John Deere 544K Loader Operator's Manual (OMT231639)
Complete Operator's Manual for John Deere 544K Loaders, with all the technical information to maintain & operate like professional mechanics.
omt231639 - John Deere 544K Loader Operator's Manual.pdf
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PRODUCT DETAILS:
Total Pages: 541 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS................1
Section 1-1: Safety—Safety and Operator Conveniences................32
Safety and Operator Convenience Features................33
Section 1-2: Safety—General Precautions................34
Recognize Safety Information................35
Follow Safety Instructions................36
Operate Only If Qualified................37
Wear Protective Equipment................38
Avoid Unauthorized Machine Modifications................39
Inspect Machine................40
Stay Clear of Moving Parts................41
Avoid High-Pressure Fluids................42
Avoid High-Pressure Oils................43
Work In Ventilated Area................44
Prevent Fires................45
Prevent Battery Explosions................46
Handle Chemical Products Safely................47
Decommissioning — Proper Recycling and Disposal of Fluids and Components................48
Prepare for Emergencies................49
Beware of Exhaust Fumes................50
Clean Debris from Machine................51
Add Cab Guarding for Special Uses................52
Section 1-3: Safety—Operating Precautions................53
Use Steps and Handholds Correctly................54
Start Only From Operator's Seat................55
Use and Maintain Seat Belt................56
Prevent Unintended Machine Movement................57
Avoid Work Site Hazards................58
Use Special Care When Operating Loader................60
Keep Riders Off Machine................61
Avoid Backover Accidents................62
Avoid Machine Tip Over................63
Operating or Traveling On Public Roads................65
Inspect and Maintain ROPS................66
Add and Operate Attachments Safely................67
Operating on Slopes................68
Section 1-4: Safety—Maintenance Precautions................69
Park and Prepare for Service Safely................70
Service Cooling System Safely................71
Remove Paint Before Welding or Heating................72
Make Welding Repairs Safely................73
Drive Metal Pins Safely................74
Service Tires Safely................75
Section 1-5: Safety—Safety Signs................77
Safety Signs................77
Section 2-1: Operation—Operator’s Station................79
Levers—Two Function Hydraulic Control................81
Levers—Three Function Hydraulic Control................83
Levers—Four Function Hydraulic Control................86
Levers—Joystick Steering Control................87
Pedals................88
Advanced Display Unit (ADU)................89
Display Unit Functions................91
Sealed Switch Module (SSM)................95
Switch Module Functions................97
Display Unit—Normal Display................101
Display Unit—Main Menu................102
Display Unit—Main Menu—Codes................104
Display Unit—Main Menu—Codes—Active Codes................106
Display Unit—Main Menu—Codes—Stored Codes................107
Display Unit—Main Menu—Machine Settings................108
Display Unit—Main Menu—Machine Settings—Reverse Fan Cycle................111
Display Unit—Main Menu—Machine Settings—Camera Mode................112
Display Unit—Main Menu—Machine Settings—Job Timer................113
Display Unit—Main Menu—Machine Settings—Stopwatch................114
Display Unit—Main Menu—Machine Settings—Ride Control—If Equipped................195
Display Unit—Main Menu—Machine Settings—Quick Shift................116
Display Unit—Main Menu—Machine Settings—Counters................117
Display Unit—Main Menu—Diagnostics................118
Display Unit—Main Menu—Diagnostics—Machine ID................120
Display Unit—Main Menu—Diagnostics—Battery Monitor................121
Display Unit—Main Menu—Diagnostics—Engine Sensors................122
Display Unit—Main Menu—Diagnostics—Transmission Sensors................123
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors................124
Display Unit—Main Menu—Diagnostics—Machine Sensors................125
Display Unit—Main Menu—Diagnostics—FNR Selector................126
Display Unit—Main Menu—Diagnostics—Cab Switches................127
Display Unit—Main Menu—Diagnostics—Switch Module................128
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped................129
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped................130
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped................131
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped................132
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped................133
Display Unit—Main Menu—Payload Scale—If Equipped................134
Display Unit—Main Menu—Payload Scale—Long Total................135
Display Unit—Main Menu—Payload Scale—Display Units................136
Display Unit—Main Menu—Payload Scale—Auto Add................137
Display Unit—Main Menu—Payload Scale—Diagnostics................138
Display Unit—Main Menu—Payload Scale—Setup................139
Display Unit—Main Menu—Monitor Settings................140
Display Unit—Main Menu—Security................141
Display Unit—Main Menu—Security—Security................143
Display Unit—Main Menu—Security—Change Owner PIN................144
Display Unit—Main Menu—Security—Manage Operator PINs................145
Display Unit—Main Menu—Security—Manage Transport PIN................146
Display Unit—Main Menu—Security—Delayed Operator Logout................148
Horn Button................149
Turn Signals................150
Tilt Steering Column Adjustment................151
Joystick Steering Armrest Adjustment— if Equipped................152
Air Conditioner and Heater Operation................154
Opening and Securing Side Door................156
Opening Side Window/Secondary Exit................158
Opening Rear Side Window................159
Seat Adjustment................160
Section 2-2: Operation—Operating the Machine................162
Inspect Machine Daily Before Starting................164
Check Instruments Before Starting................166
Engine Break-In Period................167
Starting the Engine................490
Starting Fluid (Cold Weather Starting Aid)—If Equipped................172
Engine Block Heater—If Equipped................174
Warmup................175
Minimizing the Effect of Cold Weather on Diesel Engines................256
Cold Weather Warmup................178
Automatic Idle and Automatic Shutdown................179
Neutral Lock................180
Park Brake Switch................181
Shifting the Transmission................492
Joystick Bucket and Boom Control................186
Two Lever Bucket and Boom Control................188
Auxiliary Control................190
Joystick Steering Control—If Equipped................191
Ride Control—If Equipped................195
Secondary Steering—If Equipped................199
Differential Lock Operation................201
Counter Switch Operation................202
Rear Camera and Radar Object Detection System (RODS)—If Equipped................204
Embedded Payload Scale—If Equipped................207
Security System................214
Boom Height Kickout Adjustment................215
Return-to-Carry Kickout Adjustment................216
Return-to-Dig Adjustment for Z-Bar Linkage................217
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped................219
Operating Loader Coupler—If Equipped................222
Using the Loader Bucket................223
Backdragging................226
Fork Attachment................227
Operating in Water and Mud................229
Parking the Machine................230
Loading Machine on a Trailer................232
Towing Procedure................235
Lifting the Machine................238
Section 3-1: Maintenance—Machine................240
Alternative and Synthetic Lubricants................241
Hydraulic Oil................242
Grease................244
Transmission, Park Brake, and Axle Oil................246
Lubricant Storage................247
Mixing of Lubricants................248
Diesel Fuel................249
Lubricity of Diesel Fuel................251
Handling and Storing Diesel Fuel................252
Biodiesel Fuel................253
Testing Diesel Fuel................255
Minimizing the Effect of Cold Weather on Diesel Engines................256
Low Sulfur Diesel Fuel Conditioner................258
Diesel Engine Break-In Oil................259
Diesel Engine Oil — Tier 3 and Stage IIIA................260
Diesel Engine Oil and Filter Service Intervals................289
Diesel Engine Coolant (engine with wet sleeve cylinder liners)................264
Drain Intervals for Diesel Engine Coolant................266
John Deere COOL-GARD™ II Coolant Extender................267
Supplemental Coolant Additives................268
Operating in Warm Temperature Climates................269
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender................270
Testing Diesel Engine Coolant................272
Section 3-2: Maintenance—Periodic Maintenance................273
Service Machine at Specified Intervals................274
Check Hour Meter Regularly................275
Prepare Machine for Maintenance................276
Frame Locking Bar................279
Boom Lock................280
Pin Removal—If Equipped With Powerllel™ Linkage................282
Engine Service Doors and Side Shields................283
Cooling System Doors................285
Fuel Tank................287
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit................288
Service Intervals................289
Required Parts................292
Section 3-3: Maintenance—As Required................294
Inspect Tires and Check Pressure................295
Tire Pressures................297
Check Wheel Bolt Torque................302
Inspect Engine Air Cleaner Elements................303
Inspect Air Conditioner Compressor and Alternator Belt................305
Clean Cooler Cores................307
Check Windshield Washer Fluid Level................309
Drain Water From Auxiliary Fuel Filter/Water Separator—If Equipped................310
Drain Water From Primary Fuel Filter................311
Drain Water from Final Fuel Filter................312
Check and Clean or Replace Cab Fresh Air Filter................313
Check and Clean or Replace Cab Recirculating Air Filter................315
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped................317
Check Transmission Oil Level................319
Check Coolant................377
Section 3-4: Maintenance—Every 10 Hours or Daily................323
Check Coolant Level in Surge Tank................324
Check and Clean or Replace Air Cleaner Dust Unloader Valve................371
Check Engine Oil Level................326
Check Hydraulic Oil Level................327
Inspect Outer Pin Seals................328
Section 3-5: Maintenance—Every 100 Hours................330
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage................331
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage................333
Section 3-6: Maintenance—Initial Service - 250 Hours................335
Drain and Refill Engine Oil and Replace Filter................350
Drain and Refill Front and Rear Axle Oil................383
Replace Axle Oil Filters—If Equipped................374
Section 3-7: Maintenance—Every 250 Hours................341
Take Engine Oil Sample................342
Section 3-8: Maintenance—Every 500 Hours................343
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints................344
Check Air Intake Hoses and Charge Air Cooler Tube Couplings................345
Check Battery Water Level and Terminals................346
Drain and Refill Engine Oil and Replace Filter................350
Replace Primary Fuel Filter................352
Replace Final Fuel Filter................354
Replace Auxiliary Fuel Filter/Water Separator—If Equipped................356
Replace In-Line Fuel Strainer................358
Replace Hydraulic Reservoir Breather Filter................359
Check Park Brake Oil Level................360
Lubricate Front and Rear Shaft Seals on Park Brake................499
Check Front and Rear Axle Oil Level................362
Lubricate Front and Rear Axle Shaft Seals................364
Check Ride Control Accumulator—If Equipped................365
Take Fluid Samples................368
Section 3-9: Maintenance—Every 1000 Hours................369
Clean Engine Crankcase Vent Tube................370
Replace Air Cleaner Dust Unloader Valve................371
Replace Engine Air Cleaner Elements................372
Replace Axle Oil Filters—If Equipped................374
Lubricate Frame Hinge Pivots................375
Drain and Refill Park Brake Oil................376
Check Coolant................377
Section 3-10: Maintenance—Every 2000 Hours................378
Replace Outer Pin Seals................379
Drain and Refill Transmission Oil and Replace Filter................380
Drain and Refill Front and Rear Axle Oil................383
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped................385
Rerun Transmission Clutch Calibration................386
Adjust Engine Valve Lash (Clearance)................387
Section 3-11: Maintenance—Every 4000 Hours................388
Clean Hydraulic Pump Case Drain Screen................389
Drain and Refill Hydraulic System Oil................393
Clean Hydraulic System Fill Strainer................396
Replace Hydraulic System Return Filter................397
Replace Crankshaft Dampener................399
Section 3-12: Maintenance—Every 5000 Hours................400
Inspect Driveline Damper................401
Section 3-13: Maintenance—Every 6000 Hours................402
Drain Cooling System................403
Refill Cooling System................405
Section 4-1: Miscellaneous—Machine................407
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped................408
Check Air Inlet Cover................409
Inspect Fuel Tank Vent Hose and Breather................410
Bleed Fuel System................411
Bleed Fuel System With Low Pressure Fuel Pump—If Equipped................412
Check Fire Extinguisher—If Equipped................413
Precautions for Alternator and Regulator................414
Handle Batteries Safely................415
Using Booster Batteries—24 Volt System................417
Using Battery Charger................419
Battery Disconnect Switch................421
Replacement Batteries................422
Remove and Install Batteries................423
12-Volt Auxiliary Power Outlet—If Equipped................407
JDLink™ Machine Monitoring System (MMS)—If Equipped................426
Fuse Identification and Replacement................427
Replacing Halogen Bulbs................431
Fluid Sampling Test Ports—If Equipped................433
Air Conditioner System Service................435
External Service Brake Inspection................436
Clean Oil Coolers, Charge Air Cooler, and Radiator................438
Service Recommendations For Snap-To-Connect (STC®) Fittings................439
Do Not Service Control Valves, Cylinders, Pumps, or Motors................441
Keep ROPS Installed Properly................442
Welding On Machine................443
Replacing Bucket Teeth—TK Series................444
Hardware Torque Specifications................445
Unified Inch Bolt and Screw Torque Values................446
Metric Bolt and Screw Torque Values................448
Section 4-2: Miscellaneous—Operational Checkout................451
Operational Checkout................451
Section 4-3: Miscellaneous—Troubleshooting................488
Troubleshooting Procedure................489
Engine................490
Transmission................492
Differential And Axle................495
Service Brake................497
Driveline................498
Park Brake................499
Hydraulic System................500
Steering................503
Air Conditioning System................504
Heater System................506
Section 4-4: Miscellaneous—Storage................507
Prepare Machine For Storage................508
Monthly Storage Procedure................510
Section 4-5: Miscellaneous—Machine Numbers................512
Record Product Identification Number (PIN)................513
Record Engine Serial Number................514
Record Transmission Serial Number................515
Record Hydraulic Pump Serial Number................516
Record Axle Serial Number................517
Keep Proof of Ownership................518
Keep Machines Secure................519
Section 4-6: Miscellaneous—Specifications................520
Engine Specifications................521
Drain and Refill Capacities................522
Standard Z-Bar Specifications................523
High Lift Z-Bar Specifications................525
Powerllel™ Specifications................527
Travel Speeds................529
John Deere 544K Loader Operator's Manual (OMT231639)
