John Deere 544K-II 4WD Loader Operator’s Manual OMT387131X19 PDF

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John Deere 544K-II 4WD Loader Operator’s Manual OMT387131X19 – PDF DOWNLOAD

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John Deere 544K-II 4WD Loader Operator’s Manual OMT387131X19 – PDF DOWNLOAD

P/N:OMT387131X19_22
Language: English
Division: Construction
Product Lines: Loaders
Publication Type: Operator’s Manuals
Associated Models: 544K SERIES II
Series: 0
Serial:
For complete service information also see: PC15082, T387123X19

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 544K-II 4WD Loader Operator’s Manual OMT387131X19 – 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 35
Avoid High-Pressure Oils 36
Work In Ventilated Area 36
Avoid Static Electricity Risk When Refueling 37
Prevent Fires 37
In Case of Machine Fire 38
Prevent Battery Explosions 38
High Debris Applications 38
Clean Debris from Machine 39
Handle Chemical Products Safely 39
Handle Starting Fluid Safely 39
Decommissioning — Proper Recycling and Disposal of Fluids and Components 40
Prepare for Emergencies 40
Exhaust Filter Ash Handling and Disposal 40
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
Avoid Power Lines 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
Service Machines Safely 50
Clean Exhaust Filter Safely 51
Service Cooling System Safely 52
Service Tires Safely 52
Use Proper Lifting Equipment 53
Remove Paint Before Welding or Heating 53
Make Welding Repairs Safely 53
Drive Metal Pins Safely 54
Safety—Safety Signs and Other Instructions 55
Safety Signs and Other Instructions 55
Operation—Operator’s Station 63
Levers—Two Function Hydraulic Control 63
Levers—Three Function Hydraulic Control 64
Levers—Four Function Hydraulic Control 66
Pedals 66
Sealed Switch Module (SSM) 67
Switch Module Functions 68
Advanced Display Unit (ADU) 71
Display Unit Functions 72
Horn Button 77
Turn Signals 77
Air Conditioner and Heater Operation 78
Counter Switch 79
Radio—If Equipped 80
Opening and Securing Side Door 84
Opening Side Window/Secondary Exit 85
Opening Rear Side Window 85
Seat Adjustment 86
Fire Extinguisher Mounting Location 87
Operation—Operating the Machine 88
Before Starting Work 88
Inspect Machine Daily Before Starting 88
Check Instruments Before Starting 88
Security System 89
Battery Disconnect Switch 89
Engine Break-In Period 90
Starting the Engine 91
Cold Start Aid—Block Heater—If Equipped 93
Cold Start Aid—Glow Plug 93
Warm-Up Procedure 93
Cold Weather Warm-Up 94
Required Machine Stop Warning 94
Park Brake Switch 96
Shifting the Transmission 97
Automatic Idle and Automatic Shutdown 99
Turbocharger Cool Down 99
Joystick Bucket and Boom Control 100
Two Lever Bucket and Boom Control 101
Auxiliary Control 102
Ride Control—If Equipped 103
Secondary Steering—If Equipped 105
Differential Lock Operation 105
Service ADVISOR™ Remote (SAR) Software Delivery Process 106
Exhaust Filter 107
Selective Catalytic Reduction (SCR) System Overview 109
Qualified Emergency Use — SCR Override Option 111
Restored Operation Option 112
Rear Camera and Radar Object Detection (ROD) System—If Equipped 113
Counter Switch Operation 115
Embedded Payload Scale—If Equipped 116
Boom Height Kickout Adjustment 120
Return-to-Carry Kickout Adjustment 120
Return-to-Dig Adjustment for Z-Bar Linkage 121
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 123
Operating Loader Coupler—If Equipped 124
Using the Loader Bucket 125
Backdragging 126
Fork Attachment 127
Operating in Water and Mud 128
Parking the Machine 129
Loading Machine on a Trailer 130
Towing Procedure 132
Lifting the Machine 133
Operation—Monitor Operation 134
Aftertreatment Indicators Overview 134
Display Unit—Normal Display 135
Display Unit—Main Menu 136
Display Unit—Main Menu—Codes 137
Display Unit—Main Menu—Codes—Active Codes 137
Display Unit—Main Menu—Codes—Stored Codes 138
Display Unit—Main Menu—Settings 139
Display Unit—Main Menu—Settings—Reverse Fan Cycle 140
Display Unit—Main Menu—Settings—Courtesy Lights 140
Display Unit—Main Menu—Settings—Quick Shift 141
Display Unit—Main Menu—Settings—Job Timer 141
Display Unit—Main Menu—Settings—Stopwatch 142
Display Unit—Main Menu—Settings—Ride Control—If Equipped 142
Display Unit—Main Menu—Settings—Counters 142
Display Unit—Main Menu—Settings—Camera Mode 143
Display Unit—Main Menu—Settings—Operator Configuration 143
Display Unit—Main Menu—Settings—Clutch Cutoff 144
Display Unit—Main Menu—Diagnostics 145
Display Unit—Main Menu—Diagnostics—Machine ID 146
Display Unit—Main Menu—Diagnostics—Battery Monitor 146
Display Unit—Main Menu—Diagnostics—Engine Sensors 147
Display Unit—Main Menu—Diagnostics—Transmission/Axle 147
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 148
Display Unit—Main Menu—Diagnostics—Machine Sensors 148
Display Unit—Main Menu—Diagnostics—FNR Selector 149
Display Unit—Main Menu—Diagnostics—Cab Switches 149
Display Unit—Main Menu—Diagnostics—Switch Module 149
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 150
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 151
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 151
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 152
Display Unit—Main Menu—Diagnostics—JDLink™ System Info 152
Display Unit—Main Menu—Diagnostics—Park Brake Test 153
Display Unit—Main Menu—Payload Scale—If Equipped 154
Display Unit—Main Menu—Payload Scale—Long Total 154
Display Unit—Main Menu—Payload Scale—Display Units 155
Display Unit—Main Menu—Payload Scale—Auto Add 155
Display Unit—Main Menu—Payload Scale—Diagnostics 155
Display Unit—Main Menu—Payload Scale—Setup 155
Display Unit—Main Menu—Security 156
Display Unit—Main Menu—Security—Security 157
Display Unit—Main Menu—Security—Change Owner PIN 157
Display Unit—Main Menu—Security—Manage Operator PINs 158
Display Unit—Main Menu—Security—Manage Transport PIN 159
Display Unit—Main Menu—Security—Delayed Operator Logout 160
Display Unit—Main Menu—Exhaust Filter 161
Display Unit—Main Menu—Exhaust Filter—Auto Cleaning 162
Display Unit—Main Menu—Exhaust Filter—Parked Cleaning 163
Display Unit—Main Menu—Exhaust Filter—Emergency Override 164
Display Unit—Main Menu—Software Delivery 165
Display Unit—Main Menu—Software Delivery—Software Update 166
Maintenance—Machine 167
Diesel Fuel 167
Diesel Fuel Specifications 167
Lubricity of Diesel Fuel 168
Biodiesel Fuel 169
Handling and Storing Diesel Fuel 170
Testing Diesel Fuel 170
Fuel Filters 170
Minimizing the Effect of Cold Weather on Diesel Engines 171
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 172
Storing Diesel Exhaust Fluid (DEF) 173
Refilling Diesel Exhaust Fluid (DEF) Tank 174
Testing Diesel Exhaust Fluid (DEF) 175
Disposal of Diesel Exhaust Fluid (DEF) 175
Supplemental Diesel Fuel Additives 175
Alternative and Synthetic Lubricants 176
Lubricant Storage 176
Mixing of Lubricants 176
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 177
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 178
Oil Filters 178
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 179
Diesel Engine Oil Service Interval for Operation at High Altitude 179
Transmission, Park Brake, and Axle Oil 180
Hydraulic Oil 181
Grease 182
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 183
Operating in Warm Temperature Climates 184
Required Emission-Related Information 184
Testing Coolant Freeze Point 185
Water Quality for Mixing with Coolant Concentrate 186
Disposing of Coolant 186
Maintenance—Periodic Maintenance 187
Service Machine at Specified Intervals 187
Check Hour Meter Regularly 187
Prepare Machine for Maintenance 188
Frame Locking Bar 189
Boom Lock 190
Pin Removal—If Equipped With Powerllel™ Linkage 191
Engine Service Doors and Side Shields 192
Cooling System Doors 193
Fuel Tank 194
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 194
Service Intervals 195
Required Parts 197
Maintenance—As Required 199
Check Window Washer Fluid Level 199
Inspect Tires and Check Pressure 199
Tire Pressures 200
Check Wheel Bolt Torque 202
Inspect Engine Air Cleaner Elements 203
Inspect Air Conditioner Compressor and Alternator Belt 204
Clean Cooler Cores 205
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 206
Drain Water From Primary Fuel Filter With Water Separator 207
Service Exhaust Filter 208
Drain, Flush, and Refill Fuel Tank 208
Clean Fuel Sending Unit Pickup Screen 209
Check and Clean or Replace Cab Fresh Air Filter 209
Check and Clean or Replace Cab Recirculating Air Filter 210
Clean and Tighten Battery Terminals 210
Maintenance—Every 10 Hours or Daily 211
Clean Air Cleaner Dust Unloader Valve 211
Check Coolant Level at Surge Tank 211
Check Engine Oil Level 212
Check Hydraulic System Oil Level 212
Check Transmission Oil Level 213
Inspect Outer Pin Seals—If Equipped 214
Maintenance—Every 100 Hours 215
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 215
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 216
Maintenance—Initial Service—250 Hours 217
Drain and Refill Front and Rear Axle Oil 217
Replace Axle Oil Filters—If Equipped 218
Maintenance—Every 250 Hours 219
Take Engine Oil Sample 219
Maintenance—Every 500 Hours 220
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 220
Check Front and Rear Axle Oil Level 221
Lubricate Front and Rear Axle Shaft Seals 221
Check Hybrid Battery Electrolyte Level—If Equipped 222
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 224
Take Fluid Samples 224
Drain and Refill Engine Oil and Replace Filter 225
Replace Primary Fuel Filter 226
Replace Final Fuel Filter 227
Replace Hydraulic Reservoir Breather Filter 227
Check Park Brake Oil Level 228
Lubricate Front and Rear Shaft Seals on Park Brake 228
Check Ride Control Accumulator—If Equipped 229
Maintenance—Every 1000 Hours 230
Replace Air Cleaner Dust Unloader Valve 230
Replace Engine Air Cleaner Elements 231
Replace Fuel Tank Breather Filter 231
Check Coolant Condition 232
Replace Axle Oil Filters—If Equipped 232
Lubricate Frame Hinge Pivots 232
Drain and Refill Park Brake Oil 233
Maintenance—Every 2000 Hours 234
Drain and Refill Transmission Oil and Replace Filter 234
Drain and Refill Front and Rear Axle Oil 236
Replace Open Crankcase Ventilation (OCV) Filter 237
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter 237
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter 238
Check and Adjust Engine Valve Lash 238
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
Replace Diesel Exhaust Fluid (DEF) Baffle (S N —XXXXXX) 239
Replace Diesel Exhaust Fluid (DEF) Header Suction Filter (S N —XXXXXX) 239
Clean Diesel Exhaust Fluid (DEF) Tank (S N —XXXXXX) 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
Maintenance—Every 5000 Hours 245
Check Driveline Damper For Cracks 245
Maintenance—Every 6000 Hours 246
Drain Cooling System 246
Refill Cooling System 247
Miscellaneous—Machine 248
Check Air Inlet Cover—If Equipped 248
Bleed Fuel System 248
Do Not Service Control Valves, Cylinders, Pumps, or Motors 248
Precautions for Alternator and Regulator 249
Handling, Checking, and Servicing Batteries Carefully 250
Using Booster Batteries—24-Volt System 251
Using Battery Charger 252
Replacement Batteries 253
Remove and Install Batteries 254
12-Volt Auxiliary Power Outlet—If Equipped 256
JDLink™ Machine Monitoring System (MMS)—If Equipped 256
Replacing Fuses 257
Remove and Install Halogen Bulbs 259
Fluid Sampling Test Ports—If Equipped 260
Air Conditioning System Service 261
Welding on Machine 262
Keep Electronic Control Unit Connectors Clean 262
External Service Brake Inspection 263
Service Recommendations For Snap-To-Connect (STC®) Fittings 264
Replacing Bucket Teeth—TK Series 265
Keep ROPS Installed Properly 265
Hardware Torque Specifications 265
Unified Inch Bolt and Screw Torque Values 266
Metric Bolt and Screw Torque Values 267
Bleeding Brakes 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 298
Troubleshooting Procedure 298
Engine 299
Transmission 302
Differential and Axle 305
Service Brake 306
Driveline 306
Park Brake 307
Hydraulic System 308
Steering 310
Air Conditioning System 311
Heater System 312
Software Update 313
Miscellaneous—Storage 314
Prepare Machine for Storage 314
Monthly Storage Procedure 315
Preparing Engine for Long-Term Storage 316
Removing Engine From Long-Term Storage 317
Miscellaneous—Machine Numbers 318
Record Product Identification Number (PIN) 318
Record Engine Serial Number 318
Record Transmission Serial Number 318
Record Hydraulic Pump Serial Number 319
Record Front and Rear Axle Housing Serial Numbers 319
Keep Proof of Ownership 319
Keep Machines Secure 320
Miscellaneous—Specifications 321
Engine Specifications 321
Drain and Refill Capacities 321
Standard Z-Bar Specifications 322
High Lift Z-Bar Specifications 324
Powerllel™ Specifications 326
Travel Speeds 327
Eurasian Economic Union 328
Machine Design Life 328
Page Number 25
Section 1-1 31
Section 1-2 32
Section 1-3 42
Section 1-4 50
Section 1-5 55
Section 2-1 63
Section 2-2 88
Section 2-3 134
Section 3-1 167
Section 3-2 187
Section 3-3 199
Section 3-4 211
Section 3-5 215
Section 3-6 217
Section 3-7 219
Section 3-8 220
Section 3-9 230
Section 3-10 234
Section 3-11 239
Section 3-12 245
Section 3-13 246
Section 4-1 248
Section 4-2 269
Section 4-3 298
Section 4-4 314
Section 4-5 318
Section 4-6 321

S.V 04/24