444J (S.N.

—611274)
544J (S.N. —611799)
624J (S.N. —611796)
Loaders

OPERATOR’S MANUAL
444J, 544J, and 624J Loaders
OMT197190 ISSUE G0 (ENGLISH)

CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its constituents

are known to the State of California to cause cancer,
birth defects, and other reproductive harm.

If this product contains a gasoline engine:

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.

The State of California requires the above two warnings.

Additional Proposition 65 Warnings can be found in this manual.

Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
 Introduction
Foreword
READ THIS MANUAL carefully to learn how to operate equipment as described in this manual. The warranty is
and service your machine correctly. Failure to do so explained on the warranty certificate or statement which
could result in personal injury or equipment damage. you should have received from your dealer.
This manual and safety signs on your machine may also
be available in other languages. (See your John Deere This warranty provides you the assurance that John
dealer to order.) Deere will back its products where defects appear within
the warranty period. In some circumstances, John Deere
THIS MANUAL SHOULD BE CONSIDERED a permanent also provides field improvements, often without charge
part of your machine and should remain with the machine to the customer, even if the product is out of warranty.
when you sell it. Should the equipment be abused, or modified to change
its performance beyond the original factory specifications,
MEASUREMENTS in this manual are given in both the warranty will become void and field improvements
metric and customary U.S. unit equivalents. Use only may be denied. Setting fuel delivery above specifications
correct replacement parts and fasteners. Metric and inch or otherwise overpowering machines will result in such
fasteners may require a specific metric or inch wrench. action.
RIGHT­HAND AND LEFT­HAND sides are determined by THE TIRE MANUFACTURER’S warranty supplied with
facing in the direction of forward travel. your machine may not apply outside the U.S.
WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) If you are not the original owner of this machine, it is in
in the Machine Numbers section. Accurately record all your interest to contact your local John Deere dealer to
the numbers to help in tracing the machine should it be inform them of this unit’s serial number. This will help John
stolen. Your dealer also needs these numbers when you Deere notify you of any issues or product improvements.
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
DX,IFC7 ­19­03APR09­1/1

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 Introduction

Emission Control Statement

EMISSIONS CONTROL WARRANTY STATEMENT FOR
NEW JOHN DEERE CONSTRUCTION EQUIPMENT (U.S. AND CANADA)
To determine if the engine in your machine qualifies for the additional warranties set forth below, look for the "Engine Information"
label located on your engine. If you reside in the United States and the engine label states: "Engine conforms to
US EPA regulations on heavy duty non road diesel cycle engines," you are entitled to the "U.S. Emission Control Warranty
Statement." If you reside in California, and the engine label states: "Engine conforms to California regulations on heavy duty
non road diesel cycle engines," you are entitled to the "California Emission Control Warranty Statement."
U.S. EPA EMISSIONS CONTROL WARRANTY STATEMENT
Emissions control-related parts and components are warranted Operator's Manual. John Deere recommends that you retain all
by John Deere for five years or 3000 hours of operation, whichever receipts covering maintenance on your heavy-duty engine, but
occurs first. John Deere further warrants that the engine covered John Deere cannot deny warranty solely for the lack of receipts
by this warranty was designed, built, and equipped so as to or for your failure to ensure the performance of all scheduled
conform at the time of sale with all U.S. emissions standards at maintenance.
the time of manufacture, and that it is free of defects in materials
and workmanship which would cause it not to meet these However, as the heavy-duty engine owner, you should be aware
standards within the period of five years or 3000 hours of that John Deere may deny you warranty coverage if your heavy-
operations, whichever occurs first. duty engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine Your engine is designed to operate on diesel fuel only. Use of
warranty, less emisions-related parts and components, is any other fuel may result in your engine no longer operating in
provided separately as "John Deere "Secure Warranty" For New compliance with California's emissions requirements.
Construction Products."
You are responsible for initiating the warranty process. The CARB
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT suggests that you present your machine to the nearest authorized
YOUR WARRANTY RIGHTS AND OBLIGATIONS John Deere dealer as soon as a problem is suspected. The
warranty repairs should be completed by the service dealer as
The California Air Resources Board (CARB) and John Deere are expeditiously as possible.
pleased to explain the emission control system on your new If you have any questions regarding your warranty rights and
engine. In California, new heavy-duty engines must be designed, responsibilities, you should contact John Deere at 1-319-292-
built and equipped to meet the State's stringent anti-smog 5400, or the State of California Air Resources Board, Mobile Source
standards. John Deere must warrant the emission control system Operation Division, PO Box 8001, El Monte, CA 91731-2900
on your engine for the periods of time listed below provided there
has been no abuse, neglect, or improper maintenance of your The warranty period begins on the date the machine is delivered
machine. to an ultimate purchaser, or when otherwise put into service.
John Deere warrants to the ultimate purchaser and each
subsequent purchaser that the engine is designed, built and
Your emissions control system includes: equipped so as to conform with all applicable regulations adopted
by the Air Resources Board, and that it is free from defects in
Fuel Metering System materials and workmanship which would cause the failure of a
Fuel Injection System warranted part.
Air Induction System Any warranted part which is scheduled for replacement as
Intake Manifold required maintenance by the operator's manual is warranted by
Turbocharger System John Deere for the period of time prior to the first scheduled
Charge Air Cooling System replacement point for that part. If the part fails prior to the first
scheduled replacement point, the part shall be repaired or
Miscellaneous Items used in Above Systems replaced under warranty. Any such part repaired or replaced
under warranty is warranted for the remainder of the period prior
to the first scheduled replacement point for that part.
Where a warrantable condition exists, i.e. failure due to defect in
John Deere-supplied material and/or workmanship, John Deere Any warranted part which is not scheduled for replacement as
will repair your heavy-duty engine at no cost to you including required maintenance, or which is scheduled only for regular
diagnosis, parts and labor inspection to the effect of repairing or replacing as necessary, is
warranted for the warranty period.
JOHN DEERE'S WARRANTY COVERAGE:
Repair or replacement of a warranted part will be performed at no
The emission control system of your heavy-duty engine is charge to you by an authorized John Deere dealer. You will not
warranted for five years or 3000 hours of operation, whichever be charged for diagnostic labor which leads to the determination
occurs first. If any emission-related part on your engine is that a warranted part is defective, if the diagnostic work is
defective, the part will be repaired or replaced by John Deere. performed by a John Deere dealer.
Warranties stated on this certificate refer only to emissions-related
parts and components of your engine. The complete machine John Deere is liable for damages to other engine components
T132126 —19—28JUN00

warranty, less emissions-related parts and components, is caused by failure under warranty of any warranted part.
provided separately as the "John Deere "Secure Warranty" For John Deere is NOT liable for travel or mileage on extended
New Construction Products." emissions warranty service calls.
OWNER'S WARRANTY RESPONSIBILITIES: Any replacement part may be used in the performance of any
maintenance or repairs, and such use will not reduce the warranty
As the heavy-duty engine owner, you are responsible for the obligations of John Deere. However, the use of add-on or
performance of the required maintenance as outlined in the modified parts are grounds for disallowing a warranty claim.

OUO1065,000006C ­19­08JAN08­1/1

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 Introduction

Technical Information Feedback Form

We need your help to continually improve our technical
publications. Please copy this page and FAX or mail your
comments, ideas and improvements.
SEND TO: John Deere Dubuque Works
18600 South John Deere Road
Attn: Publications, Dept. 324
Dubuque, IA 52004­0538
USA

FAX NUMBER: 1­563­589­5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:

THANK YOU!
TX,II,FAX ­19­10JUL01­1/1

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 Contents
Page Page

Safety—Safety and Operator Conveniences Safety Signs ......................................................1­5­2

Safety and Operator Convenience Features .....1­1­1 Replace Safety Signs ........................................1­5­3

Safety—General Precautions Operation—Operator’s Station

Recognize Safety Information ...........................1­2­1 Levers................................................................2­1­1
Follow Safety Instructions..................................1­2­1 Pedals................................................................2­1­2
Operate Only If Qualified ...................................1­2­1 Monitor Panel (CMU).........................................2­1­3
Wear Protective Equipment...............................1­2­2 Monitor Panel Functions ...................................2­1­4
Avoid Unauthorized Machine Modifications.......1­2­2 Switch Pad ........................................................2­1­6
Add Cab Guarding For Special Uses ................1­2­2 Switch and Accessory Functions ......................2­1­7
Inspect Machine ................................................1­2­3 Monitor Display Unit—Accessory Menu
Stay Clear of Moving Parts................................1­2­3 Normal Display..............................................2­1­8
Avoid High­Pressure Fluids ...............................1­2­3 Monitor Display Unit—Main Menu .....................2­1­9
Avoid High­Pressure Oils ..................................1­2­4 Monitor Display Unit—Main Menu—Codes .....2­1­10
Work In Ventilated Area.....................................1­2­4 Monitor Display Unit—Main
Prevent Fires .....................................................1­2­5 Menu—Codes—Active Codes ....................2­1­10
Prevent Battery Explosions ...............................1­2­5 Monitor Display Unit—Main
Handle Chemical Products Safely .....................1­2­5 Menu—Codes—Stored Codes....................2­1­11
Dispose of Waste Properly ................................1­2­6 Monitor Display Unit—Main
Prepare for Emergencies...................................1­2­6 Menu—Machine Settings ............................2­1­11
Clean Debris from Machine ...............................1­2­6 Monitor Display Unit—Main
Menu—Machine Settings—Quick Shift .......2­1­12
Monitor Display Unit—Main
Safety—Operating Precautions Menu—Machine Settings—Auto to 1st .......2­1­12
Use Steps and Handholds Correctly .................1­3­1 Monitor Display Unit—Main
Start Only From Operator’s Seat.......................1­3­1 Menu—Machine Settings—Job
Use and Maintain Seat Belt ...............................1­3­1 Timer ...........................................................2­1­13
Prevent Unintended Machine Movement ..........1­3­1 Monitor Display Unit—Main
Avoid Worksite Hazards ....................................1­3­2 Menu—Machine Settings—Stopwatch........2­1­13
Use Special Care When Operating Loader .......1­3­2 Monitor Display Unit—Main
Keep Riders Off Machine ..................................1­3­3 Menu—Diagnostics .....................................2­1­13
Avoid Backover Accidents .................................1­3­3 Monitor Display Unit—Main
Avoid Machine Tip Over ....................................1­3­4 Menu—Diagnostics—Battery
Operating on Slopes..........................................1­3­4 Monitor ........................................................2­1­14
Operating or Traveling On Public Roads...........1­3­5 Monitor Display Unit—Main
Inspect and Maintain ROPS ..............................1­3­5 Menu—Diagnostics—Engine
Add and Operate Attachments Safely ...............1­3­5 Sensors .......................................................2­1­15
Monitor Display Unit—Main
Safety—Maintenance Precautions Menu—Diagnostics—Transmission ............2­1­16
Park And Prepare For Service Safely................1­4­1 Monitor Display Unit—Main
Service Cooling System Safely .........................1­4­1 Menu—Diagnostics—Hydraulic ..................2­1­17
Remove Paint Before Welding or Heating.........1­4­2 Monitor Display Unit—Main
Make Welding Repairs Safely ...........................1­4­2 Menu—Diagnostics—Machine....................2­1­17
Drive Metal Pins Safely .....................................1­4­2 Monitor Display Unit—Main
Menu—Diagnostics—Machine
Safety—Safety Signs Switches......................................................2­1­18
Safety Signs ......................................................1­5­1

Continued on next page

Original Instructions. 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.
COPYRIGHT © 2010
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ® Manual
Previous Editions
Copyright © 2005, 2006, 2008, 2009

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 Contents

Page Page

Monitor Display Unit—Main Towing Procedure............................................2­2­21

Menu—Diagnostics—Switch Lifting the Machine ..........................................2­2­23
Module ........................................................2­1­19
Monitor Display Unit—Main Maintenance—Machine
Menu—Diagnostics—Machine Diesel Fuel.........................................................3­1­1
I.D................................................................2­1­19 Lubricity of Diesel Fuel ......................................3­1­1
Monitor Display Unit—Main Handling and Storing Diesel Fuel ......................3­1­2
Menu—Monitor Settings..............................2­1­20 Biodiesel Fuel ....................................................3­1­3
Monitor Display Unit—Main Low Sulfur Diesel Fuel Conditioner ...................3­1­4
Menu—Monitor Settings—Units..................2­1­20 Testing Diesel Fuel ............................................3­1­4
Monitor Display Unit—Main Minimizing the Effect of Cold Weather
Menu—Monitor Settings—Backlighting.......2­1­20 on Diesel Engines .........................................3­1­5
Monitor Display Unit—Main Alternative and Synthetic Lubricants .................3­1­6
Menu—Monitor Settings—LCD Diesel Engine Oil ...............................................3­1­6
Contrast.......................................................2­1­21 Diesel Engine Oil and Filter Service Intervals ...3­1­7
Horn Button .....................................................2­1­21 Transmission, Park Brake, and
Turn Signals ....................................................2­1­21 Differential Oil................................................3­1­8
Air Conditioning Controls and Heater Hydraulic Reservoir Oil......................................3­1­8
Operation ....................................................2­1­22 Grease...............................................................3­1­9
Adjusting Steering Wheel Tilt ..........................2­1­22 Heavy Duty Diesel Engine Coolant .................3­1­10
Opening and Securing Side Door....................2­1­23
Opening Side Window/Secondary Exit............2­1­24
Opening Rear Side Window ............................2­1­24 Maintenance—Periodic Maintenance
Adjusting Seat .................................................2­1­25 Service Your Machine at Specified Intervals .....3­2­1
Seat Belt ..........................................................2­1­25 Check Hour Meter Regularly .............................3­2­1
Prepare Machine for Maintenance ....................3­2­2
Opening Engine Side Shields and
Operation—Operating the Machine Service Doors................................................3­2­3
Inspect Machine Daily Before Starting ..............2­2­1 Locking Machine Frame ....................................3­2­3
Check Instruments Before Starting....................2­2­1 Boom Lock.........................................................3­2­4
Starting the Engine ............................................2­2­2 Pin Removal—If Equipped With
Starting Fluid—If Equipped (Cold Powerllel Linkage ..........................................3­2­5
Weather Starting Aid)....................................2­2­3 Opening Grille Door...........................................3­2­5
Engine Heater—If Equipped..............................2­2­4 Check Windshield Washer Fluid Level ..............3­2­6
Using Coolant Heater—If Equipped ..................2­2­4 Fluid Analysis Program Test Kits and
Warm­Up ...........................................................2­2­4 3­Way Coolant Test Kit..................................3­2­6
Cold Weather Warm­Up ....................................2­2­4 Service Intervals ................................................3­2­7
Neutral Lock ......................................................2­2­5 Required Parts...................................................3­2­9
Shifting the Transmission ..................................2­2­5
Park Brake Switch .............................................2­2­6
Boom and Bucket Control Lever—One Maintenance—As Required
Lever Design .................................................2­2­7 Check Tire Pressure..........................................3­3­1
Boom and Bucket Control Lever Tire Pressures (444J Z­Bars and High Lifts) .....3­3­2
Two Lever Design .........................................2­2­8 Tire Pressures (444J Powerllels and
Quick Shift Switch..............................................2­2­9 Tool Carriers).................................................3­3­3
Ride Control—If Equipped...............................2­2­10 Tire Pressures (544J Z­Bars and High Lifts) .....3­3­4
Secondary Steering—If Equipped ...................2­2­11 Tire Pressures (544J Powerllels and
Differential Lock Switch ...................................2­2­12 Tool Carriers).................................................3­3­5
Boom Height Kickout Adjustment ....................2­2­12 Tire Pressures (624J Z­Bars and High Lifts) .....3­3­6
Return­to­Carry Kickout Adjustment................2­2­12 Tire Pressures (624J Powerllels and
Return­To­Dig Adjustment for Z­Bar Tool Carriers).................................................3­3­7
Linkage Only ...............................................2­2­13 Tighten Wheel Retainer Nuts ............................3­3­8
Return­To­Dig Adjustment—If Clean or Replace Air Cleaner Elements............3­3­9
Equipped With Powerllel Linkage................2­2­14 Drain and Clean Primary Fuel Filter ................3­3­10
Using the Loader Bucket .................................2­2­15 Check Cab Fresh Air Filter—If
Backdragging...................................................2­2­16 Equipped With Cab .....................................3­3­10
Fork Attachment ..............................................2­2­17 Check Cab Recirculating Air Filter—If
Parking the Machine........................................2­2­18 Equipped With Cab .....................................3­3­13
Loading Machine on a Trailer ..........................2­2­19 Inspect Serpentine Belt ...................................3­3­14
Replace Final Fuel Filter..................................3­3­14

Continued on next page

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 Contents

Page Page

Draining the Cooling System ...........................3­10­1

Maintenance—Every 10 Hours or Daily Filling the Cooling System ...............................3­10­2
Check Recovery Tank Coolant Level.................3­4­1 Change Transmission Oil ................................3­10­3
Clean Air Cleaner Dust Unloader Valve ............3­4­1 Change Front and Rear
Check Engine Oil Level .....................................3­4­2 Differential/Axle Oil......................................3­10­4
Check Hydraulic Oil Level .................................3­4­3 Clean Axle Differential Recirculation Screen...3­10­5
Check Transmission Oil Level ...........................3­4­4 Re­Run Clutch Calibration...............................3­10­6

Maintenance—Every 100 Hours Maintenance—Every 4000 Hours

Grease Loader Linkage and Cylinder Pivots .....3­5­1 Change Hydraulic Oil.......................................3­11­1
Grease Front Steering Cylinder Pivots ..............3­5­4 Clean Hydraulic System Strainer.....................3­11­2
Grease Oscillating Rear Axle and Rear
Steering Cylinder Pivots................................3­5­4 Maintenance—Every 4500 Hours
Replace Engine Crankshaft Dampener
Maintenance—Initial Service ­ 250 Hours (544J and 624J Only)..................................3­12­1
Change Engine Break­In Oil and
Replace Filter ................................................3­6­1 Miscellaneous—Machine
Change Front and Rear Bleed the Fuel System ......................................4­1­1
Differential/Axle Oil........................................3­6­2 Precautions for Alternator and Regulator ..........4­1­3
Handling, Checking, and Servicing
Maintenance—Every 250 Hours Batteries Carefully.........................................4­1­4
Grease Front Driveline Sliding Joint ..................3­7­1 Using Booster Batteries—24­Volt System .........4­1­5
Check Surge Tank Level....................................3­7­2 Using Battery Charger .......................................4­1­6
Take Engine Oil Sample ....................................3­7­2 Replacing Batteries ...........................................4­1­6
Removing Batteries ...........................................4­1­7
Maintenance—Every 500 Hours Replacing Fuses................................................4­1­7
Lubricate Upper and Lower Drive Line Sliding Fuse (Blade­Type) Color Codes ........................4­1­9
Joints .................................................................3­8­1 Replacing Halogen Bulbs ................................4­1­10
Check Air Intake Hoses .....................................3­8­2 Engine Speeds ................................................4­1­10
Check Battery Electrolyte Level and Checking Neutral Start System .......................4­1­11
Terminals.......................................................3­8­2 Servicing Air Conditioning System ..................4­1­11
Change Engine Oil and Replace Filter ..............3­8­4 Welding on Machine ........................................4­1­11
Replace Primary Fuel Filter ...............................3­8­5 External Service Brake
Replace Primary Fuel Filter Strainer Inspection—444J (S.N. —604689),
(444J, S.N. 598949—; 544J, 624J, 544J, 624J...................................................4­1­12
S.N. 598854—) .............................................3­8­5 External Service Brake
Replace Final Fuel Filter....................................3­8­5 Inspection—444J (S.N. 604690— ) ............4­1­13
Replace Hydraulic System Return Filter............3­8­6 Checking Brake Accumulators—444J
Grease Rear Oscillating Support Cover ............3­8­6 (S.N. —604689), 544J, 624J.......................4­1­14
Replace Hydraulic Reservoir Breather Filter .....3­8­6 Checking Brake Accumulators—444J
Check Park Brake Oil Level...............................3­8­7 (S.N. 604690— ) .........................................4­1­14
Check Front and Rear Differential/Axle Checking Ride Control Accumulator—If
Oil Level ........................................................3­8­7 Equipped .....................................................4­1­15
Take Fluid Samples ...........................................3­8­8 Transmission Cooler and Radiator
External Cleaning Procedure ......................4­1­16
Service Recommendations For
Maintenance—Every 1000 Hours Snap­To­Connect (STC®) Fittings ..............4­1­17
Clean Engine Crankcase Vent Tube .................3­9­1 Do Not Service Control Valves,
Replace Air Cleaner Dust Unloader Valve.........3­9­1 Cylinders, Pumps or Motors........................4­1­18
Replace Air Cleaner Elements ..........................3­9­2 Hardware Torque Specifications......................4­1­18
Replace Transmission Oil Filter.........................3­9­3 Keep ROPS Installed Properly ........................4­1­18
Check Coolant ...................................................3­9­4 Metric Bolt and Screw Torque Values..............4­1­19
Check Radiator Hoses.......................................3­9­5 Unified Inch Bolt and Screw Torque Values.....4­1­20
Grease Frame Hinge Pivots ..............................3­9­5
Change Park Brake Oil......................................3­9­6
Miscellaneous—Operational Checkout
Operational Checkout........................................4­2­1
Maintenance—Every 2000 Hours
Adjust Engine Valve Lash (Clearance) ............3­10­1

Continued on next page

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 Contents

Page

Miscellaneous—Troubleshooting
Troubleshooting Procedure ...............................4­3­1
Diagnostic Trouble Codes Quick
Reference List ...............................................4­3­2
Engine ...............................................................4­3­6
Diagnose
Transmission System Malfunctions...............4­3­8
Differential And Axle Malfunctions ..............4­3­10
Service Brake Malfunctions.........................4­3­11
Drive Line Malfunctions...............................4­3­11
Park Brake Malfunctions .............................4­3­12
Loader Hydraulic System Malfunctions.......4­3­13
Steering Malfunctions..................................4­3­14
Air Conditioning System ..................................4­3­15
Heater System.................................................4­3­16

Miscellaneous—Storage
Prepare Machine For Storage ...........................4­4­1
Monthly Storage Procedure...............................4­4­1

Miscellaneous—Machine Numbers
Record Product Identification Number (PIN) .....4­5­1
Record Engine Serial Number...........................4­5­1
Record Transmission Serial Number.................4­5­1
Record Hydraulic Pump Serial Number.............4­5­2
Record Axle Serial Number ...............................4­5­2
Keep Machines Secure .....................................4­5­3
Keep Proof of Ownership ..................................4­5­3

Miscellaneous—Specifications
444J Specifications............................................4­6­1
444J Tool Carrier Specifications ........................4­6­3
444J High Lift Specifications .............................4­6­5
444J Powerllel Specifications ............................4­6­7
444J Drain and Refill Capacities .......................4­6­8
544J Specifications............................................4­6­9
544J Tool Carrier Specifications ......................4­6­11
544J High Lift Specifications ...........................4­6­13
544J Powerllel Specifications ..........................4­6­15
544J Drain and Refill Capacities .....................4­6­16
624J Specifications..........................................4­6­17
624J Tool Carrier Specifications ......................4­6­19
624J High Lift Specifications ...........................4­6­21
624J Powerllel Specifications ..........................4­6­23
624J Drain and Refill Capacities .....................4­6­24

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 Safety—Safety and Operator Conveniences
Safety and Operator Convenience Features

TX1004727 —UN—13MAR06
Please remember, the operator is the key to preventing 7. Articulation Locking Bar. A self­storing mechanical
accidents. lock is provided for transport or service.
8. Handholds. Large, conveniently placed handholds
1. ROPS, FOPS, and OPS. Structures designed to help make it easy to enter or exit the operator’s station or
protect the operator are certified to ISO, SAE, and service area.
OSHA. Enclosures also deflect sun and rain. 9. Horn. Standard horn is useful when driving or
2. Pressurized Cab with Heater/Defroster. Positive signaling coworkers.
pressure ventilation system circulates both outside 10. Independent Parking Brake. Electronically controlled
and inside air through filters for a clean working and engages whenever the engine is stopped.
environment. Built in defroster vents direct air flow for 11. Seat Belt Retractors. Seat belt retractors help keep
effective window defogging/deicing. belts clean and convenient to use.
3. Mirrors. Large exterior mirrors on both sides and 12. Bypass Start Protection. Shielding over the starter
an inside mirror offers operator a broad view of area terminals helps prevent dangerous bypass starting.
behind machine. 13. Engine Fan Guard. A secondary fan guard inside the
4. Large Windshield Wiper with Washer. Extra long engine compartment helps prevent contact with the
wiper cleans large windshield area. rotating fan blades.
5. Loader Boom Service Lock. Loader includes a 14. Back Up Alarm. Alerts bystanders when reverse
mechanical lock for securing boom in the raised travel direction is selected by operator.
position before work is started on or around the 15. Stop and Signal Lights. Highly visible stop lights are
machine. standard equipment.
6. Halogen Lights and Turn Signals. High intensity
halogen drive/work lights and high­visibility turn
signals are standard equipment.
MM61211,000142D ­19­21JUN10­1/1

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 Safety—General Precautions
Recognize Safety Information
This is the safety alert symbol. When you see this

T133555 —UN—28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION —
is used with the safety alert symbol. DANGER identifies
the most serious hazards.
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are

T133588 —19—28AUG00
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.

TX03679,00016CC ­19­03NOV08­1/1

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
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are

TS201 —UN—23AUG88
available from your John Deere dealer.
There can be additional safety information contained on
parts and components sourced from suppliers that is not
reproduced in this operator’s manual.
Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition.
If you do not understand any part of this manual and need
Unauthorized modifications to the machine may impair the
assistance, contact your John Deere dealer.
function and/or safety and affect machine life.
DX,READ ­19­16JUN09­1/1

Operate Only If Qualified

Do not operate this machine unless you have read the Know and observe all safety rules that may apply to your
operator’s manual carefully and you have been qualified work situation and your work site.
by supervised training and instruction.
Familiarize yourself with the job site and your surroundings
before operating. Try all controls and machine functions
with the machine in an open area before starting to work.
TX03679,00016FA ­19­03NOV08­1/1

1­2­1 PN=10
072310
 Safety—General Precautions

Wear Protective Equipment

Guard against injury from flying pieces or metal or debris;
wear goggles or safety glasses.
Wear close fitting clothing and safety equipment
appropriate to the job.

TS206 —UN—23AUG88
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises. Radio or music headphones
are not suitable to use for hearing protection.
OUT4001,0000570 ­19­12FEB10­1/1

Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere reliability, and may create a hazard for the operator or
replacement parts to ensure machine performance. others near the machine. The installer of any modification
Never substitute genuine John Deere parts with alternate which may affect the electronic controls of this machine is
parts not intended for the application as these can responsible for establishing that the modification does not
create hazardous situations or hazardous performance. adversely affect the machine or its performance.
Non­John Deere Parts, or any damage or failures
resulting from their use are not covered by any John Always contact an authorized John Deere dealer before
Deere warranty. making machine modifications that change the intended
use, weight or balance of the machine, or that alter
Modifications of this machine, or addition of unapproved machine controls, performance or reliability.
products or attachments, may affect machine stability or
AM40430,00000A9 ­19­14JAN08­1/1

Add Cab Guarding For Special Uses

Special work situations or machine attachments may
create an environment with falling or flying objects.
Loading logs, using fork attachments, or operating in
waste management applications requires special work
tools. Added cab guarding to protect the operator may

T141893 —UN—04MAY01
also be required.
Use load­clamping grapples to keep bulky loads from
falling and add special screens or guarding when objects
may be directed toward the cab. Contact your authorized
John Deere dealer for information on devices intended to
protect the operator from falling or flying objects in special
work situations.
TX03679,00017C6 ­19­18OCT07­1/1

1­2­2 PN=11
072310
 Safety—General Precautions

Inspect Machine
Inspect machine carefully each day by walking around it
before starting.
Keep all guards and shields in good condition and properly
installed. Fix damage and replace worn or broken parts

T6607AQ —UN—18OCT88
immediately. Pay special attention to hydraulic hoses and
electrical wiring.

TX03679,0001734 ­19­03NOV08­1/1

Stay Clear of Moving Parts

T133592 —UN—12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining
any part of machine with moving parts.
Keep guards and shields in place. Replace any guard
or shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 ­19­03NOV08­1/1

Avoid High­Pressure Fluids

Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all

X9811 —UN—23AUG88
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from high­pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable
medical source. Such information is available in Moline, Illinois, U.S.A., by calling 1­800­822­8262 or +1
English from Deere & Company Medical Department in 309­748­5636.
DX,FLUID ­19­20AUG09­1/1

1­2­3 PN=12
072310
 Safety—General Precautions

Avoid High­Pressure Oils

This machine uses a high­pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.

T133509 —UN—17MAR06
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.

T133840 —UN—20SEP00
TX03679,00016D3 ­19­03NOV08­1/1

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.

TS220 —UN—23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.

DX,AIR ­19­17FEB99­1/1

1­2­4 PN=13
072310
 Safety—General Precautions

Prevent Fires

T133552 —UN—14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
T133553 —UN—07SEP00
materials inside a machine compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a
multipurpose fire extinguisher on or near the machine.
Know how to use extinguisher properly. T133554 —UN—07SEP00

TX03679,00016F5 ­19­03NOV08­1/1

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,
and open flame away from the top of battery.
Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.

TS204 —UN—23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).

TX03679,000174A ­19­03NOV08­1/1

Handle Chemical Products Safely

Exposure to hazardous chemicals can cause serious
T133580 —UN—25AUG00

injury. Under certain conditions, lubricants, coolants,

paints and adhesives used with this machine may be
hazardous.
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 ­19­03JAN07­1/1

1­2­5 PN=14
072310
 Safety—General Precautions

Dispose of Waste Properly

Improper disposal of waste can threaten the environment.

T133567 —UN—25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants can damage the atmosphere.
Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your
local environmental or recycling center or your dealer for
more information.
TX03679,0001733 ­19­03NOV08­1/1

Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your telephone.

TS291 —UN—23AUG88
TX03679,000174B ­19­03NOV08­1/1

Clean Debris from Machine

Keep engine compartment, radiator, batteries, hydraulic
lines, exhaust components, fuel tank, and operator’s
station clean and free of debris.
Clean any oil spills or fuel spills on machine surfaces.

T6669AG —UN—18OCT88
Temperature in engine compartment may go up
immediately after engine is stopped. BE ON GUARD
FOR FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean
engine compartment.

OUT4001,00000E3 ­19­20AUG09­1/1

1­2­6 PN=15
072310
 Safety—Operating Precautions
Use Steps and Handholds Correctly
Prevent falls by facing the machine when getting on and

T133468 —UN—30AUG00
off. Maintain 3­point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.

TX03679,00016F2 ­19­15MAR07­1/1

Start Only From Operator’s Seat

T133715 —UN—07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.

TX03679,0001799 ­19­22APR10­1/1

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to

T133716 —19—14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
Examine seat belt frequently. Be sure webbing is not
cut or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced
every 3 years, regardless of appearance.
TX03679,00016DD ­19­03NOV08­1/1

Prevent Unintended Machine Movement

When coworkers are present, disable hydraulics.
Lower all equipment to the ground during work
T142001 —UN—15MAY01

interruptions. Lock transmission control in neutral, engage

park brake and stop engine before allowing anyone to
approach the machine.
Follow these same precautions before standing up,
leaving the operator’s seat, or exiting the machine.

TX03679,00017C7 ­19­08MAR07­1/1

1­3­1 PN=16
072310
 Safety—Operating Precautions

Avoid Worksite Hazards

Avoid contact with gas lines, buried cables and water
lines. Call utility line location services to identify all

T192984 —UN—26AUG03
underground utilities before starting work.
Prepare worksite properly. Avoid operating near
structures or objects that could fall onto the machine.
Clear away debris that could move unexpectedly if run
over.
Avoid boom or attachment contact with overhead
obstacles or overhead electrical lines. Never move
machine closer than 3 m (10 ft) plus twice the line insulator
length to overhead wires.
Keep bystanders clear at all times. Keep bystanders
away from raised booms, attachments and unsupported
loads. Avoid swinging or raising booms, attachments, or

T141904 —UN—15MAY01
loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a
signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient
to support machine. Be especially alert working near
embankments or excavations.
snow removal or clearing mud, dirt, etc.). At high speeds
Avoid working under over­hanging embankments or hitting obstacles (rocks, uneven concrete or manholes)
stockpiles that could collapse under or on machine. can cause a sudden stop. Always wear your seat belt.
Reduce machine speed when operating with tool on or
near ground when obstacles may be hidden (e.g., during
AM40430,0000098 ­19­15JUN10­1/1

Use Special Care When Operating Loader

Never use the loader to lift people. Do not allow
anyone to ride in the bucket or use the bucket as a

T141957 —UN—15MAY01
work platform.
Operate carefully with raised loads. Raising the load
reduces machine stability, especially on side slopes or an
unstable surface. Drive and turn slowly with a raised load.
Ensure that objects in the bucket are secure. Do not
attempt to lift or carry objects that are too big or too long
to fit inside the bucket unless secured with an adequate
chain or other device. Keep bystanders away from raised
loads.
Be careful when lifting objects. Never attempt to lift
T141902 —UN—07MAY01

objects too heavy for your machine. Assure machine

stability and hydraulic capability with a test lift before
attempting other maneuvers. Use an adequate chain or
sling and proper rigging techniques to attach and stabilize
loads. Never lift an object above or near another person.

TX03768,0000B70 ­19­14MAY01­1/1

1­3­2 PN=17
072310
 Safety—Operating Precautions

Keep Riders Off Machine

Only allow operator on machine.
Riders are subject to injury. They may fall from machine,

T141671 —UN—04MAY01
be caught between machine parts, or be struck by foreign
objects.
Riders may obstruct operator’s view or impair his ability
to operate machine safely.

TX03679,000179B ­19­20APR01­1/1

Avoid Backover Accidents

Before moving machine, be sure all persons are clear
of machine path. Turn around and look directly for best

T141673 —UN—04MAY01
visibility. Use mirrors to assist in checking all around
machine. Keep windows and mirrors clean, adjusted, and
in good repair.
Be certain reverse warning alarm is working properly.
Use a signal person when backing if view is
obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03679,000179C ­19­20APR01­1/1

1­3­3 PN=18
072310
 Safety—Operating Precautions

Avoid Machine Tip Over

Use seat belt at all times.

T133716 —19—14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Be careful on slopes. Avoid sharp turns. Balance loads
so weight is evenly distributed and load is stable. Carry
tools and loads close to the ground to aid visibility and
lower center of gravity. Use extra care on soft, rocky or
frozen ground.

T141676 —UN—04MAY01
Know the capacity of the machine. Do not overload. Be
careful with heavy loads. Using oversize buckets or lifting
heavy objects reduces machine stability.
Ensure solid footing. Use extra care in soft ground
conditions that may not uniformly support the wheels,
especially when raising the boom. Do not operate close to
banks or open excavations that may cave in and cause
machine to tip or fall.

T141672 —UN—04MAY01
TX03679,000179D ­19­02MAY01­1/1

Operating on Slopes
Avoid side slope travel whenever possible. Drive up steep
slope in forward and down in reverse.

T141681 —UN—30APR01
Select low gear speed before starting down slope. The
grade of the slope will be limited by ground condition and
load being handled.
Use service brakes to control speed. Sudden brake
application with a loaded bucket on downhill side could
cause machine to tip forward.
TX03679,000179E ­19­14MAY01­1/1

1­3­4 PN=19
072310
 Safety—Operating Precautions

Operating or Traveling On Public Roads

Machines that work near vehicle traffic or travel slower
than normal highway speeds must have proper lighting

T141891 —UN—22MAY01
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle
(SMV) emblems, or other devices and use as required
to make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
TX03679,00017C8 ­19­02MAR07­1/1

Inspect and Maintain ROPS

A damaged roll­over protective structure (ROPS) should To maintain the ROPS:
be replaced, not reused.
The protection offered by ROPS will be impaired if ROPS
• Replace missing hardware using correct grade
hardware.
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
• Check hardware torque.
bending, drilling, or cutting.
• Check isolation mounts for damage, looseness or wear;
replace them if necessary.
If ROPS was loosened or removed for any reason, inspect • Check ROPS for cracks or physical damage.
it carefully before operating the machine again.
TX03679,000179F ­19­07SEP06­1/1

Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting is required or recommended. Verify that all connections
your authorized dealer. Adding unapproved attachments are secure and attachment responds properly to controls.
may affect machine stability or reliability, and may create
a hazard for others near the machine. Carefully read attachment manual and follow all
instructions and warnings. In an area free of bystanders
Ensure that a qualified person is involved in attachment and obstructions, carefully operate attachment to learn its
installation. Add guards to machine if operator protection characteristics and range of motion.
TX03679,00016F0 ­19­24JAN07­1/1

1­3­5 PN=20
072310
 Safety—Maintenance Precautions
Park And Prepare For Service Safely
Warn others of service work. Always park and prepare
your machine for service or repair properly.
• Park machine on a level surface and lower equipment
to the ground.

T133332 —19—14DEC01
• Engage park brake.
• Stop engine and remove key.
• Install articulation locking bar.
• Attach a “Do Not Operate” tag in an obvious place in
the operator’s station.
Securely support machine or attachment before working
under it.
• Do not support machine with boom, bucket, or other
hydraulically actuated equipment.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other
devices that may slip out of place.

TS229 —UN—23AUG88
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.

TX03679,00017A0 ­19­18SEP01­1/1

Service Cooling System Safely

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop

TS281 —UN—23AUG88
to relieve pressure before removing completely.

DX,RCAP ­19­04JUN90­1/1

1­4­1 PN=21
072310
 Safety—Maintenance Precautions

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:

TS220 —UN—23AUG88
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes Do all work in an area that is well ventilated to carry toxic
before welding or heating. fumes and dust away.

Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
DX,PAINT ­19­24JUL02­1/1

Make Welding Repairs Safely

IMPORTANT: Disable electrical power before

T133547 —UN—31AUG00
welding. Turn off main battery switch
or disconnect positive battery cable.
Separate harness connectors to engine
and vehicle microprocessors.

Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Make sure there is good ventilation. Wear eye protection
Remove paint properly. Do not inhale paint dust or fumes. and protective equipment when welding.
Use a qualified welding technician for structural repairs.
TX03679,00016D5 ­19­25APR08­1/1

Drive Metal Pins Safely

Always wear protective goggles or safety glasses and T133738 —UN—14SEP00
other protective equipment before striking hardened
parts. Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.

TX03679,0001745 ­19­03JAN07­1/1

1­4­2 PN=22
072310
 Safety—Safety Signs
Safety Signs

T203576 —19—05OCT04

Left Side Shown

TX03679,00017F6 ­19­30SEP04­1/1

1­5­1 072310

PN=23
 Safety—Safety Signs

Safety Signs

T203577 —19—05OCT04

Right Side Shown

HG31779,0000043 ­19­01OCT04­1/1

1­5­2 072310

PN=24
 Safety—Safety Signs

Replace Safety Signs

Replace missing or damaged safety signs. Use this
operator’s manual for correct safety sign placement.
There can be additional safety information contained on
parts and components sourced from suppliers that is not

TS201 —UN—23AUG88
reproduced in this operator’s manual.

DX,SIGNS ­19­18AUG09­1/1

1­5­3 PN=25
072310
 Operation—Operator’s Station
Levers

T194168A —UN—18SEP03
Single Lever with Auxiliary Control Design Shown with Joystick FNR

T194169A —UN—18SEP03
Two Lever with Auxiliary Control Design
HG31779,0000152 ­19­08AUG03­1/2

1— Column FNR 2— Turn Signal

T195153A —UN—25SEP03

HG31779,0000152 ­19­08AUG03­2/2

2­1­1 PN=26
072310
 Operation—Operator’s Station

Pedals
Accelerator pedal (1): Depress to increase speed of
machine.
Brake pedals (2 and 3): Depress left brake pedal (3) or

TX1012982 —UN—06OCT06
right brake pedal (2) to stop machine.
NOTE: Brake pedals also serve as clutch cutoff
pedals when clutch cutoff switch is in “clutch
disengaged” position.

Differential Lock Foot Switch (4)—If Equipped:

Depress switch (4) to lock front axle differential. Release
switch to unlock differential.
NOTE: Use differential lock only when conditions require 1— Accelerator 3— Brake/Clutch Cutoff Pedal
traction. Avoid using differential lock when steering. 2— Brake/Clutch Cutoff Pedal 4— Differential Lock Foot
Switch—If Equipped

TX,10,JC1191 ­19­18DEC06­1/1

2­1­2 PN=27
072310
 Operation—Operator’s Station

Monitor Panel (CMU)

1 2 3

4 6
5

7 8 9 10 11 12 13 14 15

T193262 —UN—21JUL03
16 17 18 19 20 21 22 23 24 25

T193262
1— Engine Coolant Temperature 8— Engine Air Filter Restriction 15— Park Brake Indicator 22— Work Lights ON Indicator—If
Gauge Indicator 16— Left Turn Indicator Equipped
2— Transmission Oil 9— Fasten Seat Belt Indicator 17— Check Engine Indicator 23— Pin Disconnect Indicator
Temperature Gauge 10— Engine Alt Volts Indicator 18— Ride Control Indicator 24— Fuel Filter Restriction
3— Hydraulic Oil Temperature 11— STOP Indicator 19— Transmission Fault Indicator Indicator
Gauge 12— Brake Pressure Indicator 20— Service Required Indicator 25— Right Turn Indicator
4— Engine Oil Pressure Gauge 13— Hydraulic Oil Filter 21— Secondary Steering Warning
5— Display Window Restriction Indicator Indicator—If Equipped
6— Fuel Gauge 14— Transmission Oil Filter
7— Engine Heater Indicator—If Indicator
Equipped

• MENU provides initial entry into machine settings, • SELECT toggles between the odometer, hour meter,
diagnostics, and monitor settings. Once a main menu and speedometer displays during normal operation.
has been selected, pressing MENU again will return to During menu modes, SELECT will activate the currently
the Normal Display Mode Menu. chosen menu, provide additional information on codes,
• BACK will back out of a menu, one item each time the make selection, reset timers, or turn on/off stop watch.
key is pressed. The BACK key will eventually return to
the normal display.
• NEXT will move to the next selection within a menu or
mode. Press NEXT to cycle through all the possible
selections in a menu.
HG31779,00002BC ­19­23JUN03­1/1

2­1­3 072310

PN=28
 Operation—Operator’s Station

Monitor Panel Functions

1—Engine Coolant Temperature Gauge: Indicator will
light, STOP indicator will flash and audible alarm will If pointer deflects to the far left side of the scale, electronic
sound when pointer is in red zone. Stop machine and communication is lost or a sensor error is active. Indicator
allow engine to cool. Shut off engine and take corrective will not light.
action. Always fill tank at the end of the day to eliminate
If pointer deflects to the far left side of the scale, electronic condensation in fuel tank.
communication is lost or a sensor error is active. Indicator 7—Engine Heater Indicator—If Equipped: If preheat
will not light. is needed, Indicator will light when key switch is
2—Hydraulic Oil Temperature Gauge: Indicator will light turned clockwise to the “On” position. Light will turn
and service required indicator will light when pointer is off approximately 15­45 seconds depending on engine
in red zone. Stop work cycle and cycle loader functions temperature, indicating that preheating is completed.
without load to lower indicator reading. If indicator still Light will turn off while cranking engine. Indicator will also
stays in red zone, stop machine and see your authorized light for approximately 15­45 seconds after engine is
dealer. running, indicating post heat.

If pointer deflects to the far left side of the scale, electronic 8—Engine Air Filter Restriction Indicator: Indicator
communication is lost or a sensor error is active. Indicator will light and service required indicator will light when air
will not light. elements are restricted.

3—Engine Oil Pressure Gauge: 9—Fasten Seat Belt Indicator: Indicator will light for
the first 5 seconds after the engine is started to warn the
IMPORTANT: Prevent possible engine damage. If operator to fasten seat belt.
engine oil pressure indicator light comes
on while operating, stop machine. STOP 10—Engine Alt Volts Indicator: Indicator will light and
ENGINE IMMEDIATELY. service required indicator will light when alternator output
is below 24 volts with engine running or below 18 volts
Indicator will flash, STOP indicator will flash, and alarm when engine is not running. Check battery charge under
will sound when engine oil pressure gauge indicates low Diagnostics—Battery Monitor on digital display.
pressure. Stop machine. STOP ENGINE IMMEDIATELY. 11—STOP Indicator:
If pointer deflects to the far left side of the scale, electronic
communication is lost or a sensor error is active. Indicator CAUTION: Prevent possible injury or machine
will not light. damage. If STOP indicator flashes and alarm
sounds, stop immediately and investigate
NOTE: Extreme steep slope (off level) operation cause of problem.
may cause indicator to light.
Indicator will light when a problem has developed.
4—Transmission Oil Temperature Gauge: If pointer is in
red zone, indicator will light, STOP indicator will flash, and 12—Brake Pressure Indicator:
audible alarm will sound indicating that the temperature
is too high. Stop machine and allow transmission to cool. CAUTION: Prevent possible injury or machine
Shut off engine and take corrective action. damage. If brake pressure indicator comes on
while operating, stop machine immediately.
If pointer deflects to the far left side of the scale, electronic
communication is lost or a sensor error is active. Indicator Indicator will flash, STOP indicator will flash, and alarm will
will not light. sound when brake oil pressure is low or brake accumulator
5—Display Window: The display window has eight has lost its charge. Stop machine immediately and push
displays: park brake switch to ON.
13—Hydraulic Oil Filter Restriction Indicator:
• Actual Gear
• Requested Gear IMPORTANT: Prevent possible hydraulic pump
• TCL (Transmission Control Lever) damage. Change hydraulic oil filter as soon
• Auto/Manual Transmission Mode as possible when a problem occurs.
• Tachometer
• Hour Meter Indicator will light and service required indicator will light
• Odometer when hydraulic filter element is restricted.
• Speedometer
NOTE: Cold oil may cause hydraulic oil filter restriction
6—Fuel Gauge: Gauge will reflect fuel level in tank. indicator to light until oil is warm.
Indicator will flash to indicate low level condition.
Continued on next page HG31779,00002BD ­19­10NOV06­1/2

2­1­4 072310

PN=29
 Operation—Operator’s Station

14—Transmission Oil Filter Indicator: Indicator will It is not necessary to stop the engine immediately but the
light and the service required indicator will light when the cause should be investigated as soon as possible.
transmission filter is restricted.
21—Secondary Steering Warning Indicator—If
15—Park Brake Indicator: Indicator will light when park Equipped:
brake is engaged.
IMPORTANT: Prevent possible damage to secondary
If transmission is shifted out of “Neutral” with engine steering system. Stop machine immediately
running and park brake engaged, the STOP indicator will if secondary steering indicator light and alarm
flash, park brake indicator will flash and alarm will sound come on while operating. THE SECONDARY
until park brake is disengaged or transmission shifted STEERING SYSTEM IS NOT INTENDED
back to neutral. FOR CONTINUOUS USE.
16—Left Turn Indicator : Indicator will light when left turn Indicator will flash, STOP indicator will flash, and alarm
signal switch or 4­way flashers switch is engaged. will sound when secondary steering system is activated.
17—Check Engine Indicator: Indicator will flash when Stop machine immediately and take corrective action. The
excessive water is present in final fuel filter or a fuel secondary steering system is not intended for continuous
system failure has been detected. STOP indicator will use.
flash, alarm will sound, and engine will derate to 50% of 22—Cab Work Lights Indicator: Indicator will light when
full power until water is drained. cab work lights switch is activated.
When water is drained, indicators and alarm will turn off 23—Pin Disconnect Indicator: Indicator will light and
and the engine will return to full power. alarm will sound every ten seconds when pin disconnect
18—Ride Control Indicator: Indicator will light when ride switch is activated to retract cylinders for removal of
control is activated. attachments.

19—Transmission Fault Indicator: Transmission fault 24—Fuel Filter Restriction Indicator:

indicator and service required indicator will light and stay NOTE: Indicator may come on during cold startups or
on when a transmission clutch slippage service code when machine is under heavy loads.
has been detected or if “limp home” mode has been
requested. The transmission will shift to “Neutral” and A flickering light is an early warning that fuel
then machine can only be moved in “limp home” mode. A filter needs to be changed.
service code will be logged in Monitor Display Unit.
Indicator will light and service required indicator will light
The indicator light will turn off when key switch has when fuel pressure drops below 300 kPa (43.5 psi).
been turned off. Every time clutch slippage occurs,
the transmission service indicator and service required If pressure drops below 200 kPa (29 psi), indicator will
indicator will light and will remain on until key switch is remain on. Service required indicator will light and engine
turned off. will derate to 50% of full power.
20—Service Required Indicator (Yellow): Indicator will 25—Right Turn Indicator: Indicator will light when right
light when a problem is developing. It is not necessary turn signal switch or 4­way flashers switch is engaged.
to stop the engine immediately, but the cause should be
investigated as soon as possible.
HG31779,00002BD ­19­10NOV06­2/2

2­1­5 072310

PN=30
 Operation—Operator’s Station

Switch Pad

T192095B —UN—18SEP03
1— Not Used 6— Cab Work Light Switch—If 11— Air Conditioning Switch—If 16— Return­to Dig Switch
2— Drive, Tail and Marker Switch Equipped Equipped 17— Boom Height Kickout Switch
3— Automatic Transmission 7— Beacon Switch—If Equipped 12— Pin Disconnect Switch—If 18— Return­to­Carry Switch
Switch 8— Axle Disconnect Switch—If Equipped 19— Rear Washer Switch
4— Ride Control Switch—If Equipped 13— Reversing Cooling Fan 20— Rear Wiper Switch
Equipped 9— Spin Control Switch—If Switch—If Equipped
5— Pilot Enable/Boom Down Equipped (Not Available on 14— Front Washer Switch
Switch 444, 544, 624 models) 15— Front Wiper Switch
10— Clutch Cut­Off Switch
AM40430,0000045 ­19­09FEB05­1/1

2­1­6 072310

PN=31
 Operation—Operator’s Station

Switch and Accessory Functions

1—Not Used
• Press switch and release until one light is illuminated
2—Drive and Marker Light Switch: The switch has to turn on front lights
three positions: • Press switch and release until two lights are illuminated
to turn on front and rear lights
• Press and release switch until one light is illuminated to • Third selection not used
turn on marker lights • Press switch and release until no lights are illuminated
• Press and release switch until two lights are illuminated to turn lights off
to turn on drive lights and marker lights
• Press and release switch until no lights are illuminated 7—Beacon Switch—If Equipped: Press and release
to turn lights off switch until light is illuminated to turn beacon light on.
Press and release switch until light is not illuminated to
NOTE: When marker or drive lights are turned on, turn beacon light off.
the backlighting of the switch pad will turn on
and the intensity of the lights will be decreased 8—Axle Disconnect Switch—If Equipped: Press and
automatically for nighttime operation. release switch until light is illuminated to disconnect front
axle. Press and release switch until light is not illuminated
When a communication fault occurs between the to connect front axle.
switch pad and Flex Load Controller (FLC) or a
stuck button condition, the marker lights, drive 9—Spin Control Switch—If Equipped (Not Available
lights, and backlighting turn on automatically. on 444, 544, 624J models)
10—Clutch Cut­Off Switch: This switch has four
3—Automatic Transmission Switch: Press and release positions:
switch until light is illuminated. The transmission is now
in “Auto” mode. Move transmission lever to 3 or 4.
Transmission will start in 2nd gear. As speed increases, CAUTION: Prevent possible injury from
transmission will automatically shift to 3rd and 4th gear. unexpected machine movement. When stopping
As load increases or speed decreases, transmission will on inclines, press switch until no lights are
automatically shift to 3rd and 2nd gear. illuminated to engage clutch cutoff before
releasing left service brake. This will prevent
NOTE: Transmission will start in first gear if ”Auto the machine from rolling downhill during
to 1st” mode is selected in Machine Settings transmission re­engagement cycle.
Menu on the display monitor.
NOTE: By turning one of these functions on, the other
Press and release switch until light is not illuminated. The two are automatically turned off.
transmission is now in manual mode.
4—Ride Control Switch—If Equipped: The switch has • Press and release switch until one light is illuminated
to turn on the Level Slope setting. On this setting the
three positions:
clutch releases with low brake pedal pressure.
• Press switch until one light is illuminated to turn ride • Press and release switch until two lights are illuminated
control on to turn on Small Slope setting. On this setting the clutch
• Press switch until two lights are illuminated to “Auto” releases with medium brake pedal pressure.
position that functions the same as the “On” position • Press and release switch until three lights are
with one exception. The ride control is turned off when illuminated to turn on Steep Slope setting. On this
ground speed is approximately 6 km/h (3—1/2 mph) setting the clutch releases with high brake pressure.
or less • Press and release switch until no lights are illuminated
• Press switch until no lights are illuminated to turn ride to disable clutch cutoff.
control off
Use the switch in situations such as truck loading where
5—Pilot Enable/Boom Down Switch: The switch has machine positioning and maximum hydraulics are needed.
three positions:
NOTE: The park brake will also disengage the
• Press and hold switch while actuating boom down to transmission clutches. Release park brake
lower boom with engine off and key switch on before operating.
• Press and release switch until light is illuminated to
unlock pilot controllers; normal operation 11—Air Conditioning Switch—If Equipped: Press
• Press and release switch until light is not illuminated to and release switch until light is illuminated to turn air
lock pilot controllers; locks hydraulic controls conditioning on. Press and release switch until light is not
illuminated to turn air conditioning off.
6—Cab Work Light Switch—If Equipped: The switch
has four positions: NOTE: Engine must be running and blower fan speed
switch must be on for air conditioning to function.
Continued on next page AM40430,0000046 ­19­09FEB05­1/2

2­1­7 072310

PN=32
 Operation—Operator’s Station

12—Pin Disconnect Switch—If Equipped: Press and 17—Boom Height Kickout Switch: The switch has three
hold switch for 2 seconds to retract cylinders for removal positions:
of attachments. The light will remain illuminated, the pin
disconnect indicator will light, and the audible alarm will • Press and release switch until one light is illuminated to
sound every ten seconds. activate boom height kickout. Pull boom lever to raise
detent position. Boom will kick­out of detent position
Press and release switch until light is not illuminated to when it reaches a preset height from ground.
extend cylinders for attachment. • While light is illuminated, press and hold switch to set
boom height. Light will flash and audible alarm will
13—Reversing Cooling Fan Switch—If Equipped: sound to indicate position has been set.
Every 30 minutes the radiator cooling fan will automatically
reverse direction for 15 seconds without intervention from
• Press and release switch until no light is illuminated to
deactivate boom height kickout
the operator. Press switch and hold for 2 seconds to turn
on “Manual” mode to manually reverse the direction of 18—Return­to­Carry Switch: The switch has three
the fan for 15 seconds. positions:
NOTE: The reversing fan function shall not be reactivated • Press and release switch until one light is illuminated
within one minute of its last completion (this to activate return­to­carry. Push boom lever to float
time includes “Automatic” cycle). position. Boom will kick­out of float position when it
reaches a preset distance from ground.
14—Front Washer Switch: Push switch to wash front • Press and hold switch to set return­to­carry height
window. Pressing switch will also activate low speed front • Press and release switch until no light is illuminated to
wiper operation. After releasing washer switch the wiper deactivate return­to­carry
blade will swipe three times and automatically turn off .
NOTE: Boom float will not work once the boom is below
15—Front Wiper Switch: The switch has four positions: preset distance from ground. Press switch to
“Off” position to activate boom float.
• Press and release switch until one light is illuminated
for intermittent front wiper operation 19—Rear Washer Switch: Push switch to wash rear
• Press and release switch until two lights are illuminated window. Pressing switch will also activate low speed rear
for low speed front wiper operation wiper operation. After releasing washer switch the wiper
• Press and release switch until three lights are blade will swipe five times and automatically turn off .
illuminated for high speed front wiper operation
• Press and release switch until no lights are illuminated 20—Rear Wiper Switch: The switch has four positions:
to turn front wipers off
• Press and release switch until one light is illuminated
16—Return­to­Dig Switch:The switch has three for intermittent rear wiper operation
positions: • Press and release switch until two lights are illuminated
for low speed rear wiper operation
• Press and release switch until one light is illuminated for • Press and release switch until three lights are
bucket position on Powerllel linkage machines only. illuminated for high speed rear wiper operation
• Press and release switch until two lights are illuminated • Press and release switch until no lights are illuminated
for fork position on Powerllel linkage machines only. to turn rear wipers off
• Press and release switch until no lights are illuminated
to turn return­to­dig off for Z­Bar linkage machines.
AM40430,0000046 ­19­09FEB05­2/2

Monitor Display Unit—Normal Display

When key switch is turned on, all lights on display monitor
will come on, all gauges will position gauge needle to the
12 o’clock position, and alarm will sound.
The basic display window will show the bulb check mode. John Deere
T193366 —UN—05AUG03

After bulb check mode, the stop indicator and engine oil 444
pressure indicator will flash.
The machine model number will show in the basic display
window.

444J Monitor Shown

Continued on next page HG31779,0000320 ­19­11AUG03­1/2

2­1­8 PN=33
072310
 Operation—Operator’s Station

Approximately five seconds later, the Normal display will

be shown.
The Actual Gear Display (1) shows the gear the 2 5
transmission has engaged when machine is not in neutral.
When a transmission controller unit failure occurs, this
display will show gear 1.
The FNR Display (2) shows the forward, neutral, reverse
status. When a transmission controller unit failure occurs,
1
4F 950 rpm
the FNR display will show neutral. 3
1234
323.3

T194715 —UN—17SEP03
The Requested Gear Display (3) shows the requested
gear position of the shift lever or gear select. AUTO ODM HOURS SPEED
The Transmission Mode Display (4) shows whether the
transmission is in "Auto" mode or “Manual” mode. When 4 6 7 8
a transmission controller unit failure occurs, this display
will show manual mode.
The Tachometer Display (5) shows the engine revolutions
per minute to the nearest fifth of a rpm. When a 1— Actual Gear Display 5— Tachometer Display
transmission controller unit malfunction occurs, a "­­­" is 2— FNR Display 6— Odometer Display
displayed. 3— Requested Gear Display 7— Hour Meter Display
4— Transmission Mode Display 8— Speedometer
NOTE: Press SELECT or NEXT to toggle between the
odometer, hour meter, and speedometer displays.
hours only when the engine is on; and the icon flashes
The Odometer Display (6) shows the odometer reading in once per second. The hour meter displays up to 99,999.9
miles/km to the nearest tenth. The odometer is capable hours.
of displaying up to 99,999.9 total kilometers or 62137.1
miles. The odometer runs only when the engine is on. The Speedometer Display (8) will show speed in
mph/km/h. When a flex load controller failure occurs, a “­
The Hour Meter Display (7) shows the machine hours to ­ ­” is displayed.
the nearest tenth of an hour. The hour meter accumulates
HG31779,0000320 ­19­11AUG03­2/2

Monitor Display Unit—Main Menu

The Main Menu provides the capability to select the next
sub menus. The Main Menu is accessed by pressing the Main Menu 1/4
MENU key. The sub menus under Main Menu include:
1-Codes
• “Codes” menu allows service personnel or operator to 2-Machine Settings
view “active” or “stored” diagnostic trouble codes. T194565 —19—30SEP03
• “Machine Settings” menu allows the operator to make 3-Diagnostics
changes to various operating characteristics of the
machine. 4-Monitor Settings
• “Diagnostics” menu provides a limited set of tools, and is
intended to be used by service personnel and machine
operator’s for diagnostic and troubleshooting functions.
• “Monitor Settings” menu allows the operator to make
changes to various operating characteristics of the
monitor.
HG31779,0000309 ­19­11AUG03­1/1

2­1­9 PN=34
072310
 Operation—Operator’s Station

Monitor Display Unit—Main Menu—Codes

The Codes menu provides the capability to select the next
sub menus. Codes 1/2
At the Main Menu with “1­Codes” highlighted, press 1-Active Codes
SELECT to display sub menu.
2-Stored Codes

T193353 —19—22SEP03
HG31779,000030A ­19­11AUG03­1/1

Monitor Display Unit—Main

Menu—Codes—Active Codes
The Active Code sub menu will display up to twenty of the Active Codes 1/3
latest Diagnostic Trouble Codes that are currently active
on the machine. As the diagnostic codes are resolved or Right Turn Lts

T193355 —19—30SEP03
fixed, the code will be removed from the active code list.
High Current
The following will be displayed:
FLC 2370.6
• Text description of the DTC (Diagnostic Trouble Code)
• Source controller of fault (ECU, CMU, FLC, SSM, or
TCU)
• SPN (Suspect Parameter Number)
• FMI (Failure Mode Indicator)
• Circuit information: fuse number, wire numbers, Active Codes 2/3
connector and pin numbers of source controller, and
schematic section number
Fuse: F18 F28
NOTE: Information on the circuit will vary based Wires: M12 YEL M13 GRN

T195057 —19—07NOV03
upon diagnostic trouble code. P18 RED P28 RED
Press SELECT. An active diagnostic trouble code will be CONN PIN: X23 25
displayed.
X23 26 23 68 45
Press SELECT again to view circuit information to help
diagnose problem. SECTION: SE23
Press NEXT to display next active code.
HG31779,000030E ­19­11AUG03­1/1

2­1­10 PN=35
072310
 Operation—Operator’s Station

Monitor Display Unit—Main

Menu—Codes—Stored Codes
The Stored Code sub menu will display up to twenty of Stored Codes 2/3
the latest diagnostic trouble codes that have occurred on
the machine. Each diagnostic trouble code will be saved CAN Comm

T193356 —19—08OCT03
in the order it occurred. If twenty codes exist and another
DTC is present, the listing will be adjusted first in/first out.
Lost for TCU
The following will be displayed: CMU 2003.9
• Text description of the DTC (Diagnostic Trouble Code)
• Source controller of fault (ECU, CMU, FLC, SSM, or
TCU)
• SPN (Suspect Parameter Number)
• FMI (Failure Mode Indicator)
• Value of sensor at time of fault (if applicable) Stored Codes 2/3
• Current value of sensor (if applicable)
• Hour meter reading at first and last occurrence Occurrences: 7
• Total number of occurrences

T195058 —19—23SEP03
• Circuit information: fuse number, wire numbers,
connector and pin numbers of source controller, and First: Last:
schematic section number
NOTE: Information on the circuit will vary based
118.0 hrs 119.5 hrs
upon diagnostic trouble code.

Press SELECT. A stored diagnostic trouble code will be

displayed. Stored Codes 2/3
Press SELECT again to view circuit information to help Fuse: F18 F28
diagnose problem.
Press NEXT to display next active code.
Wires: M12 YEL M13 GRN

T195059 —19—30SEP03
P18 RED P28 RED
CONN PIN: X23 25
X23 26 23 68 45
SECTION: SE23
HG31779,000030F ­19­11AUG03­1/1

Monitor Display Unit—Main Menu—Machine

Settings
The Machine Settings menu allows the operator to make Machine Settings 1/4
changes to various operating conditions of the machine. 1-Quick Shift
The last selection of the machine settings will be stored
T193357 —19—06OCT03

and upon turning the ignition switch on, the last value will 2-Auto to 1st
be retrieved.
3-Job Timer
Press NEXT at Main Menu to highlight Machine Settings.
Press SELECT to display sub menu.
4-Stopwatch

HG31779,000030B ­19­08AUG03­1/1

2­1­11 PN=36
072310
 Operation—Operator’s Station

Monitor Display Unit—Main Menu—Machine

Settings—Quick Shift
The Quick Shift mode allows the operator to choose Quick Shift 1/2
between Down/Up and Down Only shift functions when
the transmission is in manual or automatic operation. Down/Up

T193358 —19—05AUG03
Down/Up: When this function is turned On, the Down Only
transmission will down shift one gear when the Quick Shift
Switch (at top of pilot controller handle) is pressed down
once. It is not possible to down shift more than one gear.
When the quick shift switch is pressed down again, the
transmission will electronically shift up one gear again.
Down Only—Transmission in Manual Operation:
When this function is turned On, each time the quick shift If the operator presses down on the quick shift switch while
switch (at top of pilot controller handle) is pressed down, an up shift is taking place, the transmission controller will
the transmission will shift down one gear (regardless of cause the transmission to shift down to the previous gear.
selected gear).
In “Auto” mode, if the operator presses down on the
If the operator presses down on the quick shift switch quick shift switch while a down shift is taking place, the
while no shift is taking place, the controller will cause transmission controller will ignore the request for the
the transmission to shift down one gear (regardless of down shift.
selected gear).
Transmission will automatically shift up or down from the
Once a down shift is made by pressing the quick shift gear displayed in basic display window until shifter switch
switch, the transmission will not shift up again unless a is moved to Neutral. This will cancel down shift mode and
direction or gear change is made. transmission will go back to fully automatic mode.
Down Only—Transmission in Automatic Operation: Press SELECT at Machine Settings menu.
If the operator presses the quick shift switch when the
transmission is in automatic operation, the transmission If the display shows a checkmark next to Down/Up, the
will down shift to one gear below the gear displayed in Down/Up function is on.
basic display window. This change is made independent To turn on Down Only function and disable Down/Up
from shifter switch selection. function, press NEXT then press SELECT.
Down Only works basically the same in automatic as in Press BACK to return to Machine Settings menu.
manual, except it will shift Up or Down from the highest
gear downshifted to.
HG31779,0000310 ­19­08AUG03­1/1

Monitor Display Unit—Main Menu—Machine

Settings—Auto to 1st
In Auto to 1st mode, the transmission will shift to first gear Auto to 1st 1/2
if a high load is sensed while the transmission is actually
in second gear. This shift change is made independent Off
T193359 —19—05AUG03
from shifter switch selection.
On
A direction change during normal conditions will not cause
the transmission to shift down into first gear. If a direction
change is made during high transmission load conditions,
the transmission will shift down into first gear.
Press NEXT at Machine Settings menu to highlight Auto
to 1st.
Press SELECT.
If Auto to 1st function is off, press NEXT then press
SELECT to turn Auto to 1st function on.
HG31779,0000311 ­19­08AUG03­1/1

2­1­12 PN=37
072310
 Operation—Operator’s Station

Monitor Display Unit—Main Menu—Machine

Settings—Job Timer
The job timer is a resettable hour meter that can be Job Timer
used to time tasks to the nearest tenth of an hour. The
maximum capacity displayed is 999.9 hours. The job SELECT to Reset

T193360 —19—05AUG03
timer will stop and the value will be set to zero when it
exceeds 999.9 hours. The job timer will run even when
BACK to Exit
the Job Timer sub menu is not active. The job timer value
will be stored when the ignition switch is turned off.
0.0 hours
At Machine Settings menu, press NEXT to highlight Job
Timer.
Press SELECT.
Press SELECT to reset the timer to zero. Press BACK to exit.
HG31779,0000312 ­19­08MAR07­1/1

Monitor Display Unit—Main Menu—Machine

Settings—Stopwatch
The stop watch is a resettable timer that is used to STOPWATCH
measure time in hours, minutes, seconds and tenths of
seconds. The maximum capacity displayed is 24:00:00:0
SELECT on/off

T193361 —19—30SEP03
hours. The stopwatch will stop and the value will be set to
zero when it exceeds 24:00:00:0 hours. The stopwatch
NEXT to reset
will run even when the Stop Watch sub menu is not active. BACK to Exit
The stopwatch will be turned off and will reset to zero
when the ignition switch is turned off. 00:00:00.0
At Machine Settings menu, press NEXT to highlight Stop
Watch.
Press SELECT.
Press NEXT to reset the timer.
Press SELECT again to start the timer when the stopwatch
is off and has a value of zero. Press BACK to exit.

Press SELECT to stop the timer when the stopwatch is on.

HG31779,0000313 ­19­08MAR07­1/1

Monitor Display Unit—Main

Menu—Diagnostics Diagnostics 1/8
The Diagnostics menu provides a limited set of tools and 1-Battery Monitor
is intended for use by service personnel and machine
operators for diagnostic and troubleshooting functions.
2-Engine Sensors
Press NEXT at Main Menu to highlight Diagnostics.
3-Transmission
Press SELECT to display sub menu.
4-Hydraulic
5-Machine
T193362 —19—30SEP03

6-Machine Switches
7-Switch Module
8-Machine I.D.
HG31779,000030C ­19­08AUG03­1/1

2­1­13 PN=38
072310
 Operation—Operator’s Station

Monitor Display Unit—Main

Menu—Diagnostics—Battery Monitor
Press SELECT when “Battery Monitor” is highlighted to Battery Monitor
view the current voltage of the left and right batteries.
Left Battery
Press BACK to return to sub menu. 13.7

T193363 —19—05AUG03
NOTE: If 12 volt center tap wire is not connected to Right Battery
the right battery, left battery will display system
voltage and right battery will display 0.0. 13.7

HG31779,0000314 ­19­08AUG03­1/1

2­1­14 PN=39
072310
 Operation—Operator’s Station

Monitor Display Unit—Main

Menu—Diagnostics—Engine Sensors Engine Sensors 1/8
This mode allows the technician to monitor all engine 1-Display All
sensors that are accessible to the Engine Controller Unit
(ECU).
2-Coolant Temp
Press NEXT at Diagnostics menu to highlight Engine
3-Oil Pressure
Sensors. 4-Throttle Sensor
Press SELECT. 5-MAT

T193364 —19—01OCT03
Press SELECT again at Display All sub menu to display
all data items. Continue to press SELECT or NEXT to
6-Fuel Temp
scroll through the engine coolant temperature, engine oil 7-Fuel Pressure
pressure, throttle sensor, manifold air temperature, and
fuel temperature displays. 8-MAP
OR
Press NEXT to highlight Coolant Temp.
Press SELECT. Engine Sensors 1/7
Engine Coolant Temperature will be displayed in °C or Coolant
°F (depending on setting selected in “Units” display in

T195234 —19—30SEP03
“Monitor Settings” menu.) Temperature
Press BACK. 141 F
Press NEXT to highlight Oil Pressure.
Press SELECT.
Coolant Temp Display Shown
Engine Oil Pressure will be displayed in kPa or psi.
Press BACK.
Press BACK.
Press NEXT to highlight Throttle Sensor.
NOTE: Fuel Pressure and MAP (Manifold Air Pressure)
Press SELECT. will not be displayed on menu if machine is
not equipped with sensor.
Throttle Sensor voltage will be displayed as a percentage.
Press BACK. Press NEXT to highlight Fuel Pressure.

Press NEXT to highlight MAT. Fuel Pressure will be displayed in kPa or psi.

Press SELECT. Press BACK.

Intake Air Manifold Temperature will be displayed in °C Press NEXT to highlight MAP.
or °F. Press SELECT.
Press BACK. Manifold Air Pressure will be displayed in kPa or psi.
Press NEXT to highlight Fuel Temp. Press BACK twice to return to the Diagnostics menu.
Press SELECT.
Fuel Temperature will be displayed in °C or °F.
HG31779,0000315 ­19­08AUG03­1/1

2­1­15 PN=40
072310
 Operation—Operator’s Station

Monitor Display Unit—Main

Menu—Diagnostics—Transmission Transmission 1/7
This mode allows the technician to monitor all transmission 1-Display All
sensors that are accessible to the Transmission Controller
(TCU).
2-Oil Temp
Press NEXT at Diagnostics Menu to highlight
3-TC Input Speed
Transmission. 4-TC Output Speed
Press SELECT. 5-Clutch Speed

T193372 —19—01OCT03
Press SELECT again at Display All sub menu to display all
data items. Continue to press SELECT or NEXT to scroll
6-Output Shaft Spd
through the transmission oil temperature, torque converter 7-Clutch Cutoff V
input speed, torque converter output speed, clutch speed,
output shaft speed, and clutch cutoff voltage displays.
OR
Press NEXT to highlight Oil Temp. Press SELECT.
Press SELECT. Internal Clutch Speed will be displayed in rpm.
Transmission Oil Temperature will be displayed in °C or °F. Press BACK.
Press BACK. Press NEXT to highlight Output Shaft Spd.
Press NEXT to highlight TC Input Speed. Press SELECT.
Press SELECT. Output Shaft Speed will be displayed in rpm.
Torque Converter Input Speed will be displayed in rpm. Press BACK.
Press BACK. Press NEXT to highlight Clutch Cutoff V.
Press NEXT to highlight TC Output Speed. Press SELECT.
Press SELECT. Clutch Cut–off will be displayed in volts.
Torque Converter Output Speed will be displayed in rpm. Press BACK to exit.
Press BACK.
Press NEXT to highlight Clutch Speed.
HG31779,0000316 ­19­08AUG03­1/1

2­1­16 PN=41
072310
 Operation—Operator’s Station

Monitor Display Unit—Main

Menu—Diagnostics—Hydraulic
This mode allows the technician to monitor hydraulic Hydraulic 1/3
sensors that are accessible to the Flex Load Controller 1-Display All
(FLC).
2-Oil Temp

T193379 —19—25JUL03
Press NEXT at Diagnostics Menu to highlight Hydraulic.
Press SELECT. 3-Hyd Sys Press
Press SELECT again at Display All sub menu to display
all data items. Continue to press SELECT or NEXT to
scroll through the hydraulic oil temperature and hydraulic
system pressure displays.
Press NEXT to highlight Oil Temp. Press SELECT.
Press SELECT. Hydraulic System Pressure will be displayed in kPa or psi.
Hydraulic Oil Temperature will be displayed in °C or Press BACK twice to exit.
°F (depending on setting selected in “Units” display in
“Monitor Settings” menu). NOTE: Hydraulic system pressure will only be displayed
on machines equipped with spin control.
Press BACK.
Press NEXT to highlight Hyd Sys Press.
HG31779,0000317 ­19­08AUG03­1/1

Monitor Display Unit—Main

Menu—Diagnostics—Machine Machine 1/4
This mode allows the technician to monitor machine 1-Display All
sensors that are accessible to the Flex Load Controller
(FLC).
2-Boom Height

T196065 —19—04NOV03
Press NEXT at Diagnostics Menu to highlight Machine. 3-Bucket Position
Press SELECT. 4-Fuel Level
Press SELECT again at Display All sub menu to display 5-Ambient Air
all data items. Continue to press SELECT or NEXT to
scroll through the boom height and fuel level displays.
OR
Press NEXT to highlight Boom Height. Press NEXT to highlight Fuel Level.

Press SELECT. Press SELECT.

Boom Height will be displayed as a percentage. Fuel Level will be displayed as a percentage of fuel
remaining in tank.
Press BACK.
Press BACK.
NOTE: Bucket position will only be displayed on machine
equipped with linkage coupler. Press NEXT to highlight Ambient Air.
Ambient Air Temperature will be displayed in °C or °F
Press NEXT to highlight Bucket Position. (depending on setting selected in “Units” display in
Press SELECT. “Monitor Settings” menu).

Bucket Position will be displayed as a percentage. Press BACK twice to exit.

HG31779,0000318 ­19­08AUG03­1/1

2­1­17 PN=42
072310
 Operation—Operator’s Station

Monitor Display Unit—Main

Menu—Diagnostics—Machine Switches
Machine Switches 1/4
This mode allows the technician to monitor all machine
switches hardwired to the Flex Load Controller (FLC). Off Hyd Oil Filt Res
When a change occurs to the machine switch, the box to Off Brake Accum Chg
the left of the machine switch description will change and
the audible alarm will sound. Off Steering Press
“Off” indicates no signal present and “On” indicates a
signal present to the FLC.

Machine Switches 2/4

Off Brake Light
Off Ret to Dig Bkt
Off Start Signal

Machine Switches 3/4

Off 4 Way Flashers
Off Blower
Off Front Wiper Park

Machine Switches 4/4

Off Rear Wiper Park

T193385 —19—15OCT03

HG31779,000031B ­19­08AUG03­1/1

2­1­18 PN=43
072310
 Operation—Operator’s Station

Monitor Display Unit—Main

Menu—Diagnostics—Switch Module
This mode allows the technician to check continuity SSM
function of the Sealed Switch Module (SSM). Test
Pressing a switch on the SSM will change the status of

T193389 —19—22SEP03
the corresponding switch icon on the monitor.
Press
When a change occurs to the SSM, the corresponding any
switch icon will change and audible alarm will sound. Button..
A blank square indicates no switch pressed.
”On” indicates switch pressed.
”?” indicates no CAN communication between the Can
Monitor Unit (CMU) and Sealed Switch Module (SSM). Press BACK to return to previous screen.
HG31779,0000319 ­19­08AUG03­1/1

Monitor Display Unit—Main

Menu—Diagnostics—Machine I.D. Machine ID 1/5
This mode allows the service technician to view the
version of software and controller numbers. 1-CMU
Press NEXT to highlight CMU. 2-FLC

T193390 —19—01OCT03
Press SELECT. 3-SSM
The box serial number, box part number, software part 4-TCU
number and software version number for the CAN Monitor
Unit will be displayed. 5-Serial #
Press BACK.
Press NEXT to highlight FLC.
Press SELECT. CMU
The box serial number, box part number, software part Serial #: 100040
number and software version number for the FLC (Flex

T193391 —19—08OCT03
Load Controller) will be displayed. Part #: AT226327
Press BACK. Software #: AT226948
Press NEXT to highlight SSM. Software Ver. 0.1.0.2
Press SELECT.
The box part number, software part number and software CMU Display Shown
version number for the SSM (Sealed Switch Module) will
be displayed.
Press BACK.
Press BACK.
Press NEXT to highlight Serial #.
Press NEXT to highlight TCU.
Press SELECT.
Press SELECT.
The machine serial number will be displayed.
The machine model, machine serial number, box part
number and software version for the TCU (Transmission
Control Unit) will be displayed.
HG31779,000031A ­19­08AUG03­1/1

2­1­19 PN=44
072310
 Operation—Operator’s Station

Monitor Display Unit—Main Menu—Monitor

Settings
The Monitor Settings Menu provides the capability to Monitor Settings 1/5
select sub menus. 1-Units

T193394 —19—07NOV03
2-Backlighting
3-LCD Contrast

HG31779,000030D ­19­08AUG03­1/1

Monitor Display Unit—Main Menu—Monitor

Settings—Units
This mode allows the technician to choose between metric Units 1/2
and English unit displays.
English
When there is a checkmark next to English, all values will

T193395 —19—05AUG03
be shown in English units. When there is checkmark next Metric
to Metric, all values will be shown in metric.

HG31779,000031C ­19­08AUG03­1/1

Monitor Display Unit—Main Menu—Monitor

Settings—Backlighting
This mode allows the operator to adjust the backlighting Backlighting
of the monitor. The backlight value is displayed in
percentage and is incremented by 1. The range of BACK to decrease

T193397 —19—15OCT03
adjustment is from 0 (no light) to 10 (brightest setting).
The default backlight value is 10%.
NEXT to increase
Press NEXT to highlight Backlighting. SELECT to store
Press SELECT. 10
Press NEXT to increase backlighting by 1.
Press BACK to decrease backlighting by 1.
the backlighting until the key switch is turned off.
Press SELECT to store currently displayed value. The The previously stored value will be used when
stored value will be used as the default backlight value the key switch is turned on again.
until changed.
NOTE: Changing the backlight value without storing Press MENU to exit.
the setting with the SELECT key will only affect
HG31779,000031E ­19­08AUG03­1/1

2­1­20 PN=45
072310
 Operation—Operator’s Station

Monitor Display Unit—Main Menu—Monitor

Settings—LCD Contrast
This mode allows the operator to adjust the contrast LCD Contrast
setting of the monitor display. The range of adjustment is
from 1 (lightest, or least contrast) to 9 (darkest, or most BACK to decrease

T193398 —19—22SEP03
contrast). The default contrast value is 5.
NEXT to increase
Press NEXT at Monitor Settings menu to highlight LCD
Contrast. SELECT to store
Press SELECT. 9
Press NEXT to increase contrast by 1.
Press BACK to decrease contrast by 1.
contrast until the key switch is turned off. The
Press SELECT to store currently displayed value. The previously stored value will be used when the
stored value will be used as default contrast value until it key switch is turned on again.
is changed.
NOTE: Changing the contrast without storing the Press MENU to exit.
setting with the SELECT key will only affect the
HG31779,000031F ­19­08AUG03­1/1

Horn Button
1— Horn Button

T192867A —UN—18SEP03
Horn Button

HG31779,00002CD ­19­26JUN03­1/1

Turn Signals
Push turn signal lever (1) forward to signal a left turn. Pull
turn signal lever rearward to signal a right turn.

1— Turn Signal Lever

T192869A —UN—18SEP03

HG31779,00002CE ­19­26JUN03­1/1

2­1­21 PN=46
072310
 Operation—Operator’s Station

Air Conditioning Controls and Heater

Operation
IMPORTANT: Before you start air conditioner first
time in the season, check filters and condenser.
Clean them if necessary. Check refrigerant level.

T192344B —UN—18SEP03
NOTE: Engine must be running and blower fan speed
switch must be on for air conditioning to function.

To Operate Air Conditioning—If Equipped:

Press air conditioning switch (1) until light is illuminated.
Turn temperature control knob (2) clockwise to increase
temperature.
Turn blower speed knob (3) clockwise to increase blower
speed. (Knob also turns on heater blower.) Blower has
four speeds.

T194783A —UN—18SEP03
To Operate Heater:
Air conditioning switch (1) should be in the “Off” position.
Temperature control knob (2) should be in the heat
position.
Turn blower speed knob (3) to desired blower speed.

1— Air Conditioning Switch 3— Blower Speed Knob

2— Temperature Control Knob

HG31779,00002C0 ­19­23JUN03­1/1

Adjusting Steering Wheel Tilt

Lift lever (1) to adjust steering column to desired tilt.
Release lever.

1— Lever

T192870A —UN—18SEP03

HG31779,00002FD ­19­07JUL03­1/1

2­1­22 PN=47
072310
 Operation—Operator’s Station

Opening and Securing Side Door

To open left side cab door from inside, push forward on
lever (A).

A—Lever

T131654B —UN—13JUN00
CED,OUOE035,10 ­19­14JUN00­1/2

Open door until outside latch (A) fastens into notch (B).
Door must be secure against bumper (C). Adjust rubber
bumper as necessary to maintain proper tension.
To release secured open door from inside the cab or on
the ground, pull up on lever (D) located to the left of the
operator’s seat.
Door will latch when closed.

A—Outside Latch C—Bumper

T118147 —UN—02NOV98
B—Notch D—Release Lever

T160585B —UN—17OCT02

CED,OUOE035,10 ­19­14JUN00­2/2

2­1­23 PN=48
072310
 Operation—Operator’s Station

Opening Side Window/Secondary Exit

NOTE: The cab right side window can be used
as a secondary exit.

Push up on lever (A) to open window.

Position outer notch (B) over catch to hold window open.
To release secured window, push down on lever (C)
located behind cab seat.

A—Lever C—Lever
B—Outer Notch

T160249C —UN—15OCT02
T103919B —UN—12DEC96
HG31779,0000151 ­19­15OCT02­1/1

Opening Rear Side Window

Pull on latch tab (A) to release window lock.

A—Latch Tab

T131655B —UN—19JUN00

TX,10,JC1589 ­19­14JUN00­1/1

2­1­24 PN=49
072310
 Operation—Operator’s Station

Adjusting Seat

CAUTION: You can lose control of machine and be

injured if seat is loose. Be sure seat is properly
locked in position before operating the machine.

Use flip­out lever to turn weight adjustment knob (F). Turn

knob clockwise for firm ride and counterclockwise for soft
ride.
Lift fore­aft lever (H) to move seat forward and rearward.
Release handle at one of several positions.
Remove your weight from seat. Lift seat height adjustment
lever (E) and move seat to desired height.
Move seat to mid­to­aft position. While sitting in seat, turn
weight adjustment knob (F) to support weight. Check
weight indicator (G) for appropriate weight setting and
continue to turn until yellow pointer inside tube is flush
with tube opening.

T103679B —UN—22NOV96
While sitting in seat, lift backrest tilt adjustment knob (D)
and allow cushion to angle forward or lean backward into
desired position and release handle.
While sitting in seat, rotate armrest tilt knob (C) to tilt to
desired armrest position.
To raise or lower armrest height, loosen two nuts on
armrest height adjustment bracket (B) and adjust to
desired position. Tighten nuts to secure.
While sitting in seat, rotate lumbar support lever (A) to
increase or decrease support to lower back
On air ride equipped seats, to lower seat height or
decrease firmness in ride, pull out on height/firmness

T105452 —UN—26NOV96
adjustment knob (I). To raise seat or increase firmness
in ride, turn key to ON and push in on height/firmness
adjustment knob.

A—Lumbar Support Lever F— Weight Adjustment Knob

B—Armrest Height Adjustment G—Weight Indicator
Screw H—Fore­Aft Adjustment Lever
C—Armrest Adjustment Knob I— Height/Firmness
D—Backrest Tilt Adjustment Adjustment Knob (air
Knob ride seat only)
E—Seat Height Adjustment
Lever

TX,10,JC1742 ­19­01OCT04­1/1

Seat Belt
Seat belt and mounting hardware must be inspected for Replace the complete seat belt assembly every 3 years
wear or damage before operating the machine. Replace regardless of appearance.
the belt or mounting hardware if worn or damaged.
TX,10,JC1623 ­19­21JUL09­1/1

2­1­25 PN=50
072310
 Operation—Operating the Machine
Inspect Machine Daily Before Starting
Do periodic service checks.
A—Check wheels (front and rear) for loose or missing
hardware.
B—Clean operator’s station.
C—Check air inlet cover.
D—Clean radiator.
E—Check fuel level on monitor.
F—Check tires (front and rear).
ELECTRICAL SYSTEM: Check for worn or frayed wires
and loose or corroded connections.
BOOM, BUCKET, SHEET METAL: Check for bent,
broken, loose, or missing parts.
HARDWARE: Check for loose or missing parts.
PARK BRAKE: Check for correct operation.

T103802 —UN—18SEP96
HYDRAULIC SYSTEM: Check for leaks, missing or loose
clamps, kinked hoses, and lines or hoses that rub against
each other or other parts.
LUBRICATION: Check lubrication points shown on
Periodic Maintenance Chart.
PROTECTIVE DEVICES: Check guards, shields, ROPS,
covers, seat belt. A—Wheels (front and rear) D—Radiator
B—Operator’s Station E—Fuel Level (monitor)
SAFETY: Walk around machine to clear all persons from C—Air Inlet Cover F— Tires
machine area.
TX,20,JC1199 ­19­01OCT04­1/1

Check Instruments Before Starting OFF

Turn key switch clockwise to “On” position. All lights on
display monitor will come on, all gauges will position
gauge needle to the 12 o’clock position, and alarm will ON
sound.

T195405 —19—07OCT03
The basic display window will show the bulb check mode.
After bulb check mode, the stop indicator and engine oil START
pressure indicator will flash.

HG31779,00000B1 ­19­18JUL02­1/1

2­2­1 PN=51
072310
 Operation—Operating the Machine

Starting the Engine

CAUTION: Avoid possible injury or death

from a runaway machine.
DO NOT start engine by shorting across
starter terminals. Machine will start in gear

TS177 —UN—11JAN89
if normal circuitry is bypassed.
NEVER start engine while standing on ground.
Start engine only from operator’s seat, with
FNR in “Neutral”. Engage park brake.
Use of seat belt with roll­over protective
structure (ROPS) is recommended under
all operating conditions.

1. Fasten seat belt.

HG31779,00002CF ­19­26JUN03­1/2

2. Move FNR (1) to N.

NOTE: Engine will not start with FNR in F “Forward”
or R “Reverse”. The FNR must be in N
“Neutral” before starting engine.

T194598A —UN—18SEP03
3. Turn key switch to “On” position. Push horn button
to sound horn to alert bystanders that machine will
be started.
IMPORTANT: Never operate starter motor for more
than 20 seconds at a time. If engine fails to start
after two or three tries, return key switch to “Off”
position. Wait for about 2 minutes, then try again.
Column FNR Shown
After a false start, DO NOT turn key switch until
engine stops or starter may be damaged.
Engine will not start by towing or pushing.
Permanent damage to transmission will result.

4. Turn key switch to “Start” position. DO NOT crank

T194851A —UN—18SEP03
engine more than 20 seconds. Wait 2 minutes before
trying again. Release key when engine starts.
IMPORTANT: If STOP indicator light does not go out
within 10 seconds after starting engine, STOP
THE ENGINE. Find and correct the cause.

5. Operate machine at less than normal loads and at Joystick FNR Shown
slow idle speed until engine warms up.
IMPORTANT: If engine stops when operating under 1— FNR
load, remove load. Restart engine immediately.
Run 30 seconds at 1/2 speed before adding load.
HG31779,00002CF ­19­26JUN03­2/2

2­2­2 PN=52
072310
 Operation—Operating the Machine

Starting Fluid—If Equipped (Cold Weather

Starting Aid)
USE STARTING FLUID

CAUTION: Prevent possible injury from exploding

container. Starting fluid is highly flammable. Keep

TS281 —UN—23AUG88
container away from heat, sparks, and open flame.
Contents are pressurized. DO NOT puncture or
incinerate container. Remove container from
machine if 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.

AM40430,0000044 ­19­09FEB05­1/2

IMPORTANT: Excess starting fluid could damage

engine; press starting aid button only when
engine is cold and cranking. Do not hold the
starting aid button for more than 5 seconds.
Starting aid fluid is being injected into engine
as long as you press button.

T192675A —UN—18SEP03
2. While cranking engine, press start aid button (1).
Crank engine for 20 seconds maximum, then allow 2
minutes between cranking periods.
REPLACING START AID CONTAINER
1. Loosen hose clamp (2).
2. Turn start aid container (3) counterclockwise to
remove.
3. Remove safety cap from new container.
4. Turn container clockwise in starting aid base to install.

T192875A —UN—18SEP03
5. Tighten hose clamp.
OPERATING MACHINE WITHOUT START AID
CONTAINER INSTALLED
IMPORTANT: Protect starting aid components
from possible damage. Install starting aid
plug in starting aid base.

Remove container from base and install plug (4) in base. 1— Start Aid Button 3— Start Aid Container
2— Hose Clamp 4— Plug

AM40430,0000044 ­19­09FEB05­2/2

2­2­3 PN=53
072310
 Operation—Operating the Machine

Engine Heater—If Equipped

IMPORTANT: DO NOT USE ETHER WITH THIS
SYSTEM. Damage to your engine may occur.

NOTE: As long as monitor light remains on,

T194774A —UN—18SEP03
heater will be operating.

1. Turn key switch to “On”. If engine temperature is

below 10°C (50°F), engine heater indicator (1) will
light and stay on 0—30 seconds, depending on initial
engine temperature. Light will turn off, indicating that
preheating is completed.
2. Turn key to “Start”. Light will turn off while cranking or
if battery voltage drops below 20 volts. 1— Engine Heater Indicator
3. If engine temperature is 20°C (68°F) or lower, heater
indicator will light and will remain on for approximately
30 seconds depending on current engine temperature. NOTE: Battery voltage light may come on during post
IMPORTANT: Warm up at 1/2 speed and DO NOT heat and may remain on for a short period of time.
accelerate rapidly during warm­up.
HG31779,00002D1 ­19­26JUN03­1/1

Using Coolant Heater—If Equipped cord. Use a heavy­duty, grounded cord to

connect heater to electrical power.
CAUTION: Prevent property damage as a result
of possible fire from an overheated electrical Connect the coolant heater to 115­volt outlet, as needed,
before you start the engine.
T82,25,C53 ­19­19DEC06­1/1

Warm­Up
Operate machine at less­than­normal loads and speeds
for first few minutes until temperatures and pressures
reach normal operating range.
TX,25,JC247 ­19­29NOV94­1/1

Cold Weather Warm­Up

IMPORTANT: If hydraulic oil and transmission oil
are cold, functions move slowly. Do not • Machine—stopped
attempt normal machine operations until • Engine—slightly above low idle
hydraulic and transmission functions move • Bucket—off the ground and empty
at close­to­normal cycle times. • Brakes—apply right or left brake pedal with clutch
cutoff disengaged
1. Start engine. Run engine at minimum speed for 5 • Parking brake—released
minutes. • Cycle transmission 10 times by shifting:
Neutral­F1—R1—F1—R1—F1—Neutral. Each
2. Cycle boom with bucket stalled in rollback position cycle should be approximately 5 seconds.
until bucket functions move at normal speed.
4. Shift from F1­R1 without braking until transmission
3. Check transmission oil level with engine at low idle. operates normally.
Prepare machine to shift transmission as follows:
ER93822,000006D ­19­19NOV07­1/1

2­2­4 PN=54
072310
 Operation—Operating the Machine

Neutral Lock
CAUTION: Prevent possible injury from
unexpected machine movement. Always
move transmission control lever (TCL) to
neutral "N", and engage neutral lock before

T192873B —UN—18SEP03
starting or dismounting.

Move neutral lock (1) to the locked position to engage

neutral lock. Move lock to the unlocked position to
disengage neutral lock.

1— Neutral Lock

HG31779,00002D2 ­19­08FEB07­1/1

Shifting the Transmission

Unlock neutral lock (if equipped with column FNR).
Release park brake.
Change direction of machine by moving FNR (1) to F

T194598A —UN—18SEP03
“Forward" or R “Reverse".
If equipped with column FNR, change speed of machine
by rotating transmission control lever to desired gear. If
equipped with joystick FNR, press button (2) to increase
speed. Press button (3) to decrease speed. Machine
has four forward gears and three reverse gears. Shifting
to 4th gear reverse will give same travel speed as 3rd Column FNR Shown
gear reverse. Select a gear suitable to operating and
road conditions.
When automatic transmission switch (4) is on,
transmission will shift up or down as required to
highest gear selected. In automatic transmission mode,
transmission starts out in 2nd gear.

T194597C —UN—02OCT03
1— FNR 3— Decrease Speed Button
2— Increase Speed Button 4— Automatic Transmission
Switch

Joystick FNR Shown

T192455D —UN—02OCT03

HG31779,00002D6 ­19­26JUN03­1/1

2­2­5 PN=55
072310
 Operation—Operating the Machine

Park Brake Switch

CAUTION: Prevent possible injury or death
from machine runaway. Before disengaging
park brake, be sure engine is running and
service brakes are operational.

T192869C —UN—18SEP03
NOTE: Transmission clutches are disengaged when
park brake is applied.

The park brake switch (1) has three positions:

• Park brake ON
• Neutral, center detented position
• Park brake release, momentary position
1— Park Brake Switch
To engage park brake, move switch from the neutral,
center detented position to the park brake ON, detented
position. and alarm will sound. Monitor display will read
To release park brake, move switch to the neutral, center “N” until park brake is released.
detented position, then the park brake release momentary If engine is stopped with park brake switch OFF,
position. park brake is automatically applied. Press park
NOTE: If park brake is engaged when engine is running brake switch to ON and then back to momentary
and transmission control lever (TCL) is in “Neutral”, position to release park brake after starting engine.
park brake indicator will light. Park brake will come on if transmission
If park brake is engaged when engine is running pressure drops below 150 psi.
and TCL is moved to F or R, park brake
indicator will flash, STOP indicator will flash,
HG31779,00002D3 ­19­08FEB07­1/1

2­2­6 PN=56
072310
 Operation—Operating the Machine

Boom and Bucket Control Lever—One Lever

Design
Move control lever forward (1) to lower boom, or rearward
(4) to raise boom.

DW1051735A —UN—19NOV08
NOTE: Pilot enable/boom down switch (9) must be
pushed and held down while moving control lever
forward to lower boom with engine stopped.

Move control lever left (6) to roll back bucket, or right (3)
to dump bucket.
Return­to­Carry (10)—If Equipped: With Return­to­Carry
switch on, push boom down lever to “Float” position (lever
in full forward detent position [2]). The boom will stop at
a preset height and lever will return to neutral position
automatically.
NOTE: Return­to­carry will override float position.
Return­to­carry must be off for float detent to operate.

T192344E —UN—18SEP03
NOTE: Boom float will not work once the boom is below
preset distance from ground. Push switch to
“Off” position to activate boom float.

Float (lever in full forward detent position [4]): This position

allows oil to flow in and out both ends of cylinders so the
bucket can follow the contour of the ground. Manually
release lever from this position. 1— Lower Boom 6— Rollback Bucket
2— Float 7— Return­to­Dig
Return­to­Dig (RTD) (lever in full left detent position [7]): 3— Dump Bucket 9— Pilot Enable/Boom Down
Bucket will return to set dig position. 4— Raise Boom Switch
5— Boom Height Kickout 10— Return­to­Carry Switch—If
NOTE: For Z­Bar linkage machines, the LED light Equipped
of the RTD switch must be illuminated for
the RTD feature to function.
in this position until boom is at a preset height, then will
NOTE: For Powerllel linkage machines, RTD will return return to neutral automatically.
to the memory position setting of either the
left memory position or right memory position, Boom and bucket functions can be operated
depending which LED is illuminated. simultaneously by moving lever between positions. For
example, to raise boom and roll back bucket, move lever
Boom Height Kickout (lever in full rear detent position [5]): between positions (4) and (6).
With the Boom Height Kickout switch on, lever will remain
MD04263,0000025 ­19­19NOV08­1/1

2­2­7 PN=57
072310
 Operation—Operating the Machine

Boom and Bucket Control Lever—Two Lever

Design
Move left control lever forward (1) to dump bucket, or
rearward (2) to roll back bucket.

DW1051741A —UN—19NOV08
Return­to­Carry (10)—If Equipped: With Return­to­Carry
switch on, push boom down lever to “Float” position (lever
in full forward detent position [4]). The boom will stop at
a preset height and lever will return to neutral position
automatically.
NOTE: Pilot enable/boom down switch (9) must be
pushed and held down while moving control lever
forward to lower boom with engine stopped.

Move right control lever forward (5) to lower boom or

rearward (6) to raise boom.
NOTE: Return­to­carry will override float position.
Return­to­carry must be off for float detent to operate.

T192344E —UN—18SEP03
NOTE: Boom float will not work once the boom is below
preset distance from ground. Push switch to
“Off” position to activate boom float.

Float (right lever in full forward detent position [4]): This

position allows oil to flow in and out both ends of cylinders
so the bucket can follow the contour of the ground.
Manually release lever from this position. 1— Dump Bucket 6— Raise Boom
2— Rollback Bucket 7— Boom Height Kickout
Return­to­Dig (left lever in full rearward detent position 3— Return­to­Dig 9— Pilot Enable/Boom Down
[3]): Bucket will return to set dig position. 4— Float Switch
5— Lower Boom 10— Return­to­Carry Switch—If
NOTE: For Z­Bar linkage machines, the LED light Equipped
of the RTD switch must be illuminated for
the RTD feature to function.

NOTE: For Powerllel linkage machines, RTD will return Boom Height Kickout (lever in full rear detent position [7]):
to the memory position setting of either the With the Boom Height Kickout switch on, lever will remain
left memory position or right memory position, in this position until boom is at a preset height, then will
depending which LED is illuminated. return to neutral automatically.
MD04263,0000026 ­19­19NOV08­1/1

2­2­8 PN=58
072310
 Operation—Operating the Machine

Quick Shift Switch

Down/Up
Press switch (1) to down shift from selected gear to next
lower gear when transmission is in gears 2—4. Press
again to return to original gear.

T194775A —UN—18SEP03
NOTE: Machine can be programmed with Quick
Shift Mode in the Machine Settings Menu
for down/up or down only.

Down Only
This mode will allow transmission to down shift one gear Single Lever with Auxiliary Control Design Shown
for each pressing of button. Once a down shift is made by
pressing the quick shift switch, the transmission will not
shift up again unless a direction or gear change is made.

1— Switch

T194778A —UN—18SEP03
Two Lever with Auxiliary Control Design Shown

HG31779,00002D7 ­19­26JUN03­1/1

2­2­9 PN=59
072310
 Operation—Operating the Machine

Ride Control—If Equipped

Ride control will improve machine ride and reduce tire
flexing when traveling through rough terrain or at high
speeds. Ride control will also reduce material spillage
from the bucket by cushioning boom movement.
The Ride Control Auto Speed set point is adjustable via

T192456A —UN—18SEP03
the monitor with a range of adjustment from 3.0 km/h to
24.0 km/h or 2.0 mph to 15.0 mph in increments of 0.5
units. The default Ride Control Speed set point value is
6.0 km/h.
“On” Position
NOTE: The “On” position has ride control on 100%
of the time. It is best suited for fork and
non­bucket loading applications.
1— Ride Control Switch
Once engine is running and the ride control switch (1)
is cycled to the “On” position (left light illuminated), ride
control will remain on with or without the engine running. Operating Ride Control
If key switch is turned “Off” and then “On” with ride control
switch in “On” position, ride control is automatically turned
off. Ride control will remain off until the ride control switch CAUTION: Prevent possible injury from
is cycled to “Off” then “On”. unexpected boom movement. The boom may
move up when ride control switch is turned
“Auto” Position ON. Clear all bystanders from area.
NOTE: The “Auto” position is best suited for bucket 1. Make sure area around bucket is clear.
loading applications since it will temporarily
disengage ride control to stop boom movement 2. Start the engine.
while crowding the pile for improved bucket loading.
Observe ride control switch:
With the ride control switch in the “Auto” position (both • If ride control switch light are not illuminated, cycle
lights illuminated), ride control will remain on as long as switch to select “On” or “Auto” mode.
engine is running and ground speed is above the auto • If switch left light is illuminated it is in “On” position,
speed set point. The key switch will not turn off “Auto” cycle switch to “Off” then “On” to activate ride control.
ride control. • If switch has two lights illuminated it is in “Auto”
position, ride control will automatically reactivate
“Off” Position as soon as a ground speed greater than 6 km/h
(3.5 mph) is reached and will operate until switch
Ride control is turned off (no lights illuminated). is turned “Off”.
Continued on next page AM40430,00001BE ­19­23MAY06­1/2

2­2­10 PN=60
072310
 Operation—Operating the Machine

Discharging Ride Control Accumulator

1. Turn ride control “Off”.
2. Lower boom and bucket to ground and stop engine.
3. Turn return­to­carry switch (1) “Off”.

T192464A —UN—18SEP03
4. Make sure area around bucket is clear.

CAUTION: Prevent possible injury from

unexpected boom movement. The boom may
move up when ride control switch is turned
ON. Clear all bystanders from area.

5. Turn key switch to “On” without starting the engine

and cycle ride control switch (2) to the “On” position 1— Return­to­Carry Switch 3— Pilot Enable/Boom Down
(left light illuminated). 2— Ride Control Switch Switch

6. Press and hold the pilot enable/boom down switch (3)

while holding the boom control in the float position for
5 seconds. 7. Turn key “Off”.
AM40430,00001BE ­19­23MAY06­2/2

Secondary Steering—If Equipped

IMPORTANT: Prevent possible damage to secondary
steering system. Stop machine immediately
if steering pressure indicator light and
audible alarm come on while operating. THE

T194774B —UN—18SEP03
SECONDARY STEERING SYSTEM IS NOT
INTENDED FOR CONTINUOUS USE.

NOTE: For optimum secondary steering performance,

ensure electrical system and batteries are
properly maintained.

Steering pressure indicator (2) will flash, STOP indicator

(1) will flash, and audible alarm will sound when secondary
steering system is activated. The light indicates low A—STOP Indicator B—Steering Pressure Indicator
hydraulic pressure resulting from mechanical malfunction,
such as loss of engine power. An electrically driven pump
will actuate to provide steering
NOTE: Secondary steering is activated if the engine dies
The secondary steering system will function only when with key switch “On”. The secondary steering motor
key switch is “On”. will stop when the key switch is turned to “Off”.

AM40430,00002D5 ­19­12JAN06­1/1

2­2­11 PN=61
072310
 Operation—Operating the Machine

Differential Lock Switch

Hold switch (A) down to lock front differential or front and
rear differential, if equipped.
Release switch to unlock differential.
NOTE: Use differential lock only when conditions require

T113525 —UN—13FEB98
traction. Avoid using differential lock when steering.

A—Switch

TX,35,JC1943 ­19­02SEP98­1/1

Boom Height Kickout Adjustment

1. With engine running and pilot enable/boom down
switch (2) on, position boom in desired boom height
kickout position.
2. Press and release boom height kickout switch (1) to

T192344C —UN—07OCT03
turn on function.
3. Press and hold boom height kickout switch until
audible alarm sounds and light flashes.
NOTE: The boom height kickout position will remain
the same until a new position is set.

1— Boom Height Kickout 2— Pilot Enable/Boom Down

Switch Switch

HG31779,0000307 ­19­09FEB05­1/1

Return­to­Carry Kickout Adjustment

1. With engine running and pilot enable/boom down
switch (2) on, position boom in desired return­to­carry
position.
2. Press and release return­to­carry switch (1) to turn
function on. T192344K —UN—07OCT03

3. Press and hold return­to­carry switch until audible

alarm sounds.
NOTE: The return­to­carry position will remain the
same until a new position is set.

1— Return­to­Carry Switch 2— Pilot Enable/Boom Down

Switch

HG31779,0000308 ­19­22JUL03­1/1

2­2­12 PN=62
072310
 Operation—Operating the Machine

Return­To­Dig Adjustment for Z­Bar Linkage Only

T131917 —UN—12MAR09
A—Air Gap Switch­To­Bar C—Cap Screws E—Hex Nuts
B—Adjustable Bar D—Alignment Marks F— Switch

NOTE: The machines hydraulic system must be at Apply medium strength thread lock and sealer to cap
operating temperatures and the boom and bucket screws.
cylinders should be cycled their full length 4 times
before setting return­to­dig to assure there is 6. Install cap screws but do not tighten. Adjust bar to
warm hydraulic oil in the cylinders. Do not set align marks on switch bracket and end of bar. Tighten
return­to­dig with a cold hydraulic system! cap screws to specification.
Specification
1. Raise boom approximately 300 mm (12 in.) above Cap Screw—Torque....................................................................121 N∙m
ground. Move bucket from full rollback to dump. 89 lb­ft

NOTE: Engine speed should be approximately

1500 to 1700 rpm.
7. Loosen hex nuts (E) to switch bracket. Adjust air gap
2. Move loader control lever to return­to­dig detent (A) between switch and adjustable bar to specification.
position and release. Tighten hex nuts to specification.
Specification
3. After control lever returns to neutral, scribe a mark (D) Air Gap Between Switch
on the switch bracket and adjustable bar (B) to align and Bar—Distance.....................................................................5—8 mm
with each other. 0.197— 0.315 in.
4. Position the boom and bucket in the desired Hex Screw—Torque......................................................................75 N∙m
return­to­dig position. Stop engine. 55 lb­ft

5. Remove cap screws (C), one at a time and remove old

thread lock and sealer using Clean and Cure Primer.
AM40430,000003A ­19­12MAR09­1/1

2­2­13 PN=63
072310
 Operation—Operating the Machine

Return­To­Dig Adjustment—If Equipped With

Powerllel Linkage
NOTE: The machine’s hydraulic system must be at
operating temperatures and the boom and bucket
cylinders should be cycled its full length 4 times

T192456B —UN—08SEP04
before setting return­to­dig to assure there is
warm hydraulic oil in the cylinders. Do not set
return­to­dig with a cold hydraulic system!

1. Position bucket or attachment in the desired tilt

position.
2. Press the return­to­dig switch (1) until the desired
position memory is illuminated.
3. Press and hold the return­to­dig switch until the
monitor alarm beeps. The monitor will display
on­screen instructions.
OUT4001,0000001 ­19­20JUL06­1/2

RTD Calibration 1/4 RTD Calibration 2/4

1-Position Bucket 4-Do NOT move Bucket
or Forks Lever
TX1006707 —19—26APR06

TX1006710 —19—26APR06
2-Lower Bucket/Forks 5-Raise Boom to Max
until touches ground Height
3-Press RTD Button 6-Press RTD Button

RTD Calibration 3/4 RTD Calibration 4/4

7-Do NOT move Bucket
Lever Complete
TX1006714 —19—26APR06
TX1006711 —19—26APR06

8-Lower Bucket/Fork until

touches ground
9-Press RTD Button

OUT4001,0000001 ­19­20JUL06­2/2

2­2­14 PN=64
072310
 Operation—Operating the Machine

Using the Loader Bucket

1. Place bucket in the return­to­dig position and lower
to ground.
NOTE: Bucket and boom can be positioned while
machine is on­the­go.

T7747BB —UN—19MAY92
2. Move transmission control lever to 1st or 2nd gear
depending on ground condition.
3. Move forward into the material.

OUT4001,000025C ­19­21MAR07­1/4

4. Raise and curl bucket to hold load.

T7747BC —UN—19MAY92
OUT4001,000025C ­19­21MAR07­2/4

EXCAVATING ON THE LEVEL: Position bucket at a

slightly downward angle on ground (use bucket teeth for
this type of digging).
IMPORTANT: Prevent possible damage to the
bellcrank linkage. DO NOT bulldoze with
bucket in dump position. When dozing, keep

T7208AR —UN—30JAN90
bucket bottom parallel to the ground.

Continued on next page OUT4001,000025C ­19­21MAR07­3/4

2­2­15 PN=65
072310
 Operation—Operating the Machine

DOZING: With bucket parallel to ground, remove as little

dirt as possible from the top surface. Let dirt spill from
partially dumped bucket to fill in low spots.
USING BOOM IN FLOAT POSITION: Place the boom
in float position and bucket in return­to­dig position to
prevent gouging the surface, as in cleaning concrete and

T7747BD —UN—19MAY92
snow removal. Also use float position to avoid mixing
surface material with stockpile material.
DIGGING IN HARD, DENSE, OR TIGHTLY­PACKED
MATERIAL: To break material loose, use a gentle
up­and­down motion of the bucket.

OUT4001,000025C ­19­21MAR07­4/4

Backdragging
Leveling and grading can be done with the boom in the
float position by backdragging the loader bucket while
traveling in reverse. (Float position allows the bucket to
follow contour of the ground.)

T7747BG —UN—19MAY92
OUT4001,000025D ­19­21MAR07­1/1

2­2­16 PN=66
072310
 Operation—Operating the Machine

Fork Attachment

T110742 —UN—06AUG97
LOADING
LIFTING CAPACITY
• Center forks and carriage before lifting.
To maintain stability, only lift loads equal to or less than
• Inspect load to ensure stability when lifted.
mast capacity or rated operating capacity of machine,
• Never attempt to lift load with one fork.
whichever is less. (See Specifications chapter for machine
• Approach load slowly and squarely with fork tips level.
lifting capacities.)
Move forks slowly under load with load positioned
equally on forks. Continue to drive forward until load is TRAVELING
against backrest of forks.
• Operate machine controls from operator seat only.
UNLOADING • While driving, carry load low for good visibility and
machine stability.
• Always use a signal person if you cannot see the • Downshift with care. A sudden deceleration could shift
placement area for the load. Make certain area is clear
or topple load.
of all objects.
• Lower load to ground and tilt forks to a level position. • A sudden reversal of travel direction could tip load or
over turn the machine. Come to a gradual stop before
Back away carefully to disengage forks.
reversing directions.
ELEVATED LOADS • Slow travel speed when making turns to avoid an
overturn.
• Slowly raise load with a slight back tilt to cradle load. • Use low gear for hillside or ramp operation. Never coast
Never tilt load forward unless load is over landing area downhill with transmission in neutral. The machine
and ready to be set down. could go out of control and tip over.
• If there is any indication of load instability during the • Reduce speed when driving over rough terrain, carrying
lift such as movement, leaning, or swaying, stop lifting a heavy load, or working in a congested area. Avoid
immediately. Lower load and restock. rocks, curbs, and ditches.
• As load approaches desired height, slow the lift speed
to a minimum. Continue the lift until load is slightly OPERATING TIPS
higher than the landing point.
• After load is securely in place, retract forks clear of load • Never use the fork attachment as a working platform.
and lower forks to traveling height before moving. • Know locations of bystanders in the working area at
all times.
DRIVING ON A SLOPE • DO NOT touch, lean on, or reach through the mast,
boom or lift mechanism or permit others to do so. Never
CAUTION: Prevent possible injury from machine climb on the mast, boom, or attachments.
rollover, do not turn on slopes. Do not drive • NEVER allow anyone to stand or pass under the raised
across slopes under any circumstances. forks, mast, carriage, boom, or attachments.
• Reduce speed and sound horn at blind intersections,
Driving up or down slope WITH load on forks: exits, and when approaching pedestrians.

• Lower load near to ground. FORK INSPECTION

• Keep mast tilted back to retain load. Slowly drive The forks are the main load bearing components of the
straight up or back straight down slope. mast. Forks must be maintained and checked periodically
Driving up or down slope WITHOUT load on forks: to assure safe operation.

• Lower forks near to ground. Inspect forks daily. If any of the following conditions exist,
• Keep mast tilted back. replace forks before operating machine.
• Slowly drive straight down or back straight up slope.
Continued on next page CED,TX03679,5542 ­19­03NOV99­1/2

2­2­17 072310

PN=67
 Operation—Operating the Machine

• Check for visibly bent forks and abrasions. If forks are CAUTION: To prevent injury, never stand under
bent more than 3°, replace forks. (Tapered forks are 90°
nominal and standard forks are 87° nominal.) If a flat forks or any part of lift mechanism.
spot is clearly evident from abrasive wear, replace forks.
• Inspect forks for cracks along the inside radius of heel. 1. Lower forks to approximately 25 mm (1 in.) above
• Inspect hanger block welds for visible cracks. ground.
• Check to see that the spring loaded keeper, with
washer, is in position in the upper hanger block and that CAUTION: To prevent injury when sliding
the keeper is functioning properly. (Spring in keeper forks, keep hands and fingers out of
must pull pin down into hanger block when pin is pulled fork adjustment path.
out and released.)
• Inspect hanger blocks for any sign of deformation, 2. Lift pin and slide fork to desired position. Slide fork by
cracks, and wear. placing a foot on tine and palm of other hand on top
• Bent forks are not always detectable by sight. Remove of fork. Alternately push fork with hand (top) and foot
forks and measure the interior angle of each fork to (lower) in a rocking motion until fork reaches desired
detect a bent fork. position.
• Tapered tip forks have an interior angle of 90°. Standard
3. Release pin and check that fork is engaged in notch.
square tip forks have an interior angle of 87°. If angle
is bent more than 3°, replace fork. 4. Check that mast backing plate pins are in place at
each end. Measure backing plate pins for wear. Pins
FORK ADJUSTMENT
should be equal in length on both sides of plate.
To change fork position: Replace pins if worn or damaged.
CED,TX03679,5542 ­19­03NOV99­2/2

Parking the Machine

1. Park machine on a level surface.
2. Lower bucket to ground.
3. Move FNR (1) to N. If equipped with column FNR,

T192873A —UN—18SEP03
engage neutral lock (2).

CAUTION: Prevent possible injury from

unexpected machine movement. Machine can
unexpectedly roll or move under power, resulting
in death or serious injury. Always turn engine off
or push park brake switch to ON to hold machine.
Column FNR Shown
4. Push park brake switch to ON.
IMPORTANT: Turbocharger may be damaged if
engine is not properly shut down.

5. Run engine at 1/2 speed without load for 2 minutes

T194597A —UN—18SEP03

before stopping, to avoid damage to turbocharger.

Release accelerator pedal to slow idle.
6. Turn key switch to “Off”.
7. Turn battery disconnect switch OFF.

1— FNR 2— Neutral Lock

Joystick FNR Shown
HG31779,00002DB ­19­26JUN03­1/1

2­2­18 PN=68
072310
 Operation—Operating the Machine

Loading Machine on a Trailer

1. Keep the trailer bed clean. Put chock blocks against
trailer wheels.
2. Use a ramp or loading dock. Ramps must be strong
enough, have a low angle, and correct height.

T192873A —UN—18SEP03
3. Fasten seat belt before starting engine.

CAUTION: Prevent possible injury from tipover.

Position the machine so that its centerline is
over the centerline of the truck bed. NEVER
steer the machine while on the ramp. If changing
Column FNR Shown
direction is required on the ramp, unload the
machine from the ramp, reposition the machine
on the ground, then try loading again.

4. Drive the machine onto the ramp slowly. The

centerline of the machine should be over the centerline
of the trailer.

T194597A —UN—18SEP03
5. Lower all equipment onto blocks or trailer bed.
6. Move FNR (1) to N. If equipped with column FNR,
engage neutral lock (2).

CAUTION: Prevent possible injury from

unexpected machine movement. Machine can Joystick FNR Shown
unexpectedly roll or move under power, resulting
in death or serious injury. Always turn off engine
1— FNR 2— Neutral Lock
or push park brake switch to ON to hold machine.

7. Push park brake switch to ON.

11. Cover exhaust opening to prevent entry of debris and
8. Connect articulation locking bar. water.
9. Turn key switch to “Off”.
10. Turn battery disconnect switch OFF.
Continued on next page HG31779,00002DC ­19­26JUN03­1/2

2­2­19 PN=69
072310
 Operation—Operating the Machine

12. Fasten the machine to the trailer with chains or cables

with appropriate load binders at the following tiedown
points:
• Left Side and Right Side Rear Counterweight (1)
• Left Side and Right Side Front Axle (2)

T196308A —UN—12NOV03
1— Left Side and Right Side 2— Left Side and Right Side
Rear Counterweight Front Axle

Right Rear Counterweight Shown

T195632A —UN—17OCT03
Left Front Axle Shown

HG31779,00002DC ­19­26JUN03­2/2

2­2­20 PN=70
072310
 Operation—Operating the Machine

Towing Procedure

T138646 —UN—20MAR01
1— Front Driveshaft 3— Park Brake Hose 5— Rear Driveshaft
2— Park Brake Fitting Plug 4— Telescoping Driveshaft

3. Start engine if possible, and install articulation locking

CAUTION: Do not allow an operator on the bar.
machine being towed unless the operator can
control the steering and brakes. 4. Move FNR to “Neutral” position. If equipped with
column FNR, engage neutral lock.
IMPORTANT: Engine cannot be started by towing.
5. If park brake indicator does not come on, the park
Tow the machine off­road to the nearest location brake is OFF. Go to Step 11.
where repair work can be done. Haul the machine
if it must be moved further than 460 m (500 yd). If park brake indicator is on, the park brake is ON. Go
to Step 6.
Never tow machine faster than 3.2 km/hr (2
mph) to avoid transmission damage. 6. Stop engine.

If the engine or the transmission hydraulic system are CAUTION: Prevent possible injury from
non­functional, the park brake is ON. unexpected machine movement. Install
articulation locking bar.
CAUTION: Prevent possible injury from
unexpected machine movement. Place 7. Disconnect park brake hose (3) from park brake fitting
blocks at front and rear of tires to prevent (2). Plug hose.
machine from rolling. 8. Connect a hose from a hand operated hydraulic pump
to the fitting on park brake.
1. Place blocks at front and rear of tires.
NOTE: Keep hydraulic hand operated pump filled with oil.
2. Connect the towed and towing machines together.
NOTE: Articulation locking bar is installed to prevent
weaving as machine is towed.

Continued on next page OUOE003,000009E ­19­18JUL02­1/2

2­2­21 072310

PN=71
 Operation—Operating the Machine

attempt to remove driveshafts without

CAUTION: Prevent possible injury from blocking front and rear tires.
unexpected machine movement. Sit in operator’s
seat when pumping the hydraulic pump. When 11. Remove driveshafts if a hand operated pump is not
towing the machine, maintain at least 1379 kPa available to release the park brake.
(13.8 bar) (200 psi). If pressure is below 1379
Disconnect driveshafts (1 and 4) at differential and
(13.8 bar) (200 psi), park brake may engage.
transmission and remove from machine.
9. Place hydraulic hand pump on left side of operator’s
station floor. CAUTION: Prevent possible injury from
unexpected machine movement. Place
IMPORTANT: Do not pump pressure up to more blocks at front and rear of tires to prevent
than 2068 kPa (20.7 bar) (300 psi) to avoid machine from rolling.
damage to the park brake.
NOTE: Limit tow to 460 m (500 yd) maximum.
10. Pump handle until gauge needle indicates 1379 kPa
(13.8 bar) (200 psi) which will be required to disengage 12. Tow the machine slowly.
park brake.
13. Place blocks at front and at rear of tires.
To engage the park brake, open the valve in the
hand­operated pump to relieve pressure. 14. Reapply park brake or reinstall driveshaft if it was
removed. See your authorized dealer for installation
information.
CAUTION: Prevent possible injury from
unexpected machine movement. Never
OUOE003,000009E ­19­18JUL02­2/2

2­2­22 072310

PN=72
 Operation—Operating the Machine

Lifting the Machine

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.
Specification
444J (S.N. –604689)
Loader—Weight....................................................................... 10 272 kg
22 645 lb
444J (S.N. 604690– )
Loader—Weight....................................................................... 10 042 kg
22 139 lb
444J (S.N. –604689)
High Lift—Weight..................................................................... 10 377 kg
22 877 lb
444J (S.N. 604690– )
High Lift—Weight..................................................................... 10 147 kg
22 370 lb
444J (S.N. –604689) Tool

T7477AV —UN—19MAR91
Carrier—Weight........................................................................ 10 615 kg
23 406 lb
444J (S.N. 604690– )
Tool Carrier—Weight................................................................ 10 385 kg
22 895 lb
444J (S.N. –604689)
Powerllel—Weight.................................................................... 10 851 kg
23 926 lb
444J (S.N. 604690– )
A—Cables
Powerllel—Weight.................................................................... 10 621 kg
23 415 lb
544J Loader—Weight............................................................... 12 469 kg
27 489 lb 3. Attach a tether cable to machine to control machine
544J High Lift—Weight............................................................. 12 538 kg as it is lifted.
27 641 lb
544J Tool 4. Test lift by raising machine 0.3 m (1 ft) off the ground.
Carrier—Weight........................................................................ 12 521 kg
5. Lift machine and swing to unloading area.
27 609 lb
544J Powerllel—Weight........................................................... 12 987 kg
28 636 lb
624J Loader—Weight............................................................... 14 375 kg
31 691 lb
624J High Lift—Weight............................................................. 14 463 kg
31 885 lb
624J Tool
Carrier—Weight........................................................................ 14 375 kg
31 691 lb
624J Powerllel—Weight........................................................... 15 208 kg
33 534 lb

1. Install machine frame locking bar.

2. Attach cables (A) to machine so cables do not rub
machine.
MM61211,00013D1 ­19­16MAR06­1/1

2­2­23 PN=73
072310
 Maintenance—Machine
Diesel Fuel
Consult your local fuel distributor for properties of the
Sulfur Content for Interim Tier 4 and EU
diesel fuel available in your area.
Stage IIIB Engines
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in • Diesel fuel quality and fuel sulfur content must comply
which they are marketed. with all existing emissions regulations for the area in
which the engine operates.
Diesel fuels specified to EN 590 or ASTM D975 are • Use ONLY ultra low sulfur diesel (ULSD) fuel with a
recommended. Renewable diesel fuel produced by maximum of 0.0015% (15 mg/kg) sulfur content.
hydrotreating animal fats and vegetable oils is basically
identical to petroleum diesel fuel. Renewable diesel that Sulfur Content for Other Engines
meets EN 590 or ASTM D975 is acceptable for use at all
percentage mixture levels.
• Diesel fuel quality and fuel sulfur content must comply
with all existing emissions regulations for the area in
Required Fuel Properties which the engine operates.
• Use of diesel fuel with sulfur content less than 0.10%
In all cases, the fuel shall meet the following properties: (1000 mg/kg) is STRONGLY recommended.
Cetane number of 43 minimum. Cetane number greater
• Use of diesel fuel with sulfur content 0.10% (1000
mg/kg) to 0.50% (5000 mg/kg) may result in REDUCED
than 47 is preferred, especially for temperatures below oil and filter change intervals. Refer to table in Diesel
–20°C (–4°F) or elevations above 1500 m (5000 ft). Engine Oil and Filter Service Intervals.
Cold Filter Plugging Point (CFPP) should be at least 5°C • BEFORE using diesel fuel with sulfur content greater
(9°F) below the expected lowest temperature or Cloud than 0.50% (5000 mg/kg), contact your John Deere
Point below the expected lowest ambient temperature. dealer.

Fuel lubricity should pass a maximum scar diameter of IMPORTANT: Do not mix used diesel engine oil or any
0.45 mm as measured by ASTM D6079 or ISO 12156­1. other type of lubricating oil with diesel fuel.
Improper fuel additive usage may cause damage
on fuel injection equipment of diesel engines.
DX,FUEL1 ­19­03AUG09­1/1

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, If fuel of low or unknown lubricity is used, add John Deere
Canada, and the European Union have adequate lubricity PREMIUM DIESEL FUEL CONDITIONER (or equivalent)
to ensure proper operation and durability of fuel injection at the specified concentration.
system components. However, diesel fuels manufactured
in some areas of the world may lack the necessary Lubricity of Biodiesel Fuel
lubricity.
Significant improvement in lubricity can occur with
IMPORTANT: Make sure the diesel fuel used biodiesel blends up to B20. The gain in lubricity above a
in your machine demonstrates good 20% blend is limited.
lubricity characteristics.

Fuel lubricity should pass a maximum scar diameter of

0.45 mm as measured by ASTM D6079 or ISO 12156­1.
DX,FUEL5 ­19­05OCT07­1/1

3­1­1 072310

PN=74
 Maintenance—Machine

Handling and Storing Diesel Fuel

CAUTION: Handle fuel carefully. Do not fill the When using bio­diesel fuel, the fuel filter may require more
fuel tank when engine is running. frequent replacement due to premature plugging.
DO NOT smoke while you fill the fuel tank Check engine oil level daily prior to starting engine. A
or service the fuel system. rising oil level may indicate fuel dilution of the engine oil.
IMPORTANT: The fuel tank is vented through the
Fill the fuel tank at the end of each day’s operation to
filler cap. If a new filler cap is required, always
prevent water condensation and freezing during cold
replace it with an original vented cap.
weather.
Keep all storage tanks as full as practicable to minimize When fuel is stored for an extended period or if there is a
condensation. slow turnover of fuel, add a fuel conditioner to stabilize the
fuel and prevent water condensation. Contact your fuel
Ensure that all fuel tank caps and covers are installed supplier for recommendations.
properly to prevent moisture from entering.
Monitor water content of the fuel regularly.
DX,FUEL4 ­19­19DEC03­1/1

3­1­2 072310

PN=75
 Maintenance—Machine

Biodiesel Fuel
Biodiesel is a fuel comprised of mono­alkyl esters of long
chain fatty acids derived from vegetable oils or animal When using biodiesel fuel, the engine oil level must be
fats. Biodiesel blends are biodiesel mixed with petroleum checked daily. If oil becomes diluted with fuel, shorten oil
diesel fuel on a volume basis. change intervals. Refer to Diesel Engine Oil and Filter
Service Intervals for more details regarding biodiesel and
Biodiesel users in the U.S. are strongly encouraged to engine oil change intervals.
purchase biodiesel blends from a BQ­9000 Certified
Marketer and sourced from a BQ­9000 Accredited The following must be considered when using biodiesel
Producer (as certified by the National Biodiesel Board). blends up to B20:
Certified Marketers and Accredited Producers can be • Cold weather flow degradation
found at the following website: http://www.bq­9000.org. • Stability and storage issues (moisture absorption,
While 5% blends are preferred (B5), biodiesel oxidation, microbial growth)
concentrations up to a 20% blend (B20) in petroleum • Possible filter restriction and plugging (usually a
diesel fuel can be used in all John Deere engines. problem when first switching to biodiesel on used
Biodiesel blends up to B20 can be used ONLY if the engines.)
biodiesel (100% biodiesel or B100) meets ASTM D6751 • Possible fuel leakage through seals and hoses
(US), EN 14214 (EU), or equivalent specification. Expect • Possible reduction of service life of engine components
a 2% reduction in power and a 3% reduction in fuel The following must also be considered when using
economy when using B20. biodiesel blends above B20.
John Deere approved fuel conditioners containing • Possible coking and/or blocked injector nozzles,
detergent/dispersant additives are recommended when resulting in power loss and engine misfire if John
using lower biodiesel blends, but are required when using Deere approved fuel conditioners containing
blends of B20 or greater. detergent/dispersant additives are not used
John Deere engines can also operate on biodiesel blends • Possible crankcase oil dilution, requiring more frequent
above B20 (up to 100% biodiesel) ONLY if the biodiesel oil changes
meets the EN 14214 specification (primarily available in • Possible corrosion of fuel injection equipment
Europe). Engines operating on biodiesel blends above • Possible lacquering and/or seizure of internal
B20 may not fully comply with all applicable emissions components
regulations. Expect up to a 12% reduction in power • Possible formation of sludge and sediments
and an 18% reduction in fuel economy when using • Possible thermal oxidation of fuel at elevated
100% biodiesel. John Deere approved fuel conditioners temperatures
containing detergent/dispersant additives are required. • Possible elastomer seal and gasket material
degradation ( primarily an issue with older engines)
The petroleum diesel portion of biodiesel blends must • Possible compatibility issues with other materials
meet the requirements of ASTM D975 (US) or EN 590 (including copper, lead, zinc, tin, brass, and bronze)
(EU) commercial standards. used in fuel systems and fuel handling equipment
Biodiesel blends up to B20 must be used within 90 days of
• Possible reduction in water separator efficiency
the date of biodiesel manufacture. Biodiesel blends from
• Potential high acid levels within fuel system
B21 to B100 must be used within 45 days of the date of
• Possible damage to paint if exposed to biodiesel
biodiesel manufacture. IMPORTANT: Raw pressed vegetable oils are
NOT acceptable for use as fuel in any
Request a certificate of analysis from your fuel distributor concentration in John Deere engines. Their
to ensure that the fuel is compliant with the above use could cause engine failure.
specifications.
Consult your John Deere dealer for approved biodiesel
fuel conditioners to improve storage and performance
with biodiesel fuels.
DX,FUEL7 ­19­04OCT07­1/1

3­1­3 072310

PN=76
 Maintenance—Machine

Low Sulfur Diesel Fuel Conditioner CONDITIONER. It provides lubricating properties along
with other useful benefits, such as cetane improver,
When possible, use existing fuel formulations for engines anti­oxidant, fuel stabilizer, corrosion inhibitor and others.
used off­highway. This fuel will not require any additives John Deere PREMIUM DIESEL FUEL CONDITIONER is
to provide good performance and engine reliability. specifically for use with low sulfur fuels. Nearly all other
However, many local fuel distributors will not carry both diesel fuel conditioners only improve cold weather flow
low and regular sulfur diesel fuels. and stabilize long­term fuel storage. They do not contain
If the local fuel distributor will supply only low sulfur fuel, the lubrication additives needed by rotary fuel injection
order and use John Deere PREMIUM DIESEL FUEL pumps.
TX,45,JC2126 ­19­15AUG97­1/1

Testing Diesel Fuel water content, suitability for cold weather operation, and
whether the fuel meets specifications.
DIESELSCAN™ is a John Deere fuel analysis program
that can be used to monitor the quality of your fuel. The Check with your John Deere dealer for availability of
DIESELSCAN analysis verifies fuel type, cleanliness, DIESELSCAN kits.
DIESELSCAN is a trademark of Deere & Company
DX,FUEL6 ­19­14NOV05­1/1

3­1­4 072310

PN=77
 Maintenance—Machine

Minimizing the Effect of Cold Weather on Diesel Engines

John Deere diesel engines are designed to operate chemistry, or equivalent fuel conditioner to treat non­winter
effectively in cold weather. grade fuel (No. 2­D in North America) during the
cold­weather season. This generally extends operability
However, for effective starting and cold­weather operation, to about 10 °C (18 °F) below the fuel cloud point. For
a little extra care is necessary. The following information operability at even lower temperatures, use winter grade
outlines steps that can minimize the effect that cold fuel.
weather may have on starting and operation of your
engine. See your John Deere dealer for additional IMPORTANT: Treat fuel when outside temperature
information and local availability of cold­weather aids. drops below 0 °C (32 °F). For best results, use
with untreated fuel. Follow all recommended
Use Winter Grade Fuel instructions on label.
When temperatures fall below 0 °C (32 °F), winter
grade fuel (No. 1­D in North America) is best suited for BioDiesel
cold­weather operation. Winter grade fuel has a lower When operating with biodiesel blends, wax formation can
cloud point and a lower pour point. occur at warmer temperatures. Begin using John Deere
Cloud point is the temperature at which wax will begin to PREMIUM BIODIESEL FUEL CONDITIONER (winter
form in the fuel and this wax causes fuel filters to plug. formula) at 5 °C (41 °F) to treat biodiesel fuels during
Pour point is the lowest temperature at which movement the cold­weather season. Use B5 or lower blends at
of the fuel is observed. temperatures below 0 °C (32 °F). Use only winter grade
petroleum diesel fuel at temperatures below ­10 °C (14
NOTE: On an average, winter grade diesel fuel has a lower °F).
BTU (heat content) rating. Using winter grade fuel
may reduce power and fuel efficiency, but should not Winterfronts
cause any other engine performance effects. Check
Use of fabric, cardboard, or solid winterfronts is not
the grade of fuel being used before troubleshooting
recommended with any John Deere engine. Their use
for low­power complaints in cold­weather operation.
can result in excessive engine coolant, oil, and charge
air temperatures. This can lead to reduced engine life,
Air Intake Heater
loss of power and poor fuel economy. Winterfronts may
An air intake heater is an available option for some also put abnormal stress on fan and fan drive components
engines to aid cold weather starting. potentially causing premature failures.

Ether If winterfronts are used, they should never totally close

off the grill frontal area. Approximately 25% area in the
An ether port on the intake is available to aid cold weather center of the grill should remain open at all times. At no
starting. time should the air blockage device be applied directly
to the radiator core.
CAUTION: Ether is highly flammable. Do not Radiator Shutters
use ether when starting an engine equipped
with glow plugs or an air intake heater. If equipped with a thermostatically controlled radiator
shutter system, this system should be regulated in such
Coolant Heater a way that the shutters are completely open by the time
the coolant reaches 93 °C (200 °F) to prevent excessive
An engine block heater (coolant heater) is an available intake manifold temperatures. Manually controlled
option to aid cold weather starting. systems are not recommended.
Seasonal Viscosity Oil and Proper Coolant If air­to­air aftercooling is used, the shutters must be
Concentration completely open by the time the intake manifold air
temperature reaches the maximum allowable temperature
Use seasonal grade viscosity engine oil based on the
out of the charge air cooler.
expected air temperature range between oil changes
and a proper concentration of low silicate antifreeze as For more information, see your John Deere dealer.
recommended. (See DIESEL ENGINE OIL and ENGINE
COOLANT requirements in this section.)
Diesel Fuel Flow Additive
Use John Deere PREMIUM DIESEL FUEL
CONDITIONER (winter formula), which contains anti­gel
DX,FUEL10 ­19­03AUG09­1/1

3­1­5 072310

PN=78
 Maintenance—Machine

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require
Avoid mixing different brands or types of oils. Oil
lubricant recommendations different from those printed
manufacturers blend base stock and additives to
in this manual. Some John Deere brand coolants and
create their oils and to meet certain specifications and
lubricants may not be available in your location.
performance requirements. Mixing different oils can
Synthetic lubricants may be used if they meet the interfere with proper functioning of these formulations and
performance requirements as shown in this manual. degrade lubricant performance.
The temperature limits and service intervals shown in this Consult your authorized John Deere dealer to obtain
manual apply to both conventional and synthetic oils. specific information and recommendations.

Re­refined base stock products may be used if the

finished lubricant meets the performance requirements.
AM40430,00000AA ­19­03NOV08­1/1

Diesel Engine Oil

Use oil viscosity based on the expected air temperature
range during the period between oil changes. 50 o C 122o F

John Deere Plus­50™ II oil is preferred. 40 o C 104o F

John Deere Plus­50™ is also recommended. 30 o C 86 o F

SAE 15W-40
Other oils may be used if they meet one or more of the

SAE 10W-40
following: 20 o C 68 o F

SAE 10W-30

SAE 0W-40
SAE 5W-30
• John Deere Torq­Gard Supreme™ 10 o C 50 o F
• API Service Category CJ­4
• API Service Category CI­4 PLUS 0o C 32 o F
• API Service Category CI­4
• API Service Category CH­4 -10 o C 14 o F
• ACEA Oil Sequence E9
• ACEA Oil Sequence E7 -20 o C -4 o F

TS1689 —UN—18JUL07
• ACEA Oil Sequence E6
• ACEA Oil Sequence E5 -30 o C -22 o F
• ACEA Oil Sequence E4
• ACEA Oil Sequence E3 -40 o C -40 o F
Multi­viscosity diesel engine oils are preferred.
Diesel fuel quality and fuel sulfur content must comply Oil Viscosities for Air Temperature Ranges
with all existing emissions regulations for the area in
which the engine operates.
DO NOT use diesel fuel with sulfur content greater than
1.0% (10 000 mg/kg).
Plus­50 is a trademark of Deere & Company
Torq­Gard Supreme is a trademark of Deere & Company
DX,ENOIL7 ­19­03AUG09­1/1

3­1­6 PN=79
072310
 Maintenance—Machine

Diesel Engine Oil and Filter Service Intervals

The oil and filter service intervals in the following table • Use of diesel fuel with sulfur content 0.05% (500 mg/kg)
should be used as guidelines. Actual service intervals to 0.50% (5000 mg/kg) may result in REDUCED oil and
also depend on operation and maintenance practices. It filter change intervals as shown in the table.
is suggested to use oil analysis to determine the actual • BEFORE using diesel fuel with sulfur content greater
useful life of the oil and to aid in selection of the proper than 0.50% (5000 mg/kg), contact your John Deere
oil and filter service interval. dealer.
Oil and filter service intervals are based on a combination IMPORTANT: When using biodiesel blends greater
of oil pan capacity, type of engine oil and filter used, and than B20, reduce the oil and filter service
sulfur content of the diesel fuel. interval by 50% or monitor engine oil based
Engine Oil and Filter Service Intervals
on test results from Oilscan.
Standard Drain Oil Pan Extended Drain
Oil Pan
Oil types in the table include:
Fuel Sulfur Less than 0.05% (500 mg/kg) • John Deere Plus­50™ II and John Deere Plus­50 oils.
Plus­50 375 hours 500 hours • “Other Oils” include John DeereTorq­Gard Supreme™,
Other Oils 250 hours 250 hours API CJ­4, API CI­4 PLUS, API CI­4, API CH­4, ACEA
Fuel Sulfur 0.05 ­ 0.50% (500 ­ 5000 mg/kg)
E9, ACEA E7, ACEA E6, ACEA E5, ACEA E4, or ACEA
E3 oils.
Plus­50 275 hours 400 hours
Other Oils 150 hours 150 hours NOTE: The 500 hour extended oil and filter change interval
Fuel Sulfur 0.50 ­ 1.00% (5000 ­ 10 000 mg/kg) is only allowed if all the following conditions are met:
Plus­50 187 hours 250 hours • Engine equipped with an extended drain
Other Oils 125 hours 125 hours interval oil pan
The service interval of “Other Oils” may be extended only if oil analysis • Use of diesel fuel with sulfur content less
is performed to determine the actual service life, to a maximum not than 0.05% (500 mg/kg)
to exceed that of Plus­50. • Use of John Deere Plus­50™ II or John
Deere Plus­50 oil
Diesel fuel sulfur level will affect engine oil and filter • Use of an approved John Deere oil filter
service intervals. Higher fuel sulfur levels reduce oil and
filter service intervals as shown in the table.
• Use of diesel fuel with sulfur content less than 0.05%
(500 mg/kg) is strongly recommended.

Plus­50 is a trademark of Deere & Company

Torq­Gard Supreme is a trademark of Deere & Company
DX,ENOIL12 ­19­03AUG09­1/1

3­1­7 072310

PN=80
 Maintenance—Machine

Transmission, Park Brake, and Differential

Oil
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
The following oils are preferred:
• John Deere HY­GARD®
• John Deere Low Viscosity HY­GARD®
Other oils may be used if they meet one of the following:
• John Deere Standard JDM J20C
• John Deere Standard JDM J20D
Use John Deere BIO­HY­GARD™oil when a

TS1660 —UN—10OCT97
biodegradable fluid is required.

HY­GARD is a registered trademark of Deere & Company

BIO­HY­GARD is a trademark of Deere & Company
HG31779,0000336 ­19­08DEC03­1/1

Hydraulic Reservoir Oil

Use oil viscosity based on the expected air temperature
range during the period between oil changes.
The following oil is preferred:
• John Deere PLUS­50™
The following oil is also recommended:
• John Deere TORQ­GARD SUPREME™
Other oils may be used if they meet one or more of the
following:
• API Service Classification CH­4
• API Service Classification CG­4

T148385 —UN—19NOV01

PLUS­50 is a trademark of Deere & Company

TORQ­GARD SUPREME is a trademark of Deere & Company
HG31779,0000335 ­19­08DEC03­1/1

3­1­8 PN=81
072310
 Maintenance—Machine

Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
John Deere SD POLYUREA GREASE is preferred.
The following greases are also recommended
• John Deere HD LITHIUM COMPLEX GREASE
• John Deere HD WATER RESISTANT GREASE
• John Deere GREASE­GARD™
Other greases may be used if they meet the following:
NLGI Performance Classification GC­LB
IMPORTANT: Some types of grease thickeners are not

TS1673 —UN—31OCT03
compatible with others. Consult your grease
supplier before mixing different types of grease.

GREASE­GARD is a trademark of Deere & Company

DX,GREA1 ­19­07NOV03­1/1

3­1­9 PN=82
072310
 Maintenance—Machine

Heavy Duty Diesel Engine Coolant

The engine cooling system is filled to provide year­round unavailable in the geographical area where service is
protection against corrosion and cylinder liner pitting, and performed.
winter freeze protection to ­37°C (­34°F). If protection at
lower temperatures is required, consult your John Deere If these coolants are unavailable, use a coolant
dealer for recommendations. concentrate or prediluted coolant intended for use with
heavy duty diesel engines and with a minimum of the
John Deere COOL­GARD™ II Premix Coolant following chemical and physical properties:
is preferred.
• Is formulated with a quality nitrite­free additive package.
John Deere COOL­GARD II Premix is available in a • Provides cylinder liner cavitation protection according to
concentration of 50% ethylene glycol. either the John Deere Cavitation Test Method or a fleet
study run at or above 60% load capacity.
Additional Recommended Coolants • Protects the cooling system metals (cast iron, aluminum
alloys, and copper alloys such as brass) from corrosion.
The following engine coolants are also recommended:
The additive package must be part of one of the following
• John Deere COOL­GARD II Concentrate in a 40% to coolant mixtures:
60% mixture of concentrate with quality water.
• John Deere COOL­GARD Premix (available in a • ethylene glycol or propylene glycol base prediluted
concentration of 50% ethylene glycol). (40% to 60%) heavy duty coolant
• John Deere COOL­GARD Concentrate in a 40% to 60% • ethylene glycol or propylene glycol base heavy duty
mixture of concentrate with quality water. coolant concentrate in a 40% to 60% mixture of
• John Deere COOL­GARD PG Premix (available in a concentrate with quality water
concentration of 55% propylene glycol).
Water Quality
John Deere COOL­GARD II Premix and COOL­GARD II
Concentrate coolants do not require use of supplemental Water quality is important to the performance of the
coolant additives. cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol and
John Deere COOL­GARD Premix, COOL­GARD propylene glycol base engine coolant concentrate.
Concentrate, and COOL­GARD PG Premix do not require
use of supplemental coolant additives, except for periodic IMPORTANT: Do not use cooling system sealing
replenishment of additives during the drain interval. additives or antifreeze that contains
sealing additives.
Use John Deere COOL­GARD PG Premix when a
non­toxic coolant formulation is required. Do not mix ethylene glycol and propylene
glycol base coolants.
Other Coolants
Do not use coolants that contain nitrites.
It is possible that John Deere COOL­GARD II,
COOL­GARD, and COOL­GARD PG coolants are

COOL­GARD is a trademark of Deere & Company

DX,COOL3 ­19­03NOV08­1/1

3­1­10 072310

PN=83
 Maintenance—Periodic Maintenance
Service Your Machine at Specified Intervals
Lubricate, make service checks and adjustments at
intervals shown on the periodic maintenance chart (A)
and on the following pages.
Service items at multiples of the original requirement.

T133372C —UN—18AUG00
For example, at 500 hours also service those items (if
applicable) listed under 250 hours, 100 hours, 50 hours
and 10 hours or daily.

A—Periodic Maintenance Chart

CED,OUOE035,32 ­19­17FEB06­1/1

Check Hour Meter Regularly

Check hour meter display (1) to determine when your
machine needs periodic maintenance. 4F 950 rpm
Intervals on the periodic maintenance chart are for
operating in normal conditions. If you operate your 1234
323.3

T193351 —19—13OCT03
machine in severe conditions, you should service it at
SHORTER INTERVALS. AUTO ODM HOURS SPEED
1— Hour Meter Display
1

HG31779,00002DE ­19­26JUN03­1/1

3­2­1 PN=84
072310
 Maintenance—Periodic Maintenance

Prepare Machine for Maintenance

Before performing maintenance procedures given in the
following sections, and before leaving the operator’s seat,
park the machine as described below unless another
position is specified in the procedure.

T192464A —UN—18SEP03
1. Lower equipment to ground.
If bucket needs to be off ground for maintenance, see
Boom Lock. (Section 3­2.)
2. Stop engine.
3. Turn key switch to “On”.
4. Press return­to­carry switch (1) to “Off” position, if
equipped.

CAUTION: Prevent possible injury from

unexpected boom movement. The boom may

T192873C —UN—18SEP03
move up when ride control switch is turned
ON. Clear all bystanders from area.

5. Cycle ride control switch (2) from “OFF” (no lights)

to “ON” (left light only illuminated), if equipped, to
discharge ride control accumulator.
6. Press and hold pilot enable/boom down switch (3)
Column FNR Shown
while moving control lever forward to lower boom.
7. While still holding the pilot enable/boom down switch,
put boom in float position for 5 seconds, then cycle
each hydraulic control lever to relieve pressure.
8. Move FNR (4) to N. If equipped with column FNR,

T194851B —UN—18SEP03
engage neutral lock (5).

CAUTION: Prevent possible injury from

unexpected machine movement. Push park
brake switch to ON to hold machine.

9. Push park brake switch to ON.

Joystick FNR Shown
10. Turn key switch to “Off”. If maintenance must be
performed with engine running, do not leave machine
unattended. 1— Return­to­Carry Switch 4— FNR
2— Ride Control Switch 5— Neutral Lock Lever
11. Turn battery disconnect switch OFF, if equipped. 3— Pilot Enable/Boom Down
Switch

VD76477,000046C ­19­23MAY06­1/1

3­2­2 PN=85
072310
 Maintenance—Periodic Maintenance

Opening Engine Side Shields and Service

Doors
CAUTION: Prevent possible injury from engine
service door closing. Always keep service
door in the open locked position when

T192358A —UN—18SEP03
servicing the engine area.

1. Pull out on latch (1) to open lower engine service door.

1— Latch

HG31779,00002B9 ­19­19JUN03­1/2

2. Open service door to full extent. Gas cylinder (A) will

lock door in place.

A—Cylinder

T131518B —UN—07JUN00
HG31779,00002B9 ­19­19JUN03­2/2

Locking Machine Frame

CAUTION: Prevent possible injury from

unexpected machine movement. Connect
frame locking bar to both frames before
you work in frame pivot area.

T161062B —UN—29OCT02
1. Align machine frames.
2. Remove quick lock ring (1) and pull locking pin (2)
from hole.
3. Rotate locking bar (3) to align with hole in machine
frame.
4. Install locking pin through hole in loader frame and
end of locking bar. Install quick lock ring to secure
locking bar in place.

1— Quick Lock Ring 3— Locking Bar

T161061B —UN—29OCT02

2— Locking Pin

HG31779,0000171 ­19­29OCT02­1/1

3­2­3 PN=86
072310
 Maintenance—Periodic Maintenance

Boom Lock
CAUTION: Prevent possible crushing injury
from falling boom. Always install boom lock
before working on or around this machine
with the boom raised.

T161064B —UN—29OCT02
Empty bucket and place in dump position
before installing boom lock.

1. Raise boom. Empty bucket and place in dump position

before installing boom lock (1).
2. Loosen hand bolt (2) and remove boom lock from side
of machine.
3. Install lock on boom cylinder and lock lever facing to
outside of machine and lower boom onto lock.
4. Tighten hand bolt.

T161065B —UN—29OCT02
5. Perform the Prepare Machine for Maintenance
procedure. (Section 3­2).
6. Before removing boom lock from cylinder, raise boom
slightly to relieve pressure. Return boom lock to
storage position on side of machine and tighten hand
hold.

1— Boom Lock 2— Hand Bolt

HG31779,0000172 ­19­23MAY06­1/1

3­2­4 PN=87
072310
 Maintenance—Periodic Maintenance

Pin Removal—If Equipped With Powerllel

Linkage

CAUTION: Avoid injury from sudden linkage

movement. Support powerllel bell crank
before removing any pins.

Before removing any pin on the powerllel linkage, you

must support the bell crank (1) with hoist. See your
authorized dealer for further details.

T202191B —UN—28SEP04
HG31779,000003E ­19­30SEP04­1/1

Opening Grille Door

IMPORTANT: Avoid machine damage. Open
right and left cooling package side doors
prior to opening grille door.

T196239A —UN—18NOV03
Push up on side door release lever (1) to open cooling
package side door (2) to full extent.
Press down on release lever (3) to open grille door.

1— Cooling Package Side Door 3— Release Lever

Release Lever (one on each
side)
2— Cooling Package Side Door Cooling Package Side Door and Release Lever (one on each side)
(one on each side)
T196240A —UN—11NOV03

HG31779,00002DF ­19­26JUN03­1/1

3­2­5 PN=88
072310
 Maintenance—Periodic Maintenance

Check Windshield Washer Fluid Level

Open lower left engine side shield.
Check fluid in windshield washer bottle (1).
During winter season, use all season windshield washer

T192360A —UN—18SEP03
fluid which will not freeze.

1— Windshield Washer Bottle

HG31779,00002BA ­19­19JUN03­1/1

Fluid Analysis Program Test Kits and 3­Way

Coolant Test Kit
Fluid Analysis Program Test Kits and the 3­Way Coolant
Test Kit are John Deere fluid sampling products to help

TX1003513A —UN—20FEB06
you monitor machine maintenance and system condition.
The objective of a fluid sampling program is to ensure
machine availability when you need it and to reduce
repair costs by identifying potential problems before they
become critical.
Engine, hydraulic, power train, and coolant samples
should be taken from each system on a periodic basis,
usually prior to a filter and/or fluid change interval. Certain
systems require more frequent sampling. Consult your
authorized John Deere dealer on a maintenance program you in lowering your overall operating costs through fluid
for your specific application. Your authorized John Deere sampling.
dealer has the sampling products and expertise to assist
AM40430,00002FE ­19­25MAR10­1/1

3­2­6 PN=89
072310
 Maintenance—Periodic Maintenance

Service Intervals
Model: 444J, 544J and 624J Loader PIN/Serial Number:
Hour Meter Reading:

SERVICE INTERVALS
Service your machine at intervals shown on this chart. Also, perform service on items at multiples of the original requirement. For example, at 500
hours also service those items (if applicable) listed under 250 hours, 100 hours, 50 hours, and 10 hours or daily.
FLUID SAMPLING
Take fluid samples from each system as indicated on this form. The manufacturer of the fluid analysis kits will provide maintenance
recommendations based upon the results of the fluid analysis and the operating information you supply. Regular fluid sampling extends the
operational life of your machine.

As Required
□ Inspect tires and check pressure □ Drain primary fuel filter and clean strainer
□ Tighten wheel retainer nuts □ Check and clean cab fresh air filter
□ Clean or replace air cleaner elements □ Check and clean cab recirculating air filter
□ Inspect belt, A/C compressor and alternator □ Replace final fuel filter

Every 10 Hours or Daily

□ Check coolant recovery tank level □ Check hydraulic system oil level
□ Clean air cleaner dust unloader valve □ Check transmission oil level
□ Check engine oil level

Every 100 Hours

□ Grease loader linkage and cylinder pivots □ Grease oscillating rear axle
□ Grease front steering cylinder pivots □ Grease rear steering cylinder pivots

Initial Service—250 Hours1

□ Change engine break­in oil and replace filter □ Change front and rear differential/axle oil
1
Perform initial service once after the first 250 hours of operation.

Every 250 Hours

□ Grease driveline sliding joints □ Check surge tank level
□ Take engine oil sample

Every 500 Hours

□ Grease drive line sliding joints, upper and lower □ Replace hydraulic reservoir breather filter
□ Check air intake hoses □ Check park brake oil level
□ Check battery electrolyte level and terminals □ Check front and rear differential/axle oil level
□ Change engine oil and replace filter □ Take transmission oil sample
□ Replace final fuel filter □ Take engine coolant sample
□ Replace primary fuel filter and fuel strainer □ Take diesel fuel sample
□ Replace hydraulic system return filter □ Take axle oil sample
□ Lubricate rear oscillating support cover □ Take hydraulic oil sample

Every 1000 Hours

□ Remove and clean engine crankcase vent tube □ Grease frame hinge pivots
□ Replace air cleaner dust unloader valve □ Drain and refill park brake oil
□ Replace air cleaner elements □ Check radiator coolant and hoses
□ Replace transmission oil filter

Continued on next page CS58540,0000062 ­19­23JUN10­1/2

3­2­7 072310

PN=90
 Maintenance—Periodic Maintenance

Every 2000 Hours

□ Check and adjust engine valve lash □ Clean magnetic axle oil drain plug2
□ Drain and refill cooling system □ Change transmission oil (normal operation)3
□ Change front and rear differential/axle oil □ Re­run clutch calibration (cab monitor)
□ Clean axle differential recirculation screen (if equipped)4
2
The magnetic axle oil drain plug is serving its function when a ball of fine metal particles or machining chips are found on the magnet. If
concerned with the amount of debris on the magnet of the drain plug, the magnet could be cleaned and checked again after running a short period
of time with fresh oil.
3
Service intervals should be reduced to 1500 hours in severe applications, which run the torque converter at high loads for more than approximately
25% of the time. (Examples may include basement digging, land clearing, etc.)
4
Axle differential recirculation screen is equipped with the optional axle oil coolers.

Every 4000 Hours

□ Drain, flush, and refill hydraulic oil □ Clean hydraulic system fill strainer

Every 4500 Hours

□ Replace engine crankshaft dampener
CS58540,0000062 ­19­23JUN10­2/2

3­2­8 072310

PN=91
 Maintenance—Periodic Maintenance

Required Parts
REQUIRED PARTS
Insure machine performance and availability; use only genuine John Deere parts. Verify part numbers are current and that any associated
parts are also on hand i.e. filter O­rings.
Initial
Every Every Every Every Every Every
Part Service1 ­
Description 250 500 1000 2000 4000 4500
Number 250
Hours Hours Hours Hours Hours Hours
Hours
Engine Oil Filter RE541420 1 1 1 1 1 1
Primary Fuel Filter:
• 444J RE517180 1 1 1 1 1
• 544J & 624J RE509036 1 1 1 1 1
Fuel Strainer AH162914 1 1 1 1 1
In­line Fuel Filter: AT223493 1 1 1 1 1
Final Fuel Filter RE509032 1 1 1 1 1
Transmission Filter AT336140 1 1 1
Hydraulic System Return AT310905 1 1 1 1 1
Filter
Hydraulic Reservoir AM39653 1 1 1 1 1
Breather Filter
Air Cleaner Dust Unloader M89679 1 1 1
Valve
Air Filter (Primary) AT300487 1 1 1
Air Filter (Secondary) AT314583 1 1 1
Engine Rocker Arm Cover Gasket:
• 444J R123542 1 1
• 544J R123543 1 1
• 624J R504882 1 1
Engine Crankshaft Dampener:
• 544J RE59355 1
• 624J RE508577 1
John Deere Plus­50™ II Engine & Hydraulic Oil:
• 444J TY266745 17.5 L 17.5 L 17.5 L 17.5 L 114.0 L 17.5 L
(4.6 gal) (4.6 gal) (4.6 gal) (4.6 gal) (30.0 gal) (4.6 gal)
• 544J TY266745 18.5 L 18.5 L 18.5 L 18.5 L 115.0 L 18.5 L
(5.0 gal) (5.0 gal) (5.0 gal) (5.0 gal) (30.3 gal) (5.0 gal)
• 624J TY266745 24.0 L 24.0 L 24.0 L 24.0 L 143.0 L 24.0 L
(6.3 gal) (6.3 gal) (6.3 gal) (6.3 gal) (37.8 gal) (6.3 gal)
HY­GARD™ Oil:
• 444J (S.N.—604689) TY63545 34.0 L 0.3 L 52.5 L 148.0 L
(9.0 gal) 0.3 qt (13.8 gal) (39.0 gal)
• 444J (S.N.604690— ) TY63545 44.0 L 0.3 L 62.5 L 161.0 L
(11.6 gal) 0.3 qt 16.5 gal) (42.5 gal)
• 544J TY63545 36.0 L 0.3 L 54.5 L 148.0 L
(9.5 gal) 0.3 qt (14.4 gal) (39.0 gal)
• 624J TY63545 44.5 L 0.3 L 65.5 L 189.0 L
(11.8 gal) 0.3 qt (17.8 gal) (50.0 gal)
Pre­Diluted Coolant:
• 444J & 544J TY25081 21.0 L 21.0 L
(5.5 gal) (5.5 gal)
• 624J TY25081 22.0 L 22.0 L
(5.8 gal) (5.8 gal)
Coolant Conditioner TY16004 As Required

Fluid Analysis Kits6

Diesel Engine Oil AT317904 1 1 1 1 1 1
Transmission Oil AT303189 1 1 1 1 1

Continued on next page CS58540,0000068 ­19­21JUL10­1/2

3­2­9 072310

PN=92
 Maintenance—Periodic Maintenance

Axle Oil AT303189 2 2 2 2 2

Hydraulic Oil AT303189 1 1 1 1 1
Diesel Fuel AT180344 1 1 1 1 1
Engine Coolant AT183016 1 1 1 1 1
3­Way Heavy Duty TY16175 1 1 1 1 1
Coolant Test Kit
1
Perform initial service once after the first 250 hours of operation.
5
For recommended oil type and oil viscosities based on operating temperatures, see Maintenance—Machine. (Section 3­1.)
6
Based on fluid analysis results, intervals may need to be adjusted for your operating conditions. Consult your local John Deere dealer.

PLUS­50 is a trademark of Deere & Company

HY­GARD is a trademark of Deere & Company
CS58540,0000068 ­19­21JUL10­2/2

3­2­10 072310

PN=93
 Maintenance—As Required
Check Tire Pressure
CAUTION: Explosive separation of a tire and rim
parts can cause serious injury or death.
Always maintain the correct tire pressure. DO NOT
inflate tires above the recommended pressure.
Inspect tires and wheels daily. DO NOT operate
with low pressure, cuts, bubbles, damaged
rims, or missing lug bolts.
Carefully inspect any tire and rim assembly that
has been run flat or severely underinflated before
reinflating the tire. Damage to the rim and tire
may have developed. Call your authorized dealer
or a qualified repair service to inspect the rim and
tire assembly and make necessary repairs.
When inflating tires, use a clip­on chuck and
extension hose long enough to allow you to stand
to one side and NOT in front of or over the tire
assembly. Use a safety cage if available.

TS211 —UN—23AUG88
NEVER cut or weld on an inflated tire or
rim assembly. Heat from welding could
cause an increase in pressure and may
result in tire explosion.
Do not attempt to mount a tire if you do not
have the proper equipment and experience to
perform the job. Have it done by your authorized
dealer or a qualified repair service.

Check tire pressure with an accurate gauge having 7.0

kPa (0.07 bar) (1 psi) graduations.

T108057B —UN—12MAR97
1. Remove pipe cap (A).
2. Shut off air supply to hose.
3. Move gauge hand to correct pressure.
4. Lock air chuck on tire valve.
5. Turn on air supply. Stand to front or rear of tire when
you add air to tire.
6. After tire is at correct pressure, shut off air supply.
Release chuck. (See following Tire Pressure chart.)
7. Inspect tire for damage.
T87502 —UN—21OCT88

A—Pipe Cap

TX,55,JC1944 ­19­11MAR97­1/1

3­3­1 PN=94
072310
 Maintenance—As Required

Tire Pressures (444J Z­Bars and High Lifts) To increase side­to­side stability, increase front tire
The following tables indicate the recommended Tire pressures in 2 PSI increments.
Pressures (PSI) for 22,500 pound loader with 2.5 cubic
To adjust fore­aft stability, increase or decrease rear tire
yard bucket, handling 3400 pound per cubic yard material.
pressures in 2 PSI increments.
Recommended ply ratings for Bias Ply Tires and star See Tire Manufacturer’s charts for detailed load, pressure
ratings for Radial Tires in parenthesis. and distance recommendations.
Addition of fluids, water and/or calcium chloride does not
affect recommended tire pressures.
Bridgestone Firestone General Goodyear
Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
15.5­25 L2, L2/E2, 400 kPa 276 kPa 12 400 kPa 276 kPa 12 400 kPa 276 kPa 12 400 kPa 276 kPa 12
L2/E2/G2, (4.00 bar) (2.76 bar) (4.00 bar) (2.76 bar) (4.00 bar) (2.76 bar) (4.00 bar) (2.76 bar)
L3, L3/E3, (58 psi) (33 psi) (58 psi) (33 psi) (58 psi) (33 psi) (58 psi) (33 psi)
L3/E3/G3,
L4, L5
17.5­25 L2, L2/E2, 303 kPa 152 kPa 12 303 kPa 152 kPa 12 303 kPa 152 kPa 12 303 kPa 152 kPa 12
L2/E2/G2, (3.03 bar) (1.52 bar) (3.03 bar) (1.52 bar) (3.03 bar) (1.52 bar) (3.03 bar) (1.52 bar)
L3, L3/E3, (44 psi) (22 psi) (44 psi) (22 psi) (44 psi) (22 psi) (44 psi) (22 psi)
L3/E3/G3,
L4, L5
20.5­25 L2, L2/E2, 276 kPa 110 kPa 12 276 kPa 110 kPa 12 276 kPa 110 kPa 12 276 kPa 110 kPa 12
L2/E2/G2, (2.76 bar) (1.10 bar) (2.76 bar) (1.10 bar) (2.76 bar) (1.10 bar) (2.76 bar) (1.10 bar)
L3, L3/E3, (33 psi) (16 psi) (33 psi) (16 psi) (33 psi) (16 psi) (33 psi) (16 psi)
L3/E3/G3,
L4, L5
28L­26 LS2 241 kPa 207 kPa 14
(2.41 bar) (2.07 bar)
(35 psi) (30 psi)

Bridgestone Firestone Goodyear Michelin

Size Front Rear StarFront Rear Star Front Rear StarFront Rear Star
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
15.5R25 L2, L2/E2, 503 kPa 234 kPa * 503 kPa 234 kPa * 503 kPa 234 kPa * 448 kPa 200 kPa *
L2/E2/G2 (5.03 bar) (2.34 bar) (5.03 bar) (2.34 bar) (5.03 bar) (2.34 bar) (4.48 bar) (2.00 bar)
(73 psi) (34 psi) (73 psi) (34 psi) (73 psi) (34 psi) (65 psi) (29 psi)
L3, L3/E3, 503 kPa 234 kPa * 503 kPa 234 kPa * 503 kPa 234 kPa * 400 kPa 200 kPa *
L3/E3/G3, (5.03 bar) (2.34 bar) (5.03 bar) (2.34 bar) (5.03 bar) (2.34 bar) (4.00 bar) (2.00 bar)
L4, L5 (73 psi) (34 psi) (73 psi) (34 psi) (73 psi) (34 psi) (58 psi) (29 psi)
17.5R25 L2, L2/E2, 400 kPa 200 kPa * 400 kPa 200 kPa * 379 kPa 193 kPa * 352 kPa 200 kPa *
L2/E2/G2 (4.00 bar) (2.00 bar) (4.00 bar) (2.00 bar) (3.79 bar) (1.93 bar) (3.52 bar) (2.00 bar)
(58 psi) (29 psi) (58 psi) (29 psi) (55 psi) (28 psi) (51 psi) (29 psi)
L3, L3/E3, 400 kPa 200 kPa * 400 kPa 200 kPa * 379 kPa 193 kPa * 303 kPa 200 kPa *
L3/E3/G3, (4.00 bar) (2.00 bar) (4.00 bar) (2.00 bar) (3.79 bar) (1.93 bar) (3.03 bar) (2.00 bar)
L4, L5 (58 psi) (29 psi) (58 psi) (29 psi) (55 psi) (28 psi) (44 psi) (29 psi)
550/65R25 L3 324 kPa 166 kPa * 248 kPa 200 kPa *
(3.24 bar) (1.66 bar) (2.48 bar) (2.00 bar)
(47 psi) (24 psi) (36 psi) (29 psi)
20.5R25 L2, L2/E2, 310 kPa 159 kPa * 310 kPa 159 kPa * 310 kPa 159 kPa * 248 kPa 200 kPa *
L2/E2/G2 (3.10 bar) (1.59 bar) (3.10 bar) (1.59 bar) (3.10 bar) (1.59 bar) (2.48 bar) (2.00 bar)
(45 psi) (23 psi) (45 psi) (23 psi) (45 psi) (23 psi) (36 psi) (29 psi)
L3, L3/E3, 310 kPa 159 kPa * 310 kPa 159 kPa * 310 kPa 159 kPa * 200 kPa 200 kPa *
L3/E3/G3, (3.10 bar) (1.59 bar) (3.10 bar) (1.59 bar) (3.10 bar) (1.59 bar) (2.00 bar) (2.00 bar)
L4, L5 (45 psi) (23 psi) (45 psi) (23 psi) (45 psi) (23 psi) (29 psi) (29 psi)

NOTE: Tire shipping pressure may not be the same pressures to suit working condition according to
as tire operating pressure. You may change tire tire manufacturer’s recommendations.
HG31779,000013A ­19­25SEP02­1/1

3­3­2 072310

PN=95
 Maintenance—As Required

Tire Pressures (444J Powerllels and Tool To increase side­to­side stability, increase front tire
Carriers) pressures in 2 PSI increments.
The following tables indicate the recommended Tire To adjust fore­aft stability, increase or decrease rear tire
Pressures (PSI) for 25,000 pound loader with 2.5 cubic pressures in 2 PSI increments.
yard bucket, handling 3400 pound per cubic yard material.
See Tire Manufacturer’s charts for detailed load, pressure
Recommended ply ratings for Bias Ply Tires and star and distance recommendations.
ratings for Radial Tires in parenthesis.
Addition of fluids, water and/or calcium chloride does not
affect recommended tire pressures.
Bridgestone Firestone General Goodyear
Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
17.5­25 L2, L2/E2, 352 kPa 179 kPa 12 352 kPa 179 kPa 12 352 kPa 179 kPa 12 352 kPa 179 kPa 12
L2/E2/G2, (3.52 bar) (1.79 bar) (3.52 bar) (1.79 bar) (3.52 bar) (1.79 bar) (3.52 bar) (1.79 bar)
L3, L3/E3, (51 psi) (26 psi) (51 psi) (26 psi) (51 psi) (26 psi) (51 psi) (26 psi)
L3/E3/G3,
L4, L5
20.5­25 L2, L2/E2, 228 kPa 110 kPa 12 228 kPa 110 kPa 12 228 kPa 110 kPa 12 228 kPa 110 kPa 12
L2/E2/G2, (2.28 bar) (1.10 bar) (2.28 bar) (1.10 bar) (2.28 bar) (1.10 bar) (2.28 bar) (1.10 bar)
L3, L3/E3, (33 psi) (16 psi) (33 psi) (16 psi) (33 psi) (16 psi) (33 psi) (16 psi)
L3/E3/G3,
L4, L5
28L­26 LS2 241 kPa 207 kPa 14
(2.41 bar) (2.07 bar)
(35 psi) (30 psi)

Bridgestone Firestone Goodyear Michelin

Size Front Rear StarFront Rear Star Front Rear StarFront Rear Star
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
17.5R25 L2, L2/E2, 414 kPa 207 kPa * 414 kPa 207 kPa * 414 kPa 207 kPa * 352 kPa 200 kPa *
L2/E2/G2 (4.14 bar) (2.07 bar) (4.14 bar) (2.07 bar) (4.14 bar) (2.07 bar) (3.52 bar) (2.00 bar)
(60 psi) (30 psi) (60 psi) (30 psi) (60 psi) (30 psi) (51 psi) (29 psi)
L3, L3/E3, 414 kPa 207 kPa * 414 kPa 207 kPa * 414 kPa 207 kPa * 303 kPa 200 kPa *
L3/E3/G3, (4.14 bar) (2.07 bar) (4.14 bar) (2.07 bar) (4.14 bar) (2.07 bar) (3.03 bar) (2.00 bar)
L4, L5 (60 psi) (30 psi) (60 psi) (30 psi) (60 psi) (30 psi) (44 psi) (29 psi)
550/65R25 L3 324 kPa 166 kPa * 303 kPa 200 kPa *
(3.24 bar) (1.66 bar) (3.03 bar) (2.00 bar)
(47 psi) (24 psi) (44 psi) (29 psi)
600/65R25 L3 324 kPa 166 kPa * 241 kPa 200 kPa *
(3.24 bar) (1.66 bar) (2.41 bar) (2.00 bar)
(47 psi) (24 psi) (35 psi) (29 psi)
20.5R25 L2, L2/E2, 345 kPa 172 kPa * 345 kPa 172 kPa * 345 kPa 172 kPa * 296 kPa 200 kPa *
L2/E2/G2 (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (2.96 bar) (2.00 bar)
(50 psi) (25 psi) (50 psi) (25 psi) (50 psi) (25 psi) (43 psi) (29 psi)
L3, L3/E3, 345 kPa 172 kPa * 345 kPa 172 kPa * 345 kPa 172 kPa * 248 kPa 200 kPa *
L3/E3/G3, (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (2.48 bar) (2.00 bar)
L4, L5 (50 psi) (25 psi) (50 psi) (25 psi) (50 psi) (25 psi) (36 psi) (29 psi)

NOTE: Tire shipping pressure may not be the same pressures to suit working condition according to
as tire operating pressure. You may change tire tire manufacturer’s recommendations.
HG31779,000013A ­19­25SEP02­1/1

3­3­3 072310

PN=96
 Maintenance—As Required

Tire Pressures (544J Z­Bars and High Lifts) To increase side­to­side stability, increase front tire
The following tables indicate the recommended Tire pressures in 2 PSI increments.
Pressures (PSI) for 26,000 pound loader with 3 cubic yard
To adjust fore­aft stability, increase or decrease rear tire
bucket, handling 3400 pound per cubic yard material.
pressures in 2 PSI increments.
Recommended ply ratings for Bias Ply Tires and star See Tire Manufacturer’s charts for detailed load, pressure
ratings for Radial Tires in parenthesis. and distance recommendations.
Addition of fluids, water and/or calcium chloride does not
affect recommended tire pressures.
Bridgestone Firestone General Goodyear
Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
17.5­25 L2, L2/E2, 400 kPa 200 kPa 14 400 kPa 200 kPa 14 400 kPa 200 kPa 14 400 kPa 200 kPa 14
L2/E2/G2, (4.00 bar) (2.00 bar) (4.00 bar) (2.00 bar) (4.00 bar) (2.00 bar) (4.00 bar) (2.00 bar)
L3, L3/E3, (58 psi) (29 psi) (58 psi) (29 psi) (58 psi) (29 psi) (58 psi) (29 psi)
L3/E3/G3,
L4, L5
20.5­25 L2, L2/E2, 248 kPa 124 kPa 12 248 kPa 124 kPa 12 248 kPa 124 kPa 12 248 kPa 124 kPa 12
L2/E2/G2, (2.48 bar) (1.24 bar) (2.48 bar) (1.24 bar) (2.48 bar) (1.24 bar) (2.48 bar) (1.24 bar)
L3, L3/E3, (36 psi) (18 psi) (36 psi) (18 psi) (36 psi) (18 psi) (36 psi) (18 psi)
L3/E3/G3,
L4, L5
23.1­26 LS2 276 kPa 241 kPa 10
(2.76 bar) (2.41 bar)
(40 psi) (35 psi)
28L­26 LS2 241 kPa 207 kPa 14
(2.41 bar) (2.07 bar)
(35 psi) (30 psi)

Bridgestone Firestone Goodyear Michelin

Size Front Rear StarFront Rear Star Front Rear StarFront Rear Star
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
17.5R25 L2, L2/E2, 476 kPa 241 kPa * 476 kPa 241 kPa * 483 kPa 241 kPa * 400 kPa 200 kPa *
L2/E2/G2 (4.76 bar) (2.41 bar) (4.76 bar) (2.41 bar) (4.83 bar) (2.41 bar) (4.00 bar) (2.00 bar)
(69 psi) (35 psi) (69 psi) (35 psi) (70 psi) (35 psi) (58 psi) (29 psi)
L3, L3/E3, 476 kPa 241 kPa * 476 kPa 241 kPa * 483 kPa 241 kPa * 352 kPa 200 kPa *
L3/E3/G3, (4.76 bar) (2.41 bar) (4.76 bar) (2.41 bar) (4.83 bar) (2.41 bar) (3.52 bar) (2.00 bar)
L4, L5 (69 psi) (35 psi) (69 psi) (35 psi) (70 psi) (35 psi) (51 psi) (29 psi)
600/65R25 L3, E3 324 kPa 166 kPa * 310 kPa 206 kPa
(3.24 bar) (1.66 bar) (3.10 bar) (2.06 bar)
(47 psi) (24 psi) (45 psi) (30 psi)
20.5R25 L2, L2/E2, 345 kPa 172 kPa * 345 kPa 172 kPa * 345 kPa 172 kPa * 269 kPa 200 kPa *
L2/E2/G2 (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (2.69 bar) (2.00 bar)
(50 psi) (25 psi) (50 psi) (25 psi) (50 psi) (25 psi) (39 psi) (29 psi)
L3, L3/E3, 345 kPa 172 kPa * 345 kPa 172 kPa * 345 kPa 172 kPa * 221 kPa 200 kPa *
L3/E3/G3, (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (3.45 bar) (1.72 bar) (2.21 bar) (2.00 bar)
L4, L5 (50 psi) (25 psi) (50 psi) (25 psi) (50 psi) (25 psi) (32 psi) (29 psi)

NOTE: Tire shipping pressure may not be the same pressures to suit working condition according to
as tire operating pressure. You may change tire tire manufacturer’s recommendations.
HG31779,0000332 ­19­25NOV03­1/1

3­3­4 072310

PN=97
 Maintenance—As Required

Tire Pressures (544J Powerllels and Tool To increase side­to­side stability, increase front tire
Carriers) pressures in 2 PSI increments.
The following tables indicate the recommended Tire To adjust fore­aft stability, increase or decrease rear tire
Pressures (PSI) for 30,000 pound loader with 3 cubic yard pressures in 2 PSI increments.
bucket, handling 3400 pound per cubic yard material.
See Tire Manufacturer’s charts for detailed load, pressure
Recommended ply ratings for Bias Ply Tires and star and distance recommendations.
ratings for Radial Tires in parenthesis.
Addition of fluids, water and/or calcium chloride does not
affect recommended tire pressures.
Bridgestone Firestone General Goodyear
Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
17.5­25 L2, L2/E2, 476 kPa 241 kPa 16 476 kPa 241 kPa 16 476 kPa 241 kPa 16 476 kPa 241 kPa 16
L2/E2/G2, (4.76 bar) (2.41 bar) (4.76 bar) (2.41 bar) (4.76 bar) (2.41 bar) (4.76 bar) (2.41 bar)
L3, L3/E3, (69 psi) (35 psi) (69 psi) (35 psi) (69 psi) (35 psi) (69 psi) (35 psi)
L3/E3/G3,
L4, L5
20.5­25 L2, L2/E2, 303 kPa 152 kPa 16 303 kPa 152 kPa 16 303 kPa 152 kPa 16 303 kPa 152 kPa 16
L2/E2/G2, (3.03 bar) (1.52 bar) (3.03 bar) (1.52 bar) (3.03 bar) (1.52 bar) (3.03 bar) (1.52 bar)
L3, L3/E3, (44 psi) (22 psi) (44 psi) (22 psi) (44 psi) (22 psi) (44 psi) (22 psi)
L3/E3/G3,
L4, L5
23.1­26 LS2 310 kPa 241 kPa 10
(3.10 bar) (2.41 bar)
(45 psi) (35 psi)
28L­26 LS2 276 kPa 207 kPa 14
(2.76 bar) (2.07 bar)
(40 psi) (30 psi)

Bridgestone Firestone Goodyear Michelin

Size Front Rear StarFront Rear Star Front Rear StarFront Rear Star
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
17.5R25 L2, L2/E2, 572 kPa 290 kPa ** 572 kPa 324 kPa ** 552 kPa 276 kPa ** 496 kPa 248 kPa *
L2/E2/G2 (5.72 bar) (2.90 bar) (5.72 bar) (3.24 bar) (5.52 bar) (2.76 bar) (4.96 bar) (2.48 bar)
(83 psi) (42 psi) (83 psi) (47 psi) (80 psi) (40 psi) (72 psi) (36 psi)
L3, L3/E3, 572 kPa 290 kPa ** 572 kPa 324 kPa ** 552 kPa 276 kPa ** 448 kPa 248 kPa *
L3/E3/G3, (5.72 bar) (2.90 bar) (5.72 bar) (3.24 bar) (5.52 bar) (2.76 bar) (4.48 bar) (2.48 bar)
L4, L5 (83 psi) (42 psi) (83 psi) (47 psi) (80 psi) (40 psi) (65 psi) (36 psi)
600/65R25 L3,E3 324 kPa 166 kPa * 310 kPa 207 kPa *
(3.24 bar) (1.66 bar) (3.10 bar) (2.07 bar)
(47 psi) (24 psi) (45 psi) (30 psi)
20.5R25 L2, L2/E2, 379 kPa 207 kPa ** 379 kPa 207 kPa ** 379 kPa 207 kPa ** 352 kPa 200 kPa *
L2/E2/G2 (3.79 bar) (2.07 bar) (3.79 bar) (2.07 bar) (3.79 bar) (2.07 bar) (3.52 bar) (2.00 bar)
(55 psi) (30 psi) (55 psi) (30 psi) (55 psi) (30 psi) (51 psi) (29 psi)
L3, L3/E3, 379 kPa 207 kPa * 379 kPa 207 kPa * 379 kPa 207 kPa * 303 kPa 200 kPa *
L3/E3/G3, (3.79 bar) (2.07 bar) (3.79 bar) (2.07 bar) (3.79 bar) (2.07 bar) (3.03 bar) (2.00 bar)
L4, L5 (55 psi) (30 psi) (55 psi) (30 psi) (55 psi) (30 psi) (44 psi) (29 psi)

NOTE: Tire shipping pressure may not be the same pressures to suit working condition according to
as tire operating pressure. You may change tire tire manufacturer’s recommendations.
HG31779,000013A ­19­25SEP02­1/1

3­3­5 072310

PN=98
 Maintenance—As Required

Tire Pressures (624J Z­Bars and High Lifts) To increase side­to­side stability, increase front tire
The following tables indicate the recommended Tire pressures in 2 PSI increments.
Pressures (PSI) for 30,000 pound loader with 3.5 cubic
To adjust fore­aft stability, increase or decrease rear tire
yard bucket, handling 3400 pound per cubic yard material.
pressures in 2 PSI increments.
Recommended ply ratings for Bias Ply Tires and star See Tire Manufacturer’s charts for detailed load, pressure
ratings for Radial Tires in parenthesis. and distance recommendations.
Addition of fluids, water and/or calcium chloride does not
affect recommended tire pressures.
Bridgestone Firestone General Goodyear
Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
20.5­25 L2, L2/E2, 352 kPa 179 kPa 16 352 kPa 179 kPa 16 324 kPa 159 kPa 16 324 kPa 159 kPa 16
L2/E2/G2, (3.52 bar) (1.79 bar) (3.52 bar) (1.79 bar) (3.24 bar) (1.59 bar) (3.24 bar) (1.59 bar)
L3, L3/E3, (51 psi) (26 psi) (51 psi) (26 psi) (47 psi) (23 psi) (47 psi) (23 psi)
L3/E3/G3,
L4, L5
28L­26 LS2 276 kPa 241 kPa 14
(2.76 bar) (2.41 bar)
(40 psi) (35 psi)

Bridgestone Firestone Goodyear Michelin

Size Front Rear StarFront Rear Star Front Rear StarFront Rear Star
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
650/65R25 L3, E3 324 kPa 166 kPa * 296 kPa 200 kPa *
(3.24 bar) (1.66 bar) (2.96 bar) (2.00 bar)
(47 psi) (24 psi) (43 psi) (29 psi)
20.5R25 L2, L2/E2, 400 kPa 200 kPa * 400 kPa 200 kPa * 379 kPa 193 kPa * 352 kPa 200 kPa *
L2/E2/G2 (4.00 bar) (2.00 bar) (4.00 bar) (2.00 bar) (3.79 bar) (1.93 bar) (3.52 bar) (2.00 bar)
(58 psi) (29 psi) (58 psi) (29 psi) (55 psi) (28 psi) (51 psi) (29 psi)
L3, L3/E3, 400 kPa 200 kPa * 400 kPa 200 kPa * 379 kPa 193 kPa * 303 kPa 200 kPa *
L3/E3/G3, (4.00 bar) (2.00 bar) (4.00 bar) (2.00 bar) (3.79 bar) (1.93 bar) (3.03 bar) (2.00 bar)
L4, L5 (58 psi) (29 psi) (58 psi) (29 psi) (55 psi) (28 psi) (44 psi) (29 psi)

NOTE: Tire shipping pressure may not be the same pressures to suit working condition according to
as tire operating pressure. You may change tire tire manufacturer’s recommendations.
HG31779,0000333 ­19­25NOV03­1/1

3­3­6 072310

PN=99
 Maintenance—As Required

Tire Pressures (624J Powerllels and Tool To increase side­to­side stability, increase front tire
Carriers) pressures in 2 PSI increments.
The following tables indicate the recommended Tire To adjust fore­aft stability, increase or decrease rear tire
Pressures (PSI) for 35,000 pound loader with 3.5 cubic pressures in 2 PSI increments.
yard bucket, handling 3400 pound per cubic yard material.
See Tire Manufacturer’s charts for detailed load, pressure
Recommended ply ratings for Bias Ply Tires and star and distance recommendations.
ratings for Radial Tires in parenthesis.
Addition of fluids, water and/or calcium chloride does not
affect recommended tire pressures.
Bridgestone Firestone General Goodyear
Size Front Rear Ply Front Rear Ply Front Rear Ply Front Rear Ply
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
20.5­25 L2, L2/E2, 372 kPa 186 kPa 16 372 kPa 186 kPa 16 372 kPa 186 kPa 16 372 kPa 186 kPa 16
L2/E2/G2, (3.72 bar) (1.86 bar) (3.72 bar) (1.86 bar) (3.72 bar) (1.86 bar) (3.72 bar) (1.86 bar)
L3, L3/E3, (54 psi) (27 psi) (54 psi) (27 psi) (54 psi) (27 psi) (54 psi) (27 psi)
L3/E3/G3,
L4, L5
28L­26 LS2 310 kPa 241 kPa 14
(3.10 bar) (2.41 bar)
(45 psi) (35 psi)

Bridgestone Firestone Goodyear Michelin

Size Front Rear StarFront Rear Star Front Rear StarFront Rear Star
Rat­ Rat­ Rat­ Rat­
ing ing ing ing
600/65R25 L3,E3 324 kPa 166 kPa * 352 kPa 200 kPa *
(3.24 bar) (1.66 bar) (3.52 bar) (2.00 bar)
(47 psi) (24 psi) (51 psi) (29 psi)
20.5R25 L2, L2/E2, 448 kPa 228 kPa * 448 kPa 228 kPa * 448 kPa 228 kPa * 400 kPa 200 kPa *
L2/E2/G2 (4.48 bar) (2.28 bar) (4.48 bar) (2.28 bar) (4.48 bar) (2.28 bar) (4.00 bar) (2.00 bar)
(65 psi) (33 psi) (65 psi) (33 psi) (65 psi) (33 psi) (58 psi) (29 psi)
L3, L3/E3, 448 kPa 228 kPa * 448 kPa 228 kPa * 448 kPa 228 kPa * 352 kPa 200 kPa *
L3/E3/G3, (4.48 bar) (2.28 bar) (4.48 bar) (2.28 bar) (4.48 bar) (2.28 bar) (3.52 bar) (2.00 bar)
L4, L5 (65 psi) (33 psi) (65 psi) (33 psi) (65 psi) (33 psi) (51 psi) (29 psi)

NOTE: Tire shipping pressure may not be the same pressures to suit working condition according to
as tire operating pressure. You may change tire tire manufacturer’s recommendations.
HG31779,000013A ­19­25SEP02­1/1

3­3­7 072310

PN=100
 Maintenance—As Required

Tighten Wheel Retainer Nuts that, tighten as required. Threads should

be clean and lightly oiled.
NOTE: Tighten nuts after first 10 hours, then again
after first 50 hours of loaded operation. After

Item Measurement Specification

444J (S.N.–604689), 544J/624J Torque 501 N∙m

Wheel Nut — During Inspection 370 lb­ft
Item Measurement Specification

444J (S.N. 604690–) Wheel Nut Torque 580 N∙m

— During Inspection 428 lb­ft
Item Measurement Specification

444J (S.N.–604689), 544J/624J Torque 624 N∙m

Wheel Nut — If Servicing Wheels 460 lb­ft
Item Measurement Specification

444J (S.N. 604690–) Wheel Nut Torque 725 N∙m

— If Servicing Wheels 535 lb­ft
MM61211,0001431 ­19­16MAR06­1/1

3­3­8 072310

PN=101
 Maintenance—As Required

Clean or Replace Air Cleaner Elements

1. Lift and hold lever (1) to unlock cover.
2. Rotate cover counterclockwise and remove cover.
3. Remove primary element (2).

T200914 —UN—15JUN04
4. Remove secondary element (3).
5. Clean air cleaner canister.
6. Install new filter elements into housing one at a
1
time making sure secondary element is centered in
canister.
7. Attach cover by rotating clockwise until lock arrows on
body and cover are aligned.

1— Lever 3— Secondary Element

2— Primary Element

T196122A —UN—07NOV03
T196123A —UN—07NOV03
HG31779,00002E1 ­19­26JUN03­1/1

3­3­9 PN=102
072310
 Maintenance—As Required

Drain and Clean Primary Fuel Filter

1. Open left engine side shield to access primary fuel
filter.
2. Put container under drain valves (B and C).

T117049 —UN—10SEP98
3. Rotate retaining ring around filter element
counterclockwise 1/4 turn. Lifting ring as it is rotated
helps get it past retaining detent. Ring should drop
down and release filter from base.
4. Remove hand primer (A) from fuel filter base.
Disassemble hand primer assembly and clean out
any debris. 444J Shown

A—Hand Primer C—Drain Valve (Final Fuel

B—Drain Valve (Primary Fuel Filter)
Filter)

AM40430,00002F4 ­19­20JAN06­1/2

5. Remove fuel inlet line (A) and fuel drain plug (C).
6. Flush any debris from filter base (B).
7. Install fuel inlet drain plug and fuel inlet line.
8. Assemble primer assembly and install onto fuel filter

T8387AD —UN—17DEC94
base.
9. Install filter element to fuel filter base.
10. Bleed fuel system.
11. Close side shield.
12. Dispose of waste properly.

A—Fuel Inlet line C—Fuel Drain Plug

B—Filter Base

AM40430,00002F4 ­19­20JAN06­2/2

Check Cab Fresh Air Filter—If Equipped With

Cab
1. Open cab fresh air filter door by pulling up on lever (A)
to the left of the operator’s seat. T105479B —UN—12DEC96

A—Lever

Continued on next page TX,70,JC2295 ­19­03SEP98­1/3

3­3­10 PN=103
072310
 Maintenance—As Required

2. Remove filter assembly by turning knob (A).

A—Knob

T117050 —UN—10SEP98
Continued on next page TX,70,JC2295 ­19­03SEP98­2/3

3­3­11 PN=104
072310
 Maintenance—As Required

NOTE: If operating in dusty conditions, cab fresh air filter

should be checked and cleaned as necessary.

3. Release clips (B).

4. Remove filter (C). Replace if damaged.
5. Clean filter in one of these ways:

CAUTION: Prevent possible injury from flying

chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to less
than 210 kPa (2.1 bar) (30 psi) when using for
cleaning purposes. Clear area of bystanders,
guard against flying chips, and wear personal
protection equipment including eye protection.

• Tap filter on a flat surface with the dirty side down.

• Use compressed air opposite to the normal air flow.
• Wash the filter in warm, soapy water. Flush the filter.
Let it dry before using the heater, defroster, or air
conditioner.

T105493B —UN—12DEC96
6. Remove dust from filter housing.
7. Install filter and filter duct work.
8. Install filter assembly. Close cab fresh air filter door.

B—Clip (2 used) C—Filter

T105494B —UN—12DEC96
TX,70,JC2295 ­19­03SEP98­3/3

3­3­12 PN=105
072310
 Maintenance—As Required

Check Cab Recirculating Air Filter—If

Equipped With Cab
NOTE: The cab recirculating air filter is located
next to the seat.

T159520B —UN—18SEP02
1. Loosen wing bolt (1) holding grille. Remove grille.
2. Remove filter.

CAUTION: Prevent possible injury from flying

chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Reduce compressed air to less
than 210 kPa (2.1 bar) (30 psi) when using for
cleaning purposes. Clear area of bystanders,
guard against flying chips, and wear personal 1— Wing Bolt
protection equipment including eye protection.

3. Clean filter in one of these ways:

4. Install filter.
• Tap it on a flat surface with the dirty side down. 5. Install grille.
• Use compressed air opposite to the normal air flow.
HG31779,0000121 ­19­18SEP02­1/1

3­3­13 PN=106
072310
 Maintenance—As Required

Inspect Serpentine Belt

1. Open cooling package left access door.
2. Check belt (2) regularly for cracks, frayed edges, or
wear at bottom of grooves.

T195677A —UN—24OCT03
3. Remove rear engine access panel.
4. Hold tension adjuster assembly (1) away from belt
while removing old belt and installing new belt.
5. Install rear engine access panel.

1— Belt Tensioner Assembly 5— Alternator Pulley

2— Belt 6— Belt Tensioner
3— Crankshaft Pulley 7— Water Pump
4— Idler 8— Air Conditioner
Compressor

T195684 —UN—07NOV03
T195684
Belt Routing Without Air Conditioning

T195685 —UN—07NOV03
T195685
Belt Routing With Air Conditioning
HG31779,0000331 ­19­17NOV03­1/1

Replace Final Fuel Filter

1. Turn filter locking ring (A) counterclockwise to remove
filter. Allow sediment to drain into a container. Dispose
of waste properly.
2. Clean filter base.
T117066 —UN—10SEP98

3. Install new filter. (Follow instructions on filter.)

4. Bleed fuel system.

A—Filter Locking Ring

444J Shown

HG31779,00002EB ­19­26JUN03­1/1

3­3­14 PN=107
072310
 Maintenance—Every 10 Hours or Daily
Check Recovery Tank Coolant Level
With the engine cold, coolant level must be between FULL
and ADD marks on the recovery tank.
If coolant is below the ADD mark, add coolant to the
recovery tank.

T192360B —UN—18SEP03
CAUTION: Prevent possible injury from hot
spraying coolant. DO NOT remove radiator
filler cap unless engine is cool. Then turn
cap slowly to the stop. Release all pressure
before you remove cap.

If coolant recovery tank (1) is empty, check for leaks.

Repair as required. Add coolant to the radiator and the
recovery tank.
NOTE: If recovery tank is full and radiator is low, check
for leaks in radiator cap and hose connections

T6274AQ —UN—18OCT88
between radiator and coolant recovery tank.

Coolant level must be at bottom of the filler neck.

1— Coolant Recovery Tank

Radiator Cap

HG31779,00002BB ­19­19JUN03­1/1

Clean Air Cleaner Dust Unloader Valve

IMPORTANT: A missing, damaged, or hardened dust
unloader valve will make the dust cup precleaner
ineffective, causing very short element life. Valve
should suck closed above 1/3 engine speed.

T195376A —UN—03OCT03
Squeeze dust valve (1) to remove dust from the air
cleaner.
If operating in high dust conditions, squeeze dust valve
every couple of hours of operation to release dust.

1— Dust Valve

HG31779,00002E5 ­19­26JUN03­1/1

3­4­1 PN=108
072310
 Maintenance—Every 10 Hours or Daily

Check Engine Oil Level

IMPORTANT: If oil level is low, the engine can be
damaged. DO NOT operate the engine when
oil level is below the ADD mark.

T117051 —UN—11SEP98
The most accurate oil level reading is obtained when the
engine is cold, before starting the engine for the day’s
operation.
1. Park machine on a level surface.
2. Push park brake switch to ON.
3. Make sure dipstick (A) is fully seated.
4. BEFORE THE ENGINE IS STARTED: The engine A—Dipstick B—Filler Cap
is full when oil level is in the cross hatched area. It
is acceptable to run the engine when the oil level is
above the ADD mark.
5. If necessary, remove filler cap (B) to add oil. See
AFTER THE ENGINE HAS BEEN RUN: Allow the oil Diesel Engine Oil. (Section 3­1.)
to drain into the oil pan for 10 minutes before checking
the oil level. Ten minutes after shutdown the engine oil
level must be above the ADD mark.
CED,OUOE002,1723 ­19­03SEP98­1/1

3­4­2 PN=109
072310
 Maintenance—Every 10 Hours or Daily

Check Hydraulic Oil Level

IMPORTANT: Prevent possible hydraulic pump
damage. DO NOT operate engine without
oil in the hydraulic reservoir.

T196188A —UN—11NOV03
1. Park machine on a level surface.
2. Lower equipment to the ground.
3. When oil is cold, oil level must be in FULL range on
sight glass (2).
4. If necessary, remove filler cap (1) and add oil. See
Hydraulic Reservoir Oil. (Section 3­1.)
5. Install filler cap.

1— Filler Cap 2— Sight Glass

T192369A —UN—18SEP03
VD76477,00004FD ­19­26JUN06­1/1

3­4­3 PN=110
072310
 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.

T159631B —UN—20SEP02
1. Before starting engine, check oil level on sight gauge
(1). If oil level is higher than the sight gauge, there is
sufficient oil to start the engine.
2. If necessary, add oil at filler tube (2). See
Transmission, Park Brake, and Differential Oil.
(Section 3­1.)
3. Start engine.
4. Engage service brakes. Move clutch cut­off switch to
disengaged position.
5. Move auto transmission switch to “Off” position.
Release park brake.
6. Move FNR to 3rd speed forward "3F" position.
Operate engine at fast idle for 30 seconds. Reduce
engine speed to slow idle and place FNR in neutral
"N", for 15 seconds.
Repeat this step until transmission oil reaches normal
operating temperature (approximately (80 °C) (175
°F)).
7. Move FNR to neutral "N". If equipped with column
FNR, engage neutral lock. Lower all equipment to
ground.
8. Push park brake switch to ON.
9. Release service brakes.

T161201 —19—01NOV02
10. Allow 2 minutes for oil level to stabilize.
11. Check oil level with engine at slow idle. With oil at
normal operating temperature, oil level should be
between HOT marks on sight gauge.
12. If necessary, add oil. See Transmission, Park Brake,
and Differential Oil. (Section 3­1.)
1— Sight Gauge 2— Filler Tube

VD76477,00004FE ­19­26JUN06­1/1

3­4­4 PN=111
072310
 Maintenance—Every 100 Hours
Grease Loader Linkage and Cylinder Pivots

T160586B —UN—17OCT02

T106375B —UN—24JAN97
6 Points 3 Points, Right Side Shown

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before lubricating.

444J, 544J, and 624J Loader Lubricating Points

Lower bucket flat on ground.
Lubricate following 13 points until grease escapes around
seals. See Grease. (Section 3­1.)
Lubricate every 10 hours when operating in severe
T106379C —UN—10APR97

conditions such as deep mud, water, or snow.

4 Points, Right Side Shown

Continued on next page MM61211,0001515 ­19­30MAR06­1/3

3­5­1 PN=112
072310
 Maintenance—Every 100 Hours

444J, 544J, and 624J Tool Carrier Lubricating points

T106377B —UN—24JAN97
TX1005053A —UN—20MAR06
2 Points, Left Side Shown

12 Points, Right Side Shown

Lower bucket flat on ground.

Lubricate following 26 points until grease escapes around
seals. See Grease. (Section 3­1.)
Lubricate every 10 hours when operating in severe
conditions such as deep mud, water, or snow.

T106378C —UN—04MAR97
12 Points, Right Side Shown

Continued on next page MM61211,0001515 ­19­30MAR06­2/3

3­5­2 PN=113
072310
 Maintenance—Every 100 Hours

444J, 544J, and 624J Powerllel Lubricating Points

TX1005747A —UN—31MAR06

TX1005749A —UN—31MAR06
7 Points, Right Side Shown
3 Points, Left Side Shown

Lower bucket flat on ground.

Lubricate following 13 points until grease escapes around
seals. See Grease. (Section 3­1.)
Lubricate every 10 hours when operating in severe
conditions such as deep mud, water, or snow.

TX1005752A —UN—30MAR06

3 Points, Left side Shown

MM61211,0001515 ­19­30MAR06­3/3

3­5­3 PN=114
072310
 Maintenance—Every 100 Hours

Grease Front Steering Cylinder Pivots

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before lubricating.

T106372B —UN—28JAN97
Lubricate each point with three shots of grease. See
Grease. (Section 3­1.)
Grease daily when operating in severe conditions such as
deep mud, water or snow.

Two Points, Right Side Shown

TX,70,JC1817 ­19­20JAN06­1/1

Grease Oscillating Rear Axle and Rear

Steering Cylinder Pivots

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame

T196189A —UN—11NOV03
locking bar before lubricating.

Lubricate oscillating rear axle with 10 shots of grease and

rear steering cylinder pivots with three shots of grease.
See Grease. (Section 3­1.) Grease daily when operating
in severe conditions such as deep mud, water, or snow.

Four Points

HG31779,00002E8 ­19­20JAN06­1/1

3­5­4 PN=115
072310
 Maintenance—Initial Service ­ 250 Hours
Change Engine Break­In Oil and Replace
Filter
IMPORTANT: If fuel sulphur content exceeds
0.5 percent, change engine oil at 1/2
the normal interval.

T117053 —UN—10SEP98
1. Run engine to warm oil.
2. Park machine on a level surface.
3. Lower equipment to ground.
4. Move FNR to neutral "N". If equipped with column
FNR, engage neutral lock.
A—Engine Oil Drain Valve
CAUTION: Prevent possible injury from
unexpected machine movement. Machine can
unexpectedly roll or move under power, resulting
in death or serious injury. Always turn engine off NOTE: Drain located at front left corner of fuel tank cradle.
or push park brake switch to ON to hold machine.
7. Open drain valve (A). Allow oil to drain into a container.
5. Push park brake switch to ON. Dispose of waste oil properly.

6. Turn key switch to “Off”.

VD76477,00004E3 ­19­20JUN06­1/2

8. Turn filter (C) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasket
of new filter.
NOTE: Before installing filter, to assure proper lubrication
at start­up, fill the engine oil filter with engine oil.

T117054 —UN—10SEP98
10. Install new filter. Turn filter clockwise by hand until
gasket touches mounting surface.
11. Tighten 1/2—1 turn more.
12. Tighten drain valve.
13. Remove filler cap (B).
A—Dipstick C—Filter
14. Fill engine with oil. See Diesel Engine Oil. (Section B—Filler Cap
3­1.)
Engine Oil With Filter—Specification
444J—Capacity.............................................................................. 17.5 L 17. Check that engine oil pressure light on monitor goes
18.5 qt out and audible alarm stops immediately. If not, stop
544J—Capacity.............................................................................. 18.5 L engine immediately and find cause.
20 qt
624J—Capacity................................................................................. 24 L 18. Stop the engine. Check oil level. The engine is full
25 qt when oil level is in the cross hatched area on the
dipstick (A).
15. Install filler cap.
19. Check for any leakage at filter. Tighten filter only
16. Start engine and run at slow idle. enough to stop leakage.
VD76477,00004E3 ­19­20JUN06­2/2

3­6­1 PN=116
072310
 Maintenance—Initial Service ­ 250 Hours

Change Front and Rear Differential/Axle Oil

NOTE: Perform this service at the first 250 hours of
operation and then at 2000 hour intervals thereafter.

TX1004689A —UN—13MAR06
CAUTION: Prevent possible injury from hot
spraying oil. Slowly loosen dipstick to
relieve any air pressure.

NOTE: The axle drain plug is magnetized and should

be cleaned when changing differential/axle oil.
Axle differential recirculation screens (if equipped)
should also be cleaned at this time. See Clean Axle Front Differential 444J (S.N. —604689), 544J, 624J Shown
Differential Recirculation Screen in this section.

1. ALL MACHINES— Remove hose (1) and screen

fitting (2). Allow oil to drain into a container. Dispose
of waste oil properly. Install screen fitting and hose.

TX1004688A —UN—13MAR06
2. 444J (S.N. 604690— ) only Remove plugs (3) from
axle ends and clean magnetized ends of plugs. Allow
oil to drain into a container. Dispose of waste oil
properly.
Front Differential/Axle Oil—Specification
444J (S.N.
—604689)—Capacity........................................................................ 17 L
18 qt Axle End Drain Plug 444J (S.N. 604690— ) Shown
444J (S.N. 604690—
)—Capacity........................................................................................ 22 L
23 qt 1— Hose 3— Axle End Drain Plug (4
2— Screen Fitting (If Equipped) used)
544J—Capacity................................................................................. 18 L
19 qt
624J—Capacity.............................................................................. 24.5 L
544J—Capacity................................................................................. 18 L
26 qt
19 qt
Rear Differential/Axle Oil—Specification 624J—Capacity................................................................................. 20 L
444J (S.N. 21 qt
—604689)—Capacity........................................................................ 17 L
18 qt
444J (S.N. 604690—
)—Capacity........................................................................................ 22 L
23 qt
Continued on next page MH66O88,000013C ­19­04APR06­1/2

3­6­2 PN=117
072310
 Maintenance—Initial Service ­ 250 Hours

3. 444J (S.N. —604689), 544J, 624J Remove dipstick

(4). 444J (S.N. 604690— ) Remove dipstick (5).
4. 444J (S.N. —604689), 544J, 624J only— add oil
slowly through dipstick port on left front and left rear

TX1004673A —UN—13MAR06
differential .
5. 444J (S.N. 604690— ) only— fill front differential/axle
housing with oil through right side dipstick port
(5). And through left rear dipstick port for the rear
differential/axle housing.
IMPORTANT: To properly check oil level, do not
thread dipstick into dipstick port.
Left Front Axle Shown 444J (S.N. —604689), 544J, 624J
6. Check oil level.
7. Install dipstick and tighten.

4— Dipstick 5— Dipstick

TX1004674A —UN—13MAR06
Right Front Axle Shown 444J (S.N. 604690— )
MH66O88,000013C ­19­04APR06­2/2

3­6­3 PN=118
072310
 Maintenance—Every 250 Hours
Grease Front Driveline Sliding Joint

CAUTION: Prevent possible injury from

unexpected machine movement. Turn engine off
and lower bucket to ground before lubricating.

T161066B —UN—29OCT02
NOTE: To prevent plug loss, lubricate the machine
when it is fully articulated or half articulated
and NOT in the straight position.

Install frame lock bar using hole (1) for articulated position.

1— Frame Locking Bar

TX,75,JC1818 ­19­11NOV98­1/2

T118181 —UN—02NOV98
Lubricate until grease escapes around vent holes in drive NOTE: Grease daily when operating in deep
shaft end. See Grease. (Section 3­1.) mud, water, or snow.
TX,75,JC1818 ­19­11NOV98­2/2

3­7­1 PN=119
072310
 Maintenance—Every 250 Hours

Check Surge Tank Level

CAUTION: Prevent possible injury from hot

spraying coolant. DO NOT remove filler
cap unless engine is cool. Then turn cap
slowly to the stop. Release air to relieve all

T6642EK —UN—01NOV88
pressure before you remove cap.

1. Slowly remove cap. Coolant level should be to top

of tank.
2. Add coolant, if necessary.
3. Install filler cap.

1— Surge Tank

T211310A —UN—13MAY05
AM40430,00000B3 ­19­11MAY05­1/1

Take Engine Oil Sample

See your authorized dealer.
OUT4001,000039B ­19­25FEB09­1/1

3­7­2 PN=120
072310
 Maintenance—Every 500 Hours
Grease Upper and Lower Drive Line Sliding
Joints
CAUTION: Prevent possible injury from
unexpected machine movement. Turn engine off
and lower bucket to ground before lubricating.

T161066B —UN—29OCT02
Install frame lock bar using hole (1) for articulated position.

1— Frame Locking Bar

TX,80,JC1821 ­19­11NOV98­1/2

Lubricate until grease escapes around vent holes in drive T118182 —UN—04NOV98
NOTE: Grease daily when operating in deep
shaft end. See Grease. (Section 3­1.) mud, water, or snow.
TX,80,JC1821 ­19­11NOV98­2/2

3­8­1 PN=121
072310
 Maintenance—Every 500 Hours

Check Air Intake Hoses

Check hoses (A) for cracks.
Check hose clamps for tightness.

T106360C —UN—24JAN97
A—Hose

HG31779,00002E9 ­19­26JUN03­1/1

Check Battery Electrolyte Level and

Terminals
CAUTION: Battery gas can explode. Keep sparks
and flames away from batteries. Use a flashlight
to check battery electrolyte level.
NEVER check battery charge by placing
a metal object across the posts. Use a
voltmeter or hydrometer.
ALWAYS remove grounded (­) battery clamp
first and replace it last.
Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness
if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well­ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when

TS203 —UN—23AUG88
electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help
neutralize the acid.
2. Drink large amounts of water or milk, but
3. Flush your eyes with water for 15—30 minutes.
do not exceed 1.9 L (2 quarts).
Get medical attention immediately.
3. Get medical attention immediately.
If acid is swallowed:
1. Remove battery box cover.
1. Do not induce vomiting.
Continued on next page TX,75,DH1574 ­19­28APR93­1/3

3­8­2 PN=122
072310
 Maintenance—Every 500 Hours

IMPORTANT: If water is added to batteries during

freezing weather, batteries must be charged
after water is added to prevent batteries from
freezing. Charge battery using a battery
charger or by running the engine.

T6996DB —UN—10FEB89
2. Fill each cell to within specified range with distilled
water. DO NOT overfill.

CAUTION: Prevent possible injury. ALWAYS

remove grounded (­) battery clamp first
and replace it last.

3. Disconnect battery clamps, grounded clamp first.

A—Battery Post C—Electrolyte Level Range

B—Fill Tube

T6996DA —UN—10FEB89
TX,75,DH1574 ­19­28APR93­2/3

4. Clean battery terminals (A) and clamps with a stiff

brush.
5. Apply lubricating grease (B) around battery terminal
base only.
6. Install and tighten clamps, grounded clamp last.

T6758AA —UN—21OCT88
A—Battery Terminal B—Lubricating Grease

TX,75,DH1574 ­19­28APR93­3/3

3­8­3 PN=123
072310
 Maintenance—Every 500 Hours

Change Engine Oil and Replace Filter

IMPORTANT: If fuel sulphur content exceeds
0.5 percent, change engine oil at 1/2
the normal interval.

T117053 —UN—10SEP98
NOTE: If engine has not run 500 hours before the
season changes, change oil.

1. Run engine to warm oil.

2. Park machine on a level surface.
3. Lower equipment to ground.
4. Move FNR to neutral "N". If equipped with column
FNR, engage neutral lock. A—Engine Oil Drain Valve

CAUTION: Prevent possible injury from

unexpected machine movement. Machine can 6. Turn key switch to “Off”.
unexpectedly roll or move under power, resulting
in death or serious injury. Always turn engine off NOTE: Drain located at front left corner of fuel tank cradle.
or push park brake switch to ON to hold machine.
7. Open drain valve (A). Allow oil to drain into a container.
5. Push park brake switch to ON. Dispose of waste oil properly.
VD76477,00004E4 ­19­20JUN06­1/2

8. Turn filter (C) counterclockwise to remove.

9. Clean mounting surface. Apply thin film of oil to gasket
of new filter.
NOTE: Before installing filter, to assure proper lubrication
at start­up, fill the engine oil filter with engine oil.

T117054 —UN—10SEP98
10. Install new filter. Turn filter clockwise by hand until
gasket touches mounting surface.
11. Tighten 1/2—1 turn more.
12. Tighten drain valve.
13. Remove filler cap (B).
A—Dipstick C—Filter
14. Fill engine with oil. See Diesel Engine Oil. (Section B—Filler Cap
3­1.)
Engine Oil With Filter—Specification
444J—Capacity.............................................................................. 17.5 L 17. Check that engine oil pressure light on monitor goes
18.5 qt out and audible alarm stops immediately. If not, stop
544J—Capacity.............................................................................. 18.5 L engine immediately and find cause.
20 qt
624J—Capacity................................................................................. 24 L 18. Stop the engine. Check oil level. The engine is full
25 qt when oil level is in the cross hatched area on the
dipstick (A).
15. Install filler cap.
19. Check for any leakage at filter. Tighten filter only
16. Start engine and run at slow idle. enough to stop leakage.
VD76477,00004E4 ­19­20JUN06­2/2

3­8­4 PN=124
072310
 Maintenance—Every 500 Hours

Replace Primary Fuel Filter

1. Turn filter locking ring (A) counterclockwise to remove
filter. Allow sediment to drain into a container. Dispose
of waste properly.
2. Turn sediment bowl (B) counterclockwise to remove

T117067 —UN—10SEP98
from filter assembly.
3. Clean filter base.
4. Install new filter. (Follow instructions on filter.)
5. Install sediment bowl.
6. Bleed fuel system. See Bleeding Fuel System.
(Section 4­1.) A—Filter Locking Ring B—Sediment Bowl

HG31779,00002EA ­19­26JUN03­1/1

Replace Primary Fuel Filter Strainer (444J,

S.N. 598949—; 544J, 624J, S.N. 598854—)
1. Loosen and slide hose clamps away from fuel strainer
(1). Remove hoses.
2. Remove fuel filter.

T212528A —UN—23JAN06
3. Install new filter.
4. Install hoses and tighten clamps.
5. Bleed fuel system. See Bleeding Fuel System.
(Section 4­1.)
444J Shown
1— Fuel Strainer

AM40430,00002F7 ­19­20JAN06­1/1

Replace Final Fuel Filter

1. Turn filter locking ring (A) counterclockwise to remove
filter. Allow sediment to drain into a container. Dispose
of waste properly.
2. Clean filter base.

T117066 —UN—10SEP98
3. Install new filter. (Follow instructions on filter.)
4. Bleed fuel system.

A—Filter Locking Ring

444J Shown

HG31779,00002EB ­19­26JUN03­1/1

3­8­5 PN=125
072310
 Maintenance—Every 500 Hours

Replace Hydraulic System Return Filter

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before changing filter.

T107880B —UN—06MAR97
1. Turn filter (A) counterclockwise to remove.
2. Clean mounting surface. Apply thin film of oil to gasket
of new filter.
3. Install new filter. Tighten filter 3/4 of a full turn after
seal contacts mounting base.
Cover removed for clarity of photograph
4. Fully loosen filter element. Repeat step 3.
5. Start engine. Check for leaks around filter base. A—Filter
Tighten filter only enough to stop leaks.
6. Stop engine. Check oil level.
MM61211,000142A ­19­08MAR06­1/1

Grease Rear Oscillating Support Cover

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before lubricating.

TX1004718A —UN—13MAR06
Lubricate point (1) with three shots of grease. See
Grease. (Section 3­1.)
Grease daily when operating in severe conditions such as
deep mud, water or snow.

1— Lubrication Fitting

MM61211,000142C ­19­10MAR06­1/1

Replace Hydraulic Reservoir Breather Filter

Hydraulic reservoir breather filter is located on back side
of reservoir under the hood.
1. Turn filter (1) counterclockwise to remove.
T195377A —UN—03OCT03

2. Install new filter and tighten until snug.

1— Filter

HG31779,00002ED ­19­26JUN03­1/1

3­8­6 PN=126
072310
 Maintenance—Every 500 Hours

Check Park Brake Oil Level

NOTE: Park brake oil should be changed every 500 hours
for applications running in deep water, mud or snow.

1. Remove plug (A). Check oil level.

T114802 —UN—14APR98
IMPORTANT: Do not operate machine with park
brake overfilled. Oil must be at bottom of
the check plug on the side of the park brake.
Too much oil can cause overheating; too
little can cause bearing failure. Drain excess
oil down before replacing plug.

2. Add oil if necessary. Allow 2 minutes for oil to settle to

bottom of level plug. A—Plug
3. Check oil level and install plug.
CED,OUOE002,1730 ­19­10MAY05­1/1

Check Front and Rear Differential/Axle Oil

Level
NOTE: Dipsticks are located on left front and left rear
axle housing on 444J (S.N. —604689), 544J, 624J.

TX1004765A —UN—13MAR06
Dipsticks for 444J (S.N. 604690— ) are located on
the right front and left rear axle housings.

1. Clean area around dipstick.

IMPORTANT: To properly check oil level, do not
thread dipstick into dipstick port.

2. 444J (S.N. —604689), 544J, 624J remove dipstick (1). Front Axle Dipstick Plug 444J (S.N. —604689), 544J, 624J Shown
444J (S.N. 604690— ) remove dipstick (2).

1— Dipstick 2— Dipstick

TX1004764A —UN—13MAR06

Front Axle Dipstick Plug 444J (S.N. 604690— ) Shown

Continued on next page VD76477,00004FF ­19­26JUN06­1/3

3­8­7 PN=127
072310
 Maintenance—Every 500 Hours

IMPORTANT: Each differential housing has three

separate components. Allow 10 minutes for oil
to stabilize in each sump before checking.

3. 444J (S.N. —604689), 544J, 624J only— Check front

TX1004765A —UN—13MAR06
and rear differential/axle housing through left side
dipstick port (1).

1— Dipstick

Front Axle Dipstick Plug 444J (S.N. —604689), 544J, 624J Shown

VD76477,00004FF ­19­26JUN06­2/3

4. 444J (S.N. 604690— ) only— Check front

differential/axle housing through right side dipstick port
and left rear dipstick port for the rear differential/axle
housing.

TX1004764A —UN—13MAR06
5. Oil must be to the FULL level on dipstick.
NOTE: If axle is hot and dipstick is too warm to hold with
bare hands, the oil can expand and may be as much
as 25 mm (1 in.) above FULL mark. This is normal.
DO NOT adjust level. If oil level is above the FULL
mark after axle cools, drain and check oil level.

6. If necessary, add oil. See Transmission, Park Brake,

Front Axle Dipstick Plug 444J (S.N. 604690— ) Shown
and Differential Oil. (Section 3­1.)
7. Install dipstick. 2— Dipstick

VD76477,00004FF ­19­26JUN06­3/3

Take Fluid Samples • Transmission Oil

See your authorized dealer for taking the following fluid
• Axle Oil
samples:
• Coolant
• Diesel Fuel
• Hydraulic Oil
CS58540,0000069 ­19­22JUN10­1/1

3­8­8 PN=128
072310
 Maintenance—Every 1000 Hours
Clean Engine Crankcase Vent Tube
Remove crankcase vent tube (A) and clean.
IMPORTANT: Do not pull on hose. Connector
damage may occur.

T117069 —UN—10SEP98
Remove hose (A) and clean.

A—Crankcase Vent Tube

HG31779,00002EE ­19­26JUN03­1/1

Replace Air Cleaner Dust Unloader Valve

NOTE: A missing, damaged, or hardened dust valve will
cause the air filter elements to be ineffective.

Replace dust unloader valve (1).

T196190A —UN—11NOV03
1— Dust Unloader Valve

HG31779,00002EF ­19­26JUN03­1/1

3­9­1 PN=129
072310
 Maintenance—Every 1000 Hours

Replace Air Cleaner Elements

1. Lift and hold lever (1) to unlock cover.
2. Rotate cover counterclockwise and remove cover.
3. Remove primary element (2).

T200914 —UN—15JUN04
4. Remove secondary element (3).
5. Clean air cleaner canister.
6. Install new filter elements into housing one at a
1
time making sure secondary element is centered in
canister.
7. Attach cover by rotating clockwise until lock arrows on
body and cover are aligned.

1— Lever 3— Secondary Element

2— Primary Element

T196122A —UN—07NOV03
T196123A —UN—07NOV03
HG31779,00002F0 ­19­26JUN03­1/1

3­9­2 PN=130
072310
 Maintenance—Every 1000 Hours

Replace Transmission Oil Filter

1. Operate machine under load until transmission oil
reaches normal operating temperature.
2. Park machine on a level surface.

T192391A —UN—18SEP03
3. Lower bucket to ground.
4. Move FNR to neutral "N". If equipped with FNR,
engage neutral lock.

CAUTION: Prevent possible injury from

unexpected machine movement. Machine can
unexpectedly roll or move under power, resulting
in death or serious injury. Always turn engine off
or push park brake switch to ON to hold machine.

5. Push park brake switch to ON.

T192390A —UN—18SEP03
CAUTION: Prevent possible injury from
unexpected machine movement. Install frame
locking bar before changing oil filter.

6. Install frame locking bar.

IMPORTANT: Turbocharger may be damaged if
engine is not properly shut down.

7. Run engine at 1/2 speed for 2 minutes before stopping 1— Transmission Oil Filter 2— Sight Gauge
to avoid damage to turbocharger. Release accelerator
pedal to slow idle.
8. Turn key switch to “Off”. 13. Start engine and run for 2 minutes.
9. Turn filter (1) counterclockwise to remove. 14. Move FNR to neutral "N". If equipped with column
10. Clean mounting surface. Apply thin film of oil to gasket FNR, engage neutral lock.
of new filter. 15. Check oil level. Oil must be between marks on sight
11. Install new filter. Turn filter clockwise by hand until gauge (2). Add oil if necessary.
gasket touches mounting surface. 16. Check for leaks around the filter base. Tighten filter
12. Tighten 3/4 of a full turn more. only enough to stop leaks.
HG31779,00002CB ­19­24JUN03­1/1

3­9­3 PN=131
072310
 Maintenance—Every 1000 Hours

Check Coolant
CAUTION: Explosive release of fluids
from pressurized cooling system can
cause serious burns.
Only remove filler cap when engine is cold or

TS281 —UN—23AUG88
when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.

IMPORTANT: John Deere Liquid Coolant Conditioner

does not protect against freezing. Coolant
conditioner prevents rust, scale, and
liner cavitation.

NOTE: Check coolant every 500 hours or 6 months,

or when replacing 1/3 or more of coolant. Add
coolant conditioner as necessary.

T196191A —UN—12NOV03
1. Remove radiator cap (1) and test coolant solution.
Use one of the following kits to check coolant.
• 3­WAY Heavy Duty Coolant Test Kit (TY16175)
Coolant test strips provide an effective method to
check freeze point and additive levels of engine
coolant. See your authorized dealer for 3­WAY
Heavy Duty Coolant Test Kit and follow instructions
on kit.
2. Add TY16004 John Deere Coolant Conditioner or
equivalent non­chromatic conditioner/rust inhibitor
as necessary. Follow instructions on container for
amount.

T111110 —UN—13AUG97
Cooling System—Specification
444J—Capacity.............................................................................. 21.0 L
5.5 gal
544J—Capacity.............................................................................. 21.0 L
5.5 gal
624J—Capacity.............................................................................. 22.0 L
5.8 gal 3­Way Test Kit
3. Install cap.
1— Radiator Cap

HG31779,00002F1 ­19­30JUN10­1/1

3­9­4 PN=132
072310
 Maintenance—Every 1000 Hours

Check Radiator Hoses

1. Check upper (1) and lower radiator hoses for cracks
and leaks. Replace if necessary.
2. Tighten clamps.

T196192A —UN—11NOV03
1— Upper Radiator Hose

Upper Radiator Hose Shown

HG31779,00002F2 ­19­26JUN03­1/1

Grease Frame Hinge Pivots

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before lubricating.

Lubricate each point with a minimum of three shots of

grease and until grease escapes around the seals. See
Grease. (Section 3­1.)

Two Points T106386C —UN—10MAR97

TX,85,JC1832 ­19­13OCT03­1/1

3­9­5 PN=133
072310
 Maintenance—Every 1000 Hours

Change Park Brake Oil

NOTE: Park brake oil should be changed every 500 hours
for applications running in deep water, mud or snow.

CAUTION: Prevent possible injury from

T114802 —UN—14APR98
unexpected machine movement. Always
install frame locking bar.

IMPORTANT: Do not operate machine with park

brake overfilled. Oil must be at bottom of
the check plug on the side of the park brake.
Too much oil can cause overheating; too
little can cause bearing failure. Drain excess
oil down before replacing plug. A—Plug
Specification
Park Brake
Oil—Capacity............................................................................... 300 mL 3. Add John Deere HY­GARD® oil. Allow oil to settle for
10 oz approximately 2 minutes after filling.
1. Remove plug (A). 4. Drain or add oil if necessary.
2. Drain oil into a container. Dispose of waste oil properly. 5. Install plug.
HY­GARD is a trademark of Deere & Company.
CED,OUOE002,1733 ­19­01OCT04­1/1

3­9­6 PN=134
072310
 Maintenance—Every 2000 Hours
Adjust Engine Valve Lash (Clearance)
See your authorized dealer.
TX03679,00017DD ­19­08MAY01­1/1

Draining the Cooling System

CAUTION: Explosive release of fluids

from pressurized cooling system can
cause serious burns.
Shut off engine. Only remove filler cap when

TS281 —UN—23AUG88
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.

1. Check radiator hoses for cracks and leaks. Replace, if

necessary.
2. Tighten clamps.
3. Check radiator and oil cooler for dirt, damage, leaks,
and loose or broken mountings. Clean radiator and
oil cooler fins.

T196223A —UN—11NOV03
4. Connect a hose to drain valve (1) on radiator.
5. Turn drain valve counterclockwise to open. Allow
coolant to drain into a container. Dispose of used
coolant properly.
6. Turn drain valve (2) counterclockwise to drain engine
block. Allow coolant to drain into a container. Dispose
of used coolant properly.

1— Radiator Drain Valve 2— Engine Drain Valve

T196219A —UN—11NOV03
HG31779,00002F6 ­19­26JUN03­1/1

3­10­1 PN=135
072310
 Maintenance—Every 2000 Hours

Filling the Cooling System

CAUTION: Prevent possible injury from hot

spraying coolant. DO NOT remove radiator cap
unless the engine is cool. Then turn cap slowly to
the stop. Release pressure before removing cap.
Cooling System—Specification
444J—Capacity................................................................................. 21 L

TS281 —UN—23AUG88
22 qt
544J—Capacity................................................................................. 21 L
22 qt
624J—Capacity................................................................................. 22 L
23 qt

IMPORTANT: Use only permanent­type, low

silicate, ethylene glycol base antifreeze in
coolant solution. Other types of antifreeze The cooling system requires several warm­up and cool
may damage cylinder seals. down cycles to deaerate. It will NOT deaerate during
normal operation. Only during warm­up and cool down
FREEZING TEMPERATURES: Fill with permanent­type, cycles will the system deaerate.
low silicate, ethylene glycol antifreeze (without stop­leak
additive) and clean, soft water. Add TY16004 John Deere • Start engine. Run engine until coolant reaches a warm
Coolant Conditioner or equivalent. temperature.
• Stop engine. Allow coolant to cool.
NOTE: All machines are shipped from the factory • Check coolant level at recovery tank.
with a 50­50 mixture for protection to ­34 °C • Repeat Steps 1—3 until recovery tank coolant level is
(­30 °F). Adjust mixture accordingly to provide repeatedly at the same level (stabilized).
freeze protection for your machine.
NOTE: The level of the coolant in the cooling system
FILL MUST BE repeatedly checked after all drain and
refill procedures to insure that all air is out of the
• Fill radiator to the bottom of the radiator fill neck. system which allows the coolant level to stabilize.
• Fill the recovery tank to the FULL mark. Check coolant level only when the engine is cold.
DEAERATION
HG31779,00002F7 ­19­26JUN03­1/1

3­10­2 PN=136
072310
 Maintenance—Every 2000 Hours

Change Transmission Oil

NOTE: *Most applications would be considered "normal" operation. Service intervals should be reduced in severe applications which run the torque
converter at high load more than approximately 25% of the time. (Examples may include basement digging, land clearing, etc.)

Oil type
John Deere Hy­Gard ­ Oils meeting JDM J20C John Deere Low Viscosity Hy­Gard ­ Oils meeting JDM
Operation*
J20D
Normal 2000 1500
Severe 1500 1000

1. Operate machine under load until transmission oil

reaches normal operating temperature.
2. Park machine on a level surface.
3. Lower bucket to ground.

T106393C —UN—24JAN97
4. Move FNR to N. Engage neutral lock.

CAUTION: Prevent possible injury from

unexpected machine movement. Machine can
unexpectedly roll or move under power, resulting
in death or serious injury. Always turn engine off
or push park brake switch to ON to hold machine.

5. Push park brake switch to ON.

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before changing oil.

T159631D —UN—07OCT02
6. Install frame locking bar.
IMPORTANT: Turbocharger may be damaged if
engine is not properly shut down.

7. Run engine at 1/2 speed for 2 minutes before stopping

to avoid damage to turbocharger. Release accelerator
pedal to slow idle.
A—Plug C—Sight Gauge
8. Turn key switch to “Off”. Let machine sit for B—Filler Tube
approximately 10 minutes.
NOTE: Drain plug is magnetic. If an excessive
amount of metal particles appear on plug, Transmission Case and Filter Oil—Specification
see your John Deere dealer. 444J—Capacity.............................................................................. 18.5 L
19.5 qt
9. Remove bottom guard, if equipped. Remove plug 544J—Capacity.............................................................................. 18.5 L
(A), located inside hole in bottom guard, to drain oil. 19.5 qt
Allow oil to drain into a container. Dispose of waste 624J—Capacity.............................................................................. 26.5 L
oil properly. 28 qt

10. Install drain plug. Tighten to specification. 12. Start engine and run for 2 minutes.
Specification 13. Move FNR to N. If equipped with column FNR, engage
Drain Plug—Torque.......................................................................80 N∙m neutral lock.
59 lb­ft
14. Check oil level with oil at operating temperature. Oil
11. Fill transmission with oil at filler tube (B). See must be between marks on sight gauge (C).
Transmission, Park Brake, and Differential Oil.
(Section 3­1.)
VD76477,0000501 ­19­26JUN06­1/1

3­10­3 PN=137
072310
 Maintenance—Every 2000 Hours

Change Front and Rear Differential/Axle Oil

NOTE: Perform this service at the first 250 hours of
operation and then at 2000 hour intervals thereafter.

TX1004689A —UN—13MAR06
CAUTION: Prevent possible injury from hot
spraying oil. Slowly loosen dipstick to
relieve any air pressure.

NOTE: The axle drain plug is magnetized and should

be cleaned when changing differential/axle oil.
Axle differential recirculation screens (if equipped)
should also be cleaned at this time. See Clean Axle Front Differential 444J (S.N. —604689), 544J, 624J Shown
Differential Recirculation Screen in this section.

1. ALL MACHINES— Remove hose (1) and screen

fitting (2). Allow oil to drain into a container. Dispose
of waste oil properly. Install screen fitting and hose.

TX1004688A —UN—13MAR06
2. 444J (S.N. 604690— ) only Remove plugs (3) from
axle ends and clean magnetized ends of plugs. Allow
oil to drain into a container. Dispose of waste oil
properly.
Front Differential/Axle Oil—Specification
444J (S.N.
—604689)—Capacity........................................................................ 17 L
18 qt Axle End Drain Plug 444J (S.N. 604690— ) Shown
444J (S.N. 604690—
)—Capacity........................................................................................ 22 L
23 qt 1— Hose 3— Axle End Drain Plug (4
2— Screen Fitting (If Equipped) used)
544J—Capacity................................................................................. 18 L
19 qt
624J—Capacity.............................................................................. 24.5 L
544J—Capacity................................................................................. 18 L
26 qt
19 qt
Rear Differential/Axle Oil—Specification 624J—Capacity................................................................................. 20 L
444J (S.N. 21 qt
—604689)—Capacity........................................................................ 17 L
18 qt
444J (S.N. 604690—
)—Capacity........................................................................................ 22 L
23 qt
Continued on next page MM61211,0001433 ­19­04APR06­1/2

3­10­4 PN=138
072310
 Maintenance—Every 2000 Hours

3. 444J (S.N. —604689), 544J, 624J Remove dipstick

(4). 444J (S.N. 604690— ) Remove dipstick (5).
4. 444J (S.N. —604689), 544J, 624J only— add oil
slowly through dipstick port on left front and left rear

TX1004673A —UN—13MAR06
differential .
5. 444J (S.N. 604690— ) only— fill front differential/axle
housing with oil through right side dipstick port
(5). And through left rear dipstick port for the rear
differential/axle housing.
IMPORTANT: To properly check oil level, do not
thread dipstick into dipstick port.
Left Front Axle Shown 444J (S.N. —604689), 544J, 624J
6. Check oil level.
7. Install dipstick and tighten.

4— Dipstick 5— Dipstick

TX1004674A —UN—13MAR06
Right Front Axle Shown 444J (S.N. 604690— )

MM61211,0001433 ­19­04APR06­2/2

Clean Axle Differential Recirculation Screen

1. Disconnect hose (A) and remove screen fitting (B).
2. Drain differential oil into a container. Dispose of waste
properly.

T117325 —UN—22SEP98
NOTE: Fitting and screen are of a one piece design.
Screen should be thoroughly cleaned and reused.

3. Clean screen with solvent.

4. Install screen fitting.
5. Install hose. Front Differential Shown 444J (S.N. —604689), 544J, 624J
6. Refill differential with oil.

A—Hose B—Screen Fitting

T117326 —UN—22SEP98

Rear Differential Shown

MM61211,00013CF ­19­22APR08­1/1

3­10­5 PN=139
072310
 Maintenance—Every 2000 Hours

Re­Run Clutch Calibration

See your authorized dealer.
HG31779,000032E ­19­07NOV03­1/1

3­10­6 072310

PN=140
 Maintenance—Every 4000 Hours
Change Hydraulic Oil
1. Lower bucket to the ground.
2. Stop engine.
3. Turn key switch to “On.”

T192344L —UN—13OCT03
NOTE: Return­to­carry (1) must be OFF for float
detent to operate.

4. Move hydraulic control lever to float detent position.

CAUTION: Prevent possible injury from

unexpected boom movement. The bucket may
“jump up” when ride control switch is turned
ON. Clear all bystanders from area.

5. Cycle ride control switch (2) from OFF to ON.

6. Push pilot enable/boom down switch (3) to release

T196188B —UN—14NOV03
accumulator pressure.
7. Turn key switch “Off”.
8. Remove hydraulic reservoir filler cap (4).

1— Return­to­Carry Switch 3— Pilot Enable/Boom Down

2— Ride Control Switch Switch
4— Filler Cap

VD76477,0000502 ­19­26JUN06­1/2

9. Loosen hose clamp and remove plug (1) from end

of drain hose (2). Allow oil to drain into a container.
Dispose of waste oil properly.
10. Flush reservoir with diesel fuel.
11. Reinstall plug on end of drain hose and tighten hose

T196383A —UN—14NOV03
clamp.
12. Fill reservoir. See Hydraulic Reservoir Oil. (Section
3­1.)
Hydraulic Reservoir and Filters—Specification
444J—Capacity.............................................................................. 96.5 L
25.5 gal
544J—Capacity.............................................................................. 98.5 L
26 gal
624J—Capacity............................................................................... 119 L
31.5 gal
T192369B —UN—14NOV03

13. Install filler cap.

14. Check oil level in sight glass (3). Oil should be in
FULL range.

1— Plug 3— Sight Glass

2— Drain Hose

VD76477,0000502 ­19­26JUN06­2/2

3­11­1 PN=141
072310
 Maintenance—Every 4000 Hours

Clean Hydraulic System Strainer

1. Remove hydraulic reservoir filler cap (1).
2. Remove snap ring.
3. Remove strainer (2) and clean with solvent.

T196236A —UN—11NOV03
4. Install strainer and snap ring.
5. Replace cap.

1— Filler Cap 2— Strainer

HG31779,00002F5 ­19­26JUN03­1/1

3­11­2 PN=142
072310
 Maintenance—Every 4500 Hours
Replace Engine Crankshaft Dampener (544J whichever occurs first, or whenever crankshaft is
and 624J Only) replaced. See your authorized dealer.

The crankshaft dampener assembly is not repairable

and should be replaced every five years or 5000 hours,
OUT4001,000025F ­19­10JUN09­1/1

3­12­1 072310

PN=143
 Miscellaneous—Machine
Bleed the Fuel System

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Relieve
pressure before disconnecting fuel or other
lines. Tighten all connections before applying
pressure. Keep hands and body away from
pinholes and nozzles that eject fluids under high

X9811 —UN—23AUG88
pressure. Use a piece of cardboard or paper to
search for leaks. Do not use your hand.
If ANY fluid is injected into the skin, a doctor
familiar with this type of injury must surgically
remove it within a few hours or gangrene
may result. Doctors unfamiliar with this
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.

Whenever the fuel system has been opened up for service

(lines disconnected or filters removed), it will be necessary
to bleed air from the system.
RG41221,0000031 ­19­22APR02­1/3

1. Drain water and contaminates from water separator

bowl by opening the drain valve (D).

D—Drain Valve

RG11519B —UN—14DEC00

Drain Valve on Final Filter

Continued on next page RG41221,0000031 ­19­22APR02­2/3

4­1­1 PN=144
072310
 Miscellaneous—Machine

2. Connect JT03472 coupler and hose to diagnostic port

(A). If JT03472 coupler is not available, loosen the
diagnostic port to allow air and fuel to escape. Bleed
fuel into suitable container.
3. Unlock and operate hand primer (B) until a steady
flow of fuel (without bubbles) flows out of hose. This

RG11081 —UN—10NOV00
could take 270 ­ 330 strokes until steady fuel flow is
free of bubbles.
4. Continue to pump hand primer while disconnecting
JT03472 coupler from diagnostic port, or while
tightening diagnostic port to specification below.
Specification Diagnostic Port
Diagnostic
Port—Torque.................................................................. 14 N∙m (10 lb­ft)

5. Start engine and run at 1200­1500 RPM for 3­5

minutes.
6. If engine fails to start, loosen high pressure fuel line

RG12279A —UN—22APR02
fittings (C). Pump hand primer (B) until steady flow
of fuel escapes the fuel pump. Tighten fuel lines to
specification below and lock hand primer. This could
take an addition 90 ­ 120 strokes until steady fuel flow
is free of bubbles.
Specification
High Pressure Fuel
Lines—Torque................................................................ 27 N∙m (20 lb­ft) Diagnostic Port

7. Crank engine up to 15 seconds. If engine does not

start, wait 15 seconds and then crank for an additional
15 seconds. If engine starts, run at 1200­1500 RPM
for 3­5 minutes.
8. If engine fails to start, loosen fuel line fitting on HPCR
flow limiter #6. Place rag around fitting to absorb fuel.
Pump hand primer (B) until steady flow of fuel escapes
the flow limiter. Tighten fuel lines to specification
below and lock hand primer (pull up, then push down

RG11518 —UN—11DEC00
and lock).
Specification
High Pressure Fuel
Lines—Torque................................................................ 27 N∙m (20 lb­ft)

9. Crank engine up to 15 seconds. If engine does not

start, wait 15 seconds and then crank for an additional Hand Primer
15 seconds. If engine starts, run at 1200­1500 RPM
for 3­5 minutes.
A—Diagnostic Port C—High Pressure Fuel Line
B—Hand Primer Fittings

RG41221,0000031 ­19­22APR02­3/3

4­1­2 PN=145
072310
 Miscellaneous—Machine

Precautions for Alternator and Regulator

When batteries are connected, follow these rules: 6. Connect batteries or a booster battery in the correct
1. Disconnect negative (­) battery cable when you work polarity (positive [+] to positive [+] and negative [­] to
on or near alternator or regulator. negative [­]).

2. DO NOT TRY TO POLARIZE ALTERNATOR OR 7. Do not disconnect the batteries when engine is
REGULATOR. running and alternator is charging.

3. Be sure alternator wires are correctly connected 8. Disconnect battery cables before you connect battery
BEFORE you connect batteries. charger to the batteries. If machine has more than one
battery, each battery must be charged separately.
4. Do not ground alternator output terminal.
5. Do not disconnect or connect any alternator or
regulator wires while batteries are connected or while
alternator is operating.
04T,90,C151 ­19­20JUL92­1/1

4­1­3 072310

PN=146
 Miscellaneous—Machine

Handling, Checking, and Servicing Batteries

Carefully

CAUTION: Battery gas can explode. Keep sparks

and flames away from batteries. Use a flashlight
to check battery electrolyte level.

TS204 —UN—23AUG88
Never check battery charge by placing
a metal object across the posts. Use a
voltmeter or hydrometer.
Always remove grounded (­) battery clamp
first, and replace it last.
Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness
if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well­ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when
electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush contacted skin with water.
2. Apply baking soda or lime to contacted
area to help neutralize the acid.
3. Flush eyes with water for 15—30 minutes.
Get medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.

TS203 —UN—23AUG88
2. Drink large amounts of water or milk, but
do not exceed 1.9 L (2 qts).
3. Get medical attention immediately.

WARNING: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.
IMPORTANT: Do not overfill the battery cells.
If electrolyte spills on the floor, use one of the following
mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda Check the specific gravity of electrolyte in each battery
in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia in cell.
4 L (1 gal) water.
Continued on next page TX03679,0001788 ­19­04AUG09­1/2

4­1­4 PN=147
072310
 Miscellaneous—Machine

See your authorized dealer for JT05460

SERVICEGARD™ battery and coolant tester.
Follow directions included with the tester.
A fully charged battery will have a corrected specific
gravity reading of 1.260. If the reading is below 1.200,

T85402 —UN—10NOV88
charge the battery.

SERVICEGARD is a trademark of Deere & Company

TX03679,0001788 ­19­04AUG09­2/2

Using Booster Batteries—24­Volt System

Before boost starting, machine must be properly shut
down and secured to prevent unexpected machine
movement when engine starts.

CAUTION: An explosive gas is produced while

TS204 —UN—23AUG88
batteries are in use or being charged. Keep flames
or sparks away from the battery area. Make sure
the batteries are charged in a well ventilated area.

IMPORTANT: The machine electrical system is

a 24­volt negative (­) ground. Connect
two 12­volt booster batteries together in
series as shown for 24 volts.

1. Connect one end of the positive cable to the lug on

starter (1) and the other end to the positive terminal of
booster batteries (2).

TX1014128 —UN—16NOV06
2. Connect one end of the negative cable to the negative
terminal of booster batteries. Then connect the other
end of negative cable to the machine frame (3) as far
away from the machine batteries as possible.
3. Start the engine.
4. Immediately after starting the engine, disconnect the
end of negative cable from the machine frame first.
Then disconnect the other end of negative cable from
the negative terminal of booster batteries.
5. Disconnect the positive cable from the booster
batteries and lug on starter.
TX1015327A —UN—21NOV06

1— Lug on Starter 3— Machine Frame

2— Booster Batteries

OUT4001,0000058 ­19­02JUL09­1/1

4­1­5 PN=148
072310
 Miscellaneous—Machine

Using Battery Charger

CAUTION: Prevent possible injury from exploding

battery. Do not charge a battery if the battery
is frozen or it may explode. Warm battery
to 16°C (60°F) before charging.

TS204 —UN—23AUG88
Turn off charger before connecting or
disconnecting it.

IMPORTANT: Do not use battery charger as a

booster if a battery has a 1.150 specific
gravity reading or lower.
Disconnect battery ground (­) clamp before
you charge batteries in the machine to prevent
damage to electrical components.

A battery charger may be used as a booster to start

engine.
Ventilate the area where batteries are being charged.
Stop or cut back charging rate if battery case feels hot,
or is venting electrolyte. Battery temperature must not
exceed 52°C (125°F).

N36890 —UN—07OCT88
OUT4001,0000239 ­19­16MAR10­1/1

Replacing Batteries Specification

Your machine is equipped with a negative ground Battery—BCI Group...........................................................................30H
electrical system. It uses two 12­volt batteries. If one of Cold Cranking Amps at
the two batteries fails, both batteries must be replaced. ­18°C (0°F) ........................................................................................ 625
Use only batteries meeting following specifications. Reserve Capacity at 25
amps.....................................................................................160 Minutes
CED,OUOE002,1772 ­19­15SEP98­1/1

4­1­6 PN=149
072310
 Miscellaneous—Machine

Removing Batteries
NOTE: Turn off master shut­off switch (1), if equipped,
before disconnecting cables.

1. Open battery compartment door.

T196314A —UN—11NOV03
2. Remove bolts (2) to remove battery cover.

CAUTION: To prevent injury from battery

covers dropping, remove when servicing or
replacing batteries. Hinge is in place to aid
in removal only. Cover must not be held or
propped open during servicing.

CAUTION: To prevent injury from explosion

or fire, disconnect the right side battery first
regardless of which battery is being removed.

T196316A —UN—11NOV03
3. Disconnect negative (­) battery cable (3) first, then
positive (+) cable (4).
4. Remove hex nut and washer (5) and battery
disconnect bracket.
5. Remove capscrew and washer (6) and hold­down
bracket.
6. Remove batteries.
1— Master Shut­off Switch 4— Positive (+) Cable
2— Bolts (2 used) 5— Hex Nut and Washer
3— Negative (­) Cable 6— Capscrew and Washer

HG31779,00002F8 ­19­26JUN03­1/1

Replacing Fuses
The fuse block is located in the load center. Remove fuse
panel cover (1) to access fuse panel.
IMPORTANT: Install fuse with correct amperage rating
to prevent electrical system damage

T195538A —UN—16OCT03
from overload.

1— Fuse Panel Cover

Continued on next page MM61211,00013D2 ­19­22FEB06­1/3

4­1­7 PN=150
072310
Miscellaneous—Machine

T192491 —UN—12SEP03

Continued on next page MM61211,00013D2 ­19­22FEB06­2/3

4­1­8 072310

PN=151
 Miscellaneous—Machine

F1— Flashers (5A) F15— (FLC) Flex Load Controller F32— Park Brake Release F56— Front Wiper Motor (5A)
F2— Brake Light Pressure Switch Ignition Power (5A) Switch/Backup Alarm K1—Horn Relay
(5A) F16— Spare Ignition Power (15A) (5A) V2— Start Aid Solenoid Diode
F3— (ECU) Engine Control Unit F17— Spare Battery Power (15A) F33— Pressurizer Motor (10A) (3A)
Battery Power (20A) F18— (TCU) Transmission F34— (CMU) Can Monitor Unit V3— Ignition Relay Diode (3A)
F4— Converter Battery Power Control Unit Battery power Battery Power (5A) V4— Start Relay Diode (3A)
(15A) (5A) F38— Differential Lock Foot V5— Alternator Excitation Diode
F5— Blower Motor (25A) F19— Horn (5A) Switch (5A) (3A)
F8— Electric Adjust Seat (10A) F20— Spare Battery Power (5A) F40— Transmission Output V7— Reverse Polarity Diode (3A)
F9— Converter Ignition Power F21— (FLC) Flex Load Controller Speed Sensor (5A)
(10A) Battery Power (10A) F41— Start Relay (5A)
F10— (ECU) Engine Control Unit F23— Brake/Steering Pressure F46— Start Aid Solenoid Switch
Ignition Power (5A) Switch (5A) (10A)
F11— Restriction Switch/Radio F28— (TCU) Transmission F49— Radio, Diagnostic
Ignition Power (10A) Control Unit Ignition power Connector, Dome Light
F13— (CMU) Can Monitor Unit, (5A) Battery Power (10A)
(SSM) Sealed Switch F31— Spare Ignition Power (5A) F53— Alternator Excitation (5A)
Module, Ignition Power F55— Rear Wiper Motor (5A)
(5A)
MM61211,00013D2 ­19­22FEB06­3/3

Fuse (Blade­Type) Color Codes

Amperage Rating Color
1 Black
3 Violet
4 Pink
5 Tan
7.5 Brown
10 Red
15 Light Blue
20 Yellow
25 Natural (White)
30 Light Green
CED,OUO1021,127 ­19­13MAR98­1/1

4­1­9 072310

PN=152
 Miscellaneous—Machine

Replacing Halogen Bulbs

IMPORTANT: To get the correct lighting pattern, lens
must be installed so the word "TOP" is on
top when lamp is installed so wider section
is on top when lamp is installed.

T5894AG1 —UN—17APR89
Before disassembling, remember how bezel and lens are
installed with respect to mounting stud.
1. Remove four screws (H) to remove bezel (G) and lens
(F).
2. Disconnect wiring lead and release retainer clip to
remove bulb (D).
3. To disconnect ground wiring lead, push tab up, then
pull connector from terminal.
IMPORTANT: Do not touch the halogen bulb with
bare hands. Oil and moisture may cause

T5894AI1 —UN—20OCT88
premature bulb failure. Clean bulb using a
soft, oil­free cloth and alcohol.

4. Install new bulb so square notch is aligned with square

tab on reflector back.
5. Install retainer clip into locking tabs on reflector back.
6. Connect wiring leads. Check wiring leads are free of
clip.
7. Install lens assembly (F) in housing (C) making sure
wires are not crimped, or keeping lens assembly from
seating on gasket.

T6249AU —UN—19OCT88
8. Install bezel so wider section is on top. Sealing
flange must be inside housing on all four sides before
tightening screws.
9. Tighten screws alternately. Do not overtighten as
screws may strip out plastic.

A—Flange Nut E—Gasket

B—Lock Washer F— Lens
C—Housing G—Bezel
D—Bulb H—Screw

TX,90,RR,1725 ­19­11MAR94­1/1

Engine Speeds
Specification
Engine—Slow Idle
Speed.................................................................................. 900 ± 25 rpm
Fast Idle Speed ................................................................ 2350 ± 25 rpm
TX,90,JC2103 ­19­01OCT04­1/1

4­1­10 PN=153
072310
 Miscellaneous—Machine

Checking Neutral Start System

CAUTION: Avoid possible injury or death. DO NOT 1. WILL start with the FNR in neutral "N" position.
attempt to start machine unless you are sitting
in operator’s seat with the FNR in neutral "N" 2. WILL start with the FNR in forward "F" or reverse "R"
position with park brake applied. DO NOT bypass position, but will not move until it has been cycled
or disable any of the starting system parts. back to “N”.
If starting system fails to operate correctly, have your
Check the neutral start system to ENSURE that the John Deere dealer repair the system immediately.
machine:
TX,90,JC1862 ­19­18MAY05­1/1

Servicing Air Conditioning System

1. Check compressor clutch engagement.
2. Check evaporator core for clogging.
3. Check air intake filters for clogging.

T106394C —UN—08APR97
4. Check blowers for proper operation.
5. Check the condenser core to see that it is not partially
or completely plugged with dirt or trash. Clean with
compressed air or water when needed.
6. Run air conditioning system for several minutes.
7. Check sight glass (1) on receiver dryer (from outside
of cab). Bubbles must not be present in sight glass. 1— Receiver Dryer Sight Glass
If bubbles are present, see your authorized dealer for
charging the air conditioning system.
TX,90,JC1978 ­19­20MAR97­1/1

Welding on Machine NOTE: Machine is adequately grounded. It is

IMPORTANT: Disconnect battery ground strap or turn not necessary to disconnect any controllers
battery disconnect switch to "OFF" to prevent (microprocessors).
voltage spikes through alternator or monitor.
Connect welder ground clamp close to each
weld area so electrical current does not arc
inside any bearings, bushings or pins.
TX,90,JC1603 ­19­29AUG96­1/1

4­1­11 PN=154
072310
 Miscellaneous—Machine

External Service Brake Inspection—444J

(S.N. —604689), 544J, 624J
Do first inspection at 5000 hours followed by 1000­hour
inspection intervals after the first 5000­hour inspection.

T105193B —UN—02NOV98
If the service brakes are subjected to severe duty, inspect
more frequently.
1. Remove plug from brake inspection port.
2. Start engine and run for 1 minute.
3. Stop and apply the brakes. Block pedal or have
someone hold brakes on.
4. Using a tool (A), measure the thickness of disks (B) at
dimension (C). Check dimension of two different disks.
Specification
Used Service Brake Disk

T117102 —UN—10SEP98
Thickness—Distance.................................................................. 2.29 mm
0.090 in.
New Service Brake Disk
Thickness—Distance.................................................................. 2.90 mm
0.114 in.

5. If either of the disk thickness at dimension (C) is less

than the minimum specification, the brake packs must
be replaced.

A—Feeler Gauge C—Dimension

B—Disks D—Plates

T117103 —UN—23SEP98

MM61211,0000DAA ­19­16MAR06­1/1

4­1­12 PN=155
072310
 Miscellaneous—Machine

External Service Brake Inspection—444J

(S.N. 604690— )

CAUTION: Prevent possible injury from

hot spraying oil. Slowly loosen plug to

TX1003414 —UN—07FEB06
relieve any pressure.

IMPORTANT: Perform first inspection at 5000 hours

followed by 1000­hour inspection intervals
after the first inspection, or if ever any of
the following are suspected:
• Brake Noises.
• Reduced Braking Power. 1— Feeler Gauge
• Deceleration Changes.
• Brake Fluid Level Changes.
2. Remove plug from brake inspection port.
• Brake Pressure Changes.
If the service brakes are subjected to severe
duty, inspect more frequently.

1. Apply brakes and block pedal or have someone hold

brakes on.
MM61211,0000DA9 ­19­04APR06­1/2

3. Using a feeler gauge (1), measure the dimension (2)

between plates (3). Check measurements on both
output sides.
Specification
Service Brake Disk

TX1003413 —UN—07FEB06
Thickness—If Distance Is
Less Than..................................................................................... 4.0 mm
0.15 in.

4. If the disk thickness at dimension (2) is less than

the minimum specification, the brake packs must be
replaced.

2— Dimension 3— Plates
TX1003419 —UN—07FEB06

Exploded View
MM61211,0000DA9 ­19­04APR06­2/2

4­1­13 PN=156
072310
 Miscellaneous—Machine

Checking Brake Accumulators—444J (S.N. 5. Turn key switch to ON position.

—604689), 544J, 624J
NOTE: Accumulators are precharged and must be
1. Start engine. replaced, not recharged.
NOTE: If machine is equipped with return­to­carry, the
return­to­carry switch must be in the OFF position. 6. Apply brake pedal. The brake low pressure indicator
light may come on after 18 to 35 full brake applications.
2. Lower boom by placing controller handle in “float” If brake light comes on with less than 18 applications,
position. see your authorized dealer.
3. Run engine for 1 minute at slow idle. Apply brake 7. Repeat procedure three times to ensure accurate
pedal four or five times. results.
4. Stop engine.
MM61211,00013BD ­19­16MAR06­1/1

Checking Brake Accumulators—444J (S.N.

604690— )

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

X9811 —UN—23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high­pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.

T214029A —UN—30AUG05
1. Start engine.
2. Run engine for 1 minute at slow idle. Apply brake
pedal four or five times.
3. Stop engine.
4. Turn key switch to ON position.
NOTE: Accumulators are precharged and must be
replaced, not recharged. 1— Brake Accumulator (2 used)

5. Apply brake pedal. The brake low pressure indicator

light may come on after five to six full brake 6. Repeat procedure three times to ensure accurate
applications. The indicator light will stay on 2—3 results.
seconds after each application and then go off. After
seven to eight applications, indicator light will stay on.
If brake light comes on with less than four applications,
individual accumulators (1) should be replaced.
MM61211,00013BC ­19­16MAR06­1/1

4­1­14 PN=157
072310
 Miscellaneous—Machine

Checking Ride Control Accumulator—If

Equipped

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

X9811 —UN—23AUG88
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high­pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result.

CAUTION: Prevent possible injury from

unexpected machine movement. The boom

T192456A —UN—18SEP03
will jump upward during this check. Make
sure area around bucket is clear.

1. Start engine.
2. Push ride control switch (1) to OFF position.
3. Raise boom to maximum height and hold control lever
over relief for 2 seconds.
4. Lower boom and bucket to ground and stop engine. 1— Ride Control Switch
Put boom control lever in neutral.
Continued on next page MM61211,00013BE ­19­19APR06­1/2

4­1­15 PN=158
072310
 Miscellaneous—Machine

NOTE: When ride control switch is in “A” (automatic)

position, ride control works at 6.0 km/h
(3.7 mph) or above.

5. Turn key switch to the ON position.

T108328C —UN—27AUG97
6. Push ride control switch to the MANUAL/ON
position. Switch will light. Boom will jump upward,
approximately 100 mm (4 in.), as accumulator (A)
pressure is released.
7. If ride control accumulator has lost gas charge, see
your authorized dealer.
To Discharge Accumulator
1. Start engine. A—Accumulator
2. Raise boom to access front cover on frame.
NOTE: If machine is equipped with return­to­carry, the NOTE: If ride control switch is already in the MANUAL/ON
return­to­carry switch must be in the OFF position. position, it must be cycled to OFF then back
to MANUAL/ON position.
3. Install boom lock.
NOTE: Boom should be raised and boom lock installed 7. Push and hold pilot enable/boom down switch.
so there is approximately 6” between the 8. Push and hold hydraulic control lever in the boom
boom lock and cylinder barrel. float position until the boom lock contacts the cylinder
barrel.
4. Stop engine.
NOTE: If pressure still remains in the accumulators it will
5. Turn key switch to the ON position. be difficult to connect the transducer to the diagnostic
6. Push ride control switch to the MANUAL/ON position. quick coupler. Repeat process if necessary.
Switch will light.
MM61211,00013BE ­19­19APR06­2/2

Transmission Cooler and Radiator External

Cleaning Procedure
1. If dust or debris is light, clean oil cooler by blowing air
through the fins. Do not exceed 6 bar (90 psi). Blow
air straight through fins to avoid bending them.

T196193A —UN—11NOV03
2. If air fails to clean the oil cooler, use a high­pressure
washer with soap and water not to exceed 48 bar
(700 psi). Direct water straight through fins to avoid
bending them.

HG31779,00002FC ­19­26JUN03­1/1

4­1­16 PN=159
072310
 Miscellaneous—Machine

Service Recommendations For Snap­To­Connect (STC®) Fittings

Snap­To­Connect (STC®) fittings are used on this
machine. The fittings are designed to allow the hydraulic
hose to rotate as needed when the system is not
pressurized. This prevents the hydraulic hoses from
binding when components are put back to their operating
position.

T134792C —UN—24OCT00
Fittings are easily disconnected using special tool,
JDG1385 STC Fitting Release Tool (1) (supplied in
machine with Operator’s Manual). The special tool has a
different size slot cut into each end. The narrow slot is
for ­06 size fittings. The wide slot is for ­08 size fittings.
Use appropriate end of special tool on fitting being
disconnected. To connect fittings, simply push each half
of fitting together.
1— JDG1385 STC Fitting 3— Release Sleeve
IMPORTANT: DO NOT pry against release sleeve Release Tool
(3) or damage to fitting may result. 2— Shoulder Of Fitting

DO NOT force release sleeve beyond normal

range of travel, otherwise, release sleeve
may fall off when hose is disconnected. If b. While keeping JDG1385 STC Fitting Release Tool
this happens and fitting is connected without (1) perpendicular to the fitting, insert tool between
the release sleeve installed, fitting will not release sleeve (3) and shoulder (2).
be able to be disconnected again.
c. Gently push, DO NOT PRY, release sleeve away
from shoulder to disconnect the fitting.
1. Disconnect STC type fittings:
d. Pull hose to disconnect.
a. Clean area around fitting, especially around the
release sleeve (3).
Snap­To­Connect (STC) is a trademark of Eaton Corp.
OUO1010,0000457 ­19­22JUL10­1/2

2. Inspect STC fittings:

a. Check seal mating surfaces for nicks, scratches,
or flat spots.
b. Check O­ring (4), backup ring (5), and retaining ring
(2) for wear or damage.
c. Make sure O­ring, backup ring, and retaining ring T133922 —UN—21SEP00

are in position before connecting fitting halves

together.
3. Connect STC fittings:
a. Make sure fitting halves (3 and 6) are clean and
free of contaminants.
1— Release Sleeve 4— O­Ring
b. Make sure release sleeve (1) is on male half (6) of 2— Retaining Ring 5— Backup Ring
fitting before connecting fitting halves together. 3— Female Half of STC Fitting 6— Male Half of STC Fitting
c. Push fitting halves together until a definite snap and
solid stop is felt.
e. To prevent hoses from binding, move component
d. Pull back on hose to make sure fitting halves are into position before pressurizing hydraulic system.
locked together.
OUO1010,0000457 ­19­22JUL10­2/2

4­1­17 PN=160
072310
 Miscellaneous—Machine

Do Not Service Control Valves, Cylinders, If these parts need service, see your authorized dealer.
Pumps or Motors
Special tools and information are needed to service
control valves, cylinders, pumps, or motors.
TX,90,DH2537 ­19­03SEP92­1/1

Hardware Torque Specifications

Check cap screws and nuts to be sure they are tight.
If hardware is loose, tighten to torque shown on the
following charts unless a special torque is specified.
T82,SKMA,AT ­19­01AUG94­1/1

Keep ROPS Installed Properly

CAUTION: Make certain all parts are reinstalled

correctly if the roll­over protective structure
(ROPS) is loosened or removed for any reason.
Tighten mounting bolts to proper torque.

TS176 —UN—23AUG88
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident,
or is in any way altered. A damaged ROPS
should be replaced, not reused.

When installation of equipment on a machine necessitates

loosening or removing ROPS, mounting bolts must be
tightened.
Specification
ROPS Mounting
Bolt—Torque.............................................................................. 1150 N∙m
850 lb­ft
TX,90,JC1925 ­19­05NOV08­1/1

4­1­18 PN=161
072310
 Miscellaneous—Machine

Metric Bolt and Screw Torque Values

TS1670 —UN—01MAY03

4.8 8.8 9.8 10.9 12.9 12.9

4.8 8.8 9.8 10.9 12.9 12.9

Bolt or Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Screw Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N∙m lb.­ft. N∙m lb.­ft. N∙m lb.­ft. N∙m lb.­ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N∙m lb.­ft. N∙m lb.­ft. N∙m lb.­ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N∙m lb.­ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on U­bolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B zinc flake coating.
DX,TORQ2 ­19­08DEC09­1/1

4­1­19 PN=162
072310
 Miscellaneous—Machine

Unified Inch Bolt and Screw Torque Values

TS1671 —UN—01MAY03

Bolt or SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c
Screw Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Size N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in. N∙m lb.­in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N∙m lb.­ft. N∙m lb.­ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N∙m lb.­ft. N∙m lb.­ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N∙m lb.­ft. N∙m lb.­ft. N∙m lb.­ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N∙m lb.­ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1­1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1­1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1­3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1­1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on U­bolts, see the properly start thread engagement. When possible, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6. in (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8
in. and larger fasteners with JDM F13C zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B zinc flake coating.
DX,TORQ1 ­19­08DEC09­1/1

4­1­20 PN=163
072310
 Miscellaneous—Operational Checkout
Operational Checkout
Use this procedure to check all systems and functions
Complete the necessary visual checks (oil levels, oil
on the machine. It is designed so you can make a quick
condition, external leaks, loose hardware, linkage, wiring,
check of the operation of the machine while doing a walk
etc.) prior to doing the checkout. The machine must be at
around inspection and performing specific checks from
operating temperature for many of the checks.
the operator’s seat.
Before starting this operational checkout, check diagnostic
Should you experience a problem with your machine, you
Service codes in monitor. These service codes must be
will find helpful diagnostic information in this checkout
corrected or cleared before starting this checkout.
that will pinpoint the cause. This information may allow
you to perform a simple adjustment which will reduce the Start at the top of the left column and read completely
downtime of your machine. Use the table of contents to down column before performing check, follow this
help find adjustment procedures. sequence from left to right. In the far right column, if no
problem is found (YES), you will be instructed to go to
The information you provide after completing the
next check. If a problem is indicated (NO) or (NOT OK),
operational checkout will allow you or your authorized
you will be referred to either a section in this manual or
dealer to pinpoint the specific test or repair work needed
to your authorized dealer.
to restore the machine to design specifications.
A location will be required which is level and has adequate
space to complete the checks. No tools or equipment are
needed to perform the checkout.
HG31779,000032B ­19­12JAN06­1/31

•
1 Engine Off Checks

HG31779,000032B ­19­12JAN06­2/31

Battery Check

65.1
25.0
T194308 —UN—11SEP03

Key OFF.
Press SELECT button and hold until battery volts are displayed. YES: Go to next check.
LOOK: Does battery volts read a minimum of 24 volts? NO: See Monitor Display
Unit—Diagnostics Menu.
Check voltage on each
battery before recharging.
If one battery will not hold
a charge, replace both
batteries.

Continued on next page HG31779,000032B ­19­12JAN06­3/31

4­2­1 PN=164
072310
 Miscellaneous—Operational Checkout

Monitor Check Key switch ON.

Observe Monitor and note changes for first 3 seconds (Bulbs, Indicators and Gauges).
LOOK/LISTEN: Do all lights come ON and does alarm sound?
Does the LCD display show John Deere and the model number?
Do all the gauge indicators point to approximately 12:00 O’ clock position?
Is backlighting of gauges ON?
After 4 seconds observe changes in Monitor. YES: Go to next check.
LOOK: Do gauge indicators change from 12:00 O’clock to normal readings? NO: Check CMU / SSM
Does the LCD show gear, engine speed, and hourmeter/speedometer/odometer? ignition power 5 A fuse.
HG31779,000032B ­19­12JAN06­4/31

Cab System Checks Check the following for proper working order:
• Seat Adjustment
• Seat Belt
• Tilt Wheel Counsel
• Front and rear work lights
• Drive and marker lights
• Turn signals
• Dome light
• Horn
• Front and rear windshield wiper and washer
• Four speed (five position) blower fan
• Door and window latches
• Side shield latches
• Grill housing door latch
• Fuel fill cap and fuel door
• Cab Mount Ladder
• Boom Lock check YES: Go to next check.
• Service Decal check NO: Go to specific
problem.
Continued on next page HG31779,000032B ­19­12JAN06­5/31

4­2­2 072310

PN=165
 Miscellaneous—Operational Checkout

Transmission Gear Shift

Switch And Neutral Lock
Latch Checks

T194310 —UN—11SEP03

Push automatic transmission switch to OFF position (LED unlit).

Move transmission gear shift to Forward (F), Neutral and Reverse (R) positions.
LISTEN/LOOK: Does switch move into Forward, Neutral and Reverse positions.
Does switch stay in detented positions?
Does Backup alarm sound when in Reverse?
NOTE: Neutral lock only applies to steering column mounted shifter switch.
Put neutral lock in LOCKED position.
Apply slight effort to move lever into forward (F) and reverse (R).
LOOK: Does neutral lock stay engaged and lever stay in neutral?
Put neutral lock in UNLOCK position.
NOTE: The following check applies only to steering column mounted shifter switch.
Twist lever to shift into each gear 1st, 2nd, 3rd and 4th.
LOOK: Does gear number align with pointer in each detented position?
Does twist handle remain in detented positions?
Does LCD display indicate correct gear and “N” position? (1 N, 2 N, 3 N and 4 N)
NOTE: The following checks applied only to hydraulic control lever YES: Go to next check.
mounted shift controls.
Press the up­shift button and down­shift button on the control lever. NO: If lever does not move
or lock properly, replace
lever.
LOOK: Does LCD display indicate correct gear and “N” position? (1 N, 2 N, 3 N and NO: If gears do not change
4 N) on monitor, see your
authorized dealer.
HG31779,000032B ­19­12JAN06­6/31

Neutral Start Check Move FNR to 1st gear forward (1F) of to 1st gear reverse (1R), turn key switch to START.
LOOK/LISTEN: Does engine start? YES: Go to next check.
Does LCD display indicate a neutral gear selection?
NOTE: Gear display will not display “F” for forward or “R” for reverse until shifter NO: See your authorized
is cycled back to neutral and park brake released. dealer.
HG31779,000032B ­19­12JAN06­7/31

•
2 Engine Running Checks

Continued on next page HG31779,000032B ­19­12JAN06­8/31

4­2­3 072310

PN=166
 Miscellaneous—Operational Checkout

Monitor Check Start Engine.

Observe CMU and check bulbs, indicators and gauges.
LOOK/LISTEN: Do all lights illuminate? YES: Go to next check.
Does monitor alarm sound?
Is backlighting of gauges ON?
After 4 seconds observe changes in Monitor. NO: Check CMU / SSM
ignition power 5 A fuse
(F13).
LOOK: Do gauges show normal readings? IF OK: Check appropriate
Does home screen change to show gear, rpm, and hourmeter/speedometer/odometer? diagnostic item on
Does engine speed read idle speed? diagnostics menu.
Does seat belt indicator go OFF 5 seconds after engine starts?
HG31779,000032B ­19­12JAN06­9/31

Park Brake Check

T103441 —UN—09SEP96

Release park brake by pushing park brake switch to OFF position.

LOOK: Does park brake indicator go off when brake is released? Will machine move if
put into gear?

CAUTION: Seat belt must be worn during this check to prevent

possible injury from sudden machine stops.
Fasten seat belt.
Place transmission in 1st gear forward.
Drive machine at 3 MPH and push park brake switch to ON. YES: Go to next check.
LOOK/FEEL: Does machine come to a stop within 1 meters (3 feet) when park brake NO: If machine does
is engaged at 3 MPH? Does transmission shift to neutral? Does alarm sound? not stop within specified
distance, see your
authorized dealer.
Continued on next page HG31779,000032B ­19­12JAN06­10/31

4­2­4 072310

PN=167
 Miscellaneous—Operational Checkout

Service Brake Check Move each pedal with hand to check “free travel.” YES: Go to next check.
FEEL: Does each pedal have about 6 mm (0.25 in.) free travel? NO: Inspect for debris
under brake pedal. Inspect
brake pedal linkage for
damage.

T194311 —UN—11SEP03
Push clutch cutoff switch until function is OFF (LEDs unlit).
Fully apply either service brake pedal.
Push park brake switch to OFF.
Put transmission in 2nd forward.
Increase engine speed to high idle.
LOOK: Does machine remain stationary or move very slowly? YES: Go to next check.
Repeat check three times to ensure accurate results. NO: See your authorized
dealer.
HG31779,000032B ­19­12JAN06­11/31

Pilot Controller Lock

Check

T194312 —UN—11SEP03

T103429 —UN—09SEP96

Press pilot enable/boom down switch to lock the pilot controls (LED unlit).
Hold control lever in boom raise position.
Press pilot enable/boom down switch to unlock the pilot controls (LED illuminated).
LOOK: Does boom raise when pilot controls are unlocked?
Press pilot enable/boom down switch to lock the pilot controls (LED unlit) and observe
boom.
LOOK: Does boom stop when controls are locked?
Unlock pilot controls and check all hydraulic functions.
• Boom Up/Down
• Bucket Roll/Dump
• Auxiliary functions (if equipped)
• Steering (Left and Right)
• Pin Disconnect (if equipped) YES: Go to next check.
LOOK: Do all equipped hydraulic functions operate correctly? NO: See your authorized
dealer.
Continued on next page HG31779,000032B ­19­12JAN06­12/31

4­2­5 072310

PN=168
 Miscellaneous—Operational Checkout

Pilot Enable/Boom Down

Solenoid Check

T194312 —UN—11SEP03

Raise boom.
Stop engine.
Turn key to ON position.
Press and hold Pilot Enable/Boom Down Switch.

CAUTION: Boom will quickly lower to ground.

Move control lever to boom lower position. YES: Go to next check.
LOOK: Does boom lower? NO: See your authorized
dealer.
HG31779,000032B ­19­12JAN06­13/31

Service Brake Pressure

Switch And Brake
Accumulator Precharge

T194312 —UN—11SEP03
Stop engine.
Turn key to ON position.
Press and hold Pilot Enable/Boom Down Switch and cycle hydraulic control lever in all
directions 20 times to bleed charge pressure from PRV/brake accumulator.
Press brake pedal and record number of applications until brake pressure indicator
comes on.
Continue pushing brake pedal and counting applications until brake lights fail to come YES: Go to next check.
on.
LOOK: Are at least 12 brake pedal applications needed before brake pressure NO: If brake oil pressure
indicator comes on? indictor does not come on,
see your authorized dealer.
LOOK: Are at least 30 brake pedal applications needed before brake lights fail to NO: If brake lights fail
come on? to come on, see your
authorized dealer.
Continued on next page HG31779,000032B ­19­12JAN06­14/31

4­2­6 072310

PN=169
 Miscellaneous—Operational Checkout

Pilot Control Valve Boom

Float Check

Run engine at idle.

Turn ride control off.
Turn return­to­carry off.
With the bucket partially dumped, lower boom to raise front of machine.
Push control lever to the float detent position and release lever. YES: Go to next check.
LOOK: Does front of machine lower to the ground and valve remain in float position NO: See your authorized
when lever is released? dealer.
HG31779,000032B ­19­12JAN06­15/31

Return­to­Dig Check

T194314 —UN—11SEP03
Raise the boom to about eye level.
Fully dump the bucket.
Verify that return­to­dig function is turned on.
Place controller in the bucket load detent position. YES: Go to next check.
LOOK/FEEL: Does pilot controller detent? NO: Verify that the sensor
is adjusted correctly. See
Return­to­Dig Adjustment.
LOOK: Does bucket travel stop upon reaching dig position? NO: See your authorized
dealer.
HG31779,000032B ­19­12JAN06­16/31

Return­to­Carry Check

T194315 —UN—11SEP03
Fully raise boom.
Place bucket in dig position.
Verify that the return­to­carry function is turned on.
Place controller in the boom down detent position.
LOOK/FEEL: Does pilot controller detent? YES: Go to next check.
LOOK: Does boom travel stop upon reaching carry position? NO: Verify that the sensor
is adjusted correctly. See
your authorized dealer.
Continued on next page HG31779,000032B ­19­12JAN06­17/31

4­2­7 072310

PN=170
 Miscellaneous—Operational Checkout

Boom Height Kickout

Check

T194316 —UN—11SEP03
Lower boom to the ground.
Place bucket in dig position.
Verify that boom height kickout function is turned on.
Place controller in the boom up detent position.
LOOK/FEEL: Does pilot controller detent? YES: Go to next check.
LOOK: Does boom travel stop before reaching full height? NO: Verify that the sensor
is adjusted correctly. See
your authorized dealer.
HG31779,000032B ­19­12JAN06­18/31

Pin Disconnect System

Check (If Equipped)

T194317 —UN—11SEP03
Run engine at slow idle.
Position bucket flat on the ground.
Push and hold pin disconnect switch on the sealed switch module (SSM). YES: Go to next check.
LOOK: Does pin disconnect cylinder retract both pins while switch is pressed? NO: See your authorized
dealer.
Continued on next page HG31779,000032B ­19­12JAN06­19/31

4­2­8 072310

PN=171
 Miscellaneous—Operational Checkout

Ride Control Check

T194313 —UN—11SEP03

CAUTION: Boom will jump upward during this check. Make

sure area around bucket is clear.
Press ride control switch on SSM to enable ride control manual mode. Left LED will
illuminate.
Raise boom to maximum height and hold control lever over relief for 2 seconds.
Lower boom and bucket to eye level. Observe loader boom as Ride Control Switch
is switched to ON.
LOOK/FEEL: Does boom jump upward 30 cm (12 in) or more?
Press ride control switch on the SSM once more to enable auto mode. Right LED
will illuminate.
Raise boom to maximum height and hold control lever over relief for 2 seconds.
Lower boom and bucket to eye level and slowly accelerate to 5 mph while watching YES: Go to next check.
speedometer and bucket.
LOOK/FEEL: Does ride control come on at approximately 3 mph and bucket raise NO: See your authorized
slightly? dealer.
HG31779,000032B ­19­12JAN06­20/31

Differential Lock Check

T103168 —UN—05SEP96

Park unit on a hard surface.

Release brakes.
Push differential lock switch and steer unit left and right.
Release switch and steer unit left and right.
LOOK: Do front wheels slide with differential lock on?
NOTE: It is normal to get a "clunk" sound when you release switch. YES: Go to next check.
LOOK: Do front wheels rotate in opposite directions with differential lock switch NO: See your authorized
released? dealer.
Continued on next page HG31779,000032B ­19­12JAN06­21/31

4­2­9 072310

PN=172
 Miscellaneous—Operational Checkout

Clutch Cutoff Check

T194311 —UN—11SEP03
Press clutch cutoff switch to enable clutch cutoff at any slope. LED(s) will illuminate.
Apply brake.
Increase engine rpm to 1500.
Press clutch cutoff switch until clutch cutoff is turned off. All LEDs will be off.
LISTEN/LOOK: Does engine rpm drop? YES: Go to next check.
FEEL: Can you feel machine pull through brakes? NO: See your authorized
dealer.
HG31779,000032B ­19­12JAN06­22/31

Boom And Bucket

Cylinder Drift Check

T6564NZ —UN—19OCT88

Set bucket flat on the ground and raise about 50 mm (2 in.).

Stop engine. Observe bucket for 1 minute.
LOOK: Does bucket remain in position? Bucket should not settle to the ground. YES: Go to next check.
NOTE: Use good judgement to determine if the amount of drift is objec­ NO: See your authorized
tionable for your loader application. dealer.
Continued on next page HG31779,000032B ­19­12JAN06­23/31

4­2­10 072310

PN=173
 Miscellaneous—Operational Checkout

Automatic Shift And NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selected
Speedometer Check as ground speed increases, or will down shift to 2nd as ground speed
decreases. Transmission will never shift to 1st gear. In AUTO MODE TO
FIRST the transmission will start in 1st when initially shifted from Neutral to
Forward or Reverse. After the initial shift from Neutral, the transmission will
downshift no lower than 2nd unless a high load is encountered. Transmission
will upshift or downshift as ground speed dictates.

T194310 —UN—11SEP03

Press automatic transmission switch to place transmission in automatic mode. LED

is illuminated.
Release park brake and shift to (4th) forward.
Drive machine on level ground and slowly accelerate to fast idle speed and note speed
when shifts are made until engaged in 4th gear. Reduce engine rpm to idle and note
speed when transmission makes each downshift.
LOOK: Does the transmission shift at following approximate speeds?
644J, 724J YES: Go to next check.
Shift MPH Km/H
2nd­3rd 6 9
3rd­4th 10 16
4th­3rd 7 11
3rd­2nd 4 6

NOTE: In 4th Forward automatic the transmission starts out in 2nd gear and upshifts to NO: See your authorized
3rd then 4th. When transmission downshifts it returns to 2nd. Transmission will dealer.
shift at different speeds depending on machine loads. Use only as reference.
Continued on next page HG31779,000032B ­19­12JAN06­24/31

4­2­11 072310

PN=174
 Miscellaneous—Operational Checkout

Transmission Shift
Mode Check

T194310 —UN—11SEP03
Press automatic transmission switch to place transmission in manual mode. LED is off.
Press MENU to bring up the main menu, select Machine Settings (2), then Quick
Shift (1).
Press SELECT to set quick shift in Down/Up mode.
Release park brake and shift to 3rd forward.
Drive machine at approximately 1600 rpm and press Quick Shift Switch once.
LOOK/FEEL: Does transmission shift to and remain in 2nd gear?
Press Quick Shift Switch once more.
LOOK/FEEL: Does transmission shift back to 3rd gear?
NOTE: If Quick Shift Switch is pressed twice, transmission will shift down one gear then
immediately back up to where it was. Quick Shift feature operates in all gears.
Press MENU to bring up the main menu, select Machine Settings (2), then Quick
Shift (1).
Press NEXT to highlight Down Only then press SELECT to set quick shift in Down
only mode.
Release park brake and shift to 4th forward.
Drive machine at approximately 1200 rpm and press Quick Shift Switch once.
LOOK/FEEL: Does transmission shift to and remain in 3rd gear?
Press Quick Shift Switch once more.
LOOK/FEEL: Does transmission shift to and remain in 2nd gear?
Press Quick Shift Switch once more.
LOOK/FEEL: Does transmission shift to and remain in 1st gear?
Press Quick Shift Switch once more. YES: Go to next check.
LOOK/FEEL: Does transmission stay in 1st gear? NO: Check restriction
switch / radio ignition power
10 A fuse (F11).
NOTE: In DOWN ONLY mode pressing Quick Shift Switch will not change gears once NO: See your authorized
1st gear is reached, unless a direction or gear change is made. dealer.
Continued on next page HG31779,000032B ­19­12JAN06­25/31

4­2­12 PN=175
072310
 Miscellaneous—Operational Checkout

Axle Disconnect Check

(If Equipped)

T6601AA —UN—19OCT88

T194318 —UN—11SEP03

Operate machine in an open area away from bystanders.

With bucket partially dumped, lower boom to raise front wheels off the ground.
Press Axle Disconnect Switch on Sealed Switch Module (SSM) to disconnect axle.
Watch front wheels while operating the machine in reverse. Front wheels must not YES: Go to next check.
rotate as machine moves backwards.
LOOK: Do front wheels remain stationary while machine moves backwards? NO: See your authorized
dealer.
HG31779,000032B ­19­12JAN06­26/31

Transmission Shift
Modulation Check

T194311 —UN—11SEP03
Press clutch cutoff switch to turn off clutch cutoff (all LEDs off).
Press automatic transmission switch to place transmission in manual mode. LED is off.

CAUTION: Fasten seat belt before performing this check. Machine

will change directions abruptly!
Shift transmission to 1st forward, increase engine speed to fast idle, shift from forward
to reverse and reverse to forward several times, allowing machine to reach full speed in
forward and reverse before changing directions. Repeat check in 2nd gear.
LOOK: Does machine slow down and change direction smoothly?
Drive machine in 2nd gear at high idle, apply service brakes to slow engine down to YES: Go to next check.
1800 rpm, then while still holding service brakes, shift to 1st gear.
FEEL: Does transmission shift smooth without jerking? NO: See your authorized
dealer.
Continued on next page HG31779,000032B ­19­12JAN06­27/31

4­2­13 072310

PN=176
 Miscellaneous—Operational Checkout

Torque Converter and

Engine Power Check

T194311 —UN—11SEP03

T106883 —UN—14FEB97

Release park brake.

Press clutch cutoff switch to turn off clutch cutoff (all LEDs off).
Apply service brakes so machine does not move.
Shift transmission to 3rd forward.
Push accelerator pedal until it touches stop bolt. Record engine speed in basic display
window.
LOOK: Is torque converter stall speed within following range:
• No. 1 fuel: 2040—2170 rpm
• No. 2 fuel: 2070—2190 rpm YES: Go to next check.
Move FNR to neutral "N" position and run for 15 seconds to cool oil. NO: If stall speed is outside
range, see your authorized
dealer.
HG31779,000032B ­19­12JAN06­28/31

Steering Valve Check

T6471AQ —UN—19OCT88

Transmission in Neutral.
Run engine at low idle.
Remove foot from brake pedal.
Release park brake.
Turn steering wheel until machine frames contact right and left frame stops.
LOOK: Does machine steer smoothly in both directions?
NOTE: It is normal for machine frames to drift away from frame stops
when steering wheel is released.
When steering wheel is stopped, frames must stop. YES: Go to next check.
FEEL: Is excessive effort required to turn steering wheel? NO: See your authorized
dealer.
Continued on next page HG31779,000032B ­19­12JAN06­29/31

4­2­14 PN=177
072310
 Miscellaneous—Operational Checkout

Secondary Steering IMPORTANT: Do not operate secondary steering pump for more than 15 seconds
System Check (If with the steering in neutral or damage to the pump and motor can occur.
Equipped)
Park unit on a hard level surface with engine running and machine frames straight.
Remove ECU ignition power fuse (F10).
Secondary steering will activate.
Steer unit to right and left. YES: Go to next check.
LOOK: Does machine steer approximately half way to stops in both directions? Does NO: See your authorized
light in monitor come on and stay on until key is turned off? dealer.
HG31779,000032B ­19­12JAN06­30/31

Diagnostic Trouble Check Diagnostic Trouble Codes. Diagnostic Trouble Codes can be displayed using
Codes Check SERVICE ADVISOR™ system or machine CAN monitor unit (CMU).
Display diagnostic trouble codes using machine CMU:
Press MENU to reach main menu. Press SELECT to view code menu, then select
Active Codes or Stored Codes. Press NEXT to view the next code or press SELECT
to view more information on that code.
If any codes appear, see Diagnostic Trouble Codes. IF OK: Operational
Checkout complete.

SERVICE ADVISOR is a trademark of Deere & Company

HG31779,000032B ­19­12JAN06­31/31

4­2­15 072310

PN=178
 Miscellaneous—Troubleshooting
Troubleshooting Procedure Step 1. Operational Checkout Procedure
NOTE: Troubleshooting charts are arranged from the Step 2. Troubleshooting Charts
simplest to verify, to least likely, more difficult
to verify. When diagnosing a problem, use Step 3. Adjustments
all possible means to isolate the problem to a
single component or system. Use the following Step 4. See your authorized John Deere dealer.
steps to diagnose problems:
HG31779,0000020 ­19­06MAY10­1/1

4­3­1 072310

PN=179
 Miscellaneous—Troubleshooting

Diagnostic Trouble Codes Quick Reference List

The diagnostic trouble code number is indicated by an • 637.08—Timing Sensor
(SPN) Suspect Parameter Number and a (FMI) Failure • 637.10—Crank Position Sensor
Mode Indicator number. (91.03) 91 is the SPN number • 651.05—Cylinder #1 Injector
and 03 is the FMI number. • 651.06—Cylinder #1 Injector
Use SERVICE ADVISOR™ system or see Stored Codes
• 651.07—Cylinder #1 Injector
in the Display Menu to view stored diagnostic trouble
• 652.05—Cylinder #2 Injector
codes.
• 652.06—Cylinder #2 Injector
• 652.07—Cylinder #2 Injector
(ECU) Engine Controller Unit Diagnostic Trouble • 653.05—Cylinder #3 Injector
Codes • 653.06—Cylinder #3 Injector
• 653.07—Cylinder #3 Injector
• 91.03—Engine Throttle Short To Power/Voltage Above • 654.05—Cylinder #4 Injector
Normal • 654.06—Cylinder #4 Injector
• 91.04—Engine Throttle Open or Short To Ground • 654.07—Cylinder #4 Injector
• 91.14—Engine Throttle Input Invalid • 655.05—Cylinder #5 Injector
• 94.03—Fuel Pressure Open or Short To Power • 655.06—Cylinder #5 Injector
• 94.04—Fuel Pressure Open or Short To Ground • 655.07—Cylinder #5 Injector
• 94.10—Fuel Pressure Abnormal • 656.05—Cylinder #5 Injector
• 94.17—Fuel Pressure To Low • 656.06—Cylinder #5 Injector
• 100.01—Engine Oil Pressure Low • 656.07—Cylinder #5 Injector
• 100.03—Engine Oil Pressure Short To Power/Voltage • 1076.00—Fuel Injection Pump Control Valve
Above Normal • 1076.01—Fuel Injection Pump Control Valve
• 100.04—Engine Oil Pressure Open or Short To • 1076­03—Fuel Injection Pump Control Valve
Ground/Voltage Below Normal • 1076.05—Fuel Injection Pump Control Valve
• 100.16— Engine Oil Pressure High • 1076.06—Fuel Injection Pump Control Valve
• 100.18— Engine Oil Pressure Low • 1076.07—Fuel Injection Pump Control Valve
• 105.03— Manifold Air Temperature Open or Short To • 1076.10—Fuel Injector Problem
Power/Voltage Above Normal • 1076.13—Fuel Injection Pump Control Valve
• 105.04— Manifold Air Temperature Open or Short To • 1079.03—Excitation Voltage Too High
Ground/Voltage Below Normal • 1079.04—Excitation Voltage Too Low
• 105.16— Manifold Air Temperature Too High • 1080.03 —Sensor Supply Voltage Too High
• 107.00— Engine Air Filter Restriction • 1080.04 —Sensor Supply Voltage Short To Ground
• 110.00— Engine Coolant Temperature Too High (Most • 1347.03—Fuel Pump Solenoid Short to Power
Severe) • 1347.05—Fuel Pump Solenoid 1 Open
• 110.03— Engine Coolant Temperature Voltage Above • 1347.07—Fuel System Failure
Normal • 1569.31—Engine Protection Derate
• 110.04— Engine Coolant Temperature Voltage Short To • 2000.06—Control Of Injector Bad
Ground/Voltage Below Normal
• 110.16— Engine Coolant Temperature High (Moderately (CMU) Can Monitor Unit Diagnostic Trouble Codes
Severe)
• 829.05—Fuel Level Sensor Open Or Short To Power
• 158.17— ECU Can Not Power Down • 2000.09—Missing Message From ECU
• 174.03— Fuel Temperature Open or Short To Power • 2003.09—Missing Message From TCU
Voltage To High
• 174.04— Fuel Temperature Short To Ground Voltage • 2033.09—Missing Message From FLC
To Low
• 2140.09—Missing Message From SSM
• 174.16—Fuel Temperature High (Moderately Severe) • 2367.04—Left Turn Switch Shorted To Ground
• 2369.04—Right Turn Switch Shorted To Ground
• 523.09—Current Gear Message Not Received Or
Invalid (FLC) Flex Load Controller Diagnostic Trouble Codes
• 611.03—Injector Wiring Short To Power • 1045.04—Brake Light Pressure Switch Shorted To
• 611.04—Injector Wiring Short To Ground Ground
• 620.03—Sensor Supply Voltage Too High • 1071.31—Variable Speed Fan Circuit
• 620.04—Sensor Supply Voltage Too Low • 117.01—Service Brake Accumulator Low
• 627.01—Battery Supply Voltage Is Low • 117.04—Service Brake Accumulator Short To Ground
• 629.13—ECU Not Programed • 1638.00—Hydraulic Oil Temperature High
• 636.02—Engine Position Sensor • 1638.04—Hydraulic Oil Temperature Circuit Shorted
• 636.08—Engine Position Sensor To Ground
• 636.10—Engine Position Sensor • 167.16—System Voltage High (Engine Running)
• 637.02—Timing Sensor • 167.18—System Voltage Low (Engine Running)
• 637.07—Timing Sensor • 168.16—System Voltage High (Engine Off)
Continued on next page HG31779,000032D ­19­14OCT03­1/4

4­3­2 072310

PN=180
 Miscellaneous—Troubleshooting

• 168.18—System Voltage Low (Engine Off) • 523577.06—M8 Secondary Steering Pump High
• 171.04—Ambient Air Temperature Short To Ground Current
• 1713.01—Hydraulic Oil Filter Restricted • 523786.03—B45 Analog Boom Position Sensor Voltage
• 1762.03—Hydraulic System Pressure Sensor Voltage Too High
High • 523786.04—B45 Analog Boom Position Sensor Voltage
• 1762.04—Hydraulic System Pressure Sensor Voltage Too Low
Low • 523948.03—Y18, Y34 Ride Control Solenoids Short
• 2000.19—Missing Message From ECU To Power
• 2003.19—Missing Message From TCU • 523948.05—Y18, Y34 Ride Control Solenoids Open
• 2023.19—Missing Message From CMU • 523948.06—Y18, Y34 Ride Control Solenoids High
• 2140.19—Missing Message From SSM Current
• 2350.05—Drive Light Circuit Open or Short To Power • 522435.03—Front Wiper (High Speed) Short To Power
• 2350.06—Drive Light Circuit High Current • 522435.05—Front Wiper (High Speed) Open Circuit
• 2356.06—Front Work Lights Circuit High Current • 522435.06—Front Wiper (High Speed) High Current
• 2356.05—Front Work Lights Circuit Open or Short To • 522434.05—Front Wiper (Low Speed) Open or Short
Power To Power Circuit
• 2362.06—Rear Work Lights Circuit High Current • 522434.06—Front Wiper (Low Speed) High Current
• 2362.05—Rear Work Lights Circuit Open or Short To • 522427.04—Front Wiper (Park) Missing
Power • 522797.03—Front Washer Pump Short To Power
• 2366.06—Docking Work Lights Circuit High Current • 522797.05—Front Washer Pump Open Circuit
• 2366.05—Docking Work Lights Circuit Open or Short • 522797.06—Front Washer Pump High Current
To Power • 522426.04—Rear Wiper (Park) Signal Missing
• 2368.03—Left Turn Lights Circuit Short To Power • 522432.03—Rear Wiper (High Speed) Short To Power
• 2368.05—Left Turn Lights Circuit Open • 522432.05—Rear Wiper (High Speed) Open Circuit
• 2368.06—Left Turn Lights Circuit High Current • 522432.06—Rear Wiper (High Speed) High Current
• 2370.03—Right Turn Lights Circuit Short To Power • 522433.05—Rear Wiper (Low Speed) Open Circuit or
• 2370.05—Right Turn Lights Circuit Open Short To Power
• 2370.06—Right Turn Lights Circuit High Current • 522433.06—Rear Wiper (Low Speed) High Current
• 2378.03—Marker/Tail Lights Circuit Short To Power • 522796.03—Rear Washer Pump Short To Power
• 2378.05—Marker/Tail Lights Circuit Open • 522796.05—Rear Washer Pump Open Circuit
• 2378.06—Marker/Tail Lights Circuit High Current • 522796.06—Rear Washer Pump High Current
• 2386.06—E15 Beacon Circuit High Current • 785.03—Y14, Y15 Pilot Enable Solenoids Short To
• 2386.05—E15 Beacon Circuit Open or Short To Power Power
• 2875.04—S24 Four Way Flasher Switch Short To • 785.05—Y14, Y15 Pilot Enable Solenoids Open Circuit
Ground • 785.06—Y14, Y15 Pilot Enable Solenoids High Current
• 522438.03—Y20 Pin Disconnect Solenoid Short To • 880.03—Brake Lights Short To Power
Power • 880.05—Brake Lights Open Circuit
• 522438.05—Y20 Pin Disconnect Solenoid Open • 880.06—Brake Lights High Current
• 522438.06—Y20 Pin Disconnect Solenoid High Current • 928.03—Y28 Axle Disconnect Solenoid Short To Power
• 522437.03—S17 Return To Dig Switch (Bucket) Short • 928.05—Y28 Axle Disconnect Solenoid Open Circuit
To Ground • 928.06—Y28 Axle Disconnect Solenoid High Current
• 522436.03—S37 Return To Dig Sensor (Bucket) Short • 977.03—Y38 Reverse Fan Solenoid Short To Power
To Power • 977.05—Y38 Reverse Fan Solenoid Open Circuit
• 522436.04—S37 Return To Dig Sensor (Bucket) Open • 977.06—Y38 Reverse Fan Solenoid High Current
or Short To Ground • 1079.04—FLC Sensor Supply #1 Voltage Short To
• 299261.02—Machine Configuration Error Ground
• 444.05—12V Center Tap Open or Short to Ground • 1080.04—FLC Sensor Supply #2 Voltage Short To
• 444.18—Battery Voltage Imbalance Ground
• 523137.01—Steering Pressure Low • 524265.19—Data Error
• 523137.04—Steering System Pressure Switch Short • 522431.2—Hardware Failure
To Ground
(SSM) Sealed Switch Module Unit Diagnostic Trouble
• 523214.05—No Power From VEC To FLC
Codes
• 523215.05—No Power From VEC To FLC
• 523216.05—No Power From VEC To FLC • 629.12—SSM Software Failure
• 523217.05—No Power From VEC To FLC • 2033.09—Missing CAN Message From FLC
• 523218.05—No Power From VEC To FLC • 639.12—SSM Can Hardware Failure
• 523219.05—No Power From VEC To FLC • 639.19—SSM Lost CAN Communications
• 523436.17—FLC Internal Timer Failure • 523523.10—Rear Wiper Keypad Stuck
• 523577.03—M8 Secondary Steering Pump Short To • 523524.10—Front Wiper Keypad Stuck
Power • 523525.10—Front Washer Keypad Stuck
• 523577.05—M8 Secondary Steering Pump Open • 523526.10—Reverse Fan Keypad Stuck
• 523527.10—Pin Disconnect Keypad
Continued on next page
Stuck
HG31779,000032D ­19­14OCT03­2/4

4­3­3 072310

PN=181
 Miscellaneous—Troubleshooting

• 523528.10—A/C Keypad Stuck • 522402.12—B30 Transmission Internal Clutch Speed

• 523529.10—Work Lights Keypad Stuck Sensor Open
• 523530.10—Beacon Light Keypad Stuck • 522401.03—B31 Transmission Output Speed Sensor
• 523531.10—Axle Disconnect Keypad Stuck Open or Short To Power
• 523532.10—Spin Control Keypad Stuck • 522401.04—B31 Transmission Output Speed Sensor
• 523533.10—Clutch Cutoff Keypad Stuck Short To Ground
• 523534.10—Pilot Enable Keypad Stuck • 522401.12—B31 Transmission Output Speed Sensor
• 523535.10—Ride Control Keypad Stuck Open
• 523536.10—Auto Transmission Keypad Stuck • 522401.02—B31 Transmission Output Speed Sensor
• 523537.10—Drive Lights Keypad Stuck Failed Signals
• 523538.10—Keypad Not Used • 2023.09—Can Communication Lost For CMU
• 523607.10—Return To Dig Keypad Stuck • 2033.09—Can Communication Lost For FLC
• 523608.10—Boom Height Kickout Keypad Stuck • 522399.03—Y1 Solenoid Short To Power
• 523609.10—Return To Carry Keypad Stuck • 522399.04—Y1 Solenoid Short To Ground
• 523610.10—Rear Washer Keypad Stuck • 522399.05—Y1 Solenoid Open
(TCU) Transmission Controller Unit Diagnostic
• 522395.03—Y2 Solenoid Short To Power
Trouble Codes
• 522395.04—Y2 Solenoid Short To Ground
• 522395.05—Y2 Solenoid Open
• 522421.02—Can Signal For Automatic Downshift Is • 522392.03—Y3 Solenoid Short To Power
Defective • 522392.04—Y3 Solenoid Short To Ground
• 522420.02—Can Signal For Manual Downshift Is • 522392.05—Y3 Solenoid Open
Defective • 522389.03—Y4 Solenoid Short To Power
• 522419.02—Can Signal For Clutch Cutoff Is Defective • 522389.04—Y4 Solenoid Short To Ground
• 522399.02—Clutch K1 Calculated Value Is Out Of • 522389.05—Y4 Solenoid Open
Range • 522386.03—Y5 Solenoid Short To Power
• 522395.02—Clutch K2 Calculated Value Is Out Of • 522386.04—Y5 Solenoid Short To Ground
Range • 522386.05—Y5 Solenoid Open
• 522392.02—Clutch K3 Calculated Value Is Out Of • 522383.03—Y6 Solenoid Short To Power
Range • 522383.04—Y6 Solenoid Short To Ground
• 522389.02—Clutch K4 Calculated Value Is Out Of • 522383.05—Y6 Solenoid Open
Range • 522382.03—H3 Backup Alarm Short To Power
• 522386.02—Clutch KV Calculated Value Is Out Of • 522382.04—H3 Backup Alarm Short To Ground
Range • 522382.05—H3 Backup Alarm Open
• 522383.02—Clutch KR Calculated Value Is Out Of • 522379.03—Y19 Park Brake Release Solenoid Short
Range To Power
• 522412.12—Gear Selector Fault • 522379.04—Y19 Park Brake Release Solenoid Short
• 522411.12—FNR Selector Fault To Ground
• 522409.12—FNR Selector #2 Selector Fault • 522379.05—Y19 Park Brake Release Solenoid Open
• 522407.03—Clutch Cutoff Sensor Short To Power • 522376.0—Transmission Oil Temperature Max Value
• 522407.04—Clutch Cutoff Sensor Open • 522375.0—Transmission Oil Filter Restricted
• 522406.03—Transmission Oil Temperature Sensor • 522374.03—TCU Supply Voltage Short To Power
Short To Power • 522374.04—TCU Supply Voltage Short To Ground
• 522406.04—Transmission Oil Temperature Sensor • 522373.03—TCU Supply Voltage High
Short To Ground • 522373.04—TCU Supply Voltage Low
• 522404.03—B28 Torque Converter Input Speed Sensor • 522371.02—TCU P78 Red Wire Shorted To Power Or
Short To Power Ground
• 522404.04—B28 Torque Converter Input Speed Sensor • 522370.02—TCU P78 Red Wire Shorted To Power Or
Short To Ground Ground
• 522404.12—B28 Torque Converter Input Speed Sensor • 522369.03—X1 Service ADVISOR System Connector
Open Shorted To Power
• 522403.03—B29 Torque Converter Output Speed • 522369.04—X1 Service ADVISOR System Connector
Sensor Open or Short To Power Shorted To Ground
• 522403.04—B29 Torque Converter Output Speed • 522368.02—TCU Memory Failure
Sensor Short To Ground • 522367.13—TCU Configuration Lost
• 522403.12—B29 Torque Converter Output Speed • 522366.13—TCU Application Error
Sensor Open • 522365.13—TCU Limp Home Request
• 522402.03—B30 Transmission Internal Clutch Speed • 522364.07—Transmission Clutch Adjustment Out Of
Sensor Open or Short To Power Limit
• 522402.04—B30 Transmission Internal Clutch Speed
Sensor Short To Ground

Continued on next page HG31779,000032D ­19­14OCT03­3/4

4­3­4 072310

PN=182
 Miscellaneous—Troubleshooting

• 522364.13—TCU Was Unable To Read Clutch

Adjustment Parameters
SERVICE ADVISOR is a trademark of Deere & Company
HG31779,000032D ­19­14OCT03­4/4

4­3­5 072310

PN=183
 Miscellaneous—Troubleshooting

Engine
Symptom Problem Solution

Engine Cranks/Won’t Start Fuel quality and quantity Check fuel quality and quantity.

Engine cranking speed Check engine cranking speed.

Oil viscosity Check for correct oil viscosity.

Intake or exhaust restrictions Check for intake and exhaust

restrictions.

Air heater not working If engine has an air heater, verify air
heater operation in cold temperatures.

Engine Misfires/Runs Irregularly Intake manifold air leaks Check for intake manifold air leaks

Mechanical problems Check for mechanical problems.

Transmission problems Check for transmission problems.

Engine accessories cycling on and off Check engine accessories, such as

A/C, cycling on and off.

Electronic interference Check for improperly installed radios,

etc.

Engine Does Not Develop Full Restricted or plugged air and fuel Check for restricted or plugged air and
Power filters fuel filters.

Fuel quality Check fuel quality.

Transmission problems Check for transmission problems.

Engine mechanical problems Check for engine mechanical

problems.

Excessive load Check for excessive load on the

engine.

Engine Emits Excessive White Fuel quantity and quality Check fuel quantity and quality.
Exhaust Smoke
Low engine coolant temperature Check for extremely low engine
coolant temperature.

Engine Emits Excessive Black Or Fuel quantity and quality Check fuel quantity and quality.
Gray Smoke
Restricted or plugged air filter Check for restricted or plugged air
filter.

Excessively loaded engine Check for excessively loaded engine.

Engine Will Not Crank Weak battery Replace battery.

Continued on next page TX17961,000000B ­19­03OCT02­1/2

4­3­6 072310

PN=184
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Corroded or loose battery connections Clean battery terminals and

connections.

Defective main switch or start safety Repair switch as required.

switch
Starter solenoid defective Replace solenoid.

Starter defective Replace starter.

Start circuit defective Check wiring, fuses, and relays.

Engine is seized Check by rotating engine by hand.

Engine Idles Poorly Poor fuel quality Drain fuel and replace with quality fuel
of the proper grade.

Air leak on suction side of air intake Check hose and pipe connections for
system tightness; repair as required.

TX17961,000000B ­19­03OCT02­2/2

4­3­7 072310

PN=185
 Miscellaneous—Troubleshooting

Transmission
Symptom Problem Solution

Transmission Clutch Slippage Low oil level See Transmission, Hydraulic System,
Park Brake, and Differential Oil.

Wrong oil grade See Transmission, Hydraulic System,

Park Brake, and Differential Oil.

Restricted Transmission pump suction Remove and clean screen.

screen
Machine Will Not Move Diagnostic Trouble Code (DTC) Check Diagnostic Trouble Codes to
related problem define problem.

Applied park brake (electrical problem) Check park brake fuse.

Check operation of park brake.

Low oil level Check transmission oil level.

Clutch cutoff activated Check that brake pedal is fully

released.

No power to transmission control unit Check transmission control switched

5A fuse.

Check monitor and transmission

control unswitched fuse.

Hydraulic failure of park brake Check operation of park brake.

Failed shift switch Check that display window shows

correct gear when shift switch is
moved.

Broken drive shafts Inspect drive shafts and universal

joints for external damage.

Machine Does Not Engage Clutch cutoff activated Check that brake pedal is fully
released.

Shift switch problem Check Diagnostic Trouble Codes to

define problem.

Machine Will Not Shift Correctly Speed sensor disconnected or failed Check electrical connectors on
transmission speed sensors.

Low oil level Add oil.

Transmission Shifts Too Slow Low oil level (aeration of oil) Add oil.

Restricted transmission pump suction Remove and clean suction screen.

screen
Transmission Hydraulic System High oil level Check transmission oil level.
Overheats
Continued on next page TX17961,000016A ­19­03OCT02­1/2

4­3­8 072310

PN=186
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Transmission overfilled or hydraulic

pump seal leaking.

Low oil level Check transmission oil level.

Wrong oil grade Check oil type.

Park brake dragging Check for heat in park brake area.

Pinched, restricted or leaking lube Check cooler lines.

lines
Malfunction in temperature gauge or Install temperature sensor to verify
sender temperature.

Restricted air flow through oil cooler Check oil cooler and radiator for
or radiator debris. Clean if needed.

Excessive Transmission Noise Worn parts or damaged in Inspect suction screen for metal
(under load or no load) transmission particles.

Damaged drive dampener Inspect drive dampener.

Driveline or park brake Inspect drive line and park brake.

Foaming Oil Incorrect type of oil Check oil type. Change oil if needed.

High oil level Check oil level. Transmission

overfilled or hydraulic pump seal
leaking.

Low oil level Check oil level. Add oil if needed.

Oil Ejected From Dipstick Plugged breather Inspect breather on top of

transmission. Replace if needed.

Machine Vibrates Aerated oil Check oil level. Add oil if needed.

Failed universal joints on transmission Check universal joints.

drive shaft or differential drive shafts
Damaged drive dampener. Inspect drive dampener.

Machine Lacks Power And Incorrect transmission oil Drain transmission oil and refill. See
Acceleration Change Transmission Oil.

Aerated oil Check oil level. Add oil if needed.

TX17961,000016A ­19­03OCT02­2/2

4­3­9 072310

PN=187
 Miscellaneous—Troubleshooting

Differential and Axle

Symptom Problem Solution

No differential Lock Operation Malfunction in electrical circuit With engine stopped and key switch
on, activate differential lock and listen
for a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switch
on, activate differential lock and listen
for a click from solenoid valve.

Excessive leakage in differential lock Check differential oil level.

piston seals
Differential Lock Slips Or Chatters Axle oil broken down Change axle oil. See Change Front
When Engaged and Rear Differential/Axle Oil.

Excessive leakage differential lock Check differential oil level.

piston seals
Differential Lock Will Not Release Stuck foot switch Inspect.

Malfunction in electrical circuit With engine stopped and key switch

on, activate differential lock and listen
for a click from solenoid valve.

Stuck differential lock solenoid valve With engine stopped and key switch
on, activate differential lock and listen
for a click from solenoid valve.

Differential Low On Oil External leakage Inspect axle and differential for leaks.

Excessive Differential And/Or Axle Low oil level in differential Check oil. Remove drain plug
Noise and inspect for metal particles in
differential case. See Check Front
and Rear Differential Oil Level.

Engaged differential lock Release lock.

If circuit remains pressurized, check if

foot switch is sticking. Remove and
inspect.

Check solenoid valve for sticking.

Remove and inspect valve.

Oil Seeping From Outer Axle Seal Dirt in face seal Inspect face seals.

Overfilled differential Check differential lock oil return

system for excessive internal
restriction.

High pressure in axle Check axle breather.

Axle Overheats Low differential oil Check oil level. Add oil if needed.

Continued on next page MM61211,00013D3 ­19­23FEB06­1/2

4­3­10 072310

PN=188
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Overfilled differential Check oil level. Drain oil if needed.

Axle recirculation motor dual pump Inspect axle recirculation filter screen
screens plugged located in differential housing below
input yoke. See Clean Axle Differential
Recirculation Screen.

MM61211,00013D3 ­19­23FEB06­2/2

Service Brake
Symptom Problem Solution

Poor or No Brakes Axle overheated Check axle temperature.

Brake disks worn or warped Inspect service brake pads.

Aggressive Brakes Clutch cutoff mode set to steep slope Press clutch cutoff switch until “OFF”
position.

Brakes Drag Brake pedal not returning Inspect floor mat and pedal.

Brakes Chatter Brake disk friction material worn Inspect brake disks.

Oil broken down Change oil. See Change Front and

Rear Differential/Axle Oil.

Wrong oil in hydraulic system Drain hydraulic reservoir and

differentials. Refill with correct
oil. See Change Front and Rear
Differential/Axle Oil.

MM61211,00013D4 ­19­23FEB06­1/1

Drive Line
Symptom Problem Solution

Excessive Drive Line Vibration Or Lack of lube in park brake Inspect park brake oil level and adjust
Noise as required. See Check Park Brake
Oil Level.

Bent drive shaft Inspect all drive shafts.

Loose yoke retaining nuts (drive shafts Inspect. Replace.

wobble at high speed)
Rear axle oscillating support Inspect.

Lack of lubrication Lubricate with proper grade of grease.

TX17961,000016E ­19­03OCT02­1/1

4­3­11 072310

PN=189
 Miscellaneous—Troubleshooting

Park Brake
Symptom Problem Solution

Brake Will Not Hold Breather plugged Inspect and clean breather.

Malfunctioning park brake solenoid Inspect.

Brake Overheats Overfilled with oil Adjust oil level. See Check Park
Brake Oil Level.

Breather plugged Inspect and clean breather.

Park Brake Indicator In Monitor Low oil level Check oil level. Add oil if needed.
Comes On When Shifting From Fwd
to Rev (All Other Gears OK)
Cold oil Warm oil.

Park Brake Light Comes On For Cold oil Warm oil.

Each Shift
Park Brake Indicator In Monitor Faulty wiring or switch Inspect for loose or broken wires
Does Not Come On When Brake between brake indicator switch and
Applied indicator on dash.

TX17961,000016F ­19­03OCT02­1/1

4­3­12 072310

PN=190
 Miscellaneous—Troubleshooting

Hydraulic System
Symptom Problem Solution

No Hydraulic Functions Pilot enable switch OFF Turn switch ON

Pilot enable switch failed Check pilot enable switch.

Slow Hydraulic Functions Cold oil Warm oil.

Slow engine speed Check fast idle speed.

Suction line air leak Check for foamy oil.

Low oil supply Add recommended oil.

Wrong oil viscosity Use recommended oil.

Blocked or damaged line Inspect lines.

Noisy Hydraulic Pump Low oil supply or wrong viscosity Fill reservoir with recommended oil.

Plugged or pinched suction line Clean or replace line.

Air in oil Check for foamy oil. Tighten

connections. Replace O­rings and/or
lines.

Loose or missing hydraulic line clamps Tighten or replace clamps.

Hydraulic lines in contact with frame Inspect and repair.

Boom Float Function Does Not Return­to­carry switch ON Turn switch OFF.
Work
One Hydraulic Function Does Not Blockage in oil lines or valve Inspect lines for damage.
Work
Function Drifts Down Leaking cylinders Check cylinder leakage.

Boom lower solenoid valve Check Solenoid.

Leaking loader control valve Replace valve section.

Boom Down Does Not Work (Engine Pilot enable/boom down switch not Push and hold pilot enable/boom
Off) held down down switch as loader control lever is
moved.

Boom down solenoid failed Replace solenoid.

Pilot enable/boom down switch failed. Replace switch.

Oil Overheats Low oil viscosity in hot weather Use recommended oil.

Cylinder Leakage Check cylinder leakage.

Continued on next page TX17961,0000170 ­19­03OCT02­1/2

4­3­13 072310

PN=191
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Restriction in oil lines or loader valve Inspect for dented or kinked lines.

Hydraulic Oil Foams Low oil level Add recommended oil.

Wrong oil Change to recommended oil.

Water in oil Drain oil from reservoir and cylinders.

Fill with recommended oil.

Loose or faulty suction lines (air leak Tighten or install new lines.
in system)
Pin Disconnect Cylinders Will Not Electrical circuit failure Hold a screwdriver against end of pin
Retract disconnect solenoid valve and check
for magnetism with switch pushed.

Solenoid valve failure Remove and inspect.

Cylinder binding Inspect cylinder and adjust loads.

TX17961,0000170 ­19­03OCT02­2/2

Steering
Symptom Problem Solution

No Steering Functions Articulation locking bar in place Pin locking bar in unused position.

Low oil level Add recommended oil.

Pinched steering line Inspect and repair line.

Erratic Steering Air in oil Check for foamy oil.

Low oil level Add recommended oil.

Spongy or Soft Steering Air in oil Check for foamy oil.

Low oil level Add recommended oil.

Machine Turns in Opposite Lines to cylinders connected to wrong Connect lines to correct ports.
Direction ports at steering valve.
TX17961,0000171 ­19­03OCT02­1/1

4­3­14 072310

PN=192
 Miscellaneous—Troubleshooting

Air Conditioning System

Symptom Problem Solution

Air Conditioning System Does Not FLC ignition power 5A fuse (F15) Replace fuse.
Operate
FLC battery power 10A fuse (F21) Replace fuse.

Blower motor 25A fuse (F5) Replace fuse.

Pressurizer motor 10A fuse (F33) Replace fuse.

Blower speed switch (S21) Check switch.

Blower speed resistor (R3) Check resistor.

Main blower motor (M6) Check motor.

Pressurizer blower motor (M7) Check motor.

A/C (On/Off) switch (S22) Check switch.

Freeze control switch (B35) Check switch.

A/C binary pressure switch (B50) Check switch.

A/C compressor clutch solenoid (Y16) Check clutch operation.

Air Conditioner Does Not Cool Fresh air filter clogged Clean or replace filter.
Interior of Cab
Condenser fins clogged with debris Clean condenser fins.

Recirculating air filter clogged Clean or replace filter.

Compressor pulley worn Replace pulley.

Refrigerant hose kinked, pinched or Re­route or re­index hoses, replace

collapsed kinked or collapsed hoses.

Heater or evaporator core fins clogged Clean heater or evaporator core fins.
with dirt or dust
Pressurizer blower motor failed or Check motor speed.
operating too slowly
Compressor clutch slipping or failed Inspect and/or replace compressor
clutch.

Warm outside air leaking into cab Inspect, repair or replace door and
window seals.

Heater valve remaining open Inspect, repair, adjust or replace

heater valve or cable.

System refrigerant (R134A) charge Inspect system for leaks.

low

Continued on next page TX17961,0000172 ­19­03OCT02­1/2

4­3­15 072310

PN=193
 Miscellaneous—Troubleshooting

Symptom Problem Solution

Evaporator fins frosting or freezing Freeze control switch capillary tube

not positioned correctly in evaporator
core.

Air Conditioner Runs Constantly, Freeze control switch capillary tube Reposition capillary tube in evaporator
Too Cold not positioned in evaporator correctly core

Interior Windows Continue To Fog Fresh air filter clogged Clean or replace filter.

A/C system off Turn A/C (ON/OFF) switch ON.

TX17961,0000172 ­19­03OCT02­2/2

Heater System
Symptom Problem Solution

Heater System Does Not Operate Blower motor fuse Replace fuse.

Blower speed switch Check switch.

Heater Does Not Warm Interior Of Fresh air filter clogged Clean or replace filter.
Cab
Recirculating air filter clogged Clean or replace filter.

Heater hose kinked, pinched or Re­route or re­index hoses, replace

collapsed collapsed hoses.

Heater core fins clogged with dirt or Clean heater fins.

dust
Heater valve remaining closed Inspect, repair, adjust or replace
heater valve or cable.

Temperature control switch failed Inspect, repair or replace switch.

Interior Windows Continue To Fog Fresh air filter clogged Clean or replace filter.

A/C system off (if equipped) Turn A/C ON/OFF switch ON (if
equipped).

TX17961,0000173 ­19­03OCT02­1/1

4­3­16 072310

PN=194
 Miscellaneous—Storage
Prepare Machine For Storage
1. Repair worn or damaged parts. Install new parts, if
necessary, to avoid needless delays later.
2. Check primary air cleaner. Replace filter, if necessary.

T5813AM —UN—09FEB89
IMPORTANT: High pressure washing greater than
1379 kPa (13.8 bar) (200 psi) can damage freshly
painted finishes. Paint should be allowed to
air dry for 30 days minimum after receipt of
machine before cleaning parts or machines
with high pressure. Use low pressure wash
operations until 30 days have elapsed.

3. Wash the machine. Use low pressure wash operations

(less than 1379 kPa (13.8 bar) (200 psi) until 30 days 6. Retract all hydraulic cylinders, if possible. If not, coat
after receipt of machine have elapsed. Paint areas to exposed cylinder rods with LPS ® 3 Rust Inhibitor.
prevent rust. Replace decals, where needed. 7. Place a "DO NOT OPERATE" tag on the right control
4. Apply waste oil to track chains. Run machine back and lever.
forth several times. Park machine on a hard surface to 8. Lubricate all grease points.
prevent tracks from freezing to ground.
9. Remove batteries.
5. Store machine in a dry, protected place. If stored
outside, cover with a waterproof material. 10. Remove seat cushion and other perishable items.
IMPORTANT: LPS 3 Rust Inhibitor can destroy 11. Remove keys and lock all covers and doors.
painted finish. DO NOT spray LPS 3 Rust
Inhibitor on painted areas.
LPS is a trademark of the Holt Lloyd Corporation.
TX,105,FF2313 ­19­03NOV08­1/1

Monthly Storage Procedure

CAUTION: Prevent possible injury or death

from asphyxiation. Engine exhaust fumes
can cause sickness or death. Start engine
ONLY in a well­ventilated area.

T6191AA —UN—18OCT88
1. Drain water and sediment from fuel tank when air
temperature is above freezing.
2. Remove LPS 3 ® Rust Inhibitor from cylinder rods with
a cleaning solvent.

LPS 3 Rust Inhibitor is manufactured by Holt Lloyd Corporation.

Continued on next page VD76477,00016A3 ­19­08JAN08­1/2

4­4­1 PN=195
072310
 Miscellaneous—Storage

IMPORTANT: Prevent possible engine damage.

During cold temperatures, check fluidity of
engine oil on dipstick. If the oil appears waxy
and/or jelly­like rather than liquid, DO NOT
attempt to start engine. Use external heat source
to warm the crankcase until oil appears fluid.

T6181AU —UN—18OCT88
3. Check all fluid levels. If low, check for leaks and add
oil as required.
4. Check belts.
5. Check condition of all hoses and connections.
6. Check battery electrolyte level. Charge and install
battery.
run until it reaches operating temperature. Run at 1/2
7. For machines with tires, check condition of tires and speed for five minutes. Do not run at fast or slow idle.
tire pressure.
• If engine fails to start or runs poorly after starting,
For machines with tracks, check condition of tracks change fuel filter(s). Bleed fuel system.
and track sag.
12. Operate all controls, levers, seat adjustments, etc.
On crawler machines with non sealed­and­lubricated
track chains, apply oil to the pin­to­bushing joints. Run CAUTION: Prevent possible injury from
machine back and forth several times. unexpected machine movement. Clear the
8. Park machine on a hard surface to prevent tracks from area of all persons before running machine
freezing to ground. through the operation procedure.

9. Fill fuel tank. 13. Make sure the area is clear to allow for movement.
Cycle all hydraulic functions several times. Check
10. Pre­lubricate turbocharger bearings, if equipped:
condition of all hoses and connections.
a. Disconnect fuel shutoff fuse.
14. Park the machine with cylinder rods retracted, if
b. Crank engine for 10 seconds. possible. Turn key switch to OFF.
c. Connect fuel shutoff fuse. 15. Apply LPS 3 Rust Inhibitor to exposed cylinder rod
areas.
11. Inspect engine compartment, and remove any foreign
material that may have accumulated. Start engine and
VD76477,00016A3 ­19­08JAN08­2/2

4­4­2 PN=196
072310
 Miscellaneous—Machine Numbers
Record Product Identification Number (PIN)
Purchase Date

NOTE: Record all 13 characters of the Product

Identification Number.

T106371B —UN—24JAN97
A—Product Identification
Number

TX,110,JC1841 ­19­31JAN97­1/1

Record Engine Serial Number

Engine Serial Number

A—Engine Serial Number

T117111 —UN—10SEP98
CED,OUOE002,1739 ­19­08SEP98­1/1

Record Transmission Serial Number

Transmission Serial Number

Located near lower left corner of case.

T132627B —UN—17JUL00
A—Transmission Serial
Number

CED,OUOE002,1740 ­19­10AUG00­1/1

4­5­1 PN=197
072310
 Miscellaneous—Machine Numbers

Record Hydraulic Pump Serial Number

Hydraulic Pump Serial Number

A—Hydraulic Pump Serial

Number

T106391B —UN—24JAN97
TX,110,JC1859 ­19­05FEB97­1/1

Record Axle Serial Number

Axle Serial Number

A—Axle Serial Number—444J

(S.N. —604689), 544J, 624J

T117115 —UN—10SEP98
Axle—444J (S.N. —604689), 544J, 624J
MM61211,00013C7 ­19­16MAR06­1/2

1— Axle Serial Number—444J

(S.N. 604640— )

TX1003880 —UN—15FEB06

Axle—444J (S.N. 604690— )

MM61211,00013C7 ­19­16MAR06­2/2

4­5­2 PN=198
072310
 Miscellaneous—Machine Numbers

Keep Machines Secure

1. Install vandal­proof devices.
2. When machine is in storage:
­ Lower equipment to the ground
­ Set wheels to widest position to make loading more
difficult

TS230 —UN—24MAY89
­ Remove any keys and batteries
3. When parking indoors, put large equipment in front of
exits and lock your storage buildings.
4. When parking outdoors, store in a well­lighted and
fenced area.
5. Make note of suspicious activity and report any thefts
immediately to law enforcement agencies.
6. Notify your John Deere dealer of any losses.
DX,SECURE2 ­19­18NOV03­1/1

Keep Proof of Ownership

1. Maintain in a secure location an up­to­date inventory
of all product and component serial numbers.
2. Regularly verify that identification plates have not
been removed. Report any evidence of tampering to
law enforcement agencies and order duplicate plates.

TS1680 —UN—09DEC03
3. Other steps you can take:
­ Mark your machine with your own numbering
system
­ Take color photographs from several angles of each
machine

DX,SECURE1 ­19­18NOV03­1/1

4­5­3 PN=199
072310
 Miscellaneous—Specifications
444J Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3597 mm

11 ft 10.0 in.
B—Dump Height 2674 mm
8 ft 9.3 in.
C—Dump Reach 1024 mm
3 ft 4.3 in.
D—Overall Machine Height 3154 mm
10 ft 4.2 in.
E—Wheelbase Length 2750 mm
9 ft 0.3 in.
F—Machine­to­Ground Clearance 396 mm
15.6 in.
G—Overall Machine Length 6752 mm
22 ft 2.0 in.
Weight (S.N. —604689) 10 272 kg
Continued on next page MM61211,00013D5 ­19­16MAR06­1/2

4­6­1 072310

PN=200
 Miscellaneous—Specifications

Item Measurement Specification

22,645 lb
Weight (S.N. 604690— ) 10 042 kg
22 139 lb
H—Maximum Digging Depth Depth 86 mm
3.4 in.
J—Maximum Rollback at Full Height Angle 55°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 40°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard rear
without notice. Wherever applicable, specifications axle, 2 spool valve with two lever control, heater
are in accordance with SAE standards. Except and defroster, 79 kg (175 lb) operator, 2.5 cu
where otherwise noted, specifications are based on yd. pin­on­bucket (2.5 cu yd coupler bucket for
a machine equipped with all standard equipment, a Tool Carrier), and full fuel tank.
MM61211,00013D5 ­19­16MAR06­2/2

4­6­2 072310

PN=201
 Miscellaneous—Specifications

444J Tool Carrier Specifications

T203674 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3682 mm

12 ft 1.0 in.
B—Dump Height 2676 mm
8 ft 9.4 in.
C—Dump Reach 1258 mm
4 ft 1.5 in.
D—Overall Machine Height 3135 mm
10 ft 4.2 in.
E—Wheelbase Length 2750 mm
9 ft 0.3 in.
F—Machine­to­Ground Clearance 396 mm
15.6 in.
G—Overall Machine Length 7104 mm
23 ft 4.0 in.
Weight (S.N. —604689) 10 615 kg
Continued on next page MM61211,00013D6 ­19­16MAR06­1/2

4­6­3 072310

PN=202
 Miscellaneous—Specifications

Item Measurement Specification

23,406 lb
Weight (S.N. 604690— ) 10 385 kg
22 895 lb
H—Maximum Digging Depth Depth 145 mm
5.7 in.
J—Maximum Rollback at Full Height Angle 54.2°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 50.2°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard rear
without notice. Wherever applicable, specifications axle, 2 spool valve with two lever control, heater
are in accordance with SAE standards. Except and defroster, 79 kg (175 lb) operator, 2.5 cu
where otherwise noted, specifications are based on yd coupler bucket, and full fuel tank.
a machine equipped with all standard equipment,
MM61211,00013D6 ­19­16MAR06­2/2

4­6­4 072310

PN=203
 Miscellaneous—Specifications

444J High Lift Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3975 mm

13 ft 0.5 in.
B—Dump Height 3052 mm
10 ft 0.2 in.
C—Dump Reach 1050 mm
3 ft 5.3 in.
D—Overall Machine Height 3154 mm
10 ft 4.24 in.
E—Wheelbase Length 2750 mm
9 ft 0.3 in.
F—Machine­to­Ground Clearance 396 mm
15.6 in.
G—Overall Machine Length 7133 mm
23 ft 5.0 in.
Weight (S.N. —604689) 10 377 kg
Continued on next page MM61211,00013D7 ­19­16MAR06­1/2

4­6­5 072310

PN=204
 Miscellaneous—Specifications

Item Measurement Specification

22,877 lb
Weight (S.N. 604690— ) 10 147 kg
22 370 lb
H—Maximum Digging Depth Depth 105 mm
4.1 in.
J—Maximum Rollback at Full Height Angle 49°
K—Bucket Dump at Full Height Angle 45°
L—Maximum Rollback at Angle 40°
Ground Level
MM61211,00013D7 ­19­16MAR06­2/2

4­6­6 072310

PN=205
 Miscellaneous—Specifications

444J Powerllel Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3650 mm

12 ft 0 in.
B—Dump Height 2680 mm
8 ft 9.5 in.
C—Dump Reach 1138 mm
3 ft 8.8 in.
D—Overall Machine Height 3154 mm
10 ft 4.2 in.
E—Wheelbase Length 2750 mm
9 ft 0.3 in.
F—Machine­to­Ground Clearance 396 mm
15.6 in.
G—Overall Machine Length 6937 mm
22 ft 9.0 in.
Weight (S.N. —604689) 10 851 kg
Continued on next page MM61211,00013D8 ­19­16MAR06­1/2

4­6­7 072310

PN=206
 Miscellaneous—Specifications

Item Measurement Specification

23,926 lb
Weight (S.N. 604690— ) 10 621 kg
23 415 lb
H—Maximum Digging Depth Depth 151 mm
5.9 in.
J—Maximum Rollback at Full Height Angle 48°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 42°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard rear
without notice. Wherever applicable, specifications axle, 2 spool valve with two lever control, heater
are in accordance with SAE standards. Except and defroster, 79 kg (175 lb) operator, 2.5 cu
where otherwise noted, specifications are based on yd. pin­on­bucket (2.5 cu yd coupler bucket for
a machine equipped with all standard equipment, a Tool Carrier), and full fuel tank.
MM61211,00013D8 ­19­16MAR06­2/2

444J Drain and Refill Capacities

Item Measurement Specification

Cooling System Capacity 21.0 L

5.5 gal
Fuel Tank Capacity 246.0 L
65.0 gal
Engine Crankcase and Filter Capacity 17.5 L
4.6 gal
Transmission Case and Filter Capacity 18.5 L
19.5 qt
Front Differential—444J (S.N. Capacity 17.0 L
—604689) 4.5 gal
Front Differential—444J, (S.N. Capacity 22.0 L
604690— ) 5.8 gal
Rear Differential—444J (S.N. Capacity 17.0 L
—604689) 4.5 gal
Rear Differential—444J, (S.N. Capacity 22.0 L
604690— ) 5.8gal
Hydraulic Reservoir and Filters Capacity 96.5 L
25.5 gal
Park Brake Capacity 0.300 L
10 oz
MM61211,0000DA8 ­19­30JUN10­1/1

4­6­8 072310

PN=207
 Miscellaneous—Specifications

544J Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3836 mm

12 ft 7.0 in.
B—Dump Height 2787 mm
9 ft 3.5 in.
C—Dump Reach 997 mm
3 ft 3.3 in.
D—Overall Machine Height 3241 mm
10 ft 7.6 in.
E—Wheelbase Length 2900 mm
9 ft 6.2 in.
F—Machine­to­Ground Clearance 451 mm
17.7 in.
G—Overall Machine Length 7385 mm
24 ft 3.0 in.
Weight 12 469 kg
Continued on next page CED,TX03679,5730 ­19­30SEP04­1/2

4­6­9 072310

PN=208
 Miscellaneous—Specifications

Item Measurement Specification

27,489 lb
H—Maximum Digging Depth Depth 83 mm
3.25 in.
J—Maximum Rollback at Full Height Angle 55°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 40°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard rear
without notice. Wherever applicable, specifications axle, 2 spool valve with two lever control, heater
are in accordance with SAE standards. Except and defroster, 79 kg (175 lb) operator, 3.5 cu
where otherwise noted, specifications are based on yd. pin­on­bucket, and full fuel tank.
a machine equipped with all standard equipment,
CED,TX03679,5730 ­19­30SEP04­2/2

4­6­10 072310

PN=209
 Miscellaneous—Specifications

544J Tool Carrier Specifications

T203674 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3894 mm

12 ft 9.0 in.
B—Dump Height 2846 mm
9 ft 4.0 in.
C—Dump Reach 1298 mm
4 ft 3.0 in.
D—Overall Machine Height 3241 mm
10 ft 7.6 in.
E—Wheelbase Length 2900 mm
9 ft 6.2 in.
F—Machine­to­Ground Clearance 451 mm
17.7 in.
G—Overall Machine Length 7518 mm
24 ft 8.0 in.
Weight 12 521 kg
Continued on next page CED,TX03679,5735 ­19­30SEP04­1/2

4­6­11 072310

PN=210
 Miscellaneous—Specifications

Item Measurement Specification

27,609 lb
H—Maximum Digging Depth Depth 74 mm
2.9 in.
J—Maximum Rollback at Full Height Angle 56°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 50.2°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard rear
without notice. Wherever applicable, specifications axle, 2 spool valve with two lever control, heater
are in accordance with SAE standards. Except and defroster, 79 kg (175 lb) operator, 3.0 cu
where otherwise noted, specifications are based on yd. coupler bucket, and full fuel tank.
a machine equipped with all standard equipment,
CED,TX03679,5735 ­19­30SEP04­2/2

4­6­12 072310

PN=211
 Miscellaneous—Specifications

544J High Lift Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 4188 mm

13 ft 9.0 in.
4188 mm
13 ft 9.0 in.
B—Dump Height 3139 mm
10 ft 3.6 in.
C—Dump Reach 999 mm
3 ft 3.3 in.
D—Overall Machine Height 3241 mm
10 ft 7.6 in.
E—Wheelbase Length 2900 mm
9 ft 6.2 in.
F—Machine­to­Ground Clearance 451 mm
17.7 in.

Continued on next page CED,TX03679,5813 ­19­30SEP04­1/2

4­6­13 072310

PN=212
 Miscellaneous—Specifications

Item Measurement Specification

G—Overall Machine Length 7689 mm

25 ft 3.0 in.
Weight 12 538 kg
27,641 lb
H—Maximum Digging Depth Depth 265 mm
6.5 in.
J—Maximum Rollback at Full Height Angle 49°
K—Bucket Dump at Full Height Angle 46°
L—Maximum Rollback at Angle 40°
Ground Level
CED,TX03679,5813 ­19­30SEP04­2/2

4­6­14 072310

PN=213
 Miscellaneous—Specifications

544J Powerllel Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3870 mm

12 ft 8.0 in.
B—Dump Height 2841 mm
(9 ft 4.0 in.
C—Dump Reach 999 mm
3 ft 5.1 in.
D—Overall Machine Height 3241 mm
10 ft 7.6 in.
E—Wheelbase Length 2900 mm
9 ft 6.2 in.
F—Machine­to­Ground Clearance 451 mm
17.7 in.
G—Overall Machine Length 7422 mm
24 ft 4.0 in.
Weight 12 987 kg
Continued on next page HG31779,0000040 ­19­30SEP04­1/2

4­6­15 072310

PN=214
 Miscellaneous—Specifications

Item Measurement Specification

28,636 lb
H—Maximum Digging Depth Depth 127 mm
5.0 in.
J—Maximum Rollback at Full Height Angle 50°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 42°
Ground Level
HG31779,0000040 ­19­30SEP04­2/2

544J Drain and Refill Capacities

Item Measurement Specification

Cooling System Capacity 21.0 L

5.5 gal
Fuel Tank Capacity 322.0 L
85.0 gal
Engine Crankcase and Filter Capacity 18.5 L
5.0 gal
Transmission Case and Filter Capacity 18.5 L
5.0 gal
Front Differential Capacity 18.0 L
4.75 gal
Rear Differential Capacity 18.0 L
4.75 gal
Hydraulic Reservoir and Filters Capacity 96.5 L
25.5 gal
Park Brake Capacity 0.300 L
10 oz
CED,TX03679,5734 ­19­30JUN10­1/1

4­6­16 072310

PN=215
 Miscellaneous—Specifications

624J Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 3966 mm

13 ft 0.0 in.
B—Dump Height 2885 mm
9 ft 5.6 in.
C—Dump Reach 1031 mm
3 ft 4.6 in.
D—Overall Machine Height 3317 mm
10 ft 10.6 in.
E—Wheelbase Length 3030 mm
9 ft 11 in.
F—Machine­to­Ground Clearance 436 mm
17.1 in.
G—Overall Machine Length 7572 mm
24 ft 10.0 in.
Weight 14 375 kg
Continued on next page CED,OUOE002,1791 ­19­30SEP04­1/2

4­6­17 072310

PN=216
 Miscellaneous—Specifications

Item Measurement Specification

31,691 lb
H—Maximum Digging Depth Depth 88 mm
3.5 in.
J—Maximum Rollback at Full Height Angle 55°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 40°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard rear
without notice. Wherever applicable, specifications axle, 2 spool valve with two lever control, heater
are in accordance with SAE standards. Except and defroster, 79 kg (175 lb) operator, 3.5 cu
where otherwise noted, specifications are based on yd. pin­on­bucket, and full fuel tank.
a machine equipped with all standard equipment,
CED,OUOE002,1791 ­19­30SEP04­2/2

4­6­18 072310

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 Miscellaneous—Specifications

624J Tool Carrier Specifications

T203674 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 4005 mm

13 ft 2.0 in.
B—Dump Height 2907 mm
9 ft 6.5 in.
C—Dump Reach 1278 mm
4 ft 2.3 in.
D—Overall Machine Height 3317 mm
10 ft 10.6 in.
E—Wheelbase Length 3030 mm
9 ft 11 in.
F—Machine­to­Ground Clearance 436 mm
17.1 in.
G—Overall Machine Length 7572 mm
24 ft 10.0 in.
Weight 14 375 kg
Continued on next page CED,OUOE002,1791 ­19­30SEP04­1/2

4­6­19 072310

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 Miscellaneous—Specifications

Item Measurement Specification

31,691 lb
H—Maximum Digging Depth Depth 188 mm
7.4 in.
J—Maximum Rollback at Full Height Angle 55°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 40°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard rear
without notice. Wherever applicable, specifications axle, 2 spool valve with two lever control, heater
are in accordance with SAE standards. Except and defroster, 79 kg (175 lb) operator, 3.5 cu
where otherwise noted, specifications are based on yd. coupler bucket, and full fuel tank.
a machine equipped with all standard equipment,
CED,OUOE002,1791 ­19­30SEP04­2/2

4­6­20 072310

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 Miscellaneous—Specifications

624J High Lift Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 4332 mm

14 ft 3.0 in.
B—Dump Height 3251 mm
10 ft 8.0 in.
C—Dump Reach 1117 mm
3 ft 8.0 in.
D—Overall Machine Height 3317 mm
10 ft 10.6 in.
E—Wheelbase Length 3030 mm
9 ft 11 in.
F—Machine­to­Ground Clearance 436 mm
17.1 in.
G—Overall Machine Length 7984 mm
26 ft 2.0 in.
Weight 14 463 kg
Continued on next page CED,TX03679,5802 ­19­30SEP04­1/2

4­6­21 072310

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 Miscellaneous—Specifications

Item Measurement Specification

31,885 lb
H—Maximum Digging Depth Depth 193 mm
7.6 in.
J—Maximum Rollback at Full Height Angle 49°
K—Bucket Dump at Full Height Angle 46°
L—Maximum Rollback at Angle 40°
Ground Level
CED,TX03679,5802 ­19­30SEP04­2/2

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 Miscellaneous—Specifications

624J Powerllel Specifications

T203668 —UN—01OCT04
A—Bucket Hinge Height D—Machine Overall Height G—Machine Overall Length K—Bucket Dump at Full Height
B—Dump Height E—Wheelbase H—Maximum Digging Depth L— Maximum Rollback at Ground
C—Dump Reach F— Machine­to­Ground J— Maximum Roll Back at Full Level
Clearance Height

Item Measurement Specification

A—Bucket Hinge Height 4000 mm

13 ft 2.0 in.
B—Dump Height 2837 mm
9 ft 3.7 in.
C—Dump Reach 1112 mm
3 ft 7.8 in.
D—Overall Machine Height 3317 mm
10 ft 10.6 in.
E—Wheelbase Length 3030 mm
9 ft 11 in.
F—Machine­to­Ground Clearance 436 mm
17.1 in.
G—Overall Machine Length 7757 mm
25 ft 5.0 in.
Weight 15 208 kg
Continued on next page HG31779,0000041 ­19­30SEP04­1/2

4­6­23 072310

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 Miscellaneous—Specifications

Item Measurement Specification

33,534 lb
H—Maximum Digging Depth Depth 129 mm
5.1 in.
J—Maximum Rollback at Full Height Angle 50°
K—Bucket Dump at Full Height Angle 50°
L—Maximum Rollback at Angle 42°
Ground Level
NOTE: Specifications and design subject to change ROPS cab, diff lock front axle with standard
without notice. Wherever applicable, specifications rear axle, 2 spool valve with two lever control,
are in accordance with SAE standards. Except heater and defroster, 79 kg (175 lb) operator,
where otherwise noted, specifications are based on 3.5 pin­on­bucket, and full fuel tank.
a machine equipped with all standard equipment,
HG31779,0000041 ­19­30SEP04­2/2

624J Drain and Refill Capacities

Item Measurement Specification

Cooling System Capacity 22.0 L

5.8 gal
Fuel Tank Capacity 348.0 L
92.0 gal
Engine Crankcase and Filter Capacity 24.0 L
6.3 gal
Transmission Case and Filter Capacity 23.0 L
6.0 gal
Front Differential Capacity 24.5 L
6.5 gal
Rear Differential Capacity 20.0 L
5.0 gal
Hydraulic Reservoir and Filters Capacity 119.0 L
31.5 gal
Park Brake Capacity 0.300 L
10 oz
CED,OUOE002,1792 ­19­30JUN10­1/1

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Miscellaneous—Specifications

4­6­25 072310

PN=224
 Index
Page Page

A Accumulator—444J (S.N. —604689),

544J, 624J.......................................................... 4­1­14
Accumulator Brakes
Brake Check—444J (S.N. 604690— ) ................. 4­1­14 External inspection—444J (S.N.
Brake—444J (S.N. —604689), 544J, 624J.......... 4­1­14 —604689), 544J, 624J....................................... 4­1­12
Acid burns.................................................................. 3­8­2 Bucket
Adjustment Control lever­one lever design ............................... 2­2­7
Engine valve clearance........................................ 3­10­1 Control lever­two lever design ............................... 2­2­8
Seat...................................................................... 2­1­25
Steering wheel tilt................................................. 2­1­22 C
Air cleaner
Clean elements ...................................................... 3­3­9 Cab
Replace elements .................................................. 3­9­2 Fresh air filter ....................................................... 3­3­10
Unloader valve ....................................................... 3­4­1 Recirculating air filter ........................................... 3­3­13
Air conditioning Cab fresh air filter
Control ................................................................. 2­1­22 Clean.................................................................... 3­3­10
Diagnose malfunctions......................................... 4­3­15 Cab recirculating air filter
Service ................................................................. 4­1­11 Clean.................................................................... 3­3­13
Air heater ................................................................... 2­2­4 Capacities, drain and refill
Air intake 444J ....................................................................... 4­6­8
Hose....................................................................... 3­8­2 544H .................................................................... 4­6­16
Alternator ................................................................... 4­1­3 624H/TC62H ........................................................ 4­6­24
Attachments Chemical products
Adding safely ......................................................... 1­3­5 Handling................................................................. 1­2­5
Operating safely..................................................... 1­3­5 Control lever
Axle Shifting transmission.............................................. 2­2­5
Clean recirculation screen ................................... 3­10­5 Coolant
Serial number......................................................... 4­5­2 Diesel engine ....................................................... 3­1­10
Engine.................................................................... 3­9­4
B Heater .................................................................... 2­2­4
Level recovery tank................................................ 3­4­1
Backdragging........................................................... 2­2­16 Sample................................................................... 3­8­8
Batteries Cooling
Using battery charger............................................. 4­1­6 Drain .................................................................... 3­10­1
Battery System fill............................................................. 3­10­2
Acid burns .............................................................. 3­8­2 Crankshaft dampener replacement ......................... 3­12­1
Booster................................................................... 4­1­5 Cylinder ................................................................... 4­1­18
Electrolyte level check ........................................... 3­8­2
Explosion ............................................................... 3­8­2 D
Handling, checking, and servicing ......................... 4­1­4
Removing............................................................... 4­1­7 Daily inspection ......................................................... 2­2­1
Replacing ............................................................... 4­1­6 Dampener replacement, crankshaft ........................ 3­12­1
Terminals................................................................ 3­8­2 Diagnose
Battery explosions Drive Line Malfunctions........................................ 4­3­11
Prevent................................................................... 1­2­5 Diagnose malfunction
Bleed Fuel System .................................................... 4­1­1 Hydraulic system.................................................. 4­3­13
Bolt and screw torque values Transmission system ............................................. 4­3­8
Metric ................................................................... 4­1­19 Diagnose malfunctions
Unified inch .......................................................... 4­1­20 Troubleshooting procedure .................................... 4­3­1
Boom Diesel fuel........................................................3­1­1, 3­1­3
Control lever­one lever design ............................... 2­2­7 Sample................................................................... 3­8­8
Control lever­two lever design ............................... 2­2­8 Diesel fuel conditioner
Height kickout adjustment.................................... 2­2­12 Low sulfur............................................................... 3­1­4
Boom Lock Differential
Storage .................................................................. 3­2­4 Clean axle recirculation screen............................ 3­10­5
Brake Lock foot switch ..................................................... 2­1­2
Accumulator Check—444J (S.N.604690— ) ....... 4­1­14 Lock pedal............................................................ 2­2­12

Continued on next page

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PN=1
 Index

Page Page

Oil change..................................................3­6­2, 3­10­4 Frame

Oil specification...................................................... 3­1­8 Machine lock bar.................................................... 3­2­3
Differential oil Front driveline
Check level ............................................................ 3­8­7 Lubricate ................................................................ 3­7­1
Differential/axle Fuel
Diagnose malfunctions......................................... 4­3­10 Diesel ...........................................................3­1­1, 3­1­3
Digging Filter change .......................................................... 3­8­5
Loader bucket ...................................................... 2­2­15 Handling and storing .............................................. 3­1­2
Door Lubricity.................................................................. 3­1­1
Grille....................................................................... 3­2­5 Fuel System
Locking open side ................................................ 2­1­23 Bleed the Fuel System........................................... 4­1­1
Driving metal pins ...................................................... 1­4­2 Fuse
Dust valve.................................................................. 3­9­1 Specification........................................................... 4­1­7

E G
Electrical Gauge
Fuse Specifications................................................ 4­1­7 Engine coolant temperature................................... 2­1­3
Emergency preparation ............................................. 1­2­6 Fuel ........................................................................ 2­1­3
Engine Transmission oil temperature................................. 2­1­3
Air heater ............................................................... 2­2­4 Grease
Boost starting ......................................................... 4­1­5 Alternative and synthetic lubricants ....................... 3­1­6
Cold weather warm­up........................................... 2­2­4 Boom and cylinder pivots....................................... 3­5­1
Coolant conditioner ................................................ 3­9­4 Extreme pressure and multipurpose ...................... 3­1­9
Crankshaft dampener replacement...................... 3­12­1 Frame hinge pivots ................................................ 3­9­5
Oil change....................................................3­6­1, 3­8­4 Oscillating rear axle ............................................... 3­5­4
Oil level .................................................................. 3­4­2 Steering cylinder pivots.......................................... 3­5­4
Serial number......................................................... 4­5­1 Grille door .................................................................. 3­2­5
Speed................................................................... 4­1­10
Starting................................................................... 2­2­2 H
Valve clearance adjust ......................................... 3­10­1
Vent tube................................................................ 3­9­1 Halogen bulbs.......................................................... 4­1­10
Engine side shields Handhold use ............................................................ 1­3­1
Opening ................................................................. 3­2­3 Hardware
Explosion Torque specifications ........................................... 4­1­18
Battery.................................................................... 1­2­5 Hardware torque values
External service brake inpection Metric ................................................................... 4­1­19
444J (S.N. 604690— ) ......................................... 4­1­13 Unified inch .......................................................... 4­1­20
Hazards
F Avoiding ................................................................. 1­3­2
Heater
Features Control ................................................................. 2­1­22
Operator convenience............................................ 1­1­1 Coolant................................................................... 2­2­4
Safety..................................................................... 1­1­1 Engine air............................................................... 2­2­4
Filter Heater system
Cab air recirculating ............................................. 3­3­13 Diagnose malfunctions......................................... 4­3­16
Cab fresh air ........................................................ 3­3­10 High­pressure oils
Engine oil .....................................................3­6­1, 3­8­4 Avoid ...................................................................... 1­2­4
Final fuel ....................................................3­3­14, 3­8­5 Horn button.............................................................. 2­1­21
Fuel ........................................................................ 3­8­5 Hose
Fuel drain ............................................................. 3­3­10 Air intake ................................................................ 3­8­2
Hydraulic reservoir breather................................... 3­8­6 Coolant................................................................. 3­10­1
Hydraulic return...................................................... 3­8­6 Hoses
Primary fuel drain and clean ................................ 3­3­10 Check..................................................................... 3­9­5
Transmission oil ..................................................... 3­9­3 Hydraulic
Final fuel filter Oil........................................................................... 3­1­8
Replace......................................................3­3­14, 3­8­5 Oil change............................................................ 3­11­1
Fire prevention........................................................... 1­2­5 Oil level .................................................................. 3­4­3
Fluid analysis test kit ................................................. 3­2­6 Oil specification...................................................... 3­1­8

Continued on next page

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 Index

Page Page

Reservoir breather filter ......................................... 3­8­6 Maintenance

Return filter ............................................................ 3­8­6 Preparing machine................................................. 3­2­2
Hydraulic pump Required parts ....................................................... 3­2­9
Serial number......................................................... 4­5­2 Service intervals..................................................... 3­2­7
Hydraulic system Metal pins .................................................................. 1­4­2
Malfunctions......................................................... 4­3­13 Metric bolt and screw torque values ........................ 4­1­19
Suction strainer .................................................... 3­11­2 Monitor display unit
Check..................................................................... 3­2­1
I Normal display ....................................................... 2­1­8
Motor ....................................................................... 4­1­18
Indicator
Location ................................................................. 2­1­3 N
Secondary steering .............................................. 2­2­11
Inspection Neutral
External service brake—444J (S.N. Lock ....................................................................... 2­2­5
—604689), 544J, 624J....................................... 4­1­12 Start system check............................................... 4­1­11
Instruments
Check before starting............................................. 2­2­1 O
J Oil
Alternative and synthetic lubricants ....................... 3­1­6
Jump starting ............................................................. 4­1­5 Axle sample ........................................................... 3­8­8
Change differential.....................................3­6­2, 3­10­4
L Change engine.............................................3­6­1, 3­8­4
Change hydraulic ................................................. 3­11­1
Lamps...................................................................... 4­1­10 Change park brake ................................................ 3­9­6
Lever Change transmission ........................................... 3­10­3
Boom control­one lever design .............................. 2­2­7 Check level park brake .......................................... 3­8­7
Boom control­two lever design............................... 2­2­8 Engine sample ....................................................... 3­7­2
Bucket control­one lever design............................. 2­2­7 Hydraulic reservoir ................................................. 3­1­8
Bucket control­two lever design ............................. 2­2­8 Hydraulic sample ................................................... 3­8­8
Loader.................................................................... 2­1­1 Level engine........................................................... 3­4­2
Lifting Level hydraulic system........................................... 3­4­3
Machine ............................................................... 2­2­23 Level transmission ................................................. 3­4­4
Lock Specification differential ......................................... 3­1­8
Bar, machine frame................................................ 3­2­3 Specification hydraulic system............................... 3­1­8
Neutral ................................................................... 2­2­5 Specification park brake......................................... 3­1­8
Low sulfur diesel fuel conditioner .............................. 3­1­4 Specification transmission ..................................... 3­1­8
Lubricants Transmission sample ............................................. 3­8­8
Alternative and synthetic lubricants ....................... 3­1­6
Lubricate P
Boom and cylinder pivots....................................... 3­5­1
Frame hinge pivots ................................................ 3­9­5 Park brake
Front driveline ........................................................ 3­7­1 Change oil.............................................................. 3­9­6
Oscillating rear axle ............................................... 3­5­4 Diagnose malfunctions......................................... 4­3­12
Rear driveline......................................................... 3­8­1 Oil level check........................................................ 3­8­7
Rear oscillating support cover................................ 3­8­6 Oil specification...................................................... 3­1­8
Rear steering cylinder pivots.................................. 3­5­4 Operation ............................................................... 2­2­6
Steering cylinder pivots.......................................... 3­5­4 Switch .................................................................... 2­2­6
Lubricity of diesel fuel ................................................ 3­1­1 Pedal
Differential lock .................................................... 2­2­12
M Pedals
Accelerator............................................................. 2­1­2
Machine Brake...................................................................... 2­1­2
Frame locking bar .................................................. 3­2­3 Powerllel linkage
Machine modifications Return­to­dig adjustment ..................................... 2­2­14
Avoid ...................................................................... 1­2­2 Prepare Machine for Maintenance ............................ 3­2­2

Continued on next page

Index­3 072310

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 Index

Page Page

Primary fuel filter Signs ...................................................................... 1­5­1

Strainer .................................................................. 3­8­5 Stay clear of moving parts ..................................... 1­2­3
Product Identification Number ................................... 4­5­1 Seat
Pump Adjust ................................................................... 2­1­25
Service ................................................................. 4­1­18 Seat belt .................................................................. 2­1­25
Use and maintenance ............................................ 1­3­1
Q Secondary steering
Operation ............................................................. 2­2­11
Quick shift Serial number
Switch .................................................................... 2­2­9 Axle ........................................................................ 4­5­2
Engine.................................................................... 4­5­1
R Hydraulic pump ...................................................... 4­5­2
Transmission.......................................................... 4­5­1
Radiator Service
External cleaning ................................................. 4­1­16 Interval .........................................................3­2­1, 3­3­1
Radiator hoses Service brake inspection, external
Check..................................................................... 3­9­5 444J (S.N. 604690— ) ......................................... 4­1­13
Rear driveline Service brakes
Lubricate ................................................................ 3­8­1 External inspection—444J (S.N.
Rear oscillating support cover —604689), 544J, 624J....................................... 4­1­12
Grease ................................................................... 3­8­6 Service codes
Lubricate ................................................................ 3­8­6 Quick reference list ................................................ 4­3­2
Rear steering cylinder pivots Service Doors
lubricate ................................................................. 3­5­4 Opening ................................................................. 3­2­3
Recovery tank Service intervals
Coolant level .......................................................... 3­4­1 Maintenance .......................................................... 3­2­7
Regulator ................................................................... 4­1­3 Shifting
Required parts ........................................................... 3­2­9 Transmission.......................................................... 2­2­5
Return­to­carry Snap­to­connect (STC) fittings
Height kickout adjustment.................................... 2­2­12 Service recommendations ................................... 4­1­17
Return­to­dig Specification
Adjustment Fuse ....................................................................... 4­1­7
Powerllel linkage .............................................. 2­2­14 Specifications
Return­to­dig circuit 444J ....................................................................... 4­6­1
Adjustment ........................................................... 2­2­13 444J High Lift ...............................................4­6­5, 4­6­7
Ride control 544H ...................................................................... 4­6­9
Accumulator ......................................................... 4­1­15 544H High Lift ..........................................4­6­13, 4­6­15
Switch .................................................................. 2­2­10 624H high lift ........................................................ 4­6­21
Roads 624H/TC62H ............................... 4­6­17, 4­6­19, 4­6­23
Operating or traveling ............................................ 1­3­5 Cooling system ...................................................... 3­9­4
Roll­over protective structure Differential oil ......................................................... 3­1­8
Torque value ........................................................ 4­1­18 Hardware torque .................................................. 4­1­18
ROPS Hydraulic oil ........................................................... 3­1­8
Inspect ................................................................... 1­3­5 Park brake.............................................................. 3­1­8
Maintain ................................................................. 1­3­5 TC444J .................................................................. 4­6­3
Rust inhibitor.............................................................. 3­9­4 TC54H.................................................................. 4­6­11
Transmission oil ..................................................... 3­1­8
Speed
S Engine.................................................................. 4­1­10
Starting
Safety The engine ............................................................. 2­2­2
Add cab guarding for special uses......................... 1­2­2 Starting fluid
Clean debris from machine .................................... 1­2­6 If equipped ............................................................. 2­2­3
Features................................................................. 1­1­1 STC fittings
Inspect machine..................................................... 1­2­3 Service recommendations ................................... 4­1­17
Operate only if qualified ......................................... 1­2­1 Steering
Operator's seat ...................................................... 1­3­1 Wheel tilt adjust.................................................... 2­1­22
Protective equipment ............................................. 1­2­2 Steps use................................................................... 1­3­1
Recognize safety information................................. 1­2­1

Continued on next page

Index­4 072310

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 Index

Page Page

Storage Traveling
Machine ................................................................. 4­4­1 On public roads...................................................... 1­3­5
Monthly .................................................................. 4­4­1 Troubleshooting procedure........................................ 4­3­1
Storing fuel ................................................................ 3­1­2
Strainer U
Primary fuel filter .................................................... 3­8­5
Suction strainer Unified inch bolt and screw torque values ............... 4­1­20
Hydraulic system.................................................. 3­11­2 Unloader valve
Surge Tank Air cleaner.............................................................. 3­4­1
Level ...................................................................... 3­7­2
Switch V
Differential lock ...................................................... 2­1­2
Park brake.............................................................. 2­2­6 Valve
Quick shift .............................................................. 2­2­9 Air cleaner dust unloader ....................................... 3­4­1
Ride control.......................................................... 2­2­10 Control ................................................................. 4­1­18
Dust unloader......................................................... 3­9­1
T Vent tube
Engine crankcase .................................................. 3­9­1
Tank Vibration
Surge ..................................................................... 3­7­2 Crankshaft damenper replacement...................... 3­12­1
Test
Bleed the Fuel System........................................... 4­1­1 W
Tire
Pressure check ...................................................... 3­3­1 Warm­up
Pressures.....................................................3­3­2, 3­3­7 Engine, cold weather ............................................. 2­2­4
Torque charts Washer
Metric ................................................................... 4­1­19 Windshield fluid level ............................................. 3­2­6
Unified inch .......................................................... 4­1­20 Waste disposal .......................................................... 1­2­6
Torque specifications Welding.................................................................... 4­1­11
Hardware ............................................................. 4­1­18 Welding repairs.......................................................... 1­4­2
Roll­over protective structure ............................... 4­1­18 Wheel
Torque values Cap screw torque................................................... 3­3­8
Wheel retaining cap screw..................................... 3­3­8 Window
Towing Procedure.................................................... 2­2­21 Opening ............................................................... 2­1­24
Transmission Sliding .................................................................. 2­1­24
Oil change............................................................ 3­10­3 Windshield
Oil filter replace ...................................................... 3­9­3 Washer fluid ........................................................... 3­2­6
Oil level .................................................................. 3­4­4 Worksite hazards
Oil specification...................................................... 3­1­8 Avoid ...................................................................... 1­3­2
Serial number......................................................... 4­5­1
Shifting ................................................................... 2­2­5
Transmission cooler
External cleaning ................................................. 4­1­16

Index­5 072310

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 Index

Index­6 072310

PN=6