John Deere 4WD Loader 544K Operator's Manual (OMT346593X19)
Operator's Manual for John Deere 4WD Loader 544K, with all the shop information to maintain, and operate your loader.
omt346593x19 - 544K 4WD Loader Operator's Manual.pdf
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Total Pages: 536 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
TABLE OF CONTENTS............1
Section 1-1: Safety—Safety and Operator Conveniences............41
Safety and Operator Convenience Features............42
Section 1-2: Safety—General Precautions............43
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance............44
Recognize Safety Information............48
Follow Safety Instructions............49
Operate Only If Qualified............50
Wear Protective Equipment............51
Avoid Unauthorized Machine Modifications............52
Inspect Machine............53
Stay Clear of Moving Parts............54
Avoid High-Pressure Fluids............55
Avoid High-Pressure Oils............56
Work In Ventilated Area............57
Avoid Static Electricity Risk When Refueling............58
Prevent Fires............60
Clean Debris from Machine............61
Prevent Battery Explosions............62
Handle Chemical Products Safely............63
Decommissioning — Proper Recycling and Disposal of Fluids and Components............64
Prepare for Emergencies............65
Add Cab Guarding for Special Uses............66
Section 1-3: Safety—Operating Precautions............67
Use Steps and Handholds Correctly............68
Start Only From Operator's Seat............69
Use and Maintain Seat Belt............70
Prevent Unintended Machine Movement............71
Avoid Work Site Hazards............72
Use Special Care When Operating Loader............74
Keep Riders Off Machine............75
Avoid Backover Accidents............76
Avoid Machine Tip Over............77
Operating on Slopes............79
Operating or Traveling On Public Roads............80
Inspect and Maintain ROPS............81
Add and Operate Attachments Safely............82
Section 1-4: Safety—Maintenance Precautions............83
Park and Prepare for Service Safely............84
Service Cooling System Safely............85
Service Tires Safely............86
Remove Paint Before Welding or Heating............87
Make Welding Repairs Safely............88
Drive Metal Pins Safely............89
Section 1-5: Safety—Safety Signs............91
Safety Signs............91
Section 2-1: Operation—Operator’s Station............100
Levers—Two Function Hydraulic Control............101
Levers—Three Function Hydraulic Control............104
Pedals............107
Sealed Switch Module (SSM)............108
Switch Module Functions............110
Advanced Display Unit (ADU)............114
Display Unit Functions............116
Horn Button............123
Turn Signals............124
Air Conditioner and Heater Operation............125
Opening and Securing Side Door............127
Opening Side Window/Secondary Exit............129
Opening Rear Side Window............130
Seat Adjustment............131
Fire Extinguisher Mounting Location............133
Section 2-2: Operation—Operating the Machine............134
Before Starting Work............136
Inspect Machine Daily Before Starting............137
Check Instruments Before Starting............138
Security System............139
Battery Disconnect Switch............140
Engine Break-In Period............141
Starting the Engine............496
Cold Start Aid—Starting Fluid—If Equipped............146
Cold Start Aid—Block Heater—If Equipped............148
Warmup............149
Cold Weather Warmup............150
Automatic Idle and Automatic Shutdown............151
Park Brake Switch............152
Shifting the Transmission............500
Joystick Bucket and Boom Control............157
Two Lever Bucket and Boom Control............159
Auxiliary Control............161
Ride Control—If Equipped............162
Differential Lock Operation—If Equipped............166
Service ADVISOR™ Remote (SAR) Software Delivery Process............167
Rear Camera and Radar Object Detection (ROD) System—If Equipped............168
Boom Height Kickout Adjustment............171
Return-to-Carry Kickout Adjustment............172
Return-to-Dig Adjustment for Z-Bar Linkage............173
Operating Loader Coupler—If Equipped............177
Using the Loader Bucket............178
Backdragging............181
Fork Attachment............182
Operating in Water and Mud............184
Parking the Machine............185
Loading Machine on a Trailer............187
Towing Procedure............190
Lifting the Machine............193
Section 2-3: Operation—Monitor Operation............195
Display Unit—Normal Display............197
Display Unit—Main Menu............199
Display Unit—Main Menu—Codes............201
Display Unit—Main Menu—Codes—Active Codes............203
Display Unit—Main Menu—Codes—Stored Codes............204
Display Unit—Main Menu—Settings—If Equipped............205
Display Unit—Main Menu—Settings—Reverse Fan Cycle............208
Display Unit—Main Menu—Settings—Courtesy Lights............209
Display Unit—Main Menu—Settings—Quick Shift............210
Display Unit—Main Menu—Settings—Job Timer............211
Display Unit—Main Menu—Settings—Stopwatch............212
Display Unit—Main Menu—Settings—Ride Control—If Equipped............213
Display Unit—Main Menu—Settings—Counters............214
Display Unit—Main Menu—Settings—Camera Mode—If Equipped............215
Display Unit—Main Menu—Settings—Operator Configuration............216
Display Unit—Main Menu—Diagnostics............217
Display Unit—Main Menu—Diagnostics—Machine ID............219
Display Unit—Main Menu—Diagnostics—Battery Monitor............220
Display Unit—Main Menu—Diagnostics—Engine Sensors............221
Display Unit—Main Menu—Diagnostics—Transmission/Axle............222
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors............223
Display Unit—Main Menu—Diagnostics—Machine Sensors............224
Display Unit—Main Menu—Diagnostics—FNR Selector............225
Display Unit—Main Menu—Diagnostics—Cab Switches............226
Display Unit—Main Menu—Diagnostics—Switch Module............227
Display Unit—Main Menu—Diagnostics—Joystick Steering............512
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped............229
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped............230
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped............231
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped............233
Display Unit—Main Menu—Diagnostics—JDLink™ System Info............234
Display Unit—Main Menu—Diagnostics—Park Brake Test............235
Display Unit—Main Menu—Payload Scale—If Equipped............237
Display Unit—Main Menu—Monitor Settings............238
Display Unit—Main Menu—Security............239
Display Unit—Main Menu—Security—Security............242
Display Unit—Main Menu—Security—Change Owner PIN............243
Display Unit—Main Menu—Security—Manage Operator PINs............244
Display Unit—Main Menu—Security—Manage Transport PIN............245
Display Unit—Main Menu—Security—Delayed Operator Logout............247
Display Unit—Main Menu—Software Delivery............248
Display Unit—Main Menu—Software Delivery—Software Update............516
Section 3-1: Maintenance—Machine............252
Diesel Fuel............253
Lubricity of Diesel Fuel............255
Handling and Storing Diesel Fuel............256
Biodiesel Fuel............257
Testing Diesel Fuel............259
Supplemental Diesel Fuel Additives............260
Fuel Filters............261
Minimizing the Effect of Cold Weather on Diesel Engines............262
Alternative and Synthetic Lubricants............264
Lubricant Storage............265
Mixing of Lubricants............266
Diesel Engine Break-In™ Oil............267
Diesel Engine Oil — Tier 3 and Stage IIIA............268
Engine Oil and Filter Service Intervals—Tier 3 and Stage III Engines............270
Oil Filters............272
Transmission, Park Brake, and Axle Oil............273
Hydraulic System Oil............274
Grease............275
Diesel Engine Coolant (engine with wet sleeve cylinder liners)............277
Water Quality for Mixing with Coolant Concentrate............279
Operating in Warm Temperature Climates............280
Testing Coolant Freeze Point............281
Disposing of Coolant............283
Section 3-2: Maintenance—Periodic Maintenance............284
Service Machine at Specified Intervals............285
Check Hour Meter Regularly............286
Prepare Machine for Maintenance............287
Frame Locking Bar............290
Boom Lock............291
Engine Service Doors and Side Shields............293
Cooling System Doors............295
Fuel Tank............297
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit............298
Service Intervals............299
Required Parts............302
Maintenance Legend............304
Section 3-3: Maintenance—As Required............306
Inspect Tires and Check Pressure............307
Tire Pressures............309
Check Wheel Bolt Torque............313
Inspect Engine Air Cleaner Elements............314
Inspect Air Conditioner Compressor and Alternator Belt............316
Clean Cooler Cores............318
Check Windshield Washer Fluid Level............320
Drain Water From Primary Fuel Filter and Water Separator............321
Drain Water From Final Fuel Filter............322
Drain Water From Auxiliary Fuel Filter and Water Separator—If Equipped............323
Check and Clean or Replace Cab Fresh Air Filter............324
Check and Clean or Replace Cab Recirculating Air Filter............326
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped............328
Check Coolant............386
Section 3-4: Maintenance—Every 10 Hours or Daily............332
Clean Air Cleaner Dust Unloader Valve............333
Check Coolant Level in Surge Tank............334
Check Engine Oil Level............335
Check Hydraulic Oil Level............336
Check Transmission Oil Level............337
Inspect Outer Pin Seals............339
Section 3-5: Maintenance—Every 100 Hours............341
Lubricate Loader Linkage and Cylinder Pivots............342
Section 3-6: Maintenance—Initial Service - 250 Hours............344
Drain and Refill Engine Oil and Replace Filter............364
Drain and Refill Front and Rear Axle Oil............392
Replace Axle Oil Filters—If Equipped............385
Section 3-7: Maintenance—Every 250 Hours............350
Take Engine Oil Sample............351
Section 3-8: Maintenance—Every 500 Hours............352
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints............353
Check Front and Rear Axle Oil Level............355
Lubricate Front and Rear Axle Shaft Seals............357
Check Battery Water Level and Terminals............358
Check Air Intake Hoses and Charge Air Cooler Tube Couplings............362
Take Fluid Samples............363
Drain and Refill Engine Oil and Replace Filter............364
Replace Primary Fuel Filter............366
Replace Final Fuel Filter............368
Replace Auxiliary Fuel Filter—If Equipped............370
Replace In-Line Fuel Strainer............371
Replace Hydraulic Reservoir Breather Filter............372
Check Park Brake Oil Level............373
Lubricate Front and Rear Shaft Seals on Park Brake............507
Check Ride Control Accumulator—If Equipped............375
Section 3-9: Maintenance—Every 1000 Hours............378
Clean Engine Crankcase Vent Tube............379
Replace Air Cleaner Dust Unloader Valve............380
Replace Engine Air Cleaner Elements............381
Lubricate Frame Hinge Pivots............383
Drain and Refill Park Brake Oil............384
Replace Axle Oil Filters—If Equipped............385
Check Coolant............386
Section 3-10: Maintenance—Every 2000 Hours............387
Replace Outer Pin Seals............388
Drain and Refill Transmission Oil and Replace Filter............389
Drain and Refill Front and Rear Axle Oil............392
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped............394
Adjust Engine Valve Lash (Clearance)............395
Rerun Transmission Clutch Calibration............396
Section 3-11: Maintenance—Every 4000 Hours............397
Drain, Flush, and Refill Hydraulic System Oil............398
Clean Hydraulic System Fill Strainer............401
Replace Hydraulic System Return Filter............402
Clean Hydraulic Pump Case Drain In-Line Screen............404
Replace Crankshaft Damper............408
Section 3-12: Maintenance—Every 5000 Hours............409
Inspect Driveline Damper............410
Section 3-13: Maintenance—Every 6000 Hours............411
Drain Cooling System............412
Refill Cooling System............414
Section 4-1: Miscellaneous—Machine............416
Check Air Inlet Cover............417
Inspect Fuel Tank Vent Hose and Breather Filter............418
Bleed Fuel System............419
Do Not Service Control Valves, Cylinders, Pumps, or Motors............420
Precautions for Alternator and Regulator............421
Handling, Checking, and Servicing Batteries Carefully............422
Using Booster Batteries—24-Volt System............425
Using Battery Charger............427
Replacement Batteries............429
Remove and Install Batteries............430
12-Volt Auxiliary Power Outlet—If Equipped............416
JDLink™ Machine Monitoring System (MMS)—If Equipped............433
Replacing Fuses............434
Remove and Install Halogen Bulbs............438
Fluid Sampling Test Ports—If Equipped............440
Air Conditioner System Service............442
External Service Brake Inspection............443
Service Recommendations For Snap-To-Connect (STC®) Fittings............445
Welding On Machine............447
Keep Electronic Control Unit Connectors Clean............448
Replacing Bucket Teeth—TK Series............449
Keep ROPS Installed Properly............450
Hardware Torque Specifications............451
Metric Bolt and Screw Torque Values............452
Unified Inch Bolt and Screw Torque Values............454
Section 4-2: Miscellaneous—Operational Checkout............457
Operational Checkout............457
Section 4-3: Miscellaneous—Troubleshooting............494
Troubleshooting Procedure............495
Engine............496
Transmission............500
Differential and Axle............503
Service Brake............505
Driveline............506
Park Brake............507
Hydraulic System............509
Steering............512
Air Conditioning System............513
Heater System............515
Software Update............516
Section 4-4: Miscellaneous—Storage............517
Prepare Machine for Storage............518
Monthly Storage Procedure............520
Section 4-5: Miscellaneous—Machine Numbers............522
Record Product Identification Number (PIN)............523
Record Engine Serial Number............524
Record Transmission Serial Number............525
Record Hydraulic Pump Serial Number............526
Record Front and Rear Axle Housing Serial Numbers............527
Keep Proof of Ownership............528
Keep Machines Secure............529
Section 4-6: Miscellaneous—Specifications............530
Engine Specifications............531
Drain and Refill Capacities............532
Standard Z-Bar Specifications............533
High Lift Z-Bar Specifications............535
Travel Speeds............537
Eurasian Economic Union............538
Machine Design Life............539
John Deere 4WD Loader 544K Operator's Manual (OMT275694)
