John Deere 544J Loader Operator’s Manual – PDF DOWNLOAD
FILE DETAILS:
John Deere 544J Loader Operator’s Manual – PDF DOWNLOAD
P/N: OMT229869_QT
Language: English
Division: Construction
Product Lines: Loaders
Publication Type: Operator’s Manuals
Associated Models: 544J
Series: J SERIES
Serial: 611800–
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
John Deere 544J Loader Operator’s Manual – PDF DOWNLOAD
Contents 11
Safety—Safety and Operator Conveniences 15
Safety and Operator Convenience Features 15
Safety—General Precautions 16
Recognize Safety Information 16
Follow Safety Instructions 16
Operate Only If Qualified 16
Wear Protective Equipment 16
Avoid Unauthorized Machine Modifications 17
Add Cab Guarding For Special Uses 17
Inspect Machine 17
Stay Clear of Moving Parts 18
Avoid High-Pressure Fluids 18
Avoid High-Pressure Oils 18
Beware of Exhaust Fumes 19
Prevent Fires 19
Prevent Battery Explosions 20
Handle Chemical Products Safely 20
Dispose of Waste Properly 20
Prepare for Emergencies 21
Safety—Operating Precautions 22
Use Steps and Handholds Correctly 22
Start Only From Operator’s Seat 22
Use and Maintain Seat Belt 22
Prevent Unintended Machine Movement 22
Avoid Work Site Hazards 22
Use Special Care When Operating Loader 23
Keep Riders Off Machine 23
Avoid Backover Accidents 24
Avoid Machine Tip Over 24
Operating on Slopes 25
Operating or Traveling On Public Roads 25
Inspect and Maintain ROPS 26
Add and Operate Attachments Safely 26
Prevent Unintended Detonation of Explosive Devices 26
Safety—Maintenance Precautions 27
Park And Prepare For Service Safely 27
Service Cooling System Safely 27
Service Tires Safely 27
Remove Paint Before Welding or Heating 28
Make Welding Repairs Safely 28
Drive Metal Pins Safely 29
Safety—Safety Signs 30
Safety Signs 30
Operation—Operator’s Station 32
Levers 32
Pedals 32
Monitor Panel (CMU) 34
Monitor Panel Functions 34
Switch Pad 37
Switch and Accessory Functions 37
Monitor Display Unit—Normal Display 40
Monitor Display Unit—Main Menu 41
Monitor Display Unit—Main Menu—Codes 41
Monitor Display Unit—Main Menu—Codes—Active Codes 41
Monitor Display Unit—Main Menu—Codes—Stored Codes 42
Monitor Display Unit—Main Menu—Machine Settings 43
Monitor Display Unit—Main Menu—Machine Settings—Quick Shift 43
Monitor Display Unit—Main Menu—Machine Settings—Auto to 1st 44
Monitor Display Unit—Main Menu—Machine Settings—Job Timer 44
Monitor Display Unit—Main Menu—Machine Settings—Stopwatch 45
Monitor Display Unit—Main Menu—Machine Settings—Ride Control—If Equipped 45
Monitor Display Unit—Main Menu—Diagnostics 45
Monitor Display Unit—Main Menu—Diagnostics—Battery Monitor 46
Monitor Display Unit—Main Menu—Diagnostics—Engine Sensors 46
Monitor Display Unit—Main Menu—Diagnostics—Transmission 48
Monitor Display Unit—Main Menu—Diagnostics—Hydraulic 49
Monitor Display Unit—Main Menu—Diagnostics—Machine 49
Monitor Display Unit—Main Menu—Diagnostics—Machine Switches 50
Monitor Display Unit—Main Menu—Diagnostics—Switch Module 53
Monitor Display Unit—Main Menu—Diagnostics—Machine I D 53
Monitor Display Unit—Main Menu—Diagnostics—More Diagnostics 55
Monitor Display Unit—Main Menu—Monitor Settings 55
Monitor Display Unit—Main Menu—Monitor Settings—Units 55
Monitor Display Unit—Main Menu—Monitor Settings—Backlighting 56
Monitor Display Unit—Main Menu—Monitor Settings—LCD Contrast 56
Monitor Display Unit—Main Menu—Monitor Settings—Hide Main Menu 56
Horn Button 57
Turn Signals 57
Adjusting Steering Wheel Tilt 57
Air Conditioning Controls and Heater Operation 58
Opening and Securing Side Door 59
Opening Side Window/Secondary Exit 59
Opening Rear Side Window 60
Adjusting Seat 60
Operation—Operating the Machine 62
Inspect Machine Daily Before Starting 62
Check Instruments Before Starting 62
Starting the Engine 62
Starting Fluid—If Equipped (Cold Weather Starting Aid) 64
Engine Heater—If Equipped 66
Using Coolant Heater—If Equipped 66
Warm-Up 66
Minimizing the Effect of Cold Weather on Diesel Engines 66
Cold Weather Warm-Up 67
Neutral Lock 68
Shifting the Transmission 68
Park Brake Switch 69
Boom and Bucket Control Lever—One Lever Design 71
Boom and Bucket Control Lever—Two Lever Design 72
Quick Shift Switch 73
Ride Control—If Equipped 73
Secondary Steering—If Equipped 75
Differential Lock Switch 76
Boom Height Kickout Adjustment 76
Return-to-Carry Kickout Adjustment 76
Return-To-Dig Adjustment for Z-Bar Linkage Only 76
Return-To-Dig Adjustment—If Equipped With Powerllel Linkage 77
Using the Loader Bucket 78
Backdragging 80
Fork Attachment 80
Parking the Machine 82
Loading Machine on a Trailer 82
Towing Procedure 84
Lifting the Machine 86
Maintenance—Machine 87
Diesel Fuel 87
Biodiesel Fuel 87
Low Sulfur Diesel Fuel Conditioner 89
Testing Diesel Fuel 89
Handling and Storing Diesel Fuel 89
Alternative and Synthetic Lubricants 89
Diesel Engine Break-In Oil 90
Diesel Engine Oil 90
Diesel Engine Oil and Filter Service Intervals 91
Transmission, Park Brake, and Axle Oil 92
Hydraulic Reservoir Oil 93
Grease 93
Heavy Duty Diesel Engine Coolant 94
Maintenance—Periodic Maintenance 96
Service Machine at Specified Intervals 96
Check Hour Meter Regularly 96
Prepare Machine for Maintenance 96
Locking Machine Frame 98
Boom Lock 98
Pin Removal—If Equipped With Powerllel™ Linkage 98
Opening Engine Service Doors and Side Shields 99
Opening Grille Door 100
Fuel Tank 101
Maintenance and Repair Record Keeping System 101
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 102
Service Intervals 102
Required Parts 105
Maintenance—As Required 106
Inspect Tires and Check Pressure 106
Tire Pressures (Z-Bars and High Lifts) 106
Tire Pressures (Powerllels) 108
Check Wheel Bolt Torque 110
Clean or Replace Air Cleaner Elements 110
Inspect A/C Compressor and Alternator Belt 112
Check Windshield Washer Fluid Level 112
Drain Water From Primary Fuel Filter and Clean Strainer 112
Replace Final Fuel Filter 113
Check Cab Fresh Air Filter—If Equipped With Cab 114
Check Cab Recirculating Air Filter—If Equipped With Cab 114
Maintenance—Every 10 Hours or Daily 116
Clean Air Cleaner Dust Unloader Valve 116
Check Coolant Level in Surge Tank 116
Check Engine Oil Level 116
Check Hydraulic Oil Level 118
Check Transmission Oil Level 118
Maintenance—Every 100 Hours 120
Grease Loader Linkage and Cylinder Pivots—If Equipped 120
Grease Front Steering Cylinder Pivots (S N —618134) 122
Grease Rear Steering Cylinder Pivots (S N —618134) 123
Grease Oscillating Rear Axle Pivots 123
Maintenance—Initial Service – 250 Hours 124
Change Engine Oil and Replace Filter 124
Change Front and Rear Axle Oil 125
Maintenance—Every 250 Hours 126
Take Engine Oil Sample 126
Take Hydraulic Oil Sample 126
Maintenance—Every 500 Hours 127
Lubricate Upper and Lower Drive Line Sliding Joints 127
Check Air Intake and Charged Air Cooler Hoses 127
Check Battery Electrolyte Level and Terminals 128
Change Engine Oil and Replace Filter 131
Replace Primary and Final Fuel Filters 132
Replace In-Line Fuel Strainer 132
Replace Hydraulic System Return Filter 133
Replace Hydraulic Reservoir Breather Filter 133
Check Park Brake Oil Level 133
Check Front and Rear Axle Oil Level 134
Take Diesel Fuel Sample 134
Take Engine Coolant Sample 134
Take Transmission Oil Sample 134
Take Axle Oil Sample 134
Maintenance—Every 1000 Hours 135
Clean Engine Crankcase Vent Tube 135
Replace Air Cleaner Dust Unloader Valve 135
Replace Air Cleaner Elements 135
Check Coolant 136
Check Radiator Hoses 137
Replace Transmission Oil Filter 138
Inspect and Clean Hydraulic Pump Case Drain Fittings 138
Lubricate Frame Hinge Pivots 139
Change Park Brake Oil 139
Maintenance—Every 2000 Hours 141
Change Transmission Oil 141
Change Front and Rear Axle Oil 142
Clean Axle Oil Recirculation Screen—If Equipped 143
Grease Front and Rear Axle Input Seals 143
Re-Run Clutch Calibration 143
Adjust Engine Valve Lash (Clearance) 144
Maintenance—Every 4000 Hours 145
Change Hydraulic Oil 145
Clean Hydraulic System Strainer 146
Replace Crankshaft Dampener 146
Maintenance—Every 5000 Hours 147
Draining the Cooling System 147
Filling the Cooling System 147
Inspect Driveline Dampener 149
Miscellaneous—Machine 150
Inspect Fuel Tank Vent Hose and Breather 150
Bleeding the Fuel System 150
Checking Fire Extinguisher—If Equipped 152
Precautions for Alternator and Regulator 152
Handling Batteries Safely 152
Using Booster Batteries—24-Volt System 154
Using Battery Charger 154
Battery Disconnect Switch 155
Replacing Batteries 155
Removing and Installing Batteries 155
JDLink™ Machine Monitoring System (MMS)—If Equipped 156
Replacing Fuses 157
Fuse (Blade-Type) Color Codes 159
Replacing Halogen Bulbs 159
Engine Speeds 160
Fluid Sampling Test Ports—If Equipped 160
Checking Neutral Start System 162
Servicing Air Conditioning System—If Equipped 162
Welding on Machine 163
External Service Brake Inspection 163
Checking Brake Accumulators 164
Checking Ride Control Accumulator—If Equipped 165
Transmission Oil Cooler, Hydraulic Oil Cooler, Air-to-Air Aftercooler, and Radiator External Cleaning Procedure 167
Service Recommendations For Snap-To-Connect (STC®) Fittings 167
Do Not Service Control Valves, Cylinders, Pumps or Motors 169
Hardware Torque Specifications 169
Keep ROPS Installed Properly 169
Metric Bolt and Screw Torque Values 169
Unified Inch Bolt and Screw Torque Values 170
Miscellaneous—Operational Checkout 172
Operational Checkout 172
Engine Off Checks 172
Engine Running Checks 174
Miscellaneous—Troubleshooting 187
Troubleshooting Procedure 187
Engine 187
Transmission 189
Differential and Axle 191
Service Brake 193
Service Brake 193
Drive Line 194
Park Brake 194
Hydraulic System 195
Steering 197
Air Conditioning System 197
Heater System 199
Miscellaneous—Storage 200
Prepare Machine For Storage 200
Monthly Storage Procedure 200
Miscellaneous—Machine Numbers 202
Record Product Identification Number (PIN) 202
Record Engine Serial Number 202
Record Transmission Serial Number 202
Record Hydraulic Pump Serial Number 202
Record Axle Serial Number 203
Keep Machines Secure 203
Keep Proof of Ownership 203
Miscellaneous—Specifications 205
Specifications 205
High Lift Specifications 206
Powerllel Specifications 208
Drain and Refill Capacities 210
Page Number 11
Section 1-1 15
Section 1-2 16
Section 1-3 22
Section 1-4 27
Section 1-5 30
Section 2-1 32
Section 2-2 62
Section 3-1 87
Section 3-2 96
Section 3-3 106
Section 3-4 116
Section 3-5 120
Section 3-6 124
Section 3-7 126
Section 3-8 127
Section 3-9 135
Section 3-10 141
Section 3-11 145
Section 3-12 147
Section 4-1 150
Section 4-2 172
Section 4-3 187
Section 4-4 200
Section 4-5 202
Section 4-6 205
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