Jlg 534D-10 User Manual

An Oshkosh Corporation CompanyService ManualModels534D-9,534D-10& 544D534D-9 & 534D-10S/N 0160000447 & After544DS/N 0160000192 & After

Safety Practices1.2 534D-9, 534D-10 & 544D1.1 INTRODUCTIONThis service manual provides general directions for accomplishing service and repair pro

Hydrostatic Drive Pump6.2 534D-9, 534D-10 & 544D6.1 DRIVE PUMP ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance i

6.3534D-9, 534D-10 & 544DHydrostatic Drive Pump6.2 DRIVE PUMP DESCRIPTION Instructions in this section pertain mainly to general specifications, t

Hydrostatic Drive Pump6.4 534D-9, 534D-10 & 544D2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the

6.5534D-9, 534D-10 & 544DHydrostatic Drive Pump6.6 HYDROSTATIC DRIVE PERFORMANCE CHECKSThese tests ensure that the Hydrostatic Drive System operat

Hydrostatic Drive Pump6.6 534D-9, 534D-10 & 544D6.6.4 Park BrakePark brake wear can cause park brake failure and reduce braking effectiveness on a

6.7534D-9, 534D-10 & 544DHydrostatic Drive PumpAnother test to determine the loss of charge pressure is to cap off lines to the drive motors (3).

Hydrostatic Drive Pump6.8 534D-9, 534D-10 & 544DIf charge pressure is not achieved, main pump is leaking internally.Note: Do Not stall pump for m

6.9534D-9, 534D-10 & 544DHydrostatic Drive Pump6.6.8 Front Motor Begin PointThe front motor begin point is when the motor begins to stroke toward

Hydrostatic Drive Pump6.10 534D-9, 534D-10 & 544D6.6.9 Drive Pump Pressure Drive pump pressure determines the drive power of the machine. Low driv

7.1534D-9, 534D-10 & 544DSection 7EngineContentsPARAGRAPH TITLE PAGE7.1 Introduction: John Deere 4045TF275 & 4045HF275. . . . . . . . . . . .

1.3534D-9, 534D-10 & 544DSafety Practices1.5 SAFETY INFORMATIONTo avoid possible death or injury, carefully read, understand and comply with all s

Engine7.2 534D-9, 534D-10 & 544D7.1 INTRODUCTION: JOHN DEERE 4045TF275 & 4045HF2757.1.1 Disclaimer and ScopeThese instructions are written for

7.3534D-9, 534D-10 & 544DEngine7.1.2 Component TerminologyTo understand the safety, operation and maintenance information presented in this sectio

Engine7.4 534D-9, 534D-10 & 544D7.2 ENGINE SERIAL NUMBERThe John Deere serial number Is stamped on a plate which is secured to the engine block, n

7.5534D-9, 534D-10 & 544DEngine7.4 INTRODUCTION: CUMMINS QSB4.57.4.1 Disclaimer and ScopeThese instructions are written for worldwide use. In terr

Engine7.6 534D-9, 534D-10 & 544D7.4.2 Component TerminologyTo understand the safety, operation and maintenance information presented in this secti

7.7534D-9, 534D-10 & 544DEngine7.5 ENGINE SERIAL NUMBERThe Cummins QSB4.5 serial number is stamped on a plate which is typically located on the en

Engine7.8 534D-9, 534D-10 & 544D5. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant le

7.9534D-9, 534D-10 & 544DEngineb. Radiator/Oil Cooler Installation1. Install the isolator mounts to the bottom of the radiator. Place the radiator

Engine7.10 534D-9, 534D-10 & 544D3. Open the engine cover. Allow the system fluids to cool.4. Remove the battery negative (-) cable from the batte

7.11534D-9, 534D-10 & 544DEngine3. Fill the fuel tank with fresh, clean diesel fuel as required.CumminsRefer to Section 8.5.1, “Hydraulic Oil Rese

Safety Practices1.4 534D-9, 534D-10 & 544D1.6.3 General HazardsSOLVENTS: Only use approved solvents that are known to be safe for use.HOUSEKEEPING

Engine7.12 534D-9, 534D-10 & 544D7.11.2 Air Cleaner Assembly InstallationNote: Apply Loctite® 242 threadlock to the capscrew threads before insta

7.13534D-9, 534D-10 & 544DEngine18. Remove the exhaust flex pipe from the exhaust pipe. Remove the exhaust pipe from the exhaust manifold.19. Loos

Engine7.14 534D-9, 534D-10 & 544D22. If installing new hydraulic oil filters, fill with Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46) before in

7.15534D-9, 534D-10 & 544DEngine7.14 ENGINE TROUBLESHOOTINGTrouble Possible Causes (see key, below)Low Cranking PowerWill Not StartDifficult Start

Engine7.16 534D-9, 534D-10 & 544DThis Page Intentionally Left Blank

8.1534D-9, 534D-10 & 544DSection 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . .

Hydraulic System8.2 534D-9, 534D-10 & 544D8.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information presented

8.3534D-9, 534D-10 & 544DHydraulic System8.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this machine. The temperature of hydra

Hydraulic System8.4 534D-9, 534D-10 & 544D8.3 HYDRAULIC PRESSURE DIAGNOSISJLG Parts Department has a kit available to use for hydraulic system mai

8.5534D-9, 534D-10 & 544DHydraulic System8.3.2 Pressure and Speed SettingsNote: All readings and adjustments are to be done with warm oil (minimu

2.1534D-9, 534D-10 & 544DSection 2General Information and SpecificationsPARAGRAPH TITLE PAGE2.1 Replacement Parts and Warranty Information . . . .

Hydraulic System8.6 534D-9, 534D-10 & 544D8.4 HYDRAULIC CIRCUITSThis section covers the hydraulic circuits and includes listings for all hydraulic

8.7534D-9, 534D-10 & 544DHydraulic SystemNote: High idle may be needed to allow the steering to bottom against the steering stop.5. With the engi

Hydraulic System8.8 534D-9, 534D-10 & 544D5. If the proper pressure cannot be set, use the accompanying hydraulic schematic, electrical schematic,

8.9534D-9, 534D-10 & 544DHydraulic System8.4.2 Hydraulic Schematic-534D-9LPFILTERB =75882700PSIPRIORITYFLOW DIVIDER.071"DIA2000PSI2000PSISTE

Hydraulic System8.10 534D-9, 534D-10 & 544D8.4.3 Hydraulic Schematic-534D-10LPFILTERB =75882700PSIPRIORITYFLOW DIVIDER.071"DIA2000PSI2000PSI

8.11534D-9, 534D-10 & 544DHydraulic System8.4.4 Hydraulic Schematic-544DMX07103500PSICOMPENSATINGCYLINDERPARK BRAKESWITCHSTEERCYLINDERSLPFILTERB

Hydraulic System8.12 534D-9, 534D-10 & 544D8.5 HYDRAULIC RESERVOIRThe hydraulic reservoir (1) is located on the right side of the frame behind the

8.13534D-9, 534D-10 & 544DHydraulic Systemc. Cleaning and DryingIf contaminated hydraulic oil or foreign material is in the tank, the tank can usu

Hydraulic System8.14 534D-9, 534D-10 & 544D8. Label, disconnect and cap the hydraulic hoses attached to the pump.9. Remove the two bolts and two l

8.15534D-9, 534D-10 & 544DHydraulic Systemb. Front Drive Motor DisassemblyAlthough individual parts are available for the drive motor, it is recom

General Information and Specifications2.2 534D-9, 534D-10 & 544D2.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONBefore ordering parts or initiating

Hydraulic System8.16 534D-9, 534D-10 & 544D8.8 CONTROL VALVES8.8.1 Main Control ValveThe main control valve is mounted on the frame of the cab bel

8.17534D-9, 534D-10 & 544DHydraulic SystemAssemble the Main Control Valve.1. Place all three tie rods with the washers and nuts through the inlet

Hydraulic System8.18 534D-9, 534D-10 & 544D544D MAIN CONTROL VALVE

8.19534D-9, 534D-10 & 544DHydraulic Systemf. Main Control Valve Installation1. Install the main control valve onto the frame, aligning the bolts w

Hydraulic System8.20 534D-9, 534D-10 & 544Db. Service Brake Valve Installation1. Install the service brake valve with the four capscrews, four loc

8.21534D-9, 534D-10 & 544DHydraulic System8.8.4 Steering Orbitrol ValveThe steering orbitrol valve (4) is located at the base of the steering whee

Hydraulic System8.22 534D-9, 534D-10 & 544D5. Using a pin spanner wrench, unscrew the head gland from the tube. A considerable amount of force wil

8.23534D-9, 534D-10 & 544DHydraulic System4. Lubricate and slide the head gland over the cylinder rod. Install the piston head on to the end of th

Hydraulic System8.24 534D-9, 534D-10 & 544D8.9.6 Cylinder Torque Specifications534D-9/10544DNote: If reusing the cylinder gland, torque the cylin

9.1534D-9, 534D-10 & 544DSection 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology . . . . . . . . . . . . . . .

2.3534D-9, 534D-10 & 544DGeneral Information and Specifications2.2 TORQUE CHARTS2.2.1 ASTM Fastener Torque Chart (English)VALUES FOR ZINC PLATED /

Electrical System9.2 534D-9, 534D-10 & 544D9.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information presen

9.3534D-9, 534D-10 & 544DElectrical System9.2 SPECIFICATIONSElectrical system specifications are listed in Section 2, “General Information and Spe

Electrical System9.4 534D-9, 534D-10 & 544D9.5 ELECTRICAL SYSTEM SCHEMATICS 9.5.1 Electrical Schematic 534D-9, 534D-10 - John DeereMX0680BATTERY-+

9.5534D-9, 534D-10 & 544DElectrical System9.5.2 Electrical Schematic 544D - John DeereMX0690BATTERY-+PS IGNBATT#1#2ALTERNATORHORNBATIGNITIONBIASNS

Electrical System9.6 534D-9, 534D-10 & 544D9.5.3 Electrical Schematic 534D-9, 534D-10, 544D - CumminsMX1230WAIT-TO-STARTLIGHTDIAG.LIGHTC-CONNECTOR

9.7534D-9, 534D-10 & 544DElectrical System9.5.4 Start Circuit 534D-9, 534D-10, 544DMX075030 878685BATTERY-+START-CSTARTERMOTORSTARTERSOLENOID17172

Electrical System9.8 534D-9, 534D-10 & 544D9.5.5 Charge Circuit 534D-9, 534D-10, 544DMX0771ALT EXC-ABATTERY-+BAT12ALTERNATORIGNITIONBIAALT EXC-BST

9.9534D-9, 534D-10 & 544DElectrical System9.6 ENGINE START CIRCUIT9.6.1 StarterThe starter (1) is located on the right side of the engine.a. Testi

Electrical System9.10 534D-9, 534D-10 & 544D9.7 CHARGING CIRCUITBefore using a battery charger, an attempt can be made to recharge the battery by

9.11534D-9, 534D-10 & 544DElectrical System9.8 WINDSHIELD WIPER MOTOR (IF EQUIPPED)a. RemovalNote: It may be necessary to remove several hydrauli

General Information and Specifications2.4 534D-9, 534D-10 & 544D2.2.2 ASTM Fastener Torque Chart (Metric) VALUES FOR ZINC PLATED / YELLOW CHR

Electrical System9.12 534D-9, 534D-10 & 544D4. Rotate the washer reservoir, label and remove the cab harness connectors from the washer reservoir

9.13534D-9, 534D-10 & 544DElectrical Systemb. Solenoid DisassemblyDO NOT disassemble a solenoid. Replace a defective solenoid with a new part.c. S

Electrical System9.14 534D-9, 534D-10 & 544D4. Start the engine, allow it to reach operating temperature and observe the operator’s instrument clu

9.15534D-9, 534D-10 & 544DElectrical System3. If the fuel level indicator needle does not move after the ignition key switch is turned to the RUN

Electrical System9.16 534D-9, 534D-10 & 544DIf all wires do not show proper continuity, replace the ignition switch.d. Ignition Switch Installatio

9.17534D-9, 534D-10 & 544DElectrical System3. Connect the battery negative (-) cable at the negative battery (-) terminal.4. Start the machine and

Electrical System9.18 534D-9, 534D-10 & 544D9.15 TROUBLESHOOTING - CUMMINS9.15.1 Fault DetectionFaults are detected while the key switch is in the

9.19534D-9, 534D-10 & 544DElectrical System9.15.4 Engine Fault Codes ChartFault Code SPN Code FMI Code Description0001 Exhaust Gas Pressure Sensor

Electrical System9.20 534D-9, 534D-10 & 544D245 647 4/4 Fan Control Circuit - Low253 98 1 Engine Oil Level268 94 2 Injector Metering Rail 1 Pressu

9.21534D-9, 534D-10 & 544DElectrical System429 97 4/4 Water-In-Fuel Indicator Sensor Circuit - Low431 558 2/2 Accelerator Pedal or Lever Idle Vali

2.5534D-9, 534D-10 & 544DGeneral Information and Specifications2.2.3 Metric Fastener Torque ChartVALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENER

Electrical System9.22 534D-9, 534D-10 & 544D778 723 2 Engine Speed Sensor (Camshaft) Error - Erratic779 703 11 Auxiliary Equipment Sensor Input #3

9.23534D-9, 534D-10 & 544DElectrical System1682 3362 11/31 Catalyst Reagent Dosing Unit Input Lines1683 3449 3 Catalyst Tank Heater Circuit - High

Electrical System9.24 534D-9, 534D-10 & 544D2348 27 13/13 EGR Valve Failed Automatic Calibration Procedure2349 2791 5/5 EGR Valve Control Circuit

JLG Worldwide LocationsAn Oshkosh Corporation CompanyJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: +

General Information and Specifications2.6 534D-9, 534D-10 & 544D2.3 SPECIFICATIONS2.3.1 Travel Speeds2.3.2 Hydraulic Cylinder PerformanceNote: Ma

2.7534D-9, 534D-10 & 544DGeneral Information and Specifications2.3.4 Engine Performance Specifications a. John Deereb. CumminsDescription 534D-9 5

General Information and Specifications2.8 534D-9, 534D-10 & 544D2.3.5 Tires Note: Standard wheel lug nut torque is 350-400 lb-ft (475-542 Nm).Not

2.9534D-9, 534D-10 & 544DGeneral Information and Specifications2.4 FLUID AND LUBRICANT CAPACITIESEngine Crankcase OilCapacity w/Filter Change (Joh

General Information and Specifications2.10 534D-9, 534D-10 & 544D2.5 SERVICE AND MAINTENANCE SCHEDULES 2.5.1 10, 1st 50 & 50 HourMX0080Check W

2.11534D-9, 534D-10 & 544DGeneral Information and Specifications2.5.2 250, 500, 1000 & 1500 Hour 500EVERYCheck WheelLug NutTorqueLB/FT (Nm)Cha

General Information and Specifications2.12 534D-9, 534D-10 & 544D2.6 LUBRICATION SCHEDULES2.6.1 534D-9, 534D-10a. 50 HourOX0341250EVERYMYSTIK TETR

2.13534D-9, 534D-10 & 544DGeneral Information and Specificationsb. 250 HourOX03512250EVERYMYSTIK TETRIMOLY(NLGI 2 GC-LB)

General Information and Specifications2.14 534D-9, 534D-10 & 544D2.6.2 544Da. 50 HourMX0051250EVERYMYSTIK TETRIMOLY(NLGI 2 GC-LB)

2.15534D-9, 534D-10 & 544DGeneral Information and Specificationsb. 250 HourMX0071250EVERYMYSTIK TETRIMOLY(NLGI 2 GC-LB)

General Information and Specifications2.16 534D-9, 534D-10 & 544DThis Page Intentionally Left Blank

3.1534D-9, 534D-10 & 544DSection 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology 534D-9, 534D-10 . . . . . . . . . . . . .

EFFECTIVITY PAGE31200170 534D-9, 534D-10 & 544D aFebruary 5, 2007 - A - Original Issue Of ManualMay 7, 2008 - B - Added second battery on page 2.6

Boom3.2 534D-9, 534D-10 & 544D3.10 Boom Maintenance - Four Section (Complete Removal). . . . . . . . . . . . . . . . . . . 3.213.10.1 Boom Removal

3.3534D-9, 534D-10 & 544DBoom3.1 BOOM SYSTEM COMPONENT TERMINOLOGY 534D-9, 534D-10The following illustrations identify the components that are ref

Boom3.4 534D-9, 534D-10 & 544D3.2 BOOM SYSTEM - THREE SECTION3.2.1 Boom System OperationThe three section boom consists of the first, second and t

3.5534D-9, 534D-10 & 544DBoom3.3.2 Second & Third Boom Section Removal1. Set the complete boom on level ground and by repositioning the slings

Boom3.6 534D-9, 534D-10 & 544D3. Loosen and remove all extend cable sheave components from the front of the pivot beam.4. Pull the extend cables f

3.7534D-9, 534D-10 & 544DBoom7. Connect the auxiliary hoses to the quick disconnects on the side of the boom head. Connect the electrical cable to

Boom3.8 534D-9, 534D-10 & 544D4. Set the second and third boom sections onto a suitable support and reset the sling under the boom head of the thi

3.9534D-9, 534D-10 & 544DBoom3.4 BOOM MAINTENANCE - THREE SECTION (INDIVIDUAL SECTION REMOVAL)These general instructions help with the removal of

Boom3.10 534D-9, 534D-10 & 544D23. Slowly pull the push beam out of the front of the third boom section. The extend cables will come out along wit

3.11534D-9, 534D-10 & 544DBoom10. Loosen and remove the bolts holding the strong back to the rear of the first boom section. Remove the strong bac

EFFECTIVITY PAGE534D-9, 534D-10 & 544D 31200170-b

Boom3.12 534D-9, 534D-10 & 544D3.5 BOOM CABLES - THREE SECTION3.5.1 General Cable InformationThe 534D-9 & 534D-10 Parts Manual covers part num

3.13534D-9, 534D-10 & 544DBoom3.5.3 Retract Cable RemovalThe removal of the retract cable is a difficult operation; but it can be accomplished. Yo

Boom3.14 534D-9, 534D-10 & 544D3.5.4 Retract Cable Installation1. Fasten the rope left in the boom from the retract cable removal to the new retra

3.15534D-9, 534D-10 & 544DBoom1. Remove any attachment from the quick switch assembly. Refer to Section 3.16.1, “Disconnecting from an Attachment.

Boom3.16 534D-9, 534D-10 & 544DNote: When adjusting cables, make sure the cables are not turning.13. Install the jam nut (12) to the adjusting nu

3.17534D-9, 534D-10 & 544DBoom3.6 AUXILIARY ELECTRIC CABLE - THREE SECTIONThe electric cable is fed through the right side of the boom assembly in

Boom3.18 534D-9, 534D-10 & 544Dstrain relief fittings on the cable. Do not tighten at this time.5. Pull the electric cable through the boom to the

3.19534D-9, 534D-10 & 544DBoom3.7.2 Extend/Retract Cylinder Installation1. Install the extend/retract cylinder into the push beam and line up the

Boom3.20 534D-9, 534D-10 & 544D3.8 BOOM SYSTEM COMPONENT TERMINOLOGY 544DThe following illustrations identify the components that are referred to

3.21534D-9, 534D-10 & 544DBoom3.9 BOOM SYSTEM - FOUR SECTION 3.9.1 Boom System OperationThe four section boom consists of the first, second, third

SECTION CONTENTSSection Subject Page534D-9, 534D-10 & 544DiSection 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.22 534D-9, 534D-10 & 544D3. Remove the snap rings and pin from each end of the extend/retract cylinder.4. Remove the extend/retract cylinder

3.23534D-9, 534D-10 & 544DBoom3.10.5 Third & Fourth Boom Section Removal Note: Work on the boom assembly is performed with the assembly up-si

Boom3.24 534D-9, 534D-10 & 544D4. Loosen and remove the front wear pads and supports from the third boom section. Tag each pad, backing plate, shi

3.25534D-9, 534D-10 & 544DBoom10. Torque all fasteners and hydraulic fittings per Section 2.2, “Torque Charts.”3.10.8 Fourth Boom Section Install

Boom3.26 534D-9, 534D-10 & 544D18. Connect the 3/4 in (19 mm) retract chain (4) to the clevis at the rear of the fourth boom section.19. Connect t

3.27534D-9, 534D-10 & 544DBoom23. At the rear of the boom, bolt on the bracket to the back of the hose carrier.24. Install the hose guide bracket

Boom3.28 534D-9, 534D-10 & 544D12. Install the top front chain roller (14) to the second and third boom sections.13. Install the hoses (15) to the

3.29534D-9, 534D-10 & 544DBoom3.11.1 Fourth Boom Section Removal1. Park the machine on a firm, level surface, fully retract the boom, lower the bo

Boom3.30 534D-9, 534D-10 & 544D19. Loosen and remove the wear pads from the top rear and one side of the fourth boom section. Note the location of

3.31534D-9, 534D-10 & 544DBoom4. Loosen and remove the tilt/aux hose take-up bracket (5) from the bottom of the first boom section.Pull the tilt/a

Section Subject Pageii534D-9, 534D-10 & 544DSection 5Axles, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.32 534D-9, 534D-10 & 544D5. Wrap the two extend chains around the chain rollers on the second boom section and connect to the clevises on th

3.33534D-9, 534D-10 & 544DBoomEnvironments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mil

Boom3.34 534D-9, 534D-10 & 544DDistorted or Battered Link PlatesDistorted or battered link plates (5) on a leaf chain can cause tight joints and p

3.35534D-9, 534D-10 & 544DBoomIf the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re

Boom3.36 534D-9, 534D-10 & 544Dadjustment required. The correct dimension is 17 in (432 mm).8. Loosen the adjusting nut (6) at the top front of th

3.37534D-9, 534D-10 & 544DBoom5. Fasten the chain into the clevis by installing the pin and cotter pin.6. Torque the jam nuts to 100 lb-ft (135 Nm

Boom3.38 534D-9, 534D-10 & 544D3.13 BOOM SECTION SEPARATION ADJUSTMENT - FOUR SECTIONThe second, third and fourth boom sections are set to dimensi

3.39534D-9, 534D-10 & 544DBoom11. Loosen and remove the sub-assembly bracket (4) at the rear of the third boom section.12. Install a sling around

Boom3.40 534D-9, 534D-10 & 544D3. Fully collapse the hose carriers and secure together using plastic tie wraps or nylon straps to keep them from s

3.41534D-9, 534D-10 & 544DBoom3.15 BOOM WEAR PADSA total of 27 wear pads are installed on the boom sections of the 534D-9 and 534D-10 machines.A t

Section Subject Pageiii534D-9, 534D-10 & 544D9.3 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.42 534D-9, 534D-10 & 544D3.16 QUICK SWITCH ASSEMBLY This machine is equipped with a quick switch assembly system for easy attachment changes

3.43534D-9, 534D-10 & 544DBoom3.17 FORKSForks should be cleaned and inspected prior to being attached to carriage. If the following criteria is no

Boom3.44 534D-9, 534D-10 & 544D3.18 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur duri

3.45534D-9, 534D-10 & 544DBoom5. Drooping chain, or jerky boom extend or retract functions.1. Chain(s) tension not properly adjusted. 1. Adjust ch

Boom3.46 534D-9, 534D-10 & 544D9. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3

4.1534D-9, 534D-10 & 544DSection 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . .

Cab and Covers4.2 534D-9, 534D-10 & 544D4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance inf

4.3534D-9, 534D-10 & 544DCab and Covers4.2 OPERATOR’S CAB4.2.1 Cab Safety 4.2.2 Serial Number DecalThe cab serial number decal is located on the l

Cab and Covers4.4 534D-9, 534D-10 & 544Db. Orbitrol Valve Installation1. Secure the steering valve to the steering column with four hex-flange cap

4.5534D-9, 534D-10 & 544DCab and Covers4.3.3 Throttle Pedala. Throttle Pedal Removal1. Park the machine on a firm, level surface, level the machin

Section Subject Pageiv534D-9, 534D-10 & 544D

Cab and Covers4.6 534D-9, 534D-10 & 544D2. Install the bolts securing the boom joystick to the cab.3. Connect the battery negative (-) cable to th

4.7534D-9, 534D-10 & 544DCab and Covers3. Disconnect the battery negative (-) cable at the battery negative (-) terminal.4. Remove the four bolts

Cab and Covers4.8 534D-9, 534D-10 & 544Db. Heater Assembly Installation1. Position the heater assembly to its original orientation in the cab. Sec

4.9534D-9, 534D-10 & 544DCab and Covers12. Remove the mirrors and all other cab components as needed, if not previously removed.13. Carefully begi

Cab and Covers4.10 534D-9, 534D-10 & 544DThis Page Intentionally Left Blank

5.1534D-9, 534D-10 & 544DSection 5Axles, Wheels and TiresContentsPARAGRAPH TITLE PAGE5.1 Axles, Wheel and Tire Component Terminology . . . . . . .

Axles, Wheels and Tires5.2 534D-9, 534D-10 & 544D5.1 AXLES, WHEEL AND TIRE COMPONENT TERMINOLOGYTo understand the safety, operation and maintenanc

5.3534D-9, 534D-10 & 544DAxles, Wheels and Tires5.2 GENERAL INFORMATIONBefore performing any inspection, maintenance or service operation, thoroug

Axles, Wheels and Tires5.4 534D-9, 534D-10 & 544D5.3.5 Axle RemovalThe front axle assembly is equipped with a parking brake mechanism and a limite

5.5534D-9, 534D-10 & 544DAxles, Wheels and Tires5.3.6 Axle Installation1. Before proceeding, ensure that the machine will remain in place during a

1.1534D-9, 534D-10 & 544DSection 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .

Axles, Wheels and Tires5.6 534D-9, 534D-10 & 544D5.3.7 Axle Assembly TroubleshootingProblem Cause Remedy1. Excessive axle noise while driving.1. O

5.7534D-9, 534D-10 & 544DAxles, Wheels and Tires3. Oil leaking from axle (differential housing and/or axle housings).1. Drain and/or inspection pl

Axles, Wheels and Tires5.8 534D-9, 534D-10 & 544D6. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with Mobilfluid 424® (IS

5.9534D-9, 534D-10 & 544DAxles, Wheels and Tires5.4 REAR DRIVE HUBS5.4.1 Rear Drive Hub ServiceDetailed drive hub service instructions (covering r

Axles, Wheels and Tires5.10 534D-9, 534D-10 & 544D5.5 REAR STEER AXLE5.5.1 Rear Axle RemovalThe rear steer axle assembly is equipped with two stee

5.11534D-9, 534D-10 & 544DAxles, Wheels and Tires4. Position the axle under the frame, and align the axle housing with the holes in the frame.5. I

Axles, Wheels and Tires5.12 534D-9, 534D-10 & 544D5.6.1 Removing Wheel and Tire Assembly from Machine1. Park the machine on a firm, level surface,

5.13534D-9, 534D-10 & 544DAxles, Wheels and Tires5.7 BRAKESCheck the brake disks for wear every 1,000 hours of operation or yearly.For more inform

Axles, Wheels and Tires5.14 534D-9, 534D-10 & 544DAfter the machine has been towed to a secure location, reactivate the parking brake. 1. Block al

6.1534D-9, 534D-10 & 544DSection 6Hydrostatic Drive PumpContentsPARAGRAPH TITLE PAGE6.1 Drive Pump Assembly Component Terminology . . . . . . . .