John Deere 544 G 4WD Loader Operator’s Manual OMT468695X019 PDF

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John Deere 544 G 4WD Loader Operator’s Manual OMT468695X019 – PDF DOWNLOAD

FILE DETAILS:

John Deere 544 G 4WD Loader Operator’s Manual OMT468695X019 – PDF DOWNLOAD

• P/N: OMT468695X019_53
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Models: 544 G
• Serial Ranges:
  • 1YN544GA_LA00001—
  • 1YN544GA_DA00001—

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 544 G 4WD Loader Operator’s Manual OMT468695X019 – PDF DOWNLOAD

Contents 29
Safety-Safety and Operator Conveniences 33
Safety and Operator Convenience Features 33
Safety—General Precautions 35
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 35
Recognize Safety Information 37
Follow Safety Instructions 37
Operate Only If Qualified 37
Wear Protective Equipment 38
Protect Against Noise 38
Avoid Unauthorized Machine Modifications 38
Inspect Machine 39
Stay Clear of Moving Parts 39
Avoid High-Pressure Fluids 39
Avoid High-Pressure Oils 40
Work In Ventilated Area 40
Avoid Static Electricity Risk When Refueling 41
High Debris Applications 41
Prevent Fires, Clean Debris From Machine 42
In Case of Machine Fire 42
Prevent Battery Explosions 43
Handle Chemical Products Safely 43
Handle Starting Fluid Safely 43
Decommissioning — Proper Recycling and Disposal of Fluids and Components 44
Exhaust Filter Ash Handling and Disposal 44
Prepare for Emergencies 44
Clean Debris from Machine 45
Add Cab Guarding for Special Uses 45
Safety—Operating Precautions 46
Use Steps and Handholds Correctly 46
Start Only From Operator’s Seat 46
Use and Maintain Seat Belt 46
Prevent Unintended Machine Movement 47
Avoid Work Site Hazards 48
Keep Riders Off Machine 49
Avoid Backover Accidents 49
Avoid Machine Tip Over and Machine Damage 50
Avoid Power Lines 50
Use Special Care When Operating Loader 51
Operating on Slopes 51
Operating or Traveling On Public Roads 51
Inspect and Maintain ROPS 52
Travel Safely 52
Prevent Acid Burns 52
Add and Operate Attachments Safely 53
Safety—Maintenance Precautions 54
Park and Prepare for Service Safely 54
Service Machines Safely 54
Service Cooling System Safely 55
Service Accumulator Systems Safely 55
Remove Paint Before Welding or Heating 55
Make Welding Repairs Safely 56
Drive Metal Pins Safely 56
Service Tires Safely 57
Use Proper Lifting Equipment 57
Clean Exhaust Filter Safely 58
Safety—Safety Signs and Other Instructions 59
Safety Signs and Other Instructions 59
Operation—Operator’s Station 77
Using the Seat Belt 77
Levers—Two Function Hydraulic Control 77
Levers—Three Function Hydraulic Control 77
Levers—Four Function Hydraulic Control 78
Multi-Function Lever Operation 78
Steering Column Control 79
Pedals 79
Switch Module 1 (SM1) Functions 80
Primary Display Unit (PDU) Functions 83
Right Console 89
Armrest Adjustment 90
Dome Light 90
Air Conditioner and Heater Operation 91
Radio—If Equipped 92
Opening and Securing Side Door 93
Alternative Exit Tool—If Equipped 93
Opening Side Window (Alternative Exit)—If Equipped 94
Seat Adjustment 95
Fire Extinguisher Mounting Location—If Equipped 97
Operation—Operating the Machine 98
Before Starting Work 98
Inspect Machine Daily Before Starting 99
Check Instruments Before Starting 100
Security System 101
Battery Disconnect Switch 101
Engine Break-In Period 102
Starting the Engine 103
Cold Start Aid—Block Heater—If Equipped 105
Cold Start Aid—Glow Plug 106
Cold Weather Warm-Up 106
Operator Ability 107
Operating in Water and Mud 107
Required Machine Stop Warning 107
Park Brake Switch 109
Shifting the Transmission 110
Standby Idle 111
Automatic Idle and Automatic Shutdown 112
Driving Up a Steep or Slippery Slope 112
Engine Delayed Shutdown 113
Stopping the Engine 114
Joystick Bucket and Boom Control 115
Two Lever Bucket and Boom Control—If Equipped 117
Auxiliary Control—If Equipped 118
Ride Control—If Equipped 119
Secondary Steering—If Equipped 121
Differential Lock Operation—If Equipped 121
Service ADVISOR™ Remote (SAR) Software Delivery Process 122
Exhaust Filter 123
Selective Catalytic Reduction (SCR) System Overview 125
Qualified Emergency Use — SCR Override Option 126
EU Qualified Emergency Use — SCR Derate Override Option 127
Rear Camera—If Equipped 128
Boom Height Kickout (BHKO) Adjustment 128
Return-to-Carry (RTC) Adjustment 129
Return-to-Dig (RTD) Adjustment 130
Operating Loader Coupler—If Equipped 131
Using the Loader Bucket 132
Backdragging 133
Fork Attachment—If Equipped 134
Parking the Machine 136
Loading Machine for Transport 138
Towing-Recovery Procedure 140
Lifting the Machine 142
Drive Through Mode Operation 143
Lowering Boom—Hydraulic System or Engine Malfunction 143
Operation—Monitor Operation 144
Aftertreatment Indicators Overview 144
Primary Display Unit (PDU) 145
Navigation Buttons 145
Main Menu 146
Main Menu—Display Settings 147
Main Menu—Diagnostics 148
Main Menu—Exhaust Filter 149
Main Menu—Exhaust Filter Auto Cleaning 150
Main Menu—Exhaust Filter Parked Cleaning 151
Main Menu—Exhaust Filter Emergency Override 152
Main Menu—Software Update 152
Main Menu—Calibrations 153
Main Menu—Calibrations—Transmission Clutches 153
Main Menu—Calibrations—Brake Pedal 154
Main Menu—Calibrations—Park Brake Test 154
Main Menu—Machine Setup 155
Main Menu—Security 157
Main Menu—Machine Fan 159
Main Menu—Fuel Consumption 160
Main Menu—About 161
Main Menu—Job Timer 161
Main Menu—Camera—If Equipped 162
Maintenance—Machine 163
Required Emission-Related Information 163
Diesel Fuel 163
Diesel Fuel Specifications 164
Lubricity of Diesel Fuel 164
Handling and Storing Diesel Fuel 164
Biodiesel Fuel 165
Testing Diesel Fuel 166
Supplemental Diesel Fuel Additives 166
Fuel Filters 166
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 167
Refilling Diesel Exhaust Fluid (DEF) Tank 168
Testing Diesel Exhaust Fluid (DEF) 169
Storing Diesel Exhaust Fluid (DEF) 169
Disposal of Diesel Exhaust Fluid (DEF) 170
Minimizing the Effect of Cold Weather on Diesel Engines 171
Diesel Engine Break-In™ Oil 172
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 172
Diesel Engine Oil — Tier 2 and Stage II 173
Engine Oil and Filter Service Intervals — Tier 2 and Stage II Engines 174
Diesel Engine Oil — Tier 3 and Stage IIIA 175
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA Engines 176
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 177
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 178
Diesel Engine Oil Service Interval for Operation at High Altitude 178
Oil Filters 179
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 180
Water Quality for Mixing with Coolant Concentrate 181
Operating in Warm Temperature Climates 181
Testing Coolant Freeze Point 182
Disposing of Coolant 182
Alternative and Synthetic Lubricants 183
Lubricant Storage 183
Mixing of Lubricants 183
Hydraulic Oil 184
Transmission, Park Brake, and Axle Oil 184
Grease with Molybdenum Disulfide 185
Maintenance—Periodic Maintenance 186
Service Machine at Specified Intervals 186
Check the Hour Meter Regularly 186
Prepare Machine for Maintenance 187
Frame Locking Bar 188
Locking Loader Boom 188
Engine Service Doors and Side Shields 189
Cooling System Doors 189
Fuel Tank 190
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 191
Maintenance Legend 192
Service Intervals 193
Required Parts 196
Maintenance—As Required 199
Inspect Tires and Check Pressure 199
Tire Pressures 200
Check Wheel Bolt Torque 201
Inspect or Replace Cab Fresh Air Filter 201
Inspect or Replace Cab Recirculation Air Filter 202
Drain Water From Primary Fuel Filter With Water Separator 202
Drain Water From Final Fuel Filter—D Engine 203
Drain Water From Auxiliary Fuel Filter With Water Separator—If Equipped 203
Inspect or Replace Air Conditioner Compressor and Alternator Belt 204
Check Rear Camera—If Equipped 205
Clean Hydraulic Pump Case Drain In-Line Screen 206
Clean Cooler Cores 209
Inspect Engine Air Cleaner Elements 210
Check Windshield Washer Fluid Level 211
Service Exhaust Filter—L Engine 211
Drain, Flush, and Refill Fuel Tank 212
Clean Fuel Tank Fill Neck Strainer 212
Clean Debris From Coupler Lock Cylinder—If Equipped 213
Clean and Tighten Battery Terminals 214
Clean or Replace Diesel Exhaust Fluid (DEF) Tank Fill Screen—L Engine 215
Maintenance—Every 10 Hours or Daily 217
Clean Air Cleaner Dust Unloader Valve 217
Check Coolant Level at Surge Tank 218
Check Engine Oil Level 219
Check Hydraulic System Oil Level 220
Check Transmission Oil Level 221
Maintenance—Every 100 Hours 223
Lubricate Loader Linkage and Cylinder Pivots 223
Lubricate Coupler Lock Pins—If Equipped 224
Maintenance—Initial Service 250 Hours 225
Drain and Refill Front and Rear Axle Oil 225
Maintenance—Every 250 Hours 226
Take Engine Oil Sample 226
Maintenance—Every 500 Hours 227
Drain and Refill Engine Oil and Replace Filter 227
Replace Auxiliary Fuel Filter—If Equipped 228
Replace Primary Fuel Filter 229
Replace Final Fuel Filter 230
Check Park Brake Oil Level 231
Lubricate Front and Rear Shaft Seals on Park Brake 231
Lubricate Front and Rear Axle Shaft Seals 232
Take Fluid Samples 232
Replace Hydraulic Reservoir Breather Filter 233
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 233
Check Front and Rear Axle Oil Level 235
Lubricate Driveline Upper and Lower Sliding Joints 236
Check Ride Control Accumulator—If Equipped 237
Maintenance—Every 1000 Hours 238
Replace Air Cleaner Dust Unloader Valve 238
Replace Engine Air Cleaner Elements 239
Check Coolant Condition 240
Clean Engine Crankcase Vent Tube—D Engine 240
Lubricate Frame Hinge Pivots 241
Replace Fuel Tank Breather Filter 241
Drain and Refill Park Brake Oil 242
Maintenance—Every 2000 Hours 243
Drain and Refill Transmission Oil and Replace Filter 243
Drain and Refill Front and Rear Axle Oil 244
Check and Adjust Engine Valve Lash 244
Rerun Transmission Clutch Calibration 245
Replace Open Crankcase Ventilation (OCV) Filter—L Engine 245
Maintenance—Every 4000 Hours 246
Drain, Flush, and Refill Hydraulic System Oil 246
Replace Engine Crankshaft Damper—D Engine 247
Replace Hydraulic System Return Filter 248
Clean Hydraulic System Fill Strainer 249
Replace Diesel Exhaust Fluid (DEF) Tank Breather Filter—L Engine 249
Clean Diesel Exhaust Fluid (DEF) Tank—L Engine 249
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter—L Engine 250
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter—L Engine 251
Maintenance—Every 5000 Hours 252
Check Driveline Damper for Cracks 252
Maintenance—Every 6000 Hours 253
Drain Cooling System 253
Refill Cooling System and Deaeration Procedure 254
Replace Diesel Exhaust Fluid (DEF) In-Line Filter—L Engine 255
Miscellaneous—Machine 256
Check Air Inlet Cover 256
Bleed Fuel System 256
Do Not Service or Adjust Injection Nozzles or High-Pressure Fuel Pump 256
Do Not Service Control Valves, Cylinders, Pumps, or Motors 256
Clean Machine Regularly 257
Precautions for Alternator and Regulator 257
Handling, Checking, and Servicing Batteries Carefully 258
Using Battery Charger 259
Using Booster Batteries—24-Volt System 260
Replacing Batteries 261
Welding On Machine 262
Keep Electronic Control Unit Connectors Clean 262
JDLink™ Machine Monitoring System (MMS)—If Equipped 262
Replacing Fuses 263
Remove and Install Halogen Bulbs 269
Keep ROPS Installed Properly 270
External Service Brake Inspection 271
Inspect Seat Belt 272
Replacing Seat Belt 273
Replacing Bucket Teeth, Tooth Shanks, and Cutting Edges—If Equipped 274
Replacing Cutting Edges—If Equipped 275
Air Conditioning System Service 276
Fluid Sampling Test Ports—If Equipped 276
Hardware Torque Specifications 276
Unified Inch Bolt and Screw Torque Values 277
Metric Bolt and Screw Torque Values 278
Miscellaneous—Operational Checkout 279
Operational Checkout 279
Diagnostic Trouble Code (DTC) Check 279
Operational Checks—Ignition OFF, Engine OFF Checks 279
Operational Checks—Ignition ON, Engine OFF Checks 280
Operational Checks—Ignition On, Engine On Checks 289
Miscellaneous—Troubleshooting 309
Troubleshooting Procedure 309
Software Update 309
Engine 310
Transmission 314
Differential and Axle 316
Service Brake 317
Driveline 318
Park Brake 318
Hydraulic System 319
Steering 322
Air Conditioning System 323
Heater System 325
Miscellaneous—Storage 326
Prepare Machine for Storage 326
Monthly Storage Procedure 327
Preparing Engine for Long-Term Storage 328
Preparing Machine after Storage 329
Miscellaneous—Machine Numbers 330
Record Product Identification Number (PIN) 330
Record Engine Serial Number 330
Record Transmission Serial Number 331
Record Hydraulic Pump Serial Number 331
Record Front and Rear Axle Housing Serial Numbers 332
Keep Proof of Ownership 332
Keep Machines Secure 332
Miscellaneous—Specifications 333
Engine Specifications 333
Drain and Refill Capacities 334
Standard Z-Bar Specifications 335
High Lift Z-Bar Specifications 337
Travel Speeds 339
Eurasian Economic Union 339
Machine Design Life 339
Page Number 29
Section 1-1 33
Section 1-2 35
Section 1-3 46
Section 1-4 54
Section 1-5 59
Section 2-1 77
Section 2-2 98
Section 2-3 144
Section 3-1 163
Section 3-2 186
Section 3-3 199
Section 3-4 217
Section 3-5 223
Section 3-6 225
Section 3-7 226
Section 3-8 227
Section 3-9 238
Section 3-10 243
Section 3-11 246
Section 3-12 252
Section 3-13 253
Section 4-1 256
Section 4-2 279
Section 4-3 309
Section 4-4 326
Section 4-5 330
Section 4-6 333

S.V 04/24