JLG Gradall Telehandlers 544D-10 ANSI Service Repair Workshop Manual (P/N:9136-4003)
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91364001 544D 3
TABLE OF CONTENTS
91364001 544D 5
SECTION 1 - FRAME AND ATTACHING PARTS.............................................................................................................................. 11
FIGURE 1-1. FRAME SHROUDING AND TRIM (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ........... 12
FIGURE 1-2. FRAME SHROUDING AND TRIM (SN 0160000976 through 0160034720, Including 0160035922) ........................ 16
FIGURE 1-3. FRAME SHROUDING AND TRIM (SN 0160035037 to Present, Excluding 0160035922) ....................................... 20
FIGURE 1-4. REAR AXLE AND ATTACHING PARTS (SN 0355001 through 0455362)................................................................ 24
FIGURE 1-5. REAR AXLE AND ATTACHING PARTS (SN 0160000192 to Present) .................................................................... 28
FIGURE 1-6. FRONT AXLE MOUNTING (SN 0355001 through 0455362) .................................................................................... 32
FIGURE 1-7. FRONT AXLE MOUNTING (SN 0160000192 to Present)......................................................................................... 34
FIGURE 1-8. OUTRIGGER MOUNTING (Prior to SN 0160015062) .............................................................................................. 36
FIGURE 1-9. OUTRIGGER MOUNTING (SN 0160015062 to Present) ......................................................................................... 38
SECTION 2 - BOOM .......................................................................................................................................................................... 41
FIGURE 2-1. FIRST BOOM SECTION ........................................................................................................................................... 42
FIGURE 2-2. SECOND BOOM SECTION ...................................................................................................................................... 44
FIGURE 2-3. THIRD BOOM SECTION .......................................................................................................................................... 48
FIGURE 2-4. FOURTH BOOM SECTION ...................................................................................................................................... 52
FIGURE 2-5. EXTENSION CHAINS ............................................................................................................................................... 54
FIGURE 2-6. RETRACTION CHAINS ............................................................................................................................................ 56
FIGURE 2-7. QUICK SWITCH ASSEMBLY (Prior to SN 0160037689).......................................................................................... 60
FIGURE 2-8. QUICK SWITCH ASSEMBLY (SN 0160037689 to Present) ..................................................................................... 62
SECTION 3 - ATTACHMENTS .......................................................................................................................................................... 65
FIGURE 3-1. BUCKETS ................................................................................................................................................................. 66
FIGURE 3-2. TILT CARRIAGE (Prior to SN 0160023515) ............................................................................................................. 68
FIGURE 3-3. TILT CARRIAGE (SN 0160023515 to Present) ........................................................................................................ 70
FIGURE 3-4. TRUSS BOOM (Prior to SN 0160037689) ................................................................................................................ 72
FIGURE 3-5. TRUSS BOOM (SN 0160037689 to Present) ........................................................................................................... 74
FIGURE 3-6. TRUSS BOOM WITH WINCH (Prior to SN 0160037689) ......................................................................................... 76
FIGURE 3-7. TRUSS BOOM WITH WINCH (SN 0160037689 to Present) .................................................................................... 78
FIGURE 3-8. 6 FT VERTICAL MAST (Prior to SN 0160037689) ................................................................................................... 80
FIGURE 3-9. 48 IN SLOPE PILER CARRIAGE (Prior to SN 0160037689) .................................................................................... 84
FIGURE 3-10. 66 IN SLOPE PILER CARRIAGE (Prior to SN 0160037689) .................................................................................. 86
FIGURE 3-11. 100, SWING FORK (Prior to SN 0160037689) ....................................................................................................... 88
FIGURE 3-12. QUICK HOOK ASSEMBLY (Prior to SN 0160037689) ........................................................................................... 92
FIGURE 3-13. FORK MOUNTED LIFTING HOOK ......................................................................................................................... 94
FIGURE 3-14. 6 FT SWING MAST WITH SIDE SHIFT (Prior to SN 0160037689) ........................................................................ 96
FIGURE 3-15. 100, DRYWALL SWING CARRIAGE (Prior to SN 0160037689) .......................................................................... 102
FIGURE 3-16. SHEET MATERIAL HANDLER (SN 0160037689 to Present) ............................................................................... 106
FIGURE 3-17. SIDE TILT CARRIAGE (SN 0160037689 to Present) ........................................................................................... 108
FIGURE 3-18. 180, SWING CARRIAGE (Prior to SN 0160000976)............................................................................................. 110
FIGURE 3-19. 180, SWING CARRIAGE (SN 0160000976 through 0160023514) ....................................................................... 114
FIGURE 3-20. 180, SWING CARRIAGE (SN 0160023515 through 0160037688) ....................................................................... 118
FIGURE 3-21. 180, SWING CARRIAGE (SN 0160037689 to Present) ........................................................................................ 122
FIGURE 3-22. 90, SWING CARRIAGE (SN 0160037689 to Present) .......................................................................................... 126
FIGURE 3-23. FORKS.................................................................................................................................................................. 128
FIGURE 3-24. PERSONNEL PLATFORM (Prior to SN 0160037689) .......................................................................................... 130
FIGURE 3-25. FORK MOUNTED PLATFORM............................................................................................................................. 134
FIGURE 3-26. FORK PIN LOCK INSTALLATION (SN 0160037689 to Present) ......................................................................... 138
FIGURE 3-27. GRAPPLE BUCKET (SN 0160037689 to Present) ............................................................................................... 140
FIGURE 3-28. 8 FT STANDARD MAST (SN 0160037689 to Present)......................................................................................... 142
FIGURE 3-29. 8 FT SIDE TILT ELECTRIC MAST (SN 0160037689 to Present) ......................................................................... 146
FIGURE 3-30. 66 IN DRYWALL CARRIAGE (Prior to SN 0160037689) ...................................................................................... 152
SECTION 4 - ENGINE AND ATTACHING PARTS .......................................................................................................................... 155
FIGURE 4-1. ENGINE ASSEMBLY, LH VIEW (SN 0355001 through 0355069) .......................................................................... 156
FIGURE 4-2. ENGINE ASSEMBLY, LH VIEW (SN 0355070 through 0355140) .......................................................................... 160
FIGURE 4-3. ENGINE ASSEMBLY, LH VIEW (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ............ 164
FIGURE 4-4. ENGINE ASSEMBLY, LH VIEW (SN 0160000976 through 0160034720, Including 0160035922) ......................... 168
FIGURE 4-5. ENGINE ASSEMBLY, LH VIEW (SN 0160035037 to Present, Excluding 0160035922) ........................................ 172
FIGURE 4-6. ENGINE ASSEMBLY, RH VIEW (SN 0355001 through 0355069) ......................................................................... 176
FIGURE 4-7. ENGINE ASSEMBLY, RH VIEW (SN 0355070 through 0355140) ......................................................................... 180
FIGURE 4-8. ENGINE ASSEMBLY, RH VIEW (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ............ 184
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6 544D 91364001
FIGURE 4-9. ENGINE ASSEMBLY, RH VIEW (SN 0160000976 through 0160034720, Including 0160035922) ......................... 188
FIGURE 4-10. ENGINE ASSEMBLY, RH VIEW (SN 0160035037 to Present, Excluding 0160035922) ...................................... 192
FIGURE 4-11. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355001 through 0355069) ...................................... 196
FIGURE 4-12. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355070 through 0355140) ...................................... 198
FIGURE 4-13. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355141 through 0455362, SN 0160000192 through
0160000973) ................................................................................................................................................................................. 200
FIGURE 4-14. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0160000976 through 0160034720, Including
0160035922) ................................................................................................................................................................................. 202
FIGURE 4-15. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0160035037 to Present, Excluding 0160035922) .... 204
FIGURE 4-16. JOHN DEERE ENGINE (SN 0160000976 through 0160008588) .......................................................................... 206
FIGURE 4-17. JOHN DEERE ENGINE (SN 0160008590 through 0160034720, Including 0160035922)..................................... 208
FIGURE 4-18. CUMMINS ENGINE (SN 0160035037 to Present, Excluding 0160035922) .......................................................... 210
FIGURE 4-19. FUEL TANK AND LINES (Prior to SN 0160035037, Including 0160035922) ........................................................ 212
FIGURE 4-20. FUEL TANK AND LINES (SN 0160035037 to Present, Excluding 0160035922) .................................................. 214
FIGURE 4-21. RADIATOR ASSEMBLY (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ....................... 216
FIGURE 4-22. RADIATOR ASSEMBLY (SN 0160000976 through 0160034720, Including 0160035922).................................... 218
FIGURE 4-23. RADIATOR ASSEMBLY (SN 0160035037 to Present, Excluding 0160035922) ................................................... 220
FIGURE 4-24. AIR CLEANER PIPING (SN 0355001 through 0355579) ...................................................................................... 222
FIGURE 4-25. AIR CLEANER PIPING (SN 0355580 through 0455362, SN 0160000192 through 0160000973) ......................... 224
FIGURE 4-26. AIR CLEANER PIPING (SN 0160000976 through 0160034720, Including 0160035922) ..................................... 226
FIGURE 4-27. AIR CLEANER PIPING (SN 0160035037 to Present, Excluding 0160035922) ..................................................... 228
FIGURE 4-28. AIR CLEANER (SN 0355001 through 0355579) ................................................................................................... 230
FIGURE 4-29. AIR CLEANER (SN 0355580 through 0455362, SN 0160000192 through 0160034720, Including 0160035922) . 232
FIGURE 4-30. AIR CLEANER (SN 0160035037 to Present, Excluding 0160035922) .................................................................. 234
FIGURE 4-31. EXHAUST SYSTEM (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ............................. 236
FIGURE 4-32. EXHAUST SYSTEM (SN 0160000976 through 0160034720, Including 0160035922) .......................................... 238
FIGURE 4-33. EXHAUST SYSTEM (SN 0160035037 to Present, Excluding 0160035922) ......................................................... 240
SECTION 5 - DRIVE TRAIN ............................................................................................................................................................. 243
FIGURE 5-1. FRONT AXLE ASSEMBLY - ROCKWELL (SN 0355001 through 0455362) ........................................................... 244
FIGURE 5-2. FRONT AXLE - ROCKWELL (SN 0355001 through 0455362)................................................................................ 246
FIGURE 5-3. LEFT/RIGHT HOUSING AND AXLE SHAFT AND WHEEL FLANGE ASSEMBLY - ROCKWELL (SN 0355001
through 0455362) .......................................................................................................................................................................... 248
FIGURE 5-4. BRAKE ASSEMBLY - ROCKWELL (SN 0355001 through 0455362) ...................................................................... 250
FIGURE 5-5. CARRIER ASSEMBLY - ROCKWELL (SN 0355001 through 0455362) .................................................................. 252
FIGURE 5-6. FRONT AXLE ASSEMBLY - CARRARO (SN 0160000192 to Present) .................................................................. 256
FIGURE 5-7. FRONT AXLE - CARRARO (SN 0160000192 to Present)....................................................................................... 258
FIGURE 5-8. AXLE HOUSING ASSEMBLY - CARRARO (SN 0160000192 to Present) .............................................................. 260
FIGURE 5-9. BRAKE ASSEMBLY - CARRARO (SN 0160000192 to Present)............................................................................. 262
FIGURE 5-10. CARRIER ASSEMBLY - CARRARO (SN 0160000192 to Present) ....................................................................... 264
FIGURE 5-11. REAR STEERING AXLE DRIVE HUB (SN 0355001 through 0455362) ............................................................... 268
FIGURE 5-12. REAR STEERING AXLE DRIVE HUB (SN 0160000192 to Present) .................................................................... 270
FIGURE 5-13. TIRES AND RIMS (Prior to SN 0160000192) ........................................................................................................ 272
FIGURE 5-14. TIRES AND RIMS (SN 0160000192 to Present) ................................................................................................... 274
SECTION 6 - CAB ............................................................................................................................................................................ 277
FIGURE 6-1. OPEN CAB (SN 0355001 through 0455497, SN 0160000192 through 0160012366, Excluding 0160012298) ....... 278
FIGURE 6-2. OPEN CAB (SN 0160012437 to Present, Including 0160012298) .......................................................................... 280
FIGURE 6-3. CAB ENCLOSURE KIT INSTALLATION (SN 0355001 through 0455362, SN 0160000192 through 0160000973) 282
FIGURE 6-4. CAB ENCLOSURE KIT INSTALLATION (SN 0160000976 through 0160012366, Excluding 0160012298) ........... 286
FIGURE 6-5. CAB ENCLOSURE KIT INSTALLATION (SN 0160012437 to Present, Including 0160012298) ............................. 290
FIGURE 6-6. CAB ENCLOSURE KIT (SN 0355001 through 0455497, SN 0160000192 through 0160012366, Excluding
0160012298) ................................................................................................................................................................................. 294
FIGURE 6-7. CAB ENCLOSURE KIT (SN 0160012437 to Present, Including 0160012298) ........................................................ 300
FIGURE 6-8. DASH PANEL ASSEMBLY (SN 0355001 through 0355039) .................................................................................. 304
FIGURE 6-9. DASH PANEL ASSEMBLY (SN 0355040 through 0355069) .................................................................................. 306
FIGURE 6-10. DASH PANEL ASSEMBLY (SN 0355070 through 0455362, SN 0160000192 through 0160000973) ................... 308
FIGURE 6-11. DASH PANEL ASSEMBLY (SN 0160000976 to Present) ..................................................................................... 310
FIGURE 6-12. GAUGE PANEL ASSEMBLY (SN 0355001 through 0355069) ............................................................................. 312
FIGURE 6-13. GAUGE PANEL ASSEMBLY (SN 0355070 through 0455362, SN 0160000192 through 0160000973) ................ 314
FIGURE 6-14. GAUGE PANEL ASSEMBLY (SN 0160000976 to Present) .................................................................................. 316
FIGURE 6-15. WINDSHIELD/TOP WINDOW KIT INSTALLATION .............................................................................................. 318
FIGURE 6-16. SKYLIGHT WIPER INSTALLATION ...................................................................................................................... 322
SECTION 7 - CONTROLS ................................................................................................................................................................ 325
TABLE OF CONTENTS
91364001 544D 7
FIGURE 7-1. BRAKE AND INCHING LINKAGE (SN 0355001 through 0455362, SN 0160000192 through 0160000238) .......... 326
FIGURE 7-2. BRAKE AND INCHING LINKAGE (SN 0160000239 through 0160000973)............................................................ 330
FIGURE 7-3. BRAKE AND INCHING LINKAGE (SN 0160000976 through 0160012366, Excluding 0160012298) ..................... 334
FIGURE 7-4. BRAKE AND INCHING LINKAGE (SN 01600122437 to Present, Including 0160012298) ..................................... 338
FIGURE 7-5. ACCELERATOR PEDAL ASSEMBLY (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ... 342
FIGURE 7-6. ACCELERATOR PEDAL ASSEMBLY (SN 0160000976 to Present) ...................................................................... 344
FIGURE 7-7. STEERING COLUMN AND ATTACHING PARTS .................................................................................................. 346
FIGURE 7-8. CAB RIGHT SIDE CONTROLS .............................................................................................................................. 348
FIGURE 7-9. JOYSTICK ASSEMBLY .......................................................................................................................................... 350
FIGURE 7-10. CAB LEFT SIDE CONTROLS (SN 0160024648 to Present) ................................................................................ 352
FIGURE 7-11. CYBERTECH 5-BUTTON JOYSTICK CONTROLLER (SN 0160024648 to Present) ........................................... 358
SECTION 8 - HYDRAULIC CIRCUITS............................................................................................................................................. 361
FIGURE 8-1. OIL SUPPLY AND PRESSURE LINES (SN 0355001 through 0355140) ............................................................... 362
FIGURE 8-2. OIL SUPPLY AND PRESSURE LINES (SN 0355141 through 0455362, SN 0160000192 through 0160000973).. 366
FIGURE 8-3. OIL SUPPLY AND PRESSURE LINES (SN 0160000976 to Present) .................................................................... 370
FIGURE 8-4. DUMP CIRCUIT (SN 0355001 through 0355140) ................................................................................................... 374
FIGURE 8-5. DUMP CIRCUIT (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ..................................... 378
FIGURE 8-6. DUMP CIRCUIT (SN 0160000976 to Present) ....................................................................................................... 382
FIGURE 8-7. FRONT DRIVE CIRCUIT ........................................................................................................................................ 386
FIGURE 8-8. REAR DRIVE CIRCUIT (SN 0355001 through 0355140) ....................................................................................... 388
FIGURE 8-9. REAR DRIVE CIRCUIT (SN 0355141 through 0455362) ....................................................................................... 392
FIGURE 8-10. REAR DRIVE CIRCUIT (SN 0160000192 to Present) .......................................................................................... 396
FIGURE 8-11. SERVICE/PARKING BRAKE ................................................................................................................................ 400
FIGURE 8-12. BOOM HYDRAULICS SUB-ASSY (Prior to SN 0160024648) .............................................................................. 402
FIGURE 8-13. BOOM HYDRAULICS SUB-ASSY (SN 0160024648 to Present) ......................................................................... 404
FIGURE 8-14. AUXILIARY HYDRAULICS (SN 0160024648 through 0160037688) .................................................................... 406
FIGURE 8-15. AUXILIARY HYDRAULICS (SN 0160037689 to Present) ..................................................................................... 408
FIGURE 8-16. LIFT CYLINDER.................................................................................................................................................... 410
FIGURE 8-17. CROWD CYLINDER ............................................................................................................................................. 412
FIGURE 8-18. TILT CYLINDER AND TILT COMPENSATING CYLINDER .................................................................................. 414
FIGURE 8-19. SWAY CYLINDER ................................................................................................................................................ 416
FIGURE 8-20. STEERING CIRCUIT (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ........................... 418
FIGURE 8-21. STEERING CIRCUIT (SN 0160000976 through 0160001769, Excluding 0160001766) ....................................... 420
FIGURE 8-22. STEERING CIRCUIT (SN 0160001770 to Present, Including 0160001766) ......................................................... 422
FIGURE 8-23. JOYSTICK CIRCUIT ............................................................................................................................................. 424
FIGURE 8-24. STABILIZER CYLINDER (SN 0355001 through 0355496) ................................................................................... 426
FIGURE 8-25. STABILIZER CYLINDER (SN 0355497 through 0455362, SN 0160000192 to Present) ...................................... 428
FIGURE 8-26. OUTRIGGER CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160000973) .................... 430
FIGURE 8-27. OUTRIGGER CYLINDER (SN 0160000976 to Present) ....................................................................................... 432
FIGURE 8-28. HOSE CLAMP LOCATIONS, (REAR) (SN 0355001 through 0355140) ............................................................... 434
FIGURE 8-29. HOSE CLAMP LOCATIONS, (REAR) (SN 0355141 through 0455362, SN 0160000192 through 0160000973) .. 436
FIGURE 8-30. HOSE CLAMP LOCATIONS, (REAR) (SN 0160000976 to Present) .................................................................... 438
SECTION 9 - HYDRAULIC COMPONENTS .................................................................................................................................... 441
FIGURE 9-1. TILT CYLINDER (Prior to SN 0160033224) ............................................................................................................ 442
FIGURE 9-2. TILT CYLINDER (SN 0160033224 through 0160037688) ...................................................................................... 444
FIGURE 9-3. TILT CYLINDER (SN 0160037689 to Present) ....................................................................................................... 446
FIGURE 9-4. CROWD CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) .............................. 448
FIGURE 9-5. CROWD CYLINDER (SN 0160017525 to Present) ................................................................................................ 450
FIGURE 9-6. LIFT CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) .................................... 452
FIGURE 9-7. LIFT CYLINDER (SN 0160017525 to Present) ....................................................................................................... 454
FIGURE 9-8. COMPENSATING CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160032630) ............... 456
FIGURE 9-9. COMPENSATING CYLINDER (SN 0160033224 to Present) ................................................................................. 458
FIGURE 9-10. SWAY CYLINDER (Prior to SN 0160033224)....................................................................................................... 460
FIGURE 9-11. SWAY CYLINDER (SN 0160033224 to Present) .................................................................................................. 462
FIGURE 9-12. STEERING CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160001769, Excluding
0160001766) ................................................................................................................................................................................ 464
FIGURE 9-13. STEERING CYLINDER (SN 0160001770 through 0160033083, Including 0160001766, Excluding 0160032250,
0160032591, 0160032630, 0160032644 and 0160032679) ......................................................................................................... 466
FIGURE 9-14. STEERING CYLINDER (SN 0160033224 to Present, Including 0160032250, 0160032591, 0160032630,
0160032644 and 0160032679) ..................................................................................................................................................... 468
FIGURE 9-15. STABILIZER CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) ..................... 470
FIGURE 9-16. STABILIZER CYLINDER (SN 0160017525 to Present) ........................................................................................ 472
FIGURE 9-17. OUTRIGGER CYLINDER (SN 0355001 through 0455362, SN 0160000192 through 0160017472) .................... 474
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8 544D 91364001
FIGURE 9-18. OUTRIGGER CYLINDER (SN 0160017525 through 0160038794) ....................................................................... 476
FIGURE 9-19. OUTRIGGER CYLINDER (FOR SERVICE ONLY) ............................................................................................... 478
FIGURE 9-20. FLOW DIVIDER ASSEMBLY ................................................................................................................................ 480
FIGURE 9-21. BRAKE VALVE (SN 0355001 through 0355947) ................................................................................................... 482
FIGURE 9-22. BRAKE VALVE (SN 0355948 through 0455362) ................................................................................................... 484
FIGURE 9-23. BRAKE VALVE (SN 0160000239 to Present) ....................................................................................................... 486
FIGURE 9-24. SOLENOID VALVE ............................................................................................................................................... 488
FIGURE 9-25. THERMAL BYPASS VALVE ASSEMBLY ............................................................................................................. 490
FIGURE 9-26. INCHING VALVE (SN 0355001 through 0455362, SN 0160000192 through 0160000238) .................................. 492
FIGURE 9-27. INCHING VALVE (SN 0160000239 to Present) .................................................................................................... 494
FIGURE 9-28. MAIN CONTROL VALVE (Prior to SN 0160037689) ............................................................................................. 496
FIGURE 9-29. MAIN CONTROL VALVE (SN 0160037964 to Present) ........................................................................................ 500
FIGURE 9-30. HYDRAULIC RESERVOIR AND FILTERS ............................................................................................................ 504
FIGURE 9-31. FRONT DRIVE MOTOR ........................................................................................................................................ 506
FIGURE 9-32. MAIN HYDRAULIC PUMP ..................................................................................................................................... 508
FIGURE 9-33. HYDROSTATIC TRANSMISSION (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ........ 510
FIGURE 9-34. HYDROSTATIC TRANSMISSION (SN 0160000976 to Present) .......................................................................... 512
FIGURE 9-35. SWAY AND OUTRIGGER CYLINDER VALVES ................................................................................................... 514
FIGURE 9-36. TRACTION LOCK VALVE ..................................................................................................................................... 516
FIGURE 9-37. REAR DRIVE MOTOR .......................................................................................................................................... 518
FIGURE 9-38. OPTIONAL STABILIZER VALVE ASSEMBLY (SN 0355001 through 0355496) ................................................... 520
FIGURE 9-39. OPTIONAL STABILIZER VALVE ASSEMBLY (SN 0355497 through 0455362, SN 0160000192 to Present) ...... 522
FIGURE 9-40. OUTRIGGER VALVE ............................................................................................................................................ 524
FIGURE 9-41. QUICK START CYLINDER AND VALVE ASSEMBLY (SN 035507 through 0160000973) ................................... 526
FIGURE 9-42. 180, SWING CARRIAGE CYLINDER .................................................................................................................... 528
FIGURE 9-43. 72 IN 90, SWING CARRIAGE CYLINDER ............................................................................................................ 530
FIGURE 9-44. SIDE TILT CARRIAGE CYLINDER ....................................................................................................................... 532
FIGURE 9-45. SIDE TILT CARRIAGE CYLINDER ....................................................................................................................... 534
FIGURE 9-46. GRAPPLE BUCKET CYLINDER ........................................................................................................................... 536
SECTION 10 - ELECTRICAL............................................................................................................................................................ 539
FIGURE 10-1. BATTERY AND CABLES (Prior to SN 0160035037, Including 0160035922)........................................................ 540
FIGURE 10-2. BATTERY AND CABLES (SN 0160035037 to Present, Excluding 0160035922) .................................................. 542
FIGURE 10-3. STABILIZER PROXIMITY SENSOR ..................................................................................................................... 544
FIGURE 10-4. DASH HARNESS ASSEMBLY (SN 0355001 through 0355069) ........................................................................... 546
FIGURE 10-5. DASH HARNESS ASSEMBLY (SN 0355070 through 0455362, SN 0160000192 through 0160000973) ............. 548
FIGURE 10-6. DASH HARNESS ASSEMBLY (SN 0160000976 to Present)................................................................................ 550
FIGURE 10-7. ENGINE HARNESS ASSEMBLY (SN 0355001 through 0355140) ....................................................................... 552
FIGURE 10-8. ENGINE HARNESS ASSEMBLY (SN 0355141 through 0455362, SN 0160000192 through 0160000973) ......... 554
FIGURE 10-9. ENGINE HARNESS ASSEMBLY (SN 0160000976 through 0160034720, Including 0160035922) ...................... 556
FIGURE 10-10. ENGINE HARNESS ASSEMBLY (SN 0160035037 to Present, Excluding 0160035922).................................... 558
FIGURE 10-11. ECU ENGINE HARNESS (SN 0160000976 through 0160034720, Including 0160035922) ................................ 560
FIGURE 10-12. ECU ENGINE HARNESS (SN 0160035037 to Present, Excluding 0160035922) ............................................... 562
FIGURE 10-13. AUXILIARY ELECTRICAL INSTALLATION (SN 0160024648 to Present) .......................................................... 564
FIGURE 10-14. AUXILIARY ELECTRICAL HARNESSES (SN 0160024648 to Present) ............................................................. 568
FIGURE 10-15. COLD START (SN 0160035037 to Present, Excluding 0160035922) ................................................................. 570
SECTION 11 - DECALS ................................................................................................................................................................... 573
FIGURE 11-1. FRAME DECALS (SN 0355001 through 0455362, SN 0160000192 through 0160000973) .................................. 574
FIGURE 11-2. FRAME DECALS (SN 0160000976 through 0160003956, Excluding 0160003856) ............................................. 578
FIGURE 11-3. FRAME DECALS (SN 0160003969 to Present, Including 0160003856) ............................................................... 582
FIGURE 11-4. BOOM DECALS (SN 0355001 through 0455362, SN 0160000192 through 0160012544) ................................... 586
FIGURE 11-5. BOOM DECALS (SN 0160012602 to Present, Including 0160012298) ................................................................. 588
SECTION 12 - OPTIONS.................................................................................................................................................................. 591
FIGURE 12-1. HYDRAULIC RESERVOIR HEATER INSTALLATION .......................................................................................... 592
FIGURE 12-2. WINCH INSTALLATION ........................................................................................................................................ 594
FIGURE 12-3. STOP LIGHT INSTALLATION ............................................................................................................................... 598
FIGURE 12-4. SWING CYLINDER ............................................................................................................................................... 602
FIGURE 12-5. TRUSS BOOM WINCH (Prior to SN 0160037689) ................................................................................................ 604
FIGURE 12-6. LH SWAY ASSEMBLY (Prior to SN 0160024648) ................................................................................................ 608
FIGURE 12-7. AUXILIARY HYDRAULIC FIELD KIT (Prior to SN 0160024648) ........................................................................... 610
FIGURE 12-8. AUXILIARY HYDRAULICS AND SWAY ASSEMBLY (Prior to SN 0160024648) .................................................. 614
FIGURE 12-9. AUXILIARY ELECTRICS ASSEMBLY (Prior to SN 0160024648) ......................................................................... 618
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91364001 544D 9
FIGURE 12-10. OVERHEAD WINDOW ....................................................................................................................................... 622
FIGURE 12-11. TILT ON JOYSTICK INSTALLATION ................................................................................................................. 624
FIGURE 12-12. WINCH MOTOR.................................................................................................................................................. 628
FIGURE 12-13. ENGINE BLOCK HEATER (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ................. 630
FIGURE 12-14. ENGINE BLOCK HEATER (SN 0160000976 to Present) ................................................................................... 632
FIGURE 12-15. SWAY CYLINDER .............................................................................................................................................. 634
FIGURE 12-16. DUAL P.O. CHECK VALVE ................................................................................................................................ 636
FIGURE 12-17. SWING VALVE KIT ............................................................................................................................................. 638
FIGURE 12-18. SWING VALVE KIT ............................................................................................................................................. 640
FIGURE 12-19. LH TILT/SWAY ASSEMBLY (Prior to SN 0160024648)...................................................................................... 642
FIGURE 12-20. LH TILT ASSEMBLY (Prior to SN 0160024648) ................................................................................................. 644
FIGURE 12-21. ETHER START (SN 0355001 through 0355069) ................................................................................................ 646
FIGURE 12-22. WORK LIGHT PACKAGE (SN 0355001 through 0455497, SN 0160000192 through 0160012366, Excluding
0160012298) ................................................................................................................................................................................ 648
FIGURE 12-23. WORK LIGHT PACKAGE (SN 0160012437 to Present, Including 0160012298) ............................................... 654
FIGURE 12-24. CROSSOVER RELIEF VALVE ........................................................................................................................... 658
FIGURE 12-25. FOAM TIRE OPTION .......................................................................................................................................... 660
FIGURE 12-26. AUX. HYDRAULICS/ELECTRIC W/LH TILT AND SWAY (Prior to SN 0160024648) ......................................... 662
FIGURE 12-27. REAR AXLE ADVANTAGE KIT (SN 0355001 through 0455362) ....................................................................... 668
FIGURE 12-28. REAR AXLE ADVANTAGE KIT (SN 0160000192 to Present) ............................................................................ 672
FIGURE 12-29. R.H. AUX. HYDRAULIC ASSEMBLY (Prior to SN 0160024648) ........................................................................ 676
FIGURE 12-30. 5-BUTTON AUXILIARY HANDLE ASSEMBLY (Prior to SN 0160024648) ......................................................... 680
FIGURE 12-31. RH AUX/TILT ON JOYSTICK (Prior to SN 0160024648).................................................................................... 682
FIGURE 12-32. AUXILIARY HYDRAULIC ASSEMBLY (Prior to SN 0160024648) ...................................................................... 686
FIGURE 12-33. CAB HEATER OPTION (SN 0355001 through 0455362, SN 0160000192 through 0160000973) ..................... 690
FIGURE 12-34. CAB HEATER OPTION (SN 0160000976 through 0160035922) ....................................................................... 694
FIGURE 12-35. CAB HEATER OPTION (SN 0160036260 to Present) ........................................................................................ 698
FIGURE 12-36. ADJUSTABLE TILT ON JOYSTICK .................................................................................................................... 702
FIGURE 12-37. FUEL/WATER SEPARATOR INSTALLATION ................................................................................................... 706
FIGURE 12-38. BEACON LIGHT PACKAGE (SN 0355001 through 0455497, SN 0160000192 through 0160012665, Excluding
0160012298) ................................................................................................................................................................................ 708
FIGURE 12-39. BEACON LIGHT PACKAGE (SN 0160012842 to Present, Including 0160012298) ........................................... 710
FIGURE 12-40. CAB REPLACEMENT SERVICE KIT.................................................................................................................. 712
FIGURE 12-41. STARTER KIT (SN 0160008321 to Present) ...................................................................................................... 714
FIGURE 12-42. PINTLE HOOK INSTALLATION.......................................................................................................................... 716
FIGURE 12-43. COLD START INSTALLATION (SN 0160000976 through 0160034720, Including 0160035922) ....................... 718
SECTION 13 - RECOMMENDED SPARE PARTS .......................................................................................................................... 721
FIGURE 13-1. RECOMMENDED SPARE PARTS ....................................................................................................................... 722
PART NUMBER INDEX ................................................................................................................................................................... 725
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This is a highly detailed factory service repair manual for the JLG Gradall Telehandlers 544D-10 ANSI. The manual provides step-by-step instructions and detailed illustrations, making it useful for both DIY enthusiasts and experienced mechanics. It covers operation instructions, lubrication, testing, adjusting, axles, mechanical adjustments, miscellaneous procedures, and more.
The manual comes in PDF format, compatible with all versions of Windows and Mac. It is printable and can be viewed using Adobe Reader or Win. Purchasing from a responsible seller ensures instant access without any waiting time. This manual is a cost-effective way to ensure proper functioning of your vehicle.
Models Covered:
- JLG Gradall Telehandlers 544D-10 ANSI
Part Number: 9136-4003
