John Deere 544K Loader Operator’s Manual OMT231639 – PDF DOWNLOAD

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John Deere 544K Loader Operator’s Manual OMT231639 – PDF DOWNLOAD

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John Deere 544K Loader Operator’s Manual OMT231639 – PDF DOWNLOAD

• P/N: OMT231639_51
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Models: 544K
• Serial: (—642664) ENGINE 6068HDW74
• Additional Information: For complete service information also see PC10057, T231640

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

John Deere 544K Loader Operator’s Manual OMT231639 – PDF DOWNLOAD

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
Inspect Machine 25
Stay Clear of Moving Parts 25
Avoid High-Pressure Fluids 26
Avoid High-Pressure Oils 26
Work In Ventilated Area 27
Prevent Fires 27
Prevent Battery Explosions 28
Handle Chemical Products Safely 28
Decommissioning — Proper Recycling and Disposal of Fluids and Components 29
Prepare for Emergencies 29
Beware of Exhaust Fumes 29
Clean Debris from Machine 30
Add Cab Guarding for Special Uses 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 or Traveling On Public Roads 35
Inspect and Maintain ROPS 36
Add and Operate Attachments Safely 36
Operating on Slopes 36
Safety—Maintenance Precautions 37
Park and Prepare for Service Safely 37
Service Cooling System Safely 37
Remove Paint Before Welding or Heating 38
Make Welding Repairs Safely 38
Drive Metal Pins Safely 38
Service Tires Safely 39
Safety—Safety Signs 40
Safety Signs 40
Operation—Operator’s Station 42
Levers—Two Function Hydraulic Control 42
Levers—Three Function Hydraulic Control 43
Levers—Four Function Hydraulic Control 45
Levers—Joystick Steering Control 45
Pedals 46
Advanced Display Unit (ADU) 47
Display Unit Functions 48
Sealed Switch Module (SSM) 50
Switch Module Functions 51
Display Unit—Normal Display 54
Display Unit—Main Menu 55
Display Unit—Main Menu—Codes 56
Display Unit—Main Menu—Codes—Active Codes 56
Display Unit—Main Menu—Codes—Stored Codes 57
Display Unit—Main Menu—Machine Settings 58
Display Unit—Main Menu—Machine Settings—Reverse Fan Cycle 59
Display Unit—Main Menu—Machine Settings—Camera Mode 59
Display Unit—Main Menu—Machine Settings—Job Timer 59
Display Unit—Main Menu—Machine Settings—Stopwatch 59
Display Unit—Main Menu—Machine Settings—Ride Control—If Equipped 60
Display Unit—Main Menu—Machine Settings—Quick Shift 60
Display Unit—Main Menu—Machine Settings—Counters 61
Display Unit—Main Menu—Diagnostics 61
Display Unit—Main Menu—Diagnostics—Machine ID 62
Display Unit—Main Menu—Diagnostics—Battery Monitor 62
Display Unit—Main Menu—Diagnostics—Engine Sensors 62
Display Unit—Main Menu—Diagnostics—Transmission Sensors 63
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 63
Display Unit—Main Menu—Diagnostics—Machine Sensors 64
Display Unit—Main Menu—Diagnostics—FNR Selector 64
Display Unit—Main Menu—Diagnostics—Cab Switches 64
Display Unit—Main Menu—Diagnostics—Switch Module 64
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped 65
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 65
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 65
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 66
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 66
Display Unit—Main Menu—Payload Scale—If Equipped 67
Display Unit—Main Menu—Payload Scale—Long Total 67
Display Unit—Main Menu—Payload Scale—Display Units 67
Display Unit—Main Menu—Payload Scale—Auto Add 67
Display Unit—Main Menu—Payload Scale—Diagnostics 68
Display Unit—Main Menu—Payload Scale—Setup 68
Display Unit—Main Menu—Monitor Settings 68
Display Unit—Main Menu—Security 69
Display Unit—Main Menu—Security—Security 69
Display Unit—Main Menu—Security—Change Owner PIN 70
Display Unit—Main Menu—Security—Manage Operator PINs 70
Display Unit—Main Menu—Security—Manage Transport PIN 71
Display Unit—Main Menu—Security—Delayed Operator Logout 71
Horn Button 72
Turn Signals 72
Tilt Steering Column Adjustment 73
Joystick Steering Armrest Adjustment— if Equipped 73
Air Conditioner and Heater Operation 74
Opening and Securing Side Door 75
Opening Side Window/Secondary Exit 76
Opening Rear Side Window 76
Seat Adjustment 77
Operation—Operating the Machine 78
Inspect Machine Daily Before Starting 78
Check Instruments Before Starting 79
Engine Break-In Period 79
Starting the Engine 80
Starting Fluid (Cold Weather Starting Aid)—If Equipped 82
Engine Block Heater—If Equipped 83
Warmup 83
Minimizing the Effect of Cold Weather on Diesel Engines 84
Cold Weather Warmup 84
Automatic Idle and Automatic Shutdown 85
Neutral Lock 85
Park Brake Switch 86
Shifting the Transmission 87
Joystick Bucket and Boom Control 89
Two Lever Bucket and Boom Control 90
Auxiliary Control 91
Joystick Steering Control—If Equipped 92
Ride Control—If Equipped 94
Secondary Steering—If Equipped 96
Differential Lock Operation 96
Counter Switch Operation 97
Rear Camera and Radar Object Detection System (RODS)—If Equipped 98
Embedded Payload Scale—If Equipped 100
Security System 104
Boom Height Kickout Adjustment 104
Return-to-Carry Kickout Adjustment 105
Return-to-Dig Adjustment for Z-Bar Linkage 106
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 107
Operating Loader Coupler—If Equipped 108
Using the Loader Bucket 109
Backdragging 110
Fork Attachment 111
Operating in Water and Mud 112
Parking the Machine 113
Loading Machine on a Trailer 114
Towing Procedure 116
Lifting the Machine 118
Maintenance—Machine 120
Alternative and Synthetic Lubricants 120
Hydraulic Oil 121
Grease 122
Transmission, Park Brake, and Axle Oil 122
Lubricant Storage 123
Mixing of Lubricants 123
Diesel Fuel 124
Lubricity of Diesel Fuel 125
Handling and Storing Diesel Fuel 125
Biodiesel Fuel 126
Testing Diesel Fuel 127
Minimizing the Effect of Cold Weather on Diesel Engines 128
Low Sulfur Diesel Fuel Conditioner 129
Diesel Engine Break-In Oil 129
Diesel Engine Oil — Tier 3 and Stage IIIA 130
Diesel Engine Oil and Filter Service Intervals 131
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 132
Drain Intervals for Diesel Engine Coolant 133
John Deere COOL-GARD™ II Coolant Extender 133
Supplemental Coolant Additives 134
Operating in Warm Temperature Climates 134
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 135
Testing Diesel Engine Coolant 136
Maintenance—Periodic Maintenance 137
Service Machine at Specified Intervals 137
Check Hour Meter Regularly 137
Prepare Machine for Maintenance 138
Frame Locking Bar 139
Boom Lock 140
Pin Removal—If Equipped With Powerllel™ Linkage 141
Engine Service Doors and Side Shields 142
Cooling System Doors 143
Fuel Tank 144
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 144
Service Intervals 145
Required Parts 147
Maintenance—As Required 149
Inspect Tires and Check Pressure 149
Tire Pressures 150
Check Wheel Bolt Torque 152
Inspect Engine Air Cleaner Elements 153
Inspect Air Conditioner Compressor and Alternator Belt 154
Clean Cooler Cores 155
Check Windshield Washer Fluid Level 156
Drain Water From Auxiliary Fuel Filter/Water Separator—If Equipped 156
Drain Water From Primary Fuel Filter 157
Drain Water from Final Fuel Filter 157
Check and Clean or Replace Cab Fresh Air Filter 158
Check and Clean or Replace Cab Recirculating Air Filter 159
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 160
Check Transmission Oil Level 161
Check Coolant 162
Maintenance—Every 10 Hours or Daily 163
Check Coolant Level in Surge Tank 163
Check and Clean or Replace Air Cleaner Dust Unloader Valve 163
Check Engine Oil Level 164
Check Hydraulic Oil Level 164
Inspect Outer Pin Seals 165
Maintenance—Every 100 Hours 166
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 166
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 167
Maintenance—Initial Service – 250 Hours 168
Drain and Refill Engine Oil and Replace Filter 168
Drain and Refill Front and Rear Axle Oil 169
Replace Axle Oil Filters—If Equipped 170
Maintenance—Every 250 Hours 171
Take Engine Oil Sample 171
Maintenance—Every 500 Hours 172
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 172
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 173
Check Battery Water Level and Terminals 174
Drain and Refill Engine Oil and Replace Filter 176
Replace Primary Fuel Filter 177
Replace Final Fuel Filter 178
Replace Auxiliary Fuel Filter/Water Separator—If Equipped 178
Replace In-Line Fuel Strainer 179
Replace Hydraulic Reservoir Breather Filter 179
Check Park Brake Oil Level 179
Lubricate Front and Rear Shaft Seals on Park Brake 180
Check Front and Rear Axle Oil Level 180
Lubricate Front and Rear Axle Shaft Seals 181
Check Ride Control Accumulator—If Equipped 182
Take Fluid Samples 182
Maintenance—Every 1000 Hours 183
Clean Engine Crankcase Vent Tube 183
Replace Air Cleaner Dust Unloader Valve 183
Replace Engine Air Cleaner Elements 184
Replace Axle Oil Filters—If Equipped 185
Lubricate Frame Hinge Pivots 185
Drain and Refill Park Brake Oil 186
Check Coolant 186
Maintenance—Every 2000 Hours 187
Replace Outer Pin Seals 187
Drain and Refill Transmission Oil and Replace Filter 188
Drain and Refill Front and Rear Axle Oil 190
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 191
Rerun Transmission Clutch Calibration 191
Adjust Engine Valve Lash (Clearance) 191
Maintenance—Every 4000 Hours 192
Clean Hydraulic Pump Case Drain Screen 192
Drain and Refill Hydraulic System Oil 194
Clean Hydraulic System Fill Strainer 195
Replace Hydraulic System Return Filter 196
Replace Crankshaft Dampener 196
Maintenance—Every 5000 Hours 197
Inspect Driveline Damper 197
Maintenance—Every 6000 Hours 198
Drain Cooling System 198
Refill Cooling System 199
Miscellaneous—Machine 200
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped 200
Check Air Inlet Cover 200
Inspect Fuel Tank Vent Hose and Breather 200
Bleed Fuel System 201
Bleed Fuel System With Low Pressure Fuel Pump—If Equipped 201
Check Fire Extinguisher—If Equipped 201
Precautions for Alternator and Regulator 202
Handle Batteries Safely 203
Using Booster Batteries—24 Volt System 204
Using Battery Charger 205
Battery Disconnect Switch 206
Replacement Batteries 206
Remove and Install Batteries 207
12-Volt Auxiliary Power Outlet—If Equipped 208
JDLink™ Machine Monitoring System (MMS)—If Equipped 208
Fuse Identification and Replacement 209
Replacing Halogen Bulbs 211
Fluid Sampling Test Ports—If Equipped 212
Air Conditioner System Service 214
External Service Brake Inspection 215
Clean Oil Coolers, Charge Air Cooler, and Radiator 215
Service Recommendations For Snap-To-Connect (STC®) Fittings 216
Do Not Service Control Valves, Cylinders, Pumps, or Motors 217
Keep ROPS Installed Properly 217
Welding On Machine 217
Replacing Bucket Teeth—TK Series 218
Hardware Torque Specifications 218
Unified Inch Bolt and Screw Torque Values 219
Metric Bolt and Screw Torque Values 220
Miscellaneous—Operational Checkout 221
Operational Checkout 221
Diagnostic Trouble Code Check 221
Operational Checks—Ignition OFF, Engine OFF Checks 222
Operational Checks—Ignition ON, Engine OFF Checks 223
Operational Checks—Ignition ON, Engine ON Checks 228
Miscellaneous—Troubleshooting 248
Troubleshooting Procedure 248
Engine 249
Transmission 251
Differential And Axle 254
Service Brake 255
Driveline 256
Park Brake 256
Hydraulic System 257
Steering 259
Air Conditioning System 260
Heater System 261
Miscellaneous—Storage 262
Prepare Machine For Storage 262
Monthly Storage Procedure 262
Miscellaneous—Machine Numbers 264
Record Product Identification Number (PIN) 264
Record Engine Serial Number 264
Record Transmission Serial Number 264
Record Hydraulic Pump Serial Number 265
Record Axle Serial Number 265
Keep Proof of Ownership 265
Keep Machines Secure 265
Miscellaneous—Specifications 266
Engine Specifications 266
Drain and Refill Capacities 267
Standard Z-Bar Specifications 268
High Lift Z-Bar Specifications 270
Powerllel™ Specifications 272
Travel Speeds 273
Page Number 19
Section 1-1 23
Section 1-2 24
Section 1-3 31
Section 1-4 37
Section 1-5 40
Section 2-1 42
Section 2-2 78
Section 3-1 120
Section 3-2 137
Section 3-3 149
Section 3-4 163
Section 3-5 166
Section 3-6 168
Section 3-7 171
Section 3-8 172
Section 3-9 183
Section 3-10 187
Section 3-11 192
Section 3-12 197
Section 3-13 198
Section 4-1 200
Section 4-2 221
Section 4-3 248
Section 4-4 262
Section 4-5 264
Section 4-6 266

S.V 04/24