
Introduction
170696
PN=7
-
544G, 544G LL, and
1
-
544G TC Loaders
1
-
624G Loader
1
-
644G Loader
1
-
(Serial No. 557739-)
1
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Introduction
2
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TX,DH2121 -19-08JUN96
5
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TX,DH2283 -19-02OCT92
6
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HELP!! HELP!! HELP!! HELP!!
7
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Contents
10
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T100127 –19–21FEB96
14
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RECOGNIZE SAFETY INFORMATION
15
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UNDERSTAND SIGNAL WORDS
15
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FOLLOW SAFETY INSTRUCTIONS
15
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TX,05,DH1525 –19–21JUN91–1/1
16
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TX,05,DH1573 –19–18MAR91–1/1
17
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TX,05,DH2478 –19–26SEP92–1/1
18
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T82,BHSA,CL –19–14MAR90–1/1
18
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USE HANDHOLDS AND STEPS
19
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PREVENT MACHINE RUNAWAY
19
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USE SEAT BELT PROPERLY
19
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MAINTAIN SEAT BELT
20
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SECONDARY EXITS
20
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TRAVEL SAFELY
21
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T6964AD –UN–20DEC88
21
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DRIVE MACHINE SAFELY
21
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T6582AS –UN–25OCT88
21
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OPERATE MACHINE WITH CAUTION
22
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T6642EF –UN–18OCT88
22
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OPERATING ON SLOPES
22
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T7050AB –UN–03AUG89
22
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CARRYING LOADS
23
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AVOID POWER LINES
23
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BEWARE OF EXHAUST FUMES
23
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KEEP RIDERS OFF MACHINE
24
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PREPARE FOR EMERGENCIES
24
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HANDLE STARTING FLUID SAFELY
25
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CLEAN TRASH FROM MACHINE
25
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PROTECT AGAINST FLYING DEBRIS
25
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WEAR PROTECTIVE CLOTHING
26
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PROTECT AGAINST NOISE
26
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USE SAFETY LIGHTS AND DEVICES
27
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N36564 –UN–10FEB89
27
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KEEP THE OPERATOR PROTECTIVE
28
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STRUCTURE (OPS) IN PLACE
28
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WARN OTHERS OF SERVICE WORK
28
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T7447AO –19–22APR91
28
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PRACTICE SAFE MAINTENANCE
29
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TS218 –UN–23AUG88
29
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SUPPORT MACHINE PROPERLY
30
-
TS229 –UN–23AUG88
30
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DX,PAINT –19–03MAR93–1/1
31
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DX,TORCH –19–03MAR93–1/1
31
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AVOID HIGH-PRESSURE FLUIDS
32
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CLEAN THE MACHINE REGULARLY
32
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T6642EJ –UN–18OCT88
32
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SERVICE COOLING SYSTEM SAFELY
33
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STORE ATTACHMENTS SAFELY
33
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DISPOSE OF WASTE PROPERLY
33
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Safety Signs
34
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T7939AI –19–22MAR93
35
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T7773CV –UN–31AUG92
35
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A-Warning Decal
35
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T8417AD –19–09FEB95
36
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T7593AC –19–30AUG91
37
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T6976AE –UN–30JAN89
37
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T7939AK –19–22MAR93
38
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T8029AF –UN–15JUN93
38
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T7934AM –19–01FEB93
39
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T100703 –UN–22MAR96
39
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Left Side Shown
39
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T8029AR –19–16JUN93
40
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T8029AQ –UN–21JUN93
40
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T7829AT –19–17SEP92
41
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A-Warning Decal, If Equipped
41
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Right Side of Machine
41
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T7916AC –19–06JAN93
42
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T7773AZ –UN–10AUG92
42
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T7748CU –19–14OCT92
42
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T7773CA –UN–10AUG92
42
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T7829AQ –19–31AUG92
43
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T100702 –UN–22MAR96
43
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T7829AU –19–17SEP92
44
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T7839BB –UN–17SEP92
44
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Operator’s Station
45
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T8375AN –UN–02DEC94
46
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STOP INDICATOR AND ALARM
47
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T7673AM –UN–06JAN92
47
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T6201BL –UN–18OCT88
48
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DIGITAL DISPLAY
48
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T7747AT –UN–19MAY92
48
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FUEL GAUGE
49
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ENGINE OIL PRESSURE INDICATOR
50
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ALTERNATOR VOLTAGE INDICATOR
50
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ENGINE AIR FILTER RESTRICTION
50
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INDICATOR
50
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RIGHT TURN SIGNAL INDICATOR
52
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BRAKE OIL PRESSURE INDICATOR
52
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PARK BRAKE INDICATOR
52
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FASTEN SEAT BELT INDICATOR
53
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ETHER INJECTION INDICATOR
53
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LEFT TURN SIGNAL INDICATOR
54
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T7747AM –UN–19MAY92
55
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T7747AN –UN–19MAY92
55
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T7747AO –UN–19MAY92
56
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PARK BRAKE SWITCH
56
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NEUTRAL LOCK
57
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T7747BI –UN–19MAY92
57
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HORN BUTTON
57
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T7747BJ –UN–19MAY92
57
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TURN SIGNAL SWITCH
58
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VANDAL SHIELD—IF EQUIPPED
58
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WASHERS—IF EQUIPPED
59
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ADJUSTING STEERING WHEEL TILT
59
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OPENING SIDE WINDOW
59
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CAB DOOR RELEASE
60
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OPERATING LIGHTS
61
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HEATING AND AIR CONDITIONING
62
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CONTROLS
62
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ADJUSTING SUSPENSION SEAT
63
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SEAT BELT
64
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T8415AA –UN–09FEB95
64
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STORAGE COMPARTMENT
64
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T8029AK –UN–15JUN93
64
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Break-in
65
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AFTER THE FIRST 100 HOURS
66
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Pre-Start Inspection
67
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Operating the Engine
68
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T7747BU –UN–19MAY92
70
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WEATHER STARTING AID)
71
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COLD WEATHER WARM-UP
75
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STOPPING THE ENGINE
75
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Driving the Machine
77
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GENERAL DRIVING PRECAUTIONS
78
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SHIFTING THE TRANSMISSION
79
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TRAVEL SPEEDS
81
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STOPPING THE MACHINE
82
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PARKING THE MACHINE
83
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Operating the Machine
85
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TWO LEVER DESIGN
86
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QUICK SHIFT SWITCH
87
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T7773CE –UN–21AUG92
87
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PIN DISCONNECT SWITCH—544G TC
89
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BOOM DOWN SWITCH
89
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T7773AT –UN–30JUL92
90
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T100664 –UN–12MAR96
90
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T6601AI –UN–21OCT88
91
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ADJUSTING RETURN-TO-DIG
92
-
T6599AD –UN–21OCT88
92
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GENERAL OPERATING TIPS
93
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T7208AV –UN–30JAN90
94
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USING THE LOADER BUCKET
94
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T7747BB –UN–19MAY92
94
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T7747BC –UN–19MAY92
95
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T7208AR –UN–30JAN90
95
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T7747BD –UN–19MAY92
95
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BACKDRAGGING
96
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T7747BG –UN–19MAY92
96
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BACKFILLING
96
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T6603AO –UN–20OCT88
96
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TRUCK LOADING
97
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T7511CN –UN–27JUN91
97
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TOWING PROCEDURE—ENGINE
100
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OPERATIONAL
100
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T6629AM –UN–20OCT88
100
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TOWING PROCEDURE—ENGINE NON
101
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Transporting
102
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LIFTING THE MACHINE
104
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T7477AV –UN–19MAR91
104
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Fuels and Lubricants
105
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FUEL TANK
107
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DIESEL ENGINE OIL
108
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T101239 –19–22MAY96
108
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T100663 –19–10MAY96
109
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T8358AI –19–27MAR95
110
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LUBRICANT STORAGE
111
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MIXING OF LUBRICANTS
111
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Periodic Maintenance
112
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LOCKING MACHINE FRAME
114
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BOOM LOCK
115
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SERVICE DOORS
115
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OPENING GRILLE DOOR
116
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MAINTENANCE AND REPAIR RECORD
117
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KEEPING SYSTEM
117
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T7511CO –UN–27JUN91
117
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OILSCAN
118
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*includes 544G LL and 544G TC
119
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Maintenance—As Required
121
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TIRE PRESSURES
122
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TX,55,JC1157 –19–03JUN96–1/1
123
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TX,55,JC1158 –19–03JUN96–1/1
124
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TX,55,JC1159 –19–03JUN96–1/1
125
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TX,55,DH2551 –19–16JUN93–1/1
125
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CLEAN OR REPLACE AIR CLEANER
126
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ELEMENTS
126
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T6119AF –UN–01NOV88
126
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T6119AG –UN–01NOV88
126
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CLEAN DUSTY PRIMARY ELEMENT
127
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INSPECT ELEMENT
128
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T90684 –UN–10NOV88
128
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CHECK AIR INLET COVER
129
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T6779BQ –UN–19OCT88
129
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INSPECT SERPENTINE BELT—644G
131
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T7405BG –UN–15NOV90
131
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DRAIN FUEL TANK
131
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T7773CN –UN–21AUG92
131
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(WATER SEPARATOR)—544G, 624G
132
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T8387AD –UN–17DEC94
133
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(WATER SEPARATOR)—644G
133
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T100696 –UN–22MAR96
133
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T8295AA –UN–10AUG94
134
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LUBRICATE PIVOTS
135
-
CHECK ENGINE OIL LEVEL
135
-
544G Shown
136
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624G Shown
136
-
644G Shown
136
-
CHECK HYDRAULIC OIL LEVEL
137
-
T7773CB –UN–10AUG92
138
-
T8029AM –UN–15JUN93
138
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CHECK TRANSMISSION OIL LEVEL
139
-
T7773CP –UN–21AUG92
139
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Maintenance—Every 100 Hours
140
-
LUBRICATE BOOM, BUCKET, AND
141
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CYLINDER PIVOTS—544G TC
141
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T7829BH –UN–17SEP92
142
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Five Points
142
-
CHECK CAB FRESH AIR FILTER—IF
144
-
EQUIPPED
144
-
T7829AC –UN–31AUG92
145
-
Maintenance—Every 250 Hours
146
-
CHANGE ENGINE OIL AND REPLACE
147
-
T7853AI –UN–08OCT92
148
-
CHECK RADIATOR COOLANT LEVEL
150
-
T6642EK –UN–01NOV88
150
-
Maintenance—Every 500 Hours
151
-
AND TERMINALS
152
-
TS203 –UN–23AUG88
152
-
T6758AA –UN–21OCT88
154
-
CHECK COOLANT
155
-
T101279 –19–14MAY96
155
-
TS281 –UN–23AUG88
155
-
SEPARATOR)
156
-
T100705 –UN–22MAR96
158
-
REPLACE HYDRAULIC RESERVOIR
158
-
BREATHER FILTER
158
-
OIL LEVEL—IF EQUIPPED WITH
160
-
DIFFERENTIAL LOCK AXLE
160
-
Maintenance—Every 1000 Hours
161
-
T7853AB –UN–06OCT92
162
-
REPLACE AIR CLEANER ELEMENTS
163
-
CHANGE TRANSMISSION OIL AND
165
-
REPLACE FILTER
165
-
T7853AA –UN–23SEP92
166
-
T7853AC –UN–06OCT92
166
-
CHECK PARK BRAKE
167
-
T7773AG –UN–11JUN92
168
-
ADJUST PARK BRAKE
168
-
T7747BR –UN–19MAY92
168
-
T100701 –UN–22MAR96
169
-
LUBRICATE FRAME HINGE PIVOTS
170
-
T100690 –UN–22MAR96
170
-
Maintenance—Every 2000 Hours
171
-
T6233AG –19–27JAN89
172
-
T6233AH –19–27JAN89
172
-
ADJUST ENGINE VALVE LASH
173
-
(CLEARANCE)—644G
173
-
T6105BF –UN–24FEB89
173
-
T6233AI –19–27JAN89
174
-
T6233AJ –19–27JAN89
174
-
Maintenance—Every 3000 Hours
176
-
FILTER(S)—IF EQUIPPED
177
-
Maintenance
180
-
T7829AN –UN–31AUG92
181
-
544G, 624G Shown
181
-
T100709 –UN–22MAR96
181
-
DIESEL ENGINE COOLANT
182
-
FILLING THE COOLING SYSTEM
183
-
TEST THE COOLANT FREEZE—
183
-
PROTECTION LEVEL
183
-
T85402 –UN–10NOV88
183
-
DO NOT ADJUST INJECTION PUMP
184
-
T6523BW1 –UN–20OCT88
185
-
T7833AJ –UN–10SEP92
186
-
BLEEDING FUEL SYSTEM—644G
187
-
SERVICE BATTERIES CAREFULLY
189
-
CHECKING ELECTROLYTE SPECIFIC
191
-
USING BATTERY CHARGER
193
-
TS204 –UN–23AUG88
193
-
REPLACING BATTERIES
193
-
REMOVING BATTERIES
194
-
REPLACING FUSES
194
-
FUSE (BLADE-TYPE) COLOR CODES
194
-
RESETTING CIRCUIT BREAKERS
195
-
REPLACING HALOGEN BULBS
195
-
T6249AU –UN–19OCT88
196
-
CHECKING NEUTRAL START SYSTEM
197
-
BELT TENSION—IF EQUIPPED
199
-
WELDING ON MACHINE
199
-
INSPECTING PARK BRAKE PADS
200
-
T7853AU –UN–08OCT92
201
-
T6523BZ –UN–25OCT88
202
-
T6138AZ –UN–25OCT88
202
-
T8137AC –UN–03DEC93
202
-
CHECKING BRAKE ACCUMULATOR
203
-
T100704 –UN–22MAR96
203
-
CHECKING RIDE CONTROL
204
-
ACCUMULATOR—IF EQUIPPED
204
-
BLEEDING BRAKES
205
-
X9811 –UN–23AUG88
205
-
T6522BR –UN–20OCT88
206
-
CHECKING SECONDARY STEERING
207
-
SYSTEM—IF EQUIPPED
207
-
CLUTCH CUT-OFF ADJUSTMENT
207
-
T7817AL –UN–08SEP92
208
-
CYLINDERS, PUMPS OR MOTORS
208
-
KEEP ROPS INSTALLED PROPERLY
209
-
TS176 –UN–23AUG88
209
-
*Torque tolerance is
212
-
DX,TORQ1 –19–20JUL94–2/2
214
-
CHECK OIL LINES AND FITTINGS
215
-
T85401 –UN–24JAN89
215
-
BOSS FITTINGS
216
-
T6243AE –UN–18OCT88
216
-
T6520AB –UN–18OCT88
217
-
FACE O-RING SEAL FITTINGS
218
-
T6243AD –UN–18OCT88
218
-
T6890BB –UN–01MAR90
219
-
04T,90,K174 –19–01AUG94–2/2
221
-
Operational Checkout
222
-
– – –1/1
229
-
T7825BB –UN–21AUG92
229
-
T7825BD –UN–21AUG92
229
-
T7825BE –UN–21AUG92
229
-
LOOK: Machine MUST NOT move
231
-
Troubleshooting
256
-
ELECTRICAL SYSTEM
269
-
HYDRAULIC SYSTEM
277
-
Symptom Problem
283
-
Solution
283
-
POWER TRAIN
284
-
SERVICE BRAKES
290
-
DIFFERENTIAL AXLE
292
-
DRIVELINE
294
-
PARK BRAKE
295
-
AIR CONDITIONING
296
-
PREPARE MACHINE FOR STORAGE
297
-
T47764 –UN–09NOV88
297
-
T5813AM –UN–09FEB89
297
-
MONTHLY STORAGE PROCEDURE
298
-
T6191AA –UN–18OCT88
298
-
T6181AU –UN–18OCT88
299
-
Machine Numbers
300
-
RECORD HYDRAULIC PUMP SERIAL
301
-
Specifications
302
-
544G SPECIFICATIONS
304
-
544G LL SPECIFICATIONS
306
-
T7829AX –UN–10SEP92
306
-
544G TC SPECIFICATIONS
310
-
T7829AY –UN–21SEP92
310
-
624G SPECIFICATIONS
314
-
T6603AC1 –UN–20OCT88
314
-
644G SPECIFICATIONS
318
-
T6603AD1 –UN–20OCT88
318
-
Crime Prevention Tips
322
-
PARK INDOORS OUT OF SIGHT
323
-
TS158 –UN–23MAR89
323
-
WHEN PARKING OUTDOORS
323
-
TS144 –UN–23AUG88
323
-
REDUCE VANDALISM
324
-
T7223BB –UN–22FEB90
324
-
REPORT THEFTS IMMEDIATELY
324
-
TS146 –UN–09JAN89
324
-
Page Page
325
-
Checklists
331
-
PARTS CATALOG
333
-
OPERATOR’S MANUAL
333
-
TECHNICAL AND SERVICE MANUALS
333
-
TX,LIT1 -19-08JUN96
334
-
TS1643 -UN-12SEP95
335
-
DX,IBC,4 -19-12SEP95
335
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