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Introduction
Foreword
This manual written for experienced Essential tools required performing certain service work are identified this manual and are recommended for use.
Live with safety: Read the safety messages the introduction this manual and the cautions presented throughout the text the
This the safety - alert symbol. When this symbol seen the machine this alert for the potential personal injury
T echnical manuals are divided two parts: repair and operation and Repair sections tell how repair the components. Operation and test sections help quickly identify the majority routine failures quickly
Information organized groups for the various components requiring service the beginning each group are summary listings all applicable essential tools, service equipment and tools, other materials needed the job, service parts wear and torque
T echnical manuals are concise guides for specific They are - the - job guides containing only the vital information needed for diagnosis, analysis, testing, and repair
Fundamental service information available from other sources covering basic theory fundamentals general and basic type failures and their causes.
Introduction
Manual Identification—READ THIS FIRST!
IMPORT ANT : Use only supporting manuals designated for your specific incorrect manual improper service may occur . V erify product identification number (PIN) when choosing the correct manual.
Choosing the Correct Supporting Manuals
John Deere loaders are available dif ferent machine configurations based the various markets into which they are Dif ferent supporting manuals exist for dif ferent machine
When necessary , product identification numbers (PINs) are listed the front covers loader manuals. These numbers are used identify the correct supporting manual for your
Product Serial Number Identification
The product identification number (PIN) plate (1) located the left side the machine the loader Each machine has a - character PIN (2) shown PIN
PIN Plate
The PIN identifies the producing factory , machine model number , machine year and machine serial number
Introduction
• W orld Code: Identifies location where machine
Check Letter (variable) • (10) Manufacturing Y ear Code: Identifies year machine
1LU . . . . . . . . . . . . . . . . . W orld Code (manufacturing location)
1DW Davenport W orks
1T8 Thibodaux W orks
1T0 Dubuque W orks
1FF
1LU Liebherr
• Machine Model Identifier: Identifies model number
344K Machine Model Identifier
• (8) Model Identifier Suffix, Machine Configuration Code, Additional Machine Information: Contains additional machine information for overall machine Machine Option Code X Base Machine
. Standard Z - Bar
Manufacturing Y ear Code (variable)
Not used for calendar year
Liebherr Factory Code: Identifies factory
Bischofshofen • Machine Serial Number: Identifies machine serial number This character will change from one machine another 123456 Machine Serial Number
• (9) Check Letter: This is a random character assigned the factory This not used in machine
- - 17SEP15 - 2/2
Contents
Section Information
Group 0001 Information
Group 0003 orque V alues
Section Group and Fasteners
Section and Suspension Systems
Group 0200 and Installation
Group 0225 Shafts and U - Joints
Group 0250 and Rear Axle Reduction Gears
Section 03—T ransmission
Group 0300 Components Removal and Installation
Group 0360 Components Repair
Section Group 0400 and Installation
Section Auxiliary System
Group 0510 System
Group 0530 Exhaust Systems
Group 0560 Fuel Supply Systems
Section Drive Group 0700 and Installation
Section 09—Steering System
Group 0960 System
Section 10—Service Brakes
Group 101 1 Elements
Group 1060 System
Section 1 1—Park Brake Group 1 160 System
Section 17—Frame Supporting Structure
Group 1740 Installation
Group 1749 W eights
Section 18—Operator's Station
Group 1800 and Installation
Group 1810 Enclosure
Group 1830 and Air Conditioning System
Section Metal and Styling
Group 1910 Engine Enclosure
Group 1913 Shields
Section 21—Main Hydraulic System
Group 2160 System
Section 31—Loader
Group 3102
Group 3104 Coupler
Group 3140
Group 3160 System
Section Fabricated T ools
Group 9900 Fabricated T ools
Original All illustrations and specifications this manual are based the latest information available the time The right is reserved make changes any time without
0001 - 6 Exhaust Filter Ash Handling and Disposal - 0001 - 6
for Emergencies - 0001 - 6
Debris from Machine - 0001 - 7 Add Cab Guarding for Special Uses - 0001 - 7 Use Steps and Handholds Correctly
From Seat
0001 - 7
0001 - 7 Use and Maintain Seat Belt - 0001 - 8 Prevent Unintended Machine Movement - 0001 - 8 A void W orksite Hazards - 0001 - 9 Use Special Care When Operating Loader - 0001 - 9 Keep Riders f Machine - 0001A void Backover Accidents - 0001A void Machine T Over - 0001 - 1 1 Operating Slopes - 0001 - 1 1 Operating T raveling Public Roads
Recognize Safety Information
This the safety alert symbol. When you see this symbol your machine this alert for the potential personal injury
Follow the precautions and safe operating practices highlighted this
A signal word DANGER, W ARNING, CAUTION is used with the safety alert DANGER identifies the most serious your DANGER signs are red color , W ARNING signs are orange, and CAUTION signs are yellow . DANGER and W ARNING signs are located near specific General precautions are CAUTION
Follow Safety Instructions
Carefully read all safety messages in this manual and your machine safety signs. Keep safety signs good Replace missing damaged safety Use this operator ’ s manual for correct safety sign sure that new equipment components and repair parts include the current safety Replacement safety signs are available from your John Deere dealer
There can additional safety information contained parts and components sourced from suppliers that not reproduced this
Learn how operate the machine and how use controls properly not let anyone operate without Keep your machine in proper working Unauthorized modifications the machine could impair the function safety and fect machine life.
you not understand any part this manual and need contact your John Deere dealer
Operate Only Qualified
not operate this machine unless the manual has been read carefully , and you have been qualified supervised training and
Operator should familiar with the job site and surroundings before T all controls and
machine functions with the machine open area before starting work.
Know and observe all safety rules that may apply every work situation and work
W ear Protective Equipment
Guard against injury from flying pieces metal debris; wear goggles safety
W ear close fitting clothing and safety equipment appropriate the
Operating equipment safely requires the full attention the operator . not wear radio music headphones while operating
Prolonged exposure loud noise can cause impairment loss W ear suitable hearing protection such earmuf earplugs protect against objectionable uncomfortable loud noises. Radio music headphones are not suitable use for hearing
A void Unauthorized Machine Modifications
John Deere recommends using only genuine John Deere replacement parts ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application these can create hazardous situations hazardous Non - John Deere any damage failures resulting from their are not covered any John Deere warranty
reliability , and may create a hazard for the operator others near the machine. The installer any modification which may fect the electronic controls this machine responsible for establishing that the modification does not adversely fect the machine its
Modifications this addition unapproved products may fect machine stability
Always contact authorized John Deere dealer before making machine modifications that change the intended balance the that alter machine reliability
Inspect Machine
Inspect machine carefully each day walking around before
Keep all guards and shields good condition and properly Fix damage and replace worn broken parts immediately . Pay special attention hydraulic hoses and electrical
Stay Clear Moving Parts
Entanglements moving parts can cause serious injury .
Stop engine before maintaining any part machine with moving
Keep guards and shields place. Replace any guard shield that has been removed for access soon service repair
A void High-Pressure Fluids
Inspect hydraulic hoses periodically – least once per year – for exposed wire braid any other signs wear damage.
Replace worn damaged hose assemblies immediately with John Deere approved replacement
Escaping fluid under pressure can penetrate the skin causing serious injury
A void the hazard relieving pressure before disconnecting hydraulic other lines. T ighten all connections before applying pressure.
Search for leaks with a piece Protect hands and body from high - pressure
accident see a doctor immediately Any fluid injected into the skin must surgically removed within a few hours gangrene may Doctors unfamiliar
A void High-Pressure Oils
This machine uses a high - pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury
Never search for leaks with your Protect Use a piece cardboard find location escaping oil. Stop engine and relieve pressure before disconnecting lines working hydraulic hydraulic oil penetrates your see a doctor immediately Injected oil must removed surgically within hours gangrene could result. Contact a knowledgeable medical source the Deere & Company Medical Department
W ork V entilated Area
Engine exhaust fumes can cause sickness is necessary run engine enclosed remove the exhaust fumes from the area with exhaust pipe extension. you not have exhaust pipe open the doors and get outside air into the
Prevent Fires
Handle Fluids Safely: All most and some coolant mixtures are Store flammable fluids away from fire Never refuel machine while smoking when near sparks
Clean Machine Regularly: Keep flammable debris straw , and grease and oil from accumulating engine around fuel hydraulic exhaust and electrical wiring. Never store oily rags flammable materials inside a machine compartment.
Maintain T and W iring: Replace hoses and tubes immediately they begin and clean any oil Examine electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher A vailable: Always keep a multipurpose fire extinguisher near the Know how use extinguisher properly
A ware the Operating Environment: Airborne debris may contain sparks not operate near any
TS220
T133552
T133553
T133554
Prevent Battery Explosions
Keep lighted and open flame away from the top battery Battery gas can
Never check battery charge placing a metal object across the Use a volt - meter hydrometer
not charge a frozen battery; may W arm battery 16°C (60°F).
Handle Chemical Products Safely
Direct exposure hazardous chemicals can cause serious injury Potentially hazardous chemicals used with John Deere equipment include such items and A Material Safety Data Sheet (MSDS) provides specific details chemical products: physical and health safety and emergency response
Check the MSDS before you start any job using a hazardous That way you will know exactly what the risks are and how the job safely Then follow procedures and recommended
(See your John Deere dealer for MSDS’ s chemical products used with John Deere
Decommissioning — Proper Recycling and Disposal Fluids and Components
Safety and environmental stewardship measures must taken into account when decommissioning a machine and/or These measures include the following:
• Use appropriate tools and personal protective equipment such clothing, gloves, face shields during the removal handling objects and
• Follow instructions for specialized
• Release stored energy lowering suspended machine relaxing disconnecting the battery other electrical power , and releasing pressure hydraulic components, accumulators, and other similar
• Minimize exposure components which may have residue from agricultural such fertilizers and Handle and dispose these components appropriately
• Carefully drain fuel hydraulic cylinders, reservoirs, and lines before recycling Use leak - proof containers when draining not use food beverage
• not pour waste fluids onto the down a into any water
• Observe all and local ordinances governing the handling disposal waste fluids (example: oil, fuel, coolant, brake fluid);
filters; batteries; other substances Burning flammable fluids components other than specially designed incinerators may prohibited law and could result exposure harmful fumes
• Service and dispose air conditioning systems appropriately Government regulations may require a certified service center recover and recycle air conditioning refrigerants which could damage the atmosphere allowed
• Evaluate recycling options for rubber , and electronic components which may recyclable, part completely .
• Contact your local environmental recycling center , your John Deere dealer for information the proper way recycle dispose
Exhaust Filter Ash Handling and Disposal
CAUTION: Under federal, state, and local laws regulations, exhaust filter ash can classified a hazardous waste. Hazardous waste must disposed accordance with all applicable and local laws regulations governing hazardous waste disposal. Only a qualified service provider should remove ash from the exhaust filter Personal protective equipment and maintained a sanitary and reliable condition, should used when handling and cleaning exhaust filter . See your authorized dealer for exhaust filter ash handling and disposal.
Prepare for Emergencies
prepared a fire starts.
Keep a first aid kit and fire extinguisher handy
Keep emergency numbers for ambulance and fire department near your
Clean Debris from Machine
Keep engine radiator , hydraulic exhaust fuel and station clean and free
Clean any oil spills fuel spills machine
T emperature engine compartment could immediately after engine stopped. GUARD FOR FIRES DURING THIS
Open access door(s) cool the engine faster , and clean engine
Add Cab Guarding for Special Uses
Special work situations machine attachments could create environment with falling flying W orking near overhead demolition using a hydraulic hammer working in a forestry application wooded area, working a waste management for could require added guarding protect the operator
Use Steps and Handholds Correctly
Prevent falls facing the machine when you get and Maintain 3 - point contact with steps and Never use machine controls
Use extra care when snow , moisture present slippery Keep steps clean and free grease Never jump when exiting Never mount dismount a moving
Additional level FOPS (falling object protective forestry protection and special screens guarding should installed when falling flying objects could enter damage the A rear screen should always used with a winch protect against a snapping Before operating any special work follow the operator protection recommendations the manufacturer any specialized attachment equipment. Contact your authorized John Deere dealer for information protective guarding.
Start Only From Seat
A void unexpected machine Start engine only while sitting Ensure that all controls and working tools are in proper position for a parked
Never attempt start engine from the ground. not attempt start engine shorting across the starter solenoid
Use and Maintain Seat Belt
Use seat belt when operating machine Remember fasten seat belt when loading and unloading from trucks and during other
Examine seat belt frequently sure that webbing is not cut Replace seat belt immediately if any part is damaged does not function properly
The complete seat belt assembly should replaced every three years, regardless appearance.
Prevent Unintended Machine Movement
When coworkers are disable
Lower all equipment the ground during work
Lock transmission control in engage park brake and stop engine before allowing anyone approach the
Follow these same precautions before standing leaving the exiting the
A void W orksite Hazards
A void contact with gas lines, buried cables and water Call utility line location services identify all underground utilities before starting
Prepare worksite properly A void operating near structures objects that could fall onto the Clear away debris that could move unexpectedly if run over
A void boom attachment contact with overhead obstacles overhead electrical lines. Never move any part machine load closer than 3 m (10 ft) plus twice the line insulator length overhead
Keep bystanders clear all times. Keep bystanders away from raised and unsupported
A void swinging raising loads over near Use barricades a signal person keep vehicles and pedestrians away Use a signal person moving machine in congested areas where visibility restricted. Always keep signal person view . Coordinate hand signals before starting machine.
Operate only solid footing with strength suf ficient support especially alert working near embankments
A void working under over - hanging embankments stockpiles that could collapse
Reduce machine speed when operating with tool near ground when obstacles may hidden during snow removal clearing high speeds hitting obstacles uneven concrete manholes) can cause a sudden Always wear your seat
Use Special Care When
Loader
Never use the loader lift people. not allow anyone ride the bucket use the bucket a work
Operate carefully with raised loads. Raising the load reduces machine stability , especially side slopes unstable Drive and turn slowly with a raised
Ensure that objects the bucket are secure. not attempt lift carry objects that are too big too long fit inside the bucket unless secured with adequate chain other Keep bystanders away from raised
careful when lifting objects. Never attempt lift objects too heavy for your Assure machine stability and hydraulic capability with a test lift before attempting other Use adequate chain sling and proper rigging techniques attach and stabilize Never lift object above near another
Keep Riders Off Machine
Only allow operator
Riders are subject injury . They may fall from machine, caught between machine struck foreign
Riders may obstruct view impair his ability operate machine safely .
A void Backover Accidents
Before moving machine, sure that all persons are clear machine T urn around and look directly for best visibility Use mirrors assist checking all around machine. Keep windows and mirrors clean, adjusted, and good repair
certain reverse warning alarm working properly
Use a signal person when backing view obstructed when close quarters. Keep signal person view all Use prearranged hand signals
not rely the rear camera and radar object detection systems, equipped, determine personnel are behind the The system has limitations due maintenance environmental and operating
A void Machine T Over
Use seat belt all times.
not jump the machine tips. Y will unlikely jump clear and the machine may crush
Load and unload from trucks trailers carefully sure truck wide enough and a firm level Use loading ramps and attach them properly truck bed.
careful slopes. A void sharp Balance loads weight evenly distributed and load Carry tools and loads close the ground aid visibility and lower center gravity . Use extra care soft, rocky , frozen ground.
Know the capacity the not careful with heavy Using oversize buckets lifting heavy objects reduces machine stability
Ensure solid footing. Use extra care in soft ground conditions that may not uniformly support the especially when raising the not operate close banks open excavations that may cave in and cause machine tip fall.
Operating Slopes
A void side slope travel whenever T ravel and down slope with the heavy end the loader pointed LOADED bucket (and load) pointed EMPTY bucket pointed
Select low gear speed before starting down The grade the slope will limited ground condition and load being
Use service brakes control Sudden brake application with a loaded bucket downhill side could cause machine tip forward.
Operating T raveling Public Roads
Machines that work near vehicle traf fic travel slower than normal highway speeds must have proper lighting and markings assure they are visible other
Install additional beacon slow moving vehicle (SMV) other devices and use required make the machine visible and identify a work Check state and local regulations assure Keep these devices clean and in working
Inspect and Maintain ROPS
A damaged rollover protective structure (ROPS) should not
The protection fered ROPS could impaired ROPS subjected structural is involved overturn any way altered
T o maintain the ROPS:
• Replace missing hardware using correct grade
• Check hardware
• Check isolation mounts for wear; replace them necessary .
• Check ROPS for cracks physical
ROPS was loosened removed for any inspect carefully before operating the machine
Add and Operate Attachments Safely
required
V erify that all connections are secure and attachment responds properly
Always verify compatibility attachments contacting your authorized dealer . Adding unapproved attachments could fect machine stability reliability and could create a hazard for others near the
Carefully read attachment manual and follow all instructions and warnings. area free bystanders and carefully operate attachment learn its characteristics and range
Ensure that a qualified person is involved attachment Add guards machine if operator protection