John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD

Description

John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD

• Part Number (P/N): OMT260582_24
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Model: 544K
• Series: 0
• Serial Number Range: 1DW544K_ _ _E642665—

TABLE OF CONTENTS:

John Deere 544K 4WD Loader Operator’s Manual OMT260582 – PDF DOWNLOAD

544K 4WD Loader 1
Introduction 2
Foreword 2
Manual Identification—READ THIS FIRST! 2
IMPORTANT 4
EPA Non-road Emissions Control Warranty Statement—Compression Ignition 5
CARB Non-road Emissions Control Warranty Statement—Compression Ignition 7
Required Emission-Related Information 13
FCC Notifications to User 13
Service ADVISOR™ Remote (SAR)—SOFTWARE TERMS AND CONDITIONS 14
Technical Information Feedback Form 18
Contents 19
Safety—Safety and Operator Conveniences 23
Safety and Operator Convenience Features 23
Safety—General Precautions 24
Recognize Safety Information 24
Follow Safety Instructions 24
Operate Only If Qualified 24
Wear Protective Equipment 25
Avoid Unauthorized Machine Modifications 25
Add Cab Guarding for Special Uses 25
Inspect Machine 25
Stay Clear of Moving Parts 26
Avoid High-Pressure Fluids 26
Avoid High-Pressure Oils 26
Work In Ventilated Area 27
Prevent Fires, Clean Debris From Machine 27
Clean Debris from Machine 28
Prevent Battery Explosions 28
Handle Chemical Products Safely 28
Decommissioning — Proper Recycling and Disposal of Fluids and Components 29
Exhaust Filter Ash Handling and Disposal 29
Prepare for Emergencies 30
Safety—Operating Precautions 31
Use Steps and Handholds Correctly 31
Start Only From Operator’s Seat 31
Use and Maintain Seat Belt 31
Prevent Unintended Machine Movement 32
Avoid Work Site Hazards 33
Use Special Care When Operating Loader 34
Keep Riders Off Machine 34
Avoid Backover Accidents 34
Avoid Machine Tip Over and Machine Damage 35
Operating on Slopes 35
Operating or Traveling On Public Roads 36
Inspect and Maintain ROPS 36
Add and Operate Attachments Safely 36
Safety—Maintenance Precautions 37
Park and Prepare for Service Safely 37
Clean Exhaust Filter Safely 38
Service Cooling System Safely 39
Service Tires Safely 39
Remove Paint Before Welding or Heating 40
Make Welding Repairs Safely 40
Drive Metal Pins Safely 40
Safety—Safety Signs 41
Safety Signs 41
Operation—Operator’s Station 47
Levers—Two Function Hydraulic Control 47
Levers—Three Function Hydraulic Control 48
Levers—Four Function Hydraulic Control 50
Pedals 51
Sealed Switch Module (SSM) 52
Switch Module Functions 53
Advanced Display Unit (ADU) 56
Display Unit Functions 57
Display Unit—Normal Display 62
Display Unit—Main Menu 63
Display Unit—Main Menu—Codes 64
Display Unit—Main Menu—Codes—Active Codes 64
Display Unit—Main Menu—Codes—Stored Codes 65
Display Unit—Main Menu—Settings 66
Display Unit—Main Menu—Settings—Reverse Fan Cycle 67
Display Unit—Main Menu—Settings—Courtesy Lights 67
Display Unit—Main Menu—Settings—Quick Shift 68
Display Unit—Main Menu—Settings—Job Timer 68
Display Unit—Main Menu—Settings—Stopwatch 69
Display Unit—Main Menu—Settings—Ride Control—If Equipped 69
Display Unit—Main Menu—Settings—Counters 69
Display Unit—Main Menu—Settings—Camera Mode 70
Display Unit—Main Menu—Settings—Operator Configuration 70
Display Unit—Main Menu—Diagnostics 71
Display Unit—Main Menu—Diagnostics—Machine ID 72
Display Unit—Main Menu—Diagnostics—Battery Monitor 72
Display Unit—Main Menu—Diagnostics—Engine Sensors 73
Display Unit—Main Menu—Diagnostics—Transmission/Axle 73
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 74
Display Unit—Main Menu—Diagnostics—Machine Sensors 74
Display Unit—Main Menu—Diagnostics—FNR Selector 75
Display Unit—Main Menu—Diagnostics—Cab Switches 75
Display Unit—Main Menu—Diagnostics—Switch Module 75
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 77
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 78
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 78
Display Unit—Main Menu—Diagnostics—JDLink™ System Info 79
Display Unit—Main Menu—Diagnostics—Park Brake Test 79
Display Unit—Main Menu—Payload Scale—If Equipped 80
Display Unit—Main Menu—Payload Scale—Long Total 80
Display Unit—Main Menu—Payload Scale—Display Units 81
Display Unit—Main Menu—Payload Scale—Auto Add 81
Display Unit—Main Menu—Payload Scale—Diagnostics 81
Display Unit—Main Menu—Payload Scale—Setup 81
Display Unit—Main Menu—Security 82
Display Unit—Main Menu—Security—Security 83
Display Unit—Main Menu—Security—Change Owner PIN 83
Display Unit—Main Menu—Security—Manage Operator PINs 84
Display Unit—Main Menu—Security—Manage Transport PIN 85
Display Unit—Main Menu—Security—Delayed Operator Logout 85
Display Unit—Main Menu—Exhaust Filter 86
Display Unit—Main Menu—Exhaust Filter—Auto Cleaning 87
Display Unit—Main Menu—Exhaust Filter—Parked Cleaning 88
Display Unit—Main Menu—Software Delivery 89
Display Unit—Main Menu—Software Delivery—Software Update 90
Horn Button 91
Turn Signals 91
Joystick Steering Armrest Adjustment—If Equipped 92
Air Conditioner and Heater Operation 93
Counter Switch 94
Opening and Securing Side Door 95
Opening Side Window/Secondary Exit 96
Opening Rear Side Window 96
Seat Adjustment 97
Fire Extinguisher Mounting Location 98
Operation—Operating the Machine 99
Before Starting Work 99
Inspect Machine Daily Before Starting 99
Check Instruments Before Starting 99
Security System 100
Battery Disconnect Switch 100
Engine Break-In Period 101
Starting the Engine 102
Cold Start Aid—Glow Plug 104
Cold Start Aid—Block Heater—If Equipped 104
Warmup 104
Cold Weather Warmup 105
Park Brake Switch 106
Shifting the Transmission 107
Automatic Idle and Automatic Shutdown 109
Turbocharger Cool Down 109
Joystick Bucket and Boom Control 110
Two Lever Bucket and Boom Control 111
Auxiliary Control 111
Joystick Steering Control—If Equipped 113
Ride Control—If Equipped 115
Secondary Steering—If Equipped 117
Differential Lock Operation 117
Exhaust Filter 118
Service ADVISOR™ Remote (SAR) Software Delivery Process 120
Rear Camera and Radar Object Detection (ROD) System—If Equipped 121
Counter Switch Operation 123
Embedded Payload Scale—If Equipped 124
Boom Height Kickout Adjustment 128
Return-to-Carry Kickout Adjustment 128
Return-to-Dig Adjustment for Z-Bar Linkage 129
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 131
Operating Loader Coupler—If Equipped 132
Using the Loader Bucket 133
Backdragging 134
Fork Attachment 135
Operating in Water and Mud 136
Parking the Machine 137
Loading Machine on a Trailer 138
Towing Procedure 140
Lifting the Machine 142
Maintenance—Machine 143
Diesel Fuel 143
Diesel Fuel Specifications 143
Lubricity of Diesel Fuel 144
Handling and Storing Diesel Fuel 144
Biodiesel Fuel 145
Testing Diesel Fuel 146
Minimizing the Effect of Cold Weather on Diesel Engines 147
Alternative and Synthetic Lubricants 148
Lubricant Storage 148
Mixing of Lubricants 148
John Deere Break-In Plus™ Engine Oil 149
Diesel Engine Oil—Interim Tier 4 and Stage III B Engines 149
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 150
Transmission, Park Brake, and Axle Oil 150
Hydraulic Oil 151
Grease 152
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 153
Water Quality for Mixing with Coolant Concentrate 154
Operating in Warm Temperature Climates 154
Testing Coolant Freeze Point 155
Disposing of Coolant 155
Maintenance—Periodic Maintenance 156
Service Machine at Specified Intervals 156
Check Hour Meter Regularly 156
Prepare Machine for Maintenance 157
Frame Locking Bar 158
Boom Lock 159
Pin Removal—If Equipped With Powerllel™ Linkage 160
Engine Service Doors and Side Shields 161
Cooling System Doors 162
Fuel Tank 163
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 163
Service Intervals 164
Required Parts 166
Maintenance—As Required 167
Inspect Tires and Check Pressure 167
Tire Pressures 168
Check Wheel Bolt Torque 170
Inspect Engine Air Cleaner Elements 171
Inspect Air Conditioner Compressor and Alternator Belt 172
Clean Cooler Cores 173
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 174
Check Windshield Washer Fluid Level 175
Drain Water From Primary Fuel Filter 175
Service Exhaust Filter 176
Check and Clean or Replace Cab Fresh Air Filter 177
Check and Clean or Replace Cab Recirculating Air Filter 178
Maintenance—Every 10 Hours or Daily 179
Clean Air Cleaner Dust Unloader Valve 179
Check Coolant Level in Surge Tank 179
Check Engine Oil Level 180
Check Hydraulic System Oil Level 180
Check Transmission Oil Level 181
Inspect Outer Pin Seals 182
Maintenance—Every 100 Hours 183
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 183
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 184
Maintenance—Initial Service – 250 Hours 185
Drain and Refill Front and Rear Axle Oil 185
Replace Axle Oil Filters—If Equipped 186
Maintenance—Every 250 Hours 187
Take Engine Oil Sample 187
Maintenance—Every 500 Hours 188
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 188
Check Front and Rear Axle Oil Level 189
Lubricate Front and Rear Axle Shaft Seals 190
Check Battery Water Level and Terminals 190
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 193
Take Fluid Samples 193
Drain and Refill Engine Oil and Replace Filter 194
Replace Primary Fuel Filter 195
Replace In-Line Fuel Strainer 196
Replace Final Fuel Filter 196
Replace Hydraulic Reservoir Breather Filter 197
Check Park Brake Oil Level 197
Lubricate Front and Rear Shaft Seals on Park Brake 198
Check Ride Control Accumulator—If Equipped 199
Maintenance—Every 1000 Hours 200
Replace Air Cleaner Dust Unloader Valve 200
Replace Engine Air Cleaner Elements 200
Replace Fuel Tank Breather Filter 201
Replace Axle Oil Filters—If Equipped 201
Lubricate Frame Hinge Pivots 201
Drain and Refill Park Brake Oil 202
Check Coolant Condition 202
Maintenance—Every 2000 Hours 203
Replace Outer Pin Seals 203
Drain and Refill Transmission Oil and Replace Filter 203
Drain and Refill Front and Rear Axle Oil 205
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 206
Replace Open Crankcase Ventilation (OCV) Filter 206
Check and Adjust Engine Valve Lash (Clearance) 206
Rerun Transmission Clutch Calibration 206
Maintenance—Every 4000 Hours 207
Clean Hydraulic Pump Case Drain In-Line Screen 207
Replace Hydraulic System Return Filter 209
Drain, Flush, and Refill Hydraulic System Oil 210
Clean Hydraulic System Fill Strainer 211
Maintenance—Every 5000 Hours 212
Check Driveline Damper For Cracks 212
Maintenance—Every 6000 Hours 213
Drain Cooling System 213
Refill Cooling System 214
Miscellaneous—Machine 215
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped 215
Check Air Inlet Cover 215
Bleed Fuel System 215
Do Not Service Control Valves, Cylinders, Pumps, or Motors 216
Precautions for Alternator and Regulator 216
Handling, Checking, and Servicing Batteries Carefully 217
Using Booster Batteries—24-Volt System 218
Using Battery Charger 219
Replacement Batteries 219
Remove and Install Batteries 220
12-Volt Auxiliary Power Outlet—If Equipped 221
JDLink Machine Monitoring System (MMS)—If Equipped 221
Replacing Fuses 222
Remove and Install Halogen Bulbs 224
Fluid Sampling Test Ports—If Equipped 224
Air Conditioning System Service 225
Welding On Machine 226
Welding Near Electronic Control Units 226
Keep Electronic Control Unit Connectors Clean 227
External Service Brake Inspection 228
Service Recommendations For Snap-To-Connect (STC®) Fittings 229
Replacing Bucket Teeth—TK Series 230
Keep ROPS Installed Properly 230
Hardware Torque Specifications 230
Unified Inch Bolt and Screw Torque Values 231
Metric Bolt and Screw Torque Values 232
Miscellaneous—Operational Checkout 233
Operational Checkout 233
Miscellaneous—Troubleshooting 258
Troubleshooting Procedure 258
Engine 259
Transmission 262
Differential and Axle 265
Service Brake 266
Driveline 267
Park Brake 267
Hydraulic System 268
Steering 270
Air Conditioning System 271
Heater System 273
Software Update 273
Miscellaneous—Storage 274
Prepare Machine for Storage 274
Monthly Storage Procedure 274
Miscellaneous—Machine Numbers 276
Record Product Identification Number (PIN) 276
Record Engine Serial Number 276
Record Transmission Serial Number 276
Record Hydraulic Pump Serial Number 277
Record Front and Rear Axle Housing Serial Numbers 277
Keep Proof of Ownership 277
Keep Machines Secure 278
Miscellaneous—Specifications 279
Engine Specifications 279
Drain and Refill Capacities 279
Standard Z-Bar Specifications 280
High Lift Z-Bar Specifications 282
Powerllel™ Specifications 284
Travel Speeds 285
Page Number 23
Section 1-1 23
Section 1-2 24
Section 1-3 31
Section 1-4 37
Section 1-5 41
Section 2-1 47
Section 2-2 99
Section 3-1 143
Section 3-2 156
Section 3-3 167
Section 3-4 179
Section 3-5 183
Section 3-6 185
Section 3-7 187
Section 3-8 188
Section 3-9 200
Section 3-10 203
Section 3-11 207
Section 3-12 212
Section 3-13 213
Section 4-1 215
Section 4-2 233
Section 4-3 258
Section 4-4 274
Section 4-5 276
Section 4-6 279

S.V 04/24