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

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This service manual PDF download for the JLG Gradall 534D-9, 534D-10 & 544D 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.


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

JLG Lift 544D
S/N 0160000192 & After


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


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

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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

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