John Deere 544K-II 4WD Loader Operator’s Manual OMT387134X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 544K-II 4WD Loader Operator’s Manual OMT387134X19 – PDF DOWNLOAD
P/N:OMT387134X19_22
Language: English
Division: Construction
Product Lines: Loaders
Publication Type: Operator’s Manuals
Associated Models: 544K SERIES II
Series: 0
Serial:
PIN: 1DW544K_ _ _D677549—
For complete service information also see: PC15091, T387059X19
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
John Deere 544K-II 4WD Loader Operator’s Manual OMT387134X19 – PDF DOWNLOAD
Contents 25
Safety—Safety and Operator Conveniences 31
Safety and Operator Convenience Features 31
Safety—General Precautions 32
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance 32
Recognize Safety Information 33
Follow Safety Instructions 34
Operate Only If Qualified 34
Wear Protective Equipment 34
Avoid Unauthorized Machine Modifications 35
Inspect Machine 35
Stay Clear of Moving Parts 35
Avoid High-Pressure Fluids 35
Avoid High-Pressure Oils 36
Work In Ventilated Area 36
Avoid Static Electricity Risk When Refueling 37
Prevent Fires 37
In Case of Machine Fire 38
Prevent Battery Explosions 38
High Debris Applications 38
Clean Debris from Machine 39
Handle Chemical Products Safely 39
Handle Starting Fluid Safely 39
Decommissioning — Proper Recycling and Disposal of Fluids and Components 40
Prepare for Emergencies 40
Add Cab Guarding for Special Uses 40
Safety—Operating Precautions 41
Use Steps and Handholds Correctly 41
Start Only From Operator’s Seat 41
Use and Maintain Seat Belt 41
Prevent Unintended Machine Movement 42
Avoid Work Site Hazards 43
Use Special Care When Operating Loader 44
Keep Riders Off Machine 44
Avoid Backover Accidents 44
Avoid Machine Tip Over and Machine Damage 45
Avoid Power Lines 45
Operating on Slopes 46
Operating or Traveling On Public Roads 46
Inspect and Maintain ROPS 46
Travel Safely 46
Prevent Acid Burns 47
Add and Operate Attachments Safely 47
Safety—Maintenance Precautions 48
Park and Prepare for Service Safely 48
Service Machines Safely 48
Service Cooling System Safely 49
Service Tires Safely 49
Use Proper Lifting Equipment 50
Remove Paint Before Welding or Heating 50
Make Welding Repairs Safely 50
Drive Metal Pins Safely 51
Safety—Safety Signs and Other Instructions 52
Safety Signs and Other Instructions 52
Operation—Operator’s Station 60
Levers—Two Function Hydraulic Control 60
Levers—Three Function Hydraulic Control 61
Levers—Four Function Hydraulic Control 63
Pedals 63
Sealed Switch Module (SSM) 64
Switch Module Functions 65
Advanced Display Unit (ADU) 68
Display Unit Functions 69
Horn Button 73
Turn Signals 73
Air Conditioner and Heater Operation 74
Counter Switch 75
Radio—If Equipped 76
Opening and Securing Side Door 80
Opening Side Window/Secondary Exit 81
Opening Rear Side Window 81
Seat Adjustment 82
Fire Extinguisher Mounting Location 83
Operation—Operating the Machine 84
Before Starting Work 84
Inspect Machine Daily Before Starting 84
Check Instruments Before Starting 84
Security System 85
Battery Disconnect Switch 85
Engine Break-In Period 86
Starting the Engine 87
Cold Start Aid—Starting Fluid—If Equipped 89
Cold Start Aid—Block Heater—If Equipped 89
Warm-Up Procedure 90
Cold Weather Warm-Up 90
Park Brake Switch 91
Shifting the Transmission 92
Automatic Idle and Automatic Shutdown 94
Turbocharger Cool Down 94
Joystick Bucket and Boom Control 95
Two Lever Bucket and Boom Control 96
Auxiliary Control 97
Ride Control—If Equipped 98
Secondary Steering—If Equipped 100
Differential Lock Operation 100
Service ADVISOR™ Remote (SAR) Software Delivery Process 101
Rear Camera and Radar Object Detection (ROD) System—If Equipped 102
Counter Switch Operation 104
Embedded Payload Scale—If Equipped 105
Boom Height Kickout Adjustment 109
Return-to-Carry Kickout Adjustment 109
Return-to-Dig Adjustment for Z-Bar Linkage 110
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped 112
Operating Loader Coupler—If Equipped 113
Using the Loader Bucket 114
Backdragging 115
Fork Attachment 116
Operating in Water and Mud 117
Parking the Machine 118
Loading Machine on a Trailer 119
Towing Procedure 121
Lifting the Machine 122
Operation—Monitor Operation 123
Display Unit—Normal Display 123
Display Unit—Main Menu 124
Display Unit—Main Menu—Codes 125
Display Unit—Main Menu—Codes—Active Codes 125
Display Unit—Main Menu—Codes—Stored Codes 126
Display Unit—Main Menu—Settings 127
Display Unit—Main Menu—Settings—Reverse Fan Cycle 128
Display Unit—Main Menu—Settings—Courtesy Lights 128
Display Unit—Main Menu—Settings—Quick Shift 129
Display Unit—Main Menu—Settings—Job Timer 129
Display Unit—Main Menu—Settings—Stopwatch 130
Display Unit—Main Menu—Settings—Ride Control—If Equipped 130
Display Unit—Main Menu—Settings—Counters 130
Display Unit—Main Menu—Settings—Camera Mode 131
Display Unit—Main Menu—Settings—Operator Configuration 131
Display Unit—Main Menu—Settings—Clutch Cutoff 132
Display Unit—Main Menu—Diagnostics 133
Display Unit—Main Menu—Diagnostics—Machine ID 134
Display Unit—Main Menu—Diagnostics—Battery Monitor 134
Display Unit—Main Menu—Diagnostics—Engine Sensors 135
Display Unit—Main Menu—Diagnostics—Transmission/Axle 135
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors 136
Display Unit—Main Menu—Diagnostics—Machine Sensors 136
Display Unit—Main Menu—Diagnostics—FNR Selector 137
Display Unit—Main Menu—Diagnostics—Cab Switches 137
Display Unit—Main Menu—Diagnostics—Switch Module 137
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped 138
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped 139
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped 139
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped 140
Display Unit—Main Menu—Diagnostics—JDLink™ System Info 140
Display Unit—Main Menu—Diagnostics—Park Brake Test 141
Display Unit—Main Menu—Payload Scale—If Equipped 142
Display Unit—Main Menu—Payload Scale—Long Total 142
Display Unit—Main Menu—Payload Scale—Display Units 143
Display Unit—Main Menu—Payload Scale—Auto Add 143
Display Unit—Main Menu—Payload Scale—Diagnostics 143
Display Unit—Main Menu—Payload Scale—Setup 143
Display Unit—Main Menu—Security 144
Display Unit—Main Menu—Security—Security 145
Display Unit—Main Menu—Security—Change Owner PIN 145
Display Unit—Main Menu—Security—Manage Operator PINs 146
Display Unit—Main Menu—Security—Manage Transport PIN 147
Display Unit—Main Menu—Security—Delayed Operator Logout 148
Display Unit—Main Menu—Software Delivery 148
Display Unit—Main Menu—Software Delivery—Software Update 149
Maintenance—Machine 150
Required Emission-Related Information 150
Diesel Fuel 150
Lubricity of Diesel Fuel 151
Handling and Storing Diesel Fuel 151
Biodiesel Fuel 152
Testing Diesel Fuel 153
Minimizing the Effect of Cold Weather on Diesel Engines 154
Alternative and Synthetic Lubricants 155
Lubricant Storage 155
Mixing of Lubricants 155
Diesel Engine Break-In™ Oil— Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III 156
Diesel Engine Oil — Tier 3 and Stage IIIA 157
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA Engines 158
Diesel Engine Oil Service Interval for Operation at High Altitude 159
Oil Filters 159
Transmission, Park Brake, and Axle Oil 159
Hydraulic Oil 160
Grease with Molybdenum Disulfide 161
Diesel Engine Coolant (engine with wet sleeve cylinder liners) 162
Water Quality for Mixing with Coolant Concentrate 163
Supplemental Diesel Fuel Additives 163
Fuel Filters 163
Operating in Warm Temperature Climates 164
Testing Coolant Freeze Point 164
Disposing of Coolant 165
Maintenance—Periodic Maintenance 166
Service Machine at Specified Intervals 166
Check Hour Meter Regularly 166
Prepare Machine for Maintenance 167
Frame Locking Bar 168
Boom Lock 169
Pin Removal—If Equipped With Powerllel™ Linkage 170
Engine Service Doors and Side Shields 171
Cooling System Doors 172
Fuel Tank 173
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit 173
Service Intervals 174
Required Parts 176
Maintenance—As Required 177
Inspect Tires and Check Pressure 177
Tire Pressures 178
Check Wheel Bolt Torque 180
Inspect Engine Air Cleaner Elements 181
Inspect Air Conditioner Compressor and Alternator Belt 182
Clean Cooler Cores 183
Check Window Washer Fluid Level 184
Drain Water From Primary Fuel Filter With Water Separator 184
Drain Water From Final Fuel Filter 185
Drain Water From Auxiliary Fuel Filter With Water Separator—If Equipped 185
Check and Clean or Replace Cab Fresh Air Filter 186
Check and Clean or Replace Cab Recirculating Air Filter 187
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped 188
Clean and Tighten Battery Terminals 189
Maintenance—Every 10 Hours or Daily 190
Clean Air Cleaner Dust Unloader Valve 190
Check Coolant Level at Surge Tank 190
Check Engine Oil Level 191
Check Hydraulic System Oil Level 191
Check Transmission Oil Level 192
Inspect Outer Pin Seals—If Equipped 193
Maintenance—Every 100 Hours 194
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage 194
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage 195
Maintenance—Initial Service—250 Hours 196
Drain and Refill Front and Rear Axle Oil 196
Replace Axle Oil Filters—If Equipped 197
Maintenance—Every 250 Hours 198
Take Engine Oil Sample 198
Maintenance—Every 500 Hours 199
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints 199
Check Front and Rear Axle Oil Level 200
Lubricate Front and Rear Axle Shaft Seals 200
Check Hybrid Battery Electrolyte Level—If Equipped 201
Check Air Intake Hoses and Charge Air Cooler Tube Couplings 203
Take Fluid Samples 203
Drain and Refill Engine Oil and Replace Filter 204
Replace Auxiliary Fuel Filter—If Equipped 205
Replace Primary Fuel Filter 206
Replace In-Line Fuel Strainer 206
Replace Final Fuel Filter 207
Replace Hydraulic Reservoir Breather Filter 207
Check Park Brake Oil Level 208
Lubricate Front and Rear Shaft Seals on Park Brake 208
Check Ride Control Accumulator—If Equipped 209
Maintenance—Every 1000 Hours 210
Clean Engine Crankcase Vent Tube 210
Replace Air Cleaner Dust Unloader Valve 210
Replace Engine Air Cleaner Elements 211
Check Coolant Condition 212
Replace Axle Oil Filters—If Equipped 212
Lubricate Frame Hinge Pivots 212
Drain and Refill Park Brake Oil 213
Maintenance—Every 2000 Hours 214
Replace Outer Pin Seals—If Equipped 214
Drain and Refill Transmission Oil and Replace Filter 214
Drain and Refill Front and Rear Axle Oil 216
Check and Adjust Engine Valve Lash 216
Rerun Transmission Clutch Calibration 216
Maintenance—Every 4000 Hours 217
Replace Crankshaft Damper 217
Clean Hydraulic Pump Case Drain In-Line Screen 217
Replace Hydraulic System Return Filter 219
Drain, Flush, and Refill Hydraulic System Oil 220
Clean Hydraulic System Fill Strainer 221
Maintenance—Every 5000 Hours 222
Check Driveline Damper For Cracks 222
Maintenance—Every 6000 Hours 223
Drain Cooling System 223
Refill Cooling System 224
Miscellaneous—Machine 225
Check Air Inlet Cover—If Equipped 225
Inspect Fuel Tank Vent Hose and Breather Filter 225
Bleed Fuel System 225
Do Not Service Control Valves, Cylinders, Pumps, or Motors 226
Precautions for Alternator and Regulator 226
Handling, Checking, and Servicing Batteries Carefully 227
Using Booster Batteries—24-Volt System 228
Using Battery Charger 229
Replacement Batteries 230
Remove and Install Batteries 231
12-Volt Auxiliary Power Outlet—If Equipped 231
JDLink™ Machine Monitoring System (MMS)—If Equipped 232
Replacing Fuses 232
Remove and Install Halogen Bulbs 234
Fluid Sampling Test Ports—If Equipped 235
Air Conditioning System Service 236
External Service Brake Inspection 237
Bleeding Brakes 238
Service Recommendations For Snap-To-Connect (STC®) Fittings 239
Welding on Machine 240
Keep Electronic Control Unit Connectors Clean 240
Replacing Bucket Teeth—TK Series 241
Keep ROPS Installed Properly 241
Hardware Torque Specifications 241
Unified Inch Bolt and Screw Torque Values 242
Metric Bolt and Screw Torque Values 243
Miscellaneous—Operational Checkout 244
Operational Checkout 244
Diagnostic Trouble Code Check 244
Ignition OFF, Engine OFF Checks 244
Ignition ON, Engine OFF Checks 245
Ignition ON, Engine ON Checks 252
Miscellaneous—Troubleshooting 273
Troubleshooting Procedure 273
Engine 274
Transmission 277
Differential and Axle 280
Service Brake 281
Driveline 281
Park Brake 282
Hydraulic System 283
Steering 285
Air Conditioning System 286
Heater System 287
Software Update 288
Miscellaneous—Storage 289
Prepare Machine for Storage 289
Monthly Storage Procedure 290
Miscellaneous—Machine Numbers 291
Record Product Identification Number (PIN) 291
Record Engine Serial Number 291
Record Transmission Serial Number 291
Record Hydraulic Pump Serial Number 292
Record Front and Rear Axle Housing Serial Numbers 292
Keep Proof of Ownership 292
Keep Machines Secure 293
Miscellaneous—Specifications 294
Engine Specifications 294
Drain and Refill Capacities 294
Standard Z-Bar Specifications 295
High Lift Z-Bar Specifications 297
Powerllel™ Specifications 299
Travel Speeds 300
Eurasian Economic Union 301
Machine Design Life 301
Page Number 25
Section 1-1 31
Section 1-2 32
Section 1-3 41
Section 1-4 48
Section 1-5 52
Section 2-1 60
Section 2-2 84
Section 2-3 123
Section 3-1 150
Section 3-2 166
Section 3-3 177
Section 3-4 190
Section 3-5 194
Section 3-6 196
Section 3-7 198
Section 3-8 199
Section 3-9 210
Section 3-10 214
Section 3-11 217
Section 3-12 222
Section 3-13 223
Section 4-1 225
Section 4-2 244
Section 4-3 273
Section 4-4 289
Section 4-5 291
Section 4-6 294
S.V 04/24