® ® SERVICE MANUAL ® 534C-9 534C-10 2460-4129 July 2002 534C-9 Starting S/N 0344394 thru 0444002 534C-10 Starting S/N 0266057 thru 0266106 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES, INC. JLG INDUSTRIES, INC. 1 JLG DRIVE 406 Mill Avenue S.W. McConnellsburg, PA New Philadelphia, OH 17233-9533 44663 USA USA Telephone: (717) 485-5161 Telephone: (330) 339-2211 Fax: (717) 485-6417 Fax: (330) 339-8458 ® ® OWNER/OPERATOR MANUAL ® 534C-9 534C-10 2460-4171 July 2002 534C-9 Starting S/N 0344394 534C-10 Starting S/N 0266057 Form #20042 Original Issue 3/01 CORPORATE OFFICE GRADALL DIVISION JLG INDUSTRIES, INC. JLG INDUSTRIES, INC. 1 JLG DRIVE 406 Mill Avenue S.W. McConnellsburg, PA New Philadelphia, OH 17233-9533 44663 USA USA Telephone: (717) 485-5161 Telephone: (330) 339-2211 Fax: (717) 485-6417 Fax: (330) 339-8458 TABLE OF CONTENTS IMPORTANT SAFETY NOTICE .......................................... inside front cover TABLE OF CONTENTS INTRODUCTION ............................................................ 2 General Operator Qualifications Orientation Related Manuals & Decals Serial Number Location NOMENCLATURE ........................................................... 3 SAFETY HIGHLIGHTS ..................................................... 4 DECALS ....................................................................... 5 Optional Equipment Decals OPERATORS CAB .......................................................... 10 Control & Instrument Identification CHECKS & SERVICES BEFORE STARTING ENGINE ............. 12 ENGINE OPERATION ...................................................... 13 Starting the Engine Cold-Weather Starting Aids Normal Engine Operation Stopping the Engine WARM-UP & OPERATIONAL CHECKS ................................ 14 BRAKE SYSTEM ............................................................ 15 General Inching Travel Service Brakes Parking Brakes PARKING THE HANDLER ................................................ 16 STEERING SYSTEM ....................................................... 16 DRIVE TRAIN ............................................................... 17 BOOM ........................................................................ 18 Boom Cable Adjustment OUTRIGGERS ............................................................... 19 LEVELING THE HANDLER ............................................... 20 OPERATING PROCEDURE & TECHNIQUES ......................... 21 Hydraulic Controls Rated Capacity Chart ATTACHMENTS ............................................................. 23 Approved Attachments Non-Approved Attachments Carriage/Fork Capacities Other Attachment Capacities Attachment Installation Attachment Operation LUBRICATION & MAINTENANCE SECTION ......................... 32 Lubrication & Maintenance Diagram Recommended Lubricants & Capacities Torque Chart OBTAINING HYDRAULIC OIL SAMPLE FOR ANALYSIS.......... 35 MOVING HANDLER IN EMERGENCY.................................. 35 Moving Short Distances Moving Longer Distances To Activate Tow Bypass To Release Parking Brake To Restore Parking Brake HAND SIGNALS ............................................................ inside back cover Important Safety Notice These tests ensure that the Hydrostatic Material Drive System operates to the proper specifications. All tests should be done in a safe, open area. Apply the park brake and leave the shifter in neutral unless otherwise noted. The boom and attachment should rest on the ground unless the machine is being driven. Safe working habits must be used for these checks. Refer to Operator’s Manual (Form No. 29311 ) for further information. Read and understand this Manual, along with Operation and lubrication Manual, EMI Handler Safety Manual, GRADALL Material Handler Safety Manual and all instructional decals and plates before starting, operating or performing mechanical adjustments and maintenance procedures on this equipment. Keep Operator and Safety Manuals in cab. Safe operation depends on reliable equipment and proper operating procedures. Performing the adjustments and repairs described in this Manual will help to keep your Material Handler in reliable condition. Use of the recommended operating procedures can help you avoid accidents. Because some procedures may be new to even the experienced technician, we recommend that this Manual be read, understood and followed by all who service this unit. !DANGER, !WARNING, !CAUTION notes in this Manual will help you avoid injury and damage to this equipment. These notes are not intended to cover all eventualities. It is impossible to anticipate and evaluate all possible applications and methods of operation for this equipment. Any procedure not specifically recommended by GRADALL must be thoroughly evaluated from the standpoint of safety before it is placed in practice. If you are not sure, contact your GRADALL Distributor before operating. Do not modify this machine without written permission from GRADALL The following symbols are used to call your attention to safety notices DANGER: This symbol indicates an extreme hazard which could result in high DANGER probability of death. WARNING: This symbol indicates a hazard which could result in death or WARNING serious injury if proper precautions are not taken. CAUTION: This symbol indicates a hazard which could result in injury or CAUTION damage to equipment or property if proper precautions are not taken. RequiredRequired Tools Tools Color-coded plastic caps seal the adjustments on components in the hydraulic system. If a GRADALL Distributor makes an adjustment, the component should be sealed with a blue cap. The tools needed to make these checks are: 1. Tachometer 2. GRADALL pressure testing kit P/N 7713-4197 3. Mechanic’s hand tools (Metric included) 4. Blue plastic caps: P/N 8093-4459 (small) and P/N 8093-4460 (large) Form No. 29633 3/97 (ii) GeneralGeneral Warning Warning Information Information This Manual provides important information for those responsible for understanding, troubleshooting, testing, repairing and/or performing maintenance on the hydrostatic transmission drive system of 534C-9 and 534C-10 Material Handlers. NOTE! This Manual does not cover any of the implement systems of the machine. Accidents involving injury or serious machine damage Immediately notify your GRADALL Distributor of the incident so he may assist you in your investigation of the problem. If he is unavailable, contact the GRADALL Service Department at (330) 339-2211. Related Manuals and Decals Separate publications are furnished with your Material Handler to provide information concerning safety, replacement parts operation, maintenance procedures and vendor components. Replacement manuals and decals can be ordered from your GRADALL Distributor. Orientation When used to describe location of components on the machine, the directions front, rear, left and right relate to the orientation of a person sitting in the operator’s seat in the cab. Welding If welding on the machine becomes necessary, place the ground adjacent to the area being welded. This will prevent arcing-between components such as bearings or machined CAUTION surfaces which could cause machine damage and downtime. 1. Welding rod repairs should meet 70,000 PSI minimum tensile strength, low hydrogen process. 2. The battery leads must be disconnected before welding to prevent damage to electrical components. Fasteners 1. Grade 8 bolts are used whenever two machined surfaces or major assemblies are bolted together. Torque values for the application will be called out. 2. Grade 5 bolts are used to fasten non-machined areas such as sheet metal. Refer to bolt torque chart in Operator’s Manual. 3. Dowel pins are used in assemblies to absorb the shear load to these components and assist in correct positioning for bolt insertion. Testing and Adjustment Precautions 1. Read and understand the manuals named under the important safety notice heading above. Be sure you are familiar with the machine’s response to controls. 2. Read and understand all material relating to area to be checked, adjusted or repaired. 3. This Manual covers hydraulic testing and adjustments. Read and understand material related to hydraulics before proceeding with service of any kind on the hydraulic system. When performing maintenance, be sure there is no residual, trapped hydraulic pressure. 4. If you are working with a helper, be sure he understands the procedure. Be certain each of you knows what to Form No. 29633 3/97 (iii) 534C-9 & 534C-10 HYDROSTATIC DRIVE PERFORMANCE CHECKS MANUAL General Warning Information (continued) expect from the other, and when to expect it. 5. Be sure you understand all steps of the procedure before testing, adjusting or repairing any component or mechanical assembly. Follow the procedure carefully. 6. Always wear safety glasses, hard hat and any other locally required safety-related, protective apparel when performing testing and adjusting procedures. 7. Thoroughly clean all areas before working on them. Slippery and contaminated surfaces can cause serious accidents or mechanical failure if not removed. 8. Always mechanically secure machine components that could suddenly start in motion and cause injury or damage. 9. Remove key from ignition and place a sign in the operator’s cab informing all who come in contact with the machine that it is being worked on and that personnel are on the machine. WARNING Do not move any function. 10. Double check bolt torques. 11. Check that all lubrication fluids are at the correct level. 12. Remove mechanical restraints