John Deere 544 G, Gen-A 4WD Loader Operator’s Manual PDF

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John Deere 544 G, Gen-A 4WD Loader Operator’s Manual OMT479847X019 – PDF DOWNLOAD

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John Deere 544 G, Gen-A 4WD Loader Operator’s Manual OMT479847X019 – PDF DOWNLOAD

• P/N: OMT479847X019_82
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Models: 544 G
• Serial: 1BZ544GA_ _LA00001—

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 544 G, Gen-A 4WD Loader Operator’s Manual OMT479847X019 – PDF DOWNLOAD

Contents 31
Safety-Safety and Operator Conveniences 35
Safety and Operator Convenience Features 35
Safety—General Precautions 37
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 37
Recognize Safety Information 39
Follow Safety Instructions 39
Operate Only If Qualified 39
Wear Protective Equipment 40
Protect Against Noise 40
Avoid Unauthorized Machine Modifications 40
Inspect Machine 41
Stay Clear of Moving Parts 41
Avoid High-Pressure Fluids 41
Avoid High-Pressure Oils 42
Work In Ventilated Area 42
Avoid Static Electricity Risk When Refueling 43
High Debris Applications 43
Prevent Fires 44
In Case of Machine Fire 44
Prevent Battery Explosions 45
Handle Chemical Products Safely 45
Handle Starting Fluid Safely 45
Decommissioning — Proper Recycling and Disposal of Fluids and Components 46
Exhaust Filter Ash Handling and Disposal 46
Prepare for Emergencies 46
Clean Debris from Machine 47
Add Cab Guarding for Special Uses 47
Safety—Operating Precautions 48
Use Steps and Handholds Correctly 48
Start Only From Operator’s Seat 48
Use and Maintain Seat Belt 48
Prevent Unintended Machine Movement 49
Avoid Work Site Hazards 50
Keep Riders Off Machine 51
Avoid Backover Accidents 51
Avoid Machine Tip Over and Machine Damage 52
Avoid Power Lines 52
Use Special Care When Operating Loader 53
Operating on Slopes 53
Operating or Traveling On Public Roads 53
Inspect and Maintain ROPS 54
Travel Safely 54
Prevent Acid Burns 54
Add and Operate Attachments Safely 55
Safety—Maintenance Precautions 56
Park and Prepare for Service Safely 56
Service Machines Safely 56
Service Cooling System Safely 57
Service Accumulator Systems Safely 57
Remove Paint Before Welding or Heating 57
Make Welding Repairs Safely 58
Drive Metal Pins Safely 58
Service Tires Safely 59
Use Proper Lifting Equipment 59
Clean Exhaust Filter Safely 60
Safety—Safety Signs and Other Instructions 61
Safety Signs and Other Instructions 61
Operation—Operator’s Station 79
Levers—Two Function Hydraulic Control 79
Levers—Three Function Hydraulic Control 79
Levers—Four Function Hydraulic Control 79
Multi-Function Lever Operation 80
Steering Column Control 80
Pedals 81
Switch Module 1 (SM1) Functions 82
Primary Display Unit (PDU) Functions 85
Right Console 91
Armrest Adjustment 92
Dome Light 92
Air Conditioner and Heater Operation 93
Radio—If Equipped 94
Opening and Securing Side Door 95
Alternative Exit Tool—If Equipped 95
Seat Adjustment 96
Fire Extinguisher Mounting Location—If Equipped 98
Operation—Operating the Machine 99
Before Starting Work 99
Inspect Machine Daily Before Starting 100
Check Instruments Before Starting 101
Security System 102
Battery Disconnect Switch 102
Engine Break-In Period 103
Starting the Engine 104
Cold Start Aid—Block Heater—If Equipped 106
Cold Start Aid—Glow Plug 106
Cold Weather Warm-Up 107
Operator Ability 107
Operating in Water and Mud 107
Required Machine Stop Warning 108
Park Brake Switch 110
Shifting the Transmission 111
Standby Idle 112
Automatic Idle and Automatic Shutdown 113
Driving Up a Steep or Slippery Slope 113
Engine Delayed Shutdown 114
Stopping the Engine 115
Joystick Bucket and Boom Control 116
Two Lever Bucket and Boom Control—If Equipped 118
Auxiliary Control—If Equipped 119
Ride Control—If Equipped 120
Secondary Steering—If Equipped 122
Differential Lock Operation—If Equipped 123
Service ADVISOR™ Remote (SAR) Software Delivery Process 123
Exhaust Filter 124
Selective Catalytic Reduction (SCR) System Overview 126
Qualified Emergency Use — SCR Override Option 127
EU Qualified Emergency Use — SCR Derate Override Option 128
Rear Camera—If Equipped 129
Boom Height Kickout (BHKO) Adjustment 129
Return-to-Carry (RTC) Adjustment 130
Return-to-Dig (RTD) Adjustment 131
Operating Loader Coupler—If Equipped 132
Using the Loader Bucket 133
Backdragging 134
Fork Attachment—If Equipped 135
Parking the Machine 137
Loading Machine for Transport 139
Towing-Recovery Procedure 141
Lifting the Machine 143
Drive Through Mode Operation 144
Lowering Boom—Hydraulic System or Engine Malfunction 144
Operation—Monitor Operation 145
Aftertreatment Indicators Overview 145
Primary Display Unit (PDU) 146
Navigation Buttons 146
Main Menu 147
Main Menu—Display Settings 148
Main Menu—Diagnostics 149
Main Menu—Exhaust Filter 150
Main Menu—Exhaust Filter Auto Cleaning 151
Main Menu—Exhaust Filter Parked Cleaning 152
Main Menu—Exhaust Filter Emergency Override 153
Main Menu—Software Update 153
Main Menu—Calibrations 154
Main Menu—Calibrations—Transmission Clutches 154
Main Menu—Calibrations—Brake Pedal 155
Main Menu—Calibrations—Park Brake Test 155
Main Menu—Machine Setup 156
Main Menu—Security 158
Main Menu—Machine Fan 160
Main Menu—Fuel Consumption 161
Main Menu—About 162
Main Menu—Job Timer 162
Main Menu—Camera—If Equipped 163
Maintenance—Machine 164
Required Emission-Related Information 164
Diesel Fuel 164
Diesel Fuel Specifications 165
Lubricity of Diesel Fuel 165
Handling and Storing Diesel Fuel 165
Biodiesel Fuel 166
Testing Diesel Fuel 167
Supplemental Diesel Fuel Additives 167
Fuel Filters 167
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 168
Refilling Diesel Exhaust Fluid (DEF) Tank 169
Testing Diesel Exhaust Fluid (DEF) 170
Storing Diesel Exhaust Fluid (DEF) 170
Disposal of Diesel Exhaust Fluid (DEF) 171
Minimizing the Effect of Cold Weather on Diesel Engines 172
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 173
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 174
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 175
Diesel Engine Oil Service Interval for Operation at High Altitude 175
Oil Filters 176
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 177
Water Quality for Mixing with Coolant Concentrate 178
Operating in Warm Temperature Climates 178
Testing Coolant Freeze Point 179
Disposing of Coolant 179
Alternative and Synthetic Lubricants 180
Lubricant Storage 180
Mixing of Lubricants 180
Hydraulic Oil 181
Transmission, Park Brake, and Axle Oil 181
Grease with Molybdenum Disulfide 182
Maintenance—Periodic Maintenance 183
Service Machine at Specified Intervals 183
Check the Hour Meter Regularly 183
Prepare Machine for Maintenance 184
Frame Locking Bar 185
Locking Loader Boom 185
Engine Service Doors and Side Shields 186
Cooling System Doors 186
Fuel Tank 187
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 188
Maintenance Legend 189
Service Intervals 190
Required Parts 192
Maintenance—As Required 194
Inspect Tires and Check Pressure 194
Tire Pressures 195
Check Wheel Bolt Torque 196
Inspect or Replace Cab Fresh Air Filter 196
Inspect or Replace Cab Recirculation Air Filter 197
Drain Water From Primary Fuel Filter With Water Separator 197
Drain Water From Auxiliary Fuel Filter With Water Separator—If Equipped 198
Inspect or Replace Air Conditioner Compressor and Serpentine Belt 199
Check Rear Camera—If Equipped 200
Clean Hydraulic Pump Case Drain In-Line Screen 201
Clean Cooler Cores 204
Inspect Engine Air Cleaner Elements 205
Check Windshield Washer Fluid Level 206
Service Exhaust Filter—L Engine 206
Drain, Flush, and Refill Fuel Tank 207
Clean Fuel Tank Fill Neck Strainer 207
Clean Debris From Coupler Lock Cylinder—If Equipped 208
Clean and Tighten Battery Terminals 209
Clean or Replace Diesel Exhaust Fluid (DEF) Tank Fill Screen—L Engine 210
Maintenance—Every 10 Hours or Daily 212
Clean Air Cleaner Dust Unloader Valve 212
Check Coolant Level at Surge Tank 213
Check Engine Oil Level 214
Check Hydraulic System Oil Level 214
Check Transmission Oil Level 215
Maintenance—Every 100 Hours 217
Lubricate Loader Linkage and Cylinder Pivots 217
Lubricate Coupler Lock Pins—If Equipped 218
Maintenance—Initial Service 250 Hours 219
Drain and Refill Front and Rear Axle Oil 219
Maintenance—Every 250 Hours 220
Take Engine Oil Sample 220
Maintenance—Every 500 Hours 221
Drain and Refill Engine Oil and Replace Filter 221
Replace Primary Fuel Filter 222
Replace Final Fuel Filter 223
Check Park Brake Oil Level 223
Lubricate Front and Rear Shaft Seals on Park Brake 224
Lubricate Front and Rear Axle Shaft Seals 224
Take Fluid Samples 224
Replace Hydraulic Reservoir Breather Filter 225
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 225
Check Front and Rear Axle Oil Level 226
Lubricate Driveline Upper and Lower Sliding Joints 227
Check Ride Control Accumulator—If Equipped 228
Maintenance—Every 1000 Hours 229
Replace Air Cleaner Dust Unloader Valve 229
Replace Engine Air Cleaner Elements 230
Check Coolant Condition 231
Lubricate Frame Hinge Pivots 231
Replace Fuel Tank Breather Filter 232
Drain and Refill Park Brake Oil 232
Maintenance—Every 2000 Hours 233
Drain and Refill Transmission Oil and Replace Filter 233
Drain and Refill Front and Rear Axle Oil 234
Check and Adjust Engine Valve Lash 234
Rerun Transmission Clutch Calibration 235
Replace Open Crankcase Ventilation (OCV) Filter—L Engine 235
Maintenance—Every 4000 Hours 236
Drain, Flush, and Refill Hydraulic System Oil 236
Replace Hydraulic System Return Filter 238
Clean Hydraulic System Fill Strainer 239
Replace Diesel Exhaust Fluid (DEF) Tank Breather Filter—L Engine 239
Clean Diesel Exhaust Fluid (DEF) Tank—L Engine 239
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter—L Engine 240
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter—L Engine 241
Maintenance—Every 5000 Hours 242
Check Driveline Damper for Cracks 242
Maintenance—Every 6000 Hours 243
Drain Cooling System 243
Refill Cooling System and Deaeration Procedure 244
Replace Diesel Exhaust Fluid (DEF) In-Line Filter 245
Miscellaneous—Machine 246
Check Air Inlet Cover 246
Bleed Fuel System 246
Do Not Service or Adjust Injection Nozzles or High-Pressure Fuel Pump 246
Do Not Service Control Valves, Cylinders, Pumps, or Motors 246
Clean Machine Regularly 247
Precautions for Alternator and Regulator 247
Handling, Checking, and Servicing Batteries Carefully 248
Using Battery Charger 249
Using Booster Batteries—24-Volt System 250
Replacing Batteries 251
Welding On Machine 252
Keep Electronic Control Unit Connectors Clean 252
JDLink™ Machine Monitoring System (MMS)—If Equipped 252
Replacing Fuses 253
Remove and Install Halogen Bulbs 257
Keep ROPS Installed Properly 258
External Service Brake Inspection 259
Inspect Seat Belt 260
Replacing Seat Belt 261
Replacing Bucket Teeth, Tooth Shanks, and Cutting Edges—If Equipped 262
Replacing Cutting Edges—If Equipped 263
Air Conditioning System Service 264
Fluid Sampling Test Ports—If Equipped 264
Hardware Torque Specifications 264
Unified Inch Bolt and Screw Torque Values 265
Metric Bolt and Screw Torque Values 266
Miscellaneous—Operational Checkout 267
Operational Checkout 267
Diagnostic Trouble Code (DTC) Check 267
Operational Checks—Ignition OFF, Engine OFF Checks 267
Operational Checks—Ignition ON, Engine OFF Checks 268
Operational Checks—Ignition On, Engine On Checks 277
Miscellaneous—Troubleshooting 297
Troubleshooting Procedure 297
Software Update 297
Engine 298
Transmission 302
Differential and Axle 304
Service Brake 305
Driveline 306
Park Brake 306
Hydraulic System 307
Steering 310
Air Conditioning System 311
Heater System 313
Miscellaneous—Storage 314
Prepare Machine for Storage 314
Monthly Storage Procedure 315
Preparing Engine for Long-Term Storage 316
Preparing Machine after Storage 317
Miscellaneous—Machine Numbers 318
Record Product Identification Number (PIN) 318
Record Engine Serial Number 318
Record Transmission Serial Number 318
Record Hydraulic Pump Serial Number 319
Record Front and Rear Axle Housing Serial Numbers 319
Keep Proof of Ownership 319
Keep Machines Secure 320
Miscellaneous—Specifications 321
Engine Specifications 321
Drain and Refill Capacities 321
Standard Z-Bar Specifications 322
Travel Speeds 323
Eurasian Economic Union 324
Machine Design Life 324
Page Number 31
Section 1-1 35
Section 1-2 37
Section 1-3 48
Section 1-4 56
Section 1-5 61
Section 2-1 79
Section 2-2 99
Section 2-3 145
Section 3-1 164
Section 3-2 183
Section 3-3 194
Section 3-4 212
Section 3-5 217
Section 3-6 219
Section 3-7 220
Section 3-8 221
Section 3-9 229
Section 3-10 233
Section 3-11 236
Section 3-12 242
Section 3-13 243
Section 4-1 246
Section 4-2 267
Section 4-3 297
Section 4-4 314
Section 4-5 318
Section 4-6 321

S.V 04/24