Document Outline

• 31200170_C_D-Series_Gradall_Service
  • Table of Contents
  • Section 1 Safety Practices
    • 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
  • Section 2 General Information and Specifications
    • 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
  • Section 3 Boom
    • 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)
      • 3.4.1 Push Beam and Third Boom 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
      • 3.5.7 Tilt and Auxiliary Circuit Hose Removal/Installation
      • 3.5.8 Hose Removal
      • 3.5.9 Hose Installation
    • 3.6 Auxiliary Electric Cable - Three Section
      • 3.6.1 Electrical Wire Data
      • 3.6.2 Electrical Cable Removal
      • 3.6.3 Electrical Cable Installation
    • 3.7 Extend/Retract Cylinder Removal and Installation - Three Section
      • 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 Boom Maintenance - Four Section (Individual Section Removal)
      • 3.11.1 Fourth Boom Section Removal
      • 3.11.2 Third Boom Section Removal
      • 3.11.3 Second Boom Section Removal
      • 3.11.4 Second, Third and Fourth Boom Section Removal
      • 3.11.5 Second Boom Section Installation
      • 3.11.6 Third Boom Section Installation
      • 3.11.7 Fourth Boom Section Installation
    • 3.12 Boom Extend and Retract Chains - Four Section
      • 3.12.1 Boom Chain Inspection
      • 3.12.2 Inspection Guidelines
      • 3.12.3 Adjusting Extend Chains
      • 3.12.4 Adjusting Retract Chains
      • 3.12.5 Retract Chain Removal
      • 3.12.6 Retract Chain Installation
      • 3.12.7 Extend Chain Removal
      • 3.12.8 Extend Chain Installation
    • 3.13 Boom Section Separation Adjustment - Four Section
    • 3.14 Hydraulic Sub-Assembly Removal/Installation - Four Section
      • 3.14.1 Hydraulic Sub-Assembly Removal
      • 3.14.2 Assembling the Hydraulic Sub- Assembly
      • 3.14.3 Hydraulic Sub-Assembly Installation
    • 3.15 Boom Wear Pads
      • 3.15.1 Wear Pad Inspection
      • 3.15.2 Boom Wear Pad Replacement
      • 3.15.3 Boom Wear Pad Lubrication
    • 3.16 Quick Switch Assembly
      • 3.16.1 Disconnecting from an Attachment
      • 3.16.2 Connecting to an Attachment
      • 3.16.3 Quick Switch Removal
      • 3.16.4 Quick Switch Installation
    • 3.17 Forks
    • 3.18 Troubleshooting
  • Section 4 Cab and Covers
    • 4.1 Operator’s Cab and Covers Component Terminology
    • 4.2 Operator’s Cab
      • 4.2.1 Cab Safety
      • 4.2.2 Serial Number Decal
    • 4.3 Cab Components
      • 4.3.1 Steering Column and Orbitrol Valve
      • 4.3.2 Service Brake Pedal
      • 4.3.3 Throttle Pedal
      • 4.3.4 Boom Joystick Assembly
      • 4.3.5 Frame Sway and Attachment Tilt Levers
      • 4.3.6 Left Hand Tilt and/or Left Hand Tilt/ Sway Lever (If Equipped)
      • 4.3.7 Windshield Wiper Assembly
      • 4.3.8 Heater System (If Equipped)
    • 4.4 Cab Removal
    • 4.5 Cab Installation
  • Section 5 Axles, Wheels and Tires
    • 5.1 Axles, Wheel and Tire Component Terminology
    • 5.2 General Information
    • 5.3 Axle Assemblies
      • 5.3.1 Axle Serial Number Plate
      • 5.3.2 Axle Specifications
      • 5.3.3 Axle Internal Service
      • 5.3.4 Axle Maintenance
      • 5.3.5 Axle Removal
      • 5.3.6 Axle Installation
      • 5.3.7 Axle Assembly Troubleshooting
    • 5.4 Rear Drive Hubs
      • 5.4.1 Rear Drive Hub Service
    • 5.5 Rear Steer Axle
      • 5.5.1 Rear Axle Removal
      • 5.5.2 Rear Axle Installation
    • 5.6 Wheels and Tires
      • 5.6.1 Removing Wheel and Tire Assembly from Machine
      • 5.6.2 Installing Wheel and Tire Assembly onto Machine
    • 5.7 Brakes
      • 5.7.1 Brake Disk Inspection.
    • 5.8 Towing a Disabled Machine
  • Section 6 Hydrostatic Drive Pump
    • 6.1 Drive Pump Assembly Component Terminology
    • 6.2 Drive Pump Description
    • 6.3 Drive Pump Serial Number
    • 6.4 Drive Pump Specifications
      • 6.4.1 Drive Pump Maintenance
      • 6.4.2 Drive Pump Maintenance Schedule
    • 6.5 Drive Pump Replacement
      • 6.5.1 Drive Pump Removal
      • 6.5.2 Drive Pump Inspection and Internal Repair
      • 6.5.3 Drive Pump Installation
    • 6.6 Hydrostatic Drive Performance Checks
      • 6.6.1 Hydraulic Oil Reservoir
      • 6.6.2 Hydraulic Filter Condition
      • 6.6.3 Engine Speed
      • 6.6.4 Park Brake
      • 6.6.5 Charge Pressure
      • 6.6.6 Control Pressure
      • 6.6.7 Inching
      • 6.6.8 Front Motor Begin Point
      • 6.6.9 Drive Pump Pressure
      • 6.6.10 Machine Operation
  • Section 7 Engine
    • 7.1 Introduction: John Deere 4045TF275 & 4045HF275
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Component Terminology
    • 7.2 Engine Serial Number
    • 7.3 Specifications and Maintenance Information
    • 7.4 Introduction: Cummins QSB4.5
      • 7.4.1 Disclaimer and Scope
      • 7.4.2 Component Terminology
    • 7.5 Engine Serial Number
    • 7.6 Specifications and Maintenance Information
    • 7.7 Cooling System
      • 7.7.1 Radiator Pressure Cap
      • 7.7.2 Thermostat Replacement
      • 7.7.3 Radiator/Oil Cooler and Replacement
    • 7.8 Electrical System
    • 7.9 Fuel System
      • 7.9.1 Diesel Fuel
      • 7.9.2 Fuel Tank
      • 7.9.3 After Fuel System Service
    • 7.10 Exhaust System
      • 7.10.1 Exhaust System Removal
      • 7.10.2 Exhaust System Installation
    • 7.11 Air Cleaner Assembly
      • 7.11.1 Air Cleaner Assembly Removal
      • 7.11.2 Air Cleaner Assembly Installation
    • 7.12 Engine Replacement
      • 7.12.1 Engine Removal
      • 7.12.2 Engine Disassembly, Inspection and Service
      • 7.12.3 Engine Installation
    • 7.13 Engine Drive Plate/Coupling
      • 7.13.1 Drive Plate/Coupling Removal
      • 7.13.2 Drive Plate/Coupling Installation
    • 7.14 Engine Troubleshooting
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 Hydraulic Pressure Diagnosis
      • 8.3.1 Pressure Checks and Adjustments
      • 8.3.2 Pressure and Speed Settings
    • 8.4 Hydraulic Circuits
      • 8.4.1 Hydraulic Pressures
      • 8.4.2 Hydraulic Schematic-534D-9
      • 8.4.3 Hydraulic Schematic-534D-10
      • 8.4.4 Hydraulic Schematic-544D
    • 8.5 Hydraulic Reservoir
      • 8.5.1 Hydraulic Oil Reservoir Draining
      • 8.5.2 Hydraulic Oil Reservoir Filling
      • 8.5.3 Hydraulic Oil Reservoir Removal/ Installation
    • 8.6 Engine Implement Pump
      • 8.6.1 Pump Description
      • 8.6.2 Pump Failure Analysis
      • 8.6.3 Pump Replacement
    • 8.7 Drive Motors
      • 8.7.1 Front Drive Motor
      • 8.7.2 Rear Drive Motors
    • 8.8 Control Valves
      • 8.8.1 Main Control Valve
      • 8.8.2 Service Brake Valve
      • 8.8.3 Brake Test
      • 8.8.4 Steering Orbitrol Valve
    • 8.9 Hydraulic Cylinders
      • 8.9.1 General Cylinder Instructions
      • 8.9.2 Cylinder Disassembly
      • 8.9.3 General Cylinder Assembly Instructions
      • 8.9.4 General Cylinder Installation
      • 8.9.5 Cylinder Pressure Checking
      • 8.9.6 Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
      • 9.1.1 General Overview (Cab and Engine Harness)
    • 9.2 Specifications
    • 9.3 Service Warnings
    • 9.4 Fuses and Relays
      • 9.4.1 Cab
      • 9.4.2 Engine Compartment
    • 9.5 Electrical System Schematics
      • 9.5.1 Electrical Schematic 534D-9, 534D-10 - John Deere
      • 9.5.2 Electrical Schematic 544D - John Deere
      • 9.5.3 Electrical Schematic 534D-9, 534D-10, 544D - Cummins
      • 9.5.4 Start Circuit 534D-9, 534D-10, 544D
      • 9.5.5 Charge Circuit 534D-9, 534D-10, 544D
    • 9.6 Engine Start Circuit
      • 9.6.1 Starter
    • 9.7 Charging Circuit
      • 9.7.1 Alternator
    • 9.8 Windshield Wiper Motor (If Equipped)
      • 9.8.1 Windshield Washer Reservoir and Pump
    • 9.9 Cab Heater and Fan (If Equipped)
      • 9.9.1 Cab Heater Controls
    • 9.10 Solenoids, Sensors and Senders
      • 9.10.1 Circuit Solenoids
      • 9.10.2 Stabilizer Proximity Sensor
      • 9.10.3 Engine Senders
      • 9.10.4 Fuel Level Sender
    • 9.11 Gauges
      • 9.11.1 Analog Gauges
    • 9.12 Dash Switches
      • 9.12.1 Ignition Key Switch
      • 9.12.2 Dash Switches
      • 9.12.3 Warning or Activated Lights
    • 9.13 Transmission Lever
      • 9.13.1 Transmission Lever Replacement
    • 9.14 Traction Lock Pedal
      • 9.14.1 Traction Lock Pedal Replacement
    • 9.15 Troubleshooting - Cummins
      • 9.15.1 Fault Detection
      • 9.15.2 Flash-Out of Fault Codes
      • 9.15.3 Offboard Diagnostics
      • 9.15.4 Engine Fault Codes Chart