Lubrication And Maintenance; Boom Pivot; Fuel Filter/Water Separator With Drain; 6. Planetary And Differential Drain Plugs - JLG GRADALL 544D Owner's/Operator's Manual

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Service intervals are based on machine usage of 1500 hours
annually. Use of your unit may vary significantly and you must
adjust service frequency for your usage to obtain maximum
service life. Frequency headings in the following schedule indicate
a calendar limit and an operating hour limit. Perform service at
whichever interval occurs first.
Daily or Shift (10 hour Maximum)
Lubrication & Maintenance
9. Fuel Filler Cap (fill at end of work shift to
minimize condensation)
10. Hydraulic Return Filter Condition Indicator
(check with oil at normal operating temperature
and engine running at full throttle - replace
element before by-pass indication is reached
or at least annually)
11. Hydraulic Suction Filter (replace filter element
when return filter element is replaced)
13. Hydraulic Level Sight Gauges (level handler,
retract all other cylinders and check sight
gauges - refill as required)
21. Air Cleaner Element Condition Indicator (check
for clogged condition (red band showing) and
clean or replace element as required - item 28
is air cleaner) Note: If equipped with safety
(small) element, change it every 3rd change
of primary (large) element.
34. Engine Crankcase Dipstick (level handler and
check level - refill as required - item 36 is
filler cap)
Weekly (or 50 Hour)
Lubrication & Maintenance
(include all previous periodic services)
1. Stabilizer Cylinder Pivots
4. Sway Cylinder Pivots
7. Battery (check terminals)
8. Tires:
Standard: 14.00 x 24, 12 ply - 65 PSI (448 kpa)
Optional: 14.00 x 24, Radial - 70 PSI (482 kpa)
15. Tie Rod Ends
16. King Pins
17. Steering Cylinder Rod Pivots
18. Steering Cylinder Barrel Pivots
19. Stabilizer Arm Pivots
20. Front Axle Pivot
22. Rear Axle Pivot
23. Carriage Tilt Cylinder Pivots
24. Boom Bottom Front Slide Bearings (extend
boom fully and lube all wear paths - retract
and extend boom fully three times and wipe
excess lube from bearings)
26. Extend Chain Sheave Pin
30. Boom Lift Cylinder Pivots
31. Boom Head/Carriage Pivot
32. Radiator Fill Cap (check level and refill as
required)
37. Compensating Cylinder Pivots
38. Retract Chain Sheave Pivots
39. Boom Pivot
40. QuickSwitch Latch
44. Fuel Filter/Water Separator with Drain
(drain water)
At End of First 50 Hours Only
5. /6. Planetary and Differential Drain Plugs
(drain and refill - wait 5 minutes and fill
again - item 2 is level plug)
At End of First 30 Days Only
(250 Hours Maximum)
Lubrication & Maintenance
• Check torque of all items listed in Torque Chart (pg 17.2)
DETAILED SERVICE INSTRUCTIONS ARE CONTAINED IN THE GRADALL SERVICE
Form No. 20220 544D-10 Owner/Operator Manual
!
CAUTION
Lube
Symbol Points
DF
-
-
HF
-
EO
HM
HM
-
-
HM
HM
HM
HM
HM
HM
HM
HM
HM
HM
HM
HM
AF
HM
HM
HM
HM
-
HF
MANUAL FOR YOUR PARTICULAR MATERIAL HANDLER
5 Week (or 250 Hour)
Lubrication & Maintenance
(include all previous periodic services)
2. Drive Axle Level Plug (check level and refill as
required)
No. of
12. Hydraulic Reservoir Breather Cap (check and
clean or replace cap as required)
24. Boom Bottom Front Slide Bearings, to be
performed by experienced maintenance person
- check for damage and excessive wear - no
1
wear permitted past bevel - maximum clearance
at top bearing is 1/8 inch (3mm), shim or
replace as required; when these bearings
require service, check all other slide bearings
- shims are 1/16 inch (1.5mm) thick
1
25. Boom Top, Side and Bottom Rear Slide
Bearings (extend boom fully and lube all wear
1
paths - retract and extend boom fully three
times and wipe excess lube from bearings)
29. Vacuator Valve (rubber cone on bottom - check
1
to be sure cone is clear and undamaged)
33. Engine Oil Filter (replace filter element)
41. Drive belts (check condition - replace as
required)
42. Engine Crankcase Drain Plug (drain and refill
to level)
1
45. Rear Hub Level Plug (check level and refill
as required)
• Check torque of all items listed in Torque Chart (pg 17.2)
1
Quarterly (or 500 Hour)
Lubrication & Maintenance
(include all previous periodic services)
12. Hydraulic System (we recommend that
hyd fluid be analyzed to determine condition
4
- drain and refill reservoir if required)
2
14. Hydraulic Reservoir Screen (remove, clean
1
and install when hydraulic oil is drained)
4
27. Boom Extend Chains (check for proper switch
adjustment & adjust or replace as required)
2 35. Fuel Strainer (replace)
44. Fuel Filter/Water Separator with Drain (replace
4
filter element)
2
2
Semi-Annual (or 1000 Hour)
4
2 Lubrication & Maintenance
2
(include all previous periodic services)
2
3. Front Axle Breather (clean or replace)
5./ 6. Planetary and Differential Drain Plugs (drain,
fill to level, wait 5 minutes and fill to level
again - item 2 is level plug)
6
12. Hydraulic Reservoir Breather Cap
3
(clean or replace)
4
27. Boom Extend Chains (ext boom & lube chains)
2
46. Rear Hub Drain Plug (drain and refill - item
47 is fill plug)
1
2
Annual (or 1500 Hour)
2
Lubrication & Maintenance
2
(include all previous periodic services)
1
10. Hydraulic Return Filter (replace filter element)
11. Hydraulic Suction Filter (replace filter element)
1
12. Hydraulic System (unless fluid is analyzed
quarterly to determine degree of contamination,
reservoir must be drained and refilled on an
annual basis)
14. Hydraulic Reservoir Screen (remove, clean
3
and install when hydraulic oil is drained)
32. Engine Cooling System (drain, flush and refill
on basis of period suggested by anti-freeze
manufacturer and add Liquid Coolant Additive
if equipped with Deere engine)
Lube No. of
Symbol Points
HF 1
- 1
HM 6
HM 36
- 1
- 1
- 1
EO 1
HF 2
HF 1
- 1
- 3
- 1
- 1
- 1
HF 1
- 1
CL 3
HF 2
- 1
- 1
HF 1
- 1
AF/CC 1