Gradall 544B Operation Manual User Manual

Page 35

Item

Daily (or 10 Hour) Lubrication & Maintenance

(Service at whichever interval occurs first)

Air Cleaner Element Condition Indicator (check for
clogged condition (red band showing) & clean or
replace element as required)

Engine Crankcase Dipstick (check level & refill
as required - item 18 is filler cap)

Transmission Dipstick (check level & replenish as
required)

Hydraulic Filter Condition Indicator (check indicator
with oil at normal operating temperature and engine
running at full throttle - replace filter element before
by-pass indication is reached or at least annually)

Hydraulic Reservoir (level handler, retract
all other cylinders & check dipstick - refill as
required)

Fuel Filler Cap (fill at end of workshift to minimize
condensation)

Weekly (or 50 Hour) Lubrication & Maintenance

(Service at whichever interval occurs first)

(includes all previous services)

Carriage Tilt Cylinder Pivots

Deleted

Front Extend Sheave Pin

Boom Head/Carriage Pivot

Outrigger Cylinder Anchor Pivots

Boom Front Bottom Slide Bearings (extend boom fully
and lube all wear paths - retract and extend boom fully
three times and wipe excess lube from bearings):

Tires (check for damage & proper pressure)
Front Standard: 14.00 x 24, 12 ply - 65 psi
Rear Standard: 14.00 x 24, 12 ply - 55 psi
Front Optional: 17.50 x 25, 14 ply - 65 psi

Leveling Cylinder Pivots

Carriage Tilt/Machine Level Lever Pivots

Fuel/Water Separator (drain water)

Boom Hoist Cylinder Pivots

Compensating Cylinder Pivots

Boom Pivot

Rear Extend Sheave Pin

Quick Switch Latch

Outrigger Cylinder Rod Pivots

Outrigger Beam Pivots

Battery (check electrolyte level & refill as req’d)

Radiator Fill Cap (check level & refill as required)

Tie Rod Ends

King Pins

Steering Cylinder Pivots

Front Axle Pivot

Accelerator Pedal Pivot (under cab)

Brake Pedal Pivot (under cab)

Boom Lever Linkage (under cab)

Rear Axle Pivot

At End of FIRST 30 Days Only

Check torque of ALL ITEMS listed in Torque Table
(page 31)

Service Brake Housings (drain and refill to level)

5 Week (or 250 Hour) Lubrication & Maintenance

(Service at whichever interval occurs first)

(includes all previous services)

Boom Front Top & Side Slide Bearings (extend boom
fully and lube all wear paths - retract & extend boom fully
three times & wipe excess lube from bearings):

Item

5 Week (or 250 Hour) Lubrication & Maintenance (Cont.)

Boom Rear Slide Bearings lube paths):

Boom Front Bottom Slide Bearings (to be performed by
experienced maintenance person-check for damage,
and excessive wear - none permitted past bevel -
shim or replace as required; when these bearings
require service, check all other slide bearings; shims are
11/16" thick):

Air cleaner Vacuator Valve (rubber cone on bottom
check to be sure cone is clear and undamaged)

Engine Oil Filter (replace at 250 Hours):

Engine Crankcase Drain Plug (drain & refill to level at 250
Hours)

Drive Belts (check condition & tension-replace or adjust
as required)

Service Brake Housings (check level & refill as required)

Front Planetary Hub (check level & refill as required)

Hydraulic Reservoir Breather Cap (check & clean or
replace as required)

Rear Hub (check level & refill as required)

Drive Axle Differential Level Plug (check level & refill
as required)

Drive Shaft Universal Joints

Drive Shaft Spline

Check torque of ITEMS INDICATED in torque table
(page 31)

Quarterly (or 500 Hour) Lubrication & Maintenance

(Service at whichever interval occurs first)

(Includes all previous services)

Fuel/Water Separator (replace element at 500 hours)

Fuel Filter (replace element at 500 hours)

Hydraulic System (were commended that hydraulic fluid
be analyzed to determine condition - drain & refill
reservoir if required)

Hydraulic Reservoir Screen (remove, clean & install
when hydraulic oil is drained)

Fuel Strainer (replace element at 500 hours)

Transmission Filter (replace)

Check torque of ITEMS INDICATED in torque table
(page 31)

Semi-Annual (or 1000 Hour) Lubrication & Maintenance

(Service at whichever interval first)

(includes all previous services)

Transmission Drain Plug (drain and refill to level)

Transmission Screen (clean)

Front Axle Differential Drain Plug (drain and refill to level)

Service Brake Housings (drain & refill to level)

Front Planetary Hubs (drain and refill to level)

Front Axle Breather (clean or replace)

Rear Hubs (drain & refill to level)

Transmission Breather (clean)

Annual (or 1500 Hour) Lubrication & Maintenance

(Service at whichever Interval first)

(includes all previous services)

Hydraulic Filter (replace element)

Hydraulic System (unless fluid is analyzed quarterly to
determine degree of contamination reservoir must be
drained & refilled on annual basis - also clean or replace
breather cap)

Hydraulic Reservoir Screen (remove, clean & install
when hydraulic oil is drained)

Engine Cooling System (drain, flush & refill on basis of
period suggested by anti-freeze manufacturer)

Lube No. of

Symbol Points

3 3

13.

17.

26.

37.

38.

41.

10.

12.

14.

19.

20.

21.

22.

23.

24.

25.

35.

42.

43.

44.

46.

47.

51.

53.

55.

56.

32.

Lube No. of
Symbol Points

11.

16.

29.

30.

32.

33.

38.

45.

48.

49.

50.

14.

15.

38.

39.

40.

52.

27.

28.

31.

32.

33.

34.

45.

54.

36.

38.

39.

42.

ATF

-
-
-

2
2
2

ATF