John Deere 544G, 544G LL, 544G TC, 624G, 644G Loader Operator Manual OMT154907

• Model List:
  • 544G Loader
  • 544G LL Loader
  • 544G TC Loader
  • 624G Loader
  • 644G Loader

Contents:
Safety
RECOGNIZE SAFETY INFORMATION
UNDERSTAND SIGNAL WORDS
FOLLOW SAFETY INSTRUCTIONS
AVOID INJURY FROM ROLLOVER ACCIDENT-WEAR YOUR SEAT BEL-
AVOID INJURY FROM BACKOVEACCIDENT-BEFORE MOVING MACHINE, BE SURE ALP
AVOID INJURY FROM ROLLAWAACCIDENT-TO PREVENT ROLLAWAY, ALWAYS MAKSURE
INSPECT MACHINE
USE HANDHOLDS AND STEPS
PREVENT MACHINE RUNAWAY
USE SEAT BELT PROPERLY
MAINTAIN SEAT BELT
TRAVEL SAFELY
DRIVE MACHINE SAFELY
OPERATE MACHINE WITH CAUTION
OPERATING ON SLOPES
CARRYING LOADS
AVOID POWER LINES
BEWARE OF EXHAUST FUMES
KEEP RIDERS OFF MACHINE
HANDLE FUEL SAFELY-AVOID FIRES
PREPARE FOR EMERGENCIES
HANDLE STARTING FLUID SAFELY
CLEAN TRASH FROM MACHINE
PROTECT AGAINST FLYING DEBRIS
WEAR PROTECTIVE CLOTHING
PROTECT AGAINST NOISE
HANDLE CHEMICAL PRODUCTS SAFELY
USE SAFETY LIGHTS AND DEVICES
KEEP ROPS INSTALLED PROPERLY
WARN OTHERS OF SERVICE WORK
PRACTICE SAFE MAINTENANCE
SUPPORT MACHINE PROPERLY
REMOVE PAINT BEFORE WELDING OR HEATING
AVOID HEATING NEAR PRESSURIZED FLUID LINES
AVOID HIGH-PRESSURE FLUIDS
CLEAN THE MACHINE REGULARLY
SERVICE COOLING SYSTEM SAFELY
STORE ATTACHMENTS SAFELY
DISPOSE OF WASTE PROPERLY
Safety Signs
Operator’s Station
GAUGES, INDICATORS, SWITCHES, AND ACCESSORIES
STOP INDICATOR AND ALARM
SERVICE REQUIRED INDICATOR (YELLOW)
DIGITAL DISPLAY
ENGINE COOLANT TEMPERATURE GAUGE
FUEL GAUGE
TRANSMISSION OIL TEMPERATURE GAUGE
ENGINE OIL PRESSURE INDICATOR
ALTERNATOR VOLTAGE INDICATOR
ENGINE AIR FILTER RESTRICTION INDICATOR
ENGINE COOLANT LEVEL INDICATOR
TRANSMISSION OIL PRESSURE INDICATOR
HYDRAULIC OIL FILTER RESTRICTION INDICATOR
RIGHT TURN SIGNAL INDICATOR
BRAKE OIL PRESSURE INDICATOR
PARK BRAKE INDICATOR
FASTEN SEAT BELT INDICATOR
ETHER INJECTION INDICATOR
STEERING PRESSURE INDICATOR-IF EQUIPPED
LEFT TURN SIGNAL INDICATOR
LEVERS
FRONT AXLE DISCONNECT LEVER-IF EQUIPPED
PEDALS
PARK BRAKE SWITCH
NEUTRAL LOCK
HORN BUTTON
TURN SIGNAL SWITCH
DOME LIGHT AND SWIVEL LIGHT-IF EQUIPPED
VANDAL SHIELD-IF EQUIPPED
OPERATING WINDSHIELD WIPERS AND WASHERS-IF EQUIPPED
ADJUSTING STEERING WHEEL TILT
OPENING SIDE WINDOW
OPENING SLIDING SIDE WINDOW-IF EQUIPPED
CAB DOOR RELEASE
OPERATING LIGHTS
HEATING AND AIR CONDITIONING CONTROLS
ADJUSTING SUSPENSION SEAT
STORAGE COMPARTMENT
Break-in
OBSERVE ENGINE OPERATION CLOSELY
EVERY 10 HOURS OR DAILY
AFTER FIRST 10 AND FIRST 50 HOURS
AFTER THE FIRST 100 HOURS
Pre-Start Inspection
INSPECT MACHINE DAILY BEFORE STARTING
Operating the Engine
CHECK INSTRUMENTS BEFORE STARTING
BRAKE PRESSURE INDICATOR
STARTING THE ENGINE
STARTING FLUID-IF EQUIPPE (COLD WEATHER STARTING AID)
USING COOLANT HEATER-IF EQUIPPED
USING BOOSTER BATTERIES-12 VOLT SYSTEM
CHECK INSTRUMENTS AFTER STARTING
WARM-UP
COLD WEATHER WARM-UP
STOPPING THE ENGINE
ADJUSTING ENGINE FOR HIGH ELEVATION
Driving the Machine
DRIVING ON PUBLIC ROADS
GENERAL DRIVING PRECAUTIONS
FRONT AXLE DISCONNECT-IF EQUIPPED
NEUTRAL LOCK
SHIFTING THE TRANSMISSION
TRAVEL SPEEDS
RIDE CONTROL SWITCH-IF EQUIPPED
STOPPING THE MACHINE
PARK BRAKE SWITCH
PARKING THE MACHINE
Operating the Machine
BOOM AND BUCKET CONTROL LEVER-ONE LEVER DESIGN
BOOM AND BUCKET CONTROL LEVER-TWO LEVER DESIGN
QUICK SHIFT SWITCH
QUICK COUPLER OPERATION-544G TC
PIN DISCONNECT SWITCH-544G TC
BOOM DOWN SWITCH
CLUTCH CUT-OFF SWITCH-IF EQUIPPED
SECONDARY STEERING-IF EQUIPPED
DIFFERENTIAL LOCK PEDAL-IF EQUIPPED
ADJUSTING BOOM HEIGHT KICKOUT-IF EQUIPPED
ADJUSTING RETURN-TO-DIG
GENERAL OPERATING TIPS
EXCAVATING BANKS OR STOCKPILES
USING THE LOADER BUCKET
BACKDRAGGING
TRUCK LOADING
Transporting
TRANSPORTING PRECAUTIONS
LOADING MACHINE ON A TRAILER
TOWING PROCEDURE-ENGINE OPERATIONAL
TOWING PROCEDURE-ENGINE NON-OPERATIONAL
LIFTING THE MACHINE
Fuels and Lubricants
DIESEL FUEL
LOW SULFUR DIESEL FUEL CONDITIONER
STORING FUEL
DO NOT USE GALVANIZED CONTAINERS
FUEL TANK
DIESEL ENGINE OIL
HYDRAULIC SYSTEM OIL AND DIFFERENTIAL OIL
TRANSMISSION OIL
GREASE
ALTERNATIVE AND SYNTHETIC LUBRICANTS
LUBRICANT STORAGE
MIXING OF LUBRICANTS
Periodic Maintenance
SERVICE YOUR MACHINE AT SPECIFIED INTERVALS
CHECK THE HOUR METER REGULARLY
USE CORRECT FUELS AND LUBRICANTS
PREPARE MACHINE FOR MAINTENANCE
LOCKING MACHINE FRAME
BOOM LOCK
OPENING ENGINE SIDE SHIELDS AND SERVICE DOORS
OPENING GRILLE DOOR
CHECK WINDSHIELD WASHER FLUID LEVEL
MAINTENANCE AND REPAIR RECORD KEEPING SYSTEM
OILSCAN™
Maintenance¯As Required
CHECK TIRE PRESSURE
TIRE PRESSURES
TIGHTEN WHEEL RETAINER CAP SCREWS
CLEAN OR REPLACE AIR CLEANER ELEMENTS
CLEAN DUSTY PRIMARY ELEMENT
CLEAN OILY OR SOOTY PRIMARY ELEMENT
INSPECT ELEMENT
CHECK AIR INLET COVER
CHECK AND ADJUST BELT TENSION
DRAIN FUEL TANK
DRAIN AND CLEAN PRIMARY FUEL FILTER (WATER SEPARATOR)-544G, 624G
DRAIN AND CLEAN PRIMARY FUEL FILTER (WATER SEPARATOR)-644G
Maintenance¯Every 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
Maintenance¯Every 100 Hours
LUBRICATE BOOM, BUCKET, AND CYLINDER PIVOTS
LUBRICATE BOOM, BUCKET, AND CYLINDER PIVOTS-544G TC
LUBRICATE STEERING CYLINDER PIVOTS
LUBRICATE OSCILLATING REAR AXLE
CHECK CAB RECIRCULATING AIR FILTER-IF EQUIPPED
CHECK CAB FRESH AIR FILTER-IF EQUIPPED
Maintenance¯Every 250 Hours
CHECK RECEIVER DRYER MOISTURE INDICATOR
CHANGE ENGINE OIL AND REPLACE FILTER
CHECK RADIATOR COOLANT LEVEL
Maintenance¯Every 500 Hours
LUBRICATE FRONT DRIVELINE
CHECK AIR INTAKE HOSES
CHECK BATTERY ELECTROLYTE LEVEL AND TERMINALS
ADD COOLANT CONDITIONER TO RADIATOR
REPLACE PRIMARY FUEL FILTER (WATER SEPARATOR)
REPLACE FINAL FUEL FILTER-544G, 624G
REPLACE FINAL FUEL FILTER-644G
REPLACE HYDRAULIC SYSTEM RETURN FILTER
REPLACE HYDRAULIC RESERVOIR BREATHER FILTER
CHECK FRONT AND REAR DIFFERENTIAL OIL LEVEL-IF EQUIPPED WITH STANDARD AXLE
CHECK FRONT AND REAR DIFFERENTIAL OIL LEVEL-IF EQUIPPED WITH DIFFERENTIAL LOCK AXLE
Maintenance¯Every 1000 Hours
LUBRICATE REAR DRIVELINE
CHECK ENGINE SPEEDS
ADJUST ENGINE SPEED CONTROL LINKAGE
REPLACE AIR CLEANER DUST UNLOADER VALVE
REPLACE AIR CLEANER ELEMENTS
CLEAN ENGINE CRANKCASE VENT TUBE (A)
CHANGE TRANSMISSION OIL AND REPLACE FILTER
CHECK PARK BRAKE
ADJUST PARK BRAKE
LUBRICATE FRAME HINGE PIVOTS
Maintenance¯Every 2000 Hours
MEASURE AND ADJUST ENGINE VALVE LASH (CLEARANCE)-544G, LL, TC, 624G
ADJUST ENGINE VALVE LASH (CLEARANCE)-644G
LUBRICATE FRONT DRIVELINE SUPPORT BEARING
Maintenance¯Every 3000 Hours
CHANGE HYDRAULIC SYSTEM OIL
CLEAN HYDRAULIC SUCTION STRAINER
REPLACE DIFFERENTIAL LOCK RETURN FILTER (S)-IF EQUIPPED
CHANGE FRONT AND REAR DIFFERENTIAL OIL
Maintenance
DRAINING THE COOLING SYSTEM
HEAVY-DUTY DIESEL ENGINE COOLANT
FILLING THE COOLING SYSTEM
TEST THE COOLANT FREEZE-PROTECTION LEVEL
DO NOT SERVICE INJECTION NOZZLES
DO NOT ADJUST INJECTION PUMP
REMOVING DB4 FUEL INJECTION PUMP-544G, 624G
INSTALLING DB4 FUEL INJECTION PUMP
CLEANING FUEL TANK OUTLET SCREEN
BLEEDING FUEL SYSTEM-544G, 624G
BLEEDING FUEL SYSTEM-644G
ADJUSTING FUEL SHUT-OFF SOLENOID-644G
PRECAUTIONS FOR ALTERNATOR AND REGULATOR
SERVICE BATTERIES CAREFULLY
CHECKING ELECTROLYTE SPECIFIC GRAVITY
USING BATTERY CHARGER
REPLACING BATTERIES
REMOVING BATTERIES
REPLACING FUSES
FUSE (BLADE-TYPE) COLOR CODES
RESETTING CIRCUIT BREAKERS
REPLACING HALOGEN BULBS
CHANGING REVERSE WARNING ALARM VOLUME-IF EQUIPPED
CHECKING NEUTRAL START SYSTEM
ADDING ATTACHMENTS/ACCESSORIES TO ROLL-OVER PROTECTIVE STRUCTURE (ROPS)
SERVICING AIR CONDITIONING SYSTEM
CHECKING AND ADJUSTING COMPRESSOR BELT TENSION-IF EQUIPPED
WELDING ON MACHINE
INSPECTING PARK BRAKE PADS
EXTERNAL SERVICE BRAKE INSPECTION
CHECKING BRAKE ACCUMULATOR
CHECKING RIDE CONTROL ACCUMULATOR-IF EQUIPPED
BLEEDING BRAKES
CHECKING SECONDARY STEERING SYSTEM-IF EQUIPPED
CLUTCH CUT-OFF ADJUSTMENT
DO NOT SERVICE CONTROL VALVES, CYLINDERS, PUMPS OR MOTORS
HARDWARE TORQUE SPECIFICATIONS
KEEP ROPS INSTALLED PROPERLY
METRIC BOLT AND CAP SCREW TORQUE VALUES
ADDITIONAL METRIC CAP SCREW TORQUE VALUES
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES
CHECK OIL LINES AND FITTINGS
SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS
SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS
SERVICE RECOMMENDATIONS FOR METRIC Series FOUR BOLT FLANGE FITTING
SERVICE RECOMMENDATIONS FOR INCH Series FOUR BOLT FLANGE FITTINGS
Operational Checkout
OPERATIONAL CHECKOUT
Troubleshooting
ENGINE
ELECTRICAL SYSTEM
HYDRAULIC SYSTEM
POWER TRAIN
SERVICE BRAKES
DIFFERENTIAL AXLE
DRIVELINE
PARK BRAKE
AIR CONDITIONING
Storage
PREPARE MACHINE FOR STORAGE
MONTHLY STORAGE PROCEDURE
Machine Numbers
RECORD PRODUCT IDENTIFICATION NUMBER (PIN)
RECORD ENGINE SERIAL NUMBER-544G
RECORD ENGINE SERIAL NUMBER-624G
RECORD ENGINE SERIAL NUMBER-644G
RECORD TRANSMISSION SERIAL NUMBER
RECORD HYDRAULIC PUMP SERIAL NUMBER
Specifications
544G SPECIFICATIONS
544G SPECIFICATIONS
DRAIN AND REFILL CAPACITIES:
544G LL SPECIFICATIONS
544G LL SPECIFICATIONS
DRAIN AND REFILL CAPACITIES:
544G TC SPECIFICATIONS
544G TC SPECIFICATIONS
DRAIN AND REFILL CAPACITIES:
624G SPECIFICATIONS
624G SPECIFICATIONS
DRAIN AND REFILL CAPACITIES:
644G SPECIFICATIONS
644G SPECIFICATIONS
DRAIN AND REFILL CAPACITIES:
Crime Prevention Tips
HELP PREVENT CRIME
RECORD IDENTIFICATION NUMBERS
KEEP PROOF OF OWNERSHIP
PARK INDOORS OUT OF SIGHT
WHEN PARKING OUTDOORS
REDUCE VANDALISM
REPORT THEFTS IMMEDIATELY
Checklists
John Deere Service Literature Available
PARTS CATALOG
OPERATOR’S MANUAL
TECHNICAL AND SERVICE MANUALS
FUNDAMENTALS OF SERVICE MANUALS
John Deere Service Keeps You On The Job
JOHN DEERE IS AT YOUR SERVICE WHEN YOU NEED IT
Index
A
Accessory
Operational checkout
Accumulator
Brake
Acid burns
Acid burns
Acid burns
Adjustment
Belt tension
Boom height control
Clutch cut-off
Compressor belt tension
Engine high altitude
Engine speed control linkage
Engine valve lash-544G, 624G
Engine valve lash-644G
Park brake
Return-to-dig
Seat
Steering wheel tilt
Air
Cleaner elements clean
Cleaner elements replace
Cleaner unloader valve
Conditioning control
Conditioning service
Conditioning troubleshooting
Filter restriction indicator
Inlet cover
Intake hose
Alarm
Reverse warning
Stop engine
Alternator
Alternator
Voltage indicator
Antifreeze test
Axle
Operational checkout
B
Backdragging
Battery
Acid burns
Acid burns
Acid burns
Booster
Charging
Electrolyte level check
Explosion
Explosion
Explosion
Removing
Replacing
Safety
Terminals
Terminals
Belt
Tension adjust
Bleed
Brake
Fuel system
Fuel system
Boom
Control lever-one lever design
Control lever-two lever design
Control lever-544G TC
Down switch
Height control adjust
Booster battery
Brake
Accumulator
Bleed
Oil pressure indicator
Oil pressure indicator
Operational checkout
Break-in
Engine
10 hours
100 hours
50 hours
Bucket
Control lever-one lever design
Control lever-two lever design
C
Cab
Fresh air filter
Operational checkout
Recirculating air filter
Circuit breaker
Clutch
Cut-off adjust
Cut-off operational checkout
Cut-off switch
Compressor
Belt tension adjust
Coolant
Conditioner
Heater
Level radiator
Level recovery tank
Test
Coolant, engine
Cooling
Drain
System fill
Cylinder
D
Daily inspection
Diesel Engine Oil
Diesel fuel
Differential
Axle troubleshooting
Lock operational checkout
Lock pedal
Lock turbo boost return filter (s)
Oil change
Oil level
Oil level
Oil specification
Digging
Loader bucket
Digital display
Dome light
Door
Grille
Driveline
Troubleshooting
Driving
Operational checkout
Precautions
Dust valve
E
Electrical
Troubleshooting
Electrolyte
Specifications
Engine
Air filter restriction indicator
Break-in
Cold weather warm-up
Coolant
Coolant level indicator
Coolant temperature gauge
High altitude adjust
Oil change
Oil level
Oil pressure indicator
Operational checkout
Serial number
Speed
Speed control linkage adjust
Starting
Stopping
Troubleshooting
Valve lash adjust
Valve lash adjust
Vent tube
Engine oil
Diesel
Ether injection
Indicator
F
Fasten seat belt
Indicator
Filter
Cab fresh air
Cab recirculating air
Differential lock turbo boost
Engine oil
Fuel
Hydraulic reservoir breather
Hydraulic return
Transmission oil
Front axle
Disconnect
Disconnect lever
Fuel
Diesel
Filter change
Gauge
Injection pump
Injection pump installation
Injection pump removal
Storage
System bleed
System bleed
Tank capacity
Tank drain
Tank outlet screen
Fuse
Fuse
Color codes
G
Gauge
Engine coolant temperature
Engine coolant temperature
Fuel
Fuel
Operational checkout
Transmission oil temperature
Transmission oil temperature
Grease
Boom and cylinder pivots
Boom and cylinder pivots-544G
Extreme pressure and multipurpose
Frame hinge pivots
Front driveline
Front driveline support bearing
Oscillating rear axle
Rear driveline
Steering cylinder pivots
Grille door
H
Halogen bulbs
Heater
Control
Coolant
Horn button
Hose
Air intake
Coolant
Hour meter
Hydraulic
Oil change
Oil filter restriction indicator
Oil level
Oil specification
Pump serial number
Reservoir breather filter
Return filter
Suction strainer
System operational checkout
System troubleshooting
I
Inch torque values
Indicator
Air filter restriction
Alternator voltage
Brake oil pressure
Brake oil pressure
Engine coolant level
Engine oil pressure
Ether injection
Fasten seat belt
Hydraulic oil filter restriction
Left turn signal
Location
Operational checkout
Park brake
Receiver dryer
Right turn signal
Secondary steering
Service required
Steering pressure
STOP
Transmission oil pressure
Injection
Nozzles
Pump
Pump installation
Pump removal
Instruments
Check after starting
Check before starting
L
Lamps
Left turn signal
Indicator
Lever
Boom control-one lever design
Boom control-two lever design
Boom control-544G TC
Bucket control-one lever design
Bucket control-two lever design
Front axle disconnect
Loader control-one lever design
Loader control-two lever design
Transmission control
Lifting
Machine
Light
Dome
Operating
Swivel
Lock
Neutral
Locking bar
Machine frame
Lubricant
Alternative
Mixing
Storage
Synthetic
Lubricate
Boom and cylinder pivots
Boom and cylinder pivots-544G TC
Frame hinge pivots
Front driveline
Front driveline support bearing
Oscillating rear axle
Rear driveline
Steering cylinder pivots
M
Machine
Frame locking bar
Storage
Maintenance
Record keeping
Metric torque values
Mixing lubricants
Motor
N
Neutral
Lock
Lock
Start operational checkout
Start system check
O
O-ring boss fittings
Oil
Change differential
Change engine
Change hydraulic
Change transmission
Level differential
Level differential
Level engine
Level hydraulic system
Level transmission
Lines and fittings
Specification differential
Specification hydraulic system
Specification transmission
Oil lines and fittings
Oilscan
Operating
Light
Tips
Operational checkout
Accessory
Axle
Brake
Cab and vandal protection
Clutch cut-off
Differential
Driving
Engine
Hydraulic system
Monitor indicator and gauge
Neutral start and warning alarm
Steering system
Transmission
Outlet screen
Fuel tank
P
Park brake
Adjust
Check
Indicator
Operation
Switch
Switch
Troubleshooting
Pedal
Differential lock
Location
Pin disconnect
Switch
Power train
Troubleshooting
Product Identification Number
Pump
Fuel injection, installation
Service
Q
Quick shift
Switch
R
Radiator
Coolant level
Receiver dryer
Indicator
Recovery tank
Coolant level
Regulator
Return-to-dig
Adjustment
Reverse
Warning alarm
Ride control
Accumulator
Switch
Right turn signal
Indicator
Roll-over protective structure
Torque values
S
Seat
Adjust
Secondary steering
Check
Operation
Serial number
Engine
Hydraulic pump
Transmission
Service
Brake troubleshooting
Interval
Interval
Interval
Required indicator
Specification
Battery electrolyte
Differential oil
Hydraulic oil
Transmission oil
Speed
Engine
Travel
Starting
The engine
Steering
Pressure indicator
System, operational checkout
Wheel tilt adjust
STOP
Indicator
Stopping
Engine
The machine
Storage
Compartment
Machine
Monthly
Storing lubricants
Suction strainer
Hydraulic
Switch
Boom down
Clutch cut-off
Light
Park brake
Park brake
Pin disconnect-544G TC
Quick shift
Ride control
Swivel light
Synthetic Lubricants
T
Tire
Pressure check
Torque value
Flat face O-ring seal fitting
Inch SAE four bolt flange fitting
Metric cap screw
Metric four bolt flange fitting
O-Ring boss fitting
Wheel retaining cap screw
Torque values
Inch
Metric
Roll-over protective structure
Towing procedure
Transmission
Control lever
Oil change
Oil filter change
Oil level
Oil pressure indicator
Oil specification
Oil temperature gauge
Operational checkout
Serial number
Travel speed
Troubleshooting
Air conditioning
Differential axle
Driveline
Electrical
Engine
Hydraulic system
Park brake
Power train
Service brake
Truck loading
U
Unloader valve
Air cleaner
V
Valve
Air cleaner dust unloader
Control
Dust unloader
Lash adjust
Lash adjust
Vandal
Shield
Vent tube