John Deere 544K 4WD Loader Workshop Repair & Diagnostic Service Manual TM10688 Engine 6068HDW74 T3 PDF - MJODTM10688.zip

This Diagnostics & Tests technical manual for the John Deere 544K 4WD Loader comes complete with electrical schematics, offering workshop-level guidance to help you service, troubleshoot, and rebuild the machine the way a trained technician would.

The Diagnostics & Tests technical manual for the John Deere 544K 4WD Loader covers:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

TM10688 - John Deere 544K 4WD Loader Engine 6068HDW74 (T3) Technical Manual (Operation & Test).pdf

TM10688 - John Deere 544K 4WD Loader Engine 6068HDW74 (T3) Technical Manual (Operation & Test).epub

tm10688 (07JAN19) - John Deere 544K 4WD Loader Engine 6068HDW74 (T3) (S.N. —642664) OPERATION & TEST TECHNICAL MANUAL.PDF

PRODUCT DETAILS:

Total Pages: 2,011 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

tm10688 - 544K 4WD Loader

Table of Contents

Foreword

Section 9000: General Information

Group 01: Safety Information

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding For Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Clean Debris from Machine

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Use Special Care When Operating Loader

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating on Slopes

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

Add and Operate Attachments Safely

Park And Prepare For Service Safely

Service Cooling System Safely

Service Tires Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostic Trouble Codes (DTC)

Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000107.00 - Eng Air Filter Restricted

000171.03 - Ambient Air Temperature Out of Range High

000171.04 - Ambient Air Temperature Out of Range Low

000627.01 - ECU Unswitched Power Short to Ground

000676.05 - Engine Heat Open or Short

001253.13 - Injector Cal Required

001321.31 - Starter Solenoid Open Circuit

002003.09 - CAN Communication Lost for TCU

002033.09 - CAN Communication Lost for FLC

003587.05 - Ether Starting Aid Circuit Fault

Group 20: Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000091.09 - Timeout EEC2 Message

000513.02 - Percent Torque Invalid

000513.09 - Timeout EEC1 Message

000514.02 - Friction Invalid

000514.09 - Timeout EEC3 Message

000544.02 - Ref Torque Invalid

000544.09 - Timeout Engine Config Message

000777.02 - TC Clutch Slippage

000777.03 - TC Lockup Sol Short to Power

000777.04 - TC Lockup Sol Short to Gnd

000777.05 - TC Lockup Sol Open Circuit

000928.03 - Axle Disconnect Solenoid Short to Power

000928.04 - Axle Disconnect Solenoid High Current

000928.05 - Axle Disconnect Solenoid Open Circuit

002033.09 - CAN Communication Lost for FLC

002141.09 - CAN Communication Lost for SSM

522344.00 - Torque Converter Output Temperature Too High

522350.15 - Transmission Input Torque Overload

522364.07 - Transmission Clutch Calibration Failed

522364.13 - Transmission Clutch Calibration Fault

522365.13 - Limp Home Mode Requested

522366.13 - Application Invalid

522367.13 - TCU Configuration Invalid

522368.02 - TCU Memory Failure

522369.03 - Remote Display Short to Power

522370.02 - TCU Valve Power Supply 2 Short Circuit

522371.02 - TCU Valve Power Supply 1 Short Circuit

522373.03 - Power Supply High Voltage

522373.04 - Power Supply Low Voltage

522374.03 - Sensor Supply Short to Power

522374.04 - Sensor Supply Short to Ground

522375.00 - Transmission Oil Filter Restricted

522376.00 - Transmission Oil Temperature Over Maximum Value

522379.03 - Park Brake Release Solenoid Short to Power

522379.04 - Park Brake Release Solenoid Short to Ground

522379.05 - Park Brake Release Solenoid Open Circuit

522382.03 - Backup Alarm Short to Power

522382.04 - Backup Alarm Short to Ground

522383.02 - Transmission Clutch KR Slippage

522383.03 - Clutch Reverse Solenoid Short to Power

522383.04 - Clutch Reverse Solenoid Short to Ground

522383.05 - Clutch Reverse Solenoid Open Circuit

522386.02 - Transmission Clutch KV Slippage

522386.03 - Clutch Forward Solenoid Short to Power

522386.04 - Clutch Forward Solenoid Short to Ground

522386.05 - Clutch Forward Solenoid Open Circuit

522389.02 - Transmission Clutch K4 Slippage

522389.03 - Clutch K4 Solenoid Short to Power

522389.04 - Clutch K4 Solenoid Short to Ground

522389.05 - Clutch K4 Solenoid Open Circuit

522392.02 - Transmission Clutch K3 Slippage

522392.03 - Clutch K3 Solenoid Short to Power

522392.04 - Clutch K3 Solenoid Short to Ground

522392.05 - Clutch K3 Solenoid Open Circuit

522395.02 - Transmission Clutch K2 Slippage

522395.03 - Clutch K2 Solenoid Short to Power

522395.04 - Clutch K2 Solenoid Short to Ground

522395.05 - Clutch K2 Solenoid Open Circuit

522399.02 - Transmission Clutch K1 Slippage

522399.03 - Clutch K1 Solenoid Short to Power

522399.04 - Clutch K1 Solenoid Short to Ground

522399.05 - Clutch K1 Solenoid Open Circuit

522401.02 - Output Shaft Speed Sensor Fault

522401.03 - Output Shaft Speed Sensor Open or Short

522401.04 - Output Shaft Speed Sensor Short to Ground

522401.12 - Output Shaft Speed Sensor Fault

522401.15 - Output Shaft Speed Sensor Overspeed

522402.03 - Clutch Speed Sensor Open or Short

522402.04 - Clutch Speed Sensor Short to Ground

522402.12 - Clutch Speed Sensor Fault

522403.03 - Converter Output Speed Sensor Open or Short

522403.04 - Converter Output Speed Sensor Short to Ground

522403.12 - Converter Output Speed Sensor Fault

522404.03 - Converter Input Speed Sensor Open or Short

522404.04 - Converter Input Speed Sensor Short to Ground

522404.12 - Converter Input Speed Sensor Fault

522406.03 - Transmission Oil Temperature Sensor Open or Short

522406.04 - Transmission Oil Temperature Sensor Short to Ground

522407.03 - Clutch Cut-off Sensor Short to Power

522407.04 - Clutch Cut-off Sensor Open or Short

522409.05 - 2nd FNR Open Circuit

522409.12 - 2nd FNR Multiple Inputs

522411.05 - 1st FNR Open Circuit

522411.12 - 1st FNR Multiple Inputs

522412.12 - Gear Selection Error

522419.02 - Clutch Cut-off Disabled

522420.02 - Manual Downshift Disabled

522421.02 - Auto to 1st Disabled

524048.00 - Transmission Output Torque Exceeded

524049.00 - Transmission Input Torque Exceeded

524287.00 - Configure Machine Model

Group 30: Flex Load Controller (FLC) Diagnostic Trouble Codes

Flex Load Controller (FLC) Diagnostic Trouble Codes

000096.04 - Fuel Level Short to Ground

000096.05 - Fuel Level Open or Short

000167.16 - Alternator High Voltage

000167.18 - Alternator Low Voltage

000168.16 - High Battery Voltage

000234.02 - Invalid TCU Software Rev

000444.05 - 12 Volt Center Tap Open or Short

000444.18 - Battery Voltage Imbalance

000521.00 - Brake Pedal High Voltage

000628.12 - Controller Not Programmed

000629.12 - FLC Watchdog Time Out

000639.12 - FLC CAN Failure

000639.14 - FLC CAN Bus Off

000746.05 - Differential Lock Solenoid Open or Short

000746.06 - Differential Lock Solenoid High Current

000785.05 - Pilot Solenoid Open or Short

000785.06 - Pilot Solenoid High Current

000880.06 - Brake Lights High Current

000977.05 - Reverse Fan Solenoid Open or Short

000977.06 - Reverse Fan Solenoid High Current

001069.02 - Tire Size Incorrect

001071.05 - Fan Speed Solenoid Open or Short

001071.06 - Fan Speed Solenoid High Current

001503.04 - Arm Rest Down Switch Short to Ground

001503.11 - Arm Rest Position Undetermined

001550.06 - AC Clutch High Current

001565.04 - Arm Rest Up Switch Short to Ground

001638.00 - Hydraulic Oil High Temperature

001638.04 - Hydraulic Oil Temperature Sensor Short to Ground

001713.01 - Hydraulic Oil Filter Restricted

001762.03 - Hydraulic Pressure Sensor Short to Power

001762.04 - Hydraulic Pressure Sensor Open or Short

002000.09 - CAN Communication Lost for ECU

002003.09 - CAN Communication Lost for TCU

002040.09 - CAN Communication Lost for ADU

002051.09 - CAN Communication Lost for TPM

002052.09 - CAN Communication Lost for JSC

002129.09 - CAN Communication Lost for JSV

002132.09 - CAN Communication Lost for ROD

002141.09 - CAN Communication Lost for SSM

002169.09 - CAN Communication Lost for RDR

002350.05 - Drive Lamps Open or Short

002350.06 - Drive Lamps High Current

002355.05 - Front Work Lights Open or Short

002355.06 - Front Work Lights High Current

002356.05 - Front Work Lights Open or Short

002356.06 - Front Work Lights High Current

002359.05 - Machine Work Lights Open Circuit

002359.05 - Machine Work Lights Open Circuit

002359.06 - Machine Work Lights High Current

002362.05 - Rear Work Lights Open or Short

002362.06 - Rear Work Lights High Current

002367.04 - Left Turn Switch Short to Ground

002368.05 - Left Turn Lights Open or Short

002368.06 - Left Turn Lights High Current

002369.04 - Right Turn Switch Short to Ground

002370.05 - Right Turn Lights Open or Short

002370.06 - Right Turn Lights High Current

002378.06 - Marker/Tail Lights High Current

002386.06 - Beacon Light High Current

002680.05 - RTC/Float Detent Open or Short

002680.06 - RTC/Float Detent High Current

002697.02 - Timeout JSC Message

002717.05 - RTD Detent Open or Short

002717.06 - RTD Detent High Current

002754.05 - BHKO Detent Open or Short

002754.06 - BHKO Detent High Current

002875.04 - Hazard Wakeup Short to Ground

003509.04 - FLC Sensor 1 Voltage Low

003510.04 - FLC Sensor 2 Voltage Low

003511.04 - FLC Sensor 3 Voltage Low

299621.02 - Machine Configuration Invalid

522280.01 - Brake Pressure Low

522341.05 - Heated Mirror Open or Short

522341.06 - Heated Mirror Short to Ground

522426.04 - Rear Wiper Park Short to Ground

522427.04 - Front Wiper Park Short to Ground

522431.02 - Memory Test Failure

522432.06 - Rear Wiper High Speed High Current

522433.05 - Rear Wiper Low Speed Open or Short

522433.06 - Rear Wiper Low Speed High Current

522434.05 - Front Wiper Low Speed Open or Short

522434.06 - Front Wiper Low Speed High Current

522435.06 - Front Wiper High Speed High Current

522436.03 - Bucket Position Short to Power

522436.04 - Bucket Position Open or Short

522437.04 - Return-to-Dig Switch Short to Ground

522438.05 - Pin Disconnect Solenoid Open or Short

522438.06 - Pin Disconnect Solenoid High Current

522543.03 - Boom Cyl Rod Press Open or Short

522543.04 - Boom Cyl Rod Press Short to Ground

522544.03 - Boom Cyl Head Press Open or Short

522544.04 - Boom Cyl Head Press Short to Ground

522796.05 - Rear Washer Pump Open or Short

522796.06 - Rear Washer Pump High Current

522797.05 - Front Washer Pump Open or Short

522797.06 - Front Washer Pump High Current

523137.01 - Steering Pressure Low

523137.04 - Steering Pressure Switch Short to Ground

523219.04 - Switched Power Voltage Low

523440.04 - Unswitched Power Voltage Low

523489.05 - Engine Light Open Circuit

523577.05 - Secondary Steering Pump Open or Short

523577.06 - Secondary Steering Pump High Current

523689.04 - Differential Lock Switch Short to Ground

523767.04 - Joystick Steering Activation Switch Short to Ground

523767.10 - Joystick Steering Activation Switch Button Stuck

523786.03 - Boom Position Sensor Short to Power

523795.05 - JSV Power Open or Short

523795.06 - JSV Power High Current

523837.01 - Brake Pressure Low—Rear

523837.03 - Rear Brake Pressure Sensor Short to Power

523837.04 - Rear Brake Pressure Open or Short

523840.01 - Brake Pressure Low—Front

523840.03 - Front Brake Pressure Short to Power

523840.04 - Front Brake Pressure Open or Short

523865.04 - Add Truck Switch Short to Ground

523867.04 - Counter Switch Short to Ground

523868.04 - Add Bucket Switch Short to Ground

523948.05 - Ride Control Solenoid Open Circuit

523948.06 - Ride Control Solenoid High Current

524044.01 - Axle Oil Filter Restricted

524044.03 - Axle Oil Filter Short to Power

524250.31 - Inspect Park Brake

524265.19 - Check Sum Error

Group 40: Sealed Switch Module (SSM) Diagnostic Trouble Codes

Sealed Switch Module (SSM) Diagnostic Trouble Codes

000629.12 - SSM Watchdog Time Out

002033.09 - SSM Lost Communications

002634.04 - SSM Ignition Relay Signal Short to Ground

002634.05 - SSM Ignition Relay Signal Open Circuit

520752.04 - Button 17 Keypad Stuck

520752.09 - Button 17 LED Message

520753.04 - Front Washer Keypad Stuck