JLG 544D Telehandler Parts Manual

Name: JLG 544D Telehandler Parts Manual
Brand: MidWestTech
SKU: 91364001
Price: 79.75 USD
Availability: InStock

744 pages · Publication 91364001

$79.75

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Models: 544D
Serial coverage: 0160000192 to Present, 0355001-0455362
Manual type: Parts Manual
Pages: 744
Publication: 91364001
Condition: Brand new

JLG 544D Telehandler Parts Manual, publication 91364001

What's inside

From the manual's own table of contents: 57 sections, 144 entries. See sample pages (PDF, 627 KB)

Search the contents

General34 topics

SECTION 1 - FRAME AND ATTACHING PARTS
FIGURE 1-3. FRAME SHROUDING AND TRIM (SN 0160035037 to Present, Excluding 0160035922)
FIGURE 1-4. REAR AXLE AND ATTACHING PARTS (SN 0355001 through 0455362)
FIGURE 1-5. REAR AXLE AND ATTACHING PARTS (SN 0160000192 to Present)
FIGURE 1-7. FRONT AXLE MOUNTING (SN 0160000192 to Present)
FIGURE 1-8. OUTRIGGER MOUNTING (Prior to SN 0160015062)
FIGURE 1-9. OUTRIGGER MOUNTING (SN 0160015062 to Present)
SECTION 2 - BOOM
FIGURE 2-1. FIRST BOOM SECTION
FIGURE 2-2. SECOND BOOM SECTION
FIGURE 2-3. THIRD BOOM SECTION
FIGURE 2-4. FOURTH BOOM SECTION
FIGURE 2-5. EXTENSION CHAINS
FIGURE 2-6. RETRACTION CHAINS
FIGURE 2-7. QUICK SWITCH ASSEMBLY (Prior to SN 0160037689)
FIGURE 2-8. QUICK SWITCH ASSEMBLY (SN 0160037689 to Present)
SECTION 3 - ATTACHMENTS
FIGURE 3-1. BUCKETS
FIGURE 3-3. TILT CARRIAGE (SN 0160023515 to Present)
FIGURE 3-6. TRUSS BOOM WITH WINCH (Prior to SN 0160037689)
FIGURE 3-7. TRUSS BOOM WITH WINCH (SN 0160037689 to Present)
FIGURE 3-9. 48 IN SLOPE PILER CARRIAGE (Prior to SN 0160037689)
FIGURE 3-12. QUICK HOOK ASSEMBLY (Prior to SN 0160037689)
FIGURE 3-13. FORK MOUNTED LIFTING HOOK
FIGURE 3-14. 6 FT SWING MAST WITH SIDE SHIFT (Prior to SN 0160037689)
FIGURE 3-16. SHEET MATERIAL HANDLER (SN 0160037689 to Present)
FIGURE 3-17. SIDE TILT CARRIAGE (SN 0160037689 to Present)
FIGURE 3-23. FORKS
FIGURE 3-24. PERSONNEL PLATFORM (Prior to SN 0160037689)
FIGURE 3-25. FORK MOUNTED PLATFORM
FIGURE 3-26. FORK PIN LOCK INSTALLATION (SN 0160037689 to Present)
FIGURE 3-27. GRAPPLE BUCKET (SN 0160037689 to Present)
FIGURE 3-29. 8 FT SIDE TILT ELECTRIC MAST (SN 0160037689 to Present)
SECTION 4 - ENGINE AND ATTACHING PARTS

FIGURE 4-11. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355001 through 0355069)

FIGURE 4-12. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0355070 through 0355140)

FIGURE 4-15. ENGINE PUMP MOUNT AND FLYWHEEL HOUSING (SN 0160035037 to Present, Excluding 0160035922)

SECTION 5 - DRIVE TRAIN

FIGURE 5-1. FRONT AXLE ASSEMBLY - ROCKWELL (SN 0355001 through 0455362)

FIGURE 5-5. CARRIER ASSEMBLY - ROCKWELL (SN 0355001 through 0455362)

FIGURE 5-6. FRONT AXLE ASSEMBLY - CARRARO (SN 0160000192 to Present)

FIGURE 5-7. FRONT AXLE - CARRARO (SN 0160000192 to Present)

FIGURE 5-8. AXLE HOUSING ASSEMBLY - CARRARO (SN 0160000192 to Present)

FIGURE 5-9. BRAKE ASSEMBLY - CARRARO (SN 0160000192 to Present)

FIGURE 5-10. CARRIER ASSEMBLY - CARRARO (SN 0160000192 to Present)

FIGURE 5-11. REAR STEERING AXLE DRIVE HUB (SN 0355001 through 0455362)

FIGURE 5-12. REAR STEERING AXLE DRIVE HUB (SN 0160000192 to Present)

SECTION 6 - CAB

FIGURE 6-5. CAB ENCLOSURE KIT INSTALLATION (SN 0160012437 to Present, Including 0160012298)

FIGURE 6-11. DASH PANEL ASSEMBLY (SN 0160000976 to Present)

FIGURE 6-14. GAUGE PANEL ASSEMBLY (SN 0160000976 to Present)

FIGURE 6-15. WINDSHIELD/TOP WINDOW KIT INSTALLATION

FIGURE 6-16. SKYLIGHT WIPER INSTALLATION

SECTION 7 - CONTROLS29 topics

FIGURE 7-4. BRAKE AND INCHING LINKAGE (SN 01600122437 to Present, Including 0160012298)
FIGURE 7-6. ACCELERATOR PEDAL ASSEMBLY (SN 0160000976 to Present)
FIGURE 7-7. STEERING COLUMN AND ATTACHING PARTS
FIGURE 7-8. CAB RIGHT SIDE CONTROLS
FIGURE 7-9. JOYSTICK ASSEMBLY
FIGURE 7-10. CAB LEFT SIDE CONTROLS (SN 0160024648 to Present)
FIGURE 7-11. CYBERTECH 5-BUTTON JOYSTICK CONTROLLER (SN 0160024648 to Present)
SECTION 8 - HYDRAULIC CIRCUITS
FIGURE 8-1. OIL SUPPLY AND PRESSURE LINES (SN 0355001 through 0355140)
FIGURE 8-3. OIL SUPPLY AND PRESSURE LINES (SN 0160000976 to Present)
FIGURE 8-7. FRONT DRIVE CIRCUIT
FIGURE 8-10. REAR DRIVE CIRCUIT (SN 0160000192 to Present)
FIGURE 8-11. SERVICE/PARKING BRAKE
FIGURE 8-12. BOOM HYDRAULICS SUB-ASSY (Prior to SN 0160024648)
FIGURE 8-13. BOOM HYDRAULICS SUB-ASSY (SN 0160024648 to Present)
FIGURE 8-15. AUXILIARY HYDRAULICS (SN 0160037689 to Present)
FIGURE 8-16. LIFT CYLINDER
FIGURE 8-17. CROWD CYLINDER
FIGURE 8-18. TILT CYLINDER AND TILT COMPENSATING CYLINDER
FIGURE 8-19. SWAY CYLINDER
FIGURE 8-23. JOYSTICK CIRCUIT
FIGURE 8-27. OUTRIGGER CYLINDER (SN 0160000976 to Present)
FIGURE 8-30. HOSE CLAMP LOCATIONS, (REAR) (SN 0160000976 to Present)
SECTION 9 - HYDRAULIC COMPONENTS
FIGURE 9-3. TILT CYLINDER (SN 0160037689 to Present)
FIGURE 9-5. CROWD CYLINDER (SN 0160017525 to Present)
FIGURE 9-7. LIFT CYLINDER (SN 0160017525 to Present)
FIGURE 9-9. COMPENSATING CYLINDER (SN 0160033224 to Present)
FIGURE 9-16. STABILIZER CYLINDER (SN 0160017525 to Present)

FIGURE 9-19. OUTRIGGER CYLINDER (FOR SERVICE ONLY)

FIGURE 9-20. FLOW DIVIDER ASSEMBLY

FIGURE 9-24. SOLENOID VALVE

Show all 58 sections

FIGURE 9-25. THERMAL BYPASS VALVE ASSEMBLY

FIGURE 9-28. MAIN CONTROL VALVE (Prior to SN 0160037689)

FIGURE 9-29. MAIN CONTROL VALVE (SN 0160037964 to Present)

FIGURE 9-30. HYDRAULIC RESERVOIR AND FILTERS

FIGURE 9-31. FRONT DRIVE MOTOR

FIGURE 9-32. MAIN HYDRAULIC PUMP

FIGURE 9-34. HYDROSTATIC TRANSMISSION (SN 0160000976 to Present)

FIGURE 9-35. SWAY AND OUTRIGGER CYLINDER VALVES

FIGURE 9-36. TRACTION LOCK VALVE

FIGURE 9-37. REAR DRIVE MOTOR

FIGURE 9-38. OPTIONAL STABILIZER VALVE ASSEMBLY (SN 0355001 through 0355496)

FIGURE 9-39. OPTIONAL STABILIZER VALVE ASSEMBLY (SN 0355497 through 0455362, SN 0160000192 to Present)

FIGURE 9-40. OUTRIGGER VALVE

FIGURE 9-41. QUICK START CYLINDER AND VALVE ASSEMBLY (SN 035507 through 0160000973)

FIGURE 9-42. 180, SWING CARRIAGE CYLINDER

FIGURE 9-43. 72 IN 90, SWING CARRIAGE CYLINDER

FIGURE 9-44. SIDE TILT CARRIAGE CYLINDER

FIGURE 9-45. SIDE TILT CARRIAGE CYLINDER

FIGURE 9-46. GRAPPLE BUCKET CYLINDER

SECTION 10 - ELECTRICAL

FIGURE 10-3. STABILIZER PROXIMITY SENSOR

FIGURE 10-6. DASH HARNESS ASSEMBLY (SN 0160000976 to Present)

FIGURE 10-7. ENGINE HARNESS ASSEMBLY (SN 0355001 through 0355140)

FIGURE 10-13. AUXILIARY ELECTRICAL INSTALLATION (SN 0160024648 to Present)

FIGURE 10-14. AUXILIARY ELECTRICAL HARNESSES (SN 0160024648 to Present)

SECTION 11 - DECALS

SECTION 12 - OPTIONS

FIGURE 12-1. HYDRAULIC RESERVOIR HEATER INSTALLATION

FIGURE 12-2. WINCH INSTALLATION

FIGURE 12-3. STOP LIGHT INSTALLATION

FIGURE 12-4. SWING CYLINDER

FIGURE 12-7. AUXILIARY HYDRAULIC FIELD KIT (Prior to SN 0160024648)

FIGURE 12-8. AUXILIARY HYDRAULICS AND SWAY ASSEMBLY (Prior to SN 0160024648)

FIGURE 12-9. AUXILIARY ELECTRICS ASSEMBLY (Prior to SN 0160024648)24 topics

FIGURE 12-10. OVERHEAD WINDOW
FIGURE 12-11. TILT ON JOYSTICK INSTALLATION
FIGURE 12-12. WINCH MOTOR
FIGURE 12-14. ENGINE BLOCK HEATER (SN 0160000976 to Present)
FIGURE 12-15. SWAY CYLINDER
FIGURE 12-16. DUAL P.O. CHECK VALVE
FIGURE 12-17. SWING VALVE KIT
FIGURE 12-18. SWING VALVE KIT
FIGURE 12-19. LH TILT/SWAY ASSEMBLY (Prior to SN 0160024648)
FIGURE 12-24. CROSSOVER RELIEF VALVE
FIGURE 12-25. FOAM TIRE OPTION
FIGURE 12-26. AUX. HYDRAULICS/ELECTRIC W/LH TILT AND SWAY (Prior to SN 0160024648)
FIGURE 12-28. REAR AXLE ADVANTAGE KIT (SN 0160000192 to Present)
FIGURE 12-29. R.H. AUX. HYDRAULIC ASSEMBLY (Prior to SN 0160024648)
FIGURE 12-30. 5-BUTTON AUXILIARY HANDLE ASSEMBLY (Prior to SN 0160024648)
FIGURE 12-32. AUXILIARY HYDRAULIC ASSEMBLY (Prior to SN 0160024648)
FIGURE 12-35. CAB HEATER OPTION (SN 0160036260 to Present)
FIGURE 12-36. ADJUSTABLE TILT ON JOYSTICK
FIGURE 12-37. FUEL/WATER SEPARATOR INSTALLATION
FIGURE 12-40. CAB REPLACEMENT SERVICE KIT
FIGURE 12-42. PINTLE HOOK INSTALLATION
SECTION 13 - RECOMMENDED SPARE PARTS
FIGURE 13-1. RECOMMENDED SPARE PARTS
PART NUMBER INDEX

Inside this manual

Real pages from this parts manual (744 pages). Open the sample pages (PDF, 626 KB)

Sample pages from the JLG 544D Telehandler Parts Manual: Parts illustration, Parts illustration, Parts illustration

Parts illustration, page 98: SECTION 3 - ATTACHMENTS
Parts illustration, page 340: SECTION 7 - CONTROLS
Parts illustration, page 626: SECTION 12 - OPTIONS

This is a parts manual

Here's how it compares to the other manual types.

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

This manual

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 744 pages

Quantity one is the manual described above.

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