John Deere 544G 544G LL and 544G TC Loaders 624G Loader 644G Loader Operators Manual – PDF DOWNLOAD

Description

John Deere 544G 544G LL and 544G TC Loaders 624G Loader 644G Loader Operators Manual – PDF DOWNLOAD

DESCRIPTION:

(Serial No. 557739-)
OMT159816 Issue G6

John Deere 544G 544G LL and 544G TC Loaders 624G Loader 644G Loader Operators Manual – PDF DOWNLOAD

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 Deere’s 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 MANUFACTURER’S warranty supplied with your machine may not apply outside the U.S.

TABLE OF CONTENTS:

John Deere 544G 544G LL and 544G TC Loaders 624G Loader 644G Loader Operators Manual – PDF DOWNLOAD

Page
Safety 05-1
Safety Signs 06-1
Operator’s Station
Gauges, Indicators, Switches, and
Accessories 10-1
Stop Indicator and Alarm 10-3
Service Required Indicator (Yellow) 10-4
Digital Display 10-4
Engine Coolant Temperature Gauge 10-5
Fuel Gauge 10-5
Transmission Oil Temperature Gauge 10-5
Engine Oil Pressure Indicator 10-6
Alternator Voltage Indicator 10-6
Engine Air Filter Restriction Indicator 10-6
Engine Coolant Level Indicator 10-7
Transmission Oil Pressure Indicator—If
Equipped 10-7
Hydraulic Oil Filter Restriction Indicator 10-7
Right Turn Signal Indicator 10-8
Brake Oil Pressure Indicator10-8
Park Brake Indicator10-8
Fasten Seat Belt Indicator 10-9
Ether Injection Indicator 10-9
Steering Pressure Indicator—If Equipped 10-9
Left Turn Signal Indicator 10-10
Levers 10-10
Front Axle Disconnect Lever—If Equipped 10-11
Pedals 10-12
Park Brake Switch 10-12
Neutral Lock 10-13
Horn Button 10-13
Turn Signal Switch 10-14
Dome Light and Swivel Light—If Equipped 10-14
Vandal Shield—If Equipped 10-14
Operating Windshield Wipers and
Washers—If Equipped 10-15
Adjusting Steering Wheel Tilt 10-15
Opening Side Window 10-15
Opening Sliding Side Window—If Equipped 10-16
Cab Door Release 10-16
Operating Lights 10-17
Boom and Bucket Control Lever—One
Lever Design 35-1
Boom and Bucket Control Lever—Two
Lever Design 35-2
Quick Shift Switch 35-3
Quick Coupler Operation—544G TC 35-4
Pin Disconnect Switch—544G TC 35-5
Boom Down Switch 35-5
Clutch Cut-Off Switch—If Equipped 35-5
Secondary Steering—If Equipped35-6
Differential Lock Pedal—If Equipped 35-6
Adjusting Boom Height Kickout—If
Equipped 35-7
Adjusting Return-to-Dig 35-8
General Operating Tips 35-9
Excavating Banks or Stockpiles 35-9
Using the Loader Bucket 35-10
Backdragging 35-12
Backfilling35-12
Truck Loading 35-13
Transporting
Transporting Precautions 40-1
Loading Machine on a Trailer 40-1
Towing Procedure—Engine Operational 40-3
Towing Procedure—Engine Non-
Operational40-4
Lifting the Machine 40-7
Fuels and Lubricants
Diesel Fuel 45-1
Low Sulfur Diesel Fuel Conditioner45-2
Handling and Storing Diesel Fuel 45-2
Do Not Use Galvanized Containers 45-3
Fuel Tank 45-3
Diesel Engine Oil 45-4
Transmission Oil, Hydraulic System Oil and Differential Oil
45-5
Grease 45-6
Alternative and Synthetic Lubricants45-6
Lubricant Storage 45-7
Mixing of Lubricants 45-7
Periodic Maintenance
Service Your Machine at Specified Intervals50-1
Check the Hour Meter Regularly 50-1
Use Correct Fuels and Lubricants 50-1
Prepare Machine for Maintenance 50-2
Locking Machine Frame 50-3
Boom Lock 50-4
Opening Engine Side Shields and Service
Doors 50-4
Opening Grille Door 50-5
Check Windshield Washer Fluid Level 50-5
Maintenance and Repair Record Keeping
System50-6
OILSCAN 50-7
Maintenance Record Keeping50-8
Maintenance—As Required
Check Tire Pressure55-1
Tire Pressures 55-2
Tighten Wheel Retainer Cap Screws 55-5
Clean or Replace Air Cleaner Elements 55-6
Clean Dusty Primary Element55-7
Clean Oily or Sooty Primary Element 55-7
Inspect Element 55-8
Check Air Inlet Cover 55-9
Check and Adjust Belt Tension—544G,
624G 55-10
Inspect Serpentine Belt—644G55-11
Drain Fuel Tank 55-11
Drain and Clean Primary Fuel Filter (Water Separator)—544G, 624G
55-12
Drain and Clean Primary Fuel Filter (Water Separator)—644G
55-13
Check Cab Recirculating Air Filter 55-14
Maintenance—Every 10 Hours or Daily
Lubricate Pivots 60-1
Clean Air Cleaner Dust Unloader Valve 60-1
Check Engine Oil Level 60-1
Check Recovery Tank Coolant Level 60-3
Check Hydraulic Oil Level 60-3
Check Transmission Oil Level 60-5
Maintenance—Every 100 Hours
Lubricant Boom, Bucket, and Cylinder
Pivots70-1
Lubricate Boom, Bucket, and Cylinder
Pivots—544G TC 70-2
Lubricate Steering Cylinder Pivots 70-4
Lubricate Oscillating Rear Axle70-5
Check Cab Fresh Air Filter—If Equipped 70-5
Maintenance—Every 250 Hours
Check Receiver Dryer Moisture Indicator 75-1
Change Engine Oil and Replace Filter 75-2
Check Radiator Coolant Level 75-5
Page

Maintenance—Every 500 Hours
Lubricant Front Driveline80-1
Check Air Intake Hoses 80-1
Check Battery Electrolyte Level and
Terminals 80-2
Check Coolant 80-5
Replace Primary Fuel Filter (Water
Separator) 80-6
Replace Final Fuel Filter—544G, 624G 80-7
Replace Final Fuel Filter—644G80-7
Replace Hydraulic System Return Filter 80-7
Replace Hydraulic Reservoir Breather Filter 80-8
Check Front and Rear Differential Oil
Level—If Equipped with Standard Axle 80-9
Check Front and Rear Differential Oil Level—If Equipped with Differential Lock
Axle 80-10
Maintenance—Every 1000 Hours
Lubricate Rear Driveline 85-1
Check Engine Speeds 85-1
Adjust Engine Speed Control Linkage 85-2
Replace Air Cleaner Dust Unloader Valve 85-3
Replace Air Cleaner Elements 85-3
Clean Engine Crankcase Vent Tube (A)85-4
Change Transmission Oil and Replace
Filter85-5
Check Park Brake 85-7
Adjust Park Brake85-8
Lubricate Frame Hinge Pivots 85-10
Maintenance—Every 2000 Hours
Measure and Adjust Engine Valve Lash (Clearance)—544G, LL, TC, 624G 86-1
Adjust Engine Valve Lash (Clearance)—
644G 86-3
Lubricate Front Driveline Support Bearing 86-5
Maintenance—Every 3000 Hours
Change Hydraulic System Oil 87-1
Clean Hydraulic Suction Strainer 87-2
Replace Differential Lock Return Filter(s)—
If Equipped87-2
Change Front and Rear Differential Oil87-3
Maintenance
Draining the Cooling System 90-1
Diesel Engine Coolant 90-3
Coolant drain intervals 90-3
Filling the Cooling System 90-4
Test the Coolant Freeze—Protection Level 90-4
Do Not Service Injection Nozzles 90-5
Do Not Adjust Injection Pump90-5

Cleaning Fuel Tank Outlet Screen 90-5
Bleeding Fuel System—544G, 624G 90-7
Bleeding Fuel System—644G90-8
Adjusting Fuel Shut-Off Solenoid—644G 90-8
Precautions for Alternator and Regulator 90-9
Service Batteries Carefully 90-10
Checking Electrolyte Specific Gravity 90-12
Using Battery Charger 90-14
Replacing Batteries 90-14
Removing Batteries 90-15
Replacing Fuses90-15
Fuse (Blade-Type) Color Codes 90-15
Resetting Circuit Breakers 90-16
Replacing Halogen Bulbs 90-16
Changing Reverse Warning Alarm Volume90-18
Checking Neutral Start System90-18
Adding Attachments/Accessories to Roll-
Over Protective Structure (ROPS) 90-19
Servicing Air Conditioning System 90-19
Checking and Adjusting Compressor Belt
Tension—If Equipped 90-20
Welding on Machine90-20
Inspecting Park Brake Pads 90-21
External Service Brake Inspection 90-22
Checking Brake Accumulator 90-24
Checking Ride Control Accumulator—If
Equipped 90-25
Bleeding Brakes 90-26
Checking Secondary Steering System—If
Equipped 90-28
Clutch Cut-Off Adjustment 90-28
Do Not Service Control Valves, Cylinders,
Pumps or Motors 90-29
Hardware Torque Specifications 90-30
Keep ROPS Installed Properly 90-30
Metric Bolt and Cap Screw Torque Values 90-31
Additional Metric Cap Screw Torque Values90-33
Unified Inch Bolt and Cap Screw Torque
Values 90-34
Check Oil Lines and Fittings90-36
Service Recommendations for O-Ring Boss
Fittings 90-37
Service Recommendations for Flat Face O-
Ring Seal Fittings 90-39
Service Recommendations for Metric Series
Four Bolt Flange Fitting 90-40
Service Recommendations for Inch Series
Four Bolt Flange Fittings 90-41
Operational Checkout
Operational Checkout 95-1
Page

Monitor Indicator and Gauge Checks—
Engine Off 95-2
Hourmeter And Gauge Check 95-2
Battery Check95-2
Monitor Indicator Circuit And Key Switch
Check95-3
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 checks95-4
Engine Speed Control Linkage Check—
544G, 624G 95-5
Engine Speed Control Linkage Check—
644G 95-5
Engine Speed Control Linkage Check—
644G (Continued)95-5
Fuel Shut-off Solenoid Linkage Check—
644G 95-6
Front Axle Disconnect Check—If Equipped 95-6
Monitor Indicator and Gauge Checks
(Engine Running) 95-7
Monitor Display And Alternator Output
Check95-7
Monitor Indicator Circuit Bypass And Seat
Belt Indicator Check 95-9
Monitor Primary And Secondary Level
Checks 95-9
Transmission Temperature Gauge Check95-10
Brake System, Clutch Cut-Off, and
Differential Lock Checks95-10
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 Check95-14
Clutch Cut-Off Check 95-14
Driving Checks 95-15
Transmission Noise Check 95-15
Automatic Shift and Speedometer Check 95-16
Transmission Quickshift Check95-17
Transmission Pressure, Pump Flow, and
Leakage Check 95-17
Transmission Shift Modulation Check95-18
Hydraulic System Checks95-18
Hydraulic System Warm-Up Procedure 95-18
Boom Down Solenoid Valve Check 95-18
Page

Control Valve Lift Check 95-19
Bucket Rollback Circuit Relief Valve Check 95-19
Bucket Dump Circuit Relief Valve Pressure
Check95-19
Boom and Bucket Cylinder Drift 95-19
Boom Down Check Valve Leakage Check 95-20
Pilot Controller Check95-20
Return-To-Dig Check 95-20
Boom Height Kickout Check—If Equipped 95-21
Pin Disconnect Cylinder Check (544G-TC
Only) 95-21
Ride Control Accumulator Check—If
Equipped 95-21
Steering System Checks 95-22
Steering Valve Check95-22
Steering System Leakage Check 95-22
Priority Valve Low Pressure Check95-23
Priority Valve High Pressure Check 95-23
Secondary Steering System Check—If
Equipped 95-24
Secondary Steering System Primary Check
Valve Check95-24
Accessory Checks 95-25
Operating Lights Check 95-25
Work Light Check 95-25
Brake Light Check 95-26
Horn Circuit Check 95-26
Windshield Washer and Wiper Check—If
Equipped 95-27
Defroster Blower Check 95-27
Heater/Air Conditioner Blower Check 95-28
Heater Functional Check 95-28
Air Conditioner Functional Check 95-28
Start Aid System Check 95-29
Cab Component and Vandal Protection
Checks95-29
Cab Door and Window Hold-Open Latch
Check95-29
Cab Door Release Button95-30
Cab Door Lock Check 95-30
Dome Light Check 95-30
Cab Window Latch Check 95-31
Cab Door Window Check 95-31
Steering Column Adjustment Check 95-31
Seat And Seat Belt Check 95-32
Toolbox Door Check95-32
Air Intake Filter Door Check 95-33
Load Center Door Check 95-33
Engine Side Panels Check 95-33
Radiator Cap Access Door Check 95-34
Frame Locking Bar Check 95-34
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) 110-1
Record Engine Serial Number—544G 110-1
Record Engine Serial Number—624G 110-1
Record Engine Serial Number—644G 110-1
Record Transmission Serial Number 110-2
Record Hydraulic Pump Serial Number 110-2
Specifications
544G Specifications 115-1
544G Specifications 115-3
Drain and Refill Capacities—544G 115-5
544G LL Specifications115-5
544G LL Specifications115-7
Drain and Refill Capacities—544G LL 115-9
544G TC Specifications 115-9
544G TC Specifications 115-11
Drain and Refill Capacities—544G TC 115-13
624G Specifications 115-13
624G Specifications 115-15
Drain and Refill Capacities—624G 115-17
644G Specifications 115-17
644G Specifications 115-19
Drain and Refill Capacities—644G 115-20
Crime Prevention Tips 120-1
Index

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JOHN DEERE 544G 544G LL AND 544G TC LOADERS 624G LOADER 644G LOADER OPERATORS MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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