JLG Gradall 544D-10 Materials Handler Maintenance and Service Manual

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JLG Gradall 544D-10 Materials Handler Maintenance and Service Manual

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the JLG Gradall 544D-10 Materials Handler. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.

This service manual PDF download for the JLG Gradall 544D-10 Materials Handler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JLG Gradall Telehandler 544D-10
Starting Serial No. 0355001 thru 0455362

TABLE OF CONTENTS :

OPERATION & LUBRICATION
TESTING & ADJUSTING
AXLES
MECHANICAL ADJUSTMENT
MISCELLANEOUS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 9136-4003
Total Pages : 392

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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This page sometime can be found use following keyword : service manual, repair manual, workshop manual, technical manual, owner manual, operating manual, maintenance manual, parts manual. Please make sure you read and understand the title of this manual before decided to buy.

OPERATION & LUBRICATION
20220 544D-10 Owner/Operator Manual
Important Safety Notice
Revisions
Table of Contents
Introduction
Safety Highlights
Decals
Operator’s Cab
Control & Instrument Identification
Checks & Services Before Starting Engine
Warm-Up & Operational Checks
Engine Operation
Brake System
Parking the Handler
Steering System
Drive Train
Leveling the Handler
Operating Procedures & Techniques
Attachments
Obtaining Hydraulic Oil Sample for Analysis
Loading & Securing for Transport
Moving Handler in Emergency
Maintenance
Inspection & Maintenance Log
Hand Signals

TESTING & ADJUSTING
9116-9010 Hydraulic Schematic
GSD-1270 Gresen Directional Control Valves
SECTION I Introduction
SECTION II Description
SECTION III Maintenance
SECTION IV Parts Listing
Figure 3-1. Schematic View of Typical Model V40 Control Valve Assembly
Figure 3-2. Spool Seal Assembly
Figure 4-1. Model V40 Directional Control Valve Assembly, Typical Main Assembly
Figure 4-2. 3-Way, 3-Position Work Section
Figure 4-3. 4-Way, 3-Position Parallel and Tandem Work Section
Figure 4-4. 4-Way, 4-Position Float Work Section
Figure 4-5. 4-Way, 4-Position Regenerative Work Section
Figure 4-6. Split and Combined Mid-Inlet Section
Figure 4-7. Two-Position Mid-Inlet Section
Figure 4-8. Spring Load to Split Flow Positioner
Figure 4-9. Spring Load to Combined Flow Positioner
Figure 4-10. Spring Return to Neutral Positioner
Figure 4-11. Manual Positioner
Figure 4-12. Spring Extended Spool Positioner
Figure 4-13. 3-Position Detent Positioner
Figure 4-14. “R” Detent with Spring Return to Neutral Positioner
Figure 4-15. Spool Travel Limiter Positioner
Figure 4-16. Internal Pressure Detent Release Positioner
Figure 4-17. Electro-Magnetic Detent Positioner
Figure 4-18. Float Positioner
Figure 4-19. 4-Position Regenerative Positioner
Figure 4-20. Rotary Detent Positioner
Figure 4-21. Handle Assembly-Vertical, Horizontal and Inverted
Figure 4-22. Spool Seal Retainer
Figure 4-23. Spool Protective Boot
Figure 4-24. No Relief “NR” Plug (Main Relief)
Figure 4-25. Model KC Ball/Spring Main Relief Valve
Figure 4-26. Model RP60 Pilot-Operated Main Relief Valve
Figure 4-27. No Relief “NR” Plug (Work Port Relief Valves)
Figure 4-28. Model RD30 Differential Poppet Work Port Relief Valve (Non-Adjustable)
Figure 4-29. Model RD30A Differential Poppet Work Port Relief Valve (Adjustable)
Figure 4-30. Model RP30 Pilot-Operated Work Port Relief Valve (Non-Adjustable)
Figure 4-31. Model RP30-AC Combination Relief and Anti-Cavitation Check (Non-Adjustable)
Figure 4-32. Anti-Cavitation Check Assembly
HN21AD02 Danfoss Hydrostatic Steering Unit

AXLES
FMM9D Meritor PRA 352 Series Planetary Axles
Service Notes
Illustrations with parts list of Model:
PRA 352 – Trumpet Variation No. 1
PRA 352 – Trumpet Variation No. 2
PRA 353-383
PROA 352-382 (with Mechanical Drive Option
PROA 352/382
Section 1 Introduction
Section 2 Removal & Disassembly
Section 3 Prepare Parts for Assembly
Section 4 Assembly & Installation
Section 5 Adjustments
Section 6 Specifications
CA357248 28.46M Carraro Axle
A INFORMAZIONI GENERALI
A.1 Utilizzo del manuale
A.2 Proprietà delle informazioni
A.3 Convenzioni e definizioni
A.4 Indicazioni generali
A.5 Indicazioni generali per le operazioni di riparazione
A General information
A.1 Manual use
A.2 Information property
A.3 Agreements and definitions
A.4 General description
A.5 Recommendations for repair operations
B INFORMAZIONI SULLA SICUREZZA
B.1 Indicazioni generali per la sicurezza
B.2 Simboli di sicurezza
B.3 Precauzioni generali
B Safety instructions
B.1 General safety recommendations
B.2 Safety symbols
B.3 General precautions
C CARATTERISTICHE GENERALI
C.1 Usi previsti
C.2 Identificazione del prodotto
C.3 Descrizione generale
C.4 Caratteristiche Tecniche
C.5 Cambio olio e verifiche
C.6 Coppie di serraggio
C General specifications
C.1 Foreseen uses
C.2 Product identification
C.3 General description
C.4 Technical Features
C.5 Oil change and checks
C.6 Tightening torques
D OPERAZIONI DI MONTAGGIO E SMONTAGGIO
D.1 Gruppo flangia
D.2 Gruppo riduttore epicicloidale
D.3 Gruppo mozzo ruota
D.4 Gruppo trombe trave
D.5 Freno e supporto differenziale
D.6 Gruppo differenziale
D.7 Gruppo pignone
D.8 Sbloccaggio freno parcheggio
D.9 Riattivazione freno parcheggio
D.10 Prove dopo montaggio
D Disassembly and assembly operations
D.1 Flange group
D.2 Epicyclic reduction gear group
D.3 Wheel hub group
D.4 Axle beam trumpets group
D.5 Brake and differential support
D.6 Differential group
D.7 Pinion group
D.8 Parking brakes release
D.9 Re-activating parking brakes
D.10 Testing after assembly
E RICERCA GUASTI
E.1 Controllo ed esame dei guasti
E.2 Diagnosi per problemi all’assale
E Troubleshooting
E.1 Troubleshooting
E.2 Axle problems and diagnosis
F ATTREZZATURE SPECIALI
F.1 Attrezzature speciali
F Special tools
F.1 Special tools
MH-439-1093 Auburn Gear Double Reduction Wheel Drives Service Manual

MECHANICAL ADJUSTMENT
29702 544D-10 Boom Maintenance & Repair Manual
Introduction
Safety
Nomenclature
Boom Assembly: Overview
Boom Wear Pad Adjustments
Boom-Extend and Retact Chains
Chain Removal and Reinstallation
Chain Inspection and Replacement
Hydraulic Sub-Assembly
Hydraulic and Electrical options
Major Boom Maintenance Procedures
Crowd Cylinder Removal/Reinstallation
Carriage Tilt Cylinder Removal/Reinstallation
Chain Roller Removal/Reinstallation
Removing the Complete Boom Assembly
Reinstalling the Complete Boom Assembly
Separating Boom Sections
Reassembling Boom Sections
Assembling Boom-Section 4
Assembling Boom -Section 3
Assembling Boom-Section 2
Assembling Boom-Section 1
Fastner Torque Chart
Hose Fitting Chart

MISCELLANEOUS
29903 Kenhar User Fork Wear Standards
0009 Rim & Wheel Safety Manual
9136-9012 Electrical Schematic
9155-9012 Electrical Schematic
F114004 Donaldson Cyclopac Service Procedure
81-460-047 Mico Hydraulic Power Brake Valve Service Manual
System Schematic
Representative Performance Data
Description & Operation of Power Brake Valve
External Dimensional Views
Installation of Power Brake Valve
Cross Sectional Views of Three Power Brake Valve Designs
Specification Chart
Primary Cup Design
Teflon Seal Design
Sliding Piston Design
Service Diagnosis
Bleeding

 

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JLG Gradall 544D-10 Materials Handler Maintenance and Service Manual.pdf

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