John Deere Loader 544G 544GLL and 544GTC Loaders 624G 644G Operators Manual – PDF DOWNLOAD
DESCRIPTION:
John Deere Loader 544G 544GLL and 544GTC Loaders 624G 644G 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 Loader 544G 544GLL and 544GTC Loaders 624G 644G Operators Manual – PDF DOWNLOAD
Safety 05-1 Heating and Air Conditioning Controls 10-18
Adjusting Suspension Seat 10-19
Safety Signs 06-1 Seat Belt 10-20
Storage Compartment 10-20
Operator’s Station
Gauges, Indicators, Switches, and Break-in
Accessories 10-1 Engine Break-In Oil 15-1
Stop Indicator and Alarm 10-3 Every 10 Hours or Daily 15-1
Service Required Indicator (Yellow) 10-4 After First 10 and First 50 Hours 15-2
Digital Display 10-4 After the First 100 Hours 15-2
Engine Coolant Temperature Gauge 10-5
Fuel Gauge 10-5 Pre-Start Inspection
Transmission Oil Temperature Gauge 10-5 Inspect Machine Daily Before Starting 20-1
Engine Oil Pressure Indicator 10-6
Alternator Voltage Indicator 10-6 Operating the Engine
Engine Air Filter Restriction Indicator 10-6 Check Instruments Before Starting 25-1
Engine Coolant Level Indicator 10-7 Brake Pressure Indicator 25-1
Transmission Oil Pressure Indicator—If Starting the Engine 25-1
Equipped 10-7 Starting Fluid—If Equipped (Cold Weather
Hydraulic Oil Filter Restriction Indicator 10-7 Starting Aid) 25-4
Right Turn Signal Indicator 10-8 Using Coolant Heater—If Equipped 25-5
Brake Oil Pressure Indicator 10-8 Using Booster Batteries—12 Volt System 25-6
Park Brake Indicator 10-8 Check Instruments After Starting 25-7
Fasten Seat Belt Indicator 10-9 Warm-Up 25-7
Ether Injection Indicator 10-9 Cold Weather Warm-Up 25-8
Steering Pressure Indicator—If Equipped 10-9 Stopping the Engine 25-8
Left Turn Signal Indicator 10-10
Levers 10-10
Front Axle Disconnect Lever—If Equipped 10-11 Driving the Machine
Pedals 10-12 Driving on Public Roads 30-1
Park Brake Switch 10-12 General Driving Precautions 30-2
Neutral Lock 10-13 Front Axle Disconnect—If Equipped 30-2
Horn Button 10-13 Neutral Lock 30-3
Turn Signal Switch 10-14 Shifting the Transmission 30-3
Dome Light and Swivel Light—If Equipped 10-14 Travel Speeds 30-5
Vandal Shield—If Equipped 10-14 Ride Control Switch—If Equipped 30-6
Operating Windshield Wipers and Stopping the Machine 30-6
Washers—If Equipped 10-15 Park Brake Switch 30-7
Adjusting Steering Wheel Tilt 10-15 Parking the Machine 30-7
Opening Side Window 10-15
Opening Sliding Side Window—If Equipped 10-16 Operating the Machine
Cab Door Release 10-16
Operating Lights 10-17 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
Boom and Bucket Control Lever—One Check Windshield Washer Fluid Level 50-5
Lever Design 35-1 Maintenance and Repair Record Keeping
Boom and Bucket Control Lever—Two System 50-6
Lever Design 35-2 OILSCAN 50-7
Quick Shift Switch 35-3 Maintenance Record Keeping 50-8
Quick Coupler Operation—544G TC 35-4 50-9
Pin Disconnect Switch—544G TC 35-5
Boom Down Switch 35-5 Maintenance—As Required
Clutch Cut-Off Switch—If Equipped 35-5 Check Tire Pressure 55-1
Secondary Steering—If Equipped 35-6 Tire Pressures 55-2
Differential Lock Pedal—If Equipped 35-6 55-3
Adjusting Boom Height Kickout—If 55-4
Equipped 35-7 55-5
Adjusting Return-to-Dig 35-8 Tighten Wheel Retainer Cap Screws 55-5
General Operating Tips 35-9 Clean or Replace Air Cleaner Elements 55-6
Excavating Banks or Stockpiles 35-9 Clean Dusty Primary Element 55-7
Using the Loader Bucket 35-10 Clean Oily or Sooty Primary Element 55-7
Backdragging 35-12 Inspect Element 55-8
Backfilling 35-12 Check Air Inlet Cover 55-9
Truck Loading 35-13 Check and Adjust Belt Tension—544G,
624G 55-10
Transporting Inspect Serpentine Belt—644G 55-11
Transporting Precautions 40-1 Drain Fuel Tank 55-11
Loading Machine on a Trailer 40-1 Drain and Clean Primary Fuel Filter (Water
Towing Procedure—Engine Operational 40-3 Separator)—544G, 624G 55-12
Towing Procedure—Engine Non- Drain and Clean Primary Fuel Filter (Water
Operational 40-4 Separator)—644G 55-13
Lifting the Machine 40-7 Check Cab Recirculating Air Filter 55-14
Fuels and Lubricants Maintenance—Every 10 Hours or Daily
Diesel Fuel 45-1 Lubricate Pivots 60-1
Low Sulfur Diesel Fuel Conditioner 45-2 Clean Air Cleaner Dust Unloader Valve 60-1
Handling and Storing Diesel Fuel 45-2 Check Engine Oil Level 60-1
Do Not Use Galvanized Containers 45-3 Check Recovery Tank Coolant Level 60-3
Fuel Tank 45-3 Check Hydraulic Oil Level 60-3
Diesel Engine Oil 45-4 Check Transmission Oil Level 60-5
Transmission Oil, Hydraulic System Oil and
Differential Oil 45-5
Grease 45-6 Maintenance—Every 100 Hours
Alternative and Synthetic Lubricants 45-6 Lubricant Boom, Bucket, and Cylinder
Lubricant Storage 45-7 Pivots 70-1
Mixing of Lubricants 45-7 Lubricate Boom, Bucket, and Cylinder
Pivots—544G TC 70-2
Periodic Maintenance Lubricate Steering Cylinder Pivots 70-4
Service Your Machine at Specified Intervals 50-1 Lubricate Oscillating Rear Axle 70-5
Check the Hour Meter Regularly 50-1 Check Cab Fresh Air Filter—If Equipped 70-5
Use Correct Fuels and Lubricants 50-1
Prepare Machine for Maintenance 50-2 Maintenance—Every 250 Hours
Locking Machine Frame 50-3 Check Receiver Dryer Moisture Indicator 75-1
Boom Lock 50-4 Change Engine Oil and Replace Filter 75-2
Opening Engine Side Shields and Service Check Radiator Coolant Level 75-5
Doors 50-4
Opening Grille Door 50-5 Continued on next page
Maintenance—Every 500 Hours Cleaning Fuel Tank Outlet Screen 90-5
Lubricant Front Driveline 80-1 Bleeding Fuel System—544G, 624G 90-7
Check Air Intake Hoses 80-1 Bleeding Fuel System—644G 90-8
Check Battery Electrolyte Level and Adjusting Fuel Shut-Off Solenoid—644G 90-8
Terminals 80-2 Precautions for Alternator and Regulator 90-9
Check Coolant 80-5 Service Batteries Carefully 90-10
Replace Primary Fuel Filter (Water Checking Electrolyte Specific Gravity 90-12
Separator) 80-6 Using Battery Charger 90-14
Replace Final Fuel Filter—544G, 624G 80-7 Replacing Batteries 90-14
Replace Final Fuel Filter—644G 80-7 Removing Batteries 90-15
Replace Hydraulic System Return Filter 80-7 Replacing Fuses 90-15
Replace Hydraulic Reservoir Breather Filter 80-8 Fuse (Blade-Type) Color Codes 90-15
Check Front and Rear Differential Oil Resetting Circuit Breakers 90-16
Level—If Equipped with Standard Axle 80-9 Replacing Halogen Bulbs 90-16
Check Front and Rear Differential Oil Changing Reverse Warning Alarm Volume 90-18
Level—If Equipped with Differential Lock Checking Neutral Start System 90-18
Axle 80-10 Adding Attachments/Accessories to Roll-
Over Protective Structure (ROPS) 90-19
Maintenance—Every 1000 Hours Servicing Air Conditioning System 90-19
Lubricate Rear Driveline 85-1 Checking and Adjusting Compressor Belt
Check Engine Speeds 85-1 Tension—If Equipped 90-20
Adjust Engine Speed Control Linkage 85-2 Welding on Machine 90-20
Replace Air Cleaner Dust Unloader Valve 85-3 Inspecting Park Brake Pads 90-21
Replace Air Cleaner Elements 85-3 External Service Brake Inspection 90-22
Clean Engine Crankcase Vent Tube (A) 85-4 Checking Brake Accumulator 90-24
Change Transmission Oil and Replace Checking Ride Control Accumulator—If
Filter 85-5 Equipped 90-25
Check Park Brake 85-7 Bleeding Brakes 90-26
Adjust Park Brake 85-8 Checking Secondary Steering System—If
Lubricate Frame Hinge Pivots 85-10 Equipped 90-28
Clutch Cut-Off Adjustment 90-28
Maintenance—Every 2000 Hours Do Not Service Control Valves, Cylinders,
Measure and Adjust Engine Valve Lash Pumps or Motors 90-29
(Clearance)—544G, LL, TC, 624G 86-1 Hardware Torque Specifications 90-30
Adjust Engine Valve Lash (Clearance)— Keep ROPS Installed Properly 90-30
644G 86-3 Metric Bolt and Cap Screw Torque Values 90-31
Lubricate Front Driveline Support Bearing 86-5 Additional Metric Cap Screw Torque Values 90-33
Unified Inch Bolt and Cap Screw Torque
Maintenance—Every 3000 Hours Values 90-34
Change Hydraulic System Oil 87-1 Check Oil Lines and Fittings 90-36
Clean Hydraulic Suction Strainer 87-2 Service Recommendations for O-Ring Boss
Replace Differential Lock Return Filter(s)— Fittings 90-37
If Equipped 87-2 Service Recommendations for Flat Face OChange
Front and Rear Differential Oil 87-3 Ring Seal Fittings 90-39
Service Recommendations for Metric Series
Maintenance Four Bolt Flange Fitting 90-40
Draining the Cooling System 90-1 Service Recommendations for Inch Series
Diesel Engine Coolant 90-3 Four Bolt Flange Fittings 90-41
Coolant drain intervals 90-3
Filling the Cooling System 90-4 Operational Checkout
Test the Coolant Freeze—Protection Level 90-4 Operational Checkout 95-1
Do Not Service Injection Nozzles 90-5
Do Not Adjust Injection Pump 90-5 Continued on next page
Monitor Indicator and Gauge Checks— Control Valve Lift Check 95-19
Engine Off 95-2 Bucket Rollback Circuit Relief Valve Check 95-19
Hourmeter And Gauge Check 95-2 Bucket Dump Circuit Relief Valve Pressure
Battery Check 95-2 Check 95-19
Monitor Indicator Circuit And Key Switch Boom and Bucket Cylinder Drift 95-19
Check 95-3 Boom Down Check Valve Leakage Check 95-20
Monitor Turn Signals And Hazard Warning Pilot Controller Check 95-20
Indicator Checks 95-4 Return-To-Dig Check 95-20
Transmission Controls, Axle and Engine Boom Height Kickout Check—If Equipped 95-21
Linkages, Neutral Start Switch, and Pin Disconnect Cylinder Check (544G-TC
Reverse Warning Alarm Switch Checks 95-4 Only) 95-21
Neutral Start And Reverse Warning Alarm Ride Control Accumulator Check—If
Circuit checks 95-4 Equipped 95-21
Engine Speed Control Linkage Check— Steering System Checks 95-22
544G, 624G 95-5 Steering Valve Check 95-22
Engine Speed Control Linkage Check— Steering System Leakage Check 95-22
644G 95-5 Priority Valve Low Pressure Check 95-23
Engine Speed Control Linkage Check— Priority Valve High Pressure Check 95-23
644G (Continued) 95-5 Secondary Steering System Check—If
Fuel Shut-off Solenoid Linkage Check— Equipped 95-24
644G 95-6 Secondary Steering System Primary Check
Front Axle Disconnect Check—If Equipped 95-6 Valve Check 95-24
Monitor Indicator and Gauge Checks Accessory Checks 95-25
(Engine Running) 95-7 Operating Lights Check 95-25
Monitor Display And Alternator Output Work Light Check 95-25
Check 95-7 Brake Light Check 95-26
Monitor Indicator Circuit Bypass And Seat Horn Circuit Check 95-26
Belt Indicator Check 95-9 Windshield Washer and Wiper Check—If
Monitor Primary And Secondary Level Equipped 95-27
Checks 95-9 Defroster Blower Check 95-27
Transmission Temperature Gauge Check 95-10 Heater/Air Conditioner Blower Check 95-28
Brake System, Clutch Cut-Off, and Heater Functional Check 95-28
Differential Lock Checks 95-10 Air Conditioner Functional Check 95-28
Park Brake Transmission Lockout Check 95-10 Start Aid System Check 95-29
Service Brake Pump Flow Check 95-11 Cab Component and Vandal Protection
Service Brake Check 95-12 Checks 95-29
Brake Accumulator Precharge Check 95-12 Cab Door and Window Hold-Open Latch
Brake System Leakage Check 95-13 Check 95-29
Service Brake Pedal Check 95-13 Cab Door Release Button 95-30
Service And Park Brake System Drag Cab Door Lock Check 95-30
Checks 95-13 Dome Light Check 95-30
Differential Lock Check 95-14 Cab Window Latch Check 95-31
Clutch Cut-Off Check 95-14 Cab Door Window Check 95-31
Driving Checks 95-15 Steering Column Adjustment Check 95-31
Transmission Noise Check 95-15 Seat And Seat Belt Check 95-32
Automatic Shift and Speedometer Check 95-16 Toolbox Door Check 95-32
Transmission Quickshift Check 95-17 Air Intake Filter Door Check 95-33
Transmission Pressure, Pump Flow, and Load Center Door Check 95-33
Leakage Check 95-17 Engine Side Panels Check 95-33
Transmission Shift Modulation Check 95-18 Radiator Cap Access Door Check 95-34
Hydraulic System Checks 95-18 Frame Locking Bar Check 95-34
Hydraulic System Warm-Up Procedure 95-18
Boom Down Solenoid Valve Check 95-18 Continued on next 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 Specifications 115-5
544G LL Specifications 115-7
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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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M