Document Outline

• 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