Gradall 544D (9136-4003) Service Manual - Manual (Page 301)

This Manual covers maintenance and repair procedures on the boom assembly of
GRADALL 544C-10 and 544D MATERIAL HANDLERS. Components are referenced in full
in the relevant Parts Manual. Mechanical adjustments, repair, replacement, removal and
reinstallation of components are covered. Hydraulic system and operations are not
discussed. Refer to appropriate Manuals for this information. Areas requiring special
attention are highlighted with appropriate annotations.
Read and understand this Manual, along with the appropriate Owner/Operator Manual,
the EMI Rough Terrain forklift Safety Manual, the Gradall Material Handler Safety Manual
and all instructional decals and plates before starting, operating or performing mechanical
adjustments and maintenance procedures on this equipment. Keep Operator and Safety
Manuals in the operator’s cab.
T ESTING & A DJUSTING P RECAUTIONS
Whenever a hydraulic hose is tightened, two wrenches must be used; one to tighten the
hose, the other to hold it from twisting. Hoses must lie and roll free of stress.
Refer to the safety decals on the machine and in the relevant Owner/Operator
Manual before attempting any repair or adjustment.
If you are working with someone else, make sure they fully understand the procedure.
Make sure each of you knows what to expect and when to expect it. Make sure each
of you knows where the other is at all times.
Always remove the ignition keys before allowing a repair or adjustment to be
performed that requires reaching into or climbing on the machine.
Be sure you understand all steps of the procedure before you commence. Follow the
procedure carefully.
Clean up oil spills immediately. Slippery surfaces can cause serious accidents.
O RIENTATION
When used to describe the location of machine components, “front rear”, “left”, and
“right” indicate the point of view of a person sitting in the operator’s seat in the cab.
F ASTENER AND F ITTING T ORQUE
Torque values for mechanical fasteners and hydraulic fittings are given in Appendix A and
Appendix B. They must be adhered to of all times. LOCTITE 242 must be used on all bolt
threads. LOCTITE 545 must be used on all hydraulic fittings.
S PECIAL N OTE: W ELDING
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NTRODUCTION
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CAUTION
Gradall strongly advises against conducting welding repairs. If you
determine that welding on the machine is necessary, first consult
the Gradall Service Department.
GRADALL GRADALL