Gradall LOED 534A, Service Manual

Page 1: ...trademark for hudraulic excavators built by The Gradall Co THE COMPANY 406 MILL AVENUE S W NEW PHILADELPHIA OHIO 44663 216 339 2211 This manual describes the LOED Handler as origionally designed and...

Page 2: ...ir Power master cylinder repair Planetary hub repair Hydraulic pressure adjustment Hydraulic cylinder repair Valve repair Pump and motor troubleshooting Pump repair Rear motor repair Front motor repai...

Page 3: ...you avoid injury and damage to the equipment These notes are not intended to cover all eventualities it would be impossible to anticipate and evaluate all possible applications and methods of operati...

Page 4: ...ment parts can be ordered from your nearest LOED Handler distributor Always furnish the machine model and serial number as well as a complete description of the part and the part number This enables t...

Page 5: ...MODEL 534 6 000 Capacity 4 FIGURE 1...

Page 6: ...NCLATURE 5 FORKS FORKFRAME BOOMHEAD TILTCYLINDER THREESECTIONBOOM LIFTCYLINDER COMPENSATINGCYLINDER HYDRAULICRESERVOIR FUELTANK PLANETARYHUB CROWDCYLINDER LEVELCYLINDER 1 2 3 4 5 6 7 8 9 10 11 12 FIGU...

Page 7: ...of section Pull chain out back of boom REASSEMBLY Note Replace chain ends whenever chain is replaced Use fish wire to pull new chain from back of boom to ears in bottom of section one Lay chain over...

Page 8: ...rongback Hose Retainer Nuts Extension Chain Nuts Section One Section Two Take up Beam Take up Beam Bracket Section Three Retraction Chain Section Three Chain Ears Extension Chain 1 2 3 4 5 6 7 8 9 10...

Page 9: ...SSEMBLY Note Replace chain ends whenever chain is replaced Pin extension chain to ears at back of section three Lay chain and hoses in hose guide pan Carefully slide take up beam and guide pan into bo...

Page 10: ...Retraction Chain Retraction Chain Ears Section 1 Section Three Retraction Chain Ears Section 3 9 Guide Pan Strongback Hose Retainer Nuts Extension Chain Nuts Section One 1 2 3 4 5 6 7 8 9 FIGURE 4...

Page 11: ...t back of section three Carefully pull new hose along guide pan and around reel while pulling old hose out back of boom Connect new hose to tube line at rear of section three Reassemble hose retainer...

Page 12: ...o p A d j u s t l i n k a g e C s o m o v e m e n t o f l e v e r f r o m 1 2 a n d 3 4 m o v e s s p o o l f r o m f u l l d o w n t o f u l l u p A d j u s t l i n k a g e D s o s p o o l m o v e s...

Page 13: ...e v e r s e l e v e r i n f o r w a r d d e p r e s s b r a k e p e d a l u n t i l a l l s l o p i s t a k e n u p i n t h e b r a k e l i n k a g e A t t h a t p o i n t t h e s p o o l i n t h e f...

Page 14: ...a piece of wire through the stem to make sure it Is not plugged IMPORTANT TIREandRIMSERVICINGSAFETY INSPECTION Clean rims and repaint to stop detrimen tal effects of corrosion and facilitate checking...

Page 15: ...D RIM ON VEHICLE Don t try to drive an assembled or par tially assembled tire and rim over a cast spoke wheel by hammering Stop deflate and examine to determine the reason for the improper fit Look fo...

Page 16: ...is not seated DO NOT INFLATE UNTILLOCK RING IS PROPERLY SEATEDAND LOCKED KW KB KWX TYPE RIMS Incorrect KW KB and KWX type rims have unique configurations that deserve special mention Make sure your as...

Page 17: ...d Broken Rims and Components Replace Distorted Rims Components Distorted rims and components will not properly lock together They should be replaced This hazard besides making the tire rim assembly un...

Page 18: ...bases which almost always create an unsafe operating condition The pictures contained herein are intended only to depict some examples of incorrect procedures They are not intended to show all incorre...

Page 19: ...from the power plate 18 by introducing low pressure air 15 psi into the hydraulic inlet Make sure piston is directed away from the operator Remove O rings 15 17 and teflon back up rings 14 16 from the...

Page 20: ...19 FIGURE 19...

Page 21: ...T SECTION Refer to Figures 20 21 1 1 Remove Brake Valve from vehicle by dis connecting necessary fluid lines dis connecting push rod and removing mounting bolts Drain fluid from assembly 1 2 Separate...

Page 22: ...058 Refer to Figures 20 22 Clean all parts thoroughly before assembling Install seat item l3 and check valve item 12 in bore of housing Attach retainer item 10 to small end of spring item 11 Install...

Page 23: ...e piston item 31 from piston item 25 Remove spring item 30 from piston item 25 Remove v cup seals items 24 26 and back up rings items 23 27 from piston item 25 Remove piston item 29 from piston item 2...

Page 24: ...a l l s p r i n g i t e m 3 0 o n p i s t o n i t e m 2 5 I n s t a l l p i s t o n i t e m 3 1 o v e r s p r i n g i t e m 3 0 a n d p i s t o n i t e m 2 5 I n s t a l l r e t a i n i n g r i n g i...

Page 25: ...on a flat surface with large gears up Find marked punch marked teeth on the large gears Rotate until the marks are in a straight up position See Figure Place ring gear 4 over large gears of carrier s...

Page 26: ...is a loose fit and should not be pressed I n v e r t t h e p a r t i a l a s s e m b l y o f h u b s p i n d l e 1 A 1 B 1 C 1 D 1 E a n d 1 G D o n o t l e t s p i n d l e 1 A s l i p f r o m h u b 1...

Page 27: ...s i d e a n d c a r r i e r 3 A w a l l N O T E T h e h o l e i n p l a n e t s h a f t 3 E m u s t l i n e u p w i t h p i n h o l e i n c a r r i e r 3 A w a l l T h e c h a m f e r e d s i d e o f...

Page 28: ...CARRIER SUBASSEMBLY FRONT 24 TO 1 REAR 35 TO 1 27 FIGURE 24...

Page 29: ...r e a d 2 5 0 0 p s i TILTCIRCUITPORTRELIEFS C o n n e c t a 5 0 0 0 p s i g a u g e t o t e s t p o i n t 5 Rotate the forks full down A t 1 2 t h r o t t l e r a i s e t h e b o o m G a u g e s h o...

Page 30: ...a t e t h r e a d s w i t h h y d r a u l i c o i l a n d t o r q u e n u t t o s p e c i f i c a t i o n 1 Nut 150 175 lb ft 1 1 2 600 650 1 3 4 950 1000 2 1 2 1800 2000 L u b r i c a t e p i s t o...

Page 31: ...WEARRING O RING PISTONSEAL NUT CYLINDERBARREL BUSHING CYLINDERROD 1 2 3 4 5 6 7 WIPERRING RODSEAL RODBEARING BACKUPRING O RING O RING PISTON 8 9 10 11 12 13 14 31 FIGURE 26...

Page 32: ...Thoroughly flush valve housing grease detents and other sliding parts and reassemble valve During assembly do not damage plunger seals If a new plunger is required refit new plunger to the respective...

Page 33: ...VALVE SERVICE INFORMATION Check valve malfunctioning is usually the result of foreign matter lodging between the seat and the poppet Examine seat for dirt or metal particles Check seating face for nic...

Page 34: ...CTION AND REPAIR Clean parts with solvent and blow dry with compressed air Examine poppet and poppet seat for nicks or scratches Minor nicks or scratches can be removed by lapping poppet and seat with...

Page 35: ...nut and install acorn nut Retest to check pressure setting NOTE THE ABOVE SETTING WILL PRODUCE A RELATIVELY CONSTANT RELIEF VALVE SETTING ACROSS FULL ENGINE RPM To set pressure on the Service Port Rel...

Page 36: ...if grooves or ridges are present the valve must be returned to Husco for re machining All seats and seating surfaces should be smooth and free of nicks scratches or grooves Examine O rings and back u...

Page 37: ...plunger cap to housing DISASSEMBLY NOTE DURING DISASSEMBLY PLUNGERS MUST BE TAGGED TO ASSURE REASSEMBLY TO THE SAME BORE Remove round head screws seal plate seal and seal ring from tang end of housing...

Page 38: ...corn nut lock nut and the two washers from the adjustment screw Remove all O rings and spiral back up rings INSPECTION AND REPAIR NOTE THE MOST COMMON CAUSE OF RELIEF VALVE FAILURE IS DAMAGED OR FATIG...

Page 39: ...ffer ential area between diameters A and B main poppet D and check valve poppet K are tightly seated See Fig 35 Step 3 The loss of oil behind piston C effected by the opening of pilot poppet E causes...

Page 40: ...sive wear or dam age occurs to the plunger or bore return valve to factory for rebuilding or replacement NOTE Remove valve from machinery and thoroughly clean the exterior before attempting any disass...

Page 41: ...SECTION II TROUBLE SHOOTING 41 FIGURE 40...

Page 42: ...ntinued Step 13 Step 14 Step 15 Step 16 Step 17 Step 18 Step 19 42 ring groove is clean and has not been damaged in any way Insert plunger No 4 through the detent sleeve until the rear of the plunger...

Page 43: ...RSEVALVE Reassembly Take the plunger No 4 out of the vise and dip the tang end in oil Now gently insert it into the plunger bore of the housing No 11 being careful not to move the detent sleeve No 9 I...

Page 44: ...TROUBLESHOOTING GUIDE FOR GEAR TYPE HYDRAULIC PUMPS 44 FIGURE 43...

Page 45: ...pump and causing leakage at the port connectors Figure 45 HYDRAULICPUMP Disassembly Remove nuts 23 and washers from studs Remove pump from vise and set pump on bench with shaft end up Coat the shaft e...

Page 46: ...retainer 13 o ring 12 back up ring 14 and iso lation plate 10 Figure 48 Grasp the drive shaft extension and lift upward to dislodge the pressure plate Grasp the pressure plate between thumb and forefi...

Page 47: ...e ring retainer 13 o ring 12 back up ring 14 and isolation plate 10 Remove body 1 Using wood mallet or plastic hammer tap the sides of the body With the other hand lift body off dowel pins Remove spli...

Page 48: ...ection examine the two isolation plates 10 and 11 You will find that plate 11 has rounded edges Install this plate on the suction side of the body with the rounded edges down Figure 53 Assembly Instal...

Page 49: ...s square edges on the suction port side Install back up ring 14 o ring 12 and retainer 13 on the discharge side Figure 58 Install o ring 25 in the bearing plate 3 on the side which has the bearings ex...

Page 50: ...TIMING SKETCH 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 50 FIGURE 60...

Page 51: ...cing you and with gear bore up To assemble this pumping section repeat Steps 23 through 31 using gears 7 and 5 Install dowels 20 in body 1 Figure 62 Install and tighten stud bolts Figure 63 If a new f...

Page 52: ...ides down over the shafts Refer to Step 32 and use the same precautions in the final assembly of the flange plate Figure 65 Install washers 26 and nuts 23 Tighten two opposite nuts Use a 10 wrench to...

Page 53: ...king care that it is centered over the seal Fig 71 Seal Replacement Stand pump on end and loosen all fasteners holding flange to body Remove flange Lay the flange on a smooth clean surface and remove...

Page 54: ...same manner Take care not to damage the bores After the old bearings have been removed wash all of the parts thoroughly in solvent Press in the new body bearings They should protrude above the surface...

Page 55: ...REAR DRIVE MOTOR 55 FIGURE 72...

Page 56: ...PARTS IDENTIFICATION 56 FIGURE 73...

Page 57: ...re originally Fig 74 Securely fasten the motor in a machinist s vise shaft up Use a cream block of wood between each flat side of the motor and the vise jaws This will protect the machined surfaces fr...

Page 58: ...late Release the drive shaft and lift the pressure plate from the body Fig 80 58 8 9 FIGURE 77 FIGURE 79 FIGURE 78 FIGURE 80 Keeping the flange 1 as straight as possible lift it off the shaft and stud...

Page 59: ...1 FIGURE 83 FIGURE 82 FIGURE 84 Lift drive gear 5 and idler gear 7 straight up out of the motor body Fig 81 To remove the bottom pressure plate 9 13 in SPM25 from the motor body use an adjustable slee...

Page 60: ...st of the parts are inter changeable the body and gears may not be Fig 88 15 16 17 18 19 20 21 60 FIGURE 85 FIGURE 87 FIGURE 86 FIGURE 88 To disassemble the rear section it will be necessary to revers...

Page 61: ...dry with compressed air This action should remove any foreign matter trapped in the motor Inspect the parts carefully For detailed instructions see Inspec tion of Parts section 61 22 23 24 25 26 FIGU...

Page 62: ...Make sure that the mark made in Step 2 is facing you If a new body is used it does not matter which way the body faces Fig 91 REASSEMBLY 27 28 29 Install center separator 16 end separator 15 and seal...

Page 63: ...PLATE Coat the journals of drive gear 6 with clean hydraulic oil and with the splined end up insert it into the bore nearest you DO NOT DROP IT INTO PLACE Slide it into place gently Dropping it will d...

Page 64: ...FRONT DRIVE TO BE TIMED WITH REAR DRIVE BY LINING UP A TOOTH ON REAR DRIVE WITH VALLEY OF TWO TEETH ON FRONT DRIVE SKETCH A 64 FIGURE 97...

Page 65: ...acing you and the o ring facing down the shaft until it makes contact with the dowels Caution should be used from this point on to prevent the bearings from pinching or up setting the back up rings as...

Page 66: ...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 Install motor body 2 wit...

Page 67: ...down until they are snug Place the motor in a machinist vise using a clean block of wood between the flats on each side of the motor and the jaws of the vise Tighten two opposite nuts on each end and...

Page 68: ...ts show excessive wear replace them with new parts For further information on inspec tion of parts see applicable por tions of PUMP TROUBLESHOOTING GUIDE or DIAGNOSING TYRONE GEAR PUMP FAILURES INSPEC...

Page 69: ...jaws of a vise or other appropriate support Use a punch and mallet or a light hammer and tap the old seal out of the bore USE EXTREME CARE IN THIS PROCEDURE Do not mar the machined surfaces of the fl...

Page 70: ...e vise and press the seal into bore until it seats against the shoulder in the bore Fig 111 7 70 Install the snap ring making sure it snaps into the groove properly Fig 112 8 Wash the flange in clean...

Page 71: ...s 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 moveme...

Page 72: ...and press the seal into the bore The seal will seat with about half of its thickness dimension still protruding from the bore This protrusion serves as a pilot while reinstalling the plate on the flan...

Page 73: ...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 73 12 FIGURE 118...

Page 74: ...FRONT DRIVE MOTOR before s n 237 74 FIGURE 119...

Page 75: ...75 FIGURE 120...

Page 76: ...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 o f w o o d b e t w e e n t h e f l a t s o n e i t h e r s i d e a n d t h e j a w s o f t h e v i c e T h i s k e e p s f r o m m a r r i n...

Page 77: ...mp body Using clean hydraulic oil coat the inside of the pump body liberally This will insure easier assembly Examine the two isolation plates You will find that they are slightly dif f e r e n t C h...

Page 78: ...back up ring so that it seats itself in to the groove in the edge of the back up ring EXAMPLE Model No 25660A D Denotes Counter clockwise Rotation Model No 25660C D Denotes Clockwise Rotation If the p...

Page 79: ...g Install the back up ring Install the O ring as in the bottom of the pump Examine the seal If it is damaged or if REASSEMBLY previous leakage has been evidence replace See SEAL REPLACEMENT for detail...

Page 80: ...ght but should turn freely with a max imum of 5 to 10 lbs torque If shaft will not turn as stated dis assemble the pump and examine for burrs or foreign material causing build up or interference in th...

Page 81: ...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 blow dry 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 against the stationary jaw of a machin ist s vise Place the metal fa...

Page 82: ...t securely in the O ring groove Coat the shaft liberally with heavy grease to protect the lips of the seal Replace the retainer assembly by care fully sliding over the shaft R e p l a c e t h e c a p...

Page 83: ...screw driver Take care not to damage the bores After removal wash the parts thoroughly in sol vent Press in the body bearings so that they protrude above the surface 220 230 Press flange bearings in...

Page 84: ...m o v e d w i p e d c l e a n a n d r e i n s t a l l e d u s i n g L O C T I T E 2 4 2 b l u e m e d i u m s t r e n g t h o r L O C T I T E 2 7 1 red high strength Grade 5 3 radial dashes 120 degree...

Page 85: ...i t h e r s w a g e d o r b r a z e d t y p e T h e s w i v e l n u t s w i l l n o r m a l l y withstand this torque for a minimum of 15 repeated assemblies T h e t o r q u e r e q u i r e d t o s e...

Page 86: ...SHOWN IN 4 WHEEL HI LO SWITCH SHOWN IN LO SERIES PARALLEL SWITCH SHOWN IN PARALLEL FLOW SWITCH SHOWN IN LOW FLOW POSITION NEUTRAL START SWITCH SHOWN IN NEUTRAL 86 ELECTRIC SCHEMATIC MODEL 534 WITH CHR...

Page 87: ...SOLENOIDVALVECIRCUITSHOWNIN4 WHEEL A BSWITCHSHOWNINB SERIES PARALLELSWITCHSHOWNINPARALLEL NEUTRAL START SWITCH SHOWN IN NEUTRAL ELECTRICAL SCHEMATIC MODEL 534 WITH FORD ENGINE 87 FIGURE 150...

Page 88: ...FIGURE 150 FIGURE 151 88...

Page 89: ...FIGURE 152 89...

Page 90: ...FIGURE 151 FIGURE 153 90...

Page 91: ...FIGURE 154 91...