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John Deere 544K Troubleshooting
The
John Deere 544K wheel loader driveline system components: a 414 cu.in (6.8L)
John Deere PowerTech E 6068H 6-cylinder turbocharged diesel engine with a rated
power of 91.2 hp (68 kW), and 5-speed powershift transmission. The hydraulic
system has an axial-piston pump with a rated capacity of 50 gal/min (190 l/min). The John
Deere 544K is equipped with a power steering system, hydraulic wet disc brakes,
and 20.5R25 standard tires. The wheel loader has a maximum lift height to hinge
pin of 150.4" (3820 mm) and boom breakout force of 22300 lbs (10115 kg). The
rated operating capacity is 9800 lbs (4445 kg), and tipping load is 19600 lbs
(8890 kg).
| Engine Troubleshooting |
Engine starts up hard or won't start
Air in the fuel lines - Bleed the fuel lines.
Dirty fuel filter - Filter maintenance required.
Fuel injection nozzles are clogged or faulty - Clean or replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve out of adjustment - Correct valve clearance needs to be set.
Fuel injection pump is broken - Replacement or repair required.
Engine starts and stalls suddenly
Plugged air cleaner - Install new air cleaner element.
Dirty fuel filter - Change filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Defective or clogged fuel injectors - Clean or replace fuel injectors.
Fuel injection pump damage - Change or repair the pump.
Engine stops running suddenly
Coolant temperature is low - Warm up engine as required.
Fuel filter element is clogged - Clean or replace the filter.
Air in fuel tank - Bleed fuel tank.
Dirty or faulty injection nozzles - If necessary, replace with a new nozzle.
Wrong setting of fuel injection pump timing - Adjust according to specifications.
Engine stalling at idle
Improperly adjusted low idle speed - Adjust low idling as recommended.
Fuel injection pump malfunctioning - Repair or replace injection pump.
Fuel injector fault - Clean or replace fuel injectors.
Valve clearance is wrong - Check and adjust.
Loss of engine power
Clogged air filter - Change or service air filter element.
Fuel injection nozzles are damaged - Check and replace nozzles if required.
Improper fuel injection pressure - Correct the pressure settings.
The valve clearance is not adjusted - Have it adjusted.
Low idle speed setting is not correct - Correct the settings.
Clogged fuel lines or hoses - Fuel lines and hoses need to be cleaned.
Cylinder-head gasket is broken - Install new cylinder head gasket.
Worn or broken piston rings - Replace the piston rings as required.
Engine is overheated
Lack of coolant in cooling system - Fill the cooling system and check components for leaks or other faults.
Not enough engine oil - Add oil to the engine crankcase.
Radiator core is dirty or radiator cap is damaged - Clean radiator or replace cap.
Broken or loose fan belt - Belt replacement is recommended.
Engine overloaded - Reduce load on the engine.
Oil pressure is low
Low crankcase oil level - Add oil as required.
Clogged oil filter - Replace or service engine oil filter.
Wrong oil viscosity - Use oil of correct viscosity.
Incorrect oil clearance in main bearing - Change bearings.
Oil pump is worn or damaged - Check and replace if necessary.
Abnormal engine knocking or noise
Not enough engine oil - Need to add engine oil.
Engine not warmed up - Warm up to required temperature.
Improper fuel injection timing - Adjust as recommended.
Incorrect low idle speed adjustment - Correct low idle adjustment.
Damaged or clogged injectors - Clean fuel injectors or change it.
Misaligned or faulty connecting rod - Connecting rod needs to be aligned or changed.
Pistons are broken or worn - Pistons replacement required.
| Transmission Troubleshooting |
Transmission fluid pressure is insufficient
Transmission oil level is low - Add oil to the transmission housing.
Transmission fluid filter element is clogged (if equipped) - Clean or change transmission fluid filter.
Relief valve failure - Install a new valve.
Transmission makes noise
Insufficient transmission oil - Fill up the transmission oil.
Transmission oil is dirty - Change the oil.
Backlash is incorrect or gears are damaged - Change worn gears or adjust backlash correctly.
Worn or damaged bearings - Change the bearings.
Worn or bent gear shift forks - Change defective shift forks.
Worn or stuck shaft splines - Change defective shaft.
Gear shift is hard
Gear shift linkage is worn or rusty - Lubricate or replace shift linkage.
Worn or bent gear shift forks - Install new shift forks.
Gear shifting mechanism is defective - Defective parts must be replaced.
Worn or unadjusted clutch - Adjust correctly or replace.
Transmission oil leakage
Transmission fluid level is high - Correct the fluid level.
Damaged gaskets or seals - Install new components.
| Hydraulics Troubleshooting |
Hydraulic system overheating
Hydraulic pressure is incorrect - Adjust pressure as required.
Faulty or improperly adjusted main relief valve - Adjust relief valve or change if required.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Not enough hydraulic oil in the system - Fill the hydraulic system with oil.
Hydraulic pump is worn - Change or repair hydraulic pump if required.
Boom cannot be lowered or raised
Faulty lift controls - Change or repair.
Hydraulic pump not working - Change or repair hydraulic pump if required.
Hydraulic control valve failure - Repair or change the valve.
Damaged hydraulic cylinder - Replace or repair boom cylinder.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Bucket does not function
Damaged bucket controls - Replace or repair.
Hydraulic pump is broken - Install new pump or repair it.
Damaged hydraulic control valve - Replace or repair the valve.
Broken bucket cylinder - Change or repair cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Slow bucket or lift arm action
Hydraulic pump is worn - Check hydraulic pump flow and replace pump if necessary.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.
Faulty or incorrect setting hydraulic control valve - Set correctly or repair.
Hydraulic pressure loss - Hydraulic pressure must be set correctly.
Jerky operation of the bucket or boom
Air trapped in hydraulic system - Bleed hydraulic system.
Dirty hydraulic oil filter - Change or clean oil filter.
Dirty hydraulic fluid - Hydraulic fluid change required.
Cylinder rod or tube is scuffed - Replace failed component.
Excessive hydraulic pump noise
Low oil level or hydraulic leaks - Correct hydraulic leaks or top up oil as needed.
Dirty hydraulic filter - Service or change hydraulic filter.
Suction line is dirty - Clean suction line as required.
Air in hydraulic pump - Bleed air.
Damaged pump parts - Rebuild or change hydraulic pump.
| Electrical Troubleshooting |
Battery is not charging
Loose or corroded wire connections - Tighten or service cable connections.
Battery terminal connectors are faulty - Replace terminal connectors.
Battery bad cell - Battery replacement required.
Loose or defective belt - Adjust belt tension or change the belt.
Starter turns slow
Battery capacity is low - Battery is drained, recharge it.
Battery does not hold charge - Service or change the battery.
Wires are disconnected or battery terminals are corroded - Check cable connections and replace or service terminals.
Starter does not work
Battery is drained or worn - Battery needs to be recharged or replaced.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Low battery voltage - Battery is drained, charge it.
Starter motor is damaged - Replace or repair starter.
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| WHEEL LOADERS SPECIFICATIONS |
Bobcat
Caterpillar
Case
Doosan
John Deere
Kubota