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Service Manual

Models
3508PS, 3509PS,
3512PS, 3513PS,
4008PS, 4009PS,
4012PS, 4013PS,
4017PS,
Agrovector
40.8, 40.9
31200206

Revised
June 15, 2011

An Oshkosh Corporation Company


EFFECTIVITY PAGE

September 11, 2007 - A - Original Issue Of Manual


April 4, 2008 - B - Revised pages 2.7, 2-8, 3.12, 3.27, 5.11, 7.3, 7.7, 7.8, 8.2, 8.9, 9.10, 9.28 and pages 9.30 thru 9.70.
Added platform information.
June 15, 2011 - C - Update all Loctite® 242TM, to Loctite® 243TM. Added models 40.8 & 40.9. Revised page numbering.
Revised pages 1-3, 2-3 thru 2-9, 2-13, 8-6 thru 8-16, 9-11 thru 9-21 & 9-34 thru 9-45.

31200206 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 a
EFFECTIVITY PAGE

b 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 31200206
SECTION CONTENTS
Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology - Two and Three Section Boom . . . . . . . . . . . 3.3
3.2 Boom System - Two and Three Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3 Boom Assembly Maintenance - Two and Three Section Boom . . . . . . . . . . . . . . . . . . . 3.4
3.4 Boom System Component Terminology - Four Section Boom. . . . . . . . . . . . . . . . . . . . 3.8
3.5 Boom System - Four Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.6 Boom Assembly Maintenance - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.7 Boom Extend and Retract Chains Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.8 Boom Section Separation Adjustment - Four Section Boom . . . . . . . . . . . . . . . . . . . . . 3.21
3.9 Hose Carrier Assembly - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.11 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28

Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

3508PS,3509PS,3512PS,3513PS,4008PS,4009PS,4012PS,4013PS,4017PS,40.8,40.9 i
Section Subject Page

Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

Section 7
Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.7 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.8 Auxiliary Pump (Platform Equipped Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.9 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26

ii 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section Subject Page

Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.3 Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.7 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
9.8 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.9 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.11 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.12 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.13 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.14 Switches, Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.15 Load Stability Indicator (LSI) -
8, 9, 12 & 13M Before S/N 1160005993 excluding 1160005949 & 1160005950
17M Before S/N 1160005937 including 1160005952, 1160005960, 1160005963,
1160005966 & 1160005978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
9.16 Load Stability Indicator (LSI) -
8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950
17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963,
1160005966 & 1160005978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38
9.17 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46

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Section Subject Page

iv 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 1
Safety Practices

Contents

PARAGRAPH TITLE PAGE


1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 1-1
Safety Practices

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS


This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any
the procedures in this manual will help assure safety and service or maintenance. Remove key and disconnect
equipment reliability. battery leads.
Read, understand and follow the information in this
manual, and obey all locally approved safety practices, 1.5 SAFETY INFORMATION
procedures, rules, codes, regulations and laws.
To avoid possible death or injury, carefully read,
These instructions cannot cover all details or variations in understand and comply with all safety messages.
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency In the event of an accident, know where to obtain medical
during operation, maintenance, or testing. When additional assistance and how to use a first-aid kit and fire
information is desired consult the local JLG distributor. extinguisher/fire suppression system. Keep emergency
telephone numbers (fire department, ambulance, rescue
Many factors contribute to unsafe conditions: carelessness, squad/paramedics, police department, etc.) nearby. If
fatigue, overload, inattentiveness, unfamiliarity, even working alone, check with another person routinely to
drugs and alcohol, among others. For optimal safety, help assure personal safety.
encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair 1.5.1 Safety Alert System and Signal Words
procedures are essential for the safety of the individual
doing the work, for the safety of the operator, and for the
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
DANGER
operator seat looking in a forward direction.
Supplementary information is available from JLG in the DANGER indicates an imminently hazardous situation
form of Service Bulletins, Service Campaigns, Service which, if not avoided, will result in death or serious injury.
Training Schools, the JLG website, other literature, and
through updates to the manual itself.
WARNING
1.2 DISCLAIMER
All information in this manual is based on the latest WARNING indicates a potentially hazardous situation
product information available at the time of publication. which, if not avoided, could result in death or serious
JLG reserves the right to make changes and injury.
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation. CAUTION
1.3 OPERATION & SAFETY MANUAL
CAUTION indicates a potentially hazardous situation
The mechanic must not operate the machine until the which, if not avoided, may result in minor or moderate
Operation & Safety Manual has been read and injury.
understood, training has been accomplished and
operation of the machine has been completed under the
supervision of an experienced and qualified operator.
An Operation & Safety Manual is supplied with each
machine and must be kept in the cab. In the event that the
Operation & Safety Manual is missing, consult the local
JLG distributor before proceeding.

1-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Safety Practices

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards


SOLVENTS: Only use approved solvents that are known
Following are general safety statements to consider before
to be safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab
procedures are located throughout this manual and are clean, and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the
For all safety messages, carefully read, understand and injury may seem. Know the location of a First Aid Kit, and
follow the instructions before proceeding. know how to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high-pressure or steam cleaner
PERSONAL SAFETY GEAR: Wear all the protective before attempting service.
clothing and personal safety gear necessary to perform When removing hydraulic components, plug hose ends
the job safely. This might include heavy gloves, safety and connections to prevent excess leakage and
glasses or goggles, filter mask or respirator, safety shoes contamination. Place a suitable catch basin beneath the
or a hard hat. machine to capture fluid run-off.
LIFTING: NEVER lift a heavy object without the help of at It is good practice to avoid pressure-washing electrical/
least one assistant or a suitable sling and hoist. electronic components. In the event pressure-washing
the machine is needed, ensure the machine is shut down
1.6.2 Equipment Hazards before pressure-washing. Should pressure-washing be
utilized to wash areas containing electrical/electronic
LIFTING OF EQUIPMENT: Before using any lifting
components, it is recommended a maximum pressure of
equipment (chains, slings, brackets, hooks, etc.), verify
52 bar (750 psi) at a minimum distance of 30,5 cm (12 in)
that it is of the proper capacity, in good working order, and
away from these components. If electrical/electronic
is properly attached.
components are sprayed, spraying must not be direct and
NEVER stand or otherwise become positioned under a for brief time periods to avoid heavy saturation,
suspended load or under raised equipment. The load or
Check and obey all Federal, State and/or Local
equipment could fall or tip.
regulations regarding waste storage, disposal and
DO NOT use a hoist, jack or jack stands only to support recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load. 1.6.4 Operational Hazards
HAND TOOLS: Always use the proper tool for the job; ENGINE: Stop the engine before performing any service
keep tools clean and in good working order, and use unless specifically instructed otherwise.
special service tools only as recommended.
VENTILATION: Avoid prolonged engine operation in
enclosed areas without adequate ventilation.
SOFT SURFACES AND SLOPES: NEVER work on a
machine that is parked on a soft surface or slope. The
machine must be on a hard level surface, with the wheels
blocked before performing any service.
FLUID TEMPERATURE: NEVER work on a machine
when the engine, cooling or hydraulic systems are hot.
Hot components and fluids can cause severe burns.
Allow systems to cool before proceeding.
FLUID PRESSURE: Before loosening any hydraulic or
diesel fuel component, hose or tube, turn the engine
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use
a piece of cardboard or wood instead. If injured, seek
medical attention immediately. Diesel fluid leaking under

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 1-3
Safety Practices

pressure can explode. Hydraulic oil and diesel fuel 1.7 SAFETY DECALS
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury. Check that all safety decals are present and readable on
Relieve all pressure before disconnecting any the machine. Refer to the Operation & Safety Manual
component, part, line or hose. Slowly loosen parts and supplied with machine for information.
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque.
Capture fluid in an appropriate container and dispose of
in accordance with prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. Turn the radiator cap to the first stop and allow
pressure to escape before removing the cap completely.
Failure to follow the safety practices could result in death
or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
NEVER drain or store fluids in an open container. Engine
fuel and hydraulic oil are flammable and can cause a fire
and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause an explosion.
PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
manner, and make changes or repairs as indicated by the
test procedure to achieve the desired result.
LEAVING MACHINE: Lower the forks or attachment to
the ground before leaving the machine.
TIRES: Always keep tires inflated to the proper pressure
to help prevent tipover. DO NOT over-inflate tires.
NEVER use mismatched tire types, sizes or ply ratings.
Always use matched sets according to machine
specifications.
MAJOR COMPONENTS: Never alter, remove, or
substitute any items such as counterweights, tires,
batteries or other items that may reduce or affect the
overall weight or stability of the machine.
BATTERY: DO NOT charge a frozen battery.Charging a
frozen battery may cause it to explode. Allow the battery
to thaw before jump-starting or connecting a battery
charger.

1-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 2
General Information and Specifications

Contents

PARAGRAPH TITLE PAGE


2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2-11
2.3.3 Platform Hydraulic Performance Specifications . . . . . . . . . . . . . . . . . . . . 2-11
2.3.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.5 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.6 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.1 8 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.6.2 50 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-1
General Information and Specifications

2.1 REPLACEMENT PARTS AND


WARRANTY INFORMATION

MZ1780
1

For reference when ordering replacement parts or making


service inquiries about the machine, the machine serial
number is required to help assure the provision of correct
parts and information. Before ordering parts or initiating
service inquiries, make note of the serial number located
on the serial number plate (1).
Note: The replacement of any part on this machine with
any other than a JLG authorized replacement part can
adversely affect the performance, durability, or safety of
the machine, and will void the warranty. JLG disclaims
liability for any claims or damages, whether regarding
property damage, personal injury or death arising out of
the use of unauthorized replacement parts.
A warranty registration form must be filled out by the JLG
distributor, signed by the purchaser and returned to JLG
when the machine is sold and/or put into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the distributor
has returned the business reply card of the warranty
registration form to JLG.

2-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.2 TORQUE CHARTS

2.2.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners


SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Tensile Torque Torque Loctite® 242™ or 271™ Loctite® 262™
Size TPI Bolt Dia Clamp Load OR OR
Stress Area (Dry) Lubricated
Vibra-TITE™ 111 or 140 Vibra-TITE™ 131

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]


4 40 0.1120 0.00604 380 8 0.9 6 0.7
48 0.1120 0.00661 420 9 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS


2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND


JLG P/N Loctite® P/N ND Industries P/N Description

0100011 242TM Vibra-TITE TM 121 Medium Strength (Blue)


0100019 271TM Vibra-TITE TM 140 High Strength (Red)
0100071 262TM Vibra-TITE TM 131 Medium - High Strength (Red) MY4510J

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-3
General Information and Specifications

2.2.1 SAE Fastener Torque Chart


(Continued)

Values for Zinc Yellow Chromate Fasteners


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque Loctite® 242™ or 271™ Loctite® 262™
Tensile
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263) OR OR
Stress Area
K= 0.20 Vibra-TITE™ 111 or 140 Vibra-TITE™ 131
K=.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS


2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER MY4660J

2-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.2.1 SAE Fastener Torque Chart


(Continued)

SOCKET HEAD CAP SCREWS


Magni Coating*
Torque Torque
Loctite® 242™ or 271™ Loctite® 262™
Tensile Clamp Load Torque OR
Size TPI Bolt Dia OR
Stress Area See Note 4 (Dry) K = .17 Vibra-TITE™ 111 or 140 Vibra-TITE™ 131
OR Precoat 85®
K=0.16 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS


2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4670J

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-5
General Information and Specifications

2.2.1 SAE Fastener Torque Chart


(Continued)

SOCKET HEAD CAP SCREWS


Zinc Yellow Chromate Fasteners*
Torque
Torque
Torque (Loctite® 242TM or 271TM
Tensile Clamp Load (Loctite® 262TM
Size TPI Bolt Dia
Stress Area See Note 4
(Dry) OR Vibra-TITE TM 111 or TM
or Vibra-TITE 131)
K = .20 140 OR Precoat 85® K=0.15
K=0.18
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS


2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. MY4680J

2-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.2.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners


CLASS 8.8 METRIC BOLTS
CLASS 8 METRIC NUTS

Torque
Torque Torque Loctite®
Tensile
Clamp Torque Loctite® 262™ 242™ or 271™
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR OR
Area 263TM) Vibra-TITE™ 131 Vibra-TITE™
111 or 140

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4


3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS


2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED. MY4690J

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-7
General Information and Specifications

2.2.2 Metric Fastener Torque Chart


(Continued)

Values for Zinc Yellow Chromate Fasteners


CLASS 10.9 METRIC BOLTS
CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™
Clamp or Loctite® 262™
Size PITCH Stress OR OR
Load Loctite® 263™
Area Vibra-TITE™ Vibra-TITE™ 131
111 or 140
K = 0.20 K= 0.18 K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13


3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25.2 22.7 18.9
8 1.25 36.60 22.8 36.5 32.8 27.4
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS


2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED. MY4700J

2-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.2.2 Metric Fastener Torque Chart


(Continued)

Magni Coating*

CLASS 12.9 SOCKET HEAD CAP SCREWS


M6 AND ABOVE*

Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™ Loctite® 262™
Clamp Load or
Size PITCH Stress OR OR
See Note 4 Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131
Area
111 or 140
K = .17 K = .16 K = .15

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS


2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED. MY4710J

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-9
General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart Flats Method:


1. If equipped, lubricate o-ring with hydraulic oil. Hand
O-Ring Face Seal & JIC Torque Chart tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
Size ORFS JIC Flats Method
is 3 lb-ft (4 Nm).
13 lb-ft 13 lb-ft 2. Mark a dot on one of the swivel nut flats and another
4 1.5 to 1.75
(18 Nm) (18 Nm) dot in line on the hex of the adapter it’s connecting
23 lb-ft 23 lb-ft to.
6 1 to 1.5
(31 Nm) (31 Nm) 3. Use the double wrench method while tightening to
40 lb-ft 40 lb-ft avoid hose twist.
8 1.5 to 1.75
(54 Nm) (54 Nm) 4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
60 lb-ft 60 lb-ft
10 1.5 to 1.75 covering the dots indicating that the connection has
(81 Nm) (81 Nm)
been properly tightened.
74 lb-ft 85 lb-ft
12 1.0 to 1.5
(100 Nm) (115 Nm)
115 lb-ft 115 lb-ft
16 0.75 to 1.0
(156 Nm) (156 Nm)
170 lb-ft 170 lb-ft
20 0.75 to 1.0
(230 Nm) (230 Nm)
200 lb-ft 200 lb-ft
24 0.75 to 1.0
(271 Nm) (271 Nm)
270 lb-ft
32 N/A 0.75 to 1.0
(366 Nm)

Note: By definition the “Flats Method“ will contain some


variance. Use the “Flats Method” only when accessibility
with a torque wrench is not possible.
Torque Wrench:
1. Identify the appropriate application and refer to the
above chart for the correct torque value.
2. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of
the swivel nut can be detected. Average hand torque
is 3 lb-ft (4 Nm).
3. Use the double wrench method while tightening to
avoid hose twist.
4. Torque wrench must be held at the center of the grip.
Apply constant force until it clicks.
5. After the connection has been properly tightened,
mark a straight line across the connecting parts
indicating that the connection has been properly
tightened.

2-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

Function Speed
First Gear 5 km/h (3.1 mph)
Second Gear 10 km/h (6.2 mph)
Third Gear 25 km/h (15.5 mph)
Fourth Gear (Turbo Only) 35 km/h (21.7 mph)

2.3.2 Hydraulic Cylinder Performance Specifications


Note: Machine with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating
temperature.

Approximate Times (sec.)


Function
7M 8M 9M 12M 13M 17M
Boom Extend 11,60 11,60 13,30 14,03 16,88 23,0
Boom Retract 83 9,83 11,27 12,48 15,02 18,0
Boom Lift 8,28 9,43 14,0 12,32 14,00 15,5
Boom Lower 5,63 6,41 9,65 8,49 9,65 10,0
Attachment Tilt - UP 9,78 9,78 9,78 9,78 9,78 4,5
Attachment Tilt - DOWN 4,50 4,50 4,50 4,50 4,50 9,8
Outrigger - UP N/A N/A N/A 2,93 2,93 8,7
Outrigger - DOWN N/A N/A N/A 2,19 2,19 6,4
Frame Level 11,0 11,0 11,0 11,0 11,0 N/A

2.3.3 Platform Hydraulic Performance Specifications

Approximate Times (sec.)


Function
13M 17M
Platform Lift 31 39
Platform Lower 31 39
Platform Extend 19 27
Platform Retract 19 27
Platform Rotate 180° 14 14

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-11
General Information and Specifications

2.3.4 Electrical System


Note: Refer to Section 9.6, “Fuses and Relays,” for more information.

Battery
Type, Rating 12V DC, Negative (-) Ground, Limited Maintenance,
Wet Charged
Quantity 1 (100 Ah) (C20)
Reserve Capacity CCA @ -18° C: 880 EN
Group/Series DIN 600,38
Alternator 12V, 85 Amps
Starter 12V, 3,2 KW Type EV (Gear Reduction)

2.3.5 Engine Performance Specifications


Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

Description
Engine Make/Model Perkins 1004-40T
Low Idle 925 RPM ±50 RPM
High Idle 2340 RPM ±50 RPM
Horsepower 80,4 BHP/60 KW @ 2200 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.3.6 Tires
Note: Standard wheel lug nut torque is 500 Nm (369 lb-ft).

Size Tire Type Minimum Ply Fill Type Pressure


405/70-24 MPT01 AG 14 Ply Pneumatic 4,0 Bar (58 psi)
405/70-24 MPT04 CONST 14 Ply Pneumatic 4,0 Bar (58 psi)
405/70-24 MPT01 AG (4017PS only) 14 Ply Pneumatic 4,5 Bar (65 psi)
405/70-24 MPT04 CONST (4017PS only) 14 Ply Pneumatic 4,5 Bar (65 psi)

2-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.4 FLUIDS, LUBRICANTS AND


CAPACITIES

Engine Crankcase Oil


Capacity w/Filter Change 8,5 L (9 qt)
Oil Type
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
15W-40 CH
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DF Super ENGINE OIL 15W-40
Fuel Tank
Capacity 140 L (37 gal)
Type of Fuel #2 Diesel
Cooling System
System Capacity 20 L (5 gal)
Type of Fluid 50/50 mix of ethylene glycol and water
Hydraulic System
System Capacity (8, 9M, 40.8 & 40.9) 220 L (58 gal)
System Capacity (12, 13 & 17M) 240 L (63 gal)
Reservoir Capacity to FULL Mark 160 L (42 gal)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
Mobilfluid 424® (ISO 46)
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
Transmission
Capacity with Filter Change 12,9 L (13.6 qt)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
Mobilfluid 424® (ISO 46)
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
Transfer Case
Capacity 1,4 L (1.5 qt)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
Mobilfluid 424® (ISO 46)
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-13
General Information and Specifications

Axles
Differential Housing Capacity - Front 8,0 L (8.5 qt)
Differential Housing Capacity - Rear 7,3 L (7.7 qt)
Wheel End Capacity - Front 1,9 L (2.0 qt)
Wheel End Capacity - Rear 1,4 L (1.5 qt)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
Mobilfluid 424® (ISO 46)
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
Brake System
System Capacity 1,0 L (1.1 qt)
Type of Oil
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
Dexron II or III ATF
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DONAX TA
Air Conditioning System (if equipped)
System Capacity 2,05 kg (4.5 lb)
Type of Refrigerant R-134a Tetrafluoroethane
Type of Lubricant PAG-oil SP-20, TXV System
Quantity of Lubricant 68,3 ccm (2.3 oz)

2-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

2.5 MAINTENANCE SCHEDULES 2.5.2 50, 250 & 500 Hour Maintenance
Schedule
2.5.1 8 & 1st 50 Hour Maintenance Schedule

EVERY
50
EVERY
8
Drain Fuel/ Check Engine Lubrication Check Check Washer
Water Coolant Level Schedule Battery Fluid Level
Separator

Check Fuel
Level
Air Filter Check Engine
Oil Level
Check Tire
Condition &
Check Brake
Fluid Level
EVERY
Pressure
250

Check Hydraulic Check Additional Checks -


Oil Level Transmission Operation & Change Engine Check Axle Check Wheel Air Filter Check
Oil Level Safety Manual Oil and Oil Level End Oil Levels Vacuator Fan Belt
Filter Valve

1st
50
Check Boom Check Boom Check Transfer
Chain & Tension Wear Pads Case Oil Level
LB/FT
(Nm)
(17M Only)

Change Change Wheel Change Engine Change Check Wheel EVERY


Axle Oil End Oil Oil & Filter Transmission Lug Nut
Oil & Filter Torque 500
LB/FT
(Nm)

Check Boom Change Fuel Check Wheel Check LSI


Chain & Tension Filter Lug Nut Calibration
(17M Only) Torque
MZ1671 MZ1681

2.5.3 1000 & 1500 Hour Maintenance


Schedule

EVERY
1000

Change Change Change Change Wheel


Transmission Transfer Case Axle Oil End Oil
Oil & Filter Oil

EVERY
1500

Change Change Change Change


Engine Coolant Hydraulic Hydraulic Tank Brake Fluid
Fluid & Filters Breather
MZ1690

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-15
General Information and Specifications

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lubrication Schedule


8, 9, 12 & 13M

EVERY
8

OZ2260

2-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

17M

EVERY
8

OZ2430

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-17
General Information and Specifications

2.6.2 50 Hour Lubrication Schedule


8, 9, 12 & 13M

EVERY
50

2x

OZ2270

2-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications

17M

EVERY
50

2X

OZ2440

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-19
General Information and Specifications

This Page Intentionally Left Blank

2-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 3
Boom

Contents

PARAGRAPH TITLE PAGE


3.1 Boom System Component Terminology - Two and Three Section Boom . . . . . 3-3
3.2 Boom System - Two and Three Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance - Two and Three Section Boom . . . . . . . . . . . . . 3-4
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.2 Second Section Boom Removal (12 & 13M). . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (8 &
9M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (8
& 9M). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.5 Second Section Boom Installation (12 & 13M) . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.6 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 Boom System Component Terminology - Four Section Boom. . . . . . . . . . . . . . 3-8
3.5 Boom System - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6 Boom Assembly Maintenance - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6.2 Second, Third and Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . 3-10
3.6.3 Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.6.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6.5 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6.6 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.6.7 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6.8 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.6.9 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . 3-14
3.6.10 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.7 Boom Extend and Retract Chains Four Section Boom . . . . . . . . . . . . . . . . . . . . 3-18
3.7.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.7.3 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.7.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.8 Boom Section Separation Adjustment - Four Section Boom . . . . . . . . . . . . . . . 3-21
3.9 Hose Carrier Assembly - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.9.1 Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.9.2 Hose Carrier Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-1
Boom

3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25


3.10.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.11 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.11.1 Connecting with a Mechanical Quick Switch Device. . . . . . . . . . . . . . . . . 3-26
3.11.2 Connecting with a Hydraulic Quick Switch Device . . . . . . . . . . . . . . . . . . 3-26
3.11.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment . . . 3-26
3.11.4 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.11.5 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.12 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

3.1 BOOM SYSTEM COMPONENT


TERMINOLOGY - TWO AND THREE
SECTION BOOM
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the boom system.
The following illustration identifies the components that
are referred to throughout this section.

FIRST
BOOM
SECTION PIVOT PIN
THREE SECTION BOOM

SECOND
BOOM
SECTION

THIRD
BOOM EXTEND/RETRACT
SECTION CYLINDER

ACCESS
PANEL FIRST
BOOM
SECTION
PIVOT PIN

TILT CYLINDER

QUICK SWITCH

EXTEND/RETRACT
CYLINDER

TWO SECTION BOOM


ACCESS
PANEL
SECOND
BOOM
SECTION

TILT CYLINDER
MZ1480
QUICK SWITCH

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-3
Boom

3.2 BOOM SYSTEM - TWO AND THREE 8. Label, disconnect and cap hydraulic hoses attached
SECTION BOOM the hose rack at the left rear corner of the boom.
9. Disconnect the boom angle indicator rod from the
switch at the inside left corner of the main boom
3.2.1 Boom System Description
section and frame. Refer to Section 9.14.7, “Boom
The boom operates via an interchange among the Angle Sensor.”
electrical, hydraulic and mechanical systems. Components
10. Support the front of the boom by placing a sling
involved include the joystick, tilt cylinder, extend/retract
behind the boom head. Support the lift/lower cylinder
cylinder, lift/lower cylinder, compensation cylinder,
and remove the lock bolt and then the rod end pin.
electronic sensors, various pivots, supporting hardware
Lower the lift/lower cylinder onto the frame rails.
and other components.
11. Lower the boom to a level position and place a
3.3 BOOM ASSEMBLY MAINTENANCE - suitable support under the boom head. Reposition
the slings to each end of the boom.
TWO AND THREE SECTION BOOM
12. Remove the lock bolt and pin from the compensation
Note: Boom replacement must be completed in cylinder on each side of the first boom section.
sequence, one boom section at a time, as described in Remove the lock bolt and pivot pin from rear of first
these instructions. boom section.
Before beginning, conduct a visual inspection of the 13. Lift the complete boom off machine and set on level
machine and work area, and review the task about to be ground or supports being careful not to damage the
undertaken. Read, understand and follow these tubes on the side of the first boom section.
instructions.
a. If the boom is going to be disassembled after
3.3.1 Boom Removal removal:

1. Remove any attachment from the quick switch 1. Set the complete boom on level ground and by
assembly. Refer to Section 3.11.1, “Connecting with repositioning the slings, turn boom over on to the top
a Mechanical Quick Switch Device.” side. Set the complete boom on suitable stands to
begin teardown.
Note: If replacing the innermost boom section, remove
the quick switch assembly. Refer to Section 3.11.4, Note: With the complete boom setting upside down, the
“Quick Switch Removal.” other boom section(s), tilt cylinder and hoses are made
more accessible.
2. Park the machine on a hard, level surface. Be sure
there is enough room in front of the machine to allow 2. Remove the access panel from the boom head.
the boom sections to be removed. 3. Label, disconnect and cap the hoses attached to the
3. Fully retract the boom then raise the boom to access tilt cylinder and the hose rack on the side of the first
the rod end pin of the lift/lower cylinder. Place the boom section.
transmission control lever in (N) NEUTRAL, engage 4. Attach a sling through the rod end of the tilt cylinder.
the park brake and shut the engine OFF. Remove the clip from the barrel end of the tilt
4. Place a Do Not Operate Tag on both the ignition key cylinder pin. Remove the tilt cylinder pin and lift the
switch and steering wheel stating that the machine tilt cylinder out of the boom head.
should not be operated. 5. Remove the hose clamp inside the innermost boom
5. Open the engine cover. Allow the system fluids to section.
cool. 6. Label, disconnect and cap the hoses attached to the
6. Properly disconnect the battery. extend/retract cylinder at the rear of the boom.
7. Relieve any trapped pressure in the tilt hydraulic
system by using the handle or wrench (located in the
toolbox) and move the double nut on the side of the
actuator module on the tilt valve section back and
forth. Repeat on the auxiliary valve section and on
the extend/retract section.

3-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

1. With the boom sections sitting on suitable supports,


use a sling around the third boom section (4) to take
1 any pressure off of wear pads to make pad removal
easier.
2. Remove the top, left and right side wear pads,
backing plates and shims. Loosen the bottom wear
pad bolts and remove the shims from the first boom
2 section to gain the necessary clearance to remove
3 the first boom section from the second boom section
(5). Tag each pad, backing plate, shim and bolts
MZ1720 from each location.
7. Pull the extend/retract, tilt and auxiliary hoses (1) out 3. Pull the second and third boom sections out from the
through the rear of the boom. first boom section (6).
8. Remove the clip from the rear extend/retract cylinder 3.3.3 Third Section Boom Removal
pin (2). (12 & 13M)
9. On 12 & 13M machines, remove the 2 brackets that Second Section Boom Removal
secure the extend/retract cylinder to the second (8 & 9M)
boom section.
10. Use a sling around the innermost boom section to 7
take any pressure off of the wear pads to make pad
removal easier.
11. Use a sling to pull the remaining boom section(s) out
far enough to gain access to the rod end of the
extend/retract cylinder.
12. Remove the clip from the front extend/retract
cylinder pin. Pull the extend/retract cylinder (3) out
through the rear of the boom.

3.3.2 Second Section Boom Removal


(12 & 13M)
MZ1730

4 1. Remove the top left and right side wear pads,


backing plates and shims. Loosen the bottom wear
pad bolts and remove the shims from the innermost
boom section to gain the necessary clearance to
remove the last boom section (7). Tag each pad,
backing plate, shim and bolts from each location.
6 2. Pull out the innermost boom section (7).
3. Remove the remaining wear pads.
5

MZ1740

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-5
Boom

3.3.4 Third Section Boom Installation Note: Shim ALL side wear pads as needed to maintain
(12 & 13M) a minimum gap in the horizontal direction or a tight fit.
Second Section Boom Installation The number of shims can vary at each shim point except
(8 & 9M) on the bottom wear pads.
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly.
5. Tighten all wear pads after ensuring the minimum
gap requirements have been met. Refer to Section
3.10.1, “Wear Pad Inspection.”

3.3.5 Second Section Boom Installation


(12 & 13M)

8
MZ1750

1. Install the bottom rear wear pads (8) and bolts onto
the innermost boom section. Apply Loctite® 243TM
and torque to 90 Nm (66 lb-ft). Install the bottom rear
left and right side wear pads, backing plate and bolts
(do not shim or tighten bolts). Install top rear wear
pads, backing plates and bolts (do not shim or
tighten bolts).
9
2. Grease the inside of the next boom section on areas MZ1730
where the innermost boom section wear pads will
slide. 1. Install the bottom rear wear pads (9) and bolts onto
3. Using a suitable sling, balance the innermost boom the second boom section. Apply Loctite® 243TM and
section and carefully slide 1 m to 1,5 m (3’ to 4’) into torque to 90 Nm (66 lb-ft). Install the bottom rear left
the front of the next boom section. Set the innermost and right side wear pads, backing plate and bolts (do
boom section head onto suitable supports and reset not shim or tighten bolts). Install top rear wear pads,
sling under the boom head. Carefully slide the backing plates and bolts (do not shim or tighten
innermost boom section into the next section. Leave bolts).
15 cm to 20 cm (6” to 8”) of the innermost boom
2. Grease the inside of the first boom section on areas
section out to be able to install wear pads on the
where the third boom section wear pads will slide.
front of the next boom section.
3. Using a suitable sling, balance the first and second
4. With the boom head still supported, install the top boom sections and carefully slide 1 m to 1,5 m
wear pads, washers and bolts in the front of the (3’ to 4’) into the front of the third boom section.Set
larger boom section. Apply Loctite® 243TM and torque the third boom section head onto suitable supports
to 90 Nm (66 lb-ft). Remove the boom head from and reset sling under the boom head. Carefully slide
supports and install the bottom wear pads, backing the first and second boom sections into the first
plates, shims and bolts in the front of the larger section. Leave 15 cm to 20 cm (6” to 8”) of the
boom section. Apply Loctite® 243TM and torque to 90 second boom section out to be able to install wear
Nm (66 lb-ft). Install both left and right side front pads on the front of the first boom section.
wear pads, backing plates, shims and bolts in the
front of the larger boom section. Apply Loctite® 243TM
and torque to 50 Nm (37 lb-ft).

3-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

4. With the boom head still supported, install the top 8. Rebalance the boom assembly with slings, lift and
wear pads, washers and bolts in the front of the first carefully guide the boom into place. Align the frame
boom section. Apply Loctite® 243TM and torque to pivot bore with the boom pivot bore. Install the boom
90 Nm (66 lb-ft). Remove the boom head from pivot pin. Apply Loctite® 243TM and torque to 300 Nm
supports and install the bottom wear pads, backing (221 lb-ft).
plates, shims and bolts in the front of the first boom 9. With the sling still in place, install both compensation
section. Apply Loctite® 243TM and torque to 90 Nm cylinders, pins and lock bolts. Apply Loctite® 243TM
(66 lb-ft). Install both left and right side front wear and torque to 120 Nm (88 lb-ft).
pads, backing plates, shims and bolts in the front of
the first boom section. Apply Loctite® 243TM and 10. With the sling still in place, raise the boom enough to
torque to 50 Nm (37 lb-ft). install the lift/lower pin and lock bolt. Apply Loctite®
243TM and torque to 300 Nm (221 lb-ft).
Note: Shim ALL side wear pads as needed to maintain
a minimum gap in the horizontal direction or a tight fit. Note: Raising the boom up or down with the sling
The number of shims can vary at each shim point except maybe necessary so the boom, compensation and lift/
on the bottom wear pads. lower cylinder bores can be aligned for easier pin
installation.
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the Note: Grease the boom pivot bore, compensation
boom wear surfaces lubricated properly. cylinder rod ends, lift/lower rod end and pins before
installing.
5. Tighten all wear pads after ensuring the minimum
gap requirements have been met. Refer to Section 11. Uncap and connect the previously labeled hydraulic
3.10.1, “Wear Pad Inspection.” hoses to the hose rack on the side of the first boom
section.
3.3.6 Boom Installation 12. Connect the boom angle indicator rod from switch at
the inside left rear corner of the main boom section
1. Insert the extend/retract cylinder through the rear of
and frame. Refer to Section 9.14.7, “Boom Angle
the boom. Align the extend/retract rod end with the
Sensor,” for adjustment information.
cylinder pin mounting hole on the last boom section.
Install the extend/retract cylinder pin and retaining 13. Properly connect the battery.
clip. 14. Start the engine and operate all boom functions
Note: On 12 & 13M machines, install the two brackets several times. Check for leaks, and check the
the secure the extend/retract cylinder to the second hydraulic oil level in the reservoir; add oil if required.
boom section. 15. Install the access panel on the boom head.
2. Align the extend/retract barrel end with the cylinder 16. Remove the Do Not Operate Tags from both the
pin mounting hole on the first boom section. Install ignition key switch and the steering wheel.
the extend/retract cylinder pin and retaining clip. 17. Close and secure the engine cover.
Note: Grease extend/retract cylinder barrel end bore
and pin before installing.
3. Attach a sling through the rod end of the tilt cylinder
and position the cylinder to its original mounting
location. Install the tilt cylinder pins and retaining
clips.
4. Insert the extend/retract, tilt and auxiliary hoses
through the boom.
5. Uncap and connect the previously labeled hydraulic
hoses to the appropriate locations on each cylinder.
6. Install the hose clamps inside the innermost boom
section.
7. Using suitable slings, turn the boom over to its
original orientation.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-7
Boom

3.4 BOOM SYSTEM COMPONENT


TERMINOLOGY - FOUR SECTION
BOOM
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the major assemblies of the boom system. The
following illustration identifies the components that are
referred to throughout this section.

HOSE CARRIER

FOURTH BOOM
SECTION
THIRD BOOM
SECTION

SECOND BOOM
SECTION
AUXILIARY
QUICK RETRACT CHAINS (THREE)
CONNECTS

EXTEND/RETRACT CYLINDER

MZ0830
REAR VIEW

TILT CYLINDER

QUICK SWITCH ASSEMBLY

EXTEND CHAINS
(TWO PAIR)

FIRST BOOM
SECTION

MZ0800

BOTTOM VIEW

MZ0810

3-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

3.5 BOOM SYSTEM - FOUR SECTION 3.6.1 Boom Removal


BOOM 1. Remove any attachment from the quick switch
assembly. Refer to Section 3.11.1, “Connecting with
3.5.1 Boom System Operation a Mechanical Quick Switch Device.”

The four section boom consists of the first, second, third Note: If replacing the innermost boom section, remove
and fourth assemblies with double third and fourth the quick switch assembly. Refer to Section 3.11.4,
section extend chains, a double third section retract “Quick Switch Removal.”
chains and a single fourth section retract chain. 2. Park the machine on a firm, level surface. Be sure
As the extend/retract cylinder, which is anchored at the there is enough room in front of the machine to allow
front of the second boom section, and the rear of the first the boom sections to be removed. Fully retract the
boom section begins to extend, it forces the second boom boom then raise the boom to access the rod end pin
section out of the first boom section. of lift cylinder. Place the transmission control lever in
The first, second, third and fourth boom sections are (N) NEUTRAL, engage the park brake and shut the
connected by extend and retract chains. These chains engine OFF.
are routed around sheaves on the second and third boom 3. Place a Do Not Operate Tag on both the ignition key
sections. As the second and third boom sections are switch and the steering wheel, stating that the
forced out, the extend chain pulls the fourth boom section machine should not be operated.
out of the third boom section. 4. Open the engine cover. Allow the system fluids to
As hydraulic pressure is applied to the retract port on the cool.
extend/retract cylinder, the second boom section is pulled 5. Properly disconnect the battery.
back into the first boom section, and the retract chain
pulls the third and fourth boom sections back into the 6. Label, disconnect and cap both hoses from the
second boom section. Extend/Retract cylinder, tilt hoses and both Auxiliary
hoses from tubes at left rear corner of first boom
This mechanical linkage formed by the chains and section. Cap all fittings to prevent dirt and debris
supporting hardware, extends and retracts the third and from entering the hydraulic system.
fourth boom sections at the same rate.
7. Remove the Extend/Retract cylinder support at the
The first boom section does not extend or retract, but lifts top front of the first boom section.
and lowers via action of the lift cylinder.
8. Support the Extend/Retract cylinder and remove the
clip and pin from rod end of extend/retract cylinder.
3.6 BOOM ASSEMBLY MAINTENANCE -
Remove the clip and pin from barrel end of extend/
FOUR SECTION BOOM retract cylinder and remove the extend/retract
cylinder.
These instructions must be completed in sequence. The
second, third and fourth boom sections are removed from 9. Disconnect the boom angle indicator rod from switch
the first boom section.The third and fourth boom sections at the inside left rear corner of the main boom
are removed from the second boom section.The fourth section and frame.
boom section is removed from the third boom section. 10. Support the front of the boom by placing a sling
Before beginning, conduct a visual inspection of the behind the boom head. Support the Lift/Lower
machine and work area, and review the task about to be cylinder and remove the lock bolt and then the rod
undertaken. Read, understand and follow these end pin. Lower the Lift/Lower cylinder onto the frame
instructions. rails.
11. Remove the lock bolt and pin from Compensation
cylinder on each side of first boom section. Remove
the lock bolt and pivot pin from rear of first boom
section.
12. Lower the boom to a level position and place a
suitable support under the boom head. Reposition
the slings to each end of the boom.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-9
Boom

13. Lift the complete boom off machine and set on level Note: Before removing the extend chains, measure the
ground or supports being careful not to damage the distance (2) between the face of the jam nut to the end of
tubes on the left side of boom. the chain clevis on all four extend chains. This
measurement will be used when reassembling the
3.6.2 Second, Third and Fourth Boom boom.
Section Removal 4. At the bottom front of the first boom section, remove
the jam nuts and nuts and washers from the two
extend chain clevises. Remove clips and pins from
the two clevises and remove clevis from each chain.
1
5. At the bottom front of the second boom section
remove the jam nuts and nuts and washers from the
two extend chain clevises. Remove clips and pins
from the two clevises and remove clevis from each
chain.
6. At the rear of the boom, label, disconnect and cap
both Tilt hoses and both Auxiliary hoses from the
bulkhead on the hose carrier. Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.
MZ0740 7. Remove the clip and pin from both retract chain
clevises that are attached to the rear of the third
1. Set the complete boom on level ground and by section boom. The pins can be removed through the
repositioning the slings turn boom over on to the top access holes at the bottom left and right sides of the
side. Set the complete boom (1) on suitable stands first section boom. Do not remove the clevises.
to begin tear down. 8. Remove the clip and pin from the retract chain clevis
Note: With the complete boom setting upside down, the that is attached to the rear of the fourth boom
removal and replacing of each boom section, tilt cylinder, section. Do not remove the clevis.
hoses, extend and retract chains and hose carrier are 9. Pull the second section boom out 152 mm to
made much easier. 203 mm (6 in to 8 in) and remove all the wear pads
from the front inside of the first section boom. Label
2. At the boom head attach a sling through rod end of
all parts for installation.
tilt cylinder. Label, disconnect and cap both hoses
from Tilt cylinder. Plug the cap all fittings to prevent 10. Pull the third boom section out 152 mm to 203 mm
dirt and debris from entering the hydraulic system. (6 in to 8 in). Remove the top left and right side wear
Remove the clip from barrel end of tilt cylinder pin. pads from the second boom section. Loosen the
Remove the tilt cylinder pin and lift the Tilt cylinder bottom rear wear pad bolts and remove the shims
out of the boomhead. from the second boom section to gain the necessary
clearance to be able to remove the second boom
3. Use a suitable sling around the third section boom to
section from the first boom section. Label all parts
take any pressure off of wear pads to make pad
for installation.
removal easier.

MZ0790

2 2

3-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

11. Using a sling around the front of the second boom


section, lift and slide the three boom sections 75% of
the way out of the first boom section. Set the boom
head down on a suitable support, then center the
sling to be able to balance the three boom sections
being removed. Carefully pull the three boom
sections the remainder of the way out of the first
3
boom section and set the three boom sections down
on suitable supports.
12. Remove the clip and pin holding each retract chain
from the inside of the first boom section. Clean and
inspect chains. Replace if damaged.
13. Label, disconnect and cap the Tilt and Auxiliary
hydraulic hoses from tubes at bottom front of first
boom section. Plug all fittings to prevent dirt and
debris from entering hydraulic system. Clean and
inspect the hoses. Replace if damaged. MZ0760
14. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is 4. Place a sling around the front of the third boom
detected. section. Lift and slide the two boom sections 75% of
15. Inspect hoses, hardware, wear pads, mounting the way out of the second boom section. Set the
points, chains and other components visible with the boom head down on a suitable support, then center
first boom section. Replace any item if damaged. the sling to be able to balance the two boom
(Refer to Section 3.7.1, “Boom Chain Inspection,” sections being removed. Carefully pull the two boom
and Section 3.10.1, “Wear Pad Inspection.”) sections (3) the remainder of the way out of the
second boom section and set the two boom sections
Note: It is recommended that if any chain or hose is down on suitable supports.
damaged that ALL chains or hoses are replaced.
5. Remove the lock bolts, keeper and pin from both
sheaves at bottom rear of the second section boom.
3.6.3 Third and Fourth Boom Section
Remove the sheaves.
Removal
6. Remove the clip and pin holding retract chain from
1. With the three boom sections setting on suitable bottom front of second boom section. Clean and
supports remove bolts, keeper and pin from both inspect chain. Replace if damaged.
sheaves on the bottom front of the second boom
section. Remove sheaves. Remove all wear pads on 7. Inspect the boom and welds. Consult your local
the front inside of the second boom section. Label all authorized service distributor if structural damage is
parts for installation. detected.
2. Remove the bolts, keeper and pin from center 8. Inspect hoses, hardware, wear pads, mounting
sheave on the bottom rear of the third boom section. points, chains and other components visible with the
Remove the sheave. first boom section. Replace any item if damaged.
(Refer to Section 3.7.1, “Boom Chain Inspection,”
3. Remove the top left and right side rear wear pads on and Section 3.10.1, “Wear Pad Inspection.”)
the third boom section. Loosen the bottom rear wear
pad bolts and remove the shims from the third boom Note: It is recommended that if any chain or hose is
section to gain the necessary clearance to remove damaged that ALL chains or hoses are replaced.
the third boom section from the second boom
section. Label all parts for installation.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-11
Boom

3.6.4 Fourth Boom Section Removal Note: It is recommended that if any chain or hose is
damaged that ALL chains or hoses are replaced.
1. With the two boom sections setting on suitable
supports remove the bolts, keeper and pin from
sheave on the front of the third boom section.
3.6.5 Hose Carrier Removal
Remove the sheaves. Remove all wear pads, from 1. Label, disconnect and cap both auxiliary hydraulic
the front inside of the third boom section. Label all hoses in the boom head. Cap all fittings to prevent
parts for installation. dirt and debris from entering hydraulic system.
2. Remove the top left and right side rear wear pads on 2. With fourth boom section setting on suitable
the fourth boom section. Loosen the bottom rear supports loosen and remove the six bolts (three per
wear pad bolts and remove the shims from the fourth side) on the fourth boom section.
boom section to gain the necessary clearance to be
able to remove the fourth boom section from the
third boom section. Label all parts for installation.
5
3. Loosen and remove the two bolts holding the rear of
the hose carrier to the top of the third boom section.
Lift and push rear of hose carrier into the fourth
boom section.

MZ2720

4 3. Pull the hose carrier (5) halfway out of fourth boom


section by hand and set on a suitable support. Place
a sling around the center of the hose carrier to be
able to balance the hose carrier while being
removed. Carefully slide the hose carrier the
remainder of the way out of the fourth boom section
and set down on suitable supports.
MZ0770
3.6.6 Hose Carrier Installation
4. Place a sling around the front of the fourth boom 1. Install the hose carrier into the fourth boom section.
section (4). Lift and slide the fourth boom section 3/4 Using a suitable sling, place the sling under the
of the way out of the third boom section. Set the center of the hose carrier and guide the front of hose
boom head down on a suitable support, then center carrier into the rear of the fourth boom section. Set
the sling to be able to balance the fourth boom the rear of the hose carrier on a suitable support.
section being removed. Carefully pull the fourth Remove the sling and slide the remainder of the
boom section the remainder of the way out of the hose carrier into the fourth boom section by hand.
third boom section and set the fourth boom section
down on suitable supports. 2. Apply Loctite® 243TM to the hose carrier bolts. Install
the bolts through the three holes on each side of the
5. Remove the clip and pin holding both extend chains fourth boom section. Install the front two bolts first.
from bottom of third and fourth boom sections. Clean Install the middle two next. Then the rear two bolts
and inspect chains. Replace if damaged. last. Torque to all six bolts to 90 Nm (66 lb-ft).
6. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.
7. Inspect hoses, hardware, wear pads, mounting
points, chains and other components visible with the
first boom section. Replace any item if damaged.
(Refer to Section 3.7.1, “Boom Chain Inspection,”
and Section 3.10.1, “Wear Pad Inspection.”)

3-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

3.6.7 Fourth Boom Section Installation 5. Apply Loctite® 243TM to the sheave mounting bolts,
Install the sheave (7), pin, lock plate and bolts at the
bottom front of the third boom section. Torque bolts to
90 Nm (66 lb-ft). Grease the sheave using the
grease fitting in the pin. Spin the sheave by hand to
ensure the sheave spins freely on the pin and to
6 distribute grease evenly. Pull both extend chains from
the fourth boom section around the front and over the
sheave. Install both chain clevises, pins and clips.
6. Retract the fourth boom section the remainder of the
way into the third boom section and install the wear
pads at the rear of third and fourth boom sections.
7. Apply Loctite® 243TM to the wear pad mounting bolts
and install the bottom left and right side wear pads,
MZ0770
backing plates, shims and bolts. Shim the top wear
1. Apply Loctite® 243TM to the wear pad mounting bolts. pads on the rear of the fourth boom section. Shim
Install the bottom, left right and top wear pads. Do the top left and right wear pads on the rear of the
not shim or tighten the side and top wear pad bolts fourth boom section. Torque bolts to 90 Nm (66 lb-ft).
at this time. Install both extend chains (6) on bottom Torque grease fitting bolts to 45 Nm (33 lb-ft).
rear of fourth boom section. Lay extend chains the
length of fourth boom section. 3.6.8 Third and Fourth Boom Section
Installation
2. Grease the inside third boom section on area’s
where the fourth boom section wear pads will slide. 1. At the rear of the third boom section apply Loctite®
243TM to the wear pad mounting bolts and install the
3. Using a suitable sling, balance the fourth boom
bottom rear wear pads, washers and bolts. Torque to
section and carefully slide 914 mm to 1219 mm
90 Nm (66 lb-ft). Install the bottom rear left and right
(3 ft to 4 ft) into the front of the third boom section.
side wear pads, backing plate and bolts (do not shim
Set the fourth boom section head onto suitable
or tighten bolts). Install the top rear wear pads,
support and reset sling under the boom head of the
backing plates and bolts (front bolts are drilled and
fourth boom section. Carefully slide the fourth boom
tapped for grease fittings. do not shim or tighten
section into the third boom section. Leave
bolts). Install both extend chains on the bottom rear
1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom
of the third boom section. Lay extend chains the
section out to be able to install wear pads in front of
length of third boom section.
the third boom section.
2. Grease the inside second boom section on areas
4. With the sling still under boom head install the top
where the third boom section wear pads will slide.
wear pads. Lower the fourth boom section and install
the bottom, left and right side wear pads. Do not 3. Install retract chain, pin and clip to bottom front
shim or tighten bolts at this time. inside of the second boom section.

Note: Grease wear pads, inside sheaves, bores and Note: Keep the retract chain centered on bottom of the
pins during assembly. third boom section while installing the third boom section
7 into the second boom section.

MZ0980

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-13
Boom

4. Using a suitable sling, balance the third and fourth


boom sections and carefully slide 914 mm-1219 mm 9
(3 ft - 4 ft) into the front of the second boom section.
Set the third and fourth boom sections onto a
suitable support and reset the sling under the boom 1
head of the fourth boom section. Carefully slide the
third and fourth boom sections into the second boom
section. Leave 152 mm-203 mm (6 in - 8 in) of the
third boom section out to be able to install the wear MZ1010
pads in the front of the second boom section.
2
5. With the sling still under boom head, Apply Loctite®
243TM to the wear pad mounting bolts and install the
top wear pads, washers and bolts in the front of the
second boom section. Torque to 90 Nm (66 lb-ft).
Lower the third and fourth boom section and apply
Loctite® 243TM to the wear pad mounting bolts and
install bottom wear pads, backing plates, shims, and
the allenhead cap bolts in the front of the second
boom section. Torque to 90 Nm (66 lb-ft). Install both MZ1140
left side and right side front wear pads, backing
plates, shims and bolts in the front of the second 8. Install the retract chain sheave (1), pin, keeper and
boom section. Torque to 90 Nm (66 lb-ft). bolts to bottom rear of third boom section. Apply
Loctite® 243TM and torque to 90 Nm (66 lb-ft). Grease
Note: Grease wear pads, inside sheaves, bores and
the sheaves using the grease fitting in the pin. Spin
pins during assembly.
the sheaves by hand to ensure the sheaves spin
8
freely on the pin and to distribute grease evenly.
9. Install both retract chain sheaves (2), pin, keeper
and bolts to bottom rear of second boom section.
Apply Loctite® 243TM and torque to 90 Nm (66 lb-ft).
Grease the sheaves using the grease fitting in the
pin. Spin the sheaves by hand to ensure the
sheaves spin freely on the pin and to distribute
grease evenly.
MZ1000

6. Install both sheaves (8), pins, lock plates and bolts at 3.6.9 Second, Third and Fourth Boom
the bottom front of the second boom section. Apply Section Installation
Loctite® 243TM and torque bolts to 90 Nm (66 lb-ft). Note: Light lubrication of the boom wear surfaces with a
Grease the sheaves using the grease fitting in the factory authorized grease is recommended to keep the
pin. Spin the sheaves by hand to ensure the boom wear surfaces lubricated properly. Light lubrication
sheaves spin freely on the pin and to distribute of the boom wear surfaces is also recommended when
grease evenly. Pull both extend chains from the third the machine is stored, to help prevent rusting.
boom section around the front and over the sheaves.
Install both chain clevises, pins and clips (9). 1. Apply Loctite® 243TM to the wear pad mounting bolts.
At the rear of the second boom section, install the
7. Apply Loctite® 243TM to the wear pad mounting bolts
bottom rear wear pads, washers and bolts. Torque to
and install the bottom left and right side wear pads,
90 Nm (66 lb-ft). Install the bottom rear left and right
backing plates, shims and bolts.Shim the top wear
side wear pads, backing plate and bolts (do not shim
pads on the rear of the third boom section. Shim the
or tighten bolts). Install top rear wear pads, backing
top left and right wear pads on the rear of the third
plates and bolts (front bolts are drilled and tapped for
boom section.Torque bolts to 90 Nm (66 lb-ft).
grease fittings. do not shim or tighten bolts).
Torque grease fitting bolts to 45 Nm (33 lb-ft).

3-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

2. Grease the inside first boom section on area’s where the front of the second boom section. Torque to
the second boom section wear pads will slide. 90 Nm (66 lb-ft).
3 Note: Shim ALL side wear pads as needed to maintain
a minimum gap (1.6 mm - 1/16 in) the horizontal
direction or a snug fit. The number of shims can vary at
each shim point.
7. Install the bottom left and right side wear pads,
backing plates, shims and bolts at the rear of the
second boom section.Shim the top wear pads on the
4 5 rear of the second boom section. Shim the top left
and right wear pads on the rear of the second boom
section. Apply Loctite® 243TM and torque bolts to 90
Nm (66 lb-ft).
8. Retract the second, third and fourth boom sections
the remainder of the way into the first boom section.

MZ1190

3. Install the retract chains (3), pins and clips to bottom


front inside of the first boom section.
7
4. Install both tilt hoses (4) and both auxiliary hoses (5)
to the tubes mounted at the bottom front of the first
boom section. Make sure both sets of hoses are run
through the opening at the bottom front of the first
boom section and run down the inside center of the
boom section
6
Note: Keep the retract chains, tilt and auxiliary hoses
centered in the first boom section while installing the
second boom section into the first boom section.
5. Using a suitable sling, balance the second, third and
fourth boom sections and carefully slide
914 mm - 1219 mm (3 ft - 4 ft) into the front of the
first boom section. Set the second, third and fourth
boom sections onto a suitable support and reset
MZ1200
sling under the boom head of the fourth boom
section. Carefully slide the second, third and fourth 9. Attach the retract chain (6), pin and clip to the clevis
boom sections into the first boom section. Leave at the rear of the fourth boom section.
152 mm - 203 mm (6 in - 8 in) of the second boom
10. Attach the retract chains (7), pins and clips to the
section out to be able to install wear pads in front of
clevises at the rear of the third boom section.
the first boom section.
6. With sling still under boom head, Apply Loctite® 243TM Note: Installing the clevis pins in the third boom section
to the wear pad mounting bolts. Install the top wear can only be done when the first boom section and the
pads, washers and bolts in the front of the first boom second boom section access holes are aligned.
section. Torque to 90 Nm (66 lb-ft). Lower the
second, third and fourth boom sections and apply
Loctite® 243TM to the wear pad mounting bolts, Install
bottom wear pads, backing plates, shims, and bolts
in the front of the first boom section. Torque to
90 Nm (66 lb-ft). Install both left side and right side
front wear pads, backing plates, shims and bolts in

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-15
Boom

Note: Grease Tilt cylinder barrel end bore and pin


9 before installing.
17. Using suitable slings, lift complete boom off supports
and set on level ground. It will be necessary to place
a block under the rear of the boom to keep the tilt
and auxiliary tubes from being damaged
18. Turn the boom over being careful not to damage the
Tilt and Auxiliary tubes mounted on the side and rear
of boom.
MZ0790
19. After boom is turned upright, place a suitable
support under the rear of the boom.
8
20. Attach a sling around a balance point on the Extend/
11. Attach both extend chain clevises (8) through the Retract cylinder and carefully set on top of the first
holes in the bottom front of the first boom section. boom section.
Install the washers, adjustment nut and jam nut to
Note: Grease Extend/Retract cylinder barrel end bore
the clevises.
and rod end bore and pins before installing.
12. Attach both extend chain clevises (9) through the
3
holes in the bottom front of the second boom
2
section. Install the washers, adjustment nut and jam
nut to the clevises.
Note: Adjust all four extend chains using the
measurement taken in the beginning of the tear down
procedure. Depending on the extent of the parts being
replaced, the above measurement is to be used as a 1
starting point ONLY.
13. Pull the rear of the hose carrier over the rear of the
fourth boom section and set onto the rear of the third
boom section. Using the two bolts, washers and
nuts, bolt the rear of the hose carrier to the rear of
the third boom section. Apply Loctite® 243TM and
torque the two bolts to 90 Nm (66 lb-ft). MZ1210

14. Remove the caps from the fittings on the hose


carrier bulkhead and the plugs from the tilt and 21. Align the Extend/Retract cylinder barrel end with
auxiliary hoses. Install all four hoses and tighten until bore at rear of the first boom section. Install the pin
wrench-tight. Mark the hose fitting then tighten each and retaining clip (1).
hose firmly 1 to 1 1/2 flats. 22. Align the Extend/Retract cylinder rod end with bore
15. Remove the caps from the Auxiliary hoses in the at front of the second boom section. Install the pin
boomhead and install the Auxiliary hoses from the and retaining clip (2).
front of the hose carrier to the Auxiliary bulkhead. 23. Install Extend/Retract cylinder support (3). Apply
Tighten each hose wrench-tight. Mark the hose Loctite® 243TM and torque bolts to 90 Nm (66 lb-ft).
fitting then tighten each hose firmly 1 to 1 1/2 flats.
Bolt the auxiliary hose bulkhead to the side of the
boom head and torque the two bolts to 90 Nm
(66 lb-ft).
16. Using a suitable sling through the rod end of the Tilt
cylinder, lower the Tilt cylinder into boomhead. Align
the Tilt cylinder barrel end bore with the boomhead
bore and install the Tilt cylinder pin and retaining
clip.

3-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

3.6.10 Boom Installation Note: Grease the boom pivot bore, compensation
cylinder rod ends, lift/lower cylinder rod end and pins
Note: Light lubrication of the boom wear surfaces with a
before installing.
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly. Light lubrication
of the boom wear surfaces is also recommended when
the machine is stored, to help prevent rusting.
1. Park the machine on a hard, level surface. Make
sure park brake is set, key is removed from the 7
ignition and “Do Not Operate” tag is placed in clear
view in the cab.
4
5 9

8
5

MZ1250

MZ1230
5. Remove the caps from Extend/Retract cylinder
2. Using suitable slings, balance the boom assembly, fittings and plugs from Extend/Retract cylinder
lift and carefully guide the boom into place. Align the hoses. Attach each hose to the Extend/Retract
frame pivot bore with the boom assembly pivot bore. cylinder fittings (7) and tighten until wrench-tight.
Install boom pivot pin (4). Apply Loctite® 243TM and Mark the hose fitting then tighten each hose firmly 1
torque lock bolt to 90 Nm (66 lb-ft). to 1-1/2 flats.
3. With the sling still in place, install both 6. Remove the caps from both Tilt tubes (8) and
Compensation cylinders, pins and lock bolts (5). Auxiliary tubes (9) and plugs from both Tilt hoses
Apply Loctite® 243TM and torque to 90 Nm (66 lb-ft). and both Auxiliary hoses. Attach both sets of hoses
to the Tilt tubes and the Auxiliary tubes and tighten
until wrench-tight. Mark the hose fitting then tighten
each hose firmly 1 to 1-1/2 flats.
7. Connect the boom angle indicator rod from switch at
the inside left rear corner of the main boom section
and frame. Refer to Section 9.14.7, “Boom Angle
Sensor,” for adjustment information.
8. Start the engine and operate all boom functions
6 MZ1240
several times. Check for leaks, and check the
hydraulic oil level in the reservoir; add oil if required.
4. With the sling still in place, install the rod end of the
Lift/Lower cylinder, pin and lock bolt (6). Apply 9. Clean up all debris, hydraulic oil, etc., in, on, near
Loctite® 243TM and torque to 90 Nm (66 lb-ft). and around the machine.

Note: Raising the boom up or down with the sling


maybe necessary so the boom, Compensation and Lift/
Lower cylinder bores can be aligned for easier pin
installation.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-17
Boom

3.7 BOOM EXTEND AND RETRACT Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance
CHAINS FOUR SECTION BOOM
limit of a leaf chain.
• High velocity movement of load, followed by
3.7.1 Boom Chain Inspection sudden, abrupt stops.
• Carrying loads in suspension over irregular
WARNING surfaces such as railroad tracks, potholes, and
rough terrain.
Worn pins, stretched or cracked links or corrosive
• Attempting to “inch” loads which are beyond the
environments can cause chain failure. A chain failure
rated capacity of the vehicle.
could result in uncontrolled boom movement, loss of
load or machine instability. The above load cycles and environmental conditions
make it impossible to predict chain life. It is therefore
Under normal operating conditions the boom chains will necessary to conduct frequent inspections until
need to be inspected every 250 hours of operation. The replacement life can be predicted.
retract chains need to be exposed and inspected every
1000 hours of operation. Refer to the Service Manual for The boom chain’s normal life expectancy can be
the proper procedure. Environmental conditions and expressed as a maximum percent of elongation. This is
dynamic impulse/shock loads can drastically affect generally 3%. As the chain flexes back and forth over the
normal operating conditions and require more frequent sheave, the bearing joints (pins and inside link plates)
inspection intervals. gradually incur wear due to articulatio

Environments in which material handling vehicles 3.7.2 Inspection Guidelines


operate can vary widely from outdoor moisture to
temperature to mildly corrosive or highly corrosive 1. Park the machine on a firm, level surface, raise the
industrial atmospheres, in addition to abrasive boom to a horizontal (level) position, place the
exposures such as sand and grit. Some effects can be transmission control lever in (N) NEUTRAL, engage
as follows: the park brake switch.
• Moisture - Corrosive rusting reduces chain 2. Fully extend the boom until the extend chain is taut.
strength by pitting and cracking. Shut the engine off.
• Temperature - Low temperature reduces chain 3. The extend chains will be visible for inspection with
strength by embrittlement. Going in and out of the vehicle in this state.
cold storage results in moisture from
condensation. 4. While doing the chain inspection, check all chain
clevis ends for distortion or cracking and sheaves for
• Chemical Solutions or Vapors - Corrosive attack bearing wear or grooving from the chain.
on the chain components and/or the mechanical
connections between the chain components. 5. Inspect the retract chains every 1000 hours of
Cracking can be (and often is) microscopic. operation. Refer to the Service Manual for proper
Going from microscopic cracking to complete procedure.
failure can be either abrupt or may require an 6. Inspect the chains for the following conditions:
extended period of time.
Edge Wear
• Abrasives - Accelerated wearing and scoring of
the articulating members of the chain (pins and Check the chain for wear on the link plate edges
plates), with a corresponding reduction in chain caused by running back and forth over the sheave.
strength. Due to the inaccessibility of the bearing The maximum reduction of material should not
surfaces (pin surfaces and plate apertures), exceed 5%. This can be compared to a normal link
wear and scoring are not readily noticeable to plate height by measuring a portion of chain that
the naked eye. does not run over the sheave.

a. Extend Chains (fourth to third section)


The extend chains between the fourth and third
boom sections measures 18 mm (.713 in) (1). If the
measurement of the worn chain is less than 17 mm
(.677 in) (2), the chain should be replaced.

3-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

b. Extend Chains (third to second section)


3
The extend chains between the third and second
boom sections measures 29,6 mm (1.2 in) (1). If the 4
measurement of the worn chain is less than
28,6 mm (1.1 in) (2), the chain should be replaced.

2 1

MZ1463

MZ1464
Elongation
It is important to measure the chain in the section
that moves over the sheaves because it receives the Turning or Protruding Pins
most frequent articulation. Measuring the chain near Highly loaded chain, operating with inadequate
its clevis terminals could give an inaccurate reading. lubrication can generate abnormal frictional forces
The ends of the chains, near the clevis terminal, will between pin and link plates. When chain is allowed
not have flexed as frequently, if at all, as nearer the to operate in this condition, a pin or series of pins,
middle of the chains. can begin to twist out of a chain, resulting in failure.

a. Extend Chains (fourth to third section) Examine the pin head rivets to determine if the
“VEE” flats are still in correct alignment (5). Chain
When the original length (3) of 305 mm (12.00 in) with rotated/displaced heads (6) or abnormal pin
per foot of extend chain between the fourth and third protrusion (7) should be replaced immediately.
boom sections has elongated from wear to a length
(4) of 313 mm (12.36 in), the chain should be DO NOT attempt to repair the chain by welding or
discarded and replaced. driving the pin(s) back into the chain. Once the press
fit integrity between outside plates and pins has
Measure across a span of 16 pins at the center of been altered, it cannot be restored.
the extend chain. Measure from pin center to pin
center. Because the retract chain is inside the boom Any wear pattern on the pin heads or the sides of the
you will not be able to measure the chain. link plates indicates misalignment in the system.
This condition damages the chain as well as
The maximum measurement allowed is increases frictional loading and should be corrected.
313 mm(12.36 in). If the measurement is more than
313 mm (12.36 in), the chain should be replaced.

b. Extend Chains (third to second section)


When the original length (3) of 317 mm (12.5 in) per 6
5
foot of extend chain between the third and second
boom sections has elongated from wear to a length 7
(4) of 325 mm (12.8 in), the chain should be MZ1465
discarded and replaced.
Measure across a span of 10 pins at the center of
the extend chain. Measure from pin center to pin
center. Because the retract chain is inside the boom
you will not be able to measure the chain.
The maximum measurement allowed is
325 mm(12.8 in). If the measurement is more than
325 mm (12.8 in), the chain should be replaced.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-19
Boom

Distorted or Battered Link Plates • Tight Joints


- All joints in
Distorted or battered link plates (8) on a leaf chain can the chain
cause tight joints and prevent flexing. should flex
freely. Tight
joints (3) 3 MZ1471
88
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or
bent pins, replace the chain.

MZ1466 3.7.3 Expose Chains for Inspection

Cracked Plates c. Extend Chains

Inspect the chains very carefully, front and back as 1. Park the machine on a firm, level surface. Place the
well as side to side, for any evidence of cracked transmission control lever in (N) NEUTRAL, engage
plates. If any one crack is discovered, the chain the park brake switch and raise the boom to a
should be replaced in its entirety. horizontal (level) position.
It is important, however to determine the cause of 2. Lower both outriggers completely
the crack before installing a new chain so the 3. Fully extend the boom until both extend chains are
condition does not repeat itself. taut. Shut the engine OFF.
The types of cracks are: The extend chains will be visible for inspection with the
• Fatigue Cracking - machine in this state.
Fatigue cracks (9) are 9 While doing the chain inspection, check all chain clevis
a result of repeated ends for distortion or cracking and sheaves for bearing
cyclic loading beyond MZ1467
wear or grooving from the chain.
the chain’s endurance
limit. If during the inspection, any chain is found to be damaged
or stretched, the chain must be replaced. It is
• Stress Corrosion
recommended that when any chain is replaced, that all
Cracking - The
outside link plates 10 the chains and clevises be replaced at the same time.
are particularly MZ1468
susceptible to stress d. Retract Chains
corrosion cracking (10).
The three retract chains are only partially visible through
• Corrosion Fatigue Cracking - Corrosion the rear of the boom with all the sections retracted. It is
fatigue cracks are very similar to fatigue possible to see a section of the retract chain as the boom
cracks in appearance. Corrosion fatigue is the is slowly extended. If there is ANY question that one or all
combined action of an aggressive the retract chains are damaged, the boom should be
environment and cyclic stress. removed and disassembled with the retract chains being
Other Modes of Failure inspected and replaced if necessary.
• Ultimate Strength Failure - Note: DO NOT attempt to repair a chain. Replace a
These types of failures are stretched or damaged chain with a new part. Always
caused by overloads far in 1 replace both the chain and the clevis. It is recommended
excess of the design load. MZ1469 that when any chain is replaced, that all chains and
Either fractured plates (1) or 2 clevis’ be replaced at the same time.
enlarged holes (2) can
occur. If either of these
MZ1470
failures occurs, the chain
should be replaced immediately.

3-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

e. Removing Extend and Retract Chains 3.8 BOOM SECTION SEPARATION


The four extend chains and the three retract chains can ADJUSTMENT - FOUR SECTION
only be removed during a complete boom teardown. BOOM
While doing the chain inspection, check all chain clevis
The second, third and fourth boom sections are set to
ends for distortion or cracking and sheaves for bearing
dimensions between each section. The first and second
wear or grooving from the chain.
boom sections are connected by the extend/retract
If during the inspection, any chain is found to be damaged cylinder which has no adjustment.
or stretched, the chain must be replaced. It is
The third and fourth boom sections can be adjusted by
recommended that when any chain is replaced, that all
loosening or tightening the extend chains and the retract
the chains and clevis’ be replaced at the same time.
chains.
3.7.4 Chain Lubrication 1. Fully retract the boom and raise the boom to a
horizontal position. Place the transmission control
After inspection and before being returned to service, lever in (N) NEUTRAL, engage the park brake
chains must be lubricated with Mystik Tetrimoly Grease.
switch.
The lubricant must penetrate the chain joint to prevent 2. Measure the distance between the boom sections. If
wear. Applying lubricant to the external surfaces will
adjustments are needed, extend the boom out
prevent rust, but the chains should be articulated to
make sure the lubricant penetrates to the working 0,91 m to 1,2 m (3 ft to 4 ft). Shut off machine.
surfaces between the pins and links. 3. Loosen the locknuts on the extend chains and the
To prepare the chain for lubrication, the chain plates retract chains and adjust as needed.
should be brushed with a stiff brush or wire brush to
clear the space between the plates so that lubricant can a. To increase the separation distance: Loosen the
penetrate to the working surfaces. retract chains locknut on the rear of the third or
fourth boom sections one or two turns and
Lubricant may be applied with a narrow paint brush or
tighten the extend chain locknuts on the first and
directly poured on, but the chain should be well flooded
with lubricant and the boom should be extended and second boom sections equally the same number
retracted to be sure that the lubricant penetrates to the of turns. A minimum of one full thread on the
working surfaces. All surplus lubricant should be wiped clevis must protrude beyond the locknut.
away from the external surfaces. DO NOT use a solvent
for this wiping operation. 797mm
31.378”
Regular application of lubricant is necessary to make 499mm
19.645”
sure that all working surfaces are adequately lubricated. 229mm
In extremely dusty conditions, it may be necessary to 9.016”
lubricate the chains more often. Refer to Section 2.5,
“Maintenance Schedules,” and Section 2.6, “Lubrication
Schedules,” for detailed information.
Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special
consideration. Contact the local distributor for guidance.

37mm 20mm
1.45” .787”

b. To decrease the separation distance: Loosen the


extend chain locknuts at the front of the first or
second boom sections equally one or two turns
and tighten the retract chains locknut the same
number of turns. A minimum of one full thread
on the clevis must protrude beyond the locknut.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-21
Boom

4. Start the machine and extend and retract the boom 3.9 HOSE CARRIER ASSEMBLY - FOUR
sections two or three times. Fully retract the boom SECTION BOOM
and measure the distance between the boom
sections.
3.9.1 Hose Carrier Assembly Removal
5. If the measurements are within the tolerance, tighten
the locknuts on the chain clevises. If more 1. Remove any attachment from the quick switch
adjustment is needed, repeat procedure until the assembly. (Refer to Section 3.11.1, “Connecting with
proper boom section dimensions is achieved. a Mechanical Quick Switch Device.”)
6. With the boom sections within the proper tolerance, 2. Park the machine on a hard, level surface. Be sure
start the machine, lower the outriggers if necessary there is enough room in front and rear of the
and extend the boom to maximum extension. machine to extend the boom sections and to be able
7. Shut the machine off and measure the distance to removed the hose carrier from the rear of the
between the top of both extend chains and the boom assembly.
bottom of the second and third boom sections at the 3. Fully extend the boom and raise the boom to a
center of each boom section. horizontal position. Place the transmission control
lever in (N) NEUTRAL, engage the park brake
switch.
4. Retract the boom until the rear hose carrier
mounting bolts on the fourth boom section are
accessible through each side of the third boom
section access holes. Shut off the machine and
remove the bolts.
120mm - 4.75in 180mm - 7in
5. Start the machine and retract the boom until the
middle set of hose carrier bolts on the fourth boom
section are accessible through the third boom
MZ1220
section access holes. Shut the engine OFF and
remove the bolts.
8. The distance between the top of the extend chains
6. Start the engine and retract the boom until the front
and the bottom of the second boom section should
set of hose carrier bolts on the fourth boom section
be approximately 180 mm (7 in). The distance
are just in front of the front of the third boom section.
between the top of the extend chains and the bottom
Shut the engine OFF and remove the bolts.
of the third boom section should be approximately
120 mm (4.75 in). 7. Start the engine and slowly retract the boom
sections completely.
Note: If the second boom section to the third boom
section separation distance cannot be achieved, contact 8. Shut the engine OFF and place a Do Not Operate
the local JLG distributor or the JLG Service Department. Tag on both the ignition key switch and the steering
wheel, stating that the machine should not be
operated.
9. Relieve any trapped pressure in the tilt hydraulic
system by using the handle provided or a 9mm
wrench and move the double nut on the side of the
main control valve tilt section back and forth. Repeat
on the auxiliary valve section.
10. Locate the two hoses attached to the barrel of the tilt
cylinder inside the boomhead.

3-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

15. Remove both left and right side wear pad bolts and
both left and right bottom wear pad bolts from the
2 rear of the fourth boom section to be able to remove
the hose carrier.
16. Pull the hose carrier halfway out of the rear of the
boom, set on a suitable support. Using a sling
around the hose carrier, balance the hose carrier
and pull the remainder of the way out. Set the hose
carrier on the ground or on suitable supports.
Note: If the machine or the boom has to be moved,
replace all the bolts that were removed from the wear
pads on the rear of the fourth boom section BEFORE the
machine is started and/or the boom is retracted or
extended.

1 MZ0900 3.9.2 Hose Carrier Assembly Replacement


1. Carefully lay the new hose carrier assembly out flat
11. Label and remove the hoses from the elbow fittings on a hard surface.
on the tilt cylinder (1). Plug the hose ends and cap
2. Make sure the boom is level and that the front two
the elbow fittings on the tilt cylinder to prevent dirt
hose carrier holes (5) in the fourth boom section are
and debris from entering the hydraulic system.
accessible just in front of the front of the third boom
12. Label and remove the two auxiliary hydraulic hoses section.
(2) from the bulkhead fittings inside the boomhead.
3. Using a sling around the center of the hose carrier,
Plug the hose ends and cap the bulkhead fittings to
lift and carefully place the front of the hose carrier
prevent dirt and debris from entering the hydraulic
part way into the rear of the boom. Set the rear of the
system.
hose carrier down on a suitable support. Reposition
13. At the rear of the boom, label and remove the tilt the sling and lift the rear of the hose carrier and slide
cylinder hoses and the auxiliary hoses from the hose it the remainder of the way into the boom.
carrier bulkhead. Plug the hose ends and cap the
4. Apply Loctite®243TM to the wear pad mounting bolts
bulkhead fittings to prevent dirt and debris from
and install both left and right side wear pads and
entering the hydraulic system.
bolts and both left and right bottom wear pads and
3 bolts. torque the side wear pads to 50 Nm (37 lb-ft)
and the bottom wear pads to 90 Nm (66 lb-ft).

MZ0920
4
14. From the top rear of the hose carrier, remove both
bolts (3) holding the hose carrier (4) to the third
boom section.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-23
Boom

6 7
5

MZ0910

5. Align the front two threaded holes on the hose 11. Torque the middle two and front two hose carrier
carrier with the front two holes (5) on each side of bolts to 90 Nm (66 lb-ft).
the fourth boom section and install both bolts. Apply 12. Start the machine and retract the boom
Loctite®243TM and hand tighten only. completely.Shut the machine off.
3 13. Relieve any trapped pressure in the tilt hydraulic
system by using the handle provided or a 9mm
wrench and move the double nut on the side of the
main control valve tilt section back and forth. Repeat
on the auxiliary valve section.
14. Attach both tilt cylinder hoses from the hose carrier
to the tilt cylinder and tighten until wrench-tight. Mark
the hose fitting then tighten each hose firmly
1 to 1 1/2 flats.
15. Attach both auxiliary hoses from the hose carrier to
the auxiliary fittings on the bulkhead and tighten until
wrench-tight. Mark the hose fitting then tighten each
hose firmly 1 to 1 1/2 flats.
MZ0920 16. Bolt the auxiliary bulkhead onto the side of the boom
head. Apply Loctite® 243TM and torque to 50 Nm
6. Fasten the rear of the hose carrier (3) to the top rear (37 lb-ft).
of the third boom section. Apply Loctite®243TM and
torque both bolts to 90 Nm (66 lb-ft). 17. At the rear of the boom, attach both tilt cylinder
hoses to the tilt hose carrier bulkhead fittings and
7. Start the machine and extend the boom out until the tighten until wrench-tight. Mark the hose fitting then
middle set of holes (6) in the fourth boom section tighten each hose firmly 1 to 1 1/2 flats.
align with access holes at the front sides of the third
boom section. Shut off machine. 18. At the rear of the boom, attach both auxiliary hoses
to the auxiliary hose carrier bulkhead fittings and
8. Align the middle two threaded holes on the hose tighten until wrench-tight. Mark the hose fitting then
carrier with the middle two holes on the fourth boom tighten each hose firmly 1 to 1 1/2 flats.
section and install both bolts. Apply Loctite® 243TM
and hand tighten only. 19. Start the engine and operate all boom functions
several times. Check for leaks, and check the
9. Start the machine and extend the boom out until the hydraulic oil level in the reservoir; add oil if required.
rear set of holes (7) in the fourth boom section align
with access holes on each side of the third boom
section. Shut off machine.
10. Align the rear two threaded holes on the hose carrier
with the rear two holes on the fourth boom section
and install both bolts. Apply Loctite® 243TM and
torque to 90 Nm (66 lb-ft).

3-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

3.10 BOOM WEAR PADS • The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
The wear pads on this machine are flat rectangular wear each side.
pads with metal inserts. 5
A total of 13 wear pads are installed on the boom sections
of the 8 & 9M machines.
A total of 26 wear pads are installed on the boom sections
of the 12 & 13M machines.
A total of 50 wear pads are installed on the boom sections
of the 17M machines.

3.10.1 Wear Pad Inspection


1 1

• Maintain a total boom section clearance (5) of


1,78 - 3,30 mm (0.070 - 0.130 in) both the horizontal
and vertical directions.
Ma2070 A

Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
B
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
worn or damaged. MY3620

• The length of the wear pad bolt depends on the


3.10.2 Wear Pad Installation and Lubrication number of shims, spacers and washers being used.
Note: Inspect all wear pads. Replace as necessary. • The thickness of each threaded wear pad insert is
7,92 mm (0.312 in) (A).
The following wear pad procedure must be followed to
insure the proper wear pad installation: • The bolt length should be determined by measuring
the distance from the face of the insert to the face of
• The wear pad inserts and mounting bolts MUST be the boom (B) including any spacer, shim(s) and
clean from any grease, oil or other contaminates washer(s).
before applying Loctite® 243TM and installing
• Bolt thread engagement in the wear pad insert
mounting bolts.
should be 6,98 ± 1,0 mm (0.275 ± 0.040 in).
• Apply Loctite® 243TM to all wear pad mounting bolts.
• One or two hardened washers are to be used on
4 each wear pad bolt except where noted otherwise.
DO NOT use more than two hardened washers.
• Use only one hardened washer if mounting bolts are
recessed.
3 • Wear Pad Bolt Torque:
2 M8x25 Bolt, 50 Nm (37 lb-ft)
M8x30 Bolt, 50 Nm (37 lb-ft)
M10x20 Bolt, 50 Nm (37 lb-ft)
M10x22 Bolt, 50 Nm (37 lb-ft)
M10x25 Bolt, 50 Nm (37 lb-ft)
M10x30 Bolt, 50 Nm (37 lb-ft)
M10x35 Bolt, 50 Nm (37 lb-ft)
MAM1390
M10x40 Bolt, 50 Nm (37 lb-ft)
• A spacer (2) with holes must be used before any M12x20 Bolt, 90 Nm (66 lb-ft)
shim (3) is used. M12x25 Bolt, 90 Nm (66 lb-ft)
M12x30 Bolt, 90 Nm (66 lb-ft)
• A shim (3) must be inserted between the spacer (2)
M12x35 Bolt, 90 Nm (66 lb-ft)
and wear pad support plate, block or boom section
M12x40 Bolt, 90 Nm (66 lb-ft)
(4).

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-25
Boom

• Torque wear pad bolts after shimming is completed. 3.11.2 Connecting with a Hydraulic Quick
• Lubricate the face and pockets of each wear pad Switch Device
after being installed. 1. Retract quick switch device to provide clearance.
Boom Section Wear Pad Pathway Lubrication: Check to be sure lock pin is disengaged.
• Clean and lightly grease all wear pad pathways with 2. Align attachment pin (8) with recess in
Mystik Tetrimoly grease. attachment (9). Raise boom slightly to engage
• Clean and lightly grease the hose carrier guide bar attachment pin in recess.
pathways with Mystik Tetrimoly grease. 3. Engage quick switch device.

3.11 QUICK SWITCH ASSEMBLY 10

This machine is equipped with a quick switch system for


easy attachment changes.

3.11.1 Connecting with a Mechanical Quick MAH0980


Switch Device
4. Press the button (10) and at the same time, move
8 the joystick to engage or to disengage the quick
switch device.
9
5. Raise the boom to eye level and visually check that
the quick switch pin protrudes through the hole. If
the pin does not protrude through the hole, place the
attachment on the ground and return to step 2.
6. If attachment is equipped, connect auxiliary
hydraulic hoses. See Section 3.11.3, “Connecting
6 with a Quick Switch to a Hydraulic Operated
7 Attachment.”
1. Retract quick switch device to provide clearance.
3.11.3 Connecting with a Quick Switch to a
Check to be sure lock pin (6) and retainer pin (7) is
Hydraulic Operated Attachment
out.
2. Align attachment pin (8) with recess in 1. Lower attachment to ground. Set parking brake, shut
attachment (9). Raise boom slightly to engage off engine and turn key back to the “ON” position.
attachment pin in recess. 2. Relieve pressure in the hydraulic system by
3. Engage quick switch device. actuating the joystick.

4. Shut off engine. Exit cab and insert lick pin and 3. Connect the quick-disconnect fittings.
secure with retainer pin. 4. Start the engine.
5. If attachment is equipped, connect auxiliary
hydraulic hoses. See Section 3.11.3, “Connecting
with a Quick Switch to a Hydraulic Operated
Attachment.”

3-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

3.11.4 Quick Switch Removal 3.12 FORKS


Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met,
forks must be removed from service immediately.
Daily Inspection
11

3
12 6

7
5 4
13

1. Support the quick switch assembly. Remove the lock 2


bolt (11) holding the tilt cylinder rod end pin (12) to 1
the quick switch assembly. Remove the tilt cylinder
pin.
2. Support the quick switch assembly. Remove the four 9
bolts and covers (13) from each end of the quick 8
switch assembly. Remove the pin from the quick 11
switch assembly from either side.
3. Inspect the above pin for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion. 10 MH6460

If damaged or if it cannot be repaired, the pin must


1. Inspect forks (1) for cracks, paying special attention
be replaced.
to heel (2) and mounting tubes (3).
3.11.5 Quick Switch Installation 2. Inspect forks for broken or bent tips (4) and twisted
blades (5) and shanks (6).
1. Assemble the quick switch to the boom head. Line
up the quick switch between the mounts on the Yearly Inspection
boom head. The quick switch should be centered in 1. Straightness of the upper face of blade (5) and the
the boom head. front face of shank (6) should not exceed 0.5 percent
2. Coat the quick switch pivot pin with an anti-seize of the length of blade or height of shank.
compound. Insert the quick switch pivot pin through 2. Angle (7) between upper face of blade and front face
the quick switch and boom head. Replace the end of shank should not exceed 93 degrees.
covers and four bolts (10) to each end of the quick 3. Thickness of blade (8) and shank (9) should not be
switch. reduced to 90 percent of original thickness.
3. Align the quick switch with the tilt cylinder rod end
Note: Contact the local distributor with the fork part
and insert the tilt cylinder pin. Align the tilt cylinder
number to find the manufactured dimensions of the fork
pin and screw in the locking bolt (9). Torque as
blade.
required.
4. Ensure fork length (10) is adequate for intended
loads.
5. Fork markings should be legible, re-stamp if
required.
6. Compare fork tips (11) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent
of the length of the blade (10).

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-27
Boom

3.13 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.

Problem Cause Remedy


1. Boom will not extend or 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s)
retract tube(s) and/or connections or tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system 2. Refer to Section 8, “Hydraulic
not operating properly. System.”
3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section
8.10.4, “Cylinder Inspection.”

2. Boom will not fully extend. 1. Extend/retract hydraulic system 1. Refer to Section 8, “Hydraulic
not operating properly. System.”

3. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.10.2, “Wear
Pad Installation and
Lubrication.”
4. Excessive pivot pin noise 1. Insufficient lubrication. 1. Lubricate at regular intervals.
and/or wear. Refer to Section 2.6,
“Lubrication Schedules.”
Replace worn pins as needed.

2. Worn bearing(s). 2. Replace bearing(s) and


lubricate at regular intervals
Refer to Section 2.6,
“Lubrication Schedules.”

5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.

2. Lift/lower hydraulic system not 2. Refer to Section 8, “Hydraulic


operating properly. System.”

3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section


8.10.4, “Cylinder Inspection.”

4. Seized boom pivot pin bearing. 4. Replace bearing.

3-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom

Problem Cause Remedy


6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to
Section 3.10.2, “Wear Pad
Installation and Lubrication.”
2. Rapid cycle times with heavy 2. Reduce cycle times.
loads.

3. Contaminated, corroded or 3. Remove contamination and/or


rusted wear pad sliding corrosion from wear pad sliding
surfaces. surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).

4. Operating in extremely dusty/ 4. Clean equipment frequently.


abrasive conditions.

7. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic
operate. operating properly. System.”

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-29
Boom

This Page Intentionally Left Blank

3-30 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 4
Cab and Covers

Contents

PARAGRAPH TITLE PAGE


4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Service Brake Pedal and Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.4 Joystick Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.5 Parking Brake (8, 9, 12 & 13M). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.6 Parking Brake (17M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.7 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.8 Windshield Washer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.9 Heater/Defroster System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.10 Cab Heater/Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-1
Cab and Covers

4.1 OPERATOR CAB AND COVERS


COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the machine cab and
covers. The following illustration identifies the
components that are referred to throughout this section.

LOAD STABILITY
INDICATOR

HEATER & AC
CONTROLS
DISPLAY
PANEL

TRANSMISSION
CONTROL LEVER

BRAKE FLUID
JOYSTICK
RESERVOIR

POWER/
EMERGENCY
STOP SWITCH
(IF EQUIPPED)

IGNITION

SERVICE BRAKE
PEDAL

ACCELERATOR
PEDAL

PARKING BRAKE
MZ2061
LEVER

4-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers

WARNING
DO NOT service the machine without following all 2
safety precautions as outlined in the “Safety 4
Practices” section of this manual.

4.2 OPERATOR CAB

4.2.1 Serial Number Decal


3
The cab serial number decal is located inside the cab,
behind the seat. Information specified on the serial
number plate includes the cab model number, the cab
serial number and other data. Write this information down
in a convenient location to use in cab correspondence.
1
MZ2000
4.3 CAB COMPONENTS
7. Label, disconnect and cap the hydraulic hoses
attached to the steering valve (1). Cap all fittings to
4.3.1 Steering Column and Orbitrol Valve
prevent dirt and debris from entering the hydraulic
system.
a. Orbitrol Valve Removal
8. Remove the steering wheel (2), disconnect and
1. Park the machine on a firm, level surface, level the remove the accessory control lever (3) and
machine, fully retract the boom, lower the boom, transmission control lever (4).
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 9. Support the steering valve, and remove the four hex-
engine OFF. head capscrews and four lockwashers.
2. Place a Do Not Operate Tag on both the ignition key 10. Remove the steering assembly from the dash panel.
switch and steering wheel, stating that the machine Note: DO NOT disassemble the orbitrol valve. The
should not be operated. orbitrol valve is not serviceable and must be replaced in
3. Open the engine cover. Allow the system fluids to its entirety, if defective.
cool.
b. Orbitrol Valve Installation
4. Properly disconnect the battery.
5. Remove the lower dash panel. 1. Install the steering valve and steering column to their
original orientation on the steering bracket with four
6. Remove the steering adjustment lever.
hex-flange capscrews and four lockwashers.
2. Install the accessory control lever and transmission
control lever and connect the harness connector,
install the steering wheel assembly. Torque the
steering wheel nut to 40 Nm (29.5 lb-ft).
Note: ALWAYS use new o-rings when servicing the
machine.
3. Install new o-rings into the fittings. Lubricate the o-
rings with clean hydraulic oil.
4. Uncap and connect the previously labeled hoses to
the appropriate ports.
5. Install the steering adjustment lever.
6. Properly connect the battery.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-3
Cab and Covers

7. Start the engine and check the operation of steering


system. Check for hydraulic oil leaks. Check the
hydraulic oil level in the tank and add oil as required.
Wipe up any spilled oil. 5
8. Install the lower dash panel.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

c. Power Steering Test


Conduct a pressure check of the steering hydraulic
circuits at the main control valve. Refer to Section 8.4.1,
“Hydraulic Pressures.”

4.3.2 Service Brake Pedal and Valve MZ1960

8. Remove the service brake pedal (5) from the cab.


a. Service Brake Valve
Refer to Section 8.9.2, “Service Brake Valve,” for removal c. Service Brake Pedal Installation
and installation information.
1. Position the service brake pedal in its mounting
location within the cab.
b. Service Brake Pedal Removal
2. Install the brake pedal being careful to reposition the
1. Park the machine on a firm, level surface, level the brake plunger yoke. Install the return spring, washer,
machine, fully retract the boom, lower the boom, bushing and clip. Install clip/pin in brake plunger fork link.
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 3. Adjust the brake pedal as needed.
engine OFF. 4. Install and secure the lower dash cover.
2. Place a Do Not Operate Tag on both the ignition key 5. Properly connect the battery.
switch and steering wheel, stating that the machine 6. Close and secure the engine cover.
should not be operated.
7. Remove the Do Not Operate Tags from both the
3. Open the engine cover. Allow the system fluids to ignition key switch and the steering wheel.
cool.
4. Properly disconnect the battery. 4.3.3 Throttle Pedal Replacement
5. Remove the lower dash panel.
a. Throttle Pedal Removal
6. Remove the circlip, flat washer, bushing and the
return spring securing the service brake pedal to the 1. Park the machine on a firm, level surface, level the
cab. machine, fully retract the boom, lower the boom,
place the transmission control lever in
7. Remove the clip/pin from the brake plunger fork link.
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Properly disconnect the battery.
5. Remove the lower dash panel.

4-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers

2. From within the cab, check the engine rpm at low


idle. If the rpm is not 925 ±50 rpm, readjust the
throttle cable adjustments.
3. Check the engine rpm at full throttle. If the rpm is not
7 2340 ±50 rpm, adjust the rubber-stop screw on the
throttle pedal or the throttle cable adjustments.
Note: During the full throttle check:
• DO NOT operate any hydraulic function.
6
• DO NOT steer or apply any pressure to the
steering wheel.
• Keep the transmission in (N) NEUTRAL.
4. Close and secure the engine cover.
MZ1970
5. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
6. Remove the throttle pedal return spring (6).
7. Disconnect the throttle control cable (7) from the 4.3.4 Joystick Assembly Replacement
throttle lever.
8. Remove the retaining ring from the throttle pedal a. Joystick Assembly Removal
pivot pin. Slide the throttle pedal, bushings and 1. Park the machine on a firm, level surface, level the
washers off the pivot pin. machine, fully retract the boom, lower the boom,
9. Remove the throttle pedal assembly from the cab. place the transmission control lever in
10. If a new throttle cable is required, remove the cable (N) NEUTRAL, engage the park brake and shut the
connector from the engine. Route the cable through engine OFF.
the bottom of the cab and remove from the machine. 2. Place a Do Not Operate Tag on both the ignition key
Note the routing path for installation. switch and steering wheel, stating that the machine
should not be operated.
b. Throttle Pedal Installation 3. Open the engine cover. Allow the engine to cool.
1. If required, install a new throttle cable to the engine 4. Properly disconnect the battery.
connection and route cable to cab following the
previous routing path.
2. Slide the throttle pedal, bushings and washers onto 9
the throttle pedal pivot pin. Secure with retaining
ring.
3. Connect the throttle control cable to the throttle
lever.
4. Install the throttle pedal return spring.
5. Properly connect the battery. 8

c. Throttle Adjustment
1. Adjust the distance on each end of the throttle cable
from the locknut to the connector end. The distance MZ2030

from the connector to the locknut in the cab should


be 129 mm (5 in). In the engine compartment, the 5. Remove the capscrews securing the bottom cover
distance should be 234 mm (9.2 in). (8). Disconnect the electrical connections and
remove the four self-tapping screws from the bottom
Note: These measurements are to be used as starting of the joystick assembly.
points. If further adjustment is required, the distance may
6. Remove the joystick assembly (9).
need to be altered.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-5
Cab and Covers

b. Joystick Assembly Installation


1. Set the joystick assembly into the armrest support.
2. Install the four self-tapping screws. Connect the
electrical connections.
3. Properly connect the battery. 2

4. Test the boom joystick functions:


a. Move the joystick handle rearward, activating the
boom lift function. The boom should RISE.
b. Move the joystick handle forward, activating the
boom lower function. The boom should LOWER.
1
c. Move the joystick handle to the right, activating MZ1490
the boom extend function. The boom should
EXTEND. 7. Remove the pin attached to the park brake cable (1)
d. Move the joystick handle to the left, activating the from the park brake lever (2).
boom retract function. The boom should 8. Remove the bolts holding the park brake lever to the
RETRACT. mounting plate.
e. Move the joystick rocker switch forward 9. Loosen the nuts securing the park brake cable to the
activating the boom extend function. The boom mounting plate.
should EXTEND.
10. Feed the cable end through the bottom of the cab.
5. Install the bottom cover.
11. If necessary, remove the cable clamp from under the
6. Close and secure the engine cover.
cab.
7. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. Note: Record the routing of the park brake cable for
later installation.
4.3.5 Parking Brake (8, 9, 12 & 13M) 12. Remove the cable mounting hardware on the front
axle to free the park brake cable.
a. Park Brake Removal
1. Park the machine on a firm, level surface, level the b. Park Brake Installation
machine, fully retract the boom, lower the boom, 1. Install the park brake cable on the front axle.
place the transmission control lever in (N)
2. Route the park brake cable using the previous
NEUTRAL, engage the park brake and shut the
routing path.
engine OFF.
3. Feed the cable end through the bottom of the cab.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the 4. Secure the park brake lever to the mounting plate
machine should not be operated. using the pre-existing mounting hardware.
3. Open the engine cover. Allow the system fluids to 5. Secure the park brake cable to the park brake lever
cool. with the pre-existing pin.
4. Block the wheels. 6. Connect the park brake electrical connector switch.
5. Properly disconnect the battery. 7. Properly connect the battery.
6. Remove the cover from around the park brake lever. 8. Test the park brake for proper functionality.
9. With the park brake applied, check the display panel
for the proper indicator light.
10. Reinstall the cover around the park brake lever.
11. Unblock the wheels.
12. Close and secure the engine cover.
13. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

4-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers

4.3.6 Parking Brake (17M) 2. Uncap and connect the previously labeled hydraulic
hoses to the park brake.
a. Park Brake Removal 3. Connect the park brake electrical connector switch.
1. Park the machine on a firm, level surface, level the 4. Check the routing of all hoses for sharp bends or
machine, fully retract the boom, lower the boom, interference with any rotating members, and install
place the transmission control lever in (N) tie wraps and/or protective conduit as required.
NEUTRAL, engage the park brake and shut the
5. Start the engine and run at approximately 30-50%
engine OFF.
throttle for about one minute, without moving the
2. Place a Do Not Operate Tag on both the ignition key machine or operating any hydraulic functions.
switch and the steering wheel, stating that the
6. Bleed air from the brake circuit. Refer to Section
machine should not be operated.
8.9.3, “Brake Test.”
3. Open the engine cover. Allow the system fluids to
7. Inspect the park brake valve and connections for
cool.
leaks, and check the level of the hydraulic oil in the
4. Block the wheels. reservoir. Shut the engine OFF.
5. Properly disconnect the battery. 8. With the park brake applied, check the display panel
for the proper indicator light.
9. Wipe up any hydraulic oil spillage in, on, near and
around the machine, work area and tools.
10. Reinstall the cover around the park brake lever.
11. Properly connect the battery.
12. Unblock the wheels.
13. Close and secure the engine cover.
3
4 14. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

MZ2020 4.3.7 Windshield Wiper Assembly


6. Remove the cover (3) from around the park brake Refer to Section 9.12.1, “Windshield Wiper Motor,” for
lever. removal and installation information.
7. Disconnect the park brake electrical connector
switch (4). 4.3.8 Windshield Washer Assembly
8. Label, disconnect and cap the hydraulic hoses Refer to Section 9.12.3, “Windshield Washer Reservoir
attached to the park brake. Cap all fittings to prevent and Pump,” for removal and installation information.
dirt and debris from entering the hydraulic system.
9. Remove the bolts holding the park brake lever to the
mounting plate.
Note: DO NOT disassemble the park brake valve. The
valve is not serviceable and must be replaced in its
entirety, if defective.

b. Park Brake Installation


1. Secure the park brake lever to the mounting plate
using the pre-existing mounting hardware.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-7
Cab and Covers

4.3.9 Heater/Defroster System

a. Heater Assembly Removal


1. Park the machine on a firm, level surface, level the
7
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
6
4. Properly disconnect the battery.
5. Remove the belly pan. MZ2040

6. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap. 10. Loosen the hose clamps and disconnect the heater
hoses (6).
7. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the 11. Remove the heat duct hoses (7) from the back side
drain plug and slowly remove to allow the coolant to of the heating unit assembly.
drain. Transfer the coolant into a suitable, covered 12. Label and disconnect the electrical connectors
container and label as "Used Coolant". Dispose of attached to the heater assembly.
the used coolant at an approved recycling facility. 13. Remove the heater assembly mounting bolts.
Clean and reinstall the drain plug.
14. Carefully lift the heater assembly and remove from
the cab.

b. Heater Assembly Installation


1. Lower the heater assembly into the cab to its original
orientation. Secure with the previously used
hardware.
2. Connect the wiring harness connections to the
blower.
3. Connect the previously labeled hoses to the heater.
Secure with hose clamps.
4. Fill the cooling system completely with coolant,
allowing time for the coolant to fill the engine block.
5
The cooling system capacity is listed in Section 2.4,
MZ2050 “Fluids, Lubricants and Capacities.”
5. Properly connect the battery.
8. Remove the cab bottom and heater shield (5).
6. Start the engine and run at low idle. Check for any
9. Remove the cab floor mat to gain access to the visual signs of fluid leakage. STOP the engine
heater assembly mounting bolts. immediately if any leakage is noted, and make any
Note: Label all hoses to ensure correct installation. necessary repairs before continuing.
7. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
8. Replace the cab bottom and heater shield.

4-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers

9. Replace the belly pan. c. Installation and Testing


10. Close and secure the engine cover. 1. Install the control box into the dash panel until the
11. Remove the Do Not Operate Tags from both the side clips firmly hold the box.
ignition key switch and the steering wheel. 2. Connect the previously labeled electrical connectors
to the appropriate locations.
4.3.10 Cab Heater/Air Conditioning Controls 3. Connect the previously labeled control cables to the
appropriate control knob mechanisms.
a. Cab Heater Controls Removal
4. Properly connect the battery.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, 5. Turn the ignition key to the ON position and check
place the transmission control lever in the control functions.
(N) NEUTRAL, engage the park brake and shut the 6. Start the machine and allow engine to warm to
engine OFF. operating temperature. Check heat control at
2. Place a Do Not Operate Tag on both the ignition key different levels.
switch and the steering wheel, stating that the 7. Install the plastic side cover. If necessary, install the
machine should not be operated. seat.
3. Open the engine cover. Allow the system fluids to 8. Close and secure the engine cover.
cool. 9. Remove the Do Not Operate Tags from both the
4. Properly disconnect the battery. ignition key switch and the steering wheel.
5. Remove the plastic side cover in the cab to gain
access to the control cables and electronics. If 4.4 CAB REMOVAL
necessary, remove the seat for more accessibility.
Note: To help ensure safety and optimum performance,
replace the cab if it is damaged. Refer to the appropriate
9 parts manual for ordering information.
Before performing any inspection, maintenance or
service operation, thoroughly clean the machine. DO
NOT spray water or cleaning solution in, on, near or
around the operator dash panels and electrical
8 components.
8
MAM0310
Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
6. Label and disconnect the control cables (8) attached discovered, replace the cab. Contact your local authorized
to the control knob mechanisms. service distributor with any questions about the suitability
or condition of a cab.
7. Label and disconnect the electrical connectors
attached to the control box. Note: Remove and label cab components as needed
8. Depress the side clips (9) and push the control box before removing the cab from the machine. Label,
through the dash panel. disconnect and cap hydraulic hoses. Transfer cab parts
to the replacement cab after the replacement cab is
b. Disassembly securely mounted on the machine.

DO NOT disassemble the cab heater and fan controls. 1. Park the machine on a firm, level surface, level the
The controls are not serviceable. Replace controls if machine. Allow sufficient overhead and side
found to be defective. clearance for cab removal. Fully retract the boom,
lower the boom, place the transmission control lever
in (N) NEUTRAL, engage the park brake and shut
the engine OFF.
2. Block the wheels.
3. Open the engine cover. Allow the system fluids to
cool.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-9
Cab and Covers

4. Properly disconnect the battery.


5. Remove the belly pan.
6. Drain the engine radiator. Refer to Section 7.4.3, 1
“Radiator/Oil Cooler and Coolant Heater
Replacement.”
7. Working under the cab, remove the cab bottom
shield.
8. Label, disconnect and cap the heater hoses.
9. Remove the lens-head screws in the cab and
remove the console panel below the right side
window to access the wire harness connections, the
right rear side panel and the left rear cup holder
panel to access the two rear cab mount bolts. Also
remove the rubber floor mat to access the front two
cab mount bolts.
10. Disconnect the cab-to-wiring harness connectors at
the circuit board. Push the harness connectors
through the opening at the right front corner of the
cab.
11. 8, 9, 12 & 13M machines: Remove the park brake MZ0660

cover. Disconnect the park brake switch connector 14. Install two lifting eye bolts with a suitable lifting
and park brake cable. capacity in the existing threaded holes (1) at the top
corners of the windshield.
17M machines: Remove the park brake cover.
15. Secure the cab with a hoist or overhead crane and
Label, disconnect and cap the hydraulic hoses
sling. Do not lift the cab at this time.
attached to the park brake lever. Cap all fittings to
keep dirt and debris from entering the hydraulic
system. Disconnect the park brake switch.
12. Working under the cab, label, disconnect and cap
the hydraulic hoses at the cab fittings. Plug the
hoses and cap the fittings.
13. Disconnect the throttle cable from the throttle pedal
lever. Push the throttle cable through the bottom of
the cab.

2
MZ0640

16. Remove the four cab-to-frame bolts (2), flat washers


and nuts.

4-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers

17. Remove the mirrors and all other cab components 17M machines: Route the park brake hydraulic
as needed, if not previously removed. hoses back into the cab. Uncap and connect the
18. Use a hoist or overhead crane and sling attached to previously labeled hydraulic hoses to their
the cab, carefully begin to lift the cab. Stop and appropriate locations. Connect the previously
check that all wiring, hydraulic hoses and fasteners labeled electrical connector to the park brake lever.
are disconnected or removed. 8. Connect the throttle cable to the throttle pedal lever.
19. When all wiring, hydraulic hoses and fasteners are Adjust the throttle as required.
disconnected or removed, carefully and slowly lift 9. Route any hydraulic hoses through the opening at
the cab and remove it from the frame. the right front corner of the cab.
20. When the cab is completely clear of the machine, 10. Uncap and connect the previously labeled hydraulic
carefully lower it to the ground. Block up or support hoses to their appropriate locations.
the cab so that it does not move or fall over. Assure 11. Connect the previously labeled windshield wiper
that no personnel enter the cab while it is being fluid lines to the appropriate locations.
removed from the machine.
12. Route the wiring harness connectors through the
21. Inspect the condition of the fittings, clamps, opening at the right front corner of the cab and up
hydraulic hoses, etc. Replace parts as indicated by into the side console.
their condition.
13. Connect the previously labeled cab-to-wiring
22. Inspect and replace other machine parts that are harness connectors.
exposed with the cab removed. Repair or replace as
required. 14. Install the right side console panel, the right rear side
panel, the left rear cup holder panel and the rubber
floor mat.
4.5 CAB INSTALLATION
15. Fill the cooling system completely with coolant,
1. Block all four wheels to help prevent the machine allowing time for the coolant to fill the engine block.
from moving. Assure that there is sufficient overhead The cooling system capacity is listed in Section 2.4,
and side clearance for cab installation. “Fluids, Lubricants and Capacities.”
2. Attach a sling with suitable lifting capacity through 16. Properly connect the battery.
the previously installed eye bolts on top of the cab. 17. Start the engine and check the operation of all
3. Using a hoist or overhead crane and sling attached controls. Check for hydraulic leaks. Check the
to the two lifting eyes, carefully begin to align the cab hydraulic oil level in the tank and add oil as required.
with the mounting holes in the frame. Stop and
Note: When the engine is initially started, run it briefly at
check that wiring, hydraulic hoses, cables, etc., will
low idle and check the machine for any visual sign of
not be pinched or damaged as the cab is positioned.
fluid leakage. STOP the engine immediately if any
Readjust the position of the sling as needed to help
leakage is noted, and make any necessary repairs
balance the cab during installation.
before continuing.
4. Install the four bolts through the cab/frame mounts
and install the four washers and nuts. Remove the 18. Wait for the engine to cool and check the coolant
sling and both lifting eye bolts. Tighten and torque level. Add coolant to the overflow bottle as required
the four mounting bolts to 150 Nm (110 lb-ft). to bring the coolant to the proper level.

5. Uncap and connect the previously labeled heater 19. Reinstall engine belly pan.
hoses to the heater assembly. 20. Reinstall the cab bottom shield.
6. Uncap and connect the previously labeled air 21. Close and secure the engine cover.
conditioner lines (if equipped) to the heater 22. Unblock the wheels.
assembly.
23. Remove the Do Not Operate Tags from both the
7. 8, 9, 12, & 13M machines: Route the park brake ignition key switch and the steering wheel.
cable back into the cab. Secure the park brake cable
to the park brake lever with the pre-existing pin.
Connect the previously labeled electrical connector
to the park brake lever.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-11
Cab and Covers

This Page Intentionally Left Blank

4-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 5
Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE


5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.3 Axle Internal Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.7 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5-6
5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-10
5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5-11
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.6.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.7 Towing A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7.1 Towing (8, 9, 12 & 13M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7.2 Manually Releasing the Park Brake (17M) . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.7.3 Manually Resetting the Park Brake (17M) . . . . . . . . . . . . . . . . . . . . . . . . 5-12

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-1
Axles, Drive Shafts, Wheels and Tires

5.1 AXLE, DRIVE SHAFT AND WHEEL


COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.

REAR AXLE
ASSEMBLY

STEERING
CYLINDER
(REAR)

TRANSMISSION
DROP BOX

STEERING
CYLINDER
(FRONT)

DRIVE SHAFTS

MZ1510

FRONT
AXLE
ASSEMBLY

5-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires

5.2 GENERAL INFORMATION 5.3.3 Axle Internal Service


Detailed axle service instructions (covering the axle,
Note: To help ensure optimum performance, the drive
differential, brakes and wheel-end safety, repair,
shaft assemblies are specially balanced as a unit at the
disassembly, reassembly, adjustment and
factory. When servicing any flange yoke, slip yoke or
troubleshooting information) are provided in the Dana
drive shaft tube, order a complete assembly if
Spicer Maintenance and Repair Manual (P/N 31200162).
components are bent of damaged. Refer to the
appropriate parts manual for ordering information.
Before performing any inspection, maintenance or WARNING
service operation, thoroughly clean the unit. The axles DO NOT service the machine without following all
and drive shafts should be checked and repaired only by safety precautions as outlined in Section 1, “Safety
experienced service technicians who are aware of all Practices,” of this manual.
safety instructions and particular component features.
Use suitable products to thoroughly clean all 5.3.4 Axle Maintenance
disassembled mechanical parts to help prevent personal
CLEANING: Clean parts with machined or ground
injury to the worker and prevent damage to the parts.
surfaces (such as gears, bearings and shafts) with
Carefully inspect the integrity of all moving parts
emulsion cleaners or petroleum-based cleaners. DO
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
NOT steam clean internal components and the interior of
(nuts, bolts, washers, etc.) as they are subject to major
the planetary hub and axle housing. Water can cause
stress and wear. Always replace elastic locknuts and any
corrosion of critical parts. Rust contamination in the
damaged, worn, cracked, seized or otherwise improper
lubricant ca n cause gear and bearing failure. Remove
parts that could affect the safe and proper functioning of
old gasket material from all surfaces.
the machine, axles and drive shafts.
DRYING: Use clean, lintless towels to dry components
5.3 AXLE ASSEMBLIES after cleaning. DO NOT dry bearings by spinning them
with compressed air; this can damage mating surfaces
due to lack of lubrication. After drying, lightly coat
5.3.1 Axle Serial Number Plate components with oil or a rust-preventive chemical to help
The front and rear axle serial number plate is located on protect them from corrosion. If storing components for a
a mounting pad on the front side of the center section of prolonged period, wrap them in wax paper.
each axle. Information on the serial number plate is PERIODIC OPERATION REQUIREMENT: Every two
required in correspondence regarding the axle. weeks, drive the machine far enough to cause the drive-
Supply information from the axle serial number plate train components to make several complete revolutions.
when communicating about an axle assembly or axle This will help ensure that internal components receive
components. lubrication to minimize deterioration caused by
environmental factors such as high humidity.
5.3.2 Axle Specifications SUBMERSION: If the machine has been exposed to
General axle specifications are found in Section 2.4, water deep enough to cover the hubs, disassemble the
“Fluids, Lubricants and Capacities.” wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent
tube (breather), drain the axle and inspect internal parts
for water damage and contamination. Before assembling
and refilling the unit with the specified lubricant(s), clean,
examine and replace damaged parts as necessary.
Note: Use a suitable puller for bearing removal. Clean,
inspect and lubricate all bearings just prior to
reassembly. If replacement of a damaged bearing cup or
cone is necessary, replace the cup and cone as a set.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-3
Axles, Drive Shafts, Wheels and Tires

5.3.5 Axle Removal allow the axle oil to drain into the receptacle.
Transfer the used axle oil into a suitable covered
The front and rear axle assemblies differ in that the front
container, and label the container as "Used Oil".
axle assembly is equipped with a parking brake
Dispose of used oil at an approved recycling facility.
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal 7. Label, disconnect and cap the steering and brake
procedure, suitable for either the front or the rear axle lines at the axle. Wipe up any spilled oil.
assembly. 8. Block the front and rear of both tires on the axle that
Cleanliness is extremely important. Before attempting to is not being removed. Ensure that the machine will
remove the axle, thoroughly clean the machine. Avoid remain in place during axle removal before
spraying water or cleaning solution on the outrigger proceeding.
solenoids and other electrical components. If using a 9. Raise the machine using a suitable jack or hoist.
steam cleaner, seal all openings before steam cleaning. Place suitable supports under both sides of the
Note: Clear the work area of all debris, unnecessary frame and lower the machine onto the supports.
personnel, etc. Allow sufficient space to raise the Ensure that the machine will remain in place during
machine and to remove the axle. axle removal.
10. Support the axle that is being removed with a suitable
1. Park the machine on a firm, level surface, level the
jack, hoist or overhead crane and sling. DO NOT
machine, fully retract the boom, lower the boom,
raise the axle or the machine.
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 11. Mark and remove both wheel and tire assemblies
engine OFF. from the axle that is being removed. Refer to Section
5.5.1, “Removing Wheel and Tire Assembly from
2. Place a Do Not Operate Tag on both the ignition key
Machine.”
switch and steering wheel, stating that the machine
should not be operated. 12. Remove the drive shaft assembly. Refer to Section
5.4.3, “Drive Shaft Removal.”
3. Open the engine cover. Allow the system fluids to
cool. 13. On the front axle, remove the hardware securing the
frame level cylinder or bar. Tap the mount pin out,
4. Properly disconnect the battery.
and move the cylinder or bar to prevent it from
5. Remove the fender assemblies. interfering with axle removal.
14. Remove the park brake cable from the front axle (8,
9, 12 & 13M only).
15. Remove the bolts and locknuts securing the axle to
the frame.
16. Remove the axles from the machine using the jack,
MZ1030 hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
1 machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.

5.3.6 Axle Installation


The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and limited-slip feature; the rear axle has
2 neither. The steps below outline a typical axle installation
MZ1520
procedure, suitable for either the front or the rear axle
assembly.
6. If the axle will be disassembled after removal, place 1. Before proceeding, ensure that the machine will
a suitable receptacle under the axle (1) and wheel remain in place during axle installation. Block the
hubs drain plugs (2). Remove the drain plugs and

5-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires

front and rear of both tires on the axle that is already


installed on the machine.
2. If applicable, raise the machine using a suitable jack 5
or hoist. Place suitable supports beneath the frame
and lower the machine onto the supports, allowing
enough room for axle installation. Ensure that the
machine will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and
sling, remove the axle from its support or holding
stand. Balance the axle and prevent it from tipping, MZ5820

turning or falling while positioning it beneath the 11. Rotate wheel hubs 90 degrees so the drain plug (5)
machine. DO NOT raise or otherwise disturb the becomes the fill plug. Refer to Section 2.4, “Fluids,
machine while installing the axle. Keep the axle Lubricants and Capacities,” for proper oil and
supported and balanced on the jack, hoist or capacities.
overhead crane and sling throughout the installation
procedure. 12. Install the wheel and tire assemblies. Refer to
Section 5.5.2, “Installing Wheel and Tire Assembly
4. Position the axle under the frame, and align the axle onto Machine.”
housing with the holes in the frame.
13. Carefully remove the jack, hoist or overhead crane
5. Install the axle bolts and nuts. Tighten and torque and sling supporting the axle.
the axle nuts to 550-600 Nm (406-443 lb-ft).
14. Carefully raise the machine using a suitable jack or
6. Move the cylinder or bar into position on the front hoist. Remove the supports from beneath the frame
axle anchor (if necessary). Install the mount pin. and lower the machine to the ground.
7. Apply a multi-purpose grease through the self-
Note: ALWAYS use new o-rings when servicing the
tapping lube fitting to lubricate the self-align bearing
machine.
and the cylinder-mount pin (if required).
8. Install the drive shaft assemblies. Refer to Section 15. Install new o-rings into the fittings. Lubricate the
5.4.5, “Drive Shaft Installation.” o-rings with clean hydraulic oil.
9. If reinstalling an axle previously removed from the 16. Uncap and connect the steering and brake lines at
machine, position the driveshaft yoke on the axle their axle fittings.
according to the alignment marks made earlier. If 17. Install the park brake on the front axle (8, 9, 12 &
installing a new axle, note the position of the 13M only).
driveshaft yoke at the transmission. Align the 18. If reinstalling the front axle, the hydraulic brake
driveshaft yoke on the axle in the same plane as the circuit will need to be bled. Refer to Section 8.9.3,
yoke on the transmission. “Brake Test.”
3 19. Check the hydraulic reservoir oil level.
20. Install the fender assemblies.
21. Properly connect the battery.
22. Unblock the wheels.
23. Start the engine. Turn the steering wheel several
times lock to lock, operate the frame tilt function
MZ1030
several times in both directions and check the
4 function of the brakes. Check for hydraulic leaks,
10. Tighten the axle oil drain plug, loosen and remove and tighten or repair as necessary.
the axle oil fill plug (3). Fill the axle through the axle 24. Close and secure the engine cover.
fill plug until the oil level is even with the oil check
level plugs (4). Refer to Section 2.4, “Fluids, 25. Remove the Do Not Operate Tags from both the
Lubricants and Capacities,” for proper oil and ignition key switch and the steering wheel.
capacities.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-5
Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy


1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.4, “Fluids, Lubricants
and Capacities.”
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level
low. with Mobilfluid 424® ISO 46.
Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”

3. Incorrect alignment of ring and 3. Correct alignment by adding or


pinion gears. removing shims as needed.

4. Incorrect pinion (input) shaft 4. Correct bearing preload by


bearing preload. adding or removing shims as
needed.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end


housings and fill to correct level
with Mobilfluid 424® ISO 46.
Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”

8. Axle housing damaged. 8. Replace damaged parts.

2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal


traveling. damaged. joints as needed.

2. Differential ring and/or pinion 2. Determine cause and repair as


gears damaged. needed.

3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.

2. Drive shaft universal joint(s) 2. Repair or replace universal


worn or damaged. joints as needed.
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as
unbalanced. needed.

5-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy


4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace o-rings as needed and
(differential housing and/or loose and/or o-rings damaged tighten plugs to 130 Nm
axle housings). or missing. (96 lb-ft).
2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or 3. Replace seal and/or joint


missing and/or worn or coupling fork shaft (axle shaft).
damaged shaft sealing
surfaces.

4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or


damaged or missing and/or input shaft. Adjust ring and
worn or damaged pinion (input) pinion alignment and bearing
shaft sealing surfaces. preload as described in the
Dana Repair Manuals.

5. Axle casing to brake housing 5. Replace o-rings and seals.


and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.
6. Axle housing mounting nuts and 6. Tighten housing nuts and
capscrews loose. capscrews to 390 Nm
(288 lb-ft).

7. Differential and/or axle 7. Replace housing(s) as needed.


housing(s) damaged.

5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 130 Nm
(96 lb-ft).
2. O-ring between hub and 2. Replace o-ring.
housing (planet carrier)
damaged or missing.

3. Shaft seal damaged or missing 3. Replace seal and/or fork joint


and/or worn or damaged shaft shaft.
sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to


55 Nm (41 lb-ft).

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.


cylinder.
2. Steering cylinder o-rings and/or 2. Replace o-rings and seals.
seals worn or damaged.

3. Piston rod seal worn or 3. Replace piston rod seal.


damaged.

4. Cylinder tube damaged. 4. Replace cylinder tube.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-7
Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with
Mobilfluid 424® ISO 46. Refer to
Section 2.4, “Fluids, Lubricants
and Capacities.”

2. Axle and/or wheel end housings 2. Drain axle and fill to correct level
filled with incorrect oil or oil with Mobilfluid 424® ISO 46.
contaminated or oil level low. Refer toSection 2.4, “Fluids,
Lubricants and Capacities.”
3. Dragging park brake. 3. Adjust park brake cable as
needed.
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.10.8,
operating properly. “Steering Cylinders.”

2. Excessive joint housing swivel 2. Correct bearing preload by


bearing preload. adding or removing shims as
needed.

3. Worn or damaged swivel 3. Replace swivel bearings as


bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.10.8,
operating properly. “Steering Cylinders.”

2. Steering cylinder leaking 2. Repair or replace steering


internally. cylinder as needed.

10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 5.6, “Brakes.”
2. Brake discs damaged. 2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.10.8,
operating properly. “Steering Cylinders.”

2. Brake piston o-rings and seals 2. Replace o-rings and seals.


damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power Refer to Section 5.6, “Brakes.”
reduced.
2. Brake (hydraulic) system not 2. Refer to Section 8.9.3, “Brake
operating properly. Test.”

3. Brake piston o-rings and seals 3. Replace o-rings and seals.


damaged (leaking).

5-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires

5.4 DRIVE SHAFTS


To Transmission

5.4.1 Drive Shaft Inspection and Service


Whenever servicing the machine, conduct a visual
inspection of the drive shaft and cross and bearing
assembly (universal joints, or U-joints). A few moments 2
spent doing this can help prevent further problems and 1
down time later.
Inspect area where the drive shaft flange yoke and slip To Axle
yoke mount to the drive shaft. Attempt to turn drive shaft 3
in both directions. Look for excessive looseness, missing 4
parts, cracks or other damage. Worn or damaged drive
shaft and cross and bearing assembly may cause an 7. Remove the four capscrews (1) and two straps (2)
excessive amount of vibration or noise. securing the bearing cross to the transmission
output shaft flange. Discard capscrews.
Note: Any bolt removed from the drive shaft assembly
MUST be replaced. Do Not re-torque. 8. Remove the four capscrews (3) and two straps (4)
securing the bearing crosses to the axle. Discard
5.4.2 Drive Shaft Maintenance capscrews.
9. Remove the front drive shaft assembly.
Refer to Section 2.6, “Lubrication Schedules,” for
information regarding the lubrication of the grease fittings 10. Repeat the above procedure for the rear drive shaft.
on the drive shafts.
5.4.4 Drive Shaft Cleaning and Drying
5.4.3 Drive Shaft Removal 1. Disassemble and clean all parts using an approved
1. Park the machine on a firm, level surface, level the cleaning fluid. Allow to dry.
machine, fully retract the boom, lower the boom, 2. Remove any burrs or rough spots from all machined
place the transmission control lever in surfaces. Re-clean and dry as required.
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 5.4.5 Drive Shaft Installation
2. Place a Do Not Operate Tag on both the ignition key Note: The yoke at both ends of the drive shaft must be
switch and steering wheel, stating that the machine in the same plane to help prevent excessive vibration.
should not be operated. 1. Raise the drive shaft assembly into position. The
3. Open the engine cover. Allow the engine to cool. slip-yoke end of the drive shaft mounts toward the
4. Properly disconnect the battery. axle. If reinstalling a drive shaft previously removed,
align the flange yokes according to the alignment
5. Block the wheels. marks made during removal.
6. The drive shaft assembly is a balanced assembly. 2. Install the four capscrews and two straps securing
Mark the yoke and axle, transmission and the shaft the bearing crosses to the transmission. Torque the
and slip yoke so that these components can be capscrews to 38 Nm (28 lb-ft).
returned to their original positions when reinstalled.
Yokes at both ends of the drive shaft must be in the 3. Install the four capscrews and two straps securing
same plane to help prevent excessive vibration. the bearing crosses to the axle. Torque the
capscrews to 38 Nm (28 lb-ft).
4. Repeat the above procedure on the rear drive shaft.
5. Properly connect the battery.
6. Unblock the wheels.
7. Close and secure the engine cover.
8. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-9
Axles, Drive Shafts, Wheels and Tires

5.5 WHEELS AND TIRES 5

WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
JLG recommends a replacement tire to be the same size,
ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using a JLG approved replacement tire, JLG
MY4190
recommends that replacement tires have the following
characteristics: The wheel and tire assemblies must be installed with the
• Equal or greater ply/load rating and size of original. directional tread pattern “arrows” (5) facing in the
direction of forward travel.
• Tire tread contact width equal or greater than
original.
5.5.1 Removing Wheel and Tire Assembly
• Wheel diameter, width and offset dimensions equal from Machine
to the original.
1. Park the machine on a firm, level surface, level the
• Approved for the application by the tire manufacturer machine, fully retract the boom, lower the boom,
(including inflation pressure and maximum tire load). place the transmission control lever in
The rims installed have been designed for stability (N) NEUTRAL, engage the park brake and shut the
requirements which consist of track width, tire pressure engine OFF.
and load capacity. Size changes such as rim width, 2. Place a Do Not Operate Tag on both the ignition key
center piece location, larger or smaller diameter, etc., switch and steering wheel, stating that the machine
without written factory recommendations, may result in should not be operated.
unsafe condition regarding stability.
3. Loosen, but DO NOT remove the lug nuts on the
The tires are filled with air only when the machine leaves wheel and tire assembly to be removed.
the factory. JLG does not recommend the use of hydrofill
as a tire-fill substance because of possible environmental 4. Place a suitable jack under the axle pad closest to
impact. the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
Large-bore valve stems are used to help expedite tire sufficient room to lower the machine onto the
inflation and deflation. An inner tube may be used if a tire support and to remove the wheel and tire assembly.
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire 5. Lower the machine onto the support.
on the wheel, the tire must be mounted on the wheel 6. Remove lug nuts and lug washers in an alternating
respective of the directional tread pattern of the tire; this pattern.
produces a left or right tire and wheel assembly. 7. Remove the wheel and tire assembly from the
machine.

5-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires

5.5.2 Installing Wheel and Tire Assembly 5.6 BRAKES


onto Machine
Note: The wheel and tire assemblies must be installed 5.6.1 Brake Disk Inspection.
with the directional tread pattern “arrows” facing in the
direction of forward travel. a. Front and Rear Axles
Tread "arrows" must point 1. Block all four wheels to help prevent the machine
forward
from moving after the parking brake is disabled.
8

MZ1030

6
2. Remove the oil-level plug (6) on each side of the
axle.
3. Have an assistant sit in the cab and apply the
brakes, keeping pressure applied.

Install tires onto wheels to


rotate in proper direction

Mh3300

1. Position wheel onto studs on wheel end of axle.


2. Install wheel lug washers.
3. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
7 MZ5830
1 8
4. Using a feeler gauge, check the gap between the
brake discs (7). If the gap is less than 4,5 mm
6 3 (0.18 in), replace the brake discs.
Note: If the brake discs are worn beyond their
tolerance, the brake disc must be replaced on both sides
of the axle at the same time.
9 10
5. Repeat steps 3 and 4 for the other side of the axle.
6. Fill the axle through the axle fill plug (8) until the oil
level is even with the oil check level plugs (6). Refer
4 5 to Section 2.4, “Fluids, Lubricants and Capacities,”
for proper oil and capacities.
7 2 MY4200

4. Tighten lug nuts in an alternating pattern as


indicated in figure. Torque to 575 Nm (424 lb-ft).
5. Remove machine from supports.
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-11
Axles, Drive Shafts, Wheels and Tires

5.7 TOWING A DISABLED MACHINE Note: Turning the release bolts in to far could warp the
brake discs. DO NOT over tighten.
Towing a disabled machine should only be attempted as
Note: After the machine has been towed to a secure
a last resort, after exhausting all other options. Make
location, reactivate the park brake. Carefully follow the
every effort to repair the machine, and move it under its
procedures from start to finish. Consult your local JLG
own power, before using the emergency towing
distributor or the JLG Service Department if you are
procedures outlined below.
unsure about any part of the procedure, or for specific
On 17M machines, the park brake is hydraulically instructions concerning your particular situation.
operated. Therefore, the axle must have the park brake
manually be disabled. On 8, 9, 12 & 13M machines, the 5.7.3 Manually Resetting the Park Brake
park brake is cable operated and can be disabled in the (17M)
cab with the park brake lever.
Note: Block the wheels of the machine BEFORE
attempting to reset the machine’s park brake. Once the
5.7.1 Towing (8, 9, 12 & 13M)
park brake is reset the machine’s park brake AND
1. Secure the machine to a suitable towing vehicle. service brakes are operable.
2. Release the park brake and set the transmission 1. Loosen the jam nuts on all four manual brake
control lever in (N) NEUTRAL. release bolts.
3. Tow the machine to a suitable repair facility. 2. Turn all four manual brake release bolts OUT a
4. After towing is complete, engage the park brake. quarter turn at a time to the dimension recorded
before starting the towing procedure.
5.7.2 Manually Releasing the Park Brake 3. Tighten the jam nuts on all four manual brake
(17M) release bolts.
Note: Block the wheels of the machine BEFORE After repairs to the machine have been made, start the
attempting to release the park brake. Once the park machine and check the park brake and service brakes for
brake is released the machine’s park brake AND service proper function.
brakes are inoperable.
9

MZ1020

1. Measure the distance from the bolt head to the face


of the jam nut on all four of the manual brake release
bolts (9) located on each side of the front axle center
section (two per side). Record the measurements.
2. Loosen the jam nuts on the four manual brake
release bolts.
3. Turn all four release bolts in equally with a wrench or
socket BY HAND a quarter turn at a time up to
approximately 19 mm (0.750 in) or until resistance is
felt. Tighten the jam nuts.

5-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 6
Transmission:

Contents

PARAGRAPH TITLE PAGE


6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.5.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-1
Transmission:

6.1 TRANSMISSION ASSEMBLY


COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the major assemblies of the transmission.
The following illustration identifies the components that
are referred to throughout this section.

TORQUE CONVERTOR
DIPSTICK AND FILL TUBE

OIL FILTER
OUTPUT SHAFT
(FRONT)

BREATHER

OUTPUT SHAFT
(REAR)
BREATHER

DROP BOX OIL LEVEL


SIGHT GAUGE

MZ0670
TRANSMISSION DROP BOX
SHIFT SOLENOIDS
FLEX PLATE ASSEMBLY

6-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:

6.4.2 Transmission Maintenance Schedule


Complete transmission maintenance information is
WARNING located in the appropriate Operation & Safety Manual.
DO NOT service the machine without following all • At ten hour intervals, check the transmission oil
safety precautions as outlined in Section 1, “Safety level. Refer to the appropriate Operation & Safety
Practices,” of this manual. Manual.
• When the machine completes it’s first 50 hours of
6.2 TRANSMISSION DESCRIPTION use, change the transmission filter. Change the filter
only; DO NOT change the transmission oil at the first
Instructions in this section pertain mainly to general 50 hour maintenance level. Refer to the appropriate
specifications, towing, maintenance information, and Operation & Safety Manual.
transmission removal and installation procedures. For • At 1,000 hour intervals, change the transmission oil
internal transmission service instructions and detailed and filter. Refer to the appropriate Operation &
specifications contact your local authorized service Safety Manual.
distributor for a copy of the Dana Spicer Repair Manual Periodically, depending on operating conditions and
(P/N 31200163). other factors, back flush the transmission oil cooler,
which is located in or behind the radiator. ALWAYS back
6.3 TRANSMISSION SERIAL NUMBER flush the transmission oil cooler after removing the
transmission for repair or replacement.
The transmission serial number plate is located on the
front of the transmission case below the convertor The transmission oil cooler outlet hose, routed to the
housing. Information specified on the serial number plate lower oil cooler fitting, is located on the top of the
includes the transmission model number, the transmission. The transmission oil cooler inlet hose,
transmission serial number and other data. Information routed to the upper oil cooler fitting, is located on the top
on the serial number plate is required in correspondence of the transmission Refer to Section 7.4, “Engine Cooling
regarding the transmission. System.”
Disconnect and back flush the oil cooler portion of the
6.4 TRANSMISSION SPECIFICATIONS radiator or the oil cooler with oil and compressed air until
all foreign material is removed. If necessary, remove the
radiator or oil cooler from the machine, and clean the oil
6.4.1 Transmission Maintenance cooler circuit using oil, compressed air and steam.
Cleanliness is of extreme importance. Before attempting
Note: DO NOT use flushing compounds for cleaning
any repairs, thoroughly clean the exterior of the
purposes.
transmission to help prevent dirt from entering while
performing maintenance checks and procedures.
6.5 TRANSMISSION REPLACEMENT
Section 2.5, “Maintenance Schedules.” provides a
suggested maintenance schedule with references to Note: Contact the JLG Service Department if internal
pertinent procedures and instructions in this manual. To transmission repair is required during the warranty
help prevent transmission problems before they occur, period.
follow the maintenance schedule.
Note: To help ensure safety and optimum performance,
Note: Lubrication and Maintenance chart decals are replace the transmission if it is damaged. Refer to the
located inside the rear door of the machine or in the cab. appropriate Parts Manual for ordering information.
These decals contain a general maintenance schedule
that should be followed to maintain the machine in good Cleanliness is of extreme importance. Before attempting
operating condition. Refer to Section 2.6, “Lubrication to remove the transmission, thoroughly clean the exterior
Schedules.” The same schedule information is of the transmission to help prevent dirt from entering
presented in the appropriate Operation & Safety Manual, during the replacement process. Avoid spraying water or
with a detailed account of how to perform the cleaning solution onto or near the transmission shift
procedures. solenoids and other electrical components.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-3
Transmission:

6.5.1 Transmission Removal 11. Remove the air cleaner unit and intake tubes.
12. Remove the hydraulic pump. Refer to Section 8.7.3,

WARNING “Pump Replacement.”


13. Label and disconnect the transmission temperature
Risk of severe personal injury. NEVER lift a switch connector and shift solenoid wiring harness
transmission alone; enlist the help of at least one connectors.
assistant or use a suitable hoist or overhead crane 14. Label, disconnect and cap the transmission oil
and sling. cooler inlet and outlet hoses at the transmission. The
1. Park the machine on a firm, level surface, level the transmission oil cooler outlet hose, routed to the
machine, fully retract the boom, lower the boom, lower radiator fitting, is located on the top of the
place the transmission control lever in the transmission. the transmission oil cooler inlet hose,
(N) NEUTRAL, engage the park brake and shut the routed to the upper radiator fitting, is located on top
engine OFF. of the transmission.
2. Place a Do Not Operate Tag on both the ignition key 15. Remove the access plug from the side of the engine
switch and steering wheel, stating that the machine bell housing. This will allow access to remove the
should not be operated. eight bolts holding the flex plate to the engine
flywheel.
3. Open the engine cover. Allow the engine to cool.
16. Turn the engine over slowly by hand and align each
4. Remove the engine cover to allow easier access to
of the eight flex plate bolts to be accessed. Remove
the transmission.
them one at a time.
5. Remove the belly pan from under engine.
17. Wipe up any spilled hydraulic and transmission oil.
6. Disconnect the (+) positive and (-) negative battery
18. Connect a lifting strap or chain to the lifting eye at
cables and remove the battery.
the top of the transmission, and to a suitable hoist or
7. Thoroughly clean the transmission and surrounding overhead crane. Operate the hoist or crane to
area, including all hoses and fittings, before remove slack from the chain, but DO NOT raise the
proceeding. transmission at this time.
19. Place blocks under the rear of engine for support
BEFORE transmission mounts are removed.
20. Place blocks under the transmission to help support
it during removal.
21. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.
22. Remove the ten bolts and washers holding the
1 transmission to the engine.
MZ1380 23. Remove the four capscrews and four lockwashers
2
securing each rear transmission mount to the
8. Place a suitable receptacle under the transmission transmission.
drain plug (1). Remove the transmission drain plug 24. Remove the two transmission mounts from the
and allow the transmission oil to drain into the machine.
receptacle. Repeat drain procedure with the drop 25. Inspect the rubber mounts. Replace the mounts if
box (2). damaged.
9. Transfer the used transmission oil into a suitable, 26. Carefully remove the transmission from the
covered container, and label the container "Used machine. Avoid causing damage to the transmission
Oil". Dispose of used oil at an approved recycling or surrounding parts.
facility. Clean and reinstall the transmission drain
plug.
10. Remove the drive shafts. Refer to Section 5.4.3,
“Drive Shaft Removal.”

6-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:

27. Lift the transmission clear of the machine, and lower 6.5.3 Transmission Installation
it onto suitable supports or secure it to a stand built
1. Install both the rear transmission mounts on the
especially for transmission or engine service. Secure
transmission. Torque capscrews to 120 Nm
the transmission so that it will not move or fall.
(88 lb-ft).
28. Remove any external transmission components as
2. Install guide studs near the top of the bell housing
required, including the transmission temperature
holes and in the flex plate.
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings. 3. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
3
4. Align the torque convertor, align the transmission
bolt holes with the guide studs in the bell housing
and flex plate. Install the eight bolts and washers
and torque to 63 Nm (46 lb-ft). Remove the
alignment studs and install and torque the last two
transmission mount bolts and torque to 63 Nm
(46 lb-ft).
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite® 243TM to the transmission mount bolts
and torque to 210 Nm (155 lb-ft).
6. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Install
them one at a time. Torque to 35-39 Nm (26-29 lb-ft).
Replace access plug.
MZ0680
7. Remove the hoist or overhead crane and sling.
29. Remove the transmission oil filter (3) and dispose of
8. Connect the transmission temperature switch
properly. Clean the filter mounting surface. Cover or
connector and shift solenoid wiring harness
cap the oil filter mount.
connectors.
30. If transmission oil is suspected of contamination or
9. Secure the wiring harness to the transmission
torque convertor is damaged, remove the convertor
housing.
and flex plate from the transmission.
10. Uncap and connect the transmission oil cooler inlet
31. Remove the six bolts and washers holding the
and outlet hoses at the transmission.
convertor to the flex plate.
11. Install the hydraulic pump. Refer to Section 8.7.3,
6.5.2 Transmission Inspection and Internal “Pump Replacement.”
Repair 12. Install the transmission-to-axle drive shafts. Refer to
If replacing the entire transmission, transfer the Section 5.4.5, “Drive Shaft Installation.”
transmission temperature switch to the replacement 13. Install air cleaner and tubing.
transmission. The gear shift solenoids are included with a 14. Clean the transmission oil filter mounting surface.
new transmission.
15. Apply a thin film of clean hydraulic oil to the new
Detailed internal service instructions are provided in the transmission filter gasket. Install the new filter and
Dana Spicer Repair Manual, which can be obtained by torque to 27-34 Nm
contacting your local JLG Distributor. (20-25 lb-ft).

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-5
Transmission:

16. Remove the dipstick and add approximately 11,4


liters (3 Gallons) of hydraulic oil. Check the oil level
by taking intermittent dipstick readings as outlined in
the appropriate Operation & Safety Manual. DO
NOT overfill. Reinstall the dipstick when finished. 4
17. Remove the fill plug on the transfer case. Fill the
transmission drop box. Refer to Section 2.4, “Fluids,
Lubricants and Capacities.” Install and tighten drop
box fill plug.
18. Install the belly pan under the engine.
19. Install the engine cover.
20. Install the battery and reconnect the positive (+) and
negative (-) cables.
21. Close and secure the engine cover.
22. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
MZ0680

6.5.4 After Transmission Service or


10. Reassemble all components and fill the transmission
Replacement
through the dipstick tube opening (4). Remove the
Refer to the Dana Spicer Transmission Repair Manual dipstick and fill with approximately 11 liters
which can be obtained by calling your local JLG (2.5 gallons) of hydraulic. Check the level by taking
Distributor. intermittent dipstick readings as outlined in the
In General: appropriate Operation & Safety Manual. DO NOT
overfill. Reinstall the dipstick when finished.
1. Check the transmission oil level and add oil as
required. 11. Run the engine for two minutes at idle to help prime
the torque convertor and the transmission oil lines.
2. Check the transmission drop box oil level and add oil
as required. 12. Recheck the level of the oil in the transmission with
the engine running at idle.
3. Install a new transmission filter.
13. Add hydraulic oil as necessary to bring the oil level
4. Check the torque on the drive shaft yoke capscrews.
up until it reaches the FULL mark on the dipstick.
5. Wear suitable eye protection. When an overhauled Recheck the oil level when it reaches operating
or repaired transmission is installed, thoroughly temperature 83-94°C (180-200°F).
clean the oil cooler lines to and from the
14. Recheck all drain plugs, lines, connections, etc. for
transmission.
leaks, and tighten where necessary.
6. Drain and flush the entire system.
7. Disconnect and clean all transmission cooler hoses.
When possible, remove transmission lines from the
machine for cleaning.
8. Thoroughly clean transmission filter screens and
cases, and replace transmission filter elements.
9. Thoroughly clean transmission oil cooler.

6-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:

6.6 TROUBLESHOOTING The transmission should be checked, serviced and


repaired only by experienced service technicians who are
This section provides an easy reference guide covering aware of all safety instructions and particular component
the most common problems that may occur during features.
operation of the transmission.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.

Problem Cause Remedy


1. Transmission will not engage 1. Oil level too high or low. 1. Fill transmission to correct level
or will not shift properly. with Mobilfluid 424® ISO
Grade 46. (Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”)
2. Transmission control lever not 2. Refer to Section 9.7.1, “Cab
functioning properly and/or a Harness Electrical Schematic.”
fault in the wiring
harness.Transmission control
lever not functioning properly
and/or a fault in the wiring
harness.

3. Transmission valve body 3. Refer to Section 9.7.1, “Cab


solenoids not functioning Harness Electrical Schematic.”
properly.

4. Pilot-operated shift valves not 4. Clean the valve spool and


operating properly. housing. Replace return spring
as needed.

5. Pump output pressure low. 5. Refer to Section 6.6,


“Troubleshooting,” Problem 2.
“Low or no pump flow or
pressure.”

6. Clutch piston o-rings damaged. 6. Replace o-rings.

7. Clutch discs worn or damaged. 7. Replace clutch discs.


8. Coupling shafts or gear teeth 8. Replace couplings.
damaged.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-7
Transmission:

Problem Cause Remedy


2. Low or no pump flow or 1. Low oil level. 1. Fill transmission to correct level
pressure. with Mobilfluid 424® ISO
Grade 46. (Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”)
2. Transmission filled with incorrect 2. Drain transmission and fill to
oil, or oil contaminated. correct level with Mobilfluid 424®
ISO Grade 46. (Refer Section
2.4, “Fluids, Lubricants and
Capacities.”)

3. Pump suction pipe screen 3. Clean, repair and/or replace


clogged. suction pipe.

4. Central shaft damaged. 4. Replace central shaft.

5. Pump worn or damaged. 5. Repair or replace pump


assembly.

3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
with Mobilfluid 424® ISO
Grade 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”

2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.

3. Broken or worn coupling shaft or 3. Replace coupling and/or o-rings.


piston o-rings.

4. Pressure reducing valve stuck 4. Clean the valve spool and


open. housing.

4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.5, “Hydraulic
Schematics.”

2. Low engine rpm causes 2. Adjust the engine rpm to


converter stall. specifications. Refer to Dana-
Spicer Service Manual.

3. Pump output pressure is low. 3. Refer to Section 6.6,


“Troubleshooting,” Problem 2.
“Low or no pump flow or
pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.

5. Transmission overheating. 5. Refer to Section 6.6,


“Troubleshooting,” Problem 5.
“Transmission overheating (oil
above 120° C (248° F)).”

6-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:

Problem Cause Remedy


5. Transmission overheating 1. Low oil level. 1. Fill transmission to correct level
(oil above 120° C (248° F)). with Mobilfluid 424® ISO
Grade 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”
2. Clogged radiator. 2. Remove debris from the
radiator.

3. Transmission filled with incorrect 3. Drain transmission and fill to


oil, or oil contaminated. correct level with Mobilfluid 424®
ISO Grade 46. Refer to Section
2.4, “Fluids, Lubricants and
Capacities.”

4. Excessive “roading.” 4. Stop and idle the engine.

5. Restriction in oil cooler hoses. 5. Replace cooler hoses.

6. Pump worn or damaged. 6. Repair or replace pump


assembly.

7. Engine thermostat stuck. 7. Replace engine thermostat.


Refer to Section 7.4.2,
“Thermostat Replacement.”

6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.4, “Fluids, Lubricants
and Capacities.”

2. Transmission filled with incorrect 2. Drain transmission and fill to


oil. correct level with Mobilfluid 424®
ISO Grade 46. Refer to Section
2.4, “Fluids, Lubricants and
Capacities.”

3. Incorrect clutch engagement. 3. Refer to Section 9.14.1,


“Transmission Solenoid Valves.”

4. Internal damage. 4. Repair or replace parts as


needed.

5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate).


Refer to Section 6.5.1,
“Transmission Removal.”
6. Loose diaphragm (flex plate) 6. Tighten capscrews.
mounting capscrews.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-9
Transmission:

Problem Cause Remedy


7. Oil leaking from transmission. 1. Oil leaking from vent (high oil 1. Remove drain plug and drain oil
level). as needed, until oil is at correct
level. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.” Replace o-rings as
needed and tighten plugs to
130 Nm (96 lb-ft).
2. Drain plug loose and/or o-rings 2. Replace o-rings as needed and
damaged or missing. tighten plug to 35 Nm (26 lb-ft).

3. Hose fittings loose. 3. Tighten fittings.

4. Oil leaking at valve bodies 4. Replace gaskets and/or tighten


(possible valve body gaskets capscrews to 9,5 Nm (7 lb-ft).
damaged or missing and/or
mounting capscrews not tight).

5. Housing capscrews loose. 5. Tighten capscrews to 46 Nm


(34 lb-ft).
6. Oil leaking at pump (possible 6. Replace o-rings and/or tighten
pump-to-housing o-rings capscrews to 115 Nm (85 lb-ft).
missing or damaged, and/or
pump mounting capscrews not
tight).

7. Oil leaking at converter bell 7. Replace converter and/or input


(possible converter leak and/or shaft seal.
input shaft seal damage).

8. Oil leaking at output shaft 8. Replace output shaft seal.


(output shaft seal damaged).

9. Housing damaged. 9. Replace housing as needed.

6-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 7
Engine: Perkins 1104-42 & 1104-42T

Contents

PARAGRAPH TITLE PAGE


7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.3 Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . . 7-5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.9.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7-10
7.9.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.10 Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.10.1 Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.10.2 Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-1
Engine: Perkins 1104-42 & 1104-42T

7.1 INTRODUCTION A gradual running-in (break-in) of a new engine is not


necessary. Full load can be applied to a new engine as
soon as the engine is put into service and the coolant
7.1.1 Disclaimer and Scope temperature is at least 60° C (140° F). Extended light-
These instructions are written for worldwide use. In load operation during the early life of the engine is not
territories where legal requirements govern engine smoke recommended. DO NOT run the engine at high, no-load
emission, noise, safety factors, etc., apply all instructions, speeds. DO NOT apply an overload to the engine.
data and dimensions provided herein in such a way that
after maintenance, service and repair of the engine,
engine operation does not violate local regulations.
Note: These instructions cover only the routine
maintenance, removal, installation and troubleshooting
of the engine. For assistance with comprehensive
engine diagnosis, repair and component replacement,
contact your local Perkins Service partner.

7-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T

7.1.2 Component Terminology


To understand the safety, operation and maintenance
information presented in this section, it is necessary that
the operator/mechanic be familiar with the names and
locations of the engine components. The following
illustration identifies the components that are referred to
throughout this section.

FUEL INJECTION
PUMP

FUEL FILTER

OIL FILTER

THERMOSTAT

ALTERNATOR

TURBOCHARGER

STARTER

MZ0070

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-3
Engine: Perkins 1104-42 & 1104-42T

7.2 ENGINE SERIAL NUMBER a. Thermostat Removal


1. Park the machine on a firm, level surface, level the
The Perkins serial number is stamped on a plate which is
machine, fully retract the boom, lower the boom,
secured to the engine block, near the fuel injector pump.
place the transmission control lever in
Information contained in the serial number is required in
(N) NEUTRAL, engage the park brake and shut the
correspondence with the engine manufacturer.
engine OFF.

7.3 SPECIFICATIONS AND 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
MAINTENANCE INFORMATION should not be operated.
For engine, coolant and oil specifications, and 3. Open the engine cover. Allow the system fluids to
maintenance information, refer to Section 2, “General cool.
Information and Specifications.” 4. Properly disconnect the battery.
Note: These instructions cover only the routine 5. Slowly turn the radiator cap to the first stop and allow
maintenance, removal, installation and troubleshooting any pressure to escape. Remove the radiator cap.
of the engine. Refer to your local Perkins Engine 6. Place a funnel at the base of the radiator to channel
Distributor for assistance with comprehensive engine the drained coolant into the container. Loosen the
diagnosis, repair and component replacement. drain plug and slowly remove to allow the coolant to
drain. Transfer the coolant into a properly labeled
7.4 ENGINE COOLING SYSTEM container. Dispose of properly if coolant needs to be
replaced. Replace the radiator drain plug.
7.4.1 Radiator Pressure Cap
For a 99° C (210° F) system, use a 90 kPa (13 psi) 1
radiator cap. An incorrect or malfunctioning cap can
result in the loss of coolant and a hot-running engine.

7.4.2 Thermostat Replacement


Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If the engine seems to take a long time to warm up,
the thermostat may be stuck in the open position
and requires replacement.
• If the engine runs hot, check the temperature of the
upper radiator hose.
• If the hose is not hot, the thermostat may be stuck in
the closed position. MZ2180

• If the engine has overheated, performance may


7. Remove the two capscrews securing the thermostat
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or housing (1) to the engine.
block, and/or other internal engine damage. 8. Remove the thermostat housing, old gasket and
thermostat. Clean all gasket surfaces. DO NOT let
any debris into the thermostat opening.
Note: ALWAYS use the correct thermostat and install a
new gasket. NEVER operate the engine without a
thermostat, or engine damage will result.

7-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T

b. Thermostat Installation 5. Remove the engine cover to ease removal of


radiator/oil cooler.
1. Install the engine thermostat, thermostat gasket and
thermostat housing. Secure with the two capscrews.
Torque to 24 Nm (18 lb-ft). 6

2. Properly connect the battery.


4
3. Open the radiator cap, and fill the radiator
completely with coolant. Replace and tighten the
7
radiator cap. Add coolant to the overflow bottle until
8
the bottle is 1/4 to 1/2 full. This overfilling will
compensate for any air trapped in the cooling
system.
4. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain,
as necessary.
5. Close and secure the engine cover. 2
6. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
7
7.4.3 Radiator/Oil Cooler and Coolant 3
Heater Replacement
5 MZ2070
Before considering radiator or oil cooler replacement for
other than obvious damage, conduct a cooling system 6. Remove the coolant overflow bottle (2).
pressure test check the coolant specific gravity, coolant 7. Remove the radiator fan shroud (3) and the engine
level, fan belt tension and dash panel temperature belly pan.
indicator.
8. Slowly turn the radiator cap to the first stop and allow
• If the engine runs hot, check the temperature of any pressure to escape. Remove the radiator cap.
the upper radiator hose.
9. Place a suitable container beneath the radiator drain
• If the hose is not hot, the thermostat may be plug.
stuck in the closed position.
10. Place a funnel at the base of the radiator to channel
• If the engine has overheated, performance may the drained coolant into the container. Loosen the
suffer, indicating other damage including a leaking drain plug and slowly remove to allow the coolant to
cylinder head gasket, cracked cylinder head or drain. Transfer the coolant into a properly labeled
block, and/or other internal engine damage. container. Dispose of properly if coolant needs to be
replaced. Replace the radiator drain plug.
a. Radiator/Oil Cooler Removal
11. Loosen the radiator clamp on the top (4) and bottom
1. Park the machine on a firm, level surface, level the (5) radiator hoses. Work the hoses off the radiator.
machine, fully retract the boom, lower the boom, Position the hoses out of the way to allow radiator
place the transmission control lever in removal, or remove the hoses from the engine.
(N) NEUTRAL, engage the park brake and shut the Inspect the hoses, and replace if necessary.
engine OFF.
12. Disconnect and plug the oil cooler top (6) and
2. Place a Do Not Operate Tag on both the ignition key bottom hoses (7) and cap the fittings on the oil
switch and steering wheel, stating that the machine cooler. Inspect the hoses, and replace if necessary.
should not be operated.
13. Label, disconnect and cap the air conditioner hoses
3. Open the engine cover. Allow the system fluids to (8) (if equipped).
cool.
14. Remove the four nuts and four washers from the
4. Properly disconnect the battery. radiator mounts.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-5
Engine: Perkins 1104-42 & 1104-42T

15. Remove the air conditioner condenser (if equipped) 7.5 ENGINE ELECTRICAL SYSTEM
from the radiator assembly.
16. Carefully lift the radiator/oil cooler out of the engine The engine electrical system, including the starter,
bay. alternator and primary wiring, is described in Section 9,
“Electrical System.”
Note: If applicable the radiator can be removed with the
radiator frame. Remove the five bolts holding the 7.6 FUEL SYSTEM
radiator frame to the machine frame and remove the
radiator and radiator frame as one unit.
7.6.1 Diesel Fuel
b. Radiator/Oil Cooler Installation Fuel represents a major portion of machine operating
1. Install the isolator mounts to the bottom of the costs and therefore must be used efficiently. ALWAYS
radiator. Insert radiator through the machine frame use a premium brand of high-quality, clean diesel fuel.
mounts and install the washers and new locknuts. Low cost, inferior fuel can lead to poor performance and
expensive engine repair.
2. Install the air conditioner condenser (if equipped) to
the radiator assembly. Note: Use only diesel fuel designed for diesel engines.
3. At the top of the radiator, install the isolator mounts. Some heating fuels contain harmful chemicals that can
Install the washers and new locknuts on the back seriously affect engine efficiency and performance.
side of the weldment. Note: Due to the precise tolerances of diesel injection
4. Be sure the engine fan has clearance in regard to systems, keep the fuel clean, and free of dirt and water.
the radiator. Install the radiator fan shroud. Dirt and water in the fuel system can cause severe
damage to both the injection pump and the injection
5. Uncap and connect the previously labeled oil cooler
nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
top (6) and bottom (7) hoses to their appropriate
rating of 40. #2 diesel fuel gives the best economy and
locations.
performance under most operating conditions. Fuels
6. Uncap and connect the previously labeled radiator with Cetane numbers higher than 40 may be needed in
top (4) and bottom (5) hoses to their appropriate high altitudes or extremely low ambient temperatures to
locations. help prevent misfiring and excessive smoking.
7. Uncap and connect the previously labeled air Inform the owner/operator of the machine to use #2
conditioner hoses (8) (if equipped) to their diesel fuel, unless ambient temperatures are below 0° C
appropriate locations. (32° F). When temperatures are below 0° C (32° F), a
8. Open the radiator cap and fill the radiator completely blend of #1 diesel and #2 diesel fuels (known as
with coolant. Replace and tighten the radiator cap. “winterized” #2 diesel) may be used.
Add coolant to the overflow bottle until the bottle is 1/
Note: #1 diesel fuel may be used, however, fuel
4 to 1/2 full. This overfilling will compensate for any
economy will be reduced.
air trapped in the cooling system.
9. Properly connect the battery. Use a low-sulfur content fuel with a cloud point (the
temperature at which wax crystals form in diesel fuel) at
10. Run the engine to operating temperature. Visually
least 10° below the lowest expected fuel temperature.
check for leaks with the engine running. Check the
The viscosity of the fuel must be kept above 1.3
coolant level in the overflow bottle and fill, or drain as
centistrokes to provide adequate fuel system lubrication.
necessary.
11. Install the engine cover. Note: When using diesel fuel with a sulfur content below
1.3 percent, the filter change interval must be reduced by
12. Install the belly pan. 75 hours. The use of fuel with a sulfur content above
13. Close and secure the engine cover. 1.3 percent is not recommended.
14. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

7-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T

7.6.2 Fuel Tank properly. Reinstall the fuel tank drain plug and torque
to 26 Nm (19 lb-ft).
Note: The fuel tank is a one piece unit. It is located at
the rear of the machine, between the frame. If it is 7. Loosen and remove the strap over the fuel tank and
determined that the fuel tank must be removed, the fuel disconnect the fuel hoses from the tank.
must be drained before tank removal. Always dispose of 8. Disconnect fuel level sender (10) electrical
fuel properly. connectors from the fuel level sender.
9. Remove screws securing fuel sender to the tank.
a. Fuel Tank Removal Remove fuel sender from tank.
1. Park the machine on a firm, level surface, level the 10. Lift the empty fuel tank from between the frame rails.
machine, raise the boom to access the fuel tank,
place the transmission control lever in b. Disassembly
(N) NEUTRAL, engage the park brake and shut the
engine OFF. The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed
2. Place a Do Not Operate Tag on both the ignition key
and reused on the new replacement tank.
switch and steering wheel, stating that the machine
should not be operated.
c. Cleaning and Drying
3. Open the engine cover. Allow the engine to cool.
If contaminated fuel or foreign material is in the tank, the
4. Remove the boom. Refer to Section 3.3.1, “Boom tank can usually be cleaned.
Removal.”
Note: If a leak is suspected in the fuel tank, contact your
5. Properly disconnect the battery.
local JLG distributor.
Note: If replacing the tank, remove all internal and
To clean the fuel tank:
external components from the old tank, and retain for
use on the replacement tank. 1. Have a dry chemical (Class B) fire extinguisher near
the work area.
Note: Have a dry chemical (Class B) fire extinguisher
near the work area. 2. Remove the fuel or oil tank drain plug, and safely
drain any fuel into a suitable container. Dispose of
fuel properly.
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes and
drain the water. Dispose of contaminated water
10 properly.
4. Add a diesel fuel emulsifying agent to the tank. Refer
to the manufacturer’s instructions for the correct
emulsifying agent-to-water mixture ratio. Refill the
tank with water, and agitate the mixture for 10
minutes. Drain the tank completely. Dispose of
contaminated water properly.
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.

d. Assembly
The fuel level indicator can be removed and reused on
the new replacement tank. Dispose of the old tank
according to local regulations concerning hazardous
9 materials disposal.
MZ2690

6. Remove fuel tank drain plug (9), and drain fuel into
an approved and suitable container. Dispose of fuel

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-7
Engine: Perkins 1104-42 & 1104-42T

e. Inspection 7.7 ENGINE EXHAUST SYSTEM


Note: If a leak is suspected in the fuel tank, contact your
local JLG distributor. 7.7.1 Exhaust System Removal
1. Inspect the fuel tank thoroughly for any cracks, 1. Park the machine on a firm, level surface, level the
slices, leaks or other damage. machine, fully retract the boom, lower the boom,
2. Plug all openings except one elbow fitting. Install the place the transmission control lever in
elbow fitting, and apply approximately 7-10 kPa (N) NEUTRAL, engage the park brake and shut the
(1-1.5 psi) of air pressure through the elbow. Check engine OFF.
the tank for leaks by applying a soap solution to the 2. Place a Do Not Operate Tag on both the ignition key
exterior and look for bubbles to appear at the switch and steering wheel, stating that the machine
cracked or damaged area. should not be operated.
3. Open the engine cover. Allow the engine to cool.
f. Fuel Tank Installation
4. Properly disconnect the battery.
1. Set fuel tank between frame rails.
5. Remove the belly pan.
2. Install the fuel tank strap over the fuel tank.
3. Install the fuel sender with new gasket into the fuel
tank and secure with screws. Tighten to 5 Nm
(3.6 lb-ft). DO NOT overtighten.
4. Connect the fuel hoses to the tank. Secure with
clamps and tighten to 25 Nm (18 lb-ft).
5. Install the wire harness connections to the fuel
sender.
MZ0110
6. Fill the fuel tank according to specifications. Refer to
Section 2.4, “Fluids, Lubricants and Capacities.” 6. Loosen and remove the mounting hardware for the
7. Check fuel tank for leaks. exhaust pipe at the exhaust manifold. Replace the
hardware if damaged.
8. Install the boom. Refer to Section 3.3.6, “Boom
Installation.” 7. Disconnect and remove the clamp attaching the
exhaust pipe to the frame.
9. Properly connect the battery.
8. Disconnect and remove the clamp connecting the
10. Close and secure the engine cover. muffler to the exhaust pipe.
11. Remove the Do Not Operate Tags from both the 9. Disconnect and remove the clamp connecting the
ignition key switch and the steering wheel. tail pipe to the muffler and remove the tail pipe.

7.6.3 After Fuel System Service 10. Loosen and remove the two bolts at the front and
one bolt at the rear of the muffler, and remove the
1. Drain and flush the fuel tank if it was contaminated. muffler.
2. Replace all engine fuel filters and check fuel/water
separator. 7.7.2 Exhaust System Installation
3. Vent air from the fuel system in accordance with the Note: Keep all clamps loosened until entire exhaust
instructions found in the appropriate Operation & system is in place.
Safety Manual.
1. Install the exhaust pipe with a new seal to the
4. Fill the fuel tank with fresh, clean diesel fuel as required. exhaust manifold.
2. Install the exhaust pipe clamp under the engine.
3. Install the muffler to the exhaust pipe and bolt the
muffler to the side of the frame.
4. Install the clamp securing the muffler to the exhaust
pipe.
5. Install the clamp securing the muffler to the tail pipe.

7-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T

6. Adjust the muffler, exhaust and tail pipes for proper 6. Remove the clamp securing the air intake boot (11)
clearance then tighten all clamps. to the air cleaner assembly. Lift the air intake boot off
7. Properly connect the battery. the air cleaner.

8. Start engine and check for exhaust leaks at all 7. Remove the clamp securing the air outlet elbow (12).
exhaust connections. Adjust or repair as needed. Lift the air outlet elbow off the air cleaner.
9. Install the belly pan. 8. Remove the two capscrews and ripp nuts securing
the air cleaner mounting bracket to the air cleaner
10. Close and secure the engine cover. mounting plate. Remove the air cleaner assembly.
11. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. 7.8.2 Air Cleaner Assembly Installation
Note: Apply Loctite® 243TM threadlock to the capscrew
7.8 AIR CLEANER ASSEMBLY threads before installation.
1. With the air cleaner assembly attached, install the air
CAUTION cleaner mounting bracket using capscrews and ripp
nuts.
NEVER run the engine with only the inner safety 2. Place the loosened clamp over the air intake boot,
element installed. and install boot on the air cleaner assembly.
Note: Refer to the appropriate Operation & Safety 3. Place the loosened clamp over the air outlet elbow
Manual for the correct element change procedure. and install elbow on the air cleaner assembly.
4. Connect low pressure indicator wire connection.
7.8.1 Air Cleaner Assembly Removal
5. Adjust and tighten both clamps before starting the
1. Park the machine on a firm, level surface, level the machine.
machine, fully retract the boom, lower the boom,
6. Properly connect the battery.
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 7. Close and secure the engine cover.
engine OFF. 8. Remove the Do Not Operate Tags from both the
2. Place a Do Not Operate Tag on both the ignition key ignition key switch and the steering wheel.
switch and steering wheel, stating that the machine
should not be operated. 7.9 ENGINE REPLACEMENT
3. Open the engine cover. Allow the engine to cool.
4. Properly disconnect the battery. 7.9.1 Engine Removal
5. Disconnect the low pressure indicator wire 1. Park the machine on a firm, level surface, level the
connection on the air cleaner. machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
11
should not be operated.
3. Open the engine cover. Allow the engine to cool.
12 4. Disconnect the (+) positive and (-) negative battery
cables and remove the battery.
5. Remove the engine cover, radiator guard plate and
the engine belly pan.
6. Drain and remove the radiator assembly. Refer to
MZ2010 Section 7.4.3, “Radiator/Oil Cooler and Coolant
Heater Replacement.”
7. Remove the heater hoses attached to the engine.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-9
Engine: Perkins 1104-42 & 1104-42T

Note: The engine harness is routed and attached to the 19. Turn the engine over slowly by hand and align each
engine using hold-down clamps and plastic wire ties at of the eight flex plate bolts to be accessed. Remove
various places on the engine. Before removing engine, them one at a time.
ensure that the harness has been completely separated 20. Secure the engine with a lifting strap or chain from
(disconnected) from the engine. Move the harness clear the appropriate lifting points. Use a suitable hoist or
of the engine, and with the help of an observer, ensure overhead crane.
that engine clears the harness during removal.
8. Label and disconnect all wire harness connections
on the engine.
9. Unbolt and remove the hood latch plate. Mark the
plate to help with hood adjustment when being
reinstalled.
14
10. Unbolt the return hydraulic oil filter plate and leave in
place.
11. Disconnect and cap the fuel inlet line at the fuel filter
head.
12. Disconnect and cap the fuel return line from the fuel
filter head.

MZ2170

21. At the rear right engine mount (14), remove the bolt
and washer. Repeat for the rear left engine mount.
22. Place a support or jack under the transmission to
hold the transmission in place while engine is being
removed.
23. Remove the ten bolts holding the transmission to the
engine. Slightly lift and pull the engine out of the
machine. Have an assistant ensure that the engine
clears all frame components during removal.
13 24. Place engine on a flat, level surface.
MZ0940

13. Mark the location of the throttle cable (13) at the 7.9.2 Engine Disassembly, Inspection and
throttle cable mount. Loosen jam nuts and remove. Service
14. Disconnect the throttle cable at the engine throttle Engine disassembly, internal inspection, service, repair
lever. and assembly procedures are covered in the Perkins
service manual. Several special engine service tools are
15. Remove the exhaust pipe from the exhaust
required to properly service the engine. Contact your local
manifold. Refer to Section 7.7.1, “Exhaust System
Perkins Service partner for further information.
Removal.”
Note: If the engine is being replaced, there may be external
16. Loosen the clamps on the sleeve reducer at the
components that will be required to be transferred from the
engine and on the air suction pipe.
original engine to the replacement engine depending upon
17. Remove the air cleaner assembly. Refer to Section who you purchase the new engine from and the
7.8.1, “Air Cleaner Assembly Removal.” configuration of your replacement engine. Refer to the
18. Remove the access plug from side of the engine bell appropriate Perkins user manual for detailed procedures
housing. This will allow access to remove the eight that cover the transfer of original engine components to the
bolts holding the flex plate to the engine flywheel. replacement engine.

7-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T

7.9.3 Engine Installation 17. Install the hood latch plate. Align the mark on the
plate to help with hood adjustment.
1. Attach a lifting chain to the front and rear engine lift
brackets, and lift engine clear of the ground. 18. Secure the return hydraulic oil filter plate to the
frame.
Note: Apply Loctite® 243TM threadlock to the engine
mount bracket capscrew threads before installation. 19. Install both heater hoses to the engine and tighten
clamps.
2. Inspect the front engine mounting bracket isolator.
20. Install the complete radiator assembly. Refer to
Replace isolator if cracked or worn.
Section 7.4.3, “Radiator/Oil Cooler and Coolant
3. Install two guide studs in the bell housing holes. Heater Replacement.”
4. Lift the engine and slowly push and lower into the 21. Install the hose clamp on the bottom radiator hose
engine bay. Have an assistant ensure that the and work onto the engine. Tighten the clamp.
engine clears all frame, hose and harness
22. Install the hose clamp on the top radiator hose and
components during engine installation. Position
work onto the engine. Tighten the clamp.
engine brackets over the front frame mounts.
23. Connect the transmission inlet and outlet hoses on
5. Push the engine towards the transmission aligning
the oil cooler. Install the clamp holding the top
the guide studs and the torque converter shaft with
transmission cooler hose and the three bolts holding
the corresponding holes.
the fan screen.
6. Push the engine against the transmission and install
24. Install the engine cover and adjust.
eight of the ten bolts and washers. Remove both
guide studs and replace with the remaining two bolts 25. Install the battery and reconnect the (+) positive and
and washers. Tighten bolts. (-) negative cables.
7. Torque the transmission bolts to 63 Nm (46 lb-ft) 26. Open the radiator cap and fill the radiator completely
AFTER engine is lowered and secured with the front with coolant. Replace and tighten the radiator cap.
motor mount bolts installed and torqued. Add coolant to the overflow bottle until the bottle is 1/
4 to 1/2 full. This overfilling will compensate for any
8. Remove the support from under the transmission
air trapped in the cooling system.
and lower the engine the remainder of the way onto
the frame. Align the motor mount holes and install 27. Check that all hydraulic system, electrical system,
the bolts. Apply Loctite® 243TM threadlock to the cooling system, fuel system and exhaust system
motor mount bolts and torque to 210 Nm (155 lb-ft). connections are correct and connected tightly.
9. Turn the engine over slowly by hand and align each 28. From within the cab, lightly depress the throttle pedal
of the eight flex plate bolts through the access plug to full-throttle position. As needed, adjust the limit-
in the bell housing. Install them one at a time. DO stop screw until it touches the pedal. Tighten the
NOT fully tighten until all of the capscrews and locknut to 13,6-14,1 Nm (120-125 lb-in).
locknuts are in place. Torque to 35-39 Nm Note: Have an assistant stand by with a Class B fire
(26-29 lb-ft). Replace access plug. extinguisher.
10. Install the exhaust pipe. Refer to Section 7.7.2, 29. Start the engine and run to normal operating
“Exhaust System Installation.” temperature then shut off the engine. While the
11. Install the complete air cleaner assembly. Refer to engine is cooling, check for leaks.
Section 7.8.2, “Air Cleaner Assembly Installation.” 30. Allow the engine to cool. Check the radiator coolant
12. Install and tighten the jam nuts on the throttle cable level, and top off with coolant. Replace the radiator
at the throttle cable mount. cap.
13. Connect the throttle cable at the engine throttle 31. Check for leaks from the engine, main hydraulic
lever. pump and lines, transmission, hydraulic reservoir
14. Connect the fuel inlet line to the fuel filter head. and fuel tank. Check the levels of all fluids and
lubricants. Fill as required.
15. Connect the fuel return line to the fuel filter head.
Note: During the full throttle check:
16. Connect all the labeled wire harness connections on
the engine. • DO NOT operate any hydraulic function.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-11
Engine: Perkins 1104-42 & 1104-42T

• DO NOT steer or apply any pressure to the


steering wheel.
• Keep the transmission in (N) NEUTRAL.
32. Obtain and connect an appropriate engine analyzer 15
or tachometer. Check the engine rpm at full throttle.
If the rpm is not 2340 ±50 rpm, readjust the throttle
limit-stop screw at the throttle pedal within the cab.
33. Purge the hydraulic system of air by operating all
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
34. Check for proper operation of all components.
35. Turn the engine off. MZ0580
36. Install the engine belly pan.
37. Close and secure the engine cover. 6. Remove the eight bolts holding the drive plates (15)
38. Remove the Do Not Operate Tags from both the to the flywheel.
ignition key switch and the steering wheel. 7. With the drive plates and torque convertor removed,
loosen and remove the six bolts and six lock
7.10 ENGINE DRIVE PLATE washers holding the three drive plates to the torque
converter.
7.10.1 Drive Plate Removal 8. Replace all three drive plates if damaged
1. Park the machine on a firm, level surface, level the
7.10.2 Drive Plate Installation
machine, fully retract the boom, lower the boom,
place the transmission control lever in 1. Install the three new drive plates on the torque
(N) NEUTRAL, engage the park brake and shut the converter and torque the six bolts with lock washers
engine OFF. to 35-39 Nm (26-29 lb-ft).
2. Place a Do Not Operate Tag on both the ignition key 2. Mount the drive plate/converter assembly to the
switch and steering wheel, stating that the machine transmission.
should not be operated. 3. Refer to Section 6.5.3, “Transmission Installation,” or
3. Open the engine cover. Allow the engine to cool. Section 7.9.3, “Engine Installation,” for the
4. Properly disconnect the battery. remainder of the installation.
4. Properly connect the battery.
Note: In order to remove the engine drive plates, the
engine and transmission must be separated. 5. Close and secure the engine cover.

5. Refer to Section 6.5.1, “Transmission Removal,” or 6. Remove the Do Not Operate Tags from both the
Section 7.9.1, “Engine Removal.” ignition key switch and the steering wheel.

7-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T

7.11 TROUBLESHOOTING

Trouble Possible Causes (see key, below)


Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12

Key to Possible Causes

1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-13
Engine: Perkins 1104-42 & 1104-42T

This Page Intentionally Left Blank

7-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 8
Hydraulic System

Contents

PARAGRAPH TITLE PAGE


8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.6.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.6.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.6.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 8-17
8.7 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7.1 Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7.2 Pump Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.7.3 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.8 Auxiliary Pump (Platform Equipped Models Only) . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.8.1 Auxiliary Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.8.2 Auxiliary Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.9 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.9.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.9.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.9.3 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.9.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.9.5 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.9.6 Leveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.10 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.10.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.10.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.10.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.10.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.10.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.10.6 General Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.10.7 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.10.8 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.10.9 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-1
Hydraulic System

8.1 HYDRAULIC COMPONENT


TERMINOLOGY
To understand the safety, operation and service
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the hydraulic components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

LIFT/LOWER
CYLINDER
TILT CYLINDER

EXTEND/RETRACT
CYLINDER
(INSIDE BOOM)

OUTRIGGER CYLINDERS
(12, 13 & 17M ONLY)

STEERING
CYLINDER

HYDRAULIC OIL COMPENSATION


RESERVOIR CYLINDER

MAIN PUMP

HYDRAULIC
FILTER

MAIN CONTROL
VALVE

MZ2700
ENGINE COMPARTMENT
(ENGINE REMOVED FOR CLARITY)

8-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

8.2 SAFETY INFORMATION 8.3 HYDRAULIC PRESSURE DIAGNOSIS


Kits are available to use for hydraulic system
WARNING maintenance and troubleshooting. The kits are contained
in a durable polyethylene carrying case for demanding
DO NOT service the machine without following all field service conditions.
safety precautions as outlined in Section 1, “Safety The hydraulic pressure test kit is used to pressure test the
Practices,” of this manual. various hydraulic components in the hydraulic system.
Petroleum-based hydraulic oils are used in this machine. The kit includes:
The temperature of hydraulic oil increases during the • Gauges for testing high and low pressure circuits
operation of various hydraulic functions. A heated
petroleum-based hydraulic oil presents a fire hazard, • Fittings, couplers and hoses
especially when an ignition source is present. • Durable carrying case
Accordingly, periodically inspect all hydraulic system A flowmeter test kit is used to pinpoint hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully faults. It includes a flowmeter with load valve, magnetic
examine any deterioration and determine whether any base, photo tachometer head and flex arm. The kit
further use of the component would constitute a hazard. features:
If in doubt, replace the component. • Bi-directional for unrestricted connection and
Whenever you disconnect a hydraulic line, coupler, fitting simplified testing
or other component, slowly and cautiously loosen the part • Internal by-pass to protect system and tester
involved. A hissing sound or slow seepage of hydraulic oil from over-pressure
may occur in most cases. After the hissing sound has
ceased, continue removing the part. Any escaping oil • Measures up to 60 GPM and 6000 psi
should be directed into an appropriate container. Cap or • Durable carrying case
otherwise block off the part to prevent further oil seepage. Contact your local authorized service distributor for
Hydraulic system maintenance will, at times, require that ordering information.
the engine be operated. Always follow safety
Part Approximate Price and
precautions. Number
Description
Weight Availability
A major cause of hydraulic component failure is 70000652
Dial Hydraulic Pressure 4,5 kg
Consult Factory
contamination. Keeping the hydraulic oil as clean as Test Kit (10 lbs)
possible will help avoid downtime and repairs. Sand, grit Digital Hydraulic Pressure 3 kg
70000101 Consult Factory
Test Kit (7 lbs)
and other contaminants can damage the finely machined
surfaces within hydraulic components. If operating in an Digital Hydraulic Pressure 3 kg
70027911 Consult Factory
Test Kit (7 lbs)
exceptionally dirty environment, change filters and
1321107 Hydraulic Flowmeter Kit 12,7 kg Consult Factory
inspect the oil more often. When servicing the system, (28 lbs)
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir,
and pump openings until installation occurs. Protect
threads from contamination and damage.
Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
properly, check the electrical aspect of the malfunctioning
circuit also.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-3
Hydraulic System

8.4 HYDRAULIC CIRCUITS 8.4.1 Hydraulic Pressures

This section covers the hydraulic circuits and includes a. Checking Pressures
listings for all hydraulic function pressures, where and
1. Start the machine and warm the hydraulic system to
how to check those pressures.
operating temperature.
Electrical and hydraulic functions are often related. Verify
2. Shut off the machine and install a digital or a 345 bar
that the electrical components of the circuit are
(5000 psi) gauge to the appropriate test port.
functioning properly whenever troubleshooting the
hydraulic circuit. 3. Start the machine, run the engine and follow
procedures in Section 8.4.1, c. “Pressure
Always check the following before beginning to
Specifications.”
troubleshoot a circuit that is not functioning correctly.
1. Check the hydraulic oil level in the reservoir. Oil level b. Adjusting Hydraulic Pressure
should be at the middle of the sight glass with all
cylinders retracted. 1. Shut the machine off. Remove the cap on the relief
(if necessary).
2. Check hoses, tubes, fittings and other hydraulic
components for leaks, bends, kinks, interference, 2. Start the machine and loosen the jam nut on the
etc. relief. Turn the relief clockwise to increase pressure
or counter-clockwise to decrease pressure. Set to
3. Check for air in the hydraulic system. Erratic the correct pressure.
machine performance and/or spongy cylinder
operation are signs of air in the hydraulic system. 3. Tighten the jam nut and recheck the pressure at full
throttle. If the reading is within specification, shut the
If air in the hydraulic system is suspected, you will machine off, install the safety cap and remove the
hear air leakage when hydraulic fittings are loosened gauge from the test port.
and see air bubbles in the hydraulic oil. 4. If the proper pressure cannot be set, use the
accompanying hydraulic schematic and/or the
Loose fittings, faulty o-rings or seals, trapped oil, electrical schematic to help troubleshoot and correct
leaks, system opened for service, etc., can cause air the problem.
in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.

8-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

c. Pressure Specifications

Hydraulic Test Port Procedure Adjustment Pressure Range


Circuit Location
Implement M Connect gauge to M port, run engine at low idle, 1 250 ±5 Bar
bottom out boom retract function. Hold over relief (3626 ±73 psi)
and check pressure.
Pilot Pr Connect gauge to Pr port, run engine at low idle, 2 30 ±2 Bar
bottom out boom retract function. Hold over relief (435 ±29 psi)
and check pressure.

M 2

Pr

1
MZ2320

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-5
Hydraulic System

8.5 HYDRAULIC SCHEMATICS

8.5.1 8M, 9M, 12M & 13M (w/o trailer brakes)


Before S/N 1160005851 excluding 1160005819

8-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

S/N 1160005851 & After including 1160005819

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-7
Hydraulic System

8.5.2 8M, 9M, 12M & 13M (w/ trailer brakes)


Before S/N 1160005851 excluding 1160005819

8-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

S/N 1160005851 & After including 1160005819

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-9
Hydraulic System

8.5.3 8M, 9M, 12M & 13M - Frame Level (if equipped)
8M & 9M

12M & 13M


12M, if equipped w/out frame

8-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

8.5.4 17M
Before S/N 1160005851 excluding 1160005819

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-11
Hydraulic System

S/N 1160005851 & After including 1160005819

8-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

8.5.5 13M (if equipped for platform)


Before S/N 1160005851 excluding 1160005819

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-13
Hydraulic System

S/N 1160005851 & After including 1160005819

8-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

8.5.6 17M (if equipped for platform)


Before S/N 1160005851 excluding 1160005819

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-15
Hydraulic System

S/N 1160005851 & After including 1160005819

8-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

8.6 HYDRAULIC RESERVOIR 8.6.2 Hydraulic Oil Reservoir Filling


1. Be sure reservoir is clean and free of all debris.
The hydraulic reservoir is a one piece unit. It is located
under the rear of the machine cab. Occasionally, oil may 2. Install a new hydraulic oil filter.
seep, leak or be more forcefully expelled from the 3. Fill the reservoir with hydraulic oil. Refer to Section
breather when system pressure exceeds the rating of the 2.4, “Fluids, Lubricants and Capacities.”
filter head or breather. If the return filter becomes
4. Properly connect the battery.
plugged, the return hydraulic oil will bypass the filter when
pressure reaches 1,7 bar (25 psi) and return to the 5. Close and secure the engine cover.
reservoir unfiltered. 6. Remove the Do Not Operate Tags from both the
Carefully examine oil seepage or leaks from the hydraulic ignition key switch and the steering wheel.
reservoir to determine the exact cause. Clean the
reservoir and note where any seepage occurs. 8.6.3 Hydraulic Oil Reservoir Removal/
Installation
If it is determined that the hydraulic oil reservoir must be
removed, the hydraulic oil must be drained before the
reservoir is removed. Always dispose of hydraulic oil
properly.

a. Reservoir Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
MZ0130
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
8.6.1 Hydraulic Oil Reservoir Draining 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
1. Park the machine on a firm, level surface, level the machine should not be operated.
machine, fully retract the boom, lower the boom,
3. Open the engine cover. Allow the system fluids to
place the transmission control lever in
cool.
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 4. Properly disconnect the battery.
2. Place a Do Not Operate Tag on both the ignition key 5. Drain the hydraulic oil reservoir. Refer to Section
switch and the steering wheel, stating that the 8.6.1, “Hydraulic Oil Reservoir Draining.”
machine should not be operated. 6. Loosen the clamps and remove and cap the suction
3. Open the engine cover. Allow the system fluids to and return hoses on the hydraulic oil reservoir.
cool. 7. Plug and cap the fittings on the hydraulic oil
4. Properly disconnect the battery. reservoir.
5. Open the filler cap on the hydraulic oil reservoir. 8. Support the hydraulic oil reservoir from the bottom
Remove the drain plug at the bottom of the hydraulic and remove the six bolts, washers and nuts.
oil reservoir. 9. Carefully lower the reservoir to the ground.
6. Transfer the used hydraulic oil into a suitable,
covered container, and label as "Used Oil". Dispose b. Disassembly
of used oil at an approved recycling facility. Clean The hydraulic oil reservoir is a one-piece unit and cannot
and reinstall the drain plug. be disassembled. The hydraulic oil level sight-glass and
7. Wipe up any hydraulic oil spillage in, on, near and hydraulic oil filler cap can be removed and reused on the
around the machine and the work area. new replacement reservoir. Dispose of the old reservoir
according to local regulations concerning hazardous
materials disposal.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-17
Hydraulic System

c. Cleaning and Drying 8.7 HYDRAULIC SYSTEM PUMP


If contaminated hydraulic oil or foreign material is in the
tank, the tank can usually be cleaned. 8.7.1 Pump Description
To clean the hydraulic oil reservoir: For internal service instructions contact your local
1. Have a dry chemical (Class B) fire extinguisher near authorized service distributor.
the work area.
2. Clean the hydraulic oil reservoir with a high-pressure 8.7.2 Pump Failure Analysis
washer, or flush the tank with hot water for five
minutes and drain the water. Dispose of
contaminated water properly. 1

d. Inspection
Note: If a leak is suspected in the hydraulic oil reservoir,
contact JLG Service Department.
1. Inspect the hydraulic oil reservoir thoroughly for any
cracks, slices, leaks or other damage. MZ1950

2. With the hydraulic oil reservoir removed from the The implement pump (1) is the “heart” of the hydraulic
machine, plug all openings except one elbow fitting. system, and whenever there is a problem in the system,
Install the elbow fitting, and apply approximately the pump often is blamed. However, implement pump
0,06-0,10 bar (1-1.5 psi) of air pressure through the failure is seldom due to failure of pump components.
elbow. Check the reservoir for leaks by applying a Pump failure usually indicates another problem in the
soap solution to the exterior and look for bubbles to hydraulic system.
appear at the cracked or damaged area. According to pump manufacturer statistics, 90-95 percent
of pump failures are due to one or more of the following
e. Reservoir Installation causes:
1. Lift the hydraulic oil reservoir into place and install • Aeration
the six bolts, washers and nuts. • Cavitation
2. Uncap and connect the suction hose and return • Contamination
hose. Tighten both clamps. • Excessive Heat
3. Uncap and connect the four small return hoses to • Over-Pressurization
the fittings on the hydraulic oil reservoir. • Improper oil
4. Install the hydraulic oil level sight-glass using special In the event of pump failure, investigate further to
designed and drilled capscrews and gaskets. determine the cause of the problem.
5. Install hydraulic filter neck components and secure.
6. Fill the hydraulic oil reservoir according to
specifications. Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”
7. Check the hydraulic oil reservoir for leaks.
8. Properly connect the battery.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

8-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

8.7.3 Pump Replacement b. Pump Installation


1. While the pump is still on the bench, install all
a. Pump Removal
fittings, except the outlet hose fitting, orienting them
1. Park the machine on a firm, level surface, level the as noted during removal.
machine, fully retract the boom, lower the boom, 2. Apply Loctite® 243TM on the metal seal of the pump
place the transmission control lever in (N) NEUTRAL, and place into position on the transmission. Align the
engage the park brake and shut the engine OFF. pump shaft with the internal transmission gear, so
2. Place a Do Not Operate Tag on both the ignition key that the machined teeth mesh together.
switch and the steering wheel, stating that the 3. Align the bolt holes with the pump mount holes.
machine should not be operated. Secure the pump to the transmission with the bolts
3. Open the engine cover. Allow the system fluids to and washers. Torque to 115 Nm (85 lb-ft).
cool. 4. If necessary, slide the T-bolt band clamp onto the
4. Properly disconnect the battery. pump inlet hose. Secure the hoses to the hydraulic
5. Thoroughly clean the pump and surrounding area, reservoir outlet connection with the T-bolt band
including all hoses and fittings before proceeding. clamp.
5. Place a new oiled o-ring into position over the pump
Note: Cap all hoses as you remove them to prevent
opening. Secure the inlet hose with two flange
unnecessary oil spillage.
halves, lockwashers and bolts.
6. Remove the bolts and lockwashers securing the 6. Connect the load sense line to the fitting.
flange halves to the pump. Remove the inlet hose
and o-ring. 7. Place a new, oiled o-ring into position over the pump
opening. Secure the outlet hose with two flange
Note: Before removing any fittings from the pump, note halves, lockwashers and bolts.
their orientation to ensure correct installation.
8. Prime the pump by filling the case drain port with
7. Remove the bolts and lockwashers securing the fresh, filtered hydraulic oil from a clean container
flange halves to the pump. Remove the outlet hose before installing the case drain connector and
and o-ring. hoses.
8. Disconnect the case drain hose from the fitting. 9. Check all routing of hoses and tubing for sharp
Disconnect the load sense line. bends or interference with any rotating members. All
9. Remove the bolts and lockwashers securing the tube and hose clamps must be tight.
pump to the transmission. Remove the gasket 10. Start the engine and run at approximately one-third
located between the transmission and the pump. to one-half throttle for about one minute without
Wipe up any hydraulic oil spillage. moving the machine or operating any hydraulic
Note: DO NOT disassemble the implement pump. The functions.
pump is pre-set from the manufacturer. Any adjustments 11. Inspect for leaks and check all oil levels. The
or repairs performed by anyone other than an authorized hydraulic reservoir oil level must be to the middle of
dealer could void the warranty. the sight gauge.
12. Properly connect the battery.
13. Close and secure the engine cover.
14. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.

c. Pump Test
Refer to Section 8.4.1, “Hydraulic Pressures.”

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-19
Hydraulic System

8.8 AUXILIARY PUMP (PLATFORM b. Auxiliary Pump Installation


EQUIPPED MODELS ONLY) 1. Install the pump to its original orientation and secure
in place with the previously used hardware.
8.8.1 Auxiliary Pump Description 2. Connect the previously labeled electrical
The auxiliary pump works as a safety back up for the connections to the pump.
platform in case of engine stalling. The pump will allow 3. Uncap and connect the previously labeled hydraulic
the platform to lower without the engine running. hoses to the auxiliary pump.
4. Properly connect the battery.
8.8.2 Auxiliary Pump Replacement
5. Test the pump functions.
a. Auxiliary Pump Removal 6. Close and secure the engine cover.
1. Park the machine on a firm, level surface, level the 7. Remove the Do Not Operate Tags from both the
machine, fully retract the boom, lower the boom, ignition key switch and the steering wheel.
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 8.9 VALVES AND MANIFOLDS
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key 8.9.1 Main Control Valve
switch and the steering wheel, stating that the
The main control valve is mounted on the side rail in the
machine should not be operated.
engine compartment.
3. Open the engine cover. Allow the system fluids to
cool. 3 4 5 6
4. Properly disconnect the battery.

MZ2530
2
5. Thoroughly clean the auxiliary pump (2) and
surrounding area, including all hoses and fittings,
before proceeding.
MZ2080
6. Place a suitable container to catch hydraulic oil
drainage beneath the frame. The main control valve assembly consists of working
sections with their own valve assemblies, each providing
7. Label, disconnect and cap the hydraulic hoses
a specific hydraulic function. Those functions are:
attached to the auxiliary pump. Slowly turn hose
lift/lower (3), extend/retract (4), tilt (5) and auxiliary (6).
fittings to allow any trapped pressure in the hydraulic
system to escape. Call all fittings to prevent dirt and
a. Main Control Valve Removal
debris from entering the hydraulic system.
8. Wipe up any hydraulic oil spillage in, on, near and 1. Park the machine on a firm, level surface, level the
around the machine and work area. machine, fully retract the boom, lower the boom,
place the transmission control lever in
9. Label and disconnect the electrical connections to (N) NEUTRAL, engage the park brake and shut the
the auxiliary pump. engine OFF.
10. Support the valve and remove the bolts securing the 2. Place a Do Not Operate Tag on both the ignition key
pump to the engine pod. switch and the steering wheel, stating that the
11. Remove the pump. machine should not be operated.

8-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

3. Open the engine cover. Allow the system fluids to d. Main Control Valve Parts Inspection
cool.
Inspect all parts and internal passageways for wear,
4. Properly disconnect the battery. damage, etc. If inner surfaces of any component DO NOT
5. Thoroughly clean the main control valve and display an ultra-smooth, polished finish, or are damaged
surrounding area, including all hoses and fittings, in any way, replace the damaged part. Often, dirty
before proceeding. hydraulic oil causes failure of internal seals, damage to
the polished surfaces within the component, and wear of
6. Place a suitable container to catch hydraulic oil
and/or harm to other parts.
drainage beneath the frame.
7. Label, disconnect and cap all the hydraulic hoses, e. Main Control Valve Assembly
tubes and wires at the main control valve. Slowly
turn hose fittings to allow any trapped pressure in Note: ALWAYS replace seals, o-rings, gaskets, etc.,
the hydraulic system to escape. with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
8. Wipe up any hydraulic oil spillage in, on, near and hydraulic oil.
around the machine and the work area.
9. Support the valve and remove the four bolts Assemble each Valve Section
securing the main control valve bracket to the frame.
1. Reassemble any check valves, compensator valves,
10. Remove the main control valve and bracket from the anti-cavitation valves or shock valves from each
frame and remove the four bolts holding the individual valve sections if equipped.
mounting bracket to the valve.
2. Install the end caps on each end of the valve
section.
b. Main Control Valve Disassembly
1. To disassemble the individual sections of the main Assemble the Main Control Valve.
control valve, remove the nuts from one end of the
1. Place all three tie rods with the nuts through the end
tie rods. Pull the tie rods out through the sections.
main control valve section.
2. Disassemble each section assembly as required.
2. Stand the end main control valve section on end.
Some sections include a pre-adjusted relief valve that
3. Install the proper o-rings and load sense shuttle on
regulates pressure in a specific circuit.
the inner face of the end main control valve section.
Note: DO NOT adjust any of the relief valve assemblies. Align the next valve section over the three tie rods
Tampering with a relief valve will irrevocably alter and slide onto the end main control valve section.
pressure in the affected circuit, requiring recalibration or a 4. Using the proper o-rings and load sense shuttle,
new relief valve. repeat step three for the remaining valve sections
and lastly the inlet end valve section.
Disassemble each Valve Section
5. Install the nuts on the tie rods.
1. Carefully separate the load sense outlet section (7) from
the next section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining section.
4. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual 7
valve section if equipped.
5. Keep all parts being removed from individual valve
sections tagged and kept together.

c. Main Control Valve Parts Cleaning


MAM0100
Clean all components with a suitable cleaner, such as
triclorethylene, before continuing. Blow dry.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-21
Hydraulic System

f. Main Control Valve Installation a. Service Brake Valve Removal


1. Loosely install the four main control valve mounting 1. Park the machine on a firm, level surface, level the
bolts through bracket on the inside rail of the engine machine, fully retract the boom, lower the boom,
bay. place the transmission control lever in
2. Install the main control valve onto the bracket, (N) NEUTRAL, engage the park brake and shut the
aligning the bolts with the holes in the end sections engine OFF.
of the main control valve. Slide the main control 2. Place a Do Not Operate Tag on both the ignition key
valve into position, and tighten the bolts. switch and the steering wheel, stating that the
3. Prime the main control valve by filling the inlet machine should not be operated.
openings with fresh, filtered hydraulic oil from a 3. Open the engine cover. Allow the system fluids to
clean container, before attaching the hoses. cool.
4. Use new oiled o-rings as required. Uncap and 4. Properly disconnect the battery.
connect all hoses, clamps, etc. to the main control 5. Remove the necessary dash panels.
valve.
5. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.
6. Properly connect the battery.
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
8
8. Inspect for leaks and check the level of the hydraulic
oil in the reservoir. Shut the engine OFF. MZ1980

9. Wipe up any hydraulic oil spillage in, on, near and


around the machine, work area and tools. 6. Label, disconnect and cap all hydraulic hoses and
fittings on the service brake valve (8).
10. Close and secure the engine cover.
7. Disconnect the pin holding the yoke to the brake
11. Remove the Do Not Operate Tags from both the pedal arm.
ignition key switch and the steering wheel.
8. Remove the capscrews and lockwashers mounting
g. Main Control Valve Test the service brake valve to the steering column
support.
Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section Note: DO NOT disassemble the service brake valve.
8.4.1, “Hydraulic Pressures.” The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
8.9.2 Service Brake Valve
b. Service Brake Valve Installation
The service brake valve is at the base of the steering
column support, concealed by the lower dash cover. 1. Install the service brake valve with the lockwashers
and capscrews to mount the brake valve to the
The service brakes themselves are part of the axles (the park steering column support.
brake is part of the front axle only). Refer to Section 5, “Axles,
Drive Shafts, Wheels and Tires,” for further information. 2. Align the yoke on the brake valve with the brake
pedal arm. Insert the pin and clip into place being
sure there is a small amount of play between the
pedal and the brake plunger.

8-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

Note: ALWAYS replace seals, o-rings, gaskets, etc., Close the brake bleeder when air bubbles no longer
with new parts to help ensure proper sealing and appear in the oil. Release the brake pedal. remove
operation. Lubricate seals and o-rings with clean the tubing from the brake bleeder.
hydraulic oil. 4. Repeat Steps 2 and 3 for the remaining brake
3. Use new oiled o-rings as required. Reattach and bleeders.
secure all valves, hoses, clamps, etc. 5. Install a vacuum pump on the brake reservoir and
4. Check the routing of all hoses, and tubing for sharp remove the remainder of the trapped air from the
bends or interference with any rotating members, brake system.
and install tie wraps and/or protective conduit as 6. Check brake fluid level and add if necessary using
required. Tighten all tube and hose clamps. ATF fluid.
5. Properly connect the battery. 7. Conduct a pressure and function check of the
6. Start the engine and run at approximately one-third service brake. Refer to Section 8.3, “Hydraulic
to one-half throttle for about one minute, without Pressure Diagnosis.”
moving the machine or operating any hydraulic
functions. 8.9.4 Steering Orbitrol Valve
7. Bleed air from the brake circuit. Refer to Section Refer to Section 4.3.1, “Steering Column and Orbitrol
8.9.3, “Brake Test.” Valve,” for details.
8. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic oil in the 8.9.5 Steer Select Valve
reservoir. Shut the engine OFF. The machine can be used in the front-wheel, four-wheel
Note: Check for leaks, and repair as required before or crab steering mode. The steer select valve controls the
continuing. Add hydraulic oil to the reservoir as needed. direction of hydraulic oil flow to the steering cylinder
mounted on each axle. The steer select valve is attached
9. Close and secure the engine cover. to a mounting plate inside the frame near the left front
10. Remove the Do Not Operate Tags from both the corner of the cab.
ignition key switch and the steering wheel. Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve.
8.9.3 Brake Test The housing of the steer select valve is not serviceable
Carefully bleed the brake lines as soon as the brake valve and must be replaced if defective.
is installed in the machine. Air in the system will not allow
the brakes to apply properly. Work with an assistant to a. Steer Select Manifold and Valve Removal
perform this procedure. 1. Park the machine on a firm, level surface, fully
Note: 17M machines have an extra set of bleeders on retract the boom, lower the boom, place the
the front axle. The outside set is for the park brakes and transmission control lever in (N) NEUTRAL, engage
the inside set is for the service brakes. Be sure to bleed the park brake and shut the engine OFF.
the correct circuit. 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
1. Place the transmission control lever in (N)
machine should not be operated.
NEUTRAL, engage the park brake, and start the
engine. 3. Open the engine cover. Allow the system fluids to
cool.
2. Remove the plastic cap from the front brake bleeder.
Attach one end of a length of transparent tubing over 4. Properly disconnect the battery.
the brake bleeder. Place the other end of this tubing 5. Label, disconnect and cap all hydraulic hoses and
in a suitable transparent container that is partially fittings connected to the steering select valve.
filled with hydraulic oil. The end of the tubing must
6. Disconnect all wire terminal leads attached to the
be below the oil level in the container.
steering select valve.
3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is a pressure at
the brakes. Carefully open the bleeder with a
wrench. Have the assistant depress the brake pedal.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-23
Hydraulic System

7. Remove the two bolts holding the steer select valve Note: ALWAYS replace seals, o-rings, gaskets, etc.,
to the mounting plate on the frame. with new parts to help ensure proper sealing and
17M Frame Shown
operation. Lubricate seals and o-rings with clean
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
four new, oiled o-rings and the four socket head
capscrews.

c. Steer Select Manifold and Valve Installation


1. Install the steer select valve to the mounting plate
under the left side of the frame using the previously
used hardware.
2. Uncap and connect the previously labeled hydraulic
9
hoses and fittings to the steer select valve.
MZ0380 3. Connect all previously labeled wire terminal leads to
the steer select valve.
8. Remove the steer select manifold with the attached 4. Check the routing of all hoses, wiring and tubing for
steer select valve (9) from the machine. Wipe up any sharp bends or interference with any rotating
hydraulic oil spillage in, on, near and around the members, and install tie wraps and/or protective
machine. conduit as required. Tighten all hose clamps.
5. Properly connect the battery.
b. Steer Select Valve and Manifold Disassembly,
Cleaning, Inspection and Assembly 6. Start the engine and run at approximately 1/3-1/2
throttle for about one minute, without moving the
1. Place the steer select assembly on a suitable work machine or operating any hydraulic functions.
surface.
7. Inspect for leaks and check the level of the hydraulic
2. Separate the steer select valve from the manifold by oil in the reservoir.
removing the four socket head capscrews. Discard
the four o-rings. Note: Check for leaks and repair as required before
continuing. Add hydraulic oil to the reservoir as needed.
3. Remove the solenoid valves and cartridges from the
steer select housing. 8. Check each steering mode for proper function.
4. Clean all components with a suitable cleaner before 9. Wipe up any hydraulic oil spillage in, on, near and
inspection. around the machine, work area and tools.
5. Inspect the solenoid cartridges for proper operation. 10. Close and secure the engine cover.
Check by shifting the spool to ensure that it is 11. Remove the Do Not Operate Tags from both the
functioning properly. Check that the spring is intact. ignition key switch and the steering wheel.
Inspect the cartridge interior for contamination.
6. Inspect internal passageways of the steer select 8.9.6 Leveling Valve
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an ultra- a. Leveling Valve Removal
smooth, polished finish, or components are 1. Park the machine on a firm, level surface, fully
damaged in any way, replace the manifold or retract the boom, lower the boom, place the
appropriate part. Often, dirty hydraulic oil causes transmission control lever in (N) NEUTRAL, engage
failure of internal seals and damage to the polished the park brake and shut the engine OFF.
surfaces within the secondary function manifold.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.

8-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

3. Open the engine cover. Allow the system fluids to


cool. 2
3
4. Properly disconnect the battery.
13M MACHINE SHOWN

MZ2410

4. Remove any coils (2) or retainers (3) from the


individual valve section.
5. Keep all parts being removed from individual valve
sections tagged and kept together.
MZ2280
c. Leveling Valve Parts Cleaning
5. Label, disconnect and cap all hydraulic hoses (1)
Clean all components with a suitable cleaner, such as
and fittings connected to the leveling valve.
triclorethylene, before continuing. Blow dry.
6. Disconnect all wire terminal leads attached to the
leveling valve. d. Leveling Valve Parts Inspection
7. Remove the bolts holding the leveling valve to the Inspect all parts and internal passageways for wear,
engine compartment. damage, etc. If inner surfaces of any component DO NOT
8. Remove the leveling valve from the machine. Wipe display an ultra-smooth, polished finish, or are damaged
up any hydraulic oil spillage in, on, near and around in any way, replace the damaged part. Often, dirty
the machine. hydraulic oil causes failure of internal seals, damage to
the polished surfaces within the component, and wear of
b. Leveling Valve Disassembly and/or harm to other parts.
1. To disassemble the individual sections of the
e. Leveling Valve Assembly
leveling valve, remove the nuts from one end of the
tie rods. Pull the tie rods out through the sections. Note: ALWAYS replace seals, o-rings, etc., with new
2. Disassemble each section assembly as required. parts to help ensure proper sealing and operation.
Lubricate seals and o-rings with clean hydraulic oil.
Disassemble each Valve Section
Assemble each Valve Section
1. Carefully separate the cover plate from the next
section. 1. Reassemble any coils or retainers from each
individual valve section.
2. Remove the o-rings from between the two sections.
Assemble the Leveling Valve
3. Carefully separate each remaining section.
1. Place all three tie rods with the nuts through the end
valve section.
2. Stand the end valve section on end.
3. Install the proper o-rings on the inner face of the
valve section. Align the next valve section over the
three tie rods and slide onto the end valve section.
4. Using the proper o-rings, repeat step three for the
remaining valve sections and lastly the cover plate.
5. Install the nuts on the tie rods.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-25
Hydraulic System

f. Leveling Valve Installation 6. Label, disconnect and cap hydraulic hoses and
cylinder ports in relation to the cylinder.
1. Install the leveling valve into the engine
compartment and secure with the previously used 7. Attach a suitable sling to an appropriate lifting device
hardware. to the cylinder. Make sure the device used can
actually support the cylinder.
2. Prime the leveling valve by filling the inlet openings
with fresh, filtered hydraulic oil from a clean 8. Remove the lock bolt and/or any retaining clips
container, before attaching the hoses. securing the cylinder pins. Remove the cylinder pins.
3. Use new oiled o-rings as required. Uncap and 9. Remove the cylinder.
connect all hoses, clamps, etc. to the leveling valve. 10. Wipe up any hydraulic oil spillage in, on, near or
4. Check the routing of all hoses, wiring and tubing for around the machine.
sharp bends or interference with any rotating
members, and install tie wraps and/or protective 8.10.2 General Cylinder Disassembly
conduit as required. Tighten all tube and hose 1. Clean the cylinder with a suitable cleaner before
clamps. disassembly. Remove all dirt, debris and grease
5. Properly connect the battery. from the cylinder.
6. Start the engine and run at approximately one-third 2. Clamp the barrel end of the cylinder in a soft-jawed
to one-half throttle for about one minute without vise or other acceptable holding equipment if
moving the machine or operating any hydraulic possible.
functions.
7. Inspect for leaks and check the level of the hydraulic
oil in the reservoir. Shut the engine OFF.
WARNING
8. Wipe up any hydraulic oil spillage in, on, near and Significant pressure may be trapped inside the
around the machine, work area and tools. cylinder. Exercise caution when removing a
counterbalance valve or a pilot-operated check valve
9. Close and secure the engine cover.
from a cylinder.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
8.10 HYDRAULIC CYLINDERS cylinder securely. Excessive force can damage the
cylinder tube.

8.10.1 General Cylinder Removal 3. If applicable, remove the counterbalance valve from
Instructions the side of the cylinder barrel.

1. Remove any attachment from the machine. Park the Note: DO NOT tamper with or attempt to adjust the
machine on a firm, level surface, allowing sufficient counterbalance valve cartridge. If adjustment is
workspace. Level the machine, place the transmission necessary, replace the counterbalance valve with a new
control lever in (N) NEUTRAL, engage the park brake, part.
shut the engine OFF and block the wheels. 4. Extend the rod (5) to allow access to the base of the
2. Place a Do Not Operate Tag on both the ignition key cylinder.
switch and the steering wheel, stating that the Note: Protect the finish on the rod at all times. Damage
machine should not be operated. to the surface of the rod can cause seal failure.
3. Open the engine cover. Allow the system fluids to
5. Using a pin spanner wrench, unscrew the head
cool.
gland (6) from the barrel (1). A considerable amount
4. Properly disconnect the battery. of force will be necessary to remove the head gland.
5. Relieve any trapped pressure in the hydraulic Carefully slide the head gland down along the rod
system by using the handle or wrench (located in the toward the rod eye end, away from the cylinder
toolbox) and move the double nut on the side of the barrel.
actuator module on the valve section back and forth.

8-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

Note: When sliding the rod and piston assembly out of 10. Remove all seals, back-up rings and o-rings (2) from
the tube, prevent the threaded end of the tube from the piston head and all seals, back-up rings and o-
damaging the piston. Keep the rod centered within the rings from the head gland.
tube to help prevent binding.
Note: The head gland bearing will need to be inspected
1 to determine if replacement is necessary.
2
DO NOT attempt to salvage cylinder seals, sealing rings
3 or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
4 catalog for ordering information.

8.10.3 Cylinder Cleaning Instructions


1. Discard all seals, back-up rings and o-rings. Replace
with new items from complete seal kits to help
ensure proper cylinder function.
2. Clean all metal parts with an approved cleaning
solvent such as trichlorethylene. Carefully clean
1 cavities, grooves, threads, etc.
Note: If a white powdery residue is present on threads
and parts, it can be removed. Clean the residue away
with a soft brass wire brush prior to reassembly, and
2 5
wipe with Loctite® Cleaner before reinstallation.
6
MAH0160
8.10.4 Cylinder Inspection
1. Inspect internal surfaces and all parts for wear,
damage, etc. If the inner surface of the tube does not
6. Carefully pull the rod assembly along with the head display a smooth finish, or is scored or damaged in
gland out of the cylinder barrel. any way, replace the tube.
7. Fasten the rod end in a soft-jawed vise, and put a 2. Remove light scratches on the piston, rod or inner
padded support under and near the threaded end of surface of the tube with a 400-600 grit emery cloth.
the rod to help prevent damage to the rod. Use the emery cloth in a rotary motion to polish out
8. Remove the set screw (3) from the piston (4). and blend the scratch(es) into the surrounding
surface.
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod 3. Check the piston rod assembly for run-out. If the rod
before the piston can be removed. is bent, it must be replaced.
Some cylinder parts are sealed with a special organic
8.10.5 General Cylinder Assembly
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals 1. Use the proper tools for specific installation tasks.
from the area of the bonded parts. Wipe off any hydraulic Clean tools are required for assembly.
oil, then heat the part(s) uniformly to break the bond. A 2. Install new seals, back-up rings and o-rings (2) on
temperature of 149-204° C (300-400° F) will destroy the the piston (4) and the head gland (6).
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal Note: The extend/retract cylinder has a spacer that
while the parts are still hot. The sealant often leaves a MUST be installed over the rod AFTER the head gland
white, powdery residue on threads and other parts, which and BEFORE the piston head.
must be removed by brushing with a soft brass wire brush 3. Fasten the rod eye in a soft-jawed vise, and place a
prior to reassembly. padded support under and near the threaded end of
9. Remove the piston head (4) from the rod (5) and the rod (5) to prevent any damage to the rod.
carefully slide the head gland (6) off the end of the Note: Protect the finish on the rod at all times. Damage
rod. to the surface of the rod can cause seal failure.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-27
Hydraulic System

4. Lubricate and slide the head gland (6) over the 9. Remove the Do Not Operate Tags from both the
cylinder rod (5). Install the piston head (4) on to the ignition key switch and the steering wheel.
end of the cylinder rod. Apply Loctite® 243TM to the
setscrew (3) and install in the piston head. Refer to 8.10.7 Cylinder Pressure Checking
Section 8.10.9, “Hydraulic Cylinder Torque
Attach a 345 bar (5000 psi) gauge to the test port on the
Specifications,” for tightening guidelines for the
main control valve to check the system pressure.
piston head and the set screw.
Note: If a hydraulic cylinder pressure is greater than the
Note: Avoid using excessive force when clamping the
main control valve pressure, increase the main control
cylinder barrel in a vise. Apply only enough force to hold
valve pressure by adjusting the main relief. Generally,
the cylinder barrel securely. Excessive force can
one half turn clockwise will be adequate to check an
damage the cylinder barrel.
individual circuit. Activate the circuit and if pressure is
5. Place the cylinder barrel (1) in a soft-jawed vise or obtained, turn the main relief counter clockwise one half
other acceptable holding equipment if possible. turn. Recheck the main relief setting and adjust if
necessary.
Note: When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder
barrel from damaging the piston head. Keep the cylinder
8.10.8 Steering Cylinders
rod centered within the barrel to prevent binding. The steering cylinders (7) are attached to each axle
center housing. The steer cylinders are covered in the
6. Carefully insert the cylinder rod assembly into the
appropriate manufacturer’s axle literature.
tube.
7. Screw the head gland (6) into the cylinder barrel (1)
and tighten with a spanner wrench. Refer to Section
7
8.10.9, “Hydraulic Cylinder Torque Specifications,”
for tightening guidelines for the head gland.
8. If applicable, thread the new counterbalance valve
into the block on the cylinder barrel.

8.10.6 General Cylinder Installation


1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder
into it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or
AXLE CENTER SECTION
retaining clip.
3. Connect the hydraulic hoses in relation to the labels
or markings made during removal.
4. Properly connect the battery.
5. Before starting the machine, check oil level of the
hydraulic oil reservoir and if necessary, fill to full
mark with hydraulic oil.
6. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
7. Inspect for leaks and check level of hydraulic oil in
reservoir. Add hydraulic oil if needed. Shut the
engine OFF.
8. Wipe up any hydraulic oil spillage in, on, near and
around the machine, work area and tools.

8-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System

8.10.9 Hydraulic Cylinder Torque Specifications

a. Lift/Lower Cylinder

Machine Piston Head Set Screw


8M 2550-2600 Nm 775-825 Nm 20-25 Nm
(1881-1917 lb-ft) (571-608 lb-ft) (15-19 lb-ft)
9, 12, 13 & 17M 2490-2540 Nm 950-1000 Nm 20-25 Nm
1837-1873 lb-ft) (701-738 lb-ft) (15-19 lb-ft)

b. Extend/Retract Cylinder

Machine Piston Head Plug Set Screw


8 & 9M 1290-1340 Nm 400-450 Nm N/A 20-25 Nm
(951-988 lb-ft) (295-332 lb-ft) (15-19 lb-ft)
12M & 13M 1070-1120 Nm 480-530 Nm 50-55 Nm 20-25 Nm
(789-826 lb-ft) (354-391 lb-ft) (rear) (37-41 lb-ft) (15-19 lb-ft)
380-430 Nm
(280-317 lb-ft) (front)
17M 2160-2210 Nm 775-825 Nm N/A 20-25 Nm
(1593-1630 lb-ft) (572-608 lb-ft) (15-19 lb-ft)

c. Tilt Cylinder

Piston Head Set Screw


2850-2900 Nm (2102-2139 lb-ft) 775-825 Nm (572-608 lb-ft) 20-25 Nm (15-19 lb-ft)

d. Compensation Cylinder

Piston Head Set Screw


850-900 Nm (627-664 lb-ft) 380-430 Nm (280-317 lb-ft) 20-25 Nm (15-19 lb-ft)

e. Frame Level Cylinder

Piston Head Set Screw


1050-1100 Nm (774-811 lb-ft) 400-450 Nm (295-332 lb-ft) 20-25 Nm (15-19 lb-ft)

f. Outrigger Cylinder

Machine Piston Head


12M, 13 & 17M 1300-1350 Nm (959-995 lb-ft) 625-675 Nm (461-498 lb-ft)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-29
Hydraulic System

This Page Intentionally Left Blank

8-30 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 9
Electrical System

Contents

PARAGRAPH TITLE PAGE


9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4.1 Operator Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.4.2 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4.3 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.5 Operator Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.1 Resetting the Anti Theft Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.2 Hardware Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.3 Confirm Machine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.4 Review Service History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.5 Set Service Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5.6 Cabin Joystick Telescope: X-Axis/Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.6.1 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.6.2 Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.6.3 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.7 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.7.1 Cab Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
9.7.2 Cabin Roof Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.7.3 Power Distribution Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
9.7.4 Chassis and Boom Harness Electrical Schematic . . . . . . . . . . . . . . . . . . 9-17
9.7.5 Engine Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
9.7.6 Platform Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
9.7.7 Platform Cab Harness Schematic (if equipped) . . . . . . . . . . . . . . . . . . . . 9-21
9.8 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.8.1 Constant Power Circuit from Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
9.8.2 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
9.9 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.9.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24
9.10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.10.1 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25
9.11 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.11.1 Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-1
Electrical System

9.12 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26


9.12.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
9.12.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.12.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.13 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.13.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.14 Switches, Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.14.1 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
9.14.2 Transmission Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.14.3 Transmission Mounted Speed Sensor (if equipped) . . . . . . . . . . . . . . . . . 9-30
9.14.4 Engine Coolant Temperature Sender/Switch . . . . . . . . . . . . . . . . . . . . . . 9-31
9.14.5 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.14.6 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.14.7 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.14.8 Boom Retracted Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.15 Load Stability Indicator (LSI) - 8, 9, 12 & 13M Before S/N 1160005993 excluding
1160005949 & 1160005950 17M Before S/N 1160005937 including 1160005952,
1160005960, 1160005963, 1160005966 & 1160005978. . . . . . . . . . . . . . . . . . . . . . 9-34
9.15.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.15.2 LSI Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.15.3 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.16 Load Stability Indicator (LSI) - 8, 9, 12 & 13M S/N 1160005993 & After including
1160005949 & 1160005950 17M S/N 1160005937 & After excluding 1160005952,
1160005960, 1160005963, 1160005966 & 1160005978. . . . . . . . . . . . . . . . . . . . . . 9-38
9.16.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.16.2 LSI Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.16.3 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.16.4 LSI - CAN CHECK PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.16.5 500 Hour - LSI UGM Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.17 Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.17.1 Analyzer Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
9.17.2 Analyzer Software Version 3.5 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . 9-44
9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.18.1 Indicator Cross Reference Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
9.18.2 Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47

9-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.1 ELECTRICAL COMPONENT 9.2 SPECIFICATIONS


TERMINOLOGY
Electrical system specifications are listed in Section 2,
To understand the safety, operation, and service “General Information and Specifications.”
information presented in this section, it is necessary that
the operator/mechanic be familiar with the name and
location of the electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

LOAD
STABILITY
INDICATOR JOYSTICK

POWER
DISTRIBUTION
DISPLAY BOARD
PANEL
TRANSMISSION
SOLENOID VALVES

ALTERNATOR
UGM
CONTROLLER

STARTER

BATTERY

MZ2370

MZ2380
IGNITION KEY
SWITCH

BOOM ANGLE
SENSOR

LOAD STABILITY
SENSOR
(ON AXLE)
MZ2360

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-3
Electrical System

9.3 PLATFORM INTERLOCK CHECKS


To check the platform interlock, turn the ignition key to
position I and be sure the following are set: WARNING
• Park brake is applied While an assistant raises the boom. DO NOT leave
the cab unattended.
• Transmission control lever is in the (N) NEUTRAL
position 6. Have an assistant raise the boom above 60 degrees
• Machine outriggers are fully lowered in the platform. The boom should not raise above 60
degrees (Model 4017 only). Lower the boom.
• Machine is level
• Quick Attach locking pin is installed
It is now possible to check the platform interlock.
1. Disengage the park brake. Turn the ignition key to
the platform position. The machine should not
engage in platform mode. Reapply the park brake.
2. Shift the transmission control lever into
(F) FORWARD or (R) REVERSE. The machine
should not engage in platform mode. Shift the
transmission control back to the (N) NEUTRAL
position.
3. Raise the outriggers. The machine should not
engage in platform mode. Lower the outriggers.
4. Rotate the machine to a non-level position. The
machine should not engage in platform mode. Level
the machine.
5. Remove the quick attach locking pin from the boom
head. The machine should not engage in platform
mode. Install the quick attach locking pin.
With all the above conditions met for the machine to go
into platform mode, turn the ignition key to the platform
position.
1. Disengage the park brake. The machine should
disable platform functions. Engage the park brake.
2. Shift the transmission control lever to (F) FORWARD
or (R) REVERSE. The machine should not drive in
platform mode. Shift the machine to (N) NEUTRAL.
3. Raise the outriggers. The outriggers should NOT
raise in platform mode.
4. Unlevel the machine. The machine should disable
platform functions if the machine is not level. Level
the machine.
5. Have an assistant remove the quick attach locking
pin. The machine should disable platform functions.

9-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.4 SOFTWARE LEVEL 2 ACCESSIBILITY


The following parameters can be altered in the 2nd level of access to the machine’s software.

9.4.1 Operator Tools

Function Description
Change Anti Theft Allows the owner to change the Anti Theft Code
Code
Perform Hardware Allows the owner to restore machine data (anti theft code, engine hours, machine
Exchange personalities, etc.) in the event that the machine controller or display/cluster gauge has
been replaced
Confirm Machine Allows the owner to turn off the Service Required Warning lamp when service is
Service performed
Review Service History Allows the owner to see the last 15 times the Service Required Warning lamp was reset
Set Service Interval Allows the owner to modify the default service interval of 100 hours
Cabin Joystick Allows the owner to change/swap operation of the joystick Telescope and Fork Tilt
Telescope: X-Axis/ functions.
Roller NOTE: This change requires the installation of a new joystick operation decal in the cab.
Contact your local authorized distributor.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-5
Electrical System

9.4.2 Personalities

Function Description Range Default Value


Main Lift Allows the owner to adjust the Max Lift Up & Max Lift 900-2500 mA 1550 mA
Down function speeds
Soft Lift Allows the owner to adjust the derate value when the 0-90% 40%
boom enters the soft lift zone
Telescope Allows the owner to adjust the Max Tele In & Max Tele Out 900-2500 mA 1550 mA
function speeds
Fork Tilt Allows the owner to adjust the Max Fork Tilt Up & Max 900-2500 mA 1200 mA
Fork Tilt Down function speeds
Platform Allows the owner to adjust the Max Platform Level Up & 800-900 mA (Up) 900 mA (Up)
Level Max Platform Level Down function speeds 800-870 mA (Down) 870 mA (Down)
Platform Allows the owner to adjust the Max Platform Left & Max 720-940 mA (Right) 940 mA (Right)
Rotate Platform Right function speeds 720-970 mA (Left) 970 mA (Left)
Stabilizers Allows the owner to adjust the Max Stabilizer Up & Max 600-2500 mA 1600 mA
Stabilizer Down function speeds
Frame Allows the owner to adjust the Max Frame Level Left & 1000-2500 mA 1000 mA
Level Max Frame Level Right function speeds
Aux. Allows the owner to adjust the Accel, Decel, and Max 1100-2500 mA 1550 mA
Function 1 Function A & Max Function B function speeds
Aux. Allows the owner to adjust the Accel, Decel, and Max 1100-2500 mA 1550 mA
Function 2 Function A & Max Function B function speeds
Aux. Allows the owner to adjust the Max Momentary Aux A & 0-1800 mA 1100 mA
Momentary Max Momentary Aux B function speeds
Bucket Allows the owner to adjust the Max Bucket Up & Max 1200-2500 mA 1550 mA
Mode Bucket Down function speeds

9.4.3 Calibrations

Function Description
Boom Angle Allows the owner to calibrate the boom angle sensor if it is replaced. Refer to Section 9.14.7,
“Boom Angle Sensor.”

9-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.5 OPERATOR TOOLS 9.5.3 Confirm Machine Service


To log the machine service into the software:
9.5.1 Resetting the Anti Theft Code 1. Turn the engine to the ON position.
To reset the anti theft code: 2. Press the "C" and "OK" buttons on the dash
1. Turn the engine to the ON position. simultaneously to enter the analyzer mode.
2. Press the "C" and "OK" buttons on the dash 3. Scroll to "Access level code". Enter the code
simultaneously to enter the analyzer mode. "33271" to go into access level 2.
3. Scroll to "Access level code". Enter the code 4. Scroll to and select the "Operator Tools" screen.
"33271" to go into access level 2. 5. Scroll to and select the "Confirm Machine Service"
4. Scroll to and select the "Operator Tools" screen. screen.
5. Scroll to and select the "Change Anti Theft Code" 6. If service is complete, press ENTER for YES.
screen. Otherwise, press ESC for NO.
6. Enter the current anti theft code.
9.5.4 Review Service History
Note: If a machine does not have an anti theft code set,
To view the last 15 machine service instances:
the default code is "00000".
1. Turn the engine to the ON position.
7. Enter the new code.
2. Press the "C" and "OK" buttons on the dash
simultaneously to enter the analyzer mode.
9.5.2 Hardware Exchange
3. Scroll to "Access level code". Enter the code
After the replacement of either the display or UGM
"33271" to go into access level 2.
(Controller) the machine software will indicate a
Hardware Exchange fault. To correct this fault: 4. Scroll to and select the "Operator Tools" screen.
1. Turn the engine to the ON position. 5. Scroll to and select the "Review Service History"
screen.
2. Press the "C" and "OK" buttons on the dash
simultaneously to enter the analyzer mode. 6. Scroll through the screens to view the last 15 times
the machine was serviced.
3. Scroll to "Access level code". Enter the code
"33271" to go into access level 2.
9.5.5 Set Service Interval
4. Scroll to and select the "Operator Tools" screen.
To set the machine recommended service interval:
5. Scroll to and select the "Perform Hardware
Exchange" screen. 1. Turn the engine to the ON position.

6. Scroll to and select the proper screen for hardware 2. Press the "C" and "OK" buttons on the dash
exchange. The screen will show either simultaneously to enter the analyzer mode.
"DISPLAY -> UGM" or "UGM -> DISPLAY". The new 3. Scroll to "Access level code". Enter the code
component should be listed second. "33271" to go into access level 2.
4. Scroll to and select the "Operator Tools" screen.
5. Scroll to and select the "Set Service Interval" screen.
6. Enter a new service interval.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-7
Electrical System

9.5.6 Cabin Joystick Telescope: X-Axis/ 9.6 FUSES AND RELAYS


Roller
To change the joystick telescope function on the joystick: 9.6.1 Cab
1. Turn the engine to the ON position.
2. Press the "C" and "OK" buttons on the dash
simultaneously to enter the analyzer mode.
3. Scroll to "Access level code". Enter the code
"33271" to go into access level 2. 1
4. Scroll to and select the "Operator Tools" screen. 2
5. Scroll to and select the "Cabin Joystick Telescope"
screen.
6. Select either X-AXIS or ROLLER.
Note: When changing the joystick function, ensure the
correct joystick operation decal is installed. Contact your
local authorized distributor.
MZ1990

For access to the fuse and relay panel, remove the


screw (1) securing the right side console access
panel (2) to the cab. The fuses and sealed 12-volt relays
are mounted under the right side console access panel.
The fuse and relay panels are part of the cab harness.

9.6.2 Engine Compartment


3
4
5

MZ2100

The fuse and relay bar is located on the frame directly


above the engine. The fuse and relay bar contains the
glow plug fuse (3), glow plug relay (4) and starter
relay (5). To remove the relays from inside the engine
compartment, remove the mounting screws and washers.

9-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.6.3 Power Distribution Board

MZ2090

Fuse/Relay Function Amp Rating


F1 Rt. Headlight Low 7.5
F2 Rear Wiper 15
F3 Rt. Headlight High 7.5
F4 Lt. Headlight Low 7.5
F5 Lt. Headlight High 7.5
F6 Fan 20
F7 Front Wiper 25
F8 A/C 7.5
F9 Key 2 15
F10 Key 1 15
F11 Radio 10
F12 Lights Bat 1 15
F13 Lights Bat 2 15
F14 Lt. Marker Lights 7.5
F15 Boom Worklights 15
F16 Brake Lights 15
F17 Front Worklights 15

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-9
Electrical System

Fuse/Relay Function Amp Rating


F18 Flasher 15
F19 Rt. Marker Lights 7.5
F20 Beacon 15
F21 Rear Worklights 15
F22 Controller 25
F23 Display/Joystick 10
F24 Fuel 15
F25 Socket 15
F26 Seat 15
F27 Key Bat 15
F28 Spare Bat 15
F29 Shift/Steer 15
F30 Spare Key 15
K1 Reverse Travel
K2 1/2 Aux
K3 Flasher
K4 Ign Power 1
K5 Ign Power 2
K6 Work Lights
K7 Ign Power 3
K8 Fuel
K9 Fuel Enable

9-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.7 ELECTRICAL SYSTEM SCHEMATICS


For more detailed schematics, contact your local authorized service distributor.

9.7.1 Cab Harness Electrical Schematic


Before S/N 1160005993 excluding 1160005949 & 1160005950 (Sheet 1)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-11
Electrical System

Before S/N 1160005993 excluding 1160005949 & 1160005950 (Sheet 1 - Continued)

9-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

S/N 1160005993 & After including 1160005949 & 1160005950 (Sheet 1)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-13
Electrical System

S/N 1160005993 & After including 1160005949 & 1160005950 (Sheet 1 - Continued)

9-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.7.2 Cabin Roof Harness Electrical Schematic


(Sheet 2)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-15
Electrical System

9.7.3 Power Distribution Electrical Schematic


(Sheet 3)

9-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.7.4 Chassis and Boom Harness Electrical Schematic


Before S/N 1160005993 excluding 1160005949 & 1160005950 (Sheet 4)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-17
Electrical System

S/N 1160005993 & After including 1160005949 & 1160005950 (Sheet 4)

9-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.7.5 Engine Harness Electrical Schematic


(Sheet 5)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-19
Electrical System

9.7.6 Platform Electrical Schematic


(Sheet 7)
Note: Sheet 6 of 8 not included in electrical schematic intentionally.

9-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.7.7 Platform Cab Harness Schematic


(if equipped)
(Sheet 8

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-21
Electrical System

9.8 CIRCUIT BREAKDOWNS

9.8.1 Constant Power Circuit from Battery

POWER CONTROL BOARD

SOCKET
FLASHER
LIGHTS BAT 1
LIGHTS BAT 2

KEY BAT
SPARE BAT
XF XH
XA XD

5 4 3 2 1 1 2 6 2 4 13

PCB PWR
XA

SOCKET
KEY BAT
EMPTY
LIGHTS BAT 1
LIGHTS BAT 2

HAZARD
SWITCH
X8
S3 1
1 2
3 6
DRIVING LIGHTS
SWITCH 2 5 1
EMERG STOP
S12 1 4 FLASH BAT SWITCH AUX POWER
3 6 8 7 (PLATFORM ONLY)
SOCKET
2
2 5
FLASH BAT

X18
KEY BAT A
30
KEY BAT A
8 7 30 0P
1
15 2
X17
15 3
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
58 0P
1
58
2
3
56a

53c
56b

49a
53a

KEY
56

30

53

15
H
R
L

19 0P SWITCH
19 1
2
17 3
17
TURN/ 0P
WIPER 50 1
SWITCH 2
50
3
PCB PWR
PCB PWR
PCB PWR
PCB PWR

PCB PWR XA1 CAB HARNESS


1 2 3 4

XA1 30
AUXILIARY
PCB PWR
PCB PWR
PCB PWR
PCB PWR

POWER
87
UNIT
86 RELAY
(PLATFORM ONLY)

X110

+ -
12 VDC
BATTERY
STARTER

PCB PWR
PCB PWR
PCB PWR X36
M
PCB PWR

STRT PWR
PHEAT PWR
ALT BAT X38
ALT BAT
30
STRT PWR
STARTER
87
RELAY
86
85

ALT BAT ALTERNATOR


ALT BAT B+ X40
PHEAT PWR W G
D+
50 GLOWPLUGS
X46
FUSE
PHEAT RLY
X47 30
PHEAT RLY
87 GLOWPLUGS
86 RELAY
ENGINE HARNESS 85

MZ2260

9-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.8.2 Start Circuit

POWER CONTROL BOARD CAB UGM

CONN. CONN. CONN. CONN. CONN. CONN. CONN. CONN. CONN.


XC XF XG XH XP J1 J2 J4 J7

3 10 13 4 5 6 7 8 9 10 11 12 12 4 4 5 6 8 16 20 30 3

STRT RLY
BRK LT SW

APU ENABLE
GLOWPLUGS

CLUTCH LOCK

PREHEAT
CLUTCH

KEY IGN
NEUT
P BRK

KEY STRT
KEY 1B

FUEL PMP

IGNITION

IGNITION

IGNITION
IGNITION

KEY IGN

KEY IGN

KEY IGN
FUEL VLV
KEY BAT A

S1 7

APU ENABLE 3 2 1 8
SWITCH KEY 1B
(PLATFORM ONLY)
APU

S5 7
CLUTCH LOCK
SWITCH
(POWERSHIFT ONLY)

3 2 8
KEY 1B
CLUTCH

X10
1
KEY 1B
BRAKE BRK LT
2 EMERG STOP
PEDAL
SWITCH 3 SWITCH
CLUTCH (PLATFORM ONLY)
4 X18
2 KEY BAT A
30
1 KEY BAT A
30 0P
1 KEY 1B 1
PARK BRAKE X13 KEY IGN
OFF 2 P BRK 15 2
SWITCH KEY IGN
ON 15 3
X13B
KEY 1B 58 0P
1
P BRK 1
2 58
2
3 3 KEY
PREHEAT
X14 19 0P SWITCH
KEY 1B PREHEAT A 1
FWD PWR
1 19
2
STRT RLY

NEUT F PREHEAT A
2 17
REV N NEUT 3
SHIFTER 3
17
SWITCH
I R
4 0P
KEY STRT
II I
5 50 1
II 2
6 50
III III
7
3
FUEL PMP
IV IV
8
nc
9 FUEL VLV GLOWPLUGS

CAB HARNESS

8 20 36 37

ENGINE HARNESS CONN.


FUEL PMP
GLOWPLUGS
FUEL VLV

STRT RLY

X3
+ -
12 VDC
BATTERY
STARTER

GLOWPLUGS
50
PHEAT PWR
FUEL VLV
X43
COLD START
TEMP
M
FUSE X46
SWITCH

PHEAT RLY STRT PWR

X47 PHEAT PWR


30 PHEAT RLY X44 ALT BAT X38
GLOWPLUGS FUEL VLV FUEL
87 PHEAT 1 ALT BAT
RELAY VALVE
86 GLOWPLUGS 2 (TURBO) 30
FUEL PMP

STRT PWR
85 STARTER
87
X48 X49 RELAY
PHEAT STRT RLY 86
1 1
ENGINE
GLOWPLUGS 2 M FUEL
PUMP
85

ALT BAT ALTERNATOR


ALT BAT B+ X40
W G
D+

MZ2270

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-23
Electrical System

9.9 ENGINE START CIRCUIT can also prevent the starter from cranking the
engine.
9.9.1 Starter 3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit,
refer to Section 9.8.2, “Start Circuit.”

c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
2. Open the engine cover. Allow the engine to cool.
1 3. Properly disconnect the battery.
4. Remove the wires from the solenoid stud. Remove
MZ0150 the positive (+) battery cable from the starter. Label
and disconnect the wire from the starter solenoid
The starter (1) is located on the left side of the engine (the housing stud. Record how the wires are installed to
right side of the machine). ensure correct installation later.
5. Loosen, but DO NOT remove the three fasteners
a. Testing the Starter on the Engine
securing the starter to the flywheel housing. Support
If the starter does not engage when the ignition key the starter securely, as it is relatively heavy and will
switch is turned, check the following: fall if not supported.
1. The main fuse may be blown, requiring replacement. 6. Support the starter and remove the fasteners
Check for the cause of the blown fuse. securing the starter to the engine. Remove the
2. There may be a defect in the ignition key switch, negative (-) ground cable from its starter mounting
ignition wiring or starter solenoid. bolt.

3. Check battery condition. Clean the battery posts and 7. Remove the starter from the machine.
the connectors at each end of the battery cables.
d. Starter Cleaning and Drying
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring. 1. While the starter is being removed, wipe away any
grease or dirt that has accumulated around the
5. Check all connections at the starter solenoid, key
starter mounting opening.
switch and wiring harness plugs. Clean and tighten
all connections. 2. If reinstalling the starter, clean the exterior of the
starter with an approved solvent. DO NOT submerse
6. If the starter still does not operate after these checks
the starter or allow the solvent to contact the starter
have been performed, check the starting circuit.
bushings.
b. Starter Circuit Checks 3. Dry the starter with a clean, lint-free cloth.

1. Check wires and connections for looseness, e. Starter Periodic Maintenance


corrosion, damage, etc.
A starter requires no routine maintenance beyond the
2. If a “whirring” noise is heard but the engine does not
occasional inspection of the electrical connections, which
turn over, the starter is spinning but not engaging the
must be clean and tight. The starter is not serviceable;
flywheel. The starter drive or solenoid that pushes
replace a defective starter with a new unit.
the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel

9-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

f. Starter Installation 9.10.1 Alternator


1. Position the starter in its mounting opening on the
a. Alternator Removal
flywheel housing. Position the ground cable over the
correct starter mounting bolt. Secure the starter with 1. Park the machine on a firm, level surface, level the
fasteners. Torque fasteners to 43 Nm (32 lb-ft). machine, fully retract the boom, lower the boom,
2. Connect the positive (+) battery cable to the upper place the transmission control lever in (N)
solenoid stud. Install the wires to the upper solenoid NEUTRAL, engage the park brake and shut the
stud, and secure with lockwasher and nut. Torque engine OFF.
nuts to 43 Nm (32 lb-ft). 2. Place a Do Not Operate Tag on both the ignition key
3. Connect the wire to the solenoid mounting stud. switch and the steering wheel, stating that the
machine should not be operated.
4. Properly connect the battery.
3. Open the engine cover. Allow the engine to cool.
5. Close and secure the engine cover.
4. Properly disconnect the battery.
6. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.

9.10 CHARGING CIRCUIT


Before using a battery charger, an attempt can be made
to recharge the battery by jump-starting the machine.
(Refer to the appropriate Operation & Safety Manual.)
Allow the engine to run, which will enable the alternator to 2
charge the battery.
If the engine alternator charging warning indicator
illuminates, perform the following checks:
1. Check the all battery cable connections at the
battery, and verify that they are clean and tight.
2. Check the external alternator wiring and
connections, and verify that they are in good
condition. MZ0150

3. Check the fan belt condition and tension. 5. Loosen both alternator (2) mounting bolts and pivot
4. Verify that the alternator mounting hardware is tight. alternator in.
5. Run the engine and check the alternator for noise. A 6. With the fan belt now being loose, remove the belt
loose drive pulley, loose mounting hardware, worn or from the engine.
dirty internal alternator bearings, a defective stator Note: Record how the alternator is installed to ensure
or defective diodes can cause noise. Replace a worn correct installation later.
or defective alternator.
7. Label and disconnect the wire leads attached to the
alternator.
8. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
9. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from
the upper alternator mount. Remove the alternator
from the machine.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-25
Electrical System

b. Alternator Installation 9.12 WINDOW WIPER/WASHER


1. Position the alternator and align with the upper
alternator mount on the engine bracket. Insert the 9.12.1 Windshield Wiper Motor
upper mounting hardware through the alternator
mount. DO NOT tighten completely at this time. a. Removal
2. Align the lower alternator mount hole with the lower Note: It may be necessary to remove several hydraulic
mounting bracket on the engine. Insert the lower hoses from under the dash in order to remove and install
mounting capscrew. DO NOT tighten completely at the wiper motor housing.
this time.
1. Park the machine on a firm, level surface, level the
3. Install the fan belt, adjust the alternator for proper machine, fully retract the boom, lower the boom,
belt tension and belt alignment. Tighten the lower place the transmission control lever in (N)
capscrew and upper capscrew securely. NEUTRAL, engage the park brake and shut the
4. Connect the previously labeled wire leads. engine OFF.
5. Properly connect the battery. 2. Place a Do Not Operate Tag on both the ignition key
6. Close and secure the engine cover. switch and the steering wheel, stating that the
machine should not be operated.
7. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel. 3. Open the engine cover. Allow the engine to cool.
4. Properly disconnect the battery.
9.11 ELECTRICAL SYSTEM 5. Remove the lower dash panel.
COMPONENTS 6. Disconnect the right side defroster hose from dash
panel hose connector.
9.11.1 Back-up Alarm Note: DO NOT start the engine with the hoses not
The back-up alarm is located at the rear of the machine. connected to their proper fittings.
When the transmission shift control switch (transmission 7. Disconnect the cab harness connectors from the
control lever) is shifted to the (R) REVERSE position, the wiper motor.
back-up alarm will automatically sound.
Place the transmission control lever in (R) REVERSE to
test the back-up alarm. The back-up alarm must not
sound when the transmission control lever is in (N)
NEUTRAL or (F) FORWARD. Also, with the ignition key
switch in the RUN position, the back-up alarm will sound
when the transmission control lever is shifted into the (R)
4
REVERSE position.

a. Disassembly
DO NOT disassemble the back-up alarm. Replace a
defective or faulty alarm with a new part.
MAH0910

b. Inspection and Replacement


8. Remove the linkage attached to the wiper motor (4).
Inspect the wiring harness connector and alarm terminals 9. Loosen and remove the four bolts holding the wiper
for continuity and shorting. Test the alarm by turning the motor to the mounting bracket.
ignition key switch to the RUN position and shifting the
transmission control lever into the REVERSE position. Note: Retain all hardware removed from the wiper
The alarm should sound. assembly for possible reuse on the replacement motor
housing.
Replace a defective or faulty alarm with a new part.
10. Remove the motor from the inside of the cab.

9-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

b. Disassembly
DO NOT disassemble the motor. The motor is not 5
serviceable. Replace motor if found to be defective.

c. Inspection and Replacement


Inspect the motor terminals for continuity. Replace motor
if continuity is not found.
MAH0920
d. Installation and Testing
5. Remove the wiper arm from the wiper motor (5)
1. Install all required hardware to the motor assembly. shaft.
2. Align motor with the mounting holes and bolt the 6. Remove the nut on the wiper motor shaft and on the
motor to the mounting bracket. wiper motor.
3. Connect the wiper linkage to the wiper motor shaft. 7. From inside the cab, pull the wiper motor away from
Note: Align the wiper linkage arm with the flat on the the rear window.
motor shaft to ensure wiper stroke covers window area, 8. Pull the cab headliner down in the rear right corner.
and it does not swipe past the glass area. Label and disconnect the cab harness connectors
4. Connect the cab harness connectors to windshield from the wiper motor.
wiper motor connectors.
b. Disassembly
5. Properly connect the battery.
DO NOT disassemble the motor. The motor is not
6. Turn ignition key switch to the RUN position, and
serviceable. Replace motor if found to be defective.
operate windshield wiper in both LOW and HIGH
speeds to ensure proper operation and that correct
c. Installation and Testing
wiper travel is achieved.
7. Install right side defroster hose to the dash panel 1. Hold wiper motor up toward cab rear window and
hose connector. install the cab harness connectors. Refit the
headliner.
8. If previously removed, install hydraulic hoses under
the dash. 2. With the help of an assistant, insert the wiper motor
through the roof hole and have the assistant thread
9. Install the lower dash panel. the hex nuts onto the wiper motor shaft and the
10. Close and secure the engine cover. wiper motor. Ensure that the motor housing is facing
11. Remove the Do Not Operate Tag from the ignition the front of the cab.
key switch and the steering wheel. 3. Install the wiper arm onto the wiper motor shaft.
4. Properly connect the battery.
9.12.2 Rear Window Wiper Motor
5. Turn ignition key switch to the RUN position and turn
a. Removal the rear wiper switch to the ON position. Ensure
wiper stays on the window through a full stroke. Turn
1. Park the machine on a firm, level surface, level the the rear wiper switch to the OFF position.
machine, fully retract the boom, lower the boom,
6. Engage the washer switch and ensure washer fluid
place the transmission control lever in (N)
is sprayed on the rear window. Turn the ignition key
NEUTRAL, engage the park brake and shut the
switch to the OFF position.
engine OFF.
7. Close and secure the engine cover.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the 8. Remove the Do Not Operate Tag from the ignition
machine should not be operated. key switch and the steering wheel.
3. Open the engine cover. Allow the engine to cool.
4. Properly disconnect the battery.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-27
Electrical System

9.12.3 Windshield Washer Reservoir and c. Cleaning and Drying


Pump Without submerging the pumps, clean the pumps and
The windshield washer motor and reservoir is located in reservoir with an approved solvent and dry with a clean,
the engine compartment as a unit and cannot be serviced lint-free cloth.
separately.
d. Inspection and Replacement
a. Removal
Inspect the electrical terminals for continuity.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, e. Installation and Testing
place the transmission control lever in (N)
1. Connect the windshield washer hoses to the
NEUTRAL, engage the park brake and shut the
reservoir.
engine OFF.
2. Connect the cab wiring harness connectors to the
2. Place a Do Not Operate Tag on both the ignition key
reservoir connectors.
switch and the steering wheel, stating that the
machine should not be operated. 3. Install the reservoir tank onto the mounting studs.
3. Open the engine cover. Allow the engine to cool. 4. Install the lockwashers and nuts and secure.
4. Properly disconnect the battery. 5. Fill the washer fluid reservoir with washer fluid.
5. Remove the nuts and the lockwashers from the 6. Properly connect the battery.
washer mounting studs. 7. Turn the ignition key switch to the RUN position and
press the washer switches. Verify that fluid is
sprayed on both the windshield and rear glass.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tag from the ignition
6
key switch and the steering wheel.

9.13 CAB HEATER AND FAN

9.13.1 Cab Heater Controls


Note: If the suspect component is found to be within the
heater box, the heater box must be removed as a
complete unit and replaced. For additional information
on the removal and installation of the heater box, refer to
MZ2110 Section 4.3.9, “Heater/Defroster System.”

6. Pull the washer reservoir (6) out and away from the a. Cab Heater Controls Removal
mounting studs.
1. Park the machine on a firm, level surface, level the
7. Rotate the washer reservoir, label and remove the machine, fully retract the boom, lower the boom,
cab harness connectors from the washer reservoir place the transmission control lever in (N)
connectors. NEUTRAL, engage the park brake and shut the
8. Remove the windshield washer hoses from the engine OFF.
reservoir. 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
b. Disassembly machine should not be operated.
DO NOT disassemble the pumps. The pump is not 3. Open the engine cover. Allow the engine to cool.
serviceable. Replace pumps if found to be defective.
4. Properly disconnect the battery.

9-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.14 SWITCHES, SOLENOIDS, SENSORS


AND SENDERS

9.14.1 Transmission Solenoid Valves


7
MZ2160

5. Remove the four screws (7) from the cab heater and
fan control panel.
6. Pull the control panel out from the dash panel and
disconnect the variable speed fan control cab
harness connector and disconnect the temperature
cable.
7. Remove the control from the panel.

b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.

c. Installation and Testing


8
1. Check that the variable speed fan control is in the
OFF position. MZ0650

2. Install the temperature control cable to the back of


the control. If the transmission is not shifting properly, the
transmission control lever, wiring harness or transmission
3. Install the hex locknut on the shaft and tighten. shift solenoids (8) should be checked in order to
4. Connect the cab harness connector to the variable determine which component is defective. Specific
speed fan control. information to determine which travel position and
5. Install the screws securing the control panel to the corresponding component is not responding can be
dash panel. found in the detailed transmission service instructions are
provided in the Dana-Spicer T12000 Transmission
6. Properly connect the battery. Repair Manual, P/N 31200163 and can be obtained by
7. Turn the ignition key to the ON position and check calling your local JLG service distributor.
the fan speeds. If further repair is needed, refer to The transmission should be checked, serviced and
Section 9.7, “Electrical System Schematics.” repaired only by experienced service technicians who are
8. Start the machine and allow engine to reach aware of all safety instructions and particular component
operating temperature. Check heat control at features.
different levels.
Note: Contact the JLG Service Department if internal
9. Close and secure the engine cover. transmission repair is required during the warranty
10. Remove the Do Not Operate Tag from the ignition period.
key switch and the steering wheel.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-29
Electrical System

9.14.2 Transmission Temperature Switch defective, the problem could be elsewhere; possibly
in a shorted wire, damaged transmission, improper
or low fluid, etc.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.

9.14.3 Transmission Mounted Speed Sensor


(if equipped)

9 MZ2150

The transmission temperature switch (9) is located at the


bottom right side of the transmission housing. 10

a. Transmission Temperature Switch Removal


1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
MZ2120
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
The transmission speed sensor (10) is located at the left
engine OFF.
side of the transmission below the transmission filter.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the a. Transmission Mounted Speed Sensor Removal
machine should not be operated.
1. Park the machine on a firm, level surface, level the
3. Open the engine cover. Allow the engine to cool. machine, fully retract the boom, lower the boom,
4. Properly disconnect the battery. place the transmission control lever in (N)
5. Unplug the transmission temperature switch NEUTRAL, engage the park brake and shut the
connector from the wiring harness connector. engine OFF.
6. The switch is threaded into the transmission 2. Place a Do Not Operate Tag on both the ignition key
housing. Remove the switch. switch and the steering wheel, stating that the
machine should not be operated.
b. Transmission Temperature Switch Inspection 3. Open the engine cover. Allow the engine to cool.
and Replacement 4. Properly disconnect the battery.
Inspect the switch and the wiring harness connector 5. Unplug the speed sensor connector from the wiring
terminals for continuity. Replace a defective or faulty harness connector.
switch with a new part.
6. Loosen the screw holding the clamp and remove the
sensor, clamp and o-ring.
c. Transmission Temperature Switch Installation
and Testing
b. Transmission Mounted Speed Sensor Inspection
1. Thread the transmission temperature switch into the and Replacement
transmission housing snugly, then connect the
Inspect the sensor and the wiring harness connector
switch connector to the wiring harness connector.
terminals for continuity. Replace a defective or faulty
2. Properly connect the battery. sensor with a new part.
3. Check for proper fluid level.
4. Start the engine, allow it to reach operating
temperature and observe the operator display
cluster for warning indication. If the sender is not

9-30 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

c. Transmission Mounted Speed Sensor 2. Place a Do Not Operate Tag on both the ignition key
Installation and Testing switch and the steering wheel, stating that the
machine should not be operated.
1. Install new o-ring on speed sensor, install sensor in
transmission, install clamp on sensor, bolt down 3. Open the engine cover. Allow the engine to cool.
clamp, turn arrow on sensor 45 degrees from clamp 4. Properly disconnect the battery.
bolt and torque to 8-10 Nm (70-88 lb-in).
5. Unplug the engine coolant temperature sender/
2. Connect the sensor plug to the wire harness. switch connector from the wiring harness connector.
3. Properly connect the battery. 6. The sender/switch is threaded into the engine block.
4. Close and secure the engine cover. Remove the sender.
5. Remove the Do Not Operate Tag from the ignition
b. Engine Coolant Temperature Sender/Switch
key switch and the steering wheel.
Inspection and Replacement
d. Transmission Mounted Speed Sensor Calibration Inspect the sender/switch and the wiring harness
connector terminals for continuity. Replace a defective or
A JLG Analyzer is required to perform this calibration.
faulty sender/switch with a new part.
There is also an embedded JLG Analyzer in the cab
display. To access the JLG Analyzer, press and hold the
c. Engine Coolant Temperature Sender/Switch
C and OK buttons on the keypad simultaneously until the
Installation and Testing
JLG Analyzer Help Menu screen appears on the display.
1. Go to the Access Level menu and enter a password 1. Thread the engine coolant temperature sender into
of 33271. the engine block snugly, then connect the sender/
switch connector to the wiring harness connector.
2. Go to the Calibrations menu, select Vehicle Speed
and press the Enter button (OK button on the 2. Properly connect the battery.
embedded Analyzer). 3. Check for proper coolant level.
3. Follow the instructions on the Analyzer. The 4. Start the engine, allow it to reach operating
machine must be driven over a 50 meter straight line temperature and observe the operator instrument
course. cluster for warning indication. If the sender/switch is
• The machine cab be driven in any gear and at not defective, the problem could be elsewhere;
any speed. possibly in a shorted wire, improper-running engine,
improper or low coolant, obstructed or faulty radiator,
• The Analyzer will prompt the operator to press coolant pump, loose fan belt, defective instrument
Enter or OK when starting the 50 meter drive. display, etc.
• Drive the machine 50 meters and stop. When the 5. Close and secure the engine cover.
50 meter point is reached, press the Enter or OK
button as appropriate. 6. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
4. If the calibration fails, check the Help menu for
possible faults. 9.14.5 Ignition Key Switch
9.14.4 Engine Coolant Temperature Sender/ a. Ignition Key Switch Removal
Switch
1. Park the machine on a firm, level surface, level the
The engine coolant temperature sender/switch is located machine, fully retract the boom, lower the boom,
by the alternator. place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
a. Engine Coolant Temperature Sender/Switch engine OFF.
Removal
2. Place a Do Not Operate Tag on both the ignition key
1. Park the machine on a firm, level surface, level the switch and the steering wheel, stating that the
machine, fully retract the boom, lower the boom, machine should not be operated.
place the transmission control lever in (N)
3. Open the engine cover. Allow the engine to cool.
NEUTRAL, engage the park brake and shut the
engine OFF. 4. Properly disconnect the battery.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-31
Electrical System

5. Remove the lower dash panel. d. Ignition Key Switch Installation


6. Remove the hex nut securing the ignition key switch 1. Connect the ignition key switch to the cab harness
to the dash. connectors.
7. Reach up and under the dash to work the ignition 2. Reach up and under the dash to work the ignition
switch and wiring out of the mounting hole. key switch into the ignition key switch mounting hole
8. Disconnect the ignition switch connectors from the on the dash.
cab harness connectors, and remove the switch 3. Secure the ignition key switch with the previously
from the machine. used hex nut.
4. Install the lower dash panel.
b. Disassembly
5. Properly connect the battery.
DO NOT disassemble the ignition key switch. Replace a
defective switch with a new part. 6. Close and secure the engine cover.
7. Remove the Do Not Operate Tag from the ignition
c. Inspection and Replacement key switch and the steering wheel.
To determine the proper operation of the ignition key
switch, using the following chart, test the wires on the
9.14.6 Fuel Level Indicator and Fuel Level
back of the switch for continuity with an ohmmeter.
Sender
0 a. Fuel Level Indicator Testing
P I
1. The fuel level sender wiring harness leads can be
II accessed from the top of the fuel tank. Disconnect
the fuel level sender wiring harness leads. With the
III help of an assistant, touch both harness leads
together.
MZ2130
2. From the operator cab, have the assistant turn the
MZ2140 ignition key switch to the RUN position. DO NOT
Test the ignition key switch for continuity, by checking start the engine. Observe the fuel level indicator
from the power (#30) wire to each of the following wires needle on the operator instrument cluster. When the
in each switch position. Continuity should be present as two wires are shorted, a full tank should be shown
indicated in the following chart: on the fuel gauge.
3. Turn the ignition key switch to the OFF position. The
Switch Position Test for Continuity Between
fuel level indicator needle should return to the
Wire #30 and wires:
EMPTY position.
P #58
I #15 b. Fuel Level Circuit Tests
II #15 & #19 If the fuel level indicator is suspected of giving a false
III #15, #17 & #50 reading, perform the following checks:
1. If the fuel level indicator needle does not move,
If all connections do not show proper continuity, replace check the fuel tank for fuel.
the ignition switch.
2. Check for loose or defective wiring, faulty ground
connections or corrosion on the fuel tank sender and
wiring lead.
3. If the fuel level indicator needle does not move after
the ignition key switch is turned to the RUN position,
use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level
sender.
4. If the fuel level indicator does not move and a faulty
or defective fuel level sender in the fuel tank has

9-32 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

been ruled out and in addition, wiring and 4. Properly disconnect the battery.
connectors have been checked and ruled out, the 5. Disconnect the boom angle sensor electrical
fuel level indicator is defective and must be connector.
replaced.
6. If equipped, remove the safety spring (12).
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown. 7. Loosen and remove the nut holding the rod
assembly to the sensor arm.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator 8. Loosen and remove the two bolts holding the sensor
wiring at the cab, fuse and relay panel, ignition key to the sensor seat.
switch and from the fuel level sender on the fuel tank 9. Remove the sensor assembly.
through the wiring in the cab.
7. Check the fuel level sender. The resistance of the b. Boom Angle Sensor Inspection and Replacement
fuel level sender is <7 ohms for a full tank of fuel, Inspect the sensor and the wiring harness connector
108-128 ohms for 1/2 tank and 315-345 ohms for an terminals for continuity. Replace a defective or faulty
empty tank. A defective fuel level sender in the fuel sensor with a new sensor.
tank may also prevent the fuel level indicator from
moving. c. Boom Angle Sensor Installation

9.14.7 Boom Angle Sensor 1. Install the sensor assembly to the sensor seat and
tighten both bolts.
12
2. Install the rod end to the sensor arm and tighten nut.
11
3. If equipped, install the safety spring (12).
4. Measure and set rod length (13) to 212 ±0,5 mm if
needed on 8, 9, 12 & 13M Non-Platform equipped
machines. Set the rod length to 211,6 ±0,5 mm on
17M machines and to 226 ±0,5 mm on Platform
equipped 13M machines.
13
5. Plug the electrical connector into the sensor
assembly.
Note: At this point, the boom angle sensor will need to
be calibrated by an authorized service technician.
6. Properly connect the battery.
MZ2540
7. Close and secure the engine cover.
Note: The boom angle sensor (11) is located at the top 8. Remove the Do Not Operate Tag from the ignition
left inside rear of the machine. key switch and the steering wheel.
Note: After installation, the sensor will need to be
calibrated by an authorized service technician. 9.14.8 Boom Retracted Sensor

a. Boom Angle Sensor Removal 14

1. Park the machine on a firm, level surface, level the


machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the MZ2570

machine should not be operated.


The boom retracted sensor (14) is located at the rear of
3. Open the engine cover. Allow the engine to cool. the boom.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-33
Electrical System

a. Boom Retracted Sensor Removal 9.15 LOAD STABILITY INDICATOR (LSI) -


1. Park the machine on a firm, level surface, level the 8, 9, 12 & 13M Before S/N 1160005993
machine, fully retract the boom, lower the boom, excluding 1160005949 & 1160005950
place the transmission control lever in (N) 17M Before S/N 1160005937 including
NEUTRAL, engage the park brake and shut the 1160005952, 1160005960,
engine OFF.
1160005963, 1160005966 &
2. Place a Do Not Operate Tag on both the ignition key 1160005978
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the engine to cool. WARNING
4. Properly disconnect the battery.
TIP OVER HAZARD. The LSI considers only
5. Disconnect the boom retracted sensor electrical longitudinal stability limitations, observe all operating
connector. parameters. Failure to follow operating parameters of
6. Remove the two bolts securing the boom retracted the telehandler could damage the equipment and/or
sensor bracket to the boom. cause tip over.
7. Remove the boom retracted sensor from the sensor
bracket. 9.15.1 Load Stability Indicator
Note: The Load Stability Indicator is NOT a serviceable
b. Boom Retracted Sensor Inspection and item. The LSI must be inspected and/or replaced by a
Replacement qualified dealer or a JLG technician.
Inspect the sensor and the wiring harness connector 4
6
terminals for continuity. Replace a defective or faulty
sensor with a new sensor. 3

c. Boom Retracted Sensor Installation 2

1. Mount the boom retracted sensor to the boom with


the previously used hardware.
5
1 MZ6011
8

The LSI provides visual and audible indication of forward


stability limitations when machine is static on firm, level
surface.
5 ±0,5 mm
• Green LED (1) will illuminate when LSI power is on.
MZ2580
• When approaching forward stability limitations LEDs
progressively illuminate, green (2), then yellow (3)
2. Install the sensor into the sensor bracket. Adjust the and finally red (4).
sensor to 5 ± 0,5 mm (from the rear of the second
boom section. Tighten the sensor locknut. • The warning buzzer sounds as the first red LED
illuminates.
3. Plug the electrical connector into the sensor
assembly. • As the telehandler reaches forward stability
limitations and the red LED illuminates, the
4. Properly connect the battery. automatic function cut-out is activated. Certain
5. Close and secure the engine cover. functions are disabled (i.e. boom lift, extend, etc).
Retract boom to re-enable functions.
6. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel. • Press button (5) to disable the warning buzzer.
When disabled, yellow LED (7) will illuminate. If last
red LED illuminates, disable button is overridden
and warning buzzer sounds.

9-34 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

Test LSI (8) at the beginning of each work shift. b. LSI Sensor Installation
1. Fully retract and level the boom, with no load. Do not 1. Ensure threads of both bolt holes are clean and free
raise the boom during this test. from rust, water and debris.
2. Level frame using level in cab. 2. Clean the bare metal with a degreasing agent,
3. Press the test button (8) on the LSI display. This will Loctite® 7063TM.
cause all LEDs to flash on and an audible warning to 3. Remove any excess degreasing agent and allow to
sound. This indicates that the system is functioning dry.
properly. If the test gives a different result, the
system is not functioning properly and the machine 4. Apply a thin film of Loctite® 330TM adhesive to the flat
must be removed from service and repaired before metal surface of the sensor, ensuring the adhesive is
continued operation. spread evenly over the entire surface.
5. Apply a layer of Loctite® 7386TM to the mounting
9.15.2 LSI Sensor surface of the axle, ensuring the activator is spread
evenly over the entire surface.

15 Note: Follow all adhesive manufacturer’s


recommendations including storage life.
6. Fit the sensor, ensuring the lead exits in the corner
direction. If the existing bolts are not available, use
M10 x 40mm bolts with a minimum tensile strength
of 10.9.
Note: It is important to prevent distortion of the sensor
element, therefore tighten each bolt finger tight.
Alternately tighten each bolt to 35 Nm (26 lb-ft) and
finally to 70-80 Nm (52-59 lb-ft).
The LSI sensor (15) is bolted on the top right of the rear 7. Leave the machine undisturbed with NO load for a
axle. minimum of 6 hours before moving.
Note: If the rear axle is removed or replaced, the LSI 8. Plug the electrical connector into the sensor
Sensor must be installed AFTER the rear axle is installed assembly.
and setting on all four wheels. 9. Properly connect the battery.
10. Close and secure the engine cover.
a. LSI Sensor Removal
11. Remove the Do Not Operate Tag from the ignition
1. Remove any fork carrier or attachment from the key switch and the steering wheel.
machine.
12. Calibrate the LSI system, refer to Section 9.15.3,
2. Park the machine on a firm, level surface, level the “LSI System Calibration.”
machine, fully retract the boom, fully raise the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
4. Open the engine cover. Allow the engine to cool.
5. Properly disconnect the battery.
6. Disconnect the LSI electrical connector.
7. Loosen, remove and discard the two bolts holding
the LSI assembly to the rear axle.
8. Remove and discard the sensor assembly.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-35
Electrical System

9.15.3 LSI System Calibration .

Model Weight on Rear Axle


a. Standard Calibration
3508PS, 4008PS, 40.8 1000 kg (2204 lb)
To calibrate the LSI, certain conditions must be met:
3509PS, 4009PS, 40.9 1100 kg (2425 lb)
• The sensor must be installed at least 6 hours before
beginning calibration. 3512PS/4012PS 1300 kg (2866 lb)
• The machine control system must be powered on for 3513PS/4013PS/4017PS 1500 kg (3307 lb)
at least 10 minutes before calibration.
5. Press the TEST button on the LSI display and
• The calibration shall be conducted with the standard release. The top red led should flash for
carriage and forks attached and weights as approximately 8 seconds while the calibration point
necessary.
is read. Following a successful calibration of the
• If the machine is equipped with outriggers, they shall second point, the buzzer will be on constant, the red
remain up for the calibration procedure. led will be turned off, and the green power led will be
• The machine must be on a level surface with the on constant.
wheels steered straight and park brake off, with 6. Turn the ignition key to OFF. LSI is now calibrated.
straight driving over a distance of at least 2 m (6.5 ft)
being the last movement before entering a b. Field Calibration
calibration point.
To calibrate the LSI, certain conditions must be met:
• The calibration must be completed within 30 minutes
after starting procedure. • The sensor must be installed at least 6 hours before
Calibration Procedure: beginning calibration.

1. With ignition key in OFF position, press and hold • The test weight matches the model being calibrated
in the table shown on page 9-39.
TEST button on LSI display and turn ignition key to
engine START position. Release the ignition key • The calibration shall be conducted with standard
when engine start is achieved, but continue to hold carriage and forks attached to the machine.
TEST button on LSI display until the led power • If the machine is equipped with outriggers, they shall
indicator on LSI display begins to flash remain up for the calibration procedure.
(approximately 2 seconds). Release TEST key
within 2 seconds of power led flashing. • The machine must be on a level surface with the
wheels steered straight and park brake OFF. Drive
2. The lower green led of the scale should be on the machine forward over a distance of at least 2 m
constant. Position the machine with empty (6.5 ft) before entering a calibration point.
attachment with boom level and fully retracted, forks
• The calibration must be completed within 30 minutes
level (not contacting ground).
after starting procedure.
3. Press the TEST button on the LSI display and
release. The lower green led should flash for
approximately 8 seconds while the calibration point
is read. Following a successful calibration of the first
point, the buzzer will sound for 2 seconds, the green
led will be turned off, and the top red led will be on
constant.
4. Position the machine (using weight on the
attachment) such that the rear axle weight in the
following table is achieved

9-36 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

Field Calibration Procedure: 4. Retract the boom and place the test weight on the
ground. Disengage the weight and fully retract the
Note: If the test weight is not known, follow steps 1 & 2.
lower the boom.
Model Test Weight (W) Xtip (1) Xcal (2) 5. Ensure the boom is level and fully retracted, the
2100 kg 2300 mm 1620 mm forks are level and not contacting the ground. Apply
3508PS the park brake and shut engine OFF.
(4630 lb) (90 in) (64 in)
2000 kg 3030 mm 2060 mm 6. With the ignition key in OFF position, press and hold
3509PS TEST button on LSI display and turn ignition key to
(4409 lb) (119 in) (81 in)
engine START position. Release the ignition key
500 kg 2985 mm 2100 mm
3512PS when engine start is achieved, but continue to hold
(1102 lb) (117 in) (83 in)
TEST button on LSI display until the LED power
500 kg 3275 mm 2310 mm indicator on LSI display begins to flash
3513PS
(1102 lb) (129 in) (91 in) (approximately 2 seconds).
4008PS, 2100 kg 3107 mm 2372 mm 7. Release TEST key within 2 seconds of power LED
40.8 (4630 lb) (122 in) (93 in) flashing. The lower green LED of the scale should
4009PS, 2000 kg 3700 mm 2840 mm be on constant.
40.9 (4409 lb) (146 in) (112 in) 8. Press the TEST button on the LSI display and
700 kg 3145 mm 2340 mm release. The lower green LED should flash for
4012PS approximately 8 seconds while the calibration point
(1543 lb) (124 in) (92 in)
is read. Following successful calibration of the first
700 kg 3535 mm 2655 mm
4013PS point, the buzzer will sound for 2 seconds, the green
(1543 lb) (139 in) (105 in)
LED will be turned off, and the top red LED will be on
500 kg 2715 mm 2070 mm constant.
4017PS
(1102 lb) (107 in) (81 in) 2

1 A B C

A B C 3508PS, 4008PS, 3509PS, 4009PS, 40.8 & 40.9

3508PS, 4008PS, 3509PS, 4009PS, 40.8 & 40.9

A B C D
1

3512PS, 4012PS, 3513PS, 4013PS & 4017PS


A B C D MAM1480

9. Without moving the machine, pick up the proper test


3512PS, 4012PS, 3513PS, 4013PS & 4017PS
MAM1470
weight (W) listed in the table on page 9.39. Ensure
the forks are no more than 152 mm (6 in) off the
1. With the estimated test weight on the forks, start the ground.
machine and extend the boom horizontally until the 10. With the boom horizontal, slowly extend the boom to
machine starts to tip. This point should be at an the distance of Xcal (2). The proper calibration
extension of Xtip (1) of the second boom section. If weight is now on the rear axle and the LSI can now
the machine is not tipping at this extension, weight be calibrated.
needs to be added or removed from the forks.
2. By confirming that the machine tips at this point, the
correct amount of weight is now on the forks.
3. The machine control system must be powered on for
at least 10 minutes before calibration.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-37
Electrical System

11. Press the TEST button on the LSI display and 9.16 LOAD STABILITY INDICATOR (LSI) -
release. The top red LED should flash for 8, 9, 12 & 13M S/N 1160005993 & After
approximately 8 seconds while the calibration point
including 1160005949 & 1160005950
is read. Following successful calibration of the
second point, the buzzer will be on constant, the red 17M S/N 1160005937 & After
LED will be turned off, and the green power LED will excluding 1160005952, 1160005960,
be on constant. 1160005963, 1160005966 &
12. Disengage the test weight and fully retract the boom. 1160005978
Turn the ignition key to OFF. LSI is now calibrated.
13. Verify proper operation of the LSI System:
• Start the machine with no load, fully retract and level
WARNING
the boom. Do Not raise the boom. TIP OVER HAZARD. The LSI considers only
longitudinal stability limitations, observe all operating
• Level the machine.
parameters. Failure to follow operating parameters of
• Press the test button on the LSI display. All LEDs will the telehandler could damage the equipment and/or
flash and the audible warning will sound. cause tip over.
• The system is functioning properly.
9.16.1 Load Stability Indicator
Note: The Load Stability Indicator is NOT a serviceable
item. The LSI must be inspected and/or replaced by a
qualified dealer or a JLG technician.

14

12

10 11
13
9

MZ6120

The LSI provides visual and audible indication of forward


stability limitations when machine is static on firm, level
surface.
• Green LED (9) will illuminate when LSI power is on.
• When approaching forward stability limitations LEDs
progressively illuminate, green (10), then orange
(11) and finally red (12).
• If the red LED illuminated the warning buzzer also
sounds.
The LSI has two modes:
Active Mode (8, 9, 12, 13 & 17M)
• As the telehandler reaches forward stability
limitations and the red LED illuminates, the
automatic function cut-out is activated. All boom,
frame level and outrigger functions are disabled
except boom retract (CE & AUS) and boom lift (CE).
Retract boom to fully re-enable functions.

9-38 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

• In some instances the LSI system may slow down or 9.16.2 LSI Sensor
stop boom functions if operated close to forward
stability limitations. When LEDs begin to flash,
function can not be operated. Retract boom and/or 15
return the joystick to neutral position for a short
period to allow system to reset and LEDs to stop
flashing before proceeding with operation.
Passive Mode (8 & 9M)
• The orange LED (14) illuminates when either of the
following occurs:
• The boom is fully retracted.
• The park brake is not applied and transmission
control lever is in the forward or reverse position.
• When approching forward stability limitations, visual The LSI sensor (15) is bolted on the top right of the rear
and audible indication is provided and the automatic axle.
function cut-out and /or slow down feature is Note: If the rear axle is removed or replaced, the LSI
disabled. Sensor must be installed AFTER the rear axle is installed
• Travel in accordance with the requirements set forth and setting on all four wheels.
in Section 1 - General Safety Practices.
• When placing a load, ensure axles are not fully a. LSI Sensor Removal
steered in either direction. 1. Remove any fork carrier or attachment from the
machine.
WARNING 2. Park the machine on a firm, level surface, level the
machine, fully retract the boom, fully raise the boom,
TIP OVER HAZARD. If the green, orange and red place the transmission control lever in (N)
LEDs flash and warning buzzer sounds, retract and NEUTRAL, engage the park brake and shut the
lower boom immediately. Determine cause and engine OFF.
correct before continued use.
3. Place a Do Not Operate Tag on both the ignition key
• Test the LSI at the beginning of each work shift. switch and the steering wheel, stating that the
machine should not be operated.
1.Fully retract and level the boom, with no load. Do
not raise the boom during this test. 4. Open the engine cover. Allow the engine to cool.
2.Level frame using level in cab. 5. Properly disconnect the battery.
3.Press the system check button (13) on the LSI 6. Disconnect the LSI electrical connector.
display. This will cause all LEDs to flash on and an 7. Loosen, remove and discard the two bolts holding
audible warning to sound. This indicates that the the LSI assembly to the rear axle.
system is functioning properly. If the test gives a
8. Remove and discard the sensor assembly.
different result, the system is not functioning
properly and the machine must be removed from
b. LSI Sensor Installation
service and repaired before continued operation.
1. Ensure threads of both bolt holes are clean and free
from rust, water and debris.
2. Clean the bare metal with a degreasing agent,
Loctite® 7063TM.
3. Remove any excess degreasing agent and allow to
dry.
4. Apply a thin film of Loctite® 638TM adhesive to the flat
metal surface of the sensor, ensuring the adhesive is
spread evenly over the entire surface.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-39
Electrical System

Note: Follow all adhesive manufacturer’s • The calibration must be completed within 30 minutes
recommendations including storage life. after starting procedure.
5. Fit the sensor, ensuring the lead exits in the corner Calibration Procedure:
direction. Secure with two bolts - Socket HD 1. Start and position the machine to perform the
Capscrew M10x35x1.5, Grade 12.9. calibration procedure.
Note: It is important to prevent distortion of the sensor 2. Remove the standard carriage, fork and weight
element, therefore tighten each bolt finger tight. assembly.
Alternately tighten each bolt to 35 Nm (26 lb-ft) and 3. Fully retract the boom and if equipped, lower the
finally to 70-80 Nm (52-59 lb-ft). outriggers. Shut the machine OFF.
6. Permanently mark position of bolt head and sensor 4. With ignition key in OFF position, press and hold
body. SYSTEM CHECK button on LSI display and turn
7. Leave the machine undisturbed for a minimum of 6 ignition key to engine START position. Release the
hours before moving. ignition key when engine start is achieved, but
continue to hold SYSTEM CHECK button on LSI
8. Plug the electrical connector into the sensor
display until the orange LED on LSI display goes out
assembly.
and buzzer sounds (approximately 3 seconds).
9. Properly connect the battery. Release SYSTEM CHECK button.
10. Close and secure the engine cover. 5. The LEDs will perform a rolling sequence. When
11. Remove the Do Not Operate Tag from the ignition only the third green LED illuminates, press the
key switch and the steering wheel. SYSTEM CHECK button.
12. Calibrate the LSI system, refer to Section 9.16.3, 6. The first green LED then illuminates. With no
“LSI System Calibration.” attachment, outriggers down and boom retracted, lift
boom to maximum boom angle.
9.16.3 LSI System Calibration 7. Press the SYSTEM CHECK button on the LSI
display and release. The first 3 green LEDs will
a. Standard Calibration illuminate. The third then second green LEDs will go
To calibrate the LSI, certain conditions must be met: out as the calibration point is recorded.
8. The first green LED goes out and buzzer sounds
• The sensor must be installed according to Section
9.15.2, “LSI Sensor.” then the red LED illuminates.
9. Lower boom until level. If equipped, fully raise
• The machine control system must be powered on for
outriggers. Pressing the LMI Override button may be
at least 10 minutes before calibration.
required to lower the boom.
• The operator must remain in the cab.
10. Attach the previously removed standard carriage,
• The calibration shall be conducted with the standard forks and weight.
carriage and forks attached and weights as
necessary (a range of 60 - 80% of maximum weight 11. Slowly extend the boom until the rear axle weight in
capacity. the following table is achieved.

• The machine must be on a level surface with the


wheels steered straight and park brake off, with
straight driving over a distance of at least 2 m (6.5 ft)
being the last movement before entering a
calibration point).
• While utilizing the LSI override button, 10 times lift
and lower the boom stopping suddenly to induce the
rear axle to bounce.
• Position the rear tires centrally on the scales.

9-40 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

Note: If the test weight is not known, follow steps 1 & 2.


Model Weight on Rear Axle Model Test Weight (W) Xtip (1) Xcal (2)
3508PS 700 kg (1543 lb) 2000 kg 2468 mm 1895 mm
3508PS
(4409 lb) (97 in) (75 in)
4008PS, 40.8 800 kg (1764 lb)
2000 kg 2975 mm 2343 mm
3509PS 800 kg (1764 lb) 3509PS
(4409 lb) (117 in) (92 in)
4009PS, 40.9 850 kg (1874 lb) 3512PS NA NA NA
3512PS NA 1000 kg 2678 mm 2276 mm
3513PS
(2205 lb) (105 in) (90 in)
3513PS 800 kg (1764 lb)
4008PS, 2660 kg 2658 mm 2058 mm
4012PS NA 40.8 (5864 lb) (5860 in) (4537 in)
4013PS 1000 kg (2205 lb) 4009PS, 2100 kg 3615 mm 3024 mm
40.9 (4630 lb) (142 in) (119 in)
4017PS 1250 kg (2756 lb)
4012PS NA NA NA
12. Press the SYSTEM CHECK button on the LSI
2100 kg 1925 mm 1641 mm
display and release. As the calibration point is 4013PS
(4630 lb) (76 in) (65 in)
recorded, buzzer sounds and the LEDs will flash and
perform a sequence until all are flashing. 500 kg 2619 mm 2222 mm
4017PS
(1102 lb) (103 in) (87 in)
13. Turn the ignition key to OFF. LSI is now calibrated.
14. Perform the LSI-CAN CHECK PT. Refer to Section
1
9.16.4, “LSI - CAN CHECK PT.”

b. Field Calibration A B C

To calibrate the LSI, certain conditions must be met: 3508PS, 4008PS, 3509PS & 4009PS

• The sensor must be installed according to Section


9.15.2, “LSI Sensor.”
• The test weight matches the model being calibrated
in the table shown on page 9.40. 1
• The calibration shall be conducted with standard
carriage and forks attached to the machine.
A B C D
• While utilizing the LSI override button, 10 times lift
and lower the boom stopping suddenly to induce the 3512PS, 4012PS, 3513PS, 4013PS & 4017PS
rear axle to bounce. MAM1470

1. With the estimated test weight on the forks, start the


machine and extend the boom horizontally until the
machine starts to tip. This point should be at an
extension of Xtip (1) of the second boom section. If
the machine is not tipping at this extension, weight
needs to be added or removed from the forks.
2. By confirming that the machine tips at this point, the
correct amount of weight is now on the forks.
3. The machine control system must be powered on for
at least 10 minutes before calibration.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-41
Electrical System

4. The machine must be on a level surface with the 7. With the boom horizontal, slowly extend the boom to
wheels steered straight and park brake OFF. Drive the distance of Xcal (2). The proper calibration
the machine forward over a distance of at least 2 m weight is now on the rear axle and the LSI can now
(6.5 ft) before entering a calibration point. be calibrated.
5. Place test weight on ground, apply park brake and 8. Press the SYSTEM CHECK button on the LSI
shut engine OFF. Do Not move machine. display and release. As the calibration point is
Field Calibration Procedure: recorded, buzzer sounds and the LEDs will flash and
perform a sequence until all are flashing.
Note: The following procedure must be completed
9. Turn the ignition key to OFF. LSI is now calibrated.
within 30 minutes of starting the procedure.
10. Perform the LSI-CAN CHECK PT. Refer to Section
1. With ignition key in OFF position, press and hold 9.16.4, “LSI - CAN CHECK PT.”
SYSTEM CHECK button on LSI display and turn
ignition key to engine START position. Release the Note: The following procedure MUST be performed
ignition key when engine start is achieved, but before the calibration is finalized.
continue to hold SYSTEM CHECK button on LSI
display until the orange LED on LSI display goes out 9.16.4 LSI - CAN CHECK PT
and buzzer sounds (approximately 3 seconds). With the LSI calibrated, the UGM also need it’s “LSI_CAN
Release SYSTEM CHECK button. CHECK PT” calibrated and verified.
2. The LEDs will perform a sequence. When only the 1. Start the machine.
third green LED illuminates, press the SYSTEM
CHECK button. 2. Press the “C” and “OK” buttons simultaneously on
the keypad or the analyzer.
3. The first green LED then illuminates. With no
attachment and boom retracted, lift boom fully. 3. Go to “ACCESS LEVEL 3” and press “OK”.

4. Press the SYSTEM CHECK button on the LSI 4. Enter the proper access code and press “OK”.
display and release. The first 3 green LEDs will 5. "ACCESS LEVEL 2" is now visible.
illuminate. The third then second green LEDs will go 6. Go to "CALIBRATION" menu, press "OK".
out as the calibration point is recorded.
7. Scroll to "LSI_CAN CHECK PT", use the arrow keys
5. The first green LED goes out and buzzer sounds to change "NO" to "YES".
then the red LED illuminates.
8. “SET LSI_CAN SYSTEM CHECK POINT?”, use the
6. Lower boom and without moving the machine, pick arrow keys to change “NO” to “YES”.
up the proper test weight (W) listed in the table on
page 9.40. Pressing the LMI Override button may be 9. Follow the screen instructions:
required to lower the boom. a. “Remove Weights and Attachments”, press “OK”.
2 b. “TELESCOPE IN and FULLY LIFT UP”, press
“OK”.
c. “STOP, WAIT ONE MINUTE”, press “OK”.
A B C
d. “PRESS ENTER TO SET CHECK POINT”, press
"OK".
3508PS, 4008PS, 3509PS & 4009PS
e. Screen defaults back to Calibrations Menu.

A B C D

3512PS, 4012PS, 3513PS, 4013PS & 4017PS


MAM1480

9-42 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.16.5 500 Hour - LSI UGM Calibration Check 9.17 HAND HELD ANALYZER
1. Start machine
The hand held analyzer can be used in place of the cab
2. Press the “C” and “OK” buttons simultaneously on display panel.
the keypad or the analyzer.
3. Go to “ACCESS LEVEL 2 or 1” and press “OK”.
4. Enter the proper access code and press “OK”.
1
5. Go to “OPERATOR TOOLS” menu, press “OK”.
6. Scroll to “LSI_CAN SYSTEM CHECK”.
7. “PERFORM LSI_CAN SYSTEM CHECK?”, use the
arrow keys to change “NO” to “YES”.
8. Follow the screen instructions as follows: 2
a. “Remove Weights and Attachments”, press “OK”. 3 4
b. “TELESCOPE IN and FULLY LIFT UP”, press
“OK”.
c. “STOP, WAIT ONE MINUTE”, press “OK”.
5 6
d. “PRESS ENTER TO START TEST”
e. “PASS or “FAIL”, press “ESC”. Must receive a
“PASS”.
f. “LSI CAN SYSTEM CHECK”, press “ESC” to
return to menu. MZ6040

9. Cycle power.Turn machine OFF - ON.


1. Cable Connector.
10. Install the previously remove carriage assembly. 2. Analyzer Display Screen.
3. Escape Key: To return home or access previous
menu.
4. Enter Key: Stores and selects Top Level, Sub Level
and Items Menus.
5. Up/Down Arrow Keys: Change adjustable values.
6. Left and Right Arrow Keys: Used to move between
Top Level, Sub Levels and Item Menus.

9.17.1 Analyzer Usage


Help messages can be viewed using the Analyzer
(P/N 1001103758). The Help messages can be accessed
by pressing the ENTER key while viewing the current
Help message. The Help message shall be
EVERYTHING OK when no fault is present. The Analyzer
cable plugs into the XQ connector of the PCB board
located beside the operator seat.
For more information, contact the local JLG distributor.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-43
9-44
9.17.2
- Not ACCESSABLE

- Requires ACCESS LEVEL 3, 2, 1 and 0

- Requires ACCESS LEVEL 2, 1 and 0


Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.

MENU: ACCESS LEVEL:


ACCESS LEVEL 3 CODE: 00000
Electrical System

MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES MAIN LIFT BUCKET LIFT PLATFORM LIFT TELESCOPE BUCKET TELESCOPE PLAT. TELESCOPE FORK TILT BUCKET TILT PLATFORM LEVEL PLATFORM ROTATE STABILIZERS FRAME LEVEL AUX. FUNCTION1 AUX. FUNCTION2 AUX. MOMENTARY

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2: AUX. MOMENTARY:
ACCEL UP: x.x S ACCEL UP: x.x S ACCEL UP: x.x S ACCEL IN: x.x S ACCEL UP: x.x S ACCEL IN: x.x S ACCEL UP: x.x S ACCEL UP: x.x S ACCEL UP: x.x S ACCEL LEFT: x.x S ACCEL UP: x.x S ACCEL LEFT: x.x S ACCEL COIL A: x.x S ACCEL COIL A: x.x S COIL A: xxxx mA

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2: AUX. MOMENTARY:
DECEL UP: x.x S DECEL UP: x.x S DECEL UP: x.x S DECEL IN: x.x S DECEL UP: x.x S DECEL IN: x.x S DECEL UP: x.x S DECEL UP: x.x S DECEL UP: x.x S DECEL LEFT: x.x S DECEL UP: x.x S DECEL LEFT: x.x S DECEL COIL A: x.x S DECEL COIL A: x.x S COIL B: xxxx mA

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL OUT: x.x S ACCEL DOWN: x.x S ACCEL OUT: x.x S ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL RIGHT: x.x S ACCEL DOWN: x.x S ACCEL RIGHT: x.x S ACCEL COIL B: x.x S ACCEL COIL B: x.x S

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL OUT: x.x S DECEL DOWN: x.x S DECEL OUT: x.x S DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL RIGHT: x.x S DECEL DOWN: x.x S DECEL RIGHT: x.x S DECEL COIL B: x.x S DECEL COIL B: x.x S

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MIN UP: xxx mA MIN UP: xxx mA MIN UP: xxx mA MIN IN: xxx mA MIN UP: xxx mA MIN IN: xxx mA MIN UP: xxx mA MIN UP: xxx mA MIN UP: xxx mA MIN LEFT: xxx mA MIN UP: xxx mA MIN LEFT: xxx mA MIN COIL A: xxx mA MIN COIL A: xxx mA

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MAX UP: xxxx mA MAX UP: xxxx mA MAX UP: xxxx mA MAX IN: xxxx MA MAX UP: xxxx mA MAX IN: xxxx mA MAX UP: xxxx mA MAX UP: xxxx mA MAX UP: xxxx mA MAX LEFT: xxxx mA MAX UP: xxxx mA MAX LEFT: xxxx mA MAX COIL A: xxxx mA MAX COIL A: xxxx mA

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MIN DOWN: xxx mA MIN DOWN: xxx mA MIN DOWN: xxx mA MIN OUT: xxx mA MIN DOWN: xxx mA MIN OUT: xxx mA MIN DOWN: xxx mA MIN DOWN: xxx mA MIN DOWN: xxx mA MIN RIGHT: xxx mA MIN DOWN: xxx mA MIN RIGHT: xxx mA MIN COIL B: xxx mA MIN COIL B: xxx mA

MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX OUT: xxxx mA MAX DOWN: xxxx mA MAX OUT: xxxx mA MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX RIGHT: xxxx mA MAX DOWN: xxxx mA MAX RIGHT: xxxx mA MAX COIL B: xxxx mA MAX COIL B: xxxx mA

SOFT-LIFT ZONE: SOFT-LIFT ZONE: SOFT-LIFT ZONE:


SET ANGLE %: xx % SET ANGLE %: xx % SET ANGLE %: xx %

SOFT-LIFT %: SOFT-LIFT %: SOFT-LIFT %:


SET DERATE: xx % SET DERATE: xx % SET DERATE: xx %
Analyzer Software Version 3.5 (Sheet 1 of 2)

MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:


CALIBRATIONS TILT SENSOR BOOM ANGLE LSS PARK BRAKE TEST LSI-CAN CHECK PT

CALIBRATE TILT CALIBRATE BOOM PLATFORM TYPE: PERFORM PARK SET LSI-CAN
SENSOR? ANGLE SENSOR? 450 - EXTENDABLE BRAKE TEST? CHECK POINT: NO

CALIBRATION: PRESS ENTER AT CONFIRM PLATFORM SET PARK REMOVE WEIGHTS


COMPLETE LOWEST POSITION. IS EMPTY: NO BRAKE AND ATTACHMENTS.

BOOM ANGLE: CALIBRATION: SHIFT TO TELESCOPE IN AND


CALIBRATING … IN PROGRESS SECOND GEAR FULLY LIFT UP.

LIFT UP. PRESS WARNING: DRIVE **** STOP ****


ENTER AT TOP. WILL BE ENGAGED WAIT 1 MINUTE

BOOM ANGLE: FORWARD TO START PRESS ENTER TO


CALIBRATING … NEUTRAL TO PAUSE SET CHECK POINT

CALIBRATION: PARK BRAKE TEST


COMPLETE COMPLETE

MENU: CHANGE PERFORM HARDWARE CONFIRM MACHINE REVIEW SET SERVICE VEHICLE SPEED TEMPERATURE: OIL PRESSURE: CABIN JOYSTICK: STEER MODE: PERFORM LSI-CAN
OPERATOR TOOLS ANTI-THEFT CODE? EXCHANGE: NO SERVICE? SERVICE HISTORY? INTERVAL: 100H UNITS: KPH CELCIUS BAR TELESCOPE: X-AXIS AUTOMATIC SYSTEM CHECK? YES

ENTER CURRENT TRANSFER FROM: SERVICE COMPLETE SERVICE HISTORY VEHICLE SPEED TEMPERATURE: OIL PRESSURE: CABIN JOYSTICK: STEER MODE: REMOVE WEIGHTS
CODE: 0000 DISPLAY à UGM YES: ENTER, NO: ESC 1: XXXX HOURS UNITS: MPH FAHRENHEIT PSI TELESCOPE: ROLLER MANUAL AND ATTACHMENTS.

ENTER NEW TRANSFER FROM: FULLY DEPLOY


CODE 0000 UGM à DISPLAY STABILIZERS.

TRANSFER STATUS: TELESCOPE IN AND


CYCLE POWER NOW FULLY LIFT UP.

**** STOP ****


WAIT 1 MINUTE
MENU: HELP: (XXXXX)
HELP: PRESS ENTER ?????????????????
PRESS ENTER TO
START TEST: ----

MAM2831-3.5

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
- Not ACCESSABLE

- Requires ACCESS LEVEL 3, 2, 1 and 0

- Requires ACCESS LEVEL 2, 1 and 0


(Sheet 2 of 2)

Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.

MENU: MODEL: MARKET: ENGINE CONTROL: TRANSMISSION: LOAD MONITORING: PLATFORM OPTION: HYDRAULIC QUICK AUX. FUNCTION BOOM RETRACTED BOOM EXTENSION LOAD SENSING: BOOM RIDE: BOOM FLOAT:
MACHINE SETUP UNKNOWN CE MECHANICAL POWERSYNCHRO LSI-CAN DISABLED CONNECT: NO SELECT: NO SWITCH: NO SWITCH: NO NONE NO NO

MODEL: MARKET: ENGINE CONTROL: LOAD MONITORING: PLATFORM OPTION: HYDRAULIC QUICK AUX. FUNCTION BOOM RETRACTED BOOM EXTENSION LOAD SENSING: BOOM RIDE: BOOM FLOAT:
TH336 ANSI ELECTRONIC LMI ENABLED CONNECT: YES SELECT: YES SWITCH: YES SWITCH: YES WARN ONLY YES YES

MODEL: MARKET: LOAD MONITORING: LOAD SENSING:


TH337 AUSTRALIA LSI PLATFORM CUTOUT

MODEL: LOAD MONITORING:


TH406 LSI-CAN + LMI

MODEL:
TH407

MODEL:
TH414

MODEL:
TH514

MODEL:
TH417

MENU: SYSTEM TEST:


SYSTEM TEST ACTIVATE ?

MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS DRIVE / STEER CABIN JOYSTICK CABIN FUNCTIONS PLATFORM STABILIZERS FRAME LEVEL ENGINE SYSTEM LOAD MOMENT BOOM RIDE BOOM FLOAT PLATFORM LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS

DRIVE DIRECTION CABIN JOYSTICK: RESPONSE CURVE: MAIN LIFT STABILIZER FRAME LEVEL OPERATING STATE: GROUND MODULE LOAD MOMENT BOOM RIDE BOOM FLOAT PLATFORM LOAD CAN1 STATISTICS: CALIBRATION DATA DATALOG: ON-TIME GROUND MODULE
INPUT: FORWARD X – AXIS: 0 % TELEHANDLER INPUT: XXX% INPUT: XXX% LEFT INPUT: LOW ENGINE STOPPED VOLTAGE: XX.XV STATUS: STABLE SWITCH: LOW SWITCH: LOW STATE: OK RX/SEC: X LIFT CAL1: XXX XXXXXXH XXM SOFTWARE: PX.X

GEAR SELECTION CABIN JOYSTICK: MAIN LIFT MAIN LIFT LEFT STABILIZER FRAME LEVEL ENGINE PREHEAT PLATFORM MODULE LOAD MOMENT BOOM RIDE BOOM FLOAT PLATFORM LOAD CAN1 STATISTICS: CALIBRATION DATA DATALOG: ENGINE GROUND MODULE
INPUT: 2 X – AXIS: NEUTRAL INPUT: XXX% COMMANDED: XXXXMA UP COIL: OFF RIGHT INPUT: LOW SWITCH: OPEN VOLTAGE: XX.XV OVERRIDE: NO STATUS: OFF SWITCH: OFF ACTUAL: XXX.X KG TX/SEC: X LIFT CAL2: XXX XXXXXXH XXM CNST. DATA: PX.X

DIRECTION / GEAR CABIN JOYSTICK: MAIN LIFT MAIN LIFT LEFT STABILIZER FRAME LEVEL AIR FILTER AMBIENT LOAD MOMENT %: PLATFORM LOAD CAN1 STATISTICS: DATALOG: DRIVE GROUND MODULE
ACTUAL: FORWARD / 2 Y – AXIS: 0 % COMMANDED: XXXXMA ACTUAL: XXXXMA DOWN COIL: OFF LEFT COIL: OFF SWITCH: OPEN TEMPERATURE: XXXC XX.X GROSS: XXX.X KG BUS OFF: X XXXXXXH XXM HARDWARE: REV X

DESIRED STEER CABIN JOYSTICK: MAIN LIFT TELESCOPE RIGHT STABILIZER FRAME LEVEL BATTERY VOLTAGE: STATION CONTROL: MOMENT CELL1 RAW PLATFORM LOAD CAN1 STATISTICS: DATALOG: LIFT GROUND MODULE
MODE: 2 - WHEEL Y – AXIS: NEUTRAL ACTUAL: XXXXMA INPUT: XXX% UP COIL: OFF RIGHT COIL: OFF XX.XV CABIN VALUE: XXXXXX OFFSET: XXXXXX PASSIVE: X XXXXXXH XXM S/N: XXXXXX

CURRENT STEER CABIN JOYSTICK: TELESCOPE TELESCOPE RIGHT STABILIZER FRAME LEVEL COOLANT OPERATING MODE: MOMENT CELL2 RAW PLATFORM LOAD CAN1 STATISTICS: DATALOG: TELE. GROUND MODULE
MODE: 2 - WHEEL L – ROLLER: 0 % INPUT: XXX% COMMANDED: XXXXMA DOWN COIL: OFF COMMANDED: XXXXMA TEMPERATURE: XXXC CABIN MODE VALUE: XXXXXX CELL 1: XXX.X KG MSG ERROR: XXXX XXXXXXH XXM P/N: XXXXXXXXXX

STEER PRESSURE CABIN JOYSTICK: TELESCOPE TELESCOPE STABILIZER SPEED CONTROL OIL PRESSURE: RESPONSE CURVE: PLATFORM LOAD CAN2 STATISTICS: DATALOG: AUX. PLATFORM MODULE
SWITCH: OPEN L – ROLLER: NEUTRAL COMMANDED: XXXXMA ACTUAL: XXXXMA COMMANDED: XXXXMA ACTUAL: XXXXMA XXXX PSI TELEHANDLER CELL 2: XXX.X KG RX/SEC: X XXXXXXH XXM SOFTWARE: PX.X

STEER PRESSURE CABIN JOYSTICK: TELESCOPE LEVEL UP SPEED CONTROL JOYSTICK LOCK AMBIENT PLATFORM STATUS: PLATFORM LOAD CAN2 STATISTICS: DATALOG: PLATFORM PLATFORM MODULE
STATUS: OK R – ROLLER: 0% ACTUAL: XXXXMA SWITCH: OPEN ACTUAL: XXXXMA ENGAGED: NO TEMPERATURE: XXXC NOT ATTACHED CELL 3: XXX.X KG TX/SEC: X XXXXXXH XXM HARDWARE: REV X

SERVICE BRAKE CABIN JOYSTICK: FORK TILT LEVEL DOWN JOYSTICK LOCK FRAME LEVEL FUEL LEVEL J1-21 PLATFORM PLATFORM LOAD CAN2 STATISTICS: DATALOG: PLATFORM MODULE
SWITCH: CLOSED R – ROLLER: NEUTRAL INPUT: XXX% SWITCH: OPEN ENGAGED: NO OPERATION: OK SENSOR: FULL ATTACHED: HIGH CELL 4: XXX.XKG BUS OFF: X MAX TEMP: XXC S/N: XXXXXX

SERVICE BRAKE CABIN JOYSTICK: FORK TILT PLATFORM LEVEL STABILIZER ENGINE SPEED FUNCTION ENABLE CAN2 STATISTICS: DATALOG: PLATFORM MODULE
STATUS: OFF S1 BUTTON: OFF COMMANDED: XXXXMA COMMANDED: XXXXMA OPERATION: OK ACTUAL: XXXX RPM GROUND: OPEN PASSIVE: X MIN TEMP: XXC P/N: XXXXXXXXXX

TRANSMISSION OIL CABIN JOYSTICK: FORK TILT PLATFORM LEVEL STABILIZER INPUT FUNCTION ENABLE CAN2 STATISTICS: DATALOG: CABIN JOYSTICK
TEMP.: XXX.X C TRIGGER: OFF ACTUAL: XXXXMA ACTUAL: XXXXMA 1 DEPLOYED: NO PLATFORM: CLOSED MSG ERROR: XXXX MAX VOLTS: XX.XV SOFTWARE: PX.X

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
CABIN JOYSTICK: AUX. HYDRAULICS ROTATE LEFT STABILIZER INPUT BOOM ANGLE: DATALOG: CABIN DISPLAY
S – ROCKER: LOW INPUT: XXX% SWITCH: OPEN 2 DEPLOYED: NO XX.X DEGREES RENTAL: XXXXH XXM SOFTWARE: PX.X

CABIN JOYSTICK: AUX. HYDRAULICS ROTATE RIGHT BOOM ANGLE RAW: DATALOG: LSS MODULE
T – ROCKER: LOW COMMANDED: XXXXMA SWITCH: OPEN COUNTS: XXXXXX ANTI-THEFT: 0000 SOFTWARE: PX.X

AUX. HYDRAULICS PLATFORM ROTATE BOOM RETRACTED DATALOG: LSS MODULE


ACTUAL: XXXXMA COMMANDED: XXXXMA SWITCH: CLOSED ERASE RENTAL? HARDWARE: REV X

CONTINUOUS AUX. PLATFORM ROTATE BOOM EXTENDED ANALYZER:


INPUT: LOW ACTUAL: XXXXMA SWITCH: OPEN ANALYZER V6.3

CONTINUOUS AUX. HORN AM BOOM EXTENDED


FEATURE: ACTIVE SWITCH: OPEN SWITCH: OPEN

AUX. FUNCTION ENGINE PREHEAT TRANSPORT MODE:


SELECT: FUNCTION1 SWITCH: OPEN IN TRANSPORT

AUXILIARY POWER COUPLING PIN TELESCOPE


SWITCH: OPEN ENGAGED: NO STATUS: RETRACTED

QUICK CONNECT PARK BRAKE


ON INPUT: LOW SWITCH: CLOSED

QUICK CONNECT PARK BRAKE


OFF INPUT: HIGH STATUS: ON

JOYSTICK LOCK CHASSIS TILT:


ENGAGED: NO XX.X DEG

CHASSIS TILT:
X – AXIS: XX.X DEG
Electrical System

CHASSIS TILT:
Y – AXIS: XX.X DEG

HYDRAULIC FILTER
SWITCH: CLOSED

MAM2841-3.5

9-45
Electrical System

9.18 FAULT CODES


Active faults and fault memory will be displayed at the
operator level of access. Active faults will also be
displayed as a blink code at the controller on-board LED.
The 16 previous faults are logged in fault memory, which
can be accessed by choosing ENTER while viewing
active fault messages.

9.18.1 Indicator Cross Reference Table


Indicator # Assignment
1 = Machine System Distress
2 = Engine Fault Warning
3 = Engine Fault Critical
4 = Machine Locked
5 = Service
6 = Hydraulic Filter Restriction
7 = Air Filter Restriction
8 = Low Steer Pressure
9 = Low Engine Oil Pressure
10 = Battery Low or Not Charging
11 = High Transmission Oil Temperature
12 = High Engine Coolant Temperature
13 = Low Fuel Level
14 = Platform Overloaded
15 = Outriggers Not Deployed (Platform)
16 = Chassis Not Level

15&16 14

13 12

11
10 9 7 2 3 1 5 4 MAM1420

9-46 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

9.18.2 Fault Code Table

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

HELP COMMENT 00XXX

EVERYTHING OK 001 The system detects no problems


exist.

POWER UP 21XXX

POWER CYCLE 211 Power was cycled ON.

FUNCTION ENABLE 214 1 Ignore and inhibit all function If both J7-15 of the UGM and J7-8 Power cycled.
INPUTS – INVALID requests from the platform station. of the platform module are
SIGNAL STATES Output J2-19 Function Enable simultaneously HIGH or LOW for a
Relay of the platform module will be period of 1 second after the
deactivated. Function Enable Relay power-up
Output J2-26 Engage Starter will check have been successfully
be deactivated and inhibited from completed or J7-15 is HIGH and
the platform. J7-8 is LOW after the Function
Enable Relay power-up check have
been successfully completed and
the PLATFORM STATION is active
and a valid PLATFORM MODE
exists.

JOYSTICK AXES 215 1 Ignore command signals from the At system power-up, if the one of A CAN
NOT IN NEUTRAL joystick regarding the X axis and Y the two axes are not in the neutral message is
POSITION AT axis. position, the UGM will report and received
POWER UP log a “JOYSTICK AXES NOT IN indicating the
NEUTRAL POSITION AT X axis and Y
POWER-UP” fault. axis are in the
neutral
position.

JOYSTICK ROLLER 216 1 Ignore command signals from the At system power-up, if the roller is A CAN
NOT IN NEUTRAL joystick regarding the roller. not in the neutral position on JLG message is
POSITION AT models only. received
POWER UP indicating the
roller is in the
neutral
position.

JOYSTICK S1 217 1 Ignore command signals from the At system power-up, if the S1 button A CAN
BUTTON ACTIVE AT joystick S1 button that was active is activated. message is
POWER UP during the power-up. received
indicating the
joystick S1
button is not
activated.

JOYSTICK S2 218 1 Ignore command signals from the At system power-up, if the S2 button A CAN
BUTTON ACTIVE AT joystick S2 button that was active is activated on JLG models only. message is
POWER UP during the power-up. received
indicating the
joystick S2
button is not
activated.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-47
Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

JOYSTICK S3 219 1 Ignore command signals from the At system power-up, if the S3 button A CAN
BUTTON ACTIVE AT joystick S3 button that was active is activated on JLG models only. message is
POWER UP during the power-up. received
indicating the
joystick S3
button is not
activated.

JOYSTICK S4 2110 1 Ignore command signals from the At system power-up, if the S4 button A CAN
BUTTON ACTIVE AT joystick S4 button that was active is activated on JLG models only. message is
POWER UP during the power-up. received
indicating the
joystick S4
button is not
activated.

ENGINE START 2111 1 The engine start signal will be If a LOW on J1-14 of the platform Power cycled.
PREVENTED – ignored. module and the PLATFORM
PLATFORM START J2-26 Engage Starter will be STATION is active at system power
SWITCH HIGH AT deactivated and inhibited. up.
POWER UP

PLATFORM ROTATE 2112 1 Ignore platform rotate left function If the PLATFORM STATION is The input
LEFT PREVENTED request. active and a platform is configured goes LOW for
– INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform rotate left input at
system power up.

PLATFORM ROTATE 2113 1 Ignore platform rotate right function If the PLATFORM STATION is The input
RIGHT PREVENTED request. active and a platform is configured goes LOW for
– INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform rotate right input at
system power up.

PLATFORM LEVEL 2114 1 Ignore platform level up function If the PLATFORM STATION is The input
UP PREVENTED – request. active and a platform is configured goes LOW for
INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform level up input at system
power up.

PLATFORM LEVEL 2115 1 Ignore platform level down function If the PLATFORM STATION is The input
DOWN PREVENTED request. active and a platform is configured goes LOW for
– INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform level down input at
system power up.

9-48 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

APU SWITCH INPUT 2116 1 Still allow APU function request. If a platform is configured as The input
INVALID – INPUT If J7-4 Boom Angle reading is less ENABLED and the UGM detects goes LOW for
HIGH AT POWER than 10° and the J3-8 Boom J4-16 Auxiliary Power Unit (APU) a period of at
UP Retracted input is HIGH, cutout the Enable is HIGH at system power up. least 1
Main Lift Up and Telescope Out second.
functions.

PLATFORM 2117 1 Ignore platform lift and telescope If the PLATFORM STATION is Joystick is
JOYSTICK NOT IN function requests from the platform active and a platform is configured detected to be
NEUTRAL joystick. as ENABLED and a platform is in neutral
POSITION AT detected as attached and the position.
POWER UP platform joystick is not detected to
be in the neutral position at system
power up.

ENGINE 2118 1 Ignore engine pre-heat function If the UGM detects J4-20 Engine The input
PRE-HEAT request. Pre-Heat or the platform module goes LOW for
PREVENTED – input J1-23 Engine Pre-heat is a period of at
INPUT HIGH AT HIGH at system power up. least 1
POWER UP second.

FRAME LEVEL 2119 1 Deactivate and inhibit J2-5 Frame If J4-17 Frame Leveling Right is Power cycled.
RIGHT INPUT – Level Right Valve. HIGH at power up.
INVALID SIGNAL Deactivate and inhibit J2-7 Frame
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve (if applicable) as it relates to
frame leveling functions only.

FRAME LEVEL 2120 1 Deactivate and inhibit J2-5 Frame If J4-9 Frame Leveling Left is HIGH Power cycled.
LEFT INPUT – Level Right Valve. at power up.
INVALID SIGNAL Deactivate and inhibit J2-7 Frame
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve (if applicable) as it relates to
frame leveling functions only.

HYDRAULIC QUICK 2121 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature is Power cycled.
CONNECT INPUT – Quick Connect Valve. configured in the MACHINE SETUP
INVALID Ignore hydraulic quick connect menu and J7-35 Hydraulic Quick
SIGNAL function requests. Connect ON is HIGH at power up or
Deactivate output J2-9 Auxiliary J3-10 Hydraulic Quick Connect
Function-A Valve until the cabin’s OFF is LOW at power up or J7-35
joystick is in the neutral position matches the state of input J3-10 for
and the S4 switch is OFF and J1-23 0.5 seconds.
is confirmed to be deactivated.
Deactivate output J2-20 Auxiliary
Function-B Valve until the cabin’s
joystick is in the neutral position
and the S4 switch is OFF and J1-23
is confirmed to be deactivated.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-49
Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

CONTINUOUS 2122 1 Inhibit operation of the Continuous The UGM has detected the The input
AUXILIARY Auxiliary Hydraulics feature/logic. Continuous Auxiliary Hydraulics goes LOW for
HYDRAULICS switch is HIGH at system power up. a period of at
SWITCH HIGH AT least 1
POWER UP second.

JOYSTICK 2123 1 Ignore command signals from the At system power-up, if the joystick A CAN
TRIGGER SWITCH joystick trigger switch that was trigger switch is activated on CAT message is
ACTIVE AT POWER active during the power-up. models only. received
UP indicating the
joystick
trigger switch
is not
activated.

JOYSTICK LEFT 2124 1 Ignore command signals from the At system power-up, if the left roller Latch fault
ROLLER NOT IN joystick regarding the left roller. of the joystick is not in the neutral until a joystick
THE NEUTRAL position on CAT models only. CAN message
POSITION AT is received
POWER UP indicating the
roller is in the
neutral
position.

JOYSTICK RIGHT 2125 1 Ignore command signals from the At system power-up, if the right Latch fault
ROLLER NOT IN joystick regarding the right roller. roller of the joystick is not in the until a joystick
THE NEUTRAL neutral position on CAT models CAN message
POSITION AT only. is received
POWER UP indicating the
roller is in the
neutral
position.

BOOM RIDE 2130 1 Ignore signal from the Boom Ride At system power-up, the Boom Boom Ride
ENABLE SWITCH Enable Switch. Ride/Boom Float module has Enable Switch
NOT IN THE OFF detected the Boom Ride Enable is detected in
POSITION AT Switch is engaged. its OFF
POWER UP position.

PLATFORM 22XXX
CONTROLS

PLATFORM LEVEL – 2225 1 Not acknowledge either platform If the UGM receives CAN2 Power cycled.
CONFLICTING level function request messages. messages that indicate both J1-9
INPUT SIGNALS and J1-10 inputs to the platform
controller are HIGH together.

PLATFORM ROTATE 2226 1 Not acknowledge either platform If the UGM receives CAN2 Power cycled.
– CONFLICTING rotate function request messages. messages that indicate both J1-7
INPUT SIGNALS and J1-8 inputs to the platform
controller are HIGH together.

9-50 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System

Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code

FUNCTION ENABLE 2227 1 The requested function will be If the PLATFORM STATION is The hydraulic
INTERLOCK – ignored. active and a platform is configured function
ENABLE SWITCH as ENABLED and a platform is request is no
NOT SELECTED detected as attached and a longer active.
FIRST hydraulic function request is detect
at the platform station before the
function enable signal was
received.

FUNCTION ENABLE 2228 1 Turn OFF the functions enabled If the PLATFORM STATION is The function
INTERLOCK – NOT indicator at the platform station. active and a platform is configured enable switch
SELECTED IN TIME Ignore all function requests from as ENABLED and a platform is is released.
the platform station while the detected as attached and if a
FUNCTIONS ENABLED state is function request is not received
active. within the 7 second period from the
time the FUNCTION ENABLE state
is activated.

ENGINE START 2229 1 The engine start signal will be When the PLATFORM STATION is The function
PREVENTED – ignored. J2-26 Engage Starter will active and the engine start signal is enable switch
FUNCTION ENABLE be deactivated and inhibited. detected at the platform and the is released.
SWITCH ENGAGED UGM detects the function enable
switch is engaged.

PLATFORM 223