John Deere 544L 4WD Loader Operator’s Manual OMT406388X19 PDF

Description

John Deere 544L 4WD Loader Operator’s Manual OMT406388X19 – PDF DOWNLOAD

• Part Number (P/N): OMT406388X19_04
• Language: English
• Division: Construction
• Product Lines: Loaders
• Publication Type: Operator’s Manuals
• Associated Model: 544L
• Serial Number Range: 1DW544L_ _ _F693054—

TABLE OF CONTENTS:

John Deere 544L 4WD Loader Operator’s Manual OMT406388X19 – PDF DOWNLOAD

Contents 29
Safety—Safety and Operator Conveniences 33
Safety and Operator Convenience Features 33
Safety—General Precautions 34
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 34
Recognize Safety Information 35
Follow Safety Instructions 36
Operate Only If Qualified 36
Wear Protective Equipment 36
Protect Against Noise 37
Avoid Unauthorized Machine Modifications 37
Inspect Machine 37
Stay Clear of Moving Parts 37
Avoid High-Pressure Fluids 38
Avoid High-Pressure Oils 38
Work In Ventilated Area 38
Avoid Static Electricity Risk When Refueling 39
Prevent Fires, Clean Debris From Machine 40
In Case of Machine Fire 40
Prevent Battery Explosions 41
High Debris Applications 41
Clean Debris from Machine 41
Handle Chemical Products Safely 42
Handle Starting Fluid Safely 42
Decommissioning — Proper Recycling and Disposal of Fluids and Components 43
Prepare for Emergencies 43
Exhaust Filter Ash Handling and Disposal 43
Add Cab Guarding for Special Uses 44
Safety—Operating Precautions 45
Use Steps and Handholds Correctly 45
Start Only From Operator’s Seat 45
Use and Maintain Seat Belt 45
Prevent Unintended Machine Movement 46
Avoid Work Site Hazards 47
Keep Riders Off Machine 48
Avoid Backover Accidents 48
Avoid Machine Tip Over and Machine Damage 49
Avoid Power Lines 49
Use Special Care When Operating Loader 50
Operating on Slopes 50
Operating or Traveling On Public Roads 50
Inspect and Maintain ROPS 51
Travel Safely 51
Prevent Acid Burns 52
Add and Operate Attachments Safely 52
Safety—Maintenance Precautions 53
Park and Prepare for Service Safely 53
Service Machines Safely 53
Service Accumulator Systems Safely 54
Service Cooling System Safely 54
Remove Paint Before Welding or Heating 54
Make Welding Repairs Safely 55
Drive Metal Pins Safely 55
Service Tires Safely 56
Use Proper Lifting Equipment 56
Clean Exhaust Filter Safely 57
Safety—Safety Signs and Other Instructions 58
Safety Signs and Other Instructions 58
Operation—Operator’s Station 68
Levers—Two Function Hydraulic Control 68
Levers—Three Function Hydraulic Control 69
Levers—Four Function Hydraulic Control 70
Levers—Five or Six Function Hydraulic Control 70
Pedals 71
Sealed Switch Module (SSM) Functions 72
Primary Display Unit (PDU) Functions 77
Horn Button 85
Turn Signals 85
Power Adjustable Mirrors—If Equipped 86
Dome Light 86
Air Conditioner and Heater Operation 87
Counter Switch—If Equipped 88
Radio—If Equipped 89
Auxiliary Power Supply 93
Opening and Securing Side Door 94
Opening Side Window (Alternative Exit) 95
Seat Adjustment 96
Fire Extinguisher Mounting Location 98
Operation—Operating the Machine 99
Before Starting Work 99
Inspect Machine Daily Before Starting 99
Check Instruments Before Starting 100
Security System 101
Battery Disconnect Switch 101
Engine Break-In Period 102
Starting the Engine 103
Cold Start Aid—Block Heater—If Equipped 105
Cold Start Aid—Glow Plug 105
Cold Weather Warm-Up 106
Required Machine Stop Warning 106
Park Brake Switch 108
Shifting the Transmission 109
Operating in Water and Mud 110
Driving Up a Steep or Slippery Slope 110
Automatic Idle and Automatic Shutdown 111
Turbocharger Cool Down 111
Stopping the Engine 112
Joystick Bucket and Boom Control 113
Two Lever Bucket and Boom Control 115
Auxiliary Control 116
Ride Control—If Equipped 117
Secondary Steering—If Equipped 119
Differential Lock Operation 120
Throttle Lock—If Equipped 122
Service ADVISOR™ Remote (SAR) Software Delivery Process 123
Exhaust Filter 124
Selective Catalytic Reduction (SCR) System Overview 126
US EPA Qualified Emergency Use — SCR Derate Override Option 128
EU Qualified Emergency Use — SCR Derate Override Option 129
Rear Camera and Radar Object Detection (ROD) System—If Equipped 130
Counter Switch Operation—If Equipped 133
Embedded Payload Scale—If Equipped 134
Boom Height Kickout Adjustment 138
Return-to-Carry Adjustment 138
Return-to-Dig Adjustment 139
Operating Loader Coupler—If Equipped 139
Using the Loader Bucket 140
Backdragging 141
Fork Attachment 142
Parking the Machine 144
Loading Machine for Transport 146
Towing—Recovery Procedure 149
Drive Through Mode Operation 150
Lifting the Machine 151
Operation—Monitor Operation 152
Aftertreatment Indicators Overview 152
Primary Display Unit (PDU) 153
Main Menu 154
Main Menu—Display Settings 155
Main Menu—Diagnostics 156
Main Menu—Exhaust Filter 158
Main Menu—Exhaust Filter Auto Cleaning 159
Main Menu—Exhaust Filter Parked Cleaning 160
Main Menu—Exhaust Filter Emergency Override 161
Main Menu—Software Update 161
Main Menu—Calibrations—Electro-Hydraulic Valves 162
Main Menu—Calibrations—Implement Control Levers 163
Main Menu—Calibrations—Loader Position Sensors 164
Main Menu—Calibrations—Loader Linkage 164
Main Menu—Calibrations—Transmission Clutches 165
Main Menu—Calibrations—Brake Pedal 165
Main Menu—Machine Setup 166
Main Menu—Security 171
Main Menu—Machine Fan 173
Main Menu—Fuel Consumption 174
Main Menu—About 175
Main Menu—Job Timer 175
Main Menu—Camera—If Equipped 176
Main Menu—Payload Weighing—If Equipped 177
Main Menu—Attachments—If Equipped 178
Maintenance—Machine 179
Required Emission-Related Information 179
Alternative and Synthetic Lubricants 179
Lubricant Storage 179
Mixing of Lubricants 179
Hydraulic Oil 180
Multipurpose Extreme Pressure (EP) Grease 181
Diesel Fuel 182
Diesel Fuel Specifications 182
Lubricity of Diesel Fuel 183
Handling and Storing Diesel Fuel 183
Biodiesel Fuel 184
Testing Diesel Fuel 185
Supplemental Diesel Fuel Additives 185
Fuel Filters 185
Diesel Exhaust Fluid (DEF) — Use in Selective Catalytic Reduction (SCR) Equipped Engines 186
Refilling Diesel Exhaust Fluid (DEF) Tank 187
Testing Diesel Exhaust Fluid (DEF) 188
Storing Diesel Exhaust Fluid (DEF) 188
Disposal of Diesel Exhaust Fluid (DEF) 189
Minimizing the Effect of Cold Weather on Diesel Engines 190
John Deere Break-In Plus™ Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 191
Diesel Engine Oil — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V 192
Engine Oil and Filter Service Intervals — Interim Tier 4, Final Tier 4, Stage IIIB, Stage IV, and Stage V Engines 193
Diesel Engine Oil Service Interval for Operation at High Altitude 193
Oil Filters 194
Transmission, Park Brake, and Axle Oil 194
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 195
Water Quality for Mixing with Coolant Concentrate 196
Operating in Warm Temperature Climates 196
Testing Coolant Freeze Point 197
Disposing of Coolant 197
Maintenance—Periodic Maintenance 198
Service Machine at Specified Intervals 198
Check the Hour Meter Regularly 198
Prepare Machine for Maintenance 199
Frame Locking Bar 200
Locking Loader Boom 201
Engine Service Doors and Side Shields 202
Cooling System Doors 203
Fuel Tank 204
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 204
Service Intervals 205
Required Parts 207
Maintenance—As Required 209
Check Windshield Washer Fluid Level 209
Inspect Tires and Check Pressure 209
Tire Pressures 211
Check Wheel Bolt Torque 214
Inspect Engine Air Cleaner Elements 215
Inspect Serpentine Belt 216
Clean Cooler Cores 217
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 219
Drain Water From Primary Fuel Filter With Water Separator 220
Service Exhaust Filter 220
Drain, Flush, and Refill Fuel Tank 221
Check Cab Recirculation Air Filter 222
Check Cab Fresh Air Filter 223
Check and Clean Cab Air Filter Precleaner—If Equipped 224
Clean Hydraulic Pump Case Drain In-Line Screen 225
Clean Debris From Coupler Lock Cylinder—If Equipped 227
Lubricate Cab Door Hinges 229
Clean and Tighten Battery Terminals 229
Maintenance—Every 10 Hours or Daily 230
Clean Air Cleaner Dust Unloader Valve 230
Check Coolant Level at Surge Tank 231
Check Engine Oil Level 232
Check Hydraulic System Oil Level 232
Check Transmission Oil Level 233
Maintenance—Every 100 Hours 234
Lubricate Loader Linkage and Cylinder Pivots 234
Lubricate Coupler Lock Pins—If Equipped 238
Maintenance—Initial Service—250 Hours 239
Drain and Refill Front and Rear Axle Oil 239
Replace Axle Oil Filters—If Equipped 240
Maintenance—Every 250 Hours 241
Take Engine Oil Sample 241
Maintenance—Every 500 Hours 242
Lubricate Driveline Upper and Lower Sliding Joints 242
Lubricate Front and Rear Axle Shaft Seals 243
Check Hybrid Battery Electrolyte Level—If Equipped 244
Replace Hydraulic Reservoir Breather Filter 246
Check Front and Rear Axle Oil Level 247
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 248
Take Fluid Samples 248
Drain and Refill Engine Oil and Replace Filter 249
Replace Primary Fuel Filter 250
Replace In-Line Fuel Filter 250
Replace Final Fuel Filter 251
Check Park Brake Oil Level 251
Lubricate Front and Rear Shaft Seals on Park Brake 252
Check Ride Control Accumulator—If Equipped 253
Maintenance—Every 1000 Hours 254
Replace Air Cleaner Dust Unloader Valve 254
Replace Engine Air Cleaner Elements 255
Replace Fuel Tank Breather Filter 255
Check Coolant Condition 256
Replace Axle Oil Filters—If Equipped 256
Lubricate Frame Hinge Pivots 257
Drain and Refill Park Brake Oil 257
Maintenance—Every 2000 Hours 258
Drain and Refill Front and Rear Axle Oil 258
Replace Open Crankcase Ventilation (OCV) Filter 259
Check and Adjust Engine Valve Lash 259
Drain and Refill Transmission Oil and Replace Filter 260
Rerun Transmission Clutch Calibration 261
Maintenance—Every 4000 Hours 262
Access Diesel Exhaust Fluid (DEF) Dosing Unit Filter 262
Replace Diesel Exhaust Fluid (DEF) Dosing Unit Filter 263
Replace Diesel Exhaust Fluid (DEF) Tank Breather Filter 264
Replace Diesel Exhaust Fluid (DEF) Baffle (S N —396150) 264
Clean Diesel Exhaust Fluid (DEF) Tank (S N —396150) 264
Replace Diesel Exhaust Fluid (DEF) Header Suction Filter (S N —396150) 264
Replace Hydraulic System Return Filter 265
Drain, Flush, and Refill Hydraulic System Oil 266
Clean Hydraulic System Fill Strainer 268
Maintenance—Every 5000 Hours 269
Check Driveline Damper for Cracks 269
Maintenance—Every 6000 Hours 270
Drain Cooling System 270
Cooling System Fill and Deaeration Procedure 271
Miscellaneous—Machine 272
Check Air Inlet Cover—If Equipped 272
Bleed Fuel System 272
Do Not Service or Adjust Injection Nozzles or High-Pressure Fuel Pump 272
Do Not Service Control Valves, Cylinders, Pumps, or Motors 272
Precautions for Alternator and Regulator 273
Clean Machine Regularly 273
Handling, Checking, and Servicing Batteries Carefully 274
Using Battery Charger 275
Using Booster Batteries—24-Volt System 277
Replacing Batteries 278
Welding on Machine 279
Keep Electronic Control Unit Connectors Clean 279
JDLink Machine Monitoring System (MMS)—If Equipped 279
Replacing Fuses 280
Remove and Install Halogen Bulbs 284
Remove and Install Light-Emitting Diode (LED) Lights 285
Fluid Sampling Test Ports—If Equipped 286
Service Recommendations for Snap-To-Connect® (STC) Fittings 287
Keep ROPS Installed Properly 288
Verified Anchor Point Information 288
External Service Brake Inspection 289
Replacing Seat Belt 290
Replacing Bucket Teeth—TK Series 291
Servicing Air Conditioning System 291
Hardware Torque Specifications 291
Unified Inch Bolt and Screw Torque Values 292
Metric Bolt and Screw Torque Values 293
Miscellaneous—Operational Checkout 294
Operational Checkout 294
Diagnostic Trouble Code (DTC) Check 294
Operational Checks—Ignition Off, Engine Off Checks 294
Operational Checks—Ignition On, Engine Off Checks 295
Operational Checks—Ignition On, Engine On Checks 302
Miscellaneous—Troubleshooting 323
Troubleshooting Procedure 323
Engine 324
Transmission 329
Differential and Axle 331
Service Brake 332
Driveline 332
Park Brake 333
Hydraulic System 334
Steering 337
Air Conditioning System 338
Heating System 339
Software Update 340
Miscellaneous—Machine Storage 341
Prepare Machine for Storage 341
Monthly Storage Procedure 342
Preparing Engine for Long-Term Storage 343
Removing Engine From Long-Term Storage 344
Miscellaneous—Machine Numbers 345
Record Product Identification Number (PIN) 345
Record Engine Serial Number 345
Record Transmission Serial Number 345
Record Hydraulic Pump Serial Number 346
Record Front and Rear Axle Housing Serial Numbers 346
Keep Proof of Ownership 346
Keep Machines Secure 347
Miscellaneous—Specifications 348
Engine Specifications 348
Drain and Refill Capacities 348
Standard Z-Bar Specifications 349
High Lift Z-Bar Specifications 352
High Lift Plus Z-Bar Specifications 355
Travel Speeds 357
Eurasian Economic Union 357
Machine Design Life 358
Page Number 29
Section 1-1 33
Section 1-2 34
Section 1-3 45
Section 1-4 53
Section 1-5 58
Section 2-1 68
Section 2-2 99
Section 2-3 152
Section 3-1 179
Section 3-2 198
Section 3-3 209
Section 3-4 230
Section 3-5 234
Section 3-6 239
Section 3-7 241
Section 3-8 242
Section 3-9 254
Section 3-10 258
Section 3-11 262
Section 3-12 269
Section 3-13 270
Section 4-1 272
Section 4-2 294
Section 4-3 323
Section 4-4 341
Section 4-5 345
Section 4-6 348

 S.V 04/24