Home

Service Manual

1. s wis t Xosds 8 P M3zrilavis gt bare 3 F E wy gt e ro saos a 3onvo dN3L lI Re sunssaua ana we 2 LEEKI PN ETE HH n E TR H 3000 1 B anton NO B HOLMS a B E Honc xu E E xu o C o3 MEN C NE HA 0 gt gt ls ae THE ig a MOINS LV zu okie L2 EE H LMWH ter 2 1 gt ier i on wm 9020 B EJ tse r3 Nola as aus KS s H E 8 7 E n tekina 21333232 wisi ur ewm cron ane Tuus al E dude ons uns pee Bn i E BL E E ERE dnoxova CN w
2. 0680 5340 9 5340 10 amp 5440 uiis H senes ane Fal 1 RE Hd HR 2MS BVIS EU dni se ne E EU l um HY B NO ch Sonus 2 xl D an E aw V cuneo B dH o EB aks n nA o C CM 2 i L amyngoneros lt mr d 3 is 5 2 lt o o cum du LN E Beep HOUNS 8v Y Snr Kot I vod 1 we Re f a lt st 30331113 8 rh d
3. 19 20 21 LIII LII 15 Install the tilt cylinder and connect the hose assemblies to the hose carrier assembly and to the tilt cylinder If the machine is equipped with auxiliary hydraulics install the auxiliary hoses and electrical cable to the boomhead of the fourth boom section The boom is now complete and ready to be turned over and installed on the machine 3 28 3 10 12 Boom Assembly Installation 1 Re check that the machine is safely secured 2 Connect the lifting tackle crane and re lash the boom assembly at the balance point e Install the tackle between the extend retract cylinder and the boom Note Make sure a tag line is installed 4 Make a test lift to ensure that the rigging is hooked up correctly to lift the boom assembly in a balanced mode 5 Lubricate all pins and bushings 6 Lift the boom assembly into position on the machine 7 Line up the base pin holes insert pins and lock into place 8 Install the lift cylinder onto the boom insert the pins and lock into place 9 Install the compensation cylinder onto the boom insert the pins and lock into place 10 Uncap and reconnect the hydraulic hoses and electrical cable Torque the hose fittings per Section 2 2 Torque Charts
4. the rear of the third boom section Assembly following procedure is described with the assumption il I that all components have been removed and assembly proceeding from the beginning co 4 Gs jaa 1 L al MY2720 12 Install a sling around the sub assembly at the front of the boom With a suitable lifting device slowly pull the sub assembly loose from the bottom bracket 5 located approximately halfway in the fourth boom section MY2730 1 Place both sections on a suitable stand or support 2 Install the wear pad to the bottom of the upper hydraulic carrier 3 Install the bulkhead fittings to the each hydraulic carrier 4 Install the tube assemblies to the bulkhead fittings on each hydraulic carrier 5 Install the cushion clamps to the tube assemblies and secure to each hydraulic carrier MY2700 5 6 Install the hose carrier to each hydraulic carrier and install each tilt hose and auxiliary hose to the proper 13 When the sub assembly is pulled approximately fitting or tube connection 25 out of the boom fasten the two hydraulic 7 Tie wrap the hydraulic hoses together where they carriers together using plastic tie wraps or nylon extend from ea
5. ST IGNITION m o m g 5 lt ALTERNATOR EH WARNING LIGHT lt ABCDEFGHJKLMNP VIN ABCDEFGHJKLMNP 9 en 8 RESISTOR lt lt lt m o gt lt H 18 17 16 15 14 13 12 100 9 8 7 6 5 4 3 2 1 NC NMA 18 17 16 15 14 13 12 1 100 9 8 7 6 5 4 3 2 1 m o a lt a STARTER STARTER 200087 Lr 9 lt SOLENOID H b lt ALT EXC B MX0771 9 8 ALTERNATOR ALT BAT SNSR JOHN DEERE ONLY GROUND CUMMINS ONLY 534D 9 534D 10 amp 544D Electrical System 9 6 ENGINE START CIRCUIT 9 6 1 The starter 1 is located on the right side of the engine Starter 0950 a Testing the Starter on the Engine If the starter does not engage when the ignition key Switch is turned check the following 1 The main fuse may be blown requiring replacement Check for the cause of the blown fuse 2 There may be a defect in the ignition key switch ignition wiring or starter solenoid 3 Check battery condition Clean the battery posts and the connectors at each end of the battery cables 4 Check for broken wiring and damaged insulation on the wiring Replace all broken or damaged wiring 5 Check all connections at the starter solenoid
6. 8 3avubo AVS S 3avu9 AVS 519 9159 pajejd uiniupeo Ajdde jou op anbio asayy 910N 009 0725 000891 6268 0992 0988 00227 0062 261 0991 0022 078 00881 uu Spee oroe 00007 6 95 0654 0952 0918 005921 5202 5656 1 097 061 00084 0901 9 6895 006181 000 6912 0702 02 72 00181 06 1 9091 0921 0891 00062 oset el 0992 02452 009911 5090 2061 08 1 082 0000 5061 2251 001 097 00179 0501 9 0 02 088 006 01 0022 0191 0091 0002 00996 008 SELL 026 Orel 00969 0801 2 5261 05 1 00696 0002 0981 0281 00228 S LL 6001 098 021 00955 06960 4 0291 085 00958 5161 SGLL 0801 Orr 00074 G26 208 099 088 00820 09580 gy 6981 Orel 00 9 007 0801 096 0821 00 99 009 v 009 008 005 0970 4 0001 516 0099 001 96 Ord 0001 00 66 GEL 659 05 00 0022 08990 00 056 598 00909 066 189 089 006 00515 6 9 6 5 097 0 9 0098 09090 8 00 689 00606 mA 006 099 00897 025 Gov 098 0 7 00 4 06050 v G9 585 0029 099 58 097 009 00917 GLb 99 028 067 00762 02970 6 Orb 007 00 6 Sr 986 025 027 00955 066 892 022 00 oosez 0680 9L vie 007 698 0068 027 108 082 08 00108 580 072 002 092 00512 orceo 0L 022 00992 592 toZ 081 Ove 0008 061 ESL 01 0 1 0069 09660 8L gis LEZ 012 00922 ove 081 01 022 0502 691 SEL OLL
7. Crary SON Woa T 227799 1 P onus sommano k ousonovionvo TE ssanuvi 3NION3 W93 NOLOSNNOO d M m WO3 HOLO3NNOOH saioNanos EE Neb SM3lV3H n NE 521 E 6 x Liva OL NOILdO 35371718918 NIS Lg ur HOLO3NNOO T Rc Herr TE Sus ur us nr 30010 m HJ Mo193NNO9 Sino sr 49
8. ed 11 Remove the bolt and locknut 3 securing the axle pivot pin to the frame Tap the pivot pin 4 out and note the location of the shims 5 on each side of the axle 12 Remove the axles from the machine using the jack hoist or overhead crane and sling supporting the axle DO NOT raise or otherwise disturb the machine while removing the axle Balance the axle and prevent it from tipping turning or falling while removing it from beneath the machine Place the axle on a suitable support or holding stand 5 5 2 1 Before proceeding ensure that the machine will remain in place during axle installation Block the front and rear of both tires on the front axle Rear Axle Installation 2 If applicable raise the machine using a suitable jack or hoist Place suitable supports beneath the frame and lower the machine onto the supports allowing enough room for axle installation Ensure that the machine will remain in place during axle installation 3 Using a suitable jack hoist or overhead crane and sling remove the axle from its support or holding stand Balance the axle and prevent it from tipping turning or falling while positioning it beneath the machine DO NOT raise or otherwise disturb the machine while installing the axle Keep the axle supported and balanced on the jack hoist or overhead crane and sling throughout the i
9. MX0590 5 4 MX0570 8 Label disconnect and cap the brake lines at the axle Cap all fittings and openings to prevent dirt amp debris from entering the hydraulic system 9 Block the front and rear of both tires on the rear axle Ensure that the machine will remain in place during axle removal before proceeding 10 Raise the machine using a suitable jack or hoist Place suitable supports under both sides of the frame and lower the machine onto the supports Ensure that the machine will remain in place during axle removal 11 Support the axle that is being removed with a suitable jack hoist or overhead crane and sling DO NOT raise the axle or the machine 12 Mark and remove both wheel and tire assemblies from the axle that is being removed Refer to Section 5 6 1 Hemoving Wheel and Tire Assembly from Machine Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing in the direction of forward travel 13 Remove the four bolts holding the drive motor assembly to the carrier assembly Pull the drive motor back from the carrier assembly and support 14 On the front axle remove the retaining ring securing the sway cylinder pin to the frame Tap the pin out and move the cylinder to prevent it from interfering with axle removal 15 Remove the bolts and locknut
10. S 1 d ues Note lf the brake disks are worn beyond their tolerance the brake disk must be replaced on both sides of the axle at the same time TII B aiH IS WA 0610 77177177 2 5 Repeat steps 3 and 4 for the other side of the axle 534D 9 534D 10 amp 544D 6 Fill the axle with Mobilfluid 4249 ISO 46 through the axle fill hole 3 until the oil level is even with both axle level holes 1 7 See chart of approved fluids The axle capacity is 19 6 qt 18 5 Liters for the front axle Fill axle slowly the oil has to run across the differential Allow time for the oil to run across the differential Axle level is correct when oil is up to both level plugs 5 8 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort after exhausting all other options Make every effort to repair the machine and move it under its own power Towing is only possible by using the towing feature built into the hydrostatic pump and disengaging the park brake on the front axle 1 Securely block all four wheels A WARNING ALL WHEELS must be blocked to prevent machine from moving or rolling away
11. 3 36 3 12 6 Retract Chain Installation 3 36 3 12 7 Extend Chain 3 37 3 12 8 Extend Chain Installation 3 37 3 13 Section Separation Adjustment Four 3 38 3 14 Hydraulic Sub Assembly Removal Installation Four Section 3 38 3 14 1 Hydraulic Sub Assembly Removal 3 38 3 14 2 Assembling the Hydraulic Sub Assembly 3 39 3 14 8 Hydraulic Sub Assembly 3 39 315 BoomWearPads uolo c In owe ee 3 41 3 15 1 Wear Pad 3 41 3 15 2 Boom Wear Pad 3 41 3 15 3 Boom Wear Pad 3 41 3 16 Quick Switch Assembly 3 42 3 16 1 Disconnecting from an 3 42 3 16 2 Connecting to an 3 42 3 16 3 Quick Switch Removal 3 42 3 16 4 Quick Switch 8 3 42 3 17 oe US Ne PESE 3 43 3 18 Troubleshooti
12. 5 3 5 3 Axle Assemblies eee 5 3 5 3 1 Axle Serial Number 5 3 5 3 2 Axle 5 5 3 5 3 3 Axle Internal Service 5 3 5 3 4 Axle 5 3 5 3 5 Axle Removal eod tp ew feed car a 5 4 5 3 6 Axle Installation x scs Rae Dx E RR DEOR 5 5 5 3 7 Axle Assembly Troubleshooting 5 6 5 4 Rear Drive AXE nh ee ee ee ee le 5 9 5 4 1 Rear Drive Hub 5 9 5 5 Rear Steer Axle eee eee oa hb dae eet aes 5 10 5 5 1 Rear Axle 5 10 5 5 2 Rear Axle 5 5 10 5 6 Wheels and co Rl eee ele LZ exe 5 11 5 6 1 Removing Wheel and Tire Assembly from 5 12 5 6 2 Installing Wheel and Tire Assembly onto 5 12 5 7 ICLCc ECT PITE PT 5 13 5 7 1 Brake Disk Inspection 5 13 5 8 Towing a Disabled 5 13 534D 9 534D 10 amp 544D 5 1 ES Axles
13. 6 5 6 6 2 Hydraulic Filter Condition 6 5 6 6 3 Engine 6 5 6 6 4 Park Brake Gada Sod eas 6 6 6 6 5 Charge 5 6 6 6 6 6 Control 5 6 8 6 6 7 INCHING cu da cee hae be eas eons Hee ae RE wee 6 8 6 6 8 Front Motor Begin Point 6 9 6 6 9 Drive Pump Pressure 6 10 6 6 10 Machine Operation 6 10 534D 9 534D 10 amp 544D 6 1 Hydrostatic Drive Pump 6 1 DRIVE PUMP ASSEMBLY COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the drive pump The following illustration identifies the components that are referred to throughout this section POR VALVE DA CARTRIDGE PORT BLOCK TOP VIEW FE T aw DRIVE SHAFT
14. OS 2 24 1 o Qu e 9 0360 5 Pull the Hydraulic sub assembly 4 partially out through the rear of the boom to access the hoses 6 Loosen and remove the hoses 5 from the rear of the hydraulic sub assembly MX0370 7 Release the tension on the clevis before proceeding 8 Loosen and remove the chain adjustment block from the bottom of the boom 9 Loosen and remove all the wear pads from the front of the second boom section Tag each pad backing plate shim and bolts from each location 534D 9 534D 10 amp 544D MX0350 10 Carefully pull the third and fourth boom sections 6 from the second boom section 11 Remove the chain 7 from the second boom section to the third boom section after the boom sections are free from each other 12 Place the third and fourth boom section on suitable supports 3 10 6 Note Work on the boom assembly is performed with the assembly up side down Fourth Boom Section Removal 1 Remove the bottom rear and side wear pads from the fourth boom section Tag each pad backing plate shim and bolts from each location 2 Loosen and remove the 3 4 in 19 mm chain 8 through the rear of the fourth boom
15. I ae Ps 1 4 Section 2 General Information and Specifications 2 1 2 1 Replacement Parts and Warranty 2 2 2 2 Torque Charts VE De eer preis rec S e VE p 2 3 2 3 2 6 2 4 Fluid and Lubricant 2 9 2 5 Service and Maintenance 5 2 10 2 6 Lubrication Schedules 2 12 Section 3 Boom We d liU c C ne 3 1 3 1 Boom System Component Terminology 5340 9 534D 10 3 3 3 2 Boom System Three 3 4 3 3 Boom Maintenance Three Section Complete 3 4 3 4 Boom Maintenance Three Section Individual Section Removal 3 9 3 5 Boom Cables Three Section 3 12 3 6 Auxiliary Electric Cable Three 3 17 3 7 Extend Retract Cylinder Removal and Installation Three Section 3 18 3 8 Boom System Component Terminology 5440 3 20 3 9 Boom System Four Section 3 2
16. Us da ABUNDO vind 1 ALRHORd B 3AWA3AMG TH3HM HOLIMS 4019916 GNO GUYMYOd AMALIE MX0720 Howe X001 7T33HM vZ 8 10 Hydraulic System Hydraulic Schematic 544D 8 4 4 lt ONIONS Ayauya M 3AWA SSVdAg TWWH3HL HOLMS SATA 5 31 uazevis NIV cazrinssaud NON HS3N 00 SOILS 1 E X007 NOLLOVYL su a BONA SNIVSN3diio0 O LNOO va INVA i3o9nuno YIONNAD OYLNOD VO HOLOW JAYA 1NOt4 1 E amv arenos ad was a ALORA ne 3331 AYNEN din 1N3WandWi ALIMONY HOLIMS 40193735 3SH3AdH GUVMYOS Ia3HM p Ayauya LOA ZL m 9 15 HOLIMS Ayauya PV MX0710 HOUMS HOLMS TAM
17. E A 3092 a E SssNuvH E Noa Note 3onvo YUM aAA 105 E E E HONS Aa A if PUES 2 B 3 B 3 Sniona E MS m ale T j SNENS e 5103053 pauva MX1230 534D 9 534D 10 amp 544D SS3NuvH 3NION3 3AWA GIONS os MOLO3NNOO3 alae saoi Eren mom eee 29 MOI23NNOO O lE H 2 OLO3NNOO W 2 P J IN E n SN NONSE g B I HO193NNO2 1 Ss w BEB RERE sis ay mer d sex E 1 B 96 as 9 Er E Cleo 5 dd sooo Er E T noun 9 su
18. 7 2 7 1 2 Component 7 3 7 2 Engine Serial 7 4 7 3 Specifications and Maintenance 7 4 7 4 Introduction Cummins 05 4 5 7 5 7 4 1 Disclaimer and 7 5 7 4 2 Component 7 6 7 5 Engine Serial 7 7 7 6 Specifications and Maintenance 7 7 7 7 Cooling 7 7 7 7 1 Radiator Pressure 7 7 7 7 2 Thermostat 7 7 7 7 3 Radiator Oil Cooler and Replacement 7 8 7 8 Electrical System lm ull a ia ee 7 9 7 9 Fuel REI eee eee te be ee een ee 7 9 7 9 1 Diesel Fuel vet rere td he 7 9 7 9 2 Fuel TANK us nace age ete greet ac Gus e Pone ab ee ad ors 7 9 7 9 3 After Fuel System Service 7 10 7 10 7 11 7 10 1 Exhaust System
19. 3 24 3 10 8 Fourth Boom Section Install 3 25 3 10 9 Third Boom Section Install 3 25 3 10 10 Second Boom Section Install 3 26 3 10 11 First Boom Section 3 27 3 10 12 Boom Assembly Installation 3 28 3 11 Maintenance Four Section Individual Section Removal 3 28 3 11 1 Fourth Boom Section 3 29 3 11 2 Third Boom Section 3 30 3 11 3 Second Boom Section 3 30 3 11 4 Second Third and Fourth Boom Section Removal 3 31 3 11 5 Second Boom Section Installation 3 31 3 11 6 Third Boom Section Installation 3 31 3 11 7 Fourth Boom Section Installation 3 32 3 12 Extend and Retract Chains Four Section 3 32 3 12 1 Boom Chain 3 32 3 12 2 Inspection 3 33 3 12 3 Adjusting Extend 5 3 35 3 12 4 Adjusting Retract 5 3 35 3 12 5 Retract Chain
20. emm E I 20 12 6 Lift the second boom section free of the machine and place on the ground or suitable supports 3 4 3 Second and Third Boom Section Removal It is best to remove the boom sections in the order in which they were assembled If a section needs to be separated this presents an excellent opportunity to check all sections for serviceability The third and second sections can be removed as a assembly The push beam extend retract cylinder can be either removed or left in place during the third and second boom section removal 1 Release tension from the hoses on the hose take up bracket 3 2 Label disconnect and cap all hydraulic hoses attached at the take up bracket 4 Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 3 If equipped label loosen and separate all electrical cables at the take up bracket 4 Remove the take up brackets 5 5 Loosen and remove the jam nuts on the retract cable 6 at the bottom of the first boom section 6 Loosen and remove the retract cable adjustment block 12 from the bottom front of the first boom section 7 Label disconnect and cap both hydraulic hoses 7 attached to the extend retract cylinder Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 8 Loosen and remove the jam nuts on the two extend cables 8 at the strong back 9 Remove the p
21. 5 3 5 8 Axle Asseimbli68 5 vec pr E ER Buh UR e E EU 5 3 5 4 Rear Drive dro ee 5 9 5 5 Rear Steer AX enata ova oorr y prev ou Ro 5 10 5 6 Wheels and cur RD ane Bale ey Rare ats uA eel 5 11 5 7 Brakes vied ed UL whew E pL CE LIES iet xus 5 13 5 8 Towing a Disabled 5 13 Section 6 Hydrostatic Drive 225a pias wes Se ee Ra EORR 6 1 6 1 Drive Pump Assembly Component Terminology 6 2 6 2 Drive Pump Description eare reres ed da RN PW eee mee 6 3 6 3 Drive Pump Serial Number 6 3 6 4 Drive Pump 5 6 3 6 5 Drive Pump Replacement 6 3 6 6 Hydrostatic Drive Performance 5 6 5 Section 7 EHdIDG Ur CE OE C de me rr rn Tn iT 7 1 7 1 Introduction John Deere 4045TF275 amp 4045 275 7 2 7 2 Engine Serial 7 4 7 3 Specifications and Maintenance 7 4 7 4 Introduction Cummins 5 4 5
22. 8 11 5340 9 5340 10 amp 5440 Hydraulic System n 85 HYDRAULIC RESERVOIR The hydraulic reservoir 1 is located on the right side of the frame behind the fuel tank 8 5 1 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Hydraulic Oil Reservoir Draining 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover and the hydraulic oil reservoir fuel tank cover Allow the system fluids to cool 4 Disconnect the battery negative cable from the battery negative terminal 5 Open the filler cap on the hydraulic oil reservoir Remove the drain plug on the bottom of the hydraulic oil reservoir 6 Transfer the used hydraulic oil into a suitable covered container and label as Used Oil Dispose of used oil at an approved recycling facility Clean and reinstall the drain plug 7 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area 8 5 2 1 Be sure the reservoir is clean and free of all debris Hydraulic Oil Reservoir Filling 2 Install new hydraulic oil filters 3 Fill the reservoir with Mobilfluid 4249 ISO Grade 46 oil Refer to Section 2 4 Fluid and Lubricant Capacities
23. 4 5 4 3 5 Frame Sway and Attachment Tilt Levers 4 6 4 3 6 Left Hand Tilt and or Left Hand Tilt Sway Lever If Equipped 4 6 4 3 7 Windshield Wiper 4 7 4 3 8 Heater System If Equipped 4 7 4 4 Cab Removal esr Rr ee rera Re eee eee eee 4 8 4 5 Cab Installation 4 9 534D 9 534D 10 amp 544D 4 1 Cab and Covers a 41 6 AND COVERS COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers The following illustration identifies the components that are referred to throughout this section LIFTING LUG FRAME LEVEL INDICATOR f STEERING WHEEL TRANSMISSIOM CONTROL LEVER JOYSTICK BOOM CONTROL Ja INSTRUMENT PANEL N FRAME SWAY and ATTACHMENT TILT LEVERS Au IGNITION SWITCH FI SERVICE BRAKE PEDAL ACCELERATOR PEDAL 4 2 MX0850 534D 9 534D 10 amp 544D Cab and Covers Ps 2 Place a Do Not Operate Tag on both the i
24. 9 2 SPECIFICATIONS Electrical system specifications are listed in Section 2 General Information and Specifications 9 3 SERVICE WARNINGS A CAUTION When doing welding anywhere on the machine disconnect the wire harness from the Engine Control Module mounted beside the engine and disconnect both cables from the battery s and clamp both cables together John Deere CONTROL MODULE MX0940 Cummins ECM CONTROL MODULE ILL 5340 9 5340 10 amp 544D 9 4 FUSES AND RELAYS 9 4 1 Cab The fuse panel is located at the bottom right corner of the dash The relay is located at the right front corner of the cab under the dash 9 4 2 Engine Compartment The relay is located at the right rear corner of the engine 9 3
25. RSS BRR MX0240 3 Install the retract cable threaded end through the rear cable sheave bracket and cable adjusting block 4 Feed the retract cable into the inside bottom front of the first boom section to the retract cable adjustment access hole 5 Atthe front of the third boom section install the push beam and align the push beam mounting pins 6 Install the push beam mounting pins and lock bolts 7 Install the retract cable to the cable adjustment block at the bottom front of the first boom section 8 Install the retract cable sheave and all the related components 9 Install the cable guards 10 Install the hose guards at the rear of the boom 11 Place the strong back in place at the rear of the first boom section and install the extend retract cylinder mounting pin spacers and retaining clips 12 Install the previously removed shims to the top and bottom of the strong back cylinder bracket 13 Install and torque the strong back mounting bolts 14 Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations 15 Install the extend cables springs washers and lock nuts into the strong back 3 14 MX0250 16 At the retract cable adjusting block 1 located at the bottom front of the first boom section tighten the retract cable adjusting nut until the fr
26. 2 Locate the six brake release bolts 1 at the base of the front axle Mark a line on the socket so you can accurately count the number of turns each bolt makes as you perform the procedure 3 Alternately screw the release bolts clockwise in 1 2 turn increments Turn until resistance is felt 4 Alternately screw the bolts clockwise 5 to 5 1 2 turns in 1 2 turn increments 5 Hold the base of the reverse relief valve 2 using a 32mm 1 1 4 wrench Use a 22mm 7 8 wrench to turn the second section of the reverse relief valve 3 two complete turns out Repeat the procedure on the forward relief valve 4 6 Carefully remove the blocking from each tire and tow the machine to a secure location Note This procedure does not alter any relief settings 5 13 ES Axles Wheels and Tires 2 Hold the base of the reverse relief valve using a 32mm 1 1 4 wrench Use a 22mm 7 8 wrench to turn the second section of the reverse relief valve two complete turns in Repeat the procedure on the forward relief valve 3 Using a torque wrench alternately unscrew the brake release bolts 1 outward in 1 2 turn increments until the torque drops off sharply 4 Again alternately unscrew the bolts outward until you feel the bolts flange begin to contact against the special screw 5 Screw the bolts inward clockwise 1 4 turn 6 The parking brake should now be reactivated and the front wheels locked
27. 7 11 7 10 2 Exhaust System Installation 7 11 7 11 Air Cleaner 7 11 7 11 1 Air Cleaner Assembly 7 11 7 11 2 Air Cleaner Assembly 7 12 7 12 Engine 7 12 7 12 1 Engine 7 12 7 12 2 Engine Disassembly Inspection and 7 13 7 12 3 Engine 8 7 13 7 3 Engine Drive Plate Coupling 7 14 7 13 1 Drive Plate Coupling Removal 7 14 7 13 2 Drive Plate Coupling 7 14 7 14 Engine 7 15 534D 9 534D 10 amp 544D 7 1 Engine 7 1 INTRODUCTION JOHN DEERE 4045TF275 amp 4045HF275 7 1 1 Disclaimer and Scope These instructions are written for worldwide use In territories where legal requirements govern engine smoke emission noise safety factors etc apply all instructions data and dimensions provided herein in such a way that after maintenance service and repair of the engine engine operation does no
28. 8 13 8 6 1 Pump 8 13 8 6 2 Pump Failure Analysis 8 13 8 6 3 Pump 8 13 8 7 Drive Motors 8 14 8 7 1 Front Drive Motor ae s EY CER 8 14 8 7 2 Rear Drive 5 8 15 8 8 Control Valves sssri e nov a Rye ne ee ee a 8 16 8 8 1 Main Control Valve 8 16 8 8 2 Service Brake Valve 8 19 8 8 3 Brake Test siste demain RU dae sheet edhe ee 8 20 8 8 4 Steering Orbitrol Valve 8 21 8 9 Hydraulic 8 21 8 9 1 General Cylinder Instructions 8 21 8 9 5 Cylinder Pressure 8 23 8 9 6 Cylinder Torque Specifications 8 24 534D 9 534D 10 amp 544D 8 1 Hydraulic System 81 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety operation and service information presented in this section it is necessary that the operator mechanic be familiar with the name and location of the hydraulic com
29. 7 Remove the blocks from the four tires 8 Verify that the parking brake works Note If the parking brake does not work check all activation operations step by step ri MX1040 After the machine has been towed to a secure location reactivate the parking brake 1 Block all four wheels A WARNING ALL WHEELS must be blocked to prevent machine from moving or rolling away MX1050 5 14 534D 9 534D 10 amp 544D Section 6 Hydrostatic Drive Pump Contents PARAGRAPH TITLE PAGE 6 1 Drive Pump Assembly Component 6 2 6 2 Drive Pump 6 3 6 3 Drive Pump Serial 6 3 6 4 Drive Pump 6 3 6 4 1 Drive Pump Maintenance 6 3 6 4 2 Drive Pump Maintenance Schedule 6 3 6 5 Drive Pump 6 3 6 5 1 Drive Pump Removal 6 3 6 5 2 Drive Pump Inspection and Internal Repair 6 4 6 5 3 Drive Pump 6 4 6 6 Hydrostatic Drive Performance Checks 6 5 6 6 1 Hydraulic Oil
30. Ee EE 9 10 9 8 Windshield Wiper Motor If Equipped 9 11 9 8 1 Windshield Washer Reservoir and 9 11 9 9 Cab Heater and Fan If 9 12 9 9 1 Cab Heater 5 9 12 9 10 Solenoids Sensors and Senders 9 12 9 10 1 Circuit 5 9 12 9 10 2 Stabilizer Proximity 5 9 13 9 40 3 Engine 5 9 13 9 10 4 Fuel Level 9 14 9 11 Gauges IE DAR 9 Daa eee 9 15 9111 Analog Gauges xe 55559545 tee RW es dud 9 15 9 12 Dash Switches 0 6 06 eet RR eR Ar rx 9 15 9 12 1 Ignition Key Switch 9 15 9 12 2 Dash Switches 9 16 9 12 3 Warning or Activated Lights 9 17 9 13 Transmission 9 17 9 14 Traction Lock sr lr RII ARR 9 17 9 15 Troubleshooting 9 18 9 15 1 Fault Detection 9 18 9 15 2 Flash
31. 18 19 20 Remove the exhaust flex pipe from the exhaust pipe Remove the exhaust pipe from the exhaust manifold Loosen the clamps on the air intake at the engine and on the 90 elbow Remove the air intake elbow tube and 90 elbow Cover the end of the air intake tube still attached to the side of the cab Note Disregard the following directions in step 23 24 and 25 if pump is being left on machine and continue to step 26 21 22 23 24 25 26 7 12 2 Label disconnect and cap all hydraulic hoses and tubes attached to the traction lock valve Cap all fittings and openings to prevent dirt and debris from entering the hydraulic system Remove tubes and traction lock valve Loosen and remove both hydrostatic drive pump mounting bolts Pull pump back until clear of engine Loosen and remove the three engine mount bolts and washers Secure the engine with a lifting strap or chain from the appropriate lifting points Use a suitable hoist or overhead crane Have an assistant ensure that the engine clears all frame components during removal Place engine on a flat level surface Engine Disassembly Inspection and Service Engine disassembly internal inspection service repair and assembly procedures are covered in the appropriate service manual Contact the local power unit parts distributor for further information Note If the engine is being replaced there be external compo
32. When sliding the rod and piston assembly into the cylinder barrel prevent the threaded end of the cylinder barrel from damaging the piston head Keep the cylinder rod centered within the barrel to prevent binding 6 Carefully insert the cylinder rod assembly into the cylinder barrel Screw the head gland into the cylinder barrel and tighten with a spanner wrench Refer to Section 8 9 6 Cylinder Torque Specifications for torque specifications for the head gland 7 If applicable install new counter balance valve into block on the cylinder barrel 8 9 4 1 Grease the bushings at the ends of the hydraulic cylinder Using an appropriate sling lift the cylinder into it s mounting position General Cylinder Installation 2 Align cylinder bushing and install pin lock bolt or retaining clip 3 Connect the hydraulic hoses in relation to the labels or markings made during removal 4 Before starting the machine check fluid level of the hydraulic fluid reservoir and if necessary fill to full mark with Mobilfluid 4249 ISO 46 5 Start the machine and run at low idle for about one minute Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil 6 Inspect for leaks and check level of hydraulic fluid in reservoir Add hydraulic fluid if needed Shut the engine OFF 534D 9 534D 10 amp 544D 7 Wipe up any hydraulic fluid spillage in on near and around th
33. n NOLI 3A ONES SAWAGIONZIOS DNS NE EN E BOIS E ALOR gos d INWA 9 usns j da ALOR iind INITIAL HOLIMS 0193138 3AA ANYO 134 MX0700 HOLS HOLIMS 3901 133 8 9 5340 9 5340 10 amp 5440 Hydraulic System ry 8 4 3 Hydraulic Schematic 534D 10 SATA MAZIIGVLS 31 iva WNOLLdO INVA SSVdAB WWH3HL 321815 5340 9 5340 10 amp 5440 1OH1NOO NIV MIO 3S3H HS3N 001 SUBQNITAD 14n INVA 1918 ANTIXDV SUSQNITAD AMS osiNco va INYA VQ HOLOW LNOYS 9 bx alotenos Sowas XN sus anamo a 99 ES
34. Install the retract cable adjustment block to the inside front of the first boom section Install the wear pads and shims in the front of the first boom section Install the wear pads and shims at the top rear and one side of the second boom section Feed the tilt hoses and auxiliary hoses if equipped through the bottom of the hose sheaves at the rear of the second boom section Note Make sure the tilt aux hoses do not cross each other between the first and second boom sections T Install the hose take up brackets and install the tilt aux hoses to the correct fittings on the take up brackets 534D 9 534D 10 amp 544D 3 4 5 1 Third Boom Section Installation Grease the inside wear pad paths of the second boom section and the outside wear paths of the third boom section With the retract cable fed through the front of the Second boom section position the third boom section into the front of the second boom section Feed the retract cable over the cable sheave at the rear of the second boom section and out the rear of the first boom section Install the wear pads and shims in the front of the second boom section Install the wear pads and shims at the top rear and one side of the third boom section Install the back of the push beam into the head of the third boom section With the push beam installed 5096 into the third boom section feed the extend cables through the bottom and ov
35. MX1110 Shut off machine and remove the plugs from the G port 4 and M port 5 on the front drive motor Install test ports in place of each plug Attach a digital or high pressure gauge 10 000 psi 689 bar to each test port 534D 9 534D 10 amp 544D MX1090 Note 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 the engine and raise the rpm until the gauge on the Ps port is reading 240 psi 16 5 bar Maintain this rpm and pressure throughout the test With the pressure on the Ps port at 240 psi 16 5 bar the pressure at G port should read 3 300 psi 227 5 bar Adjust the begin point screw 6 on the drive motor so that the gauge on the M port reads approximately 1 650 psi 114 bar Note Begin point screw adjustment is very sensitive Note The pressure at the M port will not be steady This is the pressure that shifts the motor to maintain minimum displacement Under normal operating conditions the 3 000 psi 307 bar at the 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 6000 psi 414 bar Use procedure in Section 6 6 9 Drive Pump Pressure to adjust this relief Note Wre
36. 10 Loosen and remove the four bolts holding the drive motor to the carrier housing 11 Pull the drive motor back from the axle carrier and place on a suitable support or table 534D 9 534D 10 amp 544D Hydraulic System n b Front Drive Motor Disassembly Although individual parts are available for the drive motor itis recommended that any disassembly and reassembly is done by an authorized JLG Service Center c Front Drive Motor Installation 1 Apply Molybdenum on the splined shaft and Ultra Blue silicon sealant at the base of the drive motor 2 Align the splined shaft on the drive motor with the axle carrier and slide into place 3 Apply Loctite 242 and install the four bolts holding the drive motor to the carrier Torque to 265 Ib ft 25 0 359 Nm 34 0 4 Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations Note Uncap each hose as you install them to prevent unnecessary fluid spillage 5 Connect the battery negative cable to the battery negative terminal Install the deck cover 6 Add hydraulic oil as needed 7 Start and warm machine to operating temperature and add hydraulic oil if needed 8 7 2 The rear drive motors are mounted on each rear drive hub The motors are active in 4WD only Rear Drive Motors Note The removal disassembly and installation of the rear drive motor applies for either side a Rear Drive Motor
37. 9 C Ps oT PUMP HOUSING STROKING PISTON ADJUSTMENT pecie SIDE VIEW 9 CHARGE PUMP OUTPUT PORT 6 2 MX0870 DIRECTIONAL VALVE REVERSE HIGH PRESSURE RELIEF VALVE PORT REVERSE B CHARGE PUMP RELIEF VALVE TEST PORT FORWARD FORWARD HIGH PRESSURE RELIEF VALVE 534D 9 534D 10 amp 544D Hydrostatic Drive Pump A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual 6 2 DRIVE PUMP DESCRIPTION Instructions in this section pertain mainly to general specifications towing maintenance information and drive pump removal and installation procedures for internal drive pump service instructions and detailed specifications contact your local JLG distributor See 6 3 DRIVE PUMP SERIAL NUMBER The drive pump serial number plate is located on the front of the drive pump case Information specified on the serial number plate includes the drive pump model number the drive pump serial number and other data Information on the serial number plate is required in correspondence regarding the drive pump 6 4 DRIVE PUMP SPECIFICATIONS 6 4 1 Cleanliness is of extreme importance Before attempting
38. 9 19 Electrical System Fault Code SPN Code FMI Code Description 245 647 4 4 Fan Control Circuit Low 253 98 1 Engine Oil Level 268 94 2 Injector Metering Rail 1 Pressure 269 1195 2 Antitheft Password Valid Indicator 271 1347 4 High Fuel Pressure Solenoid Valve Circuit Low 272 1347 3 High Fuel Pressure Solenoid Valve Circuit High 275 1347 7 Fuel Pumping Element Number 1 Front 281 1347 7 Fuel Pump Pressurizing Assembly 1 284 1043 4 4 Engine Speed Position Sensor Crankshaft Supply Voltage Circuit 285 639 9 SAE J1939 Multiplexing PGN Timeout Error 286 639 13 SAE J1939 Multiplexing Configuration Error 287 91 19 SAE J1939 Multiplexing Accelerator Pedal or Lever Sensor System Error 288 974 19 SAE J1939 Multiplexing Remote Accelerator Pedal or Lever Data 291 625 9 Proprietary Datalink Error 292 441 14 Auxiliary Temperature Sensor Input 1 Special Instructions 293 441 3 Auxiliary Temperature Sensor Input 1 High 294 441 4 Auxiliary Temperature Sensor Input 1 Low 295 108 2 Barometric Pressure Erratic 296 1388 14 Auxiliary Pressure Sensor Input 1 Special Instructions 297 1388 3 Auxiliary Pressure Sensor Input 1 Circuit High 298 1388 4 Auxiliary Pressure Sensor Input 1 Circuit Low 319 251 2 2 Real Time Clock Power Interrupt 322 651 5 Injector Solenoid Driver Cylinder 1 Circuit
39. Large bore valve stems are used to help expedite tire inflation and deflation An inner tube may be usedi if a tire does not provide an airtight seal Check tire inflation pressures when the tires are cold When mounting a tire on the wheel the tire must be mounted on the wheel respective of the directional tread pattern of the tire this produces a left or right tire and wheel assembly The wheel and tire assemblies must be installed with the directional tread pattern arrows 4 facing in the direction of forward travel 5 11 ES Axles Wheels and Tires 5 6 2 Installing Wheel and Tire Assembly 4 onto Machine 2 IMPORTANT The wheel tire assemblies must be installed with the directional tread pattern arrows facing in the direction of forward travel Tread arrows must point forward Install tires onto wheels to MAHO0890 rotate in proper direction 0620 5 6 1 Removing Wheel and Tire Assembly from Machine 1 Position wheel onto studs on wheel end of axle 1 Park the machine on a firm level surface fully retract the boom lower the boom place the 2 Install wheel lug washers transmission control lever in NEUTRAL engage 3 Start all nuts by hand to prevent cross threading DO the park brake and shut the engine OFF NOT use a lubricant on threads or nuts 2 Place a Do Not Operate Tag on both the ignition key 4 Tighten lug n
40. 11 Start the machine and slowly operate the boom assembly full cycle at least 10 times 12 Check for any hydraulic leaks and repair if necessary 13 Cycle the boom assembly 10 more times to be certain that all air has been purged from the system 14 Final adjust the boom wear pads extend and retract chains hose take up assembly and any other area that needs to be serviced 3 11 BOOM MAINTENANCE FOUR SECTION INDIVIDUAL SECTION REMOVAL These instructions help with the removal of individual boom sections with the complete boom still mounted on the machine Safe practices and common sense must be followed when removing boom sections Before beginning conduct a visual inspection of the machine and work area and review the task about to be undertaken Read understand and follow these instructions taking into consideration your particular situation For more detailed instructions see Section 3 10 Boom Maintenance Four Section Complete Removal 534D 9 534D 10 amp 544D Boom a 3 11 1 Fourth Boom Section Removal MX0470 1 Park the machine on a firm level surface fully retract the boom lower the boom to a level position place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating th
41. 12 mm wrench Close the brake bleeder when air bubbles no longer appear in the oil running through the transparent tubing Remove the tubing from the brake bleeder 5340 9 5340 10 amp 5440 Hydraulic System 8 8 4 Steering Orbitrol Valve The steering orbitrol valve 4 is located at the base of the steering wheel shaft The valve is not serviceable and must be replaced in its entirety if defective For detailed information refer to Section 4 3 1 Steering Column and Orbitrol Valve 8 9 HYDRAULIC CYLINDERS 8 9 1 General Cylinder Instructions a Cylinder Removal 1 Remove any attachment from the machine Park the machine on a firm level surface and fully retract the boom Allow sufficient work space around the hydraulic cylinder being removed Support the boom if the lift lower cylinder is being removed Place the travel select lever in N NEUTRAL engage the park brake shut the engine OFF and chock wheels 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Label disconnect and cap or plug hydraulic hoses in relation to the cylinder Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 5 Attach a suitable sling to an appropriate lifting device and to the cylinder Make sure the device used can actually suppor
42. 2009746 i E ku H g OT AM S s v Fa panay E BER 25 o A 8 E sm e x E cy E 2 3n8 fo une 5 euam E aane mm i gt H Am ae m m hs m oe ONE AW ay Bin MOLOSNNOO 4 99 ko Er 9 6 Electrical System 9 5 4 Start Circuit 534D 9 534D 10 544D START RELAY 0000 B START A ST IGNITION START C Q START B o 1 UN ABCGDEFGHJKLMNP 9 2 START B 5 8 17 6 15 14 13 o 10 9 8 7 6 5 4 3 2 1 N UN os 8 17 16 15 44 13 12 10 9 8 6 5 4 3 2 1 SAT 30 87 9 us tr o STARTER BATTERY MOTOR lo STARTER SOLENOID START C 534D 9 534D 10 amp 544D 9 7 Electrical System 9 5 5 Charge Circuit 534D 9 534D 10 544D
43. 4 Connect the battery negative cable to the battery negative terminal 5 Close and secure the engine cover and the hydraulic oil reservoir fuel tank cover 8 5 3 Hydraulic Oil Reservoir Removal Installation If it is determined that the hydraulic oil reservoir must be removed the hydraulic oil must be drained before the reservoir is removed Always dispose of hydraulic oil properly 8 12 a Reservoir Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover and the hydraulic oil reservoir fuel tank cover Allow the system fluids to cool 4 Disconnect the battery negative cable from the battery negative terminal 5 Drain the hydraulic oil reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 6 Remove the hydraulic oil reservoir fuel tank cover 7 Label disconnect and cap all hydraulic hoses attached to the hydraulic oil reservoir Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system 8 Remove the bolts securing the hydraulic oil reservoir to the frame 9 Remove the hydraulic oil reservoir L MX
44. Cleanliness is extremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components If using a steam cleaner seal all openings before steam cleaning Note Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom to access the front axle place the travel select lever in the N NEUTRAL position engage the parking brake straighten all wheels and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the deck cover and disconnect the battery negative cable from the battery negative terminal 5 f the axle will be disassembled after removal place a suitable receptacle under the axle 1 and wheel hubs 2 drain plugs 6 Use the breather 3 to relieve any pressure in the axle before removing the drain plug 7 Remove the drain plugs and allow the axle oil to drain into the receptacle Transfer the used axle oil into a suitable covered container and label the container as Used Dispose of used oil at an approved recycling facility
45. Remove belly pan from under the cab Clean area around solenoid to be removed Remove the battery negative cable at the negative battery terminal Disconnect the wiring connector at the valve solenoid lead 5 Loosen and remove the coil mounting nut Remove the valve solenoid being careful not to lose or damage any o rings Note the location of any orifices check valves and o rings if equipped Traction Lock Solenoid Removal Remove cover from behind engine Clean area around solenoid to be removed Remove the battery negative cable at the negative battery terminal Disconnect the wiring connector at the valve solenoid lead 5 Loosen and remove the coil mounting nut 6 Remove the valve solenoid being careful not to lose or damage any o rings Note the location of any orifices check valves and o rings if equipped Stabilizer Solenoid Removal Clean area around solenoid to be removed Remove the battery negative cable at the negative battery terminal Disconnect the wiring connector at the valve solenoid lead Loosen and remove the coil mounting nut Remove the valve solenoid being careful not to lose or damage any o rings Note the location of any orifices check valves and o rings if equipped Tilt Control Solenoid Removal Remove rear cover from behind cab Clean area around solenoid to be removed 3 Remove the battery negative cable at t
46. fastened to the bottom of the fourth boom section moves to the front or rear of the hydraulic carrier fastened to the back of the third boom section The moveable hose carrier rolls forward or backward protecting the looped hoses as they extend and retract a Hydraulic Sub Assembly Removal 1 Remove the guide bracket from the front of the hydraulic sub assembly 2 Install a sling on the hydraulic sub assembly at the rear of the boom Slowly pull it loose from the bottom bracket located on the bottom plate of the fourth boom section 3 When the sub assembly is approximately 2596 free of the boom fasten the two hose carriers together using nylon tie wraps or nylon straps to keep them from separating 3 24 Note Do Not wrap the hose carrier since it will not prevent the two hydraulic carriers from moving apart sideways 4 Continue to withdraw the sub assembly fastening the hydraulic carriers together using nylon tie wraps or nylon straps to keep them from separating 5 When the hydraulic carrier is 7596 tied together pull the assembly free of the boom and set on suitable supports Note Hydraulic and Electrical Options Hoses and electric cables for options are installed on the right hand side of the sub assembly per installation for the standard machine The electrical cable for that option should be centered between the hydraulic hoses as they pass through the hose carrier The electric tubing is mounted above
47. 11 3 Remove the chain from the clevis install a nylon tie wrap through the holes in the chain making a loop with the tie wrap and tie a rope to the loop 4 Move to the back of the boom and pull the chain to the rear to allow slack for removal 5 Remove the chain from the clevis and drop it free from the boom 6 Holding the rope at the front carefully pull the chain out through the back of the boom until it s free 7 Untie the rope and leave it in place for reinstallation of the chain 3 12 6 Retract Chain Installation Inspect and lubricate chains thoroughly before installation Articulate the chains to make sure all working surfaces are thoroughly lubricated Note Install the 3 4 in 19 mm chain first 1 Fasten a rope to the end of the 3 4 in 19 mm chain in order to pull it back into the boom 2 Attach the chain to the chain clevis at the rear of the fourth boom section 3 Carefully pull the chain into the boom until it can be fastened to the chain clevis 4 Remove the rope 534D 9 534D 10 amp 544D Boom b 5 Fasten the chain into the clevis by installing the pin and cotter pin 6 Torque the jam nuts to 100 Ib ft 135 Nm DO NOT use Loctite on the nuts 7 Forthe 1 in 25 mm chain fasten a rope to the end of the 1 in 25 mm chain in order to pull it back into the boom 8 Attach the chain to the chain clevis at the rear of the fourth boom section 9 Carefully p
48. 3 3 4 Third Boom Section Installation 3 6 3 3 5 Extend Retract Cylinder and Push Beam Assembly and Installation 3 7 3 3 6 Second amp Third Boom Section Installation 3 7 3 4 Boom Maintenance Three Section Individual Section Removal 3 9 3 4 1 Push Beam and Third Boom Section 3 9 3 4 2 Second Boom Section 3 10 3 4 3 Second and Third Boom Section 3 10 3 4 4 Second Boom Section Installation 3 11 3 4 5 Third Boom Section Installation 3 11 3 5 Boom Cables Three Section 3 12 3 5 1 General Cable Information 3 12 3 5 2 Cable Adjustments 3 12 3 5 3 Retract Cable 3 13 3 5 4 Retract Cable Installation 3 14 3 5 5 Extend Cable 3 14 3 5 6 Extend Cable Installation 3 15 3 5 7 Tilt and Auxiliary Circuit Hose Removal Installation 3 16 3 5 8 Hose 3 16 3 5 9 Hose Installations e e i 3 16 3 6 Auxiliary Electric
49. 534D 9 534D 10 amp 544D 2 13 General Information and Specifications 2 6 2 544D a 50 Hour 2 14 P a MYSTIK TETRIMOLY NLGI 2 GC LB I MX00512 534D 9 534D 10 amp 544D General Information and Specifications b 250 Hour 50x EVERY P a n MYSTIK TETRIMOLY NLGI 2 GC LB 534D 9 534D 10 amp 544D MX00712 2 15 General Information and Specifications 2 16 This Page Intentionally Left Blank 534D 9 534D 10 amp 544D Section 3 Boom Contents PARAGRAPH TITLE PAGE 3 1 Boom System Component Terminology 534D 9 534D 10 3 3 3 2 Boom System Three 3 4 3 2 1 Boom System 3 4 3 3 Boom Maintenance Three Section Complete Removal 3 4 3 3 1 Boom 3 4 3 3 2 Second amp Third Boom Section 3 5 3 3 3 Third Boom Section amp Push Beam Removal 3 5
50. 7 5 7 5 Engine Serial 7 7 7 6 Specifications and Maintenance 7 7 7 7 Cooling Systems os ond Li die ee DOR pat bee Iud bx ris 7 7 7 8 Electrical System 20 m bee RR ERE Eee ele nii 7 9 7 9 7 9 7 10 Exhaust System deb i a A a e ese 7 11 7 11 Air Cleaner 7 11 7 12 Engine 7 12 7 13 Engine Drive Plate Coupling 7 14 7 14 Engine Troubleshooting 7 15 Section 8 Hydraullc SyStelm cicius aco icine needa a ded tents CX eaten d efe 8 1 8 1 Hydraulic Component Terminology 8 2 8 2 Safety Information 8 3 8 3 Hydraulic Pressure Diagnosis 8 4 8 4 Hydraulic Circuits ie kl y moe nar bev ie 8 6 8 5 Hydraulic 8 12 8 6 Engine Implement Pump 8 13 8 7 Drive Motors ose tacts DR e read et ets ed ae he 8 14 8 8 Control ValV6s
51. 9 10 4 Fuel Level Sender 4 Start the machine and allow the engine to warm to check the engine water temperature 9 12 DASH SWITCHES Note For information on the front windshield wiper rear window wiper and washer systems refer to Section 9 8 1 Windshield Washer Reservoir and Pump 9 12 1 Ignition Key Switch a Ignition Switch Removal 1 Remove the battery negative cable at the negative battery terminal 2 Remove lower access panel 3 Remove the hex nut securing the ignition key switch to the dash 4 Reach up and under the dash to work the ignition switch and wiring out of the mounting hole 5 Disconnect the ignition switch connectors from the cab harness connectors and remove the switch from the machine b Disassembly DO NOT disassemble the ignition switch Replace a defective switch with a new part c Inspection and Replacement To determine the proper operation of the ignition key switch using the following charts test the wires on the back of the switch for continuity with an ohmmeter Test the ignition key switch for continuity by checking from the ignition Red Battery wire to each of the following wires in each switch position Continuity X should be present as indicated in the following chart 9 15 Electrical System Switch Position Test from Red Battery OFF RUN START wire to Orange Gray Wire Orange Dark Green Wire X X Vio
52. Be certain each of you know what to expect from the other and when to expect it 5 Always wear safety glasses hard hat and any other locally required safety related protective apparel when performing testing and adjusting procedures 6 Thoroughly clean all areas before working on them Slippery and contaminated surfaces can cause serious accident or mechanical failure if not removed 7 Always secure machine components that could suddenly start in motion and cause injury or damage 8 Remove the key from the ignition and place a sign in the cab informing all who come in contact with the machine 534D 9 534D 10 amp 544D 9 Double check all bolt torques 10 Check that all lubrication fluids are at the correct level 11 Remove any restraints before restarting and operating the machine following repairs 12 Clear all personnel from area adjacent to the machine when first operating after a repair or adjustment 13 Clean machine and work area before returning to service 6 6 1 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 reservoir capacity is 30 gallons Refer to Section 2 4 Fluid and Lubricant Capacities for system capacities Hydraulic Oil Reservoir 6 6 2 Dirty suction filters can restrict oil flow to the charge pump This can lower the control pressure which can af
53. Install the engine dust shield 7 8 ELECTRICAL SYSTEM The engine electrical system including the starter alternator and primary wiring is described in Section 9 5 Electrical System Schematics 7 9 FUEL SYSTEM 7 9 1 Diesel Fuel Fuel represents a major portion of machine operating costs and therefore must be used efficiently ALWAYS use a premium brand of high quality clean diesel fuel Low cost inferior fuel can lead to poor performance and expensive engine repair Note Use only diesel fuel designed for diesel engines Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance 534D 9 534D 10 amp 544D NOTICE Due to the precise tolerances of diesel injection systems keep the fuel clean and free of dirt and water Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles Use ASTM 2 diesel fuel with a minimum Cetane rating of 40 2 diesel fuel gives the best economy and performance under most operating conditions Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking Inform the owner operator of the machine to use 2 diesel fuel unless ambient temperatures are below 0 C 32 F When temperatures are below 0 C 32 F a blend of 1 diesel and 2 diesel fuels known as winterize
54. Low 323 651 5 Injector Solenoid Driver Cylinder 5 Circuit Low 324 653 5 Injector Solenoid Driver Cylinder 3 Circuit Low 325 656 5 Injector Solenoid Driver Cylinder 6 Circuit Low 331 652 5 Injector Solenoid Driver Cylinder 2 Circuit Low 332 654 5 Injector Solenoid Driver Cylinder 4 Circuit Low 334 110 2 Engine Coolant Temperature 341 630 2 2 Engine Control Module Data Lost 342 630 13 Electronic Calibration Code Incompatibility 343 629 12 12 Engine Control Module Warning Internal Hardware Failure 351 627 12 Injector Power Supply 352 1079 4 4 Sensor Supply Voltage Number 1 Circuit Low 386 1079 3 3 Sensor Supply Voltage Number 1 Circuit High 387 1043 3 3 Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit High 412 608 2 SAE J1587 J1922 Data Link Can not Transmit 415 100 1 1 Engine Oil Rifle Pressure Low 418 97 0 15 Water In Fuel Indicator High 426 639 2 SAE J1939 Data Link Can not Transmit 427 639 9 J1939 Datalink Abnormal Update Rate 428 97 3 3 Water In Fuel Indicator Sensor Circuit High 9 20 534D 9 534D 10 amp 544D Electrical System Fault Code SPN Code FMI Code Description 429 97 4 4 Water In Fuel Indicator Sensor Circuit Low 431 558 2 2 Accelerator Pedal or Lever Idle Validation Circuit Erratic 432 558 13 13 Accelerator Pedal or L
55. Note Disregard the following directions in step 10 and 11 if pump is being left on machine and continue to step 12 9 Drain the hydraulic oil reservoir or install a vacuum at the hydraulic oil reservoir filler neck 10 Disconnect and plug the hydraulic oil cooler hoses and cap the fittings on the oil cooler 11 Unplug the wire harness at the hydrostatic drive pump Disconnect label and plug the hoses on the hydrostatic drive pump if pump is being removed with the engine 12 Loosen and remove the twelve bolts holding the pump mounting plate to the engine bellhousing 13 Loosen and remove the mounting bolts and nuts holding the radiator cooler to the frame 14 Attach a suitable strap to the radiator cooler assembly and carefully remove 15 Loosen the clamps on each heater hose on the engine Plug the heater hoses if necessary Note The engine harness is routed and attached to the engine using hold down clamps and plastic wire ties at various places on the engine Before removing engine ensure that the harness has been completely separated disconnected from the engine Move the harness clear of the engine and with the help of an observer ensure that engine clears the harness during removal 16 Label and disconnect all wire harness connections on the engine 17 Disconnect the fuel lines at the engine Install a plug in the end of fuel inlet and return line 534D 9 534D 10 amp 544D Engine
56. Place the clean and inspected fourth boom section on suitable supports Grease the wear pad and hose carrier assembly sliding path areas thoroughly Fasten the wear pad for the hose carrier to the inside of the boom Attach the bracket 1 for the hose carrier to the inside of the boom Make sure that the inside guide paths for the hose carrier assembly guide bracket are greased MX0400 Install all the rear wear pads Leave one shim out of each package to aid with the installation into the third boom section Attach the chain clevis and the keeper plate to the inside rear of the boom Assemble the grease fitting extensions for the bottom rear wear pads Grease the outside wear pad paths Lubricate the 1 in 25 mm extend chain completely Make sure the chain is inspected and is in good working condition See Section 3 12 Boom Extend and Retract Chains Four Section Attach the chain to the chain clevis Attach the chain clevis to the top of the fourth boom section 534D 9 534D 10 amp 544D 3 10 9 1 Place the clean and inspected third boom section on suitable supports Third Boom Section Install 2 Grease the inside wear pad paths 3 Using a
57. Steering hydraulic system not 1 Refer to Section 8 4 Hydraulic operating properly Circuits Excessive joint housing swivel 2 Correct bearing preload by bearing preload adding or removing shims as needed Worn or damaged swivel 3 Replace swivel bearings as bearings needed 8 Slow steering response Steering hydraulic system not 1 Refer to Section 8 4 Hydraulic operating properly Circuits Steering cylinder leaking 2 Repair or replace steering internally cylinder as needed 9 Excessive noise when brakes Brake discs worn 1 Check brake discs for wear are engaged Refer to Section 2 4 Fluid and Lubricant Capacities Brake discs damaged 2 Replace brake discs 10 Brakes will not engage Brake hydraulic system not 1 Refer to Section 8 4 Hydraulic operating properly Circuits Brake piston o rings and seals 2 Replace o rings and seals damaged leaking 11 Brakes will not hold the Brake discs worn 1 Check brake discs for wear machine or braking power Refer to Section 2 4 Fluid and reduced Lubricant Capacities Brake hydraulic system not 2 Refer to Section 8 4 Hydraulic operating properly Circuits Brake piston o rings and seals 3 Replace o rings and seals damaged leaking 5 8 534D 9 534D 10 amp 544D Axles Wheels and Tires hs 5 4 REAR DRIVE HUBS 5 4 1 Rear Drive Hub Service Detailed drive hub servic
58. key switch and wiring harness plugs Clean and tighten all connections 6 If the starter still does not operate after these checks have been performed check the starting circuit b Starter Circuit Checks 1 Check wires and connections for looseness corrosion damage etc 534D 9 534D 10 amp 544D 2 If a whirring noise is heard but the engine does not turn over the starter is spinning but not engaging the flywheel The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine 3 If the starter only clicks it may indicate that the battery is discharged or that there is a loose or corroded battery cable connection Check the battery state of charge and battery condition first then check the cables and cable connections 4 For additional information on the starting circuit refer to Section 9 5 Electrical System Schematics c Starter Removal Remove the starter only if it fails To remove the starter 1 Open the engine cover 2 Remove the battery negative cable at the negative battery terminal 3 Remove the wires from the solenoid stud Remove the positive battery cable from the starter Label and disconnect the wire from the starter solenoid housing stud Record how the wires are installed to ensure correct installation later 4 Loosen but DO NOT rem
59. serviceable Replace motor if found to be defective 534D 9 534D 10 amp 544D c Inspection and Replacement Inspect the motor terminals for continuity Replace motor if continuity is not found d Installation and Testing 1 Align motor with the mounting holes and bolt the motor to the mounting bracket 2 Connect the cab harness connector to windshield wiper motor connector 3 Connect the negative battery cable to the negative battery terminal 4 Turn ignition key switch to the RUN position and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved 5 Install the wiper assembly Note Align the wiper blade with the left side of the cab windshield to ensure wiper stroke covers window area and it does not swipe past the glass area 6 If previously removed install hydraulic hoses under the dash Refer to Section 4 3 1 Steering Column and Orbitrol Valve Windshield Washer Reservoir and Pump 9 8 1 The windshield washer motor and reservoir is located in the cab compartment as a unit and cannot be serviced separately a Removal 1 Remove the battery negative cable at the negative battery terminal 2 Remove the nuts and the lock washers from the washer mounting bolts 3 Pull the washer reservoir out and away from the mounting bracket MZ0190 9 11 Electrical System 4 Rotate the was
60. terminal 5 Loosen and remove the nuts from the exhaust pipe at the exhaust manifold 6 Disconnect and remove the clamps attaching the flex pipe to the exhaust pipe 7 Disconnect and remove the clamp connecting the muffler and the exhaust pipe 8 Disconnect and remove the clamp connecting the tail pipe to the muffler and remove the tail pipe 9 Remove the exhaust system from the machine 7 10 2 Note Keep all clamps loosened until entire exhaust system is in place Exhaust System Installation 1 Install the exhaust pipe with a new seal to the exhaust manifold Note Replace the nuts and the exhaust manifold studs if damaged 2 Install the exhaust pipe clamp 534D 9 534D 10 amp 544D 3 Install the muffler to the exhaust pipe and bolt the muffler to the frame 4 Install the flex pipe and clamps between the exhaust pipes 5 Adjust the muffler exhaust and tail pipes for proper clearance then tighten all clamps 6 Connect the battery negative cable to the battery negative terminal 7 Start engine and check for exhaust leaks at all exhaust connections Adjust or repair as needed 8 Close and secure the engine cover 7 11 AIR CLEANER ASSEMBLY NEVER run the engine with only the inner safety element installed Note Hefer to the appropriate Operation amp Safety Manual for your machine for the correct element change procedure 7 11 1 1 Park the machine on a firm level sur
61. xs 9 Ts i I a uum M ol 3 y e EIS i Lu o kl H 5 EEE dd a ili H H o G B w E gt H Ld Rn m o E E gt d PPE Pf A in E mm o ae d DE E S Duis T 55 o e EA o E per o o o 9 4 Electrical System Electrical Schematic 544D John Deere 9 5 2 dani AnaL uv Souvuo NOlLISOd INVES sowa Wo NOLDAN sormea NVO EET 10
62. 091 007 09520 LL 281 591 0002 061 081 0 1 05281 SEL 601 06 021 09621 06060 8L m 01 551 00281 691 681 OLL 091 0079 021 96 08 OLL 009 ocero 1e SLL 06691 01 801 06 021 0077 00L 08 59 06 00201 6610 02 ui 021 OLL 0617 051 96 08 OLL 06 21 G8 89 GG GL 0506 60 L 28 GL 0 811 06 0 09 08 00 01 09 05 0 SG 099 8001 02 Tm LL 0 05901 08 9 SG OL 0566 SG Gp 06 0089 90L 0 v SG 05 08 8 SG Sb 06 0062 0 ze 52 S 0099 8 900 gie 08 Gp 09 06 0 Gp 0002 Ge 92 08 006 8 00 9L o 42 0089 o 50 02 52 0226 Le m vL 6L 00 08900 f m 92 SZ 0 26 og 20 81 Oey 6L 9L L LL Orgs 72500 81 91 19 91 13 81 NI 05 8 1 891 0298 v9 00 82 891 091 0818 500 20520 02 000200 c 0000 ii 21070 9 00100 2797 ze 510100 0 606000 08210 ze 1990070 8y 509000 CHFO 0 d 8TNI 81 705 NI 2 292 92 292 vauv HONI 19 207 13M 901 GWOT 30272 31901 am 314201 90 22 ani 3111901 qvo1 3 371 LNOHLIM 314207 Y0 AUC 3112201 412 1108 SQHL 310401 310301 310401 1390 3 9 13108 8 SLAN 30 9 0961 tN 8 8 JGVYD AVS 1109 SM3U98 dV 31 14 KINO SHINILSW4 31VWOHH MOTT3A d3lV T1d INIZ 804 SANTWA 2 3
63. 103 0 Turbocharger Number 1 Speed High 596 167 0 16 Electrical Charging System Voltage High 597 167 1 18 Electrical Charging System Voltage Low Moderately Severe 598 167 1 1 Electrical Charging System Voltage Low Most Severe 599 640 14 Auxiliary Commanded Dual Output Shutdown Special Instructions 649 1378 11 81 Change Lubricating Oil and Filter 687 103 18 Turbocharger Number 1 Speed Low 688 98 0 Engine Oil Level High 689 190 2 2 Engine Crankshaft Speed Position Erratic 691 1172 3 3 Turbocharger Number 1 Compressor Inlet Temperature Sensor High 692 1172 4 4 Turbocharger Number 1 Compressor Inlet Temperature Sensor Low 731 723 7 7 Engine Speed Sensor Position Camshaft and Crankshaft Misalignment 757 611 11 31 Engine Control Module Data Lost 534D 9 534D 10 amp 544D 9 21 Electrical System Fault Code SPN Code FMI Code Description 778 723 2 Engine Speed Sensor Camshaft Error Erratic 779 703 11 Auxiliary Equipment Sensor Input 3 OEM Switch 784 1590 2 Loss of Communication with Adaptive Cruise Control 951 166 2 Cylinder Power Imbalance Between Cylinders 957 27 2 EGR Valve Position Erratic 958 2795 2 VGT Position Sensor Erratic 1117 627 2 2 Power Lost Without Ignition Off Erratic 1139 651 7 Injector Solenoid Driver Cylinder 1 Not Responding 1141 652 rj Inje
64. 1907 Phone 34 93 772 4 700 Fax 46 0 850 659 534 Fax 34 93 771 1762
65. 3n0801 3n0u01 310301 5340 9 5340 10 amp 5440 BED BIS SMAYIS GVIH 1330 3 SLAN 3 vu9 531938 0961 EEE E PELES 51108 9 UE BELLE SM3U2S 49 1 KINO SU3N31SVJ JLYWOYHI MOTT3A G3LV Id 2 17 803 SINIYA 2 2 2 24 General Information and Specifications CLASS 8 8 METRIC BOLTS amp CLASS 8 METRIC NUTS 2 2 3 Metric Fastener Torque Chart TENSILE stress CLAMP pry or SIZE PITCH area LOAD Loctite TORQUE 263 LOCTITE 262 LOCTITE 242 OR 271 VALUES FOR ZINC PLATED YELLOW CHROMATE FASTENERS ONLY CLASS 10 9 METRIC BOLTS amp CLASS 10 METRIC NUTS TORQUE DRY OR LOCTITE LOCTITE LUB P 242 OR 263 211 1060 27 3 459 286 0 1540 1160 1240 1690 30 3 5 561 349 5 2100 1570 1680 2310 33 3 5 694 432 5 2600 2140 2280 2860 36 4 817 509 0 3660 2750 2930 4020 42 4 5 1120 698 0 5860 4400 4690 6440 Note These torque values do not apply to cadmium plated fasteners METRIC CLASS 8 8 METRIC CLASS 10 9 534D 9 534D 10 amp 544D 2 5 amp General Information and Specifications 2 3 SPECIFICATIONS 2 3 1 Travel Speeds 534D 9 534D 10 544D 2 Wheel Drive 18 mph 29 km h 19 mph 30 5 km h 1
66. 70 psi 4 8 bar 13 00 x 24 G 3 Rock Bias 12 Ply Foam Approx 542 Ib 246 kg 65 psi 4 5 bar 13 00 x 24 Solid b 534D 10 Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 70 psi 4 8 bar 14 00 x 24 G 2 Bias 12 ply Foam Approx 720 Ib 327 kg 62 psi 4 2 bar Pneumatic 75 psi 5 2 bar 14 00 x 24 1 2 8 2 Radial Foam Approx 720 Ib 327 kg 70 psi 4 8 bar Pneumatic 70 psi 4 8 bar 14 00 x 24 G 3 Rock Bias 12 ply Foam Approx 720 Ib 327 kg 62 psi 4 2 bar c 544D Size Tire Type Minimum Ply Fill Type Pressure Star Rating Water Calcium Chloride 70 psi 4 8 bar 14 00 x 24 G 2 Bias 12 ply Approx 623 Ib 283 kg per Foam Approx 720 Ib 327 kg 62 psi 4 2 bar Water Calcium Chloride 75 psi 5 2 bar 1400x24 L2 G2 Radial Approx 623 Ib 283 kg Foam Approx 720 Ib 327 kg 70 psi 4 8 bar Water Calcium Chloride 70 psi 4 8 bar 14 00 x 24 G 3 Rock Bias 12 ply Approx 623 Ib 283 kg Foam Approx 720 Ib 327 kg 62 psi 4 2 bar 2 8 534D 9 534D 10 amp 544D General Information and Specifications 2 4 FLUID AND LUBRICANT CAPACITIES Engine Crankcase Oil Capacity w Filter Change John Deere 15 5 quarts 14 6 liters Capacity w Filter Change Cummins 11 quarts 10 4 liters Filter Capacity 1 quart 0 9 liters Oil Type 15W 40 CD Fuel Tank Capacity 40 gallon
67. Cable Three 3 17 3 6 1 Electrical Wire Data 3 17 3 6 2 Electrical Cable Removal 3 17 3 6 3 Electrical Cable 3 17 3 7 Extend Retract Cylinder Removal and Installation Three Section 3 18 3 7 1 Extend Retract Cylinder 3 18 3 7 2 Extend Retract Cylinder Installation 3 19 3 8 Boom System Component Terminology 5440 3 20 3 9 Boom System Four 3 21 3 9 1 Boom System 3 21 534D 9 534D 10 amp 544D 3 1 3 2 Boom 3 10 Maintenance Four Section Complete Removal 3 21 3 10 1 Boom 3 21 3 10 2 Extend Retract Cylinder 3 21 3 10 3 Tilt Cylinder Removal 3 22 3 10 4 Second Third amp Fourth Boom Section 3 22 3 10 5 Third amp Fourth Boom Section 3 23 3 10 6 Fourth Boom Section 3 23 3 10 7 Hydraulic
68. Dispose of used oil at an approved recycling facility 9 Refer to Section 8 7 2 Rear Drive Motors for drive motor removal 10 Support the drive hub using a suitable jack hoist or overhead crane and sling 11 Remove the eight bolts holding the drive hub to the steering knuckle Note Mark the location of the two 12 point hub mounting bolts 12 Set the drive hub on a suitable support or table b Rear Drive Hub Installation 1 Before proceeding ensure that the machine will remain in place during drive hub installation Block the front and rear of both tires on the front axle 2 Using a suitable jack hoist or overhead crane and sling balance the hub and prevent it from tipping turning or falling while positioning it at the steering knuckle Keep the hub supported and balanced on the jack hoist or overhead crane and sling throughout the installation procedure 3 Position the hub at the steering knuckle and align the hub housing with the holes in the knuckle 4 Install the eight bolts and torque to 280 Ib ft 10 Ib ft 380 Nm 13 5 Nm 5 Refer to Section 8 7 2 Rear Drive Motors for drive motor installation 6 Refer to Section 5 6 2 Installing Wheel and Tire Assembly onto Machine 7 Align the fill mark 2 on the hub and fill to the proper level with Mobilfluid 4249 ISO 46 8 Connect the battery negative cable from the battery negative terminal 9 Close and secure th
69. Out of Fault Codes 9 18 9 15 3 Offboard 5 9 18 9 15 4 Engine Fault Codes 9 19 534D 9 534D 10 amp 544D 9 1 Electrical System 9 1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety operation and service information presented in this section it is necessary that the operator mechanic be familiar with the name and location of the electrical components of the machine The following illustration identifies the components that are referred to throughout this section 9 1 1 General Overview Cab and Engine Harness MOLDED DIODE CAB HARNESS IGNITION SWITCH 55555555 oo 52 XX 20 OE xX xX HORN BUTTON 92 5599 m m gt lt 5 EX FUSES WEATHER PACK CONNECTOR OIL PRESSURE 5 SENDER OIL PRESSURE SWITCH TN 555555556 55 25 SRR 5555 5555555 555 5555555 55558 MX0930 9 2 CHASSIS HARNESS i T T RECEPTACLE CONNECTOR PLUG CONNECTOR 534D 9 534D 10 amp 544D Electrical System
70. Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover and the hydraulic oil reservoir fuel tank cover Allow the system fluids to cool 4 Disconnect the battery negative cable from the battery negative terminal 5 With the engine OFF relieve any trapped pressure in the hydraulic system 6 Thoroughly clean the drive motor and surrounding area including all hoses and fittings before proceeding 534D 9 534D 10 amp 544D 7 Place a suitable container to catch hydraulic fluid drainage beneath the axle Note Cap all hoses and tubes as you remove them to prevent unnecessary fluid spillage 8 Label disconnect and cap all the hydraulic hoses and tubes attached to the drive motor Cap all fittings and openings to prevent dirt and debris from entering the hydraulic system 9 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area 10 Loosen and remove the four nuts holding the drive motor to the drive hub housing studs 11 Pull the drive motor back from the housing studs and place on a suitable support or table b Rear Drive Motor Disassembly Although ind
71. Thread the engine coolant temperature sender into the engine block snugly then connect the sender wire to the sender 2 Connect the battery negative cable at the negative battery terminal 3 Check for proper coolant level 9 13 Electrical System 4 Start the engine allow it to reach operating temperature and observe the operator s instrument cluster for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire improper running engine improper or low coolant obstructed or faulty radiator coolant pump loose fan belt defective instrument display etc Engine Oil Pressure Sender a Engine Oil Pressure Sender Removal 1 The engine oil pressure sender is located on the cab firewall 2 Remove the battery negative cable at the negative battery terminal 3 Remove the engine oil pressure sender wire from the sender 4 The sender is threaded into the mounting block Remove the sender b Engine Oil Pressure Sender Inspection and Replacement Inspect the sender and wiring terminal for continuity Replace a defective or faulty sender with a new part c Engine Oil Pressure Sender Installation and Testing 1 Thread the engine oil pressure sender into the mounting block snugly then connect the sender wire to the sender 2 Connect the battery negative cable at the negative battery terminal 3 Check for proper oil le
72. a firm level surface fully retract the boom lower the boom to a level position place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal Note When removing a boom section s use a lifting device with a sufficient lift capacity A complete three section boom assembly weighs approximately 5700 Ibs 5 Label disconnect and cap all hydraulic hoses attached at the tilt cylinder Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 6 Remove the tilt cylinder from the third boom section 7 Disconnect and cap the tilt hoses attached at the bulkhead bracket Disconnect and cap the auxiliary hoses attached at the bulkhead bracket if equipped 8 Remove the bulkhead brackets 1 9 Remove the guide plate and bar 2 from the top front of the push beam 534D 9 534D 10 amp 544D 13 14 20 21 22 MX1370 M 5 4 Release tension from the hoses on the hose take up bracket 3 Label disconnect and cap all hydraulic hoses attached at the take up bracket 4 Cap all fittings and openings to keep dirt and debris from entering the hydraulic
73. at a minimum of 100 F 38 C 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 Charge Pressure 6 6 Install a low pressure gauge 1 000 PSI 69 bar hose and adapter on the charge pump test port It is located near the front inside of the hydraulic reservoir Make sure the gauge can be observed in the operators cab and apply the park brake Start the engine and run at low idle The gauge should read approximately 380 psi 26 bar At high idle the gauge should read a maximum of 480 psi 33 bar and never less than 380 psi 26 bar Note Throughout the test operation charge pressure should not drop below 380 psi 26 bar and should move toward 480 psi 33 bar as RPM rises regardless of how many functions are being operated simultaneously MX1060 The charge pump relief 1 adjusts as necessary To adjust the charge pump relief loosen the locknut and turn the adjusting screw clockwise to increase pressure turn counter clockwise to decrease pressure Be sure to note the amount of 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 outlet port 2 on the pump install a
74. at the cable take up weldment area 10 Install the cable clamps to the bottom front of the first boom section 11 Plug the receptacle connector into the frame cable wiring harness TM Extra Orange Ground Yellow de EXTEND RETRACT CYLINDER REMOVAL AND INSTALLATION THREE SECTION 5 Mast Black RT Swing Blue MX0310 3 7 The extend retract cylinder hydraulically extends and retracts the second boom section A cable sheave arrangement is designed into the system to extend and retract the third boom section in proportion with the second boom section The 534D 9 and 534D 10 extend retract cylinder is installed in a push beam The base end of the cylinder mounts into a structure at the rear of the first boom section called a strong back The rod eye end of the cylinder mounts into the push beam The push beam is fastened to the rear of the second boom section As the cylinder rod extends or retracts the push beam moves the second boom section proportional Re pack kits for the extend retract cylinders are available from your Authorized JLG Distributor 3 18 3 7 1 Remove any attachment from the quick switch 10 Extend Retract Cylinder Removal assembly Refer to Section 3 16 1 Disconnecting from an Attachment Park the machine on a hard level surface retract the boom and line up the push beam extend retract cylinder rod eye access holes 1 in all three b
75. be legible re stamp if required Compare fork tips 11 when mounted on a carriage Maximum difference in height of fork tips is 3 percent of the length of the blade 13 gt 14 11 m 13 E id 12 4 MH6460 534D 9 534D 10 amp 544D 3 43 Boom b 3 18 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom Boom Troubleshooting Problem Cause Remedy 1 Boom will not extend or retract 1 Broken hydraulic hose s or tube s and or connections leaking 1 Locate break replace hose s or tube s tighten connections 2 Extend Retract hydraulic system 2 Refer to Section 8 4 Hydraulic not operating properly Circuits 3 Faulty extend retract cylinder 3 Repair cylinder Refer to Section 3 3 1 Boom Removal 4 Broken chains or anchors 4 Replace chains as needed 2 Boom shifts to right or left 1 Boom side wear pads 1 Shim wear pads to correct gap when extending improperly shimmed or worn Replace wear pads as needed Refer to Section 3 15 2 Boom Wear Pad Replacement 3 Excessive boom pivot pin 1 Insufficient lubrication 1 Lubricate at regular intervals noise and or wear Refer to Section 2 6 Lubrication Schedules 2 Worn bushing s 2 Replace bushing s and lubricate at regular inter
76. both washers should be equal Note When adjusting cables make sure the cables are not turning 15 16 3 8 Torque the cable jam nuts to 100 Ib ft 135 Nm Install the extend retract hoses 17 On the bottom side of the first boom section install the hose clamps for the tilt and auxiliary circuit hoses Note Do Not tighten clamps at this point 18 At the area between the hose take up bracket to the first hose clamp adjust the hoses to form a 4 in 102 mm partial loop between the bottom of the first boom section to the bottom of the hoses 10 19 Tighten all hose clamps Hi 0190 5340 9 5340 10 amp 5440 Boom 3 4 BOOM MAINTENANCE THREE SECTION INDIVIDUAL SECTION REMOVAL These general instructions help with the removal of individual boom sections with the boom still mounted on the machine Safe practices and common sense must be followed when removing boom sections Before beginning conduct a visual inspection of the machine and work area and review the task about to be undertaken Read understand and follow these instructions taking into consideration your particular situation For more detailed instructions see Section 3 3 Boom Maintenance Three Section Complete Removal 3 4 1 Push Beam and Third Boom Section Removal 1 Park the machine on
77. correct cable for your machine DO NOT use cable other than that supplied by JLG for replacement These cables are specifically designed for JLG Material Handlers Cables are pre stretched lengths cited below are after pre stretching Threaded stud Galvanized Plating Safe Lock Closed Socket Terminal used on Extend Cable Safe Lock or Spelter Socket used on Retract Cable Boom Cable length tolerance 0 5 in 1 0 in 12 7 mm 25 mm Use two wrenches when torqueing adjusting jam nuts Use the flats on the threaded cable ends to hold the cable straight eliminating twist 3 12 3 5 2 The cables are adjusted by tightening and or backing off the adjusting nuts at the threaded end of the cable Tightening the retract cable adjusting nuts pulls the third boom section in to the rear Tightening the extend cables adjusting nuts pulls the third boom section out to the front The opposite cable adjusting nut usually must be loosened whenever this procedure is performed Cable Adjustments The cables are properly adjusted whenever the following parameters are met 534D 9 534D 10 The extend retract cylinder rod eye pin 1 is centered in the side access hole of the push beam and or the dimension 2 from the front of the third boom section to the front of the second boom section is 17 5 in 444 5 mm MX0200 534D 9 534D 10 amp 544D Boom 3 5 3 Retract Cable Removal Th
78. from an Attachment 2 Park the machine on a hard level surface fully retract the boom level the boom assembly place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 534D 9 534D 10 amp 544D 4 Open the engine cover Allow the system fluids to cool 5 Remove the battery negative cable from the battery negative terminal 6 Unfasten the electrical socket and clamps at the front of the third boom section 7 Remove the socket from the electrical cable 8 Tie a rope to the cable end this will aid in reinstallation 9 Remove the hose guard from the right side roller at the rear of the boom 10 Pull the electric cable to the rear free of the boom 11 Remove the cable take up weldment 4 and support from the bottom front of the first boom section 12 Pull the electric cable free of the boom through the cable take up weldment 13 Remove the remaining cable clamps and unplug the receptacle H IL 4 MX0300 4 3 6 3 Electrical Cable Installation It is assumed that the electric cable has been removed and the relating parts left off the boom assembly The electric socket must n
79. front of the second boom section Cojo nid 0000 X d n _ SSE IEIEDCSIEDEIETDED OO GO GOGO MX0500 534D 9 534D 10 amp 544D 4 If adjustment is needed loosen the jam nuts on both extend chains 5 Tighten the extend chain adjusting nuts until the gap between the chain flat washer and the boom anchor is 1 4 in 6 Torque the jam nuts to 100 Ib ft 135 Nm DO NOT use Loctite on the nuts 7 Repeat the above steps to adjust the single extend chain 1 for the fourth boom section anchored at the top of the top front of the second boom section 3 12 4 1 Fully retract the boom and raise the boom to a horizontal position Place the transmission control lever in NEUTRAL engage the park brake switch Shut off machine Adjusting Retract Chains 2 Measure the distance between the second and third boom sections 2 to determine the adjustment required The correct dimension is 1 2 in 13 mm 5 2 3 If adjustment is needed loosen both extend chain adjusting nuts 3 at the first boom section anchor sufficient to allow realignment 4 Loosen the retract chain jam nut 4 located inside the bottom front of the first boom section 5 Tighten the retract chain adjusting the nut
80. incur wear due to articulation 3 12 2 Inspection Guidelines 1 Park the machine on a firm level surface level the boom place the transmission control lever in N NEUTRAL engage the park brake switch 534D 9 534D 10 amp 544D 6 Fully extend the boom until the extend chain is taut Shut the engine off The extend chains will be visible for inspection with the vehicle in this state While doing the chain inspection check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain Inspect the retract chains every 1000 hours of operation Inspect the chains for the following conditions Edge Wear Check the chain for wear on the link plate edges caused by running back and forth over the sheave The maximum reduction of material should not exceed 5 Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave If the measured plate height 1 is 5 less than the normal plate height 2 discard and replace the chain ES L M MZ1463 Elongation It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation Measuring the chain near its clevis terminals could give an inaccurate reading The ends of the chains near the clevis terminal will not have flexed as frequently if at all as the middle of the chains It is
81. lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Remove the battery negative cable from the battery negative terminal Remove the hose guards 3 from the rear of the first boom section Label disconnect and cap the extend retract cylinder hoses 4 Cap all fittings and openings to keep dirt and debris from entering the hydraulic system Remove the extend retract cylinder mounting pins 5 from the strong back cylinder bracket Remove the extend cable lock nuts washers and springs 6 from the strong back cylinder bracket Pull the cable free of the strong back cylinder bracket Fasten a rope to the cable end to aid in reinstallation Remove the strong back cylinder bracket mounting bolts and remove the strong back bracket 7 from the machine Label and tag each set of shims being removed from above and below the strong back Orin MX0260 Remove the push beam mounting bolts Pull the push beam extend cable sheave bracket free of the third boom section Remove all the extend cable sheave bracket compo
82. low pressure gauge 1 000 psi 69 bar 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 include the 2WD 4WD valve traction lock valve park brake solenoid valve and the joystick Isolate each of these valves to check for loss of charge pressure 534D 9 534D 10 amp 544D Hydrostatic Drive Pump Another test to determine the loss of charge pressure is to cap off lines to the drive motors 3 Reinstall hoses from previous test Install low pressure gauge 1 000 psi 69 bar 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 Cap the motor work ports also to prevent dirt from entering the motor with ORS 12 caps Start the machine and observe the gauge for charge pressure Engage drive forward and reverse against the park brake and observe the gauge for charge pressure simultaneously Record the findings If charge pressure recovers the motor is defective If the charge pressure does not recover repeat test for the right rear motor E MX1080 MX1090 534D 9 534D 10 amp 544D Isolate the front drive motor from the circuit if the rear motors are not defective To isolate it will require two blocking plates Install these
83. lower the cylinder free of the boom Lowering the extend retract cylinder will allow access to the chains 4 Remove tension from the chain by backing off the jam nut and adjusting nut 8 5 Remove the four bolts 9 from the chain adjustment block 6 Remove the chain from the clevis 10 at the block 7 Install a nylon tie wrap through the in the removed chain making a loop with the tie wrap and tie a rope to the loop 8 Move to the back of the boom and pull the chain to the rear to allow slack for removal 3 36 9 Remove the chain from the clevis and drop it free from the boom 10 Holding the rope at the front adjustment block carefully pull the chain out through the back of the boom until it s free 11 Untie the rope and leave it in place for reinstallation of the chain The following section explains the removal of the 3 4 in 19 mm retract chains from the fourth to second boom sections without removing the boom assembles 1 Remove the jam nut 11 from the chain clevis installed in the chain adjustment block 2 Back off the adjusting nut fully on the chain clevis DO NOT remove the nut from the clevis 9 6 9XG 9Xe 9Xo oXo oXo oXo
84. main pump does not change the pressure these valves may have to be adjusted Install a digital or high pressure gauge 10 000 psi 689 bar hose and adapter on the MA port on the pump To check these high pressure relief valves raise the setting on the POR valve on the drive pump Loosen the lock nut on the POR valve and turn the adjusting screw clockwise one turn to increase pressure With the gauge on the MA port set the park brake move the shift lever to the forward position and run the engine at full throttle Adjust the forward high pressure relief 10 10 6 10 to 6 800 psi 469 bar Move the gauge to the MB port of the drive pump to repeat the procedure with the shift lever in the reverse position Adjust the reverse high pressure relief 11 to 6 800 psi 469 bar Leave the gauge and adapter in the MB port Reset the POR valve back to the original setting With the park brake on put the shifter in reverse and run the engine at full throttle The pressure should be 6 300 psi 434 bar Adjust the POR valve as required The traction lock valve also has two high pressure anti cavitation relief valves Normally these require no adjustment However they can adversely affect drive System pressure if say they are set to low or an o ring is missing To check these valves raise the POR valve setting above 6 800 psi 469 bar Set the forward high pressure relief valve 12 on the pump to 6 800 psi 469 bar Then lower t
85. mounts Carefully lift the radiator oil cooler out of the engine compartment Note If more clearance is needed to remove the radiator the engine fan may be removed for easier access 534D 9 534D 10 amp 544D Engine 5 Radiator Oil Cooler Installation Install the isolator mounts to the bottom of the radiator Place the radiator oil cooler in the engine compartment at its original orientation Secure the radiator with the previously used hardware Note Be sure there is adequate clearance between the radiator and the engine fan 2 3 Oo Install the radiator fan shroud Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations Install both radiator hoses and with the clamp installed over the hose work the hose onto the radiator and tighten the clamp Install both charge air tubes to the charge air cooler Install the coolant overflow tank Cummins Only Open the radiator cap and fill the radiator completely with a 50 50 mixture of ethylene glycol and water Replace and tighten the radiator cap Refer to Section 2 4 Fluid and Lubricant Capacities for proper capacities Connect the battery negative cable to the battery negative terminal Run the engine to operating temperature Visually check for leaks with the engine running Check the coolant level in the overflow bottle and fill or drain as necessary 10
86. proper wear pad break in and will normally require minor further lubrication However after replacing any wear pad s or after prolonged periods of inoperation light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly Light lubrication of the boom wear surfaces is also recommended when the machine is stored to help prevent rusting Boom Wear Pad Lubrication 3 41 a Boom 3 16 QUICK SWITCH ASSEMBLY This machine is equipped with a quick switch assembly system for easy attachment changes 3 16 1 1 2 4 Disconnecting from an Attachment Park the machine on a hard level surface Place the transmission control lever in the N NEUTRAL position and engage the parking brake switch Level the boom and extend it out approximately 10 ft 3 05 m and tilt the carriage backward Exit the machine using both hand holds Note If removing a standard carriage with forks spread the forks apart on the carriage shaft This will help give the carriage better support to stand alone 5 If equipped label disconnect the auxiliary electric harness If equipped label disconnect and cap the auxiliary hydraulic hoses 7 If equipped release the swing attachment saddles 10 Remove the quick switch pin lock pin 1 and pull out the retaining pin 2 at the bottom of the quick switch assembly Return to the oper
87. reser eet Gad bee 8 16 8 9 Hydraulic Gylirniders masu rassa crani week 8 21 Section 9 El ctrical System x xc anoo een eol acad ado an Rea 9 1 9 1 Electrical Component 9 2 9 2 Specifications ear ed P e dere 9 3 ii 534D 9 534D 10 amp 544D Section Subject Page 9 3 Service Watrnifigs nuce rr rese EE eb Eae A EROR ER RU OA RR dE 9 3 9 4 Fuses andiRelays o esse ter Bub ety dw es 9 3 9 5 Electrical System Schematics 9 4 9 6 Engine Start Circuits 2 west 9 9 9 7 Charging Circuits 9 10 9 8 Windshield Wiper Motor If 9 11 9 9 Cab Heater and Fan If 9 12 9 10 Solenoids Sensors and 5 9 12 9 11 Cup P E 9 15 9 12 Dash Switch s Ba Bee dere EU Yd E md 9 15 9 13 Transmission Lever ga eoa Gem e ep ee oi TM EN 9 17 9 14 Traction Lock Pedal 5 m ER Cete eee enata 9 17 9 15 Troubleshooting 5 9 18 534D 9 534D 10 amp 544D iii Section Subject Page iv 534D 9 534D 1
88. secure the engine cover 534D 9 534D 10 amp 544D Hydrostatic Drive Pump 6 6 HYDROSTATIC DRIVE PERFORMANCE CHECKS These tests ensure that the Hydrostatic 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 the machine is being driven Color coded plastic caps seal the adjustments on components in the hydraulic system If a JLG Distributor makes an adjustment the component should be sealed with a blue cap The following tools are needed for proper adjustments 1 Tachometer 2 JLG pressure testing kit P N 77134197 3 Mechanic s hand tools Metric included 4 Blue plastic caps P N 80934459 small and P N 80934460 large Testing and Adjustment Precautions 1 Read and understand the Operating amp Safety Manual 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 section of the 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 or trapped hydraulic pressure 4 f you are working with a helper be sure he understands the procedure
89. shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover and the hydraulic oil reservoir fuel tank cover Allow the system fluids to cool 4 Disconnect the battery negative cable from the battery negative terminal 5 With the engine OFF relieve any trapped pressure in the hydraulic system 6 Thoroughly clean the main control valve and surrounding area including all hoses and fittings before proceeding 7 Place a suitable container to catch hydraulic fluid drainage beneath the frame 8 Label disconnect and cap all the hydraulic hoses tubes and wires at the main control valve 9 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area 10 Remove the three bolts washer and nuts 3 securing the main control valve to the frame b Main Control Valve Disassembly 1 To disassemble the individual sections of the main control valve remove the nuts from one end of the tie rods 4 Pull the tie rods out through the sections 2 Disassemble each section assembly as required Note Some sections include a pre adjusted relief valve that regulates pressure in a specific circuit 8 16 DO NOT adjust any of the relief valve assemblies Tampering with a relief valve will irrevocably alter pressure in the affected circuit requiring recalibration or a n
90. suitable sling lift and position the fourth boom section in front of the third boom section 4 Slowly insert the fourth boom section into the third boom section 5 Install the top front wear pads to the third boom section DO NOT torque the pad bolts 6 Install the wear pad support DO NOT torque the pad support bolts 7 Install the bottom front wear pads DO NOT torque the pad bolts 8 Install the front side wear pads 9 Torque the bolts on the front wear pads and supports 10 Shim the rear wear pads on the fourth boom section if needed and torque to 68 78 Ib ft 92 106 Nm 11 Install the wear pads on the bottom rear of the third boom section Leave bolts loose for shimming 12 Install the wear pads on the rear sides of the third boom section Leave bolts loose for shimming 13 Install the wear pads on the top rear of the third boom section Leave bolts loose for shimming oXo oXo oXo MX0410 o oXo oXo 5 oXo oXo oXo oXo oXo o 14 Install the grease fittings for the wear pad and chain roller assembly 15 Install the chain clevis 2 to the rear of the third boom section 16 Install the chain roller 3 at the bottom rear of the boom section 17 Lay out and lubricate the 3 4 in 19mm retract chain Make sure the chain has been inspected and meets the adjustment parameters in Section 3 12 Boom Extend and Retract Chains Four Section 3 25 Boo
91. the hydraulic tubing To prevent excessive cable movement the cable should be well tensioned at assembly b Hydraulic Sub Assembly Installation 1 Clean and lubricate the inside of the boom sections where the hydraulic sub assembly rides 2 Install the guide bracket 3 Collapse the hydraulic sub assembly fully 4 Fasten both hydraulic carriers together using nylon tie wraps or nylon straps 5 Using a sling lift the balanced hydraulic sub assembly and slowly insert it into the fourth boom section 6 Asthe first tie wrap nears the boom remove the tie wrap and continue inserting the sub assembly and removing each tie wrap until the sub assembly is fully inserted Note Be certain the hydraulic sub assembly locks in place on the pin bracket at the bottom of the fourth boom section 7 Re connect the hydraulic hoses and any optional circuits 8 Re install the guide bracket Note Use a long threaded rod and nuts 3 8x16 to aid in pulling the guide bracket into place if it protrudes too far from the back of the boom 9 Reinstall the hose take up compression spring Torque the jam nut to 100 Ib ft 135 Nm There should be 1 in 25 mm from the back of the jam nut to the end of the threads on the hose take up weldment 534D 9 534D 10 amp 544D Boom 10 3 10 8 1 11 12 Torque all fasteners and hydraulic fittings per Section 2 2 Torque Charts Fourth Boom Section Install
92. the battery negative cable at the battery negative terminal 4 Shut both coolant valves located on the engine 5 Plug and label both coolant hoses 6 Remove the air cleaner tubing from the side of the cab Cover the intake opening on the engine to prevent dirt or debris from entering the engine 7 Disconnect the wiring harness between the cab and frame Note Record the location and label all hoses to ensure correct installation 8 Working under the cab label disconnect all hydraulic hoses Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system 9 Disconnect the throttle electrical cable from under the cab Sling Routing 0 10 Install eyebolts and route a sling with a suitable lifting capacity 11 Remove the four cab to frame bolts flat washers and nuts 534D 9 534D 10 amp 544D Cab and Covers a 4 5 Remove the mirrors and all other cab components as needed if not previously removed Carefully begin to lift the cab Stop and check that all wiring hydraulic hoses and fasteners are disconnected or removed When all wiring hydraulic hoses and fasteners are disconnected or removed carefully and slowly lift the cab and remove it from the frame Readjust the position of the sling as needed
93. the joystick handle rearward activating the boom lift function The boom should RISE b Move the joystick handle forward activating the boom lower function The boom should LOWER c Move the joystick handle to the right activating the boom extend function The boom should EXTEND d Move the joystick handle to the left activating the boom retract function The boom should RETRACT e Depress the left side of the switch optional to activate the tilt up function The attachment should TILT UP Depress the right side of the switch optional to activate the tilt down function The attachment should TILT DOWN Close and secure engine cover Frame Sway and Attachment Tilt Levers C Q MX0810 42 Lever Removal Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake and turn the engine OFF Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Disconnect the battery negative cable at the battery negative terminal Disconnect the link 4 between the lever and the main control valve Remove the cotterpins and pull the shaft b out of the lever mounting brackets Note the location of the spacers between the levers Remove the lever from th
94. the second and third boom sections back into the first boom section This mechanical linkage formed by the cables and supporting hardware extends and retracts the second and third boom sections at the same rate The boom section lifts and lowers via action of the lift cylinder 3 3 BOOM MAINTENANCE THREE SECTION COMPLETE REMOVAL These instructions must be completed in sequence The second and third boom sections are removed from the first boom section The third boom section is removed from the second boom section Before beginning conduct a visual inspection of the machine and work area and review the task about to be undertaken Read understand and follow these instructions WARNING NEVER weld or drill the boom unless approved writing by JLG The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling 3 4 3 3 1 While the boom sections can be separated from each other on the machine JLG recommends against this procedure It is much safer more efficient and more cost effective to remove the complete boom assembly from the machine and place it on suitable supports for separation Work can then progress at a normal working height Boom Removal Note When removing a complete boom assembly use a hoist or crane with a minimum lift capacity of 6000 Ibs 1 Remove any attachment from the quick switch assembly Refer to Section 3 16 1 Disconne
95. the steering valve fittings Lubricate the o rings with clean hydraulic oil 5 Uncap and connect the previously labeled load sense hose to the steering valve 6 Uncap and connect the remaining previously labeled four hoses to the steering valve 7 Connect the battery negative cable at the battery negative terminal 8 Start the engine and check the operation of steering system Check for hydraulic fluid leaks Check the hydraulic fluid level in the tank and add fluid as required 9 Close and secure the engine cover C Steering Test Conduct a pressure check of the steering hydraulic circuits at the main control valve Refer to Section 8 3 1 Pressure Checks and Adjustments 4 3 2 Service Brake Pedal a Brake Valve Removal Refer to Section 8 8 2 Service Brake Valve for removal information b Brake Valve Installation Refer to Section 8 8 2 Service Brake Valve for installation information c Service Brake Pedal Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake and turn the engine OFF 4 4 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Disconnect the battery negative cable at the batt
96. top of the drive pump Remove and plug control hoses from 6 8 the top of the drive pump ports X1 and X2 Install two high pressure 10 000 psi 689 bar gauges hoses and adapters in the drive pump ports Ma and Mb on the side of the pump 9 Start the engine and operate at low idle Observe the gauges Pressure at the Ma port must be equal to the pressure at the Mb port If the pressure is not equal loosen the locknut on the stroking piston adjustment and turn the adjusting screw to equalize the pressures Tighten the locknut to secure the adjustment Repeat this procedure with low pressure 1 000 psi 69 bar 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 side of the drive pump 6 6 7 Loss of control pressure can affect machine speed Install a low pressure 1 000 psi 69 bar gauge hose 6 run tee and adapter between the hose and Ps port 7 on the side of the drive pump Apply the park brake and run the engine at high idle The gauge reading should be the same as in 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 10 length should be 12 1 4 311 mm from the centerline o
97. up weldment 6 Install the chain adjustment block 13 to the first boom section 7 Install the top front wear pads on the first boom section DO NOT torque the pad bolts 8 Install the front bottom wear pad support and wear pads on the first boom section DO NOT torque the pad bolts 9 Install the front side wear pads on the first boom section 10 Torque all front wear pads and supports to the correct values Note Shim ALL side wear pads as needed to maintain a minimum gap 1 16 in 1 6 mm the horizontal direction or a snug fit The number of shims can vary at each shim point 11 Adjust the wear pad shims on the top rear and sides of the second boom section 3 27 Boom 13 14 15 16 17 18 MX0480 Install the top front chain roller 14 to the second and third boom sections Install the hoses 15 to the bulkhead fittings on the hose take up weldment Install the cushion clamps around the hoses on the first boom section Install the extend retract cylinder and support to the first and second boom sections Attach the extend retract cylinder hose assembly Connect the top front chain clevises to the chains then connect the chains to the first and second boom sections Adjust the 1 in 25 mm retract chain at the bottom front of the first boom section 16 to 2 7 8 in 73 mm for the initial set up
98. 0 amp 544D Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1 1 Introduction i i l1 1 2 1 2 Disclaimer 2 2 2021s edge rx ARE eed 1 2 1 3 Operator amp Safety Manual 1 2 1 4 Do Not Operate 1 2 1 5 Safety 1 3 1 5 1 Safety Alert System and Signal 1 3 1 6 Safety Instructions 1 3 1 6 1 Personal Hazards cse eR 1 3 1 6 2 Equipment Hazards sso eee Ree D RR Res geek ee ene 1 3 1 6 3 General 5 1 4 1 6 4 Operational 1 4 1 7 Safety Decals 5 eee 1 4 534D 9 534D 10 amp 544D 1 1 Safety Practices A 11 INTRODUCTION This service manual provides general directions for accomplishing service and repair procedures Following the procedures in this manual will help assure safety and equipment reliability Read understand and follow the information in this manual and obey all locally approved safety practices procedures rules codes regulations and laws These instructions cannot cover all details or variations in the equ
99. 0 6 16S 00 0 9 90 vtt 69S 00958 Lov 698 862 107 00862 0480 9L 967 00756 69S 801 08 516 00106 98 526 42 698 0081 0880 0L 926 862 00952 698 42 vic SZE 00082 892 102 941 oez 00591 09520 420 8L gs ELE 592 00922 SZE vc 062 862 0902 voc 681 61 02 0025 09220 LL Lye voc 0002 892 602 941 062 05281 8 SYL 221 591 05621 06020 8L m 02 012 00281 voc 881 61 02 00791 591 E 80L 0091 0281 0 211 991 06691 L 221 591 0017 91 801 88 221 00 01 609 0 000 02 gl 691 61 06191 691 OEL 801 61 09 21 SLL 26 GL 201 0506 60 L LLL 201 0 81 221 S6 18 801 00 01 18 89 GL 099 UO 02 v0L 96 05901 801 58 GL 96 0996 GL 19 Ly 89 0089 901 0 vL GL 89 08 8 GL 19 Ly 89 0062 vt Ly 0096 8 800 osseo vc ge 89 19 05 89 tS Ly L9 0002 Ly gE LE 2 0265 S 0 0 9L 48 0086 Ly re 12 vt 0226 8z 6L 92 0028 08900 gig vc gu 95 0726 Ly 0 yt 02 92 22 81 z 0159 2500 gL ul N wi N a1 NI 05 NI 02 6L 0798 796070 92 0818 91500 0080 02 n 000200 ze 08710077 0060 vi 0L 7100 98 00100 990 25 2 SLOLO O 0 606000 08810 25 3 1990070 8b 709000 010 0 N NI OS NI HOLWd 292 2 292 292 v3uv HONI 734 901 134901 1 01 272 3111907 ani 3111901 qvo 272 3111501 ani 3111901 avoi 93918 vid 43 371 LNOHLIM 3111901 AUd 31015901 AH div 19 FTISNAL SGHL
100. 0080 2 10 534D 9 534D 10 amp 544D General Information and Specifications 2 5 2 250 500 1000 amp 1500 Hour y Change Engine Check Front Check Front amp Oil and Axle Rear Wheel Filter Oil Level End Oil Levels Check Boom Check Boom Check Boom Cable Tension Chain Tension Bearing 5340 9 amp 5340 10 5440 Pads Change Fuel Check Wheel Filter Lug Nut Torque Im Change Front Change Front amp Change Axle Oil Rear Wheel Hydraulic Tank End Oil Breather Engine Coolant Hydraulic Fluid amp Filters 534D 9 534D 10 amp 544D Air Filter Vacuator Rear Axle Stabilization MX0090 2 11 amp General Information and Specifications 2 6 LUBRICATION SCHEDULES 2 6 1 534D 9 534D 10 50 Hour P a EVERY OX03412 2 12 534D 9 534D 10 amp 544D General Information and Specifications b 250 Hour Pd MYSTIK TETRIMOLY NLGI 2 GC LB OX03512
101. 1 3 10 Boom Maintenance Four Section Complete 3 21 3 11 Boom Maintenance Four Section Individual Section Removal 3 28 3 12 Boom Extend and Retract Chains Four Section 3 32 3 13 Boom Section Separation Adjustment Four Section 3 38 3 14 Hydraulic Sub Assembly Removal Installation Four 3 38 3 15 Boom Wear Pads eec Ee Ex Rede 3 41 3 16 Quick Switch Assembly 3 42 3 17 uo e te et A 3 43 3 18 Troubleshooting 3 44 Section 4 and 2 2 4 4 RR RR on 4 1 4 1 Operator s Cab and Covers Component Terminology 4 2 4 2 Operators oed ertet recta tear e 4 3 4 3 Cab 4 3 4 4 Cab Hetnioval FRU Rp Ed atte et by 4 8 4 5 Cab Installation 2 4 9 534D 9 534D 10 amp 544D i Section Subject Page Section 5 Axles Wheels and Tires 5 1 5 1 Axles Wheel and Tire Component Terminology 5 2 5 2 General
102. 1280 b Disassembly The hydraulic oil reservoir is a one piece unit and cannot be disassembled The hydraulic oil level sight glass and hydraulic oil filler cap can be removed and reused on the new replacement reservoir Dispose of the old reservoir according to local regulations concerning hazardous materials disposal 534D 9 534D 10 amp 544D Hydraulic System n c Cleaning and Drying If contaminated hydraulic oil or foreign material is in the tank the tank can usually be cleaned Note lf a leak is suspected in the hydraulic oil reservoir contact JLG Service Department 1 Have a dry chemical Class B fire extinguisher near the work area 2 Remove the hydraulic oil reservoir drain plug and safely drain any hydraulic oil into a suitable container Dispose of hydraulic oil properly 3 Clean the hydraulic oil reservoir with a high pressure washer or flush the tank with hot water for five minutes and drain the water Dispose of contaminated water properly d Inspection Note lf a leak is suspected in the fuel or hydraulic oil tank contact JLG Service Department 1 Inspect the hydraulic oil reservoir thoroughly for any cracks slices leaks or other damage 2 With the hydraulic oil reservoir removed from the machine plug all openings except one elbow fitting Install the elbow fitting and apply approximately 1 1 5 psi 7 10 kPa of air pressure through the elbow Check the reservoir fo
103. 200 0 241 bar 13 8 0 Tilt Comp Relief Low 3000 psi 100 0 207 bar 6 9 0 Sway Relief Low 3000 psi 100 0 207 bar 6 9 0 Auxiliary Relief Low 2000 psi 100 100 138 bar 6 9 6 9 Crowd Extend Relief Approx 1 2 Throttle 2700 psi 100 100 186 bar 6 9 6 9 Charge Pressure Low High 380 480 psi 26 33 bar Hydrostatic Drive Relief High 6300 psi 200 100 434 bar 13 8 6 9 Brake Supply Low 580 psi 50 50 40 bar 3 4 3 4 Maximum Service Brake Pressure Low 638 psi 50 50 44 bar 3 4 3 4 Steering Pressure against steering stops Low 3000 psi 100 100 207 bar 6 9 6 9 Engine RPM Low High 800 RPM 2200 RPM Note All readings and adjustments are to be done with warm oil minimum of 100 F 534D 9 534D 10 amp 544D 8 5 Hydraulic System n 8 4 HYDRAULIC CIRCUITS This section covers the hydraulic circuits and includes listings for all hydraulic function pressures where and how to check those pressures and a hydraulic schematic Electrical and hydraulic functions are often related Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit Always check the following before beginning to troubleshoot a circuit that is not functioning correctly 1 Check the hydraulic oil level in the reservoir Oil level should be to the middle of the sight glass with all cylinders retracted 2 Check hoses tubes fittings
104. 534D 9 534D 10 amp 544D General Information and Specifications ASTM Fastener Torque Chart Metric 8 dQvuo avs S 3Q0vuo9 AVS 519 9159 pajejd wniwped Ajdde jou op ajon 1987 000891 2066 9988 909 1 8 002271 8118 9 92 vocc 6862 00228 o1 44 segt 2217 005071 0678 0025 008921 59 0 6 52 6 61 0 92 0008 0905 9 0 9 8056 OOSLEL 1907 G 62 99 2 989 001811 6185 2902 80 1 8 00 0007 05 2995 5916 009911 6566 9850 1226 000701 8902 56 1 L67 6 61 0019 09911 9 1082 692 00 01 862 812 02 2 72 00996 6921 9191 1891 00968 0401 44 TM 0192 6 60 00696 0 61 vil 8972 002 8 6691 8961 8191 ooses 06960 4 1902 81 00958 9991 pork 2561 000 601 1801 568 6LL 00920 09880 v 1981 1891 0059 8681 9651 206 00 99 896 618 6801 0027 069 0 4 ISEL LYZ 00 99 L6pL 6 01 004 9681 00 66 166 898 61 66 0022 08990 i 9821 00909 evel 166 226 0221 00919 916 98 159 898 oogse 09090 8 66 198 00606 686 vol 8 9 G68 00897 GOL 9 6 6 7 169 00 45 06050 222 vL v18 6 0029 568 859 29 618 0091 tv9 626 vtt 689 00762 0697
105. 9 mph 30 5 km h 4 Wheel Drive 9 mph 14 4 km h 9 5 mph 15 3 km h 9 5 mph 15 3 km h 2 3 2 Hydraulic Cylinder Performance Note Machine with no attachment or load engine at full throttle hydraulic oil above 130 F 54 C minimum engine at operating temperature FUNCTION APPROXIMATE TIMES seconds 534D 9 534D 10 544D Boom Extend max boom angle 15 3 14 5 18 3 Boom Retract max boom angle 12 8 13 4 17 6 Boom Lift 11 4 10 8 11 9 Boom Lower 8 6 8 1 9 2 2 3 3 Electrical System Battery Type Rating 12 BCI Negative Ground Maintenance Free Quantity John Deere 1 Cummins 2 Reserve Capacity 1 000 Cold Cranking Amps Q 0 F 18 C Group Series Group 31 Alternator John Deere 12V 65 Amps Alternator Cummins 12V 95 Amps 2 6 534D 9 534D 10 amp 544D General Information and Specifications amp 2 3 4 Engine Performance Specifications a John Deere Primary and Safety Elements Primary and Safety Elements Description 534D 9 534D 10 544D Engine Make Model John Deere John Deere John Deere PE4045TF275 PE4045TF275 PE4045HF275 Displacement 276 in 4 5 liters 276 in 4 5 liters 276 in 4 5 liters Low Idle 800 rpm 800 rpm 800 rpm High Idle 2400 rpm 2500 rpm 2200 rpm Horsepower 110 HP 82 kW 115 HP 86 kW 125 HP 93 kW 2400 rpm 2500 rpm 2200 rpm Peak Torque 289 I
106. Boom Section m Bax Removal i E 1 Set the complete boom on level ground and by repositioning the slings turn boom over on to the top Ai side Set the complete boom on suitable stands to begin tear down 4 ATTE E Note With the complete boom setting upside down the removal and replacing of each boom section tilt cylinder 5 hoses extend and retract cables and push beam are made much easier 2 Remove all wear pads shims and backing plates from the front inside of the first boom section Label and tag each set of wear pads being removed t J 3 Loosen the hose take up brackets 1 on the bottom front of the first boom section Disconnect both tilt hoses and both auxiliary hoses 2 inside the boom below the take up brackets Plug the hose ends and cap the tube ends to prevent dirt and debris from entering the hydraulic system 3 Note If the machine is equipped with auxiliary hydraulics separate the plug at the hose take up area 4 Loosen the lock nut and jam nut 3 on the retract cable at the front of the first boom section Loosen and remove the bolts holding the retract cable adjusting block 534D 9 534D 10 amp 544D 3 3 3 1 MX0130 Remove the lock nuts and jam nuts 4 from the extend cables at the rear o
107. C CABLE THREE SECTION The electric cable is fed through the right side of the boom assembly in a fashion similar to the auxiliary hydraulic hoses The electric cable lies adjacent to the hydraulic hoses and moves in unison with them whenever the boom sections are extended and retracted The receptacle and socket connector are equipped with a strain relief fitting to prevent the 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 the third boom section 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 at the area adjacent to the hydraulic hose take up weldment The receptacle and socket are equipped with six contact points One contact point is usually extra and is plugged using JLG part number 83481301 Refer to the following chart for identification in the socket as viewed from the wire insertion end 3 6 1 Electrical Wire Data Socket Body Wire Color Wire Function Letter TM Orange Panel A Blue Open Extra 5 Black Mast RT Green Swing LT Red Side Shift C Green Yellow Ground 3 6 2 Electrical Cable Removal 1 Remove any attachment from the quick switch assembly Refer to Section 3 16 1 Disconnecting
108. Change 1849 3241 10 Exhaust Gas Temperature 1 Abnormal Rate of Change 1851 3249 10 Exhaust Gas Temperature 2 Abnormal Rate of Change 1892 84 1 18 Wheel Based Vehicle Speed Low 1911 157 0 Injector Metering Rail Number 1 Pressure High 2183 1072 4 Engine Brake Actuator Driver 1 Circuit Low 2185 3 3 Sensor Supply Voltage 4 Circuit High 2186 4 4 Sensor Supply Voltage 4 Circuit Low 2215 94 1 Fuel Pump Delivery Pressure Low 2216 94 0 Fuel Pump Delivery Pressure High 2217 630 11 31 Engine Control Module Calibration Program Memory RAM Corruption 2249 157 1 Injector Metering Rail 1 Pressure Low 2265 1075 3 Electric Lift Pump for Engine Fuel Supply Circuit High 2266 1075 4 Electric Lift Pump for Engine Fuel Supply Circuit Low 2271 27 3 3 Exhaust Gas Recirculation EGR Valve Position Sensor Circuit High 2272 027 4 4 Exhaust Gas Recirculation EGR Valve Position Circuit Low 2273 411 3 3 EGR Valve Differential Pressure Sensor Circuit Shorted High 2274 411 4 4 EGR VAlve Differential Pressure Sensor Circuit Shorted Low 2292 16 Fuel Inlet Meter Device High 2293 18 Fuel Inlet Meter Device Flow Demand Low 2311 633 11 31 Fueling Actuator Number 1 Circuit Error 2321 190 2 Engine Crankshaft Speed Position Erratic 2322 723 2 Backup Engine Speed Position Sensor Number 2 Erratic 2345 103 10 10 Turbocharger Speed Invalid Rate of Change Detected 2346 2789 1 15 Exhaust Gas Temperature High 2347 611 0 15 Turbocharger Compressor Outl
109. Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Disconnect the battery negative cable at the battery negative terminal 4 Remove the four bolts holding the cover 2 below the joystick and remove the cover 5 Lift the joysticks rubber sleeve remove the bolts securing the boom joystick to the cab 3 6 Lift the boom joystick from its mounting position 7 Label disconnect and cap all hydraulic hoses attached to the boom joystick Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system Note If equipped with the optional on joystick tilt feature disconnect the electrical connector along with the hydraulic hoses 8 Remove the boom joystick assembly MX0800 b Boom Joystick Assembly Installation 1 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations Note If equipped with the optional on joystick tilt feature connect the electrical connector to its proper location at this time 4 5 a Cab and Covers 5 4 3 5 a 1 4 6 Install the bolts securing the boom joystick to the cab Connect the battery negative cable to the battery negative terminal Test the boom extend retract and boom lift lower joystick function a Move
110. ION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury 534D 9 534D 10 amp 544D 1 66 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on the telehandler Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs For all safety messages carefully read understand and follow the instructions before proceeding 1 6 1 Personal Hazards PERSONAL SAFETY GEAR Wear all the protective clothing and personal safety gear necessary to perform the job safely This might include heavy gloves safety glasses or goggles filter mask or respirator safety shoes or a hard hat LIFTING NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist 1 6 2 Equipment Hazards LIFTING OF EQUIPMENT Before using any lifting equipment chains slings brackets hooks etc verify that itis of the proper capacity in good working order and is properly attached NEVER stand or otherwise become positioned under a suspended load or under raised equipment The load or equipment could fall or tip DO NOT use a hoist jack or jack stands only to support equipment Always support equipment with the proper capacity blocks or stands prope
111. Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Disconnect the battery negative cable at the battery negative terminal 4 Remove belly pan from under cab and unplug throttle electrical connection 1 under cab floor 5 Remove the four bolts holding the throttle pedal assembly to the cab floor 6 Remove the throttle pedal assembly from the cab b Throttle Pedal Installation MX0790 1 Position and secure the throttle pedal in its mounting location on the cab floor 2 Reconnect the throttle cable connection 3 Replace the belly pan under the cab 4 Connect the battery negative cable to the battery negative terminal 5 Check the engine rpm at high idle If the rpm is not 2400 50 rpm 534D 9 2500 50 rpm 534D 10 or 2200 50 rpm 544D contact your JLG dealer Note During the full throttle check DO NOT operate any hydraulic function DO NOT steer or apply any pressure to the steering wheel Keep the transmission in N NEUTRAL 6 Close and secure the engine cover 534D 9 534D 10 amp 544D 4 3 4 Boom Joystick Assembly a Boom Joystick Assembly Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and turn the engine OFF 2 Place a
112. Tighten the lower bolt and upper capscrew securely Place a 1 2 square drive ratchet into the square hole on the serpentine belt tensioner bracket Apply pressure against the tensioner bracket and route the serpentine belt onto the alternator and engine pulleys Release and check the tensioner pulley to verify that it is pivoting freely in order to provide the proper tension on the belt Check for proper belt alignment Refer to the appropriate Operation amp Safety Manual Connect the wire leads Connect the negative battery cable to the negative battery terminal Close and secure engine cover 534D 9 534D 10 amp 544D Electrical System 9 8 WINDSHIELD WIPER MOTOR IF EQUIPPED a Removal Note It may be necessary to remove several hydraulic hoses from under the dash in order to remove and install the wiper motor housing Refer to Section 4 3 1 Steering Column and Orbitrol Valve 1 Remove the battery negative cable at the negative battery terminal 2 Disconnect the cab harness connector 1 from the wiper motor MX1210 3 Remove the wiper assembly 2 4 Loosen and remove the two bolts 3 holding the wiper motor to the mounting bracket Note Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing 5 Remove the motor from the inside of the cab b Disassembly DO NOT disassemble the motor The motor is not
113. VGT Actuator Driver Circuit High 2386 2975 6 6 Turbocharger Actuator Motor Circuit High 2387 2975 7 7 Turbocharger Actuator Motor Not Responding 2388 2795 13 13 Variable Geometry Turbocharger Actuator Position Failed Calibration 2554 1209 2 2 Exhaust Pressure Sensor Circuit Erratic 2555 729 4 Intake Air Heater 1 Circuit Low 2557 697 3 Auxiliary PWM Driver 1 High 2558 697 4 Auxiliary PWM Driver 1 Low 2771 3234 9 Aftertreatment Outlet NOx Sensor Abnormal Update Rate 2772 3226 0 15 Aftertreatment Outlet NOx Sensor High Least Severe 2773 3226 0 Aftertreatment Outlet NOx Sensor High Most Severe 2961 412 0 15 Exhaust Gas Recirculation EGR Temperature High Least Severe 2962 412 0 16 Exhaust Gas Recirculation EGR Temperature High More Severe 2963 110 0 15 Engine Coolant Temperature High Least Severe 2964 105 0 15 Intake Manifold Temperature High Least Severe 2973 102 2 2 Intake Manifold Pressure Sensor Circuit Erratic 2976 3361 2 Dosing Control Unit Temperature Erratic 9121 2791 0 15 Exhaust Gas Recirculation EGR Valve Actuator Over Temperature 9122 641 0 15 Variable Geometry Turbocharger Actuator Over Temperature 9 24 534D 9 534D 10 amp 544D An Oshkosh Corporation Company JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 1 717 485 5161 Customer Support Toll Free 1 877 554 5438 Fax 1 717 485 6417 JLG Worldwide Locations JLG Industries Australia JLG La
114. Wheels and Tires 5 1 AXLES WHEEL AND TIRE COMPONENT TERMINOLOGY To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the major assemblies of the axles wheels and tires The following illustration identifies the components that are referred to throughout this section quum FRONT DRIVE AXLE 5 2 REAR STEERING AXLE DRIVE HUBS MX1180 534D 9 534D 10 amp 544D Axles Wheels and Tires 5 2 GENERAL INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual Before performing any inspection maintenance or service operation thoroughly clean the unit The axles should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts Carefully inspect the integrity of all moving parts bearings yokes gears shafts etc and fasteners nuts bolts washers etc as they are subject to major stress and wear Always replace elastic locknuts and any damaged worn cracked seized or otherwise improper parts
115. able on the machine Refer to the Operator amp Safety Manual supplied with machine for information 534D 9 534D 10 amp 544D Section 2 General Information and Specifications PARAGRAPH TITLE 2 1 Replacement Parts and Warranty 2 2 Torque Charts dite a iene 2 2 1 ASTM Fastener Torque Chart English 2 2 2 ASTM Fastener Torque Chart Metric 2 2 3 Metric Fastener Torque 2 3 Specifications ie cece ee ees re 2 3 1 Travel 2 3 2 Hydraulic Cylinder Performance 2 3 3 Electrical System 2 3 4 Engine Performance Specifications 2 3 5 II pas Metin ad Pa ne a 2 4 Fluid and Lubricant Capacities 2 5 Service and Maintenance Schedules 2 5 1 10 1st 50 amp 50 HOUF iS aed Sind es s ER Bk dre we ee 2 5 2 250 500 1000 amp 1500 2 6 Lubrication Schedules 2 6 1 5340 9 534 10 2 6 2 Lp CD 534D 9 534D 10 amp 544D 2 1 amp Genera
116. ake and shut the engine OFF 6 3 Hydrostatic Drive Pump 10 11 12 13 14 15 16 6 4 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Remove rear cover to allow easier access to the drive pump Remove belly pan from under engine Drain the hydraulic oil reservoir Refer to Section 8 5 Hydraulic Reservoir Remove the battery negative cable from the battery negative terminal Thoroughly clean the drive pump and surrounding area including all hoses and fittings before proceeding Place a suitable receptacle under the drive pump MX0870 Label and disconnect both shift solenoid wiring harness connectors Label disconnect and cap the all hydraulic hoses and tubes attached to the drive pump Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system Wipe up any spilled hydraulic oil Loosen and remove both bolts holding the implement pump 1 to the drive pump 2 Pull the implement pump away from the drive pump Connect a lifting strap or chain to the top of the drive pump and to a suitable hoist or overhead crane Operate the hoist or crane to remove slack from the chain but DO NOT raise the drive pump at this time Loosen and remove the two bolts holding the drive pump to the engi
117. al number plate includes the cab model number the cab serial number and other data Write this information down in a convenient location to use in cab 0120 correspondence 6 Remove the steering wheel 2 disconnect and 4 3 CAB COMPONENTS remove the travel select lever 3 disconnect the instrument panel harness connector 4 4 3 1 Steering Column and Orbitrol Valve 7 Remove the steering assembly through the dash panel opening a Orbitrol Valve Removal 8 Supportthe steering valve and removOe the four hex 1 Park the machine on a firm level surface level the head capscrews and four lockwashers machine fully retract the boom lower the boom Note DO NOT disassemble the orbitrol valve The place the travel select lever in the NEUTRAL position engage the parking brake and turn the engine OFF orbitrol valve is not serviceable and must be replaced in its entirety if defective 534D 9 534D 10 amp 544D 4 3 ax Cab and Covers b Orbitrol Valve Installation 1 Secure the steering valve to the steering column with four hex flange capscrews and four lockwashers 2 Install the steering column through the dash panel opening Position steering valve to its original orientation in the cab 3 Install the travel select lever connect the instrument panel harness connector install the steering wheel assembly Torque the steering wheel nut to 29 34 Ib ft 39 46 Nm 4 Install new o rings into
118. and other hydraulic components for leaks bends kinks interference etc 3 Check for air in the hydraulic system Erratic machine performance and or spongy cylinder operation are signs of air in the hydraulic system If air in the hydraulic system is suspected you will hear air leakage when hydraulic fittings are loosened and see air bubbles in the hydraulic fluid Loose fittings faulty o rings or seals trapped oil leaks system opened for service etc can cause air in the system Determine what is causing air to enter the system and correct it Bleed air from the system 8 4 1 Hydraulic Pressures a Charge Pressure To ensure proper park brake operation charge pressure needs to be at proper specification 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 A digital pressure gauge is recommended 1 Start the machine and warm the hydraulic system to operating temperature 2 Shut off the machine and install a digital or a 10 000 psi 689 bar gauge to the test port located at the right side in front of the return filter Make sure the gauge be observed from the operator s cab 3 Start the machine leave the park brake applied 4 With the engine running at low idle the gauge should read a minimum of 380 psi 26 bar 5 With the engine running at high idle the ga
119. any repairs thoroughly clean the exterior of the drive pump to help prevent dirt from entering while performing maintenance checks and procedures Drive Pump Maintenance Your local JLG distributor can provide a suggested maintenance schedule with references to pertinent procedures and instructions in this manual To help prevent drive pump problems before they occur follow the maintenance schedule Note Lubrication and Maintenance chart decals are located inside the engine compartment access door These decals contain a general maintenance schedule that should be followed to maintain the machine in good operating condition Refer to Section 2 5 Service and Maintenance Schedules The same schedule information is presented in the appropriate Operation amp Safety Manual with a detailed account of how to perform the procedures 534D 9 534D 10 amp 544D 6 4 2 Complete hydraulic maintenance information is located in the appropriate Operation amp Safety Manual Drive Pump Maintenance Schedule Periodically depending on operating conditions and other factors back flush the hydraulic oil cooler which is located in front the radiator ALWAYS back flush the hydraulic oil cooler after removing the drive pump for repair or replacement The hydraulic oil cooler outlet hose routed to the lower oil cooler fitting is located on the top of the drive pump The drive pump oil cooler inlet hose routed to the upper oil cooler f
120. at the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal Note When removing a boom section s use a lifting device with a sufficient lift capacity A complete four section boom assembly weighs approximately 8250 Ibs 5 Release tension from the hoses on the hose take up bracket 1 6 Label disconnect and cap all hydraulic hoses attached at each end of the hose carrier assembly Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 7 Remove the hose guide 2 at the rear of the second boom section 8 If equipped label loosen and separate all electrical cables on each end of the hose carrier assembly 9 Loosen and remove the guide bracket from the front of the hose carrier assembly 10 Loosen and remove the two bolts 3 holding the hose carrier at the front of the fourth boom section 534D 9 534D 10 amp 544D 11 Loosen and remove the four bolts 4 holding the hose carrier to the rear of the third boom section GOOD OO OOOO OOOO 4 2 2 e Gb UEM 6 CLLR 12 Slowly pull the hose carrier assembly out of the front of the fourth boom section 13 When the hose car
121. ator s compartment fasten the seat belt and lower the attachment to the ground in a level position Tilt the attachment forward This will rotate the quick switch link back away from the attachment Lower and then retract the boom until the attachment pivot pins have disconnected from the attachment 0550 3 42 3 16 2 1 7 3 16 3 1 3 16 4 1 Connecting to an Attachment Retract quick switch to provide clearance Check to be sure lock pin 1 is secured in out position with retainer pin Align attachment pivot pin with recess in attachment 3 Raise boom slightly to engage attachment pivot pin in recess Engage the quick switch 4 Shut off engine Exit cab and remove the lock pin 2 and the slide retainer pin 1 in fully Secure the retainer pin in locked position using lock pin If equipped swing attachment saddles down and pin in place If equipped uncap and reconnect auxiliary hydraulic hoses If equipped connect auxiliary electric harness Quick Switch Removal Remove the lock bolt holding the tilt cylinder rod end pin to the quick switch assembly Remove the Tilt Cylinder pin 5 Support the quick switch assembly Remove the capscrew and locknut securing the head pin 6 to the boom head Inspect the above pins for nicks or surface corrosion Use fine emery cloth to fix minor nicks or corrosion If damaged or if it cannot be repaired the pin m
122. attery negative cable at the negative battery terminal 2 Loosen and remove the two allenhead screws holding the lever together Disconnect the wiring harness connector from the lever base and remove b Disassembly DO NOT disassemble the shifter or wiper lever Replace a defective lever with a new part c Inspection and Replacement Inspect the switch terminals for continuity and shorting Replace a defective or faulty lever with a new lever 534D 9 534D 10 amp 544D d Lever Installation 1 Connect the wire harness connector to the lever base 2 Install both allenhead screws into the transmission shift lever base and tighten the two screws into the wiper lever base 3 Connectthe battery negative cable at the negative battery terminal 4 Start the machine and check the functions of the replaced lever e Neutral Lock Lever The red lever on the side of the transmission shift lever base is the neutral lock With the travel lever in neutral switch the neutral lock lever to the N position This will lock the travel select lever Switch the neutral lock lever to D to unlock the travel select lever 9 14 Traction Lock Pedal 9 14 1 Traction Lock Pedal Replacement a Pedal Removal 1 Remove the battery negative cable at the negative battery terminal 2 Disconnect the wiring harness connector from the pedal base 3 Remove the two bolts holding the pedal and remove b Disa
123. ause seal failure 5 Using a pin spanner wrench unscrew the head gland from the tube A considerable amount of force will be needed to remove the head gland Carefully slide the head gland down along the rod toward the rod eye away from the cylinder barrel When sliding the rod and piston assembly out of the barrel prevent the threaded end of the barrel from damaging the piston Keep the rod centered within the barrel to help prevent binding 6 Carefully pull the rod assembly along with the head gland out of the cylinder barrel 7 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod to prevent any damage to the rod 8 Remove the set screw from the piston head Note It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed Some cylinder parts are sealed with a special organic sealant and locking compound Before attempting to disassemble these parts remove any accessible seals from the area of the bonded parts Wipe off any hydraulic oil then heat the part s uniformly to break the bond A temperature of 300 400 F 149 204 C will destroy the bond Avoid overheating or the parts may become distorted or damaged Apply sufficient torque for removal while the parts are still hot The sealant often leaves a white powdery residue on threads and other parts which must be removed by brush
124. axle 7 Replace housing s as needed housing s damaged 4 Oil leaking from wheel end 1 Oil level plugs loose and or 1 Replace o rings as needed and housing planet carrier o rings damaged or missing tighten plugs to 96 Ib ft 130 Nm 2 O ring between hub and 2 Replace o ring housing planet carrier damaged or missing 3 Shaft seal damaged or missing 3 Replace seal and or fork joint and or worn or damaged shaft shaft sealing surfaces 4 Housing capscrews loose 4 Tighten housing capscrews to 41 Ib ft 55 Nm 5 Housing planet carrier damaged 5 Replace housing planet carrier 5 Oil leaking from steering 1 Hose fittings loose 1 Tighten fittings cylinder d 2 Steering cylinder o rings and or 2 Replace o rings and seals seals worn or damaged 3 Piston rod seal worn or 3 Replace piston rod seal damaged 4 Oylinder tube damaged 4 Replace cylinder tube 534D 9 534D 10 amp 544D 5 7 Axles Wheels and Tires Problem Cause Remedy 6 Axle overheating 1 Oil level too high 1 Fill oil to correct level with Mobilfluid 4249 ISO 46 Refer to Section 2 4 Fluid and Lubricant Capacities Axle and or wheel housings 2 Drain axle and fill to correct level filled with incorrect oil or oil with Mobilfluid 4249 ISO 46 contaminated or oil level low Refer to Section 2 4 Fluid and Lubricant Capacities 7 High steering effort required
125. b ft 1400 rpm 290 Ib ft 1400 rpm 376 Ib ft 9 1500 rpm Fuel Delivery Fuel Injection Fuel Injection Fuel Injection Air Cleaner Dry Type Replaceable Dry Type Replaceable Dry Type Replaceable Primary and Safety Elements b Cummins 534D 9 534D 10 544D Engine Make Model Cummins QSB4 5 Cummins QSB4 5 Displacement 274 in 4 5 liters 274 in 4 5 liters Primary and Safety Elements Low ldle 1000 rpm 1000 rpm High Idle 2500 rpm 2500 rpm Horsepower 110 hp 82 Kw 2500 130 hp 97 Kw 2500 rpm rpm Peak Torque 360 Ib ft 488 Nm 459 Ib ft 622 Nm 9 1500 rpm 1500 rpm Fuel Delivery Fuel Injection Fuel Injection Air Cleaner Dry Type Replaceable Dry Type Replaceable Primary and Safety Elements 534D 9 534D 10 amp 544D 2 7 amp General Information and Specifications 2 3 5 Tires Note Standard wheel lug nut torque is 350 400 Ib ft 475 542 Nm Note Pressures for Foam and Water Calcium Chloride filled tires are for initial fill ONLY a 534D 9 Size Tire Type Minimum Ply Fill Type Pressure Star Rating Pneumatic 70 psi 4 8 bar 13 00 x 24 G 2 Bias 12 Ply Foam Approx 542 Ib 246 kg 65 psi 4 5 bar Pneumatic 75 psi 5 2 bar 13 00 x 24 L 2 G 2 Radial Foam Approx 542 Ib 246 kg 75 psi 5 2 bar Pneumatic
126. best to measure in 12 pin increments from pin center to pin center For example if the links are one inch from pin center to pin center the distance should be 12 in 305 mm If the links are 3 4 in 19 mm apart the distance after 12 pins should be 9 in 228 mm If the distance measured 3 is 3 greater than the normal length 4 discard and replace the chain 3 33 N Boom MY1360 MZ1465 Cracked Plates Inspect the chains very carefully front and back as well as side to side for any evidence of cracked plates If any one crack is discovered the chain should be replaced in its entirety It is important however to determine the cause of the crack before installing a new chain so the Distorted or Battered Link Plates condition does not repeat itself Distorted or battered link plates 5 on a leaf chain can The types of cracks are cause tight joints and prevent flexing MZ1466 Turning or Protruding Pins Highly loaded chain operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates When chain is allowed to operate in this condition a pin or series of pins can begin to twist out of a chain resulting in failure Examine the pin head rivets to determine if the VEE flats are still in correct alignment 6 Chain with rotated displaced heads 7 or abnormal
127. brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal 5 Slowly turn the radiator cap to the first stop and allow any pressure to escape Remove the radiator cap 6 Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain plug and slowly remove to allow the coolant to drain Transfer the coolant into a properly labeled container Dispose of properly if coolant needs to be replaced Replace the radiator drain plug 7 Disconnect the Engine Water Temperature Sender 8 Remove the capscrews securing the thermostat housing 1 to the engine 9 Remove the thermostat housing old gasket and thermostat Clean all gasket surfaces DO NOT let any debris into the thermostat opening ALWAYS use the correct thermostat and install a new gasket NEVER operate the engine without a thermostat or engine damage will result b Thermostat Installation 1 Install the engine thermostat thermostat gasket and thermostat housing Secure with the two capscrews 2 Connect the Engine Water Temperature sender 3 Connect the battery negative cable to the battery negative terminal 4 Open the radiator cap and fill the radiato
128. ch end of the hose carrier slaps TO Kaap hari Mom 8 Fasten the two hydraulic carriers together using Note Do Not wrap the hose carrier since it will not plastic tie wraps or nylon straps for stability prevent the two hydraulic carriers from moving apart sideways 3 14 3 Hydraulic Sub Assembly Installation 14 Continue withdrawing the sub assembly fastening 1 Clean and lubricate the side surfaces where the the two hydraulic carriers together hydraulic sub assembly rides 15 With the two hose carriers tied together remove the 2 Install the guide bracket 1 on the front of the sub assembly and set on the ground or proper hydraulic sub assembly supports MY2740 534D 9 534D 10 amp 544D 3 39 Boom b 3 Fully collapse the hose carriers and secure together using plastic tie wraps or nylon straps to keep them from separating 4 nstall a sling around the balance point of the sub assembly With a suitable lifting device slowly insert the sub assembly into the front of the fourth boom section 5 Remove the first plastic tie wrap or nylon strap as the hydraulic sub assembly is being inserted into the front of the fourth boom section 6 Continue inserting the hydraulic sub assembly and removing the plastic tie wraps or nylon straps until the sub assembly is fully inserted into the boom 7 Verify that the bottom bracket 2 on the sub assembly is in place on the bottom plate 3 of
129. ck cylinder bracket mounting bolts and remove the strong back bracket 5 from the machine Label and tag each set of shims being removed from above and below the strong back 534D 9 534D 10 amp 544D 12 13 14 15 i 1 AZ Ll q 2 lt Or I cmn Remove the push beam mounting pins 6 and from the front of the third boom section pull the push beam clear of third boom section MX0210 Loosen the retract cable adjustment bolts 7 and remove all the retract cable sheave components Reaching inside the rear of the boom at the cable anchor bracket remove the cotter pin from the retract cable pin Remove the retract cable The retract cable should now be free Pull the retract cable through the rear of the boom assembly Remove the ropes and leave them in place to aid in reinstallation 0220 3 13 Boom b 3 5 4 1 Fasten the rope left in the boom from the retract cable removal to the new retract cable and pull the cable through the boom sections to the approximate final position Remove the rope Retract Cable Installation 2 Install the retract cable socket end 7 to the cable anchor bracket weldment 7
130. ck other components in the system Verify that all related hydraulic components and electrical switches sensors solenoids etc are operating correctly 7 Adjust the relief valve by turning the adjustment screw clockwise will increase the pressure turning the screw counter clockwise will decrease the pressure 8 Start the engine and check the pressure again Turn the engine OFF If there is pressure reading in the gauge bleed it off then disconnect or remove the pressure gauge from the machine 534D 9 534D 10 amp 544D Hydraulic System 8 3 2 Pressure and Speed Settings 534D 9 and 534D 10 Engine Speed Settings Main Control Valve Relief High 3100 psi 200 0 213 7 bar 13 8 0 Tilt Comp Relief Low 3250 psi 100 100 224 bar 6 9 6 9 Auxiliary Relief Low 2000 psi 100 100 138 bar 6 9 6 9 Crowd Extend Relief Approx 1 2 Throttle 2700 psi 100 100 186 bar 6 9 6 9 Charge Pressure Low High 380 480 psi 26 33 bar Hydrostatic Drive Relief High 6300 psi 200 100 434 bar 13 8 6 9 Brake Supply Low 580 psi 50 50 40 bar 3 4 3 4 Maximum Service Brake Pressure Low 638 psi 50 50 44 bar 3 4 3 4 Steering Pressure against steering stops Low 2500 psi 100 100 172 bar 6 9 6 9 Engine RPM Low High 800 RPM 2400 RPM D 9 2500 RPM D 10 544D Engine Speed Settings Main Control Valve Relief High 3500 psi
131. cting from an Attachment 2 Park the machine on a hard level surface fully retract the boom level the boom assembly place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the engine cover Allow the system fluids to cool 5 Remove the battery negative cable from the battery negative terminal 6 Place a sling around the first boom section at the balance point 7 Take the weight off the boom assembly 8 Label disconnect and cap all hydraulic hoses attached to the boom Cap all fittings and openings to keep dirt amp debris from entering the hydraulic system 9 Label disconnect any electrical cables if equipped 10 Remove the pin from the rod end of the compensation cylinder being careful not to drop the cylinder Lower the cylinder to a secure position 11 Remove the pin from the rod end of both lift cylinders being careful not to drop the cylinder Lower the cylinder to a secure position 12 Confirm that the boom assembly is balanced with the sling and remove the boom assembly pivot pin 13 Lift the boom assembly from the machine and lower onto suitable supports 534D 9 534D 10 amp 544D Boom 3 3 2 Second amp Third
132. ctor Solenoid Driver Cylinder 2 Not Responding 1142 653 7 Injector Solenoid Driver Cylinder 3 Not Responding 1143 654 7 Injector Solenoid Driver Cylinder 4 Not Responding 1144 655 ri Injector Solenoid Driver Cylinder 5 Not Responding 1145 656 7 Injector Solenoid Driver Cylinder 6 Not Responding 1228 27 2 2 EGR Valve Position Erratic 1229 2795 2 2 VGT Position Sensor Erratic 1239 2623 3 3 Accelerator Pedal or Lever Position Sensor 2 Circuit High 1241 2623 4 4 Accelerator Pedal or Lever Position Sensor 2 Circuit Low 1242 091 2 2 Accelerator Pedal or Lever Position Sensor Number 1 and 2 Erratic 1633 625 2 Komnet Datalink Cannot Transmit 1639 703 11 Auxiliary Equipment Sensor Input Number 3 OEM Switch 1654 1323 11 31 Engine Misfire Cylinder 1 1655 1324 11 31 Engine Misfire Cylinder 2 1656 1325 11 31 Engine Misfire Cylinder 3 1657 1326 11 31 Engine Misfire Cylinder 4 1658 1327 11 31 Engine Misfire Cylinder 5 1659 1328 11 31 Engine Misfire Cylinder 6 1663 3241 11 31 Catalyst Inlet Temperature Sensor Swapped with Outlet 1664 3050 11 31 Catalyst Missing 1665 3241 4 Exhaust Gas Temperature 1 Circuit Low 1666 3241 3 Exhaust Gas Temperature 1 Circuit High 1667 3241 2 Exhaust Gas Temperature 1 Erratic 1668 1761 4 4 Catalyst Tank Level Sensor Circuit Low 1669 1761 3 Catalyst Tank Level Sensor Circuit High 1671 1761 1 18 Catalyst Tank Level Low Moderately Severe 1673 1761 1 Catalyst Tank Level Low Most Severe 1674 3249 4 Ex
133. cylinder into position 3 3 5 Extend Retract Cylinder and Push Beam Assembly and Installation 1 Install the extend retract cylinder 1 into the push beam 2 Install the mounting pin and hardware 2 at the extend retract cylinder rod eye 3 Install the push beam assembly 3 through the front of the third boom section leaving the sheave bracket exposed for accessibility 4 Guide the threaded end of the extend cables through the sheave bracket Note The extend cable will not feed through sheave bracket with the sheave installed 5 Lay the cables over the boom head and complete the sheave assembly installation i e sheaves pins lube system and wear pad 6 Guide the cable around the sheave and install the cable guide and guide bar 0170 7 With the push beam installed in the third boom section the third boom section and push beam are ready to be installed into the second boom section 8 Place the second boom section upside down on suitable supports 9 Lubricate the inside second boom section on area s where the third boom section wear pads will slide 10 Using a suitable sling balance the third boom section and carefully slide 3 ft 4 ft 0 9 m 1 22 m into the front of the second boom section 534D 9 534D 10 amp 544D 11 Set the third boom section onto a suitable support and reset the sling under the boom head of the third boom section Care
134. d 2 diesel may be used Note 1 diesel fuel may be used however fuel economy will be reduced Use a low sulfur content fuel with a cloud point the temperature at which wax crystals form in diesel fuel at least 10 below the lowest expected fuel temperature The viscosity of the fuel must be kept above 1 3 centistrokes to provide adequate fuel system lubrication Note When using diesel fuel with a sulfur content below 1 3 percent the filter change interval may be increased by 75 hours Do not use fuel with a sulfur content above 1 3 percent is not recommended 7 9 2 Fuel Tank John Deere Note The fuel tank is a one piece unit It is located on the right side of the machine directly behind the hydraulic oil reservoir If it is determined that the fuel tank must be removed the fuel must be drained before tank removal Always dispose of fuel properly a Fuel Tank Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 7 9 Engine O 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal 5 Remove the fuel tank hyd
135. d Adjustments 1 Check the system functions 8 7 DRIVE MOTORS 8 7 1 The front drive motor is mounted to the carrier of the front drive axle and powers the machine in 2WD and 4WD Front Drive Motor a Front Drive Motor Removal 1 Park the machine on a firm level surface level the machine fully retract the boom raise the boom to access drive motor place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover and the hydraulic oil reservoir fuel tank cover Allow the system fluids to cool 4 Remove the deck cover and disconnect the battery negative cable from the battery negative terminal 5 With the engine OFF relieve any trapped pressure in the hydraulic system 6 Thoroughly clean the drive motor and surrounding area including all hoses and fittings before proceeding 7 Place a suitable container to catch hydraulic fluid drainage beneath the frame Note Cap all hoses as you remove them to prevent unnecessary fluid spillage 8 Label disconnect and cap all the hydraulic hoses attached to the drive motor Cap all fittings and openings to prevent dirt and debris from entering the hydraulic system 9 Wipe up any hydraulic fluid spillage in on near and around the machine and the work area
136. d LG Service Manual Models 534D 9 534D 10 amp 544D 534D 9 amp 534D 10 S N 0160000447 amp After 544D S N 0160000192 amp After 31200170 Revised November 6 2008 m ES 1509001 REGISTERED COMPANY AGEMENT 0t EFFECTIVITY PAGE February 5 2007 A Original Issue Of Manual May 7 2008 B Added second battery on page 2 6 Updated Tire Specs on page 2 8 Revised Warnings on pages 3 4 3 21 3 32 4 3 5 3 5 11 5 13 5 14 6 3 8 3 amp 8 21 Added Hyd Sub Assy Removal Install on pages 3 30 3 31 amp 3 32 Changed Danger Warning Caution amp Notice as required Added Fork Info on page 3 43 Added Radiator Cap text on Page 1 4 November 6 2008 C Replaced Gradall branding with JLG brand 31200170 534D 9 534D 10 amp 544D EFFECTIVITY PAGE 534D 9 534D 10 amp 544D 31200170 SECTION CONTENTS Section Subject Page Section 1 Safety Practices TR Cd e 1 1 1 1 1 2 1 2 DiSclaitrier Et ews E we was wae oe EE T Ed 1 2 1 3 Operator amp Safety 1 2 1 4 Do Not Operate 1 2 1 5 Safety Information 1 3 1 6 Safety Instructions 1 3 1 7 Safety 2
137. d into place inside the fourth boom section 9 Secure the hose carrier at the front of the fourth boom section and at the rear of the third boom section 10 Wrap the tilt aux hoses around the hose sheaves on the second boom section and connect to the proper fittings at the rear of the hose carrier 11 Install the hose guide at the rear of the second boom section 12 Uncap and reconnect the tilt aux hoses to the hose carrier at the front of the fourth boom section 13 Adjust the complete boom to the proper dimensions 3 32 3 12 BOOM EXTEND AND RETRACT CHAINS FOUR SECTION The extend and retract chains are used to move the third and fourth boom sections in and out proportional with the movement of the boom extend retract cylinder Extend Chains The 1 in 25 mm extend chains are located at the top of the boom assembly The single fourth boom section chain attaches to the top rear of the fourth boom section passes over a chain roller mounted on the third boom section and is secured to the top front of the second boom section The third boom section has two 1 in 25 mm extend chains located at the top of the boom assembly They attach to the top rear of the third boom section pass over two rollers mounted at the front of the second boom section and are fastened to the top front of the first boom section Retract Chains The 3 4 in 19 mm retract chain is fastened at the bottom inside rear of the fourth b
138. damage mating surfaces due to lack of lubrication After drying lightly coat components with oil or a rust preventive chemical to help protect them from corrosion If storing components for a prolonged period wrap them in wax paper PERIODIC OPERATION REQUIREMENT Every two weeks drive the machine far enough to cause the drive train components to make several complete revolutions This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity SUBMERSION If the machine has been exposed to water deep enough to cover the hubs disassemble the wheel ends and inspect for water damage and contamination If the carrier housing was submerged in water especially if the water level was above the vent tube breather drain the axle and inspect internal parts for water damage and contamination Before assembling and refilling the unit with the specified lubricant s clean examine and replace damaged parts as necessary Note Use a suitable puller for bearing removal Clean inspect and lubricate all bearings just prior to reassembly If replacement of a damaged bearing cup or cone is necessary replace the cup and cone as a set 5 3 Axles Wheels and Tires hs 5 3 5 The front axle assembly is equipped with a parking brake mechanism and a limited slip feature The following steps outline a typical axle removal procedure Axle Removal
139. der wiring harness leads can be accessed from the top of the fuel tank Disconnect the fuel level sender wiring harness leads With the help of an assistant touch both harness leads together From the operator s cab have the assistant turn the ignition key switch to the RUN position DO NOT start the engine Observe the fuel level indicator needle on the operators instrument cluster The reading must be at the FULL mark Turn the ignition key switch to the OFF position The fuel level indicator needle should return to the EMPTY position b Fuel Level Circuit Tests If the fuel level sender is suspected of giving a false reading perform the following checks 1 If the fuel level indicator needle does not move check the fuel tank for fuel Check for loose or defective wiring faulty ground connections and corrosion on the fuel tank sender and wiring lead 534D 9 534D 10 amp 544D Electrical System 3 If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN position use a test lamp to determine whether current is flowing from the ignition switch to the fuel level sender 4 If the fuel level indicator does not move and a faulty or defective fuel level sender in the fuel tank has been ruled out and in addition wiring and connectors have been checked and ruled out the fuel level indicator is defective and must be replaced 5 Check that the ignition term
140. determine whether any further use of the component would constitute a hazard If in doubt replace the component Operate the hydraulic controls after the engine has stopped to relieve trapped pressure Note Residual pressure may remain in hydraulic cylinders hoses valve bodies components etc If the hydraulic lines going to or coming from a component are taut slowly and cautiously relieve bleed off pressure 534D 9 534D 10 amp 544D Whenever you disconnect a hydraulic line coupler fitting or other component slowly and cautiously loosen the part involved A hissing sound or slow seepage of hydraulic fluid may occur in most cases After the hissing sound has ceased continue removing the part Any escaping oil should be directed into an appropriate container Cap or otherwise block off the part to prevent further fluid seepage Hydraulic system maintenance will at times require that the engine be operated Always follow safety precautions A major cause of hydraulic component failure is contamination Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs Sand grit and other contaminants can damage the finely machined surfaces within hydraulic components If operating in an exceptionally dirty environment change filters and inspect the fluid more often When servicing the system cap or plug hydraulic fittings hoses and tube assemblies Plug all cylinder ports valves and the h
141. e ends to prevent dirt and debris from entering the hydraulic system 3 22 4 3 4 T gu a MX0340 Disconnect the top front chains 5 from the chain clevis on the first and second boom section 5 Release the chain tension from the front top chains 6 Remove the front top chain rollers from the second and third boom sections Remove the chain adjustment block 6 from the first boom section Remove all wear pads from the front of the first boom section Tag each pad backing plate shim and bolts from each location Carefully pull the second third and fourth boom sections together from the first boom section and place on suitable supports for further separation 534D 9 534D 10 amp 544D Boom 3 10 5 Note Work on the boom assembly is performed with the assembly up side down Third amp Fourth Boom Section Removal 1 Loosen and remove the bottom rear and side wear pads from the third boom section Tag each pad backing plate shim and bolts from each location 2 Remove standard and optional hose sheaves 1 from the rear of the second boom section 3 Remove the chain and chain clevis 2 from the rear of the second boom section 4 Remove the hydraulic sub assembly bracket 3 and hardware from the rear of the third boom section i
142. e operating properly Circuits 11 Excessive chain wear 1 Improper chain adjustment 1 Adjust to correct tension Refer to Section 3 12 Boom Extend and Retract Chains Four Section Replace chains as needed 2 Chain sheave s not properly 2 Lubricate chain sheave Refer lubricated to Section 2 6 Lubrication Schedules 3 Chain sheave s not rotating 3 Lubricate chain sheave Refer to freely Section 2 5 Service and Maintenance Schedules Repair or replace chain sheave s as needed 4 Improper chain lubrication 4 Lubricate at regular intervals Refer to Section 2 5 Service and Maintenance Schedules Replace chains as needed 3 46 534D 9 534D 10 amp 544D Section 4 Cab and Covers Contents PARAGRAPH TITLE PAGE 4 1 Operator s Cab and Covers Component Terminology 4 2 4 2 22 25222 24 4 eds ries 4 3 4 2 1 Cab 5 8 4 3 4 2 2 Serial Number Decal 4 3 4 3 Cab 4 3 4 3 1 Steering Column and Orbitrol 4 3 4 3 2 Service Brake 4 4 4 3 3 Throttle Pedal PERDER ee 4 5 4 3 4 Boom Joystick Assembly
143. e cab Lever Installation Install the lever at the mounting bracket on the cab floor Install the shaft spacers and cotter pins Install the link between the lever and the main control valve 4 Install the lever knob 5 Connect the battery negative cable to the battery 4 3 negative terminal Test the lever functions Frame Sway and Attachment Tilt Levers a Move the lever rearward activating the attachment up function The attachment should TILT UP b Move the lever forward activating the attachment down function The attachment should TILT DOWN c Move the Tilt lever rearward activating the right frame sway function The frame should SWAY to the RIGHT d Move the Tilt lever forward activating the left frame sway function The frame should SWAY to the LEFT 6 Left Hand Tilt and or Left Hand Tilt Sway Lever If Equipped Lever Removal Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and turn the engine OFF Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 534D 9 534D 10 amp 544D Cab and Covers Ps 5 OO Disconnect the battery negative cable at the battery negative terminal Remove the four bolts holding the leve
144. e engine cover 10 Remove the blocks from the front and rear of both tires on the front axle 11 Start the machine and check proper operation Check for fluid leaks Check the hydraulic fluid level in the tank and add fluid as required 5 9 Axles Wheels and Tires hs 5 5 REAR STEER AXLE 5 5 1 The rear steer axle assembly is equipped with two steer cylinders two drive hubs and two motors and can be removed as a complete assembly The following steps outline a typical axle removal procedure Rear Axle Removal Cleanliness is extremely important Before attempting to remove the axle thoroughly clean the machine Avoid spraying water or cleaning solution on the stabilizer solenoids and other electrical components If using a steam cleaner seal all openings before steam cleaning Note Clear the work area of all debris unnecessary personnel etc Allow sufficient space to raise the machine and to remove the axle 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake straighten all wheels and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negat
145. e harness at the right front side of the cab 534D 9 534D 10 amp 544D Connect the heater hoses to the engine Secure with two hose clamps Open both coolant valves on the engine Fill the cooling system completely with a 50 50 mixture of ethylene glycol and water The cooling system capacity is listed in Section 2 4 Fluid and Lubricant Capacities Connect the battery negative cable or cables to the battery negative terminal Carefully examine all cab components fasteners etc one last time before engine start up Rectify any faulty conditions Start the engine and check the operation of all controls Check for hydraulic fluid leaks Check the hydraulic fluid level in the tank and add fluid as required Note When the engine is initially started run it briefly at low idle and check the machine for any visual sign of fluid leakage STOP the engine immediately if any leakage is noted and make any necessary repairs before continuing 14 Wait for the engine to cool and check the coolant level Add coolant to the overflow bottle as required to bring the coolant to the proper level 4 9 Cab and Covers 4 10 This Page Intentionally Left Blank 534D 9 534D 10 amp 544D Section 5 Axles Wheels and Tires Contents PARAGRAPH TITLE PAGE 5 1 Axles Wheel and Tire Component 5 2 5 2 General Information
146. e instructions covering repair disassembly reassembly and adjustment are provided in the MH439 0695 Auburn Power Wheel Service Manual JLG P N 31200374 Note The removal disassembly and installation of the rear drive hub applies for either side a Rear Drive Hub Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake straighten all wheels and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal 5 Block the front and rear of both tires on the front axle 6 Raise the machine using a suitable jack or hoist Place suitable supports under both sides of the frame and lower the machine onto the supports Ensure that the machine will remain in place during hub removal 7 Mark and remove the wheel and tire assembly from the hub that is being removed Refer to Section 5 6 1 Removing Wheel and Tire Assembly from Machine 534D 9 534D 10 amp 544D 8 Remove the drain plug 1 and allow the wheel hub oil to drain into the receptacle Transfer the used axle oil into a suitable covered container and label the container as Used Oil
147. e machine work area and tools 8 Close and secure the engine cover 8 9 5 Install a digital or a 10 000 689 bar psi gauge to the test port located at the left side in front of the return filter Make sure the gauge can be observed from the operator s cab Refer to Section 8 4 1 Hydraulic Pressures for a specific hydraulic cylinder circuit pressure setting Cylinder Pressure Checking Note hydraulic cylinder pressure is greater than the main control valve pressure increase the main control valve pressure by adjusting the main relief Generally one half turn clockwise will be adequate to check an individual circuit Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn Re check the main relief setting and adjust if necessary 8 23 Hydraulic System 8 9 6 Cylinder Torque Specifications 534D 9 10 Description Lock Nut Cylinder Gland Lift Cylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Crowd Cylinder 825 875 Ib ft 1119 1186 Nm 250 400 Ib ft 339 542 Nm Tilt Cylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Comp Oylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Sway Cylinder 650 700 Ib ft 881 949 Nm Stabilizer Cylinder 650 700 Ib ft 881 949 Nm 250 400 Ib ft 339 542 Nm Steering Cylinder 400 425 Ib ft 542 576 Nm 250 400 Ib ft 339 542 Nm Ou
148. e mounting pin 3 into the strong back and secure 4 Apply Loctite 5459 to the extend retract cylinder fittings and install into the cylinder barrel 5 Apply Loctite 545 to the fittings and reconnect the hydraulic hoses 534D 9 534D 10 amp 544D 3 19 3 8 BOOM SYSTEM COMPONENT TERMINOLOGY 544D The following illustrations identify the components that are referred to throughout this section EXTEND THIRD CHAINS FOURTH BOOM SECOND BOOM SECTION BOOM SECTION SECTION FIRST BOOM SECTION AUXILIARY HYDRAULIC CONNECTIONS ATTACHMENT TILT CYLINDER ATTACHMENT BOOM HYDRAULIC ASSEMBLY inside boom EXTEND RETRACT CYLINDER underside of boom RETRACT CHAINS MY0100 3 20 534D 9 534D 10 amp 544D Boom 3 9 BOOM SYSTEM FOUR SECTION 3 9 1 The four section boom consists of the first second third and fourth assemblies with double third and fourth section extend chains a double third section retract chains and a single fourth section retract chain Boom System Operation As the extend retract cylinder which is anchored at the front of the second boom section and the rear of the first boom section begins to extend it forces the second boom section out of the first boom section The boom sections are connected by extend and retract chains These chains are routed around sheaves on the second and third boom sections As th
149. e pad bolts 8 Install the bottom front wear pad supports DO NOT torque the pad support bolts 3 26 10 11 12 13 14 15 16 17 18 19 20 21 22 Install the bottom front wear pads DO NOT torque the pad bolts Install the front side wear pads Torque all the front wear pads and supports Shim the rear wear pads on the third boom section if needed and torque to 68 78 Ib ft 92 106 Nm Lay out and lubricate the 1 in 25 mm chain on the bottom of the second boom section Install the bottom rear wear pads DO NOT torque the pad bolts Install the top rear wear pads DO NOT torque the pad bolts Install the lube fittings to the wear pad and chain roller assembly Connect the chain clevis 7 to the second boom section il EI a NM 1 EI Pa _ MX0450 Assemble the rear bottom chain roller 8 to the second boom section Install the side rear wear pads on the second boom section DO NOT torque the pad bolts Install the optional hose sheave 9 if equipped to the right rear of the second boom section Install the standard hose sheave 9 to the left rear of the sec
150. e removal of the retract cable is a difficult operation but it can be accomplished You must be able to reach into the rear of the boom assembly to unfasten the retract cable socket from the cable anchor bracket weldment If you cannot reach this bracket the boom sections must be Separated 1 Remove any attachment from the quick switch assembly Refer to Section 3 16 1 Disconnecting from an Attachment 2 Park the machine on a hard level surface fully retract the boom level the boom assembly place the transmission control lever in NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 4 Open the engine cover Allow the system fluids to cool 5 Remove the battery negative cable from the battery negative terminal 6 Remove the hose guards from the rear of the first boom section 7 Label disconnect and cap all extend retract hydraulic hoses Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 8 Remove the extend retract cylinder mounting pins 3 from the strong back cylinder bracket 9 Remove the extend cable lock nuts washers and springs 4 from the strong back cylinder bracket 10 Pull the cable free of the strong back cylinder bracket Fasten a rope to the cable end to aid in reinstallation 11 Remove the strong ba
151. e second section is forced out hydraulically the third and fourth boom sections are pulled out by the extend chains As hydraulic pressure is applied to the retract port on the extend retract cylinder the second boom section is pulled back into the first boom section and the retract chain pulls the third and fourth boom sections back into the Second boom section This mechanical linkage formed by the chains and supporting hardware extends and retracts the third and fourth boom sections at the same rate The boom section lifts and lowers via action of the lift cylinder 3 10 BOOM MAINTENANCE FOUR SECTION COMPLETE REMOVAL These instructions must be completed in sequence The second third and fourth boom sections are removed from the first boom section The third and fourth boom sections are removed from the second boom section The fourth boom section is removed from the third boom section Before beginning conduct a visual inspection of the machine and work area and review the task about to be undertaken Read understand and follow these instructions A WARNING NEVER weld or drill the boom unless approved in writing by JLG The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling 534D 9 534D 10 amp 544D 3 10 1 1 Park the machine on a hard level surface fully retract the boom lower the boom to a level position place the transmission control le
152. e switch is turned to the RUN position The diagnostic increment decrement is used to sequence forward or backwards through the active faults To enter fault flash out mode using the accelerator pedal fully depress and release the pedal 3 times Once in diagnostic mode cycling the accelerator pedal will sequence forward through the active faults The following graphic depicts the pattern of the fault code flash out scheme as indicated by the stop lamp Stop Lamp 3 The stop lamp provides critical operator messages These messages require immediate and decisive operator response The stop lamp is also used to diagnose flash out fault codes Warning Lamp 4 The warning lamp provides important operator messages These messages require timely operator attention The warning lamp is also used to delineate diagnostic fault codes 9 18 Example Fault Code Sequences Fault Code 244 P Pause N KY KN N P P P P 1Blink 2Blinks 4Blinks 4Blinks 1 Blink Fault Code 112 N p P P P lt 1Blink 1Blink 1Blink 2Blinks 1 Blink 05441 9 15 3 Offboard Diagnostics INSITE M is the Windows based service programming diagnostic tool for the Cummins engine It is used to help troubleshoot and repair the engine with extended fault diagnostics and processing power INSITE allows the u
153. ensor Inspection and Replacement Inspect the sender and the wiring harness connector terminals for continuity Replace a defective or faulty sender with a new part c Stabilizer Sensor Installation and Testing 1 Install stabilizer sensor and tighten jam nut to recorded measurement 2 Connect the stabilizer sensor connector 3 Install the battery negative cable at the negative battery terminal 4 Place an angle finder gauge on the top rear of the first boom section 5 Start machine retract the boom and raise the boom until the angle gauge reads 45 6 The red LED light in the stabilizer sensor should be illuminated 534D 9 534D 10 amp 544D MX1220 7 If stabilizer sensor is not activated adjust the sensor and or sensor bracket to illuminate sensor 9 10 3 Engine Senders Engine Coolant Temperature Sender a Engine Coolant Temperature Sender Removal 1 The engine coolant sender is located by the alternator 2 Remove the battery negative cable at the negative battery terminal 3 Remove the engine coolant temperature sender wire from the sender 4 The sender is threaded into the engine block Remove the sender b Engine Coolant Temperature Sender Inspection and Replacement Inspect the sender and the wiring harness terminals for continuity Replace a defective or faulty sender with a new part c Engine Coolant Temperature Sender Installation and Testing 1
154. er Position Sensor Circuit High 134 974 4 4 Remote Accelerator Pedal or Lever Position Sensor Circuit Low 135 100 3 Oil Pressure Sensor Circuit High 141 100 4 4 Oil Pressure Sensor Circuit Low 143 100 1 18 Engine Oil Rifle Pressure 144 110 3 3 Engine Coolant Temperature 1 Sensor Circuit High 145 110 4 4 Engine Coolant Temperature 1 Sensor Circuit Low 146 110 0 16 Engine Coolant Temperature High Warning 147 1 Accelerator Pedal or Lever Position 1 Sensor Circuit Low 148 0 Accelerator Pedal or Lever Position 1 Sensor Circuit High 151 110 0 0 Engine Coolant Temperature High Critical 153 105 3 3 Intake Manifold Air Temperature Sensor Circuit High 154 105 4 4 Intake Manifold Air Temperature Sensor Circuit Low 155 105 0 0 Intake Manifold 1 Temperature 187 1080 4 4 Sensor Supply Voltage Number 2 Circuit Low 195 111 3 3 Coolant Level Sensor Circuit High 196 111 4 4 Coolant Level Sensor Circuit Low 197 111 1 18 Coolant Level Low 221 108 3 3 Barometric Pressure Sensor Circuit High 222 108 4 4 Barometric Pressure Sensor Circuit Low 227 1080 3 3 Sensor Supply 2 Circuit High 234 190 0 0 Engine Crankshaft Speed Position 235 111 1 Coolant Level Low 237 644 2 External Speed Command Input Multiple Unit Synchronization 238 611 4 4 Sensor Supply 3 Circuit Low 241 84 2 2 Vehicle Speed Sensor Circuit 242 84 10 10 Vehicle Speed Sensor Circuit Tampering Has Been Detected 534D 9 534D 10 amp 544D
155. er is easily removed Extend Retract Cylinder Removal 1 Attach a suitable sling to the extend retract cylinder 1 and take the weight off the cylinder to aid in pin removal 2 Remove the extend retract cylinder support 2 from the front of the extend retract cylinder 3 21 Boom b 3 Remove the snap rings and pin from each end of the extend retract cylinder 4 Remove the extend retract cylinder and store in a designated area MX0330 3 10 3 See Section 8 9 1 General Cylinder Instructions Tilt Cylinder Removal 3 10 4 Second Third amp Fourth Boom Section Removal Note Work on the boom assembly is performed with the assembly up side down It is best to remove the boom sections in the order in which they were assembled If a section needs to be separated this presents an excellent opportunity to check all sections for serviceability The fourth third and second sections should be removed as a package 1 Loosen and remove the bottom rear wear pads and rear side wear pads from the second boom section Leave all the top wear pads in place to aid sliding during the section removal Tag each pad backing plate shim and bolts from each location 2 Release tension from the hoses on the hose take up weldment 3 3 Loosen the tilt circuit hoses auxiliary circuit hoses and any electrical hoses 4 if equipped on the hose take up weldment Plug the hose ends and tub
156. er of the main control valve Loosen the jam nut on the relief valve and using an allen wrench turn the relief clockwise to increase pressure or counter clockwise to decrease pressure Start the machine leave the park brake applied run the engine at high idle and bottom the extend retract cylinder The gauge should read 3100 psi 200 0 psi 213 7 bar 13 8 0 bar 534 D 9 10 3500 psi 200 0 psi 241 bar 13 8 0 bar 544D If the proper pressure cannot be set use the accompanying hydraulic schematic electrical schematic and or the troubleshooting guide to help correct the problem HOIST CROWD TILT SWAY Tilt Sway and Auxiliary Pressures AUX MX1140 Start the machine and warm the hydraulic system to operating temperature Shut off the machine and install a digital or a 10 000 689 bar psi gauge to the test port located at the left side in front of the return filter Make sure the gauge can be observed from the operators cab Start the machine leave the park brake applied run the engine at low idle and bottom the individual section in both directions The gauge should read 3250 psi 100 0 psi 224 bar 6 9 0 bar 534D 9 10 3000 psi 100 0 psi 207 bar 6 9 0 bar 544D for the tilt section and the sway section The auxiliary section should read 2000 psi 100 psi 138 bar 6 9 bar Adjusting Tilt Sway and Auxiliary Pressures Shut t
157. er the cable sheaves Install the push beam into position and pin into place at the rear of the second boom section Pull the third and second boom section out of the first section together approximately 12 in to allow slack in the tilt aux hoses Install the bulkhead brackets at the front of the third boom section Feed the tilt aux hoses through the trays at the bottom corners of the third boom sections Uncap and reconnect the previously labeled tilt aux hoses to the fittings on the bulkhead brackets Push the third and second boom section back against the first boom section Install the strong back and pin the extend retract to the strong back Uncap and reconnect the previously labeled extend retract hoses to the fittings on the extend retract cylinder Feed the extend cables through the strong back and install the jam nuts on each cable Install the guide and cable cover on the front of the push beam Install the tilt cylinder and hoses in the third boom section boom head Install the hose and cable cover at the rear of the second boom section Adjust the boom sections cables and hoses to the proper dimensions 3 11 Boom b 3 5 BOOM CABLES THREE SECTION 3 5 1 General Cable Information The 534D 9 amp 534D 10 Parts Manual covers part numbers length and key specifications Please review this manual to make certain that you are using the
158. er to Section 7 7 Cooling System Several additional components must be removed before engine removal They will be addressed in the following procedures Engine Removal Note The hydrostatic drive pump can be left in place with the engine or separated from the engine before engine removal See Section 6 5 1 Drive Pump Removal 1 Level the machine ground the attachment place the travel select lever in NEUTRAL N engage the parking brake and shut off the engine 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 7 12 4 Remove the battery negative cable from the battery negative terminal 5 Remove the engine cover rear cover and the engine dust shield 6 Place a funnel at the base of the radiator to channel the drained coolant into the container Loosen the drain plug and slowly remove to allow the coolant to drain Transfer the coolant into a properly labeled container Dispose of properly if coolant needs to be replaced Replace the radiator drain plug 7 Loosen and remove both charge air tubes from the charge air cooler 544D w John Deere engine and all Cummins engines 8 Loosen the radiator hose clamps at the engine Work the hose off the engine Position the hose out of the way to allow radiator removal Inspect the hose and replace if necessary
159. eral times in both directions Check for hydraulic leaks and tighten or repair as necessary 534D 9 534D 10 amp 544D 5 6 WHEELS AND TIRES A WARNING Mismatched tire sizes ply ratings or mixing of tire types radial tires with bias ply tires may compromise machine stability and may cause machine to tip over JLG recommends a replacement tire to be the same size ply and brand as originally installed Refer to the appropriate parts manual for ordering information If not using a JLG approved replacement tire JLG recommends that replacement tires have the following characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load The rims installed have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in unsafe condition regarding stability Foam filled tires have a positive effect on the weight stability and handling characteristics of the machine especially under load JLG does not recommend the use of hydrofill as a tire fill substance because of possible environmental impact
160. ervice FLUID TEMPERATURE NEVER work on a machine when the engine cooling or hydraulic systems are hot Hot components and fluids can cause severe burns Allow systems to cool before proceeding FLUID PRESSURE Before loosening any hydraulic or diesel fuel component hose or tube turn the engine OFF Wear heavy protective gloves and eye protection NEVER check for leaks using any part of your body use a piece of cardboard or wood instead If injured seek medical attention immediately Diesel fluid leaking under pressure can explode Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin cause infection gangrene and other serious personal injury Relieve all pressure before disconnecting any component part line or hose Slowly loosen parts and allow release of residual pressure before removing any part or component Before starting the engine or applying pressure use components parts hoses and pipes that are in good condition connected properly and are tightened to the proper torque Capture fluid in an 1 4 appropriate container and dispose of in accordance with prevailing environmental regulations RADIATOR CAP The cooling system is under pressure and escaping coolant can cause severe burns and eye injury To prevent personal injury NEVER remove the radiator cap while the cooling system is hot Wear safety glasses Turn the radiator cap to the first stop and allow pressure to escape before removi
161. ery negative terminal Disconnect the return spring 5 inching brake linkage 6 and brake master cylinder push rod 7 from the brake pedal weldment oc MX0780 Remove the bolt nut and lockwasher 8 securing the brake pedal to the brake pedal weldment and remove the brake pedal Remove the bolt and lockwasher from the pivot pin remove the pivot pin from the brake pedal bracket 9 Remove the brake pedal weldment from the cab Service Brake Pedal Installation Position the brake pedal weldment in its mounting location within the cab Secure the brake pedal weldment into position with the pivot pin 9 Install the brake pedal 8 to the brake pedal weldment sure the brake pedal has the correct range of motion Secure pivot pin with bolt and lockwasher Reconnect the return spring 5 inching brake linkage 6 and the brake master cylinder push rod 7 Connect the battery negative cable to the battery negative terminal Close and secure the engine cover 534D 9 534D 10 amp 544D Cab and Covers a 4 3 3 Throttle Pedal a Throttle Pedal Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and turn the engine OFF 2
162. et Temperature High 534D 9 534D 10 amp 544D 9 23 Electrical System Fault Code SPN Code FMI Code Description 2348 27 13 13 EGR Valve Failed Automatic Calibration Procedure 2349 2791 5 5 EGR Valve Control Circuit Low 2351 2791 4 4 EGR Valve Control Circuit Low 2352 2791 3 3 EGR Valve Control Circuit High 2353 2971 6 6 Exhaust Gas Recirculation EGR Valve Control Clrcuit High 2357 2791 7 7 Exhaust Gas Recirculation EGR Valve Control Not Responding 2359 411 0 16 Exhaust Gas Recirculation EGR Differential Pressure Sensor High 2362 1072 4 Engine Brake Actuator Circuit 1 Low 2363 1073 4 Engine Brake Actuator Circuit 2 Low 2366 1072 3 Engine Brake Actuator Circuit 1 High 2367 1073 3 Engine Brake Actuator Circuit 2 High 2373 1209 3 3 Exhaust Gas Pressure Sensor Circuit Shorted High 2374 1209 4 4 Exhaust Gas Pressure Sensor Circuit Shorted Low 2375 412 3 EGR Temperature Sensor Circuit High 2376 412 4 4 Recirculation Exhaust Gas EGR Temperature Sensor Circuit Low 2377 647 3 Fan Control Circuit High 2381 2795 4 4 Turbocharger Position Sensor Circuit Shorted High 2382 2795 4 4 Turbocharger Position Sensor Circuit Shorted Low 2383 641 5 5 Variable Geometry Turbocharger Actuator Circuit Low 2384 641 4 4 VGT Actuator Driver Circuit Low 2385 641 3 3
163. ever Idle Validation Circuit Out of Calibration 433 102 2 Intake Manifold Pressure Sensor Circuit Data incorrect 434 627 2 2 Power Supply Lost with Ignition On Erratic 435 100 2 2 Oil Pressure Switch Sensor Circuit Erratic 436 105 2 Intake Manifold 1 Temperature Erratic 441 138 1 18 Battery 1 Voltage Low 442 138 0 16 Battery 1 Voltage High 443 1043 4 4 Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit Low 449 157 0 Injector Metering Rail Number 1 Pressure High 451 157 3 Injector Metering Rail Number 1 Pressure Circuit High 452 157 4 Injector Metering Rail Number 1 Pressure Circuit Low 471 98 1 17 Engine Oil Level Low 488 105 0 16 Intake Manifold 1 Temperature High 497 1137 2 Multiple Unit Synchronization Switch Erratic 498 98 3 Engine Oil Level Sensor Circuit High 499 98 4 Engine Oil Level Sensor Circuit Low 523 611 2 Auxiliary Intermediate PTO Speed Switch Validation Erratic 527 702 3 Auxiliary Input Output 2 Circuit High 528 093 2 Auxiliary Alternate Torque Validation Switch Erratic 529 703 3 Auxiliary Input Output 3 Circuit High 545 1188 7 Turbocharger 1 Wastegate Control Not Responding 551 558 4 4 Accelerator Pedal or Lever Idle Validation Circuit Low 553 157 0 16 Injector Metering Rail 1 Pressure High 554 157 2 Injector Metering Rail 1 Pressure Erratic 559 157 1 18 Fuel Pump Delivery Pressure Low 584 677 3 3 Starter Relay Circuit High 585 677 4 4 Starter Relay Circuit Low 595
164. ew relief valve Disassemble each Valve Section 1 Carefully separate the outlet section from the auxiliary section 2 Remove the o rings from between the two sections 3 Carefully separate each remaining sections 4 Remove both end caps from each end of the valve sections then remove each control spool 5 Remove any check valves compensator valves anti cavitation valves or shock valves from individual valve section if equipped 6 Keep all parts being removed from individual valve sections tagged and kept together c Main Control Valve Parts Cleaning Clean all components with a suitable cleaner such as triclorethylene before continuing Blow dry d Main Control Valve Parts Inspection Inspect all parts and internal passageways for wear damage etc If inner surfaces of any component DO NOT display an ultra smooth polished finish or are damaged in any way replace the damaged part Often dirty hydraulic fluid causes failure of internal seals damage to the polished surfaces within the component and wear of and or harm to other parts e Main Control Valve Assembly Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hyaraulic oil Assemble each Valve Section 1 Reassemble any check valves compensator valves anti cavitation valves or shock valves from each individual valve sections if equipped 2 In
165. f the boom assembly Label disconnect and cap the extend retract hoses 5 from the cylinder Cap all fittings and openings to prevent dirt and debris from entering the hydraulic system Remove the extend retract cylinder mounting pin hose guards and strong back from the rear of the boom assembly Place a sling around the second boom section lift and slowly pull the second and third boom section approximately half way out of the first boom section Lower the second and third boom sections onto a suitable support Relocate the sling or using two slings for better stability balance the two boom sections and slowly pull them out of the first boom section being careful not to damage the hydraulic hoses or cables Lower the second and third boom sections onto suitable supports Third Boom Section amp Push Beam Removal Remove all wear pads shims from the front inside of the second boom section Label and tag each set of wear pads being removed Label disconnect and cap the tilt circuit hoses 6 from the tilt cylinder at the front of the third boom section Label disconnect and cap the auxiliary circuit hoses from the quick disconnect fittings at the front of the third boom section Cap all fittings and openings to prevent dirt and debris from entering the hydraulic system 3 5 Boom b 3 Loosen and remove all extend cable sheave components from the front of the pivot beam 4 Pull the extend cables
166. f the yoke pins The lever arm 11 position on the inching valve should set 1 8 3 2 mm off the pin as a starting point Inching HIT reg MX1120 Another check for inching adjustment is to install a high pressure gauge 10 000 psi 689 bar hose and adapter on the Ma port 9 on the side of the drive pump With the park brake on move the shift lever to the forward position At high idle depress the inching brake pedal slowly When the roller on the pedal touches the brake valve plunger the gauge should read 2 300 psi 159 bar 100 psi 6 9 bar 534D 9 534D 10 amp 544D Hydrostatic Drive Pump 6 6 8 The front motor begin point is when the motor begins to stroke toward minimum displacement Front Motor Begin Point 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 digital or high pressure gauge 10 000 psi 689 bar hose and adapter on the Mb port 1 on the drive motor Adjust the reverse high pressure relief valve 2 to 3 000 psi 207 bar by loosening the locknut Install an adapter test port 6 run tee and low pressure gauge 1 000 psi 69 bar into the Ps port 3 on the pump Ps port is the connection for the inching valve hose Set the parking brake and choke the tires to prevent movement of the machine The machine should be in 2WD
167. face level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and shut the engine OFF Air Cleaner Assembly Removal 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal 5 Remove the clamp securing the air intake elbow to the air cleaner assembly Lift the air intake elbow off the air cleaner 6 Remove the capscrews and nuts securing the air cleaner mounting bracket to the air cleaner mounting plate Remove the air cleaner assembly 7 11 MX0970 7 11 2 Air Cleaner Assembly Installation Note Apply Loctite 242 threadlock to the capscrew threads before installation 1 With the air cleaner assembly attached install the air cleaner mounting bracket using capscrews and nuts 2 Place the loosened clamps over the air outlet elbow and install elbow on the air cleaner assembly 3 Adjust and tighten both clamps before starting the machine 4 Connect the battery negative cable to the battery negative terminal 5 Close and secure the engine cover 7 12 ENGINE REPLACEMENT 7 12 1 Note The radiator and oil cooler must be removed from the machine before engine removal Ref
168. fect the machines ability to move especially when ambient pressure is below 32 F 0 C Hydraulic Filter Condition To check the hydraulic filter condition warm the hydraulic system oil to operating temperature 100 F 38 C minimum Check the filter restriction indicator on the return filter The indicator should not show filter bypass with the engine running at full throttle and the park brake engaged If the indicator shows bypass replace the suction and return filters For proper maintenance schedule see Section 2 5 Service and Maintenance Schedules 6 6 3 Low engine RPM can reduce control pressure Control pressure determines machine speed This condition can slow the machine at full RPM Engine Speed Check engine speed with an adequate tachometer At low idle the engine speed should be 800 rpm At high idle with no load the engine speed should be 2400 rpm 5340 9 2500 rpm 5340 10 2200 rpm 5440 If either the low or high idle is not within specification contact your JLG Service Distributor 6 5 Hydrostatic Drive Pump 6 6 4 Park Brake Park 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 in the 2WD position With the rear wheels aligned straight ahead move the shift lever to the forward position and run the engine at high idle If the brakes are working pro
169. free of the sheave brackets and lay them on the boom 5 At the rear of the boom loosen and remove all retract cable sheave components and the hydraulic hose rollers and components 7 6 Loosen and remove all push beam pins 8 7 Pull the push beam free from the front of the third boom section 8 Place the hydraulic hoses inside the third boom section 9 Place a sling around the third boom section lift and slowly pull the third boom section approximately half way out of the second boom section Lower the third boom section onto a suitable support 10 Relocate the sling or using two slings for better stability balance the third boom section and slowly pull the third boom section out of the second boom section Lower the third boom section onto suitable supports Note Before reassembly of the boom check the bores pins and bushings for damage Repair as needed Also check the diameters of the pins and bushings 3 6 3 3 4 Third Boom Section Installation Note During reassembly use Loctite 2429 on all bolt threads and use Loctite 5459 on all hydraulic fittings Note Shim all wear pads to 1 16 of a tight fit You may have to final adjust the wear pads after the boom assembly is installed on the machine and hydraulic power is available Note Coat the interior of all bushings and sheave
170. fully slide the third boom section into the second boom section 12 Install the push beam 3 fully into the second boom section lining up the mounting pin bores at the rear of the second boom section 13 Install the push beam mounting pins and locking hardware 4 14 Leave 6 in 8 in 152 mm 208 mm of the third boom section out to be able to install the wear pads in the front of the second boom section 15 With the sling still under boom head install the wear pads and spacers in the front of the second boom section 16 Install the top wear pads and spacers on the top rear of the third boom section 17 Install the wear pads and spacers on the bottom and both sides at the rear of the second boom section For ease of installation DO NOT install the top wear pads at this time 18 Lubricate wear pads inside sheaves bores and pins during assembly 3 3 6 Second amp Third Boom Section Installation 1 Place the first boom section upside down on suitable supports 2 Lubricate the inside first boom section on area s where the second boom section wear pads will slide 3 Using a suitable sling balance the second and third boom sections and carefully slide 3 ft 4 ft 0 9 m 1 22 the front of the first boom section 3 7 N Boom 10 11 12 13 14 Set the second and third boom sections onto a suitable support and reset
171. g Excessive Fuel Consumption Black Exhaust Blue White Exhaust Low Oil Pressure Knocking Erratic Running Vibration High Oil Pressure Overheating Excessive Crankcase Pressure Poor Compression Starts and Stops 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 22 31 32 33 5 7 8 9 10 11 12 13 14 15 16 18 19 20 21 22 24 29 31 32 33 61 63 8 9 10 11 12 13 14 18 19 20 21 22 23 24 25 26 27 31 32 33 61 63 8 9 10 12 13 14 16 18 19 20 25 26 28 29 30 32 11 13 14 16 18 19 20 22 23 24 25 27 28 29 31 32 33 63 11 13 14 16 18 19 20 22 24 25 27 28 29 31 32 33 61 63 4 16 18 19 20 25 27 31 33 34 35 45 56 62 4 96 37 38 39 40 42 43 44 58 9 14 16 18 19 22 26 28 29 31 33 35 36 45 46 59 7 8 9 10 11 12 13 14 16 20 21 23 26 28 29 30 33 35 45 59 13 14 20 23 25 26 29 30 33 45 47 48 49 4 38 41 11 13 14 16 18 19 24 25 45 50 51 52 53 54 57 25 11 19 25 28 29 31 32 33 34 46 59 10 31 33 34 45 55 60 11 12 1 Battery charge low 2 Bad electrical connection 3 Faulty starter motor 4 Incorrect grade of lubricating oil 5 Low cranking speed 6 Fuel tank empty 7 Faulty stop control operation 8 Fuel inlet restricted 9 Faulty fuel lift pump Clogged fuel filter 11 Restricted air cleaner Air in fuel system Faul
172. gnition key switch and the steering wheel stating that the machine should not be operated A WARNING DO NOT service the machine without following all cool safety precautions as outlined in the Safety 4 Practices section of this manual 3 Open the engine cover Allow the system fluids to Remove the battery negative cable at the battery negative terminal 5 Label disconnect and cap the four hoses from the side of the steering valve 1 Cap the fittings on the steering valve Label disconnect and plug the load 4 2 1 Cab Safety sense hose at the front of the steering valve Cap the fitting on the steering valve A CAUTION The protection offered by this ROPS FOPS will be impaired if subjected to any modification or structural damage at which time replacement is necessary ROPS FOPS must be properly installed using fasteners of correct size and grade and torqued to their specified value A WARNING DO NOT weld grind drill repair or modify the cab in any way Any modification or damage to cab structural components requires cab replacement 4 2 OPERATOR S CAB To help ensure optimum safety protection and performance replace the cab if it is damaged Refer to the appropriate parts manual for ordering information 4 2 2 Serial Number Decal The cab serial number decal is located on the left side of the cab behind the seat Information specified on the seri
173. harp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 4 Connect the battery negative cable to the battery negative terminal 5 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 6 Inspect the service brake valve and connections for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 7 Replace belly pan 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 8 8 3 Brake Test Carefully bleed the brake lines as soon as the brake valve is installed in the machine Air in the system will not allow the brakes to apply properly There are four brake bleeder locations on the front axle with the outer bleeders being for the service brakes Work with an assistant to perform this procedure 1 Place the travel select lever in NEUTRAL engage the park brake 2 Install a test port line between the charge pressure test port and the service brake pressure test port 3 Start the machine disengage the park brake and apply the service brake Note lf an assistant is not available block the brake pedal between the pedal pad and
174. haust Gas Temperature 2 Circuit Low 1675 3249 3 Exhaust Gas Temperature 2 Circuit High 1676 3249 2 Exhaust Gas Temperature 2 Circuit Erratic 1677 3031 4 Catalyst Tank Temperature Low 1678 3031 3 Catalyst Tank Temperature High 1679 3031 2 Catalyst Tank Temperature Erratic 1681 3361 12 Catalyst Dosing Control Unit 9 22 534D 9 534D 10 amp 544D Electrical System Fault Code SPN Code FMI Code Description 1682 3362 11 81 Catalyst Reagent Dosing Unit Input Lines 1683 3449 3 Catalyst Tank Heater Circuit High 1684 3363 4 Catalyst Tank Heater Circuit Low 1687 3050 0 Catalyst Over Temperature 1689 251 12 2 Real Time Clock Power Interrupt Erratic 1692 3234 4 Aftertreatment NOx Sensor Low 1694 3234 2 Aftertreatment NOx Sensor Erratic 1697 3489 3 Aftertreatment 1 Air Enable Actuator High 1698 3489 4 Aftertreatment 1 Air Enable Actuator Low 1699 1761 2 Catalyst Tank Level Sensor Erratic 1711 3361 9 Dosing Control Unit Datalink Abnormal Update Rate 1712 3363 1 18 Catalyst Tank Heater Circuit Low 1713 3363 0 16 Catalyst Tank Heater Circuit High 1716 411 11 Auxiliary Temperature Sensor Input 1 Circuit 1717 3241 0 15 Exhaust Gas Temperature 1 High 1718 1322 11 81 Engine Misfire for Multiple Cylinders 1848 105 10 Intake Manifold 1 Temperature Abnormal Rate of
175. he bottom front to install the retract chain adjustment block and wear pads 3 Install the retract chain adjustment block and bolt into place 4 Install the wear pads and shims at the front of the first boom section 5 Install the wear pads and shims at the rear of the second boom section 6 From the rear of the boom push the third boom section retract chain in place between the first and second boom sections Place the chain clevis through the adjustment block and install the jam nuts Do not tighten the jam nuts at this time 7 From the rear of the boom feed the tilt aux hoses between the first and second boom sections 8 Install the hose take up brackets and connect the tilt aux hoses to the proper fittings Note Do Not install the rod end of the extend retract cylinder to the second boom section at this time as it may be necessary to move the boom sections to access hoses wear pads or chains 3 11 6 Third Boom Section Installation 1 Grease the inside wear pad paths of the second boom section and the outside wear paths of the third boom section 2 Position the third boom section with the extend chains connected at the rear and laying on the third boom section into the front of the second boom section Leave room between the sections to install the wear pads 3 Install the wear pads and shims at the front of the second boom section 4 Install the wear pads and shims at the rear of the third boom sectio
176. he forward high pressure relief valve on the traction lock valve under 6 800 psi 469 bar Turn the valve in 1 8 turn and secure the lock nut Repeat the procedure for reverse 13 Then reset the POR valve to 6 300 psi 434 bar 12 qa 5 d be T MX0900 6 6 10 Complete the following checks to ensure that the traction lock valve 2WD AWD solenoid valve and the begin point on the front drive motor are operating correctly Machine Operation With the machine at operating temperature drive the machine in a flat smooth open area Set the machine for 4WD operation Depress the traction lock switch Drive the machine at full speed Release the traction lock switch the machine should pick up speed Shift the machine to 2WD and repeat this test The machine should 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 travel 100 feet 30 5 m in 3 6 4 0 seconds In 4WD the machine will travel 100 feet 30 5 m in 10 6 11 6 seconds The machine must be traveling at full speed at the start of the measured distance 534D 9 534D 10 amp 544D Section 7 Engine Contents PARAGRAPH TITLE PAGE 7 1 Introduction John Deere 4045TF275 amp 4045 275 7 2 7 1 1 Disclaimer and
177. he machine off The relief valves 5 are located at each end of the valve sections from the left side in at main control valve Loosen the jam nut on the relief valve and using an allen wrench turn the relief clockwise to increase pressure or counter clockwise to decrease pressure Start the machine leave the park brake applied run the engine at low idle and bottom the individual section in both directions The gauge should read 3250 psi 100 0 psi 224 bar 6 9 0 bar 534D 9 10 3000 psi 100 0 psi 207 bar 6 9 0 bar 544D for the tilt section and the sway section The auxiliary section should read 2000 psi 100 psi 138 bar 6 9 bar If the proper pressure cannot be set use the accompanying hydraulic schematic electrical schematic to help correct the problem 534D 9 534D 10 amp 544D Hydraulic System Hydraulic Schematic 534D 9 8 4 2 IMYA HBZIIIGVIS 31 WNOILdO TONON 21 INVA SSVdAg IWVWYAHL Homs 9718115 IMYA TOH1NOO Qi oso aaziunssaud NON MOAH3S3H HS3N 00 901NOILOVHL W3Hivaug s4 g yad Nouons 2 20 O LNOO 1081NO9 VQ SOLON 3AINQ LNON
178. he negative battery terminal Disconnect the wiring connector at the valve solenoid lead Loosen and remove the coil mounting nut and remove the coil Remove the valve solenoid being careful not to lose or damage any o rings Note the location of any orifices check valves and o rings if equipped 534D 9 534D 10 amp 544D Electrical System b Solenoid Disassembly DO NOT disassemble a solenoid Replace a defective solenoid with a new part c Solenoid Installation 1 Install the solenoid using new o rings and tighten Install coil and tighten mounting nut Do Not Over Tighten 2 Connect the wire connector to the solenoid 3 Start the machine and slowly move joystick to engage function If further trouble shooting is required refer to Section 9 5 Electrical System Schematics or Section 8 4 Hydraulic Circuits 9 10 2 The Stabilizer Proximity Sensor activates when the boom raises above 45 light on switch will light Stabilizer Proximity Sensor a Stabilizer Sensor Removal 1 The stabilizer sensor 1 is located at the left rear corner of the first boom section pivot pin 2 Remove the battery negative cable at the negative battery terminal 3 Unplug the stabilizer sensor connector from the wiring harness connector 4 Measure and record distance from end of sensor to the sensor bracket 5 Loosen and remove jam nut and sensor b Stabilizer S
179. he water Dispose of contaminated water properly 4 Adda diesel fuel emulsifying agent to the tank Refer to the manufacturer s instructions for the correct emulsifying agent to water mixture ratio Refill the tank with water and agitate the mixture for 10 7 10 minutes Drain the tank completely Dispose of contaminated water properly 5 Refill the fuel tank with water until it overflows Completely flush the tank with water Empty the fuel tank and allow it to dry completely d Assembly The fuel level indicator can be removed and reused on the new replacement tank Dispose of the old tank according to local regulations concerning hazardous materials disposal regulations e Inspection Note lf a leak is suspected in the fuel tank contact a JLG Service Department 1 Inspect the fuel tank thoroughly for any cracks slices leaks or other damage 2 With the fuel tank removed from the machine plug all openings except one elbow fitting Install the elbow fitting and apply approximately 1 1 5 psi 7 10 kPa of air pressure through the elbow Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area f Fuel Tank Installation 1 Set fuel tank in its original orientation at the side of the machine 2 Install the four fuel tank mounting bolts 3 Install the fuel sender with new gasket into the fuel tank and secure with screws DO NOT ove
180. heel hits the steering stop 534D 9 534D 10 amp 544D Hydraulic System n Note High idle may be needed to allow the steering to bottom against the steering stop 5 With the engine running at low idle turn the steering wheel into the steering stop The gauge should read 2500 psi 100 psi 172 bar 6 9 534D 9 10 3000 psi 100 psi 207 bar 6 9 544D Note Do not stall the steering orbitrol valve for more than 10 seconds as to not allow an excessive amount of heat buildup d 1 Adjusting Steering Pressure Shut the machine off The steering valve relief is located in the top rear of the flow divider valve at the left inside rear of the frame Remove the hose and fitting 1 from the flow divider MX1130 The relief adjustment is located in the port Using an allen wrench turn the relief clockwise to increase pressure or counter clockwise to decrease pressure 4 Replace the fitting and hose Start the machine and turn the steering wheel against the stop If the reading is not correct repeat steps 2 3 4 and 5 If the proper pressure cannot be set use the accompanying hydraulic schematic electrical schematic to help correct the problem 534D 9 534D 10 amp 544D e 1 Hydrostatic Drive Pressure Start the machine and warm the hydraulic system to operating temperature Shut off the machine and install a digital or a 10 000 psi 689 bar gauge
181. her reservoir label and remove the cab harness connectors from the washer reservoir connectors 5 Remove the windshield washer hoses from the reservoir b Disassembly DO NOT disassemble the pump The pump is not serviceable Replace pump if found to be defective c Installation and Testing 1 Connect the windshield washer hoses to the reservoir 2 Connect the cab wiring harness connectors to the reservoir connectors Install the reservoir tank onto the mounting bracket Install the lock washers and nuts and secure Fill the washer fluid reservoir with washer fluid o ms Connect the negative battery cable to the negative battery terminal 7 Turn the ignition key switch to the RUN position and press the washer switch Verify that fluid is sprayed on both the windshield and rear glass 9 9 HEATER AND FAN IF EQUIPPED 9 9 1 Cab Heater Controls See Section 9 12 2 Dash Switches 9 10 SOLENOIDS SENSORS AND SENDERS 9 10 1 Circuit Solenoids Depending if the machine is equipped with options there could be a total of four solenoids in the following locations Park Brake Standard Traction Lock Standard Stabilizer Standard 544D Option 534D 9 534D 10 Tilt on Joystick Option With the exception of the traction lock solenoid the remaining solenoids can be temporarily switched for trouble shooting purposes 9 12 Solenoid Removal Park Brake Solenoid Removal
182. housing with the holes in the frame Install the pivot pin and replace the shims on each end of the axle Install the pivot pin lockbolt and nut Move the sway cylinder into position on the axle cylinder anchor Insert the pin through the cylinder and cylinder anchor Secure the cylinder mount pin with the retaining clip Tighten the axle oil drain plug loosen and remove the axle oil fill plug 3 Refer to Section 2 4 Fluid and Lubricant Capacities for proper oil and capacities E C 11 9 a 8 Rotate wheel hubs 90 degrees so the drain plug 4 becomes the fill plug Refer to Section 2 4 Fluid and Lubricant Capacities for proper oil and capacities 534D 9 534D 10 amp 544D 12 MX0580 Install the wheel and tire assemblies Refer to Section 5 6 2 Installing Wheel and Tire Assembly onto Machine Carefully remove the jack hoist or overhead crane and sling supporting the axle Carefully raise the machine using a suitable jack or hoist Remove the supports from beneath the frame and lower the machine to the ground Remove the blocks from the front and rear of both tires on the other axle Note ALWAYS use new o rings when servicing the machine 13 14 15 16 17 18 19 Install new o rings into the fittings Lubricate the o rings with clean h
183. in 9 holding the extend retract cylinder at the strong back 534D 9 534D 10 amp 544D Boom b 10 Loosen and remove the bolts holding the strong back to the rear of the first boom section Remove the strong back Remove the wear pads from the front of the first boom section Note the location of the wear pads mounting bolts and number of shims from each location Remove the wear pads from the top rear and one side of the second boom section Note the location of the wear pads mounting bolts and number of shims from each location Note It be necessary to pull the boom section s out far enough to access the wear pads 13 3 4 4 1 Slowly pull the two boom sections out of the first boom section The extend cables retract cable and the tilt aux hoses will come out along with the boom sections Pay close attention to the retract cable and tilt aux hoses during the boom section removal as not to allow the cable or hoses to become jammed between the second and first boom sections Lift the two boom sections free of the machine and place on the ground or suitable supports Second Boom Section Installation Grease the inside wear pad paths of the first boom section and the outside wear paths of the second boom section Position the second boom section into the front of the first boom section Leave room at the bottom front to install the retract cable adjustment block
184. inal has current and that the fuse in the fuse panel is not blown 6 Check for broken shorted frayed disconnected or damaged wiring between the fuel level indicator wiring at the cab fuse and relay panel ignition key switch and from the fuel level sender on the fuel tank through the wiring in the cab 7 Check the fuel level sender A defective fuel level sender in the fuel tank may also prevent the fuel level indicator from moving Refer to Section 9 5 Electrical System Schematics for further information 9 11 GAUGES 9 11 1 The machine is equipped with an analog fuel level oil pressure water temperature and battery voltage gauge Analog Gauges MX0740 a Removal 1 Remove the battery negative cable at the negative battery terminal 2 Remove the four bolts holding the gauge panel unplug connectors from the harness on the backside of the gauge panel and remove the panel from the dash 534D 9 534D 10 amp 544D b Disassembly DO NOT disassemble the gauge The gauge is not serviceable Replace the gauge if found to be defective c Installation and Testing 1 Install the gauge in the dash Install the gauge bracket lock washers and nuts Connect the wire connections 2 Connectthe battery negative cable at the negative battery terminal 3 Turn the ignition to the ON position to check the fuel level If gauge is not reading properly refer to Section
185. ing with a soft brass wire brush prior to reassembly 9 Remove the piston head from the rod and carefully slide the head gland off the end of the rod 10 Remove all seals back up rings and o rings from the piston head and all seals back up rings and o rings from the head gland Note The head gland bearing will need to be inspected to determine if replacement is necessary 8 22 DO NOT attempt to salvage cylinder seals sealing rings or o rings ALWAYS use a new complete seal kit when rebuilding hydraulic components Consult the parts catalog for ordering information b Cylinder Cleaning Instructions 1 Discard all seals back up rings and o rings Replace with new items from seal kit to ensure proper cylinder function 2 Clean all metal parts with an approved cleaning solvent such as trichlorethylene Carefully clean cavities grooves threads etc Note If a white powdery residue is present on threads or parts it can be removed by using a soft brass wire brush Wipe clean with Loctite Cleaner prior to reassembly c Cylinder Inspection 1 Inspect internal surfaces and all parts for wear damage etc If the inner surface of the cylinder barrel does not display a smooth finish or is scored or damaged in any way replace the barrel 2 Remove light scratches on the piston head gland rod or inner surface of the cylinder barrel with a 400 600 grit emery cloth Use the emery cloth in a rotary motion to polish o
186. ipment procedures or processes described nor provide directions for meeting every possible contingency during operation maintenance or testing When additional information is desired consult the local JLG distributor Many factors contribute to unsafe conditions carelessness fatigue overload inattentiveness unfamiliarity even drugs and alcohol among others For optimal safety encourage everyone to think and to act safely Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work for the safety of the operator and for the safe reliable operation of the machine All references to the right side left side front and rear are given from the operator s seat looking in a forward direction Supplementary information is available from JLG in the form of Service Bulletins Service Campaigns Service Training Schools the JLG website other literature and through updates to the manual itself 1 2 1 2 DISCLAIMER All information in this manual is based on the latest product information available at the time of publication JLG reserves the right to make changes and improvements to its products and to discontinue the manufacture of any product at its discretion at any time without public notice or obligation 1 3 OPERATOR amp SAFETY MANUAL The mechanic must not operate the machine until the Operator amp Safety Manual has been read amp understood trai
187. irt or foreign substance packed in the joints clean and lubricate thoroughly before re installing the chain If the problem is caused by corrosion and rust or bent pins replace the chain c Expose Retract Chains for Inspection The three retract chains are only partially visible through the rear of the boom with all the sections retracted It is possible to see a section of the retract chain as the boom is slowly extended If there is ANY question that one or all the retract chains are damaged the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary Note DO NOT attempt to repair a chain Replace a stretched or damaged chain with a new part Always replace both the chain and the clevis It is recommended that when any chain is replaced that all chains and clevis be replaced at the same time 3 12 3 1 Raise the boom to a horizontal position and extend the boom halfway Place the transmission control lever in N NEUTRAL engage the park brake switch Shut off machine Adjusting Extend Chains 2 Measure the gaps 1 between the flat washers and the rear face of the extend chain anchor at the top front of the first boom section The correct gap measurement is 1 4 in 6 mm If the gaps measure more or less than a 1 4 in 6 mm then the chains must be adjusted 3 Repeat the check for the single extend chain for the fourth boom section anchored at the top of the top
188. ith the push beam 24 When the head of the push beam is out of the third boom section stop and pull the extend cables the remaining of the way out over the cable sheaves of the push beam 25 Slowly pull the push beam free of the machine and place on the ground or suitable support Note The extend retract hydraulic cylinder can be removed from the push beam if necessary 26 Pull the retract cable from between the second and first boom section at the rear of the boom 27 Slowly pull the third boom section free of the machine and place on the ground or suitable support 3 4 2 1 Pull the tilt hoses and if equipped the auxiliary hoses from the bottom rear of the boom sheaves Second Boom Section Removal 2 Remove the wear pads from the front of the first boom section Note the location of the wear pads mounting bolts and number of shims from each location 3 Remove the wear pads from the top rear and one side of the second boom section Note the location of the wear pads mounting bolts and number of shims from each location 4 Loosen and remove the retract cable adjustment block 12 from the bottom front of the first boom section Note It may be necessary to pull the boom section s out far enough to access the wear pads 5 Slowly pull the second boom section out of the first boom section 3 10
189. itting is located on the top of the drive pump Refer to Section 7 7 3 Radiator Oil Cooler and Replacement Disconnect and back flush the oil cooler portion of the radiator or the oil cooler located behind the radiator with oil and compressed air until all foreign material is removed If necessary remove the radiator or oil cooler from the machine and clean the oil cooler circuit using oil compressed air and steam Note DO NOT use flushing compounds for cleaning purposes 6 5 DRIVE PUMP REPLACEMENT Note Contact the JLG Service Department if internal drive pump repair is required during the warranty period Note To help ensure safety and optimum performance replace the drive pump if it is damaged Refer to the appropriate parts manual for ordering information Cleanliness is of extreme importance Before attempting to remove the drive pump thoroughly clean the exterior of the drive pump to help prevent dirt from entering during the replacement process Avoid spraying water or cleaning solution onto or near the drive pump shift solenoids and other electrical components 6 5 1 Drive Pump Removal A WARNING NEVER lift a drive pump alone enlist the help of at least one assistant or use a Suitable hoist or overhead crane and sling 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the drive pump control lever in N NEUTRAL engage the park br
190. ive terminal Note If removing rear drive motors refer to Section 8 7 2 Hear Drive Motors If removing rear drive hubs refer to Section 5 4 1 Rear Drive Hub Service 5 Label disconnect and cap the hoses on both drive motors and on both steer cylinders Wipe up any spilled oil 6 Block the front and rear of both tires on the front axle Ensure that the machine will remain in place during axle removal before proceeding 7 Raise the machine using a suitable jack or hoist Place suitable supports under both sides of the frame and lower the machine onto the supports Ensure that the machine will remain in place during axle removal 8 Support the rear axle with a suitable jack hoist or overhead crane and sling DO NOT raise the axle or the machine 9 Mark and remove both wheel and tire assemblies from the axle that is being removed Refer to Section 5 6 1 Hemoving Wheel and Tire Assembly from Machine 5 10 Note The wheel and tire assemblies must be re installed later with the directional tread pattern arrows facing in the direction of forward travel 10 On the rear axle remove the retaining pin 2 securing the stabilizer cylinder pin to the frame Tap the pin out and move the cylinder to prevent it from interfering with axle removal Note The stabilizer cylinder is standard equipment on the 544D and optional equipment on the 585D 9 amp 534D 10 0660
191. ividual parts are available for the drive motors it is recommended that any disassembly and reassembly is done by an authorized JLG Service Center c Rear Drive Motor Installation 1 Apply Molybdenum on the splined shaft and Ultra Blue silicon sealant at the base of the drive motor 2 Align the splined shaft on the drive motor with the drive hub housing and slide into place over the housing studs 3 Apply Loctite 242 and install the four nuts and lock washers holding the drive motor to the drive hub housing 4 Uncap and reconnect the previously labeled hydraulic hoses and tubes to the appropriate locations Note Uncap each hose and tube as you install them to prevent unnecessary fluid spillage 5 Connect the battery negative cable to the battery negative terminal 6 Add hydraulic oil as needed 7 Start and warm machine to operating temperature and add hydraulic oil if needed 8 15 Hydraulic System n 8 8 CONTROL VALVES 8 8 1 Main Control Valve The main control valve is mounted on the frame of the cab below the seat The main control valve assembly consists of five working sections with their own valve assemblies each providing a specific hydraulic function a Main Control Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and
192. ks to help correct the problem Service Brake Pressure Start the machine and warm the hydraulic system to operating temperature Shut off the machine and install a digital or a 1000 psi 69 bar gauge to the test port located at the top center of the front axle Make sure the gauge can be observed from the operator s cab Start machine and switch OFF park brake Depress brake pedal as far as possible to obtain maximum service brake pressure The gauge should read 638 psi 50 psi 44 bar 3 4 bar at low idle Adjusting Service Brake Pressure The brake pressure is non adjustable If the proper pressure cannot be set use the accompanying hydraulic schematic electrical schematic to help correct the problem Main Control Pressure Start the machine and warm the hydraulic system to operating temperature Shut off the machine and install a digital or a 10 000 psi 689 bar gauge to the test port located at the left side in front of the return filter Make sure the gauge can be observed from the operator s cab Start the machine leave the park brake applied Running the engine at high idle bottom the extend retract cylinder The gauge should read 3100 psi 200 0 psi 213 7 bar 13 8 0 bar 534 D 9 10 3500 psi 200 0 psi 241 bar 13 8 0 bar 544D Adjusting Main Control Pressure Shut the machine off The main relief valve 4 is located at the right rear corn
193. l Information and Specifications 2 1 REPLACEMENT PARTS AND WARRANTY INFORMATION Before ordering parts or initiating service inquiries make note of the machine serial number The machine serial number plate 1 is located at the left front corner of the frame NOTICE The replacement of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance durability or safety of the machine and will void the warranty JLG disclaims liability for any claims or damages whether regarding property damage personal injury or death arising out of the use of unauthorized replacement parts A warranty registration form must be filled out by the JLG distributor signed by the purchaser and returned to JLG when the machine is sold and or put into use Registration activates the warranty period and helps to assure that warranty claims are promptly processed To guarantee full warranty service verify that the distributor has returned the business reply card of the warranty registration form to JLG 2 2 534D 9 534D 10 amp 544D General Information and Specifications ASTM Fastener Torque Chart English 2 2 1 TORQUE CHARTS 2 2
194. l filters fill with Mobilfluid 424 Tractor Hydraulic Fluid ISO 46 before installing on the filter head 23 Check that all hydraulic system electrical system cooling system fuel system and exhaust system connections are correct and connected tightly Note Have an assistant stand by with a Class B fire extinguisher Start and idle the engine 24 Run engine to normal operating temperature then shut off the engine While the engine is cooling check for leaks 25 Allow the engine to cool Check the radiator coolant level and top off with a 50 50 mixture of ethylene glycol and water Replace the radiator cap 26 Check for leaks from the engine main hydraulic pump and lines drive pump hydraulic reservoir and fuel tank Check the levels of all fluids and lubricants Fill as required Note During the full throttle check DO NOT operate any hydraulic function DO NOT steer or apply any pressure to the steer ing wheel Keep the transmission in NEUTRAL 27 Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times Check the hydraulic oil level 28 Check for proper operation of all components 29 Turn the engine OFF 7 13 ENGINE DRIVE PLATE COUPLING 7 13 1 1 Level the machine ground the attachment place the travel select lever in NEUTRAL N engage the parking brake and shut off the engine Drive Plate Coupling Removal 2 P
195. l the boom section s out far enough to access the wear pads 20 Slowly pull the fourth boom section out of the third boom section The extend chain will come out along with the boom section The retract chain will stay with the second boom section 21 Lift the fourth boom section free of the machine and place on the ground or suitable supports 3 11 2 Third Boom Section Removal 1 Loosen the jam nuts on the extend chains at the top front of the first boom section Disconnect the extend chains 2 from the chain clevises 2 Loosen the jam nuts on the retract chain at the bottom rear of the third boom section Disconnect the retract chain 3 from the chain clevis 3 Loosen and remove the wear pads from the front of the second boom section Note the location of the wear pads mounting bolts and number of shims from each location 3 30 MX1420 Loosen and remove the wear pads from the top rear and one side of the third boom section Note the location of the wear pads mounting bolts and number of shims from each location Slowly pull the third boom section out of the second boom section The extend chains will come out along with the boom section The retract chain will stay with the first boom section Lift the third boom secti
196. lace a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Note In order to remove the engine drive plates the engine and transmission must be separated 3 Refer to Section 6 5 1 Drive Pump Removal or Section 7 12 1 Engine Removal 7 14 7 13 2 1 Loosen and remove the bolts 1 holding the pump mounting plate to the engine bell housing Remove the mounting plate Remove the bolts 2 holding the drive plate to the flywheel With the drive plates removed loosen and remove the bolts 3 holding the coupling to the drive plate Replace the drive plate and or the coupler if damaged Drive Plate Coupling Installation Install the new coupler 3 on the drive plate and torque the bolts with lock washers to 40 45 Ib ft 54 61 Nm Mount the drive plate coupler assembly 2 to the flywheel install the bolts and torque to 40 45 Ib ft 54 61 Nm Install the pump mounting plate 1 to the engine bell housing and torque the bolts to 40 45 Ib ft 54 61 Nm Refer to Section 6 5 3 Drive Pump Installation or Section 7 12 3 Engine Installation for the remainder of the installation 534D 9 534D 10 amp 544D Engine 7 14 ENGINE TROUBLESHOOTING Trouble Possible Causes see key below Low Cranking Power Will Not Start Difficult Starting Lack of Power Misfirin
197. leaks or tube s tighten connections 2 Lift Lower hydraulic system not 2 Refer to Section 8 4 Hydraulic operating properly Circuits 3 Faulty Lift cylinder 3 Repair cylinder Refer to Section 3 3 1 Boom Removal 4 Seized boom pivot pin bushing 4 Replace bushing 7 Excessive Lift Lower cylinder 1 Insufficient lubrication 1 Lubricate at regular intervals pivot pin noise and or wear Refer to Section 2 6 Lubrication Schedules Replace worn pins as needed Refer to Section 3 3 1 Boom Removal 2 Worn self aligning bushing s 2 Replace bushing s and lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules 534D 9 534D 10 amp 544D 3 45 N Boom Boom Troubleshooting Continued Problem Cause Remedy 9 Rapid boom pad wear 1 Incorrect wear pad gap 1 Check wear pad gaps and correct as needed Refer to Section 3 15 2 Boom Wear Pad Replacement 2 Rapid cycle times with heavy 2 Reduce cycle times loads 3 Contaminated corroded or 3 Remove contamination and or rusted wear pad sliding corrosion from wear pad sliding surfaces surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s 4 Operating in extremely dusty 4 Clean equipment frequently abrasive conditions 10 Auxiliary hydraulics will not 1 Auxiliary hydraulic system not 1 Refer to Section 8 4 Hydraulic operat
198. let Brown Wire X If all wires do not show proper continuity replace the ignition switch d Ignition Switch Installation 1 Connect the ignition key switch to the cab harness connectors 2 Reach up and under the dash to work the ignition switch into the ignition switch mounting hole on the lower right side of the dash 3 Align the ignition switch so that when it is in the OFF position the key slot is positioned vertically straight up and down Install the hex nut securing the ignition switch to the dash DO NOT overtighten 4 Install the lower access panel 5 Connect the battery negative cable at the negative battery terminal Note If further information is needed refer to Section 9 5 Electrical System Schematics 9 12 2 Dash Switches a Switch Removal 1 Remove the battery negative cable at the negative battery terminal 2 There are three standard switches in the gauge panel park brake 4x4 4x2 and shutdown override The machine could be equipped with one or more of these optional switches heater on off beacon work lights and wiper washer switch 9 16 John Deere HEATER sHUTDWN BEACON HIGH overrive MX1240 3 Pull the panel out of the dash disconnect the harness connector to the switch in question and rem
199. line of the head and case within plus or minus 0 30 either side of the line This hole is to be 0 438 deep and perpendicular to the centerline within plus or minus 5 Do Not drill in line with the spanner holes or wrench flats within 0 500 8 24 534D 9 534D 10 amp 544D Section 9 Electrical System Contents PARAGRAPH TITLE PAGE 9 1 Electrical Component 9 2 9 1 1 General Overview Cab and Engine Harness 9 2 9 2 Specifications ceci x ra RR ee 9 3 9 3 Service Warnings 9 3 9 4 Fuses and Relays 9 3 9 4 1 Cab LITT 9 3 9 4 2 Engine Compartment 9 3 9 5 Electrical System Schematics 9 4 9 5 1 Electrical Schematic 5340 9 5340 10 John Deere 9 4 9 5 2 Electrical Schematic 5440 John Deere 9 5 9 5 3 Electrical Schematic 5340 9 5340 10 5440 Cummins 9 6 9 5 4 Start Circuit 5340 9 5340 10 544D 9 7 9 5 5 Charge Circuit 534D 9 584D 10 544D 9 8 9 6 Engine Start Circuit cs ele ee ree 9 9 9 6 1 cl PPM NEL MM MD 9 9 9 7 Charging Circuit Pe 9 10 9 7 1
200. m b 18 Connect the 3 4 in 19 mm retract chain 4 to the clevis at the rear of the fourth boom section 19 Connect the chain to the chain clevis and the clevis to the chain adjustment block 20 The initial set up from the jam nut to the back of the clevis pin is 3 4 in 19 mm 21 Adjust the nut until the gap between the nut and the washer is 1 4 in 6 4 mm 22 Torque the jam nut to 100 Ib ft 135 Nm Lubricate the clevis threads with Anti Seize Compound 23 Lay out and lubricate the two 1 in 25 mm extend chains Make sure the chain has been inspected and meets the adjustment parameters in Section 3 12 Boom Extend and Retract Chains Four Section 24 Attach the rear chain clevis to the chains 3 10 10 Second Boom Section Install 1 Place the clean and inspected second boom section on suitable supports 2 Grease the inside wear pad paths 3 Using a suitable sling lift and position the fourth and third boom sections in front of the second boom section 4 Attach the chain clevis 5 to the top rear of the third boom section qq xii ej MX0440 5 Slowly insert the fourth and third boom sections into the second boom section 6 Bolt the chain adjustment block 6 to the bottom of the boom and torque the bolts to 340 365 Ib ft 460 495 Nm 7 Install the top front wear pads to the second boom section DO NOT torque th
201. m of one full thread on the clevis must protrude beyond the locknut b To decrease the separation distance Loosen the extend chain locknuts at the front of the first or second boom sections equally one or two turns and tighten the retract chains locknut the same number of turns A minimum of one full thread on the clevis must protrude beyond the locknut See Section 3 11 7 3 12 Boom Extend and Retract Chains Four Section Note If the second boom section to the third boom section separation distance cannot be achieved contact the local JLG distributor or the JLG Service Department 3 14 HYDRAULIC SUB ASSEMBLY REMOVAL INSTALLATION FOUR SECTION The hydraulic sub assembly locates primarily in the fourth boom section It is fastened at the bottom front of the fourth boom section and at the rear of the third boom section 3 14 1 1 Remove any attachment from the quick switch assembly Refer to Section 3 16 1 Disconnecting from an Attachment Hydraulic Sub Assembly Removal Note Allow adequate room in front of the machine when removing and installing the hydraulic sub assembly 3 38 2 Park the machine on a hard level surface level the machine fully retract the boom level the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 3 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should no
202. n 3 31 Boom b 5 Wrap the two extend chains around the chain rollers on the second boom section and connect to the clevises on the front of the first boom section Do not tighten the jam nuts at this time 6 Wrap the retract chain around the chain roller on the second boom section and connect to the rear of the third boom section Do not tighten the jam nuts at this time 3 11 7 1 Grease the inside wear pad paths of the third boom section and the outside wear paths of the fourth boom section Fourth Boom Section Installation 2 Position the fourth boom section with the extend chain connected at the rear and laying on the fourth boom section into the front of the third boom section Leave room between the sections to install the wear pads 3 Install the wear pads and shims at the front of the third boom section 4 Install the wear pads and shims at the rear of the fourth boom section 5 Wrap the extend chain around the chain roller on the third boom section and connect to the clevises on the front of the second boom section Do not tighten the jam nuts at this time 6 Wrap the retract chain around the chain roller on the third boom section and connect to the rear of the fourth boom section Install the retract chain bracket 7 Position the hose carrier into the opening at the boom head of the fourth boom section 8 Remove each nylon tie wrap or suitable strap as the hose carrier is sli
203. n the axle 7 Drain axle and or wheel end housings and fill to correct level with Mobilfluid 4249 ISO 46 Refer to Section 2 4 Fluid and Lubricant Capacities 8 Axle housing damaged 8 Replace damaged parts 2 Intermittent noise when 1 Differential ring and or pinion 1 Determine cause and repair as traveling gears damaged needed 5 6 534D 9 534D 10 amp 544D Axles Wheels and Tires hs Problem Cause Remedy 3 Oil leaking from axle differential housing and or axle housings 1 Drain and or inspection plugs loose and or o rings damaged or missing Hose fittings loose Axle shaft seal damaged or missing and or worn or damaged shaft sealing surfaces Input shaft multi seal ring damaged or missing and or worn or damaged pinion input shaft sealing surfaces Axle casing to brake housing and or brake housing to differential assembly o rings and or seals worn or damaged 1 Replace o rings as needed and tighten plugs to 96 Ib ft 130 Nm Tighten fittings Replace seal and or joint coupling fork shaft axle shaft Replace multi seal ring and or input shaft Adjust ring and pinion alignment and bearing preload as described in the Carraro Repair Manuals Replace o rings and seals 6 Axle housing mounting nuts 6 Tighten housing nuts capscrews loose capscrews to 288 Ib ft 890 Nm 7 Differential and or
204. nch size required 4 mm allen and 10 mm box 6 9 Hydrostatic Drive Pump 6 6 9 Drive pump pressure determines the drive power of the machine Low drive pressure will result in less power Drive Pump Pressure Install a digital or high pressure gauge 10 000 psi 689 bar hose and adapter on the MA port 7 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 The gauge reading should be 6 300 psi 434 bar Adjust the POR relief valve 8 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 9 of the drive pump to repeat the procedure with the shift lever in the reverse position Top View Left Side View 0890 There are also high pressure anti cavitation relief valves on the drive pump These could influence drive system pressure with a low setting or missing o ring On machines with 6 300 psi 434 bar drive pressure adjust these valves to 6 800 psi 469 bar drive pressure Normally these high pressure relief valves do not require checking However if there is a drive power problem and adjustment of the POR relief valve on the
205. ne bellhousing 17 18 6 5 2 Carefully remove the drive pump from the machine Avoid causing damage to the drive pump or surrounding parts Lift the drive pump clear of the machine and lower it onto suitable supports or secure it to a stand built especially for drive pump or engine service Secure the drive pump so that it will not move or fall Drive Pump Inspection and Internal Repair Note Contact the JLG Service Department if internal drive pump repair is required 6 5 3 1 Drive Pump Installation Use a hoist or overhead crane and sling attached to the drive pump Raise and position the drive pump within the chassis Align the input shaft align the drive pump bolt holes with the two holes in the bell housing Install the two bolts and washers and torque to 240 Ib ft 240 Nm Remove the hoist or overhead crane and sling Align the input shaft align the bolt holes of the implement pump to the drive pump Install the two bolts and washers and torque to 160 Ib ft 217 Nm Connect the drive pump shift solenoid wiring harness connectors Secure the wiring harness to the drive pump housing Uncap and connect all the hydraulic hoses and tubes 8 Install the rear cover and belly pan 10 11 12 Refill the hydraulic oil reservoir Refer to Section 8 5 Hydraulic Reservoir Connect the negative battery cable Start engine and check for any hydraulic leaks Close and
206. nents from the front of the push beam 534D 9 534D 10 amp 544D 14 3 5 6 1 2 o i 3 Pull the extend cable through the push beam extend cable sheave bracket Extend Cable Installation Tie a rope to the extend cable threaded end and pull the cable to the anchor bracket weldment area Install the extend cable socket end 8 and the mounting hardware to the extend cable anchor bracket weldment 9 MX0270 Assemble all the extend cable sheave bracket components to the front of the push beam Note The extend cable threaded end must be inserted through the sheave bracket before the sheave components are installed 4 10 Install the push beam fully into the second boom section Install the push beam mounting hardware and the tilt and auxiliary circuit hose guards at the rear of the first boom section Place the strong back in place at the rear of the first boom section and install the extend retract cylinder mounting pin spacers and retaining clips Install the previously removed shims to the top and bottom of the strong back cylinder bracket Install and torque the strong back mounting bolts Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations Install the extend cables springs washers and lock nuts into the strong back Note Be certain that the extend cables are stress free and not twisted 11 12 Remove the ro
207. nents that will be required to be transferred from the original engine to the replacement engine depending upon who you purchase the new engine from and the configuration of your replacement engine Hefer to the appropriate user manual for detailed procedures that cover the transfer of original engine components to the replacement engine 7 12 3 1 Engine Installation Secure the engine with a lifting strap or chain from the appropriate lifting points Use a suitable hoist or overhead crane Inspect the engine mounting bracket isolators Replace isolator if cracked or worn Lift the engine and slowly push and lower into the engine bay Have an assistant ensure that the 534D 9 534D 10 amp 544D engine clears all frame hose and harness components during engine installation 4 Align the motor mount holes and install the bolts Tighten the motor mount bolts 5 Push the hydrostatic drive pump splined shaft into the coupler Install and tighten both bolts 6 Torque the hydrostatic pump bolts to 240 lb ft 325 Nm 25 0 Ib ft 34 0 Nm 7 Connect the fuel inlet and return lines to the engine Note The engine harness is routed and attached at various places on the engine using hold down clamps and plastic wire ties Before installing engine and with the help of an observer ensure that engine clears the harness during installation 8 18 19 20 Connect all the labeled wire harness connection
208. ng 3 44 534D 9 534D 10 amp 544D Boom 3 1 BOOM SYSTEM COMPONENT TERMINOLOGY 534D 9 534D 10 The following illustrations identify the components that are referred to throughout this section SECOND BOOM SECTION THIRD BOOM EXTEND CABLES SECTION inside boom FIRST BOOM SECTION ATTACHMENT TILT CYLINDER ATTACHMENT RETRACT QUICK SWITCH EXTEND RETRACT CABLES CYLINDER inside boom inside boom HOSE SHEAVE inside boom 534D 9 534D 10 amp 544D 3 3 Boom b 3 2 BOOM SYSTEM THREE SECTION 3 2 1 The three section boom consists of the first second and third assemblies with second and third section extend cables and a single second and third section retract cable Boom System Operation As the extend retract cylinder which is anchored at the rear of the first boom section and the front of the push beam begins to extend it forces the second and third boom sections out of the first boom section The boom sections are connected by extend and retract cables These cables are routed around sheaves on the front of the push beam and the rear of the second boom section As the extend retract cylinder is forced out hydraulically the second and third boom sections are pulled out by the extend cables As hydraulic pressure is applied to the retract port on the extend retract cylinder the retract cable pulls
209. ng the cap completely Failure to follow the safety practices could result in death or serious injury FLUID FLAMABILTITY DO NOT service the fuel or hydraulic systems near an open flame sparks or smoking materials NEVER drain or store fluids in an open container Engine fuel and hydraulic fluid are flammable and can cause a fire and or explosion DO NOT mix gasoline or alcohol with diesel fuel The mixture can cause an explosion PRESSURE TESTING When conducting any test only use test equipment that is correctly calibrated and in good condition Use the correct equipment in the proper manner and make changes or repairs as indicated by the test procedure to achieve the desired result LEAVING MACHINE Lower the forks or attachment to the ground before leaving the machine TIRES Always keep tires inflated to the proper pressure to help prevent tipover DO NOT over inflate tires NEVER use mismatched tire types sizes or ply ratings Always use matched sets according to machine specifications MAJOR COMPONENTS Never alter remove or substitute any items such as counterweights tires batteries or other items that may reduce or affect the overall weight or stability of the machine BATTERY DO NOT charge a frozen battery Charging a frozen battery may cause it to explode Allow the battery to thaw before jump starting or connecting a battery charger 1 7 SAFETY DECALS Check that all safety decals are present and read
210. ning has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator An Operator amp Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab In the event that the Operator amp Safety Manual is missing consult the local JLG distributor before proceeding 1 4 DO NOT OPERATE TAGS Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance Remove key and disconnect battery leads 534D 9 534D 10 amp 544D A Safety Practices 1 5 SAFETY INFORMATION To avoid possible death or injury carefully read understand and comply with all safety messages In the event of an accident know where to obtain medical assistance and how to use a first aid kit and fire extinguisher fire suppression system Keep emergency telephone numbers fire department ambulance rescue squad paramedics police department etc nearby If working alone check with another person routinely to help assure personal safety 1 5 1 Safety Alert System and Signal Words A DANGER DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION CAUT
211. nstallation procedure 534D 9 534D 10 amp 544D Axles Wheels and Tires 4 Position the axle under the frame and align the axle housing with the holes in the frame 5 Install the pivot pin 6 and replace the shims 7 on each end of the axle Install the pivot pin lockbolt and nut 8 6 Move the stabilizer cylinder into position on the axle cylinder anchor Insert the pin through the cylinder and cylinder anchor 9 Secure the cylinder mount pin with the retaining pin 7 Uncap and connect the hoses on both drive motors and on both steer cylinders Wipe up any spilled oil Note ALWAYS use new o rings when servicing the machine 8 Install new o rings into the fittings Lubricate the o rings with clean hydraulic oil 0660 8 9 Install the wheel and tire assemblies Refer to Section 5 6 2 Installing Wheel and Tire Assembly onto Machine 10 Carefully remove the jack hoist or overhead crane and sling supporting the axle 11 Carefully raise the machine using a suitable jack or hoist Remove the supports from beneath the frame and lower the machine to the ground 12 Remove the blocks from the front and rear of both tires on the front axle 13 Check the hydraulic reservoir oil level 14 Start the engine Operate the steering function sev
212. o a new engine as soon as the engine is put into service and the coolant temperature is at least 60 C 140 F Extended light load operation during the early life of the engine is not recommended DO NOT run the engine at high no load speeds DO NOT apply an overload to the engine 534D 9 534D 10 amp 544D 7 5 Engine 7 4 2 Component Terminology To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the engine components The following illustration identifies the components that are referred to throughout this section ALTERNATOR A 57 SN Xs Gas 9 x STARTER TURBOCHARGER FUEL FILTER ECM MODULE MH6410 7 6 534D 9 534D 10 amp 544D Engine 7 5 ENGINE SERIAL NUMBER The Cummins QSB4 5 serial number is stamped on a plate which is typically located on the engine rocker cover but may be located on the side of the gear housing Information contained in the serial number is required in correspondence with the engine manufacturer 7 6 SPECIFICATIONS AND MAINTENANCE INFORMATION For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Note Detailed Cummins engine service instr
213. o the engine Remove the o ring located between the engine and the pump Wipe up any hydraulic oil spillage Note DO NOT disassemble the operating pump The pump is pre set from the manufacturer Any adjustments or repairs performed by anyone other than an authorized dealer could void the warranty b Pump Installation 1 Place the pump and a new oiled o ring into position on the engine Align the pump shaft with the internal engine gear so that the machined teeth mesh together 2 Align the bolt holes with the pump mount holes Secure the pump to the transmission with the two bolts and washers 3 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations 4 Fill the hydraulic reservoir Refer to Section 8 5 2 Hydraulic Oil Reservoir Filling 5 Prime the pump by filling the case drain port with fresh filtered hydraulic oil from a clean container before installing the case drain connector and hose 6 Check all routing of hoses and tubing for sharp bends or interference with any rotating members All tube and hose clamps must be tight 7 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 8 Inspect for leaks and check all fluid levels The hydraulic reservoir oil level must be to the middle of the sight gauge 8 14 c Pump Test Refer to Section 8 3 1 Pressure Checks an
214. oisture from condensation Chemical Solutions or Vapors Corrosive attack on the chain components and or the mechanical connections between the chain components Cracking can be and often is microscopic Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time Abrasives Accelerated wearing and scoring of the articulating members of the chain pins and plates with a corresponding reduction in chain strength Due to the inaccessibility of the bearing surfaces pin surfaces and plate apertures wear and scoring are not readily noticeable to the naked eye Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain High velocity movement of load followed by sudden abrupt stops Carrying loads in suspension over irregular surfaces such as railroad tracks potholes and rough terrain Attempting to inch loads which are beyond the rated capacity of the vehicle The above load cycles and environmental conditions make it impossible to predict chain life It is therefore necessary to conduct frequent inspections until replacement life can be predicted The boom chain s normal life expectancy can be expressed as a maximum percent of elongation This is generally 396 As the chain flexes back and forth over the sheave the bearing joints pins and inside link plates gradually
215. om place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover and the hydraulic oil reservoir fuel tank cover Allow the system fluids to cool 4 Disconnect the battery negative cable from the battery negative terminal 5 Remove belly pan from under cab 6 Label disconnect and cap all hose attached to the service brake valve Cap all fittings and openings to keep dirt and debris from entering the hydraulic system 7 Remove the four capscrews four nuts and four lockwashers 1 mounting the service brake valve to the service brake bracket Note DO NOT disassemble the service brake valve The service brake valve is not serviceable and must be replaced in its entirety if defective 8 19 Hydraulic System n b Service Brake Valve Installation 1 Install the service brake valve with the four capscrews four lockwashers and four nuts onto the service brake bracket Note ALWAYS replace seals o rings gaskets etc with new parts to help ensure proper sealing and operation Lubricate seals and o rings with clean hyaraulic oil 2 Use new oiled o rings as required Uncap and connect the previously labeled hoses to the service brake valve 3 Check the routing of all hoses and tubing for s
216. on free of the machine and place on the ground or suitable supports 3 11 3 Second Boom Section Removal 1 Remove the pin 4 from the rod end of the extend retract cylinder Loosen and remove the wear pads from the front of the first boom section Note the location of the wear pads mounting bolts and number of shims from each location Loosen and remove the wear pads from the top rear and one side of the second boom section Note the location of the wear pads mounting bolts and number of shims from each location 534D 9 534D 10 amp 544D Boom b 6 MX144 4 Loosen and remove the tilt aux hose take up bracket b from the bottom of the first boom section Pull the tilt aux hoses out from the rear of the boom 5 Remove the bolts holding the chain adjustment block 6 to the first boom section 6 Slowly pull the second boom section out of the first boom section The third section retract chain will stay with the first boom section 7 Lift the second boom section free of the machine and place on the ground or suitable supports 3 11 4 Second Third and Fourth Boom Section Removal It is best to remove the boom sections in the order in which they were assembled If a section needs to be separated this presents an excellent opportunity to check all sections for serviceability The fourth third and
217. ond boom section Attach the hoses and optional auxiliary hoses and electrical cable if equipped to the hose carrier assembly at the rear of the boom 534D 9 534D 10 amp 544D Boom 20 00 00 00 00 00000 GO OO GO GO GO GO G0 00 GO 00 00 00 00 Q MX0460 23 At the rear of the boom bolt on the bracket to the back of the hose carrier 24 Install the hose guide bracket 10 for the electric and hydraulic options at the rear of the boom 25 Attach the chain clevis to the chain 26 If not already completed install the hoses to the hose carrier at the rear of the boom 27 Install the hose guide bracket to the rear of the second boom section 28 Install the optional hydraulics and electric cables if equipped 29 Install the male and female hydraulic couplers to the boom head weldment of the fourth boom section 3 10 11 First Boom Section Install 1 Place the clean and inspected first boom section on suitable supports 2 Install the hose take up weldment 11 to the first boom section 3 Grease the inside wear pad paths of the first boom section and the outside wear pad paths of the second boom section 534D 9 534D 10 amp 544D MX0470 4 Using a suitable sling lift and position the fourth third and second boom sections into the front of the first boom section 5 Connect the hose assembly 12 to the take
218. ont of the threaded end lines up with the front edge of the access hole 17 At the strong back tighten the extend cable adjusting nut 2 until the gap between the cable flat washer and the strong back is 1 32 to 1 16 in 0 79 1 57 mm Gap for both washers should be the same Note When adjusting cables make sure the cables are not turning 18 Install the jam nut to the adjusting nut and torque to 100 Ib ft 135 Nm 19 Refer to Section 3 5 2 Cable Adjustments for boom section specifications Q 24 3 5 5 removal of the extend cable is difficult operation but it can be accomplished You must be able to reach into the rear of the boom assembly to unfasten the extend cable socket from the cable anchor bracket weldment The bracket is welded to the rear bottom plate of the third boom section If you cannot reach this bracket the boom sections must be separated Extend Cable Removal 534D 9 534D 10 amp 544D Boom b 10 11 12 13 Remove any attachment from the quick switch assembly Refer to Section 3 16 1 Disconnecting from an Attachment Park the machine on a hard level surface fully retract the boom level the boom assembly place the transmission control
219. oom sections level the boom assembly place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated Open the engine cover Allow the system fluids to cool Remove the battery negative cable from the battery negative terminal MX0220 Remove the cylinder rod eye mounting pin Loosen and remove the extend retract cylinder hoses at the rear of the boom assembly Plug the hose ends to prevent dirt and debris from entering the hydraulic system Loosen and remove the fittings from the rear of the extend retract cylinder barrel Attach a lifting tackle to the extend retract cylinder remove the mounting pins and carefully pull the extend retract cylinder free of the machine through the strong back Place the extend retract cylinder in a designated area for the next operation 534D 9 534D 10 amp 544D Boom 3 7 2 Extend Retract Cylinder Installation 1 Install the extend retract cylinder into the push beam and line up the rod eye to the access holes 2 Be certain that the wear pad is installed at the rod end of the cylinder 2 Install the rod eye mounting pin and secure 3 95 0 1 0320 2 3 Install the extend retract cylinder bas
220. oom section The chain passes over a roller mounted to the third boom section and is fastened to the bottom front of the first boom section The 1 in 25 mm retract chain is fastened to the bottom inside rear of the third boom section The chain passes over a roller mounted to the second boom section and is fastened to the front of the first boom section 3 12 1 Boom Chain Inspection A WARNING Worn pins stretched or cracked links or corrosive environments can cause chain failure A chain failure could result in uncontrolled boom movement loss of load or machine instability Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation The retract chains need to be exposed and inspected every 1000 hours of operation Environmental conditions and dynamic impulse shock loads can drastically affect normal operating conditions and require more frequent inspection intervals 534D 9 534D 10 amp 544D Boom a Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosive or highly corrosive industrial atmospheres in addition to abrasive exposures such as sand and grit Some effects can be as follows Moisture Corrosive rusting reduces chain strength by pitting and cracking Temperature Low temperature reduces chain strength by embrittlement Going in and out of cold storage results in m
221. or any visual sign of fluid leakage STOP the engine immediately if any leakage is noted and make any necessary repairs before continuing 7 Wait for the engine to cool and check the coolant level Add coolant as required to bring the coolant to the proper level 4 4 REMOVAL A WARNING The protection offered by this ROPS FOPS will be impaired if subjected to any modification or structural damage Any modification to this machine must be approved by JLG to assure compliance with ROPS FOPS certification for this cab machine configuration If damaged the CAB CANNOT BE REPAIRED It must be REPLACED Inspect the cab its welds and mounts If modification damage a cracked weld and or fatigued metal is discovered replace the cab Contact the JLG distributor or the JLG Service Department with any questions about the suitability or condition of a cab Note Remove and label cab components as needed before removing the cab from the machine Label disconnect and cap hydraulic hoses Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine 1 Park the machine on a firm level surface Allow sufficient overhead and side clearance for cab removal Level the machine ground the attachment place the travel select lever in the N NEUTRAL position engage the parking brake and shut the engine OFF 2 Open the engine cover Allow the system fluids to cool 3 Disconnect
222. ot be installed at this time The cable must be well tensioned in the area between the strain reliefs at the boom head on the third boom section and the boom cable take up brackets 1 Tie the rope to the cable and feed it through the strain relief fitting and cable take up weldment tube then feed to the rear trough the cable take up weldment located at the bottom front of the first boom section The cable lies in the bottom plate area between the first and second boom sections 2 Feed the electric cable around the right side hose roller through the top protection channel then to the boom head at the front of the third boom section 3 Install the hose guard at the right side hose roller located at the rear of the second boom section 4 Feed the cable through the tube weldment at the boom head at the third boom section and install the 3 17 Boom b strain relief fittings on the cable Do not tighten at this time 5 Pull the electric cable through the boom to the correct position at the boom head 6 Install the cable wires into the socket See Section 3 6 1 Electrical Wire Data for wire locations 7 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 8 Install the cable take up weldment and support at the bottom front of the first boom section 9 Tighten the strain relief fittings
223. ove the bolts securing the starter to the flywheel housing Support the starter securely as it is relatively heavy and will fall if not supported 5 Support the starter and remove the bolts securing the starter to the engine Remove the negative ground cable from its starter mounting bolt 6 Remove the starter from the machine d Starter Installation 1 Position the starter in its mounting opening on the flywheel housing Position the ground cable over the correct starter mounting bolt Secure the starter with the bolts Torque bolts to 32 Ib ft 43 3 Nm Connect the positive battery cable to the upper solenoid stud Install the wires to the upper solenoid stud and secure with lock washer and nut Connect the wire to the solenoid mounting stud A Connect the negative battery cable to the negative battery terminal 5 Close and secure engine cover 9 9 Electrical System 9 7 CHARGING CIRCUIT Before using a battery charger an attempt can be made to recharge the battery by jump starting the machine Refer to the appropriate Operation amp Safety Manual Allow the engine to run which will enable the alternator to charge the battery If the engine alternator charging warning indicator illuminates perform the following checks 1 Check the all battery cable connections at the battery and verify that they are clean and tight 2 Check the external alternator
224. ove the switch out of the panel b Disassembly DO NOT disassemble the dash switch Replace a defective switch with a new part c Inspection and Replacement Inspect the switch terminals for continuity and shorting in both the engaged and disengaged positions Replace a defective or faulty switch with a new switch d Switch Installation 1 Connect the switch to the cab harness connector 2 Position the switch into the rectangular switch bezel and snap into position 534D 9 534D 10 amp 544D Electrical System 3 Connect the battery negative cable at the negative battery terminal 4 Start the machine and check the replaced switch for proper function 9 12 3 Warning or Activated Lights 1 Park Brake Activated 2 Check Engine Warning 3 Alternator Warning 4 4x4 4x2 Activated a Bulb Removal 1 Remove the battery negative cable at the negative battery terminal 2 Pull the panel out of the dash disconnect the wire connector to the bulb in question and remove the bulb from the panel b Inspection and Replacement Inspect the bulb terminals for continuity and or shorting Replace a defective or faulty bulb with a new bulb 1 Replace bulb in panel connect wire and secure dash panel 2 Connect the battery negative cable at the negative battery terminal 9 13 Transmission Lever 9 13 1 Transmission Lever Replacement a Lever Removal 1 Remove the b
225. pe and install the extend cable springs washers and lock nuts into the strong back Tighten the extend cables adjusting nuts 10 until the gap between the cable flat washer and the strong back 11 is 1 32 to 1 16 in 0 79 mm 1 57 mm The gap for both washers should be equal 3 15 Boom b Note When adjusting cables make sure the cables are not turning 13 Install the jam nut 12 to the adjusting nut and torque to 100 Ib ft 135 Nm 14 Refer to Section 3 5 2 Cable Adjustments for boom section specifications 12 N 10 11 MX0280 3 5 7 Tilt and Auxiliary Circuit Hose Removal Installation Hoses that need replaced and are still in one piece can be removed and replaced by simply connecting a union to the fittings on the hoses being replaced and the new hoses Disconnect the hoses at the back of the boom and pull them through the boom assembly until they are free You may have to remove the hose guard at the roller assembly Follow the procedure below if the above procedure cannot be followed 3 5 8 1 Loosen the adjusting nuts 1 at the hose take up bracket to relieve the tension on the hose assemblies Hose Removal 2 Loosen the hose from the take up bracket Plug the hose ends and cap the tube ends to prevent dirt and debris from entering the hydraulic s
226. perly 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 CHARGE PRESSURE PARK BRAKE SOLENOID VALVE O PARK BRAKE o ACTUATION 11 5 f SS TANK RETURN MX1010 Backpressure should be less than 20 psi 1 38 bar with the oil at operating temperature To check this pressure tee a low pressure gauge 1 000 psi 69 bar 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 back of the park brake solenoid valve The brake actuation line should not be kinked There should be no restriction back to the reservoir To check for friction disc wear the axle must be disassembled and reassembled according to the Carraro Maintenance Manual Detailed axle service instructions are provided in the CA357248 Carraro Axle Service Manual JLG P N 31200372 6 6 5 To ensure proper park brake operation charge pressure needs to be at the proper specification Since temperature can affect results make sure to test system with hydraulic oil
227. pin protrusion 8 should be replaced immediately DO NOT attempt to repair the chain by welding or driving the pin s back into the chain Once the press fit integrity between outside plates and pins has been altered it cannot be restored Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system This condition damages the chain as well as increases frictional loading and should be corrected 3 34 e Fatigue Cracking Fatigue cracks 9 are a 9 result of repeated cyclic loading beyond MZ1467 the chain s endurance limit Cracking The AOO outside link plates 10 are particularly MZ1468 susceptible to stress corrosion cracking 10 e Stress Corrosion e Corrosion Fatigue Cracking Corrosion fatigue cracks are very similar to fatigue cracks in appearance Corrosion fatigue is the combined action of an aggressive environment and cyclic stress Other Modes of Failure Ultimate Strength Failure These types of failures are caused by overloads far in 1 excess of the design load MZ1469 Either fractured plates 1 2 enlarged holes 2 can occur If either of these MZ1470 failures occurs the chain should be replaced immediately Tight Joints All joints in the chain should flex De freely Tight 3 joints 3 MZ1471 resist flexing 534D 9 534D 10 amp 544D Boom a If the problem is caused by d
228. plates between the front drive motor work ports and the drive hoses 4 Remove the flange halves and place the blocking plates on the ports and reinstall the hoses and the 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 against the park brake Charge pressure should remain at 380 psi 26 bar MX1100 The charge pump efficiency also needs to be checked if previous tests prove inconclusive Check charge flow out of T1 port on the side of the pump 5 At 950 RPM there should be 4 GPM of flow At 2400 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 33 bar 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 6 at the main pump If the drive motors have already been isolated continue testing Install two high pressure 10 000 psi 689 bar 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 the Ma and Mb test ports should read 380 psi 26 bar Adjust relief valve to see if pressure responds Engage forward drive with park brake set raise engine speed to high idle and record drive pressure and charge pressure Repeat
229. ponents of the machine The following illustration identifies the components that are referred to throughout this section HYDRAULIC RESERVOIR and HYDRAULIC FILTERS are located on the right side of the machine CROWD CYLINDER COMP CYLINDER MAIN PUMP MX1030 OUTRIGGER CYLINDERS STEERING ORBITROL MARE E STEERING standard on 534D 10 and 544D VALVE CYLINDER STABILIZER CYLINDER standard on 544D FRAME SWAY CYLINDER right side BRAKE VALVE INCHING VALVE and PARK BRAKE VALVE are located under the cab 8 2 534D 9 534D 10 amp 544D Hydraulic System n 8 2 SAFETY INFORMATION A WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1 Safety Practices of this manual Petroleum based hydraulic fluids are used in this machine The temperature of hydraulic fluid increases during the operation of various hydraulic functions A heated petroleum based hydraulic fluid presents a fire hazard especially when an ignition source is present Hydraulic fluid has a flash point that ranges from 300 600 F 150 318 C and an auto ignition temperature of 500 750 F 262 402 C Accordingly periodically inspect all hydraulic system components hoses tubes lines fittings etc Carefully examine any deterioration and
230. r completely with a 50 50 mixture of ethylene glycol and water Replace and tighten the radiator cap Add coolant to the overflow bottle until the bottle is 1 4 to 1 2 full This overfilling will compensate for any air trapped in the cooling system 7 7 Engine 5 Run the engine to operating temperature Visually check for leaks with the engine running Check the coolant level in the overflow bottle and fill or drain as necessary 7 7 3 Radiator Oil Cooler and Replacement Before considering radiator or oil cooler replacement for other than obvious damage conduct a cooling system pressure test check the coolant specific gravity coolant level fan belt tension and dash panel temperature indicator f the engine runs hot check the temperature of the upper radiator hose f the hose is not hot the thermostat may be stuck in the closed position f the engine has overheated performance may suffer indicating other damage including a leaking cylinder head gasket cracked cylinder head or block and or other internal engine damage a Radiator Oil Cooler Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be opera
231. r assembly 1 to the dash Remove the belly pad from under the cab Disconnect the cable assembly 2 at the main control valve Remove the assembly from the cab Lever Installation Install the lever assembly in the cab dash Reconnect the cable end to the main control valve Install the belly pan Connect the battery negative cable to the battery negative terminal Test the lever function and adjust cable if needed 534D 9 534D 10 amp 544D 4 3 7 Windshield Wiper Assembly Refer to Section 9 8 Windshield Wiper Motor If Equipped for removal and installation information 4 3 8 Heater System If Equipped a Heater Assembly Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the NEUTRAL position engage the parking brake and turn the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Disconnect the battery negative cable at the battery negative terminal 5 Remove the belly pan rear cover and access cover beside heater from the cab 6 Place a suitable container beneath the heater core Slowly turn the radiator cap to the firs
232. r leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area e Reservoir Installation 1 Place the hydraulic oil reservoir into its original orientation 2 Secure the hydraulic oil reservoir to the frame with the previous mounting hardware 3 Uncap and connect the previously labeled hydraulic hoses to their appropriate locations 4 Install the hydraulic fluid level sight glass using special designed and drilled capscrews and gaskets 5 Install hydraulic filter bracket and hydraulic filters 6 Fill the hydraulic oil reservoir according to specifications Refer to Section 2 4 Fluid and Lubricant Capacities 7 Check the hydraulic oil reservoir for leaks 8 Connect the battery negative cable to the battery negative terminal 9 Install the hydraulic oil reservoir fuel tank cover 10 Close and secure the engine cover 534D 9 534D 10 amp 544D 8 6 ENGINE IMPLEMENT PUMP 8 6 1 For internal service instructions contact your local JLG distributor Pump Description 8 6 2 The pump is the heart of the hydraulic system and whenever there is a problem in the system the pump often is blamed However pump failure is seldom due to failure of pump components Pump failure usually indicates another problem in the hydraulic system Pump Failure Analysis According to pump manufacturer statistics 90 95 percent of pump failures are due
233. raulic oil reservoir cover Note If replacing the tank remove all internal and external components from the old tank and retain for use on the replacement tank Note Have a dry chemical Class B fire extinguisher near the work area 6 Remove fuel tank drain plug and drain fuel into an approved and suitable container Dispose of fuel properly 7 Label disconnect and cap the fuel lines from the bottom of the fuel tank 8 Disconnect the fuel gauge harness 9 Remove screws securing fuel sender to the tank Remove fuel sender from tank 10 Remove the four mounting bolts under the fuel tank 11 Lift the empty fuel tank from the side of the machine b Disassembly The fuel tank is a one piece unit and cannot be disassembled The fuel level indicator can be removed and reused on the new replacement tank Dispose of the old tank according to local regulations concerning hazardous materials disposal c Cleaning and Drying If contaminated fuel or foreign material is in the tank the tank can usually be cleaned Note If a leak is suspected in the fuel tank contact JLG Service Department To clean the fuel tank 1 Have a dry chemical Class B fire extinguisher near the work area 2 Remove the fuel tank drain plug and safely drain any fuel into a suitable container Dispose of fuel properly 3 Clean the fuel tank with a high pressure washer or flush the tank with hot water for five minutes and drain t
234. rier assembly is approximately 25 free of the boom fasten the two hose carriers together using nylon tie wraps or suitable straps to keep the hose carriers from separating 14 Continue to withdraw the assembly fastening the hydraulic carriers together 15 When the hose carrier is 75 tied together pull the assembly free of the boom and set on suitable supports 16 Loosen the jam nuts on the extend chain at the top front of the second boom section Disconnect the extend chain 5 from the chain clevis 17 Pull the fourth boom section out far enough to create slack in the retract chain Loosen and remove the retract chain bracket 1 which will allow the chain clevis to be lifted out of the mounting location go MX1400 18 Loosen and remove the wear pads from the front of the third boom section Note the location of the wear pads mounting bolts and number of shims from each location 3 29 N Boom 19 Loosen and remove the wear pads from the top rear and one side of the fourth boom section Note the location of the wear pads mounting bolts and number of shims from each location Note It may be necessary to pul
235. rly rated for the load HAND TOOLS Always use the proper tool for the job keep tools clean and in good working order and use special service tools only as recommended 1 3 Safety Practices A 1 6 3 SOLVENTS Only use approved solvents that are known to be safe for use HOUSEKEEPING Keep the work area and operator s General Hazards cab clean and remove all hazards debris oil tools etc FIRST AID Immediately clean dress and report all injuries cuts abrasions burns etc no matter how minor the injury may seem Know the location of a First Aid Kit and know how to use it CLEANLINESS Wear eye protection and clean all components with a high pressure or steam cleaner before attempting service When removing hydraulic components plug hose ends and connections to prevent excess leakage and contamination Place a suitable catch basin beneath the machine to capture fluid run off Check and obey all Federal State and or Local regulations regarding waste storage disposal and recycling 1 6 4 ENGINE Stop the engine before performing any service unless specifically instructed otherwise Operational Hazards VENTILATION Avoid prolonged engine operation in enclosed areas without adequate ventilation SOFT SURFACES AND SLOPES NEVER work on a machine that is parked on a soft surface or slope The machine must be on a hard level surface with the wheels blocked before performing any s
236. rope to the loop 534D 9 534D 10 amp 544D 9 Carefully pull the chain out of the boom 3 12 8 Inspect and lubricate chains thoroughly before installation Articulate the chains to make sure all working surfaces are thoroughly lubricated Extend Chain Installation 1 At the end of the chain s being inserted into the boom install a nylon tie wrap through the chain holes forming a loop and tie a rope to the loop 2 Carefully pull the chain into the boom to the chain clevis anchor 3 Fasten the chain to the clevis with a pin and cotter pin Lock the cotter pin 4 Atthe other end of the chain connect the chain to the clevis fastening the chain to the clevis with a pin and cotter pin Lock the cotter pin 5 Install the chain clevis fastening and adjusting hardware on both ends 6 Remove any clamping devises being used to keep the boom sections from runty 7 Adjust the extend chains See Section 3 12 3 Adjusting Extend Chains d Chain Lubrication After inspection and before being returned to service chains must be lubricated with a quality chain lubricant The lubricant must penetrate the chain joint to prevent wear Applying lubricant to the external surfaces will prevent rust but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links To prepare the chain for lubrication the chain plates should be brushed with a stiff brush or
237. rtighten 4 Connect the previously labeled fuel hoses to their appropriate locations Secure with clamps 5 Connect the fuel gauge harness 6 Fill the fuel tank according to specifications Refer to Section 2 4 Fluid and Lubricant Capacities 7 Check fuel tank for leaks 8 Connect the battery negative cable to the battery negative terminal 9 Install the fuel tank hydraulic oil reservoir cover 10 Close and secure the engine cover 7 9 3 1 Drain and flush the fuel tank if it was contaminated After Fuel System Service 2 Vent air from the fuel system in accordance with the instructions found in the appropriate Operator amp Safety Manual 534D 9 534D 10 amp 544D Engine 3 the fuel tank with fresh clean diesel fuel as required Cummins Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining for fuel tank information 7 10 EXHAUST SYSTEM MX0960 7 10 1 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking brake and shut the engine OFF Exhaust System Removal 2 Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative
238. s 151 4 liters Type of Fuel Low Sulfur Diesel 42 Cooling System System Capacity John Deere 24 8 quarts 23 5 liters System Capacity Cummins 22 quarts 20 8 liters Type of Fluid 50 50 ethylene glycol amp water Front Axle Differential Housing Capacity 19 6 quarts 18 5 liters Type of Fluid Mobilfluid 4249 Tractor Hydraulic Fluid ISO 46 Rear Drive Hubs Wheel End Capacity 1 5 quart 1 4 liters Type of Fluid Mobilfluid 4249 Tractor Hydraulic Fluid ISO 46 Hydraulic System System Capacity 534D 9 534D 10 47 gallons 178 liters System Capacity 544D 50 gallons 189 liters Reservoir Capacity 30 gallons 113 5 liters Type of Fluid Mobilfluid 4249 Tractor Hydraulic Fluid ISO 46 534D 9 534D 10 amp 544D 2 9 amp General Information and Specifications 2 5 SERVICE AND MAINTENANCE SCHEDULES 2 5 1 10 1st 50 amp 50 Hour 7 PER ri Check Fuel Check Tire Air Filter Check Engine Check Hydraulic Level Pressure Restriction Oil Level Oil Level Indicator Check Hydraulic Return Filter Indicator Change Change Wheel Change Engine Check Wheel Check Boom End Oi Axle Oil Oil Oil amp Filter Lug Nut Cable Tension Torque 534D 9 amp 534D 10 Check Boom Chain Tension 544D Drain Fuel Check Engine Lubrication Water Coolant Level Battery Schedule Separator MX
239. s on the engine and hydrostatic drive pump Install brackets and the traction lock valve Uncap and reconnect the previously labeled tubes and hoses to the appropriate locations on the drive pump and traction lock valve Install both heater hoses to the engine and tighten clamps Install the complete radiator cooler assembly and tighten the mounting bolts Install the hose clamps on the radiator hoses and work onto the engine Tighten the clamps Connect the drive pump inlet and outlet hoses on the oil cooler Install the charge air tubes to the charge air cooler 544D w John Deere engine and all Cummins engines Install the exhaust pipe to the exhaust manifold Install the v band clamp holding the exhaust pipe to the exhaust manifold Install the flex pipe and tighten the clamps on the exhaust pipe Install the engine cover rear cover and dust shield Connect the battery negative cable to the battery negative terminal Open the radiator cap and fill the radiator completely with a 50 50 mixture of ethylene glycol and water Replace and tighten the radiator cap Add coolant to the overflow bottle until the bottle is 1 4 to 1 2 full This overfilling will compensate for any air trapped in the cooling system Open the hydraulic oil reservoir and fill with Mobilfluid 4249 Tractor Hydraulic Fluid ISO 46 7 13 O Engine 22 If installing new hydraulic oi
240. s stamped on a plate which is secured to the engine block near the fuel injector pump Information contained in the serial number is required in correspondence with the engine manufacturer 7 3 SPECIFICATIONS AND MAINTENANCE INFORMATION For engine coolant and oil specifications and maintenance information refer to Section 2 General Information and Specifications Note Detailed John Deere engine service instructions covering disassembly inspection internal repair assembly adjustment and troubleshooting information are provided in the appropriate John Deere engine service manual 7 4 534D 9 534D 10 amp 544D Engine 7 4 INTRODUCTION CUMMINS QSB4 5 7 4 1 Disclaimer and Scope These instructions are written for worldwide use In territories where legal requirements govern engine smoke emission noise safety factors etc apply all instructions data and dimensions provided herein in such a way that after maintenance service and repair of the engine engine operation does not violate local regulations NOTICE These instructions cover only the routine maintenance removal installation and troubleshooting of the engine Refer to the local Cummins Engine Distributor and the applicable Cummins Engine Service Manual for assistance with comprehensive engine diagnosis repair and component replacement A gradual running in break in of a new engine is not necessary Full load can be applied t
241. s with Mystik Tetrimoly Grease prior to the installation of pins and bushings Wear pads and slide areas must be lubricated with Mystik Tetrimoly Grease or an equivalent 1 Place the third boom section upside down on suitable supports 2 Install the wear pads and spacers on the bottom and both sides at the rear of the third boom section For ease of installation DO NOT install the top wear pads at this time 3 Install the single retract cable and the double extend cables to the bracket 9 at the rear of the third boom section 4 Install the tilt circuit hoses auxiliary circuit hoses and if equipped the electrical cables and brackets inside protected areas 5 Install the hose brackets 10 in place at the front of the third boom section 6 Lubricate wear pad paths and lay the tilt hoses auxiliary hoses cables and if equipped electrical cable inside the third boom section to protect against being damaged when installing the third boom section into the second boom section 534D 9 534D 10 amp 544D Boom b 7 Connect the auxiliary hoses to the quick disconnects on the side of the boom head Connect the electrical cable to the plug mounted below the auxiliary quick disconnects if equipped 8 Install the tilt cylinder in the boom head install the mounting pin and keeper bolt locking the mounting pin and tilt
242. second sections can be removed as a package 1 Loosen and remove the wear pads from the top rear and one side of the second boom section Leave all the bottom wear pads in place to aid sliding during the section removal Note the location of the wear pads mounting bolts and number of shims from each location 2 Release tension from the hoses on the hose take up bracket 5 3 Loosen the tilt circuit hoses auxiliary circuit hoses and any electrical hoses if equipped on the hose take up bracket Plug the hose ends and tube ends to prevent dirt and debris from entering the hydraulic system 4 Disconnect the top front extend chains from the chain clevises on the first boom section 5 Disconnect the bottom rear retract chain from the chain clevis on the third boom section 6 Remove the chain adjustment block 6 from the first boom section 534D 9 534D 10 amp 544D 7 Remove all wear pads from the front of the first boom section Note the location of the wear pads mounting bolts and number of shims from each location 8 Carefully pull the second third and fourth boom sections together from the first boom section and place on suitable supports for further separation 3 11 5 Second Boom Section Installation 1 Grease the inside wear pad paths of the first boom section and the outside wear paths of the second boom section 2 Position the second boom section into the front of the first boom section Leave room at t
243. section 9 GOGO GOGO OO GD GO GOGO GD G0 GOGO GOGO 00 00 00 5 9 oXo oXo oXo Jil MX0380 oXo oXo 3 Loosen and remove the retract chain roller 9 at the rear of the third boom section 3 23 Boom b 4 Loosen and remove the front wear pads and supports from the third boom section Tag each pad backing plate shim and bolts from each location 5 Carefully pull the fourth boom section out of the third boom section taking care to protect the chains 6 Disconnect the chains when the boom sections are free from each other 7 Place the fourth boom section on suitable supports Note Before reassembly of the boom check the bores pins and bushings for damage Repair as needed Also check the diameters of the pins and bushings 3 10 7 The hydraulic sub assembly locates primarily in the fourth boom section It is fastened to the bottom of the fourth boom section and at the rear of the third boom section It s function is to control hose and optional electric cable movement as the boom sections extend and retract Hydraulic Sub Assembly MX0390 Components on the left side of the assembly control the tilt cylinder of the machine Components on the right side of the assembly control the auxiliary and electric options on the machine As the boom extends or retracts the hydraulic carrier
244. securing the axle pivot pin to the frame Tap the pivot pin out and note the location of the shims on each side of the axle 16 Remove the axle from the machine using the jack hoist or overhead crane and sling supporting the axle DO NOT raise or otherwise disturb the machine while removing the axle Balance the axle and prevent it from tipping turning or falling while removing it from beneath the machine Place the axle on a suitable support or holding stand 534D 9 534D 10 amp 544D Axles Wheels and Tires 5 3 6 1 Axle Installation Before proceeding ensure that the machine will remain in place during axle installation Block the front and rear of both tires on the rear axle If applicable raise the machine using a suitable jack or hoist Place suitable supports beneath the frame and lower the machine onto the supports allowing enough room for axle installation Ensure that the machine will remain in place during axle installation Using a suitable jack hoist or overhead crane and sling remove the axle from its support or holding stand Balance the axle and prevent it from tipping turning or falling while positioning it beneath the machine DO NOT raise or otherwise disturb the machine while installing the axle Keep the axle supported and balanced on the jack hoist or overhead crane and sling throughout the installation procedure Position the axle under the frame and align the axle
245. ser to view active and inactive faults and clear the inactive faults It provides a monitor function that allows the service technician to monitor measured parameters actuator status and some calculated values It also provides the technician with the capability to turn on certain drivers such as the grid heaters and lift pump as well as running diagnostic tests such as single cylinder cutout 534D 9 534D 10 amp 544D Electrical System 9 15 4 Engine Fault Codes Chart Fault Code SPN Code FMI Code Description 0001 Exhaust Gas Pressure Sensor Number 1 Circuit High 0002 Exhaust Gas Pressure Sensor Number 1 Circuit Low 0003 Exhaust Gas Pressure Sensor Number 1 Circuit Erratic 0004 Exhaust Gas Temperature Sensor Number 1 Circuit Erratic 0005 Exhaust Gas Temperature Sensor Number 1 Circuit Low 0006 Exhaust Gas Temperature Sensor Number 1 Circuit High 111 629 12 12 Engine Control Module 115 612 2 Engine Magnetic Crankshaft Speed Position 122 102 3 3 Intake Manifold Pressure Sensor Circuit High 123 102 4 4 Intake Manifold Pressure Sensor Circuit Low 124 0 16 Intake Manifold 1 Pressure Sensor Circuit 131 91 3 3 Accelerator Pedal or Lever Position Sensor Circuit High 132 91 4 4 Accelerator Pedal or Lever Position Sensor Circuit Low 133 974 3 3 Remote Accelerator Pedal or Lev
246. ssembly DO NOT disassemble the pedal Replace a defective pedal with a new part c Inspection and Replacement Inspect the switch terminals for continuity and shorting Replace a defective or faulty pedal with a new pedal d Pedal Installation 1 Connect the wire harness connector to the pedal base 2 Install both bolts and tighten base 3 Connectthe battery negative cable at the negative battery terminal 4 Start the machine and check the function of the replaced pedal 9 17 Electrical System 9 15 TROUBLESHOOTING CUMMINS 9 15 1 Faults are detected while the key switch is in the RUN position during operation of the machine itself If a fault becomes active currently detected at this time a fault is logged in memory and a snapshot of the engine parameters is logged In addition certain faults may illuminate the warning lamp amber or the stop lamp red depending upon the severity of the active fault Fault Detection For more information contact your local authorized Cummins service distributor 9 15 2 Flash Out of Fault Codes Fault flash out mode can be entered through the use of a diagnostic switch or the accelerator pedal To enter the fault flash out mode the key switch must be in the RUN position with the engine not running When a diagnostic switch is used to enter the fault flash out code mode the ECM will automatically flash the first fault code after th
247. stall the control spool being careful not to nick or scratch the valve section bore or the control spool 3 Install the end caps on each end of the valve section 534D 9 534D 10 amp 544D Hydraulic System Assemble the Main Control Valve 1 Place all three tie rods with the washers and nuts through the inlet main control valve section Stand the end main control valve section on end 3 Install the proper o rings and load sense shuttle on the inner face of the inlet main control valve section Align the hoist control valve section over the three tie rods and slide onto the inlet main control valve section Using the proper o rings repeat step three for the crowd control valve section the tilt valve section the sway valve section the tilt valve section auxiliary valve section and last the outlet end valve section Install the three washers and nuts on the tie rods Torque to 23 27 Ib ft 57 Nm 534D 9 534D 10 amp 544D 8 17 Hydraulic System 5 A FQ za 74 9 f MX1160 544D MAIN CONTROL VALVE 534D 9 534D 10 amp 544D 8 18 Hydraulic System f Main Control Valve Installation 1 Install the main control valve onto the frame aligning the bolts with the holes in the end sections of the main control valve Slide the main control valve into position and tighten the bolts 2 Prime the main control val
248. system If equipped label loosen and separate all electrical cables at the take up bracket Remove the take up brackets 5 Loosen and remove the jam nuts on the retract cable 6 at the bottom of the first boom section Label disconnect and cap both hydraulic hoses 7 attached to the extend retract cylinder Cap all fittings and openings to keep dirt and debris from entering the hydraulic system Loosen and remove the jam nuts on the two extend cables 8 at the strong back Remove the pin 9 holding the extend retract cylinder at the strong back Loosen and remove the bolts holding the strong back to the rear of the first boom section Remove the strong back Remove the two pins 10 holding the push beam at the rear of the second boom section Loosen and remove the wear pads from the front of the second boom section Note the location of the wear pads mounting bolts and number of shims from each location Loosen and remove the wear pads from the top rear and one side of the third boom section Note the location of the wear pads mounting bolts and number of shims from each location Remove hose guide 11 from the rear of the second boom section 3 9 Boom 23 Slowly pull the push beam out of the front of the third boom section The extend cables will come out along w
249. t be operated 4 Open the engine cover Allow the system fluids to cool 5 Remove the battery negative cable from the battery negative terminal 6 Loosen and remove both compression springs 1 from the hose take up weldment at the bottom of the first boom section 1 MY2690 7 Label and disconnect the tilt and auxiliary hydraulic hoses attached to the sub assembly at the rear of the boom and at the front of the boom head Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system 8 If equipped label and disconnect any electrical connections at the front and rear of the boom assembly Note Tag or identify each hose to the corresponding fitting it was removed from 9 Loosen and remove both cap screws and locknuts 2 from the sub assembly bracket at the front of the fourth boom section MY2710 10 Loosen and remove the guide bracket 3 from the front of the fourth boom section 534D 9 534D 10 amp 544D Boom 11 Loosen and remove the sub assembly bracket 4 at 3 14 2 Assembling the Hydraulic Sub
250. t stop and allow any pressure to escape Remove the radiator cap 7 Shut both coolant valves located on the engine 8 Loosen label and remove both heater hoses attached at the heater and drain the coolant to a container with a cover and label as Used Antifreeze Dispose of the used coolant at an approved recycling facility 9 Label and disconnect any electrical connections 10 Loosen and remove the heater p o HEATER HOSE RETURN C HEATER HOSE SOURCE o a 5 ooo Be 22 0 0 MX0830 4 7 Ps Cab and Covers 5 Heater Assembly Installation 1 Position the heater assembly to its original orientation in the cab Secure with the previous hardware 2 Connect the previously labeled electrical connections 3 Connect the previously labeled heater hoses to their appropriate locations 4 nstall the belly pan rear cover and access cover 5 Open both coolant valves on the engine Open the radiator cap and check the coolant level Fill if necessary The cooling system capacity is listed in Section 2 4 Fluid and Lubricant Capacities 6 Connect the battery negative cable to the battery negative terminal Note When the engine is initially started run it briefly at low idle and check the machine f
251. t the cylinder 6 Remove the lock bolt and or any retaining clips securing the cylinder pins Remove the cylinder pins 7 Remove the cylinder 8 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 534D 9 534D 10 amp 544D 8 9 2 Cylinder Disassembly MZ0400 1 Clean the cylinder with a suitable cleaner before disassembly Remove all dirt debris and grease from the cylinder 2 Clamp the barrel end of the cylinder in a soft jawed vise or other acceptable holding equipment if possible A WARNING Significant pressure may be trapped inside the cylinder Exercise caution when removing a counterbalance valve or a pilot operated check valve from a cylinder Escaping hydraulic fluid under pressure could penetrate the skin NOTICE Avoid using excessive force when clamping the cylinder in a vise Apply only enough force to hold the cylinder securely Excessive force can damage the cylinder tube 3 If applicable remove the counterbalance valve from the side of the cylinder barrel DO NOT tamper with or attempt to adjust the counterbalance valve cartridge If adjustment or replacement is necessary counterbalance valve with a new part replace the 4 Extend the rod as required to allow access to the base of the cylinder 8 21 Hydraulic System Protect the finish of the rod at all times Damage to the surface of the rod can c
252. t violate local regulations NOTICE These instructions cover only the routine maintenance removal installation and troubleshooting of the engine Refer to the local John Deere Engine Distributor and the applicable John Deere Engine Service Manual for assistance with comprehensive engine diagnosis repair component replacement A gradual running in break in of a new engine is not necessary Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 140 F 60 C Extended light load operation during the early life of the engine is not recommended DO NOT run the engine at high no load speeds DO NOT apply an overload to the engine 7 2 534D 9 534D 10 amp 544D Engine 7 1 2 Component Terminology To understand the safety operation and maintenance information presented in this section it is necessary that the operator mechanic be familiar with the names and locations of the engine components The following illustration identifies the components that are referred to throughout this section THERMOSTAT FUEL FILTER ______ rrr FUEL INJECTION PUMP M M TURBOCHARGER ECM MODULE ALTERNATOR OIL FILTER MX0910 534D 9 534D 10 amp 544D 7 3 C Engine 7 2 ENGINE SERIAL NUMBER The John Deere serial number I
253. ted 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal 5 Slowly turn the radiator cap to the first stop and allow any pressure to escape Remove the radiator cap 6 Remove the dust shield under the engine 7 Place a suitable container beneath the radiator drain 8 Place a funnel at the base of the radiator to channel the drained coolant into a container Loosen the drain cock and slowly remove to allow the coolant to drain Transfer the coolant into a properly labeled container Dispose of properly if coolant needs to be replaced Tighten the radiator drain cock 9 Loosen and remove the coolant overflow tank Cummins Only 7 8 10 11 12 13 14 15 John Deere MX0990 Loosen and remove both charge air tubes 1 from the charge air cooler Loosen the radiator clamp on the top and bottom radiator hoses 2 Work the hose off the radiator Position the hose out of the way to allow radiator removal or remove the hose from the engine Inspect the hose and replace if necessary Label disconnect and cap all hydraulic hoses 3 attached to the oil cooler Cap all fittings and openings to prevent dirt and debris from entering the hydraulic system Loosen the radiator fan shroud if necessary Remove the nuts and washers from the four radiator
254. that could affect the safe and proper functioning of the machine and axles 5 3 AXLE ASSEMBLIES 5 3 1 The front axle serial number plate is located on a mounting pad on the front side of the center section of the axle Information on the serial number plate is required in correspondence regarding the axle Axle Serial Number Plate Supply information from the axle serial number plate when communicating about an axle assembly or axle components 5 3 2 General axle specifications are found in Section 2 4 Fluid and Lubricant Capacities Axle Specifications 534D 9 534D 10 amp 544D 5 3 3 Detailed axle service instructions covering the axle differential brakes and wheel end safety repair disassembly reassembly adjustment and troubleshooting information are provided in the CA357248 Carraro Axle Service Manual JLG P N 31200372 Axle Internal Service 5 3 4 Axle Maintenance CLEANING Clean parts with machined or ground surfaces such as gears bearings and shafts with emulsion cleaners or petroleum based cleaners DO NOT steam clean internal components and the interior of the planetary hub and axle housing Water can cause corrosion of critical parts Rust contamination in the lubricant can cause gear and bearing failure Remove old gasket material from all surfaces DRYING Use clean lintless towels to dry components after cleaning DO NOT dry bearings by spinning them with compressed air this can
255. the fourth boom section Ke OKO OKO ONO MY2700 2 3 8 Install the cap screws washers and nuts to the sub assembly bracket at the rear of the third boom section 9 Install both cap screws and locknuts to the sub assembly bracket at the front of the fourth boom section 10 Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the rear of the hydraulic sub assembly 11 Uncap and reconnect the previously labeled tilt and auxiliary hydraulic hoses to the proper fittings at the front of the fourth boom section 12 If equipped reconnect any electrical connections at the front and rear of the boom assembly 3 40 MY2690 13 Install the hose take up compression springs 4 at the bottom of the first boom section Tighten the adjusting nut 5 to measure 1 inch 25 0 mm 6 between the face of the jam nut 7 and the end of the end of the threads on the hose take up weldment 14 Torque the jam nut against the adjusting nut to 100 ft lbs 534D 9 534D 10 amp 544D Boom 3 15 BOOM WEAR PADS A total of 27 wear pads are installed on the boom sections of the 534D 9 and 534D 10 machines A total of 43 wear pads are installed on the boom sections of the 544D machines 3 15 1 Inspect all wear pads for wear If the angle indicators 1 on the ends of
256. the lower edge of the dash 8 20 4 Remove the plastic cap from the service brake bleeder 2 Attach one end of a length of transparent tubing over the brake bleeder Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil The end of the tubing must be below the oil level in the container 5 DO NOT open the brake bleeder without holding the tubing firmly on the bleeder There is pressure at the brakes Carefully open the bleeder with a 12 mm wrench Close the brake bleeder when air bubbles no longer appear in the oil running through the transparent tubing Release the brake pedal Remove the tubing from the brake bleeder 6 Conduct a pressure and function check of the service brake Refer to Section 8 4 1 Hydraulic Pressures Note The inner bleeder is used to bleed the park brake 1 Place the travel select lever in N NEUTRAL engage the park brake 2 Remove the plastic cap from the park brake bleeder 3 Attach one end of a length of transparent tubing over the brake bleeder Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil The end of the tubing must be below the oil level in the container 3 Start the machine DO NOT open the brake bleeder without holding the tubing firmly on the bleeder There is 380 480 psi 26 33 bar at the park brakes Carefully open the bleeder with a
257. the sling under the boom head of the third boom section Carefully slide the two boom sections into the first boom section Leave 6 in 8 in 152 mm 203 mm in of the two boom sections out to be able to install the wear pad block and the wear pads in the front of the first boom section Install the hose take up assembly 5 components at the front of the first boom section Install the retract cable adjusting block 6 Install the retract cable Do Not tighten the retract cable Install the wear pad block to the front inside of the first boom section Use Loctite 242 and torque the wear pad block mounting bolts to 265 290 Ib ft 859 393 Nm Install the wear pads spacers and shims at the front of the first boom section Use Loctite 242 and torque the wear pad mounting bolts to 68 78 lb ft 92 106 Nm MX0180 Place the strong back 7 in place at the rear of the first boom section and install the extend retract cylinder mounting pin spacers and retaining clips Measure the space between the top and bottom of the strong back 8 and the inside of the first boom section and shim as needed Install and torque the strong back mounting bolts Install the extend cables springs washers and lock nuts into the strong back 9 Tighten the extend cables adjusting nuts until the gap between the cable flat washer and strong back is 1 32 in to 1 16 in 0 79 mm 1 57 mm Gap for
258. the wear pads are visible the wear pads can be reused If the pads show uneven wear front to back they should be replaced Replace pads as a set if worn or damaged Wear Pad Inspection 1 1 a Ma2070 3 15 2 When replacing a wear pad on the boom replace both wear pads on that side of the boom e g replace top front left and top front right wear pads at the same time Boom Wear Pad Replacement Usually shimming will remain the same when installing new wear pads Some wear pads are secured to the boom using different bolts and washers Keep bolts and washers with the same wear pad that is being replaced When installing new wear pads apply Loctite 242 to all wear pad mounting bolts and torque to required specifications Wear pad bolt torques are 3 8 in bolt 28 30lb ft 38 41 Nm 1 2 in bolt 76 86 Ib ft 103 117 Nm Hollow 3 8 in bolt 20 25 Ib ft 27 34 Nm Hollow 1 2 in bolt 45 50 Ib ft 61 68 Nm Note The first shim next to a wear pad always needs to have the two hole configuration 2 The remaining shims may have the large slot configuration Use shims 3 under the wear pads as required to maintain a maximum gap of 1 16 in 1 6 mm 4 between the wear pad and the boom Shims are available in two thicknesses 0 06 in 1 5 mm and 0 04 in 1 mm 534D 9 534D 10 amp 544D MY0630 3 15 3 The boom has been factory lubricated for
259. this procedure for reverse Drive pressure should be 6300 psi 434 bar in each direction Charge pressure should remain at 380 psi 26 bar and rise to approximately 480 psi 33 bar near full throttle 6 7 Hydrostatic Drive Pump If charge pressure is not achieved main pump is leaking internally Note Do Not stall pump for more than 15 seconds each time 6 6 6 For the machine to move at proper engine speed control pressure should match engine speed Control Pressure MX1110 Install a low pressure gauge 1 000 psi 69 bar hose and adapter on the drive pump control pressure Ps port 7 Remove the hose from the port and plug Note Before starting make sure the gauge can be observed in the operator s cab Apply park brake start engine and run at high idle 2400 RPM With the pump in neutral the gauge should read 380 psi 26 bar This reading may vary 15 psi 1 0 bar Use a tachometer to monitor engine speed Start the engine and run at 1100 RPM While watching the pressure gauge move the shift lever to the forward position The gauge should read 100 psi 6 9 bar 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 6 9 bar control pressure the stroking piston needs centered mechanically To check this adjustment install a clean hose between control ports X1 and X2 8 They are located on the
260. tino Americana Ltda JLG Industries UK Ltd JLG France SAS P O Box 5119 Rua Eng Carlos Stevenson Bentley House 2 1 de Baulieu 11 Bolwarra Road 80 Suite 71 Bentley Avenue 47400 Fauillet Port Macquarie 13092 310 Campinas SP Middleton France N S W 2444 Brazil Greater Manchester Phone 33 0 5 53 88 31 70 Australia Phone 55 193 295 0407 M24 2GP Fax 33 0 5 53 88 31 79 Phone 61 265 811 111 Fax 55 193 295 1025 England Fax 61 265 810 122 Phone 44 0 161 654 1000 Fax 44 0 161 654 1001 JLG Deutschland GmbH JLG Equipment Services Ltd JLG Industries Italia s r l JLG Europe B V Max Planck Str 21 Rm 1107 Landmark North Via Po 22 Polaris Avenue 63 D 27721 Ritterhude Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese MI 2132 JH Hoofddorp Germany Sheung Shui N T Italy The Netherlands Phone 49 0 421 69 350 20 Hong Kong Phone 39 029 359 5210 Phone 31 0 23 565 5665 Fax 49 0 421 69 350 45 Phone 852 2639 5783 Fax 39 029 359 5845 Fax 31 0 23 557 2493 Fax 852 2639 5797 JLG Polska JLG Industries Scotland Plataformas Elevadoras JLG Sverige AB UI Krolewska Wright Business Centre JLG Iberica S L Enkopingsvagen 150 00 060 Warsawa 1 Lonmay Road Trapadella 2 Box 704 Poland Queenslie Glasgow G33 4EL Castellbisbal Sur SE 176 27 Jarfalla Phone 48 0 914 320 245 Scotland 08755Castellbisbal Barcelona Sweden Fax 48 0 914 358 200 Phone 44 0 141 781 6700 Spain Phone 46 0 850 659 500 Fax 44 0 141 773
261. to help balance the cab during removal When the cab is completely clear of the machine carefully lower it to the ground Block up or support the cab so that it does not move or fall Assure that no personnel enter the cab while it is being removed from the machine Inspect the condition of the fittings clamps hydraulic hoses etc Replace parts as indicated by their condition Inspect and replace other machine parts that are exposed with the cab removed Repair or replace as required CAB INSTALLATION Block all four wheels to help prevent the machine from moving Assure that there is sufficient overhead and side clearance for cab installation Install eyebolts and route a sling with a suitable lifting capacity Use a hoist or overhead crane and sling attached to the cab Carefully begin to align the cab with the mounting holes in the frame Stop and check that wiring hydraulic hoses cables etc will not be pinched or damaged as the cab is positioned Readjust the position of the sling as needed to help balance the cab during installation Install the four bolts washers and nuts and torque to 480 Ib ft 651 Nm Connect the throttle electrical cable from under the cab Route any hoses through the opening at the right rear corner of the cab Working under the cab uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations Connect the wir
262. to obtain the 1 2 in 13 mm dimension required 6 Torque the jam nuts to 100 Ib ft 135 Nm DO NOT use Loctite on the nuts 7 Measure the distance 5 between the third boom section and the outer face of the boomhead on the fourth boom section to determine the amount of 3 35 Boom b adjustment required The correct dimension is 17 in 432 mm 8 Loosen the adjusting nut 6 at the top front of the second boom section enough to permit adjustment 9 Loosen the retract chain jam nut 7 at the bottom front of the second boom section 10 Tighten the retract chain adjusting nut to obtain the 17 in 432 mm dimension 11 Torque the jam nuts to 100 Ib ft 135 Nm DO NOT use Loctite on the nuts 12 Readjust the extend chains as described in Section 3 12 3 Adjusting Extend Chains 3 12 5 The following section explains the removal of the 1 in 25 mm retract chains from the third to first boom sections without removing the boom assembles Retract Chain Removal 1 Fully retract the boom and raise the boom to a horizontal position making sure that the chains are accessible through the front access holes Place the transmission control lever in NEUTRAL engage the park brake switch Shut off machine 2 Attach a suitable sling to the extend retract cylinder and take the weight off the extend retract cylinder 3 Remove the cylinder pin from the rod end of the extend retract cylinder and
263. to one or more of the following causes Aeration Cavitation Contamination Excessive Heat Over Pressurization Improper Fluid In the event of pump failure investigate further to determine the cause of the problem 8 6 3 Pump Replacement a Pump Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover and the hydraulic oil reservoir fuel tank cover Allow the system fluids to cool 4 Disconnect the battery negative cable from the battery negative terminal 5 Drain the hydraulic reservoir Refer to Section 8 5 1 Hydraulic Oil Reservoir Draining 6 Relieve any trapped pressure in the hydraulic system 7 Thoroughly clean the pump and surrounding area including all hoses and fittings before proceeding Note Cap all hoses as you remove them to prevent unnecessary fluid spillage 8 13 Hydraulic System n 8 Label disconnect and cap the hydraulic hoses attached to the pump MX1150 9 Remove the two bolts and two lockwashers 1 securing the pump t
264. to the bottom test port Ma 2 located at the left side of the hydrostatic drive pump Make sure the gauge can be observed from the operators cab MX1050 Start the machine leave the park brake applied and make sure the 2WD AWD switch is in the 2WD position Engage the shift lever to the forward position and run the engine at high idle The gauge should read 6300 psi 200 100 psi 434 bar 13 8 6 9 bar Note Do not stall the drive pump for more than 10 seconds as to not allow an excessive amount of heat buildup f 1 Adjusting Hydrostatic Drive Pressure Shut the machine off The POR relief valve 3 is located at the top right of the hydrostatic drive pump Remove the plastic tamper proof cap loosen the jam nut on the relief valve and using an allen wrench turn the relief clockwise to increase pressure or counter clockwise to decrease pressure Start the machine leave the park brake applied and make sure the 2WD AWD switch is in the 2WD position engage the shift lever to the forward position If the reading is within specification shut the machine off install the tamper proof cap and remove the gauge from the test port Install the gauge to the top test port Mb and repeat step 3 8 7 n Hydraulic System 8 8 If the proper pressure cannot be set use the accompanying hydraulic schematic electrical schematic and or Section 6 6 Hydrostatic Drive Performance Chec
265. trigger Cylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm 250 400 Ib ft 339 542 Nm Note Apply Amoco Rycon 2 EP Grease to cylinder gland threads and torque to spec Note All bearings in the cylinder glands use Loctite 638 Stabilizer Cylinder optional on 534D 9 amp 534D 10 Outriggers not available on 534D 9 Description Lock Nut Cylinder Gland Lift Cylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Crowd Cylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Tilt Cylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Comp Oylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Sway Cylinder 650 700 Ib ft 881 949 Nm 250 400 Ib ft 339 542 Nm Stabilizer Cylinder 650 700 Ib ft 881 949 Nm 250 400 Ib ft 339 542 Nm Steering Cylinder 400 425 lb ft 542 576 Nm 250 400 Ib ft 339 542 Nm Outrigger Cylinder 1300 1350 Ib ft 1763 1830 Nm 250 400 Ib ft 339 542 Nm Note Apply Amoco Rycon 2 EP Grease to cylinder gland threads and torque to spec Note All bearings in the cylinder glands use Loctite 638 Note lf reusing the cylinder gland torque the cylinder gland until the locking capscrew hole align Reinstall the capscrew Note lf installing a new cylinder gland torque the gland to spec and drill 0 47 to 0 152 hole in the parting
266. ty fuel injection pump Faulty fuel injectors or incorrect type Incorrect use of cold start equipment Faulty cold start equipment Broken fuel injection pump drive Incorrect fuel pump timing Incorrect valve timing Poor compression 16 17 18 19 20 534D 9 534D 10 amp 544D Key to Possible Causes Blocked fuel tank vent Incorrect grade of fuel Sticking throttle or restricted movement Exhaust pipe restriction Leaking cylinder head gasket Overheating Cold running Incorrect tappet adjustment Sticking valves Incorrect high pressure pipes Worn cylinder bores Pitted valves and seats Broken worn or sticking piston ring s Worn valve stems and guides Restricted air cleaner Worn or damaged bearings Insufficient oil in sump Inaccurate gauge Oil pump worn Pressure relief valve sticking open Pressure relief valve sticking closed Broken relief valve spring Faulty suction pipe Restricted oil filter Piston seizure pick up Incorrect piston height Damaged fan Faulty engine mounting Incorrectly aligned flywheel housing or incorrectly aligned flywheel Faulty thermostat Restriction in water jacket Loose fan belt Restricted radiator Faulty water pump Restricted breather pipe Damaged valve stem oil deflectors if fitted Coolant level too low Blocked sump strainer Broken valve spring Exha
267. uctions covering disassembly inspection internal repair assembly adjustment and troubleshooting information are provided in the appropriate Cummins engine service manual 7 7 COOLING SYSTEM 7 7 1 Radiator Pressure Cap For a 210 F 99 C system use a 13 psi 90 kPa radiator cap An incorrect or malfunctioning cap can result in the loss of coolant and a hot running engine 7 7 2 John Deere Engine Thermostat Replacement Before considering thermostat replacement check the coolant level fan belt tension and instrument cluster temperature indicator f the engine seems to take a long time to warm up the thermostat may be stuck in the open posi tion and requires replacement f the engine runs hot check the temperature of the upper radiator hose f the hose is not hot the thermostat may be stuck in the closed position e f the engine has overheated performance may suffer indicating other damage including a leak ing cylinder head gasket cracked cylinder head or block and or other internal engine damage Cummins Engine The Cummins engine thermostat is not a serviceable item For more information contact your local authorized service distributor 534D 9 534D 10 amp 544D a Thermostat Removal John Deere 1 Park the machine on a firm level surface level the machine fully retract the boom lower the boom place the travel select lever in the N NEUTRAL position engage the parking
268. uge should read a maximum of 480 psi 33 bar 8 6 Note Throughout test operation charge pressure should not drop below 380 psi 26 bar and should move toward 480 psi 33 bar as RPM rises regardless of how many functions are being operated simultaneously b Adjusting Charge Pressure 1 Shut the machine off The charge pump relief 1 is located at the left side of the hydrostatic drive pump Remove the plastic tamper proof cap 2 Loosen the jam nut on the relief and using an allen wrench turn the relief clockwise to increase pressure or counter clockwise to decrease pressure Start the machine and set the pressure to 380 psi 26 bar at low idle 3 Tighten the jam nut and recheck the pressure at low and high idle If the reading is within specification shut the machine off install the safety cap and remove the gauge from the test port 4 If the proper pressure cannot be set use the accompanying hydraulic schematic electrical schematic and or Section 6 6 Hydrostatic Drive MX1050 Steering Pressure 1 Start the machine and warm the hydraulic system to operating temperature 2 Shut off the machine and install a digital or a 10 000 psi 689 bar gauge to the test port located at the left side in front of the return filter Make sure the gauge can be observed from the operator s cab 3 Start the machine leave the park brake applied 4 Turn the steering wheel left or right until the w
269. ull the chain into the boom until it can be fastened to the chain clevis 10 Remove the rope 11 Fasten the chain into the clevis by installing the pin and cotter pin 12 Install the chain adjustment block and mounting bolts 13 Torque the chain adjustment block mounting bolts to 340 365 Ib ft 461 495 Nm 14 Adjust the retract chains See Section 3 12 4 Adjusting Retract Chains 15 Torque the jam nuts to 100 Ib ft 135 Nm DO NOT use Loctite on the nuts 3 12 7 The following section explains the removal of the 1 in retract chains without removing the boom assembles Extend Chain Removal 1 Extend the boom far enough to access the chain anchor and the clevis through the top rear access hole 2 Secure the boom sections together to prevent uncontrolled boom runout when the extend chains are removed 3 Onthe chain being removed loosen and remove the jam nut from the rear chain clevis and back off the adjusting nut on the chain clevis to the end of the threads DO NOT completely remove the nut 4 Remove the chain clevis pin and cotter pin to free the chain 5 Install a nylon tie wrap through the holes in the chain making a loop with the tie wrap and tie a rope to the loop 6 Pull the slack to the chain clevis at the front of the boom 7 Remove the clevis pin and the cotter pin from the chain and chain clevis 8 Install a nylon tie wrap through the chain holes forming a loop and tie a
270. ures Pressure Checks and Adjustments In general follow the steps below whenever conducting pressure checks and performing adjustments 1 Park the machine on a firm level surface Engage the park brake place the travel select lever in N NEUTRAL level the boom and turn the engine OFF 2 The test ports are located at the front of the filter head bracket top center of the front axle rear of the main implement pump and on the left side of the hydrostatic drive pump Install a pressure gauge capable of measuring at least 10 more pressure than that which the circuit being checked operates under 3 Start the engine Operate machine functions several times to allow hydraulic oil to reach operating temperature The hydraulic oil temperature should be between 100 120 F 38 49 C If a temperature gauge or thermometer is unavailable the hydraulic oil reservoir should be warm to the touch 4 Refer to Section 8 4 1 Hydraulic Pressures for testing procedures 5 Fully depress the accelerator pedal if required Place and hold the joystick in the position needed to operate the particular machine function being checked Continue holding the joystick in position until pressure readings are taken 6 Check the pressure gauge reading It should read as specified in the Pressure Readings column of the charts found in Section 8 4 1 Hydraulic Pressures If the reading is not as specified turn the engine OFF and che
271. ust be replaced Quick Switch Installation Assemble the quick switch to the boom head Line up the quick switch between the mounts on the boom head The quick switch should be centered in the boom head Coat the quick switch head pin with an anti seize compound Insert the quick switch head pin 6 through the quick switch and boom head Secure with the previous capscrew and locknut Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin 5 Align the tilt cylinder pin and screw in the locking bolt Torque as required 534D 9 534D 10 amp 544D Boom 3 17 FORKS Forks should be cleaned and inspected prior to being attached to carriage If the following criteria is not met forks must be removed from service immediately Daily Inspection 1 Inspect forks 4 for cracks paying special attention to heel b and mounting tubes 6 Inspect forks for broken or bent tips 7 and twisted blades 8 and shanks 9 Yearly Inspection T Straightness of the upper face of blade 8 and the front face of shank 9 should not exceed 0 5 percent of the length of blade or height of shank Angle 10 between upper face of blade and front face of shank should not exceed 93 degrees Thickness of blade 13 and shank 14 should not be reduced to 90 percent of original thickness Ensure fork length 12 is adequate for intended loads Fork markings should
272. uster or vacuum pipe leak Turbo impeller damaged or dirty Turbo lubricating oil seal leak Induction system leaks 7 15 Engine This Page Intentionally Left Blank 7 16 534D 9 534D 10 amp 544D Section 8 Hydraulic System Contents PARAGRAPH TITLE PAGE 8 1 Hydraulic Component 8 2 8 2 Safety 22 8 3 8 3 Hydraulic Pressure 8 4 8 3 1 Pressure Checks and 8 4 8 3 2 Pressure and Speed 5 8 5 8 4 25 4 e M eet ee eee 8 6 8 4 1 Hydraulic Pressures sin pe Ru eed y been ede ened 8 6 8 4 2 Hydraulic Schematic 534D 9 8 9 8 4 3 Hydraulic Schematic 534D 10 8 10 8 4 4 Hydraulic Schematic 544D 8 11 8 5 Hydraulic Reservoir 8 12 8 5 1 Hydraulic Oil Reservoir 8 12 8 5 2 Hydraulic Oil Reservoir 0 8 12 8 5 3 Hydraulic Oil Reservoir Removal Installation 8 12 8 6 Engine Implement Pump
273. ut and blend the scratch es into the surrounding surface 3 Check the piston rod assembly for run out If the rod is bent it must be replaced 8 9 3 General Cylinder Assembly Instructions 1 Use the proper tools for specific installation tasks Clean tools are required for installation 2 Install new seals back up rings and o rings on the piston and new seals back up rings o rings and bearing on the head gland Note The extend retract cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head 3 Fasten the rod eye in a soft jawed vise and place a padded support under and near the threaded end of the rod to prevent any damage to the rod Protect the finish of the rod at all times Damage to the surface of the rod can cause seal failure 534D 9 534D 10 amp 544D Hydraulic System n 4 Lubricate and slide the head gland over the cylinder rod Install the piston head on to the end of the cylinder rod Loctite and install the set screw in the piston head Refer to Section 8 9 6 Cylinder Torque Specifications for torque specifications for the piston head and the set screw Avoid using excess force when clamping the cylinder barrel in a vise Apply only enough force to hold the cylinder barrel securely Excessive force can damage the cylinder barrel 5 Place the cylinder barrel in a soft jawed vise or other acceptable holding devise
274. uts in an alternating pattern as switch and steering wheel stating that the machine indicated in figure Torque to 350 400 Ib ft should not be operated 475 542 Nm 3 Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed 4 Place a suitable jack under the axle pad closest to the wheel being removed Raise the machine and position a suitable support beneath the axle Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly 5 Lower the machine onto the support 6 Remove lug nuts and lug washers in an alternating pattern 7 Remove the wheel and tire assembly from the machine 5 Remove machine from supports 5 12 534D 9 534D 10 amp 544D Axles Wheels and Tires hs 5 7 BRAKES Check the brake disks for wear every 1 000 hours of operation or yearly For more information on brake disk inspection refer to the appropriate axle repair manual 5 7 1 Brake Disk Inspection A WARNING ALL WHEELS must be blocked to prevent machine from moving or rolling away 1 Securely block all four wheels 2 Remove the oil level plug 1 on each side of the axle 3 Have an assistant sit in the cab and apply the brakes keeping pressure applied 4 Using a feeler gauge check the gap 2 between the brake disks if the gap is less than 0 18 in 4 5 mm replace the brake disks
275. vals 4 Excessive compensation 1 Insufficient lubrication 1 Lubricate at regular intervals cylinder pivot pin noise and Refer to Section 2 6 or wear Lubrication Schedules Replace worn pins as needed 2 Worn bushing s 2 Replace bushing s and lubricate at regular intervals 3 44 534D 9 534D 10 amp 544D Boom a Boom Troubleshooting Continued Problem Cause Remedy 5 Drooping chain or jerky boom extend or retract functions 1 Chain s tension not properly adjusted 1 Adjust chain s 2 Chain s stretched or binding 2 Replace chains as needed Refer to Section 3 13 Boom Section Separation Adjustment Four Section 3 Wear pads loose contaminated Replace wear pad Refer to excessively worn or damaged Section 3 15 2 Boom Wear Pad Replacement 4 Contaminated corroded or 4 Remove contamination and or rusted wear pad sliding corrosion from wear pad sliding surfaces surfaces and lubricate If the surfaces cannot be reconditioned replace the boom section s 5 Extend Retracthydraulicsystem 5 Refer to Section 8 4 Hydraulic not operating properly Circuits 6 Damaged boom section 6 Replace the damaged boom section Refer to Section 3 10 Boom Maintenance Four Section Complete Removal 6 Boom will not raise or lower 1 Broken hydraulic hoses ortubes 1 Locate break replace hose s and or connection
276. ve by filling the inlet openings with fresh filtered hydraulic oil from a clean container before attaching the hoses 3 Use new oiled o rings as required Uncap and connect all previously labeled hoses clamps etc to the main control valve 4 Check the routing of all hoses wiring and tubing for sharp bends or interference with any rotating members and install tie wraps and or protective conduit as required Tighten all tube and hose clamps 5 Start the engine and run at approximately one third to one half throttle for about one minute without moving the machine or operating any hydraulic functions 6 Inspect for leaks and check the level of the hydraulic fluid in the reservoir Shut the engine OFF Note Check for leaks and repair as required before continuing Add hydraulic fluid to the reservoir as needed 7 Wipe up any hydraulic fluid spillage in on near and around the machine work area and tools 8 Close and secure the engine cover and the hydraulic oil reservoir fuel tank cover g Main Control Valve Test Conduct a pressure check of the hydraulic system in its entirety Adjust pressure s as required Refer to Section 8 3 1 Pressure Checks and Adjustments 534D 9 534D 10 amp 544D Service Brake Valve 8 8 2 mane J h N ic amp 1170 Service Brake Valve Removal 1 Park the machine on a firm level surface level the machine fully retract the boom lower the bo
277. vel 4 Start the engine and observe the operators display for warning indication If the sender is not defective the problem could be elsewhere possibly in a shorted wire improper running engine low oil obstructed or faulty oil pump defective instrument display Engine Oil Pressure Switch a Engine Oil Pressure Switch Removal 1 The engine oil pressure switch is located on the cab firewall 2 Remove the battery negative cable at the negative battery terminal 3 Remove and label the engine oil pressure switch wires 9 14 4 The switch is threaded into the mounting block Remove the switch b Engine Oil Pressure Switch Inspection and Replacement Inspect the switch and the wiring terminals for continuity Replace a defective or faulty switch with a new part 2 Engine Oil Pressure Switch Installation and Testing Thread the engine oil pressure switch into the mounting block Connect the previously labeled wires to the switch Connect the battery negative cable at the negative battery terminal Check for proper oil level Start the engine and observe the operator s display for warning indication If the switch is not defective the problem could be elsewhere possibly in a shorted wire improper running engine low oil obstructed or faulty oil pump defective instrument display 9 10 4 Fuel Level Sender Fuel Level Indicator Testing The fuel level sen
278. ver in N NEUTRAL engage the park brake and shut the engine OFF Boom Removal 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the system fluids to cool 4 Remove the battery negative cable from the battery negative terminal Note When removing a complete boom assembly use a hoist or crane with a minimum lift capacity of 8500 Ibs 5 Fasten suitable slings to each end of the first boom section making sure a balance point is achieved 6 Take the weight off the complete boom assembly 7 Identify and tag all hydraulic hoses and electrical cables 8 Loosen and separate all hydraulic hoses and electrical cables Plug the hose ends and tube ends to prevent dirt and debris from entering the hydraulic system 9 With the cylinder hoses blocked off the boom sections will be locked in position preventing run out 10 Remove the lock bolts and pins from the rod ends of the compensation and lift cylinders 11 Confirm that the crane has the weight of the boom 12 Remove the lock bolt and boom pivot pin 13 While lifting the boom assembly make sure the compensation and lift cylinders are properly supported 14 Lift the complete boom assembly free of the machine and place on the ground or suitable supports 3 10 2 With the boom assembly now turned upside down the extend retract cylind
279. w HERE iting ay Sos Lec Sat 5 EJ ay ungui 3010 92 B 5 I E ne 2 le le g BO berg an Y eA 8 Li M d a EE eR NAR BEER FPP 2 07 oS 3 ls ESI H Lj Fee Hd E 2525 BREE j GUB rem H a Gao 8 ano 6 le le b EIL Ta F E ROSE swr H am un 3sn4 anon aua an EU TN Houms BBR v MAA T E ms 5 52 m amis L 2 52 Tus SYN E E II 9 5 534D 9 534D 10 amp 544D Electrical Schematic 534D 9 534D 10 544D Cummins Electrical System 9 5 3 sommano sm
280. wire brush to clear the space between the plates so that the lubricant can penetrate to the working surfaces Lubricant may be applied with a narrow paint brush or directly poured on but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces All surplus lubricant should be wiped away from the external surfaces DO NOT use a solvent for this wiping operation Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated In extremely dusty conditions it may be necessary to lubricate the chains more often Lubrication of chains on machines working consistently in extreme hot or cold conditions requires special consideration 3 37 Boom b 3 13 BOOM SECTION SEPARATION ADJUSTMENT FOUR SECTION The second third and fourth boom sections are set to dimensions between each section The first and second boom sections are connected by the extend retract cylinder which has no adjustment The third and fourth boom sections can be adjusted by loosening or tightening the extend chains and the retract chains a Toincrease the separation distance Loosen the retract chains locknut on the rear of the third or fourth boom sections one or two turns and tighten the extend chain locknuts on the first and second boom sections equally the same number of turns A minimu
281. wiring and connections and verify that they are in good condition 3 Check the fan belt condition and tension 4 Run the engine and check the alternator for noise loose drive pulley loose mounting hardware worn or dirty internal alternator bearings a defective stator or defective diodes can cause noise Replace a worn or defective alternator 9 7 1 Alternator a Alternator Removal 1 Open the engine cover 2 Remove the battery negative cable at the negative battery terminal 3 Install a 1 2 square drive ratchet into the square hole in the serpentine belt tensioner bracket 4 While lifting the automatic belt tensioner away from the belt remove the fan serpentine belt Note Record how the alternator is installed to ensure correct installation later 5 Label and disconnect the wire leads 6 Remove the lower mounting bolt 1 securing the alternator to the lower mounting hole on the engine 7 While supporting the alternator with one hand remove the upper mounting bolt 2 from the alternator mount Remove the alternator from the machine 9 10 b Alternator Installation Position the alternator and align with the upper alternator mount on the engine bracket Insert the upper mounting bolt through the alternator mount DO NOT tighten completely at this time Align the lower alternator mount hole with the lower mounting bracket on the engine and insert the lower mounting bolt
282. ydraulic oil Uncap and connect the brake lines at their axle fittings Install the drive motor assembly Check the hydraulic reservoir oil level Connect the battery negative cable from the battery negative terminal and install the deck cover Close and secure the engine cover Start the engine Operate the frame sway function several times in both directions and check the function of the brakes Check for hydraulic leaks and tighten or repair as necessary Note The service brake circuit will need to bled after axle installation Refer to Section 8 8 3 Brake Test 5 5 hs Axles Wheels and Tires 5 3 7 Axle Assembly Troubleshooting Problem Cause Remedy 1 Excessive axle noise while 1 Oil level too low 1 Fill oil to correct level Refer to driving Section 2 4 Fluid and Lubricant Capacities 2 Axle and or wheel end housings 2 Drain axle and or wheel end filled with incorrect oil or oil level housings and fill to correct level low with Mobilfluid 4249 ISO 46 Refer to Section 2 4 Fluid and Lubricant Capacities 3 Incorrect alignment of ring and 3 Correct alignment by adding or pinion gears removing shims as needed 4 Incorrect pinion input shaft 4 Correct bearing preload by bearing preload adding or removing shims as needed 5 Worn or damaged bearings 5 Replace bearings as needed 6 Worn or broken gear teeth 6 Replace gears as needed 7 Contamination i
283. ydraulic reservoir and pump openings until installation occurs Protect threads from contamination and damage Some hydraulic functions are actuated by interfacing with electrical system components switches solenoids and sensors When the hydraulic system is not functioning properly check the electrical aspect of the malfunctioning circuit also Refer to Section 9 5 Electrical System Schematics in this manual 8 3 Hydraulic System n 8 3 HYDRAULIC PRESSURE DIAGNOSIS JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting the JLG Pressure Test Kit The kit is contained in a durable polyethylene carrying case for demanding field service conditions Pressure Test Kit The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system The kit includes e Gauges for testing high and low pressure circuits Fittings couplers and hoses MZ1460 Contact JLG Parts Department at 717 485 6472 for ordering information Part Description Approximate Price and Number Weight Availability 70000652 Hydraulic Pressure Test Kit 10 Ibs Consult Factory 70000101 Digital Hydraulic Pressure 7 Ibs Consult Factory Test Kit 8 4 8 3 1 When diagnosing trouble in the hydraulic system use the hydraulic testing information in Section 8 4 1 Hydraulic Press
284. ystem X MX0120 1 3 From the rear of the boom remove the hose guard 2 for the hose being removed 3 16 4 Loosen the hose from the bulkhead at the front of the boomhead Plug the hose ends and cap the tube ends to prevent dirt and debris from entering the hydraulic system 5 Tie a rope to the hose end and through the rear of the boom pull the separated hose free of the boom assembly N N 4 2 2 MX0260 3 5 9 Hose Installation 1 Tie a rope to the new hose end below the hose take up bracket below the third boom section 2 Slowly pull the rope from the rear of the boom and feed the hose around the roller and pull the hose through the protective channels in the third boom section to the boom head 3 At the boom head apply Loctite 5459to the hose fittings at the bulk head connect and torque the hoses and install clamps 4 Install the hose guard at the rear boom roller 5 Atthe hose take up bracket apply Loctite 545 to the hose fittings connect and torque the hoses 3 MX0290 6 Tighten the hose take up bracket adjusting nuts Ensure the 4 in 101 mm dimension 3 is held at the hose area between the take up bracket and the first hose clamp 534D 9 534D 10 amp 544D Boom b 3 6 AUXILIARY ELECTRI

Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents