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Summary of Contents for Gradall LOED 534A
Page 1
READ AND UNDERSTAND THIS MANUAL BEFORE STARTING, OPERATING PERFORMING MAINTENANCE PROCEDURES ON THIS MACHINE. KEEP THESE MANUAL IN CAB COMPANY 406 MILL AVENUE S.W. NEW PHILADELPHIA, OHIO 44663 Gradall is a registered trademark for hudraulic (216) 339-2211 excavators built by The Gradall Co.
CONTENTS Service/replacement parts ............. Capacity .
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Safe operation depends on reliable equipment and proper operating procedures. Performing the checks and services described in this manual will help to keep your Gradall Handler in reliable condition and use of the recommended operating procedures can help you avoid accidents. Because some procedures may be new to even the experienced operator we recommend that this manual be read, understood and followed by all who operate the unit.
SERVICE Yo u r L O E D H a n d l e r d i s t r i b u t o r i s p r o p e r l y e q u i p p e d t o s e r v i c e y o u r L O E D H a n d l e r. R e p a i r s s h o u l d b e m a d e b y t r a i n e d a n d q u a l i f i e d s e r v i c e p e r s o n n e l o n l y.
RETRACTION CHAIN REPLACEMENT DISSASSEMBLY Retract boom completely. Remove rear boom cover. Remove extension (large) chain adjusting nut and jam nut. Remove hose retainer nuts and jam nuts. Disconnect hoses. Remove bolts holding hose guide pan to front of strongback. Remove strongback. Unpin retraction (small) chain from chain ears at back of third s e c t i o n .
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FIGURE 3 Guide Pan Take-up Beam Strongback Take-up Beam Bracket Hose Retainer Nuts Section Three Extension Chain Nuts Retraction Chain Section One Section Three Chain Ears Section Two Extension Chain...
EXTENSION CHAIN REPLACEMENT DISSASSEMBLY Retract boom completely. Remove rear boom cover. Remove extension (large) chain adjusting and jam nuts. Remove hose retainer and jam nuts. Disconnect hoses. Remove bolts holding hose guide pan to front of strongback. Remove strongback. Unpin retraction (small) chain from chain ears at back of third section. Allow chain to lie on bottom of 1st section.
BOOM HOSE REPLACEMENT IF HOSE IS INTACT Remove rear boom cover. Disconnect hose retainer and remove tensioning spring. Connect new hose to old hose with short length of steel wire. Disconnect old hose at back of section three. Carefully pull new hose along guide pan and around reel while pulling old hose out back of boom.
SHIFT CONTROL LINKAGE ADJUSTMENT P u t s h i f t c o n t r o l i n 1 s t g e a r . A d j u s t v a l v e l i n k a g e ( A ) s o m i c r o s w i t c h ( B ) i s a c t u a t e d w i t h s p o o l p u l l e d d o w n t o s t o p .
BRAKE ADJUSTMENT SERVICE BRAKE N o t e : P r i o r t o a n y b r a k e a d j u s t m e n t t h e f o r w a r d - r e v e r s e l i n k a g e m u s t b e a d j u s t e d a s f o l l o w s : W i t h t h e f o r w a r d - r e v e r s e l e v e r i n n e u t r a l , a d j u s t l i n k a g e r o d “...
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TIRE and RIM SERVICING SAFETY IMPORTANT For safety’s sake, always remove the valve core and exhaust all air from a single tire and from both tires of a dual assembly prior to removing any rim components, or any wheel components, such as nuts and rim clamps.
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Mixing parts of one type rim with those of the improper fit. Look for distortion or to another potentially dangerous. Always components that properly locked check chart manufacturer or seated. a p p r o v a l . Block the tire and wheel on the opposite Don’t reinflate a tire that has been run flat side vehicle...
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TWO-PIECE RIMS Correct Incorrect FIGURE 9 FIGURE 7 The components in a correctly assembled and locked An incorrectly assembled two-piece rim could have a large two-piece rim fit snugly. gap in side ring. Components are not firmly locked in place. DO NOT INFLATE TIRE AND RIM ASSEMBLY UNTIL COMPONENTS ARE PROPERLY SEATED AND LOCKED.
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Replace Worn, Rusted & Corroded Replace Distorted Rims & Rim Parts Components Badly worn, rusted and corroded rims and components are Distorted rims and components will not properly lock dangerous and should be replaced with new together. They should be replaced. parts.
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WARNING! MISMATCHED RIM PARTS ARE DANGEROUS AND COULD CAUSE SEVERE INJURY Most highway rims look alike, but all vary somewhat in are present, frequently difficult to see. The rim certain design features. It is these differences between cross-sections below show correct, safe matchings of rim rims of different types that makes “part-mixing”...
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PARKING BRAKE FUNCTION The Parking Brake is spring loaded to apply the brake. Hydraulic pressure is used to release or hold “off” the brake. DISSASSEMBLY PROCEDURE L o o s e n 2 b o l t s ( 2 2 ) a l t e r n a t e l y. S e p a r a t e p o w e r p l a t e ( 1 8 ) a s s e m b l y f r o m t h e r e m a i n d e r o f t h e b r a k e .
POWER BRAKE MASTER CYLINDER REPAIR FIGURE 20 1.0 REMOVING BRAKE VALVE FROM VEHICLE AND SEPARATlNG CYLINDER RESERVOIR SECTION FROM POWER ASSIST SECTION. Refer Figures 20 & 21. 1.1 Remove Brake Valve from vehicle by dis- connecting necessary fluid lines, dis- connecting push rod,...
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CYLINDER RESERVOIR SECTION D I S A S S E M B LY O F C Y L I N D E R R E S E RV O I R S E C T I O N . R e f e r t o F i g u r e s 1 & 3 . 2 .
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POWER ASSIST SECTION DISASSEMBLY OF POWER ASSIST SECTION. Refer to Figures 20 & 23. 4 . 0 D r a i n f l u i d f r o m u n i t b e f o r e d i s a s s e m b l i n g . 4 .
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AS S E M B LY O F P O W E R A S S I S T S E C T I O N . U s e o n l y h y d r a u l i c o i l i n P o w e r A s s i s t S e c t i o n . 5 .
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PLANETARY HUBS ASSEMBLY PROCEDURE FOR MAJOR ASSEMBLY Start with hub-spindle sub-assembly (1) with large open end up. Assemble internal gear (2) onto the spindle of hub-spindle sub-assembly (1). Place thrust washer (15) onto the spindle pilot of hub-spindle sub-assembly (1). Place thrust bearing (16) onto spindle pilot of hub-spindle sub-assembly (1).
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S e c u r e c o v e r s u b - a s s e m b l y ( 6 ) a n d r i n g g e a r ( 4 ) i n p l a c e w i t h b o l t s . U s e f o u r s h o u l d e r b o l t s ( 1 8 ) f o r c o u n t e r b o r e d h o l e s i n h u b o f h u b - s p i n d l e s u b - a s s e m b l y ( 1 ) a n d u s e b o l t s ( 1 7 ) f o r r e m a i n i n g h o l e s .
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Pl a c e t h r u s t w a s h e r s ( 3 B ) i n s i d e c a r r i e r ( 3 A ) w i t h g r e a s e d s i d e a g a i n s t c a r r i e r ( 3 A ) a n d t h e t a n g s h o u l d b e i n c u t a w a y s e c t i o n o f c a r r i e r ( 3 A ) .
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FRONT: 24 TO 1 FIGURE 24 REAR: 35 TO 1 CARRIER SUBASSEMBLY...
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HYDRAULIC PRESSURE CHECKS N O T E : D o n o t a t t e m p t t o a d j u s t t h e h y d r a u l i c p r e s s u r e s e t t i n g s o n t h i s m a c h i n e .
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HYDRAULIC CYLINDERS N O T E : R e p l a c e a l l s e a l s w h e n e v e r a c y l i n d e r i s d i s s a s s e m b l e d f o r r e p a i r. DISSASSEMBLY R e m o v e c y l i n d e r f r o m m a c h i n e .
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FIGURE 26 WIPER RING WEAR RING “O” RING ROD SEAL PISTON SEAL ROD BEARING BACKUP RING “O” RING CYLINDER BARREL “O” RING BUSHING CYLINDER ROD PISTON...
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SECTION V EMERGENCY PLUNGER AND HOUSING REPAIR To manufacture a high quality control valve having a minimum amount of leakage, each plunger is honed to fit its respective bore. It is, therefore, recommended that the valve returned to the factory to repair or replacement.
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HUSCO MODEL “5000” SECTIONAL VALVE SERVICE INFORMATION The design and construction of the HUSCO Model 5000 Check valve malfunctioning is usually the result of foreign Sectional Valve allows for easy service or replacement of matter lodging between the seat and the poppet. Examine the various sections, seals and components.
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MAINTENANCE PROCEDURES LOAD CHECK VALVES C. LOAD CHECK VALVES FIGURE 28 Load Check Valve Load check valves used on HUSCO control valves normally do not require servicing; malfunction is usually t h e r e s u l t o f f o r e i g n m a t t e r l o d g i n g b e t w e e n t h e s e a t a n d p o p p e t . DISASSEMBLY Remove valve plug, poppet spring and poppet.
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FIELD TESTING PROCEDURES FIGURE 29 Pilot Operated - Sleeve Type Main Relief Valve To set main relief valve pressure, install a pressure gauge in the inlet line and set pressure as follows Remove acorn nut and loosen jam nut. Back off pilot adjustment screw and reset so that pilot adjustment screw just seats against pilot p o p p e t .
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MAINTENANCE PROCEDURES - RELIEF VALVES FIGURE 31 . Service Port Relief Cartridge DISASSEMBLY The cartridge type service port reliefs used in the Husco valves are of the pilot poppet type with external adjustment. Any malfunctioning is usually the result of foreign matter lodging between the piston, relief valve poppet, and check valve.
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MAINTENANCE PROCEDURES - PLUNGERS FIGURE 33 Double Acting - Spring Centered Plunger (Hydraulically Balanced) SEAL REPLACEMENT A one piece molded combination wiper and seal is used at each end of the plunger. The seals are positioned with a seal ring and retained by seal plates. To replace seal at tang end of plunger, remove screws and seal plate from housing.
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MAINTENANCE PROCEDURES - RELIEF VALVES FIGURE 34 Relief Valve - Pilot Operated (External Adjustment) The Cartridge relief valve shown it, Figure -1 is of the differential area type. When fluid enters the relief valve through the hole in the piston, an unbalanced condition in this area keeps main poppet and piston tightly sealed.
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MAINTENANCE PROCEDURES - RELIEF VALVES A combination cylinder relief valve and anti-void unit is illustrated in Figure 5 8. The service port relief valve is designed to control the maximum pressure obtained in the circuit. By discharging oil to the low pressure return passage, the service port relief valve provides maximum structural protection of circuit c o m p o n e n t s .
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INTRODUCTION The following information relates to the main and auxiliary hydraulic control valves used on the LOED H a n d l e r. GENERAL INFORMATION Disassembly and repair procedures are included in this Manual for the different types of relief valves, plunger styles, check valves, and special devices incorporated in the HUSCO control valves.
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MAINTENANCE PROCEDURES - FORWARD - REVERSE VALVE (Disassembly) FIGURE 41 Step 1: Remove socket head cup screws (No. 1), spacers Continued ring groove is clean and has not been damaged (No. 2), and plunger cap (No. 3). in any way. Insert plunger (No. 4) through the Step 2: detent sleeve until the rear of the plunger is even Insert rod through all holes in tang end of plungers...
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MAINTENANCE PROCEDURE - FORWARD - REVERSE VALVE (Reassembly) FIGURE 42 Take the plunger (No. 4) out of the vise and dip Step 1: Clean all parts in solvent and blow dry with com- Step 7: the tang end in oil. Now gently insert it into the pressed air.
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TROUBLESHOOTING GUIDE FOR GEAR TYPE HYDRAULIC PUMPS FIGURE 43...
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HYDRAULIC PUMP Disassembly Remove nuts (23) and washers from Clean outside of pump thoroughly. s t u d s . M a r k t h e P u m p s e c t i o n s o n t h e s i d e n e a r e s t t o t h e d r i v e s h a f t e x t e n - s i o n s o t h a t t h e y c a n b e r e a s s e m b l e d b a c k t o t h e o r i g i n a l r e l a t i o n s h i p .
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Grasp the drive shaft extension and Using vise grip pliers, remove stud lift upward to dislodge the pressure bolts (22) from pump. (Figure 47) plate. Grasp the pressure plate between thumb and forefinger and lift straight up off the shafts. (Figure 49) FIGURE 49 FIGURE 47...
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It will be necessary to remove any Bearing plate (3) can be removed burrs from the gear “track-in” in by using method described in the body (1) before attempting to Step 14. remove pressure plate (9). After burrs have been removed, the plate Disassemble the next section by can be lifted out.
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Assembly Install back-up ring (14), o-ring If Parts 1, 2, 3, and 4 are re- (12), and retainer ring (13). placed, examine the new parts and (Figure 54) remove any nicks or burrs. flash in clean solvent. Make sure that an identifying mark is put on each new part and on the same side as it was on the old part.
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Install the isolation plate (10) Install the drive gear and idler gear. The drive gear should be in with its square edges on the suction the bore nearest the identifying port side. Install back-up ring (14), o-ring (12), and retainer (13) mark made in Step 2, with the splined end up.
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FIGURE 60 FRONT DRIVE GEAR TO BE TIMED WITH REAR DRIVE GEAR BY LINING UP A TOOTH ON REAR DRIVE WITH VALLEY OF TWO TEETH ON FRONT DRIVE TIMING SKETCH...
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Install the spline coupling (16) and Install and tighten stud bolts. O-ring (25). (Figure 61) (Figure 63) FIGURE 61 FIGURE 63 If a new flange plate (4) is used, Install dowels (20). plug (27) will have to be pressed into seal drain hole on the dis- Install body (1) with identifying charge side of the flange plate.
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Install o-ring (24) in the flange Correct the cause of interference plate. Use heavy grease to hold and reassemble the pump. the o-ring in the groove while the plate slides down over the shafts. Refer to Step 32 and use the same precautions in the final assembly of the flange plate.
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Seal Replacement Stand pump on end and loosen all The rubber lip of the seal should fasteners holding flange to body. point toward the rear of the pump Remove flange. so that the garter spring is inside. (Fig. 70) Lay the flange on a smooth clean surface and remove snap ring.
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By tightening the vise firmly, but gently, press the seal into the bore. Stop the pressure when the seal touches the shoulder inside the bore. Replace snap ring, making sure that it snaps into the groove properly. Wash the flange thoroughly in sol- vent.
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D I S A S S E M B LY Clean the outside of the motor thoroughly. Mark the motor sections on the drive shaft extension side so that they can be reassembled exactly in the same order as they were originally. (Fig. 74) FIGURE 75 Remove nuts (21) and washers (22) from the flange.
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Keeping the flange (1) as straight Use a stud driver or vise-grip pliers as possible, lift it off the shaft and remove studs (42). (Fig. 79) and stud bolts. If the flange is stuck, use a wooden mallet or plastic hammer and tap around the edge to loosen it.
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Lift drive gear (5) and idler gear Remove isolation plate (11), sealing ( 7 ) s t r a i g h t u p o u t o f t h e m o t o r strip (17), end separators (15) body.
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To disassemble the rear section, it Remove the valve body by tapping will be necessary to reverse its lightly on the plugs (39) with a soft position in the vise (rear end up). hammer. (Fig 87) (Fig. 85) FIGURE 87 FIGURE 85 Remove nut (21) and washer (22).
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To disassemble the valve from the Items (28) and (30) are not service- valve body, remove plug (39) and able separate from valve body (3). o-ring (40). (Fig. 16) Wash all of the motor parts thoroughly with clean solvent and blow them dry with compressed air.
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REASSEMBLY Take cover plate (23) and place it on a clean flat surface with the o-ring groove facing up. Install o-ring (20). (SPM20 only) Place the motor body (4) on the cover plate (SPM20) with the gear bore facing up. Make sure that the mark made in, Step 2 is facing you.
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Examine the isolation plates. You will note that they are slightly different. Choose the two having rounded edges as shown. Install these two (11) in the bottom of the motor body with the rounded edges down and in their proper location.
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FRONT DRIVE TO BE TIMED WITH REAR DRIVE BY LINING UP A TOOTH ON REAR DRIVE WITH VALLEY OF TWO TEETH ON FRONT DRIVE FIGURE 97 SKETCH ‘A’...
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Install center separator (16), end Pick up valve body (3). Turn separators (15), sealing strip (17), it so that the side which has the and isolation plates (10). (No bearings extended will face up. separators nor isolation plates in Apply enough clean, heavy grease SPM25.) (Fig.
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Position the assembly with the valve body up and install o-ring (34) and spline coupling (31). Make sure the gears are not turned from the timing position until after the other set of gears has been assembled. (Fig. 103) FIGURE 101 FIGURE 103 Lay the partially assembled unit on Install motor body (2) with the mark...
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Install stud (42). Use 10" wrench and check to see if the drive shaft will turn freely. The shaft will be tight but should S e e a p p l i c a b l e s e a l R e p l a c e m e n t turn with a maximum of 5 to 10 lb/ft.
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INSPECTION OF MOTOR PARTS In stall a piston (27) and spring (32) in each piston bore. (Fig. 107) Visually inspect all parts. There will be a gear track on the inside of the motor body. Measure the depth of this gear track. The nominal depth of this cut is .008"...
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SEAL REPLACEMENT INSTRUCTIONS SPM20 Stand the motor on end, shaft up. Use a brush and solvent and wash the flange end thoroughly. Dry it with compressed air or by thorough wiping with a clean, dry rag. This action will help to prevent foreign material from entering the motor.
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Install the snap ring, making sure it snaps into the groove properly. (Fig. 112) FIGURE 110 FIGURE 112 Position the new seal over the bore with the rubber lip entering first. Wash the flange in clean solvent, Center a press ring (or a socket blow it dry and coat the seal lips wrench of appropriate size) against with clean grease.
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SEAL REPLACEMENT INSTRUCTIONS SPM25 Stand the motor on end, shaft up. Press the old seal out of the plate. USE EXTREME CARE IN REMOVING THE SEAL. Press it straight out of the seal bore. If a punch and hammer are used, move the punch around the seal so that it causes even movement of the seal down the bore.
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Place a smooth, clean block of wood Place the seal plate between the against the rubber face of the seal. open jaws of a machinist’s vise with Carefully tighten the vise and press the cast surface against the station- the seal into the bore. The seal any jaw.
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FIGURE 118 Place the assembled seal plate over the shaft and carefully slide it down into position on the flange. Install and tighten the seal plate capscrews.
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F R O N T D R I V E M O T O R ( b e f o r e s / n 2 3 7 ) FIGURE 119...
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DISASSEMBLY C l e a n t h e o u t s i d e t h e p u m p t h o r - oughly. P l a c e t h e p u m p m a c h i n i s t ’s v i c e s e c u r e l y, s h a f t u p , u s i n g a c l e a n b l o c k...
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REASSEMBLY Remove the remaining O-ring, back- up ring, retainer ring, and isolation plates. FIGURE 128 E x a m i n e t h e t w o i s o l a t i o n p l a t e s . Yo u w i l l f i n d t h a t t h e y a r e s l i g h t l y d i f - f e r e n t .
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REASSEMBLY I n f a l l t h e O - r i n g i n p l a c e a g a i n s t t h e b a c k - u p r i n g s o t h a t i t s e a t s i t s e l f i n - EXAMPLE t o t h e g r o o v e i n t h e e d g e o f t h e b a c k - up ring.
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REASSEMBLY previous leakage been evidence, replace. (See SEAL REPLACEMENT f o r d e t a i l e d i n s t r u c t i o n s . ) FIGURE 135 Pick up the other pressure plate. Hold- bronze side down,...
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REASSEMBLY FIGURE 139 Insert two of the capscrews with washers installed into opposite holes and torque to 175 lbs. ft. Using a 10" wrench, check to see if the drive shaft will turn. Shaft will be tight but should turn freely with a max- imum of 5 to 10 lbs.
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SEAL REPLACEMENT Wa s h t h e s e a l r e t a i n e r i n s o l v e n t a n d Stand the pump on end, shaft up. b l o w d r y. Using a brush and solvent, wash the P l a c e t h e c a s t s u r f a c e o f t h e r e t a i n e r entire flange end of the pump ONLY,...
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SEAL REPLACEMENT FIGURE 144 R e p l a c e t h e O - r i n g w i n g , h e a v y g r e a s e t o h o l d i t s e c u r e l y i n t h e O - r i n g g r o o v e . C o a t t h e s h a f t...
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BEARING REPLACEMENT-INSPECTION OF PARTS INSPECTION OF PARTS BEARING REPLACEMENT MOBIL-MASTER SERIES 20 & 25 Visually inspect parte. There will be a gear track on the inside of the Mobil-Master Series Pumps pump body. Measure depth this built with highest capacity bearings gear track.
BOLT TORQUE CHART FIGURE 146 Grade 5--3 radial dashes 1 2 0 d e g r e e s a p a r t . Grade 8--6 radial dashes 6 0 d e g r e e s a p a r t . FIGURE 147 B o l t s f o u n d...
HYDRAULIC FITTING TORQUE CHART W i p e f i t t i n g s . Apply LOCTITE Hydraulic Sealant first (closest f l a n g e o r s e a s ) o f t h e f i t t i n g t h r e a d s . S e a t f l a n g e h a n d t i g h t , t h e n t o r q u e t o s p e c i f i c a t i o n .
FIGURE 149 ELECTRIC SCHEMATIC -SOLENOID VALVE CIRCUIT SHOWN -IN 4-WHEEL -HI-LO SWITCH SHOWN IN LO -SERIES/PARALLEL SWITCH SHOWN -IN PARALLEL MODEL 534 WITH -FLOW SWITCH SHOWN IN LOW FLOW POSITION -NEUTRAL START SWITCH SHOWN IN NEUTRAL CHRYSLER ENGINE...
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FIGURE 150 ELECTRICAL SCHEMATIC -SOLENOID VALVE CIRCUIT SHOWN IN 4-WHEEL -A-B SWITCH SHOWN IN B MODEL 534 WITH -SERIES/PARALLEL SWITCH SHOWN IN PARALLEL -NEUTRAL START SWITCH SHOWN IN NEUTRAL FORD ENGINE...
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