JLG Gradall 534D-9, 534D-10 & 544D Telehandler Service Manual (ANSI)

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This service manual PDF download for the 534D-9, 534D-10 & 544D JLG Gradall Telehandler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG Lift 534D-9 & 534D-10
S/N 0160000447 & After

JLG Lift 544D
S/N 0160000192 & After


TABLE OF CONTENTS :

    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operator & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
        1.6 Safety Instructions
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torque Charts
        2.3 Specifications
        2.4 Fluid and Lubricant Capacities
        2.5 Service and Maintenance Schedules
        2.6 Lubrication Schedules
            
    Section 3 Boom
        3.1 Boom System Component Terminology 534D-9, 534D-10
        3.2 Boom System - Three Section
        3.3 Boom Maintenance - Three Section (Complete Removal)
        3.4 Boom Maintenance - Three Section (Individual Section Removal)
        3.5 Boom Cables - Three Section
        3.6 Auxiliary Electric Cable - Three Section
        3.7 Extend/Retract Cylinder Removal and Installation - Three Section
        3.8 Boom System Component Terminology 544D
        3.9 Boom System - Four Section
        3.10 Boom Maintenance - Four Section (Complete Removal)
        3.11 Boom Maintenance - Four Section (Individual Section Removal)
        3.12 Boom Extend and Retract Chains - Four Section
        3.13 Boom Section Separation Adjustment - Four Section
        3.14 Hydraulic Sub-Assembly Removal/Installation - Four Section
        3.15 Boom Wear Pads
        3.16 Quick Switch Assembly
        3.17 Forks
        3.18 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
        4.3 Cab Components
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Wheels and Tires
        5.1 Axles, Wheel and Tire Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
        5.4 Rear Drive Hubs
        5.5 Rear Steer Axle
        5.6 Wheels and Tires
        5.7 Brakes
        5.8 Towing a Disabled Machine
        
    Section 6 Hydrostatic Drive Pump
        6.1 Drive Pump Assembly Component Terminology
        6.2 Drive Pump Description
        6.3 Drive Pump Serial Number
        6.4 Drive Pump Specifications
        6.5 Drive Pump Replacement
        6.6 Hydrostatic Drive Performance Checks
            
    Section 7 Engine
        7.1 Introduction: John Deere 4045TF275 & 4045HF275
        7.2 Engine Serial Number
        7.3 Specifications and Maintenance Information
        7.4 Introduction: Cummins QSB4.5
        7.5 Engine Serial Number
        7.6 Specifications and Maintenance Information
        7.7 Cooling System
        7.8 Electrical System
        7.9 Fuel System
        7.10 Exhaust System
        7.11 Air Cleaner Assembly
        7.12 Engine Replacement
        7.13 Engine Drive Plate/Coupling
        7.14 Engine Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
        8.4 Hydraulic Circuits
        8.5 Hydraulic Reservoir
        8.6 Engine Implement Pump
        8.7 Drive Motors
        8.8 Control Valves
        8.9 Hydraulic Cylinders
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Service Warnings
        9.4 Fuses and Relays
        9.5 Electrical System Schematics
        9.6 Engine Start Circuit
        9.7 Charging Circuit
        9.8 Windshield Wiper Motor (If Equipped)
        9.9 Cab Heater and Fan (If Equipped)
        9.10 Solenoids, Sensors and Senders
        9.11 Gauges
        9.12 Dash Switches
        9.13 Transmission Lever
        9.14 Traction Lock Pedal
        9.15 Troubleshooting - Cummins


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200170
Total Pages : 174


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31200170_C_D-Series_Gradall_Service
    Table of Contents
    
    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operator & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
            1.5.1 Safety Alert System and Signal Words
        1.6 Safety Instructions
            1.6.1 Personal Hazards
            1.6.2 Equipment Hazards
            1.6.3 General Hazards
            1.6.4 Operational Hazards
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torque Charts
            2.2.1 ASTM Fastener Torque Chart (English)
            2.2.2 ASTM Fastener Torque Chart (Metric)
            2.2.3 Metric Fastener Torque Chart
        2.3 Specifications
            2.3.1 Travel Speeds
            2.3.2 Hydraulic Cylinder Performance
            2.3.3 Electrical System
            2.3.4 Engine Performance Specifications
            2.3.5 Tires
        2.4 Fluid and Lubricant Capacities
        2.5 Service and Maintenance Schedules
            2.5.1 10, 1st 50 & 50 Hour
            2.5.2 250, 500, 1000 & 1500 Hour
        2.6 Lubrication Schedules
            2.6.1 534D-9, 534D-10
            2.6.2 544D
            
    Section 3 Boom
        3.1 Boom System Component Terminology 534D-9, 534D-10
        3.2 Boom System - Three Section
            3.2.1 Boom System Operation
        3.3 Boom Maintenance - Three Section (Complete Removal)
            3.3.1 Boom Removal
            3.3.2 Second & Third Boom Section Removal
            3.3.3 Third Boom Section & Push Beam Removal
            3.3.4 Third Boom Section Installation
            3.3.5 Extend/Retract Cylinder and Push Beam Assembly and Installation
            3.3.6 Second & Third Boom Section Installation
        3.4 Boom Maintenance - Three Section (Individual Section Removal)
            3.4.1 Push Beam and Third Boom Section Removal
            3.4.2 Second Boom Section Removal
            3.4.3 Second and Third Boom Section Removal
            3.4.4 Second Boom Section Installation
            3.4.5 Third Boom Section Installation
        3.5 Boom Cables - Three Section
            3.5.1 General Cable Information
            3.5.2 Cable Adjustments
            3.5.3 Retract Cable Removal
            3.5.4 Retract Cable Installation
            3.5.5 Extend Cable Removal
            3.5.6 Extend Cable Installation
            3.5.7 Tilt and Auxiliary Circuit Hose Removal/Installation
            3.5.8 Hose Removal
            3.5.9 Hose Installation
        3.6 Auxiliary Electric Cable - Three Section
            3.6.1 Electrical Wire Data
            3.6.2 Electrical Cable Removal
            3.6.3 Electrical Cable Installation
        3.7 Extend/Retract Cylinder Removal and Installation - Three Section
            3.7.1 Extend/Retract Cylinder Removal
            3.7.2 Extend/Retract Cylinder Installation
        3.8 Boom System Component Terminology 544D
        3.9 Boom System - Four Section
            3.9.1 Boom System Operation
        3.10 Boom Maintenance - Four Section (Complete Removal)
            3.10.1 Boom Removal
            3.10.2 Extend/Retract Cylinder Removal
            3.10.3 Tilt Cylinder Removal
            3.10.4 Second, Third & Fourth Boom Section Removal
            3.10.5 Third & Fourth Boom Section Removal
            3.10.6 Fourth Boom Section Removal
            3.10.7 Hydraulic Sub-Assembly
            3.10.8 Fourth Boom Section Install
            3.10.9 Third Boom Section Install
            3.10.10 Second Boom Section Install
            3.10.11 First Boom Section Install
            3.10.12 Boom Assembly Installation
        3.11 Boom Maintenance - Four Section (Individual Section Removal)
            3.11.1 Fourth Boom Section Removal
            3.11.2 Third Boom Section Removal
            3.11.3 Second Boom Section Removal
            3.11.4 Second, Third and Fourth Boom Section Removal
            3.11.5 Second Boom Section Installation
            3.11.6 Third Boom Section Installation
            3.11.7 Fourth Boom Section Installation
        3.12 Boom Extend and Retract Chains - Four Section
            3.12.1 Boom Chain Inspection
            3.12.2 Inspection Guidelines
            3.12.3 Adjusting Extend Chains
            3.12.4 Adjusting Retract Chains
            3.12.5 Retract Chain Removal
            3.12.6 Retract Chain Installation
            3.12.7 Extend Chain Removal
            3.12.8 Extend Chain Installation
        3.13 Boom Section Separation Adjustment - Four Section
        3.14 Hydraulic Sub-Assembly Removal/Installation - Four Section
            3.14.1 Hydraulic Sub-Assembly Removal
            3.14.2 Assembling the Hydraulic Sub- Assembly
            3.14.3 Hydraulic Sub-Assembly Installation
        3.15 Boom Wear Pads
            3.15.1 Wear Pad Inspection
            3.15.2 Boom Wear Pad Replacement
            3.15.3 Boom Wear Pad Lubrication
        3.16 Quick Switch Assembly
            3.16.1 Disconnecting from an Attachment
            3.16.2 Connecting to an Attachment
            3.16.3 Quick Switch Removal
            3.16.4 Quick Switch Installation
        3.17 Forks
        3.18 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
            4.2.1 Cab Safety
            4.2.2 Serial Number Decal
        4.3 Cab Components
            4.3.1 Steering Column and Orbitrol Valve
            4.3.2 Service Brake Pedal
            4.3.3 Throttle Pedal
            4.3.4 Boom Joystick Assembly
            4.3.5 Frame Sway and Attachment Tilt Levers
            4.3.6 Left Hand Tilt and/or Left Hand Tilt/ Sway Lever (If Equipped)
            4.3.7 Windshield Wiper Assembly
            4.3.8 Heater System (If Equipped)
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Wheels and Tires
        5.1 Axles, Wheel and Tire Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
            5.3.1 Axle Serial Number Plate
            5.3.2 Axle Specifications
            5.3.3 Axle Internal Service
            5.3.4 Axle Maintenance
            5.3.5 Axle Removal
            5.3.6 Axle Installation
            5.3.7 Axle Assembly Troubleshooting
        5.4 Rear Drive Hubs
            5.4.1 Rear Drive Hub Service
        5.5 Rear Steer Axle
            5.5.1 Rear Axle Removal
            5.5.2 Rear Axle Installation
        5.6 Wheels and Tires
            5.6.1 Removing Wheel and Tire Assembly from Machine
            5.6.2 Installing Wheel and Tire Assembly onto Machine
        5.7 Brakes
            5.7.1 Brake Disk Inspection.
        5.8 Towing a Disabled Machine
        
    Section 6 Hydrostatic Drive Pump
        6.1 Drive Pump Assembly Component Terminology
        6.2 Drive Pump Description
        6.3 Drive Pump Serial Number
        6.4 Drive Pump Specifications
            6.4.1 Drive Pump Maintenance
            6.4.2 Drive Pump Maintenance Schedule
        6.5 Drive Pump Replacement
            6.5.1 Drive Pump Removal
            6.5.2 Drive Pump Inspection and Internal Repair
            6.5.3 Drive Pump Installation
        6.6 Hydrostatic Drive Performance Checks
            6.6.1 Hydraulic Oil Reservoir
            6.6.2 Hydraulic Filter Condition
            6.6.3 Engine Speed
            6.6.4 Park Brake
            6.6.5 Charge Pressure
            6.6.6 Control Pressure
            6.6.7 Inching
            6.6.8 Front Motor Begin Point
            6.6.9 Drive Pump Pressure
            6.6.10 Machine Operation
            
    Section 7 Engine
        7.1 Introduction: John Deere 4045TF275 & 4045HF275
            7.1.1 Disclaimer and Scope
            7.1.2 Component Terminology
        7.2 Engine Serial Number
        7.3 Specifications and Maintenance Information
        7.4 Introduction: Cummins QSB4.5
            7.4.1 Disclaimer and Scope
            7.4.2 Component Terminology
        7.5 Engine Serial Number
        7.6 Specifications and Maintenance Information
        7.7 Cooling System
            7.7.1 Radiator Pressure Cap
            7.7.2 Thermostat Replacement
            7.7.3 Radiator/Oil Cooler and Replacement
        7.8 Electrical System
        7.9 Fuel System
            7.9.1 Diesel Fuel
            7.9.2 Fuel Tank
            7.9.3 After Fuel System Service
        7.10 Exhaust System
            7.10.1 Exhaust System Removal
            7.10.2 Exhaust System Installation
        7.11 Air Cleaner Assembly
            7.11.1 Air Cleaner Assembly Removal
            7.11.2 Air Cleaner Assembly Installation
        7.12 Engine Replacement
            7.12.1 Engine Removal
            7.12.2 Engine Disassembly, Inspection and Service
            7.12.3 Engine Installation
        7.13 Engine Drive Plate/Coupling
            7.13.1 Drive Plate/Coupling Removal
            7.13.2 Drive Plate/Coupling Installation
        7.14 Engine Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
            8.3.1 Pressure Checks and Adjustments
            8.3.2 Pressure and Speed Settings
        8.4 Hydraulic Circuits
            8.4.1 Hydraulic Pressures
            8.4.2 Hydraulic Schematic-534D-9
            8.4.3 Hydraulic Schematic-534D-10
            8.4.4 Hydraulic Schematic-544D
        8.5 Hydraulic Reservoir
            8.5.1 Hydraulic Oil Reservoir Draining
            8.5.2 Hydraulic Oil Reservoir Filling
            8.5.3 Hydraulic Oil Reservoir Removal/ Installation
        8.6 Engine Implement Pump
            8.6.1 Pump Description
            8.6.2 Pump Failure Analysis
            8.6.3 Pump Replacement
        8.7 Drive Motors
            8.7.1 Front Drive Motor
            8.7.2 Rear Drive Motors
        8.8 Control Valves
            8.8.1 Main Control Valve
            8.8.2 Service Brake Valve
            8.8.3 Brake Test
            8.8.4 Steering Orbitrol Valve
        8.9 Hydraulic Cylinders
            8.9.1 General Cylinder Instructions
            8.9.2 Cylinder Disassembly
            8.9.3 General Cylinder Assembly Instructions
            8.9.4 General Cylinder Installation
            8.9.5 Cylinder Pressure Checking
            8.9.6 Cylinder Torque Specifications
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
            9.1.1 General Overview (Cab and Engine Harness)
        9.2 Specifications
        9.3 Service Warnings
        9.4 Fuses and Relays
            9.4.1 Cab
            9.4.2 Engine Compartment
        9.5 Electrical System Schematics
            9.5.1 Electrical Schematic 534D-9, 534D-10 - John Deere
            9.5.2 Electrical Schematic 544D - John Deere
            9.5.3 Electrical Schematic 534D-9, 534D-10, 544D - Cummins
            9.5.4 Start Circuit 534D-9, 534D-10, 544D
            9.5.5 Charge Circuit 534D-9, 534D-10, 544D
        9.6 Engine Start Circuit
            9.6.1 Starter
        9.7 Charging Circuit
            9.7.1 Alternator
        9.8 Windshield Wiper Motor (If Equipped)
            9.8.1 Windshield Washer Reservoir and Pump
        9.9 Cab Heater and Fan (If Equipped)
            9.9.1 Cab Heater Controls
        9.10 Solenoids, Sensors and Senders
            9.10.1 Circuit Solenoids
            9.10.2 Stabilizer Proximity Sensor
            9.10.3 Engine Senders
            9.10.4 Fuel Level Sender
        9.11 Gauges
            9.11.1 Analog Gauges
        9.12 Dash Switches
            9.12.1 Ignition Key Switch
            9.12.2 Dash Switches
            9.12.3 Warning or Activated Lights
        9.13 Transmission Lever
            9.13.1 Transmission Lever Replacement
        9.14 Traction Lock Pedal
            9.14.1 Traction Lock Pedal Replacement
        9.15 Troubleshooting - Cummins
            9.15.1 Fault Detection
            9.15.2 Flash-Out of Fault Codes
            9.15.3 Offboard Diagnostics
            9.15.4 Engine Fault Codes Chart
            
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