John Deere 544K 4WD Loader Operator’s Manual OMT337074X19 PDF

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John Deere 544K 4WD Loader Operator’s Manual OMT337074X19 – PDF DOWNLOAD

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John Deere 544K 4WD Loader Operator’s Manual OMT337074X19 – PDF DOWNLOAD

P/N: OMT337074X19_22
Language: English
Division: Construction
Product Lines: Loaders
Publication Type: Operator’s Manuals
Associated Models: 544K
Series: 0
Serial:
PIN: 1DW544K_ _ _F670309—677548
For complete service information also see: PC11368, T337073X19

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 544K 4WD Loader Operator’s Manual OMT337074X19 – PDF DOWNLOAD

Contents 25
Safety—Safety and Operator Conveniences 31
Safety and Operator Convenience Features 31
Safety—General Precautions 32
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 32
Recognize Safety Information 33
Follow Safety Instructions 34
Operate Only If Qualified 34
Wear Protective Equipment 34
Avoid Unauthorized Machine Modifications 35
Inspect Machine 35
Stay Clear of Moving Parts 35
Avoid High-Pressure Fluids 36
Avoid High-Pressure Oils 36
Work In Ventilated Area 37
Avoid Static Electricity Risk When Refueling 37
Prevent Fires 38
In Case of Machine Fire 38
Prevent Battery Explosions 39
Clean Debris from Machine 39
Handle Chemical Products Safely 39
Handle Starting Fluid Safely 40
Decommissioning — Proper Recycling and Disposal of Fluids and Components 40
Exhaust Filter Ash Handling and Disposal 40
Prepare for Emergencies 41
Add Cab Guarding for Special Uses 41
Safety—Operating Precautions 42
Use Steps and Handholds Correctly 42
Start Only From Operator’s Seat 42
Use and Maintain Seat Belt 42
Prevent Unintended Machine Movement 43
Avoid Work Site Hazards 44
Keep Riders Off Machine 45
Avoid Backover Accidents 45
Avoid Machine Tip Over and Machine Damage 46
Use Special Care When Operating Loader 47
Operating on Slopes 47
Operating or Traveling On Public Roads 47
Inspect and Maintain ROPS 48
Travel Safely 48
Prevent Acid Burns 49
Add and Operate Attachments Safely 49
Safety—Maintenance Precautions 50
Park and Prepare for Service Safely 50
Clean Exhaust Filter Safely 51
Service Cooling System Safely 52
Service Tires Safely 52
Remove Paint Before Welding or Heating 53
Make Welding Repairs Safely 53
Drive Metal Pins Safely 53
Safety—Safety Signs and Other Instructions 54
Safety Signs and Other Instructions 54
Operation—Operator’s Station 62
Levers—Two Function Hydraulic Control 62
Levers—Three Function Hydraulic Control 63
Levers—Four Function Hydraulic Control 65
Pedals 65
Sealed Switch Module (SSM) 66
Switch Module Functions 67
Advanced Display Unit (ADU) 70
Display Unit Functions 71
Horn Button 76
Turn Signals 76
Air Conditioner and Heater Operation 77
Counter Switch 78
Radio—If Equipped 79
Opening and Securing Side Door 83
Opening Side Window/Secondary Exit 84
Opening Rear Side Window 84
Seat Adjustment 85
Fire Extinguisher Mounting Location 86
Operation—Operating the Machine 87
Before Starting Work 87
Inspect Machine Daily Before Starting 87
Check Instruments Before Starting 87
Security System 88
Battery Disconnect Switch 88
Engine Break-In Period 89
Starting the Engine 90
Cold Start Aid—Glow Plug 92
Cold Start Aid—Block Heater—If Equipped 92
Warm-Up Procedure 92
Cold Weather Warm-Up 93
Required Machine Stop Warning 93
Park Brake Switch 95
Shifting the Transmission 96
Automatic Idle and Automatic Shutdown 98
Turbocharger Cool Down 98
Joystick Bucket and Boom Control 99
Two Lever Bucket and Boom Control 100
Auxiliary Control 101
Ride Control—If Equipped 102
Secondary Steering—If Equipped 104
Differential Lock Operation 104
Exhaust Filter 105
Selective Catalytic Reduction (SCR) System Overview 107
Qualified Emergency Use — SCR Override Option 109
Restored Operation Option 110
Service ADVISOR™ Remote (SAR) Software Delivery Process 110
Rear Camera and Radar Object Detection (ROD) System—If Equipped 111
Counter Switch Operation 113
Embedded Payload Scale—If Equipped 114
Boom Height Kickout Adjustment 118
Return-to-Carry Kickout Adjustment 118
Return-to-Dig Adjustment for Z-Bar Linkage 119
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 121
Operating Loader Coupler—If Equipped 122
Using the Loader Bucket 123
Backdragging 124
Fork Attachment 125
Operating in Water and Mud 126
Parking the Machine 127
Loading Machine on a Trailer 128
Towing Procedure 130
Lifting the Machine 131
Operation—Monitor Operation 132
Aftertreatment Indicators Overview 132
Display Unit—Normal Display 133
Display Unit—Main Menu 134
Display Unit—Main Menu—Codes 135
Display Unit—Main Menu—Codes—Active Codes 135
Display Unit—Main Menu—Codes—Stored Codes 136
Display Unit—Main Menu—Settings 137
Display Unit—Main Menu—Settings—Reverse Fan Cycle 138
Display Unit—Main Menu—Settings—Courtesy Lights 138
Display Unit—Main Menu—Settings—Quick Shift 139
Display Unit—Main Menu—Settings—Job Timer 139
Display Unit—Main Menu—Settings—Stopwatch 140
Display Unit—Main Menu—Settings—Ride Control—If Equipped 140
Display Unit—Main Menu—Settings—Counters 140
Display Unit—Main Menu—Settings—Camera Mode 141
Display Unit—Main Menu—Settings—Operator Configuration 141
Display Unit—Main Menu—Diagnostics 142
Display Unit—Main Menu—Diagnostics—Machine ID 143
Display Unit—Main Menu—Diagnostics—Battery Monitor 143
Display Unit—Main Menu—Diagnostics—Engine Sensors 144
Display Unit—Main Menu—Diagnostics—Transmission/Axle 144
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 145
Display Unit—Main Menu—Diagnostics—Machine Sensors 145
Display Unit—Main Menu—Diagnostics—FNR Selector 146
Display Unit—Main Menu—Diagnostics—Cab Switches 146
Display Unit—Main Menu—Diagnostics—Switch Module 146
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 147
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 148
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 148
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 149
Display Unit—Main Menu—Diagnostics—JDLink™ System Info 149
Display Unit—Main Menu—Diagnostics—Park Brake Test 150
Display Unit—Main Menu—Payload Scale—If Equipped 151
Display Unit—Main Menu—Payload Scale—Long Total 151
Display Unit—Main Menu—Payload Scale—Display Units 152
Display Unit—Main Menu—Payload Scale—Auto Add 152
Display Unit—Main Menu—Payload Scale—Diagnostics 152
Display Unit—Main Menu—Payload Scale—Setup 152
Display Unit—Main Menu—Security 153
Display Unit—Main Menu—Security—Security 154
Display Unit—Main Menu—Security—Change Owner PIN 154
Display Unit—Main Menu—Security—Manage Operator PINs 155
Display Unit—Main Menu—Security—Manage Transport PIN 156
Display Unit—Main Menu—Security—Delayed Operator Logout 157
Display Unit—Main Menu—Exhaust Filter 158
Display Unit—Main Menu—Exhaust Filter—Auto Cleaning 159
Display Unit—Main Menu—Exhaust Filter—Parked Cleaning 160
Display Unit—Main Menu—Exhaust Filter—Emergency Override 161
Display Unit—Main Menu—Software Delivery 162
Display Unit—Main Menu—Software Delivery—Software Update 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
Minimizing the Effect of Cold Weather on Diesel Engines 168
Alternative and Synthetic Lubricants 169
Lubricant Storage 169
Mixing of Lubricants 169
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 170
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 171
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 172
Diesel Engine Oil Service Interval for Operation at High Altitude 172
Oil Filters 173
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 173
Refilling Diesel Exhaust Fluid (DEF) Tank 174
Testing Diesel Exhaust Fluid (DEF) 175
Storing Diesel Exhaust Fluid (DEF) 175
Disposal of Diesel Exhaust Fluid (DEF) 176
Transmission, Park Brake, and Axle Oil 176
Hydraulic Oil 177
Grease 178
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 179
Water Quality for Mixing with Coolant Concentrate 180
Operating in Warm Temperature Climates 180
Testing Coolant Freeze Point 181
Disposing of Coolant 181
Maintenance—Periodic Maintenance 182
Service Machine at Specified Intervals 182
Check Hour Meter Regularly 182
Prepare Machine for Maintenance 183
Frame Locking Bar 184
Boom Lock 185
Pin Removal—If Equipped With Powerllel™ Linkage 186
Engine Service Doors and Side Shields 187
Cooling System Doors 188
Fuel Tank 189
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 189
Service Intervals 190
Required Parts 192
Maintenance—As Required 194
Check Windshield Washer Fluid Level 194
Inspect Tires and Check Pressure 195
Tire Pressures 196
Check Wheel Bolt Torque 198
Inspect Engine Air Cleaner Elements 199
Inspect Air Conditioner Compressor and Alternator Belt 200
Clean Cooler Cores 201
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 203
Drain Water From Primary Fuel Filter With Water Separator 204
Service Exhaust Filter 205
Drain, Flush, and Refill Fuel Tank 205
Clean Fuel Sending Unit Pickup Screen 206
Check and Clean or Replace Cab Fresh Air Filter 206
Check and Clean or Replace Cab Recirculating Air Filter 207
Maintenance—Every 10 Hours or Daily 208
Clean Air Cleaner Dust Unloader Valve 208
Check Coolant Level at Surge Tank 208
Check Engine Oil Level 209
Check Hydraulic System Oil Level 209
Check Transmission Oil Level 210
Inspect Outer Pin Seals—If Equipped 211
Maintenance—Every 100 Hours 212
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 212
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 213
Maintenance—Initial Service—250 Hours 215
Drain and Refill Front and Rear Axle Oil 215
Replace Axle Oil Filters—If Equipped 216
Maintenance—Every 250 Hours 217
Take Engine Oil Sample 217
Maintenance—Every 500 Hours 218
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 218
Check Front and Rear Axle Oil Level 219
Lubricate Front and Rear Axle Shaft Seals 219
Check Battery Electrolyte Level and Terminals 220
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 222
Take Fluid Samples 222
Drain and Refill Engine Oil and Replace Filter 223
Replace Primary Fuel Filter With Water Separator 224
Replace Final Fuel Filter 225
Replace Hydraulic Reservoir Breather Filter 225
Check Park Brake Oil Level 226
Lubricate Front and Rear Shaft Seals on Park Brake 226
Check Ride Control Accumulator—If Equipped 227
Maintenance—Every 1000 Hours 228
Replace Air Cleaner Dust Unloader Valve 228
Replace Engine Air Cleaner Elements 229
Replace Fuel Tank Breather Filter 229
Check Coolant Condition 230
Replace Axle Oil Filters—If Equipped 230
Lubricate Frame Hinge Pivots 230
Drain and Refill Park Brake Oil 231
Maintenance—Every 2000 Hours 232
Drain and Refill Transmission Oil and Replace Filter 232
Drain and Refill Front and Rear Axle Oil 234
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 235
Replace Open Crankcase Ventilation (OCV) Filter 235
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter 236
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter 237
Replace Diesel Exhaust Fluid (DEF) Header Suction Screen and Baffle (S N —675480) 237
Clean Diesel Exhaust Fluid (DEF) Tank (S N —675480) 237
Check and Adjust Engine Valve Lash 237
Replace Outer Pin Seals—If Equipped 238
Rerun Transmission Clutch Calibration 238
Maintenance—Every 4000 Hours 239
Replace Diesel Exhaust Fluid (DEF) Tank Breather Filter 239
Clean Hydraulic Pump Case Drain In-Line Screen 240
Replace Hydraulic System Return Filter 242
Drain, Flush, and Refill Hydraulic System Oil 243
Clean Hydraulic System Fill Strainer 244
Replace Diesel Exhaust Fluid (DEF) Header Suction Filter and Baffle (S N 675481— ) 245
Clean Diesel Exhaust Fluid (DEF) Tank (S N 675481— ) 245
Maintenance—Every 5000 Hours 246
Check Driveline Damper For Cracks 246
Maintenance—Every 6000 Hours 247
Drain Cooling System 247
Refill Cooling System 248
Miscellaneous—Machine 249
Check Air Inlet Cover—If Equipped 249
Bleed Fuel System 249
Do Not Service Control Valves, Cylinders, Pumps, or Motors 249
Precautions for Alternator and Regulator 250
Handling, Checking, and Servicing Batteries Carefully 251
Using Booster Batteries—24-Volt System 252
Using Battery Charger 253
Replacement Batteries 253
Remove and Install Batteries 254
12-Volt Auxiliary Power Outlet—If Equipped 256
JDLink™ Machine Monitoring System (MMS)—If Equipped 256
Replace Coolant In-Line Filter 257
Replacing Fuses 258
Remove and Install Halogen Bulbs 260
Fluid Sampling Test Ports—If Equipped 261
Air Conditioning System Service 262
Welding on Machine 263
Keep Electronic Control Unit Connectors Clean 263
External Service Brake Inspection 264
Service Recommendations For Snap-To-Connect (STC®) Fittings 265
Replacing Bucket Teeth—TK Series 266
Keep ROPS Installed Properly 266
Hardware Torque Specifications 266
Unified Inch Bolt and Screw Torque Values 267
Metric Bolt and Screw Torque Values 268
Miscellaneous—Operational Checkout 269
Operational Checkout 269
Diagnostic Trouble Code Check 269
Operational Checks—Ignition OFF, Engine OFF Checks 269
Operational Checks—Ignition ON, Engine OFF Checks 270
Operational Checks—Ignition ON, Engine ON Checks 277
Miscellaneous—Troubleshooting 299
Troubleshooting Procedure 299
Engine 300
Transmission 303
Differential and Axle 306
Service Brake 307
Driveline 307
Park Brake 308
Hydraulic System 309
Steering 311
Air Conditioning System 312
Heater System 313
Software Update 314
Miscellaneous—Storage 315
Prepare Machine for Storage 315
Monthly Storage Procedure 316
Preparing Engine for Long-Term Storage 317
Removing Engine From Long-Term Storage 318
Miscellaneous—Machine Numbers 319
Record Product Identification Number (PIN) 319
Record Engine Serial Number 319
Record Transmission Serial Number 319
Record Hydraulic Pump Serial Number 320
Record Front and Rear Axle Housing Serial Numbers 320
Keep Proof of Ownership 320
Keep Machines Secure 321
Miscellaneous—Specifications 322
Engine Specifications 322
Drain and Refill Capacities 322
Standard Z-Bar Specifications 323
High Lift Z-Bar Specifications 325
Powerllel™ Specifications 327
Travel Speeds 328
Eurasian Economic Union 329
Machine Design Life 329
Page Number 25
Section 1-1 31
Section 1-2 32
Section 1-3 42
Section 1-4 50
Section 1-5 54
Section 2-1 62
Section 2-2 87
Section 2-3 132
Section 3-1 164
Section 3-2 182
Section 3-3 194
Section 3-4 208
Section 3-5 212
Section 3-6 215
Section 3-7 217
Section 3-8 218
Section 3-9 228
Section 3-10 232
Section 3-11 239
Section 3-12 246
Section 3-13 247
Section 4-1 249
Section 4-2 269
Section 4-3 299
Section 4-4 315
Section 4-5 319
Section 4-6 322

S.V 04/24