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John Deere 644K 4WD Loader Operator Manual OMT227998 – PDF DOWNLOAD
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John Deere 644K 4WD Loader Operator Manual OMT227998 – PDF DOWNLOAD
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Description
John Deere 644K 4WD Loader Operator Manual OMT227998 – PDF DOWNLOAD
- P/N: OMT227998_04
- Language: English
- Division: Construction
- Product Lines: Loaders
- Publication Type: Operator’s Manuals
- Associated Models: 644K
- Serial: (-642443) ENGINE 6068HDW80, 6068HDW83
For complete service information also see: T228000, PC10060
TABLE OF CONTENTS:
John Deere 644K 4WD Loader Operator Manual OMT227998 – PDF DOWNLOAD
644K 4WD Loader 1
Introduction 2
Foreword 2
Manual Identification—READ THIS FIRST! 2
Conformity Marking 5
IMPORTANT 5
License Agreement for John Deere Software 6
EPA Non-road Emissions Control Warranty Statement—Compression Ignition 9
CARB Non-road Emissions Control Warranty Statement—Compression Ignition 11
FCC Notifications to User 18
John Deere Online Bookstore 18
Technical Information Feedback Form 19
Contents 21
Safety—Safety and Operator Conveniences 25
Safety and Operator Convenience Features 25
Safety—General Precautions 26
Recognize Safety Information 26
Follow Safety Instructions 26
Operate Only If Qualified 26
Wear Protective Equipment 27
Avoid Unauthorized Machine Modifications 27
Add Cab Guarding for Special Uses 27
Inspect Machine 27
Stay Clear of Moving Parts 28
Avoid High-Pressure Fluids 28
Avoid High-Pressure Oils 28
Work In Ventilated Area 29
Prevent Fires, Clean Debris From Machine 29
Clean Debris from Machine 30
Prevent Battery Explosions 30
Handle Chemical Products Safely 30
Decommissioning — Proper Recycling and Disposal of Fluids and Components 31
Prepare for Emergencies 31
Safety—Operating Precautions 32
Use Steps and Handholds Correctly 32
Start Only From Operator’s Seat 32
Use and Maintain Seat Belt 32
Prevent Unintended Machine Movement 33
Avoid Work Site Hazards 34
Use Special Care When Operating Loader 35
Keep Riders Off Machine 35
Avoid Backover Accidents 35
Avoid Machine Tip Over and Machine Damage 36
Operating on Slopes 36
Operating or Traveling On Public Roads 37
Inspect and Maintain ROPS 37
Add and Operate Attachments Safely 37
Safety—Maintenance Precautions 38
Park and Prepare for Service Safely 38
Service Cooling System Safely 38
Service Tires Safely 39
Remove Paint Before Welding or Heating 39
Make Welding Repairs Safely 40
Drive Metal Pins Safely 40
Safety—Safety Signs 41
Safety Signs 41
Operation—Operator’s Station 43
Levers—Two Function Hydraulic Control 43
Levers—Three Function Hydraulic Control 44
Levers—Four Function Hydraulic Control 45
Levers—Joystick Steering Control 46
Pedals 47
Advanced Display Unit (ADU) 48
Display Unit Functions 49
Sealed Switch Module (SSM) 51
Switch Module Functions 52
Display Unit—Normal Display 55
Display Unit—Main Menu 56
Display Unit—Main Menu—Codes 56
Display Unit—Main Menu—Codes—Active Codes 57
Display Unit—Main Menu—Codes—Stored Codes 57
Display Unit—Main Menu—Machine Settings 58
Display Unit—Main Menu—Machine Settings—Reverse Fan Cycle 59
Display Unit—Main Menu—Machine Settings—Camera Mode 59
Display Unit—Main Menu—Machine Settings—Job Timer 59
Display Unit—Main Menu—Machine Settings—Stopwatch 59
Display Unit—Main Menu—Machine Settings—Ride Control—If Equipped 60
Display Unit—Main Menu—Machine Settings—Quick Shift 60
Display Unit—Main Menu—Machine Settings—Counters 60
Display Unit—Main Menu—Diagnostics 61
Display Unit—Main Menu—Diagnostics—Machine ID 61
Display Unit—Main Menu—Diagnostics—Battery Monitor 62
Display Unit—Main Menu—Diagnostics—Engine Sensors 62
Display Unit—Main Menu—Diagnostics—Transmission Sensors 62
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 63
Display Unit—Main Menu—Diagnostics—Machine Sensors 63
Display Unit—Main Menu—Diagnostics—FNR Selector 63
Display Unit—Main Menu—Diagnostics—Cab Switches 64
Display Unit—Main Menu—Diagnostics—Switch Module 64
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped 64
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 65
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 65
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 66
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 66
Display Unit—Main Menu—Payload Scale—If Equipped 67
Display Unit—Main Menu—Payload Scale—Long Total 67
Display Unit—Main Menu—Payload Scale—Display Units 67
Display Unit—Main Menu—Payload Scale—Auto Add 67
Display Unit—Main Menu—Payload Scale—Diagnostics 68
Display Unit—Main Menu—Payload Scale—Setup 68
Display Unit—Main Menu—Monitor Settings 68
Display Unit—Main Menu—Security 69
Display Unit—Main Menu—Security—Security 69
Display Unit—Main Menu—Security—Change Owner PIN 70
Display Unit—Main Menu—Security—Manage Operator PINs 70
Display Unit—Main Menu—Security—Manage Transport PIN 71
Display Unit—Main Menu—Security—Delayed Operator Logout 71
Horn Button 72
Turn Signals 72
Tilt Steering Column Adjustment 73
Joystick Steering Armrest Adjustment— if Equipped 73
Air Conditioner and Heater Operation 74
Opening and Securing Side Door 75
Opening Side Window/Secondary Exit 76
Opening Rear Side Window 76
Seat Adjustment 77
Operation—Operating the Machine 78
Inspect Machine Daily Before Starting 78
Engine Break-In Period 79
Minimizing the Effect of Cold Weather on Diesel Engines 80
Engine Heater 81
Engine Block Heater—If Equipped 81
Check Instruments Before Starting 82
Starting the Engine 83
Warmup 85
Cold Weather Warmup 86
Automatic Idle and Automatic Shutdown 86
Neutral Lock 87
Park Brake Switch 88
Shifting the Transmission 89
Joystick Bucket and Boom Control 91
Two Lever Bucket and Boom Control 92
Auxiliary Control 92
Joystick Steering Control—If Equipped 94
Ride Control—If Equipped 96
Secondary Steering—If Equipped 98
Differential Lock Operation 98
Counter Switch Operation 99
Rear Camera and Radar Object Detection System (RODS)—If Equipped 100
Embedded Payload Scale—If Equipped 102
Security System 106
Boom Height Kickout Adjustment 106
Return-to-Carry Kickout Adjustment 107
Return-to-Dig Adjustment for Z-Bar Linkage 108
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 109
Operating Loader Coupler—If Equipped 110
Using the Loader Bucket 111
Backdragging 112
Fork Attachment 113
Operating in Water and Mud 114
Parking the Machine 115
Loading Machine on a Trailer 116
Towing Procedure 118
Lifting the Machine 120
Maintenance—Machine 122
Diesel Fuel 122
Lubricity of Diesel Fuel 123
Handling and Storing Diesel Fuel 123
Biodiesel Fuel 124
Testing Diesel Fuel 125
Minimizing the Effect of Cold Weather on Diesel Engines 126
Low Sulfur Diesel Fuel Conditioner 127
Alternative and Synthetic Lubricants 127
Diesel Engine Break-In™ Oil 127
Diesel Engine Oil—Tier 2 and Stage II Engines 128
Diesel Engine Oil—Tier 3 and Stage III A Engines 129
Diesel Engine Oil and Filter Service Intervals—Tier 2/Stage II Engine 130
Diesel Engine Oil and Filter Service Intervals—Tier 3/Stage III A Engine 131
Transmission, Park Brake, and Axle Oil 132
Hydraulic Oil 133
Grease 134
Lubricant Storage 134
Mixing of Lubricants 134
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 135
Drain Intervals for Diesel Engine Coolant 136
John Deere COOL-GARD™ II Coolant Extender 136
Supplemental Coolant Additives 136
Operating in Warm Temperature Climates 137
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 137
Testing Diesel Engine Coolant 138
Maintenance—Periodic Maintenance 139
Engine Identification 139
Service Machine at Specified Intervals 141
Check Hour Meter Regularly 141
Prepare Machine for Maintenance 142
Frame Locking Bar 143
Boom Lock 144
Pin Removal—If Equipped With Powerllel™ Linkage 145
Engine Service Doors and Side Shields 146
Cooling System Doors 147
Fuel Tank 148
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 148
Service Intervals 149
Required Parts 151
Maintenance—As Required 153
Inspect Tires and Check Pressure 153
Tire Pressures 154
Check Wheel Bolt Torque 156
Inspect Engine Air Cleaner Elements 157
Inspect Air Conditioner Compressor and Alternator Belt 159
Clean Cooler Cores 160
Check Windshield Washer Fluid Level 161
Drain Water From Auxiliary Fuel Filter/Water Separator—If Equipped 161
Drain Water From Primary Fuel Filter 162
Replace Final Fuel Filter 162
Replace Fast Fill Fuel Breather—If Equipped 162
Check and Clean or Replace Cab Fresh Air Filter 163
Check and Clean or Replace Cab Recirculating Air Filter 164
Check Transmission Oil Level 165
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 166
Check Coolant 167
Maintenance—Every 10 Hours or Daily 168
Check Coolant Level in Surge Tank 168
Check and Clean or Replace Air Cleaner Dust Unloader Valve 169
Check Engine Oil Level 170
Check Hydraulic Oil Level 170
Inspect Outer Pin Seals 171
Maintenance—Every 100 Hours 172
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 172
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 173
Maintenance—Initial Service – 250 Hours 174
Drain and Refill Engine Oil and Replace Filter 174
Drain and Refill Front and Rear Axle Oil 175
Replace Axle Oil Filters—If Equipped 176
Maintenance—Every 250 Hours 177
Take Engine Oil Sample 177
Maintenance—Every 500 Hours 178
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 178
Check Air Intake and Charge Air Cooler Hoses 179
Check Battery Water Level and Terminals 179
Drain and Refill Engine Oil and Replace Filter 182
Replace Primary Fuel Filter 183
Replace Final Fuel Filter 184
Replace Auxiliary Fuel Filter/Water Separator—If Equipped 185
Replace In-Line Fuel Strainer 185
Replace Fast Fill Fuel Breather Filter—If Equipped 185
Replace Hydraulic Reservoir Breather Filter 186
Check Park Brake Oil Level 186
Lubricate Front and Rear Shaft Seals on Park Brake 187
Check Front and Rear Axle Oil Level 187
Lubricate Front and Rear Axle Shaft Seals 188
Check Ride Control Accumulator—If Equipped 189
Take Fluid Samples 189
Maintenance—Every 1000 Hours 190
Replace Air Cleaner Dust Unloader Valve 190
Replace Engine Air Cleaner Elements 191
Clean Engine Crankcase Vent Tube 193
Lubricate Frame Hinge Pivots 193
Drain and Refill Park Brake Oil 194
Replace Axle Oil Filters—If Equipped 194
Check Coolant 194
Maintenance—Every 2000 Hours 195
Replace Outer Pin Seals 195
Adjust Engine Valve Lash (Clearance) 195
Rerun Transmission Clutch Calibration 195
Drain and Refill Transmission Oil and Replace Filter 196
Drain and Refill Front and Rear Axle Oil 198
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 199
Maintenance—Every 4000 Hours 200
Clean Hydraulic Pump Case Drain Screen 200
Drain and Refill Hydraulic System Oil 202
Clean Hydraulic System Fill Strainer 203
Replace Hydraulic System Return Filter 204
Replace Crankshaft Damper 204
Maintenance—Every 5000 Hours 205
Inspect Driveline Damper 205
Maintenance—Every 6000 Hours 206
Drain Cooling System 206
Refill Cooling System 207
Miscellaneous—Machine 208
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped 208
Check Air Inlet Cover 208
Inspect Fuel Tank Vent Hose and Breather 208
Precautions for Alternator and Regulator 209
Do Not Service Control Valves, Cylinders, Pumps, or Motors 209
Handle Batteries Safely 210
Using Booster Batteries—24-Volt System 211
Using Battery Charger 212
Battery Disconnect Switch 213
Replacement Batteries 214
Remove and Install Batteries 214
12-Volt Auxiliary Power Outlet—If Equipped 215
JDLink Machine Monitoring System (MMS)—If Equipped 215
Fuse Identification and Replacement 216
Replacing Halogen Bulbs 218
Fluid Sampling Test Ports—If Equipped 218
Air Conditioner System Service 220
External Service Brake Inspection 221
Clean Oil Coolers, Charge Air Cooler, and Radiator 221
Welding On Machine 222
Welding Near Electronic Control Units 222
Keep Electronic Control Unit Connectors Clean 223
Service Recommendations For Snap-To-Connect (STC®) Fittings 223
Replacing Bucket Teeth—TK Series 224
Hardware Torque Specifications 224
Keep ROPS Installed Properly 225
Unified Inch Bolt and Screw Torque Values 226
Metric Bolt and Screw Torque Values 227
Miscellaneous—Operational Checkout 228
Operational Checkout 228
Miscellaneous—Troubleshooting 251
Troubleshooting Procedure 251
Engine 252
Transmission 254
Differential And Axle 256
Service Brake 257
Driveline 257
Park Brake 258
Hydraulic System 259
Steering 260
Air Conditioning System 261
Heater System 262
Miscellaneous—Storage 263
Prepare Machine for Storage 263
Monthly Storage Procedure 263
Miscellaneous—Machine Numbers 265
Record Product Identification Number (PIN) 265
Record Engine Serial Number 266
Record Transmission Serial Number 267
Record Hydraulic Pump Serial Number 267
Record Axle Serial Number 267
Keep Proof of Ownership 267
Keep Machines Secure 268
Miscellaneous—Specifications 269
Engine Specifications 269
Drain and Refill Capacities 270
Standard Z-Bar Specifications 271
High Lift Z-Bar Specifications 273
Powerllel™ Specifications 275
Travel Speeds 276
Page Number 25
Section 1-1 25
Section 1-2 26
Section 1-3 32
Section 1-4 38
Section 1-5 41
Section 2-1 43
Section 2-2 78
Section 3-1 122
Section 3-2 139
Section 3-3 153
Section 3-4 168
Section 3-5 172
Section 3-6 174
Section 3-7 177
Section 3-8 178
Section 3-9 190
Section 3-10 195
Section 3-11 200
Section 3-12 205
Section 3-13 206
Section 4-1 208
Section 4-2 228
Section 4-3 251
Section 4-4 263
Section 4-5 265
Section 4-6 269
Introduction 2
Foreword 2
Manual Identification—READ THIS FIRST! 2
Conformity Marking 5
IMPORTANT 5
License Agreement for John Deere Software 6
EPA Non-road Emissions Control Warranty Statement—Compression Ignition 9
CARB Non-road Emissions Control Warranty Statement—Compression Ignition 11
FCC Notifications to User 18
John Deere Online Bookstore 18
Technical Information Feedback Form 19
Contents 21
Safety—Safety and Operator Conveniences 25
Safety and Operator Convenience Features 25
Safety—General Precautions 26
Recognize Safety Information 26
Follow Safety Instructions 26
Operate Only If Qualified 26
Wear Protective Equipment 27
Avoid Unauthorized Machine Modifications 27
Add Cab Guarding for Special Uses 27
Inspect Machine 27
Stay Clear of Moving Parts 28
Avoid High-Pressure Fluids 28
Avoid High-Pressure Oils 28
Work In Ventilated Area 29
Prevent Fires, Clean Debris From Machine 29
Clean Debris from Machine 30
Prevent Battery Explosions 30
Handle Chemical Products Safely 30
Decommissioning — Proper Recycling and Disposal of Fluids and Components 31
Prepare for Emergencies 31
Safety—Operating Precautions 32
Use Steps and Handholds Correctly 32
Start Only From Operator’s Seat 32
Use and Maintain Seat Belt 32
Prevent Unintended Machine Movement 33
Avoid Work Site Hazards 34
Use Special Care When Operating Loader 35
Keep Riders Off Machine 35
Avoid Backover Accidents 35
Avoid Machine Tip Over and Machine Damage 36
Operating on Slopes 36
Operating or Traveling On Public Roads 37
Inspect and Maintain ROPS 37
Add and Operate Attachments Safely 37
Safety—Maintenance Precautions 38
Park and Prepare for Service Safely 38
Service Cooling System Safely 38
Service Tires Safely 39
Remove Paint Before Welding or Heating 39
Make Welding Repairs Safely 40
Drive Metal Pins Safely 40
Safety—Safety Signs 41
Safety Signs 41
Operation—Operator’s Station 43
Levers—Two Function Hydraulic Control 43
Levers—Three Function Hydraulic Control 44
Levers—Four Function Hydraulic Control 45
Levers—Joystick Steering Control 46
Pedals 47
Advanced Display Unit (ADU) 48
Display Unit Functions 49
Sealed Switch Module (SSM) 51
Switch Module Functions 52
Display Unit—Normal Display 55
Display Unit—Main Menu 56
Display Unit—Main Menu—Codes 56
Display Unit—Main Menu—Codes—Active Codes 57
Display Unit—Main Menu—Codes—Stored Codes 57
Display Unit—Main Menu—Machine Settings 58
Display Unit—Main Menu—Machine Settings—Reverse Fan Cycle 59
Display Unit—Main Menu—Machine Settings—Camera Mode 59
Display Unit—Main Menu—Machine Settings—Job Timer 59
Display Unit—Main Menu—Machine Settings—Stopwatch 59
Display Unit—Main Menu—Machine Settings—Ride Control—If Equipped 60
Display Unit—Main Menu—Machine Settings—Quick Shift 60
Display Unit—Main Menu—Machine Settings—Counters 60
Display Unit—Main Menu—Diagnostics 61
Display Unit—Main Menu—Diagnostics—Machine ID 61
Display Unit—Main Menu—Diagnostics—Battery Monitor 62
Display Unit—Main Menu—Diagnostics—Engine Sensors 62
Display Unit—Main Menu—Diagnostics—Transmission Sensors 62
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 63
Display Unit—Main Menu—Diagnostics—Machine Sensors 63
Display Unit—Main Menu—Diagnostics—FNR Selector 63
Display Unit—Main Menu—Diagnostics—Cab Switches 64
Display Unit—Main Menu—Diagnostics—Switch Module 64
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped 64
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 65
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 65
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 66
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 66
Display Unit—Main Menu—Payload Scale—If Equipped 67
Display Unit—Main Menu—Payload Scale—Long Total 67
Display Unit—Main Menu—Payload Scale—Display Units 67
Display Unit—Main Menu—Payload Scale—Auto Add 67
Display Unit—Main Menu—Payload Scale—Diagnostics 68
Display Unit—Main Menu—Payload Scale—Setup 68
Display Unit—Main Menu—Monitor Settings 68
Display Unit—Main Menu—Security 69
Display Unit—Main Menu—Security—Security 69
Display Unit—Main Menu—Security—Change Owner PIN 70
Display Unit—Main Menu—Security—Manage Operator PINs 70
Display Unit—Main Menu—Security—Manage Transport PIN 71
Display Unit—Main Menu—Security—Delayed Operator Logout 71
Horn Button 72
Turn Signals 72
Tilt Steering Column Adjustment 73
Joystick Steering Armrest Adjustment— if Equipped 73
Air Conditioner and Heater Operation 74
Opening and Securing Side Door 75
Opening Side Window/Secondary Exit 76
Opening Rear Side Window 76
Seat Adjustment 77
Operation—Operating the Machine 78
Inspect Machine Daily Before Starting 78
Engine Break-In Period 79
Minimizing the Effect of Cold Weather on Diesel Engines 80
Engine Heater 81
Engine Block Heater—If Equipped 81
Check Instruments Before Starting 82
Starting the Engine 83
Warmup 85
Cold Weather Warmup 86
Automatic Idle and Automatic Shutdown 86
Neutral Lock 87
Park Brake Switch 88
Shifting the Transmission 89
Joystick Bucket and Boom Control 91
Two Lever Bucket and Boom Control 92
Auxiliary Control 92
Joystick Steering Control—If Equipped 94
Ride Control—If Equipped 96
Secondary Steering—If Equipped 98
Differential Lock Operation 98
Counter Switch Operation 99
Rear Camera and Radar Object Detection System (RODS)—If Equipped 100
Embedded Payload Scale—If Equipped 102
Security System 106
Boom Height Kickout Adjustment 106
Return-to-Carry Kickout Adjustment 107
Return-to-Dig Adjustment for Z-Bar Linkage 108
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 109
Operating Loader Coupler—If Equipped 110
Using the Loader Bucket 111
Backdragging 112
Fork Attachment 113
Operating in Water and Mud 114
Parking the Machine 115
Loading Machine on a Trailer 116
Towing Procedure 118
Lifting the Machine 120
Maintenance—Machine 122
Diesel Fuel 122
Lubricity of Diesel Fuel 123
Handling and Storing Diesel Fuel 123
Biodiesel Fuel 124
Testing Diesel Fuel 125
Minimizing the Effect of Cold Weather on Diesel Engines 126
Low Sulfur Diesel Fuel Conditioner 127
Alternative and Synthetic Lubricants 127
Diesel Engine Break-In™ Oil 127
Diesel Engine Oil—Tier 2 and Stage II Engines 128
Diesel Engine Oil—Tier 3 and Stage III A Engines 129
Diesel Engine Oil and Filter Service Intervals—Tier 2/Stage II Engine 130
Diesel Engine Oil and Filter Service Intervals—Tier 3/Stage III A Engine 131
Transmission, Park Brake, and Axle Oil 132
Hydraulic Oil 133
Grease 134
Lubricant Storage 134
Mixing of Lubricants 134
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 135
Drain Intervals for Diesel Engine Coolant 136
John Deere COOL-GARD™ II Coolant Extender 136
Supplemental Coolant Additives 136
Operating in Warm Temperature Climates 137
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 137
Testing Diesel Engine Coolant 138
Maintenance—Periodic Maintenance 139
Engine Identification 139
Service Machine at Specified Intervals 141
Check Hour Meter Regularly 141
Prepare Machine for Maintenance 142
Frame Locking Bar 143
Boom Lock 144
Pin Removal—If Equipped With Powerllel™ Linkage 145
Engine Service Doors and Side Shields 146
Cooling System Doors 147
Fuel Tank 148
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 148
Service Intervals 149
Required Parts 151
Maintenance—As Required 153
Inspect Tires and Check Pressure 153
Tire Pressures 154
Check Wheel Bolt Torque 156
Inspect Engine Air Cleaner Elements 157
Inspect Air Conditioner Compressor and Alternator Belt 159
Clean Cooler Cores 160
Check Windshield Washer Fluid Level 161
Drain Water From Auxiliary Fuel Filter/Water Separator—If Equipped 161
Drain Water From Primary Fuel Filter 162
Replace Final Fuel Filter 162
Replace Fast Fill Fuel Breather—If Equipped 162
Check and Clean or Replace Cab Fresh Air Filter 163
Check and Clean or Replace Cab Recirculating Air Filter 164
Check Transmission Oil Level 165
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 166
Check Coolant 167
Maintenance—Every 10 Hours or Daily 168
Check Coolant Level in Surge Tank 168
Check and Clean or Replace Air Cleaner Dust Unloader Valve 169
Check Engine Oil Level 170
Check Hydraulic Oil Level 170
Inspect Outer Pin Seals 171
Maintenance—Every 100 Hours 172
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 172
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 173
Maintenance—Initial Service – 250 Hours 174
Drain and Refill Engine Oil and Replace Filter 174
Drain and Refill Front and Rear Axle Oil 175
Replace Axle Oil Filters—If Equipped 176
Maintenance—Every 250 Hours 177
Take Engine Oil Sample 177
Maintenance—Every 500 Hours 178
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 178
Check Air Intake and Charge Air Cooler Hoses 179
Check Battery Water Level and Terminals 179
Drain and Refill Engine Oil and Replace Filter 182
Replace Primary Fuel Filter 183
Replace Final Fuel Filter 184
Replace Auxiliary Fuel Filter/Water Separator—If Equipped 185
Replace In-Line Fuel Strainer 185
Replace Fast Fill Fuel Breather Filter—If Equipped 185
Replace Hydraulic Reservoir Breather Filter 186
Check Park Brake Oil Level 186
Lubricate Front and Rear Shaft Seals on Park Brake 187
Check Front and Rear Axle Oil Level 187
Lubricate Front and Rear Axle Shaft Seals 188
Check Ride Control Accumulator—If Equipped 189
Take Fluid Samples 189
Maintenance—Every 1000 Hours 190
Replace Air Cleaner Dust Unloader Valve 190
Replace Engine Air Cleaner Elements 191
Clean Engine Crankcase Vent Tube 193
Lubricate Frame Hinge Pivots 193
Drain and Refill Park Brake Oil 194
Replace Axle Oil Filters—If Equipped 194
Check Coolant 194
Maintenance—Every 2000 Hours 195
Replace Outer Pin Seals 195
Adjust Engine Valve Lash (Clearance) 195
Rerun Transmission Clutch Calibration 195
Drain and Refill Transmission Oil and Replace Filter 196
Drain and Refill Front and Rear Axle Oil 198
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 199
Maintenance—Every 4000 Hours 200
Clean Hydraulic Pump Case Drain Screen 200
Drain and Refill Hydraulic System Oil 202
Clean Hydraulic System Fill Strainer 203
Replace Hydraulic System Return Filter 204
Replace Crankshaft Damper 204
Maintenance—Every 5000 Hours 205
Inspect Driveline Damper 205
Maintenance—Every 6000 Hours 206
Drain Cooling System 206
Refill Cooling System 207
Miscellaneous—Machine 208
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped 208
Check Air Inlet Cover 208
Inspect Fuel Tank Vent Hose and Breather 208
Precautions for Alternator and Regulator 209
Do Not Service Control Valves, Cylinders, Pumps, or Motors 209
Handle Batteries Safely 210
Using Booster Batteries—24-Volt System 211
Using Battery Charger 212
Battery Disconnect Switch 213
Replacement Batteries 214
Remove and Install Batteries 214
12-Volt Auxiliary Power Outlet—If Equipped 215
JDLink Machine Monitoring System (MMS)—If Equipped 215
Fuse Identification and Replacement 216
Replacing Halogen Bulbs 218
Fluid Sampling Test Ports—If Equipped 218
Air Conditioner System Service 220
External Service Brake Inspection 221
Clean Oil Coolers, Charge Air Cooler, and Radiator 221
Welding On Machine 222
Welding Near Electronic Control Units 222
Keep Electronic Control Unit Connectors Clean 223
Service Recommendations For Snap-To-Connect (STC®) Fittings 223
Replacing Bucket Teeth—TK Series 224
Hardware Torque Specifications 224
Keep ROPS Installed Properly 225
Unified Inch Bolt and Screw Torque Values 226
Metric Bolt and Screw Torque Values 227
Miscellaneous—Operational Checkout 228
Operational Checkout 228
Miscellaneous—Troubleshooting 251
Troubleshooting Procedure 251
Engine 252
Transmission 254
Differential And Axle 256
Service Brake 257
Driveline 257
Park Brake 258
Hydraulic System 259
Steering 260
Air Conditioning System 261
Heater System 262
Miscellaneous—Storage 263
Prepare Machine for Storage 263
Monthly Storage Procedure 263
Miscellaneous—Machine Numbers 265
Record Product Identification Number (PIN) 265
Record Engine Serial Number 266
Record Transmission Serial Number 267
Record Hydraulic Pump Serial Number 267
Record Axle Serial Number 267
Keep Proof of Ownership 267
Keep Machines Secure 268
Miscellaneous—Specifications 269
Engine Specifications 269
Drain and Refill Capacities 270
Standard Z-Bar Specifications 271
High Lift Z-Bar Specifications 273
Powerllel™ Specifications 275
Travel Speeds 276
Page Number 25
Section 1-1 25
Section 1-2 26
Section 1-3 32
Section 1-4 38
Section 1-5 41
Section 2-1 43
Section 2-2 78
Section 3-1 122
Section 3-2 139
Section 3-3 153
Section 3-4 168
Section 3-5 172
Section 3-6 174
Section 3-7 177
Section 3-8 178
Section 3-9 190
Section 3-10 195
Section 3-11 200
Section 3-12 205
Section 3-13 206
Section 4-1 208
Section 4-2 228
Section 4-3 251
Section 4-4 263
Section 4-5 265
Section 4-6 269
S.V 04/24
