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

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This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the 544D-10 JLG Gradall 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 544D-10 JLG Gradall 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.

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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
            
    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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