicator will light and service required indicator will light

when air filter elements are restricted. Clean or change
filter elements.
UN19MAY92
ENGINE AIR FILTER RESTRICTION

INDICATOR
TX,10,DH2154 1908FEB931/1
106
PN=37
Operators Station
ENGINE COOLANT LEVEL INDICATOR
T7747AC
Indicator light will light, STOP indicator light will flash, and
alarm will sound when engine coolant level is low. Stop
machine and allow engine to cool. Shut off engine and
take corrective action.
UN19MAY92
IMPORTANT: Prevent machine damage. Low coolant

will result in engine or radiator
damage.
TX,10,DH2152 1902OCT921/1
T7747AD
Indicator light will light and STOP indicator light will light
when transmission oil pressure is low. Stop machine and
action.
UN19MAY92
TRANSMISSION OIL PRESSURE

INDICATORIF EQUIPPED
TX,10,JC1048 1916JAN961/1
Indicator light will light and service required indicator light

will light when hydraulic filter element is restricted.
NOTE: Cold oil may cause hydraulic oil filter restriction

indicator light to light until oil is warm.
T7747AE
IMPORTANT: Prevent possible hydraulic pump

damage. Change hydraulic oil filter as
soon as possible when a problem
occurs.
UN19MAY92
HYDRAULIC OIL FILTER RESTRICTION

INDICATOR
TX,10,DH2158 1913SEP941/1
107
PN=38
Operators Station
RIGHT TURN SIGNAL INDICATOR
T6201BK
UN18OCT88
Indicator light will light when right turn signal switch is

engaged.
TX,DH,39
1912APR931/1
BRAKE OIL PRESSURE INDICATOR
Indicator light will light, STOP indicator light will flash, and
alarm will sound when brake oil pressure is low, or brake
accumulator has lost its charge. Stop machine
immediately and engage park brake. Take corrective
action.
UN19MAY92
CAUTION: Prevent possible injury or machine

damage. If brake pressure indicator light comes
on while operating, stop machine immediately.
T7747AF
TX,10,DH2157 1905OCT921/1
PARK BRAKE INDICATOR
T7747AG
If park brake is engaged and transmission control lever is

in forward "F" or reverse "R", the STOP indicator light will
flash and alarm will sound. Disengage park brake.
UN19MAY92
Indicator light will light when park brake is engaged and

transmission control lever is in neutral "N".
TX,10,DH2156 1905OCT921/1
108
PN=39
Operators Station
FASTEN SEAT BELT INDICATOR
T7747AH
UN19MAY92
Indicator light will light for the first 5 seconds after the
engine is started to warn the operator to fasten seat belt.
TX,10,DH2344 1931JUL921/1
ETHER INJECTION INDICATOR
T7747AI
UN19MAY92
Indicator light will light when the ether injection button is

pressed by the operator.
TX,10,DH2345 1931JUL921/1
Indicator light will light, STOP indicator light will flash and
alarm will sound when secondary steering system is
activated. Stop machine immediately and take corrective
action. The secondary steering system is not intended for
continuous use.
T7747AJ
IMPORTANT: Prevent possible damage to secondary

steering system. Stop machine
immediately if secondary steering
indicator light and alarm come on while
operating. THE SECONDARY STEERING
SYSTEM IS NOT INTENDED FOR
CONTINUOUS USE.
UN19MAY92
STEERING PRESSURE INDICATORIF

EQUIPPED
TX,10,DH2159 1902OCT921/1
109
PN=40
Operators Station
LEFT TURN SIGNAL INDICATOR
T6201BG
UN18OCT88
Indicator light will light when left turn signal switch is

engaged.
TX,DH,38
1912APR931/1
T7747BO
UN11JUN92
LEVERS
ALoader Control LeverOne

Lever Design
T7747BN
UN11JUN92
TX,10,DH2133 1931JUL921/3
ALoader Control LeversTwo

Lever Design
TX,10,DH2133 1931JUL922/3
1010
PN=41
T7747AM
UN19MAY92
Operators Station
ATransmission Control Lever
TX,10,DH2133 1931JUL923/3
T7747AN
UN19MAY92
FRONT AXLE DISCONNECT LEVERIF

EQUIPPED
AFront Axle Disconnect Lever
TX,10,DH2137 1931JUL921/1
1011
PN=42
Operators Station
T7747AO
UN19MAY92
PEDALS
AAccelerator Pedal
BRight Brake Pedal
CSteering Column Tilt Pedal
DLeft Brake/Clutch Cut-off Pedal
EDifferential Lock PedalIf
Equipped
TX,10,DH2136 1907OCT921/1
T7773AG
UN11JUN92
PARK BRAKE SWITCH
APark Brake Switch
TX,10,DH2285 1918SEP921/1
1012
PN=43
Operators Station
T7747BI
UN19MAY92
NEUTRAL LOCK
ANeutral Lock
TX,10,DH2138 1902OCT921/1
T7747BJ
UN19MAY92
HORN BUTTON
AHorn Button
TX,10,DH2279 1918SEP921/1
1013
PN=44
Operators Station
T7747BK
UN19MAY92
TURN SIGNAL SWITCH
ATurn Signal Switch
TX,10,DH2280 1931JUL921/1
DOME LIGHT AND SWIVEL LIGHTIF

EQUIPPED
Push switch (A) to light dome light.
T7773AU
UN10AUG92
Push switch (B) to light swivel light.
ADome Light
BSwivel Light
TX,10,DH2139 1931JUL921/1
VANDAL SHIELDIF EQUIPPED
T7853AG
UN08OCT92
A vandal shield (A) is available for canopy equipped

machines. Shield covers the side instrument panel and
locks with the ignition key.
TX,10,DH2140 1902OCT921/1
1014
PN=45
Operators Station
OPERATING WINDSHIELD WIPERS AND

WASHERSIF EQUIPPED
UN02DEC94
Turn front windshield wiper knob (A) clockwise to first

position for low speed. Turn windshield wiper knob
clockwise to second position for high speed.
Push windshield wiper knob in to wash window.
T8375AO
Press rear windshield wiper switch (B) to operate rear

wiper.
Hold switch down to wash window
AFront Wiper and Washer Switch
BRear Wiper and Washer Switch
TX,10,JC271 1929NOV941/1
ADJUSTING STEERING WHEEL TILT
T7747BH
UN19MAY92
Depress pedal (A) to adjust steering column to desired tilt.

Release pedal.
TX,10,DH2143 1931JUL921/1
OPENING SIDE WINDOW
Pull in (B) on latch handle, positioning inner notch over

catch, to close window.
Position outer notch over catch to hold window slightly
open.
T6783AC
Push out (A) on latch handle to open window.
UN19OCT88
NOTE: The side window can be used as a secondary

exit.
TX,10,JC1052 1918JAN961/1
1015
PN=46
Operators Station
OPENING SLIDING SIDE WINDOWIF

EQUIPPED
T6603AQ1
UN20OCT88
Squeeze latch tabs (A) together and slide window down to

desired position. Release tabs.
02T,10,MM27 1931JUL921/1
CAB DOOR RELEASE
T8029AI
UN15JUN93
Push lever (A) to release cab door.
TX,10,DH2960 1916JUN931/2
T8029AJ
UN15JUN93
Push button (B) to release opened cab door from inside

the cab or on the ground.
TX,10,DH2960 1916JUN932/2
1016
PN=47
Operators Station
OPERATING LIGHTS
Press light switch (A). Lights (E and I) will come on.
UN02DEC94
Press light switch (B). Lights (D and G) will come on.
T8373BD
Press turn signal switch to left or right position. One turn

indicator light on monitor, if equipped, will be on. One
front amber light (F) and one rear amber light (H) will be
flashing.
T7773AY
UN10AUG92
T7773AX
UN10AUG92
Press hazard light switch (C). Both front amber lights (F)
and both rear amber lights (H) will be flashing.
AOperating Light Switch

BWork Light Switch
CHazard Light Switch
DFront Work LightsIf Equipped
EHeadlights
FTurn Signals/Hazard Lights
GRear Work LightsIf Equipped
HTurn Signals/Hazard Lights
ITail Lights/Brake Lights
TX,10,DH2144 1929NOV941/1
1017
PN=48
Operators Station
HEATING AND AIR CONDITIONING

CONTROLS
NOTE: Open valve (E) before operating heater.
UN02DEC94
Turn temperature control knob (A) clockwise to increase

temperature.
T8373AY
Turn defroster blower knob (B) clockwise to increase

blower speed. (Knob also turns on heater blower.) Blower
has three speeds.
IMPORTANT: Before you start air conditioner first
time in the season, check filters and
condenser. Clean them if necessary.
Check refrigerant level. (See
Maintenance chapter.)
T100706
UN22MAR96
Press air conditioning switch (D) and turn blower knob (C)
clockwise to increase blower speed in rear vents to
operate air conditioning. Blower has three speeds.
544G Shown
ATemperature Control Knob
BDefroster Blower Knob
CBlower Knob
DAir Conditioning Switch
EHeater Valve
TX,10,JC1103 1918MAR961/1
1018
PN=49
Operators Station
ADJUSTING SUSPENSION SEAT
CAUTION: You can lose control of machine

and be injured if seat is loose. Be sure seat is
properly locked in position before operating
the machine.
Suspension seat is equipped with a weight adjustment

feature of 50130 kg (110285 lb). Turn knob (F) to
adjust seat to weight of the operator. Weight is
displayed in window (E). Turn knob clockwise for a
heavier operator and counterclockwise for a lighter
operator.
Turn knob (A) to make lumbar adjustment. Turn knob
counterclockwise to move backrest cushion forward
against operators back. Turn knob clockwise to move
lower cushion forward against operators back.
UN31AUG92
Turn knob (B) clockwise to raise tilt of armrest. Turn

knob counterclockwise to lower tilt of armrest.
T7829AP
Lift lever (C) to tilt backrest cushion forward or

rearward. Keep weight off seat when making this
adjustment. Release lever to lock in place.
Lift lever (D) to move seat forward or rearward.
Release lever and slide seat to lock in place.
CAUTION: Seat can move rapidly and may

cause an injury. DO NOT put your full weight on
seat while adjusting height.
ALumbar Depth Adjustment Knob

BArmrest Tilt Adjustment Knob
CBackrest Tilt Adjustment Knob
DFore-Aft Adjustment Lever
EWindow
FWeight Adjustment Knob
TX,10,JC246 1929NOV941/2
T6782AF
UN19OCT88
To raise seat, stand over seat, grasp at bottom edge of

seat cushion, and slowly lift; each click is a position. To
lower seat, lift as high as possible and release. Seat will
return to lowest position.
TX,10,JC246 1929NOV942/2
1019
PN=50
Operators Station
T8415AA
UN09FEB95
SEAT BELT
Seat belt and mounting hardware must be inspected

for wear or damage before operating the machine.
Replace the belt or mounting hardware if worn or
damaged.
Replace the complete seat belt assembly every three

years regardless of appearance. A date label, to
determine the age of the belt, is attached to each belt.
MODTX10DH3548 1907FEB951/1
STORAGE COMPARTMENT
T8029AK
UN15JUN93
Store operators manual and tools in storage compartment

(A) (located under seat). Door can be locked with the
ignition key.
TX,10,DH2961 1918JUN931/1
1020
PN=51
Break-in
ENGINE BREAK-IN OIL
New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL. During the break-in period, add
John Deere ENGINE BREAK-IN OIL as needed to
maintain the specified oil level.
Change the oil and filter after the first 100 hours of
operation of a new or rebuilt engine.
After engine overhaul, fill the engine with John Deere
ENGINE BREAK-IN OIL.
If John Deere ENGINE BREAK-IN OIL is not available,
use a diesel engine oil with oil viscosity based on the
expected air temperature range, and meeting one of the
following, during the first 100 hours of operation:
API Service Classification CE
CCMC Specification D4
After the break-in period, use John DeerePLUS-50 oil
or other diesel engine oil as recommended in this manual.
IMPORTANT: Do not use John Deere PLUS-50 oil or
engine oils meeting API CG4, API CF4,
or CCMC D5 performance levels during
the first 100 hours of operation of a
new or rebuilt engine. These oils will
not allow the engine to break-in
properly.
TX,15,JC1131 1921MAY961/1
EVERY 10 HOURS OR DAILY

1. Perform 10 hour or daily service. (See Maintenance
Every 10 Hours or Daily chapter.)
2. Watch for fluid leaks.
3. Lubricate working tool pivots every 10 hours for first
100 hours and when working in mud and water.
TX,15,DH1800 1906JUN911/1
151
PN=52
Break-in
AFTER FIRST 10 AND FIRST 50 HOURS

Tighten wheel retainer cap screws to 542 Nm (400 lb-ft).
TX,15,DH1828 1916JUN931/1
AFTER THE FIRST 100 HOURS

1. Check hardware torque. (See Hardware Torque
Specifications in Maintenance chapter.)
2. Perform 100 hours service. (See MaintenanceEvery
100 Hours chapter.)
3. Change engine oil and filter. (See Maintenance
Every 250 Hours chapter.)
4. Change hydraulic reservoir return filter. (See
MaintenanceEvery 500 Hours chapter.)
5. Change transmission oil and filter. (See
MaintenanceEvery 1000 Hours chapter.)
6. Change differential oil. (See MaintenanceEvery
3000 Hours chapter.)
7. Change differential lock return filter(s)if equipped.
(See MaintenanceEvery 3000 Hours chapter.)
TX,15,DH2147 1916JUN931/1
152
PN=53
Pre-Start Inspection
INSPECT MACHINE DAILY BEFORE
STARTING
Do periodic service checks in the MaintenanceEvery 10
Hours or Daily chapter.
A-Check wheels (front and rear) for loose or missing
hardware.
B-Clean operators station.
C-Check air inlet cover.
D-Clean radiator.
E-Check fuel level.
F-Check tires (front and rear).
ELECTRICAL SYSTEM: Check for worn or frayed wires
and loose or corroded connections.
BOOM, BUCKET, SHEET METAL: Check for bent,
broken, loose, or missing parts.
HARDWARE: Check for loose or missing parts.
LUBRICATION: Check lubrication points shown on

Periodic Maintenance Chart.
PROTECTIVE DEVICES: Check guards, shields, ROPS,
covers, seat belt.
T8374AB
HYDRAULIC SYSTEM: Check for leaks, missing or loose

clamps, kinked hoses, and lines or hoses that rub against
each other or other parts.
UN02DEC94
PARK BRAKE: Check for correct operation.
SAFETY: Walk around machine to clear all persons from

machine area.
TX,20,JC273 1929NOV941/1
201
PN=54

CHECK INSTRUMENTS BEFORE STARTING
Turn key switch clockwise to ON position.
All indicator lights must light. If any indicator light fails to
light, the bulb may be burned out. If bulb is not burned
out, but indicator light still fails to light, see your
authorized dealer.
TX,25,DH2148 1922JUN931/1
BRAKE PRESSURE INDICATOR
T7739AJ
UN30JUL92
The brake pressure indicator light (A), STOP indicator

light (B), and audible alarm may come on during initial
start-up, but must be off during normal operation. DO
NOT operate machine if the lights remain on. See your
authorized dealer.
TX,25,DH2149 1922JUN931/1
STARTING THE ENGINE
DO NOT start engine by shorting across starter

terminals. Machine will start in gear if normal
circuitry is bypassed.
NEVER start engine while standing on ground.
Start engine only from operators seat, with
transmission control lever in neutral "N".
Engage park brake.
UN11JAN89
CAUTION: Avoid possible injury or death from a

runaway machine.
TS177
Use of seat belt with roll-over protective

structure (ROPS) is recommended under all
operating conditions.
1. Fasten seat belt.
2. Sound the horn.
TX,25,DH2284 1931JUL921/3
251
PN=55
T7747BR
UN19MAY92
3. Move transmission control lever (A) to neutral "N".

Engage neutral lock (B).
TX,25,DH2284 1931JUL922/3
252
PN=56

4. Hold accelerator pedal (C) down 1/3 of the way to the
floor.
T7747BU
IMPORTANT: Never operate starter motor for more

than 20 seconds at a time. If engine
fails to start after two or three tries,
return key switch to STOP position.
Wait for about 2 minutes, then try again.
UN19MAY92
5. Turn key switch to ON position. Push horn button to

sound horn.
After a false start, DO NOT turn key

switch until engine stops or starter
may be damaged.
Engine will not start by towing or
pushing. Permanent damage to
transmission will result.
6. Turn key switch to START position. DO NOT crank
engine more than 20 seconds. Wait 2 minutes before
trying again. Release key when engine starts.
IMPORTANT: If STOP indicator light does not go out
within 10 seconds after starting engine,
STOP THE ENGINE. Find and correct
the cause.
7. Operate machine at less than normal loads and at slow
idle speed until engine warms up.
IMPORTANT: If engine stops when operating under
load, remove load. Restart engine
immediately. Run 30 seconds at 1/2
speed before adding load.
TX,25,DH2284 1931JUL923/3
253
PN=57
STARTING FLUIDIF EQUIPPED (COLD

WEATHER STARTING AID)

exploding container. Starting fluid is highly
flammable. Keep container away from heat,
sparks, and open flame. Contents are
pressurized. DO NOT puncture or incinerate
container. Remove container from machine if
engine does not need starting fluid.
TS281
UN23AUG88
USE STARTING FLUID
IMPORTANT: Prevent damage to engine. Use starting

aid when temperatures are below 4C
(40F) and only when engine is COLD.
1. Turn key switch clockwise to START position.
TX,25,JC1155 1903JUN961/2
254
PN=58
REPLACING STARTING AID CAN
T7747BT
2. After one or two revolutions of engine crankshaft, press

starting aid button (A) at short intervals. Crank engine
for 20 seconds maximum, then allow 2 minutes
between cranking periods.
UN19MAY92
IMPORTANT: Excess starting fluid could damage

engine; press starting aid button only
when engine is cold and cranking.
Starting aid fluid is being injected into
engine as long as you press button.
1. Turn container (B) counterclockwise to remove the

container and starting aid can.
2. Remove safety cap and spray button from new can.
4. Turn container clockwise in starting aid base (C) to

install starting aid can.
OPERATING MACHINE WITHOUT STARTING AID CAN
INSTALLED
T7527EF
UN01AUG91
3. Place new can in container.
IMPORTANT: Protect starting aid components from

possible damage. Install the starting
aid can container upside down.
Remove container from base, turn upside down, and
reinstall.
TX,25,JC1155 1903JUN962/2
USING COOLANT HEATERIF EQUIPPED
CAUTION: Prevent possible injury from fire

from an overheated electrical cord. Use a
heavy-duty, grounded cord to connect heater to
electrical power.
Connect the coolant heater to 115-volt electrical power 10

hours before you start the engine.
T82,25,C53 1903DEC911/1
255
PN=59
USING BOOSTER BATTERIES12 VOLT

SYSTEM
Before boost starting, machine must be properly shut
down and secured to prevent unexpected machine
movement when engine starts.
CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep
flames or sparks away from the battery area.
Make sure the batteries are charged in a well
ventilated area.
IMPORTANT: The machine electrical system is a 12volt negative (-) ground. Use only 12volt booster batteries.
UN24OCT91
NOTE: Machine can be equipped with one or two 12-volt

batteries.
T6508AE1
2. Connect booster batteries as shown. Make ground

connection to frame last.
3. Turn battery disconnect switch ON, if equipped.
T6713AI1
UN24OCT91
AMachine Battery (12-volt)

BBooster Battery (12-volt)
TX,25,DH2166 1912SEP921/1
256
PN=60
CHECK INSTRUMENTS AFTER STARTING
CAUTION: Prevent possible injury, or machine

damage. If STOP indicator light does not go
out within 10 seconds after starting engine,
STOP THE ENGINE. Find and correct the cause.
Cold oil may cause hydraulic oil filter restriction indicator

light to come on temporarily.
Turn signal and park brake lights will come on if the
function is engaged.
Engine coolant temperature gauge will flash until
temperature reaches 38C (100F).
Fuel gauge first arrow will flash if fuel is low.
TX,25,DH2550 1912MAY931/1
WARM-UP
Operate machine at less-than-normal loads and speeds
for first few minutes until temperatures and pressures
reach normal operating range.
TX,25,JC247 1929NOV941/1
257
PN=61
COLD WEATHER WARM-UP

IMPORTANT: If hydraulic oil is cold, hydraulic
functions move slowly. Do not attempt
normal loader operation until hydraulic
functions move at close-to-normal
cycle times.
1. Run engine at 1/2 speed for 5 minutes.
2. Cycle boom and bucket functions until functions move
at normal speed.
TX,DH,40 1917JUN911/1
STOPPING THE ENGINE

IMPORTANT: Prevent possible engine damage. If
engine stops when operating under
load, remove load. Restart engine
immediately. Run 30 seconds at 1/2
speed before adding load.
1. Park machine on level surface.
2. Lower bucket to ground.
TX,25,DH2168 1916JUN931/2
258
PN=62

T7747BR
UN19MAY92

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.
5. Run engine at 1/2 speed for 2 minutes before stopping,
to avoid damage to turbocharger. Release accelerator
pedal to slow idle.
TX,25,DH2168 1916JUN932/2
259
PN=63
Driving the Machine

DRIVING ON PUBLIC ROADS
Before driving on public roads, check state and local laws
that may apply to tractors, self-propelled machines, and
towed equipment. Additional lights, mirrors, SMV
emblems, or reflectors may be required.
TX,30,DH2123 1931JUL921/2
T6458AN1
UN25OCT88
For best visibility and stability, raise bucket approximately

406 mm (16 in.) (A) and tilt it back completely.
TX,30,DH2123 1931JUL922/2
301
PN=64
Driving the Machine
GENERAL DRIVING PRECAUTIONS
CAUTION: Riders on machine are subject to

injury. Never allow riders on the machine.
In general observe all safe driving rules such as:

Slowing down for curves
Avoiding rapid steering or braking
Slowly stopping machine with flat tire
Watching out for bystanders
Watching out for other operators
Driving up a slope in forward and backing down in
reverse
Looking behind before backing up
When carrying loads up or down a steep hill, use extreme
caution. Use a safe speed. Keep bucket in low position.
Use right brake for stopping.
02T,30,C47 1931JUL921/1
FRONT AXLE DISCONNECTIF EQUIPPED

IMPORTANT: Prevent possible axle or transmission
damage. DO NOT connect or
disconnect front axle with machine in
motion. Start the engine. Turn steering
wheel slowly back and forth to connect
or disconnect.
Disconnect the front axle before driving on hard surface
roads.
TX,30,DH2169 1931JUL921/2
302
PN=65
Driving the Machine

Pull up lever (A) to disconnect front axle.
T7747AN
UN19MAY92
Push down lever to connect front axle.
TX,30,DH2169 1931JUL922/2

unexpected machine movement. Always move
transmission control lever to neutral "N", and
engage neutral lock before starting or
dismounting.
T7747BI
Move neutral lock (A) to the locked position to engage

neutral lock. Move lock to the unlocked position to
disengage neutral lock.
UN19MAY92
NEUTRAL LOCK
TX,30,DH2170 1902OCT921/1
SHIFTING THE TRANSMISSION

Unlock neutral lock.
TX,30,JC248 1929NOV941/2
303
PN=66
Driving the Machine
When transmission control lever is positioned in 4th gear,

transmission is in "automatic" mode. In "automatic" mode,
transmission starts out in 2nd gear, then shifts to 3rd and
4th gear as speed increases. It will also automatically
downshift from 4th to 3rd to 2nd gear as speed
decreases.
T7747AM
Change speed of machine by moving transmission control

lever to desired gear. Machine has four forward gears
and three reverse gears. Shifting to 4th gear reverse will
give same travel speed as 3rd gear reverse. Select a
gear suitable to operating and road conditions.
UN19MAY92
Change direction of machine by moving transmission

control lever (A) to forward "F" or reverse "R" position.
IMPORTANT: Prevent possible transmission damage.

DO NOT change forward and reverse
directions at high speeds.
If speed is less than 7 mph, a direction
change can be made in any gear. If
speed is greater than 7 mph,
transmission will automatically shift
down to 2nd gear prior to changing
directions.
Forward and reverse directions can be
changed without stopping the machine
in 1st and 2nd gears.
TX,30,JC248 1929NOV942/2
304
PN=67
Driving the Machine
TRAVEL SPEEDS
NOTE: Km/h and mph will only display in full
increments on digital display.
544G, LL, TC:
Forward Speeds
km/h
mph
Reverse Speeds
km/h
mph
07.4
04.6
07.4
04.6
012.3
07.7
012.3
07.7
027.2
016.9
027.2
016.9
038.4
023.8
624G:
Forward Speeds
km/h
mph
Reverse Speeds
km/h
mph
07.3
04.5
07.3
04.5
011.6
07.2
011.6
07.2
024.5
015.2
024.5
015.2
037.3
023.0
644G:
Forward Speeds
km/h
mph
Reverse Speeds
km/h
mph
07.0
04.4
07.0
04.4
011.2
07.0
011.2
07.0
022.0
013.7
022.0
013.7
034.6
021.5
TX,30,DH2172 1902OCT921/1
305
PN=68
Driving the Machine

unexpected boom movement. The bucket may
"jump up" when ride control switch is turned
ON.
Turn ride control switch ON to improve machine ride and

reduce tire flexing when traveling over rough terrain at a
high speed with loaded bucket.
If engine is stopped with ride control switch in ON
position, ride control is automatically disengaged. Start
the engine, press switch to OFF and then back to ON to
engage ride control. Switch will be backlit when engaged
(ON).
T7829AV
UN08SEP92
RIDE CONTROL SWITCHIF EQUIPPED
To discharge the energy in the ride control accumulator,

do the following:
1. Make sure area around bucket is clear.
3. Stop engine.
4. Turn key switch to ON.
5. Move hydraulic control lever to float detent position.
6. Cycle ride control switch from OFF to ON.
7. Push boom down switch to release accumulator
pressure.
TX,30,DH2505 1916JUN931/1
STOPPING THE MACHINE

Depress left brake pedal (A) or right brake pedal (B) to
stop the machine.
T7747BS
UN19MAY92
Left brake pedal also serves as a clutch cut-off pedal

when clutch cut-off switch is in "clutch disengaged"
position.
TX,30,DH2173 1931JUL921/1
306
PN=69
Driving the Machine
CAUTION: Prevent possible injury or death from

machine runaway. Before disengaging park
brake, be sure engine is running and service
brakes are operational.
T7773AG
NOTE: Transmission clutches are disengaged when park

brake is applied.
UN11JUN92
PARK BRAKE SWITCH
Press park brake switch (A) to ON position to engage

park brake.
Press park brake switch to OFF position to disengage
park brake.
NOTE: If park brake is engaged when engine is running

and transmission control lever is in neutral "N",
park brake indicator light will light.
If park brake is engaged when engine is running
and transmission control lever is moved to
forward "F", or reverse "R", park brake indicator
light will light, STOP indicator light will light, and
alarm will sound.
If engine is stopped with park brake switch in OFF
position, park brake is automatically applied.
Press park brake switch to ON and then back to
OFF to release park brake after starting engine.
TX,30,DH2174 1906OCT921/1
PARKING THE MACHINE

TX,30,DH2176 1916JUN931/2
307
PN=70
Driving the Machine

T7747BR
UN19MAY92


5. Run engine at 1/2 speed without load for 2 minutes
before stopping, to avoid damage to turbocharger.
Release accelerator pedal to slow idle.
TX,30,DH2176 1916JUN932/2
308
PN=71

BOOM AND BUCKET CONTROL LEVER
ONE LEVER DESIGN
UN11JUN92
Move control lever forward (A) to lower boom, or rearward

(D) to raise boom.
T7773AC
NOTE: Boom down switch (I) must be pushed while

moving control lever forward to lower boom with
engine stopped.
Move control lever left (F) to roll back bucket, or right (C)
to dump bucket. 544G LL and 544G TC will also have a
fast dump bucket position (H).
UN02DEC94
Float (lever in full forward detent position [B]): This

position allows oil to flow in and out both ends of
cylinders so the bucket can follow the contour of the
ground. Manually release lever from this position.
Return-to-Dig (lever in full left detent position [G]): Bucket
will return to set dig position.
Boom and bucket functions can be operated

simultaneously by moving lever between positions. For
example, to raise boom and roll back bucket, move lever
between positions (D) and (F).
T8373BA
Boom Height Kickout (lever in full rear detent position [E]):

Lever will remain in this position until boom is at a pre-set
height, then will return to neutral automatically.
ALower Boom
BFloat
CDump Bucket
DRaise Boom
EBoom Height Kickout
FRollback Bucket
GReturn-to-Dig
HFast Bucket Dump
IBoom Down Switch
TX,35,DH2177 1929NOV941/1
351
PN=72
BOOM AND BUCKET CONTROL LEVER

TWO LEVER DESIGN
UN11JUN92
Move left control lever forward (A) to dump bucket, or

rearward (B) to roll back bucket. 544G LL and 544G TC
will also have a fast dump bucket position (H).
T7773AE
NOTE: Boom down switch (I) must be pushed while

engine stopped.
Move right control lever forward (E) to lower boom or
rearward (F) to raise boom.
UN02DEC94
Float (right lever in full forward detent position [D]): This

position allows oil to flow in and out both ends of
cylinders so the bucket can follow the contour of the
ground. Manually release lever from this position.
Return-to-Dig (left lever in full rearward detent position
[C]): Bucket will return to set dig position.
T8373BA
Boom Height Kickout (right lever in full rearward detent

position [G]): Lever will remain in this position until boom
is at a pre-set height, then will return to neutral
automatically.
ADump bucket
BRollback Bucket
CReturn-to-Dig
DFloat
ELower Boom
FRaise Boom
GBoom Height Kickout
HFast Bucket Dump
IBoom Down Switch
TX,35,DH2178 1929NOV941/1
352
PN=73
QUICK SHIFT SWITCH
T7773CE
Press down on switch to downshift from 2nd gear to 1st

gear when transmission control lever is positioned in 2nd
gear. Press again to return to 2nd gear.
UN21AUG92
Press down on switch (A) to downshift from 3rd gear to

2nd gear when transmission control lever is positioned in
3rd gear. Press again to return to 3rd gear.
Quick shift will not function in 4th gear.
TX,35,DH2490 1908OCT921/1
353
PN=74
QUICK COUPLER OPERATION544G TC
Move control lever left (D) to tilt coupler rearward. Move it

right (C) to tilt coupler forward.
T7773AF
NOTE: Boom down switch must be pushed while moving

control lever forward to lower boom with engine
stopped.
UN11JUN92
Move control lever forward (A) to lower boom, or rearward

(B) to raise boom.
1. Align equipment to be used so hooks fit over coupler

and eyelet is centered.
Boom and tilt functions can be operated simultaneously

by moving lever between positions. For example, to
raise boom and tilt coupler rearward move lever
between positions (B and D).
T8373AV
3. Roll coupler back to align pins with attachment.

Release switch to lock pins in place.
UN02DEC94
2. Push down and hold pin disconnect switch (E) to

retract connecting pins when engaging equipment.
T6975AF
UN29MAR89
ALower Boom
BRaise Boom
CTilt Forward
DTilt Rearward
EPin Disconnect Switch
TX,35,DH2286 1929NOV941/1
354
PN=75
PIN DISCONNECT SWITCH544G TC

Use the pin disconnect switch (A) when adding or
changing equipment.
UN02DEC94
Hold down switch to retract pins on coupler.
T8373AW
Release switch to extend and lock pins in place.
TX,35,DH2287 1929NOV941/1
BOOM DOWN SWITCH
T8373AX
UN02DEC94
Push boom down switch (A) while moving control lever

forward to lower boom with the engine stopped.
TX,35,DH2179 1929NOV941/1

unexpected machine movement. When stopping
on inclines, push clutch cut-off switch to
engaged position before releasing left service
brake. This will prevent the machine from
rolling downhill during transmission reengagement cycle.
The clutch cut-off switch (A) must be in clutch disengaged

position before left brake pedal (B) can be used to
disengage transmission clutches. Move switch up to
clutch disengaged position.
T8373AZ
UN02DEC94
CLUTCH CUT-OFF SWITCHIF EQUIPPED
T7747BY
NOTE: The park brake will also disengage the

transmission clutches. Release park brake before
operating.
UN19MAY92
Use the clutch cut-off switch in situations such as truck

loading where machine positioning and maximum
hydraulics are needed.
TX,35,DH2180 1929NOV941/1
355
PN=76
Steering pressure indicator light (A) will light, STOP

indicator light (B) will flash, and audible alarm will sound
when secondary steering system is activated. The light
indicates low hydraulic pressure resulting from
mechanical malfunction, such as loss of engine power. An
electrically driven pump will actuate to provide steering
T7773AT
IMPORTANT: Prevent possible damage to secondary

steering system. Stop machine
immediately if steering pressure
indicator light and audible alarm come
on while operating. THE SECONDARY
STEERING SYSTEM IS NOT INTENDED
FOR CONTINUOUS USE.
UN30JUL92
SECONDARY STEERINGIF EQUIPPED
The secondary steering system will function only when

key switch is on.
NOTE: Secondary steering is activated if you try to start

the machine unsuccessfully. Turn key switch off to
stop secondary steering motor.
TX,35,DH2181 1902OCT921/1
DIFFERENTIAL LOCK PEDALIF EQUIPPED

Hold pedal (A) down to lock front axle differential.
T100664
NOTE: Use differential lock only when conditions require

traction. Avoid using differential lock when
steering.
UN12MAR96
Release pedal to unlock differential.
TX,35,DH2182 1902OCT921/1
356
PN=77
ADJUSTING BOOM HEIGHT KICKOUTIF

EQUIPPED
1. Start engine.
2. Move control lever to boom raise detent position and
release.
TX,35,DH2183 1931JUL921/2
3. After control lever returns to neutral, make a mark (D)

on the magnet and the boom height kickout switch.
4. Position the boom in the desired boom height kickout
position. Stop engine.
5. Loosen cap screws (B) and slide bracket to align
marks on magnet and boom kickout switch.
6. Loosen cap screws (C) and adjust clearance (A)
between magnet and boom height kickout switch to 9
3 mm (0.35 0.12 in.).
T6601AI
UN21OCT88
7. Check boom height kickout for correct adjustment.
AClearance
BCap Screws
CCap Screws
DMark
TX,35,DH2183 1931JUL922/2
357
PN=78
ADJUSTING RETURN-TO-DIG
1. Start engine.
2. Move control lever to return-to-dig detent position and
release.
TX,35,DH2184 1902OCT921/2
NOTE: On 544G LL and 544G TC, the return-to-dig

switch and magnet are located below the
cylinder.
UN21OCT88
3. After control lever returns to neutral, make a mark (B)

on magnet and return-to-dig switch.
T6599AD
4. Position the boom and bucket in the desired return-todig position. Stop engine.
5. Loosen cap screws (D) and slide bar to align marks
on magnet and return-to-dig switch.
6. Loosen cap screws (C) and adjust clearance (A)
between magnet and return-to-dig switch to 9 3 mm
(0.35 0.12 in.).
AClearance
BMark
CCap Screws
DCap Screws
7. Raise boom. Cycle bucket from full rollback to dump.

Check return-to-dig for correct adjustment.
TX,35,DH2184 1902OCT922/2
358
PN=79
GENERAL OPERATING TIPS

Carry loaded bucket low to the ground for a better view
and to improve machine stability.
Keep the bottom of the bucket parallel to the ground when
dozing. DO NOT doze with the bucket in dump position.
Use bucket teeth when digging in hard material.
When bucket digs in, decreasing traction, roll bucket back
slightly.
In float position, the bucket will follow the contour of the
ground. Use float position to back drag.
Clean and level the work area while waiting for truck.
If possible, keep wind at your back while dumping load,
for improved viewing and to keep dust away from engine.
TX,DH,49 1906JUN911/1
EXCAVATING BANKS OR STOCKPILES

CAUTION: Prevent possible injury from falling
material. Remove overhanging material first
from top of bank or stockpile .
T7747BE
Remove any overhang before starting to dig at the base

of a bank or stockpile. This can be done with the bucket.
UN19MAY92
TX,35,DH2276 1902OCT921/3
T7747BF
UN19MAY92
Reduce bucket breakout force required when digging into

a bank or stockpile of hard, dense, or tightly-packed
material by working from the top of bank or stockpile to
the bottom.
TX,35,DH2276 1902OCT922/3
359
PN=80
Work bank or stockpile with machine at a 90 angle to the

bank or stockpile.
T7208AV
1. Position bucket on the ground in return-to-dig position.
UN30JAN90
Normally, a bank or stockpile is excavated from the

bottom and then up the side. Work the face of the bank
or stockpile evenly to prevent outcroppings and
overhangs.
2. Move transmission control lever to 1st or 2nd gear

depending on ground conditions.
In loose material, use 2nd gear for better traction. Use
1st gear for better bucket fill.
3. Move forward into the bank or stockpile.
NOTE: Use differential lock as necessary.

4. Raise and curl bucket as bucket fills.
TX,35,DH2276 1902OCT923/3
USING THE LOADER BUCKET

1. Place bucket in the return-to-dig position and lower to
ground.
UN19MAY92
NOTE: Bucket and boom can be positioned while

machine is on-the-go.
T7747BB
2. Move transmission control lever to 1st or 2nd gear

depending on ground condition.
3. Move forward into the material.
TX,35,JC1049 1917JAN961/4
3510
PN=81
T7747BC
UN19MAY92
4. Raise and curl bucket to hold load.
TX,35,JC1049 1917JAN962/4
T7208AR
UN30JAN90
EXCAVATING ON THE LEVEL: Position bucket at a

slightly downward angle on ground (use bucket teeth for
this type of digging).
TX,35,JC1049 1917JAN963/4
USING BOOM IN FLOAT POSITION: Place the boom in

float position and bucket in return-to-dig position to
prevent gouging the surface, as in cleaning concrete and
snow removal. Also use float position to avoid mixing
surface material with stockpile material.
T7747BD
DOZING: With bucket parallel to ground, remove as little

dirt as possible from the top surface. Let dirt spill from
partially dumped bucket to fill in low spots.
UN19MAY92
IMPORTANT: Prevent possible damage to the

bellcrank linkage. DO NOT bulldoze with
bucket in dump position. When dozing,
keep bucket bottom parallel to the
ground.
DIGGING IN HARD, DENSE, OR TIGHTLY-PACKED

MATERIAL: To break material loose, use a gentle upand-down motion of the bucket.
TX,35,JC1049 1917JAN964/4
3511
PN=82
T7747BG
Leveling and grading can be done with the boom in the

float position by backdragging the loader bucket while
traveling in reverse. (Float position allows the bucket to
follow contour of the ground.)
UN19MAY92
BACKDRAGGING
TX,35,DH2278 1931JUL921/1
BACKFILLING
1. Use loader bucket as a dozer. As bucket approaches

the trench, material being pushed will fall into the
trench. Reverse direction and reposition loader to
maintain a 90 angle to the trench line.
T6603AO
IMPORTANT: DO NOT bulldoze with bucket in the

dump position, as damage could result
to the bellcrank linkage. When dozing,
keep bucket bottom parallel to the
ground.
UN20OCT88
There are two effective methods of backfilling.
2. Push material to the trench as in method 1. Use clutch

cut-off to maintain high engine rpm.
Dump material into the trench while placing direction
selector lever in neutral.
When bucket is dumped, release clutch cut-off and
reposition loader for a 90 angle to the trench line.
If filling, spread material in thin layers. Operate at
nearly full rpm and dump material on-the-go. Reverse
direction just prior to emptying bucket. Loader will
compact fill material as it works.
TX,35,JC1064 1914FEB961/1
3512
PN=83
TRUCK LOADING
The most efficient technique for truck loading is the "V"
method.
2. Run engine near fast idle to penetrate material.

3. Increase engine speed to fast idle and crowd into the
pile.
T7511CN
UN27JUN91
1. Level bucket and lower to the ground.
4. As engine rpm starts to decrease, pull loader control

lever back and to the left.
5. Feather hydraulics to obtain a smooth combination of
bucket rollback and boom lift.
6. After filling the bucket, reverse loader and articulate
3540 degrees. If truck is positioned close to the
stockpile, raise boom to level position while reversing.
7. Travel forward to the truck while raising the boom to
clear truck sideboards. Dump load.
8. Reverse direction and lower bucket to several inches
above ground level.
02T,35,J8 1925JUN911/1
3513
PN=84
Transporting
TRANSPORTING PRECAUTIONS
If machine is transported, check route for road width and
overhead clearance. Check any bridges for weight limits.
(See Specifications chapter.)
TX,40,FF3416 1927MAY931/1
LOADING MACHINE ON A TRAILER
3. Fasten seat belt before starting engine.
CAUTION: Position the machine so that its

centerline is over the centerline of the truck
bed. NEVER steer the machine while on the
ramp. If changing direction is required on the
ramp, unload the machine from the ramp,
reposition the machine on the ground, then try
loading again.
T8301AK
2. Use a ramp or loading dock. Ramps must be strong

enough, have a low angle, and correct height.
UN17AUG94
1. Keep the trailer bed clean. Put chock blocks against

trailer wheels.
4. Drive the machine onto the ramp slowly. The centerline

of the machine should be over the centerline of the
trailer.
5. Lower all equipment onto blocks or trailer bed.
TX,40,JC274 1929NOV941/2
401
PN=85
Transporting

T7747BR
UN19MAY92

8. Connect frame locking bar.

11. Cover exhaust opening to prevent entry of debris and
water.
12. Fasten each corner of the machine to the trailer with
a chain or cable with appropriate load binder.
13. Place blocks in front of and behind tires.
TX,40,JC274 1929NOV942/2
402
PN=86
Transporting
CAUTION: Use flashing warning lights and turn

signals when towing this equipment on public
roads unless prohibited by state or local
regulations. An implement safety lighting kit is
available from your John Deere dealer. Keep
safety items in good condition. Replace missing
or damaged items.
IMPORTANT: Engine cannot be started by towing

because machine is equipped with a
torque converter.
T6629AM
UN20OCT88
TOWING PROCEDUREENGINE
OPERATIONAL
For towing distances longer than 460 m

(500 yd), drive shafts must be
disconnected or transmission will be
damaged due to a lack of lubrication.
For towing short distances at slow
speed, park brake is manually released.
A rigid tow bar must be used so towing
machine can stop machine being
towed. Towing machine must be of
sufficient size to adequately handle or
stop load being towed.
Never tow machine faster than 10 km/h
(6.2 mph).
NOTE: For towing distances longer than 460 m (500 yd),

use Steps 19. For towing short distances at
slow speed, use Steps 1019.
Steps for towing machine more than 460 m (500 yd):
1. Connect a rigid tow bar to drawbar pin (A) of machine
being towed.
2. Start engine.
3. Install frame locking bar.
NOTE: Frame locking bar is installed to prevent weaving

as machine is towed.
TX,40,DH2288 1912MAY931/2
403
PN=87
Transporting
4. Move transmission control lever to neutral. Engage
neutral lock.
5. Raise boom, and support so bucket is off ground.
6. Stop engine.
TX,40,DH2288 1912MAY932/2
TOWING PROCEDUREENGINE NONOPERATIONAL

unexpected machine movement. Always install
frame locking bar, and block wheels to hold
machine when working on park brake.
1. Install frame locking bar. Put blocks at front and rear

of tires.
TX,40,JC1101 1918MAR961/4
404
PN=88
Transporting
2. Manually release park brake: Remove (3) screws and
remove sheet metal cover from brake. Loosen lock nut
(A).
3. Back out adjustment screw (B) to release park brake.
4. Remove blocks. Slowly tow machine.

unexpected machine movement. Always apply
park brake to hold machine if drive shafts are
connected.
5. When towing is completed, adjust park brake to hold

machine. (See Adjust Park Brake in Maintenance
6. Install sheet metal cover. Tighten cover screws.
CAUTION: Machine may roll when drive shafts
are disconnected. Use blocks at front and rear
of tires to prevent machine from rolling.
UN22MAR96
T100701
7. Put blocks at front and rear of tires.
644G Show
TX,40,JC1101 1918MAR962/4
8. Remove front (B) and rear (C) drive shafts so

transmission output shaft does not turn.
T6518BM6
UN20OCT88
Steps for towing machine less than 460 m (500 yd):
TX,40,JC1101 1918MAR963/4
405
PN=89
Transporting
10. Connect a rigid tow bar to drawbar pin (A) of machine
being towed.
NOTE: Frame locking bar is installed to prevent weaving

as machine is towed.
13. Move transmission control lever to neutral. Engage
neutral lock.
T6629AM
UN20OCT88
11. Start engine.
14. Raise boom, and support so bucket is off ground.

15. Stop engine.
16. Put blocks at front and rear of tires.
CAUTION: Machine may roll when park brake is

released. Use blocks at front and rear of tires to
prevent machine from rolling.
17. Release park brake.

19. Engage park brake when towing is completed.
TX,40,JC1101 1918MAR964/4
406
PN=90
Transporting
LIFTING THE MACHINE

unexpected machine movement. Clear all
bystanders from lifting area. Select correct
lifting cable strength for weight of machine.
Test lift by raising machine 0.3 m (1 ft) off the
ground.
10 262 kg (22,624 lb)
Approximate machine weight (LL)
10 377 kg (22,881 lb)
Approximate machine weight

(TC)
10 466 kg (23,078 lb)

(624G)
12 398 kg (27,338 lb)

(644G)
15 666 kg (34,538 lb)
1. Attach cables (A) to machine so cables do not rub

machine.
2. Attach a tether cable to machine to control machine
as it is lifted.
T7477AV

(544G)
UN19MAR91
SPECIFICATIONS
3. Test lift by raising machine 0.3 m (1 ft) off the ground.

4. Lift machine and swing to unloading area.
TX,40,DH2187 1912SEP921/1
407
PN=91

DIESEL FUEL
Consult your local fuel distributor for properties of the
diesel fuel available in your area.
gram load level as measured by the BOCLE scuffing

test.
In general, diesel fuels are blended to satisfy the low

temperature requirements of the geographical area in
which they are marketed.
Sulfur content:
1. Sulfur content should not exceed 0.5% Sulfur
content less than 0.05% is preferred.
Diesel fuels specified to EN 590 or ASTM D975 are

recommended.
2. If diesel fuel with sulfur content greater than

0.5% sulfur content is used, reduce the service
interval for engine oil and filter by 50%
In all cases, the fuel shall meet the following

properties:
Cetane Number 40 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20C (-4F) or elevations
above 1500 m (5000 ft).
Cold Filter Plugging Point (CFPP) below the
expected low temperature OR Cloud Point at least
5C (9F) below the expected low temperature
3. DO NOT use diesel fuel with sulfur content

greater than 1.0%
Bio-diesel fuels with properties and meeting DIN 51606
or equivalent specifications may be used.
DO NOT mix used engine oil or any other type of
lubricant with diesel fuel.
Fuel Lubricity should pass a minimum of 3100
TX,45,JC1132 1922MAY961/1
451
PN=92
LOW SULFUR DIESEL FUEL CONDITIONER

When possible, use existing fuel formulations for engines
used off-highway. This fuel will not require any additives
to provide good performance and engine reliability.
However, many local fuel distributors will not carry both
low and regular sulfur diesel fuels.
If the local fuel distributor will supply only low sulfur fuel,
order and use John Deere TY22030 Diesel Fuel
Conditioner. It provides lubricating properties along with
other useful benefits, such as cetane improver, antioxidant, fuel stabilizer, corrosion inhibitor and others.
TY22030 is specifically for use with low sulfur fuels.
Nearly all other diesel fuel conditioners only improve cold
weather flow and stabilize long-term fuel storage. They do
not contain the lubrication additives needed by rotary fuel
injection pumps.
TX,45,DH3124 1920OCT931/1
HANDLING AND STORING DIESEL FUEL
CAUTION: Handle fuel carefully. Do not fill

the fuel tank when engine is running.
DO NOT smoke while you fill the fuel tank or

service the fuel system.
Fill the fuel tank at the end of each days operation to
prevent condensation and freezing during cold
weather.
CAUTION: The fuel tank is vented through

the filler cap. If a new filler cap is required,
always replace it with an original vented
cap.
When fuel is stored for an extended period of time or if

there is a slow turnover of fuel, add a fuel conditioner
to stabilize the fuel and prevent water condensation.
Contact your fuel supplier for recommendations.
TX,45,JC1156 1903JUN961/1
452
PN=93
DO NOT USE GALVANIZED CONTAINERS

IMPORTANT: Diesel fuel stored in galvanized
containers reacts with zinc coating on
the container to form zinc flakes. If fuel
contains water, a zinc gel will also
form. The gel and flakes will quickly
plug fuel filters and damage fuel
injectors and fuel pumps.
DO NOT USE a galvanized container to store diesel fuel.
Store fuel in:
plastic containers.
aluminum containers.
specially coated steel containers made for diesel fuel.
DO NOT USE brass-coated containers: brass is an alloy
of copper and zinc.
MX,FLBT,C 1904JUN901/1
FUEL TANK
CAUTION: Handle fuel carefully. If the engine

is hot or running, DO NOT fill the fuel tank.
DO NOT smoke while you fill fuel tank or
work on fuel system.
FUEL TANK CAPACITY

544G, LL, TC,
218 L (58 gal)
624G
249 L (66 gal)
644G
284 L (75 gal)
To avoid condensation, fill the fuel tank at the end of

each days operation. Shut off engine before filling.
TX,45,DH2188 1917AUG921/1
453
PN=94
T101239
1922MAY96
DIESEL ENGINE OIL
John Deere UNI-GARD
Use oil viscosity based on the expected air

temperature range during the period between oil
changes.
API Service Classification CG-4
The following oil is preferred:
API Service Classification CF-4
John Deere PLUS-50
ACEA Specification E3
If John Deere PLUS-50 engine oil and a John Deere

oil filter are used, the service interval for oil and filter
changes may be extended by 50 hours.
ACEA specification E2
The following oil is also recommended:
John Deere TORQ-GARD SUPREME
Other oils may be used if they meet one or more of

the following:
Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is
used, reduce the service interval by 50%.
TX,45,JC1133 1922MAY961/1
454
PN=95
T100663
1910MAY96
TRANSMISSION OIL, HYDRAULIC SYSTEM OIL AND DIFFERENTIAL OIL
Use oil viscosity based on the expected air

temperature range during the period between oil
changes.
John Deere Standard JDM J20D
The following oils are preferred:
Use the following oil when a biodegradable fluid is

required:
JOHN DEERE HY-GARD
John Deere Standard JDM J27A
John Deere Low Viscosity HY-GARD
John DeereBIO-HY-GARD 1
1
BIO-HY-GARD meets or exceeds the minimum

biodegradability of 80% within 21 days according to
CEC-L-33T-82 test method.BIO-HY-GARD should
not be mixed with mineral oils because this reduces
the biodegradability and makes proper oil recycling
impossible.
The following oil is also recommended:

John Deere UNI-GARD
Other oils may be used if they meet one of the
following:
John Deere Standard JDM J20C
TX,45,JC1050 1918JAN961/1
455
PN=96
T8358AI
1927MAR95
GREASE
Use grease based on NLGI consistency numbers and

the expected air temperature range during the service
interval.
John Deere HIGH TEMPERATURE EP GREASE
The following greases are preferred:
Other greases may be used if they meet one of the

following:
John Deere GREASE-GARD
John Deere MOLY HIGH TEMPERATURE EP

GREASE
NLGI Performance Classification GC-LB
TX,45,JC1134 1922MAY961/1
ALTERNATIVE AND SYNTHETIC LUBRICANTS

Conditions in certain geographical areas may require
lubricant recommendations different from those
printed in this manual. Some John Deere lubricants
may not be available in your location. Consult your
John Deere dealer to obtain information and
recommendations.
The temperature limits and service intervals shown in

this manual apply to both conventional and synthetic
oils.
Re-refined base stock products may be used if the
finished lubricant meets the performance
requirements.
Synthetic lubricants may be used if they meet the

performance requirements listed in this manual.
DX,ALTER 1901FEB941/1
456
PN=97
LUBRICANT STORAGE
Your equipment can operate at top efficiency only if
clean lubricants are used.
Make certain that all containers are properly marked to

identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual

lubricant they may contain.
Store lubricants and containers in an area protected

from dust, moisture, and other contamination. Store
containers on their side to avoid water and dirt
accumulation.
TX,45,JC1135 1922MAY961/1
MIXING OF LUBRICANTS
In general, avoid mixing different brands or types of oil.
Oil manufacturers blend additives in their oils to meet
certain specifications and performance requirements.
Mixing different oils can interfere with the proper
functioning of these additives and degrade lubricant
performance.
Consult your John Deere dealer to obtain specific
information and recommentations.
TX,45,JC1136 1922MAY961/1
457
PN=98
SERVICE YOUR MACHINE AT SPECIFIED
INTERVALS
T100700
Service items at multiples of the original requirement. For

example, at 500 hours also service those items (if
applicable) listed under 250 hours, 100 hours, 50 hours
and 10 hours or daily.
UN22MAR96
Lubricate, make service checks and adjustments at

intervals shown on the periodic maintenance chart (A)
and on the following pages.
TX,50,JC1104 1918MAR961/1
CHECK THE HOUR METER REGULARLY
UN19MAY92
Press the SELECT switch to display the hour meter on

the digital display, to determine when your machine
needs periodic maintenance.
T7747AT
Intervals on the periodic maintenance chart are for

operating in normal conditions. If you operate your
machine in severe conditions, you should service it at
SHORTER INTERVALS.
TX,50,DH2193 1902OCT921/1
USE CORRECT FUELS AND LUBRICANTS

IMPORTANT: To prevent machine damage when
servicing your machine, use only
recommended fuels and lubricants. (See
Fuels and Lubricants chapter.)
TX,50,DH1964 1903JAN921/1
501
PN=99
PREPARE MACHINE FOR MAINTENANCE

Before performing maintenance procedures given in the
following chapters, and before leaving the operators
seat, park the machine as described below unless
another position is specified in the procedure.
TX,50,DH2194 1929NOV941/2

T7747BR

UN19MAY92
NOTE: Boom down switch (C) must be pushed while

engine stopped.
5. Turn key switch to STOP. If maintenance must be

performed with engine running, do not leave machine
unattended.
T8375AM
UN02DEC94
TX,50,DH2194 1929NOV942/2
502
PN=100
LOCKING MACHINE FRAME

unexpected machine movement. Connect frame
locking bar to both frames before you work in
frame pivot area.
1. Align machine frames.
TX,50,DH2199 1917AUG921/2
2. Remove pin (A), and move locking bar forward.
T7773CL
UN21AUG92
3. Install pin through holes in machine frame (B) and end

of locking bar.
T7773CM
UN21AUG92
624G Shown
TX,50,DH2199 1917AUG922/2
503
PN=101
BOOM LOCK
CAUTION: Always install boom lock before
working on or around this machine with the
boom raised.
UN17SEP92
Empty bucket and place in dump position

before installing boom lock.
T7839BB
1. Raise boom. Empty bucket and place in dump position

before installing boom lock.
2. Remove boom lock from side of machine by turning
lock lever counterclockwise.
UN22MAR96
3. Install boom lock on boom cylinder with lock lever

facing to the outside of machine. Lower boom onto
boom lock.
4. Tighten boom lock lever.
T100699
5. Store boom lock on side of machine when not in use.
644G Shown
TX,50,JC255 1929NOV941/1
OPENING ENGINE SIDE SHIELDS AND

SERVICE DOORS
T100697
UN22MAR96
3. To open lower side shield, remove cotter pin and

washers from engine service door. Open door to its full
extent. Pull lower side shield outward.
T7773CJ
2. Position rod in notch (B) to hold door open.
UN21AUG92
1. Pull out on latch (A) to open engine service door.
TX,50,JC269 1929NOV941/1
504
PN=102
OPENING GRILLE DOOR

Push down on latch (A) to open grille door.
T7773CD
UN10AUG92
T6785CD
UN19OCT88
Rotate stop (B) 180 to hold door open.
TX,50,DH2198 1931JUL921/1
CHECK WINDSHIELD WASHER FLUID LEVEL

Check fluid in windshield washer bottle (A).
T7829AD
UN31AUG92
During winter season, use all season windshield washer

fluid which will not freeze.
544G Shown
TX,50,DH2200 1926AUG921/1
505
PN=103
MAINTENANCE AND REPAIR RECORD

KEEPING SYSTEM
The checklist on the following page summarizes
scheduled maintenance, and parts and oil required at
each maintenance interval.
Use the checklist to:
Remind you to perform machine maintenance at
specified intervals to minimize downtime.
Calculate cost of machine operation and ownership
allowing you to make better job estimates.
Place yourself in a stronger position at trade-in time.
Do not tear out or mark on Checklist in the Periodic

Maintenance chapter; keep it to make extra copies.
T7511CO
As maintenance is performed, check off each item on the

list and record date and hour meter reading. Use the
second (perforated) copy of this form (immediately
preceding the Service Literature order form inside the
back cover).
UN27JUN91
Satisfy your SECURE contract requirements.
TX,50,FF2898 1909JUL931/1
506
PN=104
OILSCAN
Oil samples should be taken from each system prior to its

recommended oil change interval.
T6829AB
UN18OCT88
T6828AB
OILSCAN kits are available from your dealer.
UN15JUN89
OILSCAN is a John Deere oil sampling program to help

you monitor machine performance and identify potential
problems before they cause serious damage.
TX,50,JC1061 1912FEB961/1
507
PN=105
MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM

SERVICE INTERVALS
Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example,
at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.
As Required
Inspect tires and check pressure
Inspect belts and check tension
Check wheel retainer cap screws
Drain water and clean fuel tank strainer
Clean or replace air cleaner elements
Drain and clean primary fuel filter
Check and clean air inlet cover
Check and clean cab recirculating air filter

Every 10 Hours or Daily
Lubricate pivots
Check recovery tank coolant level
Clean air cleaner dust unloader valve
Check hydraulic system oil level
Check engine oil level
Check transmission oil level

Every 100 Hours
Lubricate loader boom and cylinder pivots
Check cab recirculating air filter
Lubricate front steering cylinder pivots
Lubricate oscillating rear axle
Check cab fresh air filter
Lubricate rear steering cylinder pivots

REQUIRED PARTS
Insure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated
parts are also on hand i.e. filters, O-rings.
Engine Oil Filter
Part Number
250 HOURS
500 HOURS
1000 HOURS
3000 HOURS
*544G, 624G
T19044
644G
RE57394
Primary Fuel Filter
All
RE63136
Final Fuel Filter
*544G, 624G
RE62419
644G
RE62419
Hydraulic System Return Filter
*544G
AT144879
624G, 644G
AT140315
Hydraulic Reservoir Breather

Filter
All
AM39653
Transmission Filter
All
AT168989
Air Filter Primary
*544G, 624G
AR79679
644G
AR80652
Air Filter Secondary
*544G, 624G
AR79680
644G
AR80653
Differential Lock Return Filter(s)
All
T19044
TORQ-GARD SUPREME PLUS

50 Oil
*544G, 624G
19 L (20 qt)
19 L (20 qt)
644G
24 L (25 qt)
24 L (25 qt)
24 L (25 qt)
24 L 25 qt)
HY-GARD Transmission and

Hydraulic Oil
*544G
9.5 L (10 qt)
117 L (31 gal)
624G
11 L (12 qt)
151 L (40 gal)
644G
Coolant Conditioner
TY16004
OILSCAN Kit
IPSKIT1
COOLSCAN Kit
DSO251
1
1 or 2
*includes 544G LL and 544G TC
19 L (20 qt)
19 L 20 qt)
14 L (15 qt)
174 L (46 gal)
TX,50,JC1137 1922MAY961/1
508
PN=106

Model:
544G
544G LL
PIN/Serial Number:
544G TC
624G
Delivery Date:
644G
Customer:
Hour Meter Reading:
Oil Sampling
Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form. Maintenance
recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply. Regular oil
sampling will extend the operational life of your machines systems.
Every 250 Hours
Check receiver dryer moisture indicator
Replace engine oil filter
Drain and refill engine oil
Check radiator coolant level
Comments:
Date:
Hour Meter Reading:
Maintenance Performed By:

Every 500 Hours
Lubricate front drive line
Replace final fuel filter
Check air intake hoses
Replace hydraulic system return filter
Check battery water level
Replace hydraulic reservoir breather filter
Add rust inhibitor to radiator
Check front and rear differential oil level
Replace primary fuel filter

Comments:
Date:
Hour Meter Reading:

Every 1000 Hours
Lubricate rear drive line
Change transmission oil
Check and adjust engine speed linkage
Replace transmission filter
Replace air cleaner dust unloader valve
Inspect and adjust park brake
Replace air cleaner elements
Lubricate frame hinge pivots
Remove and clean engine crankcase vent tube

Comments:
Date:
Hour Meter Reading:

Every 2000 Hours
Adjust engine valve lash
Lubricate front driveline support bearing
Comments:
Date:
Hour Meter Reading:

Every 3000 Hours
Change hydraulic system oil
Replace differential lock return filters
Clean hydraulic system suction strainer
Change front and rear differential oil
Comments
Date:
Hour Meter Reading:
TX,50,JC1160 1903JUN961/1
509
PN=107
CHECK TIRE PRESSURE
CAUTION: Explosive separation of a tire and

rim parts can cause serious injury or death.
Always maintain the correct tire pressure. DO
NOT inflate tires above the recommended
pressure.
Inspect tires and wheels daily. DO NOT operate
with low pressure, cuts, bubbles, damaged
rims, or missing lug bolts.
TS211
When inflating tires, use a clip-on chuck and

extension hose long enough to allow you to
stand to one side and NOT in front of or over
the tire assembly. Use a safety cage if
available.
UN23AUG88
Carefully inspect any tire and rim assembly that

has been run flat or severely underinflated
before reinflating the tire. Damage to the rim
and tire may have developed. Call your
authorized dealer or a qualified repair service
to inspect the rim and tire assembly and make
necessary repairs.
T87502
Do not attempt to mount a tire if you do not

have the proper equipment and experience to
perform the job. Have it done by your
authorized dealer or a qualified repair service.
UN21OCT88
NEVER cut or weld on an inflated tire or rim

assembly. Heat from welding could cause an
increase in pressure and may result in tire
explosion.
Check tire pressure with an accurate gauge having 7.0

kPa (0.07 bar) (1 psi) graduations.
1. Shut off air supply to hose.
2. Move gauge hand to correct pressure.
3. Lock air chuck on tire valve.
TX,55,FF2820 1925OCT941/2
551
PN=108
4. Turn on air supply. Stand to front or rear of tire when
you add air to tire.
5. After tire is at correct pressure, shut off air supply.
Release chuck. (See following Tire Pressure chart.)
6. Inspect tire for damage.
TX,55,FF2820 1925OCT942/2
TIRE PRESSURES
544G, 544G TC
Operating Pressure*
Tire Size
Type
Ply Rating
kPa
bar
psi
14 x 24
G2
10
300
3.8
55
15.5 x 25
L2
12
380
3.8
55
15.5R x 25
L2 or L3 Equiv
(1) Star
**Front 415
4.1
60
**Rear 205
2.0
30
Rear, alternate 310
3.1
45
17.5 x 25
L2
12
345
3.4
50
17.5 x 25
L3
12
345
3.4
50
17.5R x 25
L2 or L3 Equiv
(1) Star
**Front 345
3.4
50
**Rear 170
1.7
25
Rear, alternate 275
2.8
40
20.5 x 25
L2
12
275
2.8
40
20.5 x 25
L3
12
275
2.8
40
20.5 x 25
L3
16
345
3.4
50
20.5R x 25
L2 or L3 Equiv
(1) Star
**Front 205
2.0
30
**Rear 170
1.7
25
Rear, alternate 205
2.0
30
23.1 x 26
LS-2
10
140
1.4
20
28L x 26
LS-2
14
170
1.7
25
*Shipping pressure may vary from operating pressure.

**These radial tire pressures are recommended for
optimum traction and tire wear under typical conditions. If
a higher rear tire pressure is used, it should not exceed
the alternator pressure listed.
TX,55,JC248 1929NOV941/1
552
PN=109
544G LL
Operating Pressure*
Tire Size
Type
Ply Rating
kPa
bar
psi
17.5 x 25
L2
12
345
3.4
50
17.5 x 25
L3
12
345
3.4
50
17.5R x 25
L2 or L3 Equiv
(1) Star
**Front 345
3.4
50
**Rear 170
1.7
25
Rear, alternate 275
2.8
40
20.5 x 25
L2
12
275
2.8
40
20.5 x 25
L3
12
275
2.8
40
20.5 x 25
L3
16
345
3.4
50
23.1 x 26
LS-2
10
140
1.4
20
28L x 26
LS-2
14
170
1.7
25

TX,55,JC1157 1903JUN961/1
553
PN=110
624G
Ply
Tire Size
Type
Operating Pressure*
Rating
kPa
bar
psi
14 x 24
G2
10
380
3.8
55
17.5 x 25
L3
12
345
3.4
50
17.5 x 25
L2
12
345
3.4
50
17.5 R25
L2 or L3 Equiv
(1) Star
**Front 450
4.5
65
**Rear 205
2.0
30
Rear, alternate 310
3.1
45
20.5 x 25
L3
12
275
2.8
40
20.5 x 25
L3
16
345
3.4
50
20.5 x 25
L2
12
275
2.8
40
20.5R x 25
L2 or L3 Equiv
(1) Star
**Front 310
3.1
45
**Rear 170
1.7
25
Rear, alternate 275
2.8
40
23.1 x 26
LS-2
10
140
1.4
20
28L x 26
LS-2
14
170
1.7
25

TX,55,JC1158 1903JUN961/1
554
PN=111
644G
Ply
Tire Size
Type
Operating Pressure*
Rating
kPa
bar
psi
16.0 X 24
G2
12
380
3.8
55
20.5 X 25
L2
12
275
2.8
40
20.5 x 25
L2
16
345
3.4
50
20.5 x 25
L3
16
345
3.4
50
20.5R x 25
L2 or L3 Equiv
(I) Star
**Front 415
4.1
60
**Rear 205
2.0
30
Rear, alternate 310
3.1
45
23.5 x 25
L2
12
240
2.4
35
23.5 x 25
L3
16
310
3.1
45
23.5 x 25
L3
20
380
3.8
55
23.5R x 25
L2 or L3 Equiv
(1) Star
**Front 275
2.8
40
**Rear 205
2.0
30
28L x 26
LS-2
14
Rear, alternate 240
2.4
35
170
1.7
25

TX,55,JC1159 1903JUN961/1
TIGHTEN WHEEL RETAINER CAP SCREWS

NOTE: Tighten cap screws after first 10 hours, then again
after first 50 hours of loaded operation. After that,
tighten as required.
Tighten wheel cap screws to 542 Nm (400 lb-ft).
TX,55,DH2551 1916JUN931/1
555
PN=112
CLEAN OR REPLACE AIR CLEANER

ELEMENTS
1. Open left service door.
2. Loosen wing nut to remove cover.
TX,55,DH2226 1931JUL921/3
T6119AF
UN01NOV88
3. Remove wing nut and primary element (A).
TX,55,DH2226 1931JUL922/3
T6119AG
UN01NOV88
4. Remove wing nut from 544G, LL, TC, and 644G, or

hex nut from 624G, and remove secondary element
(B).
TX,55,DH2226 1931JUL923/3
556
PN=113
CAUTION: Prevent possible injury from flying

chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to
less than 210 kPa (2.1 bar) (30 psi) when using
for cleaning purposes. Clear area of
bystanders, guard against flying chips, and
wear personal protection equipment including
eye protection.
T47764
1. Tap element with the palm of your hand, NOT ON A

HARD SURFACE.
UN09NOV88
CLEAN DUSTY PRIMARY ELEMENT
2. If this does not remove dust, use compressed air under

210 kPa (2.1 bar) (30 psi).
3. Direct air up and down the pleats from inside to
outside. Be careful not to make a break in the element.
03T,55,MM11 1918NOV921/1
CLEAN OILY OR SOOTY PRIMARY ELEMENT
2. Flush with clean water. Use water pressure under 280

kPa (2.8 bar) (40 psi).
T90673
1. Wash element in warm water and John Deere R36757

Filter Element Cleaner or equivalent non-sudsing
detergent.
UN10NOV88
IMPORTANT: You can damage element. DO NOT

wash element in fuel oil, oil, gasoline,
or solvent. DO NOT use compressed air
to remove water from an element.
3. Shake the element to remove water. Do not install

element unless it is dry.
03T,55,C19 1924JUL911/1
557
PN=114
INSPECT ELEMENT
IMPORTANT: A damaged or dirty element may cause
engine damage.
If the element shows damage.

If element will not clean.
After 1000 hours service or annually.
T90684
UN10NOV88
Install a new primary element:
Install a new secondary element:

If the primary element is damaged
and needs to be replaced.
If the element is visibly dirty.
After 1000 hours service or annually.
DO NOT clean a secondary element.
Install a new element carefully centering
it in the canister.
1. Inspect element and gasket for damage.
2. Air restriction indicator will not signal correctly if an
element has a break or is not correctly sealed in air
cleaner housing. Throw away element that has the
slightest damage. If gasket is broken or missing,
install a new element.
03T,55,C67 1924JUL911/1
558
PN=115
CHECK AIR INLET COVER

1. Loosen clamp and slide strap (B) down stack.

eye protection.
T6779BQ
UN19OCT88
2. Remove air inlet cover (A).
3. Clean cover with compressed air or soapy water. Dry

cover.
4. Install cover on stack. Tighten clamp.
TX,55,DH2206 1931JUL921/1
559
PN=116
CHECK AND ADJUST BELT TENSION544G,

624G
1. Check belt regularly for wear. Replace if necessary.
UN18OCT88
2. Check belt tension of belt closest to fan midway

between pulleys. 544G, LL, TC, 624G: right side of
engine. 644G: left side of engine.
T6603AK
SPECIFICATIONS
544G, LL, TC, 624G:
Force: 67 N (15 lb)
Deflection: 19 mm (0.75 in.)
544G, 624G Shown
3. If deflection is not within specifications, loosen

alternator mounting cap screws.
UN30NOV94
4. Apply force to FRONT alternator housing only (near

the belt) until tension is correct.
T8372BK
5. Tighten cap screws to 57 Nm (40 lb-ft).
544G Shown
AAlternator Pulley
BFan Pulley
CCrankshaft Pulley
DStraight Edge
EBelt Deflection Gauge
FCap Screws
TX,55,JC1138 1922MAY961/1
5510
PN=117
INSPECT SERPENTINE BELT644G

1. Check belt regularly for wear, especially for cracks at
the bottom of grooves and for frayed edges.
2. If necessary, replace belt.
3. Place the drive of a 1/2 in. drive ratchet in square
hole. Turn ratchet counterclockwise to pull tension
adjuster assembly away from belt, releasing belt
tension.
4. Hold tension adjuster assembly away from belt while
removing old belt and installing new belt.
5. Slowly turn ratchet clockwise to place tension adjuster
assembly against new belt. Tension is automatically
adjusted.
T7405BG
UN15NOV90
6. Remove ratchet from assembly.
TX,55,JC1118 1920MAR961/1
DRAIN FUEL TANK

1. Remove fuel tank filler cap.
TX,55,DH2491 1916MAY951/2
NOTE: Petcock located at left front of machine frame

bottom guard.
2. Loosen petcock (A).
3. Drain water and sediment into a container.
4. Tighten petcock.
T7773CN
UN21AUG92
5. Install filler cap.
TX,55,DH2491 1916MAY952/2
5511
PN=118
DRAIN AND CLEAN PRIMARY FUEL FILTER

(WATER SEPARATOR)544G, 624G
1. Open left side shield to access primary fuel filter
(water separator).
TX,55,JC283 1916MAY951/3
2. Put container under drain valves (D and F).
UN10SEP92
3. Rotate retaining ring around filter element

counterclockwise 1/4 turn. Lifting ring as it is rotated
helps get it past retaining detent. Ring should drop
down and release filter from base.
T8387AE
UN17DEC94
T7833AJ
4. Remove hand primer (B) from fuel filter base.

Disassemble hand primer assembly and clean out any
debris.
ABleed Screw (Final Fuel Filter)

BPump
CPrimary Fuel Filter (Water
Separator)
DDrain Valve (Primary Fuel Filter)
EBleed Screw (Primary Fuel
Filter)
FDrain Valve
GFinal Fuel Filter
TX,55,JC283 1916MAY952/3
5512
PN=119
5. Remove fuel inlet line (A) and fuel drain plug (C).
6. Flush any debris from filter base (B).
UN17DEC94
7. Install fuel inlet drain plug and fuel inlet line.

8. Assemble primer assembly and install onto fuel filter
base.
T8387AD
9. Install filter element to fuel filter base.

10. Close side shield.
11. Dispose of waste properly.
TX,55,JC283 1916MAY953/3
DRAIN AND CLEAN PRIMARY FUEL FILTER

(WATER SEPARATOR)644G
1. Open left side shield to access primary fuel filter (F).
2. Place container under filter.
3. Open drain valve (G) and press pump (D) to extract
water from fuel system.
T100696
UN22MAR96
4. Close drain valve.
AFinal Fuel Filter

BBleed Screw
CBleed Screw
DPump
EFuel Supply Line
FPrimary Fuel Filter
GDrain Valve
TX,55,JC1105 1918MAR961/1
5513
PN=120
CHECK CAB RECIRCULATING AIR FILTER
2. Remove filter.
CAUTION: Reduce compressed air to less than

210 kPa (2 bar) (30 psi) when using for cleaning
purposes. Clear area of bystanders, guard
against flying chips, and wear personal
protection equipment, including eye protection.
T8295AA
1. Loosen two thumbscrews (A) holding grille. Remove

grille.
UN10AUG94
NOTE: The cab recirculating air filter is located behind

the seat.
3. Clean filter in one of these ways:

Tap it on a flat surface with the dirty side down.
Use compressed air opposite to the normal air flow.
Wash the filter in warm, soapy water. Flush the filter
and let it dry before using the air conditioner.
4. Replace filter and grille.
5. Tighten thumbscrews.
TX,55,JC1122 1916APR961/1
5514
PN=121

LUBRICATE PIVOTS
Lubricate working tool pivots every 10 hours or daily when
operating in deep mud, water, or snow.
TX,60,DH2560 1902OCT921/1
IMPORTANT: A missing, damaged, or hardened dust

unloader valve will make the dust cup
precleaner ineffective, causing very
short element life. Valve should suck
closed above 1/3 engine speed.
T7773CQ
Squeeze dust valve (A) to remove dust from the air

cleaner.
UN21AUG92
CLEAN AIR CLEANER DUST UNLOADER

VALVE
If operating in high dust conditions, squeeze dust valve

every couple of hours of operation to release dust.
TX,60,DH2210 1917AUG921/1
CHECK ENGINE OIL LEVEL

IMPORTANT: If oil level is low, the engine can be
damaged. DO NOT operate the engine
when oil level is below the ADD mark.
The most accurate oil level reading is obtained when the
engine is cold, before starting the engine for the days
operation.
TX,60,JC1106 1918MAR961/2
601
PN=122

3. 544G, 624G: Make sure dipstick (A) is fully seated.
4. 544G, 624G: Remove dipstick to check oil level.
UN31AUG92
644G: Tighten filler cap (B) to fully seat. Remove filler

cap to check oil level.
AFTER THE ENGINE HAS BEEN RUN: Allow the oil

to drain into the oil pan for 10 minutes before
checking the oil level. Ten minutes after shutdown the
engine oil level must be above the ADD mark.
T7829AE
BEFORE THE ENGINE IS STARTED: The engine is

full when oil level is in the cross hatched area. It is
acceptable to run the engine when the oil level is
above the ADD mark.
544G Shown
T7829AF
UN31AUG92
5. If necessary, remove filler cap (B) to add oil. (See

T100695
UN22MAR96
624G Shown
644G Shown
TX,60,JC1106 1918MAR962/2
602
PN=123
CHECK RECOVERY TANK COOLANT LEVEL
CAUTION: Prevent possible injury from hot

spraying water. DO NOT remove radiator filler
cap unless engine is cool. Then turn cap slowly
to the stop. Release all pressure before you
remove cap.
T8385AE
If coolant is below the COLD mark, add coolant to the

recovery tank.
UN15DEC94
With the engine cold, coolant level must be between HOT

and COLD marks on the recovery tank.
If recovery tank is full and radiator is low, check for leaks

in radiator cap and hose connections between radiator
and coolant recovery tank.
T6274AQ
Coolant level must be at bottom of the filler neck.
UN18OCT88
If recovery tank is empty, check for leaks. Repair as

required. Add coolant to the radiator and the recovery
tank.
TX,60,JC280 1916MAY951/1
CHECK HYDRAULIC OIL LEVEL

IMPORTANT: Prevent possible hydraulic pump
damage. DO NOT operate engine
without oil in the hydraulic reservoir.
2. Lower equipment to the ground.
TX,60,DH2213 1916JUN931/3
603
PN=124
T7773CB
UN10AUG92
3. When oil is cold, oil level must be in FULL range on

sight glass (A).
TX,60,DH2213 1916JUN932/3
4. If necessary, add oil to filler cap (B). (See Fuels and

Lubricants chapter.)
T8029AM
UN15JUN93
TX,60,DH2213 1916JUN933/3
604
PN=125
CHECK TRANSMISSION OIL LEVEL

IMPORTANT: Prevent possible transmission damage.
DO NOT operate engine when
transmission oil level is low.
1. Before starting engine, check oil level on dipstick (A). If
oil is to upper mark when oil is cold, there is sufficient
oil to start the engine.
2. If necessary, add oil to filler tube. (See Fuels and
3. Install dipstick.
UN21AUG92
4. Start engine.
T7773CP
5. Engage service brakes. Move clutch cut-off switch up,

to disengaged position.
6. Release park brake.
7. Move transmission control lever to 3rd speed forward
"F" position.
624G Shown
Operate engine at fast idle for 30 seconds. Reduce

engine speed to slow idle and place transmission
control lever in neutral "N", for 15 seconds.
Repeat this step until transmission oil reaches normal
operating temperature.
8. Move transmission control lever to neutral "N", and
engage neutral lock. Lower all equipment to ground.
10. Release service brakes.
11. Check oil level with engine at slow idle. Oil must be
between marks on dipstick.
TX,60,DH2214 1902OCT921/1
605
PN=126

LUBRICANT BOOM, BUCKET, AND
CYLINDER PIVOTS

unexpected machine movement. Install frame
locking bar before lubricating.
Lower bucket flat on ground.

Lubricate following 13 points until grease escapes around
seals. (See Fuels and Lubricants chapter.)
T6523CP1
UN20OCT88
Lubricate every 10 hours or daily when operating in deep

mud, water, or snow.
T8029AS
UN21JUN93
Six Points, 544G Shown
T6570AR1
UN25OCT88
Four Points, 544G Shown
Three Points, 644G Shown

TX,70,DH2215 1916JUN931/1
701
PN=127
LUBRICATE BOOM, BUCKET, AND

CYLINDER PIVOTS544G TC
UN17SEP92
Lower equipment to ground.
T7829BF
Lubricate following 17 points until grease escapes around

seals. (See Fuels and Lubricants chapter.)
T7829BG
UN17SEP92
Four Points, Right Side Shown
Eight Points
TX,70,DH2290 1902OCT921/2
702
PN=128
T7829BH
UN17SEP92
Lubricate every 10 hours or daily when operating in deep

mud, water, or snow.
Five Points
TX,70,DH2290 1902OCT922/2
703
PN=129
LUBRICATE STEERING CYLINDER PIVOTS

UN22MAR96
T100694
Lubricate each point with three shots of grease. (See

T6597AB1
UN25OCT88
Four Points, 644G Left Side Shown
ARight Steering Cylinder (Head

End)
BLeft Steering Cylinder (Head
End)
TX,70,JC1107 1918MAR961/1
704
PN=130
LUBRICATE OSCILLATING REAR AXLE

UN22MAR96
T100693
Lubricate each point with 10 shots of grease. (See Fuels

and Lubricants chapter.) Grease daily when operating in
deep mud, water, or snow.
T6597AB
UN25OCT88
Two Points, 644G Shown
ARear Axle Front Oscillating

Pivot
BRear Axle Rear Oscillating Pivot
TX,70,JC1108 1918MAR961/1
CHECK CAB FRESH AIR FILTERIF

EQUIPPED
T6629AK
UN20OCT88
1. Open door (A).
TX,70,JC1056 1924JAN961/2
705
PN=131

NOTE: If operating in dusty conditions, cab fresh air filter
should be checked and cleaned as required.

eye protection.
T7829AC
3. Clean filter in one of these ways:
UN31AUG92
2. Remove filter (B). Replace if damaged.
Tap filter on a flat surface with the dirty side down.

Use compressed air opposite to the normal air flow.
Wash the filter in warm, soapy water. Flush the
filter. Let it dry before using the heater, defroster, or
air conditioner.
4. Replace filter. Close door.
TX,70,JC1056 1924JAN962/2
706
PN=132
1. Remove rubber plug (A) on right front panel.
T8372BH
IMPORTANT: Prevent possible compressor damage. If

receiver dryer moisture eye color
indicates "WET" (yellow), dryer is
saturated and should be changed
within the next 100 machine hours to
prevent further buildup of moisture in
the refrigerant.
UN30NOV94
CHECK RECEIVER DRYER MOISTURE

INDICATOR
TX,75,JC260 1916MAY951/2
3. If wet (yellow), see your authorized dealer within the

next 100 machine hours to service the receiver dryer.
T8372BG
4. Install plug.
UN30NOV94
2. Check sight glass (B) with engine running and air

conditioning turned ON to determine if color indicates
dryer is dry (green) or wet (yellow).
TX,75,JC260 1916MAY952/2
751
PN=133
CHANGE ENGINE OIL AND REPLACE

FILTER
IMPORTANT: If fuel sulphur content exceeds 0.5
percent, change engine oil at 1/2 the
normal interval.
NOTE: If engine has not run 250 hours before the season
changes, change oil.
1. Run engine to warm oil.


TX,75,JC1109 1918MAR961/4
752
PN=134
T7853AI
UN08OCT92
7. Install hose on drain valve (A). Turn valve

counterclockwise with a 1/4 in. hex key wrench. Allow
oil to drain into a container. Dispose of waste oil
properly.
624G Shown
TX,75,JC1109 1918MAR962/4
753
PN=135

8. Turn filter (A) counterclockwise to remove.
9. Clean mounting surface. Apply thin film of oil to gasket
of new filter.
UN31AUG92
10. Install new filter. Turn filter clockwise by hand until

gasket touches mounting surface.
T7829AH
11. Tighten 1/23/4 turn more.

12. Tighten drain valve.
544G Shown
13. Remove filler cap (B).

14. Fill engine with oil. (See Fuels and Lubricants
chapter.)
SPECIFICATION
544G, LL, TC, 624G
19 L (20 qt)
644G
24 L (25 qt)
UN31AUG92
Includes filter change:
IMPORTANT: Before starting engine after a filter

change, crank engine for 10 seconds
without starting to refill filter and
prelubricate turbocharger.
T7829AI
624G Shown
16. Remove engine shut-off fuse.

Crank engine for 10 seconds using starting motor.
Install engine shut-off fuse.
17. Start engine and run at slow idle.
UN22MAR96
18. Check that engine oil pressure light on monitor goes

out and audible alarm stops immediately. If not, stop
engine immediately and find cause.
T100692
19. Stop the engine. Check oil level. The engine is full
when oil level is in the cross hatched area on the
dipstick.
644G Shown
TX,75,JC1109 1918MAR963/4
754
PN=136

20. Check for any leakage at filter. Tighten filter only
enough to stop leakage.
TX,75,JC1109 1918MAR964/4

spraying water. DO NOT remove radiator filler
cap unless engine is cool. Then turn cap slowly
to the stop. Release air to relieve all pressure
before you remove cap.
1. Slowly remove cap. Coolant level must be at bottom

of the filler neck.
NOTE: If radiator coolant level is low, check for leaks on

radiator cap, and hose connections between
radiator and coolant recovery tank.
T6642EK
UN01NOV88
CHECK RADIATOR COOLANT LEVEL
2. Add coolant, if necessary.

TX,75,DH3501 1929NOV941/1
755
PN=137

LUBRICANT FRONT DRIVELINE
UN08OCT92
T7853AJ
NOTE: To prevent plug loss, lubricate the machine when

it is fully articulated or half articulated and NOT in
the straight position.
Lubricate until grease escapes around vent holes in drive
shaft end. (See Fuels and Lubricants chapter.)
One Point
NOTE: Grease daily when operating in deep mud, water,

or snow.
TX,80,JC1139 1923MAY961/1
CHECK AIR INTAKE HOSES

Check hoses for cracks (A).
T7829BD
UN17SEP92
Tighten hose clamps.
T100707
UN22MAR96
544G Shown
644G Shown
TX,80,JC1110 1918MAR961/1
801
PN=138
CHECK BATTERY ELECTROLYTE LEVEL

AND TERMINALS
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
NEVER check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
ALWAYS remove grounded (-) battery clamp
first and replace it last.
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
UN23AUG88
Avoid the hazard by:

Filling batteries in a well-ventilated area.
Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is
added.
TS203
Avoiding spilling or dripping electrolyte.

Use proper jump start procedure.
If you spill acid on yourself:
Flush your skin with water.
Apply baking soda or lime to help neutralize
the acid.
Flush your eyes with water for 1530
minutes. Get medical attention immediately.
If acid is swallowed:
Do not induce vomiting.
TX,75,DH1574 1928APR931/4
802
PN=139

Drink large amounts of water or milk, but do
not exceed 1.9 L (2 quarts).
Get medical attention immediately.
1. Remove battery box cover.
TX,75,DH1574 1928APR932/4
UN10FEB89
IMPORTANT: If water is added to batteries during

freezing weather, batteries must be
charged after water is added to prevent
batteries from freezing. Charge battery
using a battery charger or by running
the engine.
T6996DB
2. Fill each cell to within specified range with distilled

water. DO NOT overfill.
CAUTION: Prevent possible injury. ALWAYS
remove grounded (-) battery clamp first and
replace it last.
T6996DA
UN10FEB89
3. Disconnect battery clamps, grounded clamp first.
ABattery Post
BFill Tube
CElectrolyte Level Range
TX,75,DH1574 1928APR933/4
803
PN=140

4. Clean battery terminals (A) and clamps with a stiff
brush.
UN21OCT88
5. Apply lubricating grease (B) around battery terminal

base only.
T6758AA
6. Install and tighten clamps, grounded clamp last.
TX,75,DH1574 1928APR934/4
804
PN=141

spraying water. DO NOT remove radiator cap
unless the engine is cool. Then loosen cap
slowly to the stop. Release all pressure before
removing cap.
1. Turn cap slowly to the stop to release pressure. Then

remove cap.
NOTE: A coolant strip test, available from your dealer,

provides a simple, effective way to check freeze
point and molybdate/nitrite levels. These results
can be compared to the SCA chart to determine
the amount of coolant conditioner in your system.
UN23AUG88
2. Add TY16004 John Deere Coolant Conditioner or

equivalent non-chromate conditioner/rust inhibitor,
following instructions on container. Drain enough
coolant from the radiator to allow room for the
conditioner.
Approx. 24 L (25 qt)
624G Cooling system capacity
Approx. 28 .5 L (30 qt)
TS281
SPECIFICATIONS
T101279
1914MAY96
CHECK COOLANT
NOTE: Add conditioner every 500 hours or 6 months, or

if you replace 1/3 or more of coolant.
John Deere Liquid Coolant Conditioner does not
protect against freezing.
DO NOT add John Deere liquid coolant
conditioner to a cooling system already equipped
with an operational filter conditioner system. Too
much conditioner in a cooling system may cause
silicate-dropout. When this happens, a gel-type
despot is created which can restrict coolant
passages in the radiator and engine, resulting in
engine overheating.
TX,80,JC1140 1923MAY961/1
805
PN=142
REPLACE PRIMARY FUEL FILTER (WATER

SEPARATOR)
UN31AUG92
1. Turn filter assembly (A) counterclockwise to remove.

Allow sediment to drain into a container. Dispose of
waste properly.
3. Rotate retaining ring around filter element

counterclockwise 1/4 turn. Lifting ring as it is rotated
helps get it past retaining detent. Ring should drop
down and release filter from base.
T7829AR
2. Turn sediment bowl (B) counterclockwise to remove

from filter assembly.
624G Shown
T8387AE
UN17DEC94
4. Remove hand primer from fuel filter base.

Disassemble hand primer assembly and clean out any
debris.
TX,80,JC427 1918JAN961/2
5. Remove fuel inlet line (A) and drain plug (C).

6. Flush any debris from filter base (B).
8. Assemble primer assembly and install onto new fuel

filter base.
T8387AD
9. Install new filter. (Follow instructions on filter.)
UN17DEC94
7. Install fuel inlet drain plug and fuel inlet line.
10. Bleed fuel system. (See Bleeding Fuel System in

TX,80,JC427 1918JAN962/2
806
PN=143
REPLACE FINAL FUEL FILTER544G, 624G
UN31AUG92
1. Turn filter assembly (A) counterclockwise to remove.

Allow sediment to drain into a container. Dispose of
waste properly.
2. Clean filter base.
T7829AS
3. Install new filter. (Follow instructions on filter.)

544G Shown
TX,80,DH2506 1902OCT921/1
REPLACE FINAL FUEL FILTER644G

1. Loosen clamps (A) to remove filter (B).
UN01MAY89
2. Clean filter base.

3. Install new filter. Tighten clamps.
T7034AH

TX,80,DH2225 1929AUG921/1
REPLACE HYDRAULIC SYSTEM RETURN

FILTER
1. Remove hydraulic reservoir filler cap.
TX,80,JC1111 1918MAR961/2
807
PN=144

of new filter.
4. Install new filter. Tighten filter 3/41 full turn after
seal contacts mounting base.
5. Fully loosen filter element. Repeat step 4.
6. Start engine. Check for leaks around the filter base.
Tighten filter only enough to stop leaks.
T100705
UN22MAR96
7. Stop engine. Check oil level.
644G Shown
TX,80,JC1111 1918MAR962/2
REPLACE HYDRAULIC RESERVOIR

BREATHER FILTER
Hydraulic reservoir breather filter is located on back side
of reservoir under the hood.
TX,80,JC1112 1918MAR961/2
808
PN=145

T7829BE
UN17SEP92
2. Install new filter.
T100708
UN22MAR96
544G Shown
644G Shown
TX,80,JC1112 1918MAR962/2
CHECK FRONT AND REAR DIFFERENTIAL

OIL LEVELIF EQUIPPED WITH STANDARD
AXLE
UN08OCT92
NOTE: Each differential housing has three sumps. Fill

center housing slowly to let oil drain into all
sumps.
2. Oil must be to bottom of opening.
T7853AK
1. Loosen plugs (A). If oil seeps from plugs, differential oil

level is OK. If not, remove plugs.
Front Differential Shown
3. If necessary, add oil. (See Fuels and Lubricants

chapter.)
T6570AC2
UN20OCT88
4. Install or tighten plugs.
Rear Differential Shown

TX,80,DH2552 1923JUN931/1
809
PN=146
CHECK FRONT AND REAR DIFFERENTIAL

OIL LEVELIF EQUIPPED WITH
DIFFERENTIAL LOCK AXLE
spraying oil. Slowly loosen plugs to relieve any
air pressure.
UN08OCT92
2. Start engine.
T7853AK
1. Remove plugs (A). Oil must be to bottom of opening. If

not, install plugs.
3. Hold down differential lock pedal for 1 minute with

engine running at slow idle.
4. Stop engine.
UN20OCT88
5. Slowly remove plugs. Oil must be to bottom of

opening. If not, install plugs and repeat steps 24 until
oil seeps from opening.
T6570AC2
6. If necessary, add oil to hydraulic reservoir. (See Fuels

and Lubricants chapter.)
TX,80,DH2965 1923JUN931/1
8010
PN=147

LUBRICATE REAR DRIVELINE
UN11JUN91
T7516BG
NOTE: To prevent plug loss, lubricate the machine when

it is fully articulated or half articulated and NOT in
the straight position.
Lubricate until grease escapes around vent holes in drive
shaft end. (See Fuels and Lubricants chapter.)
One Point
NOTE: Grease daily when operating in deep mud, water,

or snow.
TX,85,DH2477 1931JUL921/1
CHECK ENGINE SPEEDS

1. Warm engine to normal operating temperature.
2. Connect a tachometer and check engine speeds.
SPECIFICATIONS
SLOW IDLE
544G, LL, TC
624G
825875 rpm
825875 rpm
644G
775825 rpm
(S.N. -544523)
875925 rpm
(S.N. 544524- )
FAST IDLE
23502400
rpm
23002350
rpm
23002350
rpm
If engine speeds need adjustment, check engine speed

linkage. If speeds still need adjusting, see your
authorized dealer.
TX,85,JC254 1929NOV941/1
851
PN=148
T7853AB
UN06OCT92
ADJUST ENGINE SPEED CONTROL LINKAGE
ASwivel
BCable
CLever
1. With accelerator pedal at slow idle, disconnect

swivel (A) on speed control cable (B) and adjust
until:
DStop Screw
2. Depress accelerator pedal until injection pump

lever is against fast idle stop and hold.
3. Adjust pedal stop screw (D) until it makes contact
with the pedal. Release pedal.
544G, LL, TC, and 624G: Injection pump lever (C)

has 24 mm (0.080.16 in.) of override at the
slow idle position. Connect cable to injection pump
lever.
4. 544G, LL, TC, and 624G: Shorten pedal stop

screw until 24 mm (0.090.16 in.) override is
obtained at the pump.
644G: Hole in injection pump lever just lines up with

swivel at the slow idle position. Lengthen cable two
turns. Connect to injection pump lever.
644G: Tighten lock nut.
TX,85,DH2229 1902OCT921/1
852
PN=149
REPLACE AIR CLEANER DUST UNLOADER

VALVE
UN21AUG92
NOTE: A missing, damaged, or hardened dust valve will

cause the air filter elements to be ineffective.
T7773CQ
Replace dust valve (A).
624G Shown
TX,85,DH2246 1926AUG921/1
REPLACE AIR CLEANER ELEMENTS

1. Remove cover.
TX,85,DH2245 1931JUL921/3
T6119AF
UN01NOV88
2. Remove wing nut to remove primary element (A).
TX,85,DH2245 1931JUL922/3
3. Remove wing nut from 544G and 644G, or hex nut

from 624G to remove secondary element (B).
5. Install new elements making sure secondary element

is centered in canister.
T6119AG
6. Install cover.
UN01NOV88
4. Clean air cleaner canister.
TX,85,DH2245 1931JUL923/3
853
PN=150
T7829AK
UN31AUG92
CLEAN ENGINE CRANKCASE VENT TUBE

(A)
T7829AL
UN31AUG92
544G Shown
T100691
UN22MAR96
624G Shown
644G Shown
TX,85,DH2230 1902OCT921/1
854
PN=151
CHANGE TRANSMISSION OIL AND

REPLACE FILTER
1. Operate machine under load until transmission oil
reaches normal operating temperature.


locking bar before changing oil.

7. Run engine at 1/2 speed for 2 minutes before stopping
to avoid damage to turbocharger. Release accelerator
pedal to slow idle.
8. Turn key switch to STOP. Let machine sit for
approximately 10 minutes.
TX,85,JC1057 1924JAN961/4
855
PN=152
T7853AA
UN23SEP92
9. Remove plug (A), located inside hole in bottom guard,

to drain oil. Allow oil to drain into a container. Dispose
of waste oil properly.
TX,85,JC1057 1924JAN962/4
11. Clean mounting surface. Apply thin film of oil to

gasket of new filter.
T7853AC
12. Install new filter. Turn filter clockwise by hand until

gasket touches mounting surface.
UN06OCT92
10. Remove right panel under cab to gain access to

transmission filter (A). Clear area around filter before
removing. Turn filter counterclockwise to remove.
13. Tighten 1/2 to 3/4 turn more.

14. Apply pipe sealant with TEFLON to threads of
transmission drain plug. Install drain plug.
TX,85,JC1057 1924JAN963/4
856
PN=153

15. Remove transmission dipstick (A).
16. Fill transmission with oil. (See Fuels and Lubricants
chapter.)
SPECIFICATIONS
Includes filter change
544G, LL, TC,
9.5 L (10 qt)
624G
11 L (12 qt)
644G
14 L (15 qt)
17. Start engine and run for 2 minutes.
UN21AUG92
18. Move transmission control lever to neutral "N", and

engage neutral lock.
T7773CP
19. Check oil level. Oil must be between marks on

dipstick.
20. Check for leaks around the filter base. Tighten filter
only enough to stop leaks.
624G Shown
TEFLON is a trademark of the DuPont Company.
TX,85,JC1057 1924JAN964/4
CHECK PARK BRAKE

IMPORTANT: The park brake is also designed to
function as the secondary braking
system. The park brake must be
properly maintained and adjusted.
1. Start engine.
CAUTION: Prevent possible injury from sudden

machine stop. Fasten seat belt for this check.
2. Fasten seat belt.

3. Press the SELECT switch until MPH reading is
displayed.
TX,85,DH2561 1909OCT921/2
857
PN=154
5. Drive machine at 5 mph and move park brake switch

to ON. Machine must stop within 2 m (6 ft), and
transmission must shift to neutral.
T7773AG
6. If necessary, adjust park brake.
UN11JUN92
4. Move park brake switch (A) to OFF, and move

transmission control lever to 2nd gear forward.
TX,85,DH2561 1909OCT922/2
ADJUST PARK BRAKE

TX,85,JC1141 1923MAY961/3

loader bucket to keep machine from moving.
Machine can unexpectedly roll or move under
power, resulting in death or serious injury.
Always block wheels to hold machine when
working on park brake.
T7747BR
UN19MAY92

5. Stop engine; this will engage park brake.

6. Place blocks in front of and behind tires.
TX,85,JC1141 1923MAY962/3
858
PN=155

7. Remove screws and remove sheet metal cover from
brake. Loosen lock nut (A).
8. Loosen the 4 mounting capscrews that hold the park
brake to the mounting bracket.
9. Tighten adjustment screw (B) to 100 Nm (75 lb-ft).
10. Tighten the 4 mounting capscrews to 70 Nm (50 lbft).
11. Back the adjustment screw off 180 (1/2 turn). (This
will give approximately 0.5 mm (.02 in.) pad to disk
clearance with park brake released and engine
running.)
12. While holding the adjustment screw in place, tighten
the lock nut.
T100701
UN22MAR96
13. Install sheet metal cover. Tighten cover screws.
TX,85,JC1141 1923MAY963/3
859
PN=156
LUBRICATE FRAME HINGE PIVOTS

T100690
UN22MAR96
Lubricate each point with three shots of grease. (See

644G Shown
TX,85,JC1113 1918MAR961/1
8510
PN=157

MEASURE AND ADJUST ENGINE VALVE
LASH (CLEARANCE)544G, LL, TC, 624G
1. Remove precleaner or air intake cover, hood, air
cleaner bracket with air cleaner intake manifold, and
engine crankcase vent tube.
2. Plug all openings.
3. Check crankcase ventilation tube for restriction. Clean
with solvent or diesel fuel.
4. Remove rocker arm cover.
TX,85,DH2239 1931JUL921/5
5. Install JDE-81-1 Flywheel Turning Tool (A).
T6129AJ
7. Try to move both pushrods at number one cylinder. If

both are loose, proceed with adjustment per chart on
No. 1 TDC. If both pushrods at number six are loose,
proceed with adjustment per chart on No. 6 TDC.
UN27OCT88
6. Turn flywheel until JDE-81-4 Timing Pin (B) goes into

hole in flywheel.
TX,85,DH2239 1931JUL922/5
T6119AI
8. Measure and adjust valve clearance with No. 1 piston

or No. 6 at TDC. To change piston position, pull timing
pin out of flywheel, rotate flywheel 360, and insert
timing pin.
UN13MAR89
NOTE: Valve clearance can be adjusted whether engine

is hot or cold.
TX,85,DH2239 1931JUL923/5
861
PN=158

9. Remove turning tool and timing pin.
544G, LL, TC, 624G VALVE CLEARANCE SPECIFICATIONS
0.36 mm (0.014 in.)
Exhaust Valve (E)
0.46 mm (0.018 in.)
T6233AG
1927JAN89
Intake Valves (I)
TX,85,DH2239 1931JUL924/5
0.36 mm (0.014 in.)
Exhaust Valve (E)
0.46 mm (0.018 in.)
10. Clean cylinder head and rocker arm cover mating

surfaces.
11. Install rocker arm cover gasket. Do not use sealant
on the gasket.
12. Install rocker arm cover. Tighten screws to 10.8 Nm
(96 lb-in.). Do not overtighten cap screws.
T6233AH
Intake Valves (I)
1927JAN89
544G, LL, TC, 624G VALVE CLEARANCE SPECIFICATIONS
13. Install parts.
TX,85,DH2239 1931JUL925/5
862
PN=159
ADJUST ENGINE VALVE LASH

(CLEARANCE)644G
1. Remove precleaner, hood, air cleaner support with
starting aid and air cleaner, engine crankcase vent
tube.
2. Plug all openings.
3. Check crankcase ventilation tube for restriction. Clean
with solvent or diesel fuel.
4. Remove rocker arm cover.
5. Remove plugs. Install JDE-81-I Flywheel Turning Tool
(A) and JDE-81-4 Timing Pin (B).
6. Rotate flywheel until timing pin fits into hole in
flywheel.
7. Try to move both pushrods at number one cylinder. If
both are loose, proceed with adjustment per chart on
No. 1 TDC. If both pushrods at number six are loose,
proceed with adjustment per chart on No. 6 TDC.
TX,86,JC1142 1923MAY961/4
NOTE: Valve clearance can be adjusted whether engine

is hot or cold.
T6105BF
9. Loosen hex nut.
UN24FEB89
8. Measure and adjust valve clearance with No. 1 piston

or No. 6 at TDC. To change piston position, pull timing
pin out of flywheel, rotate flywheel 360, and insert
timing pin.
10. Use screwdriver to adjust valve clearance.

11. Tighten hex nut and torque to 9.5 4 Nm (84 36
lb-in.).
TX,86,JC1142 1923MAY962/4
863
PN=160

12. Remove flywheel turning tool and timing pin. Install
plugs.
644G VALVE CLEARANCE SPECIFICATIONS
0.38 mm (0.015 in.)
Exhaust Valve (E)
0.71 mm (0.028 in.)
T6233AI
1927JAN89
Intake Valves (I)
TX,86,JC1142 1923MAY963/4
Intake Valves (I)
0.38 mm (0.015 in.)
Exhaust Valve (E)
0.71 mm (0.028 in.)
13. Clean cylinder head and rocker arm cover mating

surfaces. Apply gasket cement to rocker arm cover.
T6233AJ
14. Install rocker arm cover. Tighten cap screws to 10.8

Nm (96 lb-in).
1927JAN89
644G VALVE CLEARANCE SPECIFICATIONS
15. Install parts.

16. Remove flywheel turning tool and timing pin. Install
plugs.
TX,86,JC1142 1923MAY964/4
864
PN=161
LUBRICATE FRONT DRIVELINE SUPPORT

BEARING
UN23AUG89
T7114AS
Lubricate until grease escapes around seal. (See Fuels

NOTE: Grease every 250 hours if operating in deep mud

or water.
One Point
TX,86,JC1143 1923MAY961/1
865
PN=162

CHANGE HYDRAULIC SYSTEM OIL
T8029AN
UN15JUN93
1. Remove hydraulic reservoir filler cap (A).
TX,86,JC281 1916MAY951/3
2. Install hose on hydraulic reservoir drain valve (B).

Loosen valve with a 1/4 in. hex key wrench. Allow oil
to drain into a container. Dispose of waste oil properly.
UN15DEC94
3. Flush reservoir with diesel fuel.

4. Tighten drain valve.
T8385AF
5. Fill reservoir. (See Fuels and Lubricants chapter.)

SPECIFICATIONS
544G, LL, TC
624G
644G
TX,86,JC281 1916MAY952/3
T7773CC
UN10AUG92
7. Check oil level in sight glass (C). Oil should be in

FULL range.
TX,86,JC281 1916MAY953/3
871
PN=163
CLEAN HYDRAULIC SUCTION STRAINER

UN15JUN93
2. Remove cap screws and cover (B).
T8029AO
3. Inspect gasket and replace if necessary.
TX,86,DH2963 1916JUN931/1
REPLACE DIFFERENTIAL LOCK RETURN

FILTER(S)IF EQUIPPED
UN15JUN93
2. Remove cap screws and cover (B).
T8029AO
3. Inspect gasket and replace if necessary.
TX,86,DH2250 1916JUN931/2
4. Turn filter(s) (C) counterclockwise to remove.

of new filter(s).
UN21SEP92
6. Install new filter(s). Turn filter(s) clockwise by hand

until tight.
T7829BI
7. Install cover, cap screws, and filler cap.
TX,86,DH2250 1916JUN932/2
872
PN=164
CHANGE FRONT AND REAR DIFFERENTIAL

OIL
UN08OCT92
1. Remove drain plug (A). Allow oil to drain into a

container. Dispose of waste oil properly.
NOTE: It is normal for differential lock axles to be filled

approximately 12 L (12 qt) above level plug.
624G Front
624G Rear
644G Front and Rear, each
T7853AO
SPECIFICATIONS
544G Front and Rear, each
T7853AP
UN08OCT92
2. Install drain plug.

TX,87,JC1058 1924JAN961/5
T6523CY
UN20OCT88
3. Open service door (A).
TX,87,JC1058 1924JAN962/5
T7853AQ
UN08OCT92
4. Remove fill plug (B) from front differential.
TX,87,JC1058 1924JAN963/5
873
PN=165
T7853AR
UN08OCT92
5. Open left service door. Remove fill plug (A) from rear
differential.
TX,87,JC1058 1924JAN964/5
NOTE: Each differential housing has three sumps. Fill

center housing slowly so oil drains into all sumps.
UN08OCT92
6. Add oil slowly until it appears in the bottom of the

check level plugs (A). (See Fuels and Lubricants
chapter.)
T7853AK
7. Install fill plugs.
T6570AC2
UN20OCT88

TX,87,JC1058 1924JAN965/5
874
PN=166
Maintenance
DRAINING THE COOLING SYSTEM
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns
TS281
Shut off engine. Only remove filler cap when

cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
UN23AUG88
1. Check hoses (A) for cracks and leaks. Replace, if

necessary.
2. Tighten clamps.
T6523CC
UN20OCT88
3. Check radiator and oil cooler for dirt, damage, leaks,

and loose or broken mountings. Clean radiator and oil
cooler fins.
TX,90,JC1114 1918MAR961/4
4. Connect a hose to draincock (A) on radiator.
T6518BN
UN10FEB89
5. Turn draincock counterclockwise to open. Allow

coolant to drain into a container. Dispose of used
coolant properly.
TX,90,JC1114 1918MAR962/4
901
PN=167
Maintenance
T7829AN
UN31AUG92
6. 544G, 624G: Remove plug (A) to drain engine block.

Allow coolant to drain into a container. Dispose of
used coolant properly.
544G, 624G Shown
TX,90,JC1114 1918MAR963/4
644G: Turn draincock (B) counterclockwise to drain

engine block. Allow coolant to drain into a container.
Dispose of used coolant properly.
T100709
UN22MAR96
7. Disconnect hose from recovery tank to drain the tank.
644G Shown
TX,90,JC1114 1918MAR964/4
902
PN=168
Maintenance
DIESEL ENGINE COOLANT

The engine cooling system is filled to provide yearround protection against corrosion and cylinder liner
pitting, and winter freeze protection to -37C (-34F).
The following engine coolant is preferred for service:
John Deere PREDILUTED ANTIFREEZE/SUMMER
COOLANT
The following engine coolant is also recommended:
John Deere ANTIFREEZE/SUMMER COOLANT
CONCENTRATE in a 40 to 60 percent mixture of
concentrate and quality water.
Other low silicate ethylene glycol base coolants for
heavy-duty diesel engines may be used if they meet
one of the following specifications:
ASTM D5345 (prediluted coolant)
ASTM D4985 (coolant concentrate) in a 40 to 60
percent mixture of concentrate with quality water
Coolants meetings these specifications require use of
supplemental coolant additives, formulated for heavy-
duty diesel engines, for protection against corrosion

and cylinder liner erosion and pitting.
A 50 percent mixture of ethylene glycol engine coolant
in water provides freeze protection to -37C (-34F). If
protection at lower temperatures is required, consult
your John Deere dealer for recommendations.
Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
base engine coolant concentrate.
IMPORTANT: Do not use cooling system sealing
additives or antifreeze that contains
sealing additives.
COOLANT DRAIN INTERVALS
Drain and flush the cooling system and refill with fresh
coolant every 24 months or 2000 hours of operation.
When John Deere PREDILUTED ANTIFREEZE/
SUMMER COOLANT is used, the service interval may
be extended to 36 months or 3000 hours of operation.
TX,90,JC1144 1923MAY961/1
903
PN=169
Maintenance
FILLING THE COOLING SYSTEM

SPECIFICATIONS
Approx. 28.5 L (30 qt)
IMPORTANT: After filling radiator, operate engine

to purge air from the engine block.
When air is purged, the coolant level
sensor in the radiator will turn
warning alarm on, STOP indicator
will flash, and engine coolant
indicator will light. Shut off engine
and add coolant immediately. Start
engine and run until engine is at
normal operating temperature. Stop
engine and verify that radiator is
completely full, and that surge tank
is at normal level.
HOT WEATHER (above 95C [35F]): Antifreeze

reduces cooling system efficiency. When maximum
cooling system efficiency is required, completely drain
and flush system. Refill with clean, soft water, and add
RE23182 John Deere Coolant Conditioner or
equivalent.
IMPORTANT: Use only permanent-type, low
silicate, ethylene glycol base
antifreeze in coolant solution. Other
types of antifreeze may damage
cylinder seals.
NOTE: All machines are shipped from the factory with

a 50-50 mixture for protection to -37C (-34F).
Adjust mixture accordingly to provide freeze
protection for your machine.
FREEZING TEMPERATURES: Fill with permanenttype, low silicate, ethylene glycol antifreeze (without
stop-leak additive) and clean, soft water. Add
RE23182 John Deere Coolant Conditioner or
equivalent.
TX,90,JC1145 1923MAY961/1
If you operate your engine in extremely cold temperatures,

see your John Deere dealer for information on arctic
operation.
T85402
See your John Deere dealer for JT05460 SERVICEGARD coolant and battery tester. Follow directions
included with the tester.
UN10NOV88
TEST THE COOLANT FREEZE

PROTECTION LEVEL
TX,90,JC1117 1918MAR961/1
904
PN=170
Maintenance
DO NOT SERVICE INJECTION NOZZLES

IMPORTANT: Do not service or remove injection
nozzles. The service life of the injection
nozzles may be shortened by:
Overheating
Improper operation
Poor quality fuel
Excessive idling
If injection nozzles are not working correctly or are dirty,
the engine will not run normally. (See your authorized
dealer for service.)
T82,SKMA,A 1928JUL941/1
DO NOT ADJUST INJECTION PUMP

IMPORTANT: Never steam clean or pour cold
water on an injection pump while
the engine is running, or while
injection pump is still warm. To do
so may cause seizure of pump.
Clean trash regularly from injection
pump.
Adjusting the injection pump in any way not approved

by the manufacturer will end the warranty. (See your
copy of the John Deere warranty on this machine.)
Do not attempt to service an injection pump that is not
operating correctly. (See your authorized injection
pump service center.)
TX,DH,236 1906JUN911/1
CLEANING FUEL TANK OUTLET SCREEN

If fuel screen is plugged, debris must be removed and
screen cleaned.
TX,90,DH2259 1912MAY931/2
905
PN=171
Maintenance
1. Connect hose to fuel tank draincock (B).
2. Remove fuel tank cap.
4. Disconnect fuel hose. Remove hose clamp (A).
T6523BW1
5. Remove fitting to remove screen from inside fuel tank.
UN20OCT88
3. Drain fuel from tank.
6. Remove debris from screen with clean solvent or

diesel fuel, or install a new screen.
7. Flush debris out of fuel tank.
8. Clean fitting threads and threads in fuel tank with
clean and cure primer.
9. Apply thread lock and sealer (maximum strength) on
threads and shoulder of fitting. Apply a band of flexible
sealant on threads and shoulder of fitting.
10. Install fitting in fuel tank until shoulder is tight against
tank. Tighten hose clamp.
IMPORTANT: Wait 20 minutes before filling fuel tank
to allow sealant to dry.
11. Fill fuel tank.
TX,90,DH2259 1912MAY932/2
906
PN=172
Maintenance
BLEEDING FUEL SYSTEM544G, 624G

1. Place container under filters (C and G).
UN10SEP92
2. Loosen bleed screw (E).

3. Pump hand primer (B) until bleed screw (E) has solid
stream of fuel.
T7833AJ
4. Open bleed screw (A). Pump hand primer until bleed

screw has solid stream of fuel coming from it. Tighten
bleed screw on final fuel filter.
ABleed Screw (Final Fuel Filter)
BHand Primer
CPrimary Fuel Filter (Water
Separator)
DDrain Valve (Primary Fuel Filter)
EBleed Screw (Primary Fuel
Filter)
FDrain Valve
GFinal Fuel Filter
TX,90,JC285 1916MAY951/1
907
PN=173
Maintenance
BLEEDING FUEL SYSTEM644G

1. Place container under primary fuel filter (F).
2. Loosen bleed screw (C), and push pump (D) until fuel
free of bubbles flows from around bleed screw.
3. Tighten bleed screw.
T100696
UN22MAR96
4. Loosen bleed screw (B) from final fuel filter (A), and
push pump (D) until fuel free of bubbles flows from
around bleed screw.
AFinal Fuel Filter

BBleed Screw
CBleed Screw
DPump
EFuel Supply Line
FPrimary Fuel Filter
GDrain Valve
TX,90,JC1115 1918MAR961/1
ADJUSTING FUEL SHUT-OFF SOLENOID

644G
1. Disconnect linkage (A) from fuel shut-off lever (B).
UN21JUN93
2. Hold shut-off lever against lower position stop.
T8030AM
3. Adjust linkage so linkage aligns with hole in shut-off

lever, and turn out two complete turns.
NOTE: Failure to have the shut-off lever against upper

position stop can result in low engine horsepower.
ALinkage
BShut-off Lever
4. Start engine and make sure shut-off lever is tight

against upper position stop.
TX,90,DH2534 1916JUN931/1
908
PN=174
Maintenance
PRECAUTIONS FOR ALTERNATOR AND REGULATOR

When batteries are connected, follow these rules:
1. Disconnect negative (-) battery cable when you
work on or near alternator or regulator.
2. DO NOT TRY TO POLARIZE ALTERNATOR OR
REGULATOR.
3. Be sure alternator wires are correctly connected
BEFORE you connect batteries.
6. Connect batteries or a booster battery in the

correct polarity (positive [+] to positive [+] and
negative [-] to negative [-]).
7. Do not disconnect the batteries when engine is
running and alternator is charging.
8. Disconnect battery cables before you connect
battery charger to the batteries. If machine has
more than one battery, each battery must be
charged separately.
4. Do not ground alternator output terminal.

5. Do not disconnect or connect any alternator or
regulator wires while batteries are connected or
while alternator is operating.
04T,90,C151 1920JUL921/1
909
PN=175
Maintenance
SERVICE BATTERIES CAREFULLY
Always remove grounded (-) battery clamp first

and replace it last.
TS204
Never check battery charge by placing a metal

hydrometer.
UN23AUG88


eyes.
added.

the acid.
UN23AUG88
TS203
TX,90,DH1018 1930APR941/2
9010
PN=176
Maintenance
If electrolyte spills on the floor, use one of the following
mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda
in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia
in 4 L (1 gal) water.
IMPORTANT: Electrolyte can damage paint and metal
surfaces of your machine. Do not
overfill the battery cells.
TX,90,DH1018 1930APR942/2
9011
PN=177
Maintenance
CHECKING ELECTROLYTE SPECIFIC

GRAVITY
Always remove grounded (-) battery clamp first

and replace it last.
TS204
Never check battery charge by placing a metal

hydrometer.
UN23AUG88


eyes.
added.

the acid.
UN23AUG88
TS203
04T,90,FF20 1912MAY931/3
9012
PN=178
Maintenance
Check the specific gravity of electrolyte in each battery
cell.
04T,90,FF20 1912MAY932/3
A fully charged battery will have a corrected specific

gravity reading of 1.260. If the reading is below 1.200,
charge the battery.
T85402
NOTE: In tropical areas, use 1.225 for the full charge

reading. In cold areas, use 1.280 for the fullcharge reading.
UN10NOV88
See your John Deere dealer for JT05460 SERVICEGARD battery and coolant tester. Follow directions
included with the tester.
04T,90,FF20 1912MAY933/3
9013
PN=179
Maintenance

exploding battery. Do not charge a battery if
the battery is frozen or it may explode. Warm
battery to 16C (60F). Disconnect battery
ground () clamp before you charge batteries
in the machine to prevent damage to electrical
components.
IMPORTANT: Do not use a battery charger as a

booster if a battery has a 1.150 specific
gravity reading or lower. Turn off
charger before connecting or
disconnecting it.
TS204
UN23AUG88
USING BATTERY CHARGER
A battery charger may be used as a booster to start

engine.
TX,FF,121 1915MAR931/1
REPLACING BATTERIES
Your machine is equipped with a negative ground
electrical system. It uses one or two 12-volt batteries. If
one of the two batteries fails, both batteries must be
replaced. Use only batteries meeting following
specifications.
BCI Group Size: 27
544G, 624G:
625 cold cranking amps at -18C (0F)
160 minutes reserve capacity at 25 amps
644G:
950 cold cranking amps at -18C (0F)
180 minutes reserve capacity at 25 amps
TX,90,JC1146 1923MAY961/1
9014
PN=180
Maintenance
REMOVING BATTERIES
1. Remove battery cover.
TX,90,DH1768 1906JUN911/2
2. Disconnect negative (-) battery cable (A) first, then

positive (+) cable (B).
3. Remove nuts and washers (C) and hold down bracket.
T6570AD2
UN20OCT88
4. Lift battery out of compartment.
TX,90,DH1768 1906JUN912/2
REPLACING FUSES
UN08OCT92
IMPORTANT: Install fuses with correct amperage

rating to prevent electrical system
damage from overload.
T7853AS
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.
TX,90,DH2266 1902OCT921/1
FUSE (BLADE-TYPE) COLOR CODES

Amperage Rating
Color
Black
Violet
Pink
Tan
7-1/2
Brown
10
Red
15
Light Blue
20
Yellow
25
Natural (White)
30
Light Green
04T,90,J22 1928SEP921/1
9015
PN=181
Maintenance
RESETTING CIRCUIT BREAKERS

Air conditioning system contains two circuit breakers. If
circuit breakers open because of a short circuit or
overloading, air conditioner will shut off.
Turn off air conditioning switch. Wait a couple of minutes
before restarting, to allow a cooling off period. Circuit
breaker will reset itself. If circuit breaker opens
repeatedly, see your John Deere dealer.
04T,90,C155 1906JUN911/1
T5894AI1
UN20OCT88
Before disassembling, remember how bezel and lens are

installed with respect to mounting stud.
T5894AG1
IMPORTANT: To get the correct lighting pattern, lens

must be installed so the word "TOP" is
on top when lamp is installed so wider
section is on top when lamp is
installed.
UN17APR89
REPLACING HALOGEN BULBS
TX,90,RR,1725 1911MAR941/2
9016
PN=182
Maintenance
1. Remove four screws (H) to remove bezel (G) and lens
(F).
UN19OCT88
2. Disconnect wiring lead and release retainer clip to

remove bulb (D).
3. To disconnect ground wiring lead, push tab up, then
pull connector from terminal.
T6249AU
IMPORTANT: Do not touch the halogen bulb with

bare hands. Oil and moisture may
cause premature bulb failure. Clean
bulb using a soft, oil-free cloth and
alcohol.
4. Install new bulb so square notch is aligned with square
tab on reflector back.
5. Install retainer clip into locking tabs on reflector back.
AFlange Nut
BLock Washer
CHousing
DBulb
EGasket
FLens
GBezel
HScrew
6. Connect wiring leads. Check wiring leads are free of

clip.
7. Install lens assembly (F) in housing (C) making sure
wires are not crimped, or keeping lens assembly from
seating on gasket.
8. Install bezel so wider section is on top. Sealing flange
must be inside housing on all four sides before
tightening screws.
9. Tighten screws alternately. Do not overtighten as
screws may strip out plastic.
TX,90,RR,1725 1911MAR942/2
9017
PN=183
Maintenance
IMPORTANT: The reverse warning alarm is set on

high volume at the factory. It may be
necessary to adjust the volume to meet
local regulations.
T7853AT
NOTE: Alarm removed from machine for clarity of

photograph.
UN08OCT92
CHANGING REVERSE WARNING ALARM

VOLUME
To change alarm volume, move switch (A) to desired

position.
TX,90,DH2566 1903FEB951/1
CHECKING NEUTRAL START SYSTEM
CAUTION: Avoid possible injury or death. DO

NOT attempt to start machine unless you are
sitting in operators seat with the transmission
control lever in neutral "N" position. DO NOT
bypass or disable any of the starting system
parts.
Engage park brake before attempting to start
engine.
This machine has a neutral start switch that is activated

by the transmission control lever.
Check the neutral start system to ENSURE that the
machine:
1. WILL start with the transmission control lever in
neutral "N" position.
2. WILL NOT start with the transmission control lever in
forward "F" or reverse "R" position.
If starting system fails to operate correctly, have your
John Deere dealer repair the system immediately.
TX,90,DH2556 1902OCT921/1
9018
PN=184
Maintenance
ADDING ATTACHMENTS/ACCESSORIES TO
ROLL-OVER PROTECTIVE STRUCTURE
(ROPS)
Do not add attachments or accessories to the ROPS
without contacting your John Deere dealer for
information. Improper attachment may impair the
protection offered by the ROPS.
04T,90,K117 1916MAR881/1
SERVICING AIR CONDITIONING SYSTEM

1. Check and adjust compressor belt tension.
2. Check compressor clutch engagement.
3. Check evaporator core for clogging.
4. Check air intake filters for clogging.
5. Check blowers for proper operation.
6. Check the condenser core to see that it is not partially
or completely plugged with dirt or trash. Clean with
compressed air or water when needed.
7. Run air conditioning system for several minutes.
TX,90,DH2539 1912MAY931/2
T7829BL
8. Check sight glass (A) on receiver dryer (from outside

of cab). Bubbles must not be present in sight glass. If
bubbles are present, see your authorized dealer for
charging the air conditioning system.
UN21SEP92
NOTE: Access door on right side of cab opened for clarity

of drawing. Door must be closed to check air
conditioning operation. Remove sight glass plug
from door.
TX,90,DH2539 1912MAY932/2
9019
PN=185
Maintenance
CHECKING AND ADJUSTING COMPRESSOR

BELT TENSIONIF EQUIPPED
1. A force of 111 N (25 lb force) halfway between pulleys
must move belt 13 mm (0.5 in.).
2. To adjust tension, loosen mounting cap screws.
3. Apply force to FRONT compressor housing only (near
the belt) until tension is correct.
4. Tighten cap screws.
TX,90,DH1756 1931JUL921/1
WELDING ON MACHINE
IMPORTANT: Disconnect battery ground strap or turn
battery disconnect switch to "OFF" to
prevent voltage spikes through
alternator or monitor.
If machine is equipped with a controller
(microprocessor) like Engine Controller
(EC), Pump and Valve Controller (PVC)
or Transmsision Controller disconnect
harness connector from controller to
prevent voltage spikes through
microprocessor.
Connect welder ground clamp close to
each weld area so electrical current
does not arc inside any bearings,
bushings or pins.
TX,90,JC1060 1925JAN961/1
9020
PN=186
Maintenance
INSPECTING PARK BRAKE PADS

TX,90,DH2348 1919MAY931/3

T7747BR
UN19MAY92

5. Stop engine.
TX,90,DH2348 1919MAY932/3
9021
PN=187
Maintenance
T7853AU
UN08OCT92
6. Check the combined thickness of backing plates, brake

pads (C), (2nd pad not shown) and disk (D). If
thickness of backing plates, pads, and disk is less
than 29.0 mm (1.20 in.) or if grooves are worn off
pads, replace pads. New backing plates, pads and
disk measure 35.0 mm (1.40 in). (See your authorized
dealer.)
TX,90,DH2348 1919MAY933/3
EXTERNAL SERVICE BRAKE INSPECTION

spraying oil. Slowly loosen plug to relieve any
air pressure.
Do first inspection at 5000 hours followed by 1000 hours

inspection intervals after the first 5000 hours inspection.
If the service brakes are subjected to severe duty, inspect
more frequently.
TX,90,JC263 1929NOV941/4
9022
PN=188
Maintenance
T6523BZ
UN25OCT88
1. Remove brake inspection port plug (A).
TX,90,JC263 1929NOV942/4
T6138AZ
UN25OCT88
2. Inspect the brake linings (A) on brake disk.
TX,90,JC263 1929NOV943/4
3. Remove axle housing and replace brake disc if oil

grooves (B) on facing material are no longer visible.
T8137AC
UN03DEC93
4. If further inspection of brake elements or replacement

of brake linings is necessary, see your authorized
dealer.
TX,90,JC263 1929NOV944/4
9023
PN=189
Maintenance
CHECKING BRAKE ACCUMULATOR

1. Start engine.
2. Run engine for 1 minute at slow idle.
TX,90,JC1116 1918MAR961/2
3. Quickly apply brake pedal as hard as possible, and

hold down.
If brake low pressure indicator light comes on, brake
accumulator (A) pressure is low.
T100704
UN22MAR96
4. Replace brake accumulator.
TX,90,JC1116 1918MAR962/2
9024
PN=190
Maintenance
CAUTION: The boom will jump upward during

this check. Make sure area around bucket is
clear.
1. Start engine.
2. Push ride control switch to OFF position.
3. Raise boom to maximum height and hold control lever
over relief for 2 seconds.
T7829AV
UN08SEP92
CHECKING RIDE CONTROL

ACCUMULATORIF EQUIPPED
4. Lower boom and bucket to ground and stop engine.
TX,90,DH2560 1912MAY931/2
T7853AV
6. If ride control accumulator has lost gas charge, go to

UN08OCT92
5. Turn key switch to ON position. Turn ride control

switch to ON. Boom will jump upward, approximately
200 mm (8.0 in.) as accumulator (A) pressure is
released.
TX,90,DH2560 1912MAY932/2
9025
PN=191
Maintenance
CAUTION: Escaping fluid under pressure can

penetrate skin causing serious injury. Relieve
pressure before disconnecting hydraulic or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles which eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
X9811
UN23AUG88
BLEEDING BRAKES
If ANY fluid is injected into skin, it must be

surgically removed within a few hours by a
doctor familiar with this type of injury or
gangrene may result.
NOTE: Two people are required to bleed brake system

oil, one to operate brake valve and the other to
open and close bleed screws.
2. Start engine and run at slow idle.
3. Push and hold brake pedal down until brake bleeding
procedure is complete.
TX,DH,114 1906JUN911/2
9026
PN=192
Maintenance
4. Put a clear plastic tube on bleed screw (B) to route
flow to hydraulic reservoir filler tube (A) or to a
container.
5. Open one bleed screw on differential and axle
assembly until hydraulic oil starts to flow. Close bleed
screw when oil is free of air.
6. Repeat steps 24 for each bleed screw (two bleed
screws on each differential).
7. Release brake pedal and stop engine.
T6522BR
UN20OCT88
8. Check hydraulic oil level. (See MaintenanceEvery

10 Hours or Daily chapter.)
TX,DH,114 1906JUN912/2
9027
PN=193
Maintenance
CHECKING SECONDARY STEERING

SYSTEMIF EQUIPPED
2. Shut off engine. Release brakes.
3. Momentarily turn key switch to START but DO NOT
start the engine. Release key to ON.
4. The secondary steering motor must be heard running.
Secondary steering indicator must light and alarm must
sound.
5. Turn steering wheel; Machine should turn partway.
Machine will not turn fully when machine is stopped.
6. Start engine. Secondary steering motor, secondary
steering indicator and alarm must be off within 3
seconds.
TX,DH,115 1906JUN911/1
CLUTCH CUT-OFF ADJUSTMENT

The clutch cut-off switch assembly is easily adjustable to
suit operators preference. Adjusting it can increase or
decrease the braking action prior to disconnecting the
transmission.
TX,90,DH2541 1902OCT921/2
9028
PN=194
Maintenance
1. Loosen nut (A).
2. Rotate switch assembly (C) to desired gap (D)
between lever (B) and bottom of pedal.
NOTE: Increasing gap (D) increases the amount of

braking applied prior to disengaging the
transmission.
3. Tighten nut (A).
T7817AL
UN08SEP92
4. Operate machine with clutch cut-off ON to check if

adjustment is to operators preference for his work
application. Adjust as required.
ANut
BLever
CSwitch Assembly
DGap
TX,90,DH2541 1902OCT922/2
DO NOT SERVICE CONTROL VALVES,

CYLINDERS, PUMPS OR MOTORS
Special tools and information are needed to service
control valves, cylinders, pumps, or motors.
If these parts need service, see your authorized dealer.
TX,90,DH2537 1903SEP921/1
9029
PN=195
Maintenance
HARDWARE TORQUE SPECIFICATIONS

Check cap screws and nuts to be sure they are tight. If
hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.
T82,SKMA,AT 1901AUG941/1
KEEP ROPS INSTALLED PROPERLY
The protection offered by ROPS will be

impaired if ROPS is subjected to structural
damage, is involved in an overturn incident, or
is in any way altered. A damaged ROPS should
be replaced, not reused.
UN23AUG88
CAUTION: Make certain all parts are reinstalled

correctly if the roll-over protective structure
(ROPS) is loosened or removed for any reason.
Tighten mounting bolts to proper torque.
TS176
When installation of equipment on a machine necessitates

loosening or removing ROPS, mounting bolts must be
tightened to 620 120 Nm (457 88 lb-ft).
04T,90,MM8 1925JUN911/1
9030
PN=196
Maintenance
TS1163
1904MAR91
METRIC BOLT AND CAP SCREW TORQUE VALUES
Class 4.8
Size
Lubricated
Nm
lb-ft
M6
4.8
M8
12
M10
M12
Class 8.8 or 9.8

Dry
Lubricated
Nm
lb-ft
4.5
11
22
29
21
50
37
Class 10.9
Dry
Lubricated
Nm
lb-ft
6.5
11
16
28
43
32
55
75
55
95
Class 12.9
Dry
Nm
lb-ft
Nm
8.5
13
9.5
17
20
32
24
40
40
63
47
80
70
110
80
140
Lubricateda
lb-ft
Drya
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
3.5
8.5
15
12
15
30
37
11.5
19
14.5
28
47
35
23
17
40
29
60
75
55
95
70
105
130
95
165
120
M14
63
47
80
60
120
88
150
110
175
130
225
165
205
150
260
190
M16
100
73
125
92
190
140
240
175
275
200
350
255
320
240
400
300
M18
135
100
175
125
260
195
330
250
375
275
475
350
440
325
560
410
M20
190
140
240
180
375
275
475
350
530
400
675
500
625
460
800
580
M22
260
190
330
250
510
375
650
475
725
540
925
675
850
625
1075
800
M24
330
250
425
310
650
475
825
600
925
675
1150
850
1075
800
1350
1000
M27
490
360
625
450
950
700
1200
875
1350
1000
1700
1250
1600
1150
2000
1500
M30
675
490
850
625
1300
950
1650
1200
1850
1350
2300
1700
2150
1600
2700
2000
M33
900
675
1150
850
1750
1300
2200
1650
2500
1850
3150
2350
2900
2150
3700
2750
M36
1150
850
1450
1075
2250
1650
2850
2100
3200
2350
4050
3000
3750
2750
4750
3500
DX,TORQ2 1920JUL941/2
9031
PN=197
Maintenance
DO NOT use these values if a different torque value or
tightening procedure is given for a specific application.
Torque values listed are for general use only. Check
tightness of fasteners periodically.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical
property class.
Fasteners should be replaced with the same or higher
property class. If higher property class fasteners are
used, these should only be tightened to the strength
of the original.
properly start thread engagement. This will prevent

them from failing when tightening.
Tighten plastic insert or crimped steel-type lock nuts to
approximately 50 percent of the dry torque shown in
the chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a
Lubricated means coated with a lubricant such as

engine oil, or fasteners with phosphate and oil
coatings. Dry means plane or zinc plated without
any lubrication.
Make sure fasteners threads are clean and that you
9032
PN=198
Maintenance
Check tightness of cap screws periodically. Torque values

listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
T6873AA
CAUTION: Use only metric tools on metric

hardware. Other tools may not fit properly.
They may slip and cause injury.
T-Bolt
UN18OCT88
UN18OCT88
ADDITIONAL METRIC CAP SCREW TORQUE

VALUES

loads. Always replace shear bolts with identical grade.
T6873AB

grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
H-Bolt
UN18OCT88
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
T6873AC
Tighten cap screws having lock nuts to approximately 50

percent of amount shown in chart.
METRIC CAP SCREW TORQUE VALUES
Nominal
Dia
8
T-Bolt
H-Bolt
Nm
lb-ft
29
21
Nm
lb-ft
M-Bolt
Nm
lb-ft
20
15
10
10
63
46
45
33
20
15
12
108
80
88
65
34
25
14
176
130
137
101
54
40
16
265
195
206
152
78
58
18
392
289
294
217
118
87
20
539
398
392
289
167
125
22
735
542
539
398
216
159
24
931
687
686
506
274
202
27
1372
1012
1029
759
392
289
30
1911
1410
1421
1049
539
398
33
2548
1890
1911
1410
735
542
36
3136
2314
2401
1772
931
687
M-Bolt
*Torque tolerance is 10%.
04T,90,M170 1901AUG941/2
9033
PN=199
Maintenance
TS1162
1904MAR91
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
Grade 2b
Grade 1
Size
Lubricated
Dry
Lubricated
Nm
lb-ft
Nm
lb-ft
Grade 5, 5.1, or 5.2

Dry
Lubricateds
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Dry
Nm
Grade 8 or 8.2
Lubricateda
lb-ft
Nm
lb-ft
Drya
Nm
lb-ft
1/4
3.7
2.8
4.7
3.5
4.5
7.5
5.5
9.5
12
13.5
10
17
12.5
5/16
7.7
5.5
10
12
15
11
20
15
25
18
28
21
35
26
3/8
14
10
17
13
22
16
27
20
35
26
44
33
50
36
63
46
7/16
22
16
28
20
35
26
44
32
55
41
70
52
80
58
100
75
1/2
33
25
42
31
53
39
67
50
85
63
110
80
120
90
150
115
9/16
48
36
60
45
75
56
95
70
125
90
155
115
175
130
225
160
5/8
67
50
85
62
105
78
135
100
170
125
215
160
240
175
300
225
3/4
120
87
150
110
190
140
240
175
300
225
375
280
425
310
550
400
7/8
190
140
240
175
190
140
240
175
490
360
625
450
700
500
875
650
290
210
360
270
290
210
360
270
725
540
925
675
1050
750
1300
975
1-1/8
400
300
510
375
400
300
510
375
900
675
1150
850
1450
1075
1850
1350
1-1/4
570
425
725
530
570
425
725
530
1300
950
1650
1200
2050
1500
2600
1950
1-3/8
750
550
950
700
750
550
950
700
1700
1250
2150
1550
2700
2000
3400
2550
1-1/2
1000
725
1250
925
990
725
1250
930
2250
1650
2850
2100
3600
2650
4550
3350
DO NOT use these values if a different torque value or

tightening procedure is given for a specific application.
Torque values listed are for general use only. Check
tightness of fasteners periodically.
loads. Always replace shear bolts with identical grade.
9034
PN=200
Maintenance
a

grade. If higher grade fasteners are used, these
should only be tightened to the strength of the
original.
Lubricated means coated with a lubricant such as

engine oil, or fasteners with phosphate and oil
coatings. Dry means plain or zinc plated without any
lubrication.
Make sure fasteners threads are clean and that you

properly start thread engagement. This will prevent
them from failing when tightening.
Grade 2 applies for hex cap screws (not hex bolts)

up to 152 mm (6 in.) long. Grade 1 applies for hex cap
screws over 152 mm (6 in.) long and for all other
types of bolts and screws of any length.
Tighten plastic insert or crimped steel-type lock nuts to

approximately 50 percent of the dry torque shown in
the chart, applied to the nut, not to the bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
9035
PN=201
Maintenance
Check all oil lines, hoses, and fittings regularly for leaks or
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving
machine parts. If abrasion or wear occurs, replace
immediately.
X9811
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere &
Company Medical Department in Moline, Illinois,
or other knowledgeable medical source.
UN24JAN89
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
T85401
UN23AUG88
CHECK OIL LINES AND FITTINGS
Tubing with dents may cause the oil to overheat. If you

find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified in torque
chart.
When you tighten connections, use two wrenches to
prevent bending or breaking tubing and fittings.
TX,90,DH1559 1901AUG941/1
9036
PN=202
Maintenance
SERVICE RECOMMENDATIONS FOR O-RING

BOSS FITTINGS
2. Lubricate O-ring with petroleum jelly. Place electrical

tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
T6243AE
1. Inspect O-ring boss seat for dirt or defects.
UN18OCT88
STRAIGHT FITTING
TX,90,DY323 19 2MAY961/2
9037
PN=203
Maintenance
ANGLE FITTING
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.
T6520AB
2. Turn fitting into threaded boss until back-up washer

contacts face of boss.
UN18OCT88
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
NOTE: Do not allow hoses to twist when tightening

fittings.
TORQUE VALUE
Thread Size
3/8-24
Nm
lb-ft
UNF
7/16-20
UNF
12
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%.
TX,90,DY323 19 2MAY962/2
9038
PN=204
Maintenance
SERVICE RECOMMENDATIONS FOR FLAT

FACE O-RING SEAL FITTINGS
UN18OCT88
1. Inspect the fitting sealing surfaces. They must be free

of dirt or defects.
2. Inspect the O-ring. It must be free of damage or
defects.
T6243AD
3. Lubricate O-rings and install into groove using

petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum
jelly so O-ring is not displaced during assembly.
5. Index angle fittings and tighten by hand pressing joint
together to insure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the
chart per dash size stamped on the fitting. Do not allow
hoses to twist when tightening fittings.
FLAT FACE O-RING SEAL FITTING TORQUE
Nominal Tube O.D.
mm
in.
Swivel Nut
Dash Size
Thread Size
in.
Bulkhead Nut
Nm
lb-ft
Nm
lb-ft
6.35
0.250
-4
9/16-18
16
12
5.0
3.5
9.52
0.375
-6
11/16-16
24
18
9.0
6.5
12.70
0.500
-8
13/16-16
50
37
17.0
12.5
15.88
0.625
-10
1-14
69
51
17.0
12.5
19.05
0.750
-12
1 3/16-12
102
75
17.0
12.5
22.22
0.875
-14
1 3/16-12
102
75
17.0
12.5
25.40
1.000
-16
1 7/16-12
142
105
17.0
12.5
31.75
1.250
-20
1 11/16-12
190
140
17.0
12.5
38.10
1.500
-24
2-12
217
160
17.0
12.5
NOTE: Torque tolerance is +15 -20%.
04T,90,K67 1901AUG941/2
9039
PN=205
Maintenance
T6890BB
UN01MAR90
SERVICE RECOMMENDATIONS FOR METRIC SERIES FOUR BOLT FLANGE FITTING
ASealing Surface
BSplit Flange
CPinched O-Ring
1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects
cannot be polished out, replace component.
DSingle Piece Flange
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
TORQUE CHART*
2. Install the correct O-ring (and backup washer if

required) into groove using petroleum jelly to
hold it in place.
3. Split flange: Loosely assemble split flange (B)
halves. Make sure split is centrally located and
perpendicular to the port. Hand tighten cap
screws to hold parts in place. Do not pinch Oring (C).
4. Single piece flange (D): Place hydraulic line in
center of flange and install four cap screws.
Flange must be centrally located on port. Hand
tighten cap screws to hold flange in place. Do
not pinch O-ring.
Thread**
Nm
lb-ft
M6
12
M8
30
22
M10
57
42
M12
95
70
M14
157
116
M16
217
160
M18
334
246
M20
421
318
*Tolerance 10%. The torques given are enough

for the given size connection with the
recommended working pressure. Increasing cap
screw torque beyond these amounts will result in
flange and cap screw bending and connection
failures.
5. After components are properly positioned and

cap screws are hand tightened, tighten one cap
screw, then tighten the diagonally opposite cap
screw. Tighten two remaining cap screws.
Tighten all cap screws as specified in the chart
below.
**Metric standard thread.
04T,90,K175 1901AUG941/1
9040
PN=206
Maintenance
T6890BB
UN01MAR90
SERVICE RECOMMENDATIONS FOR INCH SERIES FOUR BOLT FLANGE FITTINGS
ASealing Surface
BSplit Flange
CPinched O-Ring
1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.
Out-of-flat causes seal extrusion. If defects
cannot be polished out, replace component.
DSingle Piece Flange
must be centrally located on port. Hand tighten

cap screws to hold flange in place. Do not pinch
O-ring.
5. Tighten one cap screw, then tighten the
diagonally opposite cap screw. Tighten two
remaining cap screws. Tighten all cap screws
as specified in the chart below.
2. Install O-ring (and backup washer if required)

into groove using petroleum jelly to hold it in
place.
3. Split flange: Loosely assemble split flange (B)
halves. Make sure split is centrally located and
perpendicular to port. Hand tighten cap screws
to hold parts in place. Do not pinch O-ring (C).
DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO
NOT over tighten.
4. Single piece flange (D): Place hydraulic line in

center of flange and install cap screws. Flange
04T,90,K174 1901AUG941/2
9041
PN=207
Maintenance
TORQUE CHART*
Nm
Nominal Flange
Size
lb-ft
Cap Screw Size

Min
Max
Min
1/2
5/16-18
UNC
20
31
15
23
3/4
3/8-16
UNC
28
54
21
40
3/8-16
UNC
37
54
27
40
1-1/4
7/16-14
UNC
47
85
35
63
1-1/2
1/2-13
UNC
62
131
46
97
1/2-13
UNC
73
131
54
97
2-1/2
1/2-13
UNC
107
131
79
97
5/8-11
UNC
158
264
117
195
3-1/2
5/8-11
UNC
158
264
117
195
5/8-11
UNC
158
264
117
195
5/8-11
UNC
158
264
117
195
*Tolerance 10%. The torques given are enough

for the given size connection with the
recommended working pressure. Torques can be
increased to the maximum shown for each cap
screw size if desired.
Max
Increasing cap screw torque beyond this maximum

will result in flange and cap screw bending and
connection failures.
04T,90,K174 1901AUG942/2
9042
PN=208
OPERATIONAL CHECKOUT
Use this procedure to check all systems and functions
on the machine. It is designed so you can make a
quick check of the operation of the machine while
doing a walk around inspection and performing specific
checks from the operators seat.
Should you experience a problem with your machine,
you will find helpful diagnostic information in this
checkout that will pinpoint the cause. This information
may allow you to perform a simple adjustment which
will reduce the downtime of your machine. Use the
table of contents to help find adjustment procedures.
The information you provide after completing the
operational checkout will allow you or your authorized
dealer to pinpoint the specific test or repair work
needed to restore the machine to design specifications.
A location will be required which is level and has
adequate space to complete the checks. No tools or
equipment are needed to perform the checkout.
Complete the necessary visual checks (oil levels, oil
condition, external leaks, loose hardware, linkage,
wiring, etc.) prior to doing the checkout. The machine
must be at operating temperature for many of the
checks.
Start at the top of the left column and read completely
down column before performing check, follow this
sequence from left to right. In the far right column, if
no problem is found (OK), you will be instructed to go
to next check. If a problem is indicated (NOT OK), you
will be referred to either a section in this manual or to
TX,95,DH2538 1903SEP921/1
951
PN=209
' MONITOR INDICATOR AND GAUGE CHECKSENGINE OFF
1/1
HOURMETER AND
GAUGE CHECK
OK: Go to next check

NOT OK: Temperature
gauge is solid, 9 arrows
showing, circuit is open or
shorted. Go to your
authorized dealer.
Key switch OFF.
T7773BC UN05AUG92
Press SELECT button.
LOOK: Hourmeter reading must be displayed. The Engine Temperature, Fuel, and
Transmission Temperature gauges must have single arrow pointing to correct reading.
Backlighting of gauges must be ON.
NOT OK: One arrow

blinking on fuel gauge.
Add fuel. If still blinking,
circuit is open or shorted.
Go to your authorized
dealer.
NOTE: Hourmeter only displays in hours, not in tenths of hour.
1/1
BATTERY CHECK
Press SELECT button and hold until battery volts are

displayed.
Key switch OFF.
LOOK: Battery volts must read a minimum of 12.3 volts.
OK: Go to next check.

NOT OK: See Monitor
Display and Alternator
Output Check in this
group.
IF OK: Check and
recharge batteries.
T7825BC UN21AUG92
1/1
952
PN=210
MONITOR INDICATOR
CIRCUIT AND KEY
SWITCH CHECK

NOT OK: Check monitor
ACC fuse.
NOT OK: If brake
pressure stays off after
10 pumps, see Brake
Accumulator Precharge
check.
IF OK: Go to your
authorized dealer.
T7773BA UN05AUG92
Apply brake pedal 10 times.

Turn key switch to accessory position.
LISTEN: Accessory relay must click.

LOOK & LISTEN: All monitor indicators and functions, including the alarm, must come
ON after 1 second and remain ON for 5 seconds.
After 5 seconds:
LOOK: Hourmeter and gauges must display a reading and backlighting must be ON.
LOOK & LISTEN: The following indicators must be ON: STOP, Engine Oil Pressure,
Engine Alternator Volts, Transmission Pressure, Steering Pressure (If equipped) and
Brake Pressure.
Turn key switch to ON.
LISTEN: Accessory relay must click.

All monitor indicators and functions must come ON after 1 second and remain ON for
5 seconds.
After 5 seconds:
LOOK: Hourmeter and gauges must display a reading and backlighting must be ON.
LOOK & LISTEN: The following indicators must be ON: STOP, Engine Oil Pressure,
Engine Alternator Volts, Transmission Pressure, Steering Pressure (If equipped), Park
Brake and Brake Pressure.
1/1
953
PN=211
MONITOR TURN
SIGNALS AND HAZARD
WARNING INDICATOR
CHECKS

NOT OK: Check fuse.
IF OK: Check bulbs and
wiring. Go to your
authorized dealer.
T7773BB UN21AUG92
T6564OL UN19OCT88
T6633AB2 UN18OCT88
Move turn signal switch left, then right. Move hazard warning switch to ON.
LOOK: Left, right, and then both turn signal indicators must be flashing. Front and rear
lights (A and B) must flash as indicated by monitor lights.
1/1
( TRANSMISSION CONTROLS, AXLE AND ENGINE LINKAGES, NEUTRAL START SWITCH, AND REVERSE
WARNING ALARM SWITCH CHECKS
1/1
NEUTRAL START AND

REVERSE WARNING
ALARM CIRCUIT
CHECKS
Turn key switch to ON position and wait 5 seconds.
With transmission control lever in reverse "R", forward

"F", and neutral "N" positions, turn key switch to START
.
NOT OK: Check fuse.

IF OK: Go to your
authorized dealer.
LISTEN: Starting motor must run while lever is in neutral

"N" position only.
T7773BI1 UN05AUG92
LISTEN: Reverse warning alarm must sound with lever

in reverse "R".
1/1
954
PN=212
ENGINE SPEED
CONTROL LINKAGE
CHECK544G, 624G

NOT OK: Adjust linkage.
See Adjust Engine Speed
Control Linkage in
MaintenanceEvery
1000 Hours chapter.
Engine OFF.
Right engine service door
open.
T6564NL UN19OCT88
T6564NM UN19OCT88
Check injection pump lever with accelerator pedal up.
LOOK: Slow idle stop screw (A) must contact injection pump housing.
Have someone fully depress accelerator pedal (or use a weight). Check injection
pump lever position.
LOOK: Long lever must slightly over-travel short lever (B).

FEEL: Accelerator pedal must contact stop bolt (C).
1/1
ENGINE SPEED
CONTROL LINKAGE
CHECK644G
Release accelerator pedal.
OK: Continue.
Push up on injection pump lever.
LOOK: Lever MUST NOT move up.
T8030AN UN21JUN93
1/1
ENGINE SPEED
CONTROL LINKAGE
CHECK644G
(CONTINUED)
Have someone fully depress accelerator pedal (or use a weight).
LOOK: Injection pump lever must be against fast idle stop.
NOT OK: Adjust speed

control linkage. See
Adjust Engine Speed
Control Linkage in
MaintenanceEvery
1000 Hours chapter.
1/1
955
PN=213
FUEL SHUT-OFF
SOLENOID LINKAGE
CHECK644G
Open right engine side shield and inspect linkage.
LOOK: Fuel shut-off cam must be tight against the lower

stop.
NOT OK: Adjust fuel

shut-off solenoid linkage.
See Adjusting Fuel ShutOff Solenoid in
Maintenance chapter.
Start engine and engage park brake.

Open right engine side shield and inspect linkage.
T8030AN UN21JUN93
LOOK: Fuel shut-off cam must be tight against the upper

stop.
1/1
FRONT AXLE
DISCONNECT CHECK
IF EQUIPPED
Move front axle disconnect lever (A) up, to disconnect

axle.
Start engine.

NOT OK: Inspect cable
linkage to axle, repair as
required.
Lower boom to raise front wheels off ground.

Move transmission control lever to reverse R.
T7747AN1 UN21AUG92
IF OK: Go to your
authorized dealer.
Back drag with bucket.

Observe front wheels.
LOOK: Front wheels MUST NOT turn.

Push lever down to reconnect axle.
Observe front wheels when back dragging
LOOK: Front wheels must turn.
1/1
956
PN=214
) MONITOR INDICATOR AND GAUGE CHECKS (ENGINE RUNNING)
1/1
MONITOR DISPLAY AND

ALTERNATOR OUTPUT
CHECK
Turn key switch to on and wait 5 seconds.
LOOK: Hourmeter reading must appear.
T7825BD UN21AUG92
Press SELECT button once.
LOOK: Battery volts reading must be 12.313.8.
T7825BC UN21AUG92
LOOK: Engine rpm must read 0.

LOOK: MPH reading must be 0.

T7825BF1 UN24AUG92
LOOK: km/H reading must be 0.

Start engine and run at slow idle. Observe monitor
display.
LOOK: The following engine rpm readings must be

displayed. 544G/624G: 825875 rpm 644G: 775825
rpm (SN -544523) 875925 rpm (SN 544524- )
T8368BP UN02JAN94
1/1
957
PN=215
Increase engine speed to fast idle
andobserve monitor display.
OK: Go to next
check
LOOK: The following engine rpm readings

must be displayed. 544G: 23502400 rpm
624G/644G: 23002350 rpm
NOT OK: No
monitor reading
displayed. Check
ACC fuse to
monitor.
Press SELECT button until hourmeter icon is

displayed.
IF OK: Go to your
authorized dealer.
LOOK: Hourmeter icon must be flashing and

hourmeter reading must be displayed.
NOT OK: Check

speed control
linkage.
T7825BB UN21AUG92
T7825BD UN21AUG92
Reduce engine speed to slow idle and press

select button until battery voltage is
displayed.
LOOK: Battery voltage should be higher than

in step 5 and should be approximately
13.614.5 volts.
T7825BE UN21AUG92
IF OK: See Adjust

Engine Speed
Control Linkage in
Maintenance
Every 1000 Hours
chapter.
NOT OK: Check
alternator circuit
output. Go to your
authorized dealer.
1/1
958
PN=216
MONITOR INDICATOR
CIRCUIT BYPASS AND
SEAT BELT INDICATOR
CHECK
In a single motion, turn key and start engine.
LOOK & LISTEN: Engine should start and bypass the

bulb check mode.
NOT OK: Check for an

unhooked wiring
connecter.
Depress service brake

pedal 10 times.
Lock transmission control
lever in neutral "N".
IF OK: Go to your
authorized dealer.
T7773BH1 UN05AUG92
T7747AH1 UN24AUG92
T7773BB UN21AUG92
LOOK: Seat belt indicator must go out after 5 seconds after engine starts.
LOOK: Monitor must display engine rpm and gauges must indicate only one reading.
Release park brake.
LOOK: Park brake indicator must go out.

NOTE: It is normal for Engine Oil Pressure, Brake Pressure, and Transmission
Pressure indicators to stay on 46 seconds after engine starts.
1/1
MONITOR PRIMARY AND

SECONDARY LEVEL
CHECKS
Engage park brake
LOOK: Park brake indicator must come ON.
NOT OK: Go to your

authorized dealer.
Engine running.
Move transmission control lever to forward "F".
LOOK: Park brake indicator must remain ON and STOP

indicator must come ON and flash at 1 second intervals.
T7747AG1 UN24AUG92
Engage park brake.
1/1
959
PN=217
TRANSMISSION
TEMPERATURE GAUGE
CHECK

NOT OK: If gauge shows
solid arrows, check
connector at sender.
Engine running.
IF OK: Go to your
authorized dealer.
T7773BO2 UN05AUG92
T7773BF UN05AUG92
Release park brake.

Move clutch cut-off switch to the ON position.
Apply service brakes.
Move transmission control lever to 3rd gear forward.
Increase engine speed to fast idle for 30 seconds.
LOOK: Transmission temperature indicator arrow must move to the right.

1/1
* BRAKE SYSTEM, CLUTCH CUT-OFF, AND DIFFERENTIAL LOCK CHECKS
1/1
PARK BRAKE
TRANSMISSION
LOCKOUT CHECK

NOT OK: Do not operate
machine without interlock
working. Go to your
authorized dealer.
Engine running.
T7773BM UN05AUG92
T7773BN UN05AUG92
Move park brake switch to ON.

Move transmission control lever to 1st gear forward.
Slowly increase engine speed to fast idle.
LOOK: Machine MUST NOT move.
1/1
9510
PN=218
SERVICE BRAKE PUMP
FLOW CHECK

NOT OK: Check for
brake circuit leakage. Go
to your authorized dealer.
NOTE: Hydraulic oil must

be at operating
temperature for this
check.
Engine OFF.
T7747AF1 UN24AUG92
T7773BQ3 UN21AUG92
Stop engine.
Operate brake pedal approximately 15 times.
Start engine and run at slow idle.
Record number of seconds required for low brake pressure indicator light to go out.
LOOK: Indicator light must go out in less than 10 seconds from time engine starts.
NOTE: Indicator light will not come on for approximately 1 second after starting
engine.
1/1
9511
PN=219
SERVICE BRAKE CHECK
Engine running.
NOT OK: Go to your

authorized dealer.
T7773BO2 UN05AUG92
T7773BQ3 UN21AUG92
Move clutch disconnect switch to OFF.

Apply service brakes, release park brake, and move transmission control lever to 2nd
gear forward.
Increase engine speed to fast idle.
LOOK: Machine MUST NOT move or move at a very slow speed.

Repeat check three times to ensure accurate results.
1/1
BRAKE ACCUMULATOR
PRECHARGE CHECK
NOTE: The axles and

hydraulic oil must be at
operating temperature for
this check.
Start engine and run engine for 30 seconds.
Stop engine. Turn key switch to ON and wait 5 seconds.
NOT OK: Make sure

brake pedal is not binding
and keeping brakes
partially engaged.
NOTE: STOP indicator light will be on due to no engine oil pressure.

Count the number of times the brake pedal can be fully depressed before the low
brake pressure warning light comes ON.
LOOK: Warning light must come ON in 15

applications.
Start engine and operate at slow idle.
Observe monitor while applying brake pedal with
maximum force.
T7747AF1 UN24AUG92
IF OK: Bleed brakes.

See Bleeding Brakes in
Maintenance chapter.
NOT OK: If light comes
ON with engine running,
accumulator not charged.
dealer.
LOOK & LISTEN: Brake pressure indicator MUST NOT

come ON.
1/1
9512
PN=220
BRAKE SYSTEM
LEAKAGE CHECK

NOT OK: Go to your
authorized dealer.
T7773BI1 UN05AUG92
T7747AF1 UN24AUG92
Start engine and wait 30 seconds.

Stop engine.
Wait 2 minutes.
Turn key switch to ON and wait 5 seconds.
LOOK: Brake low pressure warning light MUST NOT come ON within 2 minutes after
stopping engine.
1/1
SERVICE BRAKE PEDAL

CHECK
Slowly depress each brake pedal one at a time.
Listen for a hissing noise that indicates oil is flowing to brake pistons.
NOT OK: Inspect for

debris under brake pedal.
Inspect clutch cut-off
linkage.
Engine OFF.
LISTEN & FEEL: A hissing noise must be heard when pedal is depressed
approximately 6 mm (1/4 in.)
1/1
SERVICE AND PARK

BRAKE SYSTEM DRAG
CHECKS
Position machine on a gradual slope.
Lower bucket approximately 50 mm (2 in.) from ground.
Engine running.
Release park and service brakes.
NOT OK: Adjust park

brake. See Adjusting Park
Brake in Maintenance
chapter.
LOOK: Machine must move or coast.

T6522CH UN19OCT88
NOTE: If machine does not move, check brake pedals to

be sure they fully release when feet are removed from
pedals.
Drive machine at high speed for about 5 minutes. Brake
drag is indicated if brake areas in differential case are
hot.
NOTE: Observe park brake. If disk is hot, park brake

drag is indicated.
1/1
9513
PN=221
DIFFERENTIAL LOCK
CHECK
Park machine on a hard surface.
Release brakes.
NOT OK: See Differential

Axle in Troubleshooting
chapter.
Engage differential lock.

Steer machine back and forth.
LOOK: Front wheels MUST NOT turn in opposite

direction.
NOTE: It is normal to get a "clunk" sound when you
release pedal.
T7773BQ1 UN21AUG92
1/1
CLUTCH CUT-OFF
CHECK

NOT OK: Adjust clutch
cut-off switch. See
Adjusting Clutch Cut-Off
Switch in Maintenance
chapter.
T7773BO2 UN05AUG92
T7773BQ2 UN21AUG92
Move clutch cut-off switch to ON position.

Release park brake.
Run engine at 1/2 speed in 1st gear forward.
Firmly depress left brake pedal.
FEEL: Transmission must disengage when left brake pedal is depressed.

NOTE: Clutch cut-off switch on left brake pedal can be adjusted to operator
preference to match your loading needs.
1/1
9514
PN=222
+ DRIVING CHECKS
NOTE: Transmission oil must be at operating temperature for these checks.
1/1
TRANSMISSION NOISE
CHECK
NOT OK: Go to
Transmission Makes
Excessive Noise in
Troubleshooting chapter.
Engine running.
T7825BH UN21AUG92
T7773BN UN05AUG92
Run engine at approximately 1600 rpm.

Drive machine with transmission in each forward and reverse gear.
LISTEN: Transmission MUST NOT make excessive noise in any range.

Engine rpm MUST NOT "lug down" as transmission is shifted between gears.
1/1
9515
PN=223
AUTOMATIC SHIFT AND
SPEEDOMETER CHECK
Press SELECT button on monitor until MPH or Km/H is

displayed.
Engine running.
Release park brake and move transmission control lever

to 4th gear forward.
T7825BG UN21AUG92
Drive machine on level ground and slowly accelerate to

fast idle speed. Note speed when shifts are made until
4th gear. Reduce engine rpm to idle and note speed
when transmission makes each downshift.

NOT OK: Monitor is
programmed for wrong
machine model. Go to
NOT OK: Transmission
controller does not match
machine model. Go to
LOOK: Transmission should shift at following speeds:

544G
624G
644G
Shift
MPH
Km/
H
MPH
Km/
H
MPH
Km/H
2nd3rd
3rd4th
13
21
12
18
11
17
4th3rd
12
18
11
17
10
16
3rd2nd
NOTE: In 4th gear automatic the transmission starts out

in 2nd gear.
1/1
9516
PN=224
TRANSMISSION
QUICKSHIFT CHECK
Release park brake and move transmission control lever

to 2nd gear forward.
Engine running.
Drive machine at approximately 1600 rpm and press

boom control lever switch once.
LOOK & FEEL: Transmission must shift to 1st gear.

T7825BL1 UN31AUG92

NOT OK: Check
connector at base of
control valve.
IF OK: Go to your
authorized dealer.
Press boom control lever switch once.
LOOK & FEEL: Transmission must shift back to 2nd

gear.
Shift to (4th) gear and press boom control lever switch
once.
LOOK & FEEL: Transmission must not shift down.

NOTE: If boom lever switch is pressed twice,
transmission will shift down, then immediately back to
2nd. Transmission will also quickshift from 3rd gear, but
quickshift will not work in any gear when in 4th gear
"automatic" mode.
1/1
TRANSMISSION
PRESSURE, PUMP
FLOW, AND LEAKAGE
CHECK
Engine running.
Run engine at slow idle.
Release park brake.
NOT OK: Go to your

authorized dealer.
Shift transmission control lever to reverse, then forward, and then to 1st, 2nd, 3rd and
4th gears.
Wait 5 seconds after each shift and observe transmission pressure indicator light.
LOOK: Indicator light MUST NOT come ON.

NOTE: If light comes ON in one gear only, leakage is
indicated on that gear.
If light comes ON in all gears, low pump flow or pressure
is indicated.
T7747AD1 UN24AUG92
1/1
9517
PN=225
TRANSMISSION SHIFT
MODULATION CHECK

NOT OK: See Machine
Shifts Too Fast in
Troubleshooting chapter.
Engine running.
T7825BH UN21AUG92
T7773BN UN05AUG92
Run engine at approximately 1600 rpm.

Move transmission control lever to 1st gear forward. Shift several times from forward
to reverse and reverse to forward. Repeat check in 2nd gear.
LOOK: Machine must slow down and change direction without excessive delay.
1/1
, HYDRAULIC SYSTEM CHECKS
1/1
HYDRAULIC SYSTEM
WARM-UP PROCEDURE
Run engine at fast idle.
Hold a hydraulic function over relief to heat oil.

Engine running.
Periodically cycle all hydraulic functions to distribute warm oil.
Repeat procedure until oil is at operating temperature.
FEEL: Hydraulic reservoir must be uncomfortable to hold your hand against

(approximately 50C [120F]).
1/1
BOOM DOWN SOLENOID

VALVE CHECK
Raise boom to full height. Roll bucket back.
Stop engine.
NOT OK: Check fuse.
Hold boom down switch down.
IF OK: Go to your
authorized dealer.
Engine running.
Move control lever to bucket dump position.

T7773BO1 UN05AUG92
Move control lever to boom lower position.
LOOK: Bucket must dump and boom must lower.
1/1
9518
PN=226
CONTROL VALVE LIFT
CHECK
With bucket partially dumped, lower boom to raise front

of machine.
Slowly move boom control lever to boom lower position.

Slowly move bucket control lever to bucket dump
position.
T6601AA UN19OCT88

NOT OK: Repair lift
checks in loader control
valve. Go to your
authorized dealer.
LOOK: Boom MUST NOT raise before moving down.

Bucket MUST NOT rollback before dumping.
1/1
BUCKET ROLLBACK
CIRCUIT RELIEF VALVE
CHECK
Position bucket at a 45 angle against an immovable

object.
Move transmission control lever to 3rd gear forward.
LOOK: Bucket angle MUST NOT change.

NOT OK: Check loader
system and circuit relief
valve pressures. Go to
T6564OD UN19OCT88
1/1
BUCKET DUMP CIRCUIT

RELIEF VALVE
PRESSURE CHECK
Raise front of machine with bucket at 45 angle.
Backdrag with bucket while observing bucket angle.
NOT OK: Check loader

system and circuit relief
valve pressure. Go to
LOOK: Bucket MUST NOT rollback.
T6601AA UN19OCT88
1/1
BOOM AND BUCKET

CYLINDER DRIFT
Raise bucket about 50 mm (2 in.) off ground with bucket

level.
Stop engine. Wait 1 minute.

NOT OK: Go to your
authorized dealer.
LOOK: Bucket MUST NOT touch ground.
T6564NZ UN19OCT88
NOTE: Use good judgement to determine if the amount

of drift is objectionable for your loader application.
1/1
9519
PN=227
BOOM DOWN CHECK
VALVE LEAKAGE
CHECK
Position bucket flat on ground.
Run engine at slow idle for 2 minutes.
Heat hydraulic oil to

(See Hydraulic System
Warm-up Procedure in
this group.)
LOOK: Bucket MUST NOT drift up.
NOT OK: Replace boom

lower check valve. Go to
T7010AO UN15MAR89
1/1
PILOT CONTROLLER
CHECK

NOT OK: Repair pilot
controllers. Go to your
authorized dealer.
T7827AI2 UN24AUG92
T7827AD UN24AUG92
Stop engine. Turn key switch to OFF position.

Move control lever to all positions and then release.
LOOK: Lever must return to neutral when released from all positions.
1/1
RETURN-TO-DIG CHECK
Position bucket fully dumped just above ground level.
Move control lever to return-to-dig detent position and

release.
NOT OK: Check fuse.
LOOK: Bucket must rollback to the level position and

control lever must return to neutral.
T7827AI3 UN24AUG92
IF OK: Adjust switch.

See Adjusting Return-ToDig in Operating the
Machine chapter.
NOTE: If bucket is in a rolled back position when key

switch is turned ON, control lever must be returned to
neutral manually if placed in the return-to-dig detent
position. After bucket is dumped once, return-to-dig will
work normally.
1/1
9520
PN=228
BOOM HEIGHT KICKOUT
CHECKIF EQUIPPED
Position bucket flat on ground.
Move control lever to boom raise detent position and

release.
NOT OK: Check fuse.
LOOK: Boom must raise to the set height and stop.

Control lever must return to neutral.
IF OK: See Adjusting

Boom Height Kickout in
chapter.
T7825BL UN24AUG92
1/1
PIN DISCONNECT
CYLINDER CHECK
(544G-TC ONLY)
Lower boom to ground.
Engine running.
Push and hold down pin disconnect switch.
NOT OK: Hold a

screwdriver blade
against the end of the
solenoid valve and check
for magnetism with the
switch pushed.
LOOK: Pin disconnect cylinder must retract both pins, while switch is depressed.
If the problem is
electrical, check fuse.
IF OK: Go to your
authorized dealer.
If the problem is
hydraulic, go to your
authorized dealer.
1/1
RIDE CONTROL
ACCUMULATOR
CHECKIF EQUIPPED
Start engine.
Push ride control switch to OFF position.
CAUTION: The boom will

jump upward during this
check. Make sure area
around bucket is clear.
Raise boom to maximum height and hold control lever

over relief for 2 seconds.
NOT OK: Check ride

control fuse. IF OK: Ride
control accumulator has
lost gas charge. Go to
Lower boom and bucket to ground and stop engine.

T7010AO UN15MAR89
Turn key switch to ON position.

Observe loader boom as ride control switch is switched
to ON.
LOOK & FEEL: Boom will jump upward, approximately

200 mm (8.0 in.) as accumulator pressure is released.
1/1
9521
PN=229
- STEERING SYSTEM CHECKS
1/1
STEERING VALVE
CHECK
Turn steering wheel until frames are at maximum right

(A) and then left (B) positions.
NOT OK: Go to next

check.
LOOK: Frames must move smoothly in both directions.
T6471AQ UN19OCT88
NOTE: It is normal for steering to drift away from

steering stops when steering wheel is released.
When steering wheel is stopped, frames must stop.
FEEL: Excessive effort must not be required to turn

steering wheel.
1/1
STEERING SYSTEM
LEAKAGE CHECK
Turn steering wheel rapidly until frames are against

stops. Hold approximately 22 N (5 lb force) pressure on
steering wheel.
Heat hydraulic oil to

(See Hydraulic System
Warm-Up Procedure in
this group.)

NOT OK: Go to your
authorized dealer.
Count steering wheel revolutions for 1 minute. Repeat

test in opposite direction.
LOOK: Steering wheel must rotate less than 5 rpm.

T6601AC UN19OCT88
NOTE: Use good judgement; excessive steering wheel

rpm does not mean steering will be affected.
Note: Cold oil may give

increased RPMs during
this check.
1/1
9522
PN=230
PRIORITY VALVE LOW
PRESSURE CHECK
Park machine on a hard
surface.
Hold brake pedal down.
Steer machine to the right and left as far as possible.
NOT OK: Adjust priority

valve pressure. Go to
LOOK: machine must turn at least 1/2 way to the right and left stops.
1/1
PRIORITY VALVE HIGH

PRESSURE CHECK

NOT OK: Priority
pressure is set too high.
dealer.
T7827AI3 UN24AUG92
T7825BJ UN21AUG92
Steer to steering stop and release wheel.

Roll bucket back and hold over relief and observe engine rpm.
Turn wheel to steering stop and hold. Observe engine rpm.
LOOK: Steering stall engine rpm must be higher than hydraulic stall rpm.
1/1
9523
PN=231
SECONDARY STEERING
SYSTEM CHECKIF
EQUIPPED
IMPORTANT: DO NOT
operate secondary steering
pump for more than 15
seconds with the steering
in neutral or damage to the
pump and motor can
occur.

NOT OK: If secondary
steering pump and motor
do not operate, go to your
authorized dealer.
T7773BH1 UN05AUG92
T6601AC UN19OCT88
Park machine on a hard level surface with bucket off of ground and steering straight
ahead. Stop engine.
If secondary steering
pump and motor operate
but machine does not
steer, go to your
authorized dealer.
Without starting engine, turn key switch to START position and release.
Steer machine to right and left.
LOOK: Machine must steer approximately 1/2 way to

stops in both directions. Light in monitor must come ON
and stay ON until key switch is turned to STOP.
T7747AJ1 UN24AUG92
1/1
SECONDARY STEERING
SYSTEM PRIMARY
CHECK VALVE CHECK
Turn steering wheel rapidly until frames are against stops. Hold approximately 22 N (5
lb force) pressure on steering wheel.
Actuate a hydraulic function and hold over relief. Return control lever to neutral.

NOT OK: Go to your
authorized dealer.
FEEL: Steering wheel MUST NOT "kick back" as hydraulic function is released.
NOTE: Steering wheel "kickback" is normal on machines without secondary steering.
1/1
9524
PN=232
. ACCESSORY CHECKS
NOTE: Engine must be stopped and key switch must be ON for these checks
1/1
OPERATING LIGHTS
CHECK

NOT OK: Check fuse.
IF OK: Go to your
authorized dealer.
T7773BO3 UN05AUG92
T6633AB UN18OCT88
T6637AA UN18OCT88
Push light switch.

Note light operation.
LOOK: Headlights (C), and taillights (D) must come on.
1/1
WORK LIGHT CHECK

NOT OK: Check fuse.
IF OK: Check bulbs and
replace as required. Go
T7773BO4 UN05AUG92
T6633AB1 UN18OCT88
T6564OI UN19OCT88
Push light switch.

Note light operation.
LOOK: Front work lights (C) and rear work lights (D) must come on.
1/1
9525
PN=233
BRAKE LIGHT CHECK
Depress brake pedal and observe brake lights (A).
LOOK: Brake lights must come on.
NOT OK: Check brake

light fuse.
NOTE: Brake light switch is a pressure switch. If

accumulator is empty, engine may need to be started
for brake lights to come on.
IF OK: Check bulbs,

replace as required. Go
T6633AB3 UN18OCT88
1/1
HORN CIRCUIT CHECK
Push horn button (A).
LISTEN: Horn must sound.
NOT OK: Check fuse

IF OK: Check wiring and
ground at horn. Go to
T7747BJ1 UN21AUG92
1/1
9526
PN=234
WINDSHIELD WASHER
AND WIPER CHECKIF
EQUIPPED
Turn front wiper switch knob clockwise to first detent,

then to second position.
LOOK: Front wiper must operate at slow speed with

switch in first detent, and fast speed with switch in
second position.
Push knob in to turn front washer on.
T7773AN UN05AUG92

NOT OK: If wiper and
washer do not work,
check fuses.
IF OK: Check wiring. Go
LOOK: Washer must spray water on windshield.

Turn wiper off.
LOOK: Front wiper must park at side of windshield.

Push rear wiper switch down to first detent position.
LOOK: Rear wiper must operate at one speed with

switch in first detent.
Push rear wiper switch past detent to turn rear washer
on.
LOOK: Washer must spray water on rear window.

Turn wiper off.
LOOK: Rear wiper must park at side of rear window.
1/1
DEFROSTER BLOWER
CHECK
Turn defroster blower switch knob to low, medium and

high speeds. (Heater blower will also come on
automatically.)
FEEL & LISTEN: Blower must have three speeds and

OFF.
IF OK: Go to your
authorized dealer.
NOT OK: Check fuse.
T7773BP2 UN05AUG92
1/1
9527
PN=235
HEATER/AIR
CONDITIONER BLOWER
CHECK
Turn blower switch knob to low, medium and high

speeds.

NOT OK: Check fuse.
FEEL & LISTEN: Blower must have three speeds and

OFF.
IF OK: Go to your
authorized dealer.
T7773BP3 UN05AUG92
1/1
HEATER FUNCTIONAL
CHECK
Open heater shut-off valve on water pump.
Start engine. Run at fast idle.
NOT OK: Go to your

authorized dealer.
Wait 2 minutes.
Turn temperature control knob to maximum heat
position.
T7773BP1 UN05AUG92
FEEL: Air from ducts must be warm.
1/1
AIR CONDITIONER
FUNCTIONAL CHECK
Start engine and run at fast idle.
Turn air conditioner switch to maximum COOL setting.
NOT OK: Check fuse.
Wait for any warm air in duct system to dissipate.
IF OK: Go to your
authorized dealer.
FEEL: Air from ducts must be cool.

T7773BP1 UN05AUG92
1/1
9528
PN=236
START AID SYSTEM
CHECK

NOT OK: Check for
empty start aid can (A).
IF OK: Check fuse.
Replace.
T7747AI1 UN14SEP92
NOT OK: If light does

not come ON, go to your
authorized dealer.
T6477AP UN19OCT88
Start engine and run at slow idle.

Momentarily push start aid button.
LISTEN: Engine speed must increase slightly.

LOOK: Light in monitor must come ON when button is pushed.
1/1
/ CAB COMPONENT AND VANDAL PROTECTION CHECKS
1/1
CAB DOOR AND

WINDOW HOLD-OPEN
LATCH CHECK

NOT OK: Adjust rubber
stop. Repair latch.
T6633AK UN18OCT88
T6633AN UN18OCT88
T6633AJ UN18OCT88
Push window and door to full open position.

Release window and door by turning lever (D) clockwise.
LOOK: Pin (B) must fit into latch notch (A). Latch must retain door and window
against rubber stops (C).
1/1
9529
PN=237
CAB DOOR RELEASE
BUTTON
Press door release button.
LOOK & LISTEN: Latch must click and release door.
NOT OK: If latch does

not release, check fuse.
IF OK: Go to your
authorized dealer.
NOT OK: If door does
not latch tightly, adjust
latch assembly.
T7832AJ UN27AUG92
1/1
CAB DOOR LOCK

CHECK
Lock cab door.
LOOK: Cab door handle MUST NOT move.
NOT OK: Lubricate or

repair lock.
FEEL: Lock must operate freely and key must not stick
in lock.
T6564PB UN19OCT88
1/1
DOME LIGHT CHECK
Move each dome light toggle switch to ON position.
Key switch OFF.
LOOK: Dome lights must come on.
NOT OK: Check fuse

and bulb.
Turn both switches OFF.
T7832AI UN24AUG92
1/1
9530
PN=238
CAB WINDOW LATCH
CHECK
Inspect window seals.
Open right side cab window. Pull window closed.
NOT OK: Lubricate

latch. Replace window
seals if necessary.
LOOK: Latch must hold window tightly closed.

LOOK: Window seals MUST NOT have gaps between
seals and window frames.
T6633AO UN18OCT88
Position latch outer notch (A) over catch.

Open latch.
LOOK: When window latch is in outer notch position,

window must be held slightly open.
1/1
CAB DOOR WINDOW

CHECK
Inspect window seals.
Open sliding window to maximum open position and

back to 1/2 open notch and release latches (A).
NOT OK: Oil latch.

Replace window seals if
necessary.
Close sliding window.
T7409AQ UN27NOV90
LOOK: Latches must hold window tightly closed, and

hold in any notched position.
LOOK: Window seals must not have gaps between seals
and window frames.
1/1
STEERING COLUMN
ADJUSTMENT CHECK
Depress pedal (A) and move steering wheel column to

all positions.
Release pedal at each position.

NOT OK: Check and
adjust pedal linkage.
LOOK: When pedal is released, steering column must

lock securely in that position.
T7773BQ UN05AUG92
1/1
9531
PN=239
SEAT AND SEAT BELT
CHECK
IMPORTANT: Replace the
complete seat belt
assembly every three
years regardless of
appearance. A date label,
to determine the age of
the belt, is attached to
each seat belt.
Standing over seat reach down and lift seat assembly to

top of travel then let go. Lift seat slowly until latch "
clicks", and release seat. Repeat for upper latch.
LOOK & FEEL: Seat must have 3 positions and must

latch in 2 upper positions.
T7747AP UN21AUG92
Inspect seat shell and suspension for cracks, broken

welds or looseness.

NOT OK: Replace any
worn or broken parts.
Lubricate moving parts of
suspension and seat
adjusters. Go to your
authorized dealer.
LOOK: Seat must be in safe condition.

Check seat adjustment functions (A, B, C, E, F).
LOOK: Seat must adjust freely and remain in locked

position.
Bounce on seat to check suspension operation.
FEEL: Seat suspension must not bottom out and must

support operators weight.
Inspect seat belt (D) for damage.
LOOK: Seat belt must lock and not be damaged or worn.

FEEL: Seat belt must stay adjusted snugly and not slip
in adjuster.
1/1
TOOLBOX DOOR CHECK
Unlock and open toolbox door under seat in operators station.
Close and lock door.
NOT OK: Lubricate

hinges. Lubricate or
repair lock.
LOOK: Door must open and close smoothly.

FEEL: Lock must operate freely and key MUST NOT stick in lock.
1/1
9532
PN=240
AIR INTAKE FILTER
DOOR CHECK
Unlock and open door on left side of operators station.
NOT OK: Lubricate

repair lock.

FEEL: Lock must operate freely and key MUST NOT
stick in lock.
T6633AW UN18OCT88
1/1
LOAD CENTER DOOR

CHECK
Unlock and open door on right side of operators station.
NOT OK: Lubricate

repair lock.

FEEL: Lock must operate freely and key MUST NOT
stick in lock.
T7832AK UN27AUG92
1/1
ENGINE SIDE PANELS

CHECK
Unlock and open side panel (A).
Latch side panel in open position.
NOT OK: Lubricate

hinges. Repair latch.
Pull rear of panel up and slide out side panel (B).

Install side panel (B).
T6633AS UN18OCT88
Close panel (A).
LOOK: Panels must open and close smoothly.

FEEL: Latch must operate freely and locking tab must
be able to accept a padlock.
Repeat with other side.
1/1
9533
PN=241
RADIATOR CAP ACCESS
DOOR CHECK
Open and close access door on top of grille housing.
LOOK: Door must move freely. Locking pin for padlock

MUST NOT be bent.
NOT OK: Lubricate

hinges. Repair door.
T6633AY UN18OCT88
1/1
LOOK: Red frame locking bar must be pinned to engine

frame below left side cab step.
FRAME LOCKING BAR

CHECK

NOT OK: Order new
parts and install new
locking bar and pins.
T7799CX UN23SEP92
1/1
BOOM LOCK CHECK
LOOK: Red boom lock must be fastened to front frame at hinge in vertical position.

NOT OK: Order new
parts and install new
boom lock.
1/1
SERVICE DECAL CHECK
Check service decal (A) above left side battery

compartment.
OK: Operational
Checkout completed.
LOOK: Service decal must be legible.
NOT OK: Replace

service decal.
T8385AC UN15DEC94
1/1
9534
PN=242
Troubleshooting
USING TROUBLESHOOTING CHARTS
NOTE: Troubleshooting charts are arranged from the
simplest to verify, to least likely, more difficult to
verify. When diagnosing a problem, use all
possible means to isolate the problem to a single
component or system. Use the following steps to
diagnose problems:
Step 1. Operational Checkout Procedure.
Step 2. Troubleshooting charts.
Step 3. Adjustments.
Step 4. See your authorized dealer.
TX,FF,105 1915JUL941/1
1001
PN=243
Troubleshooting
ENGINE
Symptom
Problem
Solution
Engine Will Not Start Or Starts

Hard
Fuel tank empty.
Check fuel quantity.
Fuel tank vent hose clogged.
Loosen cap and listen for air rushing

into tank. Clean or replace hose.
Water in fuel or water frozen in line.
Drain water from fuel tank. Inspect

fuel filter(s) for water. Change
filter(s).
Fuel shut-off fuse.
Replace fuse.
Fuel filter(s) clogged.
Inspect and replace fuel filter(s).
Incorrect grade of fuel.
Drain fuel tank and add correct fuel.
Air leak on suction side of fuel

system.
Check and tighten connection.

Check fuel lines for damage.
644GFuel shut-off solenoid

incorrectly adjusted.
Adjust so fuel shut-off lever is

against run stop on injection pump.
544G, LL, TC, 624GInjection

pump metering valve sticking.
Lightly tap injection pump housing. If

engine starts, see your authorized
dealer.
544G, LL, TC, 624GElectric shutoff.
See your authorized dealer.
Fuel pump.
Slow cranking speed.
Check batteries and connections.
Restricted air filter(s).
Check air filter restriction indicator

and air filter(s).
Incorrect injection pump timing.
644GFuel drains from filter(s) with

engine stopped, due to leakage in
check valve.
Disconnect filter inlet line from check

valve. Inspect for leakage.

TX,100,DH2481 1902OCT921/12
1002
PN=244
Troubleshooting
Symptom
Engine Surges Or Stalls

Frequently
Problem
Solution
Injection nozzle(s).
Low compression or blown head

gasket.
544G, LL, TC, 624GRemove fuel

shut-off fuse. Crank engine and
listen for air leaking past valves or
an uneven starter speed. Start
engine and observe blow-by from
vent tube. See your authorized
dealer.
Fuel injection pump.
Loosen cap and listen for air rushing

into tank. Clean or replace hose.
Water in fuel or water frozen in line.
Drain water from fuel tank trap.

Inspect fuel filter(s) for water.
Change filter(s).
Replace filter(s).
Air leak on suction side of fuel

system.
Check and tighten connections.

Check fuel lines for damages.
Fuel pump.
Fuel return line from injection pump

to tank restricted.
Disconnect fuel return line from

injection pump. Connect a hose to
pump and route fuel into a container.
If engine runs normally, return hose
is restricted.
644GClogged overflow valve in

injection pump.
Restrictor fitting on top fitting in

injection pump clogged.
Remove, inspect and clean.

TX,100,DH2481 1902OCT922/12
1003
PN=245
Troubleshooting
Symptom
Engine Misses
Problem
Solution


dealer.
Fuel injection pump out of time.
Engine overheating.
644GIncorrect slow idle, or

supplementary idling screw
adjustment.
Check and adjust slow idle. See

Incorrect valve clearance.
Check and adjust valve clearance.

(See MaintenanceEvery 1000
Hours chapter.)
Valves sticking or burned.
Remove fuel shut-off fuse. Crank

engine and listen for air leaking past
valves or an uneven starter speed.
Worn or broken compression rings

or cylinder head gasket leaking.
Start engine and observe blow-by

from vent tube. See your authorized
dealer.
Injection pump.
Air in fuel.
Disconnect return hose from leak-off

lines. Crank engine and check for
air in fuel at leak-off lines. Tighten
connections. Check fuel lines for
damage.
Fuel injection pump out of time.

TX,100,DH2481 1902OCT923/12
1004
PN=246
Troubleshooting
Symptom
Engine Does Not Develop Full

Power
Problem
Solution
Slow idle speed too low.
Check slow idle speed. (See

chapter.) See your authorized
dealer.
Fuel pump.
Engine overheats.

hours chapter.)
Bent push rods.
Valve sticking or burned.

Cylinder head gasket leaking.
Worn or broken compression rings.
Injection pump.
Loosen fuel cap and listen for air

rushing into tank. Clean or replace
hose.
Fuel shut-off solenoid lever not

against stop on injection pump.
Adjust solenoid. (See Adjusting Fuel

Shut-Off Solenoid in Maintenance
chapter.)
Air intake system restricted.
Check air filter elements and air filter

restriction indicator switch. (See
MaintenanceAs Required chapter.)

(See Fuels and Lubricants chapter.)

TX,100,DH2481 1902OCT924/12
1005
PN=247
Troubleshooting
Symptom
Problem
Solution
Excess drag in transmission.
Excess drag in brakes.
Check service and park brake drag.

Fast idle speed set too low.
Check and adjust fast idle. See your

authorized dealer.
Change filter(s).
Fuel line restricted.
Check for pinched or kinked lines or

debris in lines. Route return line into
separate container. If engine
operation returns to normal, repair
fuel return system lines.
Fuel pump.
Clogged overflow valve in injection

pump.
544G, LL, TC, 624GRestrictor

fitting on top fitting in injection pump
clogged.
Remove, inspect and clean.


dealer.
Air leak in intake manifold.

Hours chapter.)
Worn camshaft.

TX,100,DH2481 1902OCT925/12
1006
PN=248
Troubleshooting
Symptom
Engine Emits Excessive Black Or

Gray Exhaust Smoke
Problem
Solution
Turbocharger.
Remove air intake hose and exhaust

elbow. Leading edge of compressor
vanes must be sharp and straight.
Spin compressor wheel and listen
for noisy bearings. Turbine and
compressor wheels must not rub in
housing.
Muffler restricted.
Run engine without muffler. If engine

operation is now normal, install a
new muffler.
Low compression.

Start engine and observe blow-by
from vent tube. See your authorized
dealer.
Incorrect camshaft timing.
Injection pump.
Restricted air filter.
Check air filter restriction indicator

and air filter(s). (See Maintenance
As Required chapter.) Replace.

(See Fuels and Lubricants chapter.)
Air leak between turbo and manifold.
Excessive fuel delivery.

TX,100,DH2481 1902OCT926/12
1007
PN=249
Troubleshooting
Symptom
Engine Emits Excessive Blue Or

White Smoke
Slow Acceleration.
Detonation
Problem
Solution
Turbocharger.

Spin compressor wheel and listen
for noisy bearings. Turbine and
housing.
Cranking speed too low.
Check batteries and connections.

(See Fuel and Lubricants chapter.)
Injection pump out of time.
Engine running too cold.
Low compression.
Remove injection pump fuse. Crank

valves. Start engine and observe
blow-by from vent tube. See your
authorized dealer.
Excessive wear in liners and/or

piston rings stuck.
Worn valve guides.
Fuel injection pump.
Starting aid solenoid stuck open.
Incorrect injection pump advance.

TX,100,DH2481 1902OCT927/12
1008
PN=250
Troubleshooting
Symptom
Problem
Solution
Abnormal Engine Noise
Low or incorrect engine oil.
Add correct oil.
Loose or worn dampener drive.
Engine oil diluted with fuel.
Inspect engine oil. Inspect fuel pump

spindle, seal, and housing. Clean
and use or replace.
Incorrect fuel injection pump timing.
Turbocharger.
Excessive valve clearance.
Adjust valve clearance. (See

chapter.)
Bent push rods.
Worn rocker arm shafts.
Loose connecting rod caps.
Loose main bearing caps.
Worn main bearing.
Worn connecting rod bearings.
Incorrect camshaft timing.
Scored piston.
Worn piston pin bushings and pins.
Low oil level.
Add oil.
Wrong viscosity oil or oil diluted with

diesel fuel.
Change oil. 644Ginspect fuel

pump spindle, seal, and housing.
544G, LL, TC, 624G,inspect fuel
pump diaphragm. Clean and use or
replace.
Low Oil Pressure

TX,100,DH2481 1902OCT928/12
1009
PN=251
Troubleshooting
Symptom
High Oil Pressure
Engine Overheats
Problem
Solution
Oil pressure gauge or sensor.
Oil pressure regulating valve.
Turbocharger shaft seal leaking.
Clogged oil pump intake screen.
Loose oil pump drive gear.
Worn oil pump gear or housing.
Excessive main bearing clearance.
Excessive connecting rod bearing

clearance.
Cracked cylinder block.
Piston cooling orifice missing.
Leakage at internal oil passage.
Wrong viscosity oil (too thick).
Check for antifreeze in oil. Change

oil.
Oil pressure gauge or sender.
Oil pressure regulating valve.
Low coolant level.
Fill cooling system and check for

leaks.
Low engine oil level.
Add oil.
Loose or broken fan belt.
Tighten or replace belt.
Fan on backwards, damaged, or

wrong fan installed.
Check for correct fan installation.
Radiator dirty, clogged, or fins

damaged.
Check air flow. Clean radiator.

Straighten fins.

TX,100,DH2481 1902OCT929/12
10010
PN=252
Troubleshooting
Symptom
Engine Runs Cold
Oil In Coolant Or Coolant In Oil
Problem
Solution
Radiator shroud missing, damaged,

or baffles missing.
Inspect. Repair or replace.
Engine overloaded.
Reduce load.
Radiator cap.
Replace cap.
Faulty gauge or sender.
Faulty thermostats (stuck).
Thermostats missing.
Cooling system coated with lime

deposits.
Flush cooling system.
Excessive brake drag.
Excessive transmission drag.
Water pump.
Excessive fuel delivery.
Scored piston.
Combustion leak into cooling

system.
Remove radiator cap. Start engine

and check for bubbles in radiator.
Temperature gauge or sender.
Thermostat (stuck open).
Leaking heat exchanger.
Leaking cylinder head gasket.
Leaking cylinder liner packings.

TX,100,DH2481 1902OCT9210/12
10011
PN=253
Troubleshooting
Symptom
Excessive Fuel Consumption
Turbocharger Excessively Noisy

Or Vibrates
Oil Dripping From Turbocharger

Adapter
Problem
Solution
Cracked cylinder liner.
Cracked cylinder block.
Air system restricted.
Check filter restriction indicator and

air filters. Replace. (See
MaintenanceAs Required chapter.)
Leakage in fuel system.
Inspect and repair.
Drain and refill with correct fuel.
Turbocharger.

Spin compressor wheel to check for
rough bearings. Turbine and
housing.
Faulty injection nozzle(s).
Bearings not lubricated.
Insufficient oil pressure. Check for

restricted turbocharger oil line.
Air leak in engine, intake or exhaust

manifold.
Incorrect clearance between turbine

wheel and turbine housing.
Remove exhaust elbow and air inlet

hose. Inspect and repair.
Broken blades on turbine.
Remove exhaust elbow and air inlet

hose. Inspect and repair.
Damaged or worn bearings and/or

worn seals.
Inspect compressor and turbine

wheel for damaged blades. Check
for proper engine service intervals or
dirt entering engine.
Excessive crankcase pressure.
Check for clogged vent tube. Clean.

TX,100,DH2481 1902OCT9211/12
10012
PN=254
Troubleshooting
Symptom
Excessive Drag In Turbocharger

Rotating Members
Problem
Solution
Carbon build-up in turbocharger oil

return line where line passes
exhaust manifold.
Remove line. Inspect and clean.
Carbon build-up behind turbine

wheel caused by combustion
deposits.
Dirt build-up behind compressor

wheel caused by air intake leaks.
Bearing seizure of dirty or worn

bearings caused by excessive
temperature, unbalanced wheel, dirty
oil, oil starvation, or insufficient
lubrication.
Check for clogged air filters.
TX,100,DH2481 1902OCT9212/12
10013
PN=255
Troubleshooting
ELECTRICAL SYSTEM
Symptom
Problem
Solution
Nothing Works
Power circuit components.
Battery undercharged or dead.
Battery cables making poor

connections.
Clean cable connections at battery

and starter solenoid.
Neutral start fuse.
Replace fuse.
Battery undercharged or dead.
Battery cables making poor

connections.
Clean connections at battery, starter,

and ground to frame.
Start relay.
Starter solenoid.
Fuel shut-off solenoid.
Starter motor.
Starter motor pinion "jammed" in

flywheel gear.
Key switch.
Transmission control lever.
Engine.
Batteries undercharged.
Starter armature bearings worn,

causing starter "drag".
Battery cable connections loose or

corroded.
Clean and/or tighten connections.
Starter Will Not Crank Engine
Engine Cranks Slowly

TX,100,DH2482 1902OCT921/8
10014
PN=256
Troubleshooting
Symptom
Problem
Solution
Starting Motor Turns, But Engine

Will Not Crank
Starter pinion not engaging flywheel

ring gear.
Starter pinion or flywheel gear teeth

broken.
Starter solenoid stuck.
Starter not disengaging.
Starter relay stuck.
Key switch.
Wiring harness shorted.
Battery being overcharged.
High ambient temperature.
Refill with distilled water.
Cracked battery case.
Replace battery. Install hold down

correctly.
Low water level.
(See "Battery Using Too Much

Water" and "Cracked Battery Case"
in this group.)
Dirty or wet battery top, causing

discharge.
Clean battery and wipe dry.
Corroded or loose battery cable

ends.
Clean and tighten cable end clamps.

Recharge battery. If unit has two
batteries, recharge separately.
Broken or loose battery posts.
Move posts by hand. If posts are

loose or will turn, replace battery. If
unit has two batteries, replace both
batteries.
Loose fan/alternator belt, or worn

pulleys.
Inspect belt or pulley. Adjust or

replace as necessary.
Starting Motor Continues To Run

After Engine Starts
Battery Using Too Much Water
Low Battery Output

TX,100,DH2482 1902OCT922/8
10015
PN=257
Troubleshooting
Symptom
Problem
Solution
Starter Solenoid Chatters
Poor connections at batteries or

starter.
Clean connections.
Low battery charge.
Recharge or replace batteries.
Starter solenoid "hold-in" windings

open.
Fuel shut-off solenoid.
Key switch.
Wiring harness.
Empty start aid can.
Replace start aid can.
Start aid switch.
Start aid solenoid.
Worn drive belt.
Inspect and replace.
Pulley misaligned.
Adjust alternator mount.
Alternator bearing.
Loosen alternator belts. Turn pulley

by hand. If any roughness is felt,
repair alternator.
Internal alternator.
Loose or glazed alternator belt.
Check belt. Replace if glazed,

tighten if loose.
Engine rpm low.
Raise engine rpm. If light remains

on, see your authorized dealer.
Excessive electrical load from added

accessories.
Remove accessories or install higher

output alternator.
Loose or corroded electrical

connections on battery, ground
strap, starter, or alternator.
Inspect, clean, or tighten electrical

connections.
Engine Cranks But Does Not

Start
Start Aid Does Not Work
Noisy Alternator
Charging Indicator Light

Remains ON

TX,100,DH2482 1902OCT923/8
10016
PN=258
Troubleshooting
Symptom
Hour Meter Does Not Work
Fuel Gauge Displays One

Flashing Arrow
Transmission Temperature
Gauge Displays Nine (9) Arrows
No Display Monitor Functions
Individual Light In Monitor Panel

Is Inoperative (Not During Bulb
Check)
Individual Light In Monitor Panel

Is Inoperative (During Normal
Operation And Bulb Check)
Problem
Solution
Alternator.
Display monitor.
Key switch.
Hour meter.
Wiring harness.
Fuel gauge.
Fuel gauge sender.
Wiring harness.
Gauge.
Gauge sender.
Wiring harness.
Key switch.
Display monitor.
Logic module.
Wiring harness.
Sending unit for that function.
Wiring harness.
Monitor panel.
Bulb.
Inspect and replace.
Display monitor.

TX,100,DH2482 1902OCT924/8
10017
PN=259
Troubleshooting
Symptom
Problem
Solution
Horn Inoperative
Fuse.
Replace fuse.
Horn.
Horn switch.
Wiring harness.
Fuse.
Replace fuse.
Reverse alarm.
Reverse alarm switch.
Wiring harness.
Fuse.
Replace fuse.
Proximity switch.
Solenoid.
Accessory relay.
Wiring harness.
Wiper fuse.
Replace fuse.
Wiper switch.
Wiper motor.
Wiring harness.
Fuse.
Replace fan fuse.
Fan switch.
Fan motor resistor.
Wiring harness.
Reverse Alarm Does Not Work
Return-To-Dig Does Not Work
Front Or Rear Wiper Does Not

Work
Defrost Fan Motor Does Not

Work

TX,100,DH2482 1902OCT925/8
10018
PN=260
Troubleshooting
Symptom
Problem
Solution
Defrost Fan Motor Does Not

Work In All Speeds
Fan motor switch.
Fan motor resistor.
Wiring harness.
Fuse.
Replace fuse.
Fan motor switch.
Fan motor resistor.
Wiring harness.
Fuse.
Replace fuse.
Light switch.
Cab work light relay.
Wiring harness.
Fuse.
Replace fuse.
Driving light switch.
Wiring harness.
Bulb.
Replace bulb.
Fuse.
Replace fuse.
Dome light switch.
Wiring harness.
Accessory relay.
Fuse.
Replace fuse.
Turn signal flasher.
Pressurizer Fan Motor Does Not

Work
Cab Work Lights Do Not Operate
Driving Lights Do Not Work
Dome Light Does Not Work
Turn Signals Do Not Operate

TX,100,DH2482 1902OCT926/8
10019
PN=261
Troubleshooting
Symptom
Brake Lights Do Not Operate
Differential Lock Does Not Work
Secondary Steering Does Not

Operate
Secondary Steering Indicator

Light Does Not Operate
Problem
Solution
Turn signal switch.
Wiring harness.
Fuse.
Replace fuse.
Brake light switch.
Wiring harness.
Key switch.
Accessory relay.
Fuse.
Replace fuse.
Differential lock switch.
Differential lock solenoid.
Wiring harness.
Key switch.
Fuse.
Replace fuse.
Neutral start switch.
Start circuit relay.
Secondary steering controller.
Secondary steering switch.
Secondary steering motor solenoid.
Secondary steering pump motor.
Wiring harness.
Secondary steering controller.

TX,100,DH2482 1902OCT927/8
10020
PN=262
Troubleshooting
Symptom
Problem
Solution
Indicator light bulb.
Replace bulb.
Secondary steering light relay.
Wiring harness.
TX,100,DH2482 1902OCT928/8
10021
PN=263
Troubleshooting
HYDRAULIC SYSTEM
Symptom
Problem
Solution
Noisy Hydraulic Pump
Low oil supply or wrong viscosity.
Fill reservoir with proper oil.
Suction line clogged or pinched.
Clean or replace line.
Air in oil.
Check for foamy oil. Tighten

connections. Replace O-rings and/
or lines.
Clogged suction strainer.
Inspect and clean strainer in

reservoir.
Loose or missing hydraulic line

clamps.
Tighten or replace clamps.
Hydraulic lines in contact with frame.
Inspect and repair.
Worn or damaged pump.
Cold oil.
Warm the oil.
Suction line air leak.
Check for foamy oil.
Low oil supply.
Fill reservoir with recommended oil.
Wrong oil viscosity.
Use recommended oil.
Slow engine speed.
Adjust engine speed control linkage.

Check fast idle speed. (See
chapter.)
Oil leaking past cylinders or control

valve.
Blocked or damaged line.
Inspect lines.
Misadjusted pressure reducing valve.
Pilot control valve.
Slow Hydraulic Functions

TX,100,DH2483 1909SEP921/7
10022
PN=264
Troubleshooting
Symptom
No Steering Or Hydraulic
Functions
No Hydraulic Functions, Steering

Normal
Boom Float Function Does Not

Work
Boom Down Does Not Work

Engine Off
One Hydraulic Function Does Not

Work
Problem
Solution
Binding loader control valve spool.
Secondary steering check valve

leaking.
Steering valve leaking.
Low oil level.
Check oil level.
Clogged suction strainer.
Clean strainer in reservoir.
Hydraulic pump.
Main hydraulic pump dampener

drive.
Main hydraulic pump drive.
Boom lower solenoid valve ground

wire shorted or wrong ground wire
connected to solenoid.
Boom lower solenoid valve stuck in

actuated position.
System relief valve.
Pilot control pressure low.
Loader control valve spool binding in

bore.
Boom down switch not pushed.
Push switch.
Electrical problem

TX,100,DH2483 1909SEP922/7
10023
PN=265
Troubleshooting
Symptom
Problem
Solution
Circuit relief valve.
Oil leaking past cylinder packings.
Blockage in oil lines or valve.
Loader control valve spool stuck in

bore.
Leakage within work circuit.
Low system relief valve setting.
Low circuit relief valve setting.
Leaking system relief valve.
Worn hydraulic pump.
Leaking cylinders.
Leaking seals in circuit relief valve or

valve stuck open.
Leaking loader control valve.
Boom Drifts Up
Leakage in boom lower solenoid

valve, or O-rings.
Oil Overheats
Low oil viscosity in hot weather.
Use recommended oil. (See Fuels

Excessive load.
Reduce load.
Holding hydraulic system over relief.
Reduce load.
Leakage in work circuit.
Clogged fins in oil cooler.
Inspect and clean oil cooler.
Low Hydraulic Power
Functions Drift Down

TX,100,DH2483 1909SEP923/7
10024
PN=266
Troubleshooting
Symptom
Problem
Solution
Oil cooler clogged internally.
Incorrect system or circuit relief

valve setting.
Restriction in oil lines or loader

valve.
Pinched or restricted priority valve

"LS" line.
Priority valve.
Leaking system relief valve.
Worn hydraulic pump (internal

leakage).
Function Drops Before Raising

When Valve Is Activated
Stuck open lift check.
Hydraulic Oil Foams
Low oil level.
Fill to correct level. (See

MaintenanceEvery 10 Hours or
Daily chapter.)
Wrong oil.
Change to recommended oil. (See

Water in oil.
Change oil. (See Maintenance

Loose or faulty suction lines (air leak

in system).
Tighten or install new lines.
Cold oil.
Warm the hydraulic oil.
Low priority valve pressure setting.
Worn hydraulic pump.
Sticking priority valve spool.
Broken priority valve spring.
Pinched or restricted "LS" line.
Slow Or Hard Steering

TX,100,DH2483 1909SEP924/7
10025
PN=267
Troubleshooting
Symptom
No Steering
Constant Steering To Maintain

Straight Travel
Slow Steering Wheel Movement

Will Not Cause Any Frame
Movement
Steering Wheel Can Be Turned

With Frames Against Steering
Stop
Steering Wheel Turns With No

Resistance And Causes No
Frame Movement
Erratic Steering
Problem
Solution
Secondary steering check valve

leakage.
Stuck priority valve spool.
Broken priority valve spring.
Relief valve in priority valve stuck

open.
Air in system.
Leakage in steering system.
Worn steering valve.
Broken centering springs in steering

valve.
Worn steering valve gerotor.
Low crossover relief valve pressure

setting.
Broken steering column or splined

coupling.
Lack of oil in steering valve.
Start engine and check steering

operation.
Steering valve malfunction.
Air in oil.

TX,100,DH2483 1909SEP925/7
10026
PN=268
Troubleshooting
Symptom
Spongy Or Soft Steering
Free Play At Steering Wheel
Steering Valve Binding Or

Steering Wheel Does Not
Immediately Return To Neutral
When Released
Steering Valve Locks Up
Problem
Solution
Low oil level.
Add oil.
Sticking priority valve spool.
Loose cylinder piston.
Damaged steering valve.
Air in oil.
Low oil level.
Add oil.
Loose steering wheel nut.
Tighten.
Worn or damaged splines on

steering column or valve.
Binding in steering column or

misalignment of column.
High return pressure.
Check for a pinched or damaged

return line.
Contamination in steering valve.
Inspect hydraulic filter for

contamination. Repair cause of
contamination. Flush hydraulic
system. (See MaintenanceEvery
Large particles of contamination in

steering valve.
Inspect hydraulic filter for

contamination. Repair cause of
contamination. Flush hydraulic
system. (See MaintenanceEvery
*Thermal shock
Worn or damaged steering valve.

TX,100,DH2483 1909SEP926/7
10027
PN=269
Troubleshooting
Symptom
Problem
Solution
Abrupt Steering Wheel

Oscillation
Gerotor gear in steering valve not

properly timed.
Steering Wheel Turns By Itself
Lines connected to wrong port.
Reconnect lines.
Vibration In Steering System Or

Hoses Jump
High priority valve setting.
Low crossover relief valve pressure

setting.
Machine Turns In Opposite

Direction
Lines to cylinders connected to

wrong ports at steering valve or
crossover relief valve.
Machine Turns When Steering

Valve Is In Neutral
Steering valve leakage.
Steering Wheel Kickback
Failed check valve in secondary

steering manifold block.
Secondary Steering Motor Will

Not Run
Electrical problem.
Pump seized up.
Secondary steering manifold block

primary check valve stuck open.
Low relief valve setting.
Pump or pump coupling.
Priority valve.
See your authorized dealer
Secondary Steering Pump Runs

But Will Not Steer Machine
"Jerky" Steering
*Thermal shock is caused by a large temperature differential (approximately 30C (50F)) between the steering valve
and hydraulic oil. If the steering is not operated for a long period of time and the orifice in the bottom of the priority
valve spool is clogged, the steering valve may bind up when the steering is operated if the hydraulic oil is hot
enough.
TX,100,DH2483 1909SEP927/7
10028
PN=270
Troubleshooting
POWER TRAIN
Symptom
Problem
Solution
Transmission Slippage
Low oil level.
Check and add oil.
Wrong oil grade.
Check oil grade. (See Fuels and

Weak or broken pressure regulating

valve spring.
Transmission pump suction screen

restricted.
Low transmission pump flow due to

worn pump.
Transmission control valve or gasket

leakage.
Clutch cut-off switch sticking.
Restricted modulation orifice.
Excessive transmission element

leakage.
Worn clutch disks.
Applied park brake.
Low or no transmission pressure.
See Transmission Pressure Is Low,

this group.
Service brakes will not release.
Stuck control valve spool.
Broken shafts or gears.
Drain transmission oil to determine if

large pieces of metal contamination
are present.
Broken drive shafts.
Machine Will Not Move

TX,100,DH2484 1927OCT921/6
10029
PN=271
Troubleshooting
Symptom
Machine Does Not Engage In

Low Gear
Transmission Will Not Shift

Correctly
Transmission Pressure Is Low

(All Gears)
Problem
Solution
Broken ring or pinion gear.
Transmission control solenoid valve.
Stuck spool in transmission control

valve.
Stuck modulation valve.
Transmission shifts fast in 4th gear

automatic.
Wrong transmission controller for

machine model number. See your
authorized dealer.
Transmission will not shift out of 2nd

gear in automatic mode.
Wrong transmission controller for

machine model number. See your
authorized dealer.
Low oil level.
Check transmission oil level and refill

if necessary.
Switch.
Suction strainer is clogged.
Transmission pump may be noisy if

transmission suction screen is
clogged. Drain transmission.
Remove and clean suction screen.
Also, check condition of transmission
filter.
Transmission pressure regulating

valve is stuck, or spring is broken.
Control valve gasket.
Inspect transmission control valve for

external leakage. Remove control
valve. Inspect and replace gasket, if
necessary.
Pressure regulating valve.
Modulation valve.
Transmission pump.

TX,100,DH2484 1927OCT922/6
10030
PN=272
Troubleshooting
Symptom
Problem
Solution
Transmission System Pressure Is

Low (One Or Two Gears)
Transmission control valve gasket.
Inspect transmission control valve for

external leakage. Remove control
valve. Inspect and replace gasket, if
necessary.
Clutch piston or seal ring leakage.
Low oil level (aeration of oil).
Check and add oil. (See

MaintenanceEvery 10 Hours or
Daily chapter.)
Low transmission pressure.
Transmission pump suction screen

restricted.
Low transmission pump flow.
Excessive transmission element

leakage.
Modulation valve.
Two-stage piston.
Oil passages restricted between

control valve and transmission
elements.
System pressure too high.
Stuck or missing check valves.
Damaged or missing orifice seal in

control valve.
Broken piston return spring.
Transmission Shifts Too Slow
Transmission Shifts Too Fast

TX,100,DH2484 1927OCT923/6
10031
PN=273
Troubleshooting
Symptom
Problem
Solution
Machine "Creeps" In Neutral
Warped disks and plates in

transmission.
Transmission Hydraulic System

Overheats
High oil level.
Check and adjust.
Low oil level.
Check and correct. (See Fuels and

Lubricants Chapter.)
Wrong oil grade.
Check oil grade. (See Fuels and

Lubricants Chapter.)
Park brake engaged.
Release park brake.
Lube lines pinched, restricted, or

leaking.
Check cooler lines.
Machine operated in too high gear

range.
Operate machine in correct gear

range.
Temperature gauge or sender.
Air flow through oil cooler or radiator

restricted.
Oil cooler thermal relief bypass valve

stuck.
Oil cooler internally restricted.
Warped disks and plates in

transmission.
Leakage in transmission hydraulic

system.
Low transmission pump output.
Engine low idle too low.
Adjust. (See Adjust Engine Speed

Linkage in MaintenanceEvery
Excessive Transmission Noise

(Under Load Or No Load)

TX,100,DH2484 1927OCT924/6
10032
PN=274
Troubleshooting
Symptom
Foaming Oil
Machine Vibrates
Machine Lacks Power And

Acceleration
Problem
Solution
Parts worn or damaged in

transmission.
Remove transmission suction

screen. Inspect for metal particles.
Repair or replace as necessary.
Low or no lube.
Incorrect type of oil.
Change oil.
High oil level.
Drain some oil.
Low oil level.
Add oil.
Air leak on suction side of pump.
Check oil pickup tube on side of

transmission.
Aerated oil.
Check and add oil.
Universal joints on transmission

drive shaft or differential drive
shafts.
Check universal joints.
Engine fast idle speed set too low.
Check fast idle adjustment. (See

Adjust Engine Speed Linkage in
chapter.)
Incorrect transmission oil.
Check oil. (See Fuels and Lubricants

chapter.)
Aerated oil.
Check and add oil.
Torque converter freewheel clutch.
Warped transmission clutch.
Brake drag.
Clutch cut-off valve sticking.
Low engine power.

TX,100,DH2484 1927OCT925/6
10033
PN=275
Troubleshooting
Symptom
Problem
Solution
Torque Converter Stall RPM Too

High
Aerated oil.
Converter relief valve stuck open.
Torque converter seal leakage.
Torque converter not transferring

power (bent fins, broken stator).
Low engine power.
Mechanical malfunction.
Low oil level.
Add oil.
Cold oil.
Warm oil.
Leak in reverse pack
Cold oil.
Warm oil.
No time delay in module.
Shorted sensor.
Leak in transmission pressure circuit.
Transmission pump.
Clogged filter.
Inspect filter. Replace if necessary.
Torque Converter Stall RPM Too

Low
Transmission Pressure Light

Comes On When Shifting From
Forward To Reverse (All Other
Gears OK)
Transmission Pressure Light

Comes On For Each Shift
TX,100,DH2484 1927OCT926/6
10034
PN=276
Troubleshooting
SERVICE BRAKES
Symptom
Problem
Solution
Poor Or No Brakes
Brake accumulator charge low.
Brake pump standby pressure low.
Low brake pressure.
Air in system.
Bleed brakes. (See Bleeding Brakes

in Maintenance chapter.)
Worn brake pads.
Inspect brake pads.
Brake valve leakage.
Brake piston seal leakage.
Check for an overfilled differential.

Remove differential check plug.
Apply brakes and check for leakage
from check plug.
Internal restriction in circuit.
Remove lines and components.
Clutch cut-off switch out of

adjustment.
Adjust switch. (See Adjusting Clutch

Cut-Off Switch in Maintenance
chapter.)
Brake valve.
Low oil level.
Check oil level.
Brake pedal not returning properly.
Inspect.
Stuck brake piston.
Debris holding spool down in brake

valve.
Warped brake disk.
Inspect brake pads. (See Inspecting

Brake Pads in Maintenance
chapter.)
Brake valve.
Aggressive Brakes
Brakes Drag

TX,100,DH2485 1918SEP921/2
10035
PN=277
Troubleshooting
Symptom
Problem
Solution
Brakes Lock Up
Air in brake system.

Brake valve.
Air in brake system.

Worn brake pads.
Inspect brake pads. (See Inspecting

Brake Pads in Maintenance
chapter.)
Wrong oil in differential.
Drain. Refill. (See Fuels and

Loose brake pads.
Hissing Noise When Brake Pedal

Is Depressed With Engine
Stopped
Brake valve, or brake piston

leakage.
Brake Pressure Warning Light

Will Not Go Out
Brake pressure warning switch.
Brake accumulator pressure too low.
Low brake pump standby pressure

setting.
Leakage in pressure reducing

manifold block.
Leakage in differential lock circuit.
Leakage in brake system.
Worn brake pump.
544G TC onlyLeakage in pin

disconnect valve or cylinder.
Brakes Chatter
TX,100,DH2485 1918SEP922/2
10036
PN=278
Troubleshooting
DIFFERENTIAL AXLE
Symptom
Problem
Solution
No Differential Lock Operation
Electrical circuit.
Differential lock solenoid valves

stuck.
Pressure reducing valve malfunction

or setting low.
Excessive differential lock sealing

ring leakage.
Seals on differential lock solenoid

valve or regulating valve.
Remove and inspect seals.
Differential lock piston stuck in bore.
Excessive wear on differential lock

disks and plates.
Pressure reducing valve malfunction

or setting low.
Excessive differential lock sealing

ring leakage.
Seals on differential lock solenoid

valve or regulating valve.
Excessive wear of differential lock

disks and plates.
Warped differential lock disks and

plates.
Foot switch.
Inspect.
Differential Lock Slips Or

Chatters When Engaged
Differential Lock Will Not Release

TX,100,DH2486 1907OCT921/3
10037
PN=279
Troubleshooting
Symptom
Problem
Solution
Electrical circuit.
Differential lock solenoid valve stuck.
Warped differential lock disks and

plates.
Leak in brake piston seals.
Incorrect breather tube.
Not operating engine at full load.
Release differential lock pedal and

operate engine at full load.
Turbo boost line.
Clogged reservoir differential filter.
Remove filter and check for debris.
Low engine power, or turbocharger.
Differential Low On oil.
External leakage.
Excessive Differential And/Or

Axle Noise
Low oil level in differential.
Brakes dragging.
Engaged differential lock.
Release lock.
Pinion bearing.
Gear mesh pattern between ring and

pinion gear incorrect.
Differential pinion gears and/or cross

shafts.
Axle bearing.
Axle planetary.
Excessive axle end play.
Differential Overfilled With Oil On

Standard Axles
Differential Overfilled With Oil On

Differential Lock Axles
Oil Seeping From Outer Axle

Seal

TX,100,DH2486 1907OCT922/3
10038
PN=280
Troubleshooting
Symptom
Axle Overheats
Problem
Solution
Worn outer bearing and/or cup.
Differential overfilled with oil.
Low or high differential oil.
Turbo boost return circuit.
Release differential lock pedal and

operate engine at full load.
Brakes drag.
TX,100,DH2486 1907OCT923/3
DRIVELINE
Symptom
Problem
Solution
Excessive Driveline Vibration Or

Noise
Yokes not in line on drive shafts.
Inspect. Align drive shaft yokes.
Worn rear driveline support bearing.
Bent drive shaft.
Loose yoke retaining nuts (drive

shafts wobble at high speed).
Rear axle oscillating support.
Lack of lubrication.
Lubricate with proper grade of

grease. (See Fuels and Lubricants
chapter.)
TX,100,DH2487 1909SEP921/1
10039
PN=281
Troubleshooting
PARK BRAKE
Symptom
Problem
Solution
Brake Will Not Hold
Not adjusted correctly.
Adjust park brake. (See Adjust Park

Brake in MaintenanceEvery 1000
Hours chapter.)
Park brake solenoid.
Brake disk and/or brake pads worn.
Brake piston.
Brake pads out of adjustment.

Hours chapter.)
Brake not released.
Release park brake.
Park Brake Indicator In Monitor

Does Not Come On When Brake
Applied
Wiring or switch.
Brake Will Not Apply
Pads out of adjustment.

Hours chapter.)
Restriction between pressure

reducing valve manifold and brake.
Brake Disk Overheats
TX,100,DH2488 1902OCT921/1
10040
PN=282
Troubleshooting
AIR CONDITIONING
Symptom
Problem
Solution
Air Conditioning System Does

Not Operate
Accessory relay #2.
Fuse.
Replace fuse.
Fan motor switch.
Fan motor resistor.
Fan motor.
Wiring harness.
Temperature control switch.
Low pressure switch.
High pressure switch.
Compressor clutch coil.
Relay.
Circuit breaker.
Condenser fan motor.
Wiring harness.
TX,100,DH2489 1909SEP921/1
10041
PN=283
Storage
1. Repair worn or damaged parts. Install new parts, if
necessary, to avoid needless delays later.
T47764
2. Loosen alternator and fan belts.
UN09NOV88
PREPARE MACHINE FOR STORAGE
3. Clean primary air cleaner element.
4. Wash the machine. [Use low pressure wash

operations (less than 1379 kpa (13.8 bar) (200
psi)) until 30 days after receipt of machine.] Paint
areas to prevent rust. Replace decals, where
needed.
T5813AM
IMPORTANT: High pressure washing [greater than

1379 kpa (13.8 bar) (200 psi)] can
damage freshly painted finishes. Paint
should be allowed to air dry for 30
days minimum after receipt of machine
before cleaning parts or machine with
high pressure. Use low pressure wash
operations until 30 days have elapsed.
UN09FEB89
TX,105,FF1190 1903AUG921/3
5. Remove seat cushion and other perishable items.

IMPORTANT: LPS 3 Rust Inhibitor can destroy
painted finish. DO NOT spray LPS 3
Rust Inhibitor on painted surfaces.
6. Retract all hydraulic cylinders, if possible. If not,
coat exposed cylinder rods with LPS 3 Rust
Inhibitor.
7. Lubricate all grease points.
8. If possible, raise machine high enough so tires do
not touch the ground. If not, park on a hard surface
to prevent tires from freezing to ground.
9. Store machine in a dry, protected place. If stored
outside, cover with a waterproof material.
TX,105,FF1190 1903AUG922/3
1051
PN=284
Storage
IMPORTANT: Prevent possible machine damage from
unauthorized persons operating
machine. Attach a "DO NOT OPERATE"
tag to steering wheel.
10. Place a "DO NOT OPERATE" tag on the steering
wheel.
11. Remove keys and lock all covers and doors.
T7447AO
1922APR91
LPS 3 Rust Inhibitor is manufactured by Holt Lloyd

Corporation.
TX,105,FF1190 1903AUG923/3
MONTHLY STORAGE PROCEDURE
1. Drain water and sediment from fuel tank when air

temperature is above freezing.
2. Remove LPS 3 Rust Inhibitor from cylinder rods
with a cleaning solvent.
UN18OCT88
CAUTION: Engine exhaust fumes can cause

sickness or death. Start engine ONLY in a wellventilated area.
T6191AA
TX,105,FF,400 1906SEP941/2
1052
PN=285
3. Check all fluid levels. If low, check for leaks and

add oil as required.
T6181AU
IMPORTANT: Prevent possible engine damage.

During cold temperatures, check
fluidity of engine oil on dipstick. If the
oil appears waxy and/or jelly-like rather
than liquid, DO NOT attempt to start
engine. Use external heat source to
warm the crankcase until oil appears
fluid.
UN18OCT88
Storage
4. Check belts.
5. Check condition of all hoses and connections.
6. Check electrolyte level. Charge and install battery.
7. Fill fuel tank.
8. Pre-lubricate turbocharger bearings:
a. Remove engine shut-off fuse.
b. Crank engine for 10 seconds.
c. Install engine shut-off fuse.
d. Start engine. Run several minutes at 1/3 speed
until engine is at normal operating temperature.
9. Bleed fuel system. If engine fails to start or runs
poorly after starting, change fuel filter(s). Bleed fuel
system again.
10. Operate all controls, levers, seat adjustments, etc.
11. Cycle all hydraulic functions several times. Check
condition of all hoses and connections.
12. Check condition of tires. Check tire pressure.
TX,105,FF,400 1906SEP942/2
1053
PN=286
Machine Numbers
RECORD PRODUCT IDENTIFICATION
NUMBER (PIN)
Purchase Date
T7829BJ
UN21SEP92
NOTE: Record all 13 characters of the Product

Identification Number.
TX,110,DH2545 1911DEC921/1
RECORD ENGINE SERIAL NUMBER544G
T7829BK
UN21SEP92
Engine Serial Number (A)
TX,110,DH2272 1902OCT921/1
T7853AW
UN08OCT92
TX,110,DH2273 1907OCT921/1
T100710
UN22MAR96
TX,110,DH2274 1902OCT921/1
1101
PN=287
Machine Numbers
RECORD TRANSMISSION SERIAL NUMBER

Transmission Serial Number
Located on right side of transmission case, near lower

right corner of case.
05T,120,MM9 1906JUN911/1
RECORD HYDRAULIC PUMP SERIAL

NUMBER
Hydraulic Pump Serial Number
TX,110,DH2546 1916SEP921/1
1102
PN=288
Specifications
T6603AC
UN20OCT88
544G SPECIFICATIONS
TX,115,DH2265 1916JUN931/2
1151
PN=289
Specifications
AOverall operating height (boom full raise)
4.83 m (15 ft 10 in.)
BBucket hinge height
3.72 m (12 ft 3 in.)
CDump height
2.84 m (9 ft 4 in.)
DDump reach
0.94 m (3 ft 1 in.)
EHeight to top of cab and canopy
3.17 m (10 ft 5 in.)
FOverhang
1.63 m (5 ft 4 in.)
GWheelbase
2.90 m (9 ft 6 in.)
HGround clearance
373 mm (1 ft 3 in.)
IOverall length
6.89 m (22 ft 7 in.)
Width over tires

17.5-25 tires
2.42 m (8 ft 0 in.)
20.5-25 tires
2.46 m (8 ft 1 in.)
Standard operating weight
10 262 kg (22,624 lb)
Counterweight weight
(1st optional counterweight)
358 kg (790 lb)
(2nd optional counterweight)
434 kg (934 lb)
TX,115,DH2265 1916JUN932/2
1152
PN=290
Specifications
544G SPECIFICATIONS
NOTE: Specifications and design subject to change
without notice. Wherever applicable, specifications
are in accordance with SAE standards. Except
where otherwise noted, specifications are based
on a machine equipped with all standard, 17.5
25, 12 PR, L2 tires, one rear counterweight,
ROPS cab, full fuel tank, and 79 kg (175 lb)
operator.
Engine:
John Deere 6059T (S.N. 553285 )
89 kW (120 hp)
Piston displacement
5.884 L (359 cu in.)
Air cleaner
Dual stage dry type with restriction indicator
Electrical system
12-volt battery with 95-amp alternator
Cold cranking capacity at -18C (0F)
625 amps
Reserve capacity
160 min.
Torque Converter
Single phase, single stage
Transmission
Countershaft, power shift, automatic
Travel Speeds:
Forward Speeds:
km/h
mph
07.4
04.6
012.3
07.7
027.2
016.9
038.4
023.8
Reverse Speeds:
km/h
mph
07.4
04.6
012.3
07.7
027.2
016.9
NOTE: All travel speeds are with 20.525 tires.
TX,115,DH2267 1908DEC951/2
1153
PN=291
Specifications
Brakes, Service:
Power-actuated, 4-wheel, inboard-mounted, wet disk
Foot-operated, by either pedal
Left pedal also disconnects transmission (if selected by operator)
External inspection
Low brake pressure warning light and buzzer in monitor
Brakes, Park:
Spring applied, hydraulically released parking brake is attached to the output shaft
Transmission disconnects with park brake applied
Warning light in monitorDual-level
Amber lights with transmission in neutral
Red STOP indicator lights, and buzzer sounds with transmission in gear
Steering:
Turning radius (to centerline of outside tire)
4.95 m (16 ft 3 in.)
Rear axle oscillation
22 degrees, stop to stop
Tires
15.525, 12 PR L2
17.525, 12 PR L2
17.525, 12 PR L3
20.525, 12 PR L2
20.525, 12 PR L3
17.525, Radial, One Star L2 Equivalent
Maximum Lift Capacity With Standard Equipment
Maximum height
5 457 kg (12,031 lb)
Ground level
11 006 kg (24,264 lb)
TX,115,DH2267 1908DEC952/2
1154
PN=292
Specifications
DRAIN AND REFILL CAPACITIES544G

Metric
U.S.
Cooling system
23.5 L
25 qt
Fuel tank
218 L
58 gal
Engine crankcase and filter
19 L
20 qt
Transmission case and filter
9.5 L
10 qt
Front differential
18 L
19 qt
Rear differential
18 L
19 qt
Hydraulic reservoir
76 L
80 qt
TX,115,JC1149 1923MAY961/1
T7829AX
UN10SEP92
544G LL SPECIFICATIONS
TX,115,DH2291 1916JUN931/2
1155
PN=293
Specifications
ACoupler hinge height
3.72 m (12 ft 3 in.)
BGround to top of tine
3.53 m (11 ft 7 in.)
CHeight to top of cab and canopy
3.17 m (10 ft 5 in.)
DGround clearance
373 mm (1 ft 3 in.)
EWheelbase
2.90 m (9 ft 6 in.)
FOverall length
with 1219 mm (48 in.) tine
7.52 m (24 ft 8 in.)
7.67 m (25 ft 2 in.)
7.82 m (25 ft 8 in.)
Width over tires

17.5-25 tires
2.42 m (8 ft 0 in.)
20.5-25 tires
2.46 m (8 ft 1 in.)
23.1-26 tires
2.77 m (9 ft 1 in.)

12 019 kg (26,497 lb)
12 038 kg (26,544 lb)
12 056 kg (26,583 lb)
TX,115,DH2291 1916JUN932/2
1156
PN=294
Specifications
544G LL SPECIFICATIONS
25, 12 PR, L3 tires, two rear counterweights,
operator.
Engine:
John Deere 6059T (S.N. 553285 )
89 kW (120 hp)
Piston displacement
5.884 L (359 cu in.)
Air cleaner
Electrical system
625 amps
Reserve capacity
160 min.
Torque Converter
Transmission
Travel Speeds:
Forward Speeds:
km/h
mph
07.4
04.6
012.3
07.7
027.2
016.9
038.4
023.8
Reverse Speeds:
km/h
mph
07.4
04.6
012.3
07.7
027.2
016.9
TX,115,JC1147 1923MAY961/2
1157
PN=295
Specifications
Brakes, Service:
External inspection
Brakes, Park:
Steering:
4.95 m (16 ft 3 in.)
Tires:
17.525, 12 PR L2
17.525, 12 PR L3
17.525, Radial, One Star, L2 Equivalent
20.525, 12 PR L2
20.525, 12 PR L3
23.126, 10 PR LS-2
28 L26, 14 PR LS-2
Maximum Lift Capacity
Maximum height
Fork level
4 649 kg (10,251 lb)
Fork rolled back
4 440 kg ( 9,789 lb)
Ground level
Fork level
8 716 kg (19,215 lb)
Fork rolled back
11 748 kg (25,900 lb)
TX,115,JC1147 1923MAY962/2
1158
PN=296
Specifications
DRAIN AND REFILL CAPACITIES544G LL

Metric
U.S.
Cooling system
23.5 L
25 qt
Fuel tank
218 L
58 gal
Engine crankcase and filter
19 L
20 qt
Transmission case and filter
9.5 L
10 qt
Front differential
18 L
19 qt
Rear differential
18 L
19 qt
Hydraulic reservoir
76 L
80 qt
TX,115,JC1148 1923MAY961/1
T7829AY
UN21SEP92
544G TC SPECIFICATIONS
TX,115,DH2294 1918JUN931/2
1159
PN=297
Specifications
4.83 m (15 ft 10 in.)
3.75 m (12 ft 4 in.)
CDump height
2.82 m (9 ft 3 in.)
DDump reach
1.06 m (3 ft 6 in.)
3.17 m (10 ft 5 in.)
FGround clearance
373 mm (1 ft 3 in.)
GWheelbase
2.90 m (9 ft 6 in.)
HOverall length
7.10 m (23 ft 3 in.)
Width over tires

15.5-25 tires
2.37 m (7 ft 9 in.)
17.5-25 tires
2.42 m (8 ft 0 in.)
20.5-25 tires
2.46 m (8 ft 1 in.)
Standard operating weight with bucket
11 168 kg (24,621 lb)
TX,115,DH2294 1918JUN932/2
11510
PN=298
Specifications
544G TC SPECIFICATIONS
25, 12 PR, L2 tires, two rear counterweights,
operator.
Engine:
John Deere 6059T (S.N. 553285 )
89 kW (120 hp)
Piston displacement
5.884 L (359 cu in.)
Air cleaner
Electrical system
625 amps
Reserve capacity
160 min.
Torque Converter
Transmission
Travel Speeds:
Forward Speeds:
km/h
mph
07.4
04.6
012.3
07.7
027.2
016.9
038.4
023.8
Reverse Speeds:
km/h
mph
07.2
04.5
012.2
07.6
027.7
017.2
TX,115,DH2295 1908DEC951/2
11511
PN=299
Specifications
Brakes, Service:
External inspection
Brakes, Park:
Steering:
4.95 m (16 ft 3 in.)
Tires:
15.525, 12 PR L2
17.525, 12 PR L2
17.525, 12 PR L3
20.525, 12 PR L2
20.525, 12 PR L3
20.525, 16 PR L3
Maximum height
5 154 kg (11,365 lb)
Ground level
9 086 kg (20,035 lb)
TX,115,DH2295 1908DEC952/2
11512
PN=300
Specifications
DRAIN AND REFILL CAPACITIES544G TC

Metric
U.S.
Cooling system
23.5 L
25 qt
Fuel tank
218 L
58 gal
Engine crankcase and

filter
19 L
20 qt
Transmission case and

filter
9.5 L
10 qt
Front differential
18 L
19 qt
Rear differential
18 L
19 qt
Hydraulic reservoir
76 L
80 qt
TX,115,JC1153 1923MAY961/1
T6603AC1
UN20OCT88
624G SPECIFICATIONS
TX,115,DH2268 1916JUN931/2
11513
PN=301
Specifications
5.06 m (16 ft 7 in.)
3.89 m (12 ft 9 in.)
CDump height
2.94 m (9 ft 8 in.)
DDump reach
0.90 m (2 ft 11 in.)
3.30 m (10 ft 10 in.)
FOverhang
1.94 m (6 ft 4.5 in.)
GWheelbase
3.03 m (9 ft 11 in.)
HGround clearance
430 mm (1 ft 5 in.)
IOverall length
7.30 m (24 ft 0 in.)
Width over tires

17.5-25 tires
2.55 m (8 ft 4 in.)
20.5-25 tires
2.52 m (8 ft 3 in.)
12 398 kg (27,338 lb)
429 kg (946 lb)
530 kg (1168 lb)
TX,115,DH2268 1916JUN932/2
11514
PN=302
Specifications
624G SPECIFICATIONS
25, 12 PR, L2 tires, one rear counterweight ,
operator.
Engine:
John Deere 6068T
108 kW (145 hp)
Piston displacement
6.8 L (414 cu in.)
Air cleaner
Electrical system
625 amps
Reserve capacity
160 min.
Torque Converter
Transmission

Travel Speeds:
Forward Speeds:
km/h
mph
07.3
04.5
011.6
07.2
024.5
015.2
037.3
023.0
Reverse Speeds:
km/h
mph
07.3
04.5
011.6
07.2
024.5
015.2
TX,115,DH2269 1902OCT921/2
11515
PN=303
Specifications
Brakes, Service:
External inspection
Brakes, Park:
Steering:
Turning radius (to centerline of outside tire
5.14 m (16 ft 11 in.)
Rear axle oscillates 26 total

Tires:
17.525, 12 PR L2
17.525, 12 PR L3
20.525, 12 PR L2
20.525, 12 PR L3
Maximum height
6 414 kg (14,140 lb)
Ground level
12 217 kg (26,939 lb)
TX,115,DH2269 1902OCT922/2
11516
PN=304
Specifications

Metric
U.S.
Cooling system
24.6 L
26 qt
Fuel tank
249 L
66 gal

filter
19 L
20 qt

filter
11.4 L
12 qt
Front differential
28.4 L
30 qt
Rear differential
18 L
19 qt
Hydraulic reservoir
102 L
108 qt
TX,115,DY327 19 2MAY961/1
T6603AD1
UN20OCT88
644G SPECIFICATIONS
TX,115,DH2270 1916JUN931/2
11517
PN=305
Specifications
5.28 m (17 ft 4 in.)
4.00 m (13 ft 2 in.)
CDump height
2.99 m (9 ft 10 in.)
DDump reach
1.01 m (3 ft 4 in.)
3.42 m (11 ft 3 in.)
FOverhang
1.95 m (6 ft 5 in.)
GWheelbase
3.20 m (10 ft 6 in.)
HGround clearance
483 mm (1 ft 7 in.)
IOverall length
7.65 m (25 ft 1 in.)
Width over tires

20.5-25 tires
2.73 m (8 ft 11 in.)
20.5 R25 tires
2.74 m (9 ft 0 in.)
23.5-25 tires
2.77 m (9 ft 1 in.)
15 666 kg (34 544 lb)
413 kg (910 lb)
645 kg (1422 lb)
TX,115,DH2270 1916JUN932/2
11518
PN=306
Specifications
644G SPECIFICATIONS
25, 12 PR, L2 tires, one rear counterweight,
operator.
Engine:
John Deere 6081
127 kW (170 hp)
Piston displacement
8.1 L (494 cu in.)
Air cleaner
Electrical system
950 amps
Reserve capacity
160 min.
Torque Converter
single phase, planetary
Transmission
Travel Speeds:
Forward Speeds:
km/h
mph
07.0
04.4
011.2
07.0
022.0
013.7
034.6
021.5
Reverse Speeds:
km/h
mph
07.0
04.4
011.2
07.0
022.0
013.7
TX,115,DH2271 1916JUN931/2
11519
PN=307
Specifications
Brakes, Service:
External inspection
Brakes, Park:
Expanding shoe on transmission output shaft, foot-operated
Steering:
5.46 m (17 ft 11 in.)
Rear axle oscillates 26 total

Tires:
20.525, 12 PR L2
20.525, 16 PR L2
20.525, 16 PR L3
20.525, Radial, One Star, L2 equivalent
23.525, 12 PR L2
23.525, 20 PR L3
TX,115,DH2271 1916JUN932/2

Metric
U.S.
Cooling system
28 L
29.5 qt
Fuel tank
284 L
75 gal

filter
24 L
25 qt

filter
14.2 L
15 qt
Front differential
28.4 L
30 qt
Rear differential
28.4 L
30 qt
Hydraulic reservoir
115 L
120 qt
TX,115,DY328 19 2MAY961/1
11520
PN=308
Crime Prevention Tips

HELP PREVENT CRIME
TS140
1907OCT88
You can help take a bite out of crime by properly

documenting ownership and discouraging theft.
DX,CRPRV,A 1903MAR931/1
RECORD IDENTIFICATION NUMBERS
TS156
2. Record the Product Identification Number (PIN) of

the unit and also individual component identification
numbers for engines, axles, pumps, etc. Include
the PIN numbers on all documentation, such as
insurance, financial, and warranty papers.
UN23MAR89
1. Mark your machines with your own unique

numbering system.
DX,CRPRV,H 1904JUN901/1
KEEP PROOF OF OWNERSHIP
3. Keep your documented identification numbers,

color photographs, and inventory in a safe, secure
location.
TS157
2. Maintain an up-to-date inventory of all your

machines.
UN23MAR89
1. Take color photographs from several angles of

each machine.
DX,CRPRV,I 1904JUN901/1
1201
PN=309
PARK INDOORS OUT OF SIGHT

Make machines hard to move:
Park large equipment in front of exits.
Remove battery when unit is in storage.

Lock cab doors, windows, and vandal-proof devices.
TS158
UN23MAR89
Lower equipment to the ground. Remove key.
Lock building.
DX,CRPRV,J 1904JUN901/1
WHEN PARKING OUTDOORS

Make machines hard to move:
Park in a well-lighted, fenced area.
UN23AUG88
Lower all equipment to the ground.

Remove ignition key.
TS144
Remove battery when unit is storage.

Lock cab doors, windows, and vandal-proof devices.
DX,CRPRV,K 1904JUN901/1
1202
PN=310
REDUCE VANDALISM
3. Regularly verify that identification plates have not

been removed. If they have, notify law enforcement
agency. Order duplicate plates from your dealer.
T7223BB
2. Participate in a neighborhood watch program. Take

written notes of suspicious vehicles or persons and
report your findings to law enforcement agency.
UN22FEB90
1. Install vandal-proof devices.
TX,120,DH1093 1916SEP921/1
REPORT THEFTS IMMEDIATELY

1. Immediately notify your local law enforcement
agency and insurance agent.
2. Provide a complete description of the machine, all
of the documented identification numbers and color
photographs.
3. Request verification of the identification numbers
after they have been entered with any regional or
national crime information center. Double check the
numbers to be sure they are correct.
TS146
UN09JAN89
4. Notify your John Deere dealer of the theft and

request that its loss be posted with full description
and identification numbers.
DX,CRPRV,G 1903MAR931/1
1203
PN=311
Index
Page
A
Accessory
Operational checkout . . . . . . . . . . . . . . . . . . 95-25
Accumulator
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-24
Acid burns . . . . . . . . . . . . . . . . . . 80-2, 90-12, 90-14
Adjustment
Belt tension. . . . . . . . . . . . . . . . . . . . .55-10, 55-11
Boom height control . . . . . . . . . . . . . . . . . . . . 35-7
Clutch cut-off. . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Compressor belt tension . . . . . . . . . . . . . . . . 90-20
Engine speed control linkage . . . . . . . . . . . . . 85-2
Engine valve lash-544G, 624G . . . . . . . . . . . . 86-1
Engine valve lash-644G . . . . . . . . . . . . . . . . . 86-3
Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-8
Return-to-dig . . . . . . . . . . . . . . . . . . . . . . . . . . 35-8
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Steering wheel tilt . . . . . . . . . . . . . . . . . . . . . 10-15
Air
Cleaner elements clean . . . . . . . . . . . . . . . . . 55-6
Cleaner elements replace . . . . . . . . . . . . . . . . 85-3
Cleaner unloader valve . . . . . . . . . . . . . . . . . . 60-1
Conditioning control . . . . . . . . . . . . . . . . . . . 10-18
Conditioning service . . . . . . . . . . . . . . . . . . . 90-19
Conditioning troubleshooting . . . . . . . . . . . . 100-41
Filter restriction indicator . . . . . . . . . . . . . . . . . 10-6
Inlet cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-9
Intake hose . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Alarm
Reverse warning . . . . . . . . . . . . . . . . . . . . . . 90-18
Stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Voltage indicator . . . . . . . . . . . . . . . . . . . . . . . 10-6
Antifreeze test . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Axle
Operational checkout . . . . . . . . . . . . . . . . . . . 95-4
B
Backdragging . . . . . . . . . . . . . . . . . . . . . . . . . . 35-12
Battery
Acid burns. . . . . . . . . . . . . . . . . 80-2, 90-12, 90-14
Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-6
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
Electrolyte level check. . . . . . . . . . . . . . . . . . . 80-2
Explosion . . . . . . . . . . . . . . . . . 80-2, 90-12, 90-14
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
Page
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-10
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-2
Belt
Tension adjust . . . . . . . . . . . . . . . . . .55-10, 55-11
Bleed
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Fuel system . . . . . . . . . . . . . . . . . . . . . .90-7, 90-8
Boom
Control lever-544G TC . . . . . . . . . . . . . . . . . . 35-4
Control lever-one lever design . . . . . . . . . . . . 35-1
Control lever-two lever design . . . . . . . . . . . . . 35-2
Down switch . . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Height control adjust . . . . . . . . . . . . . . . . . . . . 35-7
Booster battery . . . . . . . . . . . . . . . . . . . . . . . . . . 25-6
Brake
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . 90-24
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-26
Oil pressure indicator . . . . . . . . . . . . . . .10-8, 25-1
Break-in
10 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Bucket
Control lever-one lever design . . . . . . . . . . . . 35-1
Control lever-two lever design . . . . . . . . . . . . . 35-2
C
Cab
Fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . . 70-5
Recirculating air filter . . . . . . . . . . . . . . . . . . 55-14
Circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . 90-16
Clutch
Cut-off adjust . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Cut-off operational checkout . . . . . . . . . . . . . 95-10
Cut-off switch . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Compressor
Belt tension adjust . . . . . . . . . . . . . . . . . . . . 90-20
Coolant, engine . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
Coolant
Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-5
Level radiator . . . . . . . . . . . . . . . . . . . . . . . . . 75-5
Level recovery tank. . . . . . . . . . . . . . . . . . . . . 60-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Index-1
040596
PN=1
Index
Page
Page
Cooling
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
System fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29

Serial number . . . . . . . . . . . . . . . . . . . . . . . . 110-1
Speed control linkage adjust . . . . . . . . . . . . . . 85-2
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-1
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 100-2
Valve lash adjust. . . . . . . . . . . . . . . . . . .86-1, 86-3
Vent tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-4
Ether injection
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
D
Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Diesel engine oil. . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Differential
Axle troubleshooting . . . . . . . . . . . . . . . . . . 100-37
Lock operational checkout. . . . . . . . . . . . . . . 95-10
Lock pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6
Lock turbo boost return filter(s) . . . . . . . . . . . . 87-2
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-3
Oil level. . . . . . . . . . . . . . . . . . . . . . . . .80-9, 80-10
Oil specification. . . . . . . . . . . . . . . . . . . . . . . . 45-5
Digging
Loader bucket . . . . . . . . . . . . . . . . . . . . . . . . 35-10
Digital display . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Dome light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Door
Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Driveline
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 100-39
Driving
Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Dust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-3
E
Electrical
Electrolyte
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 90-12
Engine oil
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-4
Engine
Air filter restriction indicator . . . . . . . . . . . . . . . 10-6
Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Cold weather warm-up . . . . . . . . . . . . . . . . . . 25-8
Coolant level indicator. . . . . . . . . . . . . . . . . . . 10-7
Coolant temperature gauge. . . . . . . . . . . . . . . 10-5
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-2
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Oil pressure indicator . . . . . . . . . . . . . . . . . . . 10-6
F
Fasten seat belt
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Filter
Cab air recirculating . . . . . . . . . . . . . . . . . . . 55-14
Cab fresh air . . . . . . . . . . . . . . . . . . . . . . . . . . 70-5
Differential lock turbo boost. . . . . . . . . . . . . . . 87-2
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-2
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6
Hydraulic reservoir breather . . . . . . . . . . . . . . 80-8
Hydraulic return. . . . . . . . . . . . . . . . . . . . . . . . 80-7
Transmission oil . . . . . . . . . . . . . . . . . . . . . . . 85-5
Front axle
Disconnect lever . . . . . . . . . . . . . . . . . . . . . . 10-11
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
Fuel
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-1
Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6
Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-2
System bleed . . . . . . . . . . . . . . . . . . . . .90-7, 90-8
Tank capacity . . . . . . . . . . . . . . . . . . . . . . . . . 45-3
Tank drain. . . . . . . . . . . . . . . . . . . . . . . . . . . 55-11
Tank outlet screen . . . . . . . . . . . . . . . . . . . . . 90-5
Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
Color codes . . . . . . . . . . . . . . . . . . . . . . . . . 90-16
G
Gauge checks
Operational checkout . . . . . .
Gauge
Engine coolant temperature .
Fuel . . . . . . . . . . . . . . . . . . .
Operational checkout . . . . . .
. . . . . . . . . . . . . 95-7
. . . . . . . . .10-1, 10-5
. . . . . . . . .10-1, 10-5
. . . . . . . . . . . . . 95-2
Index-2
PN=2
Index
Page
Page
Transmission oil temperature . . . . . . . . .10-1, 10-5

Grease
Boom and cylinder pivots-544G . . . . . . . . . . . 70-2
Boom and cylinder pivots . . . . . . . . . . . . . . . . 70-1
Extreme pressure and multipurpose . . . . . . . . 45-6
Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 85-10
Front driveline support bearing . . . . . . . . . . . . 86-5
Front driveline . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Oscillating rear axle . . . . . . . . . . . . . . . . . . . . 70-5
Rear driveline . . . . . . . . . . . . . . . . . . . . . . . . . 85-1
Steering cylinder pivots . . . . . . . . . . . . . . . . . . 70-4
Grille door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Park brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Receiver dryer . . . . . . . . . . . . . . . . . . . . . . . . 75-1
Right turn signal . . . . . . . . . . . . . . . . . . . . . . . 10-8
STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Secondary steering . . . . . . . . . . . . . . . . . . . . . 35-6
Service required . . . . . . . . . . . . . . . . . . . . . . . 10-4
Steering pressure . . . . . . . . . . . . . . . . . . . . . . 10-9
Transmission oil pressure . . . . . . . . . . . . . . . . 10-7
Injection
Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Instruments
Check after starting. . . . . . . . . . . . . . . . . . . . . 25-7
Check before starting . . . . . . . . . . . . . . . . . . . 25-1
H
Halogen bulbs . . . . . . . . . . . . . . . . . . . . . . . . . 90-16
Heater
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-5
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Hose
Air intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
Hydraulic
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-1
Oil filter restriction indicator . . . . . . . . . . . . . . . 10-7
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3
Oil specification. . . . . . . . . . . . . . . . . . . . . . . . 45-5
Pump serial number . . . . . . . . . . . . . . . . . . . 110-2
Reservoir breather filter. . . . . . . . . . . . . . . . . . 80-8
Return filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-7
Suction strainer . . . . . . . . . . . . . . . . . . . . . . . . 87-2
System operational checkout . . . . . . . . . . . . 95-18
System troubleshooting. . . . . . . . . . . . . . . . 100-22
I
Inch torque values . . . . . . . . .
Indicator
Air filter restriction . . . . . . . .
Alternator voltage . . . . . . . .
Brake oil pressure . . . . . . . .
Engine coolant level . . . . . .
Engine oil pressure . . . . . . .
Ether injection . . . . . . . . . . .
Fasten seat belt . . . . . . . . .
Hydraulic oil filter restriction
Left turn signal . . . . . . . . . .
. . . . . . . . . . . . . 90-34
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. . . . . . 10-6
. . . . . . 10-6
. .10-8, 25-1
. . . . . . 10-7
. . . . . . 10-6
. . . . . . 10-9
. . . . . . 10-9
. . . . . . 10-7
. . . . . 10-10
L
Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-16
Left turn signal
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Lever
Boom control-544G TC . . . . . . . . . . . . . . . . . . 35-4
Boom control-one lever design . . . . . . . . . . . . 35-1
Boom control-two lever design . . . . . . . . . . . . 35-2
Bucket control-one lever design . . . . . . . . . . . 35-1
Bucket control-two lever design. . . . . . . . . . . . 35-2
Front axle disconnect . . . . . . . . . . . . . . . . . . 10-11
Loader control-one lever design . . . . . . . . . . 10-10
Lifting
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-7
Light
Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Lock
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Locking bar
Machine frame . . . . . . . . . . . . . . . . . . . . . . . . 50-3
Lubricant
Alternative. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-6
Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-6
Lubricate
Boom and cylinder pivots-544G TC. . . . . . . . . 70-2
Boom and cylinder pivots . . . . . . . . . . . . . . . . 70-1
Frame hinge pivots . . . . . . . . . . . . . . . . . . . . 85-10
Front driveline support bearing . . . . . . . . . . . . 86-5
Index-3
PN=3
Index
Page
Page
Front driveline . . . . . . . . . . . . . . . . . . . . . . . . . 80-1

Oscillating rear axle . . . . . . . . . . . . . . . . . . . . 70-5
Rear driveline . . . . . . . . . . . . . . . . . . . . . . . . . 85-1
Steering cylinder pivots . . . . . . . . . . . . . . . . . . 70-4
Operational checkout
Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-25
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-4
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-10
Cab and vandal protection . . . . . . . . . . . . . . 95-29
Clutch cut-off. . . . . . . . . . . . . . . . . . . . . . . . . 95-10
Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . 95-10
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-4
Front axle disconnect . . . . . . . . . . . . . . . . . . . 95-6
Gauge checks . . . . . . . . . . . . . . . . . . . . . . . . . 95-7
Hydraulic system. . . . . . . . . . . . . . . . . . . . . . 95-18
Monitor indicator and gauge . . . . . . . . . . . . . . 95-2
Monitor indicator . . . . . . . . . . . . . . . . . . . . . . . 95-7
Neutral start and warning alarm . . . . . . . . . . . 95-4
Steering system . . . . . . . . . . . . . . . . . . . . . . 95-22
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . 95-4
Outlet screen
Fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
M
Machine
Frame locking bar . . . .
Storage . . . . . . . . . . . .
Maintenance
Record Keeping . . . . .
Record keeping. . . . . .
Metric torque values . . . .
Mixing lubricants. . . . . . .
Monitor Indicator
Operational checkout .
Motor . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 50-3
. . . . . . . . . . . . . . . . . 105-1
.50-8, 50-8, CLIS-1, CLIS-1
. . . . . . . . . . . . . . . . . . 50-6
. . . . . . . . . . . . . . . . . 90-31
. . . . . . . . . . . . . . . . . . 45-7
. . . . . . . . . . . . . . . . . . 95-7
. . . . . . . . . . . . . . . . . 90-29
P
N
Neutral
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13, 30-3
Start operational checkout. . . . . . . . . . . . . . . . 95-4
Start system check . . . . . . . . . . . . . . . . . . . . 90-18
O
O-ring boss fittings . . . . . . . . . . . . . . . . . . . . . . 90-37
Oil lines and fittings . . . . . . . . . . . . . . . . . . . . . 90-36
Oil
Change differential . . . . . . . . . . . . . . . . . . . . . 87-3
Change engine . . . . . . . . . . . . . . . . . . . . . . . . 75-2
Change hydraulic . . . . . . . . . . . . . . . . . . . . . . 87-1
Change transmission . . . . . . . . . . . . . . . . . . . 85-5
Level differential . . . . . . . . . . . . . . . . . .80-9, 80-10
Level engine . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Level hydraulic system . . . . . . . . . . . . . . . . . . 60-3
Level transmission . . . . . . . . . . . . . . . . . . . . . 60-5
Lines and fittings. . . . . . . . . . . . . . . . . . . . . . 90-36
Specification differential . . . . . . . . . . . . . . . . . 45-5
Specification hydraulic system . . . . . . . . . . . . 45-5
Oilscan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
Operating
Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-9
Park brake
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-8
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-7
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Switch . . . . . . . . . . . . . . . . . . . . . . . . . .10-12, 30-7
Pedal
Differential lock . . . . . . . . . . . . . . . . . . . . . . . . 35-6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Pin disconnect
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Power train
Product Identification Number. . . . . . . . . . . . . . 110-1
Pump
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
Q
Quick shift
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3
R
Radiator
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 75-5
Index-4
PN=4
Index
Page
Page
Receiver dryer
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-1
Recovery tank
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3
Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
Return-to-dig
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-8
Reverse
Warning alarm . . . . . . . . . . . . . . . . . . . . . . . 90-18
Ride control
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Right turn signal
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Roll-over protective structure
Torque values . . . . . . . . . . . . . . . . . . . . . . . . 90-30
The machine . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6

Storage
Compartment . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-1
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105-2
Storing lubricants . . . . . . . . . . . . . . . . . . . . . . . . 45-7
Suction strainer
Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-2
Switch
Boom down. . . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Clutch cut-off. . . . . . . . . . . . . . . . . . . . . . . . . . 35-5
Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Park brake . . . . . . . . . . . . . . . . . . . . . .10-12, 30-7
Pin disconnect-544G TC . . . . . . . . . . . . . . . . . 35-5
Quick shift. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-3
Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Swivel light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Synthetic Lubricants . . . . . . . . . . . . . . . . . . . . . . 45-6
S
STOP
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Seat belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Seat
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Secondary steering
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-6
Serial number
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-1
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . 110-2
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . 110-2
Service
Brake troubleshooting . . . . . . . . . . . . . . . . . 100-35
Interval . . . . . . . . . . . . . . . . . . . 50-1, 55-1, SLIT-1
Required indicator. . . . . . . . . . . . . . . . . . . . . . 10-4
Specification
Battery electrolyte . . . . . . . . . . . . . . . . . . . . . 90-12
Differential oil . . . . . . . . . . . . . . . . . . . . . . . . . 45-5
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . 45-5
Speed
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-1
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Starting
The engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-1
Steering
Pressure indicator . . . . . . . . . . . . . . . . . . . . . . 10-9
System, operational checkout . . . . . . . . . . . . 95-22
Wheel tilt adjust . . . . . . . . . . . . . . . . . . . . . . 10-15
Stopping
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
T
Tire
Pressure check . . . . . . . . . . . . . . . . . . . . . . . . 55-1
Torque value
Flat face O-ring seal fitting . . . . . . . . . . . . . . 90-39
Inch SAE four bolt flange fitting. . . . . . . . . . . 90-41
Metric cap screw . . . . . . . . . . . . . . . . . . . . . . 90-33
Metric four bolt flange fitting . . . . . . . . . . . . . 90-40
O-Ring boss fitting . . . . . . . . . . . . . . . . . . . . 90-37
Wheel retaining cap screw . . . . . . . . . . . . . . . 55-5
Torque values
Inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
Roll-over protective structure. . . . . . . . . . . . . 90-30
Towing procedure. . . . . . . . . . . . . . . . . . . . . . . . 40-3
Transmission
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-5
Oil filter change. . . . . . . . . . . . . . . . . . . . . . . . 85-5
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5
Oil pressure indicator . . . . . . . . . . . . . . . . . . . 10-7
Oil temperature gauge . . . . . . . . . . . . . . . . . . 10-5
Serial number . . . . . . . . . . . . . . . . . . . . . . . . 110-2
Travel speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
Troubleshooting
Air conditioning . . . . . . . . . . . . . . . . . . . . . . 100-41
Differential axle . . . . . . . . . . . . . . . . . . . . . . 100-37
Driveline . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-39
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-2
Index-5
PN=5
Index
Page
Hydraulic system. . . . . . . . . . . . . . . . . . . . . 100-22

Park brake . . . . . . . . . . . . . . . . . . . . . . . . . 100-40
Power train . . . . . . . . . . . . . . . . . . . . . . . . . 100-29
Service brake . . . . . . . . . . . . . . . . . . . . . . . 100-35
Truck loading . . . . . . . . . . . . . . . . . . . . . . . . . . 35-13
U
Unloader valve
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
V
Valve
Air cleaner dust unloader
Control . . . . . . . . . . . . . .
Dust unloader . . . . . . . . .
Lash adjust . . . . . . . . . . .
Vandal
Shield . . . . . . . . . . . . . . .
Vent tube
Engine crankcase . . . . . .
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
. . . . . . 60-1
. . . . . 90-29
. . . . . . 85-3
. .86-1, 86-3
. . . . . . . . . . . . . . . 10-14
. . . . . . . . . . . . . . . . 85-4
W
Warm-up
Engine, cold weather .
Warning alarm
Operational checkout .
Washer
Windshield fluid level .
Windshield . . . . . . . . .
Welding . . . . . . . . . . . . .
Wheel
Cap screw torque . . . .
Window
Opening . . . . . . . . . . .
Sliding. . . . . . . . . . . . .
Windshield
Washer fluid . . . . . . . .
Wiper and washer. . . .
Wiper
Windshield . . . . . . . . .
. . . . . . . . . . . . . . . . . . 25-8
. . . . . . . . . . . . . . . . . . 95-4
. . . . . . . . . . . . . . . . . . 50-5
. . . . . . . . . . . . . . . . . 10-15
. . . . . . . . . . . . . . . . . 90-20
. . . . . . . . . . . . . . . . . . 55-5
. . . . . . . . . . . . . . . . . 10-15
. . . . . . . . . . . . . . . . . 10-16
. . . . . . . . . . . . . . . . . . 50-5
. . . . . . . . . . . . . . . . . 10-15
. . . . . . . . . . . . . . . . . 10-15
Index-6
PN=6
Checklists
SERVICE INTERVALS
Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example,
at 500 hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours and 10 hours or daily.
As Required
Inspect tires and check pressure
Inspect belts and check tension
Check wheel retainer cap screws
Drain water and clean fuel tank strainer
Clean or replace air cleaner elements
Drain and clean primary fuel filter
Check and clean air inlet cover
Check and clean cab recirculating air filter

Every 10 Hours or Daily
Lubricate pivots
Check recovery tank coolant level
Clean air cleaner dust unloader valve
Check hydraulic system oil level
Check engine oil level
Check transmission oil level

Every 100 Hours
Lubricate loader boom and cylinder pivots
Check cab recirculating air filter
Lubricate front steering cylinder pivots
Lubricate oscillating rear axle
Check cab fresh air filter
Lubricate rear steering cylinder pivots

REQUIRED PARTS
Insure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated
parts are also on hand i.e. filters, O-rings.
Engine Oil Filter
Part Number
250 HOURS
500 HOURS
1000 HOURS
3000 HOURS
*544G, 624G
T19044
644G
RE57394
Primary Fuel Filter
All
RE63136
Final Fuel Filter
*544G, 624G
RE62419
644G
RE62419
Hydraulic System Return Filter
*544G
AT144879
624G, 644G
AT140315
Hydraulic Reservoir Breather

Filter
All
AM39653
Transmission Filter
All
AT168989
Air Filter Primary
*544G, 624G
AR79679
644G
AR80652
Air Filter Secondary
*544G, 624G
AR79680
644G
AR80653
Differential Lock Return Filter(s)
All
T19044
TORQ-GARD SUPREME PLUS

50 Oil
*544G, 624G
19 L (20 qt)
19 L (20 qt)
644G
24 L (25 qt)
24 L (25 qt)
24 L (25 qt)
24 L 25 qt)
HY-GARD Transmission and

Hydraulic Oil
*544G
9.5 L (10 qt)
117 L (31 gal)
624G
11 L (12 qt)
151 L (40 gal)
644G
Coolant Conditioner
TY16004
OILSCAN Kit
IPSKIT1
COOLSCAN Kit
DSO251
1
1 or 2
*includes 544G LL and 544G TC
19 L (20 qt)
19 L 20 qt)
14 L (15 qt)
174 L (46 gal)
TX,50,JC1137 1922MAY961/1
CLIS1
PN=312
Checklists

Model:
544G
544G LL
PIN/Serial Number:
544G TC
624G
Delivery Date:
644G
Customer:
Hour Meter Reading:
Oil Sampling
Oil samples should be taken from each system prior to its recommended drain/change interval indicated on this form. Maintenance
recommendations supplied by OILSCAN will be provided based upon the oil analysis and operating information you supply. Regular oil
sampling will extend the operational life of your machines systems.
Every 250 Hours
Check receiver dryer moisture indicator
Replace engine oil filter
Drain and refill engine oil
Check radiator coolant level
Comments:
Date:
Hour Meter Reading:

Every 500 Hours
Lubricate front drive line
Replace final fuel filter
Check air intake hoses
Replace hydraulic system return filter
Check battery water level
Replace hydraulic reservoir breather filter
Add rust inhibitor to radiator
Check front and rear differential oil level
Replace primary fuel filter

Comments:
Date:
Hour Meter Reading:

Every 1000 Hours
Lubricate rear drive line
Change transmission oil
Check and adjust engine speed linkage
Replace transmission filter
Replace air cleaner dust unloader valve
Inspect and adjust park brake
Replace air cleaner elements
Lubricate frame hinge pivots
Remove and clean engine crankcase vent tube

Comments:
Date:
Hour Meter Reading:

Every 2000 Hours
Adjust engine valve lash
Lubricate front driveline support bearing
Comments:
Date:
Hour Meter Reading:

Every 3000 Hours
Change hydraulic system oil
Replace differential lock return filters
Clean hydraulic system suction strainer
Change front and rear differential oil
Comments
Date:
Hour Meter Reading:
TX,50,JC1160
1903JUN961/1
CLIS2
PN=313
John Deere Service Literature Available

PARTS CATALOG
TS189
-UN-17JAN89
The parts catalog lists service parts available for your

machine with exploded view illustrations to help you
identify the correct parts. It is also useful in assembling
and disassembling.
DX,PARTS
-19-03MAR93
DX,INDOM
-19-17SEP92
OPERATORS MANUAL
-UN-02DEC88
The operators manual provides safety, operating,

maintenance, and service information about John Deere
machines.
TS191
An extra copy of the operators manual is available. The

operators manual and safety signs on your machine
may also be available in other languages. (See your
John Deere dealer to order.)
TECHNICAL AND SERVICE MANUALS
-UN-17JAN89
Technical and service manuals are service guides for

your machine. Included in the manual are specifications,
diagnosis, and adjustments. Also illustrations of assembly
and disassembly procedures, hydraulic oil flows, and
wiring diagrams.
TS224
Component technical manuals are required for some

products. These supplemental manuals cover specific
components.
DX,TM
-19-03MAR93
DX,FOS
-19-04JUN90
FUNDAMENTALS OF SERVICE MANUALS
TS193
-UN-02DEC88
These basic manuals cover most makes and types of

machines. FOS manuals tell you how to SERVICE
machine systems. Each manual starts with basic theory
and is fully illustrated with colorful diagrams and
photographs. Both the whys and hows of adjustments
and repairs are covered in this reference library.
170696
PN=12
John Deere Service Literature Available

Name
John Deere Distribution Service Center

Service Publications Department
P.O. Box 186, Moline, IL. 61266-0186
Address
To order, fill out this form and mail it to the address above. Check forCity
prices with your John Deere dealer or call 1-800-522-7448. You may
State
also place credit card orders by calling this number. Make checks
payable to Deere & Co. Service Publications. Allow three weeks for
delivery. No COD orders. Do not send cash or stamps. If you want Phone (
manuals or catalogs for equipment not shown on this list, provide the
model number, serial number, and name of the product.
Title
Order Number
544G, LL, TC, 624G, 644G Loader

Parts Catalog544G, LL, TC, 624G
Parts Catalog644G
Operators Manual
Technical Manual-Operation and Test
Technical Manual-Repair
Component Manual-Engine (6059 and 6068)
Component Manual-Engine (6076)
Component Manual-Engine Accessories
Component Manual-TeamMateII Axles (1200
and 1400 series)
Loader Safety Manual
Tire Manual
FOS ManualHydraulics
FOS ManualElectronic and Electrical Systems
FOS ManualEngines
FOS ManualPower Trains
FOS ManualShop Tools
FOS ManualWelding
FOS ManualBelts and Chains
FOS ManualBearings and Seals
FOS ManualTires and Tracks
FOS ManualAir Conditioning
FOS ManualFuels, Lubricants & Coolants
FOS ManualFasteners
FOS ManualIden. of Parts Failures
1-in. 3-Ring Binder (400 pages max.)
1-1/2-in. 3-Ring Binder (600 pages max.)
11-1/2-in. 3-Post Binder (600 pages max.)
23-1/2-in. 3-Post Binder (1400 pages max.)
24-in. 4-Post Expandable (2000 pages max.)
Method of Payment
Check or Money Order enclosed
John Deere Farm Plan
MasterCard Discover
Visa
American Express
Your Signature
)
x Quantity
= Total
PC-2364
PC-2365
OMT159816
TM-1529
TM-1530
CTM8
CTM42
CTM11
x
x
x
x
x
x
x
x
=
=
=
=
=
=
=
=
CTM43
DB1228
DB1009
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
FOS1005B
FOS2007B
FOS3007B
FOS4006B
FOS5105B
FOS5207B
FOS5305B
FOS5405B
FOS5507B
FOS5708B
FOS5807B
FOS6004B
FOS6104B
SX2062
SX2063
SX2066
SX2064
SX2056
Subtotal
$ 0.50 to $ 24.99
25.00 to 49.99
50.00 to 99.99
100.00 to 199.99
200.00 and over
Shipping
& Handling
. . . $ 3.50
. . . . . 5.00
. . . . . 6.50
. . . . 9.00
. . 4.5% of
subtotal
Credit Card Acct. No. (13 or 16 digits)

Expiration date:
Zip
Optional shipping available.

Please check and add cost to
normal shipping above.
1 day air . . . . . . . $15.00
2 day air . . . . . . . $10.00
Price Each
Subtotal
Illinois state residents add
6.25% and Iowa state residents
add 5% for Retail Occupation
Tax or show tax exemption
number. Other states excluded.
Total Shipping & Handling
Amount Due in U.S. Dollars (Prices
subject to change without notice.
SEP-95)
TX,LIT1
-19-08JUN96
170696
PN=13
John Deere Service Keeps You On The Job
TS1643
-UN-12SEP95
JOHN DEERE IS AT YOUR SERVICE WHEN YOU NEED IT
Division 1Calgary
John Deere Industrial Equipment Co.
6715 8th Street NE, Suite 218
Calgary, AB T2E 7H7 Canada
403-531-5731; fax: 403-531-5739
Division 2Denver
6101 Stapleton North Drive, Suite A
Denver, CO 80216
303-336-1204; fax: 303-336-1208
Division 3Dallas
P.O. Box 999
Lewisville, TX 75029-2610
214-355-4513; fax: 214-355-4508
Division 4Moline
400 19th Street
Moline, IL 61265
309-765-3316; fax: 309-765-3357
Division 5Grimsby
P.O. Box 999
Grimsby, ON L3M 4S9 Canada
905-945-7389; fax: 905-945-7470
Division 6Baltimore
72 Loveton Circle, Suite 101
Sparks, MD 21152
410-785-4118; fax: 410-785-4145
CUSTOMER SATISFACTION is important to John

Deere. We take pride in providing superior service.
Well be around when you need us:
We maintain a large and varied parts inventory
to help minimize downtime.
Precision tools and testing equipment enable
technicians to locate and correct troubles.
We hold regular training schools for service
technicians so they know your equipment and
how to maintain it.
Our goal is to provide prompt, efficient
service through competent dealerships.
Division 8Atlanta
1201 Roberts Blvd., Suite 230
Kennesaw, GA 30144
404-423-2400; fax: 404-423-2411
aJohn Deere Intercontinental Limited
Overseas Industrial Division
P.O. Box 2000
Moline, IL 61265 U.S.A.
309-765-3316; fax: 309-765-3279
COMPLAINT-RESOLUTION PROCEDURE
Your dealer is the best and fastest source to solving
any problems you may experience with your product.
1. Be prepared with the following information:
Machine model and product identification number
Date of purchase
Nature of problem
2. Discuss problem with dealer service manager.
3. If unable to resolve, see the dealership manager.
Explain the problem and request assistance.
4. If you have a persistent problem your dealership is
unable to satisfy, ask your dealer to contact the John
Deere area manager product support for resolution.
5. If a problem is not resolved to your satisfaction,
contact the appropriate John Deere marketing division
office for your area and ask to speak with the division
product support manager. (See map.)
DX,IBC,4
-19-12SEP95
170696
PN=14

OPERATORS MANUAL - 544G - English

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D

544G, 544G LL, and

John Deere Dubuque Works

READ THIS MANUAL carefully to learn how to

numbers when you order parts. File the identification

CALIFORNIA PROPOSITION 65 WARNING

We need your help to continually improve our Operators

SEND TO: John Deere Dubuque Works

Ideas, Comments, (Please state Page Number):

Heating and Air Conditioning Controls . . . . . . .

Operating the Machine

All information, illustrations and specifications in this manual are based on

Boom and Bucket Control LeverOne

Check Windshield Washer Fluid Level . . . . . . . . 50-5

MaintenanceEvery 10 Hours or Daily

MaintenanceEvery 100 Hours

MaintenanceEvery 250 Hours

MaintenanceEvery 500 Hours

Cleaning Fuel Tank Outlet Screen . . . . . . . . . . . 90-5

MaintenanceEvery 1000 Hours

Monitor Indicator and Gauge Checks

Control Valve Lift Check . . . . . . . . . . . . . . . . . .

Continued on next page

Boom Lock Check . . . . . . . . . . . . . . . . . . . . . . 95-34

Crime Prevention Tips . . . . . . . . . . . . . . . . . . 120-1

RECOGNIZE SAFETY INFORMATION

This is the safety-alert symbol. When you see this symbol

Follow recommended precautions and safe operating

UNDERSTAND SIGNAL WORDS

DANGER or WARNING safety signs are located near

A signal wordDANGER, WARNING, or CAUTIONis

Carefully read all safety messages in this manual and on

Learn how to operate the machine and how to use

FOLLOW SAFETY INSTRUCTIONS

Keep your machine in proper working condition.

AVOID INJURY FROM ROLLOVER

Carry tools and loads close to the ground to aid visibility

Balance loads so weight is evenly distributed and load is

Avoid sharp turns.

Know capacity of machine. Do not overload.

AVOID INJURY FROM BACKOVER

To avoid backover accidents:

AVOID INJURY FROM ROLLAWAY

Inspect your machine carefully each day by walking

USE HANDHOLDS AND STEPS

When you get on and off the machine, always maintain a

Never jump on or off the machine. Never mount or

Falling is one of the major causes of personal injury.

Be careful of slippery conditions on platforms, steps, and

PREVENT MACHINE RUNAWAY

Never start engine while standing on ground. Start engine

DO NOT start engine by shorting across starter terminals.

Avoid possible injury or death from a runaway machine.

USE SEAT BELT PROPERLY

Use your seat belt.

MAINTAIN SEAT BELT

Use a signal person when moving the machine in

Always keep the reverse warning alarm in working

DRIVE MACHINE SAFELY