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Gradall 544D (9136-4003) Service Manual manuals

Owner’s manuals and user’s guides for Hoist Gradall 544D (9136-4003) Service Manual.
We providing 1 pdf manuals Gradall 544D (9136-4003) Service Manual for download free by document types: User Manual


Gradall 544D (9136-4003) Service Manual User Manual (392 pages)


Brand: Gradall | Category: Hoist | Size: 31.60 MB |

 

Table of contents

SERVICE MANUAL

1

544D MATERIAL HANDLER

5

OWNER/OPERATOR MANUAL

5

IMPORTANT SAFETY NOTICE

6

OTHER NOTICES

6

REVISIONS

7

TABLE OF CONTENTS

8

SAFETY HIGHLIGHTS

10

Standard Shut-Down Procedure

11

Pinch Points

11

INSIDE THE CAB

12

TRACTION LOCK SWITCH

13

ENGINE OIL

14

STAY CLEAR OF MOVING PARTS

15

WHILE ENGINE IS RUNNING

15

MOVING PARTS CAN CAUSE

15

SERIOUS INJURY

15

OUTSIDE THE CAB

16

ATTACH LANYARD HERE

17

OPERATOR’S CAB

18

Form No. 20220

19

ENGINE OPERATION

23

Normal Engine Operation

24

Stopping the Engine

24

BRAKE SYSTEM

25

STEERING SYSTEM

26

PARKING THE HANDLER

26

DRIVE TRAIN

27

Always move boom to carry

28

TILT FRAME

29

TO RIGHT

29

Hydraulic Controls

30

Feathering

30

Boom Control Joystick

30

Carriage Tilt Controls

30

Some attachments may not be

32

How to read a Capacity Chart

32

STABILIZERS DOWN

33

ATTACHMENTS

34

Attachment Installation

35

Attachment Operation

35

Fork Positioner

36

Light Material Bucket

36

Swing Forks

37

Slope Piler Carriage

38

Boom Head-Mounted Winch

39

A side load or a swinging

40

Swing Mast

41

Personnel Work Platform

42

Figure 15-1

44

Figure 15-2

44

MOVING HANDLER IN EMERGENCY

45

SECTION A A

46

MAINTENANCE

49

FAILURE TO USE GRADALL

50

HYDRAULIC FILTER ELEMENTS

50

COULD VOID WARRANTY

50

TORQUE CHART

52

STABILIZER

53

Date Hourmeter Comments

54

HAND SIGNALS

55

CALIFORNIA

56

SECTION I

61

SECTION II

62

DESCRIPTION

62

SECTION III

64

PARTS ORDERING INFORMATION

66

OUTLET COVERS

67

WORK SECTIONS

68

RELIEF VALVES

69

SECTION IV

70

PARTS LISTING

70

MANUAL POSITIONER

79

3-POSITION DETENT POSITIONER

80

FLOAT POSITIONER

85

ROTARY DETENT POSITIONER

87

SPOOL SEAL RETAINER

89

SPOOL PROTECTIVE BOOT

89

TORQUE NR PLUG

90

TO 20 FT-LBS

90

No Relief (NR) Plug

90

TORQUE RELIEF

91

CARTRIDGE TO

91

20 FT. LBS [27 Nm]

91

VALVE ASSEMBLY TO

94

18-22 FT.-LBS

94

[24-30 Nm]

94

TORQUE CHECK

98

ASSEMBLY TO

98

18-22 FT. LBS

98

Service Notes

132

Item Description

134

PRA 353/383

137

PROA 352/382

141

Table of Contents

143

P R O A 3 5 2 G 2 M

145

Section 2

146

Removal and Disassembly

146

Section 3

157

Prepare Parts for Assembly

157

Section 4

167

Assembly and Installation

167

Section 5

191

Adjustments

191

Section 6

196

Specifications

196

Nut Lock

197

Special Tool

197

Torque Chart - PROA 352/382

199

Torque Chart - PRA 352

201

PROA 352 G2H, G2M

202

MANUALE DI RIPARAZIONE

205

REPAIR MANUAL

205

Rif. CA144840

205

Mod. 28.46M

206

A GENERAL INFORMATION

208

A INFORMAZIONI GENERALI

208

A.1 Manual use

209

A.1 Utilizzo del manuale

209

A.2 Information property

210

Carraro Spa

210

A.3 Convenzioni e definizioni

211

PAG.5

212

A.4 General description

213

A.4 Indicazioni generali

213

A.5 Recommendations

214

A.5 Indicazioni generali

214

PAG.8

215

B SAFETY INSTRUCTIONS

216

B INFORMAZIONI SULLA

216

B.1 General safety

217

B.2 Safety symbols

218

B.2 Simboli di sicurezza

218

B.3 General precautions

219

B.3 Precauzioni generali

219

Residual risk elimination

220

C GENERAL SPECIFICATIONS

221

C CARATTERISTICHE GENERALI

221

C.1 Foreseen uses

222

C.2 Product identification

222

C.1 Usi previsti

222

C.3 General description

223

C.3 Descrizione generale

223

C.4 Technical Features

224

C.4 Caratteristiche Tecniche

224

PAG.18

225

PAG.19

226

PAG.20

227

PAG.21

228

C.5 Oil change and checks

229

C.5 Cambio olio e verifiche

229

PAG.23

230

PAG.24

231

Primo Intervento

232

Ad ogni stagione od

232

PAG.26

233

PAG.27

234

D DISASSEMBLY AND ASSEMBLY

235

D OPERAZIONI DI MONTAGGIO E

235

D.1 Flange group

236

D.1 Gruppo flangia

236

D.1.2 Assembly

237

D.1.2 Montaggio

237

PAG.31

238

D.2.1 Disassembly

239

D.2.1 Smontaggio

239

PAG.33

240

D.2.2 Assembly

241

D.2.2 Montaggio

241

PAG.35

242

D.3 Gruppo mozzo ruota

243

D.3 Wheel hub group

243

PAG.37

244

PAG.38

245

D.3.2 Assembly

246

D.3.2 Montaggio

246

PAG.40

247

D.4 Axle beam trumpets group

248

D.4 Gruppo trombe trave

248

PAG.42

249

D.4.2 Assembly

250

D.4.2 Montaggio

250

PAG.44

251

PAG.45

252

D.5.1 Disassembly

253

D.5.1 Smontaggio

253

PAG.47

254

PAG.48

255

PAG.49

256

D.5.2 Assembly

257

D.5.2 Montaggio

257

PAG.51

258

PAG.52

259

PAG.53

260

PAG.54

261

PAG.55

262

PAG.56

263

PAG.57

264

PAG.58

265

PAG.59

266

D.6 Differential group

267

D.6 Gruppo differenziale

267

PAG.61

268

D.6.2 Assembly

269

D.6.2 Montaggio

269

PAG.63

270

D.7 Pinion group

271

D.7 Gruppo pignone

271

PAG.65

272

D.7.2 Assembly

273

D.7.2 Montaggio

273

PAG.67

274

PAG.68

275

PAG.69

276

D.8 Parking brakes release

277

PAG.71

278

D.10 Testing after assembly

279

D.10 Prove dopo montaggio

279

E TROUBLESHOOTING

280

E RICERCA GUASTI

280

PROBLEMA

281

PROBLEMS

281

PAG.75

282

RICERCA GUASTI

283

Mod. 28.46M TROUBLESHOOTING

283

E.1 PAG.76

283

E.1 PAG.77

284

E.1 Troubleshooting

285

E.1 PAG.79

286

E.2 PAG.80

287

E.2 PAG.81

288

F SPECIAL TOOLS

289

F ATTREZZATURE SPECIALI

289

F.1 Special tools

290

F.1 Attrezzature speciali

290

PAG.84

291

PowerWheel® Service Manual

293

Model 8 Series B

293

Double Reduction

293

Wheel Drives

293

AuburnGear

294

ASSEMBLY OF POWER WHEEL

295

IN ASS’Y

297

INTRODUCTION

301

S FETY

302

NOMENCLATURE

303

BOOM ASSEMBLY: OVERVIEW

304

HYDRAULICS

305

BOOM-SECTION 4:

305

BOOM WEAR PAD ADJUSTMENTS

306

ADJUSTING BOTTOM BEARING PADS

307

ADJUSTING TOP BEARING PADS

307

BOOM-SECTION 4 WEAR PADS

308

SECTION WEAR PADS

309

SECTION 2 WEAR PADS

310

SECTION 1 WEAR PADS

311

OOM-EXTEND AND RETRACT CHAINS

312

CHAIN COMPONENTS

313

ADJUSTIN6 EXTEND CHAINS

314

BOOM HEAD

314

(BOOM FULLY RETRACTED):

314

SHOWING RETRACT

314

CHAIN CHECKS

314

ETREAT CHAIN

316

EATRET CHAIN

316

ORM NO. 29702

316

OOM MAINTENANCE

316

RETRACT CHAIN REINSTALLATION

317

EXTEND CHAIN REINSTALLATION

318

HAIN LINK DIMENSIONS

319

ORM NO. 29702

320

7.0 HYDRAULIC SUB-ASSEMBLY

321

OOM HEAD:

323

HOWING HOSE TAKE-UP

323

ILDMENT AT BOTTOM

323

RONT, BOOM-SECTION 1

323

YDRAULIC SUB-ASSEMBLY

324

HYDRAULIC SUB-ASSEMBLY:

326

FORM NO. 29702

326

544C/544D BOOM MAINTENANCE

326

OOM CROWD CYLINDER

327

RONT, BOOM-SECTION 1

330

ORM NO. 29702

330

EAR, BOOM-SECTION 4

331

RONT BOOM-SECTION 2

331

OOM-SECTION 4: REAR VIEW

331

OMPLETE BOOM ASSEMBLY

331

EAR VIEW

331

EXTEND CHAIN ROLLER

332

HOSE TAKE-UP ASSEMBLY

332

SEPARATING BOOM SECTIONS

334

REMOVING THE CROWD CYLINDER

334

RONT, BOOM-SECTION 1

335

EARING PADS: TYPICAL

335

BOOM-SECTION 4 DIS-ASSEMBLY

337

REASSEMBLING BOOM SECTIONS

338

Important!

338

ASSEMBLING BOOM-SECTION 4

339

BOOM-SECTION 4: COMPLETE

340

FRONT VIEW

340

REAR VIEW

340

FORM NO. 29702

340

ASSEMBLING BOOM-SECTION 3

341

EAR, BOOM-SECTION 3

343

BOOM-SECTION 3: COMPLETE

344

ASSEMBLING BOOM-SECTION 2

345

EAR, BOOM-SECTION 2

347

OOM-SECTION 2

347

OTTOM, BOOM HEAD

347

EAR, BOOM-SECTION 2

347

ASSEMBLING BOOM-SECTION 1

349

Shim as required

353

BOLT SIZE

354

METRIC FASTENERS

355

OSE FITTING CHART

356

Gradall, 1998

358

Donaldson

375

Open Center

377

HYDRAULIC

377

POWER BRAKE

377

FIGURE 6

381

Residual Valve

382

Primary Cup

382

Ring Seal & O-Ring

382

Check Valve

382

Sliding Piston

382

SPECIFICATIONS CHART

383

FIGURE 10

385

Items included in Repair

385

Kit 06-459-002

385

FIGURE 12

389

Kit 06-459-020

389

FLOW-THRU

391




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