JLG 534D-10 User Manual

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Service Manual

Models

534D-9,

534D-10

& 544D

534D-9 & 534D-10

S/N 0160000447 & After

544D

S/N 0160000192 & After

31200170

Revised

November 6, 2008

An Oshkosh Corporation Company

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 & 8.21. Added Hyd Sub Assy Removal/Install on pages 3.30, 3.31 & 3.32. Changed Danger, Warning, Caution & 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 & 544D a

EFFECTIVITY PAGE

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

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.4 Fluid and Lubricant Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Boom System Component Terminology 534D-9, 534D-10 . . . . . . . . . . . . . . . . . . . . . . 3.3

3.2 Boom System - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3 Boom Maintenance - Three Section (Complete Removal). . . . . . . . . . . . . . . . . . . . . . . 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 Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

3.7 Extend/Retract Cylinder Removal and Installation - Three Section . . . . . . . . . . . . . . . . 3.18

3.8 Boom System Component Terminology 544D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

3.9 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

3.10 Boom Maintenance - Four Section (Complete Removal). . . . . . . . . . . . . . . . . . . . . . . . 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 Section . . . . . . . . . . . . . . . . . . . . 3.38

3.15 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

3.16 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

3.17 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

3.18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

534D-9, 534D-10 & 544D

Section Subject Page

Section 5

Axles, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5.1 Axles, Wheel and Tire Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.4 Rear Drive Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.5 Rear Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

Section 6

Hydrostatic Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6.1 Drive Pump Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 Drive Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Drive Pump Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4 Drive Pump Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Drive Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.6 Hydrostatic Drive Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

Section 7

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Introduction: John Deere 4045TF275 & 4045HF275 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4 Introduction: Cummins QSB4.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.5 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.6 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.8 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9

7.9 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9

7.10 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

7.11 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

7.12 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12

7.13 Engine Drive Plate/Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

7.14 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.6

8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12

8.6 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

8.7 Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14

8.8 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16

8.9 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

534D-9, 534D-10 & 544D

Section Subject Page

9.3 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

9.7 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10

9.8 Windshield Wiper Motor (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

9.9 Cab Heater and Fan (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12

9.10 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12

9.11 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15

9.12 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15

9.13 Transmission Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17

9.14 Traction Lock Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17

9.15 Troubleshooting - Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

534D-9, 534D-10 & 544D

iii

Section Subject Page

534D-9, 534D-10 & 544D

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

534D-9, 534D-10 & 544D

1.1

Safety Practices

1.1 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 equipment, 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 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 & SAFETY MANUAL

The mechanic must not operate the machine until the Operator & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operator & 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 & 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.

1.2

534D-9, 534D-10 & 544D

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

DANGER

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury.

1.6 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

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 it is 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 properly 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.

proceeding.

534D-9, 534D-10 & 544D

1.3

Safety Practices

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s 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 Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

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 service.

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

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 removing 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 readable on the machine. Refer to the Operator & Safety Manual supplied with machine for information.

1.4

534D-9, 534D-10 & 544D

Section 2

General Information and Specifications

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2.1 ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

2.2.2 ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

2.2.3 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.3.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

2.4 Fluid and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

2.5 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.5.1 10, 1st 50 & 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

2.5.2 250, 500, 1000 & 1500 Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.6.1 534D-9, 534D-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

2.6.2 544D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

534D-9, 534D-10 & 544D

2.1

General 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.

° 0 8

° 0

° 0 6

° 0 5

° 0 4

° 0 3

° 0 2

0°

MX0030

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 & 544D

General Information and Specifications

2.2 TORQUE CHARTS

WITH

PATCH

LOC-WEL

TORQUE

PATCH

LOC-WEL

WITHOUT

SOCKET HEAD

UNBRAKO 1960 SERIES

& SOCKET HEAD CAP SCREWS

SAE GRADE 8 BOLTS & GRADE 8 NUTS

LOAD

CLAMP

LOCTITE

TORQUE

DRY OR

LOAD

CLAMP

242 OR

LUB

LOCTITE

271

262

263

2.2.1 ASTM Fastener Torque Chart (English)

271

242 OR

LOCTITE

262

LOCTITE

TORQUE

LUB

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

GRADE 2 NUTS

SAE GRADE 5 BOLTS &

DRY OR

CLAMP

TENSILE

BOLT

THDS.

263

LOCTITE

LOAD

AREA

STRESS

DIA.

PER

INCH

SIZE

IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB

0.00604 380 8 6 — — 540 12 9 — — — — —

0.1120

48 0.00661 420 9 7 — — 600 13 10 — — — — —632

0.00909 580 16 12 — — 820 23 17 — — — — —

0.1380

40 0.01015 610 18 13 — — 920 25 19 — — — — —832

0.01400 900 30 22 — — 1260 41 31 — — — — —

0.1640

36 0.01474 940 31 23 — — 1320 43 32 — — — — —1024

0.01750 1120 43 32 — — 1580 60 45 — — — — —

0.1900

32 0.02000 1285 49 36 — — 1800 68 51 — — — — —

0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168

0.2500

28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178

1/4

0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950

0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365

0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925

1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550

12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070

1.3750

12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685

1-3/8

1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345

1.5000

1-1/2

12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600

Note: These torque values do not apply to cadmium plated fasteners.

0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28

0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50

0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77

0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120

0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170

0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231

0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400

0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645

IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB

0.3125

0.3750

0.4375

0.5000

0.5625

0.6250

0.7500

24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30

24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55

20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82

20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127

18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182

18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242

16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440

5/16

3/8

7/16

1/2

9/16

5/8

3/4

0.8750

14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700

7/8

1.0000

12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000

1.1250

12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520

1-1/8

1.2500

1-1/4

534D-9, 534D-10 & 544D

2.3

General Information and Specifications

2.2.2 ASTM Fastener Torque Chart (Metric)

WITH

PATCH

LOC-WEL

TORQUE

PATCH

LOC-WEL

WITHOUT

SOCKET HEAD

UNBRAKO 1960 SERIES

CLAMP

LOCTITE

LOAD

242 OR

LOCTITE

271

262

TORQUE

LUB

263

DRY OR

LOCTITE

& SOCKET HEAD CAP SCREWS

SAE GRADE 8 BOLTS & GRADE 8 NUTS

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

LOAD

CLAMP

271

242 OR

LOCTITE

262

LOCTITE

TORQUE

LUB

GRADE 2 NUTS

SAE GRADE 5 BOLTS &

263

DRY OR

LOCTITE

2.4

LOAD

CLAMP

AREA

0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —

0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —

0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —

40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — —832

0.1640

36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — —1024

0.01750 1120 5 3.6 — — 1580 7 5 — — — — —

0.1900

32 0.02000 1285 6 4 — — 1800 8 6 — — — — —

STRESS

TENSILE

INSQ. IN.LB.N, mN, mN, mN, mLB.N, mN, mN, mN, mLB.N, mN, m

DIA.

BOLT

PER

THDS.

SIZE

0.1120

0.1380

48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —632

INCH

0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19

0.2500

28 0.0364 2320 14 10 — 15 3280 19 14 — 2 1 3640 19 20

1/4

0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38

INSQ. IN.LB.N, mN, mN, mN, mLB.N, mN, mN, mN, mLB.N, mN, m

0.3125

24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41

5/16

0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68

0.3750

24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75

3/8

0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104

0.4375

20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111

7/16

0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163

0.5000

20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172

1/2

0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230

0.5625

18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247

9/16

0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313

0.6250

18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328

5/8

0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542

0.7500

3/4

16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597

0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874

0.8750

14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949

7/8

0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288

1.0000

12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356

0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851

1.1250

1-1/8

12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061

0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 27 12 96900 2373 2610

1.2500

1-1/4

12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 29 83 107300 2549 2807

1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457

1.3750

1-3/8

12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640

1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535

1.5000

1-1/2

12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881

Note: These torque values do not apply to cadmium plated fasteners.

534D-9, 534D-10 & 544D

General Information and Specifications

2.2.3 Metric Fastener Torque Chart

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

CLASS 8.8 METRIC BOLTS &

CLASS 8 METRIC NUTS

TORQUE

LUB

LOCTITE

262

LOCTITE

242 OR

271

CLAMP

SIZE PITCH

TENSILE

STRESS

AREA

CLAMP

LOAD

DRY OR LOCTITE

263

sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m

3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1

3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3

4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8

5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7

6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17

7 1 28.9 12.6 18 13 16 19 18 25 19 20 28

81.2536.615.92519232822.837272940

10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79

12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139

14 2 115 50.0 140 105 126 154 71.6 200 150 160 220

16 2 157 68.3 219 164 197 241 97.8 313 235 250 344

18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473

20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671

22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915

24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170

27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690

30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310

33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860

36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020

42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440

CLASS 10.9 METRIC BOLTS &

CLASS 10 METRIC NUTS

LOAD

DRY OR LOCTITE

263

LUB

TORQUE

LOCTITE

262

LOCTITE

242 OR

271

Note: These torque values do not apply to cadmium plated fasteners.

534D-9, 534D-10 & 544D

METRIC CLASS 8.8 METRIC CLASS 10.

2.5

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) 19 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 @ 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 & 544D

2.3.4 Engine Performance Specifications

a. John Deere

Description 534D-9 534D-10 544D

General Information and Specifications

Engine Make/Model John Deere

PE4045TF275

John Deere PE4045TF275

John Deere PE4045HF275

Displacement 276 in³ (4,5 liters) 276 in³ (4,5 liters) 276 in³ (4,5 liters)

Low Idle 800 rpm 800 rpm 800 rpm

High Idle 2400 rpm 2500 rpm 2200 rpm

Horsepower 110 HP (82 kW) @

2400 rpm

115 HP (86 kW) @ 2500 rpm

125 HP (93 kW) @ 2200 rpm

Peak Torque 289 lb-ft @1400 rpm 290 lb-ft @1400 rpm 376 lb-ft @1500 rpm

Fuel Delivery Fuel Injection Fuel Injection Fuel Injection

Air Cleaner Dry Type, Replaceable

Primary and Safety Elements

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 in3 (4,5 liters)

Low Idle 1000 rpm 1000 rpm

High Idle 2500 rpm 2500 rpm

Horsepower 110 hp (82 Kw) @ 2500

rpm

Peak Torque 360 lb-ft (488 Nm) @

1500 rpm

130 hp (97 Kw) @ 2500

rpm

459 lb-ft (622 Nm) @

1500 rpm

Fuel Delivery Fuel Injection Fuel Injection

Air Cleaner Dry Type, Replaceable

Primary and Safety

Elements

534D-9, 534D-10 & 544D

Dry Type, Replaceable

Primary and Safety

Elements

2.7

General Information and Specifications

2.3.5 Tires

Note: Standard wheel lug nut torque is 350-400 lb-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/

Star Rating

Pneumatic 70 psi (4,8 bar)

13.00 x 24 G - 2 Bias - 12 Ply Foam - Approx. 542 lb (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 lb (246 kg) 75 psi (5,2 bar)

Pneumatic 70 psi (4,8 bar)

13.00 x 24 G - 3 Rock Bias - 12 Ply Foam - Approx. 542 lb (246 kg) 65 psi (4,5 bar)

13.00 x 24 Solid

b. 534D-10

Size Tire Type Minimum Ply/

Star Rating

Pneumatic 70 psi (4,8 bar)

14.00 x 24 G - 2 Bias 12 ply Foam - Approx. 720 lb (327 kg) 62 psi (4,2 bar)

Pneumatic 75 psi (5,2 bar)

14.00 x 24 L-2 / G-2 Radial Foam - Approx. 720 lb (327 kg) 70 psi (4,8 bar)

Fill Type Pressure

14.00 x 24 G - 3 Rock Bias 12 ply

c. 544D

Size Tire Type Minimum Ply/

Star Rating

14.00 x 24 G - 2 Bias 12 ply

14.00 x 24 L-2 / G-2 Radial

14.00 x 24 G - 3 Rock Bias 12 ply

2.8

Pneumatic 70 psi (4,8 bar)

Foam - Approx. 720 lb (327 kg) 62 psi (4,2 bar)

Fill Type Pressure

Water/Calcium Chloride -

Approx. 623 lb (283 kg)

70 psi (4,8 bar)

Foam - Approx. 720 lb (327 kg) 62 psi (4,2 bar)

Water/Calcium Chloride -

Approx. 623 lb (283 kg)

75 psi (5,2 bar)

Foam - Approx. 720 lb (327 kg) 70 psi (4,8 bar)

Water/Calcium Chloride -

Approx. 623 lb (283 kg)

70 psi (4,8 bar)

Foam - Approx. 720 lb (327 kg) 62 psi (4,2 bar)

534D-9, 534D-10 & 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 gallons (151,4 liters)

Type of Fuel Low Sulfur Diesel #2

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 & water

Front Axle

Differential Housing Capacity 19.6 quarts (18,5 liters)

Type of Fluid Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46)

Rear Drive Hubs

Wheel End Capacity 1.5 quart (1,4 liters)

Type of Fluid Mobilfluid 424

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 424

Tractor Hydraulic Fluid (ISO 46)

534D-9, 534D-10 & 544D

2.9

General Information and Specifications

2.5 SERVICE AND MAINTENANCE SCHEDULES

2.5.1 10, 1st 50 & 50 Hour

EVERY

Check Fuel

Level

Check Hydraulic

Return Filter

Indicator

Change Axle Oil

Check Boom

Chain Tension

(544D)

Check Tire

Change Wheel

Pressure

End Oil

Air Filter

Restriction

Indicator

Change Engine

Oil & Filter

Check Engine

Oil Level

(

Check Wheel

Lug Nut

Torque

Check Hydraulic

Oil Level

)

Check Boom

Cable Tension

(534D-9 & 534D-10)

2.10

Drain Fuel/

Water

Separator

EVERY

Check Engine Coolant Level

Check

Battery

Lubrication

Schedule

MX0080

534D-9, 534D-10 & 544D

2.5.2 250, 500, 1000 & 1500 Hour

General Information and Specifications

EVERY

250

Change Engine

Oil and

Filter*

Check Boom

Cable Tension

(534D-9 & 534D-10)

Change Fuel

Filter

Check Front

Axle

Oil Level

Check Boom

Chain Tension

(544D)

(

)

Check Wheel

Lug Nut

Torque

Check Front &

Rear Wheel

End Oil Levels

Check Boom

Bearing

Pads

EVERY

500

EVERY

1000

Air Filter

Vacuator

Valve

Check

Rear Axle

Stabilization

Check

Fan Belt

534D-9, 534D-10 & 544D

Change Front

Axle Oil

Change

Engine Coolant

Change Front &

Rear Wheel

End Oil

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

EVERY

1500

MX0090

2.11

General Information and Specifications

2.6 LUBRICATION SCHEDULES

2.6.1 534D-9, 534D-10

a. 50 Hour

EVERY

MYSTIK TETRIMOLY

(NLGI 2 GC-LB)

2.12

OX03412

534D-9, 534D-10 & 544D

b. 250 Hour

General Information and Specifications

EVERY

250

MYSTIK TETRIMOLY

(NLGI 2 GC-LB)

534D-9, 534D-10 & 544D

OX03512

2.13

General Information and Specifications

2.6.2 544D

a. 50 Hour

EVERY

MYSTIK TETRIMOLY

(NLGI 2 GC-LB)

2.14

MX00512

534D-9, 534D-10 & 544D

b. 250 Hour

EVERY

General Information and Specifications

MYSTIK TETRIMOLY

(NLGI 2 GC-LB)

534D-9, 534D-10 & 544D

MX00712

2.15

General Information and Specifications

This Page Intentionally Left Blank

2.16

534D-9, 534D-10 & 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 Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3 Boom Maintenance - Three Section (Complete Removal). . . . . . . . . . . . . . . . . . 3.4

3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3.2 Second & Third Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

3.3.3 Third Boom Section & Push Beam Removal . . . . . . . . . . . . . . . . . . . . . . 3.5

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 & 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 Removal. . . . . . . . . . . . . . . . . . . . . 3.9

3.4.2 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

3.4.3 Second and Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . 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 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

3.5.4 Retract Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

3.5.5 Extend Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

3.5.9 Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

3.6 Auxiliary Electric Cable - Three Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

3.6.1 Electrical Wire Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

3.6.2 Electrical Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

3.6.3 Electrical Cable Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

3.7 Extend/Retract Cylinder Removal and Installation - Three Section . . . . . . . . . . 3.18

3.7.1 Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

3.7.2 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19

3.8 Boom System Component Terminology 544D . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

3.9 Boom System - Four Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

3.9.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

534D-9, 534D-10 & 544D

3.1

Boom

3.10 Boom Maintenance - Four Section (Complete Removal). . . . . . . . . . . . . . . . . . . 3.21

3.10.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

3.10.2 Extend/Retract Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

3.10.3 Tilt Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

3.10.4 Second, Third & Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . 3.22

3.10.5 Third & Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

3.10.6 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

3.10.7 Hydraulic Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

3.10.12 Boom Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28

3.11 Boom Maintenance - Four Section (Individual Section Removal) . . . . . . . . . . . 3.28

3.11.1 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

3.11.2 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

3.11.3 Second Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Boom Extend and Retract Chains - Four Section . . . . . . . . . . . . . . . . . . . . . . . . 3.32

3.12.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

3.12.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33

3.12.3 Adjusting Extend Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

3.12.4 Adjusting Retract Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

3.12.5 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

3.12.6 Retract Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

3.12.7 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

3.12.8 Extend Chain Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37

3.13 Boom Section Separation Adjustment - Four Section. . . . . . . . . . . . . . . . . . . . . 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

3.14.3 Hydraulic Sub-Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

3.15 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

3.15.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

3.15.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

3.15.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

3.16 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

3.16.1 Disconnecting from an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

3.16.2 Connecting to an Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

3.16.3 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

3.16.4 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42

3.17 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43

3.18 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

3.2

534D-9, 534D-10 & 544D

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

THIRD BOOM

SECTION

ATTACHMENT

TILT

CYLINDER

EXTEND CABLES

(inside boom)

FIRST

BOOM

SECTION

Boom

ATTACHMENT

QUICK SWITCH

EXTEND/RETRACT

CYLINDER

(inside boom)

HOSE

SHEAVE

(inside boom)

RETRACT

CABLES

(inside boom)

MX0110

534D-9, 534D-10 & 544D

3.3

Boom

3.2 BOOM SYSTEM - THREE SECTION

3.2.1 Boom System Operation

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.

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 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 in

writing by JLG. The structural integrity of the boom will be impaired if subjected to any repair involving welding or drilling.

3.3.1 Boom Removal

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 costeffective 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.

Note: When removing a complete boom assembly use a hoist or crane with a minimum lift capacity of 6000 lbs.

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 (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 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 & 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

3.4

534D-9, 534D-10 & 544D

3.3.2 Second & Third Boom Section Removal

1. Set the complete boom on level ground and by repositioning the slings turn boom over on to the top side. Set the complete boom on suitable stands to begin tear down.

Note: With the complete boom setting upside down, the removal and replacing of each boom section, tilt cylinder, 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.

MX0120

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.

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.

Boom

MX0130

5. Remove the lock-nuts and jam-nuts (4) from the extend cables at the rear of the boom assembly.

6. 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.

7. Remove the extend/retract cylinder mounting pin, hose guards and strong back from the rear of the boom assembly.

8. 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.

9. 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.

534D-9, 534D-10 & 544D

3.3.3 Third Boom Section & Push Beam Removal

1. Remove all wear pads, shims from the front inside of the second boom section. Label and tag each set of wear pads being removed

2. 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

3. Loosen and remove all extend cable sheave components from the front of the pivot beam.

4. Pull the extend cables free of the sheave brackets and lay them on the boom.

MX0140

3.3.4 Third Boom Section Installation

Note: During reassembly use Loctite 242® on all bolt threads and use Loctite 545

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 sheaves 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.

on all hydraulic fittings

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.

MX0150

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.

3.6

534D-9, 534D-10 & 544D

Boom

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 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.

11. Set the third boom section onto a suitable support and reset the sling under the boom head of the third boom section. Carefully 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 - 203 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.

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 & 544D

MX0170

MX0160

3.3.6 Second & 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 m)into the front of the first boom section.

3.7

Boom

4. Set the second and third boom sections onto a suitable support and reset the sling under the boom head of the third boom section.

5. 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

6. Install the hose take-up assembly (5) components at the front of the first boom section.

7. Install the retract cable adjusting block (6). Install the retract cable. Do Not tighten the retract cable.

8. 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 lb-ft (359 - 393 Nm).

9. 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).

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.

MX0180

10. 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.

11. 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.

12. Install and torque the strong back mounting bolts.

13. Install the extend cables, springs, washers and lock nuts into the strong back (9).

14. 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 both washers should be equal.

Note: When adjusting cables, make sure the cables are not turning.

MX0190

15. Torque the cable jam nuts to 100 lb-ft (135 Nm).

16. Install the extend/retract hoses.

3.8

534D-9, 534D-10 & 544D

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 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 lbs.)

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.

Boom

10. Release tension from the hoses on the hose take-up bracket (3).

11. 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.

12. If equipped, label, loosen and separate all electrical cables at the take-up bracket.

13. Remove the take-up brackets (5).

14. Loosen and remove the jam nuts on the retract cable (6) at the bottom of the first boom section.

15. 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.

16. Loosen and remove the jam nuts on the two extend cables (8) at the strong back.

17. Remove the pin (9) holding the extend/retract cylinder at the strong back.

18. Loosen and remove the bolts holding the strong back to the rear of the first boom section. Remove the strong back.

19. Remove the two pins (10) holding the push beam at the rear of the second boom section.

20. 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.

21. 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.

22. Remove hose guide (11) from the rear of the second boom section.

MX1370

534D-9, 534D-10 & 544D

3.9

Boom

MX1380

23. Slowly pull the push beam out of the front of the third boom section. The extend cables will come out along with 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 Second Boom Section Removal

1. Pull the tilt hoses, and if equipped, the auxiliary hoses, from the bottom rear of the boom sheaves.

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.

MX1390

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 pin (9) holding the extend/retract cylinder at the strong back.

3.10

534D-9, 534D-10 & 544D

Boom

10. Loosen and remove the bolts holding the strong back to the rear of the first boom section. Remove the strong back.

11. 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.

12. 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 may be necessary to pull the boom section(s) out far enough to access the wear pads.

13. 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.

14. Lift the two boom sections free of the machine and place on the ground or suitable supports.

3.4.4 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 the bottom front to install the retract cable adjustment block.

3. Install the retract cable adjustment block to the inside front of the first boom section.

4. Install the wear pads and shims in the front of the first boom section.

5. Install the wear pads and shims at the top rear and one side of the second boom section.

6. 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.

7. Install the hose take-up brackets and install the tilt/ aux hoses to the correct fittings on the take-up brackets.

3.4.5 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. 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.

3. 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.

4. Install the wear pads and shims in the front of the second boom section.

5. Install the wear pads and shims at the top rear and one side of the third boom section.

6. Install the back of the push beam into the head of the third boom section. With the push beam installed 50% into the third boom section, feed the extend cables through the bottom and over the cable sheaves.

7. 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.

8. Install the bulkhead brackets at the front of the third boom section.

9. Feed the tilt/aux hoses through the trays at the bottom corners of the third boom sections.

10. Uncap and reconnect the previously labeled tilt/aux hoses to the fittings on the bulkhead brackets.

11. Push the third and second boom section back against the first boom section.

12. Install the strong back and pin the extend/retract to the strong back.

13. Uncap and reconnect the previously labeled extend/ retract hoses to the fittings on the extend/retract cylinder.

14. Feed the extend cables through the strong back and install the jam nuts on each cable.

15. Install the guide and cable cover on the front of the push beam.

16. Install the tilt cylinder and hoses in the third boom section boom head.

17. Install the hose and cable cover at the rear of the second boom section.

18. Adjust the boom sections, cables and hoses to the proper dimensions.

534D-9, 534D-10 & 544D

3.11

Boom

3.5 BOOM CABLES - THREE SECTION

3.5.1 General Cable Information

The 534D-9 & 534D-10 Parts Manual covers part numbers, length and key specifications. Please review this manual to make certain that you are using the 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.

3.5.2 Cable Adjustments

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.

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).

3.12

MX0200

534D-9, 534D-10 & 544D

3.5.3 Retract Cable Removal

The 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 (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 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 back/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.

Boom

MX0210

12. 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.

13. Loosen the retract cable adjustment bolts (7) and remove all the retract cable sheave components.

14. 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.

15. Pull the retract cable through the rear of the boom assembly. Remove the ropes and leave them in place to aid in reinstallation.

534D-9, 534D-10 & 544D

MX0220

3.13

Boom

3.5.4 Retract Cable Installation

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.

2. Install the retract cable socket end (7) to the cable anchor bracket weldment.

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. At the 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.

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 front 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 lb-ft (135 Nm).

19. Refer to Section 3.5.2, “Cable Adjustments,” for boom section specifications.

MX0260

3.5.5 Extend Cable Removal

The removal of the extend 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 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.

3.14

534D-9, 534D-10 & 544D

Boom

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 (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 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 (3) from the rear of the first boom section.

7. 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.

8. Remove the extend/retract cylinder mounting pins (5) from the strong back/cylinder bracket.

9. Remove the extend cable lock nuts, washers and springs (6) 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 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.

MX0260

12. Remove the push beam mounting bolts. Pull the push beam extend cable sheave bracket free of the third boom section.

13. Remove all the extend cable sheave bracket components from the front of the push beam.

14. Pull the extend cable through the push beam extend cable sheave bracket.

3.5.6 Extend Cable Installation

1. Tie a rope to the extend cable threaded end and pull the cable to the anchor bracket weldment area.

2. Install the extend cable socket end (8) and the mounting hardware to the extend cable anchor bracket weldment (9).

3. 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. Install the push beam fully into the second boom section.

5. Install the push beam mounting hardware and the tilt and auxiliary circuit hose guards at the rear of the first boom section.

6. 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.

7. Install the previously removed shims to the top and bottom of the strong back/cylinder bracket.

8. Install and torque the strong back mounting bolts.

9. Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations

10. 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. Remove the rope and install the extend cable springs, washers and lock nuts into the strong back.

12. 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.

MX0270

534D-9, 534D-10 & 544D

3.15

Boom

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 lb-ft (135 Nm).

14. Refer to Section 3.5.2, “Cable Adjustments,” for boom section specifications.

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 Hose Removal

1. Loosen the adjusting nuts (1) at the hose take-up bracket to relieve the tension on the hose assemblies.

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 system.

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.

MX0260

3.5.9 Hose Installation

1. Tie a rope to the new hose end below the hose takeup 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 545 fittings at the bulk head, connect and torque the hoses and install clamps.

4. Install the hose guard at the rear boom roller.

5. At the hose take-up bracket, apply Loctite 545 hose fittings, connect and torque the hoses.

to the hose

MX0290

to the

MX0120

3. From the rear of the boom, remove the hose guard

(2) for the hose being removed.

3.16

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 & 544D

Boom

3.6 AUXILIARY ELECTRIC 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).

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.

3.6.1 Electrical Wire Data

Socket Body

Letter

“TM” Orange Panel

“A” Blue Open/Extra

“S” Black Mast

“RT” Green Swing

“LT” Red Side Shift

“C” Green/Yellow Ground

Wire Color Wire Function

3.6.2 Electrical Cable Removal

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 (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 not be operated.

MX0300

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 not 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

534D-9, 534D-10 & 544D

3.17

Boom

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 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)

“A” Open

“S” Mast (Black

3.7.1 Extend/Retract Cylinder Removal

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, retract the boom and line up the push beam extend/retract cylinder rod eye access holes (1) in all three boom sections, level the boom assembly, 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 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.

“RT” Swing (Blue)

MX0310

3.7 EXTEND/RETRACT CYLINDER REMOVAL AND INSTALLATION THREE SECTION

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.

MX0220

6. Remove the cylinder rod eye mounting pin.

7. 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.

8. Loosen and remove the fittings from the rear of the extend/retract cylinder barrel.

9. 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.

10. Place the extend/retract cylinder in a designated area for the next operation.

3.18

534D-9, 534D-10 & 544D

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.

MX0320

3. Install the extend/retract cylinder base mounting pin (3) into the strong back and secure.

4. Apply Loctite 545 fittings and install into the cylinder barrel.

5. Apply Loctite 545 hydraulic hoses.

to the extend/retract cylinder

to the fittings and reconnect the

Boom

534D-9, 534D-10 & 544D

3.19

Boom

3.8 BOOM SYSTEM COMPONENT TERMINOLOGY 544D

The following illustrations identify the components that are referred to throughout this section.

EXTEND

CHAINS

SECOND

BOOM

SECTION

FIRST

BOOM

SECTION

FOURTH

BOOM

SECTION

AUXILIARY

HYDRAULIC

CONNECTIONS

THIRD BOOM

SECTION

ATTACHMENT

QUICK SWITCH

ATTACHMENT

TILT

CYLINDER

BOOM HYDRAULIC

ASSEMBLY

(inside boom)

(underside of boom)

EXTEND/RETRACT

CYLINDER

RETRACT

CHAINS

HOSE SHEAVE

MY0100

3.20

534D-9, 534D-10 & 544D

Boom

3.9 BOOM SYSTEM - FOUR SECTION

3.9.1 Boom System Operation

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.

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 the 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.

3.10.1 Boom Removal

1. Park the machine on a hard, 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 complete boom assembly use a hoist or crane with a minimum lift capacity of 8500 lbs.

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.

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 & 544D

3.10.2 Extend/Retract Cylinder Removal

With the boom assembly now turned upside down, the extend/retract cylinder is easily removed.

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.

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Boom

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 Tilt Cylinder Removal

See Section 8.9.1, “General Cylinder Instructions.”

3.10.4 Second, Third & Fourth Boom Section Removal

Note: Work on the boom assembly is performed with the assembly up-side down.

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 tube ends to prevent dirt and debris from entering the hydraulic system.

MX0340

4. 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.

7. Remove the chain adjustment block (6) from the first boom section.

8. Remove all wear pads from the front of the first boom section. Tag each pad, backing plate, shim and bolts from each location

9. Carefully pull the second, third and fourth boom sections together from the first boom section and place on suitable supports for further separation.

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534D-9, 534D-10 & 544D

Boom

3.10.5 Third & Fourth Boom Section Removal

Note: Work on the boom assembly is performed with the assembly up-side down.

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.

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.

MX0360

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.

3.10.6 Fourth Boom Section Removal

Note: Work on the boom assembly is performed with the assembly up-side down.

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 section.

MX0380

3. Loosen and remove the retract chain roller (9) at the rear of the third boom section.

534D-9, 534D-10 & 544D

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Boom

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 Hydraulic Sub-Assembly

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.

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 (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 25% free of the boom, fasten the two hose carriers together (using nylon tie-wraps or nylon straps) to keep them from separating.

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 75% 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 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 subassembly and slowly insert it into the fourth boom section.

6. As the first tie-wrap nears the boom, remove the tiewrap 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 lb-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.

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Boom

10. Torque all fasteners and hydraulic fittings per Section

2.2, “Torque Charts.”

3.10.8 Fourth Boom Section Install

1. Place the clean and inspected fourth boom section on suitable supports.

2. Grease the wear pad and hose carrier assembly sliding path areas thoroughly.

3. Fasten the wear pad for the hose carrier to the inside of the boom.

4. Attach the bracket (1) for the hose carrier to the inside of the boom.

5. Make sure that the inside guide paths for the hose carrier assembly guide bracket are greased.

3.10.9 Third Boom Section Install

1. Place the clean and inspected third boom section on suitable supports.

2. Grease the inside wear pad paths.

3. Using a 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 lb-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.

MX0400

6. Install all the rear wear pads. Leave one shim out of each package to aid with the installation into the third boom section.

7. Attach the chain clevis and the keeper plate to the inside rear of the boom.

8. Assemble the grease fitting extensions for the bottom rear wear pads.

9. Grease the outside wear pad paths.

10. 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.”

11. Attach the chain to the chain clevis.

12. Attach the chain clevis to the top of the fourth boom section.

534D-9, 534D-10 & 544D

MX0410

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.”

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Boom

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 lb-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.

9. Install the bottom front wear pads. DO NOT torque the pad bolts.

10. Install the front side wear pads.

11. Torque all the front wear pads and supports.

12. Shim the rear wear pads on the third boom section if needed and torque to 68-78 lb-ft (92 - 106 Nm).

13. Lay out and lubricate the 1 in (25 mm) chain on the bottom of the second boom section.

14. Install the bottom rear wear pads. DO NOT torque the pad bolts.

15. Install the top rear wear pads. DO NOT torque the pad bolts.

16. Install the lube fittings to the wear pad and chain roller assembly.

17. Connect the chain clevis (7) to the second boom section.

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 lb-ft (460 - 495 Nm).

7. Install the top front wear pads to the second boom section. DO NOT torque the pad bolts.

8. Install the bottom front wear pad supports. DO NOT torque the pad support bolts.

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MX0450

18. Assemble the rear bottom chain roller (8) to the second boom section.

19. Install the side rear wear pads on the second boom section. DO NOT torque the pad bolts.

20. Install the optional hose sheave (9) if equipped, to the right rear of the second boom section.

21. Install the standard hose sheave (9) to the left rear of the second boom section.

22. 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 & 544D

Boom

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.

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-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.

534D-9, 534D-10 & 544D

3.27

Boom

MX0480

12. Install the top front chain roller (14) to the second and third boom sections.

13. Install the hoses (15) to the bulkhead fittings on the hose take-up weldment.

14. Install the cushion clamps around the hoses on the first boom section.

15. Install the extend/retract cylinder and support to the first and second boom sections.

16. Attach the extend/retract cylinder hose assembly.

17. Connect the top front chain clevises to the chains, then connect the chains to the first and second boom sections.

18. 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.

MX0490

19. Install the tilt cylinder and connect the hose assemblies to the hose carrier assembly and to the tilt cylinder.

20. If the machine is equipped with auxiliary hydraulics, install the auxiliary hoses and electrical cable to the boomhead of the fourth boom section.

21. The boom is now complete and ready to be turned over and installed on the machine.

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.

3. 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.”

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.

For more detailed instructions, see Section 3.10, “Boom Maintenance - Four Section (Complete Removal).”

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Boom

3.11.1 Fourth Boom Section Removal

MX0470

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 four section boom assembly weighs approximately 8250 lbs.)

11. Loosen and remove the four bolts (4) holding the hose carrier to the rear of the third boom section.

MX0460

12. Slowly pull the hose carrier assembly out of the front of the fourth boom section.

13. When the hose carrier 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.

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 & 544D

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

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 pull 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.

MX1410

MX1420

4. 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.

5. 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.

6. Lift the third boom section 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.

2. 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.

3. 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.

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534D-9, 534D-10 & 544D

MX1440

4. Loosen and remove the tilt/aux hose take-up bracket (5) 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

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.

Boom

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 the 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 section.

534D-9, 534D-10 & 544D

3.31

Boom

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 Fourth Boom Section Installation

1. Grease the inside wear pad paths of the third boom section and the outside wear paths of the fourth boom section.

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 slid 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.

3.12 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 boom 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

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.

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Boom

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 moisture 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 3%. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulation.

3.12.2 Inspection Guidelines

2. Fully extend the boom until the extend chain is taut. Shut the engine off.

3. The extend chains will be visible for inspection with the vehicle in this state.

4. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

5. Inspect the retract chains every 1000 hours of operation.

6. 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.

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 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.

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 & 544D

3.33

Boom

MY1360

Distorted or Battered Link Plates

Distorted or battered link plates (5) on a leaf chain can cause tight joints and prevent flexing.

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 condition does not repeat itself.

The types of cracks are:

• Fatigue Cracking Fatigue cracks (9) are a result of repeated cyclic loading beyond

MZ1467

the chain’s endurance limit.

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 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.

• Stress Corrosion Cracking - The

outside link plates are particularly susceptible to stress corrosion cracking (10).

• 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 excess of the design load. Either fractured plates (1) or enlarged holes (2) can occur. If either of these failures occurs, the chain should be replaced immediately.

• Tight Joints

- All joints in the chain should flex freely. Tight joints (3) resist flexing.

MZ1468

MZ1469

MZ1470

MZ1471

3.34

534D-9, 534D-10 & 544D

Boom

If the problem is caused by dirt 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 Adjusting Extend Chains

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.

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 front of the second boom section).

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 lb-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 Adjusting Retract Chains

1. Fully retract the boom and raise the boom to a horizontal position. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch. Shut off machine.

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).

MX0500

534D-9, 534D-10 & 544D

MX0500

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 to obtain the 1/2 in (13 mm) dimension required.

6. Torque the jam nuts to 100 lb-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

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 lb-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 Retract Chain Removal

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.

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 (N) 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 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).

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.

MX0510

3. Remove the chain from the clevis, install a nylon tiewrap 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.

MX0510

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

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 & 544D

Boom

5. Fasten the chain into the clevis by installing the pin and cotter pin.

6. Torque the jam nuts to 100 lb-ft (135 Nm). DO NOT

use Loctite

on the nuts.

7. For the 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 pull 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 lb-ft (461 - 495 Nm).

14. Adjust the retract chains. See Section 3.12.4, “Adjusting Retract Chains.”

15. Torque the jam nuts to 100 lb-ft (135 Nm). DO NOT use Loctite

on the nuts

9. Carefully pull the chain out of the boom.

3.12.8 Extend Chain Installation

Inspect and lubricate chains thoroughly before installation. Articulate the chains to make sure all working surfaces are thoroughly lubricated.

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. At the 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.”

3.12.7 Extend Chain Removal

The following section explains the removal of the 1 in. retract chains without removing the boom assembles.

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. On the 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 rope to the loop.

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 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.

534D-9, 534D-10 & 544D

3.37

Boom

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. To increase 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 minimum 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.

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 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. Loosen and remove both compression springs (1) from the hose take-up weldment at the bottom of the first boom section.

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.

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 Hydraulic Sub-Assembly Removal

1. Remove any attachment from the quick switch assembly. Refer to Section 3.16.1, “Disconnecting from an Attachment.”

Note: Allow adequate room in front of the machine when removing and installing the hydraulic subassembly.

3.38

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 & 544D

Boom

11. Loosen and remove the sub-assembly bracket (4) at the rear of the third boom section.

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.

FRONT

MY2700

13. When the sub-assembly is pulled approximately 25% out of the boom, fasten the two hydraulic carriers together using plastic tie wraps or nylon straps to keep them from separating.

Note: Do Not wrap the hose carrier since it will not prevent the two hydraulic carriers from moving apart sideways.

14. Continue withdrawing the sub-assembly, fastening the two hydraulic carriers together.

15. With the two hose carriers tied together, remove the sub-assembly and set on the ground or proper supports.

3.14.2 Assembling the Hydraulic SubAssembly

The following procedure is described with the assumption that all components have been removed and assembly proceeding from the beginning.

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.

6. Install the hose carrier to each hydraulic carrier and install each tilt hose and auxiliary hose to the proper fitting or tube connection.

7. Tie wrap the hydraulic hoses together where they extend from each end of the hose carrier.

8. Fasten the two hydraulic carriers together using plastic tie wraps or nylon straps for stability.

3.14.3 Hydraulic Sub-Assembly Installation

1. Clean and lubricate the side surfaces where the hydraulic sub-assembly rides.

2. Install the guide bracket (1) on the front of the hydraulic sub-assembly.

534D-9, 534D-10 & 544D

MY2740

3.39

Boom

3. Fully collapse the hose carriers and secure together using plastic tie wraps or nylon straps to keep them from separating.

4. Install a sling around the balance point of the subassembly. 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 subassembly is in place on the bottom plate (3) of the fourth boom section.

FRONT

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.

MY2700

8. Install the cap screws, washers and nuts to the subassembly bracket at the rear of the third boom section.

9. Install both cap screws and locknuts to the subassembly 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

534D-9, 534D-10 & 544D

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 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicators (1) on the ends of 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.

Boom

Ma2070

3.15.2 Boom Wear Pad Replacement

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.

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 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 lb-ft (103 - 117 Nm)

Hollow 3/8 in bolt: 20 - 25 lb-ft (27 - 34 Nm)

Hollow 1/2 in bolt: 45 - 50 lb-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).

#242 to all

MY0630

3.15.3 Boom Wear Pad Lubrication

The boom has been factory lubricated for 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.

534D-9, 534D-10 & 544D

3.41

Boom

3.16 QUICK SWITCH ASSEMBLY

This machine is equipped with a quick switch assembly system for easy attachment changes.

3.16.1 Disconnecting from an Attachment

1. Park the machine on a hard, level surface.

2. Place the transmission control lever in the (N) NEUTRAL position and engage the parking brake switch

3. Level the boom and extend it out approximately 10 ft (3,05 m) and tilt the carriage backward.

4. 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.

6. If equipped, label, disconnect and cap the auxiliary hydraulic hoses.

7. If equipped, release the swing attachment saddles.

8. Remove the quick switch pin lock pin (1) and pull out the retaining pin (2) at the bottom of the quick switch assembly.

9. Return to the operator’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.

10. Lower and then retract the boom until the attachment pivot pins have disconnected from the attachment.

3.16.2 Connecting to an Attachment

1. Retract quick switch to provide clearance. Check to be sure lock pin (1) is secured in out position with retainer pin.

2. Align attachment pivot pin with recess in attachment (3). Raise boom slightly to engage attachment pivot pin in recess.

3. Engage the quick switch (4).

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.

5. If equipped, swing attachment saddles down and pin in place.

6. If equipped, uncap and reconnect auxiliary hydraulic hoses.

7. If equipped, connect auxiliary electric harness.

3.16.3 Quick Switch Removal

1. Remove the lock bolt holding the tilt cylinder rod end pin to the quick switch assembly. Remove the Tilt Cylinder pin (5).

2. Support the quick switch assembly.Remove the capscrew and locknut securing the head pin (6) to the boom head.

3. 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 must be replaced.

3.16.4 Quick Switch Installation

1. 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.

2. 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.

3. 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.

3.42

MX0550

534D-9, 534D-10 & 544D

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 (5) and mounting tubes (6).

2. Inspect forks for broken or bent tips (7) and twisted blades (8) and shanks (9).

Yearly Inspection

1. 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.

2. Angle (10) between upper face of blade and front face of shank should not exceed 93 degrees.

3. Thickness of blade (13) and shank (14) should not be reduced to 90 percent of original thickness.

4. Ensure fork length (12) is adequate for intended loads.

5. Fork markings should be legible, re-stamp if required.

6. 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).

Boom

MH6460

534D-9, 534D-10 & 544D

3.43

Boom

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.

2. Boom shifts to right or left when extending.

3. Excessive boom pivot pin noise and/or wear.

4. Excessive compensation cylinder pivot pin noise and/ or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Extend/Retract hydraulic system not operating properly.

3. Faulty extend/retract cylinder. 3. Repair cylinder, Refer to Section

4. Broken chains or anchors. 4. Replace chains as needed.

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn bushing(s). 2. Replace bushing(s) and

1. Insufficient lubrication. 1. Lubricate at regular intervals.

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8.4, “Hydraulic Circuits.”

3.3.1, “Boom Removal.”

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.15.2, “Boom Wear Pad Replacement.”

(Refer to Section 2.6, “Lubrication Schedules.”)

lubricate at regular intervals

(Refer to Section 2.6, “Lubrication Schedules.”.) Replace worn pins as needed.

3.44

2. Worn bushing(s). 2. Replace bushing(s) and lubricate at regular intervals.

534D-9, 534D-10 & 544D

Boom Troubleshooting (Continued)

Problem Cause Remedy

Boom

5. Drooping chain, or jerky boom extend or retract functions.

6. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes

1. Chain(s) tension not properly adjusted.

2. Chain(s) stretched or binding. 2. Replace chains as needed.

3. Wear pads loose, contaminated, excessively worn or damaged.

4. Contaminated, corroded or rusted wear pad sliding surfaces.

5. Extend/Retract hydraulic system not operating properly.

6. Damaged boom section. 6. Replace the damaged boom

and/or connection leaks.

1. Adjust chain(s).

Refer to Section 3.13, “Boom Section Separation Adjustment Four Section.”

3. Replace wear pad. Refer to Section 3.15.2, “Boom Wear Pad Replacement.”

4. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

5. Refer to Section 8.4, “Hydraulic Circuits.”

section. Refer to Section 3.10, “Boom Maintenance - Four Section (Complete Removal).”

1. Locate break, replace hose(s) or tube(s), tighten connections.

7. Excessive Lift/Lower cylinder pivot pin noise and/or wear.

2. Lift/Lower hydraulic system not operating properly.

3. Faulty Lift cylinder. 3. Repair cylinder. Refer to Section

4. Seized boom pivot pin bushing. 4. Replace bushing.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn self-aligning bushing(s). 2. Replace bushing(s) and

2. Refer to Section 8.4, “Hydraulic Circuits.”

3.3.1, “Boom Removal.”

Refer to Section 2.6, “Lubrication Schedules.” Replace worn pins as needed. Refer to Section 3.3.1, “Boom Removal.”

lubricate at regular intervals. Refer to Section 2.6, “Lubrication Schedules.”

534D-9, 534D-10 & 544D

3.45

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 loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

10. Auxiliary hydraulics will not operate.

11. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer

1. Auxiliary hydraulic system not operating properly.

2. Chain sheave(s) not properly lubricated.

3. Chain sheave(s) not rotating freely.

2. Reduce cycle times.

3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

4. Clean equipment frequently.

1. Refer to Section 8.4, “Hydraulic Circuits.”

to Section 3.12, “Boom Extend and Retract Chains - Four Section.”- Replace chains as needed.

2. Lubricate chain sheave. (Refer to Section 2.6, “Lubrication Schedules.”

3. Lubricate chain sheave. Refer to Section 2.5, “Service and Maintenance Schedules.” Repair or replace chain sheave(s) as needed.

3.46

4. Improper chain lubrication. 4. Lubricate at regular intervals. (Refer to Section 2.5, “Service and Maintenance Schedules.” Replace chains as needed.

534D-9, 534D-10 & 544D

Section 4

Cab and Covers

Contents

PARAGRAPH TITLE PAGE

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3.1 Steering Column and Orbitrol Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.3.3 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

4.3.4 Boom Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.3.8 Heater System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

534D-9, 534D-10 & 544D

4.1

Cab and Covers

4.1 OPERATOR’S CAB 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.

FRAME LEVEL INDICATOR

LIFTING LUG

STEERING WHEEL

TRANSMISSIOM

CONTROL LEVER

INSTRUMENT PANEL

IGNITION SWITCH

JOYSTICK (BOOM CONTROL)

FRAME SWAY and

ATTACH ME NT TI LT

LEVERS

4.2

SERVICE BRAKE PEDAL

MX0850

ACCELERATOR PEDAL

534D-9, 534D-10 & 544D

WARNING

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

4.2 OPERATOR’S CAB

4.2.1 Cab Safety

Cab and Covers

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 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 sense hose at the front of the steering valve. Cap the fitting on the steering valve.

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.

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.

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 serial 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 correspondence.

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

a. Orbitrol Valve 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.

MY0120

6. Remove the steering wheel (2), disconnect and remove the travel select lever (3), disconnect the instrument panel harness connector (4).

7. Remove the steering assembly through the dash panel opening.

8. Support the steering valve, and remov0e the four hexhead capscrews and four lockwashers.

Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective.

534D-9, 534D-10 & 544D

4.3

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 lb-ft (39-46 Nm).

4. Install new o-rings into 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.

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. Disconnect the battery negative (-) cable at the battery negative (-) terminal.

5. Disconnect the return spring (5), inching brake linkage (6) and brake master cylinder push rod (7) from the brake pedal weldment.

MX0780

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

6. Remove the bolt, nut and lockwasher (8) securing the brake pedal to the brake pedal weldment and remove the brake pedal.

7. Remove the bolt and lockwasher from the pivot pin, remove the pivot pin from the brake pedal bracket (9).

8. Remove the brake pedal weldment from the cab.

d. Service Brake Pedal Installation

1. Position the brake pedal weldment in its mounting location within the cab.

2. Secure the brake pedal weldment into position with the pivot pin (9).

3. Install the brake pedal (8) to the brake pedal weldment.

4. Be sure the brake pedal has the correct range of motion. Secure pivot pin with bolt and lockwasher.

5. Reconnect the return spring (5), inching brake linkage (6) and the brake master cylinder push rod (7).

6. Connect the battery negative (-) cable to the battery negative (-) terminal.

7. Close and secure the engine cover.

4.4

534D-9, 534D-10 & 544D

Cab and Covers

4.3.3 Throttle Pedal

a. Throttle Pedal 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. 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

4.3.4 Boom Joystick Assembly

a. Boom Joystick 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. 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 & debris from entering the hydraulic system.

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.

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.

534D-9, 534D-10 & 544D

4.5

Cab and Covers

2. Install the bolts securing the boom joystick to the cab.

3. Connect the battery negative (-) cable to the battery negative (-) terminal.

4. Test the boom extend/retract and boom lift/lower joystick function:

a. Move 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.

f. Depress the right side of the switch (optional) to

activate the tilt down function. The attachment should TILT DOWN.

5. Close and secure engine cover.

4.3.5 Frame Sway and Attachment Tilt Levers

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. Disconnect the battery negative (-) cable at the battery negative (-) terminal.

4. Disconnect the link (4) between the lever and the main control valve.

5. Remove the cotterpins and pull the shaft (5) out of the lever mounting brackets. Note the location of the spacers between the levers.

6. Remove the lever from the cab.

b. Lever Installation

1. Install the lever at the mounting bracket on the cab floor.

2. Install the shaft, spacers and cotter pins.

3. 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 negative (-) terminal.

6. 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.

MX0810

a. Lever Removal

4.6

4.3.6 Left Hand Tilt and/or Left Hand Tilt/ Sway Lever (If Equipped)

a. Lever 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.

534D-9, 534D-10 & 544D

Cab and Covers

3. Disconnect the battery negative (-) cable at the battery negative (-) terminal.

4. Remove the four bolts holding the lever assembly (1) to the dash.

5. Remove the belly pad from under the cab.

6. Disconnect the cable assembly (2) at the main control valve.

7. Remove the assembly from the cab.

MX0820

b. Lever Installation

1. Install the lever assembly in the cab dash.

2. Reconnect the cable end to the main control valve.

3. Install the belly pan.

4. Connect the battery negative (-) cable to the battery negative (-) terminal.

5. Test the lever function and adjust cable if needed.

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

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 first 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.

534D-9, 534D-10 & 544D

HEATER HOSE-RETURN

HEATER HOSE-SOURCE

MX0830

4.7

Cab and Covers

b. 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. Install 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 for 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 CAB REMOVAL

WARNING

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 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 & debris from entering the hydraulic system.

9. Disconnect the throttle electrical cable from under the cab.

Sling Routing

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.

4.8

MX0840

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 & 544D

Cab and Covers

12. Remove the mirrors and all other cab components as needed, if not previously removed.

13. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.

14. 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 to help balance the cab during removal.

15. 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.

16. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

17. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

4.5 CAB INSTALLATION

1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation.

2. Install eyebolts and route a sling with a suitable lifting capacity.

3. 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.

4. Install the four bolts, washers and nuts and torque to 480 lb-ft (651 Nm).

5. Connect the throttle electrical cable from under the cab.

6. Route any hoses through the opening at the right rear corner of the cab.

7. Working under the cab, uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations.

8. Connect the wire harness at the right front side of the cab.

9. Connect the heater hoses to the engine. Secure with two hose clamps. Open both coolant valves on the engine.

10. 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.”

11. Connect the battery negative (-) cable or cables to the battery negative (-) terminal.

12. Carefully examine all cab components, fasteners, etc., one last time before engine start-up. Rectify any faulty conditions.

13. 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.

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.

534D-9, 534D-10 & 544D

4.9

Cab and Covers

This Page Intentionally Left Blank

4.10

534D-9, 534D-10 & 544D

Section 5

Axles, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axles, Wheel and Tire Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4

5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

5.3.7 Axle Assembly Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6

5.4 Rear Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.4.1 Rear Drive Hub Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.5 Rear Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.5.1 Rear Axle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.5.2 Rear Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.6.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.12

5.6.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5.12

5.7 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

5.7.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

5.8 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

534D-9, 534D-10 & 544D

5.1

Axles, 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.

5.2

FRONT DRIVE AXLE

REAR STEERING AXLE /

DRIVE HUBS

534D-9, 534D-10 & 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 that could affect the safe and proper functioning of the machine and axles.

5.3 AXLE ASSEMBLIES

5.3.1 Axle Serial Number Plate

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.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

5.3.2 Axle Specifications

General axle specifications are found in Section 2.4, “Fluid and Lubricant Capacities.”

5.3.3 Axle Internal Service

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).

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 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 drivetrain 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.

534D-9, 534D-10 & 544D

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

5.3.5 Axle Removal

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.

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. If 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 Oil.” Dispose of used oil at an approved recycling facility.

MX0590

MX0570

8. Label, disconnect and cap the brake lines at the axle. Cap all fittings and openings to prevent dirt & 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, “Removing 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 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.

5.4

534D-9, 534D-10 & 544D

5.3.6 Axle Installation

Axles, Wheels and Tires

1. 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.

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 installation procedure.

4. Position the axle under the frame, and align the axle housing with the holes in the frame.

5. Install the pivot pin and replace the shims on each end of the axle. Install the pivot pin lockbolt and nut.

6. 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.

7. 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.

MX0600

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.

LEVEL

MX0580

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 other axle.

Note: ALWAYS use new o-rings when servicing the machine.

13. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.

14. Uncap and connect the brake lines at their axle fittings.

15. Install the drive motor assembly.

16. Check the hydraulic reservoir oil level.

17. Connect the battery negative (-) cable from the battery negative (-) terminal and install the deck cover.

18. Close and secure the engine cover.

19. 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.”

534D-9, 534D-10 & 544D

5.5

Axles, Wheels and Tires

5.3.7 Axle Assembly Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Axle and/or wheel end housings

filled with incorrect oil or oil level low.

2. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

3. Incorrect alignment of ring and pinion gears.

4. Incorrect pinion (input) shaft bearing preload.

3. Correct alignment by adding or removing shims as needed.

4. Correct bearing preload by 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 in the axle. 7. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Intermittent noise when traveling.

8. Axle housing damaged. 8. Replace damaged parts.

1. Differential ring and/or pinion gears damaged.

1. Determine cause and repair as needed.

5.6

534D-9, 534D-10 & 544D

Axles, Wheels and Tires

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.

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

3. Replace seal and/or joint coupling fork shaft (axle shaft).

4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Carraro Repair Manuals.

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 288 lb-ft (390 Nm).

7. Replace housing(s) as needed.

4. Oil leaking from wheel end housing (planet carrier).

5. Oil leaking from steering cylinder.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

1. Hose fittings loose. 1. Tighten fittings.

2. Steering cylinder o-rings and/or seals worn or damaged.

3. Piston rod seal worn or damaged.

4. Cylinder tube damaged. 4. Replace cylinder tube.

1. Replace o-rings as needed and tighten plugs to 96 lb-ft (130 Nm).

2. Replace o-ring.

3. Replace seal and/or fork joint shaft.

41 lb-ft (55 Nm).

2. Replace o-rings and seals.

3. Replace piston rod seal.

534D-9, 534D-10 & 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 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

2. Drain axle and fill to correct level

with Mobilfluid 424

(ISO 46). Refer to Section 2.4, “Fluid and Lubricant Capacities.”

7. High steering effort required. 1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Correct bearing preload by adding or removing shims as needed.

3. Worn or damaged swivel bearings.

8. Slow steering response. 1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally.

9. Excessive noise when brakes

1. Brake discs worn. 1. Check brake discs for wear.

are engaged.

3. Replace swivel bearings as needed.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Repair or replace steering cylinder as needed.

Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Brake discs damaged. 2. Replace brake discs.

10. Brakes will not engage. 1. Brake (hydraulic) system not operating properly.

2. Brake piston o-rings and seals damaged (leaking).

11. Brakes will not hold the

1. Brake discs worn. 1. Check brake discs for wear.

machine or braking power reduced.

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

5.8

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Replace o-rings and seals.

Refer to Section 2.4, “Fluid and Lubricant Capacities.”

2. Refer to Section 8.4, “Hydraulic Circuits.”

3. Replace o-rings and seals.

534D-9, 534D-10 & 544D

Axles, Wheels and Tires

5.4 REAR DRIVE HUBS

5.4.1 Rear Drive Hub Service

Detailed drive hub service 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

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.”

MX0650

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.” 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 lb-ft +/- 10 lb-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 424

(ISO 46).

8. Connect the battery negative (-) cable from the battery negative (-) terminal.

9. Close and secure the 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.

534D-9, 534D-10 & 544D

5.9

Axles, Wheels and Tires

5.5 REAR STEER AXLE

5.5.1 Rear Axle Removal

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.

Note: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.

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.

Note: If removing rear drive motors, refer to Section

8.7.2, “Rear Drive Motors.” If removing rear drive hubs, refer to Section 5.4.1, “Rear Drive Hub Service.”

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 535D-9 & 534D-10.

MX0660

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. 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, “Removing Wheel and Tire Assembly from Machine.”)

5.10

5.5.2 Rear Axle Installation

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.

534D-9, 534D-10 & 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.

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 several times in both directions. Check for hydraulic leaks, and tighten or repair as necessary.

MX0660

5.6 WHEELS AND TIRES

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.

Large-bore valve stems are used to help expedite tire inflation and deflation. An inner tube may be used 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.

534D-9, 534D-10 & 544D

5.11

Axles, Wheels and Tires

5.6.2 Installing Wheel and Tire Assembly onto Machine

IMPORTANT: The wheel and 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

MAH0890

rotate in proper direction

5.6.1 Removing Wheel and Tire Assembly from Machine

1. Park the machine on a firm, level surface, 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 steering wheel, stating that the machine should not be operated.

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.

MX0620

1. Position wheel onto studs on wheel end of axle.

2. Install wheel lug washers.

3. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 350-400 lb-ft (475-542 Nm).

OY1220

5. Remove machine from supports.

5.12

534D-9, 534D-10 & 544D

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.

Axles, Wheels and Tires

6. Fill the axle with Mobilfluid 424 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.

(ISO 46) through the

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.

Note: If the brake disks are worn beyond their tolerance, the brake disk must be replaced on both sides of the axle at the same time.

MX0600

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.

WARNING

ALL WHEELS must be blocked to prevent machine

from moving or rolling away.

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.

5. Repeat steps 3 and 4 for the other side of the axle.

534D-9, 534D-10 & 544D

MX0610

Note: This procedure does not alter any relief settings.

5.13

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.

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.

MX1040

After the machine has been towed to a secure location, reactivate the parking brake.

1. Block all four wheels.

WARNING

ALL WHEELS must be blocked to prevent machine

from moving or rolling away.

MX1050

5.14

534D-9, 534D-10 & 544D

Section 6

Hydrostatic Drive Pump

Contents

PARAGRAPH TITLE PAGE

6.1 Drive Pump Assembly Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 Drive Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Drive Pump Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4 Drive Pump Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4.1 Drive Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4.2 Drive Pump Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Drive Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.6 Hydrostatic Drive Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

6.6.1 Hydraulic Oil Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

6.6.2 Hydraulic Filter Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

6.6.3 Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

6.6.4 Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

6.6.5 Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

6.6.6 Control Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8

6.6.7 Inching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 & 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.

PORT BLOCK

DRIVE SHAFT

TOP VIEW

STROKING PISTON

ADJUSTMENT

SIDE VIEW

PUMP HOUSING

P O R VALVE

DA CARTRIDGE

DIRECTIONAL VALVE

REVERSE HIGH PRESSURE RELIEF VALVE

TEST PORT (REVERSE)

6.2

CHARGE PUMP

OUTPUT PORT

CHARGE PUMP

RELIEF VALVE

TEST PORT (FORWARD)

FORWARD HIGH PRESSURE RELIEF VALVE

MX0870

534D-9, 534D-10 & 544D

JLG 534D-10 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 INTRODUCTION

1.2 DISCLAIMER

1.3 OPERATOR & SAFETY MANUAL

1.4 DO NOT OPERATE TAGS

1.5 SAFETY INFORMATION

1.5.1 Safety Alert System and Signal Words

1.6 SAFETY INSTRUCTIONS

1.6.1 Personal Hazards

1.6.2 Equipment Hazards

1.6.3 General Hazards

1.6.4 Operational Hazards

1.7 SAFETY DECALS

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

2.2 TORQUE CHARTS

2.2.1 ASTM Fastener Torque Chart (English)

2.2.2 ASTM Fastener Torque Chart (Metric)

2.2.3 Metric Fastener Torque Chart

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

2.3.2 Hydraulic Cylinder Performance

2.3.3 Electrical System

2.3.4 Engine Performance Specifications

2.3.5 Tires

2.4 FLUID AND LUBRICANT CAPACITIES

2.5 SERVICE AND MAINTENANCE SCHEDULES

2.5.1 10, 1st 50 & 50 Hour

2.5.2 250, 500, 1000 & 1500 Hour

2.6 LUBRICATION SCHEDULES

2.6.1 534D-9, 534D-10

2.6.2 544D

3.1 BOOM SYSTEM COMPONENT TERMINOLOGY 534D-9, 534D-10

3.2 BOOM SYSTEM - THREE SECTION

3.2.1 Boom System Operation

3.3 BOOM MAINTENANCE - THREE SECTION (COMPLETE REMOVAL)

3.3.1 Boom Removal

3.3.2 Second & Third Boom Section Removal

3.3.3 Third Boom Section & Push Beam Removal

3.3.4 Third Boom Section Installation

3.3.5 Extend/Retract Cylinder and Push Beam Assembly and Installation

3.3.6 Second & Third Boom Section Installation

3.4 BOOM MAINTENANCE - THREE SECTION (INDIVIDUAL SECTION REMOVAL)

3.4.2 Second Boom Section Removal

3.4.3 Second and Third Boom Section Removal

3.4.4 Second Boom Section Installation

3.4.5 Third Boom Section Installation

3.5 BOOM CABLES - THREE SECTION

3.5.1 General Cable Information

3.5.2 Cable Adjustments

3.5.3 Retract Cable Removal

3.5.4 Retract Cable Installation

3.5.5 Extend Cable Removal

3.5.6 Extend Cable Installation

3.5.8 Hose Removal

3.5.9 Hose Installation

3.6.1 Electrical Wire Data

3.6.2 Electrical Cable Removal

3.6.3 Electrical Cable Installation

3.7.1 Extend/Retract Cylinder Removal

3.7.2 Extend/Retract Cylinder Installation

3.8 BOOM SYSTEM COMPONENT TERMINOLOGY 544D

3.9 BOOM SYSTEM - FOUR SECTION

3.9.1 Boom System Operation

3.10 BOOM MAINTENANCE - FOUR SECTION (COMPLETE REMOVAL)

3.10.1 Boom Removal

3.10.2 Extend/Retract Cylinder Removal

3.10.3 Tilt Cylinder Removal

3.10.4 Second, Third & Fourth Boom Section Removal

3.10.5 Third & Fourth Boom Section Removal

3.10.6 Fourth Boom Section Removal

3.10.7 Hydraulic Sub-Assembly

3.10.8 Fourth Boom Section Install

3.10.9 Third Boom Section Install

3.10.10 Second Boom Section Install

3.10.11 First Boom Section Install

3.10.12 Boom Assembly Installation

3.11.1 Fourth Boom Section Removal