PDF Operator's Manual John Deere 544G 544G LL 544G TC 624G Loaders - 867 KB
This operator's manual covers the John Deere 544G, 544G LL, 544G TC, and 624G loaders.
It is the primary source of information for safe operation, daily checks, and proper use of controls.
By following the instructions in this manual, operators can enhance job site safety and improve the machine's efficiency and lifespan.
It is a critical document for anyone operating these versatile John Deere loaders.
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--- Page 1 ---
544G, 544G LL,and
#
544G TC Loaders
"
624G Loader
!
644G Loader (Serial
No. 553285— )
!"#$%&!$'()%*+%,
544G, 544G LL,and 544G TC Loaders 624G Loader
644G Loader (Serial No. 553285— )
OMT158711 Issue L5 English
* + '
# $ % & ' ( ) & & *
John Deere Dubuque Works
OMT158711 Issue L5
(Mark old manual OMT154907 L4 for
machines up to Serial No. 553284)
LITHO IN U.S.A.
ENGLISH
--- Page 3 ---
Safety
RECOGNIZE SAFETY INFORMATION
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.
-UN-07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT -19-03MAR93
UNDERSTAND SIGNAL WORDS
A signal word—DANGER, WARNING, or CAUTION—is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
-19-30SEP88
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.
TS187
DX,SIGNAL -19-03MAR93
FOLLOW SAFETY INSTRUCTIONS
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
-UN-23AUG88
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
Learn how to operate the machine and how to use
controls properly. Do not let anyone operate without
TS201
instruction.
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 -19-03MAR93
05-1 010596
PN=10
--- Page 4 ---
P
PROTECT AGAINST FLYING DEBRIS
When you drive connecting pins in or out, guard against
injury from flying pieces of metal or debris; wear goggles
or safety glasses.
-UN-18OCT88
T6642DK
02T,05,J45 -19-30MAY90
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
-UN-23AUG88
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
TS206
DX,WEAR2 -19-03MAR93
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
-UN-23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
TS207
DX,NOISE -19-03MAR93
05-11 010596
PN=20
--- Page 5 ---
Safety Signs
-19-30AUG91
T7593AC
-UN-30JAN89
T6976AE
TX,06,DH2949 -19-12MAY93
-19-22MAR93
-UN-15JUN93
T7939AK
T8029AF
TX,06,DH2950 -19-16JUN93
06-3 010596
PN=30
--- Page 6 ---
Operator’s Station
ENGINE COOLANT TEMPERATURE GAUGE
The first arrow will flash until engine temperature warms
to 38˚C (100˚F).
-UN-19MAY92
Audible alarm will sound once when temperature first
reaches 99-103˚C (210-217˚F).
All the arrows will flash, STOP indicator light will flash,
and audible alarm will sound when temperature reaches
T7747AU
above 103˚C (217˚F). 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.
TX,10,JC244 -19-29NOV94
FUEL GAUGE
First arrow will flash if fuel is low or system has a
malfunction.
-UN-19MAY92
Always fill fuel tank at the end of the day to eliminate
condensation in fuel tank.
T7747AV
TX,10,DH2164 -19-29NOV94
TRANSMISSION OIL TEMPERATURE GAUGE
Audible alarm will sound once when temperature first
reaches 127-132˚C (260-270˚F).
-UN-19MAY92
All arrows will flash, STOP indicator light will flash, and
audible alarm will sound when temperature reaches
above 133˚C (271˚F), 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
T7747AW
action.
TX,10,JC245 -19-29NOV94
10-5 010596
PN=40
--- Page 7 ---
Operator’s Station
OPERATING LIGHTS
Press light switch (A). Lights (E and I) will come on.
Press light switch (B). Lights (D and G) will come on.
-UN-02DEC94
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.
T8373BD
Press hazard light switch (C). Both front amber lights (F)
and both rear amber lights (H) will be flashing.
A—Operating Light Switch
B—Work Light Switch
C—Hazard Light Switch
D—Front Work Lights—If Equipped
E—Headlights
-UN-10AUG92
F—Turn Signals/Hazard Lights
G—Rear Work Lights—If Equipped
H—Turn Signals/Hazard Lights
I—Tail Lights/Brake Lights
T7773AX
-UN-10AUG92
T7773AY
TX,10,DH2144 -19-29NOV94
10-15 010596
PN=50
--- Page 8 ---
Operating the Engine
STARTING FLUID—IF EQUIPPED
(COLD WEATHER STARTING AID)
• USING STARTING FLUID
N
-UN-23AUG88
CAUTION: Prevent possible injury from
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
TS281
engine does not need starting fluid.
IMPORTANT: Prevent damage to engine. Use starting
aid when temperatures are below 4˚C
(40˚F) and only when engine is COLD.
1. Turn key switch clockwise to START position.
-UN-19MAY92
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
T7747BT
engine as long as you press button.
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.
• REPLACING STARTING AID CAN
-UN-01AUG91
1. Turn container (B) counterclockwise to remove the
container and starting aid can.
2. Remove safety cap and spray button from new can.
T7527EF
3. Place new can in container.
4. Turn container clockwise in starting aid base (C) to
install starting aid can.
• OPERATING MACHINE WITHOUT STARTING AID
CAN INSTALLED
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,DH2164 -19-29NOV94
25-3 010596
PN=60
--- Page 9 ---
Driving the Machine
RIDE CONTROL SWITCH—IF EQUIPPED
N CAUTION: Prevent possible injury from
unexpected boom movement. The bucket may
“jump up” when ride control switch is turned
-UN-08SEP92
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.
T7829AV
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).
To discharge the energy in the ride control accumulator,
do the following:
1. Make sure area around bucket is clear.
2. Lower bucket to ground.
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 -19-16JUN93
STOPPING THE MACHINE
Depress left brake pedal (A) or right brake pedal (B) to
stop the machine.
-UN-19MAY92
Left brake pedal also serves as a clutch cut-off pedal
when clutch cut-off switch is in “clutch disengaged”
position.
T7747BS
TX,30,DH2173 -19-31JUL92
30-5 010596
PN=70
--- Page 10 ---
Operating the Machine
ADJUSTING RETURN-TO-DIG
1. Start engine.
2. Move control lever to return-to-dig detent position and
-UN-21OCT88
release.
NOTE: On 544G LL and 544G TC, the return-to-dig
switch and magnet are located below the
cylinder.
T6599AD
3. After control lever returns to neutral, make a mark (B)
on magnet and return-to-dig switch.
4. Position the boom and bucket in the desired A—Clearance
return-to-dig position. Stop engine. B—Mark
C—Cap Screws
D—Cap Screws
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.).
7. Raise boom. Cycle bucket from full rollback to dump.
Check return-to-dig for correct adjustment.
TX,35,DH2184 -19-02OCT92
35-8 010596
PN=80
--- Page 11 ---
Transporting
LIFTING THE MACHINE
N CAUTION: Prevent possible injury from
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.
SPECIFICATIONS
Approximate machine weight (544G) . . . . . . . . 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)
Approximate machine weight (624G) . . . . . . . . 12 398 kg (27,338 lb)
Approximate machine weight (644G) . . . . . . . . 15 666 kg (34,538 lb)
-UN-19MAR91
1. Attach cables (A) to machine so cables do not rub
machine.
2. Attach a tether cable to machine to control machine
T7477AV
as it is lifted.
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 -19-12SEP92
40-6 010596
PN=90
--- Page 12 ---
Periodic Maintenance
PREPARE MACHINE FOR MAINTENANCE
Before performing maintenance procedures given in the
following chapters, and before leaving the operator’s
seat, park the machine as described below unless
-UN-19MAY92
another position is specified in the procedure.
1. Park machine on a level surface.
2. Lower bucket to ground.
T7747BR
NOTE: Boom down switch (C) must be pushed while
moving control lever forward to lower boom with
engine stopped.
3. Move transmission control lever (A) to neutral “N”.
Engage neutral lock (B).
N
-UN-02DEC94
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,
T8375AM
resulting in death or serious injury. Always
engage park brake to hold machine.
4. Engage park brake.
5. Turn key switch to STOP. If maintenance must be
performed with engine running, do not leave machine
unattended.
6. Turn battery disconnect switch OFF, if equipped.
TX,50,DH2194 -19-29NOV94
50-2 010596
PN=100
--- Page 13 ---
Maintenance—As Required
644G
Ply Operating Pressure*
Tire Size Type 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
Rear, alternate 240 2.4 35
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 alternate pressure listed. TX,55,DH2711 -19-12MAY93
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 N·m (400 lb-ft).
TX,55,DH2551 -19-16JUN93
55-4 010596
PN=110
--- Page 14 ---
Maintenance—Every 10 Hours or Daily
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
Lubricants chapter.)
3. Install dipstick.
-UN-21AUG92
4. Start engine.
5. Engage service brakes. Move clutch cut-off switch up,
to disengaged position.
T7773CP
6. Release park brake.
7. Move transmission control lever to 3rd speed forward 624G Shown
“F” position.
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.
9. Engage park brake.
10. Release service brakes.
11. Check oil level with engine at slow idle. Oil must be
between marks on dipstick.
TX,60,DH2214 -19-02OCT92
60-4 010596
PN=120
--- Page 15 ---
Maintenance—Every 250 Hours
CHECK RADIATOR COOLANT LEVEL
N CAUTION: Prevent possible injury from hot
spraying water. DO NOT remove radiator filler
cap unless engine is cool. Then turn cap
-UN-01NOV88
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.
T6642EK
NOTE: If radiator coolant level is low, check for leaks on
radiator cap, and hose connections between
radiator and coolant recovery tank.
2. Add coolant, if necessary.
3. Install filler cap.
TX,75,DH3501 -19-29NOV94
75-4 010596
PN=130
--- Page 17 ---
Maintenance—Every 1000 Hours
CLEAN ENGINE CRANKCASE VENT TUBE
(A)
-UN-31AUG92
T7829AK
544G Shown
-UN-31AUG92
T7829AL
624G Shown
-UN-31AUG92
T7829AM
644G Shown
TX,85,DH2230 -19-02OCT92
85-4 010596
PN=140
--- Page 18 ---
Maintenance—Every 2000 Hours
LUBRICATE FRONT DRIVELINE SUPPORT
BEARING
N CAUTION: Prevent possible injury from
unexpected machine movement. Install frame
-UN-23AUG89
locking bar before lubricating.
Lubricate until grease escapes around seal. (See Fuels
and Lubricants chapter.) Grease every 250 hours if
operating in deep mud or water.
T7114AS
One Point
TX,86,DH2553 -19-02OCT92
86-5 010596
PN=150
--- Page 19 ---
Maintenance
The DB4 Drive Gear Puller Kit now can be used on
Stanadyne’s DB4 and DB2 Injection Pumps. Earlier
pumps displayed the metal plate (A) attached to the fuel
injection pump’s mounting flange.
-UN-27JUN91
T7527DP
TX,90,RR,249 -19-29AUG94
1. Park machine on a level surface.
2. Lower bucket to ground.
3. Move transmission control lever (A) to neutral “N”.
Engage neutral lock (B).
N 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.
4. Engage park brake.
IMPORTANT: Turbocharger may be damaged if
engine is not properly shut down.
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.
6. Turn key switch to STOP.
7. Turn battery disconnect switch OFF, if equipped.
TX,90,DH2967 -19-04AUG94
90-6 010596
PN=160
--- Page 20 ---
Maintenance
USING BATTERY CHARGER
N CAUTION: Prevent possible injury from
exploding battery. Do not charge a battery if
the battery is frozen or it may explode. Warm
-UN-23AUG88
battery to 16˚C (60˚F). 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
TS204
booster if a battery has a 1.150 specific
gravity reading or lower. Turn off
charger before connecting or
disconnecting it.
A battery charger may be used as a booster to start
engine.
TX,FF,121 -19-15MAR93
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 -18˚C (0˚F)
160 minutes reserve capacity at 25 amps
644G:
925 cold cranking amps at -18˚C (0˚F)
180 minutes reserve capacity at 25 amps
TX,90,DH2264 -19-16SEP92
90-16 010596
PN=170
--- Page 21 ---
Maintenance
BLEEDING BRAKES
N CAUTION: Escaping fluid under pressure can
penetrate skin causing serious injury. Relieve
pressure before disconnecting hydraulic or
-UN-23AUG88
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
X9811
hand.
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.
1. Install frame locking bar.
2. Start engine and run at slow idle.
3. Push and hold brake pedal down until brake bleeding
procedure is complete.
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 2—4 for each bleed screw (two bleed
screws on each differential).
7. Release brake pedal and stop engine.
8. Check hydraulic oil level. (See Maintenance—Every 10
Hours or Daily chapter.) -UN-20OCT88
T6522BR
TX,DH,114 -19-06JUN91
90-26 010596
PN=180
--- Page 22 ---
Maintenance
SERVICE RECOMMENDATIONS FOR INCH SERIES FOUR BOLT FLANGE FITTINGS
-UN-01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches be centrally located on port. Hand tighten cap screws
cause leaks. Roughness causes seal wear. Out-of-flat to hold flange in place. Do not pinch O-ring.
causes seal extrusion. If defects cannot be polished
out, replace component. 5. Tighten one cap screw, then tighten the diagonally
opposite cap screw. Tighten two remaining cap
2. Install O-ring (and backup washer if required) into screws. Tighten all cap screws as specified in the
groove using petroleum jelly to hold it in place. chart below.
3. Split flange: Loosely assemble split flange (B) DO NOT use air wrenches. DO NOT tighten one cap
halves. Make sure split is centrally located and screw fully before tightening the others. DO NOT over
perpendicular to port. Hand tighten cap screws to tighten.
hold parts in place. Do not pinch O-ring (C).
4. Single piece flange (D): Place hydraulic line in
center of flange and install cap screws. Flange must
TORQUE CHART*
N·m lb-ft
Nominal Flange Size Cap Screw Size Min Max Min Max
1/2 . . . . . . . . . . . . . . . . . . . 5/16-18 UNC . . . . . . . . . 20 . . . . . 31 . . . . . . . . . . . 15 . . . . . . 23