John Deere 544K 4WD Loader Operator’s Manual OMT275694 – PDF DOWNLOAD
- P/N: OMT275694_24
- Language: English
- Division: Construction
- Product Lines: Loaders
- Publication Type: Operator’s Manuals
- Associated Models: 544K
- Series: 0
- Serial: PIN: 1DW544K___D642665—
TABLE OF CONTENTS:
John Deere 544K 4WD Loader Operator’s Manual OMT275694 – PDF DOWNLOAD
544K 4WD Loader 1
Introduction 2
Foreword 2
Manual Identification—READ THIS FIRST! 2
Conformity Marking 4
IMPORTANT 5
EPA Non-road Emissions Control Warranty Statement—Compression Ignition 5
CARB Non-road Emissions Control Warranty Statement—Compression Ignition 7
Required Emission-Related Information 13
FCC Notifications to User 13
Service ADVISOR™ Remote (SAR)—SOFTWARE TERMS AND CONDITIONS 14
Technical Information Feedback Form 18
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
Avoid Static Electricity Risk When Refueling 27
Prevent Fires, Clean Debris From Machine 28
Clean Debris from Machine 28
Prevent Battery Explosions 29
Handle Chemical Products Safely 29
Decommissioning — Proper Recycling and Disposal of Fluids and Components 30
Prepare for Emergencies 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 on Slopes 35
Operating or Traveling On Public Roads 36
Inspect and Maintain ROPS 36
Add and Operate Attachments Safely 36
Safety—Maintenance Precautions 37
Park and Prepare for Service Safely 37
Service Cooling System Safely 37
Service Tires Safely 38
Remove Paint Before Welding or Heating 38
Make Welding Repairs Safely 39
Drive Metal Pins Safely 39
Safety—Safety Signs 40
Safety Signs 40
Operation—Operator’s Station 46
Levers—Two Function Hydraulic Control 46
Levers—Three Function Hydraulic Control 47
Levers—Four Function Hydraulic Control 48
Levers—Joystick Steering Control 49
Pedals 50
Sealed Switch Module (SSM) 51
Switch Module Functions 52
Advanced Display Unit (ADU) 55
Display Unit Functions 56
Display Unit—Normal Display 60
Display Unit—Main Menu 61
Display Unit—Main Menu—Codes 62
Display Unit—Main Menu—Codes—Active Codes 62
Display Unit—Main Menu—Codes—Stored Codes 63
Display Unit—Main Menu—Settings 64
Display Unit—Main Menu—Settings—Reverse Fan Cycle 65
Display Unit—Main Menu—Settings—Courtesy Lights 65
Display Unit—Main Menu—Settings—Quick Shift 66
Display Unit—Main Menu—Settings—Job Timer 66
Display Unit—Main Menu—Settings—Stopwatch 67
Display Unit—Main Menu—Settings—Ride Control—If Equipped 67
Display Unit—Main Menu—Settings—Counters 67
Display Unit—Main Menu—Settings—Camera Mode 68
Display Unit—Main Menu—Settings—Operator Configuration 68
Display Unit—Main Menu—Diagnostics 69
Display Unit—Main Menu—Diagnostics—Machine ID 70
Display Unit—Main Menu—Diagnostics—Battery Monitor 70
Display Unit—Main Menu—Diagnostics—Engine Sensors 71
Display Unit—Main Menu—Diagnostics—Transmission/Axle 71
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 72
Display Unit—Main Menu—Diagnostics—Machine Sensors 72
Display Unit—Main Menu—Diagnostics—FNR Selector 73
Display Unit—Main Menu—Diagnostics—Cab Switches 73
Display Unit—Main Menu—Diagnostics—Switch Module 73
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped 74
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 75
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 75
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 76
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 76
Display Unit—Main Menu—Diagnostics—JDLink™ System Info 77
Display Unit—Main Menu—Diagnostics—Park Brake Test 77
Display Unit—Main Menu—Payload Scale—If Equipped 78
Display Unit—Main Menu—Payload Scale—Long Total 78
Display Unit—Main Menu—Payload Scale—Display Units 79
Display Unit—Main Menu—Payload Scale—Auto Add 79
Display Unit—Main Menu—Payload Scale—Diagnostics 79
Display Unit—Main Menu—Payload Scale—Setup 79
Display Unit—Main Menu—Monitor Settings 80
Display Unit—Main Menu—Security 81
Display Unit—Main Menu—Security—Security 82
Display Unit—Main Menu—Security—Change Owner PIN 82
Display Unit—Main Menu—Security—Manage Operator PINs 83
Display Unit—Main Menu—Security—Manage Transport PIN 84
Display Unit—Main Menu—Security—Delayed Operator Logout 84
Display Unit—Main Menu—Software Delivery 85
Display Unit—Main Menu—Software Delivery—Software Update 86
Horn Button 87
Turn Signals 87
Joystick Steering Armrest Adjustment— if Equipped 88
Air Conditioner and Heater Operation 89
Counter Switch 90
Opening and Securing Side Door 91
Opening Side Window/Secondary Exit 92
Opening Rear Side Window 92
Seat Adjustment 93
Fire Extinguisher Mounting Location 94
Operation—Operating the Machine 95
Before Starting Work 95
Inspect Machine Daily Before Starting 95
Check Instruments Before Starting 95
Security System 96
Battery Disconnect Switch 96
Engine Break-In Period 97
Starting the Engine 98
Cold Start Aid—Starting Fluid—If Equipped 101
Cold Start Aid—Block Heater—If Equipped 101
Warmup 101
Cold Weather Warmup 102
Park Brake Switch 103
Shifting the Transmission 104
Automatic Idle and Automatic Shutdown 106
Joystick Bucket and Boom Control 107
Two Lever Bucket and Boom Control 108
Auxiliary Control 108
Joystick Steering Control—If Equipped 110
Ride Control—If Equipped 112
Secondary Steering—If Equipped 114
Differential Lock Operation 114
Service ADVISOR™ Remote (SAR) Software Delivery Process 115
Rear Camera and Radar Object Detection (ROD) System—If Equipped 116
Counter Switch Operation 118
Embedded Payload Scale—If Equipped 119
Boom Height Kickout Adjustment 123
Return-to-Carry Kickout Adjustment 123
Return-to-Dig Adjustment for Z-Bar Linkage 124
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 126
Operating Loader Coupler—If Equipped 127
Using the Loader Bucket 128
Backdragging 129
Fork Attachment 130
Operating in Water and Mud 131
Parking the Machine 132
Loading Machine on a Trailer 133
Towing Procedure 135
Lifting the Machine 137
Maintenance—Machine 138
Diesel Fuel 138
Lubricity of Diesel Fuel 139
Handling and Storing Diesel Fuel 139
Biodiesel Fuel 140
Testing Diesel Fuel 141
Fuel Filters 141
Minimizing the Effect of Cold Weather on Diesel Engines 142
Alternative and Synthetic Lubricants 143
Lubricant Storage 143
Mixing of Lubricants 143
Diesel Engine Break-In™ Oil 144
Diesel Engine Oil—Tier 3 and Stage III A Engines 144
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA — PowerTech™ Engines 145
Transmission, Park Brake, and Axle Oil 146
Hydraulic Oil 147
Grease 148
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 149
Drain Intervals for Diesel Engine Coolant 150
John Deere COOL-GARD™ II Coolant Extender 150
Supplemental Coolant Additives 150
Operating in Warm Temperature Climates 151
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender 151
Testing Diesel Engine Coolant 152
Disposing of Coolant 152
Maintenance—Periodic Maintenance 153
Service Machine at Specified Intervals 153
Check Hour Meter Regularly 153
Prepare Machine for Maintenance 154
Frame Locking Bar 155
Boom Lock 156
Pin Removal—If Equipped With Powerllel™ Linkage 157
Engine Service Doors and Side Shields 158
Cooling System Doors 159
Fuel Tank 160
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 160
Service Intervals 161
Required Parts 163
Maintenance—As Required 165
Inspect Tires and Check Pressure 165
Tire Pressures 166
Check Wheel Bolt Torque 168
Inspect Engine Air Cleaner Elements 169
Inspect Air Conditioner Compressor and Alternator Belt 170
Clean Cooler Cores 171
Check Windshield Washer Fluid Level 172
Drain Water From Auxiliary Fuel Filter and Water Separator—If Equipped 172
Drain Water From Primary Fuel Filter and Water Separator 173
Drain Water From Final Fuel Filter 173
Check and Clean or Replace Cab Fresh Air Filter 174
Check and Clean or Replace Cab Recirculating Air Filter 175
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 176
Check Coolant 177
Maintenance—Every 10 Hours or Daily 178
Clean Air Cleaner Dust Unloader Valve 178
Check Coolant Level in Surge Tank 178
Check Engine Oil Level 179
Check Hydraulic Oil Level 179
Check Transmission Oil Level 180
Inspect Outer Pin Seals 181
Maintenance—Every 100 Hours 182
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 182
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 183
Maintenance—Initial Service – 250 Hours 184
Drain and Refill Front and Rear Axle Oil 184
Drain and Refill Engine Oil and Replace Filter 185
Replace Axle Oil Filters—If Equipped 186
Maintenance—Every 250 Hours 187
Take Engine Oil Sample 187
Maintenance—Every 500 Hours 188
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 188
Check Front and Rear Axle Oil Level 189
Lubricate Front and Rear Axle Shaft Seals 189
Check Battery Water Level and Terminals 190
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 192
Take Fluid Samples 192
Drain and Refill Engine Oil and Replace Filter 193
Replace Auxiliary Fuel Filter—If Equipped 194
Replace Primary Fuel Filter 194
Replace In-Line Fuel Strainer 195
Replace Final Fuel Filter 196
Replace Hydraulic Reservoir Breather Filter 196
Check Park Brake Oil Level 197
Lubricate Front and Rear Shaft Seals on Park Brake 197
Check Ride Control Accumulator—If Equipped 198
Maintenance—Every 1000 Hours 199
Clean Engine Crankcase Vent Tube 199
Replace Air Cleaner Dust Unloader Valve 199
Replace Engine Air Cleaner Elements 200
Check Coolant 200
Replace Axle Oil Filters—If Equipped 201
Lubricate Frame Hinge Pivots 201
Drain and Refill Park Brake Oil 201
Maintenance—Every 2000 Hours 202
Replace Outer Pin Seals 202
Drain and Refill Transmission Oil and Replace Filter 202
Drain and Refill Front and Rear Axle Oil 204
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped 205
Adjust Engine Valve Lash (Clearance) 205
Rerun Transmission Clutch Calibration 205
Maintenance—Every 4000 Hours 206
Replace Crankshaft Damper 206
Clean Hydraulic Pump Case Drain In-Line Screen 206
Replace Hydraulic System Return Filter 208
Drain, Flush, and Refill Hydraulic System Oil 209
Clean Hydraulic System Fill Strainer 210
Maintenance—Every 5000 Hours 211
Inspect Driveline Damper 211
Maintenance—Every 6000 Hours 212
Drain Cooling System 212
Refill Cooling System 213
Miscellaneous—Machine 214
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped 214
Check Air Inlet Cover 214
Inspect Fuel Tank Vent Hose and Breather Filter 215
Bleed Fuel System 215
Do Not Service Control Valves, Cylinders, Pumps, or Motors 215
Precautions for Alternator and Regulator 215
Handling, Checking, and Servicing Batteries Carefully 216
Using Booster Batteries—24-Volt System 217
Using Battery Charger 218
Replacement Batteries 218
Remove and Install Batteries 219
12-Volt Auxiliary Power Outlet—If Equipped 220
JDLink Machine Monitoring System (MMS)—If Equipped 220
Replacing Fuses 221
Remove and Install Halogen Bulbs 223
Fluid Sampling Test Ports—If Equipped 223
Air Conditioner System Service 225
External Service Brake Inspection 226
Service Recommendations For Snap-To-Connect (STC®) Fittings 227
Welding On Machine 228
Welding Near Electronic Control Units 228
Keep Electronic Control Unit Connectors Clean 229
Replacing Bucket Teeth—TK Series 229
Keep ROPS Installed Properly 229
Hardware Torque Specifications 230
Metric Bolt and Screw Torque Values 231
Unified Inch Bolt and Screw Torque Values 232
Miscellaneous—Operational Checkout 233
Operational Checkout 233
Miscellaneous—Troubleshooting 258
Troubleshooting Procedure 258
Engine 259
Transmission 262
Differential and Axle 265
Service Brake 266
Driveline 267
Park Brake 267
Hydraulic System 268
Steering 270
Air Conditioning System 271
Heater System 273
Software Update 273
Miscellaneous—Storage 274
Prepare Machine for Storage 274
Monthly Storage Procedure 274
Miscellaneous—Machine Numbers 276
Record Product Identification Number (PIN) 276
Record Engine Serial Number 276
Record Transmission Serial Number 276
Record Hydraulic Pump Serial Number 277
Record Front and Rear Axle Housing Serial Numbers 277
Keep Proof of Ownership 277
Keep Machines Secure 278
Miscellaneous—Specifications 279
Engine Specifications 279
Drain and Refill Capacities 280
Standard Z-Bar Specifications 281
High Lift Z-Bar Specifications 283
Powerllel™ Specifications 285
Travel Speeds 286
Page Number 23
Section 1-1 23
Section 1-2 24
Section 1-3 31
Section 1-4 37
Section 1-5 40
Section 2-1 46
Section 2-2 95
Section 3-1 138
Section 3-2 153
Section 3-3 165
Section 3-4 178
Section 3-5 182
Section 3-6 184
Section 3-7 187
Section 3-8 188
Section 3-9 199
Section 3-10 202
Section 3-11 206
Section 3-12 211
Section 3-13 212
Section 4-1 214
Section 4-2 233
Section 4-3 258
Section 4-4 274
Section 4-5 276
Section 4-6 279
S.V 04/24