Gradall 544D (9136-4003) Service Manual User Manual Page 16
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Located on boom
P/N 8060-3037
2.4
OUTSIDE THE CAB
Located on mud guard
P/N 8060-3022
Located on engine compartment
P/N 9114-3280
Located on fuel tank
P/N 9114-3286
Located on engine cover
P/N 8060-3026
Located beside battery
P/N 9114-3284
Located beside battery
P/N 9114-3285
9114-3280
EXHAUST SYSTEMS CAN BE HOT.
KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT.
HOT EXHAUST COMPONENTS CAN CAUSE
SEVERE BURNS.
8060-3026
COOLING SYSTEM
IS PRESSURIZED.
REMOVE CAP SLOWLY.
HOT FLUID CAN
CAUSE BURNS.
9114-3285
WHEN JUMP STARTING MATERIAL HANDLER
* NEVER ALLOW VEHICLES TO TOUCH
* CONNECT THE POSITIVE (+) JUMPER CABLE TO
POSITIVE (+) POST OF DISCHARGED BATTERY
* CONNECT OPPOSITE END OF POSITIVE (+) JUMPER
CABLE TO POSITIVE (+) POST OF BOOSTER BATTERY
* CONNECT THE NEGATIVE (-) JUMPER CABLE TO
NEGATIVE (-) POST ON BOOSTER BATTERY
* CONNECT OPPOSITE END OF NEGATIVE (-) JUMPER
CABLE TO GROUND POINT ON MACHINE AWAY FROM
DISCHARGED BATTERY
* FOLLOW STANDARD STARTING PROCEDURES
* REMOVE CABLES IN REVERSE ORDER AFTER MACHINE
HAS STARTED
JUMP STARTING INSTRUCTIONS
9114-3284
LEAD ACID BATTERIES PRODUCE FLAMABLE AND
EXPLOSIVE GASSES
WHEN CHECKING, TESTING, USING
BOOSTER BATTERY OR CHARGING BATTERIES:
* DO NOT USE SMOKING MATERIALS NEAR BATTERIES
* KEEP FLAMES AND SPARKS AWAY FROM BATTERIES
* WEAR SAFETY GLASSES
* ASSURE BATTERY IS NOT FROZEN AND ELECTROLYTE
IS AT PROPER LEVEL IN EACH CELL
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS INJURY OR DAMAGE TO THE
ELECTRICAL SYSTEM
8060-3037-A
PINCH POINT
KEEP OUT
REACHING INTO BOOM
HOLES AND OTHER PINCH
POINTS CAN CAUSE
SERIOUS INJURY
OR DEATH.
8060-3022
AVOID HIGH VOLTAGE LINES.
IT IS UNLAWFUL TO PLACE
ANY PART OF THIS MACHINE
OR LOAD WITHIN 10 FEET
OF HIGH VOLTAGE LINES
UP TO 50,000 VOLTS.
DEATH OR INJURY MAY
RESULT FROM CONTACTING
ELECTRIC LINES.
9114-3286
DIESEL FUEL IS FLAMMABLE
EXTINGUISH ALL OPEN FLAME AND
SMOKING MATERIALS WHEN REFUELING
INJURY OR DEATH COULD RESULT
FROM FIRE.
- 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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