JLG 534D-10 User Manual
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
i
Section Subject Page
Section 5
Axles, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axles, Wheel and Tire Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General 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
ii
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
iv
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
7
°
0
6
°
0
5
°
0
4
°
0
3
°
0
2
1
°
0
0
°
1
0°
4
E
U
Q
R
B
O
T
U
H
R
1
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
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 — — — — —
40
0.1120
48 0.00661 420 9 7 — — 600 13 10 — — — — —632
4
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
20
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
6
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
6
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
18
24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30
16
24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55
14
20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82
13
20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127
12
18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182
11
18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242
10
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
9
0.8750
14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700
7/8
8
1.0000
12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000
1
7
1.1250
12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520
1-1/8
1.2500
7
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
40
48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —632
INCH
4
0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19
20
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
18
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
16
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
14
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
13
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
12
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
11
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
10
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
9
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
8
1
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
7
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
7
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
6
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
6
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
9
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
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
3
(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
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
10
Check Fuel
Level
Check Hydraulic
Return Filter
Indicator
50
Change
Axle Oil
Check Boom
Chain Tension
(544D)
Check Tire
st
1
Change Wheel
Pressure
End Oil
Air Filter
Restriction
Indicator
Change Engine
Oil & Filter
Check Engine
Oil Level
L
B
/F
T
(
N
m
Check Wheel
Lug Nut
Torque
Check Hydraulic
Oil Level
)
Check Boom
Cable Tension
(534D-9 & 534D-10)
2.10
Drain Fuel/
Water
Separator
EVERY
50
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)
L
B
/
F
T
(
N
m
)
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
50
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
50
MYSTIK TETRIMOLY
(NLGI 2 GC-LB)
2.14
MX00512
534D-9, 534D-10 & 544D
b. 250 Hour
EVERY
50
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
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