John Deere 544J Loader Operation & Test Technical Manual S.N. 611800 PDF

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John Deere 544J Loader Operation & Test Technical Manual S.N. 611800 – PDF DOWNLOAD

FILE DETAILS:

John Deere 544J Loader Operation & Test Technical Manual S.N. 611800 – PDF DOWNLOAD

Language : English
Pages : 1080
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

John Deere 544J Loader Operation & Test Technical Manual S.N. 611800 – PDF DOWNLOAD

Contents 5
General Information 7
Safety Information 9
Recognize Safety Information 9
Follow Safety Instructions 9
Operate Only If Qualified 10
Wear Protective Equipment 10
Avoid Unauthorized Machine Modifications 10
Add Cab Guarding For Special Uses 11
Inspect Machine 11
Stay Clear of Moving Parts 11
Avoid High-Pressure Fluids 12
Avoid High-Pressure Oils 12
Beware of Exhaust Fumes 13
Prevent Fires 13
Prevent Battery Explosions 13
Handle Chemical Products Safely 14
Dispose of Waste Properly 14
Prepare for Emergencies 14
Use Steps and Handholds Correctly 15
Start Only From Operator’s Seat 15
Use and Maintain Seat Belt 15
Prevent Unintended Machine Movement 16
Avoid Work Site Hazards 17
Use Special Care When Operating Loader 18
Keep Riders Off Machine 18
Avoid Backover Accidents 19
Avoid Machine Tip Over 19
Operating on Slopes 20
Operating or Traveling On Public Roads 20
Inspect and Maintain ROPS 21
Add and Operate Attachments Safely 21
Prevent Unintended Detonation of Explosive Devices 21
Park And Prepare For Service Safely 22
Service Cooling System Safely 22
Remove Paint Before Welding or Heating 23
Make Welding Repairs Safely 24
Drive Metal Pins Safely 24
Diagnostic Trouble Codes (DTC) 25
CAN Monitor Unit (CMU) Diagnostic Trouble Codes 35
CAN Monitor Unit (CMU) Diagnostic Trouble Codes 35
00082905 — Fuel Level Open or Short 35
Fuel Level Sensor Open or Short Diagnostic Procedure 35
00200009 — CAN Comm Lost For ECU 37
CAN Comm Lost For ECU Diagnostic Procedure 38
00200309 — CAN Comm Lost For TCU 40
CAN Comm Lost For TCU Diagnostic Procedure 40
40
40
41
41
41
41
00203309 — CAN Comm Lost For FLC 42
CAN Comm Lost For FLC Diagnostic Procedure 42
00214009 — CAN Comm Lost For SSM 44
CAN Comm Lost For SSM Diagnostic Procedure 44
00236704 — Left Turn Switch Short to Ground 45
Left Turn Switch Short to Ground Diagnostic Procedure 46
46
46
47
47
00236904 — Right Turn Switch Short to Ground 47
Right Turn Switch Short to Ground Diagnostic Procedure 47
48
48
48
48
52425031 — Inspect Park Brake 49
Inspect Park Brake Diagnostic Procedure 49
49
Engine Control Unit (ECU) Diagnostic Trouble Codes 51
Engine Control Unit (ECU) Diagnostic Trouble Codes 51
00010700 — Eng Air Filter Restricted 52
Engine Air Filter Restricted Diagnostic Procedure 52
52
52
53
53
00017103 — Ambient Air Open Circuit 53
Ambient Air Open Circuit Diagnostic Procedure 53
54
54
54
00017104 — Ambient Air Short to Gnd 55
Ambient Air Short to Ground Diagnostic Procedure 55
55
56
56
57
00062701 — ECU Unswitch Short to GND 57
Engine Control Unit (ECU) Unswitched Short to Ground Diagnostic Procedure 57
57
57
58
58
00125313 — Injector Cal Required 58
Injector Calibration Required Diagnostic Procedure 58
58
59
00200309 — CAN Comm Lost for TCU 59
CAN Communication Lost for TCU Diagnostic Procedure 59
00203309 — CAN Comm Lost for FLC 61
CAN Communication Lost for FLC Diagnostic Procedure 61
Transmission Control Unit (TCU) Diagnostic Trouble Codes 63
Transmission Control Unit (TCU) Diagnostic Trouble Codes 63
00202309 — CAN Comm Lost for CMU 63
CAN Signal Missing from CMU Diagnostic Procedure 64
64
64
65
65
65
66
00203309 — CAN Comm Lost for FLC 66
CAN Signal Missing from FLC Diagnostic Procedure 66
66
67
67
67
67
52234400 — Converter Overtemp 68
Transmission Oil Temperature Too High Diagnostic Procedure 68
68
69
69
52235015 — Input Torque Overload 69
Input Torque Overload Diagnostic Procedure 69
70
70
52236407 — Trans Clutch Calibr Failed 70
Transmission Clutch Calibration Failed Diagnostic Procedure 70
71
71
71
52236413 — Trans Clutch Calibr Fault 71
Transmission Clutch Calibration Fault Diagnostic Procedure 72
72
52236513 — Limp Home Mode 72
Limp Home Mode Requested Diagnostic Procedure 72
73
73
52236613 — Application Invalid 73
Application Invalid Diagnostic Procedure 73
74
74
52236713 — TCU Configuration Invalid 74
TCU Configuration Invalid Diagnostic Procedure 74
75
75
52236802 — Memory Failure 75
TCU Memory Failure Diagnostic Procedure 75
76
76
52236903 — Remote Display Short to Power 76
Remote Display Short to Power Diagnostic Procedure 76
77
77
77
78
52236904 — Remote Display Short to Ground 78
Remote Display Short to Ground Diagnostic Procedure 78
79
79
79
80
52237002 — TCU VP2 Short Circuit 80
TCU Valve Power Supply 2 Short Circuit Diagnostic Procedure 80
81
81
82
52237102 — TCU VP1 Short Circuit 82
TCU Valve Power Supply 1 Short Circuit Diagnostic Procedure 82
83
52237303 — Power Supply High Voltage 83
Power Supply High Voltage Diagnostic Procedure 83
84
84
52237304 — Power Supply Low Voltage 84
Power Supply Low Voltage Diagnostic Procedure 84
85
85
85
52237403 — Sensor Supply Short to Power 86
Sensor Supply Short to Power Diagnostic Procedure 86
86
86
87
52237404 — Sensor Supply Short to Gnd 87
Sensor Supply Short to Ground Diagnostic Procedure 87
87
88
88
88
52237500 — Trans Oil Filter Restricted 88
Transmission Oil Filter Restricted Diagnostic Procedure 89
89
89
90
52237600 — Trans Oil Temp Max Value 90
Transmission Oil Temperature Maximum Value Diagnostic Procedure 90
91
91
52237903 — Park Brake Solenoid Short to Power 91
Park Brake Solenoid Short to Power Diagnostic Procedure 92
92
92
93
52237904 — Park Brake Solenoid Short to Gnd 93
Park Brake Solenoid Short to Ground Diagnostic Procedure 94
94
95
96
52237905 — Park Brake Solenoid Open Circuit 96
Park Brake Solenoid Open Circuit Diagnostic Procedure 97
97
98
52238203 — Backup Alarm Short to Power 98
Backup Alarm Short to Power Diagnostic Procedure 99
99
100
101
52238204 — Backup Alarm Short to Gnd 102
Backup Alarm Short to Ground Diagnostic Procedure 102
102
102
103
104
52238205 — Backup Alarm Open Circuit 105
Backup Alarm Open Circuit Diagnostic Procedure 105
105
105
106
52238302 — Clutch KR Slippage 106
Clutch KR Slippage Diagnostic Procedure 107
107
107
107
108
108
108
52238303 — Clutch Rev Sol Short to Power 109
Clutch Reverse Solenoid Short to Power Diagnostic Procedure 109
109
110
111
52238304 — Clutch Rev Sol Short to Gnd 111
Clutch Reverse Solenoid Short to Ground Diagnostic Procedure 112
112
113
114
115
52238305 — Clutch Rev Sol Open Circuit 115
Clutch Reverse Solenoid Open Circuit Diagnostic Procedure 116
116
117
52238602 — Clutch KV Slippage 117
Clutch KV Slippage Diagnostic Procedure 117
118
118
118
118
119
119
52238603 — Clutch Fwd Sol Short to Power 119
Clutch Forward Solenoid Short to Power Diagnostic Procedure 120
120
121
122
52238604 — Clutch Fwd Sol Short to Gnd 122
Clutch Forward Solenoid Short to Ground Diagnostic Procedure 123
123
124
125
126
52238605 — Clutch Fwd Sol Solenoid Open 126
Clutch Forward Solenoid Open Circuit Diagnostic Procedure 127
127
128
52238902 — Clutch K4 Slippage 128
Clutch K4 Slippage Diagnostic Procedure 128
129
129
129
129
130
130
52238903 — Clutch K4 Sol Short to Power 130
Clutch K4 Control Solenoid Short to Power Diagnostic Procedure 131
131
132
133
52238904 — Clutch K4 Sol Short to Gnd 133
Clutch K4 Control Solenoid Short to Ground Diagnostic Procedure 134
134
135
136
137
52238905 — Clutch K4 Sol Open Circuit 137
Clutch K4 Control Solenoid Open Circuit Diagnostic Procedure 138
138
139
52239202 — Clutch K3 Slippage 139
Clutch K3 Slippage Diagnostic Procedure 139
140
140
140
140
141
141
52239203 — Clutch K3 Sol Short to Power 141
Clutch K3 Control Solenoid Short to Power Diagnostic Procedure 142
142
143
144
52239204 — Clutch K3 Sol Short to Gnd 144
Clutch K3 Control Solenoid Short to Ground Diagnostic Procedure 145
145
146
147
148
52239205 — Clutch K3 Sol Open Circuit 148
Clutch K3 Control Solenoid Open Circuit Diagnostic Procedure 149
149
150
52239502 — Clutch K2 Slippage 150
Clutch K2 Slippage Diagnostic Procedure 150
151
151
151
151
152
152
52239503 — Clutch K2 Sol Short to Power 152
Transmission Clutch K2 Control Solenoid Short to Power Diagnostic Procedure 153
153
154
155
52239504 — Clutch K2 Sol Short to Gnd 155
Transmission Clutch K2 Control Solenoid Short to Ground Diagnostic Procedure 156
156
157
158
159
52239505 — Clutch K2 Sol Open Circuit 159
Transmission Clutch K2 Control Solenoid Open Circuit Diagnostic Procedure 160
160
161
52239902 — Clutch K1 Slippage 161
Transmission Clutch K1 Slippage Diagnostic Procedure 161
162
162
162
162
163
163
52239903 — Clutch K1 Sol Short to Power 163
Transmission Clutch K1 Control Solenoid Short to Power Diagnostic Procedure 164
164
165
166
52239904 — Clutch K1 Sol Short to Gnd 166
Transmission Clutch K1 Control Solenoid Short to Ground Diagnostic Procedure 167
167
168
169
170
52239905 — Clutch K1 Sol Open Circuit 170
Transmission Clutch K1 Control Solenoid Open Circuit Diagnostic Procedure 171
171
172
52240102 — Trans Speed Sensor Fault 172
Transmission Output Speed Sensor Fault Diagnostic Procedure 172
173
173
52240103 — Output Shaft Open or Short 173
Output Shaft Open or Short Diagnostic Procedure 174
174
175
176
176
52240104 — Output Shaft Short to Gnd 177
Output Shaft Short to Ground Diagnostic Procedure 177
177
178
178
52240112 — Output Shaft Fault 179
Output Shaft Fault Diagnostic Procedure 179
179
180
52240115 — Output Shaft Overspeed 180
Output Shaft Overspeed Diagnostic Procedure 180
181
52240203 — Clutch Speed Open or Short 181
Clutch Speed Open or Short Diagnostic Procedure 181
182
182
183
184
52240204 — Clutch Speed Short to Gnd 184
Clutch Speed Short to Ground Diagnostic Procedure 185
185
185
186
52240212 — Clutch Speed Sensor Fault 186
Clutch Speed Sensor Fault Diagnostic Procedure 187
187
187
52240303 — Conv Output Spd Open or Short 188
Converter Output Speed Open or Short Diagnostic Procedure 188
188
189
189
190
52240304 — Conv Output Spd Short to Gnd 190
Converter Output Speed Short to Ground Diagnostic Procedure 191
191
191
192
52240312 — Conv Output Spd Fault 192
Converter Output Speed Fault Diagnostic Procedure 193
193
193
52240403 — Conv Input Spd Open or Short 194
Converter Input Speed Open or Short Diagnostic Procedure 194
194
195
196
197
52240404 — Conv Input Spd Short to Gnd 197
Torque Converter Input Speed Short to Ground Diagnostic Procedure 198
198
199
200
52240412 — Conv Input Spd Fault 200
Converter Input Speed Fault Diagnostic Procedure 201
201
201
52240603 — Trans Oil Temp Open or Short 202
Transmission Oil Temperature Sensor Open or Short Diagnostic Procedure 202
202
203
204
205
52240604 — Trans Oil Temp Short to Gnd 205
Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure 206
206
207
208
52240703 — Clutch Cutoff Short to Power 208
Clutch Cut-Off Sensor Short to Power Diagnostic Procedure 209
209
209
209
210
52240704 — Clutch Cutoff Open or Short 210
Clutch Cut-Off Sensor Open or Short Diagnostic Procedure 210
210
211
211
211
52240905 — 2nd FNR Open Circuit 211
2nd TCL Open Circuit Diagnostic Procedure (Pilot Control Joystick) 212
212
212
52240912 — 2nd FNR Mult Inputs 213
2nd TCL Missing Inputs Diagnostic Procedure 213
213
214
214
215
52241105 — 1st FNR Open Circuit 215
1st TCL Open Circuit Diagnostic Procedure (Steering Column Shifter) 215
216
216
1st TCL Open Circuit Diagnostic Procedure (Pilot Control Joystick) 217
217
217
52241112 — 1st FNR Mult Inputs 218
1st TCL Multiple Inputs Diagnostic Procedure (Steering Column Shifter) 218
218
219
219
220
1st TCL Multiple Inputs Diagnostic Procedure (Pilot Control Joystick) 220
220
221
221
222
52241212 — Gear Selection Error 222
Gear Selection Error Diagnostic Procedure 222
223
223
224
52241902 — Clutch Cutoff Disabled 224
Clutch Cut-Off Disabled Diagnostic Procedure 225
225
225
225
52242002 — Manual Downshift Disabled 226
Manual Downshift Disabled Diagnostic Procedure 226
226
226
52242102 — Auto To 1st Disabled 227
Auto To 1st Disabled Diagnostic Procedure 227
227
227
52404800 — Trans Output Torque Exceeded 228
Trans Output Torque Exceeded Diagnostic Procedure 228
228
52404900 — Trans Input Torque Exceeded 228
Trans Input Torque Exceeded Diagnostic Procedure 229
229
52428700 — Configure Machine Model 229
Configure Machine Model Diagnostic Procedure 229
230
Flex Load Controller (FLC) Diagnostic Trouble Codes 231
Flex Load Controller (FLC) Diagnostic Trouble Codes 231
00011701 — Brake Pressure Low 231
Brake Pressure Low Diagnostic Procedure 231
232
232
232
00016716 — Alternator High Voltage 233
Alternator High Voltage Diagnostic Procedure 233
233
233
233
00016718 — Alternator Low Voltage 234
Alternator Low Voltage Diagnostic Procedure 234
234
234
234
235
00016816 — High Battery Voltage 235
High Battery Voltage Diagnostic Procedure 235
235
235
236
00016818 — Low Battery Voltage 236
Low Battery Voltage Diagnostic Procedure 236
236
236
237
237
00044405 — 12V Cntr Tap Open or Short 237
12 Volt Center Tap Open or Short Diagnostic Procedure 237
238
239
239
00044418 — Battery Voltage Imbalance 239
Battery Voltage Imbalance Diagnostic Procedure 240
240
240
241
00054419 — Refer Torq Mis-Match 241
Reference Torque MisMatch Diagnostic Procedure 241
241
00062812 — Controller Not Programmed 241
Controller Not Programmed Diagnostic Procedure 242
242
00077404 — JS Upshift Short to Gnd 242
Joystick Upshift Short to Ground Diagnostic Procedure 242
243
243
243
243
00077410 — JS Upshift Button Stuck 244
Joystick Upshift Button Stuck Diagnostic Procedure 244
244
244
245
245
00077504 — JS Downshift Short to Gnd 245
Joystick Downshift Short to Ground Diagnostic Procedure 245
246
246
246
246
00077510 — JS Downshift Button Stuck 247
Joystick Downshift Button Stuck Diagnostic Procedure 247
247
247
248
248
00078503 — Pilot Solenoid Short to Power 248
Pilot Solenoid Short to Power Diagnostic Procedure 248
249
249
250
250
00078505 — Pilot Solenoid Open Circuit 250
Pilot Solenoid Open Circuit Diagnostic Procedure 250
251
251
251
00078506 — Pilot Solenoid High Current 252
Pilot Solenoid High Current Diagnostic Procedure 252
252
253
253
253
00088003 — Brake Lights Short to Power 254
Brake Lights Short to Power Diagnostic Procedure 254
254
255
256
256
00088005 — Brake Lights Open Circuit 256
Brake Lights Open Circuit Diagnostic Procedure 257
257
258
258
00088006 — Brake Lights High Current 259
Brake Lights High Current Diagnostic Procedure 259
259
260
261
261
00097703 — Rev Fan Solenoid Short to Power 261
Reverse Fan Solenoid Short to Power Diagnostic Procedure 262
262
263
264
264
00097705 — Rev Fan Sol Open Circuit 264
Reverse Fan Solenoid Open Circuit Diagnostic Procedure 265
265
266
266
00097706 — Rev Fan Sol High Current 267
Reverse Fan Solenoid High Current Diagnostic Procedure 267
267
268
269
269
00104504 — Brake Lt Sw Shorted to Gnd 269
Brake Light Switch Shorted to Ground Diagnostic Procedure 270
270
270
271
271
00106902 — Tire Size Incorrect 271
Tire Size Incorrect Diagnostic Procedure 271
271
272
00107131 — Fan Speed Sol Circuit Fault 272
Fan Speed Solenoid Circuit Fault Diagnostic Procedure 272
272
273
275
275
00107500 — Fuel Pump On Too Long 276
Fuel Pump On Too Long Diagnostic Procedure 276
276
00107904 — FLC Sensor 1 Voltage Low 276
FLC Sensor 1 Voltage Low Diagnostic Procedure 277
277
278
278
00108004 — FLC Sensor 2 Voltage Low 278
FLC Sensor 2 Voltage Low Diagnostic Procedure 279
279
279
279
00163800 — Hydraulic Oil High Temp 280
Hydraulic Oil High Temperature Diagnostic Procedure 280
280
00163804 — Hyd Oil Temp Circuit Short to Gnd 281
Hydraulic Oil Temperature Circuit Short to Ground Diagnostic Procedure 281
281
282
282
282
00171301 — Hyd Oil Filter Restricted 283
Hydraulic Oil Filter Restricted Diagnostic Procedure 283
283
284
284
284
00176203 — Hyd Pressure Short to Power 285
Hydraulic Pressure Short to Power Diagnostic Procedure 285
285
286
286
286
00176204 — Hyd Pressure Open or Short 287
Hydraulic Pressure Open or Short Diagnostic Procedure 287
288
289
289
289
00200009 — CAN Comm Lost for ECU 290
CAN Communication Lost For ECU Diagnostic Procedure 290
290
290
291
291
291
00200309 — CAN Comm Lost for TCU 292
CAN Communication Lost for TCU Diagnostic Procedure 292
292
292
293
293
293
00202309 — CAN Comm Lost for CMU 294
CAN Communication Lost for CMU Diagnostic Procedure 294
294
295
295
295
296
296
00214009 — CAN Comm Lost for SSM 296
CAN Communication Lost for SSM Diagnostic Procedure 296
296
296
297
297
297
00235005 — Drive Lamps Open or Short 297
Drive Lamps Open or Short Diagnostic Procedure 298
298
298
299
300
300
00235006 — Drive Lamps High Current 300
Drive Lamps High Current Diagnostic Procedure 301
301
301
302
302
00235505 — Front Work Lts Open or Short 302
Auxiliary Lights Open or Short Diagnostic Procedure 303
303
304
305
306
306
00235506 — Front Work Lts High Current 307
Auxiliary Lights High Current Diagnostic Procedure 307
307
308
309
309
00235605 — Front Work Lts Open or Short 310
Front Work Lights Open or Short Diagnostic Procedure 310
310
311
312
313
313
00235606 — Front Work Lts High Current 314
Front Work Lights High Current Diagnostic Procedure 314
314
315
316
316
00236205 — Rear Work Lts Open or Short 317
Rear Work Lights Open or Short Diagnostic Procedure 317
317
318
319
320
320
00236206 — Rear Work Lts High Current 321
Rear Work Lights High Current Diagnostic Procedure 321
321
322
323
323
00236803 — Left Turn Lts Circuit Short to Power 324
Left Turn Lights Circuit Short to Power Diagnostic Procedure 324
324
325
326
327
328
328
00236805 — Left Turn Lts Open Circuit 328
Left Turn Lights Open Circuit Diagnostic Procedure 329
329
330
331
331
00236806 — Left Turn Lts Circuit High Current 332
Left Turn Lights Circuit High Current Diagnostic Procedure 332
332
333
334
335
336
336
00237003 — Right Turn Lts Short to Power 336
Right Turn Lights Short to Power Diagnostic Procedure 337
337
337
338
339
339
00237005 — Right Turn Lts Open Circuit 339
Right Turn Lights Open Circuit Diagnostic Procedure 340
340
340
341
341
00237006 — Right Turn Lts High Current 342
Right Turn Lights High Current Diagnostic Procedure 342
342
343
344
345
346
346
00237803 — Marker/Tail Lts Short to Power 346
Marker/Tail Lights Short to Power Diagnostic Procedure 347
347
348
349
350
351
351
00237805 — Marker/Tail Lts Open Circuit 351
Marker/Tail Lights Open Circuit Diagnostic Procedure 352
352
353
354
354
00237806 — Marker/Tail Lts High Current 355
Marker/Tail Lights High Current Diagnostic Procedure 355
355
356
357
358
359
359
00238606 — Beacon Light High Current 359
Beacon Light High Current diagnostic Procedure 360
360
360
361
361
00269702 — JS Mag Out of Range 361
Joystick Magnitude Out of Range Diagnostic Procedure 361
362
00287504 — 4-Way Flash Sw Short to Gnd 362
4-Way Flasher Switch Short to Ground Diagnostic Procedure 362
362
363
363
363
29926102 — Machine Config Invalid 363
Machine Configuration Invalid Diagnostic Procedure 364
364
364
52243102 — Memory Test Failure 364
Memory Test Failure Diagnostic Procedure 364
365
52243205 — R Wiper H-Spd Open Circuit 365
Rear Wiper High-Speed Open Circuit Diagnostic Procedure 365
365
366
366
52243206 — R Wiper H-Spd High Current 366
Rear Wiper High-Speed High Current Diagnostic Procedure 367
367
367
368
368
52243305 — R Wiper L-Spd Open or Short 368
Rear Wiper Low-Speed Open or Short Diagnostic Procedure 369
369
369
370
371
371
52243306 — R Wiper L-Spd High Current 371
Rear Wiper Low-Speed High Current Diagnostic Procedure 372
372
372
373
373
52243405 — F Wiper L-Spd Open or Short 373
Front Wiper Low-Speed Open or Short Diagnostic Procedure 374
374
374
375
376
376
52243406 — F Wiper L-Spd High Current 376
Front Wiper Low-Speed High Current Diagnostic Procedure 377
377
377
378
378
52243505 — F Wiper H-Spd Open Circuit 378
Front Wiper High-Speed Open Circuit Diagnostic Procedure 379
379
380
380
52243506 — F Wiper H-Spd High Current 380
Front Wiper High-Speed High Current Diagnostic Procedure 381
381
381
382
382
52243603 — Bucket Pos Short to Power 382
Bucket Position Short to Power Diagnostic Procedure 383
383
384
385
385
52243604 — Bucket Pos Open or Short 385
Bucket Position Open or Short Diagnostic Procedure 386
386
386
387
388
388
52243704 — RTDig Switch 1 Short to Gnd 388
Return-to-dig Switch 1 Short to Ground Diagnostic Procedure 389
389
389
390
390
52243803 — Pin Disc Sol Short to Power 390
Pin Disconnect Solenoid Short to Power Diagnostic Procedure 391
391
392
393
393
52243805 — Pin Disc Sol Open Circuit 393
Pin Disconnect Solenoid Open Circuit Diagnostic Procedure 394
394
395
395
52243806 — Pin Disc Sol High Current 395
Pin Disconnect Solenoid High Current Diagnostic Procedure 396
396
397
398
398
52279605 — R Washer Pump Open Circuit 398
Rear Washer Pump Open Circuit Diagnostic Procedure 399
399
399
400
52279606 — R Washer Pump High Current 400
Rear Washer Pump High Current Diagnostic Procedure 400
400
401
401
401
52279705 — F Washer Pump Open Circuit 402
Front Washer Pump Open Circuit Diagnostic Procedure 402
402
403
403
52279706 — F Washer Pump High Current 403
Front Washer Pump High Current Diagnostic Procedure 404
404
404
405
405
52313704 — Steering Press Sw Shrt to Gnd 405
Steering Pressure Switch Short to Ground Diagnostic Procedure 406
406
406
406
407
52321405 — No Voltage to FLC on VP6 407
No Voltage to FLC on VP6 Diagnostic Procedure 407
407
407
408
408
408
52321505 — No Voltage to FLC on VP5 408
No Voltage to FLC on VP5 Diagnostic Procedure 409
409
409
409
410
410
52321605 — No Voltage to FLC on VP4 410
No Voltage to FLC on VP4 Diagnostic Procedure 410
411
411
411
411
52321705 — No Voltage to FLC on VP3 412
No Voltage to FLC on VP3 Diagnostic Procedure 412
412
412
413
413
52321805 — No Voltage to FLC on VP2 413
No Voltage to FLC on VP2 Diagnostic Procedure 413
414
414
414
414
52321905 — No Voltage to FLC on VP1 415
No Voltage to FLC on VP1 Diagnostic Procedure 415
415
415
416
416
52343617 — FLC Watchdog Timed Out 416
FLC Watchdog Timed Out Diagnostic Procedure 416
416
417
52357703 — 2nd Steer Pump Short to Power 417
Secondary Steering Pump Short to Power Diagnostic Procedure 417
418
419
419
52357705 — 2nd Steer Pump Open Circuit 419
Secondary Steering Pump Open Circuit Diagnostic Procedure 420
421
421
52357706 — 2nd Steer Pump High Current 422
Secondary Steer Pump High Current Diagnostic Procedure 422
423
424
424
52378603 — Boom Position Short to Power 424
Boom Position Short to Power Diagnostic Procedure 425
425
425
426
426
52378604 — Boom Position Open or Short 426
Boom Position Open or Short Diagnostic Procedure 427
427
427
428
429
429
52383701 — Brake Pressure Low-Rear 429
Brake Pressure Low-Rear Diagnostic Procedure 430
430
52383704 — Rr Brake Pressure Open or Short 430
Rear Brake Pressure Sensor Open or Short Diagnostic Procedure 430
431
431
431
431
431
52384001 — Brake Pressure Low-Front 432
Brake Pressure Low-Front Diagnostic Procedure 432
432
52384003 — Ft Brake Pressure Short to Power 432
Front Brake Pressure Sensor Short to Power Diagnostic Procedure 433
433
433
433
434
52384004 — Ft Brake Pressure Open or Short 434
Front Brake Pressure Sensor Open or Short Diagnostic Procedure 434
434
434
435
435
435
52391131 — Hyd Pwr Sol Circuit Fault 435
52394803 — Ride Contrl Sol Short to Power 436
Ride Control Solenoid Short to Power Diagnostic Procedure 436
436
437
437
438
52394805 — Ride Contrl Sol Open Circuit 438
Ride Control Solenoid Open Circuit Diagnostic Procedure 438
438
439
439
52394806 — Ride Contrl Sol High Current 439
Ride Control Solenoid High Current Diagnostic Procedure 440
440
440
441
441
52426519 — Check Sum Error 441
Check Sum Error Diagnostic Procedure 442
442
Sealed Switch Module (SSM) Diagnostic Trouble Codes 443
Sealed Switch Module (SSM) Diagnostic Trouble Codes 443
00062812 — Controller Not Programmed 443
Controller Not Programmed Diagnostic Procedure 444
444
00062912 — SSM Watchdog Time Out 444
SSM Watchdog Time Out Diagnostic Procedure 444
445
445
00063912 — SSM Lost Message 445
SSM Lost Message Diagnostic Procedure 445
446
446
446
446
00063919 — SSM Lost CAN Communications 446
SSM Lost CAN Communications Diagnostic Procedure 447
447
447
447
447
00203309 — SSM Lost Communications 448
SSM Lost Communications Diagnostic Procedure 448
448
448
449
449
449
52352310 — Rear Wiper Keypad Stuck 450
Rear Wiper Keypad Stuck Diagnostic Procedure 450
450
450
450
451
52352410 — Front Wiper Keypad Stuck 451
Front Wiper Keypad Stuck Diagnostic Procedure 451
451
451
452
452
52352510 — Front Washer Keypad Stuck 452
Front Washer Keypad Stuck Diagnostic Procedure 452
452
453
453
453
52352610 — Reverse Fan Keypad Stuck 453
Reverse Fan Keypad Stuck Diagnostic Procedure 453
454
454
454
454
52352710 — Pin Disconnect Keypad Stuck 454
Pin Disconnect Keypad Stuck Diagnostic Procedure 455
455
455
455
455
52352810 — A/C Keypad Stuck 456
A/C Keypad Stuck Diagnostic Procedure 456
456
456
456
457
52352910 — Work Lights Keypad Stuck 457
Work Lights Keypad Stuck Diagnostic Procedure 457
457
457
458
458
52353010 — Beacon Light Keypad Stuck 458
Beacon Light Keypad Stuck Diagnostic Procedure 458
458
459
459
459
52353210 — Spin Control Keypad Stuck 459
Spin Control Keypad Stuck Diagnostic Procedure 459
460
460
460
460
52353310 — Clutch Cut-Off Keypad Stuck 460
Clutch Cut-Off Keypad Stuck Diagnostic Procedure 461
461
461
461
461
52353410 — Pilot Enable Keypad Stuck 462
Pilot Enable Keypad Stuck Diagnostic Procedure 462
462
462
462
463
52353510 — Ride Control Keypad Stuck 463
Ride Control Keypad Stuck Diagnostic Procedure 463
463
463
464
464
52353610 — Auto Transmission Keypad Stuck 464
Auto Transmission Keypad Stuck Diagnostic Procedure 464
464
465
465
465
52353710 — Drive Lights Keypad Stuck 465
Drive Lights Keypad Stuck Diagnostic Procedure 465
466
466
466
466
52353810 — Keypad Not Used 466
Keypad Not Used Diagnostic Procedure 467
467
467
467
467
52360710 — Return to Dig Keypad Stuck 468
Return-to-Dig Keypad Stuck Diagnostic Procedure 468
468
468
468
469
52360810 — BHKO Keypad Stuck 469
Boom Height Kickout Keypad Stuck Diagnostic Procedure 469
469
469
470
470
52360910 — RTCarry Keypad Stuck 470
Return-to-Carry Keypad Stuck Diagnostic Procedure 470
470
471
471
471
52361010 — Rear Washer Keypad Stuck 471
Rear Washer Keypad Stuck Diagnostic Procedure 471
472
472
472
472
Operational Checkout Procedure 473
Operational Checkout Procedure 475
Operational Checkout 475
Diagnostic Trouble Code Check 475
475
Operational Checks—Key Switch OFF, Engine OFF Checks 475
476
476
476
Operational Checks—Key Switch ON, Engine OFF Checks 476
477
477
478
478
479
Operational Checks—Key Switch ON, Engine ON Checks 479
479
480
481
481
482
483
484
485
485
486
487
487
488
488
488
489
489
490
490
491
491
491
492
492
Engine 493
Theory of Operation 495
PowerTech E 45L (4045) John Deere Engine 495
Diagnostic Information 497
PowerTech E 45L (4045) John Deere Engine 497
Engine Cooling System Component Location 498
Engine Fuel System Component Location 499
Engine Intake and Exhaust Component Location 502
Tests 505
Engine Speed Check and Adjust 505
Intake Manifold Pressure Test—Turbocharger Boost 509
Electrical System 513
System Information 516
Electrical Diagram Information 516
System Diagrams 524
Fuse and Relay Specifications 524
System Functional Schematic, Wiring Diagram and Component Location Legend 526
System Functional Schematic and Section Legend 532
JDLink™ System Functional Schematic—If Equipped (SN 615706—619284 ) 548
JDLink™ System Functional Schematic—If Equipped (SN 619285— ) 550
Loader Frame Harness (W2) Component Location 552
Loader Frame Harness (W2) Wiring Diagram 556
Load Center Harness (W3) Component Location 560
Load Center Harness (W3) Wiring Diagram 562
Front Console Harness (W4) Component Location 590
Front Console Harness (W4) Wiring Diagram 592
Engine Frame Harness (W5) Component Location 594
Engine Frame Harness (W5) Wiring Diagram 596
Engine Harness (W6) Component Location 600
Engine Harness (W6) Wiring Diagram 604
Transmission Harness (W10) Component Location 608
Transmission Harness (W10) Wiring Diagram 610
Rear Frame Harness (W13) Component Location 612
Rear Frame Harness (W13) Wiring Diagram 616
Secondary Steering Harness (W17) Component Location 618
Secondary Steering Harness (W17) Wiring Diagram 620
Cab Roof Harness (W19) Component Location 622
Cab Roof Harness (W19) Wiring Diagram 624
Heater and Air Conditioner Harness (W20) Component Location 626
Heater and Air Conditioner Harness (W20) Wiring Diagram 628
JDLink™ System Harnesses (W29, and W30) Component Location—If Equipped (S N 615706— ) 630
GlobalTRACS® Terminal (GTT) Harness (W29) Wiring Diagram—If Equipped (SN 615706— ) 632
Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (SN 615706—619284 ) 634
Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (SN 619285— ) 636
Radio Harness (W34) Component Location 638
Radio Harness (W34) Wiring Diagram 640
Sub-System Diagnostics 643
Starting and Charging Circuit Theory of Operation 643
Controller Area Network (CAN) Theory of Operation 646
Engine Control Unit (ECU) Circuit Theory of Operation 648
Flex Load Controller (FLC) Circuit Theory of Operation 654
Transmission Control Unit (TCU) Circuit Theory of Operation 670
CAN Monitor Unit (CMU) Circuit Theory of Operation 674
References 677
Diagnostic Trouble Codes (DTC) Quick Reference List 677
Service ADVISOR Diagnostic Application 689
Service ADVISOR Connection Procedure 690
Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application 692
JDLink™ Connection Procedure—If Equipped (SN 615706— ) 695
CAN Monitor Unit (CMU) Menu Structure—Service Mode 696
Flex Load Controller (FLC) Fault Exceptions 714
CAN Circuit Test 717
Controller Area Network (CAN) Diagnostics 717
718
718
719
720
721
721
722
Electrical Component Specifications 723
Transmission Control Valve Solenoid Check 728
Clutch Cut-Off Sensor Check and Adjustment 729
Boom Height Kickout/Return-to-Carry Adjustment 730
Return-To-Dig Adjustment—Z-Bar Linkage 731
Return-To-Dig Adjustment—Powerllel Linkage 732
Sensor Circuitry Check 733
Diagnostic Trouble Codes—After Machine Repair 736
Change Backup Alarm Volume 737
Pressure Switches Remove and Install 738
Alternator Test Procedure 739
Replace (Push Type) Metri-Pack Connectors 741
Replace METRI-PACK Connectors 742
Install METRI-PACK Contact 743
Replace DEUTSCH Connectors 744
Install DEUTSCH Contact 745
Replace WEATHER PACK Connector 747
Install WEATHER PACK Contact 748
Replace CINCH Connectors 749
Install CINCH Contact 751
Repair 32 and 48 Way CINCH Connectors 752
Remove Connector Body from Blade Terminals 755
Engine Control Unit (ECU) Remove and Install 755
Flex Load Controller (FLC) Remove and Install 757
Transmission Control Unit (TCU) Remove and Install 758
Sealed Switch Module (SSM) Remove and Install 759
CAN Monitor Unit (CMU) Remove and Install 760
Reprogram CAN Monitor Unit (CMU) 760
Electronic Controller Reconfiguration 762
Power Train 763
Theory of Operation 765
TEAMMATE™ Axles 765
Transmission Clutch Engagement and Solenoids Activated 765
Power Train Component Operation 766
Transmission Operation 768
Transmission Operation—First Gear Forward 770
Transmission Filter Bypass Valve Operation 773
Transmission Control Valve Component Operation 774
Transmission Clutch Modulation Operation 777
Thermal Bypass Valve Operation 778
Standard Differential Operation 780
Differential Lock Operation 781
Axle Circulation Dual Pump Operation 782
Park Brake Operation 784
Diagnostic Information 790
Transmission Control Circuit—First Forward 790
Transmission Control System 792
Power Train Component Location 794
Transmission System Diagnose Malfunctions 797
Transmission Clutch Slippage Diagnostic Procedure 797

DESCRIPTION:

John Deere 544J Loader Operation & Test Technical Manual S.N. 611800 – PDF DOWNLOAD

• Foreword :
• This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
• Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
• Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

G.B 06/01/25