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Service 2460-4129

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1. 31 Install Differential Housing Assembly into Main Housing With 5 32 Install Differential Housing Assembly into Main Housing With Adjusting Ring 2 Sides 33 ASSemble AXIG S DTE uuu anan kashay dpi Ub e no rob Lao oe ca rv Saca 34 Assemblie TU MND CE ASS SIN east adobe a cede cet d bem a m a a ec 35 Table of Contents MERITOR Assemble Hydraulic Apply Brake Housing Assembly 1 menn 38 Hydraulic Apply Brake Housing Functional Test Assemble Three Function Brake Housing Assembly nrnna 39 Assemble Ball and Ramp Brakes Brake Discs Reaction Plate and 42 Assemble Three Function Brake Brake Discs Reaction Plate and Pins 43 Install Housing Assembly into Main Housing Assemble Three Function Brake Release Bolts and Sleeves 44 Assemble Ball and Ramp Brake Cylinder Assembly and Install on Main Housing Section 5 Adjustments Check Ring Gear Runout Specification 0 008 in 0 20 47 Adjust Pinion and Ring Gear Backlash Specification 0 005 in 0 015 in 0 13 mm 0 38 mm Teeth Contact P alteris ee e
2. 4X4 FWD L REV c C Bow FORWARD REVERSE VALVE CLT TMP OIL GAG PS IGN C ha CLT TMP OIL GAG KL ALT EXC B ALT EXC A PRK BRK START C START B C CC PRK IGN AER i ALT EXC FUL GAG START C PS ION ALT EXC B eo Qo lt gt cn EN eO gt gt M N P 2 HR MTR _ BAT GND 3 nm EE c gt E PB LHT OPEN mE OPEN ND EN UU gt pases PARK BRAKE LIGHT ALT EXC A SPL ACC SPL ACC 2 A START C STRT SOL uu STARTER 9 RELAY B STRT SOL BATTERY x E m 4000 SNSR STARTER MOTOR STARTER SOLENOID GN FUL SOL OIL GAG OIL PRESSURE GAUGE FUEL SOLENOID 403 oS d PS HR OIL PRESSURE SWITCH ON ENGINE ALT BAT ALT EXC B 1 ALTERNATOR BATT 2 SNSR ALT EXC B ALTERNATOR WARNING LIGHT 80 RESISTOR DESIGNATION COLOR STRIPE GAGE ORANGEZTaN 18 ORANGE BLUE 16 ACC C 16 ALT RED TE 6 ALT EXC A VIOLET RED 16 VIOLET RED VIOLET RED 16 mme ei CLT TMP BLUE VIOLET 16 ES VIOLET 16 BROWN WH 1 Bar re GND 2 BLACK 16 60 BLACK 446 a js GND
3. SIGHT GAUGE Form No 29633 3 97 1 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL Hydraulic Filter Condition 0000000 Reason for Hydraulic Filter Condition Check Dirty suction filters can restrict oil flow to the charge pump This can lower control pressure which can affect the machine s ability to move especially when ambient temperature is under 32 F Change the hydraulic filters if they have more than 1 000 hours on them To check hydraulic filter condition warm the hydraulic system oil to operating temperature minimum 100 F Check the filter restriction indicator on the return filter The indicator should not show filter bypass with the engine at full throttle and the park brake engaged If it shows bypass replace the suction and return filters Use hydraulic filter P N 9114 3144 for both suction and return filters See Figure 3 Only GRADALL supplied filters meet or exceed the filtration requirements of the drive system If any other type of filter was installed change it to o GRADALL filter and sample oil for condition Failure to use GRADALL filters may void warranty FIGURE 3 HYDRAULIC RESERVOIR ASSEMBLY SUCTION FILTER RETURN FILTER INSIDE VIEW OF RESERVOIR Form No 29633 3 97 2 Engine Speed _ 00000 Reason for Engine Speed Check Low engine RPM can reduce control pressure Control pressure determines machine speed This condition can slow machine speed at full RPM
4. s REAR E Hy MEC PRIORITY MOTOR 25 2 FLOW DIVIDER E ee eee ee F R 3 SECT ION B SON 8 N u 9 4 ime s X OKT NZ TX E 3 6 WE LER LA I o PARK BRAKE p R 1j 72 PS FA MB SOLENOID VALVE S DA eat l l l ry T Mey FLUSHING 2E f o REY A VALVE SECTION 23 DIC CIT n 220 HAL REAR PSI 2 ga B DRIVE x AE SIN S MOTOR BRAKE SYSTEM PUMP Bia NI ee 1 2 CU IN REV ed aal N M i l babe 4 700 PSI ve E S 380 480 1 Tx M 4 Fd 111 x21 G ST t 4 FRONT DRIVE MOTOR DA CONTROL i DRIVE PUMP DA CONTROL OUTRIGGER gt COMPENSAT I NG VALVE CYLINDER lt T 062 IC lt r 4 lt i AUX 9 was gt amp OPTION M gate l RIGOER CYLINDERS SWAY n SUCTION ro FILTER C RETURN 50 50 gt ro FILTER PS12 Lj Bg 75 CROWD e L PSI FILLERZ a j LII gt gt gg BREATHER LIFT LI 100 nnd TRACT ION LOCK E hi oka is VAL VE Le 2 1 RESERVOIR 2 n
5. GRADALL SERVICE MANUAL GRADALL 534C 9 534C 10 2460 4129 July 2002 534C 9 Starting S N 0344394 thru 0444002 534C 10 Starting S N 0266057 thru 0266106 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES INC JLG INDUSTRIES INC 1 JLG DRIVE 406 Mill Avenue S W McConnellsburg PA New Philadelphia OH 17233 9533 44663 USA USA Telephone 717 485 5161 Telephone 330 339 2211 Fax 717 485 6417 Fax 330 339 8458 JL GRADALL OWNER OPERATOR MANUAL GRADALL 934 C 9 534C 10 2460 4171 July 2002 534C 9 Starting S N 0344394 534C 10 Starting S N 0266057 Form 20042 Original Issue 3 01 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES INC JLG INDUSTRIES INC 1 JLG DRIVE 406 Mill Avenue S W McConnellsburg PA New Philadelphia OH 17233 9533 44663 USA USA Telephone 717 485 5161 Telephone 330 339 2211 Fax 717 485 6417 Fax 330 339 8458 GRADALL MATERIAL HANDLERS 534 9 534C 10 MATERIAL HANDLER OPERATION amp LUBRICATION MANUAL m Mi T il 7 LAI IMPORTANT Read and understand this manual the Gradall Material Handler Safety Manual and the EMI Rough Terrain Forklift Safety Manual before starting operating or performing maintenance procedures on this machine KEEP THESE MANUALS IN CAB AVERTISSEMENT Si vous ne lisez pas l Anglais demandez a votre surveillant de vous donner les instructions de securite ATENCI N Si n
6. LE FORK FACE FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL RATED LIFTING CAPACITIES SHOWN ARE WITH MACHINE ON A FIRM LEVEL SURFACE WITH UNDAMAGED PROPERLY INFLATED TIRES MACHINE SPECIFICATIONS AND STABILITY ARE BASED OM RATED LIFT CAPACITIES AT SPECIFIC ANGLES AND BOOM LENGTHS IF SPECIFICATIONS ARE CRITICAL THE PROPOSED APPLICATION SHOULD BE DISCUSSED WITH YOUR DEALER DO HOT EXCEED RATED LIFT CAPACITY LOADS AS UNSTABLE AND DANGEROUS MACHINE CONDITIONS WILL RESULT DO MOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD CAPACITY LIMITS FOR THIS UNIT ARE BASED ACCORDANCE WITH ASME 656 6 1997 LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT Numbers at left side of sample chart 4 to 44 represent elevation to top of horizontal fork as measured from level ground Elevation relates to dimension shown on serial number plate located on right cab wall 22 Extension Numbers across bottom of sample chart 0 to 28 and numbers parallel to boom 1 to 5 represent boom reach as measured from front of tires to extended position Number decals on boom 1 2 3 4 amp 5 relate directly to boom extension The largest number which can be read from operator s seat indicates total boom extension and must be matched with boom angle to determine capacity Boom extension relates to dimension D shown on serial number plate Boom Angle Numbers shown at ends
7. kj La N TZ Lii i Yee Pon ES N IM x Y x EAS ta z d Mb PORT DEL LJ B M gt Form No 29633 3 97 17 534C 9 amp 534C 10 HYDROLASTIC DRIVE PERFORMANCE CHECKS MANUAL VIII Front Motor Begin Point continued FIGURE 19 FRONT DRIVE MOTOR SIDE VIEW G PORT BEGIN POINT ADJUSTMENT A NOT SHOWN M PORT OPPOSITE SIDE For our application this drive motor is utilized in a 180 degree inversion Form No 29633 3 97 18 EURO eee Reason for Drive Pump Pressure Check Drive pump pressure determines the drive power of the machine Low drive pressure will result in less power Install a high pressure gauge 10 000 PSI hose and adapter on the MA port located at the bottom of the drive pump Apply the park brake and put the 2WD 4WD switch in the 2WD position Move the shift lever to the forward position and run the engine at full throttle 2500 2700 RPM The gauge reading should be 6 300 PSI Adjust the POR valve located on top of the pump as necessary To adjust this relief valve loosen the lock nut and turn the adjusting screw clockwise to increase pressure and counterclockwise to decrease pressure Move the gauge to the MB port of the drive pump to repeat the procedure with the shift lever in the reverse position See Figure 20 and Figure 20A There are also high pressure anti cavitation relief valves on the drive pump These could influence drive
8. TEWPERATURE db CLEAM M ALETE CTA CLEAM OR db CONSULT OEALER FOR POCO MCATPOMT AT EXTR PDA TAY ik a ii Pe SS RIED FO LITE ac i3 GOCE THAT FILTER br m ABO FO LUERITCAMT Fai BO Dee UNITS SEWERLTT Fo AFTER Located on Mud Guard Part No 9 14 3219 Optional Equipment Decals ach aw Wow PLA OMIO ATTACHMENT SERIAL NMER WEIGHT CAPACITY HYD PRESSURE U ae COMBINATION MAY oF Located Attachment Part 9015 3001 Located on Joystick Pedestal Located on Instrument Console B Part No 9108 3341 Part No 9130 3041 AUXILIARY CONTROLS LEVER OPERATION LEFT DOWN GRADALL ATTACHMENT SERIAL NUMBER WEIGHT CAPACITY 7 HYD PRESSURE j DO NOT USE PERSONNEL WORK PLATFORM WITHOUT THE PROPER GRADALL HANOLERJPERSONNEL WORK CHART DISPLAYED 9055 3033 AUXILIARY CONTROLS LEVER BUTTON OPERATION FUNCT IONS MAST SIDE SHIFT RIGHT UP 3103 3417 Located on personnel work platform Part No 9055 3033 Located on Instrument Console Located on instrument console Part No 9108 4210 Part No 9103 3394 rk plat MAXIMUM OCCUPANCY THREE 3 PEOPLE presume vm Form DO NOT USE PERSONNEL WORK PLATFORM Par
9. 10 Section 3 Prepare Parts for Assembly Clean Ground POSE Pare nu tenes 13 Clean Parts With Rough Finish Clean Axle Assemblies Dry Cleaned Parts Prevent Corrosion Inspect Parts Inspect u uusha 14 INSPECU YV0OIG PMO RNO 66156 uu u t ecc en O 15 Inspect Main Differential Assembly Inspect Axle Shafts IASDECE MaIN HOUSING cuca k uuu u u L nat Adan 16 Inspect Yoke Inspect Planetary System Parts Inspect Brakes Repair or Replace Parts Repair Welding Ce Stas UTE 17 Disassemble Locked Sets Cleaning Reassembly Application SINC ONG GasketMal ellal uyu su ala be a a 18 Duo Cone Oil Seal Mount and Install Section 4 Assembly and Installation Assemble Differential P c HERR cU a 23 Check Rotating Resistance of Differential Gears Not Limited Slip m 26 AsSsempble Drive Pinion ana Bearing resa ica ra Ln cn n D dn E 27 Adjust Pinion Bearing Preload Without Press sss 28 Adjust Thickness of Pinion Bearing Cage Shim Pack Depth of PINION 29 Install Pinion Bearing Cage Assembly on Main
10. Fit NING 5 SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES Note If two washers were installed under the head of the pad mounting bolts and a shim was added it is imperative that one washer be removed Otherwise the bolt will not secure the pad nut properly ADJUSTMENT PROCEDURE Area 3 amp 4 Pap Locanow E amp F Inspection 1 Retract the boom assembly within ft of full retraction 2 Raise the boom assembly approximately 30 so that the weight of the assembly will force the boom package to rest against the bottom plate at the rear 3 M the rear of the boom use a feeler gauge to check the bearing pad clearance between Boom Sections amp 2 and Boom Sections 2 amp 3 at Area 3 and the top of Area 4 Pad Location F Visually check pad location F at this time Pad Location E Right Outside FE 4 Lower and extend the boom until Boom Section 3 Area 4 and all pad locations SEE NOTE ON PAGE 2 0 FOR BOOM clear the access holes in Boom Section 2 by at least ft BEARING PAD BOLT QUANTITIES 5 Using a feeler gauge check the pad clearance for Area 4 Pad location F It may be possible for a boom to show the pad clearance when fully retracted and no pad cdearance when extended pad cdearance is evident when extended do not add shims at this fime 6 If there is more than x shims must be installed to bring the boom into tolerance Note Shim pack levels should be equa
11. Boom Secion 2 ASSEMBLY Clean the work area Gather and identify parts to be used IF working with a helper be certain each of you knows your individual assignments Procure proper lifting tackle to safely lift and install components to each other Use stanchions of sufficient capacity to hold Boom Sections 1 amp 2 Be certain the work area hos sufficient space to work safely Assembly Area 1 s 2 Front Inside Stage 1 Boom Weldment Bearing Pads Pad Location Place Boom Section 2 upside down on stanchions Clean the inside and outside of Boom Section 2 thoroughly Lubricate the inside of the boom at the bearing slide path area Install Boom Section 3 into Boom Section 7 Install through the front of Boom Section 2 Ju E 5 Install bearing pads spacers and shims to the rear boom Area 3 and front boom Area 2 Do Not install pads to locations F and yet This will make insertion into Boom Section easier 6 Install bearing pads spacers and shims at Pad Location F See Section 6A Boom Section 3 Assembly Stage Step 4 page 6 1 i Arrea 3 Boom Section 2 Rear Outside v Pad Location B amp D SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES Pad Location F amp No 19906 532 534 MAINTENANCE Ao Stage 1 Retrad Cable and Hose Sheaves 532 6 534C 6 amp 5340 6 ONLY 1 Install the retraction cable sheav
12. N gt hg 0 4 2 Section 6 MERITOR Specifications Torque Chart PROA 352 382 DESCRIPTION THREAD Pinion Nut M24 x 1 5 6H 465 570 lb ft 630 775 Nem Nut Stud Center Housing M14 x 1 5 6H 120 150 lb ft 160 205 Nem Capscrew Differential Case M10 x 1 5 8G 48 64 lb ft 64 87 Nem Capscrew Spiral Gear M10 x 1 0 6G 66 75 90 100 Nem Capscrew Pinion Cage M12 x 1 75 8G 67 91 91 120 Nem Capscrew Lock Adjuster Ring M6 6G 80 115 Ib in 9 0 13 0 Nem Capscrew Adjusting Nut Lock M8 x 1 25 6G 17 23 lb ft 23 30 Nem Capscrew Brake Housing M8 x 1 25 6G 19 26 lb ft 26 36 Nem Capscrew Brake Releaser M12 x 1 75 6G 25 34 Ib ft 34 46 Nem i Capscrew Flange Adapter 3750 x 16UNC2A 39 0 53 0 Ib ft 53 72 Nem Capscrew Center Housing Cover M8 x 1 25 6G 20 27 lb ft 27 36 Nem Capscrew Axle Shaft Flange M20 x 1 5 6G 470 575 635 780 Nem Drain Plug 35 Ib ft 47 Nem Grease Fitting 31 40 Ib in 3 5 4 5 Nem Vent Plug 15 lb ft 20 Nem Level Plug 35 lb ft 47 Nem Capscrew Planetary Pinion Axle M10 x 1 5 6G 17 23 Ib ft 23 31 Nem Bolt Action Plate M6 x 1 5 6G 120 140 Ib in 13 5 16 0 Nem Capscrew Return Spring M6 x 1 0 6G 80 115 Ib in 9 0 13 0 Nem 55 gt MERITOR Section 6 Specifications PRA 352 Trumpet Variation No 2 o 56 Section 6 MERITOR Specifications Torque Chart PRA 352 D
13. With a manual press on brake housing apply pressure to brake piston until the springs compress Make sure oil seals fit in bores Figure 4 60 41 Section 4 Assembly and Installation 14 With piston still compressed apply 350 psi 24 bar into parking brake to make sure oil seals fit in bores Figure 4 61 Figure 4 61 350 PSI 24 BAR n IC E 15 Keep the parking brake under 350 psi 24 bar pressure and remove the manual press and guide pins 16 Apply medium torque liquid adhesive Loctite 241 or Three Bond 1334 to return spring holes and bolt threads Install return springs washers and return spring bolts into brake housing Tighten bolts to 80 115 Ib in 9 13 Nem Figure 4 62 uU Figure 4 62 SPRING NOTE Use same procedure to install other brake piston assemblies into main housing 42 gt e MERITOR Assemble Ball and Ramp Brakes Brake Discs Reaction Plate and Pins 1 Install sun gear Figure 4 63 Figure 4 63 NOTE After assembly friction disc lubrication holes must be perfectly aligned 2 Install friction and stationary discs alternately Make sure friction disc is against brake piston 3 For ball and ramp brakes discs must be installed alternately and a friction disc must be on each side of the expansive plate Figure 4 64 Figure 4 64 REACTION PLATE EXPANSIVE PLATE SPACER FRICTION DISC FRICTION DISC STATIONARY DISC gt e
14. eere LCS 57 oz 1685 ml ITEM DESCRIPTION NO USED ITEM DESCRIPTION NO USED NO IN ASS Y NO IN ASS Y 1 Coupling 1 18 Ring Gear 1 2 Input Shaft 1 19 Secondary Carrier Assembly 1 3 Spindle 1 20 Primary Carrier Assembly 1 4 Boot Seal 604403 1 21 Primary Sun Gear 1 5 Oil Seal 604409 1 22 Thrust Washer 1 6 Bearing Cone 14 00 133 007 1 23 Disengage Plunger 1 7 Bearing Cup 14 00 133 006 1 24 O Ring 614101 1 8 Wheel Bolt 8 10 25 Large Cover 1 9 Hub 1 26 Hex Head Bolt Grade 8 12 10 Bearing Cup 613314 1 27 Flat Washer 12 11 Bearing Cone 613315 1 28 Magnetic Plug 14 00 052 002 1 12 Thrust Washer 1 29 Pipe Plug 1 13 Lock Washer 1 30 Disengage Cover 14 02 039 005 1 14 Bearing Nut 1 31 Hex Head Bolt 2 15 Retaining Ring 2 32 Quick Disconnect Gasket 1 16 Washer 2 33 Quick Disconnect Assembly 1 17 Disengage Spring 1 34 Hex Head Bolt 2 Contact Auburn with part number and order code of drive to obtain the apropriate parts list Refer to parts list for the specific part numbers and quantities Model 8 Series B Power Wheel Service Kits Part No Description Included Items 593 RR Shown Model 8 Series B Bearing Locknut Tool Not Not Shown MH439 1093 Power Wheel is a registered trademark of Auburn Gear 532 534 BooM MAINTENANCE 4 gt ELT lt UT handlers Fm Mo 29906 Issued 11790 GRADALL material This page is provided so you may determine that this Manual is complete and current with
15. sr gt Note Select work area with sufficient space to work safely and efficiently Clean the work area Procure tools required for this operation Procure a crane or hoist and slings capable of liffing 5000 Ib working with a helper be certain each of you know your individual assignments Mechanically fasten the Boom Sections together to prevent unexpected uncontrolled movement if the crowd cylinder is removed or the crowd cylinder hydraulic line is opened or removed Procure hydraulic fluid for topping off the hydraulic system Use only Gradall approved fluids Install slings around the boom assembly at the balance point Make a trial lift to be certain the balance point is correct Connect a tog line to the front of the boom assembly to aid placement of the assembly Lubricate all cylinder and boom assembly mounting wear bushings and pins Lift the assembly and position the mounting base for pivot pin installation Install the mounting base pin and lock in position using a stover nut Position the boom assembly bores correctly to install the cylinder pins Using the sway circuit will aid Steps 5 6 and 7 Gili Install the cylinder pins and lock in position using 242 Gradall P N 1440 3364 on the pin keeper threads Lift Cylinder Compensation Cylinder Stage 1 3 Connect auxiliary electrics if the machine is so equipped 4 Check the torque on all mounting
16. 2 a 29633 3 97 13 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL VI Control Pressure continued ER FIGURE 14 MAIN PUMP ASSEMBLY TOP VIEW Form No 29633 3 97 14 uno 5 Reason for Inching Check Loss of control pressure can affect machine speed A low pressure gauge 1 000 PSI hose 6 run tee and adapter should be teed into the Ps port on the drive pump Apply the park brake and run the engine at full throttle 2500 2700 RPM The gauge reading should be the same as in the previous control pressure test Depress the brake pedal The control pressure should start to fall after one half inch of pedal travel This pressure should drop as the pedal travels farther and the service brakes apply The controlled linkage length should be 12 1 4 inches from the centerline of the yoke pins The lever arm position on the inching valve should set 1 8 inch off the pin as a starting point See Figure 16 and Figure 17 Another check for the inching adjustment is to install a high pressure gauge 10 000 PSI hose and adapter on MA port on the drive pump With the park brake on move the shift lever to the forward position At full throttle depress the inching brake pedal slowly When the roller on the pedal just touches the brake valve plunger the gauge should read 2 300 PSI 100 See Figure 15 FIGURE 15 MAIN PUMP ASSEMBLY SIDE VIEW PL NSS CONTROL PRES
17. MT FIGURE 11 foo ME 2 NOTE Residual Valve 21 is only found 22 Model 06 460 566 i i 24 Repair Kit 06 460 654 06 459 010 06 460 656 06 459 020 06 460 658 06 459 020 06 460 660 06 459 020 06 460 662 06 459 020 06 460 664 06 459 020 06 460 666 06 459 020 06 460 668 06 459 010 06 460 670 06 459 020 06 460 672 06 459 010 06 460 674 06 459 020 06 460 676 06 459 010 06 460 678 06 459 020 06 460 682 06 459 010 11 OPEN CENTER HYDRAULIC BRAKE VALVE SLIDING PISTON DESIGN Refer to Figure 12 Disassembly or broken the entire CAUTION Extreme care must be 1 Remove boot item 1 and pressure regulating spring assembly item 2 CAUTION Pressure regulating spring assembly has been set at the fac tory and should never be disas sembled Separate end cap item 20 from housing item 3 CAUTION Care must be taken as end cap is under tension of spring item 18 Remove gasket item 6 Remove piston amp poppet assembly item 15 spring item 18 and residual valve item 19 from end cap item 20 Remove cap screw item 5 from under side of housing item 3 Remove o ring item 4 from cap screw Remove sleeve amp piston assembly item 14 from housing item 3 Remove cup item 12 and piston ring item 13 from sleeve amp piston assembly item 14 Remove retaining ring item 7 carefu
18. aU AE 2 Description and Operation of Power Brake Valve a Pages 3 4 amp 5 External Dimensional Page 5 Installation of Power Brake Page 5 Cross Sectional Views of Three Power Brake Valve Designs Page 6 Specification Uu T T m Page 7 Pamay CUD Desig E Pages 8 amp 9 EE E EEE Pages 10 amp 11 Siding Ml meee ene EM I IRE eee ee eee ee eee Pages 12 amp 13 DIAGNOSIS RTT Page 14 T Pages 14 amp 15 SYSTEM SCHEMATIC TYPICAL POWER STEERING CYLINDER FIGURE 1 PERFORMANCE DATA Typical Flow capacity See Specification Chart page 7 System pressure 0 2000 psi Brake line pressure See Specification Chart page 7 Master cylinder 5 2 u u uu LITT 3 1 in Push rod travel with 0 2 approx Push rod force with power 340 Ibs at 1500 psi brake line pressure 225 lbs at 250 psi brake line pressure Model 06 460 652 only Push rod trave
19. all bearing pad mounting bolts Bearing pad mounting bolt torques are a bolt 32 37 ft lb bolt 76 86 ft lb Do Not overtorque mounting bolts This could pull the beating pad nut through Ihe bearing causing the bearing pad to fall out of the boom Lube bearing pad slide paths Shims and spacers are stamped with the Gradall Part Number and thickness Check replacement parts against the original to be certain the correct parts are being used Remove the key from the ignition and fasten a do not operate tag to the pagg steering wheel before working or inside the boom BEARING PAD INSTAUATON gu 9 Refer to bearing pad removal instructions for boom area and bearing pad placement Sections 7 amp 3 Refer to the Part Numbers of shims and spacers removed Kefer to the quantity of shims removed Place the new package bearing pad spacer and shims to installation area using the same quantity that was removed Do Not install a shim directly against the bearing pad Install the bearing pad mounting bolts Determine whether one or two flat washers must be used under the bolt head at this time Apply eeTITE 242 to the mounting bolt threads Torque the mounting bolts to 32 37 ft lb s bolt or 76 86 ft lb 2 bolt Note After new bearing pads are installed you wil have to check the boom for comect adjustment It may be possible for a bearing pad only to be installed if there is insuffici
20. dimension boom bottom to hose is held at the hose area between the toke up bracket and the first hose clamp ELECTRIC Boom CABLE The electric cable is fed through the right side of the boom assembly in fashion similar to the auxiliary hydraulic hoses The electric cable lies adjacent to the hydraulic hoses and moves in unison with them whenever the booms are extended and retracted The receptacle and socket connector are equipped with a strain relief fitting to prevent wires from pulling loose This strain relief is tie wrapped to the cable DO NOT install a cable without the strain relief connected The socket end of the electric cable is fastened to the front boom head of Boom Section 3 It is secured with a bracket at this location A strain relief fitting is installed at the cable take up weldment and support These assemblies are located in the area adjacent to the hydraulic hose take up weldment The receptical and socket are equipped with six contact points One contact point is usually extra and is plugged using Gradall Part No 8348 1301 Refer to the following chart for identification in the socket as viewed from the wire insertion end ELECTRICAL WiRE DATA x Socket Body lere Opabm Bd Md lm x R em ELECTRIC CABLE REMOVAL Stage 1 Retract the boom fully level the front of Boom Section 3 boom head unfasten the electrical socket and c
21. 166 08 31396 560 13 1112 72 1944 58 3110 05 Nm 0 40 0 82 147 2 3 3 4 6 90 13 94 28 46 56 38 98 33 156 49 244 17 476 28 823 48 1635 88 2858 85 fb 0 30 0 61 108 1 70 151 5 09 8 65 10 21 20 99 41 58 72 52 115 42 180 09 351 29 60737 1206 56 1108 58 4571 29 331 35 1040 Megapascals Min Tensile Str Nm 0 52 1 06 188 1 96 4 38 886 15 05 1177 36 54 71 38 126 25 200 93 313 50 611 52 10573 2100 38 3670 62 5870 59 1220 Megapascals Min Tensile Str ft Ib fi Ib 0 45 0 92 1 03 2 56 3 19 767 13 02 15 37 3162 62 63 109 23 173 85 271 24 51910 914 80 1817 19 3175 88 5079 34 0 61 24 231 3 47 5 14 10 59 1766 20 84 41 87 64 9 148 10 135 70 36776 71736 1240 30 1463 9 4305 92 6886 66 0 38 0 78 1 39 1 18 3 13 6 54 11 10 13 1 1695 53 39 93 12 148 20 131 22 451 03 779 83 1549 16 170731 432993 Note To check Gradall torque values set Ihe torque wrench at 95 of rated torque value and check the fastener the torque wrench releases before the fastener moves assume Ihol fastener torque is cored When setting Gradall forque values use values given on the chart exceeding allowances CODE 61 4 BOLT SPLIT FLANGE BOLT TORQUE SAE FITTINGS STRAIGHT amp ADJUSTABLE PORT SIDE ASSEMBLY TORQUE FLANGE BOLT BOLT SIZE SIZE E d
22. Check engine speed with an adequate tachometer At low idle it should be 800 900 RPM Adjust engine speed using the screw on the injection pump At full throttle with no load it should be 2500 2700 RPM When testing engine speed make sure the injection pump lever is contacting the stop The sealed adjustment screw on the pump is not adjustable Please note the initial adjustment on current accelerator pedals See Figure 4 Figure 5 Figure 6 and Figure 7 FIGURE 4 ENGINE ASSEMBLY LEFT SIDE H 100 LOCK 08 3t ll gt p e ERI RUD 4 ASSEMBLY ig Form 29633 3 97 3 534 9 amp 534 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL W U E FIGURE 5 BOTTOM OF FLOOR PLATE ASSEMBLY CURRENT ACCELERATOR PEDAL ASSEMBLY PARK BRAKE SOLENOID VALVE BRAKE INCHING PEDAL INCHING VALVE SERVICE BRAKE MASTER CYLINDER Form No 29633 3 97 4 II Engine Speed continued I FIGURE 6 ACCELERATOR PEDAL ASSEMBLY CURRENT FROM ENGINE ASSEMBLY FIGURE 7 ACCELERATOR PEDAL ASSEMBLY CURRENT AUXILIARY VIEW 6 1 2 t1 8 e 2 2 3 4 51 8 S p di 9 P E s EN VIEW SHOWN WITH BOOT INS D AND PIN REMOVED zx Pye INITIAL ADJUSTEMENT Form No 29633 3 97 5 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL BILL ME Reason for Park Brake Check Pa
23. Seat Lock Release Lever This lever unlocks and locks seat position adjustment not shown Service Brake Inching Travel Pedal This pedal operates the service brakes on front axle It also permits slow travel speed while engine speed is kept high for other handler functions The further the pedal is depressed the slower the travel speed Full depression of pedal causes service brake application Starting Aid Switch optional This switch engages and disengages cold weather starting aid Steering Wheel The steering wheel controls the angle of rear axle wheels Turning the steering wheel to the right causes a right turn by angling rear wheels to left A left turn is caused by angling rear wheels to right Traction Lock Switch Pedal This pedal operates traction lock valve which functions to restore traction when a wheel spins in four wheel drive Voltmeter This gage indicates alternator output and battery condition 4X2 4X4 Switch This switch engages and disengages rear wheel drive motors Rear drive motors are engaged for four wheel drive 4X4 Indicator Light Glows amber to indicate four wheel drive is engaged When park brake is applied this light will not glow CHECKS AND SERVICES BEFORE STARTING ENGINE To be performed at beginning of each work shift WARNING Use extreme caution when checking items beyond your normal reach Use an approved safety ladder If spark arrestors are required be sure
24. The tool can be made from a sun gear that matches the spline of the differential side gear Figure 4 11 Figure 4 11 APPROXIMATELY 12 INCHES 304 6 mm gt 1 Place differential case assembly in a vise with soft metal covers on the vise jaws Install the tool into differential until splines of tool and one side gear are engaged Figure 4 12 Figure 4 12 gt e Section 4 MERITOR Assembly and Installation 2 Attach torque wrench to the tool nut and rotate 2 Support bearing cage with metal or wood blocks differential gears As differential rotates read torque value indicated on dial Figure 4 13 o 3 Press the bearing cup into bore of bearing cage until cup is flat against bottom of bore Use correct size sleeve to install bearing cup NOTE Use same procedure for both bearing cups Figure 4 13 4 Put drive pinion in press The gear head teeth must face toward the bottom 5 Press inner bearing cone on shaft of drive pinion until cone is flat against gear head Use a sleeve of the correct size against bearing inner race Figure 4 15 Figure 4 15 3 If torque value exceeds specification of 50 Ib ft 68 Nem disassemble gears from differential case T 4 Check differential case halves spider gears and thrust washers for problem that causes excessive torque value Repair or replace parts 5 After parts are repaired or replaced assemble parts and repeat steps 1 to 4 TP 6
25. 5 Weeks 250 hours 1 8 3 Months 500 hours Check torque at whichaver interval occurs first Check torque of rear slide bearings if front bearings have become loose tRafer to page 19 for procedure to check and adjust cables 34 POUND FEET TORQUE lubricated NEWTON METRES Obtaining Hydraulic Oil Sample for Analysis 1 Operate unit until hydraluic oil reaches normal operating temperature 2 Apply parking brake and observe hydraulic filter by pass indicator with engine running at full throttle Replace filter elements if necessary 3 Obtain a container to receive waste oil and a CLEAN container to receive oil sample eS OIL SAMPLE Tf y F ic E 9 ia 4 With gage removed from hose attach mini check and hose to test port near right wall of engine compartment Hose end must be posi tioned in waste oil container 5 Allow at least one pint of oil to flow into 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 check test port 8 Cover sample container immediately with CLEAN cap 9 Stop engine and check oil level in reservoir and replenish as required 10 Contact your Gradall Distributor for information concerning oil analysis Oil sample containers are available from several Sources il
26. Extension Cable Fastener Area Block ond Fasteners At the rear of the boom assembly strong back cylinder bracket remove all fasteners from the extension cables using one wrench to hold and one to turn Separate cap and plug the crowd cylinder hydraulic hoses Remove the crowd cylinder mounting pins and fasteners At the rear of the boom assembly remove the hose guards Remove the strong back cable bracket from the rear of the boom assembly Hose Guards Strong Back Extension Cable Crowd Cylinder Mounting Pin Crowd Cylinder Hydraulic Hoses Stage 3 1 Fasten lifting tackle to Boom Sections 2 and 3 lift and partially pull out of Boom Section 2 Place stanchions under Boom Sections 2 and 3 ond take off the weight letting them rest on stanchions 3 Reinstall lifting tackle at the balance point of Boom Sections 2 and 3 and slowly extract them from Boom Section protecting all hydraulic hoses and cables 4 Place Boom Sections 2 and 3 in the designated work area for the next operation a SEPARATING BooM StcrioN 3 2 The procedures listed in this section ore complete for separating Boom Sections from each other Reassembly procedures are given Section 6 Assembling Boom Sections 2 amp 3 These procedures are given using shop conditions only with the Boom Sections inverted 180 upside down Preparation Review
27. each have a minimum allowable thickness of 0 135 The 6 thin discs 0 062 each have a minimum allowable thickness of 0 056 To remove park brake assembly remove 4 drive motor nuts and slide motor out of the way Take snap ring off and remove coupler This will allow access to pinion nut Take pinion nut off and remove park brake assembly Park Brake Assembly Rotor Discs Original Thickness No of Discs 1096 Allowable Wear Thickness 0 150 2 0 135 0 062 6 0 056 Spring free length is one inch Anything less reduces brake holding power Any combination of the above circumstances reduces brake holding capability See Figure 8 Figure 8A Figure 8B and Figure 8C Also refer to Page 6 6 in the Parts Manual P N 2460 4100 for breakdown of park brake assembly Form No 29633 3 97 6 dol MM FIGURE 8A FRONT AXLE ASSEMBLY P N 9114 5139 DRIVE MOTOR STARTING 534C 9 SERIAL NO 0344001 534C 10 SERIAL NO 0266001 m AXLE FIGURE 8B PARK BRAKE ASSEMBLY P N 9114 4160 y w LL n 4 SNAP RING ved 24 SN ZEN TC TES ies f COUPLER KAAN If sd a m R Form No 29633 3 97 7 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL FIGURE 8C BOTTOM OF FLOOR PLATE PARK BRAKE ASSEMBLY CURRENT SOLENOID VAIVE ODD S PARK BRAKE ACTUATION LIN
28. hose and adapter on the charge pump test port It locates near the front inside of the hydraulic reservoir NOTE Before starting make sure the gauge can be observed in the operator s cab and apply the park brake Start the engine and run at low idle 800 900 RPM The gauge should read approximately 380 PSI At full throttle 2500 2700 RPM the gauge should read a maximum of 480 psi and never less than 380 PSI See Figure 9 NOTE Throughout test operation charge pressure should not drop below 380 PSI and should move toward 480 PSI as RPM rises regardless of how many functions are being operated simultaneously The charge pump relief located at the left side of the main drive pump adjusts as necessary To adjust the charge pump relief loosen the locknut and turn the adjusting screw clockwise to increase charge pressure turn counterclockwise to decrease charge pressure Be sure to note the amount that the relief turns in either direction When finished tighten the locknut and install a blue plastic cap To pinpoint the loss of charge pressure start at the pump Make sure the machine is in 4WD when testing rear motors Remove the hose from the G port charge pump output port on the pump install a low pressure gauge 1 000 PSI on the fitting and plug the hose Check the charge pressure again and observe the gauge If the charge pressure comes back to specifications the loss of pressure is in one of the auxiliary valves These valves incl
29. t ignore a worn or damaged gasket in the 5 Press your fresh gasket housing replace it to see that it springs back OU bunched filter me 2 LX 6 Make sure the gasket seats F evenly cR m warped cover HEEE on a housing M 7 Ensure an airtight fit on all A connections Never substitute an and ducts r U incorrect filter model r number Brochure No F114004 4 96 Replaces 1400 23 For more Information Contact Donaldson P O Box 1299 Interleuvenlaan 1 Minneapolis MN 5544 1399 USA B 3001 Leuven Belgium Tel 800 374 1374 Tel 32 16 383811 FAX 612 887 3716 Telefax 32 16 400077 Telex 23205 Beldo B Printed in the U S A Copyright 1996 An Equal Opportunity Employer Donaldson Company Inc reserves the right to change or discontinue any model or specification at any time and without notice Open Center HYDRAULIC POWER BRAKE VALVE MICO Incorporated MICO West Division 1911 Lee Boulevard Zip Code 56003 2507 701 East Francis Street Zip Code 91761 5514 P O Box 8118 North Mankato MN U S A 56002 8118 P O Box 9058 Ontario CA U S A 91762 9058 Phone 507 625 6426 Facsimile 507 625 3212 Phone 909 947 4077 Facsimile 909 947 6054 Form No 81 460 047 Revised 10 95 Printed in U S A TABLE OF CONTENTS D e VER Fb 2 Representative Performance
30. 3 532C 6 534C 6 amp 5360 6 If it has been removed install the crowd cylinder into the boom assembly from the rear 4 f it has been removed install the extension cable sheave bracket to the front of the crowd cylinder 3320 6 534C 6 amp 5340 6 ML a Ar 5 Install the extension cable threaded end through the sheave brocket and feed to the rear of the boom 6 534C 9 C10 amp 534D 9 D 10 Assemble all extension cable sheave bracket components to the front of the push beam Be certain that the cable threaded end is inserted through the sheave bracket before the sheave components are installed 711 L 534 9 10 amp 534D 9 D 10 Insert the push beam fully into Boom Setrtion 2 1 531C 6 534C 6 amp 534D 6 Insert the crowd cylinder fully into Boom Section 2 531C 6 534C amp 0 6 Crowd Cylinder Retainers Crowd Cylinder 3 install the push beam mounting hardware crowd cylinder retainers 4 Install the tilt and auxiliary circuit hose guards at the rear of Boom Section 1 Place the strong back cable bracket place at the rear of Boom Sectian 1 534 10 amp 534D 9 D 10 Crowd Cylinder Push Beam Mounting Area 1 B Install the crowd cylinder and mounting hardware into the strong back cable bracket Replace the removed shim packs to the strong back cable bracket Install and torque the strong back cable bracket fasteners by applying 4 77 242
31. 8C Separarinc 2 AND 3 From 5 1 Review all Sofety issues before commencing Select safe clean area with sufficient space to work on the assembly Procure lifting tackle and crane capable of lifting 5000 Ib Place the boom assembly upside down inverted 180 on stanchions IF working with a helper be certain each of you know your individual assignments Procure tags for identification of hoses and components removed Designate area placement of removed components Stage 1 1 Remove all bearing pads at the front inside of Boom Section Area Pad Locations A B C D s d Location C Location tn Left Inside Right Inside NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES 2 Remove the bearing block from the front inside of Boom Section Area Note Boom Sections Upside Down Boom Section 2 Boom Section 3 Loosen the hose take up brackets 4 Separate plug and cap tilt circuit and auxiliary hydraulic hoses inside the boom at the hose take up bracket Tilt amp Auxiliary Circuits Note Boom Upside Down Hose Take Up Brackets S If auxiliary electncs are present separate the electric plug at the hose take up area GANS Stage 2 1 Loosen the retraction cable and remove all fasteners from the retraction cable Cylinder Bracket adjusting block located at the front of Boom Section cx cmn
32. After parts are repaired or replaced install main differential case and ring gear assembly into carrier Repeat steps 1 to 5 47 Section 5 Adjustments 6 Loosen one bearing adjusting ring one notch then tighten opposite ring the same amount to keep differential roller bearing preload Figure 5 3 DECREASE BACKLASH INCREASE BACKLASH NOTE When you adjust backlash only move ring gear Do not move drive pinion e Backlash is increased by moving ring gear away from drive pinion e Backlash is decreased by moving ring gear toward drive pinion 7 Repeat steps two to six until backlash is within specifications Record setting for use when you adjust pinion bearing preload Teeth Contact Patterns In the following procedures movement of the contact pattern along length of tooth is indicated as toward the heel or toe of the ring gear Figure 5 4 MERITOR Verification Procedure 1 Apply a marking compound to approximately 12 teeth of ring gear Rotate ring gear so that the 12 gear teeth are next to drive pinion Figure 5 5 h M EE 2 Apply load gear with wood Rotate gear forward and backward so 12 gear teeth go past the drive pinion six times to get contact patterns Repeat if needed to get a more clear pattern Figure 5 6 CONCAVE SIDE CONVEX SIDE 48 gt e MERITOR 3 Compare contact patterns on ring gear tee
33. FRA SEA Wak FRA EZ FRA JE2 ZM FRA GAH FRA 163 GAM FRA JEJ GAH PROA 252 WAH Ha WAH MERITOR Revised 7 99 2 50 PRA 352 Series Planetary Axles Maintenance Manual No 9D gt Service Notes MERITOR This publication provides maintenance and service procedures for Meritor PRA 352 series planetary axles The information contained in this publication was current at the time of printing and is subject to revision without notice or liability 1 You must understand all procedures and instructions before you begin maintenance and service procedures 2 You must follow your company s maintenance and service guidelines 3 You must use special tools when required to avoid serious personal injury and damage to components Meritor uses the following notations to alert the user of possible safety issues and to provide information that will help to prevent damage to equipment and components A WARNING NOTE A NOTE indicates an operation procedure A WARNING indicates a procedure that you or instruction that is important for proper ser must follow exactly to avoid serious personal vice A NOTE can also supply information that injury y can help to make service quicker and easier PIN CAUTION This symbol indicates that fasteners must A CAUTION indicates a procedure that you tightened to a specific torque value must follow exactly to avoid damaging equip ment or components Serious
34. Figure 4 6 Figure 4 6 gt a Section 4 MERITOR Assembly and Installation 10 Apply Loctite 271 or Three Bond 1305 liquid d Place disc pack stack in vise Use micrometer adhesive to capscrews Install four capscrews to determine D the height thickness of into case halves equally spaced and tighten to limited slip disc stack includes thrust washer 48 64 lb ft 64 87 Nem T and compression disc Take four readings one at each of four points Average readings 11 Install other capscrews into case halves Tighten to determine D Figures 4 8 and 4 9 the capscrews to 48 64 lb ft 64 87 Nem 12 Assemble Limited Slip Differential Case Figure 4 8 a Follow steps 1 to 5 b Place flanged case half on bench c Begin stacking of the disc pack with a drive disc followed by driven friction discs Make sure lubrication grooves are aligned Figure 4 7 Figure 4 7 Figure 4 9 TOP PLAIN HALF SIDE GEAR PLAIN HALF SIDE GEAR MOVED TO DETERMINE A LUBRICATION GROOVES SPIDER DIFF CASE FACE Maintain the following sequence NS _Y DATUM PLAIN HALF 1 Drive disc Y DIFF GEAR 2 Driven friction disc PLAIN HALF LIMITED SIDE GEAR 3 Drive disc 4 Driven friction disc A Differential case half flange to back of differential side gear distance 5 Drive disc 6 Driven friction disc B case face to side gear seat 7 Drive disc C Differential case half depth D k height thi
35. Located on Instrument Console 534 9 Part No 9114 3151 534C 10 Part No 9115 3002 214 20 1 13 i 8 EXTENSION FEET FROM TIRE TO LOAD CENTER xir 24 IM FRONT OF FORK FACE FIGURES SHOWN ARE STACKING CAPACITY TRUCK LEVEL RATED LIFTING CAPACITIES SHOWN ARE WITH MACHINE A FIRM LEVEL SURFACE WITH UNDAMAGED PROPERLY INFLATED TIRES MACHINE SPECIFICATIONS AND STABILITY ARE BASED ON RATED LIFT CAPACITIES AT SPECIFIC BOOM ANGLES AMD BOOM LENGTHS IF SPECIFICATIONS ARE CRITICAL THE PROPOSED APPLICATION SHOULD BE DISCUSSED WITH YOUR DEALER DO MOT EXCEED RATED LIFT CAPACITY LOADS AS UNSTABLE AND DANGEROUS MACHINE CONDITIONS WILL RESULT DO NOT TIP THE MACHINE FORWARD TO DETERMINE ALLOWABLE LOAD CAPACITY LIMITS FOR THIS UNIT ARE BASED IN ACCORDANCE WITH ASME 56 1994 LEVEL GRADALL HANDLER BEFORE LIFTING ABOVE 4 FT UNDERSTAND THE FOL PRIOR TO LIFTING PERSONNEL LIFTING PERSONNEL USE ONLY A GRADALL MANUFACTURED Part No 9055 3026 8114 3131 SERVICE INTERVALS mw RE NR mom TIONS 10 FITTINGS DHJ TAF cuam 2 0 1023 3023 Located on Boom Head Part No 9103 3023 FRM rial amp MA CHART amp AED GOAN TH amp CHECK iuDicATOA Dm HYDRAULIC FILTER CHEE FI MAL THROTTLE AF
36. Raise boom by pulling boom control joystick to rear and lower boom by pushing joystick forward 18 The boom is extended by a cylinder and a pair of cables within the boom Extend boom by moving boom control joystick to right and retract boom by moving joystick to left Boom functions can be operated simultaneously by moving joystick to a position between two single functions Speed of a boom movement is proportional to degree of joystick actuation A cylinder is located within the boom head to tilt fork carriage or other attachment back and forth as required Push tilt lever forward to tilt carriage forward and pull lever to rear to tilt carriage back All cylinders related to boom carriage movement attachment tilt boom up down and boom in out are protected by counterbalance valves which prevent load from falling in event of a broken hydraulic hose or tube How to check amp adjust boom cables Checking and adjusting boom cables l Position Gradall material handler in a safe level open area away from persons and equipment Apply parking brake shift forward reverse lever to neutral position and turn rear wheels to straight forward position 2 With boom horizontal extend boom two to three feet and then retract boom fully 3 Stop engine and block all wheels 4 At rear of boom measure gap between flat washer at extend cable anchor and strong back rear plate If gap is greater than 1 8 inch extend cables
37. Torque the bearing block bolts 265 290 ft Ib and beanng pad mounting bolts to 68 78 ft lb using 242 on threads SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES Location A Top Inside Location C Right Inside 6 Install and adjust bearing pads at Pad Location F amp H See 6B Boom Section 2 Assembly Stage Step 5 on page 6 4 7 Adjust the front inside pads at Area and 2 Pad Locations C D B If necessary at the rear of the boom assembly readjust the bearing pads at Areas 3 and 4 i pem Location C Location D Location G Right Inside Left inside Right Outside location B i NS S Ste NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES 6 321551 Stage 3 Boom Assembly Rear Crowd Cylinder and Mounting Bracket Extension amp Retraction Cables 532C 6 534C 6 amp 534D 6 ONLY 1 hl DO pyu M 15 Install the standard and auxiliary circuit hose guards at the sheave area located the rear of the Boom akay gt er ee a oe a Place the crowd cylinder bracket inside the rear of Boom Section Do not bolt in place yet Insert the extension cables through the adjustment holes in the crowd cylinder mounting bracket Make sure the cables are not crossed Install the crowd cylinder rod eye in the bracket Lock it in place with the pin and
38. forward reverse lever in neutral position parking brake applied and all hydraulic controls in neutral position before starting engine Check to be sure that all controls are in neutral and that all electrical components lights heater defroster etc are turned off Set parking brake NOTE Engine will not start unless forward reverse lever is in neutral and parking brake switch is in puwa position 2 Turn ignition key clockwise to ON position A CAUTION Turning ignition switch to START position while engine flywheel is rotating can cause serious damage to engine and or starting motor ENGINE OPERATION 3 Depress accelerator pedal approximately 1 4 to 1 3 of travel from top 4 Turn ignition switch to START position to engage starting motor Release key immediately when engine starts If engine fails to start within 20 seconds release key and allow starting motor to cool for a few minutes before trying again NOTE If temperature requires the use of a starting aid and if your handler is equipped with a factory installed ether starting aid depress button and release while cranking engine Repeat if necessary CAUTION Excessive ether can cause serious damage to engine 5 After engine starts observe oil pressure gage If gage remains on zero for more than ten seconds stop engine and determine cause Correct cause of malfunctioning before restarting engine Minimum pressure al operating temperatur
39. section of this Manual for safety related parameters The boom cables are an important component of your Gradall Material Handler They mechanically provide the extension retraction force of Boom Section 3 Boom Cable Data see below covers part numbers used length and key specifications Please review this table to be certain you are using the correct cable for your operation Do Not use cable other than thot supplied by Gradall for replacement These cables are specifically designed for Gradall Material Handlers General Cable Information Cables are pre stretched lengths cited below are after pre stretching Threaded stud Galvanized Plating Safe Lock or Spelter Sockel used on Retraction Cable Boom Cable length tolerances 0 5 10 Sofe Lock Closed Socket Terminal used on Extension Cable Use 2 wrenches when torqueing adjusting jam nuts Use the flat on the threaded cable end to hold the cable straight eliminating twist Boom Cable Data 534C amp D 10 534C 6 532C 6 534D 6 534C amp D 9 amp 10 534C amp 0 10 534C amp D 9 amp 10 534C 6 532C 6 5340 6 Boom Cable Part Cable Number peer Diameter 9113 3356 9112 3147 9117 2013 9114 3027 91 3355 9114 3026 9112 3146 9112 3012 Retraction Cable Extension Cable Coble Anchor Brocket Weldment aT _ _ l 7A CABLE ADJUSTMENTS The cables are adjusted by tightening and or backing off the adjus
40. to threads Crowd Cylinder Crowd Cylinder Hoses Strong Back Stage 4 1 Feed the extension cables into the strong back cable bracket mounting area Be certain that the cables are stress free and not twisted Remove the rope 2 Install the cable adjusting hardware Tighten the extension cables adjusting nuts until gap between cable flat washer and strong back is 1 32 to 1 16 inch Gap for both washers should be equal When tightening make sure thal the wire rope is not tuming 3 Install the jam nut against the adjusting nut and torque to 100 fi lb Make sure that the cable is not twisting 4 Adjust the boom cables to the parameters given on page 71 The Extension Cable is now installed 3 96 A TL AND AUXILIARY CIRCUIT HYDRAULIC ROSES Hydraulic hoses are used to carry fluid to the tilt cylinder and or auxiliary circuits At the boom the hoses are fastened to the hose take up weldment at the front outside inside bottom of Boom Section They are then fed around a roller through a protective channel at the top left and right of Boom Section 3 to the front head of Boom Section 3 Al that point another connection is made to fluid to the till or auxiliary circuit Tilt circuii hoses are fed through the left side of the boom Auxiliary circuit hoses are fed through the right side of the boom Hoses must be of correct length laying straight and flat rolling free of twist a
41. travel or to rear for reverse travel Move lever to center position for neutral DRIVE TRAIN A WARNING Bring unit to a complete stop before shifting forward reverse lever when carrying load A sudden change in direction of travel can reduce stability and or cause load to shift or fall If hydrostatic drive system senses increased travel load the system will compensate automatically by reducing travel speed to match load and engine rpm Inching Travel Inching travel is provided to permit slow travel speed while maintaining high engine speed for other handler functions SERVICE BRAKE y INCHING TRAVEL PEDAL HIGHEST INCHING TRAVEL SPEED i LOWEST INGHING TRAVEL SPEED 7 SERVICE BRAKING The service brake inching travel pedal controls inching travel The upper portion of pedal travel actuates a valve which controls travel pump output The greater the pedal travel the less the pump flow the less the pump flow the slower the travel The lower portion of pedal travel actuates service brake The greater the pedal travel the stronger the brake application Travel flow is reduced when brakes begin to apply A WARNING Practice inching braking in a safe open area until you are thoroughly familiar with response of machine to pedal travel continued Four Wheel Drive When required by travel conditions rear wheel 4 wheel drive can be engaged by moving toggle switch to
42. 10 5 Follow steps 1 through 4 to disassemble the second brake piston Section 2 Removal and Disassembly Disassemble Three Function Wet Disc Brake NOTE Do not disassemble brake piston unless necessary 1 Remove return spring capscrews with 4 mm Allen wrench Remove return springs and washers Figure 2 11 Figure 2 11 2 Remove brake piston assembly from brake housing as shown in Figure 2 12 or place brake housing on a bench with the opening turned down Inject 80 psi 5 5 bar compressed air through inlet of service brake to eject brake piston 3 Remove shims Figure 2 12 Section 2 Removal and Disassembly WARNING e Use a special tool or press to compress the brake assembly to avoid serious personal injury from the spring pressure e Observe all WARNINGS and CAUTIONS provided by the press manufacturer concerning press operation to avoid serious personal injury and damage to components 4 Compress brake piston assembly as shown in Figure 2 13 or place assembly in press and apply 1000 Ibs 450 kg pressure 5 Remove action plate capscrews Figures 2 13 and 2 14 Figure 2 13 Figure 2 14 MERITOR CAUTION Before removing action plate and other parts mark the original assembly positions of all brake piston assembly parts This procedure will make reassembly easier 6 Remove action plate and springs Figure 2 15 Figure 2 15 7 Remove internal piston by pla
43. 39 Figure 2 38 6 If shims are in good condition keep them together for use later when main housing Is reassembled 7 Before damaged shims are discarded measure and record total thickness of the pack The dimension will be needed to calculate depth of drive pinion in main housing when gear set is installed 8 Place drive pinion and bearing cage in press with pinion shaft toward top assembly Support bearing cage under flange area with metal or wood blocks Press drive pinion through bearing cage Figure 2 37 Figure 2 39 11 Section 2 Removal and Disassembly 10 If pinion bearings need to be replaced remove inner bearing cone from drive pinion with press or bearing puller Puller must fit under inner face of cone to remove cone correctly without damage Figure 2 40 Figure 2 40 SA NOTE If bearing cup is changed the bearing cone must also be replaced The cup and cone must come from the same manufacturer MERITOR gt e MERITOR Clean Ground and Polished Parts WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service WARNING If you use cleaning solvents hot solution tanks or alkaline solutions incorrectly serious personal injury can occur To prevent serious personal injury follow the instructions supplied by the manufacturer of these products Do not use gasoline to clean parts Gasoline can expl
44. 39 e To assemble ball and ramp brake see page 43 1 Check to see if the piston lodging surfaces on brake housing is free of sharp edges nicks and burrs Repair any damage if possible or replace the part 2 Repeat Step 1 on outer surfaces of brake piston 3 Apply a thin film of oil SAE W140 or SAE 90 to piston and bore Apply a dense layer of oil to brake housing chamfer 4 Carefully install piston oil seals NOTE Before pressing piston into brake housing rotate piston 15 to 20 degrees If piston does not turn easily disassemble the piston and find the cause of the interference 5 With a manual press carefully install piston into brake housing Do not damage oil seals If there is resistance in installing the piston do not proceed Figure 4 48 Figure 4 48 BRAKE HOUSING SPRING CAPSCREW 38 gt e MERITOR 6 Apply high torque liquid adhesive Loctite 271 or Three Bond 1305 to capscrew threads Install return springs and return spring capscrews Tighten to 80 115 Ib in 9 0 13 0 N m p Figure 4 49 Figure 4 49 Hydraulic Apply Brake Housing Functional Test NOTE e This test procedure is only for the hydraulic apply brake system e To perform this test it is necessary to use a device which permits the observation of possible leaks through oil seals and if the piston return system is working For an accurate evaluation the device must allow piston displacement of 0 157 to 0
45. 444 position Return unit to two wheel drive by moving toggle switch to 4X2 position Four wheel drive can be engaged and disengaged while traveling When parking brake is applied four wheel drive is disabled Traction Lock Switch This switch pedal controls the traction lock valve which functions to restore traction when a wheel tends to spin while in four wheel drive When switch pedal is depressed and held traction lock valve functions to cause delivery of full drive pressure to wheels of other axle regardless of law pressure at spinning wheel DO NOT engage traction lock function on improved surfaces Unit must be in four wheel drive to engage traction lock function CAUTION Never disengage rear hubs except for emergency towing page 35 BOOM All boom characteristics shown below are common to the 534C 9 and 534C 10 handlers elevation above horizontal is 71 and boom depression below horizontal is 7 as measured from horizontal plane at boom pivot with handler resting on a horizontal surface Fork height above grade is 40 feet and fork depth below grade is 3 feet as measured from horizontal plane at bottom of tires to top surface of horizontal forks Horizontal reach at 0 is 26 feet as measured from vertical plane at front of front tires to 24 inch load center The boom is raised and lowered by a pair of hydraulic cylinders anchored to chassis frame and to boom section number 1
46. 9 D 10 Mechanical adjustments replacement removal and reinstallation of major components are covered Hydraulic system operations are not discussed Refer to appropriate manuals for this information Areas requiring special attention are so indicated Illustrations and pictures used are taken from various models They are typical with regards to assembly and component location and should be used for reference only Information in the various charts tables and illustrations is correct at the time of printing Refer to the appropriate current Gradall Parts Manual to verify comect component Port Numbers The extension retraction boom cables used on all Gradall 532 and 534 Series Material Handlers are made of wire rope All wire ropes in service should be inspected regularly for damage and evidence of wear Refer to the Wire Rope Users Manual and OSHA Wire Rope Excerpts both published by the American Iron and Steet Institute Committee of Wire Rope Producers Users of Gradall Material Handlers equipped with wire rope should conduct a thorough inspection of all wire rope boom cables at least once a month keeping full and accurate records as to the condition of the ropes Any deterioration will lead to the depletion of original rope strength which is sufficient cause to replace the rope listed below are some conditions that warrant wire rope replacement Corrosion of wire rope More than one broken wire in any one strand Breaks in va
47. I STABILIZER 12 VOLT THERMAL BYPASS ITCH BATTERY viue M vem VE HYDRAULIC SCHEMATIC REAR AXLE STABILIZER VALVE D a34C 10 9115 9111 GRADALL MATERIAL HANDLERS 534 9 8 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL we neo nenas WI cab oo i on qup Wr A ae MC 29633 M dy a 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL Table of Contents Page Introduction ii Hydraulic Oil Reservoir l Hydraulic Filter Condition 2 1 Engine Speed 3 IV Park Brake 6 V Charge Pressure 10 VI Control Pressure 13 VI Inching 15 VII Front Motor Begin Point 17 IX Drive Pump Pressure 19 X Machine Operation 2l NOTE HIGH PRESSURE denotes 10 000 PSI gauge LOW PRESSURE denotes 1 000 PSI gauge Component changes occur in production Where the change affects a particular performance check it will be noted All other components shown will be current 34C9 amp 534C 10 Form No 29633 3 97 i 534 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL __importantSafetyNotice I 2 These tests ensure that the Hydrostatic Material Drive System operates to the proper specifications All tests should be done in a safe open area Apply the park brake and leave the shifter in neutral unless otherwise noted The boom and attachment should rest on the ground unless t
48. It is especially impor tant to make sure the lock ring is secure in the gut ter and has not been damaged prior to re inflation After first 50 to 100 miles of service re check clamp and wheel nut torque Loose wheel nuts can cause excessive wear around bolt holes dangerous wheel vibration and metal fatigue failure Excessive torque is also dangerous in that it can cause stud or wheel breakage THE GRADALL COMPANY 406 Mill Ave S W New Philadelphia Ohio 44663 How to mount and demount ACCU RIDE 5 Commander and 3 piece convertible rims Procedure applies to tires on both demountable rims and disc wheels Tools required 1 rim mallet 1 rim tool _ MOUNTING After applying tire and tube in usual manner place removable side ring flange on bead of tire Then insert tapered toe of lock ring between side ring and rim base To fasten lock ring hold with foot at one end of split and hammer end of ring into place with rim mallet Continue progressively around the rim holding ring with foot and hammering until entire ring is seated Check seating of rings and inflate tire to recommended pressure SAFETY PRECAUTIONS 1 Use only parts free from damage or heavy rust 2 Insure that lock ring is completely installed be fore inflating tire Inflate tire in safety cage or use a lock ring guard In emergency situations where a safety cage or portable safety device is not available use clip on type air chuck so tha
49. MERITOR 4 Install stationary disc lock pins 5 Install reaction plate with lubrication hole on down side of axle 6 If there is an outer spacer install it on brake housing surface Use liquid gasket material Assemble Three Function Brakes Brake Discs Reaction Plate and Pins 1 Lubricate all brake components with same oil specified for axle See page 53 2 Install sun gear Figure 4 63 3 Apply 350 psi 24 bar into parking brake 4 Install friction and stationary discs guide pins and reaction plate Figure 4 65 Figure 4 65 BRAKE HOUSING Section 4 Assembly and Installation Install Housing Assembly into Main Housing NOTE If axle is equipped with three function brake keep parking brake pressurized 1 Install housing assembly Make sure that the mark made during disassembly is correctly positioned to ensure alignment of the fastener holes Figure 4 66 Figure 4 66 2 Install capscrews and nuts that fasten housing to main housing e Tighten grade 12 9 capscrew 170 200 lb ft 230 271 Nem T e Tighten grade 10 9 capscrew 135 170 lb ft 183 230 Nem e Tighten stud nuts 120 150 Ib ft 160 205 Nem T 3 Release pressure from parking brake 4 Apply liquid gasket material Loctite 515 or Three Bond 1134 on surface of cover that fastens to main housing and on capscrew threads Install cover and capscrews on main housing Tighten capscrews to 20 27 lb ft 27 36 Nem o 43
50. Meritor Heavy Yelle Systems Sunt Etienne A Batiste Hun Joan 500 SP Bote 55 BRAZIL XX Sunt Esenne Cedar 1 Wantenanoce Manual 90 55 11 7083 8 5 10 FRANCE Himnasad 7 09 5 11 7054 5500 1 477 2 SR DO 77 22 B 91 4186573453 T Copaight 1998 hiato Sutomotive Inc Rasariud Printed in the WSA PowerWheel Service Manual Model 8 Series B AN Double Reduction a Wheel Drives Aubur nGearg U S A PHONE 219 925 3200 FAX 219 925 4725 IDENTIFICATION IMPORTANT All Power Wheel units and kits are shipped with a name plate that includes the Auburn Gear part number and order code as shown Power Wheel ORDER CODE 6WB13156C Example PART NO 6000236 SERIAL NO 143434 AuburnGear AUBURN IN U S A In addition to the nameplate Power Wheel drives are stamped with an identification number which appears on the cover or hub flange as shown Example 6000236 A 4 9 When ordering parts the information included on the nameplate or the stamped identification number is necessary to accurately identify the drive and obtain the correct replacement parts Once this information has been obtained contact Auburn Gear for appropriate parts list DISASSEMBLY OF POWER WHEEL STEP 1 Slide the coupling 1 from the splines on input shaft 2 STEP 2 Position the assembly upright on face of spindle 3 STEP 3 Remo
51. OIL SAMPLE FOR ANALYSIS 35 MOVING HANDLER IN 35 Moving Short Distances Moving Longer Distances To Activate Tow Bypass To Release Parking Brake To Restore Parking Brake HAND SIGNALS aaran rE eb cantus te ost t m tdt inside back cover INTRODUCTION General This manual provides important information to familiarize you with safe operating procedures and operator maintenance requirements for the Gradall 534C 9 and 534C 10 Material Handlers If you have any questions regarding the material handler contact your Gradall Material Handler Distributor Operator Qualifications Operators of the material handler must be in good physical and mental condition have normal reflexes and reaction time good vision and depth perception and normal hearing He she must not be using medication which could impair his abilities nor be under the influence of alcohol or any other drug during the work shift The operator should also possess a valid applicable driver s license and must have completed a course of training in the safe operation of this type of material handling equipment In addition the operator must read understand and comply with instructions contained in the following material furnished with the material handler This Operator s Manual EMI Rough Terrain Forklift Safety Manual Gradall Material Handler Safety Manual Gradall EMI Operator Orientation Video A
52. PP IMPLEMENT PUMP EK NEM 3 627 CU IN REV gt lt ll PRIORITY FLOW DIVIDER SERVICE BRAKE PARK BRAKE SOLENOID VALVE BRAKE SYSTEM PUMP 1 2 CU IN 7REV COMPENSATING CYLINDER AUX EN Q LI AUXILIARY EMI HYDRAULICS ae pe OPT ION CROWD CYLINDER THERMAL BYPASS HYDRAULIC SCHEMATIC 05340 9 z 9114 9111 LEGEND MAIN PRESSURE amp RETURN LINES PILOT LINES BRAIN LINES AAA ELECTRICAL LINES 2 4 WHEEL TRACTION Ba LOCK ull SE 12 VOLT PARK BRAKE 12 VOLT E lt gt BATTERY SWITCH STEERING ORBITROL Maud FORWARD REVERSE 2 4 WHEEL n SELECTOR SWITCH 1 FORWARD PP LL REVERSE 5 IMPLEMENT PUMP gt lt 4 3 627 CU IN REV CE oe EHE EE INCHING gt O EE 1 CYLIN VALVE m CYLINDERS NEED MIU uU sos D PZA 4 E a _ E
53. Pe Located right side of cab wall and instrument panel Part No 9055 3028 MACHINE MUST BE IN NEUTRAL AND PARK BRAKE ON TO START Located on Instrument Console Part No 9114 3120 Located on Lever Knob Part No 9108 3318 Located on Forward Reverse Switch Part No 9108 3428 TRACTION LOCK SWITCH INCREASED TRACTION DO NOT ENGAGE ON IMPROVED SURFACES MACHINE MUST BE IN 4 WHEEL DRIVE SWITCH LOCATED ON FLOOR SWITCH HYDRAUL ICALLY LOCKS FRONT AND REAR WHEELS TOGETHER FOR 9108 3314 Located on Instrument Console Part No 9108 3314 TEST PORTS IMPLEMENT PRESSUR CHARGE PRESSURE 134 3152 Located on Hyd Reservoir Cover Part No 9114 3162 Located on Lever Knob Part No 9108 3317 AWARNNG _ LAPIYAPII TED ANCHORAGE POINT ET FALLIRE TO Located on boom head and personnel work platform AX WARNING CHECK TO ASSURE QUICK SWITCH PIN IS FULLY ENGAGED AND LOCKED AFTER ATTACHMENT CHANGE CAPACITY CHART MODEL 534C 9 RATED CAPACITY 2 FT LOAD CENTER USE wiTH 92045 5051 CARRIAGE 2045 5057 CARRIAGE 32 9055 5008 72 CARRIAGE 9112 5027 INSTANT HOOK 30007 MAX FOR OTHER ATTACHMENTS CONSULT CRADALL DEALER FOR LOAD RATINGS USE LARGEST MUMBER VISIBLE FROM THE CAB TO DETERMINE EXTENSION MATCH WITH AMGLE TO DETERMINE ALLOWABLE LOAD
54. Remove cup item 9 from sleeve 7 Remove piston item 16 from housing item 11 Remove piston ring item 15 from piston 8 Remove retaining ring item 3 carefully with a small flat tool Do not scratch bore of sleeve item 10 9 Remove push rod item 4 spool item 6 and spring item 7 from sleeve item 10 Remove cup item 5 from spool item 6 Inspection Clean and inspect all component parts for scratches cracks or wear Replace any parts that are excessively worn or damaged 10 CAUTION If spool item 6 sleeve item 10 or bore of housing item 11 are in any way damaged scratched or broken the entire assembly must be replaced These parts are select fitted and are not interchangeable or replaceable with service items Assembly 1 Install new cup item 9 on sleeve item 10 and new cup item 5 on spool item 6 CAUTION Lips on cups items 5 amp 9 should be away from ends of spool item 6 and sleeve item 10 2 Place spring item 7 in sleeve item 10 3 Install spool item 6 in sleeve item 10 Note direction of spool 4 Install push rod item 4 in sleeve item 10 and secure it with retaining ring item 3 5 Install new o ring item 12 on cap screw item 13 and install in housing item 11 6 Carefully install sleeve item 10 into housing item 1 1 CAUTION Make sure that groove on sleeve will engage cap screw item 13 Install retaining ring it
55. any repair or adjustment F you are working with someone else make sure they 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 Moke sure you wear all the protective clothing and personal safety gear necessary to perform the service safely Make sure there is adequate light and ventilation in the work area Remove oil grease mud snow water or any other substance that might cause slippery surfaces from all climbing walking and working areas 5mm EPES MEM Clean around the area to be serviced to minimize any possibility of contamination Use only the correct tools to perform any check service or repair Make sure any lifting and supporting devices you use are stable and strong enough to handle the weight of the matenal handler or component Remove only the quards covers on the area being serviced Replace all quards covers immediately upon completion of the task if the material handler has special optional equipment make sure that the appropriate maintenance and operational requirements are understood by everyone who operates and services the machine What THIS MANUAL Covers This Manual covers maintenance and repair procedures for the three section boom assembly of all 532 and 534 Series Gradall Material Handlers Specifically this includes 5320 6 534C 6 7T 534C 9 C 10 534D 6 T amp 534D
56. are excessively worn or damaged CAUTION If spool item 6 sleeve 8 Place new gasket item 14 on mounting face of end cap item 21 and new primary cup item 17 END CAP LOCKWASHERS BOLTS Y Items included in Repair Kit 06 459 002 FIGURE 10 06 460 520 06 460 522 06 460 550 06 460 560 06 460 570 06 460 580 06 460 588 06 460 610 06 460 620 06 460 650 06 460 680 06 460 686 Repair Kit 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 06 459 002 9 OPEN CENTER HYDRAULIC BRAKE VALVE RING SEAL DESIGN Refer to Figure 11 Disassembly 1 Remove boot item 1 and pressure regulating spring assembly item 2 CAUTION Pressure regulating spring assembly has been set at the fac tory and should never be disas sembled 2 Separate end cap item 21 from housing item 11 CAUTION Care must be taken as end cap is under tension of spring item 20 Remove gasket item 14 3 Remove piston amp poppet assembly item 17 and spring item 20 from end cap item 22 CAUTION If you have model 06 460 566 you will also have to remove residual valve item 21 4 Remove cap screw item 13 from under side of housing item 11 Remove o ring item 12 from cap screw 5 Remove retaining ring item 8 from housing item 11 6 Remove sleeve item 10 by pulling on push rod item 4
57. bearings Radiator Fill Cap check level amp refill as req d Boom Hoist Cylinder Barrel Pivots Compensating Cylinder Pivots Quick Switch Latch FuelWater Separator drain watar At End of First 50 Hours Only 4 Diferential Drain Plug drain amp Planetary Drain Plugs drain while draining differential At End of First 30 Days Only 250 Hours Maximum Lubrication amp Maintenance of all items listed in Torque Table 34 SL Lube of Symbol Points DIF 1 1 HF 1 1 1 EO 1 4 4 OG 2 1 4 CO 4 4 2 2 CG 2 CG 2 CG 2 CG 2 CG 2 ca 1 CG 2 MG 4 1 OG 2 ca 2 OS 1 1 Lube of Item Symbol Points 5 Week or 250 Hour Lubrication amp Maintenance Service at whichever interval occurs first include all previous periodic services 3 Drive Axl Level Plug check level amp as req d SL 1 27 28 31 3 42 43 46 11 13 dB 44 45 11 AT Hydraulic Reservoir Breather Cap check amp clean or replace cap as neq d 1 Boom Front Top amp Side Slide Bearings extend boom fully amp lube all wear paths retract amp extend boom fully Ihree times wipe excess lube from bearings MG 13 Vacualor Valve rubber cone on bottom check to be sure cona clear and undamaged 1 Boom Rear Slide Bearings lube paths MG 12 Extend Cables check adjustment amp adjust as raq
58. before beginning bleeding procedures 5 Stop engine and depress brake pedal Pedal should be hard not spongy and fairly high If pedal is too spongy and or travels too far repeat bleeding process 6 It is a characteristic of the brake valve to kick the pedal back when actuated if system is not bled with engine running PRESSURE BLEEDING PROCEDURE 1 Refer to Figure 13 Install a small BLEEDER BY PASS LINE as shown A 1 4 size line or hose is sufficient 2 Start engine and allow enough time to pass for the system to become filled and thoroughly flushed with oil 3 It is necessary to develop between 50 200 PSI at the inlet to brake valve A method to throttle the oil will be needed if the system does not already have a secondary hydraulic device downstream from the brake valve THIS PRESSURE SHOULD BE HELD THROUGHOUT THE BLEEDING PROCESS AND SHOULD NOT EXCEED 250 PSI 8 9 DO NOT STEP ON THE BRAKE PEDAL DURING BLEEDING PROCESS THIS Oil will now be forced directly into the brake line by the pump and fill the brake valve master cylinder cavity This may take a minute or two Continue to hold the bleed pressure while bleeding each brake starting with the line and brake closest to the brake valve Allow a sufficient amount of fluid to pass at brake bleeder screw to insure all air is removed from each bleeder point Continue this method until all brakes and lines are bled When al
59. cable around right side hose roller through top protection channel then to the boom head at the front of Boom Section 3 3 Install the hose quard at right side hose roller located at the rear of Boom Section 7 Boom Heap gt Stage 2 1 At front boom head of Boom Section 3 feed the cable through the tube weldment and install the strain relief fittings on cable Do not tighten at this time 1 Pull the electric cable through the boom to correct position at boom head 3 Install cable wires into the socket See Electrical Wire Dota on page 9 0 for wire locations 4 Install the socket into the bracket at the boom head Tighten the strain relief fitting at the socket and tube Install and tighten the cable clamps at the boom head Stage 3 1 Install the cable toke up weldment and support at the bottom front of Boom Section 1 Tighten the strain relief fittings at the cable take up weldment area 3 Install the cable clamps to the bottom front of Boom Section 1 4 Plug the receptacle connector into the frame cable wiring harness The Electric Cable is now correctly installed 1 CROWD CYLINDER REMOVAL AND INSTALLATION The crowd cylinder hydraulically extends and retracts Boom Section 2 A cable sheave arrangement is designed into the system to extend and retract Boom Section 3 proportional to Boom Section 2 While similar in operation there are slight differences in cylinder design for 532C 6 534C 6 am
60. chart Torque Disc Pressure Torque Reduction PRA 382 06 2 5 psi 950 1200 lb ft 17 08 1 19 bar min 1288 0 1559 0 Nem PRA 353 06 2 5 psi 350 500 46 00 1 19 bar min 474 5 678 0 Nem NOTE To obtain the desired brake torque fasten or unfasten the adjusting nut For each 0 04 inch 1 mm turned on dimension X the variation in torque Is 4 7 After obtaining the desired brake torque install nut lock as shown in Figure 4 74 Tighten to 60 90 Ib in 80 120 Nem o Figure 4 74 1 47 ADJUSTING 37 0 mm NUT WITHOUT PRESSURE N GZ 46 gt e MERITOR 8 Install cover Figure 4 75 Figure 4 75 ADJUSTING NUT ALL SPRING PISTON WITHOUT PRESSURE CYLINDER N S 77 CYLINDER SUPPORT 77 ZZ 9 The dimension Y must be equal with 0 02 inch 0 5 mm on each side If dimension is larger on one of the sides after adjustment disassemble and find the cause NOTE Do not check the brake torque before the wheel has turned at least two times with the brake activated 2 Section 5 MERITOR Adjustments Check Ring Gear Runout Adjust Pinion and Ring Gear Specification 0 008 inch Backlash Specification 0 20 mm 0 005 0 015 inch 0 13 0 38 mm WARNING 1 Attach dial indicator on mounting flange of To prevent serious eye injury always wear safe carrier eye protection when you perform vehicl
61. components Remove hydraulic hose rollers and components Hydraulic Hose Rollers 3 532C 6 534 6 amp 534D 6 Remove crowd cylinder retainers Retraction Cable Sheave Step Crowd Cylinder Retainers 4 534C 9 C 10 amp 534D 9 D 10 Remove all push beam pins and fasteners 34C 9 C 10 amp 5340 9 0 10 Remove Pins Step 4 ER ___ __ 1 Stage 3 1 Stage l 1 3 4 5 4 534 9 10 amp 534D 9 D 10 From the front of Boom Section 3 pull the push beam free of the boom assemblies 532C 6 534C 6 amp 5340 6 rear of Boom Section 2 pull the crowd cylinder free of the boom assembly Place hydraulic hoses and cables inside Boom Section 3 for protection Bo NT INSIDE Install lifting tackle 10 Boom Section 3 Toke the weight and pull Boom Section 3 from Boom Section 2 far enough to rest at the balance point Place stanchions under Boom Section 3 and release the weight letting it rest on Ihe stanchions Reinstall lifting tackle at Boom Section 3 balance point and slowly extract it from Boom Section 2 Place Boom Section 3 in the designated work area for the next operation The Boom Sections are now separated No special instructions are required for component removal and or replacement Refer to Section 6 for reassembly of Boom Sections The procedures listed in this section ore complete for assembling the bare boom weldment Io final assem
62. d taler to page 18 lor procedure z 2 Boom From Bottom Slide Bearings to be par ormed by experienced maintenance person check for damage amp xcessiva waar no wear permittad pas bevel maximum clearance al top bearing is 1 8 inch shim or replace as req d when these bearings require service check all other slide bearings shims are 1 16 inch thick MG Engine Oil Filter replace filter elemant Drive Belts check condition amp tension replace as req d Engine Crankcase Drain Plug drain amp refill top teval EO Rear Hub level Plug check level as req d GO Check torque of itama indicated in torque tabla page 24 r Quarterly or 500 Hour Lubrication 8 Malntenance Service at whichever interval occurs first include all previous periodic services Hydraulic System we recommend thal hydraubc fluid be analyzed to determine condition drain amp relli reservoir req d rel page 35 HF 1 Hydraulic Reservoir Screen ramova clean amp install when hydraulic oil s drained Fuel Strainer replace Fuel Filter raplace titer element FuelWater Separator replace lher element k Semi Annual or 1000 Hour Lubrication amp Maintenance Service at whichever interval occurs first include all previous periodic services Differential amp Planetary Drain Plugs drain fill to level wait 5 minutes amp to leval again ilem 3
63. difference between dimension and dimension A minus 0 06 in 1 5 mm B A 0 06 in 1 5 mm 2 shim pack thickness d If brake piston is assembled the shim pack thickness under press pressure of 441 165 200 Kg is the difference between dimension B minus the sum of dimensions C and D minus 0 06 in 1 5 mm B C D 0 06 0 15 shim pack thickness Figure 4 52 Figure 4 52 600 Ib 300 Kg 250 Ib 113 Kg 39 Section 4 gt e Assembly and Installation MERITOR 2 Lubricate internal brake housing surfaces inner 5 Install springs into bores in inner piston and outer piston surfaces and oil seal bores with Figure 4 55 For brake with 12 springs jump one SAE 90 oil Figure 4 53 bore each three Figure 4 55 Figure 4 53 Figure 4 55 MEDIUM PISTON PISTON SMALL OIL SEAL NOTE 6 Install compression plate on piston Correctly Each piston assembly has three different sizes of align the fastener holes Use marks on piston and oil seals three large one medium one small lock pin slot Figure 4 56 3 Install medium oil seal into inner piston bore and install the small oil seal into the outer piston bore Figure 4 53 4 ONLY use a manual press to install inner piston into outer piston Be careful not to damage oil seals Do not force the inner piston assembly Figure 4 54 Figure 4 56 COMPRESSION PISTON PLATE Figure 4 54 7 Apply pressure to the compression plate until it
64. ec c Oc eser de ee ve caus gt va 48 Verification Procedure Coll C ee 5 49 Incorrect Contact Patterns High Contact Pattern Deep EE ET E SESE O UT T 50 Variations Along Length of Gear Teeth Replace EUH E uu e o Frist aS 51 Section 6 Specifications Intervals and SpeciicatlotiS uae rene ate eae tn d o riv cadat ete Pria ERR as 52 INNO CK OPE CP 53 Torque Charts PROASS20902M 0b sd S ua ELI I UM A Oed 54 PRATS TEC O 56 a dE 58 gt e Section 1 MERITOR Introduction Description Identification The Meritor PRA 352 Series Planetary Axle is a A tag on the main housing correctly identifies basic double reduction single speed unit that has axle specifications A hypoid or spiral pinion and ring gear set When ordering parts be sure to specify information Stamped on the name plate This information will allow easy identification of correct parts Bevel gears in the differential assembly with 2 or 4 differential pinion gears A differential case assembly mounted on two tapered roller bearings A planetary system with 3 or 4 planetary pinion gears A trunnion mounting option MODEL An oil bath disc brake system in three dif
65. ed prior to removal of side ring 5 Do not inflate a flat or seriously un derinflated tire while tire is on vehi cle Remove and make sure all parts are serviceable and fully reassemble before reinflating tire How to mount and demount ACCU RIDE RHP rims Tools required 2 rim tools 1 rim mallet 1 tire tool thin end MOUNTING Place tire on rim so that valve is in line with vaive hole and insert valve through valve hole Force first bead down into well of rim just to side of valve with foot Mount first bead over rim gutter with rim tool progressing from each side of foot to point approx imately opposite foot To apply second bead start at point opposite valve and press bead toe over rim gutter and into rim well with foot pressure Mount remainder of bead over rim gutter by means of thin tire tool being careful not to pinch tube DEMOUNTING Place half of side ring in rim gutter with cutaway portions in position as shown Insert thin end of rim tool or heavy screw driver and pull ring out ward toward centered position Strike with mallet forcing rim into gutter Standing clear of rim remove valve core to completely deflate tire Place tire and wheel on floor with side ring up To loosen first bead drive hooked end of rim tool between tire and rim flange and press downward on bead Progress around rim using 2 tools as shown Turn tire over and by means of rim tools loosen bead on opposite bead
66. four feet above ground level it must not be moved from its position if such movement could change the level condition 4 The combination of side tilt and load can cause the handler to tip over Note Leveling information following this note applies to all 534C 9 Handlers and also to 534C 10 Handlers if Outriggers are not being used to level handler To level handler using outriggers position left and right out riggers as appropriate to center bubble weight in level indicator There are two ways to level the handler 1 The surface which will support the handler can be leveled This method must be chosen if it will be necessary to move the handler from its position after the load has been raised over four feet from ground level AND such movement could change the level condition Remember the supporting surface must be large enough smooth enough and firm enough to keep handler level when it is moved from its position 2 The handler may be leveled by means of the frame leveling system This method may be chosen when it will not be necessary to move the handler from its position after the load has been raised above four feet from ground level OR when such movement will not change the level condition of the handler Always determine best positions for handler to raise 20 load from its present location and also to position load at its destination THEN determine which method of leveling will be required at each loca
67. horizontal forks can be inserted under a load by moving boom control joystick back and to the right until forks move forward horizontally 21 With boom lowered below horizontal forks can be removed from a load by moving boom control joystick forward and to the left until forks move rearward horizontally The closer the boom to horizontal the less boom raise lower movement required for inserting and removing forks Carriage Tilt Lever TILT TILT FORKS FORKS DOWN DCWN c TILT FORKS LP STANDARD FORK TILT CONTROLS Move lever forward to tilt forks down and move lever rearward t o tilt forks up A WARNING Always move boom to carry position horizontal or below before leveling frame Attempting to level machine with boom raised may cause it to tip over Rated Capacity Chart The rated capacity chart located on dashboard indicates maximum load capacities for handlers equipped with Gradall furnished carriage fork combination These capacities apply to the standard carriage fork combinations except as stated on the capacity chart WARNING All loads shown on rated capacity chart are based on machine being on firm level ground the forks being positioned evenly on carriage the load being centered on forks proper size tires being properly inflated and the handler being in good operating condition 24 20 16 12 B 4 0 XTEHSION FEET FROM TIRE TO LOAD CENTER
68. in direction desired Place side ring in position with operat ing notch located between two emboss ings point B approximately three inches from valve on either side CAUTION Staying clear of rim make certain tire is completely deflated To loosen tire bead from side ring drive curved bead loosening end of above recommended rim tool or a larger tire tool between ring and bead Pry down ward on bead and repeat this operation around the ring until bead is loose The two cutaway portions opposite each other in the inner diameter of the ring points A are placed so as to span the rim gutter At point C oppo site valve force half of ring into the gutter as far as possible using hand and rim mallet DEMOUNTING RU iti i E gt lt gt Remove ring by putting straight end of rim tool into notch in ring located between embossings point B Push ring downward at point opposite oper ating notch Force tool handle down ward as illustrated causing ring to disengage from rim gutter Continue operation prying away from rim gutter with flat end of tool until free Insert straight end of rim tool in oper ating notch point B then pull in direction indicated by arrow Retain pressure with tool and strike ring downward with mallet at point between tool slot and cutaway portion thereby engaging ring over rim gutter at that point Remove tool and strike addition al
69. injurious to rubber A combination lubricant and rust preventive compound is pref erable This protective measure is of particular importance with drop center tubeless rims as the air in the tire is contained by the tire side rim surface 6 Inflate tire only to recom mended air pressure SAFETY PRECAUTIONS 1 Insure that rings are properly seated prior to inflation Use safety cage or lock ring guard In emergency situations where a safety cage or portable safety de vice is not available use clip on type air chuck so that operator may stand aside during inflation When clip on air chuck is used pressure must be restricted to max inflation capacity of tire or rim whichever is lower Air tank should incorporate moisture trap when used with drop center tubeless rims in order to reduce the moisture in contact with the metal rim surfaces Rings should be cleaned with wire brush Pay particular attention to seating surfaces and bead seat areas 4 Paint rim by brush or spray with a fast drying metal primer Surfaces should be clean and dry prior to painting Insure that bare metal areas on outside or tire side of rim are covered This is especially important on drop center tubeless rims because warm and sometimes moist air is in constant contact with the metal surface on the tire side of the rim How to Insure Greater Safety and Service by Properly Matching Side and Lock Rings It is important to recogn
70. is flat against the piston NOTE Rotate pistons until marks are aligned If inner piston does not rotate easily disassemble it and find the cause Figure 4 54 40 gt e MERITOR WARNING To avoid serious personal injury be careful when using Loctite Follow the manufacturer s instructions for safe use to prevent irritation to eyes and skin Wash after skin contact If the Loctite gets in eyes flush with water for 15 minutes Have eyes checked by a doctor 8 Apply medium torque liquid adhesive Loctite 241 or Three Bond 1334 in threaded external piston bolt holes Install action plate bolts as shown in Figure 4 57 and apply a pretorque of 30 Ib in 3 3 Nem Tighten to specified torque of 120 140 13 5 16 Nem T Figure 4 57 9 Install three larger oil seals into outer piston Make sure the oil seals fit in the bores Figure 4 58 Figure 4 58 LARGER OIL SEALS Section 4 Assembly and Installation 10 Install shim pack into brake housing Use bolts to align holes Figure 4 59 Figure 4 59 GUIDE BOLTS Remove guide bolts and manually install brake piston assembly into brake housing Rotate piston assembly 15 to 20 degrees The rotation must be easy and without resistance If there is any resistance disassemble the brake piston assembly and find the cause Use bolts as guide and align piston and holes Use marks made during disassembly as reference Figure 4 60
71. maximum reach and load capacities for handlers equipped with an approved carriage fork combination These limita tions apply to standard approved carriage fork combination except as stated on the capacity chart Non standard carriage fork combinations greater or lesser capacity may be furnished by the Gradall Co at customer request or may be available for instal lation because they were furnished for a different application If a carriage fork combination of lesser capacity is used the overall machine capacity is reduced to carriage fork capacity as indicated on carriage fork serial number plate If a carriage fork combination of greater capacity is used the overall machine capacity may be reduced because of additional attachment weight and or other considerations Contact your local Gradall Distributor to determine capacity limitations Other Attachment Capacities A serial number capacity plate is attached to all Gradall furnished attachments Do not assume that any Gradall attachment may be used on any Gradall Material Handler First check the listing of approved attachments on handler serial number plate located on right cab wall If the attachment in question is not included in the list was not approved for use at time of machine shipment Contact your local Gradall Distributor for possibility of use with special limitations Next if the attachment is approved for use with your handler compare maximum capac
72. must be adjusted NOTE Always use wrenches to prevent boom cable from tuming when turning adjusting nut or tightening jam nut 5 To adjust extend cable loosen jam nut on each extend cable Tighten extend cable adjusting nut until gap between cable flat washer and strong back is 1 32 to 1 16 inch When both cables are properly adjusted gap between washers and strong back on both must be equal Torque jam nuts to 100 ft lbs Be certain to perform this check adjustment every five weeks or 250 hours NOTE After several adjustments of extend cables boom sections may be mis aligned and holes in side of boom will no longer be aligned with pins in boom When this condition occurs retract cable must be adjusted If required perform following procedure to align boom sections Outriggers stabilizers are furnished as standard equip ment on 534C 10 Handlers Outriggers are intended to be used to increase stability Study your load chart carefully to determine maximum capacities for various lift situations with and without Qutriggers Outriggers are also used to level handler before picking 1 Position unit as described in step 1 of Checking and adjusting boom cables procedure Then retract boom fully stop engine and block all wheels 2 Loosen both extend cable adjusting nuts at rear of boom far enough to permit realignment 17 1 2 1 4 3 Loosen retract cable jam nut located inside boom at bottom front of
73. of angled lines 7 iu 1 represent angle of boom to horizontal as measured from horizontal plane Maximum angles are 7 below horizontal with boom fully lowered to 71 above horizontal with boom fully raised A boom angle indicator is located on left side of boom section number one to show boom angle Be sure machine is level from front to rear or indicator will provide incorrect reading Load Center Loads shown on rated capacity chart are based on the load center being two feet above and two feet forward of surfaces of horizontal forks as indicated by dimensions B and C on serial number plate The load center of a load is the center of gravity of the load For regularly shaped loads of the same material such as a pallet of blocks the center of gravity can be located by measuring the load to find its center For irregular loads or loads of dissimilar materials keep the heaviest part of the load as close to the heel of the forks as possible In all cases the load center must be centered between the forks Load Limits Some capacities shown on the rated capacity chart are based on machine stability and some are based on hydraulic lift capacity The common sense or feel an experienced operator might apply in regard to tipping loads DOES NOT APPLY to hydraulic load limits Exceeding load limits can cause damage or in some cases the markine to tip over Approved Attachments Although the carnage fork combinati
74. of front axle Hydraulic pressure for power assist feature is provided by a brake pump circuit WARNING If power assist feature should fail for any reason IT WOULD REQUIRE GREATER EFFORT TO APPLY SERVICE BRAKE It is extremely important that you NEVER STOP ENGINE WHILE TRAVELING If power assist fails stop as soon as pos sible Do not drive unit until problem has been corrected Depressing service brake inching travel pedal to brak ing portion of pedal travel causes controlled hydraulic pressure to be applied to brake units The greater the pedal travel the greater the braking force If power assist fails it will require much greater force on pedal to apply brake and stopping distance will be greater Parking Brakes A WARNING Always move parking brake switch to ON position before leaving cab Never stop engine while traveling Park ing brake will be fully applied and unit may stop abruptly A sudden stop could cause loss of control of load The parking brake is spring applied and hydraulically released Hydraulic power to release parking brake is provided by hydraulic system and is controlled by parking brake switch located on dashboard With engine running and parking brake switch in OFF position brake is pressurized to release parking brake Moving switch to ON position releases hydraulic pressure to apply parking brake With switch in ON position 4 wheel drive is disabled Note In the ev
75. parts are to be stored wrap the parts in special paper that prevents rust and corrosion Inspect Parts lt is very important to inspect all parts carefully and completely before the axle or carrier is assembled Check all parts for wear and replace damaged parts Replacement of damaged or worn parts will prevent breakdown of assembly later 13 Section 3 gt a Prepare Parts for Assembly MERITOR Inspect Tapered Roller Deep cracks or breaks in the cup cone inner race Bearings or roller surfaces e Bright wear marks on the outer surface of the roller cage Figure 3 3 Inspect the cup cone rollers and cage of all tapered roller bearings in the assembly If any of the following conditions exist the bearing must be replaced e The center of the large diameter end of the rollers are worn level with or below the surface e The center of the large diameter end of the rollers are worn to a sharp edge Figure 3 1 Figure 3 1 WORN RADIUS WEAR MARKS e Damage on rollers and on surfaces of the cup and cone inner race that touch the rollers Figure 3 4 TCHING amp PITTIN WORN SURFACE e A visible roller groove in the cup or cone inner race surfaces The groove can be seen at the small or large diameter end of both parts Figure 3 2 Figure 3 2 14 gt a Section 3 MERITOR Prepare Parts for Assembly Damage on the cup and cone inner race surfaces Inspect Main Differential that touch the
76. planetary gear axles and rollers Inspect Brakes e For condition of friction discs brake piston springs and internal brake housing surfaces Repair or Replace Parts General Information Replace worn or damaged parts of an axle assembly The following are some examples to check for repair and possible replacement Replace any fastener if corners of the head worn Replace washers if damaged e Replace gaskets oil seals or grease seals at the time of axle repair e Clean parts and apply new liquid gasket material where required when axle is assembled e Remove nicks marks and burrs from parts having machined or ground surfaces Use a fine file India stone emery cloth or crocus cloth for this purpose e Clean and repair threads of fasteners and holes Use die or tap of the correct size or a fine file for this purpose 16 gt e MERITOR CAUTION Threads must be without damage and clean so that accurate adjustment and correct torque values can be applied to fasteners and parts e Tighten all fasteners to correct torque values See chart in Section 6 for fastener torque values WARNING Do not repair axle housings by bending or straightening Repair of axle housings by bending or straightening can cause poor performance and possible unsafe operation of the axle This can cause serious personal injury Repair Welding In the interest of safety and preserving the service li
77. residual valve item 19 spring item 18 and piston amp poppet assembly item 15 in end cap item 20 NOTE Residual valve must be checked for proper seating in end cap taken so as not to scratch ring seal item 17 when installing piston amp poppet assembly item 15 in end cap item 20 8 Place new gasket item 6 on mounting face of end cap item 20 and assembly with its components to housing item 3 9 Install lock washers items 21 and bolts items 22 Torque 16 to 18 ft Ibs 10 Install pressure regulating spring assembly item 2 on push rod item 8 Install new boot item 1 SEE BLEEDING SECTION FOR COMPLETE BLEEDING INSTRUCTIONS PARTS LIST ITEM DESCRIPTION 1 BOOT PRESSURE REGULATING SPRING ASSEMBLY HOUSING e O RING CAP SCREW e GASKET RETAINING RING PUSH ROD e CUP SPOOL SPRING e CUP OND OW 12 e PISTON RING SLEEVE amp PISTON ASSEMBLY PISTON amp POPPET ASSEMBLY e O RING RING SEAL SPRING RESIDUAL VALVE END CAP LOCKWASHERS BOLTS Items included in Repair Kit 06 459 020 FIGURE 12 Model Repair Number Kit 06 460 642 06 459 020 06 460 684 06 459 020 13 GENERAL SERVICE DIAGNOSIS With Engine Off PEDAL GOES TO FLOOR 1 Brake not adjusted 1 Check adjustment Air in system Bleed brakes Inoperative brakes Check brakes Blown hydraulic line Check brake line Worn out primary
78. respect to Gradall Engineering Specifications Revision d E 1 MP 532 534 Boom MAINTENANCE TABLE OF CONTENTS Introduction Special Note on Boom Cables Note on Using the Manual Nomenclature Boom Adjustment Bearing Pad Removal Bearing Pad Installation Separating Boom Sections Removal of the Complete Boom Assembly Reinstalling the Complete Boom Assembly Separating Boom Sections 2 and 3 from Boom Section Separating Boom Section 3 from Boom Section 1 Assembling Boom Sections 2 amp 3 Boom Section 3 Assembly Boom Section 2 Assembly Boom Section Assembly Boom Cables Cable Adjustments Retradion Coble Removal Retraction Cable Reinstallation Extension Cable Removal Extension Cable Reinstallation Tilt and Auxiliary Circuit Hydraulic Hoses Auxiliary Electric Cable Crowd Cylinder Removal and Installation Fastener Torque Chari Hose Fitting Torque Chart Boom Drawings 531 6 534 5 STARTING Sema Mo 0188002 0488378 534 9 STARTING No 0344004 THROUGH 0444189 534C 10 STARTING Sena No 0266001 THROUGH 0266139 5340 6 SraRTING Semar 0588001 5340 9 STARTING Semar Ho 0544001 0340 10 STARTING 0366001 5 5 0 B 5 1 C 5 3 5 5 6 6 1 6 4 C 69 7 A 11 72 C 74 DG E GI 8 9 Appendix Appendix B Appendix C ____INTRODUCTION o C Read and understand this Manual along with the appropri
79. rollers Figure 3 5 Assembly SPALLING amp FLAKING Parts that are damaged must be replaced Inspect the following parts for wear or stress Figure 3 6 Figure 3 6 e Inside surfaces of both case halves Inspect Hypoid Pinion and Both surfaces of all thrust washers Ring Gear Sets Four trunnion ends of spider cross Teeth and splines of both side gears A CAUTION Teeth and bore of all differential pinions e Hypoid drive pinions and ring gears are Friction disc packs if used machined in matched sets When a drive pinion or ring gear of a hypoid set needs to be Y replaced both drive gear and pinion must be CAUTION replaced at the same time Always replace old or worn thrust washers e Inspect hypoid pinions and gears for wear and differential side gears and pinion gears in sets to damage Gears that are worn or damaged avoid higher stress and early damage to parts must be replaced Also verify the cone bearing seats and spline in the pinion shaft Insp ect Axle Shaft S e For wear and cracks at flange shaft and splines Replace axle shaft if required 15 Section 3 Prepare Parts for Assembly Inspect Main Housing e Forfractures and burrs in machined areas Inspect Yoke e For wear at seal journal area Replace yoke flange or sleeve if either shows too much wear at seal journal area Inspect Planetary System Parts e For existence of cracks pitting breaks or sharp edges on planetary gear teeth
80. sign in the operator s cab informing all who come in contact with the machine that it is being worked on and that personnel are on the machine A WARNING Do not move any function Double check bolt torques Check that all lubrication fluids are at the correct level Remove mechanical restraints before restarting and operating the machine following repairs Clear all personnel from area adjacent to the machine when first operating after a repair or adjustment This can eliminate the possibility of personal injury if repairs or adjustments were performed incorrectly and or if the machine performs in an uncontrollable or unexpected manner Clean machine surfaces before returning it to work Form No 29633 3 97 iv Make sure that the machine is level before retracting all cylinders Proper level is to full mark 1 4 inch in the sight gauge located on the outside of the reservoir The system contains 47 gallons of hydraulic oil Refer to the Lubrication Specifications Chart in the Operator s Manual Oil should be in good condition See Figure 1 and Figure 2 FIGURE 1 HYDRAULIC RESERVOIR ASSEM BLY SUCTION FILTER TO DRIVE Y a TRAVEL CIRCUIT aw MANIFOLD RESERVOIR FILLER BREATHER A I SIGHT GAUGE PLATE gt CONDITION IMPLEMENT INDICATOR RETURN RETURN i FILTER ie a IMPLEMENT RETURN FLOW TO IMPLEMENT CIRCUITS FIGURE 2 SIGHT GAUGE
81. stopped signals are clearly understood by both signalman and operator EMERGENCY STOP With both arms extended laterally hands open downward move anms Back and RAISE BOOM With either arm LOWER BOOM With euner arm extended horizontally lingers extended horizontally fingers closed point Ihumb upward closed point numb downward STOP With either arm extended laterally hand open downward move arm back and Worth TILT FORKS DOWN With one arm held at sade extend other am downward al about 45 EXTEND iELESCOPIC BOOM RETRACT TELESCOPIC BOOM TILT FORKS UP With one arm held Win nom hands clenched poini Wilh borh hands clenched ai side extend other arm upward thumbs oulward thumbs inward 45 CLOSE BUCKET Hold one hand OPEN BUCKET Hold one hand closed and stationary Rotate other open and stationary Rotate other MOVE SLOWLY Place one hand hand in small vertical circle with hand small vertical circle with mouonless front of hand gwing forefinger pointing honzontally al forelinger pointing horizontally al motion signal Raise load slowly is closed hand open hand THIS FAR TO Gt With hands raised and open inward move hands laterally indicating distance to go STOP ENGINE Draw thumb or lorelingear across Inroat CALIFORNIA CALIFORNIA Proposition 65 Waming Pr
82. system pressure with a low setting or missing O ring On machines with 6 300 PSI drive pressure adjust these valves to 6 800 PSI Normally these high pressure relief valves do not require checking However if there is a drive power problem and adjustment of the POR valve on the main pump does not change the pressure these valves may have to be adjusted Install a high pressure 10 000 PSI gauge hose and adapter on MA port on the pump To check these high pressure relief valves raise the setting on the POR valve on the drive pump Loosen locknut on POR valve and turn the adjusting screw clockwise one turn to increase pressure With a high pressure gauge 10 000 PSI hose and adapter on MA port set the park brake put the shifter in forward and run engine at full throttle Adjust the forward high pressure relief to 6 800 PSI The forward high pressure relief valve is on the bottom of the pump Install the high pressure gauge 10 000 PSI hose and adapter on the MB port and repeat the procedure for reverse Adjust the reverse high pressure relief to 6 800 PSI The reverse high pressure relief valve locates on top of the pump Leave high pressure gauge 10 000 PSI hose and adapter on MB port Reset the POR back to original position With park brake on put the shifter in reverse and run engine at full throttle The pressure should be 6 300 PSI Adjust POR valve as required See Figure 20 and Figure 20A The traction lock valve also has two high pressur
83. systems hydraulic oil to operate the brakes Synthetic rubber wheel cylinder cups must be used to prevent swelling This valve reduces the braking effort to any required degree depending on pedal ratio Brake pedal force is directly proportional to brake line pressure thus giving a sense of feel in the operation of the brakes Manual braking is always available whenever the hydraulic power system is not functioning This is accomplished by a mechanical follow through within the Return Port to Tank brake valve A longer pedal stroke usually with increased pedal effort will be expected when braking in this condition The manner in which the hydraulic power brake valve funtions will be discussed in the following paragraphs Oil from the pump flows through the brake valve and on to the downstream hydraulic unit as indicated Figure 3 Sections of the valve which are communicated to the return port and the tank when the valve is not operating are shown Figure 2 The compensating port Figure 2 provides for thermal expansion of the oil in the brake lines and the master cylinder The residual valve Fig 2 if used maintains pressure of 12 20 PSI in the brake lines when the pedal FIGURE 2 Manual Brake Actuating Sleeve Sleeve Guide Brake Valve Actuated Power Steering in Neutral E RETURN LINE PRESSURE 24 BRAKE LINE 2224 PRESSURE FLOW THRU 2 PRESSURE CONTROLLED PRESSURE To
84. this operation lf working with a helper review each of your duties Be certain that the boom assembly is still retracted fully IF not mechanically push the boom into the correct posilion before commenting reinstallation DO NOT reach into the beam assembly while sections are being mechanically retracted extended Stage 1 1 Fasten a rope to the retraction cable and pull the cable through the Boom Sections to the approximate final position Remove the rope 1 Instoll the retraction cable socket end with mounting hardware to the cable anchor bracket weldment Retraction Cable 3 Install the retraction cable threaded end through the rear cable sheave bracket and cable adjusting block bolted to the bottom front of Boom Section 1 RETRACTION CABLE SHEAVE AssEMB 4 feed the cable into the inside bottom front of Boom Section to the cable 3 P6 ed SED Bea AU adjustment access hole A A 5 534C 9 C 10 amp 534D 9 D 10 Push Beam At the front of Boom Section 3 feed the push beam toward the rear of the boom assemblies to line up the push beam mounting pins 6 Install the push beam mounting pins and fasteners 7 531056 534C 6 amp 5340 6 Reinstall the crowd cylinder into the retainers at the rear of Boom Section 2 B Reinstall ond torque the crowd cylinder retainer fosteners Stage 2 1 Install the retraction cable to the cable adjustment block at the bottom front of Boom Section 2 Inst
85. 04 inch 2 60 2 65 mm shim Figure 4 31 pack thickness is enough to obtain specified backlash and differential bearing preload 3 Install differential case bearing cup axle shaft housing and brake housing studs into main housing until the thread is completely attached Apply Three Bond 1134 liquid gasket material on stud threads Figure 4 28 32 gt e MERITOR 7 Install differential case bearing adjusting nut on brake housing Figure 4 31 8 Install pinion bearing cage assembly and shim pack 9 Check backlash differential preload and teeth contact See Section 5 Adjustments WARNING Small amounts of acid vapor are present when applying some liquid gasket materials during assembly and installation procedures To prevent possible serious personal injury make sure there is good ventilation in the work area If the liquid gasket material gets in eyes flush eyes with water for 15 minutes Have eyes checked by doctor 10 If all adjustments are within specifications remove brake housing Apply liquid gasket material to main housing surface 11 Install three bolts into the brake housing to adjust differential Tighten them to 19 26 lb ft 26 36 Nem T 12 Apply medium torque liquid adhesive Loctite 241 or Three Bond 1334 to lock capscrews Install adjusting nut lock and capscrews Tighten capscrews to 80 115 Ib in 9 13 Figure 4 32 o Figure 4 32 Section 4 Assembly and I
86. 0ths of a millimeter 0 00 mm Examples PC 3 3 3 OR 3 003 inch 076 mm PC 03 PC 03MM 03 OR 03 03 To change inches to millimeters multiply inches by 25 40 To change millimeters to inches multiply millimeters by 0 039 If the old pinion cone number is a plus subtract the number from the old shim pack thickness that was measured in step 2 If the old pinion cone number is a minus add the number to the old shim pack thickness that was measured in step 2 NOTE The value calculated in step 3 or 4 Is the thick ness of the standard shim pack without a variation 9 30 Look at the pinion cone PC variation number on the new drive pinion that will be installed Record the number for later use If the new pinion cone number is a plus add the number to the standard shim pack thickness that was calculated in step 3 or 4 gt e MERITOR 7 If the new pinion cone number is a minus subtract the number from the standard shim pack thickness that was calculated in step 3 or 4 NOTE The value calculated in step 6 or 7 is the thick ness of a new shim pack that will be installed EXAMPLES Inches mm 1 Old shim pack thickness 0 030 0 76 Old PC number PC 2 0 05mm 0 002 0 05 Standard shim pack thickness 0 028 0 71 New PC number PC 5 40 13mm 0 005 0 13 New shim pack thickness 0 033 0 84 2 Old shim pack thickness 0 030 0 76 Old PC nu
87. 100 psi 50 psi 3 12 gom 06 460 686 1 2 20 UNF SAE No 10 SAE No 10 1 2 14 NPTF 1500 psi 50 psi 3 12 Complete unit replaced by 06 460 674 06 461 520 1 2 20 UNF SAE No 10 SAE No 10 1 2 14 NPTF 1850 psi 50 psi 3 24 gpm Complete unit replaced by 06 461 658 06 461 550 1 2 20 UNF SAE No 10 SAE No 10 1 2 14 NPTF 1500 psi 50 psi 3 24 gpm Complete unit replaced by 06 461 656 06 461 610 9 16 18 UNF SAE No 10 SAE No 10 1 2 14 NPTF 950 psi 50 psi 3 24 gpm Complete unit replaced by 06 461 666 06 461 656 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 24 gpm 06 461 658 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1850 psi 50 psi 3 24 gpm 06 461 660 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1150 psi 50 psi 3 24 gpm 06 461 666 9 16 18 UNF SAE No 10 SAE No 10 SAE No 10 950 psi 50 psi 3 24 gpm 06 461 674 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 12 gpm For use with drum brakes has residual check valve NOTE The valves should be used within the flow capacities indicated above for optimum performance Valves are functional at lower flows but response is reduced At the higher flow operation higher pressure drops are seen 7 OPEN CENTER HYDRAULIC BRAKE VALVE PRIMARY CUP DESIGN Refer to Figure 10 Disassembly 4 Remove boot item 1 and pressure regulating spring assembly item 2 CAUTION Pressure regulating spring assembly has been set at the fac tory and should never
88. 14 NPTF 1500 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 656 06 460 654 9 16 18 UNF SAE No 8 SAE No 8 SAE No 10 1500 psi 50 psi 3 12 gpm Complete unit replaced by 06 460 676 06 460 656 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 24 gpm 06 460 658 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1850 psi 50 psi 3 24 gpm 06 460 660 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1150 psi 50 psi 3 24 gpm 06 460 662 9 16 18 UNF SAE No 10 SAE No 10 SAE No 10 1550 psi 50 psi 3 24 gpm 06 460 664 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 12 gom 06 460 666 9 16 18 UNF SAE No 10 SAE No 10 SAE No 10 950 psi 50 psi 3 24 gpm 06 460 668 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1000 psi 50 psi 3 12 gpm 06 460 670 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1550 psi 50 psi 3 8 gom 06 460 672 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 750 psi 50 psi 3 24 gpm 06 460 674 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 12 gpm 06 460 676 9 16 18 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 12 gpm 06 460 678 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1700 psi 50 psi 3 24 gpm 06 460 680 1 2 20 UNF SAE No 8 SAE No 8 SAE No 10 1550 psi 50 psi 3 8 gpm Complete unit replaced by 06 460 670 06 460 682 1 2 20 UNF SAE No 8 SAE No 8 SAE No 10 750 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 672 06 460 684 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1
89. 197 inch 4 5 mm 1 Connect brake housing assembly into hydraulic system equipped with 1000 psi 69 bar manometer 2 Activate the cylinder at least five times with 600 psi 41 4 bar Check for leaks e f there are no leaks proceed to Step 3 e f there are leaks disassemble brake housing assembly find and correct the problem 3 Wait five minutes then apply 600 psi 41 4 bar to the cylinder again gt e MERITOR e f there are no leaks proceed to Step 4 e f there are leaks disassemble brake housing assembly find and correct the problem Repeat Steps 1 to 3 4 Wait five minutes then apply 75 to 110 psi 5 1 to 7 6 bar to the cylinder again e f there are no leaks the assembly is assembled correctly e f there are leaks find and correct the problem Repeat the test again Assemble Three Function Brake Housing Assembly NOTE Before assembling brake housing assembly make sure that all surfaces and bores of brake housing and piston are free of dirt burrs and nicks 1 Select piston shim pack with the following procedure a Position parts of piston assembly in a press Measure the dimension A under 441 Ib 200 Kg pressure Figure 4 50 b Measure the dimension B Figure 4 51 Figure 4 50 441 Ib 200 Kg PISTON WITHOUT SPRINGS ACTION PLATE BRAKE DISCS REACTION PLATE Section 4 Assembly and Installation Figure 4 51 c The shim pack thickness is the
90. 5 BLACK 16 HORN VIOLET YELLOW 16 MOR BEDEZRED 16 IGN A ORANGE GRAY 16 IGN B ORANGE LT GREEN 16 IGN C ORANGE DK GREEN 16 OIL GAG BLUE BROWN 16 PB BLUE YELLOW 16 PRK BRK VIOLET 16 PRK IGN ORANGE BLACK 16 PS IGN ORANGE YELLOW 16 REV BROWN YELLOW 16 FELE C 67 SHT IGN ORANCE BROWN 16 5 RED BLACK 16 SPL ACC ORANGE 16 SPL ORANGE VIOLET 16 START A VIOLET BROWN 16 START B VIOLET BROWN 16 START C VIOLET BROWN 16 STRT SOL REDAVIOLET 10 TRC LOK BROWv GRAY 16 4X4 BROWN 16 4X4 LHT BLUE VIOLET 16 4x4 PWR t6 ELECTRICAL SCHEMATIC 924 9040 6 534C 9 534C 10 LPR 60 9114 9012 40 Cyclopac Service Procedures Proper air cleaner servicing results in maximum engine protection against the ravages of dust Proper servicing can also save time and money by maximizing filter life and dust cleaning efficiency Two of the most common problems A Over Servicing New filter elements increase in dust cleaning efficiency as dust builds up on the Measure Restriction Measure the restriction of the air cleaner with a Donaldson restriction indicator such as The Informer a service gauge or water mano meter at th
91. 50 118 14 uu 350 400 3 4 16 450 500 1 1 8 16 450 500 15 16 12 750 800 1 5 16 12 750 800 CAUTION Insufficient mounting torque can cause wheel shimmy resulting in damage to parts and extreme tire tread wear Excessive mounting torque can cause studs to break and discs to crack in the stud hole area 1 2 nut Piloted Mtg 300 350 200 250 Ball Seat Mtg Heavy Duty Ball Seat Mtg Proper maintenance of ACCU RIDE rims and wheels Accu Ride rims and wheels are thoroughly tested in Firestone laboratories on Firestone test tracks and by both small and large fleets on the highways of America All these tests plus a rigid quality control program insure maximum performance of all Accu Ride rims and wheels In order however to maintain their built in quality and to insure RIM AND WHEEL MAINTENANCE DURING TIRE INSPECTIONS 1 Check all metal surfaces thoroughly while making tire inspections including areas between duals and on inboard side of wheel Watch for excessive rust or corrosion build up cracks in metal bent flanges resulting from road obstructions deep rim tool marks on rings or in gutter areas loose missing or damaged nuts or clamps bent or stripped studs damaged missing rim drive plates matched rim parts 2 Pull damaged rims or wheels CAUTION Excessively corroded or cracked rims or rings can be dangerous Deflate tires prior to the removal of rims or wheels from the veh
92. 95 97 100 PROA 352 382 t vi e P 352 382 7 I 14 15 16 21 22 Spiral Gear amp Pinion 24 27 31 32 34 37 4 42 44 a7 Lo LE 15 ie NEM 22 27 MUN 32 15 Lae Brake Piston Assembly O ring Piston 58 A Bearing Cone Axle Shaft Oil Seal Adjusting Nut Adjusting Nut Lock Capscrew Thrust Washer Kit Rollers Planetary Pinion Snap Ring Nut 9 50 51 52 53 54 55 56 57 59 61 62 63 64 65 67 70 71 71 72 73 74 75 76 77 78 79 81 82 83 84 85 87 88 91 92 93 94 MERITOR Table of Contents Section 1 Introduction 8275 mec 1 Identification Section 2 Removal and Disassembly REMOVE qamman usu T TUTTI 2 Disassemble Ball and Ramp Brake Disassemble Trumpet Assembly Fondo dv ed ea ed std eek e 3 Disassemble Planetary System and Axle 2 2 0 1 50 6 4 Disassemble Hydraulic Apply Wet Disc 5 Disassemble Three Function Wet Disc Brake PIS SS SSG TOUS DO 7 Disassemble Differential GaS E TT ea a a eiaa 8 Disqssemble PHON Bearing Cages ds O tt
93. AIN that keys have been removed from the ignition Place the machine in a level open area with sufficient space to work safely Procure tools and platforms required for this operation Procure a rope to tie to the cable end This rope must be of sufficient length to allow accessibility whenever the cable is removed This will assist in reinstallation working with a helper be certain each of you know your individual assignments Hose Guards Remove the hose guards from the rear of Boom Section neca T Remove the crowd cylinder mounting pins from the strong back cylinder bracket d Remove the extension cable fastener hardware from the strong back cylinder bracket Pull the cable free of strong back cylinder brocket Fasten a to the cable end to aid in reinstallation Remove the strong back cylinder bracket mounting hardware Remove the strong back cylinder bracket from the rear of the machine Extension Cable Crowd Cylinder Fasteners Mounting Pins Strong Back Cylinder Bracket Ces Stage 2 1 534C amp D 9 amp 10 Remove the push beam mounting pins 1 the front of Boom Section 3 pull the push beam clear of Boom Section 3 3 Separate plug and cap the crowd cylinder hoses 4 531 6 534C 6 8 5340 6 At the rear of Boom Section 2 remove the crowd cylinder retainers Drop the crowd cylinder to the bottom of Ihe boom to give mare clearance for access to the inside of the boom
94. Always follow correct procedures when mounting and installing DUO CONE oil seals Many DUO CONE oil seal leaks result from errors made during mounting or installation of oil seal components e Never let oil touch Toric ring or lodging ramps before both oil seal rings are installed in their mounting position gt e MERITOR A WARNING To avoid serious personal injury trichloroethylene must not come in contact with your skin Do not smoke and avoid breathing vapors in closed rooms without ventilation Do not use trichloroethylene near flames welding operations or hot surfaces exceeding 900 F 482 C 1 Remove any dust oil or foreign material from Toric ring 2 lodging ramps 4 7 ring retention lips 3 8 oil seal ring 1 and ring bore 5 Clean components with trichloroethylene and a clean cotton cloth or a paper towel Figures 3 9 and 3 10 Figure 3 9 1 OIL SEAL RING 2 TORIC RING 3 BORE RETENTION LIP 4 BORE RAMP 5 RING BORE Figure 3 10 6 RING FACE 7 BORE RAMP 8 RING RETENTION LIP 9 INSTALLATION TOOL Section 3 Prepare Parts for Assembly CAUTION Make sure that Toric ring 2 is seated in oil seal ring 1 Be careful when you work with Toric ring Cuts and scratches in Toric ring may cause leaks Figure 3 11 2 Place Toric ring 2 in oil seal ring 1 in button of ring ramps 7 and against ring retention lip 8 Figure 3 12 Fig
95. Apply axle lubricant on bearing cups in cage and Assemble Drive Pinion EC uno CONES and Bearing Cage 7 Install drive pinion into bearing cage A 8 Install bearing spacer s in pinion shaft against WARNING inner bearing cone Figure 4 16 Observe all WARNINGS and CAUTIONS provided by the press manufacturer concerning press NOTE operation to avoid serious personal injury and Spacer s controls preload adjustment of drive possible damage to components during pinion bearings assembly and installation procedures 1 Place bearing cage in press Figure 4 14 Figure 4 16 Figure 4 14 BEARING CUP DRIVE PINION 27 Section 4 gt e Assembly and Installation MERITOR 9 Install outer bearing cone on pinion shaft against 5 Use appropriate tool to fasten pinion through spacer Figure 4 16 yoke flange or splined sleeve Figure 4 17 NOTE Figure 4 17 Do not install pinion oil seal in bearing cage before bearing preload adjustment Continue adjusting preload of pinion bearings 10 Press outer cone bearing with 10 ton force and check preload of bearings Figure 4 16 Adjust Pinion Bearing Preload Without Press NOTE e If the preload value is below the specified range install a thinner bearing spacer e Ifthe preload value is over the specified range 6 Tighten pinion nut with minimum torque value of install a thicker bearing spacer 465 Ib ft 630 Nem Calculation Example 7 Rotate pinion bearing c
96. Brake Pedal Compensating Port Residual Valve Check Valve FIGURE 3 Inlet Port From Pump Land B Land A Return Line Pressure Flow Thru Port Orifice Land C Master Cylinder Piston Master Cylinder 3 Reaction Chamber Hydraulic System Pressure Equal to Brake Line Pressure RETURNLINE a PRESSURE x BRAKE LINE PRESSURE CONTROLLED PRESSURE To Brake Pedal Return Line Pressure Orifice FIGURE 4 Land C Reaction Chamber Flow Thru Port Schematic of Brake Valve in Manual Operation 285 RETURNLINE 1 PRESSURE me BRAKE LINE 22 PRESSURE To Brake Pedal Inlet Port From Pump TOO e image SS Pressure Regulating Sleeve is released In drum brake systems this low pressure aids in preventing air from entering the brakes when the vehicle is at rest The residual valve is removed from models designed for disc brake systems because of the drag which would develop in this type of brake even at these relatively low pressures When force is applied to the brake pedal this force acts through the PRESSURE REGULATING SPRING to shift the PRESSURE REGULATING SPOOL restricting the flow of oil at LAND C to build up pressure when there is no requirement for pressure to the power steering or other hydraulic device Figure 3 As the pressure builds up a small amount of oil flows through the ORIFICE and down through the passage inside the sp
97. Companies Oil Suppliers sampling Labs Gradall Company OIL CLEANLINESS IS MUST tiltration system is de signed to maintain an ISO cleanliness ratio of 18 15 or better 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 and then select a method appropriate to your situation The safest way to move a disabled handler is to use a trailer of sufficient capacity The ability to steer handler increases the safety of moving the unit in some situations The steering system permits manual steering if engine or power assist feature fails However remember the fol lowing e Although manual steering is possible without power assist steering will be slow and will require much greater force Rear drive hubs must be disengaged 35 Response to manual steering will be increased if parking brake is released and front axle drive is by passed to permit front wheels to roll MOVING SHORT DISTANCES If itis only necessary to move handler a short distance less than 100 feet it is permissible to use a vehicle of sufficient capacity to tow the unit with no previous preparation Drive wheels will not roll If the unit must be moved more than 100 feet but less than 200 yards it is permissible to use a vehicle of sufficient capacity to tow unit after com
98. Disassemble Planetary System 4 Remove pinion gear flange Lift it through planetary gear pins and Axle Shaft o Remove axle shaft assembly and cone bearing NOTE If necessary use press Figure 2 7 Before removing planetary gears place housing in horizontal position or place cloth between Figure 2 7 pinion gear flange and housing flange to keep rollers from falling down into housing To avoid mixing them be sure to put rollers and spacers of each planetary gear in separate plastic bags 1 With pliers remove snap rings Disassemble planetary gears and rollers Figure 2 5 Figure 2 5 5 5 6 If necessary to change bearing cups remove them with correct puller 7 lf necessary to replace DUO CONE oil seal or axle shaft roller bearing cone use correct puller Figure 2 8 Figure 2 8 2 Remove axle shaft adjusting nut lock 3 Remove axle shaft adjusting nut lock with special tool illustrated in Section 6 Figure 2 6 DUO CONE OIL SEAL Figure 2 6 2 MERITOR Disassemble Hydraulic Apply Wet Disc Brake 1 Remove piston return spring capscrews 2 Remove return springs 3 Remove brake piston assembly Figure 2 9 Figure 2 9 CAUTION Ground oil seal surfaces must be properly protected to avoid damage Whenever necessary use No 600 sandpaper to correct any damage 4 If necessary replace brake piston oil seals Figure 2 10 Figure 2
99. E WANK RETURN LINE A new front axle housing went into production starting 534C 9 Serial No 0344394 and 534C 10 Serial No 0266057 When the new front motor design went into production several units later the front axle housing stayed the same The park brake is internal in the front axle differential assembly The brake test procedure remains the same However the park brake components are different See Figure 8D To check for friction disc wear the axle must be disassembled and reassembled according to Rockwell Maintenance Manual No 9D The brake disc thickness is 0 1245 There is an 8 10 maximum wear factor allowed on the discs The minimum disc thickness allowed is 0 1120 See Figure 8E Form No 29633 3 97 8 FIGURE 8D FRONT AXLE ASSEMBLY P N 9114 3199 STARTING 534C 9 SERIAL NO 0344394 534C 10 SERIAL NO 0266057 FIGURE 8E DRIVE TRAIN BRAKE ASSEMBLY Form No 29633 3 97 9 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL ml ci A Reason for Charge Pressure Check To ensure proper park brake operation charge pressure needs to be at proper specification Since temperature can affect results make certain to test system with warm oil minimum 100 F Control pressure is modified charge pressure If charge pressure is low control pressure may be low and machine speed reduced Thus drive performance is adversely affected by low charge pressure Install a low pressure gauge 1 000 PSI
100. E 7 Primary Cup Ring Seal amp O Ring FIGURE 8 Check Valve Sliding Piston FIGURE 9 SPECIFICATIONS CHART Part Brake Pressure Flow Thru Return Brake Flow Number Port Port Port Port Line Pressure Capacity with power 06 460 520 1 2 20 UNF SAE No 10 SAE No 10 1 2 14 NPTF 1850 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 658 06 460 522 9 16 18 UNF SAE No 10 SAE No 10 SAE No 10 1850 psi 50 psi 3 24 gpm 06 460 550 1 2 20 UNF SAE No 10 SAE No 10 1 2 14 NPTF 1500 psi 50 psi 3 24 gom Complete unit replaced by 06 460 656 06 460 560 1 2 20 UNF SAE No 8 SAE No 8 SAE No 10 1550 psi 50 psi 3 24 gom Complete unit replaced by 06 460 656 06 460 570 9 16 18 UNF SAE No 8 SAE No 8 SAE No 10 1550 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 662 06 460 580 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 656 06 460 588 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1550 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 664 06 460 610 9 16 18 UNF SAE No 10 SAE No 10 1 2 14 NPTF 950 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 666 06 460 620 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1500 psi 50 psi 3 24 gpm Complete unit replaced by 06 460 656 06 460 642 1 2 20 UNF SAE No 10 SAE No 10 SAE No 10 1550 psi 50 psi 3 24 gpm 06 460 650 1 2 20 UNF SAE No 10 SAE No 10 1 2
101. ES DOWN PART WAY THEN BOUNCES BACK 1 Insufficient flow from pump 1 Check and fill reservoir N Small volume from pump at idle Crack throttle and recheck N CAUTION Make sure the machine is in a safe and controlled state before attempting any servicing including bleeding the brake system Manual and pressure bleeding are two methods of bleeding a brake system MICO recommends using on the brake closest to brake valve first When all flow stops from bleeder close it and allow pedal to return to rest 4 Wait at least 30 seconds and repeat the process until all air has been expelled from that brake Then go on to the next closest brake bleeder and repeat process until all brakes have been bled Brakes not adjusted Check adjustment Air in system Bleed system an AR NO POWER STEERING OR OTHER DOWNSTREAM HYDRAULIC ACTION AT ANY TIME 1 Hydraulic lines crossed 1 Recheck circuit 2 No hydraulic action at any time 2 Check and fill reservoir Check relief valve setting on pump Check for proper rotation at pump vee belt sheared keys etc NO OR SLOW POWER STEERING WITH BRAKES APPLIED 1 Recheck relief valve on pump for proper setting 2 Check and fill reservoir 3 Check and tighten pump belt if necessary one of these two methods of bleeding the Open Center Power Brake Valve and the rest of the brake system CAUTION Be sure brake valve is installed properly and brakes adjusted correctly
102. ESCRIPTION THREAD Pinion Nut M24 x 1 5 6H 465 570 lb ft 630 775 Nem Capscrew Center Housing M14 x 1 5 6G 150 185 lb ft 205 250 Nem Nut Stud Center Housing M14 x 1 5 6H 120 150 lb ft 160 205 Nem Capscrew Differential Case M10 x 1 5 6G 48 64 lb ft 64 87 Nem Capscrew Spiral Gear M10 x 1 0 6G 66 75 90 100 Nem Capscrew Pinion Cage M12 x 1 75 6G 67 91 lb ft 90 125 Nem Capscrew Lock Adjuster Ring M6 6G 80 115 Ib in 9 13 Nem Capscrew Adjusting Nut Lock M8 x 1 25 6G 17 23 lb ft 23 31 Nem Bolt Return Spring M6 x 1 0 6G 80 115 Ib in 9 0 13 0 Nem Capscrew Planetary Pinion Axle M10 x 1 5 6G 17 23 Ib ft 23 31 Nem Plug Level M24 x 1 5 35 lb ft min 47 Nem min Plug Drain M24 x 1 5 35 lb ft min 47 Nem min Plug Vent M12 x 1 5 15 lb ft min 20 Nem min 57 gt MERITOR Specifications Section 6 PROA 352 G2H G2M x y SS 19 58 MERITOR DESCRIPTION THREAD Pinion Nut M24 x 1 5 6H Capscrew Center Housing M14 x 1 5 6G Nut Stud Center Housing M14 x 1 5 6H Capscrew Differential Case M10 x 1 5 6G Capscrew Spiral Gear M10 x 1 0 6G Capscrew Pinion Cage M12 x 1 75 6G Capscrew Lock Adjuster Ring M6 6G Capscrew Adjusting Nut Lock M8 x 1 25 6G Capscrew Brake Housing M8 x 1 25 6G Capscrew Brake Cylinder Support M8 x 1 25 6G Capscrew Brake Cylinder M10 x 1 5 6G Cover Brake Cylinder M80 x 1 5 6G Capscrew Brake Cyl
103. FIRESTONE 7 5 FL5 BASE FIRESTONE 7 5 N5 SIDE RING Bead Seat ON FIRESTONE 7 5 FL5 BASE Tos High Tire Will Not Fit Properly PROPER RIM WIDTH IMPROPER RIM WIDTH NOTE When in doubt of component compatibility refer to the U S Department of Trans portation National Highway Traffic Safety Administration s Multipiece Rim Wheel Matching Chart Chart is available from D O T NHTSA Office of Defect Investigation all rim and wheel distributors and all Firestone Sales Offices GND 3 OIL GAG DIL PRESS WATER TEMP GAUGE FUL START B SWITCH A ET Ti START A SHT IGN GN B PS IGN Y O Ce HORN PRK BRK IGN C PRK IGN START C START A ae BAT Ky IGNITION q START B zn PARK BRAKE SWITCH PB LHT 4X4 PWR 2 4 WHEEL DRIVE SWITCH T 4X4 LHT 4 4 LIGHT GND 5 gt aa oe 72 2 2 2 2 2 5 HR MTR GND 2 PRK BRK DIODE gt UJ aa PARK BRAKE SOLENOID VALVE a TRACTION LOCK SWITCH 4X4 J ER J BACK UP AL ARM i GND 4 cs i TRACTION ss LOCK VALVE REV B a ACC C FUL GAG ALT EXC B ALT EXC A PRK BRK START C PRK IGN GH JK LM START B ode
104. ILTER ENGINE COMPARTMENT HYDRAULIC RESERVOIR FIGURE 10 MAIN PUMP ASSEMBLY SIDE VIEW Z TA SS 2 Cn 4 NS 8 Wa E CLIE CHARGE PUMP RELIEF VALVE GSS a mina LL pa j CHARGE PUMP OUTPUT PORT Form No 29633 3 97 11 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL _V Charge Pressure continued I FIGURE 11 REAR DRIVE MOTOR ASSEMBLIES MOUNTED FIGURE 11A FIGURE 12 SUM FRONT DRIVE MOTOR SIDE VIEW MAIN PUMP ASSEMBLY REAR VIEW G PORT BEGIN POINT ADJUSTMENT Form No 29633 3 97 12 BM Control Pressure 0000 Reason for Control Pressure Check To ensure control pressure is correct for proper machine speed For the machine to move at proper engine speed control pressure should match engine RPM Install a low pressure gauge 1 000 PSI hose and adapter on the drive pump control pressure Ps port Remove the hose from port and plug NOTE Before starting make sure the gauge can be observed in the operator s cab and apply the park brake Start the engine and run at full throttle soeed 2500 2700 RPM With the pump in neutral the gauge should read 380 PSI This may vary 15 PSI See Figure 13 Use a tachometer to monitor engine speed Start the engine and run at 1100 RPM While watching the pressure gauge
105. Location G Right Side Pod Location H Left Side Pod Location Bottom Adjustment Pad Locations 6 amp H 1 To add shims to Area 3 or 4 Pad Location or H install a wedge to Pad Location G to force the boom to the opposite side Pad Location install a shim remove the wedge and repeat step 29 on opposite side Pad Location H Apply 4 242 to the bearing pad mounting bolt threads Re torque the bearing pad mounting bolts Remove any wedges you installed prp Pad Location G Right Side x The Boom Bearing Pads are now fully adjusted AREA 1 AND Area 2 Bearing pad removal from Area and Area 2 is accomplished with the boom extended approximately three fourths of the total stroke If the pinch point is tight you may have to remove shims and spacers from the opposite bearing pod Record quantities and Part Numbers of the spacers and shims removed from each location This will assist you in reinstalling the bearing pad spacer and shim package em SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES Removal Pad Location A 1 Raise the boom assembly approximately ft off the ground Location C 1 Remove the key from the ignition and fasten a do not operate tag to the Right inside steering wheel 3 Remove the bearing pad mounting bolts and washers 4 Remove the shims s
106. N FLAME AND SMOKING MATERIALS WHEN REFUELING _ using booster battery charger always connect POSITIVE TO POSITIVE NEGATIVE TO NEGATIVE Located on Battery Cover Located on Fuel Tank Part No 7702 3007 Part No 9100 3052 Located on Side of Boom Part No 9100 3031 Located on Joystick Pedestal Part No 9130 3047 Std DO NOT INSERT HAND IN OPENING WHILE ENGINE IS RUNNING Located on Engine Compartment Part No 9103 3011 PINCH POINT AREA TO PREVENT INJURY KEEP CLEAR ANYTIME MACHINE IS RUNNING Located on Right amp Left Rear Frame Part No 9104 3209 Decals A CAUTION PRESSURIZED COOLING SYSTEM REMOVE CAP SLOWLY Located on Engine Cover Part No 9104 3210 NO RIDERS Figi EF d Located Outside Cab Part No 9104 321 I Located on Engine Compartment Part No 7734 3018 __ WARNING AMI pe ning ele EA rr p iiu WHEN LIFTING PERSOANE USE ONLY A PERSONNEL WORE PLATFORM DO NOI DRIVE MACHINE WITH IN PLATFORM WHEN PERSOMMEL ARE IN PLATFORM REMAIN SEAT ED N CAB WITH PERSONE pur PERSG E KF PLA MANUAL BEFORE LF TG PERSONNEL QC NOT USE PERSONNEL WORK PLATFORM WITHOUT PROPER GAADALL HANDLEFUPERSONINEL WORK PLATFORM CAPACI d u alse FARLRE TO CORY OMAD RESULT H SERI IS NUR OR Located mud guard Part No 9055 3027 r EW z io es
107. NOT STAND IN FRONT OF RIM TIRE DUR ING DEFLATION Follow recommended demounting procedures Check for damaged or worn parts Mark defective parts for destruction to preclude their future use During vehicle operation Before putting new vehicles into service clamps and wheel nuts should be checked for proper torque Do not overload rims or wheels Insure that the combination of load and vehicle weight does not exceed the rated load of the rims or wheels used Rims and wheels are designed to sustain their rated load using the maximum tire size recommended for that rim width by the Tire amp Rim Association Inspect rims and wheels for damage during tire checks and at periodic maintenance intervals Re move and replace defective parts Do not exceed maximum inflation pressures This is determined by the size and ply rating of the tire but is not to exceed the maximum inflation listed for the rim or wheel It is also important to main tain uniform inflation in both tires of a dual assem bly so that weight is equally sustained Do not run vehicle on one tire of dual assembly When there is loss of air in a dual tire the carrying capability is reduced and the load must be sus tained by the other tire and rim Both tires should be inflated to balanced recommended pressures be fore further operation Never re inflate a tire that has been run flat or seriously underinflated without first breaking rim down and reassembling rim
108. NSTRUMENT IDENTIFICATION FORWARD REVEARSE LE ATTACHMENT TILT LEVER MACHINE LEVEL LEVER SERVICE BRAKE d INCHING TRAVEL PEDAL Ip LEVEL 7 ENGINE COOLANT TEMPERATURE GAGE1 _ O 4 BRAKE SWITCH 4X4 IND LIGHT AX2 4XA4 SWITCH IGNITION Note Some optional items air Vonditioner defroster fan wind shield wiper etc are nol shown in this illustration ENGINE OIL PRESSURE GAGE ROTATING BEACON SWITCH LIGHTS SWITCH 1 1 AUX LIGHT SWITCH HEATER SWITCH STARTING AID SWITCH HOURMETER E 5 H HORN BUTTON CY ATTACHMENT TILT SWITCH pin BOOM CONTROL JOYSTICK SJ ER ATTACHMENT TILT LEVER OPTIONAL LOCATION FRACTION LOCK OUTRIGGER CONTROL LEVERS SWITCH PEDAL 5340 10 ONLY ACCELERATOR PEDAL ITEMS PRECEDED BY AN ASTERISK ARE OPTIONAL AND MAY NOT BE FURNISHED ON YOUR HANDLER 10 WARNING A brief description of controls and instru ments is provided here as a convenience for the operator These descriptions DO NOT provide complete operating instruc tions Read and understand this manual the EMI Rough Terrain Forklift Safety Manual and the Gradall Material Handler Safety Manual NOTE These descriptions are provided in alpha betical sequence in accordance with the nomen clature shown on the facing page Accelerator Pedal The accelerator pedal is connected to the engine spee
109. OD As the booms extend and retroct the roller rotates against the hoses maintaining the proper radius point of the hose The lips keep the hose captive on the roller Note Boom Section inverted 180 upside down Host GUARD PLATE Located in the back of the hose sheave the hose guard plate protects the hoses from contamination and prevents them from jumping the lips of the hose sheave Hose Guard Hose Guard Hose ASSEMBLY Located at the outside bottom of Boom Section 1 the Hose Take Up Assembly absorbs sudden shocks which impact the tlt circuit ond auxiliary circuit hydroulic hoses minimizing the possibility of hose failure Hose Takeup Bracket Assembly Note Boom Section Inverted 180 upside down Keep hydraulic hoses located in a fixed position Hose movement and damage is minimized when hoses are properly clamped Hose Clamps Typical Special attachments may require additional hydraulic and electric circuits These circuits ore fed to the attachments through the right side of the boom assembly They are similar to the FASTENERS Refer to Appendix at the rear of this Manual for correct torque values amp G TITE 242 P N 1440 3364 must be used on all fasteners when setting the torque ond Washer Special dimensioned pins are used in some locations to fasten components together During installation and removal care must be taken to protect the outside surface ond ony lubr
110. SURE PORT AAACN Emm nmn I ap NE T a x 5 PORT Form No 29633 3 97 15 5346 9 amp 5346 10 HYDROLASTIC DRIVE PERFORMANCE CHECKS MANUAL FLOOR PLATE ASSEMBLY FIGURE 16 SERVICE BRAKE PEDAL 12 1 4 G NS ei INCHING VALVE FIGURE 17 ROLLER BRAKE VALVE PLUNGER gt D 2 16 29633 3 97 IN sus Definition The point at which the front motor begins to stroke toward minimum displacement Reason for Front Motor Begin Point Check Without proper adjustment machine speed on a flat smooth surface will not meet specifications The motor may not be shifting to a maximum speed position Install a high pressure gauge 10 000 PSI hose and adapter on MB port on the drive pump Adjust the reverse high pressure relief valve to 3 300 PSI by loosening the locknut The reverse high pressure port relief is on the top left of the pump Install adopter test port P N 7713 3089 6 run tee and low pressure gauge 1 000 PSI into the Ps port of the pump Ps port is connection for the inching valve hose Set the parking brake and block the tires to prevent movement of the machine Machine should be in 2WD Shut off the machine Remove plugs from G and M ports of the front drive motor G port is found at the bottom of the front drive motor controls M port locates at the
111. Section 3 past the access holes in Boom Section 2 1 Lower the boom to ft off ground The front of the boom will pivot down creating clearance at Pad Location F 3 Remove the key from the ignition and fasten a do not operate tag to the steering wheel 4 Through the access hole remove the bearing pad mounting bolts at Pad Location F 5 Remove the shims spacers and bearing pads Removal Pad Location amp H Extend Boom Section 3 past the access holes in Boom Section 2 2 Remove the key from the ignition and fasten a do not operate tag to the sleenng wheel 3 Install a wedge at pad location G or and force the Boom Section to the opposite side 4 Remove the bearing pad mounting bolts 5 Remove shims spacers and bearing pads 6 Remove the wedge installed in Step 3 7 Repeat Steps 2 thru 5 for opposite side bearing pad removal Location 6 Location H Right Outside TEE Left Outside 9215215 5 clearance for spacers or shims If no spacer or shim is installed or if only the spacer is installed with the bearing pad use two 2 flat washers under the head of the bearing pad mounting bolt This will ensure the bolt will not protrude past the chamfer on the pad Do Not install a shim against a bearing pad This will min the integrity of the fastener system If there is not room for a spacer and a shim use only the spacer Use 242 Gradall P N 1440 3364
112. Section 4 gt e Assembly and Installation MERITOR Assemble Three Function Assemble Ball and Ramp Brake Release Bolts and Brake Cylinder Assembly and Sleeves Install on Main Housing 1 Apply Loctite 516 on bolt threads Figure 4 67 1 Apply liquid gasket material FAG 3 on brake cylinder surface that fastens to brake cylinder support Assemble brake cylinder oil seals piston and brake cylinder support Tighten capscrews that fasten brake cylinder support 19 26 Ib ft LOCTITE 516 SILASTIC 780 RTV 26 36 Nem Figure 4 69 p Figure 4 69 LIQUID GASKET MATERIAL NOT ALLOWED 2 Apply liquid gasket material Silastic 780 RTV Dow Corning on non threaded bolt shaft Figure 4 67 3 Install bolts and sleeves Tighten to 25 34 Ib ft minimum 34 46 Nem Figure 4 68 4 e Assemble 2 larger bolts 3 346 in 85 mm with larger sleeves 1 in 26 mm e Assemble shorter bolt 3 070 in 78 mm with shorter sleeve 0 750 in 19 mm Figure 4 68 SHORT BOLT AND SLEEVE INTO THIS BRAKE HOUSING POETON 44 gt e MERITOR 2 While out of the axle connect cylinder assembly to hydraulic system Apply 400 psi 27 6 bar pressure to compress spring until piston is against brake cylinder Repeat this operation four to five times to make sure there is no leakage Figure 4 70 Section 4 Assembly and Installation 4 While the cylinder is pressurized with 400 psi 27 6 bar apply liquid adhesive L
113. Switch optional This rotary switch con trols heater fan Rotate clockwise to start fan Continued clockwise rotation controls fan speed Horn Button Depress button to sound horn Hourmeter This meter indicates total time of engine operation in hours and tenths of hours Ignition Switch This switch is actuated by a key In ON position turned clockwise voltage is available for all electrical functions Full clockwise rotation engages starter motor Turn key counterclockwise to stop engine and remove voltage from all electrical functions Level indicator This indicator a bubble level enables the operator to determine the left to right level condition of the handler Lights Switch optional This switch controls optional lighting which may be provided with the handler Machine Level Lever Std This lever controls the relationship of the handler frame to the front axle Move the lever to left to tilt frame to left or move lever to right to tilt frame to right Outrigger Control Levers 534C 10 only Left lever controls left outrigger and right lever controls right out rigger Push levers forward to lower outriggers or pull levers to rear to raise outrigegers Parking Brake Switch This switch controls the application and release of the parking brake Parking Brake Indicator Light Glows red to indicate parking brake is applied Rotating Beacon 5witch optional This switch controls operation of rotating beacon
114. The PRESSURE REGULATING SLEEVE contacts the MANUAL BRAKE ACTUATING SLEEVE which in turn pushes directly on the master cylinder piston thereby building pressure in the MASTER CYLINDER Figure 5 This requires millimeters inches a longer stroke in the pedal This amount of pressure that can be generated in the brake lines in manual operation is proportional to the pedal ratio and the effort which the operator is able to exert on the pedal In most cases the operator is not able to build as much pressure in the brake line as can be done in power operations The ports from the pump are restricted when the valve is actuated manually however as soon as the engine is started hydraulic pressure will push the MANUAL BRAKE ACTUATING SLEEVE back against the retaining ring which contains it and the valve again functions with power This is rather an abrupt action when the engine is started causing the brake pedal to return to its power mode position and it is suggested that the brakes not be applied manually when starting the engine BRAKE PORT INSTALLATION INSTRUCTIONS 1 Mount MICO Open Center Power Brake Valve on vehicle and complete push rod and pedal hook up NOTE It is important that the system reservoir be mounted above the brake valve or that the return line have a vertical section of one foot directly above the valve The pedal assembly must have its own return spring DO NOT rely on the intern
115. age several times so Data bearings make normal contact Radius 9 3 cm 3 65 in 8 Attach torque wrench on drive pinion nut Rotate Load 2 3 Kg 5 0 Ibs pinion and check if preload is in specified range Calculation Procedure Make the reading during the rotation not the 2 3 Kg x 9 3 cm 21 4 Kg cm starting value Figure 4 18 5 0 Ib x 3 65 in 18 25 Ib in Conversion to Nem Figure 4 18 21 4 x 0 098 2 1 Nem 18 25 x 0 113 2 1 Nem NOTE e To convert to Nem multiply by 0 113 e Kg cm to Nem multiply by 0 098 1 Lubricate bearing cups and cones with specified oil 2 Install yoke or flange without pinion oil seal 3 Install pinion bearing cage assembly on main housing without bearing cage shims 9 If the pinion bearing preload torque value is under or above the specified preload torque of 5 20 Ib in 4 Fasten bearing cage assembly on main housing 0 55 2 2 Nem change shims to thick or thinner with two capscrews Apply minimum specified size as necessary Repeat pinion bearing torque of 67 lb ft 90 Nem o preload check o 28 gt e MERITOR 10 After getting specified preload remove bearing cage from main housing and disassemble yoke or input flange CAUTION Make sure oil seal lips are clean and free from dirt Dirt can cause leakage between seal and yoke or flange 11 Install pinion oil seal with the appropriate tool a Apply extreme pressure lithium soap grease to oil sea
116. ain housing on stand Figure 2 1 7 Remove drain plugs from brake housing and main housing with 12 mm Allen wrench Drain axle oil Figure 2 1 The PROA 352 axle is shown to illustrate procedures in this maintenance manual MERITOR Disassemble Ball and Ramp Brake NOTE Identify all parts before disassembly to ensure proper reassembly To disassemble hydraulic apply wet disc brake go to page 5 To disassemble three function brake go to page 5 Figure 2 2 Figure 2 2 ADJUSTING NUT M SPRING PISTON O RING WITHOUT HYDRAULIC PRESSURE 2 gt gt gt NE BRAKE CYLINDER SUPPORT N 7 WG BRAKE N CYLINDER Remove brake cylinder cover Remove nut and nut lock Loosen brake cylinder capscrews ge uem Remove brake cylinder assembly from main housing MERITOR CAUTION Loosen and remove brake cylinder capscrews alternately to avoid spring load damage to parts 5 Disassemble brake cylinder assembly Remove brake release capscrew Loosen and remove brake cylinder capscrews alternately to avoid spring load to be supported by only one capscrew 6 Remove spring piston and O ring seals Do not cut or scratch them 7 Clean cylinder and brake support surfaces Do not damage ground surfaces 8 Put parts of each brake cylinder assembly in separate plastic bags to avoid mixing them Disassemble Trumpet Assemb
117. al spring in the valve for this function Pedal should be adjusted to allow 1 32 clearance between pressure regulating rod and actuator Bleed system see bleeding instruction on page 14 Be sure all hydraulic fittings are tight and visually check system for leaks with power applied S THREE OPEN CENTER HYDRAULIC POWER BRAKE VALVE DESIGNS PRIMARY CUP DESIGN The Primary Cup Design uses a residual valve This valve will maintain a pressure of 12 20 PSI in the brake lines when the pedalis released When used in drum brake systems this low pressure aids in preventing air from entering the brakes when the vehicle is at rest RING SEAL DESIGN The Ring Seal Design is used mainly in disc brake systems The residual valve is removed from models designed for disc brake systems because of the pressure they maintain in the brake lines when the pedal is released Even these relatively low pressures 12 20 PSI would develop drag in this type of brake SLIDING PISTON DESIGN v i The Sliding Piston Design was created with a specific function in mind A specially designed piston slides inside the primary piston when the brake pedal is actuated If primary piston strokes too far the brake pedal will be pulled down witha short abrupt stroke This indicates to the operator that maintenance is required 6 ce a zum om cm a e Residual Valve FIGUR
118. all the retraction cable sheave and all the related components Be certain the cable guards are installed k LS Cable Guard 3 Install the hose guards to the rear of the boom 4 Place the strong back cylinder bracket in place at the rear of Boom Section Stage 3 1 Install the crowd cylinder into the strong back cylinder bracket 2 Install previously removed shims to the top and bottom of the strong back cylinder bracket 3 Torque the strong back cylinder bracket fasteners and apply 4 7 242 to threads 4 Reconnect the crowd cylinder hydraulic hoses 5 Reinstall fasteners and springs to the extension cable threads at the strong back cylinder bracket 6 nnn Stage 4 534C 9 C 10 amp 534D 9 D 10 ONLY 1 At the retraction cable adjusting block located at the inside bottom front of Boom Section tighten the cable adjusting nut until the third thread lines up with the front edge of the access hole Install the jam nut to the adjusting nut and torque to 100 ft Ib At the strong back tighten the extension cable adjusting nut until gap between cable flat washer and strong back is 1 32 to 1 16 inch Gap for both washers should be equal When tightening make sure that the cable is not twisting 4 Install the jam nut and torque to 100 ft lb 5 Adjust the cables to specifications given on page 7 1 Strong Back 7 Extensi
119. and cylinder locking pins 5 Refill the hydraulic system if necessary Stage 3 1 Remove lifting tackle and tag line 2 Drive the machine to an area with sufficient space for full boom circuit operation 3 Start up the machine and cycle all boom functions a sufficient length of time to warm up the hydraulic system to at least 120 F 4 After completion of Step 3 check all circuits for hydraulic leaks correcting where necessary 5 Re check the hydraulic system capacity level fill up if necessary Stage 4 1 Inspect boom bearing pads for comect adjustment If adjustment is required see Section 2 Boom Adjustment 2 Inspect retraction and extension cable for proper installation ond adjustment If adjustment is required see Section 7 3 Inspect hydraulic hose installations to ensure they are not rolling under twist If they are under twist readjust by loosening fittings and clamps to relieve the twist Re torque using two wrenches at the fittings Tighten all hose clamps 4 Inspect auxiliary circuit electric cable for proper installation should be tight and Apply eerrrE 545 Gradall P N 1440 4043 to oll hydraulic fittings Connect all hydraulic hoses to the proper circuits and torque Refer to identification tags applied during removal operation roll simultaneous with the auxiliary hydraulic hoses Correct if necessary The Boom should now be properly installed and ready to return to service
120. ange and pinion nut Fasten yoke or flange with appropriate tool Tighten pinion nut to minimum specified torque of 465 570 lb ft 630 775 Nem Figure 4 27 o Figure 4 27 CAUTION The fit between input yoke or flange splines and drive pinion is tight To install yoke or flange into pinion use pinion nut and appropriate tool to fasten it Never use hammer or mallet A hammer or mallet will damage yoke or flange 31 Section 4 gt Assembly and Installation MERITOR 5 If ring gear is mounted on opposite brake housing 4 Install differential case assembly Figure 4 29 side loosen two capscrews that fasten pinion bearing cage Remove cage and mount it after differential case is assembled Figure 4 29 If ring gear is mounted on brake housing side install other capscrews that fasten pinion bearing cage Tighten the capscrews to a torque of 67 91 lb ft 91 120 Nem Install Differential Housing Assembly into Main Housing With Shims 1 The preload of differential bearings is adjusted by selecting proper shim pack to obtain a torque of 15 35 Ib in 1 7 4 0 Nem 4p 5 Install brake housing and other differential case 2 Install shims Combine two shims to obtain bearing cup Figure 4 30 desired thickness Figure 4 28 Figure 4 30 Figure 4 28 6 Install three bolts to adjust differential on brake housing Tighten to a torque of 19 26 Ib ft 26 36 Nem Figure 4 31 o NOTE Usually a 0 102 0 1
121. are caused by im proper mounting and demounting techniques impact with road obstruc Sprung side ring resulting from improper mount ing procedures of lock ring re sulting from ex cessive corrosion This may occur with this part as tions and excessive clamping torques 2 Replace damaged parts CAUTION Insure that replacements are made with the proper sizes and ty pes of rims and rings well as others if protective meas ures described on following page are not taken Continued NOTE Openings between ends of split side rings must not be less than 3 32 except where the ring design calls for an abutting condition or more than 5 16 after ring is seated in during operation Split lock rings used with endless side rings must not butt Proper maintenance of ACCU RIDE rims and wheels 3 Thoroughly remove rust dirt and other for eign materials from all surfaces Hand or elec tric wire brushes sand blasting or chemical baths may be used Gutter of rim base should be cleared of rust and other materials obstructing safe positive continued Bead seat areas of rim should be free of rust and rubber de posits This is especially im portant for drop center tubeless rims because the 15 bead seat is the air sealing seating of rings element 5 Lubricate tire side of rim base just prior to mounting tire Avoid the use of any lubricant which contains water or solvent that is
122. ate Owner Operator Manual the Gradall Material Handler Safety Manual the Rough Terain Forklift 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 ORIENTATION When used to descnbe the location of components on the machine the directions font rear lef and right indicate the point of view of a person sitting in the operators seat in the cab FASTENER AND FITTING TORQUE Torque values for mechanical fasteners and hydraulic fittings are given in Appendix and Appendix They must be adhered to at all times 4 242 P N 1440 3364 must be used on oll bolt threads 4667 545 P N 1440 4043 must be used on all hydraulic fittings 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 twist PREPARING THE MATERIAL HANDIER FOR SERVICE 1 Before performing any maintenance or service position the material handler in a safe open level area well away from traffic lanes buildings other equipment or personnel Sel the park brake and shift the transmission to Neutral Lower the forks to the ground Place the controls in Neutral idle the engine 3 minutes for gradual coaling then shut the engine off 5 Cycle the hydraulic
123. be disas sembled re adjusted or interchanged with another valve item 10 or bore of housing item 11 are in any way dam aged scratched or broken the entire assembly must be replaced These parts are select fitted and are not inter changeable or re placeable with ser vice items on end of spring item 19 Assemble end cap item 21 with its components to housing item 11 making sure lip on primary cup item 17 has properly engaged bore of housing Install lock washer items 22 and bolts items 23 Torque 16 to 18 ft Ibs Install pressure regulating spring assembly item 2 on push rod item 4 Install new boot item 1 Assembly 1 Install new cup item 9 on sleeve SEE BLEEDING SECTION FOR 2 Separate end cap item 21 from COMPLETE BLEEDING housing item 11 item 10 and new cup item 5 on spool item 6 INSTRUCTIONS CAUTION Care must be taken as end cap is under CAUTION Lips on cups items tension of spring 5 amp 9 should be item 19 away from ends of Hemove gasket item 14 z and 3 Remove primary cup item 17 retainer item 18 spring item 19 Place spring item 7 in sleeve and residual valve item 20 from d T Install spool item 6 in sleeve end cap item 21 pool ET 4 Remove cap screw item 13 from under side of housing item 11 Remove o ring item 12 from cap screw 5 Remove retaining ring item 8 from housing it
124. blows progressively toward other cutaway portion until entire toe of ring has passed over the rim gutter Check seating of ring as shown below and in flate tire to recommended pressure Turn assembly over and unseat tire bead from back flange in same manner as loosening bead from side ring in first step Stand tire up and remove rim base NOTE It is unnecessary to free the side ring from the tire bead if tire is to be removed for tube repair and im mediately replaced Simply loosen bead from back permanent flange as in third demounting step Then turn the assembly over and remove ring with tire attached as in second demounting step IMPORTANT RH 5 side rings are not interchangeable on other size RH 5 bases Make certain side ring is right size for the rim base you are using SAFETY PRECAUTIONS 1 Before inflating tire be certain side ring has completely cleared the gut ter of rim base In this position the side ring can be depressed by hand This can be easily felt and seen DO NOT INFLATE IF SIDE RING DOES NOT MOVE FREELY 2 Inflate tire in safety cage or use lock ring guard In emergency situa tions where a safety cage or portable safety device is not available use clip on type air chuck so that opera tor may stand aside during inflation 3 Use only parts free from damage or heavy rust especially at the area of contact between the rim base and side ring 4 Insure that tire is completely deflat
125. bly of the boom Assembly procedures start with Boom Section 3 followed in order by Boom Sections 2 and They also are given using shop conditions only with the Boom Sections inverted 180 upside down The instructions cover all 532 and 534 and D series booms of any length Deviations from standard procedures that cover all models ore indicated with appropriate notations It would not be practical to attempt to cover every repair situation that might occur in the field Therefore these instructions cover the complete boom assembly and individual components You may have to adapt these procedures to fit specific field situations CAUTION Use LOCTITE 242 Grodall P N 1440 3364 on all bolt threads Use soere 545 Gradall P N 1440 4043 on all hydraulic tube fittings Torque fasteners and hydraulic fittings to the values given in Appendix amp Appendix B Shim bearing pads to of tight fit You may have to final adjust the bearing pads after the boom is installed on the machine and hydraulic power is available Follow instructions given in Section 2 for bearing pad adjustment Coat the interior of all bushings and sheaves with Mystik Tetrimoly grease Gradall P N 1440 4595 prior to installation of pins and bushings Bearing pads and slide areas must be lubricated with Mystik Tetrimoly grease or equivalent Note Assembly of the Boom Sections is quite complex Close attention to the instr
126. by torque wrench or other means should be made to insure accuracy of these air wrenches NOTE After first 50 to 100 miles of service re check clamp amp wheel nut torque 4 Check all parts for damage including wheels rings Insure that studs nuts and mounting faces of hub and wheels are clean and free from grease Replace any defec tive parts Mount single wheel or 44 inner dual wheel also Hh outer dual wheel for hub type mounting over studs being care ful not to damage stud W threads Draw up nuts alternately in the se quence shown at left Do not tighten them fully however This procedure will permit the uniform seating of nuts and insure the even face to face con tact of wheels and hub Tighten nuts fully using the same alternate sequence Mount the outer wheel for double cap mounting and re peat the entire procedure In each case be sure to tighten wheel nuts only to the torque level recommended in the table below and to maintain them at that level through planned periodic checks Note When inner cap nuts are re tightened be sure first to loosen outer cap nuts several turns then re tighten them DISC WHEELS Torque Application Thread Size Ft Lbs Dry Passenger Type Mtg 80 90 80 90 110 120 125 140 In Out Coined Mtg 9 16 18 175 200 5 8 18 175 200 w 11 16 16 3 4 16 450 500 300 3
127. c brakes is recommended for use in the wet disc brake housing Make sure that the specifications of the tractor fluid are the same as the recommended specifications of the vehicle manufacturer CAUTION e The operating temperature of the coolant must never reach or exceed 250 F 120 C If the operating temperature of the coolant reaches or exceeds 250 F 120 C the internal components of the brake will be damaged A forced cooling system may be required to assure the coolant temperature remains below 250 F 120 C e Use only the brake hydraulic fluid specified by the manufacturer of the vehicle Do not use different hydraulic fluids The wrong fluid will damage the seals on the piston 52 gt a Section 6 MERITOR Specifications Nut Lock Special Tool 13 78 in 350 0 mm 15 55 in 0 079 in 1 77 in 395 0 mm 20 0 mm 45 0 mm 0 57 in 0 078 in 14 5mm R 2 0 gt 0 197 in 5 0 45 0 984 5 0 1 97 O 50 0 THREAD 5 8 Il UNC pe 1 77 in 45 0 mm 2 44 in 62 0 mm 4 53 in 115 0 mm 0 709 in O 18 0 mm 0 079 in 2 0 mm 53 Section 6 Specifications MERITOR PROA 352 382 With Mechanical Drive Option 2 2 2 7 S gt 0 Op 2 0 577 5 0 0 Go 0 9 2 0 e Gp 0 of 10 0 nf wv 04 o De G
128. cing brake piston assembly on bench with action plate support surface turned down Tap internal piston with rubber mallet Figure 2 16 Figure 2 16 Section 2 MERITOR Removal and Disassembly 8 Use sand paper on piston surfaces if they have 5 Depending on ring gear position remove pinion nicks or hits Figure 2 17 bearing cage capscrews 6 Remove pinion bearing cage assembly from Figure 2 17 main housing Figure 2 19 7 Remove drive sleeve and snap ring Figure 2 19 Figure 2 19 Disassemble Main Housing DRIVE SLEEVE amp SNAP RING 1 Remove adjusting nut capscrew lock 2 Remove adjusting nut capscrew and adjusting nut Figure 2 20 3 Remove brake housing capscrews that are set deep in brake housing flange Use long 6mm Allen wrench 4 Remove brake housing from main housing Hit brake housing with brass hammer or use two slots to remove it from main housing Be careful not to hit ring gear Figure 2 18 Figure 2 18 9 Remove main housing cover Section 2 Removal and Disassembly MERITOR Disassem ble Differential Case 5 If differential case is integral remove differential pinion axle lock capscrew and 1 Before disassembling differential case mark differential pinion axle Then turn side gears and position of both halves and spider cross for E differential pinions side gears and easier reassembly Figure 2 21 washers Figures 2 23 2 24 and 2 25 Figure 2 23 2 Remove diff
129. ckn 8 Shims Do not stack until measurements Si giu rss complete 9 Compression disc e Use depth gauge to determine C depth of differential case half Take four readings 10 Thrust washer on side gear side Average readings for result Figure 4 9 25 Section 4 Assembly and Installation f Place removed plain half side gear on top as shown in Figure 4 10 Use depth gauge to determine A distance from differential case half flange to backside of differential side gear Take four readings Average readings for result Figure 4 10 g Determine clearance dimension B A C D A Clearance dimension must be greater than 0 05 mm and less than 0 15 mm h Use proper shim thickness to achieve clearance specified in step G Assemble friction discs in differential case using sequence in step C including shims Make sure discs are lubricated j Drop side gear spline through disc pack k Repeat steps A through I for the plain differential case half Follow steps 9 through 11 to assemble differential case Figure 4 10 TOP PLAIN HALF SIDE GEAR PLAIN HALF SIDE GEAR MOVED TO DETERMINE A DIFF CASE FACE DATUM LLLA PLAIN HALF DIFF GEAR PLAIN HALF LIMITED SLIP PACK PPE GER 26 gt e MERITOR Check Rotating Resistance of Differential Gears Not Limited Slip NOTE Make tool to check rotating resistance of the differential gears 50 6 68
130. controls remove the ignition key and fasten a Do Not Operate tag to the steering wheel 6 Dismount from the material handler facing the machine using the proper hand Note 09 and or ladders provided Always maintain 3 point contact with the Steps 4 and 5 clearly relate to handler while dismounting or mounting NE 7 l you must park on a slope or incline position the matenal handler at right nu pem angles to the slope and chock the wheels performed with the machine shut orally Nove n down Although ideal this may not ince you will occasionally have to perform service maintenance NS EN procedures with the material handler running you must take extra be possible Same procedures ah precautions to avoid being injured perhaps fatally Ar a minimum only be performed with the machine this means running Therefore this list of A set the park brake precautions headed Preparing the Chock the wheels DANGER Avoid all exposed moving parts mini Handler i Service should Post a warming in the operator s cab that you are working be modified according to the on Ihe machine specific cirrumstances of a particular Work with On assistant service maintenance procedure Maintain vision to assistant allowing you to know where he is and what he is doing Aoomona MAINTENANCE SERVICE PRECAUTIONS Refer to the safety decals on the machine and in the relevant Owner Manual before attempting
131. cr n BG Stage 2 534C 9 C 10 amp 534D 9 D 10 ONLY Crowd Cylinder 1 Remove the push beam mounting hardware 1 Pull the push beam extension cable sheave bracket free of Boom Section 3 3 Remove all extension cable sheave bracket components from the front of the push beam 4 Pull the extension cable through the push beam extension cable sheave bracket Stage 2 Crowd Cylinder Retainers 532C 6 534C 6 amp 534D 6 ONLY 1 Remove the crowd cylinder retainers from the rear of Boom Section 2 1 Drop the crowd cylinder to the bottom of the boom This will give more clearance for access to the cable anchor bracket welded to the bottom rear of Boom Section 3 3 M Boom Section 3 front boom head remove the extension cable sheave bracket assembly components This will allow the passage of the threaded end of the cable through the sheave bracket Cable Anchor Bracket Cj 42 11 Stage 3 532C 6 534C 6 amp 534D 6 1 If required for clearance access pull the crowd cylinder free of the boom through the back of the boom assembly To do this you will have to remove the extension cable sheave bracket from Ihe front of the crowd cylinder 1 Reach inside the rear of Boom Section 3 and remove the extension cable retaining ring snap ring and the extension cable pin This pin is located at the front of the cable anchor bracket weldment which is welded to the bottom rear of Bo
132. cup Check by making sure brakes are properly adjusted in good operating condition and system well bled If pedal continues to go to the floor service brake valve SPONGY PEDAL 1 Air in system 1 Bleed brakes PEDAL IS FIRM BUT STOPS TOO NEAR FLOOR 1 Brakes out of adjustment 1 Adjust brakes co BR BLEEDING The MICO Open Center Power Brake Valve and remaining brake system are sometimes difficult to bleed The difficulty arises when the hydraulic oil used does not flow easily through lines and small holes by means of gravity Generally to effectively remove air oil must be forced into the brake valve master cylinder cavity and the rest of the system MANUAL BLEEDING PROCEDURES 1 Start engine and allow enough time to pass for the system to become filled and thoroughly flushed with oil 2 With engine still running one person can stroke the brake pedal while another person opens and closes the brake bleeder screws 3 Only on the down stroke of the brake pedal open bleeder screw 14 Inoperative brakes Check for wear Displacement problem Wheel cylinders too large for valve to handle properly Consider alternate braking valve PEDAL IS FIRM BUT BRAKING IS INADEQUATE TO STOP VEHICLE IN EVENT OF ENGINE FAILURE Oo N N 1 Pedal ratio too small 1 Increase pedal ratio Brakes inoperative Check brakes for wear or oily brakes N With Engine Running PEDAL GO
133. d four wheel drive Optional equipment available for use with these units is described in appropriate sections of this manual Be certain to refer to proper information for your unit Serial Number Location Specify Model and Serial Numbers when ordering parts and when discussing specific applications and procedures with your distributor The model serial number plate is located on the cab wall to the right of the operator s seat RADALL a zx MODEL s srao WEIGHT EE FSi Camel itt Tan b B Dui Nomenclature The illustrations on page 3 include nomenclature applied to major components of the material handler The term handler will be used throughout the balance of this manual in place of the words material handler Nomenclature STEERING AXLE 1 i SAFETY HIGHLIGHTS Read and understand all manuals and instructional material listed on cover inside front cover and page 2 of this manual before starting operating or perform ing maintenance procedures on this equipment Safety information in this manual is specific to models covered Other publications listed describe general safety precautions relating to material handling Operators of this equipment must have successfully completed a training program in the safe operation of this type of material handling equipment Regardless of previous experience operating similar equipment t
134. d control by a cable to provide accurate engine speed control Depress pedal to increase specd and release pedal to decrease speed Alternator Indicator Light Glows red to indicate alternator is not charging Attachment Tilt Lever Std This lever controls tilt of the fork carriage Speed is proportional to lever act uation Push lever forward to tilt down or pull lever to rear to tilt up Attachment Tilt Switch optional Depress front of switch to tilt down or depress rear of switch to tilt up Auxiliary Control Lever optional This lever is used to control optional hydraulic attachments Follow decal instructions for lever handler movements Auxiliary Light Switch This switch turns auxiliary lights on and off Boom Control Joystick This joystick controls boom elevation and extension Pull joystick to rear to raise boom or push forward to lower boom Move joystick to right to extend boom or move to left to retract boom speed of boom movement is proportional to joystick actuation and engine RPM Engine Coolant Temperature Gage This gage dis plays engine coolant temperature Engine Oil Pressure Gage This gage displays engine oil pressure Forward Reverse Lever This lever engages forward or reverse travel Push lever fully forward for forward travel pull lever fully to rear for reverse travel or move lever to centered position for neutral Fuel Gage This gage displays level of fuel in fuel tank Heater Fan
135. e maintenance or service 2 Set dial indicator so plunger is against a tooth surface Figure 5 2 1 Attach magnetic base dial indicator to mounting flange of main housing Figure 5 1 3 Set dial indicator to ZERO Figure 5 1 2 Set dial indicator so plunger or pointer is against back surface or ring gear Figure 5 1 NOTE 3 Set dial indicator to ZERO e When you adjust backlash only move ring gear Do not move drive pinion 4 Rotate differential and ring gear assembly while you read dial indicator Ring gear runout must not exceed 0 008 inch 0 20 mm If runout exceeds e f you are using old ring gear and pinion it is recommended that you maintain original Specifications remove differential and ring gear backlash assembly from main housing 4 Hold drive pinion in position 9 Check differential parts including carrier for 5 While you read dial indicator rotate differential problem that caused ring gear runout to exceed and ring gear a small amount in both directions specifications Repair or replace parts if necessary against teeth of the drive pinion If backlash reading is within specified range of A 0 005 0 015 inch 0 13 0 38 mm continue by CAUTION checking tooth contact patterns If backlash Shock load failure will distort the differential case reading is not within specifications adjust flange and transfer damage to ring gear In this backlash as needed case differential carrier must be discarded 6
136. e Low idle 10 psi 69kPa Full throttle under load 30 psi 207kPa 6 Warm up engine at approximately 1 2 throttle until engine coolant temperature reaches operating range Cold Weather Starting Aids Diesel engine ignition is accomplished by heat generated when fuel air mixture is compressed within the cylinders Because this heat may be insufficient to start a cold engine in cold weather the use of starting aids has become common practice Because of the wide variety of starting aids available it would be impractical to attempt to provide specific instructions for their use in this manual Carefully follow instructions furnished with vour starting aid If you use a starting aid employing ether or a similar substance pay particular attention to manufacturer s warnings FOR COLD STARTING 1 TURN IGNITION SWITCH TO ON POSITION 2 HOLD COLD START SWITCH ON FOR 20 SECONDS 3 TURN KEY TO START WHILE KEEPING SWITCH ON IF ENGINE FAILS TO START IN 15 SECONDS RETURN KEY TO ON AND RELEASE SWITCH WAIT 20 SECONDS AND REPEAT STEPS 2 amp 3 Normal Engine Operation Observe gages frequently to be sure all engine systems are functioning properly The voltmeter shows the charge discharge rate of the battery charging system With the engine running meter indicates alternator output 13 5 to 14 volts With engine stopped meter indicates battery charge 12 volts The alternator indicator light gl
137. e anti cavitation relief valves Normally these require no adjustment However they can adversely affect drive system pressure if say they are set too low or an O ring is missing To check these valves raise the POR valve pressure setting above 6 800 PSI Set the forward high pressure relief valve on the pump to 6 800 PSI Then lower the forward high pressure relief valve on the traction lock valve under 6 800 PSI Turn the valve in 1 8 turn and secure locknut Repeat the procedure for reverse Then reset the POR valve to 6 300 PSI See Figure 21 FIGURE 20 T peu e MAIN PUMP ASSEMBLY SIDE VIEW C PES A f Ya Mb PORT UA A Y M ZA AA E A b A MN S 2 4 f Z rr FORWARD HIGH PRESSURE RELIEF VALVE HIDDEN Form No 29633 3 97 19 534C 9 amp 534C 10 HYDROLASTIC DRIVE PERFORMANCE CHECKS MANUAL BE T Sa FIGURE 20A MAIN PUMP ASSEMBLY TOP VIEW POR VALVE ll FIGURE 21 FIGURE 22 TRACTION LOCK VALVE TRACTION LOCK VALVE SCHEMATIC FORWARD HIGH REVERSE HIGH PRESSURE ANTICAVITAION PRESSURE RELIEF VALVE ANTICAVITATION RELIEF VALVE EEEE i i MI Kod 2 B jl 039 n 6800 6800 I 29633 3 97 20 eee Reason for Machine Operation Check To ensure that the traction lock valve is operating correctly Also to check for proper operati
138. e cylinder once it has been removed Pressure wash or steam clean the machine so that you have a clean safe working surface L Retract the boom and line up the push beam crowd cylinder rod eye access holes in all Boom Sections Remove the keys from the ignition and fasten a do not operate tag to the steering wheel Remove the cylinder rod eye mounting pin Separate plug and cap the crowd cylinder hoses at the rear of the boom assembly Remove the crowd cylinder fittings from the rear of the cylinder barrel Attach lifting tackle to the cylinder remove the mounting pins and carefully pull the crowd cylinder free of the machine through the strong back 7 Place the crowd cylinder in the designated area for Ihe next operation p Sa Ta a 0 t a Reinstallation 1 2 Feed the crowd cylinder into the push beam and line up the eye to the access Booms retracted holes Be certain that the bearing pad is installed at the rod end of the cylinder Install the rod eye mounting pin and secure Rod Mounting Pin Apply zecrrrg 545 Grodall P N 1440 4043 to cylinder fittings and install into the barrel Apply geerrre 545 to fittings and reconnect the hydraulic hoses The Crowd Cylinder is now installed l Le amm REMOVING AND REINSTALLING THE CROWD CYUNDER 531C 6 amp 534C 6 amp 534D 6 ONLY Preparation Removal S o n Re
139. e restriction tap provided in the air cleaner the transfer pipe or the blower intake One of two conditions will exist 1 If the reading indicates the maximum restriction per engine manufacturer s recommendations change out the filter 2 If the reading shows below the maximum the filter still has life left and should not be touched Empty the Dust Cup Dust should not be allowed to build up closer than one inch from the baffle On models equipped with a Donaldson Vacuator valve dust cup service is cut to a minimum all that is necessary is a quick check to see that the Vacuator valve is not inverted damaged or plugged media Don t be fooled by filter appearance the filter should look dirty By using proper filter measurement tools you will use the full life of the filter at maximum efficiency B Improper Servicing Your engine is vulnerable to abrasive dust contaminants during servicing The most common cause of engine damage is careless servicing procedures By following the steps shown you can avoid unnecessary risk to the engine Filter Servicing When restriction indicates that filter servicing is required loosen the wingnut and remove the primary filter Before installing new filter inspect the filter and gasket for shipping or storage damage See service tips on reverse side of this document Carefully install new element and wingnut Always use authentic replacement Donaldson filters
140. e the crowd cylinder retainers from the rear of Boom Section 7 Through the back of the boom carefully pull the crowd cylinder free Pull the extension cables free of the boom while extracting the crowd cylinder Keep tension against the sheave bracket This will pull the sheave bracket toward the rear to the inside cable anchor bracket Place the crowd cylinder in the designated area for the next operation Cylinder Hoses Lift and feed the cylinder into the boom assembly through the rear Carefully install the cylinder into the extension cable sheave assembly bracket The sheave bracket will be located at the cable anchor bracket area inside Boom Section 3 Be careful not to damage the sheave bracket mounting bolts while installing the cylinder inta the bracket Keep tension on the extension cable sheave while the crowd cylinder is being fully inserted Install the crowd cylinder retainers at the rear of Boom Section 7 rear Apply L CTITE 242 Gradall P N 1440 3364 to the threads and torque as required Place the cylinder bracket in place at the rear of Boom Section 1 Install the crowd cylinder mounting pins into the cylinder bracket Install and torque the cylinder bracket fasteners Use 242 on the threads Apply amp GeTITE 545 Gradall P N 1440 4043 to the hydraulic fittings and reconnect the crowd cylinder hoses Reinstall the extension cables and the hardware Adjust as required Crowd Cylinder is now ins
141. e to the bracket at rear of Area 3 1 Install the cable around the sheave and lock it in place using 4067 242 on threads 3 Install the cable adjustment block to the cable at the other end A Lm E F Fi 5 Lay out hoses and cable to the top of the boom in preparation for installation into Boom Section 1 6 Lubricate all bearing pad slide surfaces j a LL SCO Stage 3 Crowd Cylinder 531C 6 534C 6 amp 534D 6 ONLY Install the crowd cylinder into the boom assembly The crowd cylinder is installed through the rear of the boom assembly L Clean the threads at the extension cable sheave mounting area 2 Feed the cylinder into the boom until the base anchor area is secured into the bracket at the rear of Boom Section 7 3 Install the crowd cylinder retainers and torque the bolts 10 340 365 fb Stage 3 Crowd Cylinder amp Push Beam Assembly 534C 9 C 10 amp 534D 9 D 10 ONLY Part One 1 Clean the push beam weldment and all parts for the extension sheave assembly 2 Install the crowd cylinder into the push beam 3 Install the mounting pin and hardware at the crowd cylinder tod eye Bearing Pod 7 Coble Guide amp Guide Bor Crowd Cylinder Rod Eye Mounting Pin 4 Through the front of Boom Section 3 partially insert the push beam leaving the sheave bracket extended for accessibility 5 Install the extension cables and feed the threaded end through the s
142. e wedge installed under Inspection Step pa AREA 4 Rear OUTSIDE Location E Location 6 SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES eyes Area 3 amp Anca 4 Pap Locanon E F 6 amp H INSPECTION 1 Raise the boom assembly to approximately 30 and retract to approximately 18 of full retraction Shims for Area 3 Pad Locations E F G amp and Area 4 Pad Location F are odded at the rear of the boom assembly 1 Using a feeler gauge measure the clearance between the boom and the bearing pad at all the above locations 3 If there is clearance of more than at Area 3 and or Area 4 pad Location E and F shims are normally first added to Pad Location E at the rear of the boom assembly NOTE Shim packs should be equal within shim Do not have more than one extra shim level at any bearing point Adjustment Location F To add shims to Pod Location F wedge up the Boom Settion for clearance Shims are stamped with their Gradall Part Number and thickness Check the part number on the shim being installed against the part number of the one previously installed to be certain they are the same 3 Loosen bearing pad mounting bolt and install shims as required 4 Apply amp OCT TE 242 to the mounting bolt threads 5 Re torque the bearing pad mounting bolts 6 Remove any wedges you installed REAR View Pod soon Pad
143. efore working on the machine You must also observe the general wamings listed under the heading Additional Maintenance Service Precautions also in the Introduction y A s 5 1 Base boom connected to the carrier frame that houses Boom Sections 2 amp 3 OS 5 2 Intermediate Boom Section located inside Boom Section houses Boom Settion 3 3 Outer Boom Section located inside Boom Section 1 Working implements are attached to the boom head end of this section BEARING PAD gt Also known os a Slider Pad or a Wear Pad Mounts to the boom and contacts mating boom surface Reduces friction during boom extension and retraction Keeps Boom Sections centered with each other BEARING Spacer Mounts on the inside of a bearing pad facing the boom surface Provides a solid surface for boom bearing pad shims Gradall Part Number and thickness is stamped on each spacer e HE SHIM Metal plate used to fill the space between components allowing the component to be properly placed against a solid surface bearing pad strongback etc Gradall Part Number and thickness are stamped on each shim Fom No 2 534 MAINIENANGI Push Beam 534C 9 C 10 amp D 9 D 10 only Weldment that houses the crowd cylinder and the extension cable sheave asse
144. elow Items preceded by an asterisk are optional and may not be furnished on your machine Check Items during warm up period Heater defroster and windshield wiper 2 Operating lights and rotating beacon 3 Voltmeter should show 13 5 to 14 volt charging rate When engine warms to operating range check the following items 4 Service brake and parking brake 5 Forward and reverse travel 6 Steering stop to stop in both directions With engine at low idle power assist should operate smoothly at low effort 7 Inching travel should be smooth through full pedal travel 8 Horn and back up alarm 9 All boom and attachment functions full function in both directions Hydraulic Filter Condition Indicator observe engine coolant temperature gage after starting normal operation When needle has been in operating range for an hour or so stop handler in safe area apply parking brake lower forks fully shift forward reverse lever to neutral position and chock wheels With engine running at full throttle check hydraulic filter condition indicator When needle is in red area filter is clogged and hydraulic oil is bypassing filter Filter element must he changed before reaching bypass condition change before needle reaches red area 10 CAUTION Continued operation with hydraulic fluid by passing the filter can cause severe damage to hydraulic system components A WARNING All defect
145. em 11 6 Remove sleeve item 10 by pulling on push rod item 4 Remove cup item 9 from sleeve 7 Remove piston item 16 from housing item 11 Remove piston item 10 Note direction of spool Install push rod item 4 in sleeve item 10 and secure it with new retaining ring item 3 Install new o ring item 12 on cap screw item 13 and install in housing item 11 Carefully install sleeve item 10 into housing item 11 CAUTION Make sure that groove on sleeve ITEM DESCRIPTION 1 BOOT PRESSURE REGULATING SPRING ASSEMBLY RETAINING RING PUSH ROD CUP SPOOL SPRING 3 4 5 6 7 8 9 ring item 15 from piston RETAINING RING 8 Remove retaining ring item 3 e CUP carefully with a small flat tool Do Install retaining ring item 8 SLEEVE not scratch bore of sleeve item Install new piston ring item 15 HOUSING 10 on piston item 16 and install in O RING 9 Remove push rod item 4 spool housing item 11 CAP SCREW item 6 and spring item 7 from Place new residual valve item GASKET sleeve item 10 Remove cup 20 spring item 19 and retainer PISTON RING item 5 from spool item 6 item 18 in end cap item 21 PISTON i CAUTION Residual valve must PRIMARY CUP din bs hacked or RETAINER Clean and inspect all component proper seating in SPRING parts for scratches cracks or wear end cap RESIDUAL VALVE Replace any parts that
146. em 8 7 Install piston ring item 15 on piston item 16 and install in housing item 11 8 Install new o ring item 18 and new ring seal item 19 on new piston amp poppet assembly item 17 9 Install spring item 20 and piston amp poppet assembly item 17 in end cap item 22 NOTE If you have model 06 460 566 you will have to install new residual valve item 21 You must also check residual valve for proper seating in end cap CAUTION Extreme care must be taken so as not to scratch teflon seal item 19 when installing piston amp poppet assembly item 17 in end cap item 22 10 Place new gasket item 14 on mounting face of end cap item 22 and assemble with its components to housing item 1 1 11 Install lock washers item 23 and bolts item 24 Torque 16 to 18 ft Ibs 12 Install pressure regulating spring assembly item 2 on push rod item 4 Install new boot item 1 SEE BLEEDING SECTION FOR COMPLETE BLEEDING INSTRUCTIONS PARTS LIST ITEM DESCRIPTION 1 BOOT PRESSURE REGULATING SPRING ASSEMBLY RETAINING RING PUSH ROD CUP SPOOL SPRING RETAINING RING CUP SLEEVE HOUSING O RING CAP SCREW 14 GASKET PISTON RING PISTON PISTON amp POPPET ASSEMBLY 18 O RING RING SEAL SPRING RESIDUAL VALVE END CAP LOCKWASHERS BOLTS Items included in Repair Kit 06 459 010 Items included in Repair Kit 06 459 020 10 10 a 4 s t un
147. ent Readiust if necessary 1 534C 9 C 10 amp 534 D 9 D 10 Bearing Pap Spacer SHIM DATA 407 amp 45 Boom Boom Section Crowd Cylinder D strong Back Strong Back TPE BA PP TA KN 12 534 6 amp 534D 6 BEARING Pap SPACER DATA 4 wem T x 9n 108 ss sss ss Rad 9108 3063 za PE E Rear of Boom Crowd Cylinder Bracket Extension Cable Bracket 532C 6 amp 534C 6 BEARING Pap SPACER SHIM Data 36 Boom Par Number Pad Boom 5 912 3019 9108 3297 9103 3186 9103 3185 9112 3021 9108 3063 9103 3187 lt a LA TY 908 4700 9103 1136 908 1700 98 083 9112 1081 912 1024 9020 5870 912 1087 9112 1157 9108 1171 baension Coble rocket Crowd Cylinder Mounting Brocker 63 1 0 1 While the booms can be separated from each other on the machine Gradall recommends against this procedure is much safer more efficient and more cost effective to remove the complete boom assembly from the machine and place il on stanchions horses for separation Work can then progress at a normal working height 5 REMOVAL THE COMPLETE Boom ASSEMBLY FROM THE MACHINE Bhd n ration Position the handler in a safe level open area away from personnel and equipment 1 Apply the
148. ent of engine or hydraulic failure brake can be released for towing ref pages 35 amp 36 PARKING THE HANDLER Precautions Avoid parking on slopes or near an excavation Park on level ground and block wheels Avoid parking on roads or highways cannot be avoided be sure to display warning flags during day and flares or flashing lights at night Parking procedure Using service brake stop unit in appropriate parking arca Is Move parking brake switch to applied position 3 Shift forward reverse lever to neutral position 4 Position boom head or attachment on ground 5 5 Allow engine to cool at idle speed for three to five minutes and then stop engine STEERING SYSTEM Ninety degree rear wheel power steering is provided to reduce operator fatigue and to permit high maneuverability in close quarters Position boom head or attachment on ground never leave machine with boom in air If parking on a slope cannot be avoided position unit at a right angle across slope straighten rear wheels and chock all wheels 6 Block wheels as an extra precaution against rolling 7 Fill fuel tank to minimize condensation Remove ignition Key 8 Lock cab and install protective if so equipped 9 Disconnect batteries if unit is in an area where tampering seems possible COVCTS t is important that the operator practice maneuvering the handler in a safe open area until he becomes thoroughly familiar wi
149. erential case capscrews 3 Separate differential case halves If necessary use a brass or rubber hammer to separate halves 4 Remove spider cross differential pinions side gears and washers If differential case is Limited Slip remove friction disc pack Figure 2 22 Figure 2 22 Figure 2 25 MERITOR 6 If necessary separate ring gear from differential case Remove capscrews and washers that fasten ring gear With brass hammer tap ring gear to separate it from differential case Figures 2 26 and 2 27 Figure 2 26 Z Figure 2 27 WARNING Observe all WARNINGS and CAUTIONS provided by the press manufacturer concerning press operation to avoid serious personal injury and possible damage to components during removal and disassembly procedures Section 2 Removal and Disassembly 7 f differential case has two halves remove ring gear with a press after capscrews have been removed Figure 2 26 Use appropriate metal or wood supports Figure 2 28 Figure 2 28 SUPPORTS 8 If necessary remove cone bearings from differential case Use appropriate puller or press Figures 2 29 2 30 and 2 31 Figure 2 30 Figure 2 31 Section 2 Removal and Disassembly MERITOR Disassemble Pinion Bearing AX CAUTION Cage To avoid oil leaks be careful not to damage the mounting surface of the bearing cage 1 If pinion bearing cage was not removed hold yoke flange or spli
150. etermine maximum load capacity for given operating ranges consult the proper load capacity chart fumished with platform for the material handler and work platform in use If your handler is not equipped with the proper personnel work platform capacity chart get one before using the attachment Installation Procedure Remove cariage fork combination or other attachment from boom head Refer to Personnel Work Platform Manual for installation procedures Operation Gradall Personnel Work Platforms are approved for use only on Gradall Material Handlers equipped with the proper platform capacity chart When lifting personnel use only a Gradall manufactured personnel work platform No other platform is approved for use on Gradall Material Handlers WARNING Do not use the Personnel Work Platform until you study and understand the Capacity Char If your handler does not have the correct Personnel Work Platform Capacity Chart ask your supervisor to get one before using the attachment AWNNNG Do not use a boom mounted winch while the platform is mounted to the boom MULTI FUNCTION AUXILIARY CONTROL LEVER 3l AUXILIARY CONTROLS LEVER BUTTON OPERATION FUNCTIONS ILEF T DOMN MAST 2 SIDE SHIFT swING 35 M x DECAL FOR PANEL HANDLER If your unit is equipped with a multi function auxiliary control lever it is not necessary to depress b
151. fe of drive axle assemblies Meritor recommends that assemblies are not repair welded Repair welding can detract from the structural integrity of a component particularly to heat treated parts where the benefit of heat treatment may be nullified by welding Since it can be extremely hazardous and detrimental to repair weld components of any kind repair welding can be approved only where stringent controls are imposed and equipment customarily located at manufacturing facilities is employed so as to minimize the potentially detrimental effects of repair welding gt e MERITOR Liquid Adhesive Meritor uses the following liquid adhesives to retain threaded fasteners Loctite 271 High Red 2 hours 241 Medium Blue 6 hours 221 Low Violet 6 hours Three Bond 5 hours 5 hours 10 hours 1305 High 1334 Medium 1341 Low Disassemble Locked Sets CAUTION Do not use impact wrenches or strike components with a hammer To disassemble sets originally locked with liquid adhesive use the regular mechanical disassembly procedure If the removal of a capscrew for example becomes difficult due to a worn head or unusually high breakaway torque the locking strength can be reduced by heating the threaded area to approximately 300 150 C Heat slowly to avoid thermal stresses on the differential case and gears Cleaning A WARNING To avoid serious personal injury trichloroethylene must not come in contact with
152. ferent CUST NO designs PART NO 1 Ball and Ramp 2 Hydraulic Apply Wet Disc 3 Three Function Brake P PLANETARY RO IF APPLICABLE HOUSING TYPE DESIGNATION O OSCILLATING OR PIN MOUNTING A POT OR SPLIT CARRIER SER NO PROA 352 G2M DIFFERENTIAL WHEEL END NUMBER WET DISC BRAKE DESIGNATION PLANETARY GEARS 2 SPIRAL W2H 3 FUNCTION HYDRAULIC APPLY 35 3 PLANETARY GEARS 3 HYPOID G2H HYDRAULIC BALL AND RAMP 38 4PLANETARY GEARS G2M MECHANICAL BALL AND RAMP NOTE ALL BRAKES ARE 9 INCH DIAMETER 229 mm Section 2 Removal and Disassembly Remove Axle WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service WARNING Support vehicle with safety stands Do not work under a vehicle only supported by jacks Jacks can slip or fall over and cause serious personal injury NOTE While the housing configuration of the axle you service may differ from the figures shown service instructions remain the same for all axle models addressed in this manual 1 Make sure vehicle is on level surface 2 Place blocks under wheels not being serviced to keep vehicle from moving 3 Raise vehicle so that wheels to be serviced are off the ground Support vehicle with safety stands 4 Remove axle from vehicle 5 Plug fluid lines that were connected to axle 6 Place axle in appropriate repair stand Center m
153. first main boom section Tighten the retract cable adjusting nut to obtain 17 1 2 1 4 0 as shown Tighten jam nut to 100 ft Ib when correct dimension is obtained 4 Readjust extend cables as described in steps 4 and 5 of Checking and adjusting boom cables OUTRIGGERS or delivering a load refer to LEVELING THE HANDLER heading on next page Outriggers are controlled by a pair of levers to the right of operators seat The left lever controls left outrigger and the right lever controls right outrigger Push levers forward to lower outriggers or pull levers to rear to raise outriggers LEVELING THE HANDLER WARNING Raising the boom loaded or unloaded when handler is leaning to the side can cause machine to tip over with little or no warning and cause serious injury or death LEVELING means positioning the handler so that itis level from side to side left to right with respect to a man sitting in operator s seat A level indicator is located on upper portion of front window frame to permit operator to determine that handler frame Is or is not level There are four very important things to remember about handler leveling 1 Never engage a load or lift a load more than four feet above ground level unless the handler is level 2 A handler with the boom raised and or an attach ment installed is a partially loaded handler 3 Once the handler frame has been leveled and has raised a load more than
154. g pads and pad slide area on the boom with Mystik Tetrimoly grease or equivalent Gradall P N 1440 4595 Apply 5 242 Gradall P N 1440 3364 to all bolt threads Bearing pad bolt torques are Ve bolt 32 37 ft lb 1 bolt 76 86 ft lb Do not overtorque pad mounting bolts Qvertorqueing will pull the pad nut through the pad The pad will then fall out of the boom Booms should not be adjusted so tight that the lube is wiped off the sliding path Visual checking of the witness lines left on the bearing slide path may assist in determining which side of the boom is not making proper contact with the bearing pad If a wedge is used to assist in shifting a Boom Section for adjustment be certain it is removed before activating the boom circuit Damage to the boom structure will occur if the boom is retracted with a wedge left installed Do not use more than one wedge at a time during the adjustmen operation You can use 060 thick shim stock as a feeler gauge to check boom clearance to bearing pad Shims and spacers are stamped with their part number and thickness for quick reference Check the ones you are installing against the ones installed in the same area Make sure you install the right ones Cj LAL Boom ADJUSTMENT PROCEDURE Area 1 AND Area 2 Pap A amp B Inspection 1 Extend the boom three quarters of total travel Extend at least ft beyond access holes 1 Lower the boo
155. gine e Check to be sure al DANGER WARNING CAUTION and INSTRUCTION DECALS are in place and can be read Clean or replace decals as required Be certain forklift is on a firm level surface before lifting or placing load Have surface leveled if necessary Unit can tip over if load is raised with forklift on a soft or uneven surface Always look in the direction of travel Reduce speed and be especially careful when traveling in reverse and or turning f load or conditions obstruct view use a signal person when lifting carrying or placing a load Loose clothing can get caught in moving machinery and can also cause accidental actuation of controls Dress properly for the job Be alert for any unusual response to controls If unusual response is noticed position unit in a safe area if possible lower forks to rest apply parking brake stop engine and remove key from ignition switch Tag steering wheel to forbid operation and notify maintenance personnel Keep hands goves shoes control knobs and pedals clean Slippery controls can cause accidents Keep a firm grip on steering wheel when traveling Load capacities are based on load center being within 24 inches from front vertical face of forks Never service unit with engine running Release trapped pressure before disconnect ing opening or removing any hydraulic component Whenever leaving cab position unil in a safe location apply parki
156. h 48 or 66 carriage PRECAUTIONS e Read additional capacity information under Capacity heading e Because the mast increases lift height it is especially important to level the handler before lifting a load more than four feet above ground level refer to page 20 Capacity Maximum lift capacity for the mast is shown on serial number plate located on right cab wall However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler 26 mast combination separate capacity chart must be used for handlers equipped with mast Study this chart carefully before attempting to handle a load with mast attachment WARNING Do not attempt to handle a load with mast attachment until you have studied mast capacity chart carefully If your handler does not have a mast capacity chart ask your supervisor to get one Controls The carriage tilt cylinder is used to tilt the mast and the carriage tilt lever controls mast tilt LOWER FORKS AUXILIARY CONTROL LEVER RAISE FORKS If your unit is equipped with a mulli Tunction auxiliary control lever refer to page 31 The auxiliary control lever is used to raise and lower the forks in the mast Pull lever to rear to raise forks and push lever forward to lower forks Procedure Remove carriage fork combination or other attachment from boom head refer to Attachment Installation page 24 2 Install ma
157. h te va lk hhi 4 DEGAS 1555 err 5 Optional Equipment Decals OPERATORS CAB IPRC RUE LIA EP tua 10 Control amp Instrument Identification CHECKS amp SERVICES BEFORE STARTING ENGINE 12 ENGINE OPERATIONS SE ESE 13 Starting the Engine Cold Weather Starting Aids Normal Engine Operation Stopping the Engine WARM UP amp OPERATIONAL CHECKS 14 BRAKE SYSTEM E DR teense 15 General Inching Travel Service Brakes Parking Brakes PARKING THE HANDLER PO EE RESP 16 STEERING SYSTEM 16 DRIVE TRAIN oss eos A Sam Qa US UC MS UM ADEM UU 17 BOON HERD E ETE 18 Boom Cable Adjustment OD TRIGGERS Cosas da QE Gaceta d Da eios EE sex Pe 19 LEVELING THE HANDLER 20 OPERATING PROCEDURE amp TECHNIQUES 21 Hydraulic Controls Rated Capacity Chart ATTACHMENTS et qa od a Pate on nte 23 Approved Attachments Non Approved Attachments Carriage Fork Capacities Other Attachment Capacities Attachment Installation Attachment Operation LUBRICATION amp MAINTENANCE SECTION 32 Lubrication amp Maintenance Diagram Recommended Lubricants amp Capacities Torque Chart OBTAINING HYDRAULIC
158. handler truss boom combination separate capacity chart must be used for handlers equipped with truss boom Study this chart carefully before attempting to handle a load with truss boom A WARNING Aside load or a swinging load can cause the handler to tip over and or damage the boom Observe the following Special Precautions SPECIAL PRECAUTIONS Never drag the load lift vertically Use tag lines to guide and steady a suspended load whenever possible Tag lines must be long enough to keep helpers clear of load Beware of wind wind can cause a suspended load to swing and cause dangerous side loading even with tag lines Start travel turn and stop slowly to prevent load from swinging Weight of all rigging slings etc must be included as part of load Controls The carnage tilt cylinder is used to tilt the truss boom up and down from the handler boom head The carriage tilt lever controls truss boom tilt Q LOWER WINCH LOAD AUXILIARY CONTROL LEVER RAISE WINCH LOAD I your unit is equipped with a multi tunction auxiliary control lever refer to page 31 The auxiliary control lever is used when the truss boom is furnished with a winch Pull the lever to rear to raise winch load and push the lever forward to lower winch load continued Procedure l Remove carriage fork combination or other attachment from boom head refer to attachment installation page 24 Insta
159. hart ask your supervisor to get one Controls The carriage tilt cylinder is used to tilt the swing forks up and down and the carriage tilt lever controls fork tilt Qe LEFT SWING RIGHT AUXILIARY CONTROL LEVER your unit 15 equipped with a multi function auxiliary control lever refer io page 31 The auxiliary control lever is used to swing the forks to the left and right Pull lever to rear to swing forks right and push lever forward to swing forks left 27 Procedure 1 Remove carriage fork combination or other attachment from boom head refer to Attachment Installation page 24 2 Install swing fork attachment on boom head 3 Connect auxiliary hydraulic hoses to swing fork attachment WARNING Observe all precautions and load capacity limits listed previously when handling loads with swing fork attachment 4 Always position forks straight ahead before en paging load 5 To travel with load keep forks in stright ahead position and lower load to approximately one foot above ground 6 Inspect supporting surface at delivery point and have it leveled if necessary A WARNING Always bring forks to level horizontal position hefore swinging load to side Swinging unleveled forks may result in load slipping from forks 7 Use a signal man to assist in positioning the load If necessary SLOPE PILE CARRIAGE PRECAUTIONS e Level handler before tilting carriage to engage
160. he machine is being driven Safe working habits must be used for these checks Refer to Operator s Manual Form No 29311 for further information Read and understand this Manual along with Operation and lubrication Manual EMI Handler Safety Manual 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 cab Safe operation depends on reliable equipment and proper operating procedures Performing the adjustments and repairs described in this Manual will help to keep your Material Handler in reliable condition Use of the recommended operating procedures can help you avoid accidents Because some procedures may be new to even the experienced technician we recommend that this Manual be read understood and followed by all who service this unit IDANGER WARNING CAUTION notes in this Manual will help you avoid injury and damage to this equipment These notes are not intended to cover all eventualities It is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice If you are not sure contact your GRADALL Distributor before operating Do not modify this machine without written permiss
161. he operator must be given sufficient op portunity to practice with the handler in a safe open area not hazardous to people or property to gain op erating skills and proper feel for controls and oper ating clearances required for safe efficient operation The Gradall Material Handler is equipped with a right side rear view mirror This mirror is intended as operator s aid and does not replace the requirement for line of sight Certain jobsite and machine conditions may require use of a signal person to help operator when picking placing or transporting a load Never operate the handler until you know pick up point line of travel and landing point are clear Always be aware that objects in mirror are closer than they appear Watch for these symbols they call your attention to safety notices A DANGER WARNING CAUTION This symbol indicates an extreme hazard which would result in high probability of death or serious Injury if proper precautions are not taken This symbol indicates a hazard which could result in death or serious injury if proper precautions are not taken This symbol indicates a hazard which could result in injury or damage to equipment or property if proper precautions are not taken Safety Precautions A WARNING Operator must be seated with seat belt fastened forward reverse lever in neutral position parking brake applied and all hydraulic controls in neutral position before starting en
162. heave bracket The cable end will not feed through the sheave bracket with the sheave installed Lay out the cables over boom head toward the rear of boom assembly Install the extension cable sheave assembly complete ie sheaves pins lube system bearing pads Feed the cables around the sheave Install the cable quide and quide bar Install the push beam mounting pins and locking hardware at the rear of Boom Section 7 C Sop lt VA Install Cable Before Install Mounting Pins Here Sheave Components Part Two 1 Install the push beam fully into Boom Section 2 lining up the mounting pin bores 2 Install the push beam mounting pins and locking hardware at the rear of Boom Section 2 Boom Sections 3 amp 2 are now ready for insertion into Boom Section ry aa LE Stage 4 Extension Cable Sheave 5320 6 5340 6 amp 534D 6 1 3 O lt Gather and clean parts to assemble the cable extension sheave LJ Assemble the extension cable sheave bracket assembly See the appropriate current wawa Gradall Parts Manual for applicable parts Place the cable extension sheave bracket on the work table in front of Boom Section 3 Feed the extension cable around the sheaves in the bracket Install the cable guards on the sheave assembly Pulling the cables to the rear of the boom assembly install the sheave bracket on the crowd cylinder mounting bolts Install and torque the nuts at
163. hen using Loctite Follow the manufacturer s instructions for safe use to prevent irritation to eyes and skin Wash after skin contact If the Loctite gets in eyes flush with water for 15 minutes Have eyes checked by a doctor 11 Apply high torque liquid adhesive Loctite 271 or Three Bond 1334 on stud threads 12 Install studs that fasten brake housing and axle shaft housing to main housing Tighten studs until resistance is met 13 Install bearing cup and brake housing into main housing Align holes at mark made during disassembly 14 Install 3 bolts into the brake housing to adjust differential Tighten them to 19 26 lb ft 26 36 Nem Figure 4 31 o 15 Apply medium torque liquid adhesive Loctite 241 or Three Bond 1334 to lock capscrews Install adjusting nut lock and capscrews Tighten capscrews to 80 115 Ib in 9 13 o Assemble Axle Shaft 1 Use correct size sleeves to install cups into bores in axle shaft housing until cups are flat against bottom of bores Figure 4 36 Figure 4 36 N gt e MERITOR 2 Install Duo Cone oil seal into axle shaft and into axle shaft housing bore as specified on page 18 Figure 4 37 DUO CONE OIL SEAL 3 With a correct size sleeve use a press to install flange side cone bearing Install axle shaft into axle shaft housing Figure 4 37 Assemble Trumpet Assembly WARNING Observe all WARNINGS and CAUTIONS provided by the press manufacturer concer
164. his equipment This Manual covers recommended operating procedures and basic maintenance checks and services for the 534C 9 amp 534 10 Material Handler Detailed maintenance information is available in the appropriate Service Manual Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice If you are not sure contact your GRADALL Material Handler Distributor before operating Use only GRADALL authorized parts The use of counterfeit parts may cause premature failure which could lead to injuries and or machine damage Do not modify this machine without written permission from GRADALL Use only genuine GRADALL replacement parts OTHER NOTICES GRADALL retains all proprietary rights to the information contained in this Manual GRADALL reserves the right to change specifications without notice GRADALL is a registered trademark for Hydraulic Excavators Hydraulic Material Handlers and Attachments manufactured by The Gradall Company Form No 20042 Original Issue 3 0 TABLE CONTENTS IMPORTANT SAFETY NOTICE inside front cover TABLE OF CONTENTS INTRODUCTION SSS uQ a ES Dd 2 General Operator Qualifications Orientation Related Manuals amp Decals Serial Number Location NOMENCLATURE 5 PUE u ah CORREOS 3 SAFETY HIGHLIGHTS I Q detis et o
165. hrottle replace filter elamarnt before by pass indication 8 reached or al teas annually Hydraulic Level Sight Gages level handier retract all other cylinders amp check sight gages refill as req d Hydraulic Suction Filter replace filter element when return filter element is replaced Air Cleaner Elament Condition Indicator check tor clogged candition red band showing amp clean or replace element as req d fem 26 is air cleaner Engine Crankcase Dipstick level Handler amp check lave retill as req d item 37 is filler Weekly or 50 Hour Lubrication amp Maintenance Service at whichever Interval occurs first include all previous periodic services Outrigger Cylinder Pivots 2 Tires check lor damage amp proper inflation 5 15 16 I7 18 21 22 23 25 28 30 33 Ja 40 41 5340 8 Std 13 00 x 24 12PA 65 psi Option 13 00 x 24 Radial 12 PR 70 psl 534C 10 Sid 14 00 x 24 12 PH 65 psi Option 14 00 x 24 Radial 70 psi Lav ling Cylinder Pivots Battery check terminals King Pins Steering Cylinder Pivots Outrigger Arm Pivots Front Axle Pol Rear Axle Pivot Tie Rod Ends Boom Pivot Carriage Till Cylinder PAS Exlension Sheave Boom Hoist Cylinder Pivots Retraction Sheave Boom Head Carriage Pivol Boom Bottom Front Slide Bearings axtend boom fully amp luba all wear palhs retract amp extend boom fully three limes amp wipe excess lube from
166. ication passages BUSHINGS Bushings equipped with lubncation grooves are used in conjunction with pins Lubricate ID and OD of bushings before installation im parent bore and pin installation Seccion Lift Cylinder Bushing O 030 Optimum Boom Assembly Performance ond Service Life depend on proper adjustment and alignment of components A boom is considered in proper adjustment as long as the following are met Boom Sections centered to each other Extension Retraction cables are adjusted properly resulting in simultaneous extension and retraction of Boom Section 3 proportional to the crowd cylinder throughout partial and or full boom travel e Hydraulic circuit hoses including Auxiliary Hydraulic and Electric are properly installed resulting in stress free movement during boom extension retraction cycle Boom ADJUSTMENT PROCEDURE CENTERING 5 5 Each OTHER BEARING PAD PACKAGE Boom bearing pads sometimes called slider pads or wear pods spacers and shims are used as a package to achieve proper centering of Boom Settions to each other For the purpose of clarification the area and location of bearing pad packages are referenced below Location A Wop Inside Location C Location D Location G Location H Right Inside Left Inside Right Outside Left Outside pee Tw The 534C9 10 and 53409 10 booms require 3 bolts on the bottom f
167. icle 3 Mark damaged or hazardous areas with chalk so that part will be removed from service maximum service and safety a continuous main tenance program is advisable Maintenance pro cedures should be carried out during all tire inspections and changes and at periodic mainte nance intervals depending upon road and environ mental conditions of operation Uso E Ys MES 5 i 4 Replace damaged parts CAUTION Insure that replacements are made with the proper sizes and types of rims and rings 5 Inflate tires only to recommended air pressures RIM AND WHEEL MAINTENANCE DURING TIRE CHANGES 1 Check all metal surfaces as in No 1 above A more thor ough check may be made however after the tire has been Cracks in the rim base in the back flange and gutter areas These are caused by deep rim tool marks overloading and overinflating tires and using larger than recommended tire sizes Cracks through side ring spreading lat erally through the entire section These demounted Watch particularly for the damages illustrated below and refer to recommendations in this section of the catalog if corrective measures are required Cracks in the wheel disc between stud holes or hand holes These are caused by loose wheel nuts im proper installation procedures and use of incorrect sizes or types of attaching parts Erosion and chip ping of bead seat
168. inder Cover M12 x 1 75 6G Capscrew Brake Releaser M12 x 1 75 6G Capscrew Flange Adapter 3750 x 16UNC2A Capscrew Center Housing Cover M8 x 1 25 6G Capscrew Axle Shaft Flange M20 x 1 5 6G Drain Plug Grease Fitting Vent Plug Level Plug Capscrew Planetary Pinion Axle M10 x 1 5 6G Section 6 Specifications Torque Chart PROA 352 G2H G2M TORQUE 465 0 570 lb ft 630 775 Nem 180 0 215 0 lb ft 245 290 Nem 120 150 Ib ft 160 205 Nem 48 64 lb ft 64 87 Nem 66 75 lb ft 90 100 Nem 67 0 91 0 lb ft 91 120 Nem 80 0 115 0 9 13 Nem 17 23 lb ft 23 31 Nem 19 26 lb ft 26 36 Nem 19 26 lb ft 26 36 Nem 48 64 lb ft 64 87 Nem 60 90 Ib ft 80 120 Nem 22 30 lb ft 30 41 Nem 22 30 lb ft 30 41 Nem 39 0 53 0 lb ft 53 72 Nem 19 26 lb ft 26 36 Nem 470 575 lb ft 635 780 Nem 35 0 Ib ft 47 Nem 10 0 Ib ft 14 Nem 15 0 lb ft min 20 Nem min 35 0 lb ft min 47 Nem min 17 0 23 0 lb ft 23 31 Nem 59 MERITOR Em tmt ps Wu TT 135 West Maple Hoard Troy MI 4605 I8 335 1085 80 535 North amp merica WAWAPA Information comtumed in this publicatia was in uffect at tho Ema the publication vans approved for priming and is subjuct ta chango potios ar kahility Mentor Hoary Spstoms LLC reserves tha right to roviso the presented ar dscuntinug the producton of parts described at any tima Merter do Brasil Lda
169. installation l 1 B Review all safety issues before commencing work Place the machine in a safe level uncongested working area Apply the brakes and chock the wheels Procure crane and lifting tackle capable of lifting 1000 Ib If working with a helper be certain each of you knows your assigned duties Select a location to place the cylinder once it has been removed Pressure wash or steam clean the machine so that you have a clean safe working surface Level and retract the boom within approximately ft of full retraction The boom Crowd Cylinder sections should be positioned to allow the top rear cable access holes to Extension Cable Mounting Area line up Mounting Area Remove the keys from the ignition and fasten a do not operate tag to the steering wheel Remove the extension cable adjusting hardware from the rear cable bracket Reaching through the top rear access hole install a wrench to cable end flat This will keep the cable from twisting during removal the boom head of Boom Section 3 remove the four extension cable sheave bracket mounting nuts At the boom rear cable bracket remove the crowd cylinder mounting pins and hardware Remove the cable bracket from Boom Section 1 Identify top and bottom shim packs to aid in reinstallation Disconnect the hydraulic hoses from the crowd cylinder Fasten lifting tackle to the crowd cylinder and take the weight aff the cylinder Remov
170. ion 3 Location E Top Outside EA 4 OUTSIDE uc 1 79 Location G Location H ee 1 Right Outside Left Outside r 7 Beating Pads PIS __ Spacers 155 Boom Section 3 aM m TT Location F SEE NOTE ON PAGE 2 0 FOR BOOM utside eee BEARING PAD BOLT QUANTITIES Stage 2 Cables and Hoses 1 Install single retraction cable and double extension cable to the bracket at the inside rear of the boom Bracket Retraction Cable Extension Cob Form 29906 532 534 Boom 30 1 Install till circuit hoses and auxiliary circuit hoses and electric cables and brackets inside protected areas 3 Bolt hose brackets in place at the front of the boom AE Auxiliary Circuit Tilt Circuit 4 Lubricate Bearing pad paths 5 Lay cable and hose inside Boom Section 3 to protec against being pinched when installed into Boom Section 2 Stage 3 Tilt Cylinder and Auxiliary Circuits 1 Install hoses for the tilt cylinder 1 Install hoses and electric cables for any auxiliary circuits 3 Lift the tilt cylinder and place it inside the boom head section lining up the mounting pin bores Install the mounting pin through the boom head section and the tit cylinder Apply amp T TE 242 10 the keeper bolt and lock the mounting pin in position wu Boom Section 3 is now ready for insertion into Boom Section 2 65 40
171. ion from GRADALL The following symbols are used to call your attention to safety notices DANGER This symbol indicates an extreme hazard which could result in high A DAN G ER probability of death WARNING This symbol indicates hazard which could result in death WAHNIN G serious injury if proper precautions are not taken q CAUTION This symbol indicates a hazard which could result in injury or C A U damage to equipment or property if proper precautions are not taken Required Tools aaWa ii Color coded plastic caps seal the adjustments on components in the hydraulic system If a GRADALL Distributor makes an adjustment the component should be sealed with a blue cap The tools needed to make these checks are 1 Tachometer 2 GRADALL pressure testing kit P N 7713 4197 3 Mechanic s hand tools Metric included 4 Blue plastic caps P N 8093 4459 small and P N 8093 4460 large Form No 29633 3 97 il General Warning Information This Manual provides important information for those responsible for understanding troubleshooting testing repairing and or performing maintenance on the hydrostatic transmission drive system of 534C 9 and 534C 10 Material Handlers NOTE this Manual does not cover any of the implement systems of the machine Accidents involving injury or serious machine damage Immediately notify your GRADALL Distributor of the incident so he may assist you in your i
172. ity from approved attachment serial number plate to max imum capacity for that attachment as indicated on material handler serial number plate The smallest of these capacilies is correct for your handler i Attachment Installation Retract Quick Switch attachment tilt lever forward to provide clearance Check to be sure lock pin is secured in raised position with retainer pin 4 Remove retainer pin and lower lock pin fully 2 Align boom head pivot with recess in attachment Raise boom slightly to engage boom head pivot in recess 3 Engage Quick Switch attachment tilt lever backward This installation procedure is designed for one man operation If a helper is involved shut off the engine before proceeding to ste ps 4 and 5 i n 5 Secure lock pin in locked position using retainer pin DANGER Attachment Operation Operation of the handler equipped with carriage fork combination is covered in the Gradall Material Handler Safety Manual the EMI Rough Terrain Forklift Safety Manual and this manual Operation of the handler when equipped with other approved attachments is covered in this section or in separate instructions furnished with the attachment Such separate instructions must be kept in manual holder with operator s manual When an attachment is installed on the handler take extra care when engaging securing manipulating
173. ize that the various types actually do not fit properly on the rim base Seri of highway rims produced by their manufacturers ous accidents to personnel have resulted from the all differ to some degree in design This is partic use of mismatched rings ularly true of removable rings and as a result The drawings below illustrate a few of the side and lock rings of different rim types are not potentially dangerous conditions which can result interchangeable Some may appear to be but they from the mismatching of rings and bases CORRECT INCORRECT GOODYEAR 7 50V LW SIDE RING ON FIRESTONE 7 5 5 BASE Loose FIRESTONE 7 5 5 SIDE RING 4 Fit AND LOCK RING ON FIRESTONE 7 5 5 BASE 3 Bead Seat FIRESTONE 7 5 5 SIDE RING AND Too High Pare LOCK RING ON GOODYEAR Tire Will Not it 7 50V LW BASE Fit Properly Improper Seating FIRESTONE 6 5 RH5 SIDE RING ON FIRESTONE 6 5 RH5 BASE FIRESTONE 6 0 RH5 SIDE RING ON FIRESTONE 6 5 RH5 BASE IMPROPER RIM WIDTH PROPER RIM WIDTH Loose k Fit Correct Fit FIRESTONE 7 5 5 SIDE RING AND 8294 Seat Too High LOCK RING ON Tire Will Not FIRESTONE 7 33V R BASE Fit Properly FIRESTONE 7 33V R SIDE AND LOCK RING ON FIRESTONE 7 33V R BASE Improper Seating FIRESTONE 7 33V R SIDE AND LOCK Correct Fit RING ON FIRESTONE 7 5 5 BASE Loose Fit No Support Proper FIRESTONE 7 5 FL5 SIDE RING 94 Sea ON
174. k 4 Put spacers aside and install release screws Tighten each screw lightly until it just makes contact with guide pin 5 Working carefully tighten each release screw only 1 4 turn 80 degrees at a time in sequence until all three screws have been turned one full turn 360 degrees approximately 50 Ib f Larger turns could cause components to bind and cause brake failure 6 Repeat this procedure on other side of differential Parking brakes should be released To Restore Parking Brake 1 Check to be certain engine is stopped and all wheels are chocked to prevent movement 2 Loosen cach release screw only 1 4 turn at a time in sequence until each screw has lost contact with guide pin Then remove release screws 3 Install spacers and release screws and torque to 50 to 70 4 Repeat procedure on other side of differential Park ing brake should be restored to operation HAND SIGNALS Standard Signals When handler work conditions Special Signals When signals for auxiliary Instructions When is desired to give instructions require hond signals they shall be provided or posted equipment functions or conditions not covered ore to the operotor other than provided by the conspicuously for the use of both signalman ond required they shall be agreed upon in advance by established signal system all handler motions shall operator No handler motions shall be made unless Ihe operator and signalman first he
175. l brakes are bled and DOWNSTREAM SECONDARY HYDRAULIC DEVICE SUCH AS POWER STEERING T T l li BLEEDER BY PASS LINE Remove atter Bleeding 2 tc I d 2 PRESSURE fittings tight release the 50 200 PSI pressure and SHUT OFF ENGINE 10 Remove the bleeder by pass line and plug the connections Be sure not to lose fluid or ingest air at the brake line connection when removing bleeder by pass line With engine off step on brake pedal It should be fairly high and hard spongy pedal is felt the system still contains air If pedal strokes downward too far check and readjust brakes and repeat bleeding process 12 When the pedal is satisfactory restart engine and actuate brake pedal several times Now check for leaks 11 FIGURE 13 BLEEDING SCHEMATIC 15 MICO has made every attempt to present accurate information in catalogs brochures and other printed material MICO can accept no responsibility for errors from unitentional oversights that may exist Due to a continuous program of product improvement both materials and specifications are subject to change without notice or obligation
176. l lips Figure 4 19 Figure 4 19 INDUSTRIAL ADHESIVE b Apply 3M Industrial Adhesive or equivalent to oil seal outer surfaces Figure 4 19 c Press oil seal into bearing until seal flange is flat against top of bearing cage Use the correct size sleeve or seal driver that fits against metal flange of seal The diameter of the sleeve must be larger than diameter of flange Figure 4 20 Figure 4 20 Section 4 Assembly and Installation d Install yoke or flange and pinion nut Into pinion e Tighten pinion nut to specified torque after installing pinion bearing cage into main housing of 465 570 lb ft 630 775 Nem 4P Adjust Thickness of Pinion Bearing Cage Shim Pack Depth of Pinion NOTE Use this procedure if a new drive pinion and ring gear set is installed or if the depth of the drive pinion has to be adjusted Figure 4 21 Figure 4 21 BEARING CAGE SHIM PACK 1 Use a micrometer to measure the thickness of the old shim pack that was removed from under the pinion cage Record the measurement for later use Figure 4 22 Figure 4 22 29 Section 4 Assembly and Installation 2 Record the pinion cone PC variation number on the old drive pinion that is being replaced If the PC variation number cannot be located assemble the gear set with the shim pack found in step 1 Figure 4 23 Figure 4 23 NOTE The pinion cone number PC can be either 1 000ths of an inch 0 000 inch or 10
177. l top to bottom within shim pad locations T and F IF fhe shim pack level is unequal offer this adjustment equalize at the next adjustment Boom Section 2 Access Hole Boom Bearing Pads are now fully adjusted ADJUSTMENT PROCEDURE Area 4 Pap Locarnon amp H Inspection 1 With the engine off reach through the access hole install a wedge between Boom Sections 2 and 3 at Area 4 Pad Location G Force Boom Section 3 Area 4 against the opposite side Pad Location H to check the clearance 1 Using a feeler gauge check the clearance between the boom ond the bearing pad at Area 4 Pad Location G 3 If there is more than 060 clearance present shims must be installed to bring the boom into tolerance Note Shim pack levels should be equal side to side within shim pad locations 67 and AY ff the shim pack level is unequal after this adjustment equalize at the next adjustment Boom Section 3 Right side Location Left side Location H Adjustment 1 Loosen the bearing pad mounting bolts at location 6 or both and add required shims 2 Shims are stamped with the Gradall Part Number and thickness Check the number on the shim being installed agains the one previously installed to be certain they are the same Apply 4 242 to the threads on the bearing pad mounting bolts Re torque the bearing pad mounting bolts Remove th
178. l without kasa 1 844 approx Push rod force without power 1500 Ibs at 725 psi 518 165 at 250 psi Model 06 460 652 only NOTE Brake system rubber parts Buna N must be compatible with mineral based hydraulic oil 2 DESCRIPTION AND OPERATION OF THE MICO OPEN CENTER HYDRAULIC POWER BRAKE VALVE The MICO Open Center Brake Valve will provide hydraulic power braking when installed in an open center hydraulic circuit It can be used in conjunction with other hydraulic devices such as power steering also installed in the same circuit Using a single pump to provide flow and pressure the brake valve should be installed in the system circuitry in series between the pump relief valve and the other hydraulic devices The entire pump flow is directed thru the brake valve and is available to actuate the downstream devices The brake valve requires a very small volume of oil for its operation therefore it does not interfere with the rest of the circuit nor does usual actuation of the downstream hydraulic devices affect operation of the brake valve Schematic of Brake Valve in Neutral RETURN LINE L PRESSURE 777 BRAKE LINE PRESSURE FLOW THRU 4 PRESSURE To Brake Pedal Pressure Regulating Spring Pressure Regulating Spool Orifice Full system pressure is always available for operating the rest of the system The MICO Brake Valve provides a single fluid system using the
179. lamps Remove the socket from the electrical cable Remove the strain relief fitting and the tube at the boom head from the boom and cable Tie a rope to the cable end this will aid in reinstallation Bu ML Auxiliary Hydraulic Hoses Electric Cable Stage 2 At the rear of the boom remove the hose guard from the right side roller Pull the electric cable to the rear free of the boom assembly At the bottom front of Boom Section remove the cable take up weldment and Suppor Pull the electric cable free of the boom through the cable take up weldment Remove the remaining cable clamps and unplug the receptacle m mp Right Hand Hose Guard Cable Connection The Electric Cable is now free of the Boom assembly C i dE jit oo ELECTRIC CABLE INSTALLATION It is assumed the electric cable has been removed and related parts are still left off the boom assembly The electric socket must not be installed at this time The cable must be well tensioned in the area between the strain reliefs a the boom head and Boom Section cable take up brackets Stage 1 1 Tie the rope to the cable and feed il through the strain relief fitting and cable take up weldment tube then feed to the rear through the cable take up weldment located at the bottom front of Boom Section The cable lies in the bottom plate area between Boom Sections and 2 1 Feed electric
180. level plug SL Front Axle Breather clean or replace Hydraulic Reservoir Braathor Cap clean or replace Rear Hub Drain Plug drain refill tem 48 rs fill plug GO Annual or 1500 Hour Lubrication amp Maintenance Service at whichever interval occurs first include all previous periodic services Hydraulic Return Filter replace fifter element 1 Hydraulic System unless fluid is analyzed quarterly to determine degree of contamination reservoir must ba drained and refilled on an annual basis HF 1 Hydraulic Reservoir Screen remove clean amp install when hydraulic is drained 1 Hydraulic Suction Filler replace filter element 1 Engine Cooling System drain flush amp refill on basis of period suggested by anti reaeze manufacturer 1 Adjust intervals for abnormal usage and conditions See recommended lubricants page 34 Lubrication Notes Lubricate points indicated by dotted leaders on both sides of unit Intervals shown are for normal B hour day usage and conditions Apply a light coating of engine oil to all linkage pivot points Clean lubrication fittings before lubricating 33 e Clean filter housings using diesel fuel Dry components thor oughly using a lint tree cloth e Check lubricant levels when lubricant is cool Also check appearance lor contamination Drain engine and gear cases only after operation when lubricant is hot Refer to
181. ll instruction decals amp plates Any optional equipment instructions furnished The operator must also read understand and comply with all applicable Employer Industry and Governmental rules standards and regulations Regardless of previous experience operating similar equipment the operator must be given sufficient opportunity to practice with the Material Handler in safe open area not hazardous to people or property to develop the operating skills and the proper feel for controls and operating clearances required for safe efficient operation Though no offense or discrimination is intended only the masculine pronouns will be used throughout the remainder of this manual Orientation When used to describe location of components in the material handler the directions front rear right and left relate to the orientation of a person sitting in the operator s seat Related Manuals amp Decals Separate publications are furnished with the material handler to provide information concerning safety replacement parts maintenance procedures theory of operation and vendor components Replacement manuals decals and instruction plates can be ordered from your Gradall Material Handler Distributor Models Covered This manual covers the 534C 9 and 534C 10 Material Handlers 534C 9 units are furnished without outrig gers and 534C 10 units are furnished with outriggers Both units are equipped with three section booms an
182. ll truss boom on boom head If truss boom winch is furnished connect auxiliary hydraulic hoses to winch 4 Approach truss or truss bundle with boom above and parallel to load 5 Position truss boom approximately parallel with main boom 6 Position truss boom winch hook as close as possible to balance point of load and secure load to boom using short slings or other rigging B sure rigging will not allow load to slip in any direction 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 8 Close clamps to hold load lightly and secure clamps 9 Transport load to delivery site and attach tag lines if load will be freely suspended SWING MAST PRECAUTIONS Always level forks horizontally before swinging load to side Swinging un leveled forks may result in load slipping from forks The swing mast attachment has a smaller load capacity than the standard carriage fork attachment Study the swing mast capacity chart carefully before handling a load with swing mast Read additional capacity information under Capacity heading e Because the swing mast increases lift height and can swing load to side it is especially important to level handler be fore lifting a load more than four feet above ground level refer to page 20 Capacity Maximum lift capacity is shown on serial number plate located on righ
183. lleys between strands indicate problems fatigue breakage in wires not necessarily visible on the surface More than one broken wire near attached fittings Heavy wear and or broken wires in rope sections under sheaves where rope travel is limited Evidence of reduction in original rope diameter allowing for normal stretch factors Excessive abrasion scrubbing and cleaning of outside wires Pitting kink damage or evidence of other kinds of mechanical trauma In addition ta inspecting wire rope boom cables regularly inspect all sheaves quards guides and other surfaces which are in contaci with the rope dunng boom operation Any defect damage to the above listed components poses a risk to the integrity of the rape DO NOT reach into the Boom until you are CERTAIN the keys have been removed from the ignition A fully comprehensive set of inspection procedures and guidelines including replacement recommendations is practically unattainable becouse of the many variables involved In the final analysis SAFETY depends largely on the good judgment of competent service personnel in determining 0 Damage to wire ropes 1 The remaining service life expectancy of the wire rope If there is any doubt the rope must be reploced i proper procedures to replace wom or damaged you hove questions including inquiries about the American Iron and Steel Institute publications mentioned above please call your Au
184. lly with a small flat tool Do not scratch bore of sleeve amp piston assembly item 14 Remove push rod item 8 spool item 10 and spring item 11 from sleeve amp piston assembly item 14 Remove cup item 9 from spool item 10 Inspection Clean and inspect all component parts for scratches cracks or wear Replace any parts that are excessively worn or damaged CAUTION If spool item 10 sleeve item 14 or bore of housing item 3 are in any way damaged scratched 12 assembly must be replaced These parts are select fitted and are not interchangeable or replaceable with service items Assembly 1 Install new cup item 12 and new piston ring item 13 on sleeve amp piston assembly item 14 CAUTION Lips on cup item 12 should be away from end of sleeve item 14 Install new cup item 9 on spool item 10 CAUTION Lips on cup item 9 should be away from end of spool item 10 Insert spool item 10 and push rod item 8 into sleeve amp piston assembly item 14 Secure with retaining ring item 7 Carefully install sleeve amp piston assembly item 14 into housing item 3 CAUTION Make sure that groove on sleeve will engage screw item 5 Install new o ring item 4 on cap screw item 5 and install in housing item 3 Install new o ring item 16 and new ring seal item 17 on new piston amp poppet assembly item 15 Place
185. load refer to page 20 e Always level handler before lifting a load more than four feet above ground Capacity Maximum lift capacity for the slope pile carriage is shown on serial number plate located on right cab wall However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler slope pile carriage combination separate capacity chart must be used for handlers equipped with slope pile carriage Study this chart carefully before attempting to handle a load with slope pile carriage Controls The carriage tilt lever controls carriage tilt Q COUNTERCLOCKWISE AUXILIARY TILT CONTROL LEVER c I your unit is equipped with a multi function auxiliary control lever refer to page 31 The auxiliary control lever is used to tilt slope carriage Push lever forward to tilt carriage counter clockwise or pull lever to rear to tilt clockwise Procedure 1 Remove carnage fork combination or other attachment from boom head refer to Attachment Installation page 24 2 Install slope pile carriage on boom head 3 Connect auxiliary hydraulic hoses to slope pile carriape attachment 4 Approach load with forks centered on load and stop handler 5 Level handler before tilting carriage to engage load 6 Tilt carriage to left or right to align forks with load and engage load 7 Raise load slightly and then level carriage amp Travel with load lowe
186. lue will be obtained by multiplying the number read on the spring scale dial by the flange radius Make note of the value Figure 4 42 2 4 RORO Tighten adjusting nut with special tool shown on page 60 At the same time manually rotate the trumpet to assure a correct fit between bearing cups and cones and get desired preload Figure 4 43 Figure 4 43 gt e Section 4 MERITOR Assembly and Installation 8 Check trumpet assembly preload and subtract 13 Apply liquid gasket material on contact surfaces value obtained before tightening adjusting nut of trumpet and ring Figure 4 46 Value must be 15 35 Ib in 1 7 4 Nem 9 Apply Medium Torque liquid adhesive Loctite Figure 4 46 241 or Three Bond 1334 on adjusting nut lock capscrew threads Install adjusting nut lock capscrew Tighten to 17 23 lb ft 23 0 30 5 Nem 10 Install inner washer planetary gears and rollers into flange Figure 4 44 Figure 4 44 GASKET 14 Install ring gear into trumpet Use reference marks made during disassembly to align holes and contact surface Figure 4 47 Figure 4 47 11 Install outer washers 12 With correct pliers install snap rings Figure 4 45 Figure 4 45 2 228 6 SUES T 4 Ji GO Z 37 Section 4 Assembly and Installation Assemble Hydraulic Apply Brake Housing Assembly NOTE e To assemble three function brake see page
187. ly WARNING To avoid serious personal injury and possible damage to components be very careful when using lifting devices during removal and disassembly procedures e Inspect to make sure that neither lifting strap is damaged Do not subject lifting straps to any shock or drop loading 1 Support trumpet to be serviced with lifting device Figure 2 3 2 Loosen and remove trumpet nuts and bolts Section 2 Removal and Disassembly NOTE For three function brake design If bleeder and pressure ports of brake piston are open the trumpet assemblies and ring gear will come off the center section easily without using puller holes Cover pressure ports with rags to avoid contact with escaping oil 3 Use two puller holes in trumpet flange to remove trumpet assembly from main housing NOTE Use steps 1 through 3 to remove second trumpet assembly 4 Remove ring gears from both sides through the two threaded puller holes Thread M14 x 1 5 x 6 g WARNING Do not hit steel parts with a steel hammer during removal and disassembly procedures Parts can break and cause serious personal injury 5 From main housing remove sun axle shaft spacers if used compression plates stationary discs friction discs lock pins and expansive plate assemblies To make lock pin removal easier hit main housing with brass hammer Figure 2 4 Figure 2 4 Section 2 Removal and Disassembly MERITOR
188. m the ignition and fasten a do not operate tag to the steering wheel before you reach into the boom Preparation Retroct the boom assembly fully Remove the keys from the ignition and fasten a do not operote tag to the steenng wheel DO NOT reach into the boom until you are CERTAIN that keys have been removed from the ignition the machine in a level open area with sufficient space to work safely Procure the tools and platforms required for this operation Procure a rope to tie to the cable This rope must be of sufficient length to allow access to each end whenever it is pulled through the boom assemblies with the cable l working with a helper review each of your duties Stage 1 1 Remove the hose guards from the rear of Boom Section 2 Separate plug and cap the crowd cylinder hoses 3 Remove the crowd cylinder mounting pins from the strong back cable bracket 4 Remove the extension cable mounting hardware from the strong back cylinder bracket at the rear of boom 5 Pull the cable free of the strong back cylinder bracket Fasten a rope to the cable end to aid in reinstallation 6 Remove the strong back cylinder bracket from the ear of the boom assembly Keep the top and bottom shim packs together and identified This will make assembly easier Extension Cable and Adjustment Nuts Cylinder Bracket Crowd Cylinder __ Mounting Pin Crowd Cylinder Hoses
189. m using slight down pressure to remove Boom Sedion weight from the bottom 3 Using a feeler gauge measure the gap between the bearing pad and the boom at Area 7 location B SHE 1 4 If the gap is more than 1 16 shims must be added to bring the boom into tolerance Note Shim packs should be equal top to bottom within shim location and If an unequal amount of shim must be added first add the shims to location A then equalize the shim pack at the next adjustment Do no use more than 3 levels of shims The bottom of the boom Location is mast critical Shim pack levels must always be equal within shim at this location Adjustment 1 Loosen the beating pad mounting bolts ar locations or or both ond add required shims 1 Shims are stamped with the Gradall Number and thickness Check the part number on the shim in the area you are installing additional ones and make sure they are the same Apply 242 to the threads on the pad mounting bolts Re torque the bearing pad mounting bolts Repeat Inspection Steps 3 amp 4 and Adjustment Steps 8 2 for Area Location k AREA 1 AND Area 2 Pap tocanon C amp D Inspect Extend the boom three quarters of total travel Extend at least ft beyond access holes 1 Lower the boom 10 of ground clearance 3 Install a wedge be
190. mber 2 0 05mm 0 002 0 05 Standard shim pack thickness 0 032 0 81 New PC number PC 5 0 13mm 0 005 0 13 New shim pack thickness 0 037 0 94 3 Old shim pack thickness 0 030 0 76 Old PC number PC 2 0 05mm 0 002 0 05 Standard shim pack thickness 0 028 0 71 New PC number PC 5 0 13 0 005 0 13 New shim thickness 0 023 0 58 4 Old shim pack thickness 0 030 0 76 Old PC number 2 0 05mm 40 002 0 05 Standard shim pack thickness 0 032 0 81 New PC number PC 5 0 13mm 0 005 0 13 New shim pack thickness 0 027 0 68 gt e MERITOR Install Pinion Bearing Cage Assembly on Main Housing NOTE Use minimum of three shims in pack If pack is made from different thickness shims install thinnest shims on both sides of pack for maximum sealing 1 Install correct shim pack between bearing cage and main housing Figure 4 24 Figure 4 24 CAPSCREW SHIM PACK WARNING Do not hit steel parts with a steel hammer during assembly and installation procedures Parts can break and cause serious personal injury 2 Install drive pinion and bearing cage into carrier If necessary use rubber plastic or leather mallet to tap assembly into position Figure 4 25 Figure 4 25 Section 4 Assembly and Installation 3 Install two capscrews and washers that fasten bearing cage Tighten to minimum torque of 67 lb ft 90 Nem Figure 4 26 Figure 4 26 4 Install yoke or fl
191. mbly Mounts to the rear of Boom Section 2 STRONGBACK Cylinder Bracket Also known os the Cylinder Bracket the 532C 6 534 6 amp 534D 6 Located at the inside reor of Boom Section 1 Extension cables and the base end of the crowd cylinder are mounted to this weldment CROWD CYLINDER Extends and retracts the complete Boom Assembly 534C 9 C 10 Located inside the push beam Rod eye pinned to the push beam base end pinned to the strongback 5326 6 534C 6 amp 5340 6 Rod eye pinned to the cylinder bracket and barrel mounted to the rear of Boom Section 2 oq 5340 6 Crowd Cylinder CYLINDER Tilts the boom attachments forward or backward Located in the boom head of Boom Section 3 Tilt Cylinder BooM CABLE Wire Rope that mechanically extends and retracts Boom Section 3 Boom CABLE SHEAVE Grooved rollers that the boom cables ride on As the sheave rotates the cable ts extended or retracted from its anchor point There are extension and retraction sheaves used in the boom assembly They are located at the front end of the push beam and the rear of Boom Section 2 534D 6 Extend Cable Sheave Front View n Located inside boom assemblies Used to fluid to the attachment fastened to the end of Boom Section 3 Hose SHEAVE Located at the inside left of Boom Section 2 The plastic roller is designed with lips on the outer edge of the
192. mounting pin 3 Measure the clearance between the top and bottom of the strong back to Boom Section 4 Install shims as required at the top and bottom of the strong back Install and torque the strong back mounting bolts Install extension cables and hardware into the strong back Tighten the extension cables adjusting nut until gap between cable flat washer and strong back is 1 32 to 1 16 inch Gap for both washers should be equal When tightening make sure that the cable is not turning Torque cable jam nuts to 100 fr Ib Install the crowd cylinder hoses M po Crowd Cylinder Stage 5 Hose Take Up Assembly Hydraulic Hoses amp Clamps 1 Install the hose clamps for the tilt and auxiliary circuit hoses Do Not tighten them yet 2 At the area between the hose take up bracket to the first hose clamp adjust the hoses to form a 4 partial loop from the bottom of the boom to the hoses 3 Tighten all hose clamps First Clamp Area s if gt t 4 Connect Quick Disconnect tilt circuit hoses and auxiliary circuits located at the boom head area of Boom Section 3 to the fittings at the front of Boom Section 3 5 Install the lift cylinder bushings Hose Fitting Area Typical Connect Hose and Electric Cable Here Quick Disconnects Tilt Cylinder SRG The extension retraction cables are made from wire rope Review the reference to Boom Cables in the Safety
193. move the shift lever to the forward position The gauge should read 100 PSI Next repeat the test for reverse If the machine does not start to move at 1100 RPM engine speed in both directions equally at 100 PSI control pressure the stroking piston needs centered mechanically To check this adjustment install a clean hose between control ports X1 and X2 They are lotated on the top of the drive pump See Figure 14 Remove and plug control hoses from the top of the drive pump ports X1 and X2 Install two high pressure 10 000 PSI gauges hoses and adapters in the drive pump ports MA and MB on the side of the pump Start the engine and operate at low idle Observe the gauges Pressure at MA port must be equal to the pressure at MB port If pressures are not equal loosen locknut on stroking piston adjustment and turn adjusting screw to equalize pressures Tighten locknut to secure adjustment Repeat this procedure with low pressure 1 000 PSI gauges to fine tune If the inching valve and forward reverse valve work correctly but adjustment does not produce the desired pressure change replace the control pressure DA cartridge located on the left of the drive pump FIGURE 13 MAIN PUMP ASSEMBLY SIDE VIEW STROKING PISTON ADJUSTMENT r1 m CONTROL PRESSURE PORT Mb PORT SSS DA CARTRIDGE a Ma PORT T 1 I E I e 7727 ZZ 27 AE sar z y b k n ab Ld
194. must never slide on any ramp of oil seal ring or bore To prevent sliding wait at least two minutes for trichloroethylene to evaporate before continuing with installation When in the correct position Toric ring must roll only on ramps e small piece of lint can separate the oil seal surfaces and cause leaks Figure 3 17 Figure 3 17 CAUTION Do not force rings abruptly against each other A strong impact may break the oil seal components When seal is installed properly fasten all components well If DUO CONE oil seal is installed incorrectly these conditions can result e Toric ring can warp Figure 3 20 8 Clean oil seal surfaces with lint free cloth or paper Figure 3 20 9 Apply a thin uniform film of clean oil oil seal surfaces with cloth or clean finger Do not get oil on Toric ring Figure 3 18 Figure 3 18 YY ire lt KZ ETAK 21 Section 3 Prepare Parts for Assembly e Warped ring can cause irregular pressure on ring surface resulting in oscillating movements of oil seal Different pressures on oil seal surfaces can cause seepage wear and leaks e Oscillating oil seals allow dirt to enter Figure 3 21 shows an incorrect installation of an oil seal in its mounting position The upper bore is stopped and the lower lodge is rotating Figure 3 21 sss 5 pg amm Figure 3 22 shows the same lower bore after rotation of 180 degrees In this position high press
195. nd Adjustment Precautions 1 Read and understand the manuals named under the important safety notice heading above Be sure you are familiar with the machine s response to controls 2 Read and understand all material relating to area to be checked adjusted or repaired 3 This Manual covers hydraulic testing and adjustments Read and understand material related to hydraulics before proceeding with service of any kind on the hydraulic system When performing maintenance be sure there is no residual trapped hydraulic pressure 4 If you are working with a helper be sure he understands the procedure Be certain each of you knows what to Form No 29633 3 97 iii 534C 9 amp 534C 10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL General Warning Information continued d gt expect from the other and when to expect it Be sure you understand all steps of the procedure before testing adjusting or repairing any component or mechanical assembly Follow the procedure carefully Always wear safety glasses hard hat and any other locally required safety related protective apparel when performing testing and adjusting procedures Thoroughly clean all areas before working on them Slippery and contaminated surfaces can cause serious accidents or mechanical failure if not removed Always mechanically secure machine components that could suddenly start in motion and cause injury or damage Remove key from ignition and place a
196. nd level recommendations TOWING VEHICLE CAUTION The Power Wheel will not normally be damaged by towing however the hydraulic drive components may be damaged unless the Power Wheel is disengaged from the drive motor Road speeds in excess of 25 MPH should be avoided unless clearly specified to be permissible by the equipment manufacturer TO DISENGAGE POWER WHEEL CAUTION For units equipped with the standard spring disconnect assemble the disengage cover 30 with the dimpled center protruding inward For units equipped with the optional quick disconnect push in center plunger of disconnect STORAGE A protective film is applied to the Power Wheel at the factory to prevent rust during shipment Additional protection may be required if the Power Wheel is to be stored for an extended period of time SEALING COMPOUND Silastic RTV 732 sealer and General Electric Silimate RTV No 1473 or RTV No 1503 are currently recommended for sealing gasket surfaces Sealant should be applied in a continuous bead which should be centered on the surface to be sealed but should move to the inside of the hole at each bolt hole location For service requirements order Auburn Gear Part number 604101 SPECIFICATIONS Maximum Intermittent output torque sass Lu 100 000 Ib in 11 300 Nm 5 000
197. nd torqued per values in Appendix 6errT 545 Gradall P N 1440 4043 must be used on all connections Two wrenches should be used when tightening hoses to prevent twisting Use one wrench on the swivel hose fitting the other on the fixed hose fitting Grodall strongly recommends against using generic hoses as replacements Hoses for Gradall Material Handlers are specifically designed for use in this application There is no to ensure thal generic hoses will meet Gradall s strict application performance requirements AND AUXILARY Hose REMOVAL REINSTALLATION Hoses normally can be removed and reinstalled simply by connecting a union to the fittings on the hose joining them together then pulling them through the boom assembly until they are free You may have to remove the hose guard at the roller assembly If this doesn t work follow the procedures listed below Retracd the boom fully level Remove the keys from the ignition and fasten a do not operate tag to the steering wheel Procure the tools and work platforms to allow the work to progress safely Procure a rope to assist pulling the hose to the correct location during reinstall if working with a helper be certain each of you know your assigned duties Review the removal reinstallation procedure Hoes Connettion Area Adjusting Nuts Removal Stage 1 1 Loosen the adjusting nuts at the hose take up bracket to relieve
198. ned sleeve with appropriate holder to remove pinion nut Figure 2 32 3 Remove pinion oil seal Pry at several points around circumference between seal flange and bearing cage Figure 2 34 If pinion bearing cage was already removed place it on main housing and fasten with two Capscrews Figure 2 34 OIL SEAL Figure 2 32 4 Remove capscrews and washers that fasten pinion bearing cage on main housing Figure 2 35 A Figure 2 35 CAUTION Do not use a hammer or mallet to loosen or remove yoke flange or splined sleeve The hammer or mallet can damage the parts or cause alignment problems Do not damage the oil seal surface area 2 Remove yoke flange or splined sleeve from drive pinion with appropriate puller tool Figure 2 33 Section 2 MERITOR Removal and Disassembly Figure 2 37 CAUTION Do not use pry bar to remove bearing cage from carrier A pry bar can damage bearing cage shims and main housing 5 Remove pinion bearing cage and shims from main housing If bearing cage is tight within the main housing hit bearing cage at several points around flange area with leather plastic or rubber mallet Figure 2 36 Figure 2 36 NOTE The inner bearing cone and bearing spacer will remain on the pinion shatt 9 If pinion bearing needs to be replaced remove inner and outer bearing cups from inside of cage Use a press and sleeve bearing puller or small drift and hammer Figures 2 38 and 2
199. ng brake lower forks 10 ground move all controls to neutral stop engine and remove key from ignition Chock wheels if parking on a slope Never permit diesel engine to run out of fuel Doing so can cause severe damage Decals GRADALL WARNIND TO PREVENT SERIAL NO WEIGH FACTORY THIS TRUCK MELTS OS ICM ee rest Hu in anal Bas wa ZTAMDAPOS FD T TRIAL CAPACITY WITH STANDARD K 64 CARRIAGE INJURY KEEP OUT OF BOOM HOLES Located on Both Sides of Boom Part No 7702 3009 ro rara DO NOT ENGAGE PARK BRAKE WHILE MACHINE IS IN MOTION STATIC BRAKE ONLY Located on Instrument Console Part No 9114 3182 d j I Jg 3 TJ 1 ent CAPACITY EQ i T Located on Right Cab Wall 534 7 9 Part 9114 3150 534C 10 Part No 9115 3003 TO PLACE ANY PART OF hg I MACHINE OR LOAD WITHIN 1 UNLA WFUL FEET OF HIGH VOLTAGE LINES OF UP TO 50 000 VOLTS aa CLE k 1 Supe wox nmm m vibe Tren ANUL A HYDRAULIC Part No 8360 1011 AWARNING Hydraulic Tank Part No 7702 3006 IMPORTANT To prevent damage to the electrical system when FUEL DIESEL EXTINGUISH ALL OPE
200. ning press operation to avoid serious personal injury and possible damage to components during assembly and installation procedures 1 Use press to install new planetary pin into spider Make sure proper dimensions are used and holes are aligned Figures 4 38 and 4 39 Figure 4 38 Section 4 Assembly and Installation Figure 4 39 Z WARNING To avoid serious personal injury be careful when using Loctite Follow the manufacturer s instructions for safe use to prevent irritation to eyes and skin Wash after skin contact If the Loctite gets in eyes flush with water for 15 minutes Have eyes checked by a doctor 2 Apply Medium Torque liquid adhesive Loctite 241 or Three Bond 1334 to threads of planetary gear axle lock capscrews Install and tighten to 17 23 lb ft 23 31 Nem 35 Section 4 Assembly and Installation CAUTION Rollers must come from the same manufacturer 6 and have the same tolerance range Replace spacers and washers when a new roller is used 3 Apply grease Shell 71032 Alvania EP 2 or Texaco 995 Multifak EP 2 on each gear hole Install rollers and spacers into planetary gears Figure 4 40 Figure 4 40 o gt k Q 36 5 Figure 4 42 gt e MERITOR Install planetary spider and axle shaft bearing adjusting nut Measure trumpet flange radius With a spring scale check the trumpet assembly preload before tightening adjusting nut The va
201. nstallation Install Differential Housing Assembly into Main Housing With Adjusting Ring 2 Sides 1 Install adjusting ring into main housing 2 Install bearing cup 3 Install differential case assembly into main housing Figure 4 33 Figure 4 33 4 Install brake housing and other differential case bearing cup Figure 4 30 5 Install three bolts to adjust the differential on brake housing Tighten to 19 26 lb ft 26 36 Nem Figure 4 31 4 6 Install differential case bearings adjusting nut into brake housing Figure 4 31 33 Section 4 Assembly and Installation 7 Install pinion bearing cage assembly and shim pack Figure 4 34 See Install Pinion Bearing Cage Assembly on Main Housing page 31 Figure 4 34 8 Adjust adjusting rings with the following procedure Figure 4 35 Figure 4 35 a Tighten ring gear side adjusting ring to eliminate backlash between ring gear and pinion b Unfasten same adjusting ring from four to five slots c Tighten opposite side adjusting ring to obtain a preload of 15 35 lb ft 1 7 4 0 Nem Discount pinion bearing preload measured before T 34 gt e MERITOR 9 Check backlash differential preload and teeth contact See Section 5 Adjustments 10 If all adjustments are within specifications remove brake housing Apply liquid gasket material to main housing surface WARNING To avoid serious personal injury be careful w
202. nter nut of rolling torque tool and turning hub 9 slowly and steadily with the torque wrench Note mean torque An initial bearing rolling torque of greater than 52 in lbs means that the cone 11 was pressed on too tightly in step 4 In this case back off bearing cone 11 by pressing spindle 3 out of cone 11 until initial preload is relieved STEP 8 Torque bearing nut 14 with bearing nut wrench AGO7366B until a bearing rolling torque of 44 52 in lbs with a boot seal installed or 4048 in Ibs without a boot seal is reached This may require several trials of pressing the cone 11 by torqueing the nut 14 and then checking the rolling torque Rotate hub 9 by hand as nut is being tightened in order to seat bearings NOTE Up to 250 ft lbs of torque may have to be applied to bearing nut 14 in order to press cone 11 into position STEP 9 Remove bearing nut 14 and install lockwasher 13 Install nut 14 STEP 10 Re torque bearing nut 14 to 65 75 ft lbs STEP 11 Secure bearing nut 14 by bending a lockwasher 13 tab into one of four bearing nut slots If no tab aligns with a slot the nut may be tightened until one of the slots aligns with a lock washer tab STEP 12 Assemble a washer 16 spring 17 a second washer 16 and a retaining ring 15 in the middle grooves of input shaft 2 Install a second retaining ring 15 in groove near small end of input shaft 2 STEP 13 Assemble the splined end of the inpu
203. nvestigation of the problem If he is unavailable contact the GRADALL Service Department at 330 339 2211 Related Manuals and Decals Separate publications are furnished with your Material Handler to provide information concerning safety replacement parts operation maintenance procedures and vendor components Replacement manuals and decals can be ordered from your GRADALL Distributor Orientation When used to describe location of components on the machine the directions front rear left and right relate to the orientation of a person sitting in the operator s seat in the cab Welding If welding on the machine becomes necessary place the ground adjacent to the area being A CAUTION welded This will prevent arcing between components such as bearings or machined surfaces which could cause machine damage and downtime 1 Welding rod repairs should meet 70 000 PSI minimum tensile strength low hydrogen process 2 The battery leads must be disconnected before welding to prevent damage to electrical components Fasteners 1 Grade 8 bolts are used whenever two machined surfaces or major assemblies are bolted together Torque values for the application will be called out 2 Grade 5 bolts are used to fasten non machined areas such as sheet metal Refer to bolt torque chart in Operator s Manual 3 Dowel pins are used in assemblies to absorb the shear load to these components and assist in correct positioning for bolt insertion Testing a
204. o lee Ingles preguntele a su supervisor para las instricciones de seguridad Wen Sie kein Enlisch lesen bitten Sie ihren Vorgesetzten um die VORSICHT Sicherheitsvorschriften Gradall is a registered trademark for hydraulic excavators hydraulic material handlers and attachments manufactured by the Gradall Co Covers 534C 9 Units Starting Serial No 0344394 Form No 20042 AND Part No 2460 4171 Original Issue 3 01 Covers 534 10 Units Staring Serial 0266057 IMPORTANT SAFETY NOTICE Safe operation depends on reliable equipment and proper operating procedures Performing the checks and services described in this Manual will help to keep your GRADALL Material Handler in reliable condition Following recommended operating procedures can help you avoid accidents Because some procedures may be new to even the experienced operator we require that this Manual be read understood and complied with by all who operate this machine Strict attention to and compliance with instructions provided in this Manual the EMI Rough Terrain Forklift Safety Manual the GRADALL Material Handler Safety Manual the GRADALL EMI Operator Orientation Video as well as instructional decals and plates affixed to the machine will help prevent injuries to personnel and damage to the equipment The information provided herein is not intended to cover all situations i is impossible to anticipate and evaluate all possible applications and methods of operation for t
205. octite 221 or Three Bond 1341 on threads of brake shaft Install adjusting nut until it rests against piston DO NOT TIGHTEN ADJUSTING NUT Loosen the adjusting nut one full turn Figure 4 72 Figure 4 70 Figure 4 72 BRAKE SHAFT A N NN Nis i ADJUSTING NUT RETURN 1 LAP Jp f 777777707777777 B 4 A hy gt NN NS wama NNNNNNNNNNNN 8222 VA 2 2 HYDRAULIC PRESSURE HYDRAULIC PRESSURE LL SSS SSN Z AN RY NGA SS A 774 Z S 5 A 5 Release cylinder pressure to ZERO so piston CAUTION returns back against adjusting nut Check Do not use brake fluid in the hydraulic system dimension X as shown in Figure 4 73 Use Shell Donax TD or Shell Tellus 32 or equivalent Figure 4 73 3 Install brake cylinder assembly onto main ADJUSTING housing Figure 4 71 1 47 inch 37 0 mm Figure 4 71 CYLINDER CAPSCREW WITHOUT PRESSURE Y Y Y D qe NE SUPPORT CAPSCREW LU If dimension X is smaller than 1 47 inch 37 0 mm tighten adjusting nut until the dimension is reached If dimension gets larger unfasten the nut This adjustment must be made with piston activated 45 Section 4 Assembly and Installation 6 After 1 47 inch 37 0 mm dimension is obtained apply specified pressure to brake and check the brake torque on pinion as shown in
206. ode and cause serious personal injury Use a cleaning solvent to clean ground or polished parts or surfaces Kerosene or diesel fuel oil can be used for this purpose NEVER USE GASOLINE e Remove gasket material from parts Be careful not to damage ground surfaces e DO NOT clean ground or polished parts in a hot solution tank water steam or alkaline solution Clean Parts With Rough Finish e Parts with a rough finish can be cleaned with cleaning solvent or in a hot solution tank with a weak alkaline solution e Parts must remain in hot solution tanks until completely cleaned and heated e Parts must be washed with water until the alkaline solution is removed Section 3 Prepare Parts for Assembly Clean Axle Assemblies e A complete axle assembly can be steam cleaned on the outside to remove dirt e Before the axle is steam cleaned close or put a cover over all openings in the axle assembly Examples of openings are breathers and hydraulic inlets Dry Cleaned Parts e Dry the parts immediately after cleaning and washing e Dry the parts with soft clean paper or rags CAUTION Damage to bearings can be caused if dried by rotating with compressed air e Except for bearings parts can be dried with compressed air Prevent Corrosion e Apply axle lubricant to cleaned and dried parts that are not damaged and are to be assembled e Apply a special material that prevents corrosion to all surfaces If
207. om Section 3 3 The extension cable is now free and can be removed from the boom 4 Tie a rope to the extension cable socket end to aid in reinstallation Extension Cables Front Retraction Cable Rear Anchor Bracket EXTENSION CABLE REINSTALLATION To reinstall the extension cable you must be able to reach into the rear of the boom assembly to the cable anchor bracket weldment The anchor brocket is welded to the bottom rear boom plate of Boom Section 3 If you can t reach the bracket the booms must be separated Moke sure the keys have been removed from the ignition and fosten a do not operate tag to the steering wheel before you reach into the boom Preparation Place the machine in a level open area with sufficient space to work safely Procure the tools and platforms required for this operation working with a helper review each of your duties certain the boom assembly is still retracted fully If not mechanically push the boom inta the correct position DO NOT reach into the boom assembly while sections are being mechanically retracted extended STAGE 1 1 Tie a rope to the extension cable threaded end and pull the cable to the anchor bracket weldment area 1 Install the extension cable socket end and the mounting hardware to the cable anchor bracket weldment Extension Cables Retraction Cable Front Anchor Bracket Rear Anchor Bracket Anchor Bracket
208. on No 3 and hold while moving lever in appro priate direction as shown Procedure 1 Remove carriage fork combination or other attach ment from boom head refer to Attachment Instal lation page 24 2 Install swing mast on boom head and connect auxiliary hydraulic hoses to swing mast diversion valve hoses Also connect electrical cable atboom head A WARNING Observe all precautions and load capacity limits when handling load with swing mast 3 Always lower carriage fully in mast and position forks straight ahead before engaging load 4 To travel with a load keep forks straight ahead and lower load to approximately one foot above ground 5 Inspect supporting surface at delivery point and have it leveled if necessary 6 Level handler before raising load 7 If necessary perform a dry run unloaded of delivery to determine best position for handler 8 Use a signal man to assist in positioning the load if necessary Personnel Work Platform The material handler operator and personnel in the platform must read ond understand the separate personnel work platform manual number 9055 4001 prior to using the platform Capacity The Gradall personnel work platform is designed to carry a maximum of three occupants The load includes personnel materials tools etc The maximum capacity of your work platform is based on specific model material handler work platform combination To d
209. on Cable Adjustments amp Jam Nuts Crowd Cylinder raulic Hoses Stage 4 531C 6 534C 6 amp 534D 6 ONLY 1 At the retraction cable adjusting block located at the inside front bottom of Boom Section tighten the cable adjusting nut until the front of the threaded end lines up with the front edge of the access hole 2 Install the jam nut against the adjusting nut and torque to 100 fr Ib 3 Al the cable adjusting bracket tighten the extension cable adjusting nuts until gap between cable flat washer and strong back is 1 32 to 1 16 inch Gap for both washers should be equal When tightening make sure that the wire rope is nol twisting 4 Install the jam nut against the adjusting nuts and torque to 100 ft lb 5 Adjust the cables to specifications given on page 71 5 534D The Retraction Cable should now be correctly installed 42353041 Front Edge Access Hole A zi 4 k L Quod A k a o A 7D Extension CABLE REMOVAL Removal of the extension cable is difficult operation but it can be accomplished You must be able to reach into the rear of the boom assembly to unfosten the extension cable socket from the cable anchor bracket weldment The bracket is welded to the rear bottom plate of Boom Section 3 IF you con t reach this bracket the booms must be separated Make sure that the keys have been removed fro
210. on cover WARNING e Use only the type of fluid specified by the equipment manufacturer Do not use or mix different types of fluid The wrong fluid will damage the rubber parts of the assemblies which could cause loss of braking and serious personal injury e Do not reuse fluid Used fluid can be contaminated and can cause incorrect operation which could result in serious personal injury 3 Add specified oil until oil level is even with bottom of fill level hole See Section 6 Specifications 4 Install and tighten fill level plugs o 5 Road test vehicle in an unloaded condition for one two miles 1 6 3 2 km at speeds not more than 25 mph 40 kph Check the lubricant levels and the torque of all fasteners 51 Section 6 Specifications MERITOR PRA 352 Series Planetary Drive Axle Oil Change Intervals and Specifications Off Highway Operation Intervals Initial Petroleum Synthetic Oil i Meritor Military Oil Change Specification Specification Description 100 250 1 500 Petroleum Base operating operating operating SAE 10W 20W hours hours hours or 10W 30 D D or twice a or year which 1240 3100 ever comes miles first 2000 5000 km whichever comes first NOTES The checking interval depends on the individual operating conditions speeds and loads Severe operating conditions may require more frequent intervals Tractor oil universal fluid TOU types formulated for wet dis
211. on is most frequently used several other Gradall approved attachments are available for use with these material handlers Contact your Gradall Material Handler Distributor for information on approved attachments designed to solve special material handling problems Refer to serial number plate for list of attachments approved for use with your handler Non Approved Attachments 4A WARNING Attachments which have not been approved for use with your handler my cause machine damage or an accident resulting in injury or death All attachments approved for use with your handler are listed on the handler number plate located right cab Wall Use of non approved attachments is strongly dis couraged the following reasons Gradall cannot establish range and capacity limitations for will fit homemade altered or other non approved attachments An overextended or overloaded handler can tip over with little or no warning and cause serious injury or death to the operator and or those working near the handler Gradall cannot assure the ability of a non approved attachment to perform its intended function safely Non approved attachments may cause structural or other damage to the handler Such damage could cause dangerous operating conditions re sulting in serious injury or death 23 ATTACHMENTS Carriage Fork Capacities The standard carriage fork capacity chart located on the dashboard indicates
212. on of the 2WD 4WD solenoid valve and proper begin point adjustment on the front motor After completion of these checks operate the machine in a flat smooth open area Set the machine for 4WD operation Depress the traction lock switch Drive the machine at full soeed Release the traction lock switch the machine should pick up speed Shift the machine to 2WD and repeat this test The machine should pick up speed again If maximum speeds are in question check machine speed Run the machine in 2WD and 4WD in forward and reverse at maximum RPM for one minute In 2WD the machine will go 100 feet in 3 6 4 0 seconds In 4WD the machine will go 100 feet in 10 6 11 6 seconds The machine must be traveling at full soeed at the start of the measured distance Form No 29633 3 97 21 534C 9 amp 534C 10 HYDROLASTIC DRIVE PERFORMANCE CHECKS MANUAL CALIFORNIA Proposition 65 Warning Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 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 GRADALL 406 Mill Ave SW New Philadelphia Ohio 44663 Phone 330 339 2211 FAX 330 339 8468 hitp www gradall com Printed in USA Planetary Axle Model
213. ool to the REACTION CHAMBER 4 Flow Thru Port Figure 3 At the same time oil flows along a groove in the outside diameter of the MANUAL BRAKE ACTUATING SLEEVE into the chamber ahead of the MANUAL BRAKE ACTUATING SLEEVE Figure 2 Flow to the area ahead of the MANUAL BRAKE ACTUATING SLEEVE moves the MASTER CYLINDER PISTON building up pressure in the MASTER CYLINDER which in turn builds pressure in the brake lines Pressure in the REACTION CHAMBER moves the SPOOL back a small amount against the PRESSURE REGULATING SPRING and when the hydraulic pressure balances against the PRESSURE REGULATING SPRING the pressure is controlled to the MASTER CYLINDER The ORIFICE controls the rate of flow to FIGURE 5 Orifice Manual Brake Actuating Sleeve Check Valve the REACTION CHAMBER hence the rate of pressure increases and stability of the pressure regulating spool is controlled Therefore system efficiency is maintained since the power brake valve does not momentarily take all of the fluid from the pump When the pedal effort is released the spring in the REACTION CHAMBER returns the pressure regulating spool to neutral This closes LAND B to pressure and opens LAND A which allows the oil ahead of the spool in the REACTION CHAMBER to flow to the return port as well as the oil ahead of the MANUAL BRAKE ACTUATING SLEEVE The spring in the MASTER CYLINDER returns the MASTER CYLINDER PISTON In case the d
214. oposition 65 Waming Battery posts terminals and related Diesel engine exhaust and some of its accessories contain lead and lead constituents are known to the State of compounds chemicals known to the California to cause cancer birth defects State of California to cause cancer and and other reproductive harm birth defects or other reproductive harm Wash hands after handling GRADALE Material Handlers 406 Mill Ave SW New Philadelphia Ohio 44663 USA Phone 330 339 2211 Fax 330 339 8468 Web www gradall com 1001 Gradall Printed in USA LEGEND MAIN PRESSURE amp RETURN LINES PILOT LINES DRAIN LINES ELECTRICAL LINES Hill 12 VOLT BATTERY SUCTION FILTER 75 o EIEEERZ BREATHER REAR AXLE STABILIZER VALVE OPTION m FORWARD REVERSE SELECTOR SWITCH FLUSHING VALVE SECTION 100 LC MESH RESERVOIR NON PRESSUR I ZED STABILIZER SWITCH RETURN FILTER 75 FORWARD 2 4 WHEEL DRIVE SWITCH 2 4 1 l REVERSE 12 VOLT BATTERY 6800 PSI L p 6809 PSI TRACTION LOCK VALVE pret j TRACTION LOCK SWITCH WHEEL E VALVE lt ilb 12 VOLT PARK BRAKE BATTERY SWITCH STEERING ORBITROL LP
215. ork capacity chart Capacity must be reduced for areas where maximum bucket capacity would exceed standard carriage fork capacity chart Controls LOWER LOWER BUCKET BUCKET LIP LIP RAISE RAISE BUCKET BUCKET LIP LIP OPTIONAL STANDARD OPTIONAL FORK TILT CONTROLS Because the carriage tilt cylinder is used to tilt the bucket the carriage tilt lever is used to control the bucket Pull lever to rear to raise bucket lip and push lever forward to lower bucket lip Procedure Remove carriage fork combination or other attachment from boom head refer to Attachment Installation page 24 continued 2 Install light material bucket on boom head A WARNING Observe all precautions and load capacity limits listed previously when handling loads with light material bucket 3 Retract boom fully and tilt bucket up or down as required to position bottom of bucket parallel with ground 4 Raise or lower boom to appropriate height for loading material from stockpile 5 Align handler with face of stockpile and drive slowly and smoothly into pile to load bucket Do not corner load bucket 6 Tilt bucket up far enough to retain load and back away from pile 7 Lower bucket to carry position approximately one foot above ground and travel carefully to unloading point Tilt bucket down to dump load CAUTION Do not use bucket for back grading or quick switch lock pin may be damaged MAST 6 wit
216. orque the two 5 16 18 x 1 2 inch bolts 31 Torque bolts to 10 20 ft lbs STEP 20 Invert the Power Wheel assembly and assemble the coupling 1 with counterbore out to the input shaft 2 NOTE When installing a hydraulic motor to the Power Wheel drive it is necessary to place an O ring or gasket not supplied by Auburn Gear between the motor and planetary drive O ring sizes SAE A 2 042 SAE B 2 155 SAE C 2 159 CARRIER ASSEMBLIES It is recommended that the primary and secondary carrier assemblies 19 amp 20 be serviced in their entirety to protect the integrity of the Power Wheel drive LUBRICATION RECOMMENDATIONS IMPORTANT POWER WHEEL PLANETARY DRIVES ARE SHIPPED WITHOUT LUBRICANT AND MUST BE FILLED TO THE PROPER LEVEL PRIOR TO START UP Observe lubrication recommendations given by the original equipment manufacturer When specific recommendations are not available use mild extreme pressure lubricant API GL 5 No 80 or 90 when filling the Power Wheel under normal temperature ranges between 0 120 F 18 to 49 C Power Wheel is to be half full of oil when unit is mounted level and horizontal Use drain and fill plug located in cover Oil to be changed after first 50 hours of operation with subsequent changes every 1000 hours or yearly which ever comes first If unit is to be operated vertically if ambient conditions are outside the specified range or if the oil temperature exceeds 200 F 93 C contact Auburn Gear for oil a
217. ove cone from spindle STEP 12 Remove the oil seals 4 and 5 and bearing cones 6 and 11 from hub 9 Inspect bearing cups 7 and 10 in position and remove only if replacement is required ASSEMBLY OF POWER WHEEL STEP 1 Press new bearing cups 7 amp 10 in each side of the hub 9 It is recommended that bearing cups 7 amp 10 and cones 6 amp 11 be replaced in sets STEP 2 Assemble bearing cone 6 into cup 7 at seal end of hub 9 and press a new seal 5 into hub 9 Install boot seal 4 on hub 9 if unit is so equipped STEP 3 Position spindle 3 upright on bench Lubricate lips of seals 4 and 5 and lower hub 9 onto spindle 3 Hub 9 shouid be centered as it is lowered over spindle 3 to prevent seal damage STEP 4 Assemble bearing cone 11 over spindle end Press bearing cone 11 over spindle bearing journal using press and cylindrical bearing tool AGO8404B Press bearing cone 11 down until roller just touches cup 10 OPTIONAL Use hammer and bearing tool AGO08404B to install cup 11 over spindle 3 Take care when using this method to avoid pressing cone 11 too far As in other method rollers should just touch cup 10 STEP 5 Install thrust washer 12 and bearing nut 14 DO NOT install lockwasher 13 at this time STEP 6 Place rolling torque tool AG08771C over spindle 3 and bolt or pin to hub 9 STEP 7 Check initial rolling torque by installing an inch lb torque wrench on ce
218. ownstream power hydraulic system requires a pressure that is equal to or greater than one halfthe brake line pressure the PRESSURE REGULATING SPOOL shifts a minute amount and the pressure is regulated across LAND A and LAND B Figure 4 If the pressure required by the brake valve is lower than that required by the power steering the power steering will not normally interfere with the operation of the brake Figure 4 NOTE Brake line pressure can exceed preset specifica tions in the unusual condi tion of a simultaneous brake application and sud den elevation of the steer ing pressure above the value In the standard MICO Open Center Valve the pressure in the REACTION CHAMBER and ahead of the MASTER CYLINDER PISTON _ 64 00 13 075 E 32 00 1 26 NOTE Dimensions will vary slightly between units and are to be used for reference purposes only FIGURE 6 is equalto one half of the brake line pressure To accomplish this the area of the MASTER CYLINDER PISTON is twice the area of the MASTER CYLINDER Therefore any pressure that is applied to the MASTER CYLINDER PISTON will be multiplied by two to determine the master cylinder pressure The pressure regulating spring can be factory set to normally limit brake line pressure regardless of system pressure This valve will act as a manual brake master cylinder in the event of failure in the hydraulic circuit supplying power to it
219. ows red to indicate alternator is not charging Be alert for unusual noises or vibration When an unusual condition is noticed park machine in a safe position and stop engine Report condition to your supervisor or maintenance personnel Avoid prolonged idling Idling causes engine temperature to drop and this permits formation of heavy carbon deposits and dilution of lubricating oil by incompletely burned fuel If the engine is not being used turn it off CAUTION Always keep engine covers closed while engine is running continued Stopping the Engine Operate engine at low idle 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 down this practice causes raw fuel to remove oil film from cylinder walls and dilute lubricant in crankcase To stop engine apply parking brake Lower forks fully shift forward reverse lever to neutral and allow engine to run at idle for 3 to 5 minutes Then turn key counterclockwise to stop position Be sure to remove key from ignition switch before leaving operator s cab WARM UP amp OPERATIONAL CHECKS To be performed at beginning of each work shift Complete all required maintenance before operating unit The safety efficiency and service life of your unit will be increased by performing the operational checks listed b
220. p 56 287 52 7 gt i 53 2 4 lt 79 12 76 78 11 20 75S 8 AT eL 74 Z 69 C2 7 75 73 e 3 19 172 2 71 63 27 G 18 8 715 16 dE amp o4 17 29 p 30 Sed 22 EX N 21 25 89 24 555 m QN NN 51 52 P ad A 353 383 7 Differential Pinion Sat o Ces 14 Differential Case Shim 5 PionCage 21 Motor AdapterFlange 22 DienSeee SSS SnapRing 27 Washer 3 Brake Housing sa Capscrew 3 Adjuster Ringo OOOO 3 Brake Assembly 1 a2 Brake ControlRod a Song 15 6 Ea NE 15 NEM 22 24 27 MUN 32 EA 42 s 45 VI 46 O ring Adjusting Nut Kit Rollers Drain Plug Vent Plug Hydraulic Line Bleeder 47 48 49 50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 67 70 71 72 73 74 75 76 77 78 79 81 82 83 84 85 87 8 8 PROA 352 382 With Mechanical Drive Option VII PROA 352 382 With Mechanical Drive Option Description 6 Differential Case Washer 8 Friction Discs Stim Pack 9 Friction DrveDisc SS VIII Item Description 55 56 57 58 59 61 62 63 64 64 65 6 70 71 72 73 74 75 76 77 78 79 81 82 83 84 85 87 88 91 92 93 94
221. p 534D 6 machines verses 534C 9 C 10 amp 534D 9 D 10 machines The 534C 9 C 10 amp 534D 9 D 10 cylinder is installed in a push beam The base end of the cylinder mounts into a structure at the rear of Boom Section called a strong bark The rod eye end of the cylinder mounts into the push beam The push beam is fastened to the iear of Boom Section 2 As the cylinder rod extends or retracts the push beam moves Boom Section 7 proportional The 532C 6 and 534C 6 amp 534D 6 cylinder rod end is fastened to a cable bracket mounted to the rear of Boom Section similar to the strong back of the 534 9 10 amp 534D 9 D 10 The rear of the cylinder barrel is designed with a mount that fits into a retainer bracket at the rear of Boom Section 2 The front of the cylinder barrel is equipped with mounting bolts to hold the cable sheave assembly As the cylinder rad extends and retracts the barrel movement moves Boom Section 2 proportional Re patk kits for the crowd cylinders are available from your Authorized Gradall Distributor REMOVING AND REINSTALUNG THE CROWD CYLINDER 534C 9 C 10 amp 534D 9 D 1 ONLY Preparation Review all safety issues before commencing work Place the machine in a safe level uncongested working area Apply the brakes and chock the wheels Procure crane and lifting tackle capable of lifting 1000 Ib If working with a helper be certain each of you know your assigned duties Select a location to place th
222. pacers and the bearing pad Removal Pod Location B 1 Lower the boom assembly to ground and apply minimal down pressure sufficient to provide clearance at Location B 1 Remove the key from the ignition and fasten a do not operate tog to the steenng wheel 3 Remove the bearing pad mounting bolts and washers 4 Remove shims spacers and bearing pads Removal Pad Location C amp D 1 Ifthe boom is tight install a wedge to the side and force the boom to the opposite side 1 Remove the key from the ignition and fasten a da not operate tag to the steenng wheel 3 Remove the bearing pad mounting bolts 4 Remove shims spacers and bearing pads 5 Remove the wedge installed in Step 1 AREA 3 AND AREA 4 Pap LocamoN E Removal Steam dean or pressure wash the rear of the boom assembly 2 Retract the boom fully then extend ft 3 Remove the key from the ignition and fasten a do operate tag 10 the steering wheel 4 If necessary use a wedge to shift the Boom Section to the opposite side to create dearance for bolt removal If additional clearance is required remove the shim pack from the side oppasite the bearing pad being removed Remove the bearing pad mounting bolts Remove shims spacers and beanng pads Remove the wedge installed in Step 4 SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES AREA 4 Removal Pad Location F 1 Extend Boom
223. page 35 for procedure to obtain oil sample lor analysis Recommended Lubricants amp Capacities lt a SPECIFICATION ENGLISH Boom Cable Adj Threads Boom Slide Bearing Paths Engine Cooling System Engine Crankcase Front Axla Fuel Tank Grease Fittings Hydraulic System Haar Hubs MY moly lube MG extremae pres moly luba AF 50 Ant Freeze 50 Water EO engine oil SL special luba DF diesel fuel MG extreme pres moly luba HF hydraulic fluid SL special luba Capacities are approximate check level to be sure Union 76 Megaplex XD2 Tractor Hydraulic Fluid Pour point 46 F SSU 100 F 275 Flash Point 442 F Approvad Supplier amp Type Mobile Mobilfluid 424 ONLY Hydraulic Fluid Specifications r point 46 F SSU 100 F 275 Flash Point 442 F Approved Supplier amp Type Mobile Mobilfluid 424 OR Citgo Tractor Hydraulic Fluid 33310 Torque Chart P N 1440 3323 NLGI 2 Permanent 15W 40 CD MIL L 2104D one ans 2 NLGI 2 46 Check torque using an accurate torque wrench to apply maximum torque value shown DO NOT EXCEED MAXIMUM TORQUE Exceeding maximum torque may cause fastener to fail BOOM SLIDE BEARINGS front BOOM SLIDE BEARINGS rear BOOM EXTEND CABLE at rear Adjusting Nut Jam Nut WHEEL LUG NUTS amp Weeks 250 hours 3 8 24 5 5 Weeks 250 hours 1 2 20 5 3 8 24 5 is 1 2 20 5 Weeks 250 hours 1 8
224. parking broke shift the Forward Reverse lever to Neutral and tum the rear wheels straight forward 3 Level the boom assembly 4 Tum off the ignition switch remove the key and fasten a do not operate tag to the steering wheel 5 Chock the wheels to prevent machine movement during removal operation Stage 1 1 Procure a crane and lifting tackle capable of safely lifting 5000 Ib 1 Install a tag line to the front of the boom to help guide the boom once if clears Ihe machine 3 Fasten slings to Boom Section at the balance point 4 Take the weight off the boom assembly Stage 2 1 Identify and tag all hydraulic hoses and electrical cables 1 Separate plug and cap all hoses and electrical cables With the crowd cylinder hoses blocked off the Boom Sections will be locked in position preventing run out 3 Carefully remove pins from the compensation and lift cylinders Do not let the cylinders fall uncontrolled Carefully place them in a position of rest Block the lift cylinder in place to ensure it does not fall against the engine Do not install blocking over the engine valve cover Lift Cylinder M UM Wooden Block 4 Confirm the crane still has the weight of the boom in a balanced position 5 Carefully remove the boom bose pivot pin 6 Lift the boom assembly free of the machine and place in the designated work area 5B REINSTALLING THE COMPLETE Boom ASSEMBLY TO THE MACHINE k Stage
225. personal injury can also occur Visit Our Web Site How to Order Visit the Technical Library section of Call Meritor s Customer Service Center at www meritorauto com for additional product and 800 535 5560 service information on Meritor s Heavy Vehicle Systems component lineup Drivetrain Plus Technical Electronic Library TEL on CD The CD includes product and service information on Meritor s Drivetrain Plus component lineup 20 Order TP 9853 PRA 352 Trumpet Variation No 1 P ad 7 1 11 13 14 15 16 Spiral Gear amp Pinion 21 22 24 27 31 32 34 37 41 NEIN NE 33 ES _15_ 165 NEM 22 24 27 MUN 32 IX a a A 352 Trumpet Variation No 1 Outer Piston Piston O ring Bolt Return Spring 52 Bearing Cup Axle Shaft Oil Seal Planetary Pinion Snap Ring Nut 43 44 45 46 47 48 49 50 51 53 54 55 56 57 58 59 61 62 63 64 65 67 70 71 72 73 74 75 76 77 78 79 81 82 83 84 PRA 352 Trumpet Variation No 2 PRA 352 Trumpet Variation No 2 Item Description 6 Pinion Gear ThrustWasher 78 Spiral Gear Capscrew Plain Washer 9 Spiral Gear Capscrew IV Item Description O 760 Center Housing Suan 66 Center Housing Cover 78 bang iwer TT PRA 353 383 55 4 50 85 9 x 44 84 S wee am
226. pleting following preparations Disengage rear hubs By pass front drive system Release parking brake continued Towing handler with all wheels on ground for more than 200 yards can cause serious damage to hydraulic drive components MOVING LONGER DISTANCES H unit must be moved more than 200 yards it should be loaded on a trailer of sufficient capacity To Disengage Rear Hubs en HUB ENGAGED DIMPLE POINTING OUTWARD NGAGED ING INWARD k Secure both rear hub engage disengage plates with dimple pointing inward to disengage rear drive hubs To By Pass Front Drive Mark position of relief valve cartridge small hex 2 Hold large hex to prevent movement and loosen reverse relief valve cartridge small hex two full turns 3 Repeat steps 1 and 2 for forward relief valve Front axle drive is now by passed 4 Before returning machine to service be certain to return relief valve cartridges to original position and re engage rear drive hubs 36 To Release Parking Brake l If possible position unit on level ground lower attachment to approximately one foot from ground move forward reverse lever to neutral position apply parking brake and stop engine 2 Install wheel chocks at all wheels to prevent move ment 3 Working one side at a time remove three release screws and spacers from side of differential housing located at 12 o clock 4 o clock and 8 o cloc
227. preparation parameters from Section 5C Review all Safety Issues Select an appropriate place to store Boom Section 3 after removal from Boom section 2 Stage 1 1 Remove all bearing pads from the inside front of Boom Section 2 Area 1 Pad Locations B C D Eno View Area amp 2 Location A Top Inside ua m E d Location D Left Inside Location C Right Inside 2 Separate plug and cap till circuit hydraulic hoses and auxiliary circuits at the inside front of Boom Section 3 at the boom head section amp AUXILIARY Cigcum Hoses Smp 2 SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAID BOLT QUANTITIES Separate Cap amp Plug 3 534C 9 C 10 amp 534D 9 D 10 Remove all extension cable sheave components from the pivot beam front 4 5321C 6 534C 6 amp 5340 6 Remove extension cable sheave bracket fasteners EXTEND CABLE SHEAVE from the front of the crowd cylinder Front SECON 3 Extension Cable Sheave Bracket Fasteners 5 5320 6 534C 6 amp 5340 6 Pull extension cable sheave bracket free of Boom Section 3 and set aside for repair or reinstall Cj 42 LA J 1 5 532C 6 534C 6 8 5340 6 Pull extension cable sheave bracket free of Boom Section 3 and set aside for repair Or reinstall E 6 Pull the extension cables free of the sheave brackets and lay them on the boom gt Stage 2 l 1 At the rear of the boom remove all retraction cable sheave
228. reas which may be new to even the experienced operator Hydraulic Controls All boom and attachment movements are governed by hydraulic controls Rapid jerky operation of hydraulic controls will cause rapid jerky movement of the load Such movements can cause the load to shift or fall or may cause the machine to tip over Feathering Feathering is a control operation technique used for smooth load handling To feather controls move control lever very slowly until load begins to move then gradually move lever further until load is moving at desired speed Gradually move lever toward neutral as load approaches destination Continue to reduce load speed to bring load to a smooth stop Feathering effect can be increased by lowering engine speed at beginning and near end of load movement Boom Control Joystick The boom control joystick can be positioned to cause individual boom movements or combinations of boom movements as illustrated LOWER LOWER A BOOM LOWER amp AETRACT EXTEND BOOM F BOOM RETRACT EXTEND S C men es RAISE amp RAISE se Sei oy EXTEN RAISE BOOM With boom raised above horizontal forks can be Inserted under a load by moving boom control Joystick forward and to the right until forks move forward horizontally With boom 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
229. red to travel position load approximately one foot above ground 28 PRECAUTIONS e Maximum winch load capacity is reduced from normal carriage fork load rating refer to next heading Capacity Always level the handler before lifting a load refer to page 20 Travel with load and boom lowered to travel position load approximately one foot above ground e Always lower load to rest before leaving handler Capacity The winch maximum load capacity is shown on serial number plate located on right cab wall However maximum capacity may be used only in areas where it does not exceed capacities shown on standard carriage fork capacity chart located on dashboard Also note that maximum winch capacity 15 less than carriage fork maximum capacity Capacity rating 18 based on load being lifted and suspended vertically from the boom and with no load on forks A WARNING A side load or a swinging load can cause the handler to tip over and or damage the boom Observe the following Special Precautions SPECIAL PRECAUTIONS e Never drag the load lift vertically Use tag lines to guide and steady suspended load Tag lines must be long enough to keep helpers clear of load and handler e Beware of wind wind can cause a suspended load to swing and cause dangerous side loads even with lag lines e Start travel turn and stop slowly to prevent load from swinging Weight of all
230. rigging slings etc must be included as part of load Controls LOWER WINCH LOAD AUXILIARY CONTROL LEVER RAISE WINCH LOAD Il your unit equipped with a multi function auxiliary control lever r to page 31 The auxiliary control lever is used to control the winch Pull the lever to rear to raise winch load and push the lever forward to lower winch load Procedure 1 Remove carriage fork combination or other attachment 2 Install winch on boom head and connect hydraulic hoses at winch motor 3 Position winch hook directly above balance point of load and secure using appropriate rigging 4 Attach tag lines to load as appropriate and trans port load to delivery site 5 While helpers guide load with tag lines position load at delivery point PRECAUTIONS Because the truss boom extends the reach of the handler maximum load capacity is reduced refer to next heading Capacity Because of extended reach it is espe cially important to level the handler before lifting a load refer to page 20 Travel with load and boom lowered to travel position load approximately one foot above ground e Always lower load to rest before leaving handler 29 Capacity Maximum lift capacity for the truss boom with or without winch is shown on serial number plate located on right cab wall However maximum lift capacity applies only to certain areas within boom extension elevation pattern of
231. rk brake wear can cause park brake failure and reduce braking effectiveness on a slope With the park brake engaged start the engine Position the 2WD AWD switch for two wheel drive With the rear wheels aligned straight ahead move the shift lever to the forward position and run the engine full throttle 2500 RPM 2700 RPM If the brakes are working properly the machine will not drive through the brakes High backpressure in the actuation line can affect the brake holding power To determine whether the brake is at fault remove the brake actuation line and plug Check the park brake operation again If the machine does not move the brake is working properly Backpressure should be less than 20 PSI with oil at operating temperature To check this pressure tee a low pressure gauge 1 000 PSI hose and adapter in the brake actuation line If it is higher check for proper operation of the park brake solenoid valve Disconnect the brake actuation line and tank return line at the valve and plug them There should be no oil flowing from the open port on the park brake solenoid valve The brake actuation line should not be kinked There should be no restriction back to the reservoir See Figure 8C FIGURE 8 PARK BRAKE SOLENOID VALVE M CHARGE PRESSURE OIT LLL _ ES PARK BRAKE ACTUATION There is a 1096 wear factor on the 8 original rotor discs in the extended park brake assembly P N 9114 4160 Thus the 2 thick discs 0 150
232. ront bearing pads section one They also require 3 bolts an the boom bearing pods on the bottom front and top rear of section two and the top rear of section three All other boom bearing pads as well as all the boom bearing pads on the 532 534C6 534D6 require two bolts 2 m Boom Wear Pap ADIUSTMENTS To maximize boom service life wear pads must be carefully adjusted ot all times The following Service Notes are a general quide for properly adjusting boom wear pads GENERAL SERVICE NOTES Familiarize yourself with all bearing pad package components Add bearing pad spacers backing plates and shims as required to fit boom within w of tight fit to mating outer boom Boom Sections and 3 should be evenly centered to outer Boom Section Spacer and shim packs should be equal within 1 shim side to side and top to bottom It may be possible on new booms for bearing pads only to be installed There may not be room for spacers and shims Insert spacers between pad and shim Be sure no pad sits directly on the slotted surface of a shim Bolts must not extend beyond the chamfer on the bearing pad The length of pad bolts depends on the number of shims used If no shim is used with the bearing pad two washers are installed under the head of the bol against the boom Remove one washer if a shim is installed at a later date otherwise the bearing pad will not be securely held in place by the bolt Grease bearin
233. s Material Handlers Industria Maintenance Machines Attachments and other Components manufactured and marketed by The Gradall Company Certified 150 9001 this Manual are available from Gradall Product Support Call 330 339 2211 E Ext 385 Ask for the complete list of mo terii Manuals for Handlers GRADALL material handlers 406 Mill Ave SW New Philadelphia Ohio 44663 330 339 2211 Fax 330 339 8468 www gradall com Additional copies of available Technical Gradall Material Form No 0009 Important rim and wheel safety precautions NOTICE An inflated tire and rim can be very dangerous if misused or worn out Many accidents some fatal have resulted from improper handling and operation of truck rims and wheels It is therefore of the utmost importance that the precautions outlined on this page be care fully followed by all persons servicing truck rims and wheels to avoid personal injuries and costly damage How to prevent rim accidents during tire mounting Always inflate tire in safety cage or use a portable lock ring guard This is a safeguard against im proper assembly inadvertently mismatched parts and other assembly errors Remember an inflated tire contains potentially explosive energy that can blow improperly assembled rings loose In emer gency situations where a safety cage or portable safety device is not available use a clip on t
234. s in the second section The cylinder must be removed from the retainer orea Crowd Cylinder Retainers 532C 6 534 amp 5340 6 Stage 3 1 At the bottom front of Boom Section 3 loosen the retraction cable adjustment fasteners 1 Remove all the retroction cable sheave components Retraction Cable sheave Assembly Reaching inside the boom rear o the cable anchor bracket weldment remove the cotter pin from the retraction cable pin Remove the retraction cable pin The retraction coble should now be free Pull the cable from the boom assembly through the rear Remove the ropes and leave them in place to aid in reinstallation wi Retraction Cable Cable Anthor Brocket ame i em 9 aes 29906 532 534 Boom MANTENANCE 7C RETRACTION CABLE REINSTALLATION To reinstall the retraction cable you must be able to reach into the rear of the boom assembly to the cable anchor bracket weldment The anchor bracket is welded to the bottom rear boom plate of Boom Section 3 If you can t reach the bracket the booms will have to be separated Be certain that the keys have been removed from the ignition and fasten a do not operate tag to the steering wheel before you reach into the boom Preparation Place the machine in a level open area with sufficient space to work safely Procure the tools and platforms required for
235. s must be repaired before operating unit Failure to correct any defect can cause serious injury or death General The brake system includes a service brake and a parking brake Service and parking brakes are applied thru a pair of wet disc brake packs located within axle housing Because service braking and inching slow travel functions overlap some features of inching will be discussed here Refer to Drive Train Section for additional information on inching travel Inching Travel SERVICE BRAKE INCHING TRAVEL PEDAL Overlap between braking and inching occurs because the same pedal controls both functions and also because both functions control travel speed How ever the methods of controlling travel speed are quite different service braking involves a controlled stopping force applied to the front wheels while inching involves a controlled driving force applied to driving wheels SERVICE BRAKES INCHING TRAVEL PEDAL N HIGHEST INCHING TRAVEL SPEED LOWEST INCHING TRAVEL SPEED Lam D Most of the inching travel pedal stroke controls the speed of inching travel As the pedal nears the bottom of its stroke it causes service brake application WARNING Practice inching braking in a safe open area until you are thoroughly familiar with response of machine to pedal travel 15 BRAKE SYSTEM Service Brakes The power assisted service brakes are applied only to wheels
236. s very low and gear is too E ae close to drive pinion Figure 5 13 Figure 5 13 e correct a deep contact pattern increase thickness of shim pack under bearing cage This will move the drive pinion away from the ring gear Figure 5 12 e Withdraw ring gear by decreasing shim pack thickness or loosening the gear side adjusting ring and tightening opposite side adjusting ring Figure 5 12 igu When heel contact pattern indicates that backlash Is very high and gear is too far away from drive pinion Figure 5 14 Figure 5 14 INCREASE SHIM PACK THICKNESS Approach ring gear by increasing shim pack thickness or loosening gear opposite side adjusting ring and tightening gear side adjusting ring 50 gt e MERITOR An acceptable contact pattern is centralized between toe and heel along the length of gear teeth Figure 5 15 Figure 5 15 In cases where it is not possible to get a good contact pattern the contact pattern shown in Figure 5 15 is acceptable If the acceptable contact pattern is not achieved change the ring gear and pinion set Figure 5 16 indicates a good contact pattern It is toward the toe and centralized between the top and bottom of the gear teeth Figure 5 16 Section 5 Adjustments Replace Lubricant 1 Install and tighten drain plug in central housing and brake housing o 2 Clean area around fill level plug Remove fill level plug from carrier inspecti
237. seat This can be further aided by using foot pressure Make sure one portion of second bead is still in the rim well then pry opposite por tion of bead over edge of rim This will free the tire from the rim To remove ring insert tool in notch and force ring opposite of notch into gutter then pry off Pry out and up on side ring carefully but firmly Be areful not to bend side ring Force upper tire bead into well oppo site the valve slot and with tire tool pry opposite portion of bead over edge of rim SAFETY PRECAUTIONS 1 Use only parts free from damage or heavy rust 2 Insure that side ring is completely seated before inflating tire 3 Inflate tire in safety cage or use a lock ring guard In emergency situa tions where a safety cage or portable safety device is not available use clip on type air chuck so that opera tor may stand aside during inflation 4 Insure that tire is completely deflat ed prior to removal of rings 5 Do not mount 16 5 diameter tubeless tires on 16 diameter rims How to properly install ACCU RIDE rims and wheels Proper installation of rims and wheels on a vehicle is essential to safe economical trouble free service Use only the specified sizes of studs nuts and clamps RECOMMENDED INSTALLATION PROCEDURE DISC WHEELS DEMOUNTABLE RIMS Make sure that all parts including rims rings spacer bands and cast wheel studs are free from damage dirt or rus
238. snap rings Install the crowd cylinder bracket fasteners Measure the top and bottom clearance between Boom Section and the crowd cylinder bracket Install shims as required between the crowd cylinder and Boom Section Torque the crowd cylinder bracket mounting bolts see Appendix A and apply 24210 threads Install springs and nuts on the extension cables Tighten the retraction cable at the adjusting block Tighten the cable until its end lines up with the front of the cable adjustment access hole When tightening make sure that the wire rope is not turning 534C 9 C 10 amp 534D 9 D 10 The cable is tightened until the third thread from the end lines up with the cable adjustment access hole When tightening make sure that the wire rope is not tuming Tighten the extension cables adjusting nut until gop between cable flat washer and strong back is 1 32 to 1 16 inch Gap for both washers should be equal When tightening make sure that the cable is not tuming Install and torque the cable jam nuts to 100 ft lb Install all hydraulic circuit hoses to the crowd cylinder Note See Stage 4 for 534C 9 C 10 amp 534D 9 D I0 Strong Back Installation Mounting amp Fastening Area Form No 29906 532 534 Boom Mantuani Stage 4 Strong Back Installation 534C 9 C 10 amp 534D 9 D 10 ONLY 1 Place the strong back in place at the rear of Boom Section 1 2 Install and lock the crowd cylinder
239. st on boom head 3 Connect auxiliary hydraulic hoses to mast cylinder 4 Always level the handler before raising the boom or the forks with or without a load 5 Totravel with a load lower forks fully in mast and lower boom to position load approximately one foot above ground 6 Use mast as required to increase vertical reach of handler 7 Usea signal man to assist in positioning the load if necessary SWING FORKS PRECAUTIONS Read additional capacity information under Capacity heading Always level forks horizontally before swinging load to side Swinging un leveled forks may result in load slipping from forks e Because the swing forks can swing the load to the side itis especially important that the handler be level when handling a load more than four feet above ground level refer to page 20 Capacity Maximum lift capacity for swing forks is shown on serial number plate located on right cab wall However maximum lift capacity applies only to certain areas within boom extension elevation pat tern of handler swing fork combination A separate capacity chart must be used for handlers equipped with swing forks Study this chart carefully before attempting to handle a load with swing fork attachment A WARNING Do not attempt to handle a load with swing fork attachment until you have studied swing fork capacity chart carefully If your handler does not have a swing fork capacity c
240. st the park brake Charge pressure should remain at 380 PSI See Figure 11A The charge pump efficiency also needs to be checked if the previous tests prove inconclusive Check charge pump flow out of T1 port on the side of the pump See Figure 12 At 850 RPM there should be 4 GPM At 2500 RPM there should be 12 GPM of flow Disconnect run tee and plug Measure charge pump flow out of fitting against above specification The flow readings are checked at 480 psi If the test is positive on flow proceed to the next step To check internal leakage of the main pump block off ports A and B at the main pump If drive motors have already been isolated continue testing Install two high pressure 10 000 PSI gauges hoses and adapters in drive pump ports MA and MB Start machine and operate at low idle If the pump is good pressure at MA and MB test ports should read 380 PSI Adjust relief valve to see if pressure responds Engage forward drive with park brake set raise engine speed to full throttle and record drive pressure and charge pressure Repeat this procedure for reverse Drive pressure should be 6300 PSI in each direction Charge pressure should remain at 380 PSI and rise to approximately 480 PSI near full throttle If charge pressure is not achieved main pump is leaking internally See Figure 12 NOT E po not stall pump for more than 15 seconds each time Form No 29633 3 97 10 E FIGURE 9 CHARGE PRESSURE TEST PORT RETURN F
241. t Replace any defective parts Place rims and spacer band on wheel Secure clamps evenly in posi tion and draw up nuts alternately in the se quence shown at right Do not tighten them fully however This procedure will permit the inside rim to prop erly align itself on the 28 mounting bevel on the back of the cast wheel thus avoiding damaging wheel wobble ana M Man is Then tighten nuts fully using same alternate sequence Be sure to tighten these nuts only to the torque level recom mended in the table below and to maintain them at that level through planned periodic checks SPOKE WHEELS Size Ft Lbs Dry 150 175 200 250 400 450 400 450 CAUTION Insufficient mounting torque can cause rim slip page resulting in broken valves worn parts and damaged tires Excessive mounting torque can cause damage by strip ping studs collapsing spacer bands or forcing rims into an out of round condition Wrenches for Demountable Rims and Disc Wheels Double end socket wrenches for rims and disc wheels normally are adequate to install and remove Accu Ride rims and wheels when used with a 3 foot bar A 150 pound man exerting his entire weight 2 5 feet out on a bar can apply 375 foot pounds of torque to a wrench 150 x 2 5 Air wrenches however sometimes are used to save time and labor The torque they deliver depends on the air line pressure from which they operate Periodic checks
242. t operator may stand clear during inflation DEMOUNTING i 5 i Standing clear of rim completely deflate tire by removing valve core or using deflator cap Place tapered end of rim tool in depression in lock ring or between rings and press down on side ring to free bead Continue downward pressure on side ring progressively around the tire until the bead is completely freed from the bead seat a k Sii m j iit To disengage lock ring from the gutter insert rim tool in removing notch near split in the ring and push downward If desired a second similar tool may be used to facilitate removal au LS Catan ciis Insert the rim tool between the lock ring and side ring and press downward to pry ring up Move progressively around the rim until lock ring is free then lift off lock and side rings Turn assembly over unseat tire bead stand tire up and remove rim base 3 Insure that tire is completely deflated prior to re moval of rings 4 Split lock rings used with continuous side rings must not butt 5 Do not inflate a flat or seriously underinflated tire while tire is on vehicle Remove and make sure all parts are serviceable and fully reassem ble before reinflating tire How to mount and demount ACCU RIDE 5 rims Tools Required 1 Rim Mallet 1 Rim Tool MOUNTING Place disc portion of wheel on floor with rim gutter up Apply tire with valve pointing
243. t No 9055 3032 WITHOUT THE PROPER GRADALL MATERIAL HANDLER PERSONNEL WORK PLATFORM CAPACITY CHART DISPLAYED IN CAB FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY OR DEATH 0055 3031 REV Located on personne work platform Part No 9055 3031 OPERATOR S CAB The standard cab permits vision from all sides and includes an overhead guard to provide protection from falling objects A WARNING Never operate the handler unless the overhead guard is in place and In good condition A fully enclosed cab with windows and a lockable door is available as an option The cab door can be secured in the fully opened or closed position Be sure the door is fully secured when operating the handler The operator s seat is equipped with a seat belt and includes fore and aft adjustment to compensate for variations in operator size The adjustment release lock is located beneath front edge of seat Wear seat belt when operating machine An optional windshield wiper is available for use with enclosed cabs An ON OFF control switch is located on the wiper motor A 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 variable speed heater fan is available for use with units equipped witha heater AnON OFF SPEED CONTROL knob is located on the dashboard Hot water to the heater can be controlled by a valve at the engine CONTROL AND I
244. t cab wall However maximum lift capacity applies only to certain areas within boom extension elevation pattern of handler swing mast combination separate capacity chart must be used for handlers equipped with swing mast Study this 30 chart carefully before attempting to handle a load with swing mast attachment NOTE When swing mast is equipped with an optional panel handler attachment additional restrictions in operation and capacity will apply Refer to Swing Mast Capacity Chart or contact your Gradall Material Handler Distributor for complete instructions and restrictions on use A WARNING Do not attempt to handle a load with swing mast attachment until you have studied swing mast capacity chart carefully If your handler does not have a swing mast capac ity chart ask your supervisor to get one Controls The carriage tilt cylinder is used to tilt mast and the carriage tilt lever controls mast tilt RAISE LOWER SIDE RIGHT LEFT LOWER BUTTON SHIFT BUTTON CARRIAGE Q RAISE CARRIAGE MULTI FUNCTION AUXILIARY A special auxiliary control lever is furnished on units equipped with swing mast attachment The lever handle includes five push button switches Two of these switches are used for swing mast operation To raise or lower fork carriage depress Raise Lower button No 1 and hold while moving lever in appro priate direction as shown To swing forks to left or right depress Right Left butt
245. t shaft 2 down into spindle 3 STEP 14 Assemble the secondary carrier assembly 19 to spindle 3 at splines STEP 15 Clean mating surfaces and apply a bead of silicone sealant to face of hub 9 that mates with ring gear 18 See instructions on sealant package Assemble ring gear 18 to hub 9 being careful to align bolt holes STEP 16 Assemble the primary carrier assembly 20 into the ring gear 18 It will be necessary to rotate carrier to align secondary sun gear part of primary carrier assembly 20 with planet gear teeth in secondary carrier assembly 19 Assemble primary sun gear 21 over input shaft 2 Rotate primary sun gear 21 to align input shaft 2 to gear splines and gear teeth in primary carrier assembly 20 STEP 17 Lubricate O ring 24 and assemble in groove inside cover hole push disengage plunger 23 into cover 25 with pointed end facing inside of unit STEP 18 Assemble the thrust washer 22 with tangs engaged with cover 25 NOTE A small amount of grease applied to the back side of thrust washer 22 will hold washer in place Apply a bead of silicone sealant to end face of ring gear 18 Assemble cover 25 aligning holes of cover and ring gear Assemble the twelve 3 8 16 x 6 1 2 inch grade 8 bolts 26 and flat washers 27 Torque bolts to 45 50 ft lbs STEP 19 Assemble the disengage cover 30 with dimpled center protruding out if wheel is to be used to drive the vehicle Assemble and t
246. talled The following bol torque charts covering English and Metric fasteners are the ones used by Gradall Engineering Gradall ratings are for lubricated fasteners Do nol exceed the ollowoble rating Remember An over torqued bolt in most cases will fail as rapidly as an under torqued one LUBRICATED ENGLISH BOLTS BOLT SIZE lA 20 4 78 18 5 24 3 16 36 24 M 20 20 Ww 12 ib 18 5 8 1 5 6 18 3A 10 A 16 Ma 9 Ma 1 8 1 118 7 Is 12 114 7 Ha 12 138 12 4 6 4 1 GRADE 5 BOLTS GRADE 8 BOLTS 13 030 15 000 17250 18 670 21 330 24 000 15 800 34 000 37000 45 430 48 000 59 025 63 000 18 330 88 330 100 800 111 000 120 000 135 820 145 500 164 000 zn Mw 29906 531 534 Boom MANTHANG Metric FASTENERS CASS 109 CASS 12 9 900 Megapascals Min Tensile Sir 400 Megopascals Min Tensile Sir 4 4 3 3 4 6 8 Nm 0 14 0 28 0 5 0 80 1 18 2 39 405 4 78 9 84 19 49 33 99 54 10 84 40 164 64 28466 THK a LP d 565 49 988 24 1580 54 fi lb Nm 37 0 76 1 35 2 13 3 15 6 36 10 81 12 76 26 25 51 99 90 68 144 32 255 18 439 74 75943 1508 64 263649 1105 75 421666 830 Megapascals Min Tensile 51 ft Ib 0 27 0 56 100 157 1 31 4 69 197 941 19 36 38 35 66 88 106 45
247. th steering response and clearance required for tailswing and load when turning A WARNING Be alert tor any increase in effort needed to steer If any difference is noted notify maintenance personnel immediately for correction If power assist feature should fail for any reason IT WOULD BECOME VERY DIFFICULT TO STEER For this reason it is extremely important that you MEVER TURN TRAVELING ENGINE OFF WHILE In the event power steering fails stop as soon as possible Do not drive unit until problem has been corrected General All models covered by this manual are equipped with hydrostatic drive From the operator s standpoint operation is similar to a vehicle with an automatic transmission Major components of the system include a front drive axle with a differential and planetaries The differential receives torque from variable displacement piston pump and motor This combination of components eliminates the need for a conventional mechanical transmission and also provides inching travel These handlers also include piston motors to provide torque ro rear wheel drive hubs and an electrically controlled valve which functions to restore traction if conditions cause a wheel to spin Operation AL38 SERVICE BRAKE ACCELERATOR A PEDAL Sud INCHING IN PEDAL gt TRACTION LOCK SWITCH PEDAL Normal Travel Direction of travel is selected by moving forward reverse lever forward for forward
248. th to good contact patterns in Figure 5 7 If contact patterns are not satisfactory go to Incorrect Contact Patterns on this page Correct Contact Patterns The location of a good hand rolled contact pattern for a new gear set is toward toe of gear tooth and in center between top and bottom of tooth Figure 5 7 When carrier is being operated under load pattern will extend approximately the full length of tooth The top of pattern will be near top of gear tooth Figure 5 8 Section 5 Adjustments The location of a good hand rolled pattern for a used gears set must match wear pattern in ring gear The contact pattern will be smaller in area than the wear pattern Incorrect Contact Patterns High Contact Pattern A high contact pattern indicated that drive pinion was not installed deep enough into carrier Figure 5 9 ocorrect a high contact pattern decrease thickness of shim pack under bearing cage This will move drive pinion toward ring gear Figure 5 10 Figure 5 10 DECREASE SHIM PACK THICKNESS 49 Section 5 Adjustments MERITOR Deep Contact Pattern Variations Along Length of Gear Teeth A deep contact pattern indicates that the drive pinion was installed too far in the carrier Figure 5 11 Adjust backlash of ring gear within specification range to move contact patterns to correct location along length of gear teeth When toe contact pattern Figure 5 11 indicates that backlash i
249. the crowd cylinder and the cable extension bracket Install the quide bar to the cable extension sheave bracket 1 AssEMELY Clean the work area Gather and identify all the parts to be used Use stanchions of sufficient capacity to hold Boom Sections 2 amp 3 Be certain the work area has sufficient space to work safely If working with a helper be certain each of you knows your individual assignments Review the assembly operation for this Boom Section Stage 1 Boom Weldment L Place Boom Section upside down on stanchions 2 Clean the inside and outside of Boom Section thoroughly 3 Lubricate the inside of the boom at the bearing slide path area SEE NOTE ON PAGE 2 0 FOR BOOM BEARING PAD BOLT QUANTITIES Location C Right Inside 4 Through the front of Boom Section install Boom Sections 2 amp 3 513 05444 7 Stage 2 Bearing Pads amp Hose Take Up Assembly 1 install hose take up assembly components to the front of the boom Tighten components and fasten all hoses 1 Install the retraction cable adjusting block Do Not tighten the cable yet k K s 1 i 3 Install bearing block to the front inside of Boom Section This is the block on which the boom bearing pads mount at Area Pad Location B Bearing Block 4 Install bearing pads spacers and shims at Area 1 Pad Location A B C D 5
250. the tension on the hose assemblies 1 At the inside of the hose take up brackets separate plug and cap all hoses to be removed Hose Connection Typical Cc Hose Take Up Brockets Form 29906 532 534 Boma MAINTENANCE c Removal Stage 2 1 At the rear of the boom remove the hose guard for the hose being removed 1 At the front of Boom Section 3 separate cap and plug the hose to be removed Tie rope to the hose end 3 Through the rear pull the separated hose free of the boom assembly 4 At the hose take up bracket area pull the hose free of the boom assembly Auxiliary Circuit Hoses Circuit Hoses RENSTALLATION 1 Tie the rope to the hose end 1 Installing the hose at the hose bracket take up area pull the hose to the rear of the boom Hose amp Fittings 3 Feed the hose around the roller and pull it through the protective channels in Boom Section 3 to the boom head at the front 4 Al the boom head apply seenre 545 to the fittings connect and torque the hoses and install clamps 5 Install the hose guard at the rear boom roller 6 Apply geerrre 545 10 the hose fittings at the hose take up bracket area connect and torque the hose Adjusting Nuts Typical Hose Take Up Bracket Hose Reconnect Typical 7 Tighten the hose take up bracket adjusting nuts Ensure 4 The Hose is now correctly installed
251. they are in place and in good working order Check to be certain that window s and muirror s are clean and undamaged Also make certain that mirror s are properly adjusted for operator s view Before removing filler caps or fill plugs wipe all dirt and grease away from the ports If dirt is allowed to enter these ports it can shorten life of components When adding fluids refer to lubrication section of this manual to determine proper type Complete all required maintenance before operating unit gt TE Service the unit in accordance with the lubrication and maintenance schedule JA af Wy x 4 i 3 2 P 4 T F E 5 lt d Inspect unit for obvious damage vandalism and needed maintenance Check for signs of fuel lubricant coolant and hydraulic leaks Open all access doors and look for loose fittings clamps components and attaching hardware Replace hvdraulic lines that are cracked brittle cut or show signs of abrasion Inspect all structural members including attach ment for signs of damage WARNING Before operating handler complete all required maintenance Replace or repair all damaged worn or missing compo nents before starting or operating han dler Failure to properly maintain handler may cause serious injury or death Starting Engine WARNING Operator must be seated with seat belt fastened
252. thorized Gradall Distributor or Gradall Product Support at 330 339 221 THE FOLLOWING SYMBOLS CALL YOUR ATTENTION TO IMPORTANT SAFETY NOTICES probability of death or serious injury if proper precautions are not T This symbol indicates an extreme hazard which would result in high DANGER UU This symbol indicates hazard which could result in death or Jj serious injury if proper precautions are nol taken This symbol indicates hazard which could result in injury or damage to equipment or property if proper precautions are no taken DANGER WARNING and CAUTION notes in this Manual will help you avoid injury and damage to the equipment Any procedure not specifically recommended by Gradall must be thoroughly evaluated from the standpoint af SAFETY before il is placed in practice If you are not sure contact your Authonzed Gradall Distributor Do not modify this machine without written permission from Gradall Form Mo 19906 532 534 Boom This Manual contains a series of maintenance and repair procedures for Ihe Boom Assembly of all 532 and 534 Series Material Handlers In every instance unless otherwise noted there are certain basic precautions and steps you should take before working on the machine These precautions are outlined in the Introduction under the heading Preparing the Material Handler for Service You must read understand and comply with these instructions in every instance b
253. ti function auxiliary control lever refer 10 page 31 The auxiliary control lever is used to adjust fork position Pull lever to rear to close forks and push lever forward to open forks Procedure 1 Remove standard carriage fork combination or other attachment from boom head refer to Attach ment Installation page 24 2 Install carriage fork combination with positioner 3 Connect auxiliary hydraulic hoses to positioner cylinders A WARNING Observe all precautions and load capacity limits listed previously when handling loads with carriage fork positioner 4 Always adjust fork position before engaging load Moving forks after engaging load could cause load to fall from forks 25 PRECAUTIONS e Handler must be level when handling a load more than four feet above ground level refer to page 20 e Retract boom tully before loading bucket Loading bucket with boom extended could damage structural members or extension cables Avoid shock loads drive into stockpile smoothly to load bucket Do not use bucket as a lever to pry heavy material Excessive prying forces could damage the bucket e Do not use bucket for back grading or quick switch lock pin may be damaged Capacity Maximum capacity of light material bucket is shown on serial number plate located on right cab wall and may be used in areas where it does not exceed capacities shown on standard carriage f
254. ting nuts at the threaded end of the cable Tightening the retraction cable adjusting nut pulls Boom Section 3 in to the rear Tightening the extension cable adjusting nut pulls the boom out to the front The opposite cable adjusting nut usually must be loosened whenever this procedure is performed The cables are properly adjusted whenever the following parameters are met 534 9 10 amp 5340 9 0 10 Crowd cylinder rod eye pin is centered in the side access hole of the push beom and or 17177 dimension from Boom Section 3 boom head front to the front of Boom Section 2 5376 6 53406 amp 5340 6 15 dimension from Boom Section 3 boom head front to the front of Boom 5ection 2 CABLE ADJUSIMENT GUIDE Push Beam Crowd Cylinder 534C 9 C 10 amp 534 9 0 100 17 1 2 Rod Eye Access H r Hale 531C 6 534C amp 0 6 15 534C9 C 10 amp 534D 9 D 10 18 RETRACTION CABLE REMOVAL Removal of the retraction cable is a difficult operation but it can be accomplished You must be able to reach inta the rear of the boom assembly to unfasten the retraction cable socket from the cable anchor bracket weldment If you can t reach this bracket the booms must be separated Preparation Stage l 1 3 4 ddt Retract the boom assembly fully Remove the keys from the ignition and fasten a do not operate tag to the steering wheel DO NOT reach into the boom until you are CERT
255. tion FINALLY consider terrain between present location of load and its destination Never attempt to transport load across terrain which could cause handler to tip over Leveling Handler Frame The handler is designed to permit tilting main frame eight degrees to left or right to compensate for uneven ground conditions The rear axle pivots at the midpoint of the main frame to help assure that wheels will remain in contact with ground A hydraulic cylinder provides a rigid connection between front axle and main frame to help assure a solid work platform and permit tilting main frame to left or right Procedure 1 Position machine in best location to lift or place load and apply parking brake 2 Observe level indicator to determine whether machine must be leveled Note position of indicator for later realignment TT MS C i TILT FRAME TILT FRAME TO LEFT TO RIGHT TILT FRAME T RIGHT STANDARD FRAME LEVELING CONTROLS 3 If necessary to level handler position boom in carry position and move machine level lever to level machine 4 Lift or place load as appropriate 5 Retract and lower boom to carry position 6 Realign frame to position noted in step 2 A WARNING If handler cannot be leveled using leveling system do not attempt to raise or place load Have surface leveled OPERATING PROCEDURES amp TECHNIQUES This section highlights some common procedures and discusses a
256. top left side of the controls See Figure 18 and Figure 19 Install test ports P N 7713 3089 in place of the plugs Attach a high pressure gauge 10 000 PSI to both test ports 9 During the next two steps to prevent excessive heat in the hydraulic oil and possible damage to hydraulic components do not operate for more than 30 seconds at a time Start engine and raise RPM until gauge on Ps port is at 240 PSI Maintain this RPM and pressure throughout the test With pressure on Ps port at 240 PSI the pressure at G port should read 3 300 PSI Adjust begin point screw on the motor so that M port on motor sees opproximately 1 650 PSI NOTE Begin point screw adjustment is very sensitive NOTE The pressure on M port will not be steady This is the pressure that shifts the motor to maintain minimum displacement Under normal operating conditions the 3 300 PSI on G port required to shift the motor will not be constant When this pressure is reached the motor shifts Since the pressure supplied is constant the motor will not stay in a partially shifted position Reset the reverse high pressure relief valve to 6 800 PSI Use procedure 9 drive pump pressure to adjust this relief Wrench sizes required 4mm allen and 10mm box FIGURE 18 MAIN PUMP ASSEMBLY SIDE VIEW Ps PORT CONTROL PRESSURE PORT REVERSE HIGH PRESSURE RELIEF VALVE DOCTOR ht RUN C d n
257. tral Silicon Dow Corning 768 or Rhodia 567 666 e Three Bond 1134 e Loctite 515 WARNING Small amounts of acid vapor are present when applying some gasket materials To prevent possible serious personal injury make sure there is good ventilation in the work area If liquid gasket material gets in your eyes flush eyes with water for 15 minutes Have eyes checked by doctor CAUTION The amount of liquid gasket material applied must not exceed 0 125 in 3 18 mm diameter bead Too much gasket material can block lubrication passages and result in damage to component 1 Remove all old gasket material from both surfaces 2 Clean the surfaces where liquid gasket material will be applied Remove all oil grease dirt and moisture 3 Thoroughly dry both surfaces 4 Apply according to the following procedures e Three Bond 1134 or Loctite 515 Apply approximately a 0 125 inch 3 18 mm diameter continuous bead of liquid gasket material around one surface Loctite FAG 3 Apply to one surface with a paint brush Also apply all gasket material around edge of all fastener holes on that surface Figure 3 8 gt e MERITOR 5 Assemble components quickly to permit gasket material to compress evenly between parts Figure 3 8 0 125 3 18 MM DIAMETER SILICONE GASKET MATERIAL BEAD 6 Tighten fasteners with required torque See Torque Chart Section 6 DUO CONE Oil Seal Mount and Install NOTE e
258. transporting and positioning the load Always be certain that camiage or attachment is properly positioned on boom head and is secured by lock and retainer pin Failure to ensure proper installation could permit cariage attachment load to disengage and cause serious injury or death 24 Operate a handler equipped with an attachment as partially loaded handler Pay special attention to capacity and range limits for the handler attachment combination Practice operation of handler and attachment in safe open area not hazardous to yourself other persons equipment or property Become thoroughly familiar with response of handler and attachment to controls before operating in a work situation Always consider terrain between present location of load and delivery point Never attempt to transport a load across terrain which could cause handler to tip over FORK POSITIONER PRECAUTIONS Always adjust fork position before en gaging load e As with all other attachments handler must be level before handling a load more than four feet above ground level refer to page 20 Capacity Maximum load capacity for fork positioner carriage is the same as standard carriage without fork posi tioner refer to basic Capacity Chart located on dashboard Capacity varies with boom extension and elevation positions Controls OPEN AUXILIARY FORKS CONTROL LEVER CLOSE FORKS If your unit is equipped with a mul
259. tween Boom Section 2 and 3 at Area 2 Location 4 Hammer wedge into the area between Boom Section 3 and 2 at Location forcing it against the opposite side Location D A Do not distort the side plates of the boom sections CAUTION 5 Using a feeler gauge measure the gap between the bearing pad and the boom at Area 2 Location C 6 If the gap is more than 1 16 shims must be added to bring the boom into tolerance Note Shim packs should be equal side to side within shim Location C amp D if an unequal amount of shim must be added equalize the shim pack at the next adjustment Adjustment 1 Loosen the bearing pad mounting bolts at locations or D or both and add the required shims 1 Shims are stamped with their Gradall Partt Number and thickness Check the shims already in place and make sure you are installing the nght ones Apply 7 7F 242 to the threads on the pad mounting bolts Re torque the bearing pad mounting bolts Remove wedge installed in Step 3 Repeat Inspection Steps 3 6 and Adjustment Steps 1 5 for Area Location C P IE Y wedge was used to move Ihe Boom Sections for checking be certain it is removed before activating the boom circuit Failure to do so will damage the boom structure Do not use more than one wedge at a time for the adjustment operation Location A Location D Left Inside Right Inside
260. uctions is extremely important Normal mechanics tools are required as well as a hoist capable of lifting 5000 Ib to handle the weight of the complete boom assembly OO Form No 29906 531 534 Boom EI u il aed ses z 6A 3 Assemety Preparation Select an area with sufficient space ta work safely and efficiently Clean the work area Procure all tools and lifting devices required for this operation Use crane capable of lifting 5000 165 Gather and identify parts to be used If working with a helper be certain each of you know your individual assignments Use stanchions work horses of sufficient capacity to hold boom assemblies safely LJ a E Stage 1 Boom Weldment Bearing Pads 1 Place Boom Section 3 upside down on stanchions 06 43 1 2 _ 6 2 1 Clean the inside and outside boom surfaces 3 Inspect tilt carriage bushings in the boom head section for damage or excessive wear Bushing ID when new is 2 511 2 512 Replace if wom more than 1 1 or damaged 4 Install bearing pods spacers and shims to the rear of the boom Area 4 at the following locations 534C 6 534D 6 All pad locations 534C 9 C10 534D 9 D10 Locations C amp D Note Do Not install spacers and shims to bearing pads at Location E at this time This will make insertion into Boom Sechon 2 easier Eup View 3 amp 4 Boom Secr
261. ude the 2WD 4WD valve traction lock valve park brake solenoid valve and the joystick Isolate each of these valves to check for the loss of charge pressure See Figure 10 Another test to determine the loss of charge pressure is to cap off lines to the drive motors Reinstall hoses from previous test Install low pressure gauge 1 000 PSI on the charge pressure test port Check each motor separately Start at the left rear motor Remove the hoses to the motor at the tubes and plug with ORS 12 plugs P N 8471 4002 Cap motor work ports also to prevent dirt from entering the motor with ORS 12 caps P N 8471 4006 Start the machine and observe the gauge for charge pressure Engage drive forward and reverse against the park brake and observe gauge for charge pressure simultaneously Record the findings If charge pressure recovers the motor is defective lf charge pressure does not recover repeat test for right rear motor See Figure 11 Isolate the front drive motor from the circuit if the rear motors are not defective To isolate it will require two blocking plates P N 9108 1667 Install these plates between the front drive motor work ports and the drive hoses Remove the flange halves and place the blocking plates on the ports and reinstall the hoses and flanges Again start the machine and observe the pressure gauge for charge pressure If the charge pressure recovers the motor is defective To confirm check charge pressure with drive again
262. ure 3 12 19 Section 3 gt e Prepare Parts for Assembly MERITOR NOTE Do not use any liquid that leaves a film of oil or does not evaporate quickly 3 Place installation tool 9 under oil seal ring with Toric ring 2 Submerge ring in receptacle filled with trichloroethylene until entire surface of Toric ring is wet Figure 3 13 Figure 3 13 4 With Toric ring surface wet 2 use installation tool 9 to install oil seal ring and Toric ring perpendicular to ring bore Use a rapid and uniform pressure to push Toric ring under ring retention lip Figure 3 14 Figure 3 14 20 5 Verify mounting distance A in at least four places spaced 90 degrees apart The difference in the mounting distance A around ring cannot be more than 0 04 inches 1 mm Figure 3 15 Figure 3 15 A 0 04 in 1 mm 6 If adjustments are necessary use installation tool 9 to push ring Do not use your hands Figure 3 16 Figure 3 16 7 Toric ring may become distorted if not entirely wet or if there is a sharp edge on the retention lip and bore gt a Section 3 MERITOR Prepare Parts for Assembly A 10 Make sure both bores are correctly aligned and CAUTION concentric Move slowly and carefully Misalignment or a twisted Toric ring may cause Figure 3 19 leakage in the DUO CONE oil seal If installation was not correct remove oil seal from bore and Figure 3 19 repeat steps 3 6 e A Toric ring
263. ure occurs on points A and Y This high pressure variation may damage rings Points B and X will develop low pressure and possible leakage Figure 3 22 N 22 gt e MERITOR gt e MERITOR Assemble Differential Case WARNING To prevent serious eye injury always wear safe eye protection when you perform vehicle maintenance or service 1 Apply specified lubricant on all parts of differential case assembly before installation CAUTION Never attempt to press a cold ring gear on the flanged half of the differential case A cold ring gear will damage the case because of the tight fit The tight fit can cause misalignment or excessive runout and will make final backlash and teeth contact adjustments very difficult WARNING Wear safe clothing and gloves to protect yourself from serious personal injury when you touch the hot ring gear 2 Expand ring gear bore by heating ring gear in tank of water heated 160 F to 180 F 71 C to 82 C for 10 to 15 minutes DO NOT USE AN OPEN FLAME SUCH AS A TORCH FOR THIS PROCEDURE 3 Install ring gear on case half or in the integral differential case WARNING To avoid serious personal injury be careful when using Loctite or Three Bond adhesive during assembly and installation procedures Follow the manufacturer s instructions for safe use to prevent irritation to eyes and skin Wash after skin contact If the Loctite or Three Bond adhesi
264. utton s for single function attachments LUBRICATION amp MAINTENANCE DIAGRAM SYMBOLS Fitting Other Service IMPORTANT NOTICE certain to check extend cable adjust CG GREASE extreme pres ment every five weeks or 250 hours and DF DIESEL FUEL adjust as required Cable damage can EO ENGINE OIL occur if cable is not adjusted properly GO MULTI PURPOSE LUBE Refer to page 18 for procedure HF H YDRALLIC FLUID M3 MOLY LUBE extreme pres SL SPECIAL LUBE 34 1 3 3 L HLI I 182 Ear Failure to use Gradall Hydraulic Filter Elements could void Warranty SEE MANUFACTURER S COMPONENT LITERATURE FOR ADDITIONAL LUBRICATION AND MAINTENANCE INFORMATION 32 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 12 14 18 service at whichever interval occurs first Item Daily or Shift 10 Hour Maximum Lubrication amp Maintenance Service at whichever interval occurs first Fuel Filler Cap Hill af end ol work shift to minimize condensation Hydraulic Return Fitar Condition Indicator check indicator with oil al normal operating temperature and angina running at full t
265. ve gets in the eyes flush the eyes with water for 15 minutes Have eyes checked by doctor Section 4 Assembly and Installation 4 Apply Loctite 271 or Three Bond 1305 adhesive to ring gear fasteners See Section 3 Liquid Adhesive Install ring gear fasteners and fasten with the specified torque 66 75 lb ft 90 100 Nem Figure 4 1 Figure 4 1 5 Assemble new cone bearings in both halves of differential case or in both sides if it is an integral differential case Figure 4 2 6 Install side gear in flanged case hall Figure 4 2 23 Section 4 Assembly and Installation NOTE For limited slip differential go to step 12 7 Install spider cross differential pinions and washers on original assembly position Figure 4 3 Figure 4 3 SPIDER a If you have an integral differential case install side gears and washers in each original assembly side b Install differential pinions in the correct position by turning side gears until pinion holes are aligned with differential pinion axle holes Figure 4 4 c Install differential pinion washers Figure 4 4 24 MERITOR d Install differential pinion axle and lock capscrew Fasten capscrew to specified torque 17 23 lb ft 23 31 Nem o 8 Install other side gear over spider and differential pinions Figure 4 5 Figure 4 5 9 Place plain half of differential over flanged half Rotate plain half as needed to align match marks
266. ve the disengage cover 30 if necessary STEP 4 Remove twelve bolts 26 and flat washers 27 and the large cover 25 from the unit The thrustwasher 22 and the disengage plunger 23 usually remain attached to the large cover 25 when it is removed Remove thrustwasher 22 disengage plunger 23 and O ring 24 from the large cover 25 STEP 5 Remove primary sun gear 21 from end of input shaft 2 STEP 6 Remove the primary carrier assembly 20 STEP 7 Remove the secondary carrier assembly 19 It may be necesary to remove the ring gear 18 first if difficulty is encountered in removing the carrier assembly STEP 8 Remove the input shaft 2 from the spindle 3 Remove the retaining rings 15 washers 16 and disengage spring 17 from input shaft 2 only if replacement is requlred STEP 9 If not previously removed see step 7 remove ring gear 18 from hub 9 It may be necessary to strike ring gear 18 with a rubber mallet to loosen from hub 9 STEP 10 One lockwasher 13 tab will be engaged in the bearing nut 14 slot bend back to release Remove the bearing nut 14 lockwasher 13 and thrustwasher 12 NOTE A special service tool is required for the removal of the bearing nut Contact Auburn Gear for procurement of service tool STEP 11 Press spindle 3 from hub 9 NOTE Bearing cone 11 has been designed with a press fit with respect to spindle 3 Considerable force will be required to rem
267. which have been engineered to fit the air cleaner and engine intake system exactly Cover the Inlet Don t leave the air inlet exposed If the new filter won t be installed immediately cover the opening to prevent stray contaminant from entering the induction system Safety Element Service For Maximum engine protection and air cleaner service life replace the safety filter every third primary filter change or cleaning or as indicated by the Donaldson Safety oignal service indicator Note that the safety element is not intended to be cleaned Reinstall the Dust Cup Be sure the dust cup is sealed 360 around the air cleaner body Reset the restriction indicator to green Check Connections Ensure that all connections between the air cleaner and the engine are tight and leak free Air Filter Service Tips 7 Important Steps to Follow The Important Don t Don t remove filter for inspection 1 Remove the old element gently to prevent knocking dust off of it Never rap a filter to clean it Rapping only damages the filter 2 Always clean the inside of the n LEE carefully XA e Never judge the filter s life by looking at it Measure how restricted its airflow is 3 Always clean the gasket sealing surfaces of the housing Never leave an air cleaner open 4 Check for uneven dirt longer than necessary patterns in your old filter that indicate gasket leakage Don
268. x E 12 CODE 62 4 BOLT SPLIT FLANGE BOLT TORQUE FLANGE BOLT BOLT a 30 4 5 465 45 6 24 18 14 6 20 4 10 18 1 4 16 g 4 1 1 1 2 12 58 1 78 12 ft lb 153j 5 lga 16 22 1 35 604 2 1055 5 140 6 145 6 210 8 2604 12 354 12 015 1 3254 15 694 6 1254 8 TORQUE VALUES WITH AN ASTERISK ARE FROM JIC FITTING TORQUE CHART JIC 37 TUBE HOSE TO FITTING TUBE SIDE ASSEMBLY YE SIDE ASSEMBLY TORQUE Note Aluminum material ports use 50 of the steel lonque vale 9 18 1 16 B 15 16 1 14 1 3 16 12 7 12 1 12 1 2 1 ft lb 18s 278 1 404 2 63 3 90 4 1205 8 140 8 1654 8 8 24 3 8 24 amp 20 3 20 98 18 34 16 718 14 1 12 16 12 2 12 N 78 1 15 1 TORQUE ft lb 3 64 1 12 1 15 21 1 45 2 604 5 8545 5 105 5 1204 5 70 10 200 15 APPENDIX 534C 9 C 10 ano 534D 9 D 10 Ist Section 3rd Section Tilt Cylinder Q D DE AA 0 1 The information contained in this Manual is protected by copynght Unnuthonzed reproduction of this Manual in whole of in port in e any form whatsoever is strictly prohibited Specifications cored at time of publication However Grodoll reserves the ngh to make any necessary changes without prior notice Gadal is registered Trademark for Hydraulit Excavator
269. your skin Do not smoke and avoid breathing vapors in closed rooms without ventilation Do not use trichloroethylene near flames welding operations or hot surfaces exceeding 900 F 482 C Clean capscrew nut or bolt tapped hole and fastener thread carefully Use a cleaning solvent such as trichloroethylene or equivalent to remove dirt oil grease or moisture Section 3 Prepare Parts for Assembly Reassembly e Check the type of liquid adhesive to be used and where the adhesive is to be applied e n threaded holes where fasteners did not require removal check each one for tightness by applying the minimum amount of specified torque e f fasteners do not rotate they are tightened properly e f fasteners rotate to any degree they must be removed and liquid adhesive must be applied Application 1 Apply liquid adhesive to e Bolt threads when component has open hole Before installing bolts visually check to make sure that liquid adhesive has filled gap between threads e Threaded hole when component has blind hole Allow 4 to 6 drops to run down side of each hole If liquid adhesive is applied to bolt trapped air in hole will create back pressure and blow out liquid adhesive as bolt advances Figure 3 7 2 Tighten fasteners with recommended torque o 17 Section 3 Prepare Parts for Assembly Apply Silicone Gasket Material Liquid gasket material used by Meritor e Loctite FAG 3 e Neu
270. ype air chuck so that the operator can stand clear during tire inflation Important when clip on air chuck is used line pressure must be restricted to maximum inflation capacity of tire Use properly matched parts only Rim base and rings must be matched according to size and type This information is stamped on each Firestone part Replace damaged parts Abuse during road oper ations or in mounting the tire can cause dents cracks or distortions which weaken the parts In spect for and replace damaged parts Periodically inspect and remove rust and other for eign matter Accumulation of such material in the rim gutter can prevent the proper fitting of rings Parts that are excessively corroded are weakened and should be replaced Use of a rust preventative compound not containing water during mounting will minimize rusting Do not use over size or over inflated tires Use only recommended size rims for tires and do not exceed maximum inflation pressure for the rim Follow manufacturer s recommended mounting procedures ADDED PRECAUTION Re check as semblies just prior to inflation particularly if they have been rolled across the floor or have received rough handling between mounting and inflation During tire demounting Completely deflate tire prior to demounting The tire should be deflated prior to removal of the tire rim assembly from the vehicle Remove the valve core to insure complete deflation DO

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