JLG GRADALL 544D Owner'S/Operator'S Manual Download Page 1

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Summary of Contents for GRADALL 544D

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Page 3: ...D 10 STARTING SERIAL NUMBER 0355001 thru 0455632 0160000192 thru 0160003968 excluding 0160003856 IMPORTANT Read and understand this Manual and the Gradall Material Handler Safety Manual before startin...

Page 4: ...345678901234567890123456789012123456 1234567890123456789012345678901212345678901234567890123456789012123456 1234567890123456789012345678901212345678901234567890123456789012123456 IMPORTANT SAFETY NOTI...

Page 5: ...is complete and current with respect to Gradall Engineering Specifications Page Date Revision 6 03 Original Issue replaces Owner Op Manual 9136 4024 Form 20047 Cover 01 07 Revised ending serial numbe...

Page 6: ...THE HANDLER 8 0 STEERING SYSTEM 9 0 DRIVE TRAIN 10 0 LEVELING THE HANDLER 11 0 OPERATING PROCEDURE TECHNIQUES 12 0 Hydraulic Controls Rated Capacity Chart ATTACHMENTS 13 0 Approved Attachments Non Ap...

Page 7: ...th your Distributor The model serial number plate is located inside the operator s cab right wall See Figure I 2 NOTE Material handler and handler are used interchangeably throughout this Manual Thoug...

Page 8: ...aveling in reverse and or turning Be aware of tail swing due to rear pivot steering If load or conditions obstruct view use a signal person when lifting carrying or placing a load Loose clothing can g...

Page 9: ...ropriate utility company has been contacted to de energize the lines Whenever leaving the cab perform standard shut down procedure Standard Shut Down Procedure Position the handler in a safe location...

Page 10: ...ECIFICATIONS ARE CRITICAL THE PROPOSED APPLICATION SHOULD BE DISCUSSED WITH YOUR DEALER DO NOT EXCEED RATED LIFT CAPACITY LOADS AS UNSTABLE AND DANGEROUS MACHINE CONDITIONS WILL RESULT DO NOT TIP THE...

Page 11: ...STARTING AID INSTRUCTIONS 1 HOLD SWITCH ON FOR 3 SECONDS TO FILL VALVE 2 RELEASE SWITCH TO DISCHARGE ETHER WHILE CRANKING ENGINE 3 AS ENGINE STARTS USE ADDITIONAL ETHER AS REQUIRED TO KEEP ENGINE RUN...

Page 12: ...ING PLACE FORWARD REVERSE LEVER IN NEUTRAL REST BOOM ON GROUND OR SUPPORT SET PARKING BRAKE SHUT OFF ENGINE AND CHOCK WHEELS 16 BEFORE LEAVING MACHINE UNATTENDED PLACE FORWARD REVERSE LEVER IN NEUTRAL...

Page 13: ...OR IN CASE OF COOLANT LOSS PURGE AIR BY OPENING DE AERATION PETCOCK WHILE ENGINE IS RUNNING 9114 3281 STAY CLEAR OF MOVING PARTS WHILE ENGINE IS RUNNING MOVING PARTS CAN CAUSE SERIOUS INJURY ADD CHEC...

Page 14: ...ARTING 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 BO...

Page 15: ...A DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB 9055 3033 ATTACHMENT SERIAL NUMBER WEIGHT CAPACITY HYD PRESSURE...

Page 16: ...variable speed defroster fan is available for use with enclosed cabs An On Off control switch and speed control are located on the base of the fan A heater fan is available for use with units equipped...

Page 17: ...Lift push lever fully forward for forward travel Lift pull lever fully backward for reverse travel Move lever to centered position for Neutral Fuel Gauge This gauge displays level of fuel in fuel tan...

Page 18: ...evers Left lever controls left stabilizer right lever controls right stabilizer Push levers forward to lower stabilizers pull levers back to raise stabilizers Starting Aid Switch optional on Cummins E...

Page 19: ...all required maintenance Replace or repair all damaged worn or missing components before starting or operating handler Failure to properly maintain handler could cause serious injury or death WARNING...

Page 20: ...travel 9 Horn and back up alarm 10 All boom and attachment functions operate fully and correctly 11 Hydraulic level sight gauge level handler retract all cylinders and check sight gauge for hydraulic...

Page 21: ...emperature gauge on engine will detect if ether is needed Follow normal start up procedure shown above Ether is employed and additional will be released if needed to keep engine running A second batte...

Page 22: ...for 3 to 5 minutes before turning it off This allows engine coolant and lubricating oil to carry excessive heat away from critical engine areas including turbocharger Do not gun engine before shut do...

Page 23: ...y brake and stopping distance will be greater Parking Brakes The parking brakes are spring applied and hydraulically released Hydraulic power to release parking brakes is provided by the hydraulic sys...

Page 24: ...ion 8 Lock cab and install protective covers if so equipped 9 Disconnect batteries if unit is in an area where tampering is a risk Rear wheel power steering is provided to reduce operator fatigue and...

Page 25: ...avel The lower portion of pedal travel actuates the service brake The greater the pedal travel the stronger the brake application Travel flow is further reduced when brakes begin to apply See Figure 7...

Page 26: ...t 1 2m from ground OR when such movement will not change the level condition of the handler Always determine best position for handler to raise load from its present location and also to position load...

Page 27: ...osition and level machine with the lever 4 Lift or place load as appropriate 5 Retract and lower boom to carry position 6 Realign frame to position noted in step 2 Frame Leveling Controls Figure 11 1...

Page 28: ...om raised above horizontal forks can be removed from a load by moving boom control joystick back and to the left until forks move rearward horizontally With boom lowered below horizontal forks can be...

Page 29: ...amage or in some cases cause the machine to tip over 12 1 WARNING All loads shown on rated capacity chart are based on machine being on firm level ground the forks being positioned evenly on carriage...

Page 30: ...you must check to be sure the correct model number is listed See figure 12 5 The next thing to look for is that the part number of your attachment is listed under the Use With section Identify and fi...

Page 31: ...numbers must match the Part No stamped on the attachment ID Plate Boom Extension Numbers Boom Angle Regions indicate the maximum weight that may be lifted Capacity Chart Part No shown on reverse side...

Page 32: ...carriage fork combination of lesser capacity is used the overall machine capacity is reduced to the capacity stamped on the carriage or forks whichever is less If a carriage fork combination of greate...

Page 33: ...nt location of load and delivery point Never attempt to transport a load across terrain which could cause handler to tip over 13 1 Always be certain that carriage or attachment is properly positioned...

Page 34: ...ip Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 2 Install light material bucket on boom head 3 Retract boom fully and tilt bucket up or do...

Page 35: ...with or without a load To travel with a load lower forks fully in mast and lower boom to position load 4 feet 1 2m or less above ground allowing for best visibility Use mast as required to increase v...

Page 36: ...ontrols carriage tilt The auxiliary control lever is used to tilt slope piler carriage Push lever forward to tilt carriage counter clockwise pull lever back to tilt clockwise Installation Procedure 1...

Page 37: ...o compensate for load swing Attachment Tilt Controls Figure 13 6 The auxiliary control lever is used to control the boom head mounted winch Pull the lever back to raise winch load push the lever forwa...

Page 38: ...oad Installation Procedure 1 Remove carriage fork combination or other attachment from boom head See Page 13 1 2 Install truss boom on boom head Operation If truss boom winch is furnished connect auxi...

Page 39: ...connect electrical cable at boom head Operation Always lower carriage fully in mast and position forks straight ahead before engaging load To travel with a load keep forks straight ahead and lower lo...

Page 40: ...k platform is based on specific model material handler work platform combination To determine maximum load capacity for given operating ranges consult the proper load capacity chart furnished with pla...

Page 41: ...to waste oil container to eliminate any contamination from hose 6 Move hose to CLEAN container to collect sample for analysis 7 Return hose to waste oil container and disconnect adapter from mini chec...

Page 42: ...sing chains through two tie down lugs on front and rear of machine See Figures 15 1 15 2 5 Do not lower stabilizers or tie down front of boom WARNING Before loading handler for transport make sure dec...

Page 43: ...rake See Page 16 1 MOVING LONGER DISTANCES If the handler must be moved more than 200 yards 182m it must be loaded on to a trailer of sufficient capacity TO ACTIVATE TOW BYPASS Figure 16 1 1 Shut down...

Page 44: ...l all three screws have been turned one full turn 360 approximately 50 ft lb 67n m Larger turns could cause components to bind and cause brake failure 6 Repeat this procedure on other side of differen...

Page 45: ...ned approximately five full turns Larger turns could cause components to bind and cause brake failure 6 Repeat this procedure on other side of differential Parking brake should be released TO RESTORE...

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Page 47: ...R R O T U STABILIZER CYLINDER SWAY CYLINDER HYDRAULIC RESERVOIR FUEL TANK STEERING AXLE AIR CLEANER OPERATOR S CAB STABILIZER STABILIZER SHOE FRONT DRIVE AXLE HIDDEN OPERATOR S CAB ATTACHMENT TILT CY...

Page 48: ...SYMBOLS Lube Fitting Other Service Service Both Sides LUBRICATION NOTICE Apply a light coating of engine oil to all linkage pivot points Clean lubrication fittings before lubricating Intervals shown...

Page 49: ...on Maintenance Check torque of all items listed in Torque Chart pg 17 2 5 Lube No of Symbol Points 5 Week or 250 Hour Lubrication Maintenance include all previous periodic services 2 Drive Axle Level...

Page 50: ...earing HM Paths extreme pres moly lube All Year NLGI 2 1440 4595 Boom Extend Chains CL chain lube All Year 1440 4751 Coolant Conditioner CC supplemental All Year 0 5 qts 0 48 L Deere Only coolant addi...

Page 51: ...ing stabilizers to support handler load on untested surface perform following procedure 1 With handler positioned to pick or deliver load and with load on ground or pick point lower stabilizers enough...

Page 52: ...Date Hourmeter Comments Reading INSPECTION AND MAINTENANCE LOG 18 0 View thousands of Crane Specifications on FreeCraneSpecs com View thousands of Crane Specifications on FreeCraneSpecs com...

Page 53: ...ard LOWER BOOM With either arm extended horizontally fingers closed point thumb downward EXTEND TELESCOPIC BOOM With both hands clenched point thumbs outward TILT FORKS UP With one arm held at side ex...

Page 54: ...lifornia to cause cancer birth defects and other reproductive harm CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to...

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JLG GRADALL 544D, Owner'S/Operator'S Manual

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