This is the COMPLETE Service Repair Manual for the JLG 534D-9, 534D-10, 544D Models Telehandlers. It contains deep information about maintaining, assembly, disassembly and servicing your JLG 534D-9, 534D-10, 544D Models Telehandlers.
Serial Number:
534D-9 & 534D-10: S/N 0160000447 & After
544D: S/N 0160000192 & After
This Manual contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes, which give you complete step by step operations on repair, Diagnosing, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. YOU CAN DO THE REPAIRS YOURSELF AND SAVE MONEY $$$
Service Repair Manual Contains:
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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
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** Model Specification: JLG 534D-9, 534D-10, 544D Models Telehandlers
** Language: English
** Total Pages: 174
** File Format: PDF
** Requirements: Adobe PDF Reader
** Compatible: All Versions of Windows & Mac, Linux OS, Iphone, Ipad, Android etc…
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This QUALITY manual is 100 percents COMPLETE and INTACT,
no MISSING/CORRUPT pages/sections to freak you out! It also is Bookmarked and SEARCHABLE to make what you need easy to find. Complete download comes in PDF format which can work under all PC based Windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM. It can be viewed on any computer, as well as zoomed and printed.
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