Gradall 544D (9136-4003) Service Manual User Manual Page 343
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- Table of contents
- TROUBLESHOOTING
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9.16
Stage 5
Initial set-up from the jam nut to the back of the clevis pin is 3/4".
See Boom-Section 3: Complete, page 9.17, for location of this measurement
Adjust the nut until the gap between the nut and washer is 1/4".
Torque the jam nut to 100 ft-lb. Use Never
ll
ll
l
Seez (Gradall P/N 1440-3323)
on the threads.
Lay out the two 1" extend chains and lubricate them
thoroughly. Make sure chain has been inspected
and meets adjustment parameters established
in Section 4
Attach the rear chain clevis to the chain.
Boom-Section 3 is now ready to be installed into Boom-Section 2.
REAR, BOOM-SECTION 3
1.
2.
3.
4.
5.
→→
→→
→
GRADALL
GRADALL
- 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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