Gradall 544D (9136-4003) Service Manual User Manual
Service manual
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®
544D-10
9136-4003
April 30, 2007
Starting Serial No.
0355001 thru 0455362
®
®
SERVICE MANUAL
CORPORATE OFFICE
JLG INDUSTRIES, INC.
1 JLG DRIVE
McConnellsburg, PA
17233-9533
USA
Telephone: (717) 485-5161
Fax: (717) 485-6417
GRADALL DIVISION
JLG INDUSTRIES, INC.
406 Mill Avenue S.W.
New Philadelphia, OH
44663
USA
Telephone: (330) 339-2211
Fax: (330) 339-8458
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Table of contents
Document Outline
- 9136-4003 544D-10 SERVICE MANUAL
- 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
- 20220 544D-10 Owner/Operator Manual
- 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
- 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
- A INFORMAZIONI GENERALI
- 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
- 29702 544D-10 Boom Maintenance & Repair Manual
- 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
- OPERATION & LUBRICATION