Mustang 634 User manual

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

Indicator and Operation Symbols
Read Operator’s
Manual Turn SignalsParking Brake Safety Alert
Fuel
Lights
Volume Half FullVolume Full
Engine Oil
Pressure
Hazard Flasher
Battery
Work Lights
Clutch Disengaged
Transmission
Temperature
Fan
Frame Level Left
Crab Steer
Lower Load
2-Wheel Steer
Raise Load
4-Wheel Steer
Engine Coolant
Temperature Hourmeter
Retract Load
Volume Empty
Starting Aid
Injection
Tilt Rearward
Wiper/Washer
Extend LoadTilt Forward
Hydraulic OilEngine Start Horn
Frame Level Right
Clutch Engaged
Ignition Off Ignition ON
Outriggers Down
(right side shown)
Outriggers Up
(right side shown)
Brake Failure
Diesel Fuel Engine Fault
Shutdown Override

PRINTED IN U.S.A. 1913229/CP0615
Table of Contents
Chapter Description Page
International Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
9Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
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.
The model and serial numbers for this machine are on a decal located inside the operator’s station.
MODEL NO. 634
SERIAL NO.
ENGINE SERIAL NO.

913229/CP0615 2PRINTED IN U.S.A.
The information in this Operator’s Manual was written to give the owner/operator assistance in preparing, adjust-
ing, maintaining and servicing of the Telehandler. More important, this manual provides an operating plan for safe
and proper use of the machine. Major points of safe operation are detailed in the SAFETY chapter of this manu-
al.
The Mustang Manufacturing Company asks that you read and understand the contents of this
manual COMPLETELY and become familiar with the machine, before operating it.
This Telehandler is primarily intended for use as a material handler. However, it may be equipped with an option-
al system: the Work Platform Safety (WPS) System, which is intended for use when lifting personnel. When there
is no other practical option available, this machine, when equipped with the WPS System, is approved for use to
lift personnel, but only with an approved work platform, with the WPS System activated, and in full compliance
with the “Mandatory Work Platform Safety Rules” (see SAFETY chapter).
The use of this Telehandler is subject to certain hazards that cannot be eliminated by mechanical means, but only
by the exercise of intelligence, care and common sense. It is therefore essential to have competent and careful oper-
ators, who are not physically or mentally impaired, and who are thoroughly trained in the safe operation of the
equipment and the handling of the loads.
Throughout this manual information is provided that is set in italic type and introduced by the word IMPORTANT
or NOTE. Be sure to read carefully and comply with the message or directive given. Following this information
will improve operating or maintenance efficiency, help to avoid breakdowns or damage, and extend the machine’s
life. A chart of standard hardware torques is located in the back of this manual.
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.
If this machine was purchased “used,” or if the owner’s addrress has changed, please provide your Mustang deal-
er or Mustang Manufacturing Company Service Department with the owner’s name and current address, along
with the machine model and serial number. This will allow the registered owner information to be updated, so that
the owner can be notified directly in case of an important product issue, such as a safety update program.
“Right” and “left” are determined from a position sitting on the seat and facing forward.
Our wide dealership network stands ready to provide any assistance required, including providing genuine
Mustang service parts. All parts should be obtained from or ordered through your Mustang dealer. Give complete
information about the part, and include the model and serial number of the machine. Record the serial number in
the space provided on the previous page, as a handy record for quick reference.
Mustang Manufacturing Company reserves the right to make changes or improvements in the design or construc-
tion of any part without incurring the obligation to install such changes on any previously delivered unit.
Chapter 1
INTRODUCTION
Mustang, in cooperation with the Society of Automotive Engineers, has
adopted this Safety Alert Symbol
to identify potential safety hazards, which, if not properly avoided, could
result in injury. When you see this symbol in this manual or on the
machine itself, you are reminded to BE ALERT! Your personal safety is
involved!

PRINTED IN U.S.A. 3913229/CP0615
Identification
Telescopic Boom
Operator’s Station
Quickattach
System
Tilt Cylinder
Slave Cylinder
Dash Indicators
and Controls
Seat
Fuel Tank
Rear Access Cover
with Rear Lights
and Reverse Alarm
Rear Boom
Access Cover
Lift Cylinder
Frame Leveling
Cylinder
Hydraulic Tank
Extend Cylinder
Air Cleaner
Exhaust Pipe
Auxilluary
Hydraulics
(not shown)
Boom Angle
Indicator
Mirror

913229/CP0615 4PRINTED IN U.S.A.
Chapter 2
SPECIFICATIONS
Lifting Performance
Maximum lift capacity:
6000 lbs. (2721 kg)
Maximum lift height:
34’-3” (10.44 m)
Capacity at maximum lift height:
4000 lbs. (1820 kg)
Max. forward reach to load center:
23’-3” (7.09 m)
Capacity at maximum forward reach:
900 lbs. (408 kg)
Maximum below grade reach:
24” (610 mm)
Frame Leveling:
10oleft/10oright
General Dimensions
Based on standard machine equipped
with listed tires, 48” masonry carriage
and 48” pallet forks.
Recommended tire type:
15.00 x 19.5 12-ply
405/70 R 20 x M27 Traction Type
Overall length, less forks:
16’-0” (4.88 m)
Overall width:
7’-10” (2.39 m)
Overall height:
7’-9” (2.36 m)
Ground clearance: 14” (356 mm)
Wheel base: 9’-2” (2.8 m)
Outside turn radius: 12’-6” (3.81 m)
Machine weight:
15,100 lbs. (6855 kg)
Instrumentation
Gauges: Fuel level, hourmeter
and coolant temperature
Monitoring lights:
Engine oil pressure, alternator,
transmission oil temperature,
brake failure
Visual indicators:
Boom angle, frame angle
Steering System
Steer Valve: Fixed displacement rotary
Displacement/Rev: 17.9 cu. in. (293 cc)
System pressure: 2000 psi (138 bar)
Steer cylinders: 1 per axle
Steer mode valve:
3-position, 4-way solenoid with
dash-mounted switch actuation
Steer modes: 2-wheel, 4-wheel, crab
Braking System
Service brakes: Oil-immersed inboard
hydraulic wet-disc type; seperate front
and rear systems;
Manual foot pedal actuation
Parking brake: Spring-applied, hydraulic-
release disc-type in front axle
Actuation is electric switch with engine
running, automatic with engine off.
Electrical System
Type: 12-volt, negative ground
Battery: 950 cold cranking amps
Circuit protection: Fuse panel
Backup alarm: 107 dB(A)
Horn: 111 dB(A)
Standard on all models:
Brake lights, rear backup light, neutral
start switch
Alternator: 65-amp
Service Capacities
Cooling System: 17.2 qts. (16.3 L)
50/50 mixture
Anti-freeze protection: -34oF (-31oC)
Pressure cap: 10 psi (69 kPa)
Fuel tank: 29 gals. (110 L)
Hydraulic tank and
system: 35 gals. (133 L)
Transmission and cooler: 24 qts. (22.7 L)
Axles:
Differentials: 9.6 qts. (9 L) ea.
Hubs: 0.6 qts. (0.5 L) ea.
Transmission
Type: Clark Powershift T12000
Speeds: 3 fwd / 3 rev
Torque converter:
Single-stage, dual-phase
Travel Speeds:
1st gear: 3.6 mph (5.8 km/h)
2nd gear: 7.9 mph (12.7 km/h)
3rd gear: 20.2 mph (32.5 km/h)
Axles (front and rear)
Type: Dana
Drive/steer, open differential, double
reduction planetary, full-time four-
wheel drive
Overall ratio: 15.4:1
Engine Options
Common to all options:
In-line 4-cycle, 4-cylinder, direct-
injection diesel fuel system, in-line
fuel filter w/water trap, positive
pressure lubrication, liquid
pressurized cooling system,
18” (457 mm) blower fan,
dry single-element air cleaner,
spin-on oil filter.
Turbocharged aspiration:
John Deere 4045T
276 cu. in. (4523 cc) displacement
99 hp (74 kW) @ 2500 rpm
Oil capacity: 14 qts. (13.3 L)
Turbocharged aspiration:
John Deere 4045T
276 cu. in. (4523 cc) displacement
115 hp (86 kW) @ 2500 rpm
Oil capacity: 14 qts. (13.3 L)
Hydraulic System
Type: Open-center
Pump: Single-section gear type
Displacement / revolution:
2.7 cu. in. (44.3 cc)
Flow @ 2500 RPM:
29 gpm (110 L/min)
Main relief pressure:
3000 psi (207 bar)
Steer relief pressure:
2000 psi (138 bar)
Hydraulic filter:
In-tank return type, 10 micron
media, replaceable element.
Rated flow: 100 gpm (379 L/min)
Rated pressure: 100 psi (690 kPa)
By-pass pressure (full flow):
25 psi (172 kPa)
Hydraulic strainer:
In-tank suction, 149 micron media,
replaceable element.
Rated flow: 50 gpm (189 L/min)
By-pass pressure: 3 psi (21 kPa)

PRINTED IN U.S.A. 5913229/CP0615
Chapter 3
CHECKLISTS
PRE-DELIVERY
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
is taken.
Check that:

NO parts of machine have been damaged in shipment.
Check for such things as dents and loose or missing parts;
correct or replace components as required.
 Battery is securely mounted and not cracked. Cable con-
nections are tight. Electrolyte at proper level.
 Cylinders, hoses and fittings are not damaged, leaking or
loosely secured.
 Oil, fuel and air filters are not damaged, leaking or loosely
secured.
 All grease fittings have been properly lubricated and no fit-
tings are missing; see Lubrication chapter of this manual.
 Wheel nuts are torqued to 450 ft-lbs (610 Nm).
 Tires are inflated to 55 psi (380 kPa) cold.
 Hydraulic system reservoir, engine crankcase, engine
coolant, transmission and axles are filled to the proper
operating fluid levels.
 All adjustments have been made to comply with the set-
tings given in this manual and in the separate engine man-
ual.
 All guards, shields and decals are in place and securely
attached.
 Model and serial numbers for this unit are recorded in
space provided on this page and page 1.
Check that:

All indicators (lamps, switches, etc.) function properly.
 All hand and foot controls operate properly.
 The WPS System operates properly (if equipped). Refer to
Service and Storage chapter for the procedure to check the
WPS System.
 Boom, Quick-attach System with attachment tool and
frame level control all function properly.
 No hydraulic system leaks when under pressure.
 Listen for abnormal noises or vibrations; if detected, deter-
mine their cause and repair as necessary.
I acknowledge that the pre-delivery procedures were per-
formed on this unit as outlined above.
Dealership’s Name
Dealer Representative’s Name
Date Checklist Filled Out
Machine Model # Machine Serial # Engine Serial #
DELIVERY
Check that:
The following Checklist is an important reminder of valu-
able information that MUST be passed on to the customer at
the time the unit is delivered. Check off each item as you
explain it to the customer.
 Review with the customer the contents of the AEM
Safety Manual for the following:
 The Index at the back, for quickly locating topics;
 The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
the machine.
 The Lubrication, Service and Storage chapters for informa-
tion regarding proper maintenance of the machine. Explain
that regular lubrication and maintenance are required for
continued safe operation and long life.
 Give this Operator’s Manual and the AEM Safety Manual
to the customer and instruct them to be sure to read and
completely understand their contents before operating the
unit.
 Remind the customer of U.S. OSHA regulation 1910.178
(l), which specifies operator training requirements.
 Explain that the customer must consult the engine manual
(provided) for related specifications, operating adjustments
and maintenance instructions.
 Completely fill out the Owner’s Registration, including
customer’s signature, and return it to the Company.
Customer’s Signature
Date Delivered
Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.
(Dealer’s File Copy - Remove at Perforation)

913229/CP0615 6PRINTED IN U.S.A.
INTENTIONALLY BLANK
(To be removed as Dealer’s file copy)

PRINTED IN U.S.A. 7913229/CP0615
(Pages 5 and 6 have been removed at perforation)
Chapter 3
CHECKLISTS
PRE-DELIVERY
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
is taken.
Check that:

NO parts of machine have been damaged in shipment.
Check for such things as dents and loose or missing parts;
correct or replace components as required.
 Battery is securely mounted and not cracked. Cable con-
nections are tight. Electrolyte at proper level.
 Cylinders, hoses and fittings are not damaged, leaking or
loosely secured.
 Oil, fuel and air filters are not damaged, leaking or loosely
secured.
 All grease fittings have been properly lubricated and no fit-
tings are missing; see Lubrication chapter of this manual.
 Wheel nuts are torqued to 450 ft-lbs (610 Nm).
 Tires are inflated to 55 psi (380 kPa) cold.
 Hydraulic system reservoir, engine crankcase, engine
coolant, transmission and axles are filled to the proper
operating fluid levels.
 All adjustments have been made to comply with the set-
tings given in this manual and in the separate engine man-
ual.
 All guards, shields and decals are in place and securely
attached.
 Model and serial numbers for this unit are recorded in
space provided on this page and page 1.
Check that:

All indicators (lamps, switches, etc.) function properly.
 All hand and foot controls operate properly.
 The WPS System operates properly (if equipped). Refer to
Service and Storage chapter for the procedure to check the
WPS System.
 Boom, Quick-attach System with attachment tool and
frame level control all function properly.
 No hydraulic system leaks when under pressure.
 Listen for abnormal noises or vibrations; if detected, deter-
mine their cause and repair as necessary.
I acknowledge that the pre-delivery procedures were per-
formed on this unit as outlined above.
Dealership’s Name
Dealer Representative’s Name
Date Checklist Filled Out
Machine Model # Machine Serial # Engine Serial #
DELIVERY
Check that:
The following Checklist is an important reminder of valu-
able information that MUST be passed on to the customer at
the time the unit is delivered. Check off each item as you
explain it to the customer.
 Review with the customer the contents of the AEM
Safety Manual for the following:
 The Index at the back, for quickly locating topics;
 The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
the machine.
 The Lubrication, Service and Storage chapters for informa-
tion regarding proper maintenance of the machine. Explain
that regular lubrication and maintenance are required for
continued safe operation and long life.
 Give this Operator’s Manual and the AEM Safety Manual
to the customer and instruct them to be sure to read and
completely understand their contents before operating the
unit.
 Remind the customer of U.S. OSHA regulation 1910.178
(l), which specifies operator training requirements.
 Explain that the customer must consult the engine manual
(provided) for related specifications, operating adjustments
and maintenance instructions.
 Completely fill out the Owner’s Registration, including
customer’s signature, and return it to the Company.
Customer’s Signature
Date Delivered
Start the machine and test-run the unit while
checking that proper operation is exhibited by all
controls.

913229/CP0615 8PRINTED IN U.S.A.
Chapter 4
SAFETY
Mustang Manufacturing Company ALWAYS takes the
operator’s safety into consideration when designing its
machinery, and guards exposed moving parts for
his/her protection. However, some areas cannot be
guarded in order to assure proper operation. Further,
this Operator’s Manual and decals on the machine
warn of additional hazards and should be read and
observed closely.
REMEMBER! It is the owner’s responsibility for com-
municating information on the safe use and proper
maintenance of this machine! This includes providing
understandable interpretations of these instructions
for operators who are not fluent in reading English.
It is the responsibility of the operator to read and
understand the Operator’s Manual and other informa-
tion provided and use the correct operating procedure.
Machines should be operated only by qualified opera-
tors.
MANDATORY SAFETY SHUTDOWN
PROCEDURE
BEFORE cleaning, adjusting, lubricating or ser-
vicing the unit:
1. Stop machine on a level surface. (AVOID park-
ing on a slope, but if necessary, park across the
slope and block the tires.)
2. Fully retract the boom and lower the attach-
ment tool to the ground. Idle engine for gradual
cooling.
3. Place controls in neutral and apply parking
brake.
4. Shut off the engine and remove the key.
ONLY when you have taken these precautions can
you be sure it is safe to proceed. Failure to follow
the above procedure could lead to death or serious
bodily injury.
The above Safety Alert Symbol means ATTENTION!
ALWAYS BE ALERT! YOUR SAFETY IS
INVOLVED! It stresses an attitude of “Heads Up for
Safety” and can be found throughout this Operator’s
Manual and on the machine itself.
Before operating this equipment, read and
study the following safety information. In
addition, be sure that everyone who operates
or works with this equipment is familiar with
these safety precautions.
DANGER
“DANGER” indicates an imminently haz-
ardous situation which, if not avoided, will
result in death or serious injury.
WARNING
“WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION
“CAUTION” indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also alert to
unsafe practices.