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John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD
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Description
John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD
FILE DETAILS:
John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD
Language : English
Pages : 306
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD
- READ THIS MANUAL carefully to learn how to operate and service your machine correctly. Failure to do so could result in personal injury or equipment damage.
- This manual and safety signs on your machine may also be available in other languages. (See your John Deere dealer to order.)
- THIS MANUAL SHOULD BE CONSIDERED a permanent part of your machine and should remain with the machine when you sell it.
- MEASUREMENTS in this manual are given in both metric and customary U.S. unit equivalents. Use only correct replacement parts and fasteners. Metric and inch fasteners may require a specific metric or inch wrench.
- RIGHT-HAND AND LEFT-HAND sides are determined by facing in the direction of forward travel.
- WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.) in the Machine Numbers section. Accurately record all the numbers to help in tracing the machine should it be stolen. Your dealer also needs these numbers when you 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 equipment as described in this manual. The warranty is explained on the warranty certificate or statement which you should have received from your dealer.
TABLE OF CONTENTS:
John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD
Contents............................................................................................................ 21 Safety—Safety and Operator Conveniences......................................................................... 25 Safety and Operator Convenience Features.................................................................... 25 Safety—General Precautions...................................................................................... 26 Recognize Safety Information................................................................................ 26 Follow Safety Instructions.................................................................................. 26 Operate Only If Qualified................................................................................... 26 Wear Protective Equipment................................................................................... 26 Avoid Unauthorized Machine Modifications.................................................................... 27 Add Cab Guarding for Special Uses........................................................................... 27 Inspect Machine............................................................................................. 27 Stay Clear of Moving Parts.................................................................................. 28 Avoid High-Pressure Fluids.................................................................................. 28 Avoid High-Pressure Oils.................................................................................... 28 Work In Ventilated Area..................................................................................... 29 Prevent Fires............................................................................................... 29 Clean Debris from Machine................................................................................... 30 Prevent Battery Explosions.................................................................................. 30 Handle Chemical Products Safely............................................................................. 31 Dispose of Waste Properly................................................................................... 31 Exhaust Filter Ash Handling and Disposal.................................................................... 31 Prepare for Emergencies..................................................................................... 32 Safety—Operating Precautions.................................................................................... 33 Use Steps and Handholds Correctly........................................................................... 33 Start Only From Operator's Seat............................................................................. 33 Use and Maintain Seat Belt.................................................................................. 33 Prevent Unintended Machine Movement......................................................................... 33 Avoid Work Site Hazards..................................................................................... 34 Use Special Care When Operating Loader...................................................................... 35 Keep Riders Off Machine..................................................................................... 36 Avoid Backover Accidents.................................................................................... 36 Avoid Machine Tip Over...................................................................................... 36 Operating on Slopes......................................................................................... 37 Operating or Traveling On Public Roads...................................................................... 37 Inspect and Maintain ROPS................................................................................... 38 Add and Operate Attachments Safely.......................................................................... 38 Safety—Maintenance Precautions.................................................................................. 39 Park and Prepare for Service Safely......................................................................... 39 Clean Exhaust Filter Safely................................................................................. 39 Service Cooling System Safely............................................................................... 40 Service Tires Safely........................................................................................ 41 Remove Paint Before Welding or Heating...................................................................... 41 Make Welding Repairs Safely................................................................................. 42 Drive Metal Pins Safely..................................................................................... 42 Safety—Safety Signs............................................................................................. 43 Safety Signs................................................................................................ 43 Operation—Operator’s Station.................................................................................... 49 Levers—Two Function Hydraulic Control....................................................................... 49 Levers—Three Function Hydraulic Control..................................................................... 49 Levers—Four Function Hydraulic Control...................................................................... 51 Pedals...................................................................................................... 52 Sealed Switch Module (SSM).................................................................................. 53 Switch Module Functions..................................................................................... 53 Advanced Display Unit (ADU)................................................................................. 57 Display Unit Functions...................................................................................... 57 Display Unit—Normal Display................................................................................. 63 Display Unit—Main Menu...................................................................................... 63 Display Unit—Main Menu—Codes................................................................................ 65 Display Unit—Main Menu—Codes—Active Codes................................................................... 65 Display Unit—Main Menu—Codes—Stored Codes................................................................... 65 Display Unit—Main Menu—Settings............................................................................. 66 Display Unit—Main Menu—Settings—Reverse Fan Cycle........................................................... 68 Display Unit—Main Menu—Settings—Courtesy Lights............................................................. 68 Display Unit—Main Menu—Settings—Quick Shift................................................................. 68 Display Unit—Main Menu—Settings—Job Timer................................................................... 69 Display Unit—Main Menu—Settings—Stopwatch................................................................... 69 Display Unit—Main Menu—Settings—Ride Control—If Equipped.................................................... 70 Display Unit—Main Menu—Settings—Counters.................................................................... 70 Display Unit—Main Menu—Settings—Camera Mode................................................................. 70 Display Unit—Main Menu—Settings—Operator Configuration...................................................... 71 Display Unit—Main Menu—Diagnostics.......................................................................... 71 Display Unit—Main Menu—Diagnostics—Machine ID............................................................... 73 Display Unit—Main Menu—Diagnostics—Battery Monitor.......................................................... 73 Display Unit—Main Menu—Diagnostics—Engine Sensors........................................................... 73 Display Unit—Main Menu—Diagnostics—Transmission/Axle........................................................ 74 Display Unit—Main Menu—Diagnostics—Hydraulic Sensors........................................................ 74 Display Unit—Main Menu—Diagnostics—Machine Sensors.......................................................... 75 Display Unit—Main Menu—Diagnostics—FNR Selector............................................................. 75 Display Unit—Main Menu—Diagnostics—Cab Switches............................................................. 76 Display Unit—Main Menu—Diagnostics—Switch Module............................................................ 76 Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped............................................ 76 Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped................................................ 77 Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped................................................ 79 Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped............................................... 79 Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped................................................ 79 Display Unit—Main Menu—Diagnostics—JDLink™ System Info...................................................... 80 Display Unit—Main Menu—Diagnostics—Park Brake Test.......................................................... 80 Display Unit—Main Menu—Payload Scale—If Equipped............................................................ 81 Display Unit—Main Menu—Payload Scale—Long Total............................................................. 82 Display Unit—Main Menu—Payload Scale—Display Units.......................................................... 82 Display Unit—Main Menu—Payload Scale—Auto Add............................................................... 83 Display Unit—Main Menu—Payload Scale—Diagnostics............................................................ 83 Display Unit—Main Menu—Payload Scale—Setup.................................................................. 83 Display Unit—Main Menu—Security............................................................................. 83 Display Unit—Main Menu—Security—Security.................................................................... 85 Display Unit—Main Menu—Security—Change Owner PIN............................................................ 85 Display Unit—Main Menu—Security—Manage Operator PINs........................................................ 85 Display Unit—Main Menu—Security—Manage Transport PIN........................................................ 86 Display Unit—Main Menu—Security—Delayed Operator Logout..................................................... 87 Display Unit—Main Menu—Exhaust Filter....................................................................... 88 Display Unit—Main Menu—Exhaust Filter—Auto Cleaning......................................................... 90 Display Unit—Main Menu—Exhaust Filter—Parked Cleaning....................................................... 90 Display Unit—Main Menu—Software Delivery.................................................................... 92 Display Unit—Main Menu—Software Delivery—Software Update.................................................... 93 Horn Button................................................................................................. 93 Turn Signals................................................................................................ 94 Joystick Steering Armrest Adjustment—If Equipped............................................................ 94 Air Conditioner and Heater Operation........................................................................ 95 Counter Switch.............................................................................................. 96 Opening and Securing Side Door.............................................................................. 97 Opening Side Window/Secondary Exit.......................................................................... 98 Opening Rear Side Window.................................................................................... 99 Seat Adjustment............................................................................................. 99 Fire Extinguisher Mounting Location.........................................................................100 Operation—Operating the Machine.................................................................................102 Before Starting Work........................................................................................102 Inspect Machine Daily Before Starting.......................................................................102 Check Instruments Before Starting...........................................................................102 Security System.............................................................................................102 Battery Disconnect Switch...................................................................................103 Engine Break-In Period......................................................................................103 Starting the Engine.........................................................................................104 Cold Start Aid—Glow Plug....................................................................................107 Cold Start Aid—Block Heater—If Equipped.....................................................................107 Warmup......................................................................................................107 Cold Weather Warmup.........................................................................................107 Park Brake Switch...........................................................................................108 Shifting the Transmission...................................................................................109 Automatic Idle and Automatic Shutdown.......................................................................111 Turbocharger Cool Down......................................................................................112 Joystick Bucket and Boom Control............................................................................112 Two Lever Bucket and Boom Control...........................................................................114 Auxiliary Control...........................................................................................115 Joystick Steering Control—If Equipped.......................................................................115 Ride Control—If Equipped....................................................................................117 Secondary Steering—If Equipped..............................................................................120 Differential Lock Operation.................................................................................120 Exhaust Filter..............................................................................................120 Service ADVISOR™ Remote (SAR) Software Delivery Process.....................................................123 Rear Camera and Radar Object Detection (ROD) System—If Equipped.............................................123 Counter Switch Operation....................................................................................125 Embedded Payload Scale—If Equipped..........................................................................126 Boom Height Kickout Adjustment..............................................................................130 Return-to-Carry Kickout Adjustment..........................................................................131 Return-to-Dig Adjustment for Z-Bar Linkage..................................................................131 Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped.................................................133 Operating Loader Coupler—If Equipped........................................................................135 Using the Loader Bucket.....................................................................................136 Backdragging................................................................................................137 Fork Attachment.............................................................................................137 Parking the Machine.........................................................................................140 Loading Machine on a Trailer................................................................................140 Towing Procedure............................................................................................142 Lifting the Machine.........................................................................................145 Maintenance—Machine.............................................................................................146 Diesel Fuel.................................................................................................146 Diesel Fuel Specifications..................................................................................146 Lubricity of Diesel Fuel....................................................................................146 Handling and Storing Diesel Fuel............................................................................147 Biodiesel Fuel..............................................................................................147 Testing Diesel Fuel.........................................................................................148 Minimizing the Effect of Cold Weather on Diesel Engines.....................................................149 Alternative and Synthetic Lubricants........................................................................150 Lubricant Storage...........................................................................................151 Mixing of Lubricants........................................................................................151 John Deere Break-In Plus™ Engine Oil........................................................................151 Diesel Engine Oil—Interim Tier 4 and Stage III B Engines....................................................152 Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, and Stage IV Engines....153 Transmission, Park Brake, and Axle Oil......................................................................154 Hydraulic Oil...............................................................................................154 Grease......................................................................................................155 Diesel Engine Coolant (engine with wet sleeve cylinder liners)..............................................156 Drain Intervals for Diesel Engine Coolant...................................................................157 John Deere COOL-GARD™ II Coolant Extender...................................................................158 Supplemental Coolant Additives..............................................................................158 Operating in Warm Temperature Climates......................................................................159 Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender...........159 Testing Diesel Engine Coolant...............................................................................160 Disposing of Coolant........................................................................................161 Maintenance—Periodic Maintenance................................................................................162 Service Machine at Specified Intervals......................................................................162 Check Hour Meter Regularly..................................................................................162 Prepare Machine for Maintenance.............................................................................162 Frame Locking Bar...........................................................................................164 Boom Lock...................................................................................................164 Pin Removal—If Equipped With Powerllel™ Linkage.............................................................165 Engine Service Doors and Side Shields.......................................................................166 Cooling System Doors........................................................................................167 Fuel Tank...................................................................................................168 Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit.................................................169 Service Intervals...........................................................................................169 Required Parts..............................................................................................171 Maintenance—As Required.........................................................................................174 Inspect Tires and Check Pressure............................................................................174 Tire Pressures..............................................................................................174 Check Wheel Bolt Torque.....................................................................................177 Inspect Engine Air Cleaner Elements.........................................................................177 Inspect Air Conditioner Compressor and Alternator Belt......................................................178 Check Coolant...............................................................................................179 Clean Cooler Cores..........................................................................................181 Check Rear Camera and Radar Object Detection (ROD) System—If Equipped.......................................181 Check Windshield Washer Fluid Level.........................................................................183 Drain Water From Primary Fuel Filter........................................................................183 Service Exhaust Filter......................................................................................184 Check and Clean or Replace Cab Fresh Air Filter.............................................................185 Check and Clean or Replace Cab Recirculating Air Filter.....................................................185 Maintenance—Every 10 Hours or Daily.............................................................................187 Clean Air Cleaner Dust Unloader Valve.......................................................................187 Check Coolant Level in Surge Tank...........................................................................187 Check Engine Oil Level......................................................................................187 Check Hydraulic System Oil Level............................................................................188 Check Transmission Oil Level................................................................................188 Inspect Outer Pin Seals.....................................................................................189 Maintenance—Every 100 Hours.....................................................................................191 Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage..................................................191 Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage.............................................191 Maintenance—Initial Service - 250 Hours ........................................................................193 Drain and Refill Front and Rear Axle Oil....................................................................193 Replace Axle Oil Filters—If Equipped........................................................................194 Maintenance—Every 250 Hours.....................................................................................195 Take Engine Oil Sample......................................................................................195 Maintenance—Every 500 Hours.....................................................................................196 Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints.......................................196 Check Front and Rear Axle Oil Level.........................................................................197 Lubricate Front and Rear Axle Shaft Seals...................................................................198 Check Battery Water Level and Terminals.....................................................................198 Check Air Intake Hoses and Charge Air Cooler Tube Couplings.................................................201 Take Fluid Samples..........................................................................................201 Drain and Refill Engine Oil and Replace Filter..............................................................201 Replace Primary Fuel Filter.................................................................................203 Replace In-Line Fuel Strainer...............................................................................204 Replace Final Fuel Filter...................................................................................204 Replace Hydraulic Reservoir Breather Filter.................................................................205 Check Park Brake Oil Level..................................................................................205 Lubricate Front and Rear Shaft Seals on Park Brake..........................................................206 Check Ride Control Accumulator—If Equipped..................................................................206 Maintenance—Every 1000 Hours....................................................................................208 Replace Air Cleaner Dust Unloader Valve.....................................................................208 Replace Engine Air Cleaner Elements.........................................................................208 Replace Fuel Tank Breather Filter...........................................................................209 Check Coolant...............................................................................................209 Replace Axle Oil Filters—If Equipped........................................................................210 Lubricate Frame Hinge Pivots................................................................................210 Drain and Refill Park Brake Oil.............................................................................210 Maintenance—Every 2000 Hours....................................................................................212 Replace Outer Pin Seals.....................................................................................212 Drain and Refill Transmission Oil and Replace Filter........................................................212 Drain and Refill Front and Rear Axle Oil....................................................................214 Clean Front and Rear Axle Oil Recirculation Screens—If Equipped.............................................215 Replace Open Crankcase Ventilation (OCV) Filter.............................................................215 Adjust Engine Valve Lash (Clearance)........................................................................215 Rerun Transmission Clutch Calibration.......................................................................215 Maintenance—Every 4000 Hours....................................................................................216 Clean Hydraulic Pump Case Drain In-Line Screen..............................................................216 Replace Hydraulic System Return Filter......................................................................218 Drain, Flush, and Refill Hydraulic System Oil...............................................................218 Clean Hydraulic System Fill Strainer........................................................................220 Maintenance—Every 5000 Hours....................................................................................221 Check Driveline Damper For Cracks...........................................................................221 Maintenance—Every 6000 Hours....................................................................................222 Drain Cooling System........................................................................................222 Refill Cooling System.......................................................................................222 Miscellaneous—Machine...........................................................................................224 Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped............................................224 Check Air Inlet Cover.......................................................................................224 Bleed Fuel System...........................................................................................224 Do Not Service Control Valves, Cylinders, Pumps, or Motors..................................................224 Precautions for Alternator and Regulator....................................................................225 Handling, Checking, and Servicing Batteries Carefully.......................................................225 Using Booster Batteries—24-Volt System......................................................................226 Using Battery Charger.......................................................................................227 Replacement Batteries.......................................................................................228 Remove and Install Batteries................................................................................228 12-Volt Auxiliary Power Outlet—If Equipped..................................................................230 JDLink™ Machine Monitoring System (MMS)—If Equipped.........................................................230 Replacing Fuses.............................................................................................230 Remove and Install Halogen Bulbs............................................................................232 Fluid Sampling Test Ports—If Equipped.......................................................................233 Air Conditioning System Service.............................................................................234 Welding On Machine..........................................................................................235 Welding Near Electronic Control Units.......................................................................235 Keep Electronic Control Unit Connectors Clean...............................................................235 External Service Brake Inspection...........................................................................236 Service Recommendations For Snap-To-Connect (STC®) Fittings.................................................237 Replacing Bucket Teeth—TK Series............................................................................239 Keep ROPS Installed Properly................................................................................239 Hardware Torque Specifications..............................................................................239 Unified Inch Bolt and Screw Torque Values...................................................................239 Metric Bolt and Screw Torque Values.........................................................................240 Miscellaneous—Operational Checkout..............................................................................242 Operational Checkout........................................................................................242 Diagnostic Trouble Code Check...........................................................................242 Ignition OFF, Engine OFF Checks.........................................................................242 Ignition ON, Engine OFF Checks..........................................................................242 Ignition ON, Engine ON Checks...........................................................................248 Miscellaneous—Troubleshooting...................................................................................268 Troubleshooting Procedure...................................................................................268 Engine......................................................................................................268 Transmission................................................................................................271 Differential and Axle.......................................................................................274 Service Brake...............................................................................................276 Driveline...................................................................................................276 Park Brake..................................................................................................277 Hydraulic System............................................................................................277 Steering....................................................................................................280 Air Conditioning System.....................................................................................280 Heater System...............................................................................................283 Software Update.............................................................................................283 Miscellaneous—Storage...........................................................................................284 Prepare Machine for Storage.................................................................................284 Monthly Storage Procedure...................................................................................284 Miscellaneous—Machine Numbers...................................................................................286 Record Product Identification Number (PIN)..................................................................286 Record Engine Serial Number.................................................................................286 Record Transmission Serial Number...........................................................................286 Record Hydraulic Pump Serial Number.........................................................................286 Record Front and Rear Axle Housing Serial Numbers...........................................................287 Keep Proof of Ownership.....................................................................................287 Keep Machines Secure........................................................................................287 Miscellaneous—Specifications....................................................................................289 Engine Specifications.......................................................................................289 Drain and Refill Capacities.................................................................................289 Standard Z-Bar Specifications...............................................................................289 High Lift Z-Bar Specifications..............................................................................291 Powerllel™ Specifications...................................................................................293 Travel Speeds...............................................................................................295 Page Number......................................................................................................... 21 Section 1-1..................................................................................................... 25 Section 1-2..................................................................................................... 26 Section 1-3..................................................................................................... 33 Section 1-4..................................................................................................... 39 Section 1-5..................................................................................................... 43 Section 2-1..................................................................................................... 49 Section 2-2.....................................................................................................102 Section 3-1.....................................................................................................146 Section 3-2.....................................................................................................162 Section 3-3.....................................................................................................174 Section 3-4.....................................................................................................187 Section 3-5.....................................................................................................191 Section 3-6.....................................................................................................193 Section 3-7.....................................................................................................195 Section 3-8.....................................................................................................196 Section 3-9.....................................................................................................208 Section 3-10....................................................................................................212 Section 3-11....................................................................................................216 Section 3-12....................................................................................................221 Section 3-13....................................................................................................222 Section 4-1.....................................................................................................224 Section 4-2.....................................................................................................242 Section 4-3.....................................................................................................268 Section 4-4.....................................................................................................284 Section 4-5.....................................................................................................286 Section 4-6.....................................................................................................289
S.S 01/03/2025
