John Deere 544K 4WD Loader Operator’s Manual OMT361499X19 PDF

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John Deere 544K 4WD Loader Operator’s Manual OMT361499X19 – PDF DOWNLOAD

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John Deere 544K 4WD Loader Operator’s Manual OMT361499X19 – PDF DOWNLOAD

• P/N: OMT361499X19_22
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Models: 544K
• Series: 0
• Serial:
  • PIN: 1DW544K_ _ _D670308—677548
• For complete service information also see: T361500X19, PC1136

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 544K 4WD Loader Operator’s Manual OMT361499X19 – PDF DOWNLOAD

Contents 25
Safety—Safety and Operator Conveniences 29
Safety and Operator Convenience Features 29
Safety—General Precautions 30
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 30
Recognize Safety Information 31
Follow Safety Instructions 32
Operate Only If Qualified 32
Wear Protective Equipment 32
Avoid Unauthorized Machine Modifications 33
Inspect Machine 33
Stay Clear of Moving Parts 33
Avoid High-Pressure Fluids 33
Avoid High-Pressure Oils 34
Work In Ventilated Area 34
Avoid Static Electricity Risk When Refueling 35
Prevent Fires 36
In Case of Machine Fire 36
Prevent Battery Explosions 37
Clean Debris from Machine 37
Handle Chemical Products Safely 37
Handle Starting Fluid Safely 38
Decommissioning — Proper Recycling and Disposal of Fluids and Components 38
Prepare for Emergencies 39
Add Cab Guarding for Special Uses 39
Safety—Operating Precautions 40
Use Steps and Handholds Correctly 40
Start Only From Operator’s Seat 40
Use and Maintain Seat Belt 40
Prevent Unintended Machine Movement 41
Avoid Work Site Hazards 42
Use Special Care When Operating Loader 43
Keep Riders Off Machine 43
Avoid Backover Accidents 43
Avoid Machine Tip Over and Machine Damage 44
Operating on Slopes 44
Operating or Traveling On Public Roads 45
Inspect and Maintain ROPS 45
Travel Safely 45
Prevent Acid Burns 46
Add and Operate Attachments Safely 46
Safety—Maintenance Precautions 47
Park and Prepare for Service Safely 47
Service Cooling System Safely 47
Service Tires Safely 48
Remove Paint Before Welding or Heating 48
Make Welding Repairs Safely 49
Drive Metal Pins Safely 49
Safety—Safety Signs and Other Instructions 50
Safety Signs and Other Instructions 50
Operation—Operator’s Station 58
Levers—Two Function Hydraulic Control 58
Levers—Three Function Hydraulic Control 59
Levers—Four Function Hydraulic Control 61
Pedals 61
Sealed Switch Module (SSM) 62
Switch Module Functions 63
Advanced Display Unit (ADU) 66
Display Unit Functions 67
Horn Button 71
Turn Signals 71
Air Conditioner and Heater Operation 72
Counter Switch 73
Radio—If Equipped 74
Opening and Securing Side Door 78
Opening Side Window/Secondary Exit 79
Opening Rear Side Window 79
Seat Adjustment 80
Fire Extinguisher Mounting Location 81
Operation—Operating the Machine 82
Before Starting Work 82
Inspect Machine Daily Before Starting 82
Check Instruments Before Starting 82
Security System 83
Battery Disconnect Switch 83
Engine Break-In Period 84
Starting the Engine 85
Cold Start Aid—Starting Fluid—If Equipped 87
Cold Start Aid—Block Heater—If Equipped 87
Warm-Up Procedure 88
Cold Weather Warm-Up 88
Park Brake Switch 89
Shifting the Transmission 90
Automatic Idle and Automatic Shutdown 92
Turbocharger Cool Down 92
Joystick Bucket and Boom Control 93
Two Lever Bucket and Boom Control 94
Auxiliary Control 95
Ride Control—If Equipped 96
Secondary Steering—If Equipped 98
Differential Lock Operation 98
Service ADVISOR™ Remote (SAR) Software Delivery Process 99
Rear Camera and Radar Object Detection (ROD) System—If Equipped 100
Counter Switch Operation 102
Embedded Payload Scale—If Equipped 103
Boom Height Kickout Adjustment 107
Return-to-Carry Kickout Adjustment 107
Return-to-Dig Adjustment for Z-Bar Linkage 108
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 110
Operating Loader Coupler—If Equipped 111
Using the Loader Bucket 112
Backdragging 113
Fork Attachment 114
Operating in Water and Mud 115
Parking the Machine 116
Loading Machine on a Trailer 117
Towing Procedure 119
Lifting the Machine 120
Operation—Monitor Operation 121
Display Unit—Normal Display 121
Display Unit—Main Menu 122
Display Unit—Main Menu—Codes 123
Display Unit—Main Menu—Codes—Active Codes 123
Display Unit—Main Menu—Codes—Stored Codes 124
Display Unit—Main Menu—Settings 125
Display Unit—Main Menu—Settings—Reverse Fan Cycle 126
Display Unit—Main Menu—Settings—Courtesy Lights 126
Display Unit—Main Menu—Settings—Quick Shift 127
Display Unit—Main Menu—Settings—Job Timer 127
Display Unit—Main Menu—Settings—Stopwatch 128
Display Unit—Main Menu—Settings—Ride Control—If Equipped 128
Display Unit—Main Menu—Settings—Counters 128
Display Unit—Main Menu—Settings—Camera Mode 129
Display Unit—Main Menu—Settings—Operator Configuration 129
Display Unit—Main Menu—Diagnostics 130
Display Unit—Main Menu—Diagnostics—Machine ID 131
Display Unit—Main Menu—Diagnostics—Battery Monitor 131
Display Unit—Main Menu—Diagnostics—Engine Sensors 132
Display Unit—Main Menu—Diagnostics—Transmission/Axle 132
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 133
Display Unit—Main Menu—Diagnostics—Machine Sensors 133
Display Unit—Main Menu—Diagnostics—FNR Selector 134
Display Unit—Main Menu—Diagnostics—Cab Switches 134
Display Unit—Main Menu—Diagnostics—Switch Module 134
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 135
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 136
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 136
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 137
Display Unit—Main Menu—Diagnostics—JDLink™ System Info 137
Display Unit—Main Menu—Diagnostics—Park Brake Test 138
Display Unit—Main Menu—Payload Scale—If Equipped 139
Display Unit—Main Menu—Payload Scale—Long Total 139
Display Unit—Main Menu—Payload Scale—Display Units 140
Display Unit—Main Menu—Payload Scale—Auto Add 140
Display Unit—Main Menu—Payload Scale—Diagnostics 140
Display Unit—Main Menu—Payload Scale—Setup 140
Display Unit—Main Menu—Monitor Settings 141
Display Unit—Main Menu—Security 142
Display Unit—Main Menu—Security—Security 143
Display Unit—Main Menu—Security—Change Owner PIN 143
Display Unit—Main Menu—Security—Manage Operator PINs 144
Display Unit—Main Menu—Security—Manage Transport PIN 145
Display Unit—Main Menu—Security—Delayed Operator Logout 146
Display Unit—Main Menu—Software Delivery 146
Display Unit—Main Menu—Software Delivery—Software Update 147
Maintenance—Machine 148
Required Emission-Related Information 148
Diesel Fuel 148
Lubricity of Diesel Fuel 149
Handling and Storing Diesel Fuel 149
Biodiesel Fuel 150
Testing Diesel Fuel 151
Supplemental Diesel Fuel Additives 151
Fuel Filters 151
Minimizing the Effect of Cold Weather on Diesel Engines 152
Alternative and Synthetic Lubricants 153
Lubricant Storage 153
Mixing of Lubricants 153
Diesel Engine Break-In™ Oil— Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III 154
Diesel Engine Oil — Tier 3 and Stage IIIA 155
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA Engines 156
Oil Filters 156
Transmission, Park Brake, and Axle Oil 157
Hydraulic Oil 158
Grease 159
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 160
Water Quality for Mixing with Coolant Concentrate 161
Operating in Warm Temperature Climates 161
Testing Coolant Freeze Point 162
Disposing of Coolant 162
Maintenance—Periodic Maintenance 163
Service Machine at Specified Intervals 163
Check Hour Meter Regularly 163
Prepare Machine for Maintenance 164
Frame Locking Bar 165
Boom Lock 166
Pin Removal—If Equipped With Powerllel™ Linkage 167
Engine Service Doors and Side Shields 168
Cooling System Doors 169
Fuel Tank 170
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 170
Service Intervals 171
Required Parts 173
Maintenance—As Required 175
Inspect Tires and Check Pressure 175
Tire Pressures 176
Check Wheel Bolt Torque 178
Inspect Engine Air Cleaner Elements 179
Inspect Air Conditioner Compressor and Alternator Belt 180
Clean Cooler Cores 181
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 183
Drain Water From Auxiliary Fuel Filter With Water Separator—If Equipped 184
Check Windshield Washer Fluid Level 184
Drain Water From Primary Fuel Filter With Water Separator 185
Drain Water From Final Fuel Filter 185
Check and Clean or Replace Cab Fresh Air Filter 186
Check and Clean or Replace Cab Recirculating Air Filter 187
Maintenance—Every 10 Hours or Daily 188
Clean Air Cleaner Dust Unloader Valve 188
Check Coolant Level at Surge Tank 188
Check Engine Oil Level 189
Check Hydraulic System Oil Level 189
Check Transmission Oil Level 190
Inspect Outer Pin Seals 191
Maintenance—Every 100 Hours 192
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 192
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 193
Maintenance—Initial Service – 250 Hours 195
Drain and Refill Front and Rear Axle Oil 195
Replace Axle Oil Filters—If Equipped 196
Maintenance—Every 250 Hours 197
Take Engine Oil Sample 197
Maintenance—Every 500 Hours 198
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 198
Check Front and Rear Axle Oil Level 199
Lubricate Front and Rear Axle Shaft Seals 199
Check Battery Water Level and Terminals 200
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 201
Take Fluid Samples 201
Replace In-Line Fuel Strainer 202
Replace Auxiliary Fuel Filter With Water Separator—If Equipped 202
Drain and Refill Engine Oil and Replace Filter 203
Replace Primary Fuel Filter With Water Separator 204
Replace Final Fuel Filter 205
Replace Hydraulic Reservoir Breather Filter 205
Check Park Brake Oil Level 206
Lubricate Front and Rear Shaft Seals on Park Brake 206
Check Ride Control Accumulator—If Equipped 207
Maintenance—Every 1000 Hours 208
Replace Air Cleaner Dust Unloader Valve 208
Replace Engine Air Cleaner Elements 208
Replace Axle Oil Filters—If Equipped 209
Check Coolant Condition 209
Clean Engine Crankcase Vent Tube 209
Lubricate Frame Hinge Pivots 210
Drain and Refill Park Brake Oil 210
Maintenance—Every 2000 Hours 211
Drain and Refill Transmission Oil and Replace Filter 211
Drain and Refill Front and Rear Axle Oil 213
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 214
Adjust Engine Valve Lash (Clearance) 214
Rerun Transmission Clutch Calibration 214
Replace Outer Pin Seals 214
Maintenance—Every 4000 Hours 215
Clean Hydraulic Pump Case Drain In-Line Screen 215
Replace Crankshaft Damper 216
Clean Hydraulic System Fill Strainer 217
Drain, Flush, and Refill Hydraulic System Oil 217
Replace Hydraulic System Return Filter 219
Maintenance—Every 5000 Hours 220
Inspect Driveline Damper 220
Maintenance—Every 6000 Hours 221
Drain Cooling System 221
Refill Cooling System 222
Miscellaneous—Machine 223
Check Air Inlet Cover—If Equipped 223
Inspect Fuel Tank Vent Hose and Breather Filter 223
Bleed Fuel System 223
Do Not Service Control Valves, Cylinders, Pumps, or Motors 224
Precautions for Alternator and Regulator 224
Handling, Checking, and Servicing Batteries Carefully 225
Using Booster Batteries—24-Volt System 226
Using Battery Charger 227
Replacement Batteries 227
Remove and Install Batteries 228
12-Volt Auxiliary Power Outlet—If Equipped 228
JDLink™ Machine Monitoring System (MMS)—If Equipped 229
Replacing Fuses 229
Remove and Install Halogen Bulbs 231
Fluid Sampling Test Ports—If Equipped 232
Air Conditioning System Service 233
External Service Brake Inspection 234
Service Recommendations For Snap-To-Connect (STC®) Fittings 235
Welding on Machine 236
Keep Electronic Control Unit Connectors Clean 236
Replacing Bucket Teeth—TK Series 237
Keep ROPS Installed Properly 237
Hardware Torque Specifications 237
Metric Bolt and Screw Torque Values 238
Unified Inch Bolt and Screw Torque Values 239
Miscellaneous—Operational Checkout 240
Operational Checkout 240
Diagnostic Trouble Code Check 240
Ignition OFF, Engine OFF Checks 240
Ignition ON, Engine OFF Checks 241
Ignition ON, Engine ON Checks 248
Miscellaneous—Troubleshooting 269
Troubleshooting Procedure 269
Engine 270
Transmission 273
Differential and Axle 276
Service Brake 277
Driveline 277
Park Brake 278
Hydraulic System 279
Steering 281
Air Conditioning System 282
Heater System 283
Software Update 284
Miscellaneous—Storage 285
Prepare Machine for Storage 285
Monthly Storage Procedure 286
Miscellaneous—Machine Numbers 287
Record Product Identification Number (PIN) 287
Record Engine Serial Number 287
Record Transmission Serial Number 287
Record Hydraulic Pump Serial Number 288
Record Front and Rear Axle Housing Serial Numbers 288
Keep Proof of Ownership 288
Keep Machines Secure 289
Miscellaneous—Specifications 290
Engine Specifications 290
Drain and Refill Capacities 290
Standard Z-Bar Specifications 291
High Lift Z-Bar Specifications 293
Powerllel™ Specifications 295
Travel Speeds 296
Eurasian Economic Union 297
Machine Design Life 297
Page Number 25
Section 1-1 29
Section 1-2 30
Section 1-3 40
Section 1-4 47
Section 1-5 50
Section 2-1 58
Section 2-2 82
Section 2-3 121
Section 3-1 148
Section 3-2 163
Section 3-3 175
Section 3-4 188
Section 3-5 192
Section 3-6 195
Section 3-7 197
Section 3-8 198
Section 3-9 208
Section 3-10 211
Section 3-11 215
Section 3-12 220
Section 3-13 221
Section 4-1 223
Section 4-2 240
Section 4-3 269
Section 4-4 285
Section 4-5 287
Section 4-6 290

S.V 04/24