JLG GRADALL 544 Telehandler Parts Manual – PDF DOWNLOAD
FILE DETAILS:
JLG GRADALL 544 Telehandler Parts Manual – PDF DOWNLOAD
Language: English
Brand: JLG GRADALL
TABLE OF CONTENTS:
JLG GRADALL 544 Telehandler Parts Manual – PDF DOWNLOAD
SECTION 1 – INTRODUCTION
Table of Contents 1-1 thru 1-4
Alphabetical Index 1-5 thru 1-10
Service Kits 1-11
Parts Index 1-12 thru 1-27
SECTION 2 – CHASSIS & ATTACHING PARTS
Frame Shrouding & Trim 2-1
Cab Enclosure, Wiper & Defroster 2-2
Cab Heater & Hoses 2-3
Front Axle Cradle & Attaching Parts 2-4
Rear Steering Axle & Attaching Parts 2-5
Outrigger & Attaching Parts 2-6
SECTION 3 – BOOMS
First Boom Section 3-1
Second Boom Section 3-2
Third Boom Section 3-3
Fourth Boom Section 3-4
Push Beam & Cables 3-5
Quick Switch Assembly 3-6
SECTION 4 – ATTACHMENTS & ACCESSORIES
Attachments 4-1
Slope Piler Carriage 66″ 4-2
SECTION 5 – ENGINE & ATTACHING PARTS
Engine Left Side View 5-1
Engine Right Side View 5-2
Engine Mounting 5-3
Fuel Tank & Lines 5-4
Radiator & Hoses 5-5
Ether Starting Kit 5-6
Air Cleaner Piping 5-7
Air Cleaner 5-8
Exhaust System 5-9
SECTION 6 – DRIVE TRAIN
Transmission Mounting & Controls 6-1
Flex Plate & Torque Converter 6-2
Case & Converter Housing 6-3, 6-4
Transmission Drive Gearing 6-5
Clutch & Gear Group (Reverse, 2nd & Low) 6-6
Clutch & Gear Group (Forward, Output & 3rd) 6-7
Clutch Assemblies 6-8
SECTION 6 – DRIVE TRAIN (Continued)
Modulator Valve6-9
Control Valve 6-10
Propeller Shaft 6-11
Front Axle Assembly 6-12
Front Axle Housing 6-13
Front Axle Differential Carrier 6-14
Front Axle Shaft & Planetary Wheel End 6-15
Wheels & Tires 6-16
Planetary Hub & Drive Hub 6-17
SECTION 7 – CONTROLS
Forward & Reverse, Speed Selector 7-1
Boom Tilt & Sway 7-2
Accelerator Linkage 7-3
Steering Column 7-4
SECTION 8 – BRAKES
Hydraulics & Service Brake Lines 8-1
Hydraulics & Parking Brake Lines 8-1, 8-2
Brake Pedal & Inching Linkage 8-3
Accumulator, Charging Valve & Lines 8-4
SECTION 9 – HYDRAULIC CIRCUITS
Oil Supply & Pressure Lines 9-1, 9-2
Dump Circuit 9-3, 9-4
Rear Drive 9-5, 9-6
Steering 9-7
Lift Cylinder 9-8
Crowd Cylinder 9-9, 9-10
Tilt Cylinder 9-11, 9-12, 9-13
Sway Cylinder 9-14
Joystick Circuit 9-15
Outrigger Cylinder 9-16
Stabilizer Cylinder 9-17
SECTION 10 – HYDRAULIC COMPONENTS
Lift Cylinder 10-1
Crowd Cylinder 10-2
Crowd Extension Cylinder 10-3
Tilt Cylinder 10-4
Compensating Cylinder 10-5
Sway Cylinder 10-6
Steering Cylinder 10-7
Stabilizer Cylinder 10-8
INTRODUCTION
Table of Contents
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
1-2
SECTION 10 – HYDRAULIC COMPONENTS (continued)
Outrigger Cylinder 10-9
Main Control Valve 10-10
Priority Flow Contrlol Valve 10-11
Forward Reverse Control Valve 10-12
Series Parallel Control Valve 10-13
Solenoid Valve (Three-Way, Two Position) 10-14
Main Relief Valve 10-15
Outrigger Control Valve 10-16
Accumulator Charge Valve 10-17
Series-Parrallel Control Valve 10-18
Brake Valve 10-19
Parking Brake Valve 10-20
Directional Control Valve 10-21
Main Hydraulic Pump 10-22
Pilot Pump 10-23
Rear Drive Motor 10-24
Oil Reservoir Filter 10-25
Hydraulic Oil Reservoir 10-26
Solenoid Valve (Two Way, Normally Open) 10-27
Solenoid Valve (Two Way, Normally Closed) 10-28
Hydraulic Controller (Joystick) 10-29
Dual PO Check Valve 10-30, 10-31
Counterbalance Control Valve 10-32
SECTION 11 – ELECTRICAL
Instrument Panel & Wiring Harness 11-1
Batteries & Cables 11-2
Boom Section Electrical 11-3
Miscellaneous Electrical Components 11-4
SECTION 12 – MISCELLANEOUS
Frame decals 12-1
Boom Decals 12-2
SECTION 13 – OPTIONAL EQUIPMENT
Dual Hose Reel Assembly 13-1
Dual Hose Reel & Hydraulic System 13-2
Sway, Auxiliary & Tilt Controls 13-3
100 Degree Swing Fork Assembly 13-4
100 Degree Swing Fork Assembly 13-5
180 Degree Swing Frame Assembly 13-6, 13-7
Swing Valve Assembly 13-8
Single Hose Reel & Hydraulic System 13-9
Winch & Hydraulic System 13-10
Single Hose Reel Assembly 13-11
INTRODUCTION
Table of Contents
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
1-3
SECTION 13 – OPTIONAL EQUIPMENT (continued)
Winch Assembly13-12, 13-13
Hydraulic Cylinder (Jarp) 13-14
Hydraulic Cylinder (Iowa) 13-15
Electrics for Auxiliary Hydraulics 13-16
Auxiliary Hydraulics 13-17
Pintle Hook 13-18
Steering Axle Advantage Kit 13-19
INTRODUCTION
Table of contents
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
1-4
ACCELERATOR CABLE 7-3
ACCELERATOR PEDAL 7-3
ACCUMULATOR 8-4
ACCUMULATOR CHARGE VALVE 8-4, 10-17
AIR CLEANER 5-7, 5-8
AIR CLEANER ELEMENT 5-8
AIR CLEANER SERVICE INDICATOR 5-7
ALTERNATOR 5-3
ALTERNATOR FAN 5-3
AMMETER 11-1
ATTACHMENTS 4-1
BATTERY 11-2
BATTERY CABLES 11-2
BEARING PADS (Boom sections) 3-1, 3-2, 3-3, 3-4
BOOM DECALS 12-2
BOOM SECTIONS 3-1, 3-2, 3-3, 3-4
BOOM SECTIONS ELECTRICAL 11-3
BRAKE PEDAL 8-3
BRAKE VALVE 10-19
BRAKE WARNING LIGHT 11-1
BREATHER (Filler cap) 10-26
CAB 2-2
CAB DOOR 2-2
CARRIAGE & FORKS 4-1
CHARGE VALVE (Accumulator) 8-4, 10-17
CIRCUIT BREAKERS 11-1
COMPENSATING CYLINDER 10-5
COMPENSATING CYLINDER HYDRAULIC CIRCUIT 9-11, 9-12
CONTROL VALVES 10-10, 10-11, 10-12, 10-13, 10-16, 10-18, 10-21
COUNTERBALANCE VALVE 10-32
COUNTERWEIGHT 2-1
CRADLE 2-4
CRADLE MOUNTING PIN 2-4
CROWD CYLINDER 10-2
CROWD CYLINDER HYUDRAULIC CIRCUIT 9-9, 9-10
CROWD EXTENSION CYLINDER 10-3
CROWD EXTENSION HYDRAULIC CIRCUIT 9-9, 9-10
DECALS 12-1, 12-2
DECK 2-1
DEFROSTER FAN 2-2
DIRECTIONAL CONTROL VALVE 10-21
INTRODUCTION
Alphabetical Index
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
1-5
DOOR 2-2
DOOR HANDLES 2-2
DRIVE BELT 5-3
DUAL PO CHECK VALVE 10-30, 10-31
DUMP CIRCUIT 9-3, 9-4
ELECTRICAL SYSTEMS 11-1, 11-2, 11-4
ELECTRICAL SYSTEMS (boom sections) 11-3
ENGINE LEFT SIDE VIEW 5-1
ENGINE MOUNT 5-3
ENGINE RIGHT SIDE VIEW 5-2
ENGINE THROTTLE CONTROL 7-3
ETHER STARTING KIT 5-6
EXHAUST MANIFOLD 5-3
EXHAUST PIPE 5-9
EXHAUST STACK 5-9
EXHAUST SYSTEM 5-9
EXTENSION CABLE 3-5
FAN BELT 5-3
FAN GUARD 5-5
FAN SHROUD 5-5
FILTERS 5-2, 6-5, 10-25, 10-26
FILTER ELEMENT 10-25, 10-26
FIRST BOOM SECTION 3-1
FIRST BOOM SECTION MOUNTING PIN 3-1
FORWARD REVERSE CONTROL VALVE 10-12
FORWARD SHIFT CONTROL ROD7-1
FOURTH BOOM SECTION 3-4
FRAME 2-1
FRAME SHROUDING & TRIM2-1
FRONT AXLE 6-12
FRONT AXLE BRAKE 6-18
FRONT AXLE CRADLE 2-4
FRONT AXLE DIFFERENTIAL CARRIER 6-14
FRONT AXLE HOUSING 6-13
FRONT AXLE SHAFT & PLANETARY WHEEL END 6-15
FRONT DISC WHEEL & RIM 6-16
FUEL GAUGE 11-1
FUEL LEVEL SENDER 5-4
FUEL LINES 5-4
FUEL TANK & CAP 5-4
GROUND CABLE 5-2, 11-2
INTRODUCTION
Alphabetical Index
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
1-6
HEATER2-3
HEAT SHIELD5-9
HEATER SWITCH 2-3
HOOD 2-1
HORN 11-4
HORN BUTTON 11-1
HORN RELAY 11-4
HORN WIRING 11-4
HOSE CARRIER 9-11, 9-12
HOURMETER 11-1
HYDRAULIC CIRCUITS 9-1 thru 9-17
HYDRAULIC CONTROLLER (Joystick) 10-29
IGNITION SWITCH 11-1
INCHING VALVE 8-2, 8-3
INSTRUMENT PANEL 11-1
JOYSTICK (Hydraulic Controller) 10-29
JOYSTICK HYDRAULIC CIRCUIT 9-15
KITS 1-11
LIFT CYLINDER 10-9
LIFT CYLINDER HYDRAULIC CURCUIT 9-8
MAIN BOOM SECTIONS 3-1, 3-2, 3-3, 3-4
MAIN HYDRAULIC PUMP5-1, 10-22
MISCELLANEOUS ELECTRICAL COMPONENTS 11-4
MUFFLER 5-9
NEGATIVE BATTERY CABLE 11-2
OIL COOLER 9-3, 9-4
OIL FILTER (Hydraulic) 10-25, 10-26
OIL PRESSURE GAUGE 11-1
OIL PRESSURE SENDER 5-2
OIL RESERVOIR 10-26
OIL SUPPLY & PRESSURE LINES9-1, 9-2
OUTRIGGER ARM2-6
OUTRIGGER CONTROL VALVE 10-16
OUTRIGGER CYLINDER 10-9
OUTRIGGER CYLINDER HYDRAULIC CIRCUIT 9-16
OUTRIGGER SHOE 2-6
INTRODUCTION
Alphabetical Index
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
1-7
PARKING BRAKE LINES 8-2
PARKING BRAKE VALVE 10-20
PILOT PUMP 10-23
POSITIVE BATTERY CABLE 11-2
PRIORITY FLOW CONTROL VALVE 10-11
PROPELLER SHAFT 6-11
PUSH BEAM & CABLES 3-5
QUICK SWITCH ASSEMBLY 3-6
RADIATOR & HOSES 5-5
REAR AXLE FRAME 2-5
REAR AXLE MOUNTING PIN 2-5
REAR DRIVE MOTOR 10-24
REAR STEERING AXLE 2-5
REAR STEERING AXLE PLANETARY HUB 6-17
RELIEF VALVE 8-4
REPAIR KITS 1-11
RESERVOIR 10-26
RESERVOIR FILLER-BREATHER 10-26
RESERVOIR FILTER 10-20
RESERVOIR SUPPLY CIRCUIT 9-1, 9-2
RETRACTION CABLES 3-5
REVERSE SHIFT CONTROL ROD 7-1
SAND BUCKET 4-1
SEAT 2-1
SEAT BELT 2-1
SECOND BOOM SECTION 3-2
SERIES PARALLEL VALVE 10-13
SERVICE BRAKE LINES 8-1
SERVICE KITS 1-11
SHUT-OFF VALVES 2-3, 5-2
SLOPE PILER CARRIAGE 13-18
SOLENOID VALVES 10-14, 10-27, 10-28
SOLENOID VALVE (Three-Way, Two Position) 10-14
SOLENOID VALVE (Two-Way, Normally Closed) 10-28
SOLENOID VALVE (Two-Way, Normally Open) 10-27
SPINNER KNOB 7-4
INTRODUCTION
Alphabetical Index
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
STABILIZER CYLINDER 10-8
STABILIZER CYLINDER HYDRAULIC CIRCUIT 9-17
STABILIZER VALVE 10-15
STARTER BUTTON 11-1
STARTER MOTOR5-3
STARTER SOLENOID 5-1
STEERING COLUMN 7-4
STEERING CYLINDER 10-7
STEERING CYLINDER HYDRAULIC CIRCUIT9-7
STEERING KNUCKLES 2-5
STEERING ORBITROL 7-4
STEERING WHEEL 7-4
SUPPLY HYDRAULIC CIRCUIT 9-1, 9-2
SWAY CONTROL HANDLE & LINKAGE7-2
SWAY CYLINDER 10-6
SWAY CYLINDER HYDRAULIC CIRCUIT 9-14
THIRD BOOM SECTION 3-3
TIE ROD ARM 2-5
TILT CONTROL HANDLE & LINKAGE 7-2
TILT CYLINDER 10-4
TILT CYLINDER HYDRAULIC CIRCUIT 9-11, 9-12, 9-13
TORQUE CONVERTER 6-2
TRANSMISSION6-1
TRANSMISSION CASE & CONVERTER HOUSING6-3, 6-4
TRANSMISSION CHARGE PUMP6-5
TRANSMISSION CLUTCH ASSEMBLIES 6-8
TRANSMISSION CLUTCH & GEARING (Forward, Output & Third) 6-7
TRANSMISSION CLUTCH & GEARING (Reverse, Second & Low) 6-6
TRANSMISSION CONTROL VALVE 6-10
TRANSMISSION DISCONNECT SWITCH 8-3
TRANSMISSION DRIVE GEARING 6-5
TRANSMISSION FLEX PLATE & TORQUE CONVERTER 6-2
TRANSMISSION MODULATOR VALVE6-9
TRANSMISSION TEMPERATURE GAUGE 11-1
TRAVEL ALARM 11-4
V-BELT 5-3
WATER SEPARATOR 5-4
WATER TEMPERATURE GAUGE 11-1
WATER TEMPERATURE SENDER 5-2
INTRODUCTION
Alphabetical Index
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
1-9
WEATHER STRIP 2-2
WHEELS & TIRES 6-16
WINDOWS 2-2
WINDSHIELD WIPER ARM 2-2
WINDSHIELD WIPER BLADE 2-2
WINDSHEILD WIPER MOTOR 2-2
WIRING HARNESS 5-1, 11-1, 11-3
INTRODUCTION
Alphabetical Index
Starting Serial No 8655105G
Original Issue 8-86
Revised 8-97
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