Mustang 634 Operator's Manual
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Mustang 634 Operator's Manual

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634
TELEHANDLER
OPERATOR'S MANUAL
Revision C - 06/15
S/N 71102 - 71300
PART #913229
Mustang Manufacturing Company, Inc.

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  • Page 1 TELEHANDLER OPERATOR’S MANUAL Revision C - 06/15 S/N 71102 - 71300 PART #913229 Mustang Manufacturing Company, Inc.
  • Page 2 Indicator and Operation Symbols Read Operator’s Parking Brake Brake Failure Safety Alert Turn Signals Hazard Flasher Manual Ignition Off Ignition ON Engine Start Hydraulic Oil Horn Engine Oil Pressure Volume Full Volume Half Full Volume Empty Battery Fuel Transmission Temperature Engine Coolant Starting Aid Wiper/Washer...

  • Page 3: Table Of Contents

    Warranty ........Inside Back Cover IDENTIFICATION INFORMATION Write your Mustang telehandler Model and serial numbers below. Refer to these numbers when inquiring about parts or service from your Mustang dealer. MODEL NO. SERIAL NO.

  • Page 4: Introduction

    A storage pocket on the back of the seat is provided for storing the Operator’s Manual. After using the manual, please return it to the pocket and keep it with the unit at all times! If this machine is resold, Mustang Manufacturing Company recommends that this manual be given to the new owner.
  • Page 5 Identification Boom Angle Dash Indicators Telescopic Boom Indicator and Controls Quickattach System Slave Cylinder Tilt Cylinder Seat Operator’s Station Lift Cylinder Extend Cylinder Rear Boom Access Cover Auxilluary Hydraulics Exhaust Pipe (not shown) Rear Access Cover with Rear Lights and Reverse Alarm Frame Leveling Air Cleaner Hydraulic Tank...

  • Page 6: Specifications

    Chapter 2 SPECIFICATIONS Lifting Performance Steering System Axles (front and rear) Steer Valve: Fixed displacement rotary Maximum lift capacity: Type: Dana Displacement/Rev: 17.9 cu. in. (293 cc) 6000 lbs. (2721 kg) Drive/steer, open differential, double System pressure: 2000 psi (138 bar) reduction planetary, full-time four- Maximum lift height: Steer cylinders: 1 per axle...

  • Page 7: Checklists

    Chapter 3 CHECKLISTS PRE-DELIVERY I acknowledge that the pre-delivery procedures were per- formed on this unit as outlined above. The following Checklist is an important reminder of inspec- tions that MUST be made before delivering the Telehandler to the customer. Check off each item after prescribed action Dealership’s Name is taken.
  • Page 8 INTENTIONALLY BLANK (To be removed as Dealer’s file copy) 913229/CP0615 PRINTED IN U.S.A.
  • Page 9 Chapter 3 CHECKLISTS PRE-DELIVERY I acknowledge that the pre-delivery procedures were per- formed on this unit as outlined above. The following Checklist is an important reminder of inspec- tions that MUST be made before delivering the Telehandler to the customer. Check off each item after prescribed action Dealership’s Name is taken.

  • Page 10: Safety

    Chapter 4 SAFETY The above Safety Alert Symbol means ATTENTION! Mustang Manufacturing Company ALWAYS takes the ALWAYS BE ALERT! YOUR SAFETY IS operator’s safety into consideration when designing its INVOLVED! It stresses an attitude of “Heads Up for machinery, and guards exposed moving parts for Safety”...
  • Page 11 SAFETY Additional Safety Reminders WARNING User/operator safety practices, as established by industry standards, are included in this Operator’s Manual and intended to promote safe operation of U.S. OSHA regulations require employers in the machine. These guidelines do not, of course, general industry and the construction, ship- preclude the use of good judgment, care and com- yard and cargo-handling industries (excepting...
  • Page 12 SAFETY Walk around the machine and warn all personnel DO NOT exceed the machine’s rated operating who may be servicing the machine or who are in capacity for the type of attachment tool being used. the machine path prior to starting. DO NOT start DO NOT allow minors or any unqualified person- until all personnel are clearly away from the nel to operate or be near the machine unless prop-...
  • Page 13 ALWAYS wear safety glasses with side shields To ensure continued safe operation, replace dam- when striking metal against metal. In addition, it is aged or worn-out parts with genuine Mustang ser- recommended that a softer (chip-resistant) materi- vice parts before using this equipment.

  • Page 14: Work Platform Safety System

    SAFETY Safety Guards and Warning Devices MANDATORY WORK PLATFORM This machine is fitted with a Roll-Over Protective SAFETY RULES Structure (ROPS) and Falling Object Protective Structure (FOPS) in accordance with industry stan- 1. The work platform must comply with dards. It is intended to offer protection to the oper- ANSI/ITSDF B56.6-2005, Sec.

  • Page 15: Work Platform Switch

    SAFETY 14. Be sure the path of platform travel is clear of haz- WARNING ards, such as scaffolds, electrical wires and over- head obstructions. Use ONLY an approved work platform for ele- 15. The operator must keep hands and feet clear of vating personnel.

  • Page 16: Work Platform Design Requirements

    SAFETY Work Platform Design Requirements 9. Restraining means such as a guardrail or a means for securing personnel such as a body harness and (Per ANSI/ITSDF B56.6-2005, Sec. 8.24) lanyard. A guardrail or similar structure shall have 1. A platform floor having a slip-resistant surface a nominal height to the platform floor of 42 inches located not more than 8 inches (200 mm) above the (1066 mm) around its upper periphery and include...
  • Page 17 SAFETY L65926 L70307 101506 L70306 L65926 L70307 L70306 L65932 L65932 101506 PRINTED IN U.S.A. 913229/CP0615...
  • Page 18 SAFETY L70305 L70305 L65942 L65933 L65927 L65927 L65932 L65928 100359 072798 913229/CP0615 PRINTED IN U.S.A.
  • Page 19 SAFETY L65942 L65928 072798 100359 L65932 L65927 L70305 L65933 PRINTED IN U.S.A. 913229/CP0615...
  • Page 20 SAFETY L65928 L65927 L65926 L65927 L65927 L66613 913229/CP0615 PRINTED IN U.S.A.
  • Page 21 SAFETY L65928 L65927 L65926 L66613 PRINTED IN U.S.A. 913229/CP0615...
  • Page 22 SAFETY WPS System Decals L71555 L71554 L71700 L71555 102969 L71554 L71554 L71700 102969 913229/CP0615 PRINTED IN U.S.A.

  • Page 23: Indicators And Controls

    Telehandler BEFORE operating it. Know how special operating procedures. to stop the machine operation BEFORE oper- ating it. This Mustang machine is designed and intended to be used ONLY with a Mustang WARNING attachment tool, or a Mustang approved accessory...
  • Page 24 DASH PANEL AREA Coolant Temperature Gauge: The upper right gauge in the instrument panel, it indicates the temperature of Key Switch OFF: When the key is verti- the engine coolant. Under normal cal in the keyswitch, power from the bat- conditions, this gauge should indicate tery is disconnected to the control and approximately 185...
  • Page 25 Failure in one of the brake systems does not affect the Any of the steering position modes can be used in for- operation of the other system. However, the MANDA- ward and reverse travel. The operator should learn to TORY SAFETY SHUTDOWN PROCEDURE (p. anticipate changes in machine movement if the steer- 8) should be followed and any required repairs made ing selector mode must be changed.
  • Page 26 Parking Brake: When the machine is shut Wiper/Washer: The windshield and top off, this switch should be depressed to window of the operator’s station are each actuate the parking brake mechanism in equipped with a wiper and washer mecha- the front axle. nism.
  • Page 27 RIGHT SIDE PANEL Position “F” (FORWARD) These controls and indicators are used to position the Position “N” (NEUTRAL) frame, boom, attachment and outriggers. Graphic sym- Position “R” (REVERSE) bols on the side panel illustrate the control actions. Auxilliary Frame Level and Hydraulics Attachment Joystick Control...
  • Page 28 MANDATORY forward. SAFETY SHUTDOWN PROCEDURE (page 8). Auxiliary Hydraulics Control: This 2-position lever DO NOT attempt repairs. Call your Mustang dealer for assistance. is for attachment tools that require additional hydraulics. The truss boom and winch attachment tools...

  • Page 29: Side View Mirror

    Side View Test Ports Compartment Mirror ATTACHMENT TOOLS Mustang offers a versatile range of attachment tools to meet various lifting and material handling applications. Contact your Mustang dealer for specifications and ordering information. ACCESSORIES Mustang offers a range of special accessories for this machine.

  • Page 30: Operation And Adjustments

    Chapter 6 OPERATION AND ADJUSTMENTS GENERAL INFORMATION BEFORE STARTING ENGINE Before starting the engine and running the machine, CAUTION refer to the INDICATORS AND CONTROLS chapter and become familiar with the various operating con- trols, indicators and safety features. BEFORE starting the engine and operating the Telehandler, review and comply with ALL safe- STARTING THE ENGINE ty recommendations in the SAFETY chapter of...
  • Page 31 20 F (-7 C) or Apply the service brakes, stop the machine and move lower. See your Mustang dealer for recommended the direction lever to the opposite direction. heater. Shifting to the next higher gear may be done at any engine RPM while the machine is in motion.
  • Page 32 CHANGING ATTACHMENT TOOLS on the boom nose. The Telehandler boom nose will accept Quick-attach Detaching System Mustang attachment tools. The Quick-attach System has a quick-release hookup and locking mech- To detach attachment tool, proceed as follows: anism for mounting framing-type or masonry-type 1.
  • Page 33 Modifications, alterations to, or use of attach- lines. ment tools NOT authorized by Mustang (or the If the machine is found to be in need of repair or in any manufacturer) in writing can void warranty...

  • Page 34: Traffic Flow Patterns

    until it has been restored to a safe operating condition. the frame angle indicator on the ROPS/FOPS crossmember. Operate the travel controls gradually and smoothly when starting, stopping, turning and reversing direc- 4. DO NOT travel across a side hill that exceeds 18% tion.
  • Page 35 Operation of the hydraulic system depends on engine speed and the distance the controls are moved. When operating these controls it is important to develop a technique called “feathering.” Feathering the control means you start the desired motion by moving the con- Stop Raise Load Lower Load...
  • Page 36 NEVER leave the operator’s station without The following example illustrates proper use of the first lowering the attachment tool to the load zone charts for the Telehandler: ground. Then set the parking brake, place con- Example: trols in neutral, shut off engine and remove the key.

  • Page 37: Work Platform Safety Rules

    Load Elevation and Placement WARNING For ground level load placement, be sure the area under the load and around the machine is clear of NEVER exceed the rated operating capacity of equipment and personnel. Lower the load to the the Telehandler as shown on the load zone ground, tilt the forks to the horizontal position, and charts.
  • Page 38 5. Secure the lanyard from the body harness to the WP or the boom. Each person in the WP should have a body harness with a lanyard attached to the Elevating Personnel Retaining This Telehandler is primarily intended for use as a material handler.

  • Page 39: Suspended Loads

    5. No lifting of material may be done when anyone is Call your Mustang dealer. on the load, rigging or forks. As lift height increases, depth perception 6. Multiple pickup points on the load are preferred to decreases.
  • Page 40 NOTE: 3. The incline of the ramps MUST be less than 15 ALWAYS follow ALL state and local reg- degrees. Ramp length MUST be at least 16 feet ulations regarding the operation of equipment on (4.9 m) long. or across public highways. Whenever there is an appreciable distance between jobsites, or if 4.

  • Page 41: Theft Deterrents

    THEFT DETERRENTS Mustang has recorded all component part numbers and serial numbers. Users should take as many of the fol- lowing actions as possible to discourage theft, to aid in the recovery in the event the machine is stolen, and to reduce vandalism: 1.
  • Page 42 INTENTIONALLY BLANK 913229/CP0615 PRINTED IN U.S.A.

  • Page 43: Lubrication

    Chapter 7 LUBRICATION GENERAL INFORMATION Hydraulic System Reservoir Use Mobil DTE 15M, or an equivalent that WARNING contains anti-rust, anti-foam and anti-oxida- tion additives and conforms to ISO VG46. NEVER lubricate or service this unit when any Capacity: 35 Gallons (133 liters) part of the machine is in motion.
  • Page 44 REPLACEMENT FILTER CHART FUEL ENGINE HYDRAULIC TRANS. ENGINE TYPE FILTER FILTER FILTER STRAINER JOHN DEERE Primary w/ Mechanical Throttle 137498 L98978 102173 L97489 L49327 L99184 Safety 137501 JOHN DEERE Primary w/ Electronic Throttle 137498 102174 102173 L97489 L49327 L99184 Safety 137501 GREASING BOOM AREA...
  • Page 45 UNDER COVER Grease Fittings Locations PRINTED IN U.S.A. 913229/CP0615...

  • Page 46: Service And Storage

    BEFORE resuming machine operation. The following areas of internal components service replacement and operating adjustments should only be by (or under the direction of) an authorized Mustang Telehandler dealer. NOTE: All service routines, with the exception of...
  • Page 47 OPERATOR SERVICES Before removing one of these valves, you ARE REQUIRED to call your Mustang dealer Some of the operator-related services will require or Mustang Manufacturing Company Service access to components located inside the superstructure, Department.
  • Page 48 Replace any cracked or damaged parts. hydraulic, battery or fuel systems; all contain Use only genuine Mustang parts for service. highly flammable liquids or explosive gases, which can cause an explosion or fire if ignited. Use care not to damage machined and polished sur- faces.
  • Page 49 With the machine on level ground, remove the radiator When installing tires on the machine, be sure that all cap. If the coolant level is below the filler neck, add a tires are of the same size and style. ALWAYS replace low-silicate ethylene glycol base coolant mixed with tires with the same size furnished as original equip- quality water and supplemental coolant additives...
  • Page 50 Are any decals missing or damaged? Are all guards, been corrected. Contact your dealer (or shields and covers in place? Do all controls function Mustang Manufacturing Company) for service smoothly and properly? Are there any abnormal vibra- information and parts.

  • Page 51: Transmission Oil

    The carriage tilt and auxiliary functions, should three seconds of brake pedal application. now be disabled. The hydraulic joystick should If WPS System fails to perform properly, troubleshoot continue to function normally for boom using the chart on page 56. Contact your dealer for ser- raise/lower and extend/retract.
  • Page 52 CHECKING AXLE OIL LEVELS WARNING Differential NEVER service the fuel system while smok- NOTE: The Telehandler should be on a level ing, while near an open flame, or after the surface for this procedure. engine has been operated and is hot. See illustration.
  • Page 53 2. If acid contacts the skin, rinse the affected away all metallic filings from the plug and re- area with running water for 10 to 15 min- install it. utes. IMPORTANT: DO NOT discharge oil onto 3. If acid comes in contact with the eyes, ground.
  • Page 54 IMPORTANT: Two of the chains are on the top front of the boom. A BE SURE that the jumper battery third chain is accessible from inside the rear of the is also a 12-volt D. C. battery, and the vehicle boom (see boom illustration).
  • Page 55 clearance. Re-apply Loctite ® thread lock to the bolts 2. Remove and discard the oil filter. Wipe the sealing and re-torque to 30 ft-lbs (40 Nm). Bottom slide pads surface on the transmission with a clean cloth. should be replaced when the thickness is worn down to Apply a thin coat of clean oil to the new oil filter 3/8”...
  • Page 56 NOTE: Check the engine temperature gauge Inlet Cap every minute or two after coolant has been changed. Air pockets can form and it may be nec- essary to refill the cooling system after a short period of use, as the air will naturally bleed out of Mounting the system.
  • Page 57 Inner Element IMPORTANT: DO NOT discharge oil onto ground. Catch and dispose of per local waste dis- NOTE: Replace the inner element only if it is vis- posal regulations. ibly dirty or if the outer element has been replaced three times. 2.
  • Page 58 IMPORTANT: DO NOT discharge oil onto Service Every 2000 Hours or Two Years ground. Catch and dispose of per local waste dis- posal regulations. NOTE: Perform all other service requirements up to this point, as well as the following. Element Fill Cap CHECKING HYDRAULIC SYSTEM Dipstick...
  • Page 59 IMPORTANT: During Storage Hydraulic fluid and filters should be replaced any time contamination is present 1. About once each month, connect the battery and, before the normally scheduled change. before starting the engine, check all fluid levels to STORAGING make sure they are at the proper level. 2.
  • Page 60 WPS System switch. the end of the boom. System level sensor Contact your Mustang dealer for unplugged or faulty. assistance. WPS System mode lamp flash- es when switch is turned “OFF”. WPS System is not de-activated.

  • Page 61: Decal Locations

    NOTE: Refer to the Safety chapter of this manual Decal Kits for the specific information provided on the vari- 103377 634 Telehandler without WPS ous safety decals. 103378 634 Telehandler with WPS NOTE: Decals may be purchased in kits or indi- vidually.
  • Page 62 REF. DESCRIPTION PART DANGER - HANDS OUT L70305 WARNING - PINCH POINT L65927 WARNING - JUMP START L65933 MUSTANG - REAR 100155 QUICKATTACH DIAGRAM L65937 ANTI-FREEZE 056859 HALF ZONE MARKER (5 ea.) L62583 NO. “0” EXTENSION MARKER (1 ea.) L67718 NO.
  • Page 63 DECAL LOCATIONS - FRAME AND BOOM REF. DESCRIPTION PART DANGER - HANDS OUT L70305 WARNING - PINCH POINT L65927 MUSTANG RH BOOM 100623 HYDRAULIC OIL FILL 137632 WARNING - NO RIDERS L65932 MUSTANG - FRONT 100156 DANGER-PERSONNEL INJURY (units without WPS)
  • Page 64 DECAL LOCATIONS - OPERATOR STATION REF. DESCRIPTION PART WARNING-TILT HAZZARD/GENERAL OPERATOR L70306 WARNING - CARRY LOAD LOW L65926 F-N-R SHIFT L68295 MADE IN USA 140516 WARNING - PARK BRAKE/SEAT BELT 101506 STANDARD CARRIAGE LOAD CHART 100657 ROTATING CARRIAGE LOAD CHART 103341 BUCKET LOAD CHART 100660...
  • Page 65 DECAL LOCATIONS - WPS EQUIPPED UNITS REF. DESCRIPTION PART WARNING-PERSONNEL LIFT L71554 WARNING-WORK PLATFORM RULES L71555 PERSONNEL LIFT SAFETY RULES L71700 WPS LOAD CHART 103340 WPS LOGO 103016 WPS SWITCH 102969 PRINTED IN U.S.A. 913229/CP0615...

  • Page 66: Maintenance

    Chapter 10 MAINTENANCE This Maintenance Interval Chart was developed to match the Service and Storage chapter of this manual. Detailed information on each Service Procedure may be found in the Service and Storage chapter. A Maintenance Log fol- lows the Maintenance Interval Chart for recording the maintenance procedures performed. Recording the 10-Hour (or Daily) service procedures would be impractical and is therefore not recommended.
  • Page 67 MAINTENANCE INTERVAL CHART (CONT.) SERVICE PROCEDURE Every 250 Every 1000 Every 2000 Hours (or Hours (or Hours (or Quarterly) Yearly) Two Years) Checking and Torquing Boom Leaf Chains Checking Boom Slide Pad Wear and Clearance Checking Personnel Work Platform System Changing Transmission Oil and Filter Changing Radiator Coolant Changing Hydraulic Return Filter Element...
  • Page 68 MAINTENANCE LOG Date Hours Service Procedure 913229/CP0615 PRINTED IN U.S.A.
  • Page 69 MAINTENANCE LOG Date Hours Service Procedure PRINTED IN U.S.A. 913229/CP0615...
  • Page 70 MAINTENANCE LOG Date Hours Service Procedure 913229/CP0615 PRINTED IN U.S.A.

  • Page 71: Hydraulic Schematics

    Hydraulic Schematic w/o WPS PRINTED IN U.S.A. 913229/CP0615...
  • Page 72 Hydraulic Schematic with WPS 913229/CP0615 PRINTED IN U.S.A.

  • Page 73: Electrical Schematics

    Electrical Schematic PRINTED IN U.S.A. 913229/CP0615...
  • Page 74 INTENTIONALLY BLANK 913229/CP0615 PRINTED IN U.S.A.
  • Page 75 INTENTIONALLY BLANK PRINTED IN U.S.A. 913229/CP0615...

  • Page 76: Load Zone Charts

    Load Zone Charts Decal 100657 Decal 100660 Standard Carriage 1.3 Cu. Yd. Bucket Decal 103341 Decal 100659 Rotating Carriage 8-Ft. Truss Boom 913229/CP0615 PRINTED IN U.S.A.
  • Page 77 Load Zone Charts Decal 100661 Decal 103340 Winch Boom PRINTED IN U.S.A. 913229/CP0615...

  • Page 78: Torque Specifications

    Torque Specifications Use these torque values when tightening Mustang hardware (excluding: locknuts and self-tapping, thread-forming and metal screws) unless otherwise specified. Grade 2 Grade 5 Grade 8 Unified National Thread Lubed Lubed Lubed 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18...

  • Page 79: Index

    Index Floor and Seat .......27 Other Miscellaneous ......28 Access To Components Chart .
  • Page 80 Grease Fittings Oils - See Lubrication Locations ........44 Operation Types Of Grease .
  • Page 81 Shields ........23 Side View Mirror .
  • Page 82 NOTES 913229/CP0615 PRINTED IN U.S.A.

  • Page 83: Warranty

    WARRANTY MUSTANG MANUFACTURING COMPANY, INC., hereinafter referred to as Mustang, warrants new Mustang equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date.
  • Page 84 If you have any questions on proper operation, adjustment or maintenance of this machine, contact your dealer or the service department of Mustang Manufacturing Company before starting or continuing operation.

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