Documente Academic
Documente Profesional
Documente Cultură
Models
3508PS, 3509PS,
3512PS, 3513PS,
4008PS, 4009PS,
4012PS, 4013PS,
4017PS,
Agrovector
40.8, 40.9
31200206
Revised
June 15, 2011
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
EFFECTIVITY PAGE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
31200206
SECTION CONTENTS
Section
Subject
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Page
1.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
1.2
1.2
1.2
1.2
1.3
1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
2.1
2.2
2.3
2.4
2.5
2.6
2.2
2.3
2.11
2.13
2.15
2.16
...........................................................
3.1
3.3
3.4
3.4
3.8
3.9
3.9
3.18
3.21
3.22
3.25
3.26
3.27
3.28
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Section 3
Boom
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
4.1
4.2
4.3
4.4
4.5
3508PS,3509PS,3512PS,3513PS,4008PS,4009PS,4012PS,4013PS,4017PS,40.8,40.9
4.2
4.3
4.3
4.9
4.11
Section
Subject
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Page
5.1
5.2
5.3
5.3
5.9
5.10
5.11
5.12
Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
6.1
6.2
6.3
6.4
6.5
6.6
6.2
6.3
6.3
6.3
6.3
6.7
Section 7
Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2
7.4
7.4
7.4
7.6
7.6
7.8
7.9
7.9
7.12
7.13
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
ii
8.2
8.3
8.3
8.4
8.6
8.17
8.18
8.20
8.20
8.26
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section
Subject
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.14
9.15
9.16
9.17
9.18
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Page
9.1
9.3
9.3
9.4
9.5
9.7
9.8
9.11
9.22
9.24
9.25
9.26
9.26
9.28
9.29
9.34
9.38
9.43
9.46
iii
Section
iv
Subject
Page
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 1
Safety Practices
Contents
PARAGRAPH
1.1
1.2
1.3
1.4
1.5
1.6
1.7
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1
Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1
Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2
Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.3
General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.4
Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3
1-3
1-4
1-1
Safety Practices
1.1
INTRODUCTION
1.4
1.5
SAFETY INFORMATION
1.5.1
1.2
DANGER
WARNING
DISCLAIMER
1.3
CAUTION
1-2
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Safety Practices
1.6
SAFETY INSTRUCTIONS
1.6.1
Personal Hazards
1.6.2
Equipment Hazards
1.6.3
General Hazards
1.6.4
Operational Hazards
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
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen parts and
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.
1.7
SAFETY DECALS
1-4
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 2
General Information and Specifications
Contents
PARAGRAPH
2.1
2.2
2.3
2.4
2.5
2.6
TITLE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
2-2
2-3
2-3
2-7
2-10
2-11
2-11
2-11
2-11
2-12
2-12
2-12
2-13
2-15
2-15
2-15
2-15
2-16
2-16
2-18
2-1
2.1
MZ1780
2-2
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2.2
2.2.1
TORQUE CHARTS
SAE Fastener Torque Chart
Tensile
Clamp Load
Stress Area
Torque
Lubricated
Torque
Loctite 242 or 271
OR
Vibra-TITE 111 or 140
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
380
420
580
610
900
940
1120
1285
2020
2320
8
9
16
18
30
31
43
49
96
120
0.9
1.0
1.8
2.0
3.4
3.5
4.8
5.5
10.8
13.5
6
7
12
13
22
23
32
36
75
86
0.7
0.8
1.4
1.5
2.5
2.6
3.5
4
9
10
105
135
12
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
FT-LB
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
[N.m]
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
FT-LB
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
[N.m]
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
FT-LB
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
[N.m]
26
29
48
54
75
82
116
136
163
184
224
258
388
449
646
707
918
1000
1142
1258
1598
1768
2074
2380
2754
3128
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
Torque
Loctite 262
OR
Vibra-TITE 131
IN-LB
[N.m]
FT-LB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
[N.m]
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
Loctite P/N
ND Industries P/N
0100011
0100019
0100071
242TM
271TM
262TM
Vibra-TITE TM 121
Vibra-TITE TM 140
Vibra-TITE TM 131
Description
Medium Strength (Blue)
High Strength (Red)
Medium - High Strength (Red)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
MY4510J
2-3
Torque
Loctite 242 or 271
OR
Vibra-TITE 111 or 140
K=.18
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
1320
1580
1800
2860
3280
43
60
68
143
164
5
7
8
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
770
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1045
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
2-4
Tensile
Clamp Load
Stress Area
Torque
Loctite 262
OR
Vibra-TITE 131
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Clamp Load
See Note 4
Torque
(Dry) K = .17
Torque
Loctite 242 or 271
OR
Vibra-TITE 111 or 140
OR Precoat 85
K=0.16
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
122
139
14
16
114
131
13
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
20
25
35
40
60
65
90
100
130
145
180
205
320
355
515
570
730
845
1095
1225
1545
1710
2025
2300
2690
3020
[N.m]
25
35
50
55
80
90
120
135
175
195
245
280
435
485
700
775
995
1150
1490
1665
2100
2325
2755
3130
3660
4105
FT-LB
20
20
35
40
55
60
85
95
125
135
170
190
300
335
485
535
685
795
1030
1155
1455
1610
1905
2165
2530
2845
[N.m]
25
25
50
55
75
80
115
130
170
185
230
260
410
455
660
730
930
1080
1400
1570
1980
2190
2590
2945
3440
3870
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
Loctite 262
OR
Vibra-TITE 131
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-5
Clamp Load
See Note 4
Torque
(Loctite 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85
K=0.18
Torque
(Dry)
K = .20
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
143
164
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
775
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1055
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
2-6
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Size
PITCH
Tensile
Stress
Area
Sq mm
Clamp
Load
Torque
(Dry or Loctite
263TM)
Torque
(Lub)
KN
[N.m]
[N.m]
Torque
Loctite
Torque
Loctite 262 242 or 271
OR
OR
Vibra-TITE 131 Vibra-TITE
111 or 140
[N.m]
[N.m]
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
0.7
8.78
3.82
3.1
2.3
2.8
3.4
0.8
14.20
6.18
6.2
4.6
5.6
6.8
20.10
8.74
11
7.9
9.4
12
28.90
12.6
18
13
16
19
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
16
2
2
115
157
50.0
68.3
140
105
126
154
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
353
153.5
737
553
663
811
27
459
199.5
1080
810
970
1130
30
3.5
561
244.0
1460
1100
1320
1530
2090
33
3.5
694
302.0
1990
1490
1790
36
817
355.5
2560
1920
2300
2690
42
4.5
1120
487.0
4090
3070
3680
4290
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-7
Size
PITCH
Tensile
Stress
Area
Clamp
Load
Torque Dry
or
Loctite 263
K = 0.20
Sq mm
KN
[N.m]
Torque
Lube OR Loctite
242 or 271
OR
Vibra-TITE
111 or 140
K= 0.18
Torque
Loctite 262
OR
Vibra-TITE 131
[N.m]
[N.m]
K=0.15
0.5
5.03
3.13
3.5
0.6
6.78
4.22
0.7
8.78
5.47
0.8
14.20
8.85
20.10
12.5
28.90
18.0
25.2
22.7
18.9
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
16
2
2
115
157
71.6
97.8
200
180
150
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
353
222.0
1065
960
800
27
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
817
509.0
3665
3300
2750
42
4.5
1120
698.0
5865
5275
4395
2-8
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Magni Coating*
CLASS 12.9 SOCKET HEAD CAP SCREWS
M6 AND ABOVE*
Size
PITCH
Tensile
Stress
Area
Clamp Load
See Note 4
Sq mm
kN
Torque
Lube OR Loctite
Torque
Torque Dry
242 or 271 Loctite 262
or
OR
OR
Loctite 263
Vibra-TITE Vibra-TITE 131
111 or 140
K = .17
K = .16
K = .15
[N.m]
[N.m]
[N.m]
0.5
3.5
0.6
5.03
6.78
0.7
8.78
0.8
14.20
20.10
12.5
13
12
11
28.90
18.0
21
20
19
27
1.25
36.60
22.8
31
29
10
1.5
58.00
36.1
61
58
54
12
1.75
84.30
52.5
105
100
95
14
16
2
2
115
157
71.6
170
160
150
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
353
220.0
900
845
790
27
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
817
509.0
3115
2930
2750
42
4.5
1120
698.0
4985
4690
4395
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-9
Size
ORFS
JIC
Flats Method
13 lb-ft
(18 Nm)
13 lb-ft
(18 Nm)
1.5 to 1.75
23 lb-ft
(31 Nm)
23 lb-ft
(31 Nm)
1 to 1.5
40 lb-ft
(54 Nm)
40 lb-ft
(54 Nm)
1.5 to 1.75
10
60 lb-ft
(81 Nm)
60 lb-ft
(81 Nm)
1.5 to 1.75
12
74 lb-ft
(100 Nm)
85 lb-ft
(115 Nm)
1.0 to 1.5
16
115 lb-ft
(156 Nm)
115 lb-ft
(156 Nm)
0.75 to 1.0
20
170 lb-ft
(230 Nm)
170 lb-ft
(230 Nm)
0.75 to 1.0
24
200 lb-ft
(271 Nm)
200 lb-ft
(271 Nm)
0.75 to 1.0
32
N/A
270 lb-ft
(366 Nm)
0.75 to 1.0
Flats Method:
1. 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).
2. Mark a dot on one of the swivel nut flats and another
dot in line on the hex of the adapter its connecting
to.
3. Use the double wrench method while tightening to
avoid hose twist.
4. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
covering the dots indicating that the connection has
been properly tightened.
2-10
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2.3
SPECIFICATIONS
2.3.1
Travel Speeds
Function
Speed
First Gear
Second Gear
Third Gear
2.3.2
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
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
17M
Platform Lift
31
39
Platform Lower
31
39
Platform Extend
19
27
Platform Retract
19
27
14
14
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-11
Electrical System
Note: Refer to Section 9.6, Fuses and Relays, for more information.
Battery
Type, Rating
Quantity
Reserve Capacity
Group/Series
DIN 600,38
Alternator
12V, 85 Amps
Starter
2.3.5
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
High Idle
Horsepower
Fuel Delivery
Fuel Injection
Air Cleaner
2.3.6
Tires
Tire Type
Minimum Ply
Fill Type
Pressure
405/70-24
MPT01 AG
14 Ply
Pneumatic
405/70-24
MPT04 CONST
14 Ply
Pneumatic
405/70-24
14 Ply
Pneumatic
405/70-24
14 Ply
Pneumatic
2-12
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2.4
8,5 L (9 qt)
Oil Type
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9
15W-40 CH
DF Super ENGINE OIL 15W-40
Fuel Tank
Capacity
Type of Fuel
#2 Diesel
Cooling System
System Capacity
Type of Fluid
20 L (5 gal)
50/50 mix of ethylene glycol and water
Hydraulic System
System Capacity (8, 9M, 40.8 & 40.9)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9
Transmission
Capacity with Filter Change
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9
Transfer Case
Capacity
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-13
Axles
Differential Housing Capacity - Front
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9
Brake System
System Capacity
Type of Oil
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9
2-14
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2.5
MAINTENANCE SCHEDULES
2.5.1
2.5.2
50
EVERY
Drain Fuel/
Water
Separator
Check Fuel
Level
Air Filter
Check Hydraulic
Oil Level
Check
Transmission
Oil Level
Check Engine
Oil Level
Check Tire
Condition &
Pressure
Check Engine
Coolant Level
Check
Battery
Check Washer
Fluid Level
Air Filter
Vacuator
Valve
Check
Fan Belt
EVERY
Check Brake
Fluid Level
Lubrication
Schedule
250
Change Engine
Oil and
Filter
Check Axle
Oil Level
Check Wheel
End Oil Levels
Check Boom
Chain & Tension
(17M Only)
Check Boom
Wear Pads
Check Transfer
Case Oil Level
1st
50
LB/FT
Change
Axle Oil
Change Wheel
End Oil
Change Engine
Oil & Filter
Change
Transmission
Oil & Filter
(Nm)
EVERY
Check Wheel
Lug Nut
Torque
500
LB/FT
Check Boom
Chain & Tension
(17M Only)
Change Fuel
Filter
MZ1671
(Nm)
Check Wheel
Lug Nut
Torque
Check LSI
Calibration
MZ1681
2.5.3
EVERY
1000
Change
Transmission
Oil & Filter
Change
Transfer Case
Oil
Change
Axle Oil
Change Wheel
End Oil
EVERY
1500
Change
Engine Coolant
Change
Hydraulic
Fluid & Filters
Change
Hydraulic Tank
Breather
Change
Brake Fluid
MZ1690
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-15
2.6
2.6.1
LUBRICATION SCHEDULES
8 Hour Lubrication Schedule
8, 9, 12 & 13M
EVERY
OZ2260
2-16
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
EVERY
OZ2430
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-17
8, 9, 12 & 13M
EVERY
50
2x
OZ2270
2-18
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
EVERY
50
2X
OZ2440
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
2-19
2-20
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 3
Boom
Contents
PARAGRAPH
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
TITLE
PAGE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-1
Boom
3.10
3.11
3.12
3.13
3-2
3-25
3-25
3-25
3-26
3-26
3-26
3-26
3-27
3-27
3-27
3-28
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3.1
FIRST
BOOM
SECTION
PIVOT PIN
SECOND
BOOM
SECTION
THIRD
BOOM
SECTION
EXTEND/RETRACT
CYLINDER
ACCESS
PANEL
FIRST
BOOM
SECTION
PIVOT PIN
TILT CYLINDER
QUICK SWITCH
EXTEND/RETRACT
CYLINDER
ACCESS
PANEL
SECOND
BOOM
SECTION
TILT CYLINDER
QUICK SWITCH
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
MZ1480
3-3
Boom
3.2
3.2.1
3.3
3.3.1
Boom Removal
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
any pressure off of wear pads to make pad removal
easier.
3
MZ1720
3.3.3
3.3.2
6
5
MZ1740
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-5
Boom
3.3.4
3.3.5
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).
2. Grease the inside of the next boom section on areas
where the innermost boom section wear pads will
slide.
3. Using a suitable sling, balance the innermost boom
section and carefully slide 1 m to 1,5 m (3 to 4) into
the front of the next boom section. Set the innermost
boom section head onto suitable supports and reset
sling under the boom head. Carefully slide the
innermost boom section into the next section. Leave
15 cm to 20 cm (6 to 8) of the innermost boom
section out to be able to install wear pads on the
front of the next boom section.
4. With the boom head still supported, install the top
wear pads, washers and bolts in the front of the
larger boom section. Apply Loctite 243TM and torque
to 90 Nm (66 lb-ft). Remove the boom head from
supports and install the bottom wear pads, backing
plates, shims and bolts in the front of the larger
boom section. Apply Loctite 243TM and torque to 90
Nm (66 lb-ft). Install both left and right side front
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
9
MZ1730
1. Install the bottom rear wear pads (9) and bolts onto
the second 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).
2. Grease the inside of the first boom section on areas
where the third boom section wear pads will slide.
3. Using a suitable sling, balance the first and second
boom sections and carefully slide 1 m to 1,5 m
(3 to 4) into the front of the third boom section.Set
the third boom section head onto suitable supports
and reset sling under the boom head. Carefully slide
the first and second boom sections into the first
section. Leave 15 cm to 20 cm (6 to 8) of the
second boom section out to be able to install wear
pads on the front of the first boom section.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
4. With the boom head still supported, install the top
wear pads, washers and bolts in the front of the first
boom section. Apply Loctite 243TM and torque to
90 Nm (66 lb-ft). Remove the boom head from
supports and install the bottom wear pads, backing
plates, shims and bolts in the front of the first boom
section. Apply Loctite 243TM and torque to 90 Nm
(66 lb-ft). Install both left and right side front wear
pads, backing plates, shims and bolts in the front of
the first boom section. Apply Loctite 243TM and
torque to 50 Nm (37 lb-ft).
Note: Shim ALL side wear pads as needed to maintain
a minimum gap in the horizontal direction or a tight fit.
The number of shims can vary at each shim point except
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.
3.3.6
Boom Installation
3-7
Boom
3.4
HOSE CARRIER
FOURTH BOOM
SECTION
THIRD BOOM
SECTION
SECOND BOOM
SECTION
AUXILIARY
QUICK
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
3.5.1
3.6
3.6.1
Boom Removal
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
ground or supports being careful not to damage the
tubes on the left side of boom.
3.6.2
MZ0740
MZ0790
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
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.
14. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.
15. 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.)
Note: It is recommended that if any chain or hose is
damaged that ALL chains or hoses are replaced.
3.6.3
MZ0760
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-11
Boom
3.6.4
3.6.5
MZ2720
3.6.6
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3.6.7
MZ0770
3.6.8
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
(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
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
pads in the front of the second boom section.
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
left side and right side front wear pads, backing
plates, shims and bolts in the front of the second
boom section. Torque to 90 Nm (66 lb-ft).
Note: Grease wear pads, inside sheaves, bores and
pins during assembly.
8
MZ1000
3-14
MZ1010
MZ1140
3.6.9
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
2. Grease the inside first boom section on areas where
the second boom section wear pads will slide.
3
MZ1190
MZ1200
9. Attach the retract chain (6), pin and clip to the clevis
at the rear of the fourth boom section.
10. Attach the retract chains (7), pins and clips to the
clevises at the rear of the third boom section.
Note: Installing the clevis pins in the third boom section
can only be done when the first boom section and the
second boom section access holes are aligned.
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
before installing.
MZ0790
18. Turn the boom over being careful not to damage the
Tilt and Auxiliary tubes mounted on the side and rear
of boom.
19. After boom is turned upright, place a suitable
support under the rear of the boom.
20. Attach a sling around a balance point on the Extend/
Retract cylinder and carefully set on top of the first
boom section.
Note: Grease Extend/Retract cylinder barrel end bore
and rod end bore and pins before installing.
3
2
MZ1210
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
4
5
8
5
MZ1250
MZ1230
MZ1240
4. With the sling still in place, install the rod end of the
Lift/Lower cylinder, pin and lock bolt (6). Apply
Loctite 243TM and torque to 90 Nm (66 lb-ft).
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-17
Boom
3.7
3.7.1
WARNING
Worn pins, stretched or cracked links or corrosive
environments can cause chain failure. A chain failure
could result in uncontrolled boom movement, loss of
load or machine instability.
Under normal operating conditions the boom chains will
need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every
1000 hours of operation. Refer to the Service Manual for
the proper procedure. Environmental conditions and
dynamic impulse/shock loads can drastically affect
normal operating conditions and require more frequent
inspection intervals.
Environments in which material handling vehicles
operate can vary widely from outdoor moisture to
temperature to mildly corrosive or highly corrosive
industrial atmospheres, in addition to abrasive
exposures such as sand and grit. Some effects can be
as follows:
3.7.2
Inspection Guidelines
3-18
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
b. Extend Chains (third to second section)
MZ1463
MZ1464
Elongation
It is important to measure the chain in the section
that moves over the sheaves because it receives the
most frequent articulation. Measuring the chain near
its clevis terminals could give an inaccurate reading.
The ends of the chains, near the clevis terminal, will
not have flexed as frequently, if at all, as nearer the
middle of the chains.
a. Extend Chains (fourth to third section)
When the original length (3) of 305 mm (12.00 in)
per foot of extend chain between the fourth and third
boom sections has elongated from wear to a length
(4) of 313 mm (12.36 in), the chain should be
discarded and replaced.
Measure across a span of 16 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
313 mm(12.36 in). If the measurement is more than
313 mm (12.36 in), the chain should be replaced.
7
MZ1465
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-19
Boom
Distorted or Battered Link Plates
Distorted or battered link plates (8) on a leaf chain can
cause tight joints and prevent flexing.
88
MZ1466
Tight Joints
- All joints in
the chain
should flex
freely. Tight
3
MZ1471
joints (3)
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.
3.7.3
c. Extend Chains
Cracked Plates
Inspect the chains very carefully, front and back as
well as side to side, for any evidence of cracked
plates. If any one crack is discovered, the chain
should be replaced in its entirety.
d. Retract Chains
3-20
MZ1469
MZ1470
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
e. Removing Extend and Retract Chains
The four extend chains and the three retract chains can
only be removed during a complete boom teardown.
While doing the chain inspection, check all chain clevis
ends for distortion or cracking and sheaves for bearing
wear or grooving from the chain.
If during the inspection, any chain is found to be damaged
or stretched, the chain must be replaced. It is
recommended that when any chain is replaced, that all
the chains and clevis be replaced at the same time.
3.7.4
Chain Lubrication
3.8
37mm
1.45
20mm
.787
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
sections two or three times. Fully retract the boom
and measure the distance between the boom
sections.
5. If the measurements are within the tolerance, tighten
the locknuts on the chain clevises. If more
adjustment is needed, repeat procedure until the
proper boom section dimensions is achieved.
6. With the boom sections within the proper tolerance,
start the machine, lower the outriggers if necessary
and extend the boom to maximum extension.
7. Shut the machine off and measure the distance
between the top of both extend chains and the
bottom of the second and third boom sections at the
center of each boom section.
120mm - 4.75in
3.9
3.9.1
180mm - 7in
MZ1220
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
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.
MZ0900
11. Label and remove the hoses from the elbow fittings
on the tilt cylinder (1). Plug the hose ends and cap
the elbow fittings on the tilt cylinder to prevent dirt
and debris from entering the hydraulic system.
12. Label and remove the two auxiliary hydraulic hoses
(2) from the bulkhead fittings inside the boomhead.
Plug the hose ends and cap the bulkhead fittings to
prevent dirt and debris from entering the hydraulic
system.
13. At the rear of the boom, label and remove the tilt
cylinder hoses and the auxiliary hoses from the hose
carrier bulkhead. Plug the hose ends and cap the
bulkhead fittings to prevent dirt and debris from
entering the hydraulic system.
3
3.9.2
MZ0920
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
MZ0910
11. Torque the middle two and front two hose carrier
bolts to 90 Nm (66 lb-ft).
12. Start the machine and retract the boom
completely.Shut the machine off.
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
6. Fasten the rear of the hose carrier (3) to the top rear
of the third boom section. Apply Loctite243TM and
torque both bolts to 90 Nm (66 lb-ft).
7. Start the machine and extend the boom out until the
middle set of holes (6) in the fourth boom section
align with access holes at the front sides of the third
boom section. Shut off machine.
8. Align the middle two threaded holes on the hose
carrier with the middle two holes on the fourth boom
section and install both bolts. Apply Loctite 243TM
and hand tighten only.
9. Start the machine and extend the boom out until the
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.
16. Bolt the auxiliary bulkhead onto the side of the boom
head. Apply Loctite 243TM and torque to 50 Nm
(37 lb-ft).
17. At the rear of the boom, attach both tilt cylinder
hoses to the tilt hose carrier bulkhead fittings and
tighten until wrench-tight. Mark the hose fitting then
tighten each hose firmly 1 to 1 1/2 flats.
18. At the rear of the boom, attach both auxiliary hoses
to the auxiliary hose carrier bulkhead fittings and
tighten until wrench-tight. Mark the hose fitting then
tighten each hose firmly 1 to 1 1/2 flats.
19. Start the engine and operate all boom functions
several times. Check for leaks, and check the
hydraulic oil level in the reservoir; add oil if required.
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
3.10.1
Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
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.
3.10.2
3
2
MAM1390
MY3620
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-25
Boom
Torque wear pad bolts after shimming is completed.
Lubricate the face and pockets of each wear pad
after being installed.
Boom Section Wear Pad Pathway Lubrication:
Clean and lightly grease all wear pad pathways with
Mystik Tetrimoly grease.
Clean and lightly grease the hose carrier guide bar
pathways with Mystik Tetrimoly grease.
3.11
3.11.2
10
3.11.1
MAH0980
8
9
6
7
3.11.3
3-26
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3.11.4
3.12
FORKS
6
7
13
3.11.5
2
1
9
8
11
10
MH6460
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-27
Boom
3.13
TROUBLESHOOTING
Problem
1. Boom will not extend or
retract
Cause
Remedy
1. Insufficient lubrication.
2. Worn bearing(s).
4. Replace bearing.
3-28
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
Problem
6. Rapid boom pad wear.
Cause
Remedy
3. Contaminated, corroded or
rusted wear pad sliding
surfaces.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
3-29
Boom
3-30
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 4
Cab and Covers
Contents
PARAGRAPH
4.1
4.2
4.3
4.4
4.5
TITLE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
4-2
4-3
4-3
4-3
4-3
4-4
4-4
4-5
4-6
4-7
4-7
4-7
4-8
4-9
4-9
4-11
4-1
4.1
LOAD STABILITY
INDICATOR
DISPLAY
PANEL
HEATER & AC
CONTROLS
TRANSMISSION
CONTROL LEVER
BRAKE FLUID
RESERVOIR
JOYSTICK
POWER/
EMERGENCY
STOP SWITCH
(IF EQUIPPED)
IGNITION
SERVICE BRAKE
PEDAL
ACCELERATOR
PEDAL
PARKING BRAKE
LEVER
4-2
MZ2061
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
WARNING
DO NOT service the machine without following all
safety precautions as outlined in the Safety
Practices section of this manual.
4.2
4.2.1
2
4
OPERATOR CAB
Serial Number Decal
4.3
4.3.1
CAB COMPONENTS
Steering Column and Orbitrol Valve
MZ2000
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4-3
4.3.2
MZ1960
4.3.3
4-4
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4.3.4
c. Throttle Adjustment
1. Adjust the distance on each end of the throttle cable
from the locknut to the connector end. The distance
from the connector to the locknut in the cab should
be 129 mm (5 in). In the engine compartment, the
distance should be 234 mm (9.2 in).
Note: These measurements are to be used as starting
points. If further adjustment is required, the distance may
need to be altered.
MZ2030
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4-5
MZ1490
4.3.5
4-6
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
MZ2020
4.3.7
4.3.8
4-7
Heater/Defroster System
MZ2040
6. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
7. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain plug and slowly remove to allow the coolant to
drain. Transfer the coolant into a suitable, covered
container and label as "Used Coolant". Dispose of
the used coolant at an approved recycling facility.
Clean and reinstall the drain plug.
5
MZ2050
4-8
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4.3.10
8
MAM0310
1. Install the control box into the dash panel until the
side clips firmly hold the box.
2. Connect the previously labeled electrical connectors
to the appropriate locations.
3. Connect the previously labeled control cables to the
appropriate control knob mechanisms.
4. Properly connect the battery.
5. Turn the ignition key to the ON position and check
the control functions.
6. Start the machine and allow engine to warm to
operating temperature. Check heat control at
different levels.
7. Install the plastic side cover. If necessary, install the
seat.
8. Close and secure the engine cover.
9. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
4.4
CAB REMOVAL
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4-9
MZ0660
MZ0640
4-10
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4.5
CAB INSTALLATION
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4-11
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
5.1
5.2
5.3
5.4
5.5
5.6
5.7
TITLE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
5-2
5-3
5-3
5-3
5-3
5-3
5-3
5-4
5-4
5-6
5-9
5-9
5-9
5-9
5-9
5-9
5-10
5-10
5-11
5-11
5-11
5-12
5-12
5-12
5-12
5-1
5.1
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
5.2
GENERAL INFORMATION
5.3
5.3.1
AXLE ASSEMBLIES
Axle Serial Number Plate
5.3.2
Axle Specifications
5.3.3
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
5.3.4
Axle Maintenance
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
5-3
Axle Removal
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the outrigger
solenoids and other electrical components. If using a
steam cleaner, seal all openings before steam cleaning.
Note: Clear the work area of all debris, unnecessary
personnel, etc. Allow sufficient space to raise the
machine and to remove the axle.
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 steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Properly disconnect the battery.
5. Remove the fender assemblies.
MZ1030
16. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
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
2
MZ1520
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
neither. The steps below outline a typical axle installation
procedure, suitable for either the front or the rear axle
assembly.
1. Before proceeding, ensure that the machine will
remain in place during axle installation. Block the
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
MZ5820
7. Apply a multi-purpose grease through the selftapping lube fitting to lubricate the self-align bearing
and the cylinder-mount pin (if required).
17. Install the park brake on the front axle (8, 9, 12 &
13M only).
18. If reinstalling the front axle, the hydraulic brake
circuit will need to be bled. Refer to Section 8.9.3,
Brake Test.
19. Check the hydraulic reservoir oil level.
20. Install the fender assemblies.
21. Properly connect the battery.
22. Unblock the wheels.
MZ1030
10. Tighten the axle oil drain plug, loosen and remove
the axle oil fill plug (3). Fill the axle through the axle
fill plug until the oil level is even with the oil check
level plugs (4). Refer to Section 2.4, Fluids,
Lubricants and Capacities, for proper oil and
capacities.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
5-5
Problem
1. Excessive axle noise while
driving.
5-6
Cause
Remedy
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Problem
4. Oil leaking from axle
(differential housing and/or
axle housings).
Cause
Remedy
2. Tighten fittings.
2. Replace o-ring.
1. Tighten fittings.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
5-7
Problem
7. Axle overheating.
5-8
Cause
Remedy
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
5.4
DRIVE SHAFTS
To Transmission
5.4.1
5.4.2
To Axle
3
4
5.4.4
5.4.3
5.4.5
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
5-9
5.5
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
recommends that replacement tires have the following
characteristics:
Equal or greater ply/load rating and size of original.
Tire tread contact width equal or greater than
original.
Wheel diameter, width and offset dimensions equal
to the original.
Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load).
The rims installed have been designed for stability
requirements which consist of track width, tire pressure
and load capacity. Size changes such as rim width,
center piece location, larger or smaller diameter, etc.,
without written factory recommendations, may result in
unsafe condition regarding stability.
The tires are filled with air only when the machine leaves
the factory. JLG does not recommend the use of hydrofill
as a tire-fill substance because of possible environmental
impact.
Large-bore valve stems are used to help expedite tire
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire
on the wheel, the tire must be mounted on the wheel
respective of the directional tread pattern of the tire; this
produces a left or right tire and wheel assembly.
5-10
MY4190
5.5.1
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
5.6
5.6.1
BRAKES
Brake Disk Inspection.
MZ1030
Mh3300
MZ5830
10
6. Fill the axle through the axle fill plug (8) until the oil
level is even with the oil check level plugs (6). Refer
to Section 2.4, Fluids, Lubricants and Capacities,
for proper oil and capacities.
MY4200
5-11
5.7
5.7.1
5.7.3
5.7.2
MZ1020
5-12
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 6
Transmission:
Contents
PARAGRAPH
6.1
6.2
6.3
6.4
6.5
6.6
TITLE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
6-2
6-3
6-3
6-3
6-3
6-3
6-3
6-4
6-5
6-5
6-6
6-7
6-1
Transmission:
6.1
TRANSMISSION ASSEMBLY
COMPONENT TERMINOLOGY
TORQUE CONVERTOR
DIPSTICK AND FILL TUBE
OIL FILTER
OUTPUT SHAFT
(FRONT)
BREATHER
OUTPUT SHAFT
(REAR)
BREATHER
6-2
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
6.4.2
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
6.2
TRANSMISSION DESCRIPTION
6.3
6.4
6.4.1
TRANSMISSION SPECIFICATIONS
Transmission Maintenance
6.5
TRANSMISSION REPLACEMENT
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
6-3
Transmission:
6.5.1
Transmission Removal
WARNING
Risk of severe personal injury. NEVER lift a
transmission alone; enlist the help of at least one
assistant or use a suitable hoist or overhead crane
and sling.
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 the
(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. Remove the engine cover to allow easier access to
the transmission.
5. Remove the belly pan from under engine.
6. Disconnect the (+) positive and (-) negative battery
cables and remove the battery.
7. Thoroughly clean the transmission and surrounding
area, including all hoses and fittings, before
proceeding.
1
2
MZ1380
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
27. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
28. Remove any external transmission components as
required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings.
3
6.5.3
Transmission Installation
MZ0680
6.5.2
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.
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
6-6
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
6.6
TROUBLESHOOTING
Problem
1. Transmission will not engage
or will not shift properly.
Cause
Remedy
6. Replace o-rings.
8. Replace couplings.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
6-7
Transmission:
Problem
2. Low or no pump flow or
pressure.
4. Lack of power.
6-8
Cause
Remedy
5. Transmission overheating.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
Problem
5. Transmission overheating
(oil above 120 C (248 F)).
Cause
Remedy
2. Clogged radiator.
4. Excessive roading.
4. Internal damage.
6. Tighten capscrews.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
6-9
Transmission:
Problem
7. Oil leaking from transmission.
6-10
Cause
Remedy
3. Tighten fittings.
5. Tighten capscrews to 46 Nm
(34 lb-ft).
9. Housing damaged.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 7
Engine: Perkins 1104-42 & 1104-42T
Contents
PARAGRAPH
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2
Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1
Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3
Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.2
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.3
After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.1
Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.2
Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.1
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.2
Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . .
7.9.3
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.1
Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.2
Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
7-2
7-2
7-3
7-4
7-4
7-4
7-4
7-4
7-5
7-6
7-6
7-6
7-7
7-8
7-8
7-9
7-9
7-9
7-9
7-9
7-10
7-11
7-12
7-12
7-12
7-13
7-1
7.1
7.1.1
INTRODUCTION
Disclaimer and Scope
7-2
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Component Terminology
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
7.2
7.3
SPECIFICATIONS AND
MAINTENANCE INFORMATION
a. Thermostat 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
(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.
5. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
7.4
7.4.1
7.4.2
Thermostat Replacement
MZ2180
7-4
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
4
7
7.4.3
3
5
MZ2070
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
7-5
7.5
7.6
7.6.1
FUEL SYSTEM
Diesel Fuel
7-6
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Fuel Tank
10. Lift the empty fuel tank from between the frame rails.
b. Disassembly
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed
and reused on the new replacement tank.
c. Cleaning and Drying
If contaminated fuel or foreign material is in the tank, the
tank can usually be cleaned.
Note: If a leak is suspected in the fuel tank, contact your
local JLG distributor.
10
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
7.7
7.7.1
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.
6. Fill the fuel tank according to specifications. Refer to
Section 2.4, Fluids, Lubricants and Capacities.
7. Check fuel tank for leaks.
8. Install the boom. Refer to Section 3.3.6, Boom
Installation.
9. Properly connect the battery.
MZ0110
10. Loosen and remove the two bolts at the front and
one bolt at the rear of the muffler, and remove the
muffler.
7.7.2
7.6.3
7-8
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
7.8
CAUTION
NEVER run the engine with only the inner safety
element installed.
Note: Refer to the appropriate Operation & Safety
Manual for the correct element change procedure.
7.8.1
7.8.2
7.9
ENGINE REPLACEMENT
7.9.1
Engine Removal
11
MZ2010
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
7-9
19. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Remove
them one at a time.
20. Secure the engine with a lifting strap or chain from
the appropriate lifting points. Use a suitable hoist or
overhead crane.
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
MZ0940
7.9.2
7-10
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine Installation
17. Install the hood latch plate. Align the mark on the
plate to help with hood adjustment.
18. Secure the return hydraulic oil filter plate to the
frame.
19. Install both heater hoses to the engine and tighten
clamps.
20. Install the complete radiator assembly. Refer to
Section 7.4.3, Radiator/Oil Cooler and Coolant
Heater Replacement.
21. Install the hose clamp on the bottom radiator hose
and work onto the engine. Tighten the clamp.
22. Install the hose clamp on the top radiator hose and
work onto the engine. Tighten the clamp.
23. Connect the transmission inlet and outlet hoses on
the oil cooler. Install the clamp holding the top
transmission cooler hose and the three bolts holding
the fan screen.
24. Install the engine cover and adjust.
25. Install the battery and reconnect the (+) positive and
(-) negative cables.
26. Open the radiator cap and fill the radiator completely
with coolant. Replace and tighten the radiator cap.
Add coolant to the overflow bottle until the bottle is 1/
4 to 1/2 full. This overfilling will compensate for any
air trapped in the cooling system.
27. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
28. From within the cab, lightly depress the throttle pedal
to full-throttle position. As needed, adjust the limitstop screw until it touches the pedal. Tighten the
locknut to 13,6-14,1 Nm (120-125 lb-in).
Note: Have an assistant stand by with a Class B fire
extinguisher.
29. Start the engine and run to normal operating
temperature then shut off the engine. While the
engine is cooling, check for leaks.
30. Allow the engine to cool. Check the radiator coolant
level, and top off with coolant. Replace the radiator
cap.
31. Check for leaks from the engine, main hydraulic
pump and lines, transmission, hydraulic reservoir
and fuel tank. Check the levels of all fluids and
lubricants. Fill as required.
Note: During the full throttle check:
DO NOT operate any hydraulic function.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
7-11
15
MZ0580
7.10
7.10.1
7-12
7.10.2
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
7.11
TROUBLESHOOTING
Trouble
1, 2, 3, 4
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
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
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
4, 38, 41
Overheating
11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Poor Compression
11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
10, 11, 12
Key to Possible Causes
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
7-14
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 8
Hydraulic System
Contents
PARAGRAPH
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
TITLE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
8-2
8-3
8-3
8-4
8-4
8-6
8-17
8-17
8-17
8-17
8-18
8-18
8-18
8-19
8-20
8-20
8-20
8-20
8-20
8-22
8-23
8-23
8-23
8-24
8-26
8-26
8-26
8-27
8-27
8-27
8-28
8-28
8-28
8-29
8-1
Hydraulic System
8.1
HYDRAULIC COMPONENT
TERMINOLOGY
LIFT/LOWER
CYLINDER
TILT CYLINDER
EXTEND/RETRACT
CYLINDER
(INSIDE BOOM)
OUTRIGGER CYLINDERS
(12, 13 & 17M ONLY)
STEERING
CYLINDER
HYDRAULIC OIL
RESERVOIR
COMPENSATION
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
WARNING
DO NOT service the machine without following all
safety precautions as outlined in Section 1, Safety
Practices, of this manual.
8.3
Description
Approximate
Weight
Price and
Availability
70000652
4,5 kg
(10 lbs)
Consult Factory
70000101
3 kg
(7 lbs)
Consult Factory
70027911
3 kg
(7 lbs)
Consult Factory
1321107
12,7 kg
(28 lbs)
Consult Factory
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
8-3
Hydraulic System
8.4
HYDRAULIC CIRCUITS
8.4.1
8-4
Hydraulic Pressures
a. Checking Pressures
1. Start the machine and warm the hydraulic system to
operating temperature.
2. Shut off the machine and install a digital or a 345 bar
(5000 psi) gauge to the appropriate test port.
3. Start the machine, run the engine and follow
procedures in Section 8.4.1, c. Pressure
Specifications.
b. Adjusting Hydraulic Pressure
1. Shut the machine off. Remove the cap on the relief
(if necessary).
2. Start the machine and loosen the jam nut on the
relief. Turn the relief clockwise to increase pressure
or counter-clockwise to decrease pressure. Set to
the correct pressure.
3. Tighten the jam nut and recheck the pressure at full
throttle. If the reading is within specification, shut the
machine off, install the safety cap and remove the
gauge from the test port.
4. If the proper pressure cannot be set, use the
accompanying hydraulic schematic and/or the
electrical schematic to help troubleshoot and correct
the problem.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
c. Pressure Specifications
Hydraulic
Circuit
Test Port
Procedure
Adjustment
Location
Pressure Range
Implement
250 5 Bar
(3626 73 psi)
Pilot
Pr
30 2 Bar
(435 29 psi)
Pr
1
MZ2320
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
8-5
Hydraulic System
8.5
8.5.1
HYDRAULIC SCHEMATICS
8M, 9M, 12M & 13M (w/o trailer brakes)
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
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
8M, 9M, 12M & 13M - Frame Level (if equipped)
8M & 9M
8.5.3
8-10
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
8.5.4
17M
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
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
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
8.6.3
MZ0130
8.6.1
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
8-17
Hydraulic System
c. Cleaning and Drying
8.7
8.7.1
8.7.2
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.
2. With the hydraulic oil reservoir removed from the
machine, plug all openings except one elbow fitting.
Install the elbow fitting, and apply approximately
0,06-0,10 bar (1-1.5 psi) of air pressure through the
elbow. Check the reservoir for leaks by applying a
soap solution to the exterior and look for bubbles to
appear at the cracked or damaged area.
e. Reservoir Installation
1. Lift the hydraulic oil reservoir into place and install
the six bolts, washers and nuts.
2. Uncap and connect the suction hose and return
hose. Tighten both clamps.
3. Uncap and connect the four small return hoses to
the fittings on the hydraulic oil reservoir.
4. Install the hydraulic oil level sight-glass using special
designed and drilled capscrews and gaskets.
MZ1950
Aeration
Cavitation
Contamination
Excessive Heat
Over-Pressurization
Improper oil
8-18
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
8.7.3
Pump Replacement
a. Pump 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 (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.
4. Properly disconnect the battery.
5. Thoroughly clean the pump and surrounding area,
including all hoses and fittings before proceeding.
Note: Cap all hoses as you remove them to prevent
unnecessary oil spillage.
6. Remove the bolts and lockwashers securing the
flange halves to the pump. Remove the inlet hose
and o-ring.
Note: Before removing any fittings from the pump, note
their orientation to ensure correct installation.
7. Remove the bolts and lockwashers securing the
flange halves to the pump. Remove the outlet hose
and o-ring.
8. Disconnect the case drain hose from the fitting.
Disconnect the load sense line.
9. Remove the bolts and lockwashers securing the
pump to the transmission. Remove the gasket
located between the transmission and the pump.
Wipe up any hydraulic oil spillage.
Note: DO NOT disassemble the implement pump. The
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than an authorized
dealer could void the warranty.
b. Pump Installation
1. While the pump is still on the bench, install all
fittings, except the outlet hose fitting, orienting them
as noted during removal.
2. Apply Loctite 243TM on the metal seal of the pump
and place into position on the transmission. Align the
pump shaft with the internal transmission gear, so
that the machined teeth mesh together.
3. Align the bolt holes with the pump mount holes.
Secure the pump to the transmission with the bolts
and washers. Torque to 115 Nm (85 lb-ft).
4. If necessary, slide the T-bolt band clamp onto the
pump inlet hose. Secure the hoses to the hydraulic
reservoir outlet connection with the T-bolt band
clamp.
5. Place a new oiled o-ring into position over the pump
opening. Secure the inlet hose with two flange
halves, lockwashers and bolts.
6. Connect the load sense line to the fitting.
7. Place a new, oiled o-ring into position over the pump
opening. Secure the outlet hose with two flange
halves, lockwashers and bolts.
8. Prime the pump by filling the case drain port with
fresh, filtered hydraulic oil from a clean container
before installing the case drain connector and
hoses.
9. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.
10. 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.
11. Inspect for leaks and check all oil levels. The
hydraulic reservoir oil level must be to the middle of
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
8.8.1
8.8.2
8.9
8.9.1
MZ2530
MZ2080
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.
4. Properly disconnect the battery.
5. Thoroughly clean the main control valve and
surrounding area, including all hoses and fittings,
before proceeding.
6. Place a suitable container to catch hydraulic oil
drainage beneath the frame.
7. Label, disconnect and cap all the hydraulic hoses,
tubes and wires at the main control valve. Slowly
turn hose fittings to allow any trapped pressure in
the hydraulic system to escape.
8. Wipe up any hydraulic oil spillage in, on, near and
around the machine and the work area.
9. Support the valve and remove the four bolts
securing the main control valve bracket to the frame.
10. Remove the main control valve and bracket from the
frame and remove the four bolts holding the
mounting bracket to the valve.
b. Main Control Valve Disassembly
1. To disassemble the individual sections of the main
control valve, remove the nuts from one end of the
tie rods. Pull the tie rods out through the sections.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
Note: DO NOT adjust any of the relief valve assemblies.
Tampering with a relief valve will irrevocably alter
pressure in the affected circuit, requiring recalibration or a
new relief valve.
Disassemble each Valve Section
MAM0100
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
8-21
Hydraulic System
f.
8.9.2
MZ1980
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.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
3. Use new oiled o-rings as required. Reattach and
secure all valves, hoses, clamps, etc.
4. Check the routing of all hoses, 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.
5. Properly connect the battery.
8.9.4
8.9.5
8.9.3
Brake Test
8-23
Hydraulic System
7. Remove the two bolts holding the steer select valve
to the mounting plate on the frame.
17M Frame Shown
9
MZ0380
8.9.6
8-24
Leveling Valve
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
MZ2410
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
8-25
Hydraulic System
f.
8.10
8.10.1
HYDRAULIC CYLINDERS
General Cylinder Removal
Instructions
8-26
8.10.2
WARNING
Significant pressure may be trapped inside the
cylinder. Exercise caution when removing a
counterbalance valve or a pilot-operated check valve
from a cylinder.
Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
cylinder securely. Excessive force can damage the
cylinder tube.
3. If applicable, remove the counterbalance valve from
the side of the cylinder barrel.
Note: DO NOT tamper with or attempt to adjust the
counterbalance valve cartridge. If adjustment is
necessary, replace the counterbalance valve with a new
part.
4. Extend the rod (5) to allow access to the base of the
cylinder.
Note: Protect the finish on the rod at all times. Damage
to the surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head
gland (6) from the barrel (1). A considerable amount
of force will be necessary to remove the head gland.
Carefully slide the head gland down along the rod
toward the rod eye end, away from the cylinder
barrel.
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
the tube, prevent the threaded end of the tube from
damaging the piston. Keep the rod centered within the
tube to help prevent binding.
1
2
10. Remove all seals, back-up rings and o-rings (2) from
the piston head and all seals, back-up rings and orings from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
DO NOT attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
catalog for ordering information.
3
4
8.10.3
6
MAH0160
8.10.4
Cylinder Inspection
8.10.5
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
cylinder rod (5). Install the piston head (4) on to the
end of the cylinder rod. Apply Loctite 243TM to the
setscrew (3) and install in the piston head. Refer to
Section 8.10.9, Hydraulic Cylinder Torque
Specifications, for tightening guidelines for the
piston head and the set screw.
Note: Avoid using excessive force when clamping the
cylinder barrel in a vise. Apply only enough force to hold
the cylinder barrel securely. Excessive force can
damage the cylinder barrel.
5. Place the cylinder barrel (1) in a soft-jawed vise or
other acceptable holding equipment if possible.
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
rod centered within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
tube.
8.10.7
Attach a 345 bar (5000 psi) gauge to the test port on the
main control valve to check the system pressure.
Note: If a hydraulic cylinder pressure is greater than the
main control valve pressure, increase the main control
valve pressure by adjusting the main relief. Generally,
one half turn clockwise will be adequate to check an
individual circuit. Activate the circuit and if pressure is
obtained, turn the main relief counter clockwise one half
turn. Recheck the main relief setting and adjust if
necessary.
8.10.8
Steering Cylinders
7. Screw the head gland (6) into the cylinder barrel (1)
and tighten with a spanner wrench. Refer to Section
8.10.9, Hydraulic Cylinder Torque Specifications,
for tightening guidelines for the head gland.
8.10.6
8-28
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
8.10.9
a. Lift/Lower Cylinder
Machine
Piston
Head
Set Screw
8M
2550-2600 Nm
(1881-1917 lb-ft)
775-825 Nm
(571-608 lb-ft)
20-25 Nm
(15-19 lb-ft)
2490-2540 Nm
1837-1873 lb-ft)
950-1000 Nm
(701-738 lb-ft)
20-25 Nm
(15-19 lb-ft)
b. Extend/Retract Cylinder
Machine
Piston
Head
Plug
Set Screw
8 & 9M
1290-1340 Nm
(951-988 lb-ft)
400-450 Nm
(295-332 lb-ft)
N/A
20-25 Nm
(15-19 lb-ft)
1070-1120 Nm
(789-826 lb-ft)
480-530 Nm
(354-391 lb-ft) (rear)
380-430 Nm
(280-317 lb-ft) (front)
50-55 Nm
(37-41 lb-ft)
20-25 Nm
(15-19 lb-ft)
2160-2210 Nm
(1593-1630 lb-ft)
775-825 Nm
(572-608 lb-ft)
N/A
20-25 Nm
(15-19 lb-ft)
17M
c. Tilt Cylinder
Piston
Head
Set Screw
Piston
Head
Set Screw
Piston
Head
Set Screw
Piston
Head
d. Compensation Cylinder
f.
Outrigger Cylinder
Machine
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
8-29
Hydraulic System
8-30
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 9
Electrical System
Contents
PARAGRAPH
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
TITLE
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
PAGE
9-3
9-3
9-4
9-5
9-5
9-6
9-6
9-7
9-7
9-7
9-7
9-7
9-7
9-8
9-8
9-8
9-8
9-9
9-11
9-11
9-15
9-16
9-17
9-19
9-20
9-21
9-22
9-22
9-23
9-24
9-24
9-25
9-25
9-26
9-26
9-1
Electrical System
9.12
9.13
9.14
9.15
9.16
9.17
9.18
9-2
Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.1
Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.2
Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.3
Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . .
Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13.1
Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switches, Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14.1
Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14.2
Transmission Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14.3
Transmission Mounted Speed Sensor (if equipped) . . . . . . . . . . . . . . . . .
9.14.4
Engine Coolant Temperature Sender/Switch . . . . . . . . . . . . . . . . . . . . . .
9.14.5
Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14.6
Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . .
9.14.7
Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14.8
Boom Retracted Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . .
9.15.1
Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.15.2
LSI Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.15.3
LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. . . . . . . . . . . . . . . . . . . . . .
9.16.1
Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.16.2
LSI Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.16.3
LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.16.4
LSI - CAN CHECK PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.16.5
500 Hour - LSI UGM Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . .
Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.17.1
Analyzer Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.17.2
Analyzer Software Version 3.5 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . .
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.18.1
Indicator Cross Reference Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.18.2
Fault Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-26
9-26
9-27
9-28
9-28
9-28
9-29
9-29
9-30
9-30
9-31
9-31
9-32
9-33
9-33
9-34
9-34
9-35
9-36
9-38
9-38
9-39
9-40
9-42
9-43
9-43
9-43
9-44
9-46
9-46
9-47
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.1
ELECTRICAL COMPONENT
TERMINOLOGY
9.2
LOAD
STABILITY
INDICATOR
DISPLAY
PANEL
SPECIFICATIONS
JOYSTICK
POWER
DISTRIBUTION
BOARD
TRANSMISSION
SOLENOID VALVES
ALTERNATOR
UGM
CONTROLLER
STARTER
BATTERY
MZ2370
IGNITION KEY
SWITCH
MZ2380
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
WARNING
While an assistant raises the boom. DO NOT leave
the cab unattended.
6. Have an assistant raise the boom above 60 degrees
in the platform. The boom should not raise above 60
degrees (Model 4017 only). Lower the boom.
9-4
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.4
The following parameters can be altered in the 2nd level of access to the machines software.
9.4.1
Operator Tools
Function
Description
Perform Hardware
Exchange
Allows the owner to restore machine data (anti theft code, engine hours, machine
personalities, etc.) in the event that the machine controller or display/cluster gauge has
been replaced
Confirm Machine
Service
Allows the owner to turn off the Service Required Warning lamp when service is
performed
Allows the owner to see the last 15 times the Service Required Warning lamp was reset
Allows the owner to modify the default service interval of 100 hours
Cabin Joystick
Telescope: X-Axis/
Roller
Allows the owner to change/swap operation of the joystick Telescope and Fork Tilt
functions.
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
Down function speeds
900-2500 mA
1550 mA
Soft Lift
0-90%
40%
Telescope
Allows the owner to adjust the Max Tele In & Max Tele Out
function speeds
900-2500 mA
1550 mA
Fork Tilt
Allows the owner to adjust the Max Fork Tilt Up & Max
Fork Tilt Down function speeds
900-2500 mA
1200 mA
Platform
Level
800-900 mA (Up)
800-870 mA (Down)
900 mA (Up)
870 mA (Down)
Platform
Rotate
Allows the owner to adjust the Max Platform Left & Max
Platform Right function speeds
720-940 mA (Right)
720-970 mA (Left)
940 mA (Right)
970 mA (Left)
Stabilizers
600-2500 mA
1600 mA
Frame
Level
Allows the owner to adjust the Max Frame Level Left &
Max Frame Level Right function speeds
1000-2500 mA
1000 mA
Aux.
Function 1
1100-2500 mA
1550 mA
Aux.
Function 2
1100-2500 mA
1550 mA
Aux.
Momentary
0-1800 mA
1100 mA
Bucket
Mode
1200-2500 mA
1550 mA
9.4.3
Calibrations
Function
Boom Angle
9-6
Description
Allows the owner to calibrate the boom angle sensor if it is replaced. Refer to Section 9.14.7,
Boom Angle Sensor.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.5
OPERATOR TOOLS
9.5.3
9.5.1
9.5.2
Hardware Exchange
9.5.4
9.5.5
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-7
Electrical System
9.5.6
9.6
9.6.1
9.6.2
Engine Compartment
3
4
MZ2100
9-8
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.6.3
MZ2090
Fuse/Relay
Function
Amp Rating
F1
7.5
F2
Rear Wiper
15
F3
7.5
F4
7.5
F5
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
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
9-10
Function
Amp Rating
F18
Flasher
15
F19
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
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.7
For more detailed schematics, contact your local authorized service distributor.
9.7.1
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
(Sheet 2)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-15
Electrical System
9.7.3
(Sheet 3)
9-16
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.7.4
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
(Sheet 5)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-19
Electrical System
9.7.6
(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
(Sheet 8
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-21
Electrical System
9.8
9.8.1
CIRCUIT BREAKDOWNS
Constant Power Circuit from Battery
FLASHER
LIGHTS BAT 1
LIGHTS BAT 2
XA
2 1
XH
XF
XD
5 4 3
SPARE BAT
KEY BAT
SOCKET
1 2
2 4 13
EMPTY
HAZARD
SWITCH
KEY BAT
SOCKET
LIGHTS BAT 1
XA
LIGHTS BAT 2
PCB PWR
X8
S3
3
S12
DRIVING LIGHTS
SWITCH
EMERG STOP
SWITCH
(PLATFORM ONLY)
FLASH BAT
KEY BAT A
X18
30
KEY BAT A
0P
1
2
30
15
15
0P
1
2
58
58
15
53
53a
49a
30
56
56b
53c
56a
3
19
17
17
0P
1
2
50
50
PCB PWR
PCB PWR
PCB PWR
PCB PWR
TURN/
WIPER
SWITCH
KEY
SWITCH
0P
1
2
19
CAB HARNESS
XA1
PCB PWR
AUX POWER
SOCKET
X17
15 14 13 12 11 10 9
FLASH BAT
1 2 3 4
XA1
PCB PWR
PCB PWR
PCB PWR
PCB PWR
30
AUXILIARY
POWER
UNIT
RELAY
(PLATFORM ONLY)
87
86
X110
+
12 VDC
BATTERY
STARTER
PCB PWR
PCB PWR
PCB PWR
PCB PWR
X36
STRT PWR
PHEAT PWR
ALT BAT
ALT BAT
X38
30
STRT PWR
STARTER
RELAY
87
86
85
ALT BAT
ALT BAT
ALTERNATOR
B+
W
PHEAT PWR
D+
50
X46
X40
GLOWPLUGS
FUSE
PHEAT RLY
PHEAT RLY
X47
30
87
ENGINE HARNESS
86
GLOWPLUGS
RELAY
85
MZ2260
9-22
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Start Circuit
CAB UGM
KEY IGN
CLUTCH
KEY STRT
8 16 20 30
PREHEAT
APU ENABLE
NEUT
P BRK
STRT RLY
GLOWPLUGS
KEY IGN
IGNITION
KEY IGN
KEY IGN
IGNITION
12
9 10 11 12
CONN.
J7
KEY 1B
APU
S5
CLUTCH LOCK
SWITCH
(POWERSHIFT ONLY)
2
KEY 1B
CLUTCH
X10
1
BRAKE
PEDAL
SWITCH
2
3
X13
2
ON
X13B
1
2
3
KEY 1B
P BRK
SHIFTER
SWITCH
KEY BAT A
KEY BAT A
KEY IGN
KEY IGN
KEY 1B
P BRK
X18
30
0P
1
2
30
15
15
0P
1
2
58
58
3
X14
FWD
EMERG STOP
SWITCH
(PLATFORM ONLY)
2
1
CLUTCH
OFF
KEY 1B
BRK LT
PWR
NEUT
REV
II
III
IV
IV
NEUT
3
4
PREHEAT A
KEY STRT
II
III
PREHEAT
PREHEAT A
KEY 1B
STRT RLY
PARK BRAKE
SWITCH
CONN.
J4
S1
APU ENABLE
SWITCH
(PLATFORM ONLY)
CONN.
J2
CONN.
J1
CONN.
XP
4 5 6
FUEL PMP
KEY 1B
BRK LT SW
13
IGNITION
10
CONN.
XH
IGNITION
CONN.
XG
FUEL VLV
CONN.
XF
KEY BAT A
CONN.
XC
CLUTCH LOCK
9.8.2
17
17
0P
1
2
50
FUEL PMP
nc
19
50
FUEL VLV
KEY
SWITCH
0P
1
2
19
GLOWPLUGS
CAB HARNESS
FUEL VLV
50
X43
PHEAT RLY
RELAY
GLOWPLUGS
86
85
ENGINE
GLOWPLUGS
PHEAT RLY
PHEAT
87
X48
1
PHEAT
STARTER
M
STRT PWR
FUEL VLV
FUEL PMP
GLOWPLUGS
X47
COLD START
TEMP
SWITCH
X46
30
12 VDC
BATTERY
PHEAT PWR
GLOWPLUGS
FUSE
STRT RLY
FUEL PMP
CONN.
X3
20 36 37
GLOWPLUGS
ENGINE HARNESS
FUEL VLV
PHEAT PWR
X44
FUEL
VALVE
(TURBO)
1
2
ALT BAT
ALT BAT
STRT PWR
X38
30
STARTER
RELAY
87
X49
1
2
STRT RLY
FUEL
PUMP
86
85
ALT BAT
ALT BAT
ALTERNATOR
B+
W
D+
X40
MZ2270
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-23
Electrical System
9.9
9.9.1
Starter
The starter (1) is located on the left side of the engine (the
right side of the machine).
a. Testing the Starter on the Engine
If the starter does not engage when the ignition key
switch is turned, check the following:
1. The main fuse may be blown, requiring replacement.
Check for the cause of the blown fuse.
2. There may be a defect in the ignition key switch,
ignition wiring or starter solenoid.
3. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables.
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring.
5. Check all connections at the starter solenoid, key
switch and wiring harness plugs. Clean and tighten
all connections.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
f.
Starter Installation
9.10
9.10.1
Alternator
a. Alternator 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 (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 engine to cool.
4. Properly disconnect the battery.
CHARGING CIRCUIT
MZ0150
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-25
Electrical System
9.12
b. Alternator Installation
WINDOW WIPER/WASHER
9.12.1
a. Removal
9.11
9.11.1
ELECTRICAL SYSTEM
COMPONENTS
Back-up Alarm
a. Disassembly
DO NOT disassemble the back-up alarm. Replace a
defective or faulty alarm with a new part.
MAH0910
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
serviceable. Replace motor if found to be defective.
7. From inside the cab, pull the wiper motor away from
the rear window.
Note: Align the wiper linkage arm with the flat on the
motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
4. Connect the cab harness connectors to windshield
wiper motor connectors.
5. Properly connect the battery.
6. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH
speeds to ensure proper operation and that correct
wiper travel is achieved.
7. Install right side defroster hose to the dash panel
hose connector.
8. If previously removed, install hydraulic hoses under
the dash.
9. Install the lower dash panel.
10. Close and secure the engine cover.
11. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
9.12.2
a. 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 (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.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-27
Electrical System
9.12.3
a. Removal
9.13
9.13.1
MZ2110
6. Pull the washer reservoir (6) out and away from the
mounting studs.
7. Rotate the washer reservoir, label and remove the
cab harness connectors from the washer reservoir
connectors.
8. Remove the windshield washer hoses from the
reservoir.
b. Disassembly
DO NOT disassemble the pumps. The pump is not
serviceable. Replace pumps if found to be defective.
9-28
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.14
9.14.1
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
1. Check that the variable speed fan control is in the
OFF position.
2. Install the temperature control cable to the back of
the control.
3. Install the hex locknut on the shaft and tighten.
4. Connect the cab harness connector to the variable
speed fan control.
5. Install the screws securing the control panel to the
dash panel.
6. Properly connect the battery.
7. Turn the ignition key to the ON position and check
the fan speeds. If further repair is needed, refer to
Section 9.7, Electrical System Schematics.
8. Start the machine and allow engine to reach
operating temperature. Check heat control at
different levels.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
8
MZ0650
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-29
Electrical System
9.14.2
9.14.3
MZ2150
10
MZ2120
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
c. Transmission Mounted Speed Sensor
Installation and Testing
1. Install new o-ring on speed sensor, install sensor in
transmission, install clamp on sensor, bolt down
clamp, turn arrow on sensor 45 degrees from clamp
bolt and torque to 8-10 Nm (70-88 lb-in).
2. Connect the sensor plug to the wire harness.
3. Properly connect the battery.
4. Close and secure the engine cover.
5. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
d. Transmission Mounted Speed Sensor Calibration
A JLG Analyzer is required to perform this calibration.
There is also an embedded JLG Analyzer in the cab
display. To access the JLG Analyzer, press and hold the
C and OK buttons on the keypad simultaneously until the
JLG Analyzer Help Menu screen appears on the display.
1. Go to the Access Level menu and enter a password
of 33271.
2. Go to the Calibrations menu, select Vehicle Speed
and press the Enter button (OK button on the
embedded Analyzer).
3. Follow the instructions on the Analyzer. The
machine must be driven over a 50 meter straight line
course.
The machine cab be driven in any gear and at
any speed.
The Analyzer will prompt the operator to press
Enter or OK when starting the 50 meter drive.
Drive the machine 50 meters and stop. When the
50 meter point is reached, press the Enter or OK
button as appropriate.
4. If the calibration fails, check the Help menu for
possible faults.
9.14.4
9.14.5
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-31
Electrical System
5. Remove the lower dash panel.
b. Disassembly
DO NOT disassemble the ignition key switch. Replace a
defective switch with a new part.
9.14.6
II
III
MZ2130
MZ2140
#58
#15
II
III
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
connectors have been checked and ruled out, the
fuel level indicator is defective and must be
replaced.
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
wiring at the cab, fuse and relay panel, ignition key
switch and from the fuel level sender on the fuel tank
through the wiring in the cab.
7. Check the fuel level sender. The resistance of the
fuel level sender is <7 ohms for a full tank of fuel,
108-128 ohms for 1/2 tank and 315-345 ohms for an
empty tank. A defective fuel level sender in the fuel
tank may also prevent the fuel level indicator from
moving.
9.14.7
2. Install the rod end to the sensor arm and tighten nut.
11
9.14.8
MZ2570
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-33
Electrical System
9.15
WARNING
9.15.1
3
2
MZ6011
5 0,5 mm
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.
3. Press the test button (8) on the LSI display. This will
cause all LEDs to flash on and an audible warning to
sound. This indicates that the system is functioning
properly. If the test gives a different result, the
system is not functioning properly and the machine
must be removed from service and repaired before
continued operation.
9.15.2
LSI Sensor
15
The LSI sensor (15) is bolted on the top right of the rear
axle.
9-35
Electrical System
9.15.3
Model
a. Standard Calibration
To calibrate the LSI, certain conditions must be met:
The sensor must be installed at least 6 hours before
beginning calibration.
The machine control system must be powered on for
at least 10 minutes before calibration.
The calibration shall be conducted with the standard
carriage and forks attached and weights as
necessary.
If the machine is equipped with outriggers, they shall
remain up for the calibration procedure.
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.
The calibration must be completed within 30 minutes
after starting procedure.
Calibration Procedure:
1. With ignition key in OFF position, press and hold
TEST button on LSI display and turn ignition key to
engine START position. Release the ignition key
when engine start is achieved, but continue to hold
TEST button on LSI display until the led power
indicator on LSI display begins to flash
(approximately 2 seconds). Release TEST key
within 2 seconds of power led flashing.
2. The lower green led of the scale should be on
constant. Position the machine with empty
attachment with boom level and fully retracted, forks
level (not contacting ground).
3512PS/4012PS
3513PS/4013PS/4017PS
9-36
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Field Calibration Procedure:
Note: If the test weight is not known, follow steps 1 & 2.
Model
Xtip (1)
Xcal (2)
3508PS
2100 kg
(4630 lb)
2300 mm
(90 in)
1620 mm
(64 in)
3509PS
2000 kg
(4409 lb)
3030 mm
(119 in)
2060 mm
(81 in)
3512PS
500 kg
(1102 lb)
2985 mm
(117 in)
2100 mm
(83 in)
3513PS
500 kg
(1102 lb)
3275 mm
(129 in)
2310 mm
(91 in)
4008PS,
40.8
2100 kg
(4630 lb)
3107 mm
(122 in)
2372 mm
(93 in)
4009PS,
40.9
2000 kg
(4409 lb)
3700 mm
(146 in)
2840 mm
(112 in)
4012PS
700 kg
(1543 lb)
3145 mm
(124 in)
2340 mm
(92 in)
4013PS
700 kg
(1543 lb)
3535 mm
(139 in)
2655 mm
(105 in)
4017PS
500 kg
(1102 lb)
2715 mm
(107 in)
2070 mm
(81 in)
1
B
MAM1480
9-37
Electrical System
11. Press the TEST button on the LSI display and
release. The top red LED should flash for
approximately 8 seconds while the calibration point
is read. Following successful calibration of the
second point, the buzzer will be on constant, the red
LED will be turned off, and the green power LED will
be on constant.
9.16
12. Disengage the test weight and fully retract the boom.
Turn the ignition key to OFF. LSI is now calibrated.
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
WARNING
9.16.1
10
13
9
MZ6120
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
stop boom functions if operated close to forward
stability limitations. When LEDs begin to flash,
function can not be operated. Retract boom and/or
return the joystick to neutral position for a short
period to allow system to reset and LEDs to stop
flashing before proceeding with operation.
9.16.2
LSI Sensor
15
WARNING
TIP OVER HAZARD. If the green, orange and red
LEDs flash and warning buzzer sounds, retract and
lower boom immediately. Determine cause and
correct before continued use.
Test the LSI at the beginning of each work shift.
1.Fully retract and level the boom, with no load. Do
not raise the boom during this test.
The LSI sensor (15) is bolted on the top right of the rear
axle.
Note: If the rear axle is removed or replaced, the LSI
Sensor must be installed AFTER the rear axle is installed
and setting on all four wheels.
a. LSI Sensor Removal
1. Remove any fork carrier or attachment from the
machine.
2. Park the machine on a firm, level surface, level the
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.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-39
Electrical System
The calibration must be completed within 30 minutes
after starting procedure.
Calibration Procedure:
1. Start and position the machine to perform the
calibration procedure.
2. Remove the standard carriage, fork and weight
assembly.
3. Fully retract the boom and if equipped, lower the
outriggers. Shut the machine OFF.
4. With ignition key in OFF position, press and hold
SYSTEM CHECK button on LSI display and turn
ignition key to engine START position. Release the
ignition key when engine start is achieved, but
continue to hold SYSTEM CHECK button on LSI
display until the orange LED on LSI display goes out
and buzzer sounds (approximately 3 seconds).
Release SYSTEM CHECK button.
5. The LEDs will perform a rolling sequence. When
only the third green LED illuminates, press the
SYSTEM CHECK button.
9.16.3
a. Standard Calibration
To calibrate the LSI, certain conditions must be met:
The sensor must be installed according to Section
9.15.2, LSI Sensor.
The machine control system must be powered on for
at least 10 minutes before calibration.
The operator must remain in the cab.
The calibration shall be conducted with the standard
carriage and forks attached and weights as
necessary (a range of 60 - 80% of maximum weight
capacity.
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
Model
Xtip (1)
Xcal (2)
3508PS
3508PS
4008PS, 40.8
2000 kg
(4409 lb)
2468 mm
(97 in)
1895 mm
(75 in)
3509PS
3509PS
2000 kg
(4409 lb)
2975 mm
(117 in)
2343 mm
(92 in)
4009PS, 40.9
3512PS
NA
NA
NA
3512PS
NA
3513PS
3513PS
1000 kg
(2205 lb)
2678 mm
(105 in)
2276 mm
(90 in)
4012PS
NA
4008PS,
40.8
2660 kg
(5864 lb)
2658 mm
(5860 in)
2058 mm
(4537 in)
4013PS
4017PS
4009PS,
40.9
2100 kg
(4630 lb)
3615 mm
(142 in)
3024 mm
(119 in)
4012PS
NA
NA
NA
4013PS
2100 kg
(4630 lb)
1925 mm
(76 in)
1641 mm
(65 in)
4017PS
500 kg
(1102 lb)
2619 mm
(103 in)
2222 mm
(87 in)
b. Field 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
wheels steered straight and park brake OFF. Drive
the machine forward over a distance of at least 2 m
(6.5 ft) before entering a calibration point.
9.16.4
With the LSI calibrated, the UGM also need its LSI_CAN
CHECK PT calibrated and verified.
1. Start the machine.
2. Press the C and OK buttons simultaneously on
the keypad or the analyzer.
3. Go to ACCESS LEVEL 3 and press OK.
4. Enter the proper access code and press OK.
5. "ACCESS LEVEL 2" is now visible.
6. Go to "CALIBRATION" menu, press "OK".
7. Scroll to "LSI_CAN CHECK PT", use the arrow keys
to change "NO" to "YES".
8. SET LSI_CAN SYSTEM CHECK POINT?, use the
arrow keys to change NO to YES.
9. Follow the screen instructions:
a. Remove Weights and Attachments, press OK.
b. TELESCOPE IN and FULLY LIFT UP, press
OK.
9-42
MAM1480
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.16.5
1. Start machine
2. Press the C and OK buttons simultaneously on
the keypad or the analyzer.
9.17
MZ6040
1. Cable Connector.
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
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-43
9-44
MENU:
HELP: PRESS ENTER
MENU:
OPERATOR TOOLS
MENU:
CALIBRATIONS
SOFT-LIFT ZONE:
SET ANGLE %: xx %
SOFT-LIFT %:
SET DERATE:
xxxx mA
SOFT-LIFT ZONE:
SET ANGLE %: xx %
SOFT-LIFT %:
SET DERATE:
x.x S
x.x S
xxxx mA
xxx mA
x.x S
PLATFORM LEVEL:
DECEL UP: x.x S
x.x S
HELP:
(XXXXX)
?????????????????
VEHICLE SPEED
UNITS: MPH
TEMPERATURE:
FAHRENHEIT
OIL PRESSURE:
PSI
CABIN JOYSTICK:
TELESCOPE: ROLLER
STEER MODE:
MANUAL
PRESS ENTER TO
START TEST: ----
REMOVE WEIGHTS
AND ATTACHMENTS.
FULLY DEPLOY
STABILIZERS.
0000
SERVICE HISTORY
1: XXXX HOURS
TELESCOPE IN AND
FULLY LIFT UP.
PERFORM LSI-CAN
SYSTEM CHECK? YES
STABILIZERS:
MAX DOWN: xxxx mA
STABILIZERS:
MIN DOWN: xxx mA
STABILIZERS:
MAX UP: xxxx mA
STABILIZERS:
MIN UP: xxx mA
STABILIZERS:
DECEL DOWN:
x.x S
STABILIZERS:
DECEL UP: x.x S
STABILIZERS:
ACCEL DOWN:
TRANSFER STATUS:
CYCLE POWER NOW
STEER MODE:
AUTOMATIC
PLATFORM ROTATE:
MAX RIGHT: xxxx mA
PLATFORM ROTATE:
MIN RIGHT: xxx mA
PLATFORM ROTATE:
MAX LEFT: xxxx mA
PLATFORM ROTATE:
MIN LEFT: xxx mA
PLATFORM ROTATE:
DECEL RIGHT: x.x S
PLATFORM ROTATE:
ACCEL RIGHT: x.x S
PLATFORM ROTATE:
DECEL LEFT: x.x S
SERVICE COMPLETE
YES: ENTER, NO: ESC
CABIN JOYSTICK:
TELESCOPE: X-AXIS
PLATFORM LEVEL:
MAX DOWN: xxxx mA
PLATFORM LEVEL:
MIN DOWN: xxx mA
PLATFORM LEVEL:
MAX UP: xxxx mA
PLATFORM LEVEL:
MIN UP: xxx mA
PLATFORM LEVEL:
DECEL DOWN: x.x S
PLATFORM LEVEL:
ACCEL DOWN: x.x S
PERSONALITIES:
STABILIZERS
STABILIZERS:
ACCEL UP: x.x S
TRANSFER FROM:
UGM DISPLAY
OIL PRESSURE:
BAR
BUCKET TILT:
MAX DOWN: xxxx mA
BUCKET TILT:
MIN DOWN: xxx mA
BUCKET TILT:
MAX UP: xxxx mA
BUCKET TILT:
MIN UP: xxx mA
BUCKET TILT:
DECEL DOWN:
x.x S
BUCKET TILT:
DECEL UP: x.x S
BUCKET TILT:
ACCEL DOWN:
PERSONALITIES:
PLATFORM ROTATE
PLATFORM ROTATE:
ACCEL LEFT: x.x S
TRANSFER FROM:
DISPLAY UGM
TEMPERATURE:
CELCIUS
FORK TILT:
MAX DOWN:
FORK TILT:
MIN DOWN:
FORK TILT:
MAX UP: xxxx mA
FORK TILT:
MIN UP: xxx mA
FORK TILT:
DECEL DOWN:
x.x S
PERSONALITIES:
PLATFORM LEVEL
PLATFORM LEVEL:
ACCEL UP: x.x S
ENTER CURRENT
CODE:
0000
VEHICLE SPEED
UNITS: KPH
FORK TILT:
DECEL UP:
FORK TILT:
ACCEL DOWN:
PERSONALITIES:
BUCKET TILT
BUCKET TILT:
ACCEL UP: x.x S
ENTER NEW
CODE
SET SERVICE
INTERVAL: 100H
PLAT. TELESCOPE:
MAX OUT: xxxx mA
PLAT. TELESCOPE:
MIN OUT: xxx mA
PLAT. TELESCOPE:
MAX IN: xxxx mA
PLAT. TELESCOPE:
MIN IN: xxx mA
PLAT. TELESCOPE:
DECEL OUT: x.x S
PLAT. TELESCOPE:
ACCEL OUT: x.x S
PLAT. TELESCOPE:
DECEL IN: x.x S
x.x S
PERSONALITIES:
FORK TILT
FORK TILT:
ACCEL UP:
CONFIRM MACHINE
SERVICE?
REVIEW
SERVICE HISTORY?
PRESS ENTER TO
SET CHECK POINT
TELESCOPE IN AND
FULLY LIFT UP.
REMOVE WEIGHTS
AND ATTACHMENTS.
SET LSI-CAN
CHECK POINT: NO
CALIBRATIONS:
LSI-CAN CHECK PT
BUCKET TELE:
MAX DOWN: xxxx mA
BUCKET TELE:
MIN DOWN: xxx mA
BUCKET TELE:
MAX UP: xxxx mA
PERSONALITIES:
PLAT. TELESCOPE
PLAT. TELESCOPE:
ACCEL IN: x.x S
PERFORM HARDWARE
EXCHANGE: NO
CALIBRATION:
COMPLETE
x.x S
x.x S
BUCKET TELE:
MIN UP: xxx mA
BUCKET TELE:
DECEL DOWN:
BUCKET TELE:
ACCEL DOWN:
BUCKET TELE:
DECEL UP: x.x S
BUCKET TELE:
ACCEL UP: x.x S
PERSONALITIES:
BUCKET TELESCOPE
CHANGE
ANTI-THEFT CODE?
FORWARD TO START
NEUTRAL TO PAUSE
SHIFT TO
SECOND GEAR
SET PARK
BRAKE
PERFORM PARK
BRAKE TEST?
CALIBRATIONS:
PARK BRAKE TEST
TELESCOPE:
MAX OUT: xxxx mA
TELESCOPE:
MIN OUT: xxx mA
TELESCOPE:
MAX IN: xxxx MA
TELESCOPE:
MIN IN: xxx mA
TELESCOPE:
DECEL OUT: x.x S
BOOM ANGLE:
CALIBRATING
CALIBRATION:
IN PROGRESS
BOOM ANGLE:
CALIBRATING
TELESCOPE:
DECEL IN: x.x S
TELESCOPE:
ACCEL OUT: x.x S
WARNING: DRIVE
WILL BE ENGAGED
CONFIRM PLATFORM
IS EMPTY: NO
PRESS ENTER AT
LOWEST POSITION.
CALIBRATION:
COMPLETE
PERSONALITIES:
TELESCOPE
TELESCOPE:
ACCEL IN: x.x S
CALIBRATIONS:
LSS
PLATFORM TYPE:
450 - EXTENDABLE
CALIBRATIONS:
BOOM ANGLE
CALIBRATE BOOM
ANGLE SENSOR?
xx %
CALIBRATIONS:
TILT SENSOR
SOFT-LIFT %:
SET DERATE:
SOFT-LIFT ZONE:
SET ANGLE %: xx %
PLATFORM LIFT:
MAX DOWN: xxxx mA
PLATFORM LIFT:
MIN DOWN: xxx mA
PLATFORM LIFT:
MAX UP: xxxx mA
PLATFORM LIFT:
MIN UP: xxx mA
PLATFORM LIFT:
DECEL DOWN: x.x S
CALIBRATE TILT
SENSOR?
xx %
BUCKET LIFT:
MIN DOWN: xxx mA
BUCKET LIFT:
MAX DOWN: xxxx mA
xxx mA
MAIN LIFT:
MIN DOWN:
MAIN LIFT:
MAX DOWN:
xx %
BUCKET LIFT:
MAX UP: xxxx mA
MAIN LIFT:
MAX UP: xxxx mA
x.x S
BUCKET LIFT:
MIN UP: xxx mA
BUCKET LIFT:
DECEL DOWN:
MAIN LIFT:
MIN UP: xxx mA
x.x S
x.x S
MAIN LIFT:
DECEL DOWN:
x.x S
PLATFORM LIFT:
DECEL UP: x.x S
PLATFORM LIFT:
ACCEL DOWN: x.x S
BUCKET LIFT:
DECEL UP: x.x S
BUCKET LIFT:
ACCEL DOWN:
x.x S
MAIN LIFT:
ACCEL DOWN:
MAIN LIFT:
DECEL UP:
x.x S
PERSONALITIES:
PLATFORM LIFT
PLATFORM LIFT:
ACCEL UP: x.x S
PERSONALITIES:
BUCKET LIFT
BUCKET LIFT:
ACCEL UP: x.x S
PERSONALITIES:
MAIN LIFT
MENU:
PERSONALITIES
MAIN LIFT:
ACCEL UP:
ACCESS LEVEL:
CODE: 00000
MENU:
ACCESS LEVEL 3
x.x S
x.x S
FRAME LEVEL:
MAX RIGHT: xxxx mA
FRAME LEVEL:
MIN RIGHT: xxx mA
FRAME LEVEL:
MAX LEFT: xxxx mA
FRAME LEVEL:
MIN LEFT: xxx mA
FRAME LEVEL:
DECEL RIGHT:
FRAME LEVEL:
ACCEL RIGHT:
FRAME LEVEL:
DECEL LEFT: x.x S
FRAME LEVEL:
ACCEL LEFT: x.x S
PERSONALITIES:
FRAME LEVEL
AUX. FUNCTION1:
MAX COIL B: xxxx mA
AUX. FUNCTION1:
MIN COIL B: xxx mA
AUX. FUNCTION1:
MAX COIL A: xxxx mA
AUX. FUNCTION1:
MIN COIL A: xxx mA
AUX. FUNCTION1:
DECEL COIL B: x.x S
AUX. FUNCTION1:
ACCEL COIL B: x.x S
AUX. FUNCTION1:
DECEL COIL A: x.x S
AUX. FUNCTION1:
ACCEL COIL A: x.x S
PERSONALITIES:
AUX. FUNCTION1
Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.
PERSONALITIES:
AUX. FUNCTION2
AUX. FUNCTION2:
MAX COIL B: xxxx mA
AUX. FUNCTION2:
MIN COIL B: xxx mA
AUX. FUNCTION2:
MAX COIL A: xxxx mA
AUX. FUNCTION2:
MIN COIL A: xxx mA
AUX. FUNCTION2:
DECEL COIL B: x.x S
AUX. FUNCTION2:
ACCEL COIL B: x.x S
AUX. FUNCTION2:
DECEL COIL A: x.x S
AUX. FUNCTION2:
ACCEL COIL A: x.x S
AUX. MOMENTARY:
COIL B:
xxxx mA
AUX. MOMENTARY:
COIL A:
xxxx mA
PERSONALITIES:
AUX. MOMENTARY
9.17.2
- Not ACCESSABLE
Electrical System
Analyzer Software Version 3.5 (Sheet 1 of 2)
MAM2831-3.5
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
MARKET:
ANSI
MARKET:
AUSTRALIA
MODEL:
TH336
MODEL:
TH337
ENGINE CONTROL:
MECHANICAL
BOOM RETRACTED
SWITCH: CLOSED
BOOM EXTENDED
SWITCH: OPEN
AM BOOM EXTENDED
SWITCH: OPEN
TRANSPORT MODE:
IN TRANSPORT
TELESCOPE
STATUS: RETRACTED
PLATFORM LEVEL
ACTUAL: XXXXMA
ROTATE LEFT
SWITCH: OPEN
ROTATE RIGHT
SWITCH: OPEN
PLATFORM ROTATE
COMMANDED: XXXXMA
PLATFORM ROTATE
ACTUAL: XXXXMA
HORN
SWITCH: OPEN
ENGINE PREHEAT
SWITCH: OPEN
COUPLING PIN
ENGAGED: NO
FORK TILT
ACTUAL: XXXXMA
AUX. HYDRAULICS
INPUT: XXX%
AUX. HYDRAULICS
COMMANDED: XXXXMA
AUX. HYDRAULICS
ACTUAL: XXXXMA
CONTINUOUS AUX.
INPUT: LOW
CONTINUOUS AUX.
FEATURE: ACTIVE
AUX. FUNCTION
SELECT: FUNCTION1
AUXILIARY POWER
SWITCH: OPEN
CABIN JOYSTICK:
Y AXIS: NEUTRAL
CABIN JOYSTICK:
L ROLLER: 0 %
CABIN JOYSTICK:
L ROLLER: NEUTRAL
CABIN JOYSTICK:
R ROLLER: 0%
CABIN JOYSTICK:
R ROLLER: NEUTRAL
CABIN JOYSTICK:
S1 BUTTON: OFF
CABIN JOYSTICK:
TRIGGER: OFF
CABIN JOYSTICK:
S ROCKER: LOW
CABIN JOYSTICK:
T ROCKER:
LOW
DESIRED STEER
MODE: 2 - WHEEL
CURRENT STEER
MODE: 2 - WHEEL
STEER PRESSURE
SWITCH: OPEN
STEER PRESSURE
STATUS: OK
SERVICE BRAKE
SWITCH: CLOSED
SERVICE BRAKE
STATUS: OFF
TRANSMISSION OIL
TEMP.: XXX.X C
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
XXXXMA
LOW
PLATFORM MODULE
VOLTAGE: XX.XV
HYDRAULIC FILTER
SWITCH: CLOSED
CHASSIS TILT:
Y AXIS: XX.X DEG
CHASSIS TILT:
X AXIS: XX.X DEG
PARK BRAKE
STATUS: ON
BOOM ANGLE:
XX.X DEGREES
FUNCTION ENABLE
PLATFORM: CLOSED
FUNCTION ENABLE
GROUND: OPEN
J1-21 PLATFORM
ATTACHED: HIGH
PLATFORM STATUS:
NOT ATTACHED
RESPONSE CURVE:
TELEHANDLER
OPERATING MODE:
CABIN MODE
STATION CONTROL:
CABIN
AMBIENT
TEMPERATURE: XXXC
CHASSIS TILT:
XX.X DEG
ENGINE SPEED
ACTUAL: XXXX RPM
FUEL LEVEL
SENSOR: FULL
AMBIENT
TEMPERATURE: XXXC
OIL PRESSURE:
XXXX PSI
COOLANT
TEMPERATURE: XXXC
BATTERY VOLTAGE:
XX.XV
AIR FILTER
SWITCH: OPEN
ENGINE PREHEAT
SWITCH: OPEN
JOYSTICK LOCK
ENGAGED: NO
FRAME LEVEL
OPERATION: OK
JOYSTICK LOCK
ENGAGED: NO
SPEED CONTROL
ACTUAL: XXXXMA
FRAME LEVEL
COMMANDED: XXXXMA
FRAME LEVEL
RIGHT COIL: OFF
FRAME LEVEL
LEFT COIL: OFF
FRAME LEVEL
RIGHT INPUT:
PARK BRAKE
SWITCH: CLOSED
STABILIZER INPUT
2 DEPLOYED: NO
STABILIZER INPUT
1 DEPLOYED: NO
STABILIZER
OPERATION: OK
JOYSTICK LOCK
ENGAGED: NO
SPEED CONTROL
ACTUAL: XXXXMA
STABILIZER
COMMANDED: XXXXMA
RIGHT STABILIZER
DOWN COIL: OFF
RIGHT STABILIZER
UP COIL: OFF
LEFT STABILIZER
DOWN COIL: OFF
LEFT STABILIZER
UP COIL: OFF
QUICK CONNECT
OFF INPUT: HIGH
PLATFORM LEVEL
COMMANDED: XXXXMA
LEVEL DOWN
SWITCH: OPEN
LEVEL UP
SWITCH: OPEN
TELESCOPE
ACTUAL: XXXXMA
TELESCOPE
COMMANDED: XXXXMA
TELESCOPE
INPUT: XXX%
MAIN LIFT
ACTUAL: XXXXMA
MAIN LIFT
COMMANDED:
QUICK CONNECT
ON INPUT: LOW
FORK TILT
COMMANDED: XXXXMA
FORK TILT
INPUT: XXX%
TELESCOPE
ACTUAL: XXXXMA
TELESCOPE
COMMANDED: XXXXMA
TELESCOPE
INPUT: XXX%
MAIN LIFT
ACTUAL: XXXXMA
XXXXMA
MAIN LIFT
INPUT: XXX%
MAIN LIFT
COMMANDED:
GROUND MODULE
VOLTAGE: XX.XV
CABIN JOYSTICK:
Y AXIS: 0 %
OPERATING STATE:
ENGINE STOPPED
CABIN JOYSTICK:
X AXIS: NEUTRAL
FRAME LEVEL
LEFT INPUT: LOW
GEAR SELECTION
INPUT: 2
STABILIZER
INPUT: XXX%
DIRECTION / GEAR
ACTUAL: FORWARD / 2
MAIN LIFT
INPUT: XXX%
RESPONSE CURVE:
TELEHANDLER
DIAGNOSTICS:
SYSTEM
AUX. FUNCTION
SELECT: YES
AUX. FUNCTION
SELECT: NO
DIAGNOSTICS:
CABIN JOYSTICK
DIAGNOSTICS:
ENGINE
HYDRAULIC QUICK
CONNECT: YES
HYDRAULIC QUICK
CONNECT: NO
CABIN JOYSTICK:
X AXIS: 0 %
DIAGNOSTICS:
FRAME LEVEL
PLATFORM OPTION:
ENABLED
PLATFORM OPTION:
DISABLED
DIAGNOSTICS:
DRIVE / STEER
DIAGNOSTICS:
STABILIZERS
LOAD MONITORING:
LSI-CAN + LMI
LOAD MONITORING:
LSI
LOAD MONITORING:
LMI
LOAD MONITORING:
LSI-CAN
DRIVE DIRECTION
INPUT: FORWARD
DIAGNOSTICS:
PLATFORM
TRANSMISSION:
POWERSYNCHRO
MENU:
DIAGNOSTICS
DIAGNOSTICS:
CABIN FUNCTIONS
ENGINE CONTROL:
ELECTRONIC
SYSTEM TEST:
ACTIVATE ?
MODEL:
TH417
MODEL:
TH514
MODEL:
TH414
MODEL:
TH407
MODEL:
TH406
MARKET:
CE
MODEL:
UNKNOWN
MENU:
SYSTEM TEST
MENU:
MACHINE SETUP
LOAD MOMENT %:
XX.X
LOAD MOMENT
OVERRIDE: NO
LOAD MOMENT
STATUS: STABLE
DIAGNOSTICS:
LOAD MOMENT
BOOM RETRACTED
SWITCH: YES
BOOM RETRACTED
SWITCH: NO
BOOM RIDE
STATUS: OFF
BOOM RIDE
SWITCH: LOW
DIAGNOSTICS:
BOOM RIDE
BOOM EXTENSION
SWITCH: YES
BOOM EXTENSION
SWITCH: NO
BOOM FLOAT
SWITCH: OFF
BOOM FLOAT
SWITCH: LOW
DIAGNOSTICS:
BOOM FLOAT
LOAD SENSING:
PLATFORM CUTOUT
LOAD SENSING:
WARN ONLY
LOAD SENSING:
NONE
PLATFORM LOAD
CELL 4: XXX.XKG
PLATFORM LOAD
CELL 3: XXX.X KG
PLATFORM LOAD
CELL 2: XXX.X KG
PLATFORM LOAD
CELL 1: XXX.X KG
PLATFORM LOAD
OFFSET: XXXXXX
PLATFORM LOAD
GROSS: XXX.X KG
PLATFORM LOAD
ACTUAL: XXX.X KG
PLATFORM LOAD
STATE: OK
DIAGNOSTICS:
PLATFORM LOAD
BOOM RIDE:
YES
BOOM RIDE:
NO
CAN2 STATISTICS:
MSG ERROR: XXXX
CAN2 STATISTICS:
PASSIVE: X
CAN2 STATISTICS:
BUS OFF: X
CAN2 STATISTICS:
TX/SEC: X
CAN2 STATISTICS:
RX/SEC: X
CAN1 STATISTICS:
MSG ERROR: XXXX
CAN1 STATISTICS:
PASSIVE: X
CAN1 STATISTICS:
BUS OFF: X
CAN1 STATISTICS:
TX/SEC: X
CAN1 STATISTICS:
RX/SEC: X
DIAGNOSTICS:
CAN STATISTICS
BOOM FLOAT:
YES
BOOM FLOAT:
NO
CALIBRATION DATA
LIFT CAL2: XXX
CALIBRATION DATA
LIFT CAL1: XXX
DIAGNOSTICS:
CALIBRATION DATA
Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.
- Not ACCESSABLE
DIAGNOSTICS:
DATALOG
DATALOG:
ERASE RENTAL?
DATALOG:
ANTI-THEFT: 0000
DATALOG:
RENTAL: XXXXH XXM
DATALOG:
MAX VOLTS: XX.XV
DATALOG:
MIN TEMP: XXC
DATALOG:
MAX TEMP: XXC
DATALOG: PLATFORM
XXXXXXH XXM
DATALOG: AUX.
XXXXXXH XXM
DATALOG: TELE.
XXXXXXH XXM
DATALOG: LIFT
XXXXXXH XXM
DATALOG: DRIVE
XXXXXXH XXM
DATALOG: ENGINE
XXXXXXH XXM
DATALOG: ON-TIME
XXXXXXH XXM
DIAGNOSTICS:
VERSIONS
ANALYZER:
ANALYZER V6.3
LSS MODULE
HARDWARE: REV X
LSS MODULE
SOFTWARE: PX.X
CABIN DISPLAY
SOFTWARE: PX.X
CABIN JOYSTICK
SOFTWARE: PX.X
PLATFORM MODULE
P/N: XXXXXXXXXX
PLATFORM MODULE
S/N: XXXXXX
PLATFORM MODULE
HARDWARE: REV X
PLATFORM MODULE
SOFTWARE: PX.X
GROUND MODULE
P/N: XXXXXXXXXX
GROUND MODULE
S/N: XXXXXX
GROUND MODULE
HARDWARE: REV X
GROUND MODULE
CNST. DATA: PX.X
GROUND MODULE
SOFTWARE: PX.X
Electrical System
(Sheet 2 of 2)
MAM2841-3.5
9-45
Electrical System
9.18
FAULT CODES
9.18.1
14
12
13
6
8
11
10 9
9-46
MAM1420
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.18.2
Message
Fault
Code
HELP COMMENT
00XXX
EVERYTHING OK
001
POWER UP
Indicators
Latch Until
21XXX
POWER CYCLE
211
FUNCTION ENABLE
INPUTS INVALID
SIGNAL STATES
214
Power cycled.
JOYSTICK AXES
NOT IN NEUTRAL
POSITION AT
POWER UP
215
A CAN
message is
received
indicating the
X axis and Y
axis are in the
neutral
position.
JOYSTICK ROLLER
NOT IN NEUTRAL
POSITION AT
POWER UP
216
A CAN
message is
received
indicating the
roller is in the
neutral
position.
JOYSTICK S1
BUTTON ACTIVE AT
POWER UP
217
A CAN
message is
received
indicating the
joystick S1
button is not
activated.
JOYSTICK S2
BUTTON ACTIVE AT
POWER UP
218
A CAN
message is
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
Code
Indicators
Latch Until
JOYSTICK S3
BUTTON ACTIVE AT
POWER UP
219
A CAN
message is
received
indicating the
joystick S3
button is not
activated.
JOYSTICK S4
BUTTON ACTIVE AT
POWER UP
2110
A CAN
message is
received
indicating the
joystick S4
button is not
activated.
ENGINE START
PREVENTED
PLATFORM START
SWITCH HIGH AT
POWER UP
2111
Power cycled.
PLATFORM ROTATE
LEFT PREVENTED
INPUT HIGH AT
POWER UP
2112
The input
goes LOW for
a period of at
least 1
second.
PLATFORM ROTATE
RIGHT PREVENTED
INPUT HIGH AT
POWER UP
2113
The input
goes LOW for
a period of at
least 1
second.
PLATFORM LEVEL
UP PREVENTED
INPUT HIGH AT
POWER UP
2114
The input
goes LOW for
a period of at
least 1
second.
PLATFORM LEVEL
DOWN PREVENTED
INPUT HIGH AT
POWER UP
2115
The input
goes LOW for
a period of at
least 1
second.
9-48
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
2116
If a platform is configured as
ENABLED and the UGM detects
J4-16 Auxiliary Power Unit (APU)
Enable is HIGH at system power up.
The input
goes LOW for
a period of at
least 1
second.
PLATFORM
JOYSTICK NOT IN
NEUTRAL
POSITION AT
POWER UP
2117
Joystick is
detected to be
in neutral
position.
ENGINE
PRE-HEAT
PREVENTED
INPUT HIGH AT
POWER UP
2118
The input
goes LOW for
a period of at
least 1
second.
FRAME LEVEL
RIGHT INPUT
INVALID SIGNAL
2119
Power cycled.
FRAME LEVEL
LEFT INPUT
INVALID SIGNAL
2120
Power cycled.
HYDRAULIC QUICK
CONNECT INPUT
INVALID
SIGNAL
2121
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-49
Electrical System
Message
Fault
Code
Indicators
Latch Until
CONTINUOUS
AUXILIARY
HYDRAULICS
SWITCH HIGH AT
POWER UP
2122
The input
goes LOW for
a period of at
least 1
second.
JOYSTICK
TRIGGER SWITCH
ACTIVE AT POWER
UP
2123
A CAN
message is
received
indicating the
joystick
trigger switch
is not
activated.
JOYSTICK LEFT
ROLLER NOT IN
THE NEUTRAL
POSITION AT
POWER UP
2124
Latch fault
until a joystick
CAN message
is received
indicating the
roller is in the
neutral
position.
JOYSTICK RIGHT
ROLLER NOT IN
THE NEUTRAL
POSITION AT
POWER UP
2125
Latch fault
until a joystick
CAN message
is received
indicating the
roller is in the
neutral
position.
BOOM RIDE
ENABLE SWITCH
NOT IN THE OFF
POSITION AT
POWER UP
2130
Boom Ride
Enable Switch
is detected in
its OFF
position.
PLATFORM
CONTROLS
22XXX
PLATFORM LEVEL
CONFLICTING
INPUT SIGNALS
2225
Power cycled.
PLATFORM ROTATE
CONFLICTING
INPUT SIGNALS
2226
Power cycled.
9-50
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
FUNCTION ENABLE
INTERLOCK
ENABLE SWITCH
NOT SELECTED
FIRST
2227
The hydraulic
function
request is no
longer active.
FUNCTION ENABLE
INTERLOCK NOT
SELECTED IN TIME
2228
The function
enable switch
is released.
ENGINE START
PREVENTED
FUNCTION ENABLE
SWITCH ENGAGED
2229
The function
enable switch
is released.
PLATFORM
JOYSTICK OUT
OF RANGE HIGH
2230
Hydraulic functions
(Lift and Telescope) associated to
the dual-axis platform joystick are
inhibited.
Power cycle.
PLATFORM
JOYSTICK
CENTER TAP BAD
2231
Hydraulic functions
(Lift and Telescope) associated to
the dual-axis platform joystick are
inhibited.
Power cycle.
FUNCTION ENABLE
RELAY INVALID
SIGNAL
2233
Power cycle.
A valid drive
direction of
Neutral exists
(J4-4 is the
only HIGH
shifter input).
GROUND
CONTROLS
OPERATING MODE
INTERLOCK
SHIFTER NOT IN
NEUTRAL
23XXX
239
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-51
Electrical System
Message
Fault
Code
Indicators
Latch Until
PLATFORM OPTION
NOT
CONFIGURED
2311
Power cycle.
STABILIZERS NOT
CONFIGURED
2312
The S1
button on the
cabin joystick
is released.
2313
J4-17 or J4-9
goes LOW.
OPERATING
STATION
SELECTION
INVALID
2314
Power cycle.
9-52
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
OPERATING MODE
INTERLOCK STABILIZERS NOT
DEPLOYED
2315
1, 15
OPERATING MODE
INTERLOCK - PLATFORM NOT
ATTACHED
2316
The UGM
detects the
platform as
electrically
attached.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-53
Electrical System
Message
Fault
Code
Indicators
Latch Until
OPERATING MODE
INTERLOCK CHASSIS NOT
LEVEL
2317
1, 16
The UGM
detects the
machines
chassis tilt
level is within
range.
OPERATING MODE
INTERLOCK BOOM ANGLE TOO
HIGH
2318
OPERATING MODE
INTERLOCK BOOM NOT FULLY
RETRACTED
2319
9-54
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
OPERATING MODE
INTERLOCK - PARK
BRAKE NOT SET
2320
J4-5 Park
Brake is HIGH
(set).
ERRATIC
PLATFORM
ATTACHED
SIGNAL
2321
Power cycled.
CONFLICTING
FRAME LEVEL
SIGNALS
2322
Power cycled.
CABIN JOYSTICK
X AXIS FAULT
2323
Power cycled.
CABIN JOYSTICK
Y AXIS FAULT
2324
Power cycled.
CABIN JOYSTICK
ROLLER FAULT
2325
Power cycled.
CABIN JOYSTICK
S1 BUTTON FAULT
2326
Power cycled.
CABIN JOYSTICK
S2 BUTTON FAULT
2327
Power cycled.
CABIN JOYSTICK
S3 BUTTON FAULT
2328
Power cycled.
CABIN JOYSTICK
S4 BUTTON FAULT
2329
Power cycled.
CABIN JOYSTICK
S SWITCH FAULT
2330
Power cycled.
CABIN JOYSTICK
T SWITCH FAULT
2331
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-55
Electrical System
Message
Fault
Code
Indicators
Latch Until
HYDRAULIC
FILTER
RESTRICTION
2332
1, 6
N/A
J2-24
Hydraulic
Filter
Restriction
input is LOW
for 1 second.
2333
Power cycled.
CRAB STEER
INPUT INVALID
SIGNAL
2334
Power cycled.
JOYSTICK LOCK
INPUT INVALID
SIGNAL
2335
Power cycled.
LOAD MOMENT
SHUTOFF INPUT
INVALID SIGNAL
2336
Power cycled.
BUCKET MODE
INPUT INVALID
SIGNAL
2337
Power cycled.
2WHEEL STEER
INPUT INVALID
SIGNAL
2338
Power cycled.
KEYPAD OK
BUTTON INVALID
SIGNAL
2339
Power cycled.
9-56
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
KEYPAD CANCEL
BUTTON INVALID
SIGNAL
2340
Power cycled.
KEYPAD UP
BUTTON INVALID
SIGNAL
2341
Power cycled.
KEYPAD DOWN
BUTTON INVALID
SIGNAL
2342
Power cycled.
BOOM ANGLE
SENSOR NOT
CALIBRATED
2343
A valid boom
angle sensor
calibration is
completed.
BOOM ANGLE
SENSOR OUT OF
RANGE HIGH
2344
Power cycled.
BOOM ANGLE
SENSOR OUT OF
RANGE LOW
2345
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-57
Electrical System
Message
BOOM ANGLE
SENSOR NOT
RESPONDING
9-58
Fault
Code
Indicators
Latch Until
2346
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
SYSTEM
INTERLOCK SET
JOYSTICK INPUTS
TO NEUTRAL
2347
Joystick
inputs are in
the
neutral
position.
ENGINE START
INPUT INVALID
SIGNAL
2348
N/A
J4-8 Engine
Start goes
LOW for 1
second.
LIFT ANGLE
DERATED
STABILIZERS NOT
DEPLOYED
2349
N/A
Inputs J7-7
and J7-20
indicate the
stabilizers are
deployed.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-59
Electrical System
Message
Fault
Code
Indicators
Latch Until
CABIN JOYSTICK
LEFT ROLLER
FAULT
2350
Power cycled.
CABIN JOYSTICK
RIGHT ROLLER
FAULT
2351
Power cycled.
CABIN JOYSTICK
TRIGGER SWITCH
FAULT
2352
Power cycled.
BOOM ANGLE
SENSOR
INTERNAL FAILURE
2353
Power cycled.
OPERATING
INTERLOCK
ATTACHMENT
COUPLING PIN NOT
ENGAGED
2354
J1-1 of the
platform
module goes
HIGH for a
period of 3
seconds.
OPERATING
INTERLOCK
PLATFORM NOT
COUPLED
2384
The UGM
detects the
platform as
coupled for 2
seconds.
9-60
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
ERRATIC
PLATFORM
COUPLED SIGNAL
2385
Power cycled.
LOSS OF
PLATFORM
COUPLED SIGNAL
2386
N/A
Power cycled.
FUNCTION
PREVENTED
25XXX
MODEL CHANGED
HYDRAULICS
SUSPENDED
CYCLE EMS
259
Power cycled.
FUNCTIONS
LOCKED OUT
CONSTANT DATA
VERSION
IMPROPER
2520
Proper
Constant
Version is
loaded and
power is
cycled.
ENGINE START
PREVENTED
PARK BRAKE NOT
SET
2525
J4-5 Park
Brake is HIGH
(set).
BOOM EXTENDED
SWITCH
CONFLICTING
STATE
2526
N/A
Power cycled.
EXCESSIVE BOOM
ANGLE FOR
HYDRAULIC QUICK
CONNECT
OPERATION
2527
J7-35
Hydraulic
Quick
Connect ON
is LOW and
J3-10
Hydraulic
Quick
Connect OFF
is HIGH.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-61
Electrical System
Message
Fault
Code
Indicators
Latch Until
PLATFORM
ATTACHED HYDRAULIC QUICK
CONNECT CUTOUT
2528
J7-35
Hydraulic
Quick
Connect ON
is LOW and
J3-10
Hydraulic
Quick
Connect OFF
is HIGH.
ENGINE START
PREVENTED
SHIFT LEVER NOT
IN NEUTRAL
2529
Shift lever is in
neutral
position.
PLATFORM
ATTACHED ANGLE
LIMIT EXCEEDED
2533
BOOM EXTENSION
LIMIT SWITCHES
CONFLICTING
STATES
2557
Power cycled.
9-62
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
TELESCOPE
POSITION
SWITCHES
CONFLICTING
STATES
2558
Power cycled.
BOOM RETRACTED
SENSOR FAULTY
SENSING INVALID
2560
Power cycled.
UGM OUTPUT
DRIVERS
33XXX
MAIN LIFT UP
VALVE
OPEN CIRCUIT
33181
Power cycled.
33182
Power cycled.
MAIN LIFT UP
VALVE SHORT TO
GROUND
33183
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-63
Electrical System
Message
Fault
Code
Indicators
Latch Until
33184
Power cycled.
33185
Power cycled.
MAIN TELESCOPE
OUT VALVE OPEN
CIRCUIT
33186
Power cycled.
MAIN TELESCOPE
VALVES SHORT
TO BATTERY
33187
Power cycled.
MAIN TELESCOPE
OUT VALVE
SHORT TO
GROUND
33188
Power cycled.
MAIN TELESCOPE
IN VALVE OPEN
CIRCUIT
33189
Power cycled.
MAIN TELESCOPE
IN VALVE SHORT
TO GROUND
33190
Power cycled.
FORK TILT UP
VALVE
OPEN CIRCUIT
33191
Power cycled.
9-64
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
33192
Power cycled.
FORK TILT UP
VALVE SHORT TO
GROUND
33193
Power cycled.
33194
Power cycled.
33195
Power cycled.
33196
Power cycled.
AUXILIARY
FUNCTIO-A/B
VALVES SHORT
TO BATTERY
33197
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-65
Electrical System
Message
Fault
Code
Indicators
Latch Until
AUXILIARY
FUNCTION-A
VALVE SHORT TO
GROUND
33198
Power cycled.
AUXILIARY
FUNCTION-B VALVE
OPEN CIRCUIT
33199
Power cycled.
AUXILIARY
FUNCTION-B VALVE
SHORT TO
GROUND
33200
Power cycled.
STABILIZER/FRAME
LEVEL SPEED
VALVE
OPEN CIRCUIT
33201
Power cycled.
STABILIZER/FRAME
LEVEL SPEED
VALVE SHORT TO
BATTERY
33202
Power cycled.
STABILIZER/FRAME
LEVEL SPEED
VALVE SHORT TO
GROUND
33203
Power cycled.
9-66
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
HYDRAULIC QUICK
CONNECT SELECT
OPEN CIRCUIT
33204
Power cycled.
HYDRAULIC QUICK
CONNECT SELECT
SHORT TO
BATTERY
33205
Power cycled.
HYDRAULIC QUICK
CONNECT SELECT
SHORT TO
GROUND
33206
Power cycled.
HORN
OPEN CIRCUIT
33207
Power cycled.
HORN SHORT TO
BATTERY
33208
Power cycled.
HORN SHORT TO
GROUND
33209
Power cycled.
REVERSE ALARM
AND LIGHTS
OPEN CIRCUIT
33210
Power cycled.
REVERSE ALARM
AND LIGHTS
SHORT TO
BATTERY
33211
Power cycled.
REVERSE ALARM
AND LIGHTS
SHORT TO
GROUND
33212
Power cycled.
DUMP VALVE
OPEN CIRCUIT
33213
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-67
Electrical System
Message
Fault
Code
Indicators
Latch Until
DUMP VALVE
SHORT TO
BATTERY
33214
Power cycled.
DUMP VALVE
SHORT TO
GROUND
33215
Power cycled.
AUXILIARY
FUNCTION SELECT
OPEN CIRCUIT
33216
Power cycled.
AUXILIARY
FUNCTION SELECT
SHORT TO
BATTERY
33217
Power cycled.
AUXILIARY
FUNCTION SELECT
SHORT TO
GROUND
33218
Power cycled.
9-68
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
AUXILIARY
ELECTRICS OPEN
CIRCUIT
33219
Power cycled.
AUXILIARY
ELECTRICS
SHORT TO
BATTERY
33220
Power cycled.
AUXILIARY
ELECTRICS
SHORT TO
GROUND
33221
Power cycled.
LEFT STABILIZER
DOWN VALVE
OPEN CIRCUIT
33222
Power cycled.
LEFT STABILIZER
DOWN VALVE
SHORT TO
BATTERY
33223
Power cycled.
LEFT STABILIZER
DOWN VALVE
SHORT TO
GROUND
33224
Power cycled.
LEFT STABILIZER
UP VALVE OPEN
CIRCUIT
33225
Power cycled.
LEFT STABILIZER
UP VALVE SHORT
TO BATTERY
33226
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-69
Electrical System
Message
Fault
Code
Indicators
Latch Until
LEFT STABILIZER
UP VALVE SHORT
TO GROUND
33227
Power cycled.
RIGHT STABILIZER
DOWN VALVE
OPEN CIRCUIT
33228
Power cycled.
RIGHT STABILIZER
DOWN VALVE
SHORT TO
BATTERY
33229
Power cycled.
RIGHT STABILIZER
DOWN VALVE
SHORT TO
GROUND
33230
Power cycled.
RIGHT STABILIZER
UP VALVE OPEN
CIRCUIT
33231
Power cycled.
RIGHT STABILIZER
UP VALVE SHORT
TO BATTERY
33232
Power cycled.
9-70
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
RIGHT STABILIZER
UP VALVE SHORT
TO GROUND
33233
Power cycled.
FRAME LEVEL
LEFT VALVE
OPEN CIRCUIT
33234
Power cycled.
FRAME LEVEL
LEFT VALVE
SHORT TO
BATTERY
33235
Power cycled.
FRAME LEVEL
LEFT VALVE
SHORT TO
GROUND
33236
Power cycled.
FRAME LEVEL
RIGHT VALVE
OPEN CIRCUIT
33237
Power cycled.
FRAME LEVEL
RIGHT VALVE
SHORT TO
BATTERY
33238
Power cycled.
FRAME LEVEL
RIGHT VALVE
SHORT TO
GROUND
33239
Power cycled.
TRANSMISSION C
COIL
OPEN CIRCUIT
33240
A TRANSMISSION configuration of
POWERSHIFT is configured and a
GEAR SELECTION of 4F/3R is
configured and the UGM detects an
open circuit at this output.
Power cycled.
TRANSMISSION C
COIL SHORT TO
BATTERY
33241
A TRANSMISSION configuration of
POWERSHIFT is configured and a
GEAR SELECTION of 4F/3R is
configured and the UGM detects a
short to battery at this output.
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-71
Electrical System
Message
Fault
Code
Indicators
Latch Until
TRANSMISSION C
COIL SHORT TO
GROUND
33242
A TRANSMISSION configuration of
POWERSHIFT is configured and a
GEAR SELECTION of 4F/3R is
configured and the UGM detects a
short to ground at this output.
Power cycled.
TRANSMISSION B
COIL
OPEN CIRCUIT
33243
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION B
COIL SHORT TO
BATTERY
33244
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to battery
at this output.
Power cycled.
TRANSMISSION B
COIL SHORT TO
GROUND
33245
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to ground
at this output.
Power cycled.
TRANSMISSION
REVERSE COIL
OPEN CIRCUIT
33246
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION
REVERSE COIL
SHORT TO
BATTERY
33247
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to battery
at this output.
Power cycled.
TRANSMISSION
REVERSE COIL
SHORT TO
GROUND
33248
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to ground
at this output.
Power cycled.
TRANSMISSION A
COIL
OPEN CIRCUIT
33249
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION A
COIL SHORT TO
BATTERY
33250
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to battery
at this output.
Power cycled.
9-72
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
TRANSMISSION A
COIL SHORT TO
GROUND
33251
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to ground
at this output.
Power cycled.
TRANSMISSION
FORWARD COIL
OPEN CIRCUIT
33252
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION
FORWARD COIL
SHORT TO
BATTERY
33253
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to battery
at this output.
Power cycled.
TRANSMISSION
FORWARD COIL
SHORT TO
GROUND
33254
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to ground
at this output.
Power cycled.
TRANSMISSION E
COIL
OPEN CIRCUIT
33255
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION E
COIL SHORT TO
BATTERY
33256
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to battery
at this output.
Power cycled.
TRANSMISSION E
COIL SHORT TO
GROUND
33257
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to ground
at this output.
Power cycled.
TRANSMISSION 1
COIL
OPEN CIRCUIT
33258
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION 1
COIL SHORT TO
BATTERY
33259
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to battery
at this output.
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-73
Electrical System
Message
Fault
Code
Indicators
Latch Until
TRANSMISSION 1
COIL SHORT TO
GROUND
33260
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to ground
at this output.
Power cycled.
TRANSMISSION D
COIL
OPEN CIRCUIT
33261
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION D
COIL SHORT TO
BATTERY
33262
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to battery
at this output.
Power cycled.
TRANSMISSION D
COIL SHORT TO
GROUND
33263
A TRANSMISSION configuration of
POWERSHIFT is configured and
the UGM detects a short to ground
at this output.
Power cycled.
TRANSMISSION 2
COIL
OPEN CIRCUIT
33264
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects an open circuit at
this output.
Power cycled.
TRANSMISSION 2
COIL SHORT TO
BATTERY
33265
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to battery
at this output.
Power cycled.
TRANSMISSION 2
COIL SHORT TO
GROUND
33266
A TRANSMISSION configuration of
HYDROSTATIC is configured and
the UGM detects a short to ground
at this output.
Power cycled.
ENGINE FUEL
RELAY
OPEN CIRCUIT
33267
Power cycled.
9-74
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
ENGINE FUEL
RELAY SHORT TO
BATTERY
33268
Power cycled.
ENGINE FUEL
RELAY SHORT TO
GROUND
33269
Power cycled.
CRAB STEER
VALVE
OPEN CIRCUIT
33270
Power cycled.
CRAB STEER
VALVE SHORT TO
BATTERY
33271
Power cycled.
CRAB STEER
VALVE SHORT TO
GROUND
33272
Power cycled.
33273
Power cycled.
33274
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-75
Electrical System
Message
Fault
Code
Indicators
Latch Until
33275
Power cycled.
33276
Power cycled.
33277
Power cycled.
33278
Power cycled.
GLOWPLUGS
OPEN CIRCUIT
33279
1, 2
Power cycled.
GLOWPLUGS
SHORT TO
BATTERY
33280
1, 2
Power cycled.
GLOWPLUGS SHORT TO
GROUND
33281
1, 2
Power cycled.
ENGAGE STARTER
OUTPUT OPEN
CIRCUIT
33282
Power cycled.
ENGAGE STARTER
OUTPUT SHORT
TO BATTERY
33283
Power cycled.
ENGAGE STARTER
OUTPUT SHORT
TO GROUND
33284
Power cycled.
ALTERNATOR
EXCITATION LINE
SHORT TO
BATTERY
33285
1, 2, 10
Power cycled.
FRONT MOTOR
CURRENT
FEEDBACK
READING TOO LOW
33286
N/A
Power cycled.
9-76
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
LIFT CURRENT
FEEDBACK
READING TOO LOW
33287
Power cycled.
TELESCOPE
CURRENT
FEEDBACK
READING TOO LOW
33288
N/A
Power cycled.
STABILIZERS/
FRAME LEVEL
CURRENT
FEEDBACK
READING TOO LOW
33289
N/A
Power cycled.
FORK TILT
CURRENT
FEEDBACK
READING TOO LOW
33290
N/A
Power cycled.
AUXILIARY
HYDRAULICS
CURRENT
FEEDBACK
READING TOO LOW
33291
N/A
Power cycled.
FRONT MOTOR
SWIVEL ANGLE
OPEN CIRCUIT
33292
Power cycled.
FRONT MOTOR
SWIVEL ANGLE
SHORT TO
BATTERY
33293
Power cycled.
FRONT MOTOR
SWIVEL ANGLE
SHORT TO
GROUND
33294
Power cycled.
REAR AUXILIARY
HYDRAULICS
VALVE
OPEN CIRCUIT
33326
Power cycled.
REAR AUXILIARY
HYDRAULICS
VALVE SHORT TO
BATTERY
33327
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-77
Electrical System
Message
Fault
Code
Indicators
Latch Until
REAR AUXILIARY
HYDRAULICS
VALVE SHORT TO
GROUND
33328
Power cycled.
33369
Power cycled.
33338
Power cycled.
BOOM FLOAT
VALVE SHORT TO
BATTERY OR OPEN
CIRCUIT
33370
Power cycled.
BOOM FLOAT
VALVE SHORT TO
GROUND
33341
Power cycled.
33371
Power cycled.
33344
Power cycled.
ENGINE
43XXX
9-78
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
ENGINE TROUBLE
CODE: (SPN):(FMI)
437
1, 2, 3*
Power cycled
WRONG ENGINE
SELECTED ECM
DETECTED
4314
1, 2
Power cycled.
HIGH ENGINE
COOLANT
TEMPERATURE
WARNING
4316
1, 2, 12
MECHANIAL:
The engine
coolant
temperature
reaches
110C.
ELETRONIC:
The ECM no
longer
transmits the
condition as
an active fault.
HIGH ENGINE
COOLANT
TEMPERATURE
CRITICAL
4317
1, 2, 3, 12
MECHANIAL:
The engine
coolant
temperature
reaches
115C.
ELETRONIC:
The ECM no
longer
transmits the
condition as
an active fault.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-79
Electrical System
Message
Fault
Code
Indicators
Latch Until
4318
1, 2, 9
N/A
Power cycled.
4319
1, 2, 3, 9
N/A
Power cycled.
ALTERNATOR
CHARGING
FAILURE
4320
1, 2, 10
N/A
J4-7
Alternator D+
is continuously HIGH
for a period of
3 seconds.
AIR FILTER
RESTRICTION
4321
1, 2, 7
N/A
J1-34 Air
Filter
Restriction
input is HIGH
for 1 second.
LOSS OF ENGINE
SPEED SIGNAL
4322
1, 2
Power cycled.
CONFLICTING
OPERATING
ENGINE STATE
4324
1, 2
N/A
Power cycled.
BATTERY SUPPLY
9-80
44XXX
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
BATTERY VOLTAGE
TOO LOW
SYSTEM
SHUTDOWN
441
Power cycled.
(Replace/fix
battery.)
BATTERY VOLTAGE
TOO HIGH
SYSTEM
SHUTDOWN
442
Power cycled.
(Fix supply
voltage.)
LSS BATTERY
VOLTAGE TOO
HIGH
443
Power cycled.
(Fix supply
voltage.)
LSS BATTERY
VOLTAGE TOO LOW
444
Power cycled.
(Replace/fix
battery.)
BATTERY VOLTAGE
LOW
445
The UGM
detects the
battery
voltage higher
than 11V for a
period of 10
seconds or
power cycled.
REFERENCE
VOLTAGE OUT OF
RANGE GROUND
447
Power cycled.
TRANSMISSION &
DRIVE SYSTEM
46XXX
HIGH
TRANSMISSION OIL
TEMPERATURE
CRITICAL
461
1, 11
N/A
Power cycled.
CONFLICTING
DRIVE DIRECTION
SIGNALS
462
Only input
J4-4 Neutral is
HIGH.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-81
Electrical System
Message
Fault
Code
Indicators
Latch Until
DRIVE DIRECTION
SIGNAL LOST
463
Only input
J4-4 Neutral is
HIGH.
CONFLICTING
GEAR SELECTION
SIGNALS
464
J4-5 Park
Brake is HIGH
and issue
cleared or
power cycled.
GEAR SELECTION
SIGNAL LOST
465
J4-5 Park
Brake is HIGH
and issue
cleared or
power cycled.
9-82
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
INVALID
TRANSMISSION
CONFIGURATION
466
The
configuration
is corrected
and power is
cycled.
TRANSMISSION
TROUBLE CODE:
(SPN):(FMI)
467
Power cycled
VEHICLE SPEED
SENSOR NOT
RESPONDING
468
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-83
Electrical System
Message
Fault
Code
Indicators
Latch Until
COMMUNICATIONS
66XXX
CANBUS FAILURE
PLATFORM
MODULE
662
Power cycled.
CANBUS FAILURE
LOAD SENSING
SYSTEM MODULE
663
1, 14
Power cycled.
CANBUS FAILURE
ENGINE
CONTROLLER
666
1, 3
Power cycled.
CANBUS FAILURE
EXCESSIVE
CANBUS ERRORS
6613
N/A
Power cycled.
CANBUS FAILURE
TRANSMISSION
CONTROLLER
6616
Power cycled.
9-84
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
CANBUS FAILURE
CABIN JOYSTICK
6617
CANBUS FAILURE
CABIN DISPLAY
6618
Power cycled.
CANBUS FAILURE
UNKNOWN
TROUBLE CODE:
(SPN):(FMI)
6619
N/A
Power cycled.
CANBUS FAILURE
BOOM ANGLE
SENSOR
6621
Power cycled.
6622
6623
6629
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Power cycled.
9-85
Electrical System
Message
Fault
Code
Indicators
Latch Until
CANBUS FAILURE
BOOM RIDE/BOOM
FLOAT MODULE
6631
Power cycled.
6637
Power cycled.
6638
Power cycled.
TILT SENSOR
81XXX
CHASSIS TILT
SENSOR NOT
CALIBRATED
813
Successful tilt
calibration has
been completed.
CHASSIS TILT
SENSOR OUT OF
RANGE
814
Power cycle.
(Replace
board)
CHASSIS TILT
SENSOR
DISAGREEMENT
815
Power cycle.
(Replace
board)
PLATFORM LOAD
SENSE
82XXX
9-86
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
LSS CELL #1
ERROR
821
1, 14
Power cycled.
LSS CELL #2
ERROR
822
1, 14
Power cycled.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-87
Electrical System
Message
Fault
Code
Indicators
Latch Until
LSS CELL #3
ERROR
823
1, 14
Power cycled.
LSS CELL #4
ERROR
824
1, 14
Power cycled.
9-88
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
825
1, 14
A valid
calibration of
the LSS
module is
completed or
the LOAD
SENSING
menu screen
is configured
to NONE and
power is
cycled.
829
1, 14
When a rated
load of less
than 110% is
detected for a
period of at
least 3
seconds. (The
system will
then re-enable
J2-19
Function
Enable Relay
and verify the
platform
function
enable switch
is not
engaged
before
operation is
allowed.)
The LSI
System CAN
message
which
indicates the
calibration
mode status
changes to
OFF.
LOAD MOMENT
LSI NOT
CALIBRATED
85XXX
8514
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-89
Electrical System
Message
Fault
Code
Indicators
Latch Until
8515
Use analyzer
and correct
parameter
that is
improperly
configured.
8516
Power cycle.
8517
Power cycle.
LSI CUTOUT
OUTPUT SHORT
TO BATTERY OR
OPEN CIRCUIT
8518
Power cycle.
LSI OUT OF
CALIBRATION
8519
The LSI-CAN
system check
is performed
and is
completed
with a pass
condition.
1, 8
N/A
Until steer
pressure is
re-established (i.e.
J1-35 is LOW
for a period of
3 seconds).
STEERING
LOW STEERING
PRESSURE
HARDWARE
LSS WATCHDOG
RESET
9-90
86XXX
8638
99XXX
991
Power cycle.
(Replace
board)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
LSS EEPROM
ERROR
992
Power cycle.
(Replace
board)
LSS INTERNAL
ERROR PIN
EXCITATION
993
Power cycle.
(Replace
board)
LSS INTERNAL
ERROR DRDY
MISSING FROM A/D
994
Power cycle.
(Replace
board)
EEPROM FAILURE
CHECK ALL
SETTINGS
998
Power cycle.
(Replace
board)
FUNCTION
LOCKED OUT
PLATFORM
MODULE
SOFTWARE
VERSION
IMPROPER
9910
Reprogram
board and
power cycle.
(Replace
board)
FUNCTION
LOCKED OUT LSS
MODULE
SOFTWARE
VERSION
IMPROPER
9911
Reprogram
board and
power cycle.
(Replace
board)
CHASSIS TILT
SENSOR NOT GAIN
CALIBRATED
9915
Power cycle.
(Replace
board)
GROUND MODULE
FAILURE HIGH
SIDE DRIVER
CUTOUT FAULTY
9921
Power cycle.
FUNCTIONS
LOCKED OUT
MACHINE NOT
CONFIGURED
9924
The
MACHINE
SETUP menu
has been
accessed and
power is
cycled.
9944
Power cycle.
(Replace
board)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Latch Until
9-91
Electrical System
Message
Fault
Code
Indicators
Latch Until
9945
Power cycle.
(Replace
board)
CABIN DISPLAY
EEPROM WRITE
FAILURE
9946
N/A
Power cycle.
HARDWARE
EXCHANGE
REQUIRED
9947
Complete a
hardware
exchange and
cycle power.
PLATFORM
MODULE
HARDWARE
FAILURE
9948
Power cycle.
MACHINE
CONFIGURATION
OUT OF RANGE
CHECK ALL
SETTINGS
9949
Use analyzer
and correct
parameter
that is out of
range.
9976
Power cycle.
LSS CORRUPT
EEPROM
9977
At power-up or immediately
thereafter, if the PLATFORM
STATION is active and the platform
module and UGM will check the
consistency of the redundantly
stored Platform Unloaded Weight
and the Platform Maximum Allowed
Load values.
Power cycle
EEPROM VALUE
OUT OF RANGE
9978
Use analyzer
and correct
parameter
that is out of
range.
9-92
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message
Fault
Code
Indicators
Latch Until
GROUND MODULE
VLOW FET FAILURE
9986
Power cycle.
(Replace
board)
FUNCTIONS
LOCKED OUT LSI
SOFTWARE
VERSION
IMPROPER
99151
Power cycle.
(Install proper
LSI)
LSI FAULTY
SYSTEM FLASH
CRC ERROR
99152
Power cycle.
(Replace LSI)
99153
Power cycle.
(Replace LSI)
99154
Power cycle.
(Recalibrate
or replace LSI
sensor)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
9-93
Electrical System
9-94
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
31200206
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: +48 (0)914 320 245
Fax: +48 (0)914 358 200
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal, Barcelona
Spain
Phone: +34 93 772 4 700
Fax: +34 93 771 1762
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
Phone: +46 (0)850 659 500
Fax: +46 (0)850 659 534
www.jlg.com