John Deere 544 P 4WD Loader Operator’s Manual OMT453606X019 PDF

Description

John Deere 544 P 4WD Loader Operator’s Manual OMT453606X019 – PDF DOWNLOAD

• Part Number (P/N): OMT453606X019_04
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Model: 544 P
• Serial Number Range: 1DW544PA_ _L_10283—18489

TABLE OF CONTENTS:

John Deere 544 P 4WD Loader Operator’s Manual OMT453606X019 – PDF DOWNLOAD

Contents 29
Safety—Safety and Operator Conveniences 33
Safety and Operator Convenience Features 33
Safety—General Precautions 34
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 34
Recognize Safety Information 35
Follow Safety Instructions 36
Operate Only If Qualified 36
Wear Protective Equipment 36
Protect Against Noise 37
Avoid Unauthorized Machine Modifications 37
Inspect Machine 37
Stay Clear of Moving Parts 37
Avoid High-Pressure Fluids 38
Avoid High-Pressure Oils 38
Work In Ventilated Area 38
Avoid Static Electricity Risk When Refueling 39
Prevent Fires, Clean Debris From Machine 40
In Case of Machine Fire 40
Prevent Battery Explosions 41
High Debris Applications 41
Clean Debris from Machine 41
Handle Chemical Products Safely 42
Handle Starting Fluid Safely 42
Decommissioning — Proper Recycling and Disposal of Fluids and Components 43
Prepare for Emergencies 43
Exhaust Filter Ash Handling and Disposal 43
Add Cab Guarding for Special Uses 44
Safety—Operating Precautions 45
Use Steps and Handholds Correctly 45
Start Only From Operator’s Seat 45
Use and Maintain Seat Belt 45
Heated and Ventilated Operator’s Seat 46
Prevent Unintended Machine Movement 46
Avoid Work Site Hazards 47
Keep Riders Off Machine 48
Avoid Backover Accidents 48
Avoid Machine Tip Over and Machine Damage 49
Use Special Care When Operating Loader 50
Avoid Power Lines 50
Operating on Slopes 50
Operating or Traveling On Public Roads 51
Inspect and Maintain ROPS 51
Travel Safely 51
Prevent Acid Burns 52
Add and Operate Attachments Safely 52
Safety—Maintenance Precautions 53
Park and Prepare for Service Safely 53
Service Machines Safely 53
Service Accumulator Systems Safely 54
Service Cooling System Safely 54
Remove Paint Before Welding or Heating 54
Make Welding Repairs Safely 55
Drive Metal Pins Safely 55
Service Tires Safely 56
Use Proper Lifting Equipment 56
Clean Exhaust Filter Safely 57
Safety—Safety Signs and Other Instructions 58
Safety Signs and Other Instructions 58
Operation—Operator’s Station 68
Levers—Two Function Hydraulic Control 68
Levers—Three Function Hydraulic Control 69
Levers—Four Function Hydraulic Control 70
Levers—Five or Six Function Hydraulic Control 70
Pedals 71
Sealed Switch Module (SSM) Functions 72
Primary Display Unit (PDU) Functions 77
Horn Button 85
Turn Signals 85
Power Adjustable Mirrors—If Equipped 86
Dome Light 86
Air Conditioner and Heater Operation 87
Counter Switch—If Equipped 88
Radio—If Equipped 89
Auxiliary Power Supply 93
Opening and Securing Side Door 94
Opening Side Window (Alternative Exit) 95
Using the Seat Belt 95
Seat Adjustment 96
Fire Extinguisher Mounting Location 98
Operation—Operating the Machine 99
Before Starting Work 99
Operator Ability 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
Required Machine Stop Warning 107
Park Brake Switch 109
Shifting the Transmission 110
Operating in Water and Mud 111
Driving Up a Steep or Slippery Slope 111
Automatic Idle and Automatic Shutdown 112
Turbocharger Cool Down 112
Stopping the Engine 113
Joystick Bucket and Boom Control 114
Two Lever Bucket and Boom Control 116
Auxiliary Control 117
Ride Control—If Equipped 118
Secondary Steering—If Equipped 120
Differential Lock Operation 121
Throttle Lock—If Equipped 123
Service ADVISOR™ Remote (SAR) Software Delivery Process 124
Exhaust Filter 125
Selective Catalytic Reduction (SCR) System Overview 127
US EPA Qualified Emergency Use — SCR Derate Override Option 129
EU Qualified Emergency Use — SCR Derate Override Option 130
Rear Camera and Radar Object Detection (ROD) System—If Equipped 131
Counter Switch Operation—If Equipped 134
Embedded Payload Scale—If Equipped 135
Boom Height Kickout Adjustment 139
Return-to-Carry Adjustment 139
Return-to-Dig Adjustment 140
Operating Loader Coupler—If Equipped 140
Using the Loader Bucket 141
Backdragging 142
Fork Attachment 143
Parking the Machine 145
Loading Machine for Transport 147
Towing—Recovery Procedure 150
Lifting the Machine 152
Operation—Monitor Operation 153
Aftertreatment Indicators Overview 153
Primary Display Unit (PDU) 154
Main Menu 155
Main Menu—Display Settings 156
Main Menu—Diagnostics 157
Main Menu—Exhaust Filter 159
Main Menu—Exhaust Filter Auto Cleaning 160
Main Menu—Exhaust Filter Parked Cleaning 161
Main Menu—Exhaust Filter Emergency Override 162
Main Menu—Software Update 162
Main Menu—Calibrations—Electro-Hydraulic Valves 163
Main Menu—Calibrations—Implement Control Levers 164
Main Menu—Calibrations—Loader Position Sensors 165
Main Menu—Calibrations—Loader Linkage 165
Main Menu—Calibrations—Transmission Clutches 166
Main Menu—Calibrations—Brake Pedal 167
Main Menu—Machine Setup 168
Main Menu—Security 173
Main Menu—Machine Fan 175
Main Menu—Fuel Consumption 176
Main Menu—About 177
Main Menu—Job Timer 177
Main Menu—Camera—If Equipped 178
Main Menu—Payload Weighing—If Equipped 179
Main Menu—Attachments—If Equipped 180
Maintenance—Machine 181
Required Emission-Related Information 181
Alternative and Synthetic Lubricants 181
Lubricant Storage 181
Mixing of Lubricants 181
Hydraulic Oil 182
Diesel Fuel 183
Diesel Fuel Specifications 183
Lubricity of Diesel Fuel 184
Handling and Storing Diesel Fuel 184
Biodiesel Fuel 185
Testing Diesel Fuel 186
Supplemental Diesel Fuel Additives 186
Fuel Filters 186
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 187
Refilling Diesel Exhaust Fluid (DEF) Tank 188
Testing Diesel Exhaust Fluid (DEF) 189
Storing Diesel Exhaust Fluid (DEF) 189
Disposal of Diesel Exhaust Fluid (DEF) 190
Minimizing the Effect of Cold Weather on Diesel Engines 191
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 192
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 193
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 194
Diesel Engine Oil Service Interval for Operation at High Altitude 194
Oil Filters 195
Transmission, Park Brake, and Axle Oil 195
Grease with Molybdenum Disulfide 196
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 197
Water Quality for Mixing with Coolant Concentrate 198
Operating in Warm Temperature Climates 198
Testing Coolant Freeze Point 199
Disposing of Coolant 199
Maintenance—Periodic Maintenance 200
Service Machine at Specified Intervals 200
Check the Hour Meter Regularly 200
Prepare Machine for Maintenance 201
Frame Locking Bar 202
Locking Loader Boom 203
Engine Service Doors and Side Shields 204
Cooling System Doors 205
Fuel Tank 206
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 206
Service Intervals 207
Required Parts 209
Maintenance—As Required 211
Check Windshield Washer Fluid Level 211
Inspect Tires and Check Pressure 212
Tire Pressures 213
Check and Clean Cab Air Precleaner Housing—If Equipped 216
Check and Clean Heating and Air Conditioner Housing 217
Check Wheel Bolt Torque 217
Inspect Engine Air Cleaner Elements 218
Inspect Serpentine Belt 219
Clean Cooler Cores 220
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 222
Drain Water From Primary Fuel Filter With Water Separator 223
Service Exhaust Filter 223
Drain, Flush, and Refill Fuel Tank 224
Check Cab Recirculation Air Filter 225
Check Cab Fresh Air Filter 226
Clean Hydraulic Pump Case Drain In-Line Screen 227
Clean Debris From Coupler Lock Cylinder—If Equipped 229
Lubricate Cab Door Hinges 231
Clean and Tighten Battery Terminals 231
Maintenance—Every 10 Hours or Daily 232
Clean Air Cleaner Dust Unloader Valve 232
Check Coolant Level at Surge Tank 233
Check Engine Oil Level 234
Check Hydraulic System Oil Level 234
Check Transmission Oil Level 235
Maintenance—Every 100 Hours 236
Lubricate Loader Linkage and Cylinder Pivots 236
Lubricate Coupler Lock Pins—If Equipped 240
Maintenance—Initial Service—250 Hours 241
Drain and Refill Front and Rear Axle Oil 241
Replace Axle Oil Filters—If Equipped 242
Maintenance—Every 250 Hours 243
Take Engine Oil Sample 243
Maintenance—Every 500 Hours 244
Lubricate Driveline Upper and Lower Sliding Joints 244
Lubricate Front and Rear Axle Shaft Seals 245
Check Hybrid Battery Electrolyte Level—If Equipped 246
Replace Hydraulic Reservoir Breather Filter 248
Check Front and Rear Axle Oil Level 249
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 250
Take Fluid Samples 250
Drain and Refill Engine Oil and Replace Filter 251
Replace Primary Fuel Filter 252
Replace In-Line Fuel Filter 252
Replace Final Fuel Filter 253
Check Park Brake Oil Level 253
Lubricate Front and Rear Shaft Seals on Park Brake 254
Check Ride Control Accumulator—If Equipped 255
Maintenance—Every 1000 Hours 256
Replace Air Cleaner Dust Unloader Valve 256
Replace Engine Air Cleaner Elements 257
Replace Fuel Tank Breather Filter 257
Check Coolant Condition 258
Replace Axle Oil Filters—If Equipped 258
Lubricate Frame Hinge Pivots 259
Drain and Refill Park Brake Oil 259
Maintenance—Every 2000 Hours 260
Drain and Refill Front and Rear Axle Oil 260
Replace Open Crankcase Ventilation (OCV) Filter 261
Check and Adjust Engine Valve Lash 261
Drain and Refill Transmission Oil and Replace Filter 262
Rerun Transmission Clutch Calibration 263
Maintenance—Every 4000 Hours 264
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter 264
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter 265
Replace Diesel Exhaust Fluid (DEF) Tank Breather Filter 266
Replace Hydraulic System Return Filter 267
Drain, Flush, and Refill Hydraulic System Oil 268
Clean Hydraulic System Fill Strainer 270
Maintenance—Every 5000 Hours 271
Check Driveline Damper for Cracks 271
Maintenance—Every 6000 Hours 272
Drain Cooling System 272
Cooling System Fill and Deaeration Procedure 273
Replace Diesel Exhaust Fluid (DEF) In-Line Filter 274
Miscellaneous—Machine 275
Check Air Inlet Cover—If Equipped 275
Bleed Fuel System 275
Do Not Service or Adjust Injection Nozzles or High-Pressure Fuel Pump 275
Do Not Service Control Valves, Cylinders, Pumps, or Motors 275
Precautions for Alternator and Regulator 276
Clean Machine Regularly 276
Handling, Checking, and Servicing Batteries Carefully 277
Using Battery Charger 278
Using Booster Batteries—24-Volt System 280
Replacing Batteries 281
Welding On Machine 282
Keep Electronic Control Unit Connectors Clean 282
JDLink Machine Monitoring System (MMS)—If Equipped 282
Replacing Fuses 283
Remove and Install Halogen Bulbs 287
Remove and Install Light-Emitting Diode (LED) Lights 288
Fluid Sampling Test Ports—If Equipped 289
Service Recommendations for Snap-To-Connect® (STC) Fittings 290
Keep ROPS Installed Properly 291
Verified Anchor Point Information 291
External Service Brake Inspection 292
Inspect Seat Belt 293
Replacing Seat Belt 294
Replacing Bucket Teeth—TK Series 295
Servicing Air Conditioning System 295
Hardware Torque Specifications 295
Unified Inch Bolt and Screw Torque Values 296
Metric Bolt and Screw Torque Values 297
Miscellaneous—Operational Checkout 298
Operational Checkout 298
Diagnostic Trouble Code (DTC) Check 298
Operational Checks—Ignition Off, Engine Off Checks 298
Operational Checks—Ignition On, Engine Off Checks 299
Operational Checks—Ignition On, Engine On Checks 306
Miscellaneous—Troubleshooting 327
Troubleshooting Procedure 327
Engine 328
Transmission 333
Differential and Axle 335
Service Brake 336
Driveline 337
Park Brake 337
Hydraulic System 338
Steering 341
Air Conditioning System 342
Heater System 343
Software Update 344
Attachment Recognition 345
Miscellaneous—Storage 346
Prepare Machine for Storage 346
Monthly Storage Procedure 347
Preparing Engine for Long-Term Storage 348
Removing Engine From Long-Term Storage 349
Miscellaneous—Machine Numbers 350
Record Product Identification Number (PIN) 350
Record Engine Serial Number 350
Record Transmission Serial Number 350
Record Hydraulic Pump Serial Number 351
Record Front and Rear Axle Housing Serial Numbers 351
Keep Proof of Ownership 351
Keep Machines Secure 352
Miscellaneous—Specifications 353
Engine Specifications 353
Drain and Refill Capacities 353
Standard Z-Bar Specifications 354
High Lift Z-Bar Specifications 357
High Lift Plus Z-Bar Specifications 360
Travel Speeds 362
Eurasian Economic Union 362
Machine Design Life 363
Page Number 29
Section 1-1 33
Section 1-2 34
Section 1-3 45
Section 1-4 53
Section 1-5 58
Section 2-1 68
Section 2-2 99
Section 2-3 153
Section 3-1 181
Section 3-2 200
Section 3-3 211
Section 3-4 232
Section 3-5 236
Section 3-6 241
Section 3-7 243
Section 3-8 244
Section 3-9 256
Section 3-10 260
Section 3-11 264
Section 3-12 271
Section 3-13 272
Section 4-1 275
Section 4-2 298
Section 4-3 327
Section 4-4 346
Section 4-5 350
Section 4-6 353

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