JLG GRADALL 544D Owner's/Operator's Manual
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JLG GRADALL 544D Owner's/Operator's Manual

Material handler
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Summary of Contents for JLG GRADALL 544D

  • Page 1 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com...
  • Page 2 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com...
  • Page 3 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 544D M ATERIAL ANDLER WNER PERATOR ANUAL COVERING OPERATION & PERIODIC MAINTENANCE IMPORTANT! Read and understand this Manual and the Gradall Material Handler Safety Manual before starting, operating or performing maintenance procedures on this machine.

  • Page 4: Important Safety Notice

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 1 2 3 4 5 6 IMPORTANT SAFETY NOTICE...
  • Page 5 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com REVISIONS This page is provided so you may determine that this Manual 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).

  • Page 6: Table Of Contents

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com TABLE OF CONTENTS IMPORTANT SAFETY NOTICE ............. inside front cover TABLE OF CONTENTS INTRODUCTION General Operator Qualifications Orientation Related Manuals & Decals Serial Number Location NOMENCLATURE SAFETY HIGHLIGHTS ...............

  • Page 7: Introduction

    Replacement manuals, decals and instruction plates can be ordered from your GRADALL Material Handler GRADALL IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT Distributor. BUILT BY THE JLG COMPANY 1 JLG DRIVE, McCONNELLSBURG, PA. U.S.A. Models Covered (WITHOUT...

  • Page 8: Safety Highlights

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com SAFETY HIGHLIGHTS Read and understand all manuals and instructional material listed on cover, inside WATCH FOR THESE SYMBOLS ; front cover and introduction page of this Manual before starting, operating or THEY CALL YOUR ATTENTION TO SAFETY NOTICES.
  • Page 9 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com Keep all windows and mirror(s) clean. Adjust mirror(s) as required for maximum visibility, before and during operation. WARNING Never permit diesel engine to run out of fuel. Doing so can cause severe engine damage.

  • Page 10: Decals

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com DECALS INSIDE THE CAB USE CAPACITY CHART FOR SPECIFIC ATTACHMENT ON MACHINE. FOR OTHER ATTACHMENTS CONSULT A GRADALL DEALER FOR LOAD RATINGS NOT LISTED. USE LARGEST NUMBER VISIBLE FROM THE CAB TO DETERMINE BOOM EXTENSION.
  • Page 11 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com SAMPLE ONLY - USE CHART IN CAB INSIDE THE CAB TRACTION LOCK SWITCH SWITCH LOCATED DO NOT ENGAGE ON FLOOR. SWITCH WHEN WHEELS ARE TURBOCHARGER DAMAGE CAN RESULT HYDRAULICALLY IN MOTION OR FROM QUICK START-UP &...
  • Page 12 Located on left side, front cab plate P/N 9114-3283 P/N 9116-4097 (enclosed cab) P/N 9116-4093 (open cab) GRADALL IS A REGISTERED TRADEMARK FOR HYDRAULIC EQUIPMENT BUILT BY THE JLG COMPANY 1 JLG DRIVE, McCONNELLSBURG, PA. U.S.A. 32,670 LBS (WITHOUT ATTACHMENTS)
  • Page 13 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com OUTSIDE THE CAB Located on valve access cover in cab Located on hydraulic reservoir P/N 9108-3492 Genuine Parts HYDRAULIC SYSTEM WHEN REPLACING COOLANT OR IN FILL WITH TRACTOR HYDRAULIC FLUID CASE OF COOLANT LOSS PURGE AIR BY OPENING DE-AERATION PETCOCK WHILE ENGINE IS RUNNING.
  • Page 14 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com OUTSIDE THE CAB COOLING SYSTEM EXHAUST SYSTEMS CAN BE HOT. IS PRESSURIZED. KEEP AWAY FROM EXHAUST SYSTEM WHEN HOT. REMOVE CAP SLOWLY. HOT EXHAUST COMPONENTS CAN CAUSE HOT FLUID CAN SEVERE BURNS.
  • Page 15 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com OUTSIDE THE CAB GRADALL HANDLER SERVICE INTERVALS SERVICE INSTRUCTIONS DAILY WEEKLY EVERY 3 MO. 6 MO. ANNUALLY TYPE OR FOR: 544D-10 5WKS OR EQUIVALENT 10 HRS 50 HRS 250 HRS 1000 HRS...

  • Page 16: Operators Cab

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com OPERATOR’S CAB OPERATOR’S CAB The standard cab permits vision from all sides and includes an overhead guard WARNING to provide protection from falling objects. Never operate the handler unless A fully-enclosed cab with windows and a lockable door is available as an option.
  • Page 17 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com Accelerator Pedal: Depress pedal to increase speed and release pedal to WARNING decrease speed. A brief description of controls and Alternator Indicator Light: Glows (red) to indicate alternator is not charging. instruments is provided here as a convenience for the operator.
  • Page 18 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com Parking Brake Indicator Light: Glows (red) to indicate brake is applied. Rotating Beacon Switch (optional): This switch controls operation of rotating beacon. Seat Lock Release Lever: This lever unlocks and locks seat position adjustment.

  • Page 19: Checks & Services Before Starting Engine

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com CHECKS & SERVICES BEFORE STARTING ENGINE To be performed at the beginning of each work shift. WARNING • If spark arrestors are required, be sure they are in place and in good working order.

  • Page 20: Warm-Up & Operational Checks

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com WARM-UP & OPERATIONAL CHECKS To be performed at beginning of each work shift. The safety, efficiency and service life of your handler will be increased by performing the operational checks listed below.

  • Page 21: Engine Operation

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com ENGINE OPERATION Starting the Engine 1. Make sure all controls are in “Neutral” and all electrical components (lights, WARNING heater, defroster, etc.) are turned off. Set parking brake. Operator must be seated with seat belt fastened, forward/reverse 2.

  • Page 22: Normal Engine Operation

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com Normal Engine Operation Observe gauges frequently to be sure all engine systems are functioning CAUTION properly. Always keep engine cover closed The voltmeter shows the “charge/discharge” state of the battery charging while engine is running.

  • Page 23: Brake System

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com BRAKE SYSTEM General The brake system includes a service brake and a parking brake. Service and parking brakes are applied through wet disc brake packs located within axle WARNING housing.

  • Page 24: Parking The Handler

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com PARKING THE HANDLER Precautions • Avoid parking on slopes or near an excavation. • Park on level ground and chock wheels. • Avoid parking on roads or highways. If it cannot be avoided,be sure to display warning flags during day and flares or flashing lights at night.

  • Page 25: Drive Train

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 10.0 DRIVE TRAIN General The Material Handler covered by this Manual is equipped with hydrostatic drive. From the operator’s standpoint, operation is similar to driving a vehicle equipped with an automatic transmission.

  • Page 26: Leveling The Handler

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 11.0 LEVELING THE HANDLER “Leveling” means positioning the handler so that it is level from side to side WARNING (left to right). Raising the boom (loaded or A level indicator is located in the upper right corner of front window frame to unloaded) when handler is leaning permit operator to determine whether handler frame level.
  • Page 27 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 11.1 Leveling Procedure: 1. Position machine in best location to lift or place load and apply parking WARNING brake. If handler cannot be leveled using 2. Observe level indicator to determine whether machine must be leveled. leveling system, do not attempt to Note position of indicator for later realignment.

  • Page 28: Operating Procedure & Techniques

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 12.0 OPERATING PROCEDURE & TECHNIQUES Hydraulic Controls NOTE! All boom and attachment movements are governed by hydraulic controls. Rapid, Much of the material in this jerky operation of hydraulic controls will cause rapid, jerky movement of the section may be new to even the load.

  • Page 29: Rated Capacity Chart

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 12.1 Rated Capacity Chart The rated capacity chart, located on dashboard, indicates maximum load WARNING capacities for handlers equipped with GRADALL-furnished carriage/fork combination. These capacities apply to standard carriage/fork combinations All loads shown on rated capacity except as stated on the capacity chart.
  • Page 30 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 12.2 Items needed to Use a Capacity Chart NOTE! There are five items you must know and/or have in order to properly use a Some attachments may not be Capacity Chart: approved for use with certain machine models.
  • Page 31 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 12.3 Figure 12-4 Where to look on the machine. BOOM ANGLE BOOM INDICATOR EXTENSION NUMBER ATTACHMENT FORK WEIGHT IDENTIFICATION PLATE STAMP MACHINE SERIAL NUMBER PLATE Figure 12-5 Description of items on a Capacity Chart.

  • Page 32: Attachments

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.0 ATTACHMENTS Approved Attachments Although the carriage/fork combination is most frequently used, several other GRADALL-approved attachments are available for use with your material handler. Contact your GRADALL Material Handler Distributor for information on approved attachments designed to solve special material handling problems.

  • Page 33: Attachment Installation

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.1 Attachment Installation WARNING This installation procedure is designed for one-man operation. If a helper is involved, shut off the engine before proceeding to steps 4, 5, and 6. 2.
  • Page 34 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.2 Fork Positioner Capacity: WARNING Maximum load capacity for fork positioner carriage is the same as standard carriage without fork positioner. Refer to Attachment Capacity Chart. PRECAUTIONS •...
  • Page 35 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.3 Operation: • Raise or lower boom to appropriate height for loading material from stockpile. • Align handler with face of stockpile and drive slowly and smoothly into pile to load bucket.
  • Page 36 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.4 Attachment Tilt Controls: Figure 13-4 WARNING SWING The carriage tilt cylinder is used to tilt the PRECAUTIONS LEFT swing forks up and down and the carriage •...
  • Page 37 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.5 • Tilt carriage to left or right to align forks with load and engage load. WARNING • Raise load slightly and then level carriage. A side load or a swinging •...
  • Page 38 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.6 Truss Boom & Truss Boom with Winch Capacity: Maximum capacity for the truss boom (with or without winch) is shown on WARNING attachment serial number plate. However, maximum lift capacity applies only to certain areas within boom extension/elevation pattern of handler/truss boom PRECAUTIONS combination.
  • Page 39 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.7 • Open clamps at heel of truss boom far enough to clear load and tilt truss boom up until truss/bundle contacts heel of truss boom. •...
  • Page 40 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 13.8 Personnel Work Platform WARNING The material handler operator and personnel in the platform must read and understand the separate personnel work platform manual, included Do not use the Personnel Work with the attachment, prior to using the platform.
  • Page 41 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 14.0 OBTAINING HYDRAULIC OIL SAMPLE 1. Operate unit until hydraulic oil reaches normal operating temperature. 2. Apply parking brake, lower boom to ground and shift Forward/Reverse lever to “Neutral.”...

  • Page 42: Loading & Securing For Transport

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 15.0 LOADING & SECURING FOR TRANSPORT Loading & Securing Handler For Transport WARNING 1. Level the material handler prior to loading. Before loading handler 2. Using a spotter, load the handler with boom as low as possible to keep a low transport, make sure deck, ramps center of gravity.

  • Page 43: Moving Handler In Emergency

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 16.0 MOVING HANDLER IN EMERGENCY The following information assumes the handler cannot be moved under its own power. Before moving the handler, read all of the following information to understand options available.

  • Page 44: To Release Parking Brake

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 16.1 TO RELEASE PARKING BRAKE MERITOR AXLE 1. Position unit on level ground, lower attachment to approximately one foot (.3m) from ground, move forward/reverse lever to “Neutral,” apply parking brake and stop engine.
  • Page 45 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 16.2 CARRARO AXLE 1. If possible position unit on level ground lower attachment to approximately one foot from ground, move forward/reverse lever to “Neutral”, apply parking brake and stop engine.
  • Page 46 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com...
  • Page 47 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 17.0 MAINTENANCE NOMENCLATURE Figure 17-1 STABILIZER FUEL HYDRAULIC CYLINDER TANK RESERVOIR SWAY CYLINDER STEERING STABILIZER* OPERATOR’S CLEANER AXLE STABILIZER SHOE BOOM-SECTION 2 REAR AXLE COMPENSATING STABILIZER BOOM-SECTION 3 BOOM-SECTION 1 CYLINDER...
  • Page 48 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 17.1 LUBRICATION & ROUTINE MAINTENANCE SYMBOLS Figure 17-2 = Lube Fitting = Other Service = Service Both Sides 2 3 4 5* 6 9 10 11 12 13 14 16* 17* 18* Lubrication Symbols IMPORTANT NOTICE...

  • Page 49: Lubrication And Maintenance

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com CAUTION Lube No. of Symbol Points 5 Week (or 250 Hour) Service intervals are based on machine usage of 1500 hours annually. Use of your unit may vary significantly and you must Lubrication &...

  • Page 50: Torque Chart

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 17.2 RECOMMENDED LUBRICANTS & CAPACITIES APPLICATION SYMBOL WHEN USED GRADE SPECIFICATION CAPACITY* Boom Chain Adj. Threads (extreme pres. moly lube) All Year 1440-3323 Boom Slide Bearing Paths (extreme pres.

  • Page 51: Boom

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com BOOM 17.3 CHECKING & ADJUSTING BOOM CHAINS Boom is extended by a cylinder and a set of chains within the boom. For more detailed information, including boom chain checks and adjustments, see the appropriate Service Manual.

  • Page 52: Inspection And Maintenance Log

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com 18.0 INSPECTION AND MAINTENANCE LOG Date Hourmeter Comments Reading...

  • Page 53: Hand Signals

    View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com HAND SIGNALS Standard Signals - When handler work conditions require hand signals, they shall be provided or posted conspicuously for the use of both signalman and operator. No handler motions shall be made unless signals are clearly understood by both signalman and operator.
  • Page 54 View thousands of Crane Specifications on FreeCraneSpecs.com View thousands of Crane Specifications on FreeCraneSpecs.com CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm. CALIFORNIA Proposition 65 Warning Battery posts, terminals and related...

This manual is also suitable for:

Gradall 544d-10

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