John Deere 4WD Loader 544K Operator's Manual (OMT275694)
Operator's Manual for John Deere 4WD Loader 544K, with all the shop information to maintain, and operate your loader.
omt275694 - 544K 4WD Loader Operator's Manual.pdf
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PRODUCT DETAILS:
Total Pages: 584 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Manual Identification—READ THIS FIRST!
IMPORTANT
CARB Non-road Emissions Control Warranty Statement—Compression Ignition
EPA Non-road Emissions Control Warranty Statement—Compression Ignition
Conformity Marking
FCC Notifications to User
1 - Safety
Add and Operate Attachments Safely
Add Cab Guarding for Special Uses
Avoid Backover Accidents
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Avoid Machine Tip Over
Avoid Static Electricity Risk When Refueling
Avoid Unauthorized Machine Modifications
Avoid Work Site Hazards
Clean Debris from Machine
Dispose of Waste Properly
Drive Metal Pins Safely
Follow Safety Instructions
Handle Chemical Products Safely
Inspect and Maintain ROPS
Inspect Machine
Keep Riders Off Machine
Make Welding Repairs Safely
Operate Only If Qualified
Operating on Slopes
Operating or Traveling On Public Roads
Park and Prepare for Service Safely
Prepare for Emergencies
Prevent Battery Explosions
Prevent Fires
Prevent Unintended Machine Movement
Recognize Safety Information
Remove Paint Before Welding or Heating
Safety and Operator Convenience Features
Safety Signs
Service Cooling System Safely
Service Tires Safely
Start Only From Operator's Seat
Stay Clear of Moving Parts
Use and Maintain Seat Belt
Use Special Care When Operating Loader
Use Steps and Handholds Correctly
Wear Protective Equipment
Work In Ventilated Area
2 - Operation
Advanced Display Unit (ADU)
Air Conditioner and Heater Operation
Automatic Idle and Automatic Shutdown
Auxiliary Control
Backdragging
Battery Disconnect Switch
Before Starting Work
Boom Height Kickout Adjustment
Check Instruments Before Starting
Cold Start Aid—Block Heater—If Equipped
Cold Start Aid—Starting Fluid—If Equipped
Cold Weather Warmup
Counter Switch
Counter Switch Operation
Differential Lock Operation
Display Unit Functions
Display Unit—Main Menu
Display Unit—Main Menu—Codes
Display Unit—Main Menu—Codes—Active Codes
Display Unit—Main Menu—Codes—Stored Codes
Display Unit—Main Menu—Diagnostics
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped
Display Unit—Main Menu—Diagnostics—Battery Monitor
Display Unit—Main Menu—Diagnostics—Cab Switches
Display Unit—Main Menu—Diagnostics—Engine Sensors
Display Unit—Main Menu—Diagnostics—FNR Selector
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors
Display Unit—Main Menu—Diagnostics—JDLinkTM System Info
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped
Display Unit—Main Menu—Diagnostics—Machine ID
Display Unit—Main Menu—Diagnostics—Machine Sensors
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped
Display Unit—Main Menu—Diagnostics—Park Brake Test
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped
Display Unit—Main Menu—Diagnostics—Switch Module
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped
Display Unit—Main Menu—Diagnostics—Transmission_Axle
Display Unit—Main Menu—Monitor Settings
Display Unit—Main Menu—Payload Scale—Auto Add
Display Unit—Main Menu—Payload Scale—Diagnostics
Display Unit—Main Menu—Payload Scale—Display Units
Display Unit—Main Menu—Payload Scale—If Equipped
Display Unit—Main Menu—Payload Scale—Long Total
Display Unit—Main Menu—Payload Scale—Setup
Display Unit—Main Menu—Security
Display Unit—Main Menu—Security—Change Owner PIN
Display Unit—Main Menu—Security—Delayed Operator Logout
Display Unit—Main Menu—Security—Manage Operator PINs
Display Unit—Main Menu—Security—Manage Transport PIN
Display Unit—Main Menu—Security—Security
Display Unit—Main Menu—Settings
Display Unit—Main Menu—Settings—Camera Mode
Display Unit—Main Menu—Settings—Counters
Display Unit—Main Menu—Settings—Courtesy Lights
Display Unit—Main Menu—Settings—Job Timer
Display Unit—Main Menu—Settings—Operator Configuration
Display Unit—Main Menu—Settings—Quick Shift
Display Unit—Main Menu—Settings—Reverse Fan Cycle
Display Unit—Main Menu—Settings—Ride Control—If Equipped
Display Unit—Main Menu—Settings—Stopwatch
Display Unit—Main Menu—Software Delivery
Display Unit—Main Menu—Software Delivery—Software Update
Display Unit—Normal Display
Embedded Payload Scale—If Equipped
Engine Break-In Period
Fire Extinguisher Mounting Location
Fork Attachment
Horn Button
Inspect Machine Daily Before Starting
Joystick Bucket and Boom Control
Joystick Steering Armrest Adjustment— if Equipped
Joystick Steering Control—If Equipped
Levers—Four Function Hydraulic Control
Levers—Joystick Steering Control
Levers—Three Function Hydraulic Control
Levers—Two Function Hydraulic Control
Lifting the Machine
Loading Machine on a Trailer
Opening and Securing Side Door
Opening Rear Side Window
Opening Side Window _ Secondary Exit
Operating Loader Coupler—If Equipped
Park Brake Switch
Parking the Machine
Pedals
Rear Camera and Radar Object Detection (ROD) System—If Equipped
Return-to-Carry Kickout Adjustment
Return-to-Dig Adjustment for PowerllelTM Linkage—If Equipped
Return-to-Dig Adjustment for Z-Bar Linkage
Ride Control—If Equipped
Sealed Switch Module (SSM)
Seat Adjustment
Secondary Steering—If Equipped
Security System
Service ADVISORTM Remote (SAR) Software Delivery Process
Shifting the Transmission
Starting the Engine
Switch Module Functions
Towing Procedure
Turn Signals
Two Lever Bucket and Boom Control
Using the Loader Bucket
3 - Maintenance
...
TABLE OF CONTENTS................1
Section 1-1: Safety—Safety and Operator Conveniences................37
Safety and Operator Convenience Features................38
Section 1-2: Safety—General Precautions................39
Recognize Safety Information................40
Follow Safety Instructions................41
Operate Only If Qualified................42
Wear Protective Equipment................43
Avoid Unauthorized Machine Modifications................44
Inspect Machine................45
Stay Clear of Moving Parts................46
Avoid High-Pressure Fluids................47
Avoid High-Pressure Oils................48
Work In Ventilated Area................49
Avoid Static Electricity Risk When Refueling................50
Prevent Fires................52
Clean Debris from Machine................53
Prevent Battery Explosions................54
Handle Chemical Products Safely................55
Decommissioning — Proper Recycling and Disposal of Fluids and Components................56
Prepare for Emergencies................57
Add Cab Guarding for Special Uses................58
Section 1-3: Safety—Operating Precautions................59
Use Steps and Handholds Correctly................60
Start Only From Operator's Seat................61
Use and Maintain Seat Belt................62
Prevent Unintended Machine Movement................63
Avoid Work Site Hazards................64
Use Special Care When Operating Loader................66
Keep Riders Off Machine................67
Avoid Backover Accidents................68
Avoid Machine Tip Over................69
Operating on Slopes................71
Operating or Traveling On Public Roads................72
Inspect and Maintain ROPS................73
Add and Operate Attachments Safely................74
Section 1-4: Safety—Maintenance Precautions................75
Park and Prepare for Service Safely................76
Service Cooling System Safely................77
Service Tires Safely................78
Remove Paint Before Welding or Heating................79
Make Welding Repairs Safely................80
Drive Metal Pins Safely................81
Section 1-5: Safety—Safety Signs................83
Safety Signs................83
Section 2-1: Operation—Operator’s Station................91
Levers—Two Function Hydraulic Control................93
Levers—Three Function Hydraulic Control................95
Levers—Four Function Hydraulic Control................98
Levers—Joystick Steering Control................99
Pedals................100
Sealed Switch Module (SSM)................101
Switch Module Functions................103
Advanced Display Unit (ADU)................108
Display Unit Functions................110
Display Unit—Normal Display................117
Display Unit—Main Menu................119
Display Unit—Main Menu—Codes................121
Display Unit—Main Menu—Codes—Active Codes................123
Display Unit—Main Menu—Codes—Stored Codes................124
Display Unit—Main Menu—Settings................125
Display Unit—Main Menu—Settings—Reverse Fan Cycle................128
Display Unit—Main Menu—Settings—Courtesy Lights................129
Display Unit—Main Menu—Settings—Quick Shift................130
Display Unit—Main Menu—Settings—Job Timer................131
Display Unit—Main Menu—Settings—Stopwatch................132
Display Unit—Main Menu—Settings—Ride Control—If Equipped................227
Display Unit—Main Menu—Settings—Counters................134
Display Unit—Main Menu—Settings—Camera Mode................135
Display Unit—Main Menu—Settings—Operator Configuration................136
Display Unit—Main Menu—Diagnostics................137
Display Unit—Main Menu—Diagnostics—Machine ID................139
Display Unit—Main Menu—Diagnostics—Battery Monitor................140
Display Unit—Main Menu—Diagnostics—Engine Sensors................141
Display Unit—Main Menu—Diagnostics—Transmission/Axle................142
Display Unit—Main Menu—Diagnostics—Hydraulic Sensors................143
Display Unit—Main Menu—Diagnostics—Machine Sensors................144
Display Unit—Main Menu—Diagnostics—FNR Selector................145
Display Unit—Main Menu—Diagnostics—Cab Switches................146
Display Unit—Main Menu—Diagnostics—Switch Module................147
Display Unit—Main Menu—Diagnostics—Joystick Steering—If Equipped................148
Display Unit—Main Menu—Diagnostics—Tire Pressure—If Equipped................149
Display Unit—Main Menu—Diagnostics—Object Detect—If Equipped................151
Display Unit—Main Menu—Diagnostics—Auto Diff Lock—If Equipped................152
Display Unit—Main Menu—Diagnostics—Payload Scale—If Equipped................154
Display Unit—Main Menu—Diagnostics—JDLink™ System Info................155
Display Unit—Main Menu—Diagnostics—Park Brake Test................156
Display Unit—Main Menu—Payload Scale—If Equipped................158
Display Unit—Main Menu—Payload Scale—Long Total................160
Display Unit—Main Menu—Payload Scale—Display Units................161
Display Unit—Main Menu—Payload Scale—Auto Add................162
Display Unit—Main Menu—Payload Scale—Diagnostics................163
Display Unit—Main Menu—Payload Scale—Setup................164
Display Unit—Main Menu—Monitor Settings................165
Display Unit—Main Menu—Security................166
Display Unit—Main Menu—Security—Security................169
Display Unit—Main Menu—Security—Change Owner PIN................170
Display Unit—Main Menu—Security—Manage Operator PINs................171
Display Unit—Main Menu—Security—Manage Transport PIN................172
Display Unit—Main Menu—Security—Delayed Operator Logout................174
Display Unit—Main Menu—Software Delivery................175
Display Unit—Main Menu—Software Delivery—Software Update................548
Horn Button................179
Turn Signals................180
Joystick Steering Armrest Adjustment— if Equipped................181
Air Conditioner and Heater Operation................183
Counter Switch................185
Opening and Securing Side Door................187
Opening Side Window/Secondary Exit................189
Opening Rear Side Window................190
Seat Adjustment................191
Fire Extinguisher Mounting Location................193
Section 2-2: Operation—Operating the Machine................194
Before Starting Work................196
Inspect Machine Daily Before Starting................197
Check Instruments Before Starting................198
Security System................199
Battery Disconnect Switch................200
Engine Break-In Period................201
Starting the Engine................529
Cold Start Aid—Starting Fluid—If Equipped................207
Cold Start Aid—Block Heater—If Equipped................209
Warmup................210
Cold Weather Warmup................211
Park Brake Switch................212
Shifting the Transmission................533
Automatic Idle and Automatic Shutdown................217
Joystick Bucket and Boom Control................218
Two Lever Bucket and Boom Control................220
Auxiliary Control................222
Joystick Steering Control—If Equipped................223
Ride Control—If Equipped................227
Secondary Steering—If Equipped................231
Differential Lock Operation................233
Service ADVISOR™ Remote (SAR) Software Delivery Process................234
Rear Camera and Radar Object Detection (ROD) System—If Equipped................235
Counter Switch Operation................238
Embedded Payload Scale—If Equipped................240
Boom Height Kickout Adjustment................247
Return-to-Carry Kickout Adjustment................248
Return-to-Dig Adjustment for Z-Bar Linkage................249
Return-to-Dig Adjustment for Powerllel™ Linkage—If Equipped................253
Operating Loader Coupler—If Equipped................256
Using the Loader Bucket................257
Backdragging................260
Fork Attachment................261
Operating in Water and Mud................263
Parking the Machine................264
Loading Machine on a Trailer................266
Towing Procedure................269
Lifting the Machine................272
Section 3-1: Maintenance—Machine................274
Diesel Fuel................275
Lubricity of Diesel Fuel................277
Handling and Storing Diesel Fuel................278
Biodiesel Fuel................279
Testing Diesel Fuel................281
Fuel Filters................282
Minimizing the Effect of Cold Weather on Diesel Engines................283
Alternative and Synthetic Lubricants................285
Lubricant Storage................286
Mixing of Lubricants................287
Diesel Engine Break-In™ Oil................288
Diesel Engine Oil—Tier 3 and Stage III A Engines................289
Engine Oil and Filter Service Intervals—Tier 3 and Stage IIIA — PowerTech™ Engines................291
Transmission, Park Brake, and Axle Oil................293
Hydraulic Oil................294
Grease................296
Diesel Engine Coolant (engine with wet sleeve cylinder liners)................298
Drain Intervals for Diesel Engine Coolant................300
John Deere COOL-GARD™ II Coolant Extender................301
Supplemental Coolant Additives................302
Operating in Warm Temperature Climates................303
Additional Information About Diesel Engine Coolants and John Deere COOL-GARD™ II Coolant Extender................304
Testing Diesel Engine Coolant................306
Disposing of Coolant................307
Section 3-2: Maintenance—Periodic Maintenance................308
Service Machine at Specified Intervals................309
Check Hour Meter Regularly................310
Prepare Machine for Maintenance................311
Frame Locking Bar................314
Boom Lock................315
Pin Removal—If Equipped With Powerllel™ Linkage................317
Engine Service Doors and Side Shields................318
Cooling System Doors................320
Fuel Tank................322
Fluid Analysis Program Test Kits and 3-Way Coolant Test Kit................323
Service Intervals................324
Required Parts................327
Section 3-3: Maintenance—As Required................329
Inspect Tires and Check Pressure................330
Tire Pressures................332
Check Wheel Bolt Torque................337
Inspect Engine Air Cleaner Elements................338
Inspect Air Conditioner Compressor and Alternator Belt................340
Clean Cooler Cores................342
Check Windshield Washer Fluid Level................344
Drain Water From Auxiliary Fuel Filter and Water Separator—If Equipped................345
Drain Water From Primary Fuel Filter and Water Separator................346
Drain Water From Final Fuel Filter................347
Check and Clean or Replace Cab Fresh Air Filter................348
Check and Clean or Replace Cab Recirculating Air Filter................350
Check Rear Camera and Radar Object Detection (ROD) System—If Equipped................352
Check Coolant................409
Section 3-4: Maintenance—Every 10 Hours or Daily................357
Clean Air Cleaner Dust Unloader Valve................358
Check Coolant Level in Surge Tank................359
Check Engine Oil Level................360
Check Hydraulic Oil Level................361
Check Transmission Oil Level................362
Inspect Outer Pin Seals................364
Section 3-5: Maintenance—Every 100 Hours................366
Lubricate Loader Linkage and Cylinder Pivots—Z-Bar Linkage................367
Lubricate Loader Linkage and Cylinder Pivots—Powerllel™ Linkage................369
Section 3-6: Maintenance—Initial Service - 250 Hours................371
Drain and Refill Front and Rear Axle Oil................418
Drain and Refill Engine Oil and Replace Filter................390
Replace Axle Oil Filters—If Equipped................410
Section 3-7: Maintenance—Every 250 Hours................377
Take Engine Oil Sample................378
Section 3-8: Maintenance—Every 500 Hours................379
Lubricate Driveline Upper and Lower Sliding Joints and Lower U-Joints................380
Check Front and Rear Axle Oil Level................381
Lubricate Front and Rear Axle Shaft Seals................383
Check Battery Water Level and Terminals................384
Check Air Intake Hoses and Charge Air Cooler Tube Couplings................388
Take Fluid Samples................389
Drain and Refill Engine Oil and Replace Filter................390
Replace Auxiliary Fuel Filter—If Equipped................392
Replace Primary Fuel Filter................393
Replace In-Line Fuel Strainer................395
Replace Final Fuel Filter................396
Replace Hydraulic Reservoir Breather Filter................398
Check Park Brake Oil Level................399
Lubricate Front and Rear Shaft Seals on Park Brake................540
Check Ride Control Accumulator—If Equipped................401
Section 3-9: Maintenance—Every 1000 Hours................404
Clean Engine Crankcase Vent Tube................405
Replace Air Cleaner Dust Unloader Valve................406
Replace Engine Air Cleaner Elements................407
Check Coolant................409
Replace Axle Oil Filters—If Equipped................410
Lubricate Frame Hinge Pivots................411
Drain and Refill Park Brake Oil................412
Section 3-10: Maintenance—Every 2000 Hours................413
Replace Outer Pin Seals................414
Drain and Refill Transmission Oil and Replace Filter................415
Drain and Refill Front and Rear Axle Oil................418
Clean Front and Rear Axle Oil Recirculation Screens—If Equipped................420
Adjust Engine Valve Lash (Clearance)................421
Rerun Transmission Clutch Calibration................422
Section 3-11: Maintenance—Every 4000 Hours................423
Replace Crankshaft Damper................424
Clean Hydraulic Pump Case Drain In-Line Screen................425
Replace Hydraulic System Return Filter................429
Drain, Flush, and Refill Hydraulic System Oil................431
Clean Hydraulic System Fill Strainer................434
Section 3-12: Maintenance—Every 5000 Hours................435
Inspect Driveline Damper................436
Section 3-13: Maintenance—Every 6000 Hours................437
Drain Cooling System................438
Refill Cooling System................440
Section 4-1: Miscellaneous—Machine................442
Tire Removal With Tire Pressure Monitor (TPM) System—If Equipped................443
Check Air Inlet Cover................444
Inspect Fuel Tank Vent Hose and Breather Filter................445
Bleed Fuel System................446
Do Not Service Control Valves, Cylinders, Pumps, or Motors................447
Precautions for Alternator and Regulator................448
Handling, Checking, and Servicing Batteries Carefully................449
Using Booster Batteries—24-Volt System................452
Using Battery Charger................454
Replacement Batteries................456
Remove and Install Batteries................457
12-Volt Auxiliary Power Outlet—If Equipped................442
JDLink™ Machine Monitoring System (MMS)—If Equipped................460
Replacing Fuses................461
Remove and Install Halogen Bulbs................465
Fluid Sampling Test Ports—If Equipped................467
Air Conditioner System Service................469
External Service Brake Inspection................470
Service Recommendations For Snap-To-Connect (STC®) Fittings................472
Welding On Machine................474
Welding Near Electronic Control Units................475
Keep Electronic Control Unit Connectors Clean................476
Replacing Bucket Teeth—TK Series................477
Keep ROPS Installed Properly................478
Hardware Torque Specifications................479
Metric Bolt and Screw Torque Values................480
Unified Inch Bolt and Screw Torque Values................482
Section 4-2: Miscellaneous—Operational Checkout................485
Operational Checkout................485
Section 4-3: Miscellaneous—Troubleshooting................527
Troubleshooting Procedure................528
Engine................529
Transmission................533
Differential and Axle................536
Service Brake................538
Driveline................539
Park Brake................540
Hydraulic System................541
Steering................544
Air Conditioning System................545
Heater System................547
Software Update................548
Section 4-4: Miscellaneous—Storage................549
Prepare Machine for Storage................550
Monthly Storage Procedure................552
Section 4-5: Miscellaneous—Machine Numbers................554
Record Product Identification Number (PIN)................555
Record Engine Serial Number................556
Record Transmission Serial Number................557
Record Hydraulic Pump Serial Number................558
Record Front and Rear Axle Housing Serial Numbers................559
Keep Proof of Ownership................560
Keep Machines Secure................561
Section 4-6: Miscellaneous—Specifications................562
Engine Specifications................563
Drain and Refill Capacities................564
Standard Z-Bar Specifications................565
High Lift Z-Bar Specifications................567
Powerllel™ Specifications................569
Travel Speeds................571
John Deere 4WD Loader 544K Operator's Manual (OMT275694)
