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Home / Wheel Loaders / John Deere Wheel Loaders / John Deere 544J

John Deere 544J Troubleshooting

The John Deere 544J wheel loader driveline system components: 414 cu.in (6.8L) John Deere PowerTech 6068H 6-cylinder turbocharged diesel engine with a rated power of 145 hp (107 kW), and 4x3 powershift transmission with torque converter. The hydraulic system has a pump with a rated capacity of 50.1 gal/min (190 l/min). The John Deere 544J is equipped with a power steering system, hydraulic wet multi-disc brakes, and 20.5R25 tires. The wheel loader has a maximum lift height to hinge pin of 151" (3835 mm) and boom breakout force of 22670 lbs (10285 kg). The rated operating capacity is 9375 lbs (4255 kg), and tipping load is 18750 lbs (8510 kg).

Engine Troubleshooting

Engine starts up hard or will not start
There is air in the fuel system - Bleed the system.
Fuel filter element clogging - Replace the filter element.
Dirty or faulty injection nozzles - Clean or change injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is wrong - Correct valve clearance.
Fuel injection pump is faulty - Rebuild or install a new injection pump.

Diesel starts and then shuts off
Plugged air cleaner - Service or replace air cleaner.
Fuel filter plugged - Service or replace the filter.
Fuel injection pump is leaking - Repair any leaks.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Damaged fuel injection pump - Replace or repair injection pump.

Engine stalls during operation
Low coolant temperature - Warm up the engine.
Fuel filter element is clogged - Change filter element.
There is air in the fuel system - Bleed the system.
Fuel injection nozzles are clogged or faulty - Clean or change injection nozzles.
Improper fuel injection timing - Adjust fuel injection pump as required.

Engine stops while idling
Improperly adjusted low idle speed - Adjust the low idle speed.
Fuel injection pump damage - Rebuild or install a new injection pump.
Defective fuel injectors - Change or clean fuel injectors.
Incorrect valve clearance - Correct valve clearance needs to be set.

Low engine power
Plugged air filter - Replace or clean air filter element.
Faulty or dirty injection nozzles - Service or change injection nozzles.
Fuel injection pressure is wrong - Correct the pressure settings.
Valve clearance is out of adjustment - Have it adjusted.
Incorrect low idle setting - Correct the settings.
Fuel hoses or lines are dirty - Fuel hoses and lines must be clean.
Cylinder head gasket is damaged - Install new cylinder head gasket.
Leaking or damaged piston rings - Replace the piston rings as required.

Engine is overheated
Low coolant level - Fill radiator to proper level and check components for faults.
Low engine oil level - Check and refill engine oil.
Defective radiator cap or clogged radiator fins - Clean radiator or change cap.
Excessive wear of the fan belt - Fan belt must be replaced.
Engine is overloaded - Reduce engine load.

Oil pressure is low
Engine oil insufficient - Checking oil level and add if necessary.
Clogged oil filter element - Clean or change engine oil filter.
Oil grade or viscosity is wrong - Fill up with the correct oil viscosity.
Incorrect oil clearance in crankshaft bearing - Bearings need to be reinstalled.
Oil pump is defective - Check and replace if necessary.

Engine knocking or noise
Engine oil insufficient - Checking oil level and add if necessary.
Engine is not preheated - Warm up to required temperature.
Improper setting of fuel injection pump timing - Adjust according to specifications.
Incorrectly set low idle speed - Normalize low idle speed.
Fuel injectors are dirty or defective - Clean or replace fuel injectors.
Connecting rod is not aligned or defective - Need to replace or align the connecting rod.
Worn or broken pistons - Have pistons replaced.

Transmission Troubleshooting

Low transmission pressure
Transmission fluid insufficient - Fill the transmission housing to proper fluid level.
Dirty transmission fluid filter element (if equipped) - Service or change transmission fluid filter.
Defective relief valve - Install a new relief valve.

Excessive transmission noise
Transmission oil insufficient - Fill the transmission housing to proper oil level.
Transmission fluid is contaminated - Change the fluid.
Incorrect backlash or gears are worn - Replace defective gears or set backlash properly.
Bearings are damaged or worn - Faulty bearings should be changed.
Shift forks are bent or worn out - Change defective shift forks.
Shaft splines are damaged or worn - Replace the shaft.

Gears are hard to shift
Gear shift linkage is corroded or worn - Install a new gear shift linkage.
Shift forks are bent or worn out - Change defective shift forks.
Gearshift mechanism malfunction - Identify and replace failed parts.
Clutch is worn or not adjusted - Adjust correctly or replace.

External oil leaks
High transmission fluid level - Drain the excess fluid.
Damaged gaskets or seals - Replace worn seal or gaskets.

Hydraulics Troubleshooting

Hydraulic system overheating
Incorrect hydraulic pressure setting - Adjust pressure as required.
Main relief valve is faulty or misadjusted - Set up or change the relief valve.
Dirty hydraulic oil - Hydraulic oil change required.
Hydraulic fluid level is insufficient - Add fluid to the hydraulic system.
Defective hydraulic pump - Replace or repair pump if necessary.

Boom fails to lift or drop
Lift controls malfunction - Change or repair.
Defective hydraulic pump - Repair or change pump if required.
Defective hydraulic control valve - Repair or change the valve.
Hydraulic cylinder not working - Repair or install a new lift cylinder.
Insufficient hydraulic oil - Need to add oil.

Bucket does not function
Bucket tilt controls malfunction - Repair or replace.
Defective hydraulic pump - Repair or change pump if required.
Defective hydraulic control valve - Change or repair hydraulic valve.
Hydraulic bucket cylinder is broken - Repair or change cylinder.
Hydraulic oil is insufficient - Need to add oil.

Bucket or lift arm runs slowly
Defective hydraulic pump - Check pump performance and change it if necessary.
Leaking hydraulic cylinder - Change cylinder piston seals.
Hydraulic oil level low - Need to add oil.
Faulty or incorrect setting hydraulic control valve - Repair or adjust correctly.
Hydraulic pressure has dropped - Correct setting is required.

Lift arm or bucket is jerky
There is air in the hydraulic system - Need to bleed air.
Hydraulic oil filter element clogging - Clean or install new filter.
Hydraulic fluid is dirty - The fluid must be changed.
Cylinder tube or rod scoring - Change defective component.

Hydraulic pump is excessively noisy
Insufficient oil level or leaking hydraulic system - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter is dirty - Replace or clean the filter.
Dirty suction line - Suction line must be serviced.
Air in hydraulic pump - Need to bleed air.
Damaged pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery will not charge
Loose or corroded electrical wiring connections - Service or tighten connections.
Electrical terminal connectors are defective - Change terminal connectors.
Faulty cell in battery - Replace the battery.
Worn or loose belt - Install a new belt or adjust belt tension.

Starter turns slow
Low battery output - Battery is drained, charge it.
Battery is draining quickly - Battery needs service or replacement.
Terminals are faulty or battery cables are disconnected - Connect wiring correctly or install new terminals.

Starter motor won't turn
Battery is drained or worn - Battery needs to be recharged or replaced.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery output - Battery needs to be recharged.
Starter motor failure - Repair or replace starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders