Professional Documents
Culture Documents
Models
3508PS, 3509PS,
3512PS, 3513PS,
4008PS, 4009PS,
4012PS, 4013PS,
4017PS,
Agrovector
40.8, 40.9
31200206
Revised
June 15, 2011
31200206 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 a
EFFECTIVITY PAGE
b 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 31200206
SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology - Two and Three Section Boom . . . . . . . . . . . 3.3
3.2 Boom System - Two and Three Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3 Boom Assembly Maintenance - Two and Three Section Boom . . . . . . . . . . . . . . . . . . . 3.4
3.4 Boom System Component Terminology - Four Section Boom. . . . . . . . . . . . . . . . . . . . 3.8
3.5 Boom System - Four Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.6 Boom Assembly Maintenance - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.7 Boom Extend and Retract Chains Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.8 Boom Section Separation Adjustment - Four Section Boom . . . . . . . . . . . . . . . . . . . . . 3.21
3.9 Hose Carrier Assembly - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.11 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
3.12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
3.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
3508PS,3509PS,3512PS,3513PS,4008PS,4009PS,4012PS,4013PS,4017PS,40.8,40.9 i
Section Subject Page
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Section 7
Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.7 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.8 Auxiliary Pump (Platform Equipped Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.9 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
ii 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section Subject Page
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.3 Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.7 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
9.8 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.9 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.11 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.12 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.13 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.14 Switches, Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
9.15 Load Stability Indicator (LSI) -
8, 9, 12 & 13M Before S/N 1160005993 excluding 1160005949 & 1160005950
17M Before S/N 1160005937 including 1160005952, 1160005960, 1160005963,
1160005966 & 1160005978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34
9.16 Load Stability Indicator (LSI) -
8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950
17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963,
1160005966 & 1160005978 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38
9.17 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43
9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 iii
Section Subject Page
iv 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 1
Safety Practices
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 1-1
Safety Practices
1-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Safety Practices
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 1-3
Safety Practices
pressure can explode. Hydraulic oil and diesel fuel 1.7 SAFETY DECALS
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury. Check that all safety decals are present and readable on
Relieve all pressure before disconnecting any the machine. Refer to the Operation & Safety Manual
component, part, line or hose. Slowly loosen parts and supplied with machine for information.
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque.
Capture fluid in an appropriate container and dispose of
in accordance with prevailing environmental regulations.
RADIATOR CAP: The cooling system is under pressure,
and escaping coolant can cause severe burns and eye
injury. To prevent personal injury, NEVER remove the
radiator cap while the cooling system is hot. Wear safety
glasses. Turn the radiator cap to the first stop and allow
pressure to escape before removing the cap completely.
Failure to follow the safety practices could result in death
or serious injury.
FLUID FLAMABILTITY: DO NOT service the fuel or
hydraulic systems near an open flame, sparks or smoking
materials.
NEVER drain or store fluids in an open container. Engine
fuel and hydraulic oil are flammable and can cause a fire
and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The
mixture can cause an explosion.
PRESSURE TESTING: When conducting any test, only
use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
manner, and make changes or repairs as indicated by the
test procedure to achieve the desired result.
LEAVING MACHINE: Lower the forks or attachment to
the ground before leaving the machine.
TIRES: Always keep tires inflated to the proper pressure
to help prevent tipover. DO NOT over-inflate tires.
NEVER use mismatched tire types, sizes or ply ratings.
Always use matched sets according to machine
specifications.
MAJOR COMPONENTS: Never alter, remove, or
substitute any items such as counterweights, tires,
batteries or other items that may reduce or affect the
overall weight or stability of the machine.
BATTERY: DO NOT charge a frozen battery.Charging a
frozen battery may cause it to explode. Allow the battery
to thaw before jump-starting or connecting a battery
charger.
1-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 2
General Information and Specifications
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-1
General Information and Specifications
MZ1780
1
2-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-3
General Information and Specifications
2-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-5
General Information and Specifications
2-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
Torque
Torque Torque Loctite®
Tensile
Clamp Torque Loctite® 262™ 242™ or 271™
Size PITCH Stress (Dry or Loctite®
Load (Lub) OR OR
Area 263TM) Vibra-TITE™ 131 Vibra-TITE™
111 or 140
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-7
General Information and Specifications
Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™
Clamp or Loctite® 262™
Size PITCH Stress OR OR
Load Loctite® 263™
Area Vibra-TITE™ Vibra-TITE™ 131
111 or 140
K = 0.20 K= 0.18 K=0.15
2-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
Magni Coating*
Torque
Lube OR Loctite® Torque
Tensile Torque Dry 242™ or 271™ Loctite® 262™
Clamp Load or
Size PITCH Stress OR OR
See Note 4 Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131
Area
111 or 140
K = .17 K = .16 K = .15
3 0.5 5.03
3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 54
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 220.0 900 845 790
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-9
General Information and Specifications
2-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
2.3 SPECIFICATIONS
Function Speed
First Gear 5 km/h (3.1 mph)
Second Gear 10 km/h (6.2 mph)
Third Gear 25 km/h (15.5 mph)
Fourth Gear (Turbo Only) 35 km/h (21.7 mph)
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-11
General Information and Specifications
Battery
Type, Rating 12V DC, Negative (-) Ground, Limited Maintenance,
Wet Charged
Quantity 1 (100 Ah) (C20)
Reserve Capacity CCA @ -18° C: 880 EN
Group/Series DIN 600,38
Alternator 12V, 85 Amps
Starter 12V, 3,2 KW Type EV (Gear Reduction)
Description
Engine Make/Model Perkins 1004-40T
Low Idle 925 RPM ±50 RPM
High Idle 2340 RPM ±50 RPM
Horsepower 80,4 BHP/60 KW @ 2200 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety Elements
2.3.6 Tires
Note: Standard wheel lug nut torque is 500 Nm (369 lb-ft).
2-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-13
General Information and Specifications
Axles
Differential Housing Capacity - Front 8,0 L (8.5 qt)
Differential Housing Capacity - Rear 7,3 L (7.7 qt)
Wheel End Capacity - Front 1,9 L (2.0 qt)
Wheel End Capacity - Rear 1,4 L (1.5 qt)
Type of Fluid
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
Mobilfluid 424® (ISO 46)
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid
Brake System
System Capacity 1,0 L (1.1 qt)
Type of Oil
3508PS, 3509PS, 3512PS, 3513PS, 4008PS,
Dexron II or III ATF
4009PS, 4012PS, 4013PS & 4017PS
40.8 & 40.9 DONAX TA
Air Conditioning System (if equipped)
System Capacity 2,05 kg (4.5 lb)
Type of Refrigerant R-134a Tetrafluoroethane
Type of Lubricant PAG-oil SP-20, TXV System
Quantity of Lubricant 68,3 ccm (2.3 oz)
2-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
2.5 MAINTENANCE SCHEDULES 2.5.2 50, 250 & 500 Hour Maintenance
Schedule
2.5.1 8 & 1st 50 Hour Maintenance Schedule
EVERY
50
EVERY
8
Drain Fuel/ Check Engine Lubrication Check Check Washer
Water Coolant Level Schedule Battery Fluid Level
Separator
Check Fuel
Level
Air Filter Check Engine
Oil Level
Check Tire
Condition &
Check Brake
Fluid Level
EVERY
Pressure
250
1st
50
Check Boom Check Boom Check Transfer
Chain & Tension Wear Pads Case Oil Level
LB/FT
(Nm)
(17M Only)
EVERY
1000
EVERY
1500
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-15
General Information and Specifications
EVERY
8
OZ2260
2-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
17M
EVERY
8
OZ2430
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-17
General Information and Specifications
EVERY
50
2x
OZ2270
2-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
General Information and Specifications
17M
EVERY
50
2X
OZ2440
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2-19
General Information and Specifications
2-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 3
Boom
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-1
Boom
3-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
FIRST
BOOM
SECTION PIVOT PIN
THREE SECTION BOOM
SECOND
BOOM
SECTION
THIRD
BOOM EXTEND/RETRACT
SECTION CYLINDER
ACCESS
PANEL FIRST
BOOM
SECTION
PIVOT PIN
TILT CYLINDER
QUICK SWITCH
EXTEND/RETRACT
CYLINDER
TILT CYLINDER
MZ1480
QUICK SWITCH
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-3
Boom
3.2 BOOM SYSTEM - TWO AND THREE 8. Label, disconnect and cap hydraulic hoses attached
SECTION BOOM the hose rack at the left rear corner of the boom.
9. Disconnect the boom angle indicator rod from the
switch at the inside left corner of the main boom
3.2.1 Boom System Description
section and frame. Refer to Section 9.14.7, “Boom
The boom operates via an interchange among the Angle Sensor.”
electrical, hydraulic and mechanical systems. Components
10. Support the front of the boom by placing a sling
involved include the joystick, tilt cylinder, extend/retract
behind the boom head. Support the lift/lower cylinder
cylinder, lift/lower cylinder, compensation cylinder,
and remove the lock bolt and then the rod end pin.
electronic sensors, various pivots, supporting hardware
Lower the lift/lower cylinder onto the frame rails.
and other components.
11. Lower the boom to a level position and place a
3.3 BOOM ASSEMBLY MAINTENANCE - suitable support under the boom head. Reposition
the slings to each end of the boom.
TWO AND THREE SECTION BOOM
12. Remove the lock bolt and pin from the compensation
Note: Boom replacement must be completed in cylinder on each side of the first boom section.
sequence, one boom section at a time, as described in Remove the lock bolt and pivot pin from rear of first
these instructions. boom section.
Before beginning, conduct a visual inspection of the 13. Lift the complete boom off machine and set on level
machine and work area, and review the task about to be ground or supports being careful not to damage the
undertaken. Read, understand and follow these tubes on the side of the first boom section.
instructions.
a. If the boom is going to be disassembled after
3.3.1 Boom Removal removal:
1. Remove any attachment from the quick switch 1. Set the complete boom on level ground and by
assembly. Refer to Section 3.11.1, “Connecting with repositioning the slings, turn boom over on to the top
a Mechanical Quick Switch Device.” side. Set the complete boom on suitable stands to
begin teardown.
Note: If replacing the innermost boom section, remove
the quick switch assembly. Refer to Section 3.11.4, Note: With the complete boom setting upside down, the
“Quick Switch Removal.” other boom section(s), tilt cylinder and hoses are made
more accessible.
2. Park the machine on a hard, level surface. Be sure
there is enough room in front of the machine to allow 2. Remove the access panel from the boom head.
the boom sections to be removed. 3. Label, disconnect and cap the hoses attached to the
3. Fully retract the boom then raise the boom to access tilt cylinder and the hose rack on the side of the first
the rod end pin of the lift/lower cylinder. Place the boom section.
transmission control lever in (N) NEUTRAL, engage 4. Attach a sling through the rod end of the tilt cylinder.
the park brake and shut the engine OFF. Remove the clip from the barrel end of the tilt
4. Place a Do Not Operate Tag on both the ignition key cylinder pin. Remove the tilt cylinder pin and lift the
switch and steering wheel stating that the machine tilt cylinder out of the boom head.
should not be operated. 5. Remove the hose clamp inside the innermost boom
5. Open the engine cover. Allow the system fluids to section.
cool. 6. Label, disconnect and cap the hoses attached to the
6. Properly disconnect the battery. extend/retract cylinder at the rear of the boom.
7. Relieve any trapped pressure in the tilt hydraulic
system by using the handle or wrench (located in the
toolbox) and move the double nut on the side of the
actuator module on the tilt valve section back and
forth. Repeat on the auxiliary valve section and on
the extend/retract section.
3-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
MZ1740
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-5
Boom
3.3.4 Third Section Boom Installation Note: Shim ALL side wear pads as needed to maintain
(12 & 13M) a minimum gap in the horizontal direction or a tight fit.
Second Section Boom Installation The number of shims can vary at each shim point except
(8 & 9M) on the bottom wear pads.
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly.
5. Tighten all wear pads after ensuring the minimum
gap requirements have been met. Refer to Section
3.10.1, “Wear Pad Inspection.”
8
MZ1750
1. Install the bottom rear wear pads (8) and bolts onto
the innermost boom section. Apply Loctite® 243TM
and torque to 90 Nm (66 lb-ft). Install the bottom rear
left and right side wear pads, backing plate and bolts
(do not shim or tighten bolts). Install top rear wear
pads, backing plates and bolts (do not shim or
tighten bolts).
9
2. Grease the inside of the next boom section on areas MZ1730
where the innermost boom section wear pads will
slide. 1. Install the bottom rear wear pads (9) and bolts onto
3. Using a suitable sling, balance the innermost boom the second boom section. Apply Loctite® 243TM and
section and carefully slide 1 m to 1,5 m (3’ to 4’) into torque to 90 Nm (66 lb-ft). Install the bottom rear left
the front of the next boom section. Set the innermost and right side wear pads, backing plate and bolts (do
boom section head onto suitable supports and reset not shim or tighten bolts). Install top rear wear pads,
sling under the boom head. Carefully slide the backing plates and bolts (do not shim or tighten
innermost boom section into the next section. Leave bolts).
15 cm to 20 cm (6” to 8”) of the innermost boom
2. Grease the inside of the first boom section on areas
section out to be able to install wear pads on the
where the third boom section wear pads will slide.
front of the next boom section.
3. Using a suitable sling, balance the first and second
4. With the boom head still supported, install the top boom sections and carefully slide 1 m to 1,5 m
wear pads, washers and bolts in the front of the (3’ to 4’) into the front of the third boom section.Set
larger boom section. Apply Loctite® 243TM and torque the third boom section head onto suitable supports
to 90 Nm (66 lb-ft). Remove the boom head from and reset sling under the boom head. Carefully slide
supports and install the bottom wear pads, backing the first and second boom sections into the first
plates, shims and bolts in the front of the larger section. Leave 15 cm to 20 cm (6” to 8”) of the
boom section. Apply Loctite® 243TM and torque to 90 second boom section out to be able to install wear
Nm (66 lb-ft). Install both left and right side front pads on the front of the first boom section.
wear pads, backing plates, shims and bolts in the
front of the larger boom section. Apply Loctite® 243TM
and torque to 50 Nm (37 lb-ft).
3-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
4. With the boom head still supported, install the top 8. Rebalance the boom assembly with slings, lift and
wear pads, washers and bolts in the front of the first carefully guide the boom into place. Align the frame
boom section. Apply Loctite® 243TM and torque to pivot bore with the boom pivot bore. Install the boom
90 Nm (66 lb-ft). Remove the boom head from pivot pin. Apply Loctite® 243TM and torque to 300 Nm
supports and install the bottom wear pads, backing (221 lb-ft).
plates, shims and bolts in the front of the first boom 9. With the sling still in place, install both compensation
section. Apply Loctite® 243TM and torque to 90 Nm cylinders, pins and lock bolts. Apply Loctite® 243TM
(66 lb-ft). Install both left and right side front wear and torque to 120 Nm (88 lb-ft).
pads, backing plates, shims and bolts in the front of
the first boom section. Apply Loctite® 243TM and 10. With the sling still in place, raise the boom enough to
torque to 50 Nm (37 lb-ft). install the lift/lower pin and lock bolt. Apply Loctite®
243TM and torque to 300 Nm (221 lb-ft).
Note: Shim ALL side wear pads as needed to maintain
a minimum gap in the horizontal direction or a tight fit. Note: Raising the boom up or down with the sling
The number of shims can vary at each shim point except maybe necessary so the boom, compensation and lift/
on the bottom wear pads. lower cylinder bores can be aligned for easier pin
installation.
Note: Light lubrication of the boom wear surfaces with a
factory authorized grease is recommended to keep the Note: Grease the boom pivot bore, compensation
boom wear surfaces lubricated properly. cylinder rod ends, lift/lower rod end and pins before
installing.
5. Tighten all wear pads after ensuring the minimum
gap requirements have been met. Refer to Section 11. Uncap and connect the previously labeled hydraulic
3.10.1, “Wear Pad Inspection.” hoses to the hose rack on the side of the first boom
section.
3.3.6 Boom Installation 12. Connect the boom angle indicator rod from switch at
the inside left rear corner of the main boom section
1. Insert the extend/retract cylinder through the rear of
and frame. Refer to Section 9.14.7, “Boom Angle
the boom. Align the extend/retract rod end with the
Sensor,” for adjustment information.
cylinder pin mounting hole on the last boom section.
Install the extend/retract cylinder pin and retaining 13. Properly connect the battery.
clip. 14. Start the engine and operate all boom functions
Note: On 12 & 13M machines, install the two brackets several times. Check for leaks, and check the
the secure the extend/retract cylinder to the second hydraulic oil level in the reservoir; add oil if required.
boom section. 15. Install the access panel on the boom head.
2. Align the extend/retract barrel end with the cylinder 16. Remove the Do Not Operate Tags from both the
pin mounting hole on the first boom section. Install ignition key switch and the steering wheel.
the extend/retract cylinder pin and retaining clip. 17. Close and secure the engine cover.
Note: Grease extend/retract cylinder barrel end bore
and pin before installing.
3. Attach a sling through the rod end of the tilt cylinder
and position the cylinder to its original mounting
location. Install the tilt cylinder pins and retaining
clips.
4. Insert the extend/retract, tilt and auxiliary hoses
through the boom.
5. Uncap and connect the previously labeled hydraulic
hoses to the appropriate locations on each cylinder.
6. Install the hose clamps inside the innermost boom
section.
7. Using suitable slings, turn the boom over to its
original orientation.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-7
Boom
HOSE CARRIER
FOURTH BOOM
SECTION
THIRD BOOM
SECTION
SECOND BOOM
SECTION
AUXILIARY
QUICK RETRACT CHAINS (THREE)
CONNECTS
EXTEND/RETRACT CYLINDER
MZ0830
REAR VIEW
TILT CYLINDER
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
The four section boom consists of the first, second, third Note: If replacing the innermost boom section, remove
and fourth assemblies with double third and fourth the quick switch assembly. Refer to Section 3.11.4,
section extend chains, a double third section retract “Quick Switch Removal.”
chains and a single fourth section retract chain. 2. Park the machine on a firm, level surface. Be sure
As the extend/retract cylinder, which is anchored at the there is enough room in front of the machine to allow
front of the second boom section, and the rear of the first the boom sections to be removed. Fully retract the
boom section begins to extend, it forces the second boom boom then raise the boom to access the rod end pin
section out of the first boom section. of lift cylinder. Place the transmission control lever in
The first, second, third and fourth boom sections are (N) NEUTRAL, engage the park brake and shut the
connected by extend and retract chains. These chains engine OFF.
are routed around sheaves on the second and third boom 3. Place a Do Not Operate Tag on both the ignition key
sections. As the second and third boom sections are switch and the steering wheel, stating that the
forced out, the extend chain pulls the fourth boom section machine should not be operated.
out of the third boom section. 4. Open the engine cover. Allow the system fluids to
As hydraulic pressure is applied to the retract port on the cool.
extend/retract cylinder, the second boom section is pulled 5. Properly disconnect the battery.
back into the first boom section, and the retract chain
pulls the third and fourth boom sections back into the 6. Label, disconnect and cap both hoses from the
second boom section. Extend/Retract cylinder, tilt hoses and both Auxiliary
hoses from tubes at left rear corner of first boom
This mechanical linkage formed by the chains and section. Cap all fittings to prevent dirt and debris
supporting hardware, extends and retracts the third and from entering the hydraulic system.
fourth boom sections at the same rate.
7. Remove the Extend/Retract cylinder support at the
The first boom section does not extend or retract, but lifts top front of the first boom section.
and lowers via action of the lift cylinder.
8. Support the Extend/Retract cylinder and remove the
clip and pin from rod end of extend/retract cylinder.
3.6 BOOM ASSEMBLY MAINTENANCE -
Remove the clip and pin from barrel end of extend/
FOUR SECTION BOOM retract cylinder and remove the extend/retract
cylinder.
These instructions must be completed in sequence. The
second, third and fourth boom sections are removed from 9. Disconnect the boom angle indicator rod from switch
the first boom section.The third and fourth boom sections at the inside left rear corner of the main boom
are removed from the second boom section.The fourth section and frame.
boom section is removed from the third boom section. 10. Support the front of the boom by placing a sling
Before beginning, conduct a visual inspection of the behind the boom head. Support the Lift/Lower
machine and work area, and review the task about to be cylinder and remove the lock bolt and then the rod
undertaken. Read, understand and follow these end pin. Lower the Lift/Lower cylinder onto the frame
instructions. rails.
11. Remove the lock bolt and pin from Compensation
cylinder on each side of first boom section. Remove
the lock bolt and pivot pin from rear of first boom
section.
12. Lower the boom to a level position and place a
suitable support under the boom head. Reposition
the slings to each end of the boom.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-9
Boom
13. Lift the complete boom off machine and set on level Note: Before removing the extend chains, measure the
ground or supports being careful not to damage the distance (2) between the face of the jam nut to the end of
tubes on the left side of boom. the chain clevis on all four extend chains. This
measurement will be used when reassembling the
3.6.2 Second, Third and Fourth Boom boom.
Section Removal 4. At the bottom front of the first boom section, remove
the jam nuts and nuts and washers from the two
extend chain clevises. Remove clips and pins from
the two clevises and remove clevis from each chain.
1
5. At the bottom front of the second boom section
remove the jam nuts and nuts and washers from the
two extend chain clevises. Remove clips and pins
from the two clevises and remove clevis from each
chain.
6. At the rear of the boom, label, disconnect and cap
both Tilt hoses and both Auxiliary hoses from the
bulkhead on the hose carrier. Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.
MZ0740 7. Remove the clip and pin from both retract chain
clevises that are attached to the rear of the third
1. Set the complete boom on level ground and by section boom. The pins can be removed through the
repositioning the slings turn boom over on to the top access holes at the bottom left and right sides of the
side. Set the complete boom (1) on suitable stands first section boom. Do not remove the clevises.
to begin tear down. 8. Remove the clip and pin from the retract chain clevis
Note: With the complete boom setting upside down, the that is attached to the rear of the fourth boom
removal and replacing of each boom section, tilt cylinder, section. Do not remove the clevis.
hoses, extend and retract chains and hose carrier are 9. Pull the second section boom out 152 mm to
made much easier. 203 mm (6 in to 8 in) and remove all the wear pads
from the front inside of the first section boom. Label
2. At the boom head attach a sling through rod end of
all parts for installation.
tilt cylinder. Label, disconnect and cap both hoses
from Tilt cylinder. Plug the cap all fittings to prevent 10. Pull the third boom section out 152 mm to 203 mm
dirt and debris from entering the hydraulic system. (6 in to 8 in). Remove the top left and right side wear
Remove the clip from barrel end of tilt cylinder pin. pads from the second boom section. Loosen the
Remove the tilt cylinder pin and lift the Tilt cylinder bottom rear wear pad bolts and remove the shims
out of the boomhead. from the second boom section to gain the necessary
clearance to be able to remove the second boom
3. Use a suitable sling around the third section boom to
section from the first boom section. Label all parts
take any pressure off of wear pads to make pad
for installation.
removal easier.
MZ0790
2 2
3-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-11
Boom
3.6.4 Fourth Boom Section Removal Note: It is recommended that if any chain or hose is
damaged that ALL chains or hoses are replaced.
1. With the two boom sections setting on suitable
supports remove the bolts, keeper and pin from
sheave on the front of the third boom section.
3.6.5 Hose Carrier Removal
Remove the sheaves. Remove all wear pads, from 1. Label, disconnect and cap both auxiliary hydraulic
the front inside of the third boom section. Label all hoses in the boom head. Cap all fittings to prevent
parts for installation. dirt and debris from entering hydraulic system.
2. Remove the top left and right side rear wear pads on 2. With fourth boom section setting on suitable
the fourth boom section. Loosen the bottom rear supports loosen and remove the six bolts (three per
wear pad bolts and remove the shims from the fourth side) on the fourth boom section.
boom section to gain the necessary clearance to be
able to remove the fourth boom section from the
third boom section. Label all parts for installation.
5
3. Loosen and remove the two bolts holding the rear of
the hose carrier to the top of the third boom section.
Lift and push rear of hose carrier into the fourth
boom section.
MZ2720
3-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3.6.7 Fourth Boom Section Installation 5. Apply Loctite® 243TM to the sheave mounting bolts,
Install the sheave (7), pin, lock plate and bolts at the
bottom front of the third boom section. Torque bolts to
90 Nm (66 lb-ft). Grease the sheave using the
grease fitting in the pin. Spin the sheave by hand to
ensure the sheave spins freely on the pin and to
6 distribute grease evenly. Pull both extend chains from
the fourth boom section around the front and over the
sheave. Install both chain clevises, pins and clips.
6. Retract the fourth boom section the remainder of the
way into the third boom section and install the wear
pads at the rear of third and fourth boom sections.
7. Apply Loctite® 243TM to the wear pad mounting bolts
and install the bottom left and right side wear pads,
MZ0770
backing plates, shims and bolts. Shim the top wear
1. Apply Loctite® 243TM to the wear pad mounting bolts. pads on the rear of the fourth boom section. Shim
Install the bottom, left right and top wear pads. Do the top left and right wear pads on the rear of the
not shim or tighten the side and top wear pad bolts fourth boom section. Torque bolts to 90 Nm (66 lb-ft).
at this time. Install both extend chains (6) on bottom Torque grease fitting bolts to 45 Nm (33 lb-ft).
rear of fourth boom section. Lay extend chains the
length of fourth boom section. 3.6.8 Third and Fourth Boom Section
Installation
2. Grease the inside third boom section on area’s
where the fourth boom section wear pads will slide. 1. At the rear of the third boom section apply Loctite®
243TM to the wear pad mounting bolts and install the
3. Using a suitable sling, balance the fourth boom
bottom rear wear pads, washers and bolts. Torque to
section and carefully slide 914 mm to 1219 mm
90 Nm (66 lb-ft). Install the bottom rear left and right
(3 ft to 4 ft) into the front of the third boom section.
side wear pads, backing plate and bolts (do not shim
Set the fourth boom section head onto suitable
or tighten bolts). Install the top rear wear pads,
support and reset sling under the boom head of the
backing plates and bolts (front bolts are drilled and
fourth boom section. Carefully slide the fourth boom
tapped for grease fittings. do not shim or tighten
section into the third boom section. Leave
bolts). Install both extend chains on the bottom rear
1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom
of the third boom section. Lay extend chains the
section out to be able to install wear pads in front of
length of third boom section.
the third boom section.
2. Grease the inside second boom section on areas
4. With the sling still under boom head install the top
where the third boom section wear pads will slide.
wear pads. Lower the fourth boom section and install
the bottom, left and right side wear pads. Do not 3. Install retract chain, pin and clip to bottom front
shim or tighten bolts at this time. inside of the second boom section.
Note: Grease wear pads, inside sheaves, bores and Note: Keep the retract chain centered on bottom of the
pins during assembly. third boom section while installing the third boom section
7 into the second boom section.
MZ0980
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-13
Boom
6. Install both sheaves (8), pins, lock plates and bolts at 3.6.9 Second, Third and Fourth Boom
the bottom front of the second boom section. Apply Section Installation
Loctite® 243TM and torque bolts to 90 Nm (66 lb-ft). Note: Light lubrication of the boom wear surfaces with a
Grease the sheaves using the grease fitting in the factory authorized grease is recommended to keep the
pin. Spin the sheaves by hand to ensure the boom wear surfaces lubricated properly. Light lubrication
sheaves spin freely on the pin and to distribute of the boom wear surfaces is also recommended when
grease evenly. Pull both extend chains from the third the machine is stored, to help prevent rusting.
boom section around the front and over the sheaves.
Install both chain clevises, pins and clips (9). 1. Apply Loctite® 243TM to the wear pad mounting bolts.
At the rear of the second boom section, install the
7. Apply Loctite® 243TM to the wear pad mounting bolts
bottom rear wear pads, washers and bolts. Torque to
and install the bottom left and right side wear pads,
90 Nm (66 lb-ft). Install the bottom rear left and right
backing plates, shims and bolts.Shim the top wear
side wear pads, backing plate and bolts (do not shim
pads on the rear of the third boom section. Shim the
or tighten bolts). Install top rear wear pads, backing
top left and right wear pads on the rear of the third
plates and bolts (front bolts are drilled and tapped for
boom section.Torque bolts to 90 Nm (66 lb-ft).
grease fittings. do not shim or tighten bolts).
Torque grease fitting bolts to 45 Nm (33 lb-ft).
3-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
2. Grease the inside first boom section on area’s where the front of the second boom section. Torque to
the second boom section wear pads will slide. 90 Nm (66 lb-ft).
3 Note: Shim ALL side wear pads as needed to maintain
a minimum gap (1.6 mm - 1/16 in) the horizontal
direction or a snug fit. The number of shims can vary at
each shim point.
7. Install the bottom left and right side wear pads,
backing plates, shims and bolts at the rear of the
second boom section.Shim the top wear pads on the
4 5 rear of the second boom section. Shim the top left
and right wear pads on the rear of the second boom
section. Apply Loctite® 243TM and torque bolts to 90
Nm (66 lb-ft).
8. Retract the second, third and fourth boom sections
the remainder of the way into the first boom section.
MZ1190
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-15
Boom
3-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3.6.10 Boom Installation Note: Grease the boom pivot bore, compensation
cylinder rod ends, lift/lower cylinder rod end and pins
Note: Light lubrication of the boom wear surfaces with a
before installing.
factory authorized grease is recommended to keep the
boom wear surfaces lubricated properly. Light lubrication
of the boom wear surfaces is also recommended when
the machine is stored, to help prevent rusting.
1. Park the machine on a hard, level surface. Make
sure park brake is set, key is removed from the 7
ignition and “Do Not Operate” tag is placed in clear
view in the cab.
4
5 9
8
5
MZ1250
MZ1230
5. Remove the caps from Extend/Retract cylinder
2. Using suitable slings, balance the boom assembly, fittings and plugs from Extend/Retract cylinder
lift and carefully guide the boom into place. Align the hoses. Attach each hose to the Extend/Retract
frame pivot bore with the boom assembly pivot bore. cylinder fittings (7) and tighten until wrench-tight.
Install boom pivot pin (4). Apply Loctite® 243TM and Mark the hose fitting then tighten each hose firmly 1
torque lock bolt to 90 Nm (66 lb-ft). to 1-1/2 flats.
3. With the sling still in place, install both 6. Remove the caps from both Tilt tubes (8) and
Compensation cylinders, pins and lock bolts (5). Auxiliary tubes (9) and plugs from both Tilt hoses
Apply Loctite® 243TM and torque to 90 Nm (66 lb-ft). and both Auxiliary hoses. Attach both sets of hoses
to the Tilt tubes and the Auxiliary tubes and tighten
until wrench-tight. Mark the hose fitting then tighten
each hose firmly 1 to 1-1/2 flats.
7. Connect the boom angle indicator rod from switch at
the inside left rear corner of the main boom section
and frame. Refer to Section 9.14.7, “Boom Angle
Sensor,” for adjustment information.
8. Start the engine and operate all boom functions
6 MZ1240
several times. Check for leaks, and check the
hydraulic oil level in the reservoir; add oil if required.
4. With the sling still in place, install the rod end of the
Lift/Lower cylinder, pin and lock bolt (6). Apply 9. Clean up all debris, hydraulic oil, etc., in, on, near
Loctite® 243TM and torque to 90 Nm (66 lb-ft). and around the machine.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-17
Boom
3.7 BOOM EXTEND AND RETRACT Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance
CHAINS FOUR SECTION BOOM
limit of a leaf chain.
• High velocity movement of load, followed by
3.7.1 Boom Chain Inspection sudden, abrupt stops.
• Carrying loads in suspension over irregular
WARNING surfaces such as railroad tracks, potholes, and
rough terrain.
Worn pins, stretched or cracked links or corrosive
• Attempting to “inch” loads which are beyond the
environments can cause chain failure. A chain failure
rated capacity of the vehicle.
could result in uncontrolled boom movement, loss of
load or machine instability. The above load cycles and environmental conditions
make it impossible to predict chain life. It is therefore
Under normal operating conditions the boom chains will necessary to conduct frequent inspections until
need to be inspected every 250 hours of operation. The replacement life can be predicted.
retract chains need to be exposed and inspected every
1000 hours of operation. Refer to the Service Manual for The boom chain’s normal life expectancy can be
the proper procedure. Environmental conditions and expressed as a maximum percent of elongation. This is
dynamic impulse/shock loads can drastically affect generally 3%. As the chain flexes back and forth over the
normal operating conditions and require more frequent sheave, the bearing joints (pins and inside link plates)
inspection intervals. gradually incur wear due to articulatio
3-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
2 1
MZ1463
MZ1464
Elongation
It is important to measure the chain in the section
that moves over the sheaves because it receives the Turning or Protruding Pins
most frequent articulation. Measuring the chain near Highly loaded chain, operating with inadequate
its clevis terminals could give an inaccurate reading. lubrication can generate abnormal frictional forces
The ends of the chains, near the clevis terminal, will between pin and link plates. When chain is allowed
not have flexed as frequently, if at all, as nearer the to operate in this condition, a pin or series of pins,
middle of the chains. can begin to twist out of a chain, resulting in failure.
a. Extend Chains (fourth to third section) Examine the pin head rivets to determine if the
“VEE” flats are still in correct alignment (5). Chain
When the original length (3) of 305 mm (12.00 in) with rotated/displaced heads (6) or abnormal pin
per foot of extend chain between the fourth and third protrusion (7) should be replaced immediately.
boom sections has elongated from wear to a length
(4) of 313 mm (12.36 in), the chain should be DO NOT attempt to repair the chain by welding or
discarded and replaced. driving the pin(s) back into the chain. Once the press
fit integrity between outside plates and pins has
Measure across a span of 16 pins at the center of been altered, it cannot be restored.
the extend chain. Measure from pin center to pin
center. Because the retract chain is inside the boom Any wear pattern on the pin heads or the sides of the
you will not be able to measure the chain. link plates indicates misalignment in the system.
This condition damages the chain as well as
The maximum measurement allowed is increases frictional loading and should be corrected.
313 mm(12.36 in). If the measurement is more than
313 mm (12.36 in), the chain should be replaced.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-19
Boom
Inspect the chains very carefully, front and back as 1. Park the machine on a firm, level surface. Place the
well as side to side, for any evidence of cracked transmission control lever in (N) NEUTRAL, engage
plates. If any one crack is discovered, the chain the park brake switch and raise the boom to a
should be replaced in its entirety. horizontal (level) position.
It is important, however to determine the cause of 2. Lower both outriggers completely
the crack before installing a new chain so the 3. Fully extend the boom until both extend chains are
condition does not repeat itself. taut. Shut the engine OFF.
The types of cracks are: The extend chains will be visible for inspection with the
• Fatigue Cracking - machine in this state.
Fatigue cracks (9) are 9 While doing the chain inspection, check all chain clevis
a result of repeated ends for distortion or cracking and sheaves for bearing
cyclic loading beyond MZ1467
wear or grooving from the chain.
the chain’s endurance
limit. If during the inspection, any chain is found to be damaged
or stretched, the chain must be replaced. It is
• Stress Corrosion
recommended that when any chain is replaced, that all
Cracking - The
outside link plates 10 the chains and clevises be replaced at the same time.
are particularly MZ1468
susceptible to stress d. Retract Chains
corrosion cracking (10).
The three retract chains are only partially visible through
• Corrosion Fatigue Cracking - Corrosion the rear of the boom with all the sections retracted. It is
fatigue cracks are very similar to fatigue possible to see a section of the retract chain as the boom
cracks in appearance. Corrosion fatigue is the is slowly extended. If there is ANY question that one or all
combined action of an aggressive the retract chains are damaged, the boom should be
environment and cyclic stress. removed and disassembled with the retract chains being
Other Modes of Failure inspected and replaced if necessary.
• Ultimate Strength Failure - Note: DO NOT attempt to repair a chain. Replace a
These types of failures are stretched or damaged chain with a new part. Always
caused by overloads far in 1 replace both the chain and the clevis. It is recommended
excess of the design load. MZ1469 that when any chain is replaced, that all chains and
Either fractured plates (1) or 2 clevis’ be replaced at the same time.
enlarged holes (2) can
occur. If either of these
MZ1470
failures occurs, the chain
should be replaced immediately.
3-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
37mm 20mm
1.45” .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 3.9 HOSE CARRIER ASSEMBLY - FOUR
sections two or three times. Fully retract the boom SECTION BOOM
and measure the distance between the boom
sections.
3.9.1 Hose Carrier Assembly Removal
5. If the measurements are within the tolerance, tighten
the locknuts on the chain clevises. If more 1. Remove any attachment from the quick switch
adjustment is needed, repeat procedure until the assembly. (Refer to Section 3.11.1, “Connecting with
proper boom section dimensions is achieved. a Mechanical Quick Switch Device.”)
6. With the boom sections within the proper tolerance, 2. Park the machine on a hard, level surface. Be sure
start the machine, lower the outriggers if necessary there is enough room in front and rear of the
and extend the boom to maximum extension. machine to extend the boom sections and to be able
7. Shut the machine off and measure the distance to removed the hose carrier from the rear of the
between the top of both extend chains and the boom assembly.
bottom of the second and third boom sections at the 3. Fully extend the boom and raise the boom to a
center of each boom section. horizontal position. Place the transmission control
lever in (N) NEUTRAL, engage the park brake
switch.
4. Retract the boom until the rear hose carrier
mounting bolts on the fourth boom section are
accessible through each side of the third boom
section access holes. Shut off the machine and
remove the bolts.
120mm - 4.75in 180mm - 7in
5. Start the machine and retract the boom until the
middle set of hose carrier bolts on the fourth boom
section are accessible through the third boom
MZ1220
section access holes. Shut the engine OFF and
remove the bolts.
8. The distance between the top of the extend chains
6. Start the engine and retract the boom until the front
and the bottom of the second boom section should
set of hose carrier bolts on the fourth boom section
be approximately 180 mm (7 in). The distance
are just in front of the front of the third boom section.
between the top of the extend chains and the bottom
Shut the engine OFF and remove the bolts.
of the third boom section should be approximately
120 mm (4.75 in). 7. Start the engine and slowly retract the boom
sections completely.
Note: If the second boom section to the third boom
section separation distance cannot be achieved, contact 8. Shut the engine OFF and place a Do Not Operate
the local JLG distributor or the JLG Service Department. Tag on both the ignition key switch and the steering
wheel, stating that the machine should not be
operated.
9. Relieve any trapped pressure in the tilt hydraulic
system by using the handle provided or a 9mm
wrench and move the double nut on the side of the
main control valve tilt section back and forth. Repeat
on the auxiliary valve section.
10. Locate the two hoses attached to the barrel of the tilt
cylinder inside the boomhead.
3-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
15. Remove both left and right side wear pad bolts and
both left and right bottom wear pad bolts from the
2 rear of the fourth boom section to be able to remove
the hose carrier.
16. Pull the hose carrier halfway out of the rear of the
boom, set on a suitable support. Using a sling
around the hose carrier, balance the hose carrier
and pull the remainder of the way out. Set the hose
carrier on the ground or on suitable supports.
Note: If the machine or the boom has to be moved,
replace all the bolts that were removed from the wear
pads on the rear of the fourth boom section BEFORE the
machine is started and/or the boom is retracted or
extended.
MZ0920
4
14. From the top rear of the hose carrier, remove both
bolts (3) holding the hose carrier (4) to the third
boom section.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-23
Boom
6 7
5
MZ0910
5. Align the front two threaded holes on the hose 11. Torque the middle two and front two hose carrier
carrier with the front two holes (5) on each side of bolts to 90 Nm (66 lb-ft).
the fourth boom section and install both bolts. Apply 12. Start the machine and retract the boom
Loctite®243TM and hand tighten only. completely.Shut the machine off.
3 13. Relieve any trapped pressure in the tilt hydraulic
system by using the handle provided or a 9mm
wrench and move the double nut on the side of the
main control valve tilt section back and forth. Repeat
on the auxiliary valve section.
14. Attach both tilt cylinder hoses from the hose carrier
to the tilt cylinder and tighten until wrench-tight. Mark
the hose fitting then tighten each hose firmly
1 to 1 1/2 flats.
15. Attach both auxiliary hoses from the hose carrier to
the auxiliary fittings on the bulkhead and tighten until
wrench-tight. Mark the hose fitting then tighten each
hose firmly 1 to 1 1/2 flats.
MZ0920 16. Bolt the auxiliary bulkhead onto the side of the boom
head. Apply Loctite® 243TM and torque to 50 Nm
6. Fasten the rear of the hose carrier (3) to the top rear (37 lb-ft).
of the third boom section. Apply Loctite®243TM and
torque both bolts to 90 Nm (66 lb-ft). 17. At the rear of the boom, attach both tilt cylinder
hoses to the tilt hose carrier bulkhead fittings and
7. Start the machine and extend the boom out until the tighten until wrench-tight. Mark the hose fitting then
middle set of holes (6) in the fourth boom section tighten each hose firmly 1 to 1 1/2 flats.
align with access holes at the front sides of the third
boom section. Shut off machine. 18. At the rear of the boom, attach both auxiliary hoses
to the auxiliary hose carrier bulkhead fittings and
8. Align the middle two threaded holes on the hose tighten until wrench-tight. Mark the hose fitting then
carrier with the middle two holes on the fourth boom tighten each hose firmly 1 to 1 1/2 flats.
section and install both bolts. Apply Loctite® 243TM
and hand tighten only. 19. Start the engine and operate all boom functions
several times. Check for leaks, and check the
9. Start the machine and extend the boom out until the hydraulic oil level in the reservoir; add oil if required.
rear set of holes (7) in the fourth boom section align
with access holes on each side of the third boom
section. Shut off machine.
10. Align the rear two threaded holes on the hose carrier
with the rear two holes on the fourth boom section
and install both bolts. Apply Loctite® 243TM and
torque to 90 Nm (66 lb-ft).
3-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3.10 BOOM WEAR PADS • The number of shims can vary at each shim point.
• The bottom wear pads must be shimmed equally on
The wear pads on this machine are flat rectangular wear each side.
pads with metal inserts. 5
A total of 13 wear pads are installed on the boom sections
of the 8 & 9M machines.
A total of 26 wear pads are installed on the boom sections
of the 12 & 13M machines.
A total of 50 wear pads are installed on the boom sections
of the 17M machines.
Inspect all wear pads for wear. If the angle indicators (1)
on the ends of the wear pads are visible, the wear pads
B
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
worn or damaged. MY3620
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-25
Boom
• Torque wear pad bolts after shimming is completed. 3.11.2 Connecting with a Hydraulic Quick
• Lubricate the face and pockets of each wear pad Switch Device
after being installed. 1. Retract quick switch device to provide clearance.
Boom Section Wear Pad Pathway Lubrication: Check to be sure lock pin is disengaged.
• Clean and lightly grease all wear pad pathways with 2. Align attachment pin (8) with recess in
Mystik Tetrimoly grease. attachment (9). Raise boom slightly to engage
• Clean and lightly grease the hose carrier guide bar attachment pin in recess.
pathways with Mystik Tetrimoly grease. 3. Engage quick switch device.
4. Shut off engine. Exit cab and insert lick pin and 3. Connect the quick-disconnect fittings.
secure with retainer pin. 4. Start the engine.
5. If attachment is equipped, connect auxiliary
hydraulic hoses. See Section 3.11.3, “Connecting
with a Quick Switch to a Hydraulic Operated
Attachment.”
3-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
3
12 6
7
5 4
13
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-27
Boom
3.13 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the boom.
2. Boom will not fully extend. 1. Extend/retract hydraulic system 1. Refer to Section 8, “Hydraulic
not operating properly. System.”
3. Boom shifts to right or left 1. Boom side wear pads 1. Shim wear pads to correct gap.
when extending. improperly shimmed or worn. Replace wear pads as needed.
Refer to Section 3.10.2, “Wear
Pad Installation and
Lubrication.”
4. Excessive pivot pin noise 1. Insufficient lubrication. 1. Lubricate at regular intervals.
and/or wear. Refer to Section 2.6,
“Lubrication Schedules.”
Replace worn pins as needed.
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s)
and/or connection leaks. or tube(s), tighten connections.
3-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Boom
7. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic
operate. operating properly. System.”
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3-29
Boom
3-30 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 4
Cab and Covers
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-1
Cab and Covers
LOAD STABILITY
INDICATOR
HEATER & AC
CONTROLS
DISPLAY
PANEL
TRANSMISSION
CONTROL LEVER
BRAKE FLUID
JOYSTICK
RESERVOIR
POWER/
EMERGENCY
STOP SWITCH
(IF EQUIPPED)
IGNITION
SERVICE BRAKE
PEDAL
ACCELERATOR
PEDAL
PARKING BRAKE
MZ2061
LEVER
4-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers
WARNING
DO NOT service the machine without following all 2
safety precautions as outlined in the “Safety 4
Practices” section of this manual.
4-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers
c. Throttle Adjustment
1. Adjust the distance on each end of the throttle cable
from the locknut to the connector end. The distance MZ2030
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-5
Cab and Covers
4-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers
4.3.6 Parking Brake (17M) 2. Uncap and connect the previously labeled hydraulic
hoses to the park brake.
a. Park Brake Removal 3. Connect the park brake electrical connector switch.
1. Park the machine on a firm, level surface, level the 4. Check the routing of all hoses for sharp bends or
machine, fully retract the boom, lower the boom, interference with any rotating members, and install
place the transmission control lever in (N) tie wraps and/or protective conduit as required.
NEUTRAL, engage the park brake and shut the
5. Start the engine and run at approximately 30-50%
engine OFF.
throttle for about one minute, without moving the
2. Place a Do Not Operate Tag on both the ignition key machine or operating any hydraulic functions.
switch and the steering wheel, stating that the
6. Bleed air from the brake circuit. Refer to Section
machine should not be operated.
8.9.3, “Brake Test.”
3. Open the engine cover. Allow the system fluids to
7. Inspect the park brake valve and connections for
cool.
leaks, and check the level of the hydraulic oil in the
4. Block the wheels. reservoir. Shut the engine OFF.
5. Properly disconnect the battery. 8. With the park brake applied, check the display panel
for the proper indicator light.
9. Wipe up any hydraulic oil spillage in, on, near and
around the machine, work area and tools.
10. Reinstall the cover around the park brake lever.
11. Properly connect the battery.
12. Unblock the wheels.
13. Close and secure the engine cover.
3
4 14. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-7
Cab and Covers
6. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap. 10. Loosen the hose clamps and disconnect the heater
hoses (6).
7. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the 11. Remove the heat duct hoses (7) from the back side
drain plug and slowly remove to allow the coolant to of the heating unit assembly.
drain. Transfer the coolant into a suitable, covered 12. Label and disconnect the electrical connectors
container and label as "Used Coolant". Dispose of attached to the heater assembly.
the used coolant at an approved recycling facility. 13. Remove the heater assembly mounting bolts.
Clean and reinstall the drain plug.
14. Carefully lift the heater assembly and remove from
the cab.
4-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers
DO NOT disassemble the cab heater and fan controls. 1. Park the machine on a firm, level surface, level the
The controls are not serviceable. Replace controls if machine. Allow sufficient overhead and side
found to be defective. clearance for cab removal. Fully retract the boom,
lower the boom, place the transmission control lever
in (N) NEUTRAL, engage the park brake and shut
the engine OFF.
2. Block the wheels.
3. Open the engine cover. Allow the system fluids to
cool.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-9
Cab and Covers
cover. Disconnect the park brake switch connector 14. Install two lifting eye bolts with a suitable lifting
and park brake cable. capacity in the existing threaded holes (1) at the top
corners of the windshield.
17M machines: Remove the park brake cover.
15. Secure the cab with a hoist or overhead crane and
Label, disconnect and cap the hydraulic hoses
sling. Do not lift the cab at this time.
attached to the park brake lever. Cap all fittings to
keep dirt and debris from entering the hydraulic
system. Disconnect the park brake switch.
12. Working under the cab, label, disconnect and cap
the hydraulic hoses at the cab fittings. Plug the
hoses and cap the fittings.
13. Disconnect the throttle cable from the throttle pedal
lever. Push the throttle cable through the bottom of
the cab.
2
MZ0640
4-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Cab and Covers
17. Remove the mirrors and all other cab components 17M machines: Route the park brake hydraulic
as needed, if not previously removed. hoses back into the cab. Uncap and connect the
18. Use a hoist or overhead crane and sling attached to previously labeled hydraulic hoses to their
the cab, carefully begin to lift the cab. Stop and appropriate locations. Connect the previously
check that all wiring, hydraulic hoses and fasteners labeled electrical connector to the park brake lever.
are disconnected or removed. 8. Connect the throttle cable to the throttle pedal lever.
19. When all wiring, hydraulic hoses and fasteners are Adjust the throttle as required.
disconnected or removed, carefully and slowly lift 9. Route any hydraulic hoses through the opening at
the cab and remove it from the frame. the right front corner of the cab.
20. When the cab is completely clear of the machine, 10. Uncap and connect the previously labeled hydraulic
carefully lower it to the ground. Block up or support hoses to their appropriate locations.
the cab so that it does not move or fall over. Assure 11. Connect the previously labeled windshield wiper
that no personnel enter the cab while it is being fluid lines to the appropriate locations.
removed from the machine.
12. Route the wiring harness connectors through the
21. Inspect the condition of the fittings, clamps, opening at the right front corner of the cab and up
hydraulic hoses, etc. Replace parts as indicated by into the side console.
their condition.
13. Connect the previously labeled cab-to-wiring
22. Inspect and replace other machine parts that are harness connectors.
exposed with the cab removed. Repair or replace as
required. 14. Install the right side console panel, the right rear side
panel, the left rear cup holder panel and the rubber
floor mat.
4.5 CAB INSTALLATION
15. Fill the cooling system completely with coolant,
1. Block all four wheels to help prevent the machine allowing time for the coolant to fill the engine block.
from moving. Assure that there is sufficient overhead The cooling system capacity is listed in Section 2.4,
and side clearance for cab installation. “Fluids, Lubricants and Capacities.”
2. Attach a sling with suitable lifting capacity through 16. Properly connect the battery.
the previously installed eye bolts on top of the cab. 17. Start the engine and check the operation of all
3. Using a hoist or overhead crane and sling attached controls. Check for hydraulic leaks. Check the
to the two lifting eyes, carefully begin to align the cab hydraulic oil level in the tank and add oil as required.
with the mounting holes in the frame. Stop and
Note: When the engine is initially started, run it briefly at
check that wiring, hydraulic hoses, cables, etc., will
low idle and check the machine for any visual sign of
not be pinched or damaged as the cab is positioned.
fluid leakage. STOP the engine immediately if any
Readjust the position of the sling as needed to help
leakage is noted, and make any necessary repairs
balance the cab during installation.
before continuing.
4. Install the four bolts through the cab/frame mounts
and install the four washers and nuts. Remove the 18. Wait for the engine to cool and check the coolant
sling and both lifting eye bolts. Tighten and torque level. Add coolant to the overflow bottle as required
the four mounting bolts to 150 Nm (110 lb-ft). to bring the coolant to the proper level.
5. Uncap and connect the previously labeled heater 19. Reinstall engine belly pan.
hoses to the heater assembly. 20. Reinstall the cab bottom shield.
6. Uncap and connect the previously labeled air 21. Close and secure the engine cover.
conditioner lines (if equipped) to the heater 22. Unblock the wheels.
assembly.
23. Remove the Do Not Operate Tags from both the
7. 8, 9, 12, & 13M machines: Route the park brake ignition key switch and the steering wheel.
cable back into the cab. Secure the park brake cable
to the park brake lever with the pre-existing pin.
Connect the previously labeled electrical connector
to the park brake lever.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4-11
Cab and Covers
4-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-1
Axles, Drive Shafts, Wheels and Tires
REAR AXLE
ASSEMBLY
STEERING
CYLINDER
(REAR)
TRANSMISSION
DROP BOX
STEERING
CYLINDER
(FRONT)
DRIVE SHAFTS
MZ1510
FRONT
AXLE
ASSEMBLY
5-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-3
Axles, Drive Shafts, Wheels and Tires
5.3.5 Axle Removal allow the axle oil to drain into the receptacle.
Transfer the used axle oil into a suitable covered
The front and rear axle assemblies differ in that the front
container, and label the container as "Used Oil".
axle assembly is equipped with a parking brake
Dispose of used oil at an approved recycling facility.
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal 7. Label, disconnect and cap the steering and brake
procedure, suitable for either the front or the rear axle lines at the axle. Wipe up any spilled oil.
assembly. 8. Block the front and rear of both tires on the axle that
Cleanliness is extremely important. Before attempting to is not being removed. Ensure that the machine will
remove the axle, thoroughly clean the machine. Avoid remain in place during axle removal before
spraying water or cleaning solution on the outrigger proceeding.
solenoids and other electrical components. If using a 9. Raise the machine using a suitable jack or hoist.
steam cleaner, seal all openings before steam cleaning. Place suitable supports under both sides of the
Note: Clear the work area of all debris, unnecessary frame and lower the machine onto the supports.
personnel, etc. Allow sufficient space to raise the Ensure that the machine will remain in place during
machine and to remove the axle. axle removal.
10. Support the axle that is being removed with a suitable
1. Park the machine on a firm, level surface, level the
jack, hoist or overhead crane and sling. DO NOT
machine, fully retract the boom, lower the boom,
raise the axle or the machine.
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 11. Mark and remove both wheel and tire assemblies
engine OFF. from the axle that is being removed. Refer to Section
5.5.1, “Removing Wheel and Tire Assembly from
2. Place a Do Not Operate Tag on both the ignition key
Machine.”
switch and steering wheel, stating that the machine
should not be operated. 12. Remove the drive shaft assembly. Refer to Section
5.4.3, “Drive Shaft Removal.”
3. Open the engine cover. Allow the system fluids to
cool. 13. On the front axle, remove the hardware securing the
frame level cylinder or bar. Tap the mount pin out,
4. Properly disconnect the battery.
and move the cylinder or bar to prevent it from
5. Remove the fender assemblies. interfering with axle removal.
14. Remove the park brake cable from the front axle (8,
9, 12 & 13M only).
15. Remove the bolts and locknuts securing the axle to
the frame.
16. Remove the axles from the machine using the jack,
MZ1030 hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the
1 machine while removing the axle. Balance the axle
and prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
5-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires
turning or falling while positioning it beneath the 11. Rotate wheel hubs 90 degrees so the drain plug (5)
machine. DO NOT raise or otherwise disturb the becomes the fill plug. Refer to Section 2.4, “Fluids,
machine while installing the axle. Keep the axle Lubricants and Capacities,” for proper oil and
supported and balanced on the jack, hoist or capacities.
overhead crane and sling throughout the installation
procedure. 12. Install the wheel and tire assemblies. Refer to
Section 5.5.2, “Installing Wheel and Tire Assembly
4. Position the axle under the frame, and align the axle onto Machine.”
housing with the holes in the frame.
13. Carefully remove the jack, hoist or overhead crane
5. Install the axle bolts and nuts. Tighten and torque and sling supporting the axle.
the axle nuts to 550-600 Nm (406-443 lb-ft).
14. Carefully raise the machine using a suitable jack or
6. Move the cylinder or bar into position on the front hoist. Remove the supports from beneath the frame
axle anchor (if necessary). Install the mount pin. and lower the machine to the ground.
7. Apply a multi-purpose grease through the self-
Note: ALWAYS use new o-rings when servicing the
tapping lube fitting to lubricate the self-align bearing
machine.
and the cylinder-mount pin (if required).
8. Install the drive shaft assemblies. Refer to Section 15. Install new o-rings into the fittings. Lubricate the
5.4.5, “Drive Shaft Installation.” o-rings with clean hydraulic oil.
9. If reinstalling an axle previously removed from the 16. Uncap and connect the steering and brake lines at
machine, position the driveshaft yoke on the axle their axle fittings.
according to the alignment marks made earlier. If 17. Install the park brake on the front axle (8, 9, 12 &
installing a new axle, note the position of the 13M only).
driveshaft yoke at the transmission. Align the 18. If reinstalling the front axle, the hydraulic brake
driveshaft yoke on the axle in the same plane as the circuit will need to be bled. Refer to Section 8.9.3,
yoke on the transmission. “Brake Test.”
3 19. Check the hydraulic reservoir oil level.
20. Install the fender assemblies.
21. Properly connect the battery.
22. Unblock the wheels.
23. Start the engine. Turn the steering wheel several
times lock to lock, operate the frame tilt function
MZ1030
several times in both directions and check the
4 function of the brakes. Check for hydraulic leaks,
10. Tighten the axle oil drain plug, loosen and remove and tighten or repair as necessary.
the axle oil fill plug (3). Fill the axle through the axle 24. Close and secure the engine cover.
fill plug until the oil level is even with the oil check
level plugs (4). Refer to Section 2.4, “Fluids, 25. Remove the Do Not Operate Tags from both the
Lubricants and Capacities,” for proper oil and ignition key switch and the steering wheel.
capacities.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-5
Axles, Drive Shafts, Wheels and Tires
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
5-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace o-rings as needed and
housing (planet carrier). o-rings damaged or missing. tighten plugs to 130 Nm
(96 lb-ft).
2. O-ring between hub and 2. Replace o-ring.
housing (planet carrier)
damaged or missing.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-7
Axles, Drive Shafts, Wheels and Tires
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level
filled with incorrect oil or oil with Mobilfluid 424® ISO 46.
contaminated or oil level low. Refer toSection 2.4, “Fluids,
Lubricants and Capacities.”
3. Dragging park brake. 3. Adjust park brake cable as
needed.
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.10.8,
operating properly. “Steering Cylinders.”
10. Excessive noise when brakes 1. Brake discs worn. 1. Check brake discs for wear.
are engaged. Refer to Section 5.6, “Brakes.”
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.10.8,
operating properly. “Steering Cylinders.”
5-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-9
Axles, Drive Shafts, Wheels and Tires
WARNING
Mismatched tire sizes, ply ratings or mixing of tire
types (radial tires with bias-ply tires) may compromise
machine stability and may cause machine to tip over.
JLG recommends a replacement tire to be the same size,
ply and brand as originally installed. Refer to the
appropriate parts manual for ordering information. If not
using a JLG approved replacement tire, JLG
MY4190
recommends that replacement tires have the following
characteristics: The wheel and tire assemblies must be installed with the
• Equal or greater ply/load rating and size of original. directional tread pattern “arrows” (5) facing in the
direction of forward travel.
• Tire tread contact width equal or greater than
original.
5.5.1 Removing Wheel and Tire Assembly
• Wheel diameter, width and offset dimensions equal from Machine
to the original.
1. Park the machine on a firm, level surface, level the
• Approved for the application by the tire manufacturer machine, fully retract the boom, lower the boom,
(including inflation pressure and maximum tire load). place the transmission control lever in
The rims installed have been designed for stability (N) NEUTRAL, engage the park brake and shut the
requirements which consist of track width, tire pressure engine OFF.
and load capacity. Size changes such as rim width, 2. Place a Do Not Operate Tag on both the ignition key
center piece location, larger or smaller diameter, etc., switch and steering wheel, stating that the machine
without written factory recommendations, may result in should not be operated.
unsafe condition regarding stability.
3. Loosen, but DO NOT remove the lug nuts on the
The tires are filled with air only when the machine leaves wheel and tire assembly to be removed.
the factory. JLG does not recommend the use of hydrofill
as a tire-fill substance because of possible environmental 4. Place a suitable jack under the axle pad closest to
impact. the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
Large-bore valve stems are used to help expedite tire sufficient room to lower the machine onto the
inflation and deflation. An inner tube may be used if a tire support and to remove the wheel and tire assembly.
does not provide an airtight seal. Check tire inflation
pressures when the tires are cold. When mounting a tire 5. Lower the machine onto the support.
on the wheel, the tire must be mounted on the wheel 6. Remove lug nuts and lug washers in an alternating
respective of the directional tread pattern of the tire; this pattern.
produces a left or right tire and wheel assembly. 7. Remove the wheel and tire assembly from the
machine.
5-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Axles, Drive Shafts, Wheels and Tires
MZ1030
6
2. Remove the oil-level plug (6) on each side of the
axle.
3. Have an assistant sit in the cab and apply the
brakes, keeping pressure applied.
Mh3300
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5-11
Axles, Drive Shafts, Wheels and Tires
5.7 TOWING A DISABLED MACHINE Note: Turning the release bolts in to far could warp the
brake discs. DO NOT over tighten.
Towing a disabled machine should only be attempted as
Note: After the machine has been towed to a secure
a last resort, after exhausting all other options. Make
location, reactivate the park brake. Carefully follow the
every effort to repair the machine, and move it under its
procedures from start to finish. Consult your local JLG
own power, before using the emergency towing
distributor or the JLG Service Department if you are
procedures outlined below.
unsure about any part of the procedure, or for specific
On 17M machines, the park brake is hydraulically instructions concerning your particular situation.
operated. Therefore, the axle must have the park brake
manually be disabled. On 8, 9, 12 & 13M machines, the 5.7.3 Manually Resetting the Park Brake
park brake is cable operated and can be disabled in the (17M)
cab with the park brake lever.
Note: Block the wheels of the machine BEFORE
attempting to reset the machine’s park brake. Once the
5.7.1 Towing (8, 9, 12 & 13M)
park brake is reset the machine’s park brake AND
1. Secure the machine to a suitable towing vehicle. service brakes are operable.
2. Release the park brake and set the transmission 1. Loosen the jam nuts on all four manual brake
control lever in (N) NEUTRAL. release bolts.
3. Tow the machine to a suitable repair facility. 2. Turn all four manual brake release bolts OUT a
4. After towing is complete, engage the park brake. quarter turn at a time to the dimension recorded
before starting the towing procedure.
5.7.2 Manually Releasing the Park Brake 3. Tighten the jam nuts on all four manual brake
(17M) release bolts.
Note: Block the wheels of the machine BEFORE After repairs to the machine have been made, start the
attempting to release the park brake. Once the park machine and check the park brake and service brakes for
brake is released the machine’s park brake AND service proper function.
brakes are inoperable.
9
MZ1020
5-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 6
Transmission:
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-1
Transmission:
TORQUE CONVERTOR
DIPSTICK AND FILL TUBE
OIL FILTER
OUTPUT SHAFT
(FRONT)
BREATHER
OUTPUT SHAFT
(REAR)
BREATHER
MZ0670
TRANSMISSION DROP BOX
SHIFT SOLENOIDS
FLEX PLATE ASSEMBLY
6-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-3
Transmission:
6.5.1 Transmission Removal 11. Remove the air cleaner unit and intake tubes.
12. Remove the hydraulic pump. Refer to Section 8.7.3,
6-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
27. Lift the transmission clear of the machine, and lower 6.5.3 Transmission Installation
it onto suitable supports or secure it to a stand built
1. Install both the rear transmission mounts on the
especially for transmission or engine service. Secure
transmission. Torque capscrews to 120 Nm
the transmission so that it will not move or fall.
(88 lb-ft).
28. Remove any external transmission components as
2. Install guide studs near the top of the bell housing
required, including the transmission temperature
holes and in the flex plate.
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings. 3. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
3
4. Align the torque convertor, align the transmission
bolt holes with the guide studs in the bell housing
and flex plate. Install the eight bolts and washers
and torque to 63 Nm (46 lb-ft). Remove the
alignment studs and install and torque the last two
transmission mount bolts and torque to 63 Nm
(46 lb-ft).
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite® 243TM to the transmission mount bolts
and torque to 210 Nm (155 lb-ft).
6. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Install
them one at a time. Torque to 35-39 Nm (26-29 lb-ft).
Replace access plug.
MZ0680
7. Remove the hoist or overhead crane and sling.
29. Remove the transmission oil filter (3) and dispose of
8. Connect the transmission temperature switch
properly. Clean the filter mounting surface. Cover or
connector and shift solenoid wiring harness
cap the oil filter mount.
connectors.
30. If transmission oil is suspected of contamination or
9. Secure the wiring harness to the transmission
torque convertor is damaged, remove the convertor
housing.
and flex plate from the transmission.
10. Uncap and connect the transmission oil cooler inlet
31. Remove the six bolts and washers holding the
and outlet hoses at the transmission.
convertor to the flex plate.
11. Install the hydraulic pump. Refer to Section 8.7.3,
6.5.2 Transmission Inspection and Internal “Pump Replacement.”
Repair 12. Install the transmission-to-axle drive shafts. Refer to
If replacing the entire transmission, transfer the Section 5.4.5, “Drive Shaft Installation.”
transmission temperature switch to the replacement 13. Install air cleaner and tubing.
transmission. The gear shift solenoids are included with a 14. Clean the transmission oil filter mounting surface.
new transmission.
15. Apply a thin film of clean hydraulic oil to the new
Detailed internal service instructions are provided in the transmission filter gasket. Install the new filter and
Dana Spicer Repair Manual, which can be obtained by torque to 27-34 Nm
contacting your local JLG Distributor. (20-25 lb-ft).
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-5
Transmission:
6-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-7
Transmission:
3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level
with Mobilfluid 424® ISO
Grade 46. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”
2. Main pressure valve stuck open. 2. Clean the valve spool and
housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.5, “Hydraulic
Schematics.”
6-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Transmission:
6. Grinding or “clunking” noise 1. Oil level too low. 1. Fill oil to correct level. Refer to
from transmission. Section 2.4, “Fluids, Lubricants
and Capacities.”
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6-9
Transmission:
6-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 7
Engine: Perkins 1104-42 & 1104-42T
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-1
Engine: Perkins 1104-42 & 1104-42T
7-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T
FUEL INJECTION
PUMP
FUEL FILTER
OIL FILTER
THERMOSTAT
ALTERNATOR
TURBOCHARGER
STARTER
MZ0070
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-3
Engine: Perkins 1104-42 & 1104-42T
7.3 SPECIFICATIONS AND 2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
MAINTENANCE INFORMATION should not be operated.
For engine, coolant and oil specifications, and 3. Open the engine cover. Allow the system fluids to
maintenance information, refer to Section 2, “General cool.
Information and Specifications.” 4. Properly disconnect the battery.
Note: These instructions cover only the routine 5. Slowly turn the radiator cap to the first stop and allow
maintenance, removal, installation and troubleshooting any pressure to escape. Remove the radiator cap.
of the engine. Refer to your local Perkins Engine 6. Place a funnel at the base of the radiator to channel
Distributor for assistance with comprehensive engine the drained coolant into the container. Loosen the
diagnosis, repair and component replacement. drain plug and slowly remove to allow the coolant to
drain. Transfer the coolant into a properly labeled
7.4 ENGINE COOLING SYSTEM container. Dispose of properly if coolant needs to be
replaced. Replace the radiator drain plug.
7.4.1 Radiator Pressure Cap
For a 99° C (210° F) system, use a 90 kPa (13 psi) 1
radiator cap. An incorrect or malfunctioning cap can
result in the loss of coolant and a hot-running engine.
7-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-5
Engine: Perkins 1104-42 & 1104-42T
15. Remove the air conditioner condenser (if equipped) 7.5 ENGINE ELECTRICAL SYSTEM
from the radiator assembly.
16. Carefully lift the radiator/oil cooler out of the engine The engine electrical system, including the starter,
bay. alternator and primary wiring, is described in Section 9,
“Electrical System.”
Note: If applicable the radiator can be removed with the
radiator frame. Remove the five bolts holding the 7.6 FUEL SYSTEM
radiator frame to the machine frame and remove the
radiator and radiator frame as one unit.
7.6.1 Diesel Fuel
b. Radiator/Oil Cooler Installation Fuel represents a major portion of machine operating
1. Install the isolator mounts to the bottom of the costs and therefore must be used efficiently. ALWAYS
radiator. Insert radiator through the machine frame use a premium brand of high-quality, clean diesel fuel.
mounts and install the washers and new locknuts. Low cost, inferior fuel can lead to poor performance and
expensive engine repair.
2. Install the air conditioner condenser (if equipped) to
the radiator assembly. Note: Use only diesel fuel designed for diesel engines.
3. At the top of the radiator, install the isolator mounts. Some heating fuels contain harmful chemicals that can
Install the washers and new locknuts on the back seriously affect engine efficiency and performance.
side of the weldment. Note: Due to the precise tolerances of diesel injection
4. Be sure the engine fan has clearance in regard to systems, keep the fuel clean, and free of dirt and water.
the radiator. Install the radiator fan shroud. Dirt and water in the fuel system can cause severe
damage to both the injection pump and the injection
5. Uncap and connect the previously labeled oil cooler
nozzles. Use ASTM #2 diesel fuel with a minimum Cetane
top (6) and bottom (7) hoses to their appropriate
rating of 40. #2 diesel fuel gives the best economy and
locations.
performance under most operating conditions. Fuels
6. Uncap and connect the previously labeled radiator with Cetane numbers higher than 40 may be needed in
top (4) and bottom (5) hoses to their appropriate high altitudes or extremely low ambient temperatures to
locations. help prevent misfiring and excessive smoking.
7. Uncap and connect the previously labeled air Inform the owner/operator of the machine to use #2
conditioner hoses (8) (if equipped) to their diesel fuel, unless ambient temperatures are below 0° C
appropriate locations. (32° F). When temperatures are below 0° C (32° F), a
8. Open the radiator cap and fill the radiator completely blend of #1 diesel and #2 diesel fuels (known as
with coolant. Replace and tighten the radiator cap. “winterized” #2 diesel) may be used.
Add coolant to the overflow bottle until the bottle is 1/
Note: #1 diesel fuel may be used, however, fuel
4 to 1/2 full. This overfilling will compensate for any
economy will be reduced.
air trapped in the cooling system.
9. Properly connect the battery. Use a low-sulfur content fuel with a cloud point (the
temperature at which wax crystals form in diesel fuel) at
10. Run the engine to operating temperature. Visually
least 10° below the lowest expected fuel temperature.
check for leaks with the engine running. Check the
The viscosity of the fuel must be kept above 1.3
coolant level in the overflow bottle and fill, or drain as
centistrokes to provide adequate fuel system lubrication.
necessary.
11. Install the engine cover. Note: When using diesel fuel with a sulfur content below
1.3 percent, the filter change interval must be reduced by
12. Install the belly pan. 75 hours. The use of fuel with a sulfur content above
13. Close and secure the engine cover. 1.3 percent is not recommended.
14. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
7-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T
7.6.2 Fuel Tank properly. Reinstall the fuel tank drain plug and torque
to 26 Nm (19 lb-ft).
Note: The fuel tank is a one piece unit. It is located at
the rear of the machine, between the frame. If it is 7. Loosen and remove the strap over the fuel tank and
determined that the fuel tank must be removed, the fuel disconnect the fuel hoses from the tank.
must be drained before tank removal. Always dispose of 8. Disconnect fuel level sender (10) electrical
fuel properly. connectors from the fuel level sender.
9. Remove screws securing fuel sender to the tank.
a. Fuel Tank Removal Remove fuel sender from tank.
1. Park the machine on a firm, level surface, level the 10. Lift the empty fuel tank from between the frame rails.
machine, raise the boom to access the fuel tank,
place the transmission control lever in b. Disassembly
(N) NEUTRAL, engage the park brake and shut the
engine OFF. The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed
2. Place a Do Not Operate Tag on both the ignition key
and reused on the new replacement tank.
switch and steering wheel, stating that the machine
should not be operated.
c. Cleaning and Drying
3. Open the engine cover. Allow the engine to cool.
If contaminated fuel or foreign material is in the tank, the
4. Remove the boom. Refer to Section 3.3.1, “Boom tank can usually be cleaned.
Removal.”
Note: If a leak is suspected in the fuel tank, contact your
5. Properly disconnect the battery.
local JLG distributor.
Note: If replacing the tank, remove all internal and
To clean the fuel tank:
external components from the old tank, and retain for
use on the replacement tank. 1. Have a dry chemical (Class B) fire extinguisher near
the work area.
Note: Have a dry chemical (Class B) fire extinguisher
near the work area. 2. Remove the fuel or oil tank drain plug, and safely
drain any fuel into a suitable container. Dispose of
fuel properly.
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes and
drain the water. Dispose of contaminated water
10 properly.
4. Add a diesel fuel emulsifying agent to the tank. Refer
to the manufacturer’s instructions for the correct
emulsifying agent-to-water mixture ratio. Refill the
tank with water, and agitate the mixture for 10
minutes. Drain the tank completely. Dispose of
contaminated water properly.
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.
d. Assembly
The fuel level indicator can be removed and reused on
the new replacement tank. Dispose of the old tank
according to local regulations concerning hazardous
9 materials disposal.
MZ2690
6. Remove fuel tank drain plug (9), and drain fuel into
an approved and suitable container. Dispose of fuel
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-7
Engine: Perkins 1104-42 & 1104-42T
7.6.3 After Fuel System Service 10. Loosen and remove the two bolts at the front and
one bolt at the rear of the muffler, and remove the
1. Drain and flush the fuel tank if it was contaminated. muffler.
2. Replace all engine fuel filters and check fuel/water
separator. 7.7.2 Exhaust System Installation
3. Vent air from the fuel system in accordance with the Note: Keep all clamps loosened until entire exhaust
instructions found in the appropriate Operation & system is in place.
Safety Manual.
1. Install the exhaust pipe with a new seal to the
4. Fill the fuel tank with fresh, clean diesel fuel as required. exhaust manifold.
2. Install the exhaust pipe clamp under the engine.
3. Install the muffler to the exhaust pipe and bolt the
muffler to the side of the frame.
4. Install the clamp securing the muffler to the exhaust
pipe.
5. Install the clamp securing the muffler to the tail pipe.
7-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T
6. Adjust the muffler, exhaust and tail pipes for proper 6. Remove the clamp securing the air intake boot (11)
clearance then tighten all clamps. to the air cleaner assembly. Lift the air intake boot off
7. Properly connect the battery. the air cleaner.
8. Start engine and check for exhaust leaks at all 7. Remove the clamp securing the air outlet elbow (12).
exhaust connections. Adjust or repair as needed. Lift the air outlet elbow off the air cleaner.
9. Install the belly pan. 8. Remove the two capscrews and ripp nuts securing
the air cleaner mounting bracket to the air cleaner
10. Close and secure the engine cover. mounting plate. Remove the air cleaner assembly.
11. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. 7.8.2 Air Cleaner Assembly Installation
Note: Apply Loctite® 243TM threadlock to the capscrew
7.8 AIR CLEANER ASSEMBLY threads before installation.
1. With the air cleaner assembly attached, install the air
CAUTION cleaner mounting bracket using capscrews and ripp
nuts.
NEVER run the engine with only the inner safety 2. Place the loosened clamp over the air intake boot,
element installed. and install boot on the air cleaner assembly.
Note: Refer to the appropriate Operation & Safety 3. Place the loosened clamp over the air outlet elbow
Manual for the correct element change procedure. and install elbow on the air cleaner assembly.
4. Connect low pressure indicator wire connection.
7.8.1 Air Cleaner Assembly Removal
5. Adjust and tighten both clamps before starting the
1. Park the machine on a firm, level surface, level the machine.
machine, fully retract the boom, lower the boom,
6. Properly connect the battery.
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the 7. Close and secure the engine cover.
engine OFF. 8. Remove the Do Not Operate Tags from both the
2. Place a Do Not Operate Tag on both the ignition key ignition key switch and the steering wheel.
switch and steering wheel, stating that the machine
should not be operated. 7.9 ENGINE REPLACEMENT
3. Open the engine cover. Allow the engine to cool.
4. Properly disconnect the battery. 7.9.1 Engine Removal
5. Disconnect the low pressure indicator wire 1. Park the machine on a firm, level surface, level the
connection on the air cleaner. machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
11
should not be operated.
3. Open the engine cover. Allow the engine to cool.
12 4. Disconnect the (+) positive and (-) negative battery
cables and remove the battery.
5. Remove the engine cover, radiator guard plate and
the engine belly pan.
6. Drain and remove the radiator assembly. Refer to
MZ2010 Section 7.4.3, “Radiator/Oil Cooler and Coolant
Heater Replacement.”
7. Remove the heater hoses attached to the engine.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-9
Engine: Perkins 1104-42 & 1104-42T
Note: The engine harness is routed and attached to the 19. Turn the engine over slowly by hand and align each
engine using hold-down clamps and plastic wire ties at of the eight flex plate bolts to be accessed. Remove
various places on the engine. Before removing engine, them one at a time.
ensure that the harness has been completely separated 20. Secure the engine with a lifting strap or chain from
(disconnected) from the engine. Move the harness clear the appropriate lifting points. Use a suitable hoist or
of the engine, and with the help of an observer, ensure overhead crane.
that engine clears the harness during removal.
8. Label and disconnect all wire harness connections
on the engine.
9. Unbolt and remove the hood latch plate. Mark the
plate to help with hood adjustment when being
reinstalled.
14
10. Unbolt the return hydraulic oil filter plate and leave in
place.
11. Disconnect and cap the fuel inlet line at the fuel filter
head.
12. Disconnect and cap the fuel return line from the fuel
filter head.
MZ2170
21. At the rear right engine mount (14), remove the bolt
and washer. Repeat for the rear left engine mount.
22. Place a support or jack under the transmission to
hold the transmission in place while engine is being
removed.
23. Remove the ten bolts holding the transmission to the
engine. Slightly lift and pull the engine out of the
machine. Have an assistant ensure that the engine
clears all frame components during removal.
13 24. Place engine on a flat, level surface.
MZ0940
13. Mark the location of the throttle cable (13) at the 7.9.2 Engine Disassembly, Inspection and
throttle cable mount. Loosen jam nuts and remove. Service
14. Disconnect the throttle cable at the engine throttle Engine disassembly, internal inspection, service, repair
lever. and assembly procedures are covered in the Perkins
service manual. Several special engine service tools are
15. Remove the exhaust pipe from the exhaust
required to properly service the engine. Contact your local
manifold. Refer to Section 7.7.1, “Exhaust System
Perkins Service partner for further information.
Removal.”
Note: If the engine is being replaced, there may be external
16. Loosen the clamps on the sleeve reducer at the
components that will be required to be transferred from the
engine and on the air suction pipe.
original engine to the replacement engine depending upon
17. Remove the air cleaner assembly. Refer to Section who you purchase the new engine from and the
7.8.1, “Air Cleaner Assembly Removal.” configuration of your replacement engine. Refer to the
18. Remove the access plug from side of the engine bell appropriate Perkins user manual for detailed procedures
housing. This will allow access to remove the eight that cover the transfer of original engine components to the
bolts holding the flex plate to the engine flywheel. replacement engine.
7-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T
7.9.3 Engine Installation 17. Install the hood latch plate. Align the mark on the
plate to help with hood adjustment.
1. Attach a lifting chain to the front and rear engine lift
brackets, and lift engine clear of the ground. 18. Secure the return hydraulic oil filter plate to the
frame.
Note: Apply Loctite® 243TM threadlock to the engine
mount bracket capscrew threads before installation. 19. Install both heater hoses to the engine and tighten
clamps.
2. Inspect the front engine mounting bracket isolator.
20. Install the complete radiator assembly. Refer to
Replace isolator if cracked or worn.
Section 7.4.3, “Radiator/Oil Cooler and Coolant
3. Install two guide studs in the bell housing holes. Heater Replacement.”
4. Lift the engine and slowly push and lower into the 21. Install the hose clamp on the bottom radiator hose
engine bay. Have an assistant ensure that the and work onto the engine. Tighten the clamp.
engine clears all frame, hose and harness
22. Install the hose clamp on the top radiator hose and
components during engine installation. Position
work onto the engine. Tighten the clamp.
engine brackets over the front frame mounts.
23. Connect the transmission inlet and outlet hoses on
5. Push the engine towards the transmission aligning
the oil cooler. Install the clamp holding the top
the guide studs and the torque converter shaft with
transmission cooler hose and the three bolts holding
the corresponding holes.
the fan screen.
6. Push the engine against the transmission and install
24. Install the engine cover and adjust.
eight of the ten bolts and washers. Remove both
guide studs and replace with the remaining two bolts 25. Install the battery and reconnect the (+) positive and
and washers. Tighten bolts. (-) negative cables.
7. Torque the transmission bolts to 63 Nm (46 lb-ft) 26. Open the radiator cap and fill the radiator completely
AFTER engine is lowered and secured with the front with coolant. Replace and tighten the radiator cap.
motor mount bolts installed and torqued. Add coolant to the overflow bottle until the bottle is 1/
4 to 1/2 full. This overfilling will compensate for any
8. Remove the support from under the transmission
air trapped in the cooling system.
and lower the engine the remainder of the way onto
the frame. Align the motor mount holes and install 27. Check that all hydraulic system, electrical system,
the bolts. Apply Loctite® 243TM threadlock to the cooling system, fuel system and exhaust system
motor mount bolts and torque to 210 Nm (155 lb-ft). connections are correct and connected tightly.
9. Turn the engine over slowly by hand and align each 28. From within the cab, lightly depress the throttle pedal
of the eight flex plate bolts through the access plug to full-throttle position. As needed, adjust the limit-
in the bell housing. Install them one at a time. DO stop screw until it touches the pedal. Tighten the
NOT fully tighten until all of the capscrews and locknut to 13,6-14,1 Nm (120-125 lb-in).
locknuts are in place. Torque to 35-39 Nm Note: Have an assistant stand by with a Class B fire
(26-29 lb-ft). Replace access plug. extinguisher.
10. Install the exhaust pipe. Refer to Section 7.7.2, 29. Start the engine and run to normal operating
“Exhaust System Installation.” temperature then shut off the engine. While the
11. Install the complete air cleaner assembly. Refer to engine is cooling, check for leaks.
Section 7.8.2, “Air Cleaner Assembly Installation.” 30. Allow the engine to cool. Check the radiator coolant
12. Install and tighten the jam nuts on the throttle cable level, and top off with coolant. Replace the radiator
at the throttle cable mount. cap.
13. Connect the throttle cable at the engine throttle 31. Check for leaks from the engine, main hydraulic
lever. pump and lines, transmission, hydraulic reservoir
14. Connect the fuel inlet line to the fuel filter head. and fuel tank. Check the levels of all fluids and
lubricants. Fill as required.
15. Connect the fuel return line to the fuel filter head.
Note: During the full throttle check:
16. Connect all the labeled wire harness connections on
the engine. • DO NOT operate any hydraulic function.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-11
Engine: Perkins 1104-42 & 1104-42T
5. Refer to Section 6.5.1, “Transmission Removal,” or 6. Remove the Do Not Operate Tags from both the
Section 7.9.1, “Engine Removal.” ignition key switch and the steering wheel.
7-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Engine: Perkins 1104-42 & 1104-42T
7.11 TROUBLESHOOTING
1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7-13
Engine: Perkins 1104-42 & 1104-42T
7-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Section 8
Hydraulic System
Contents
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-1
Hydraulic System
LIFT/LOWER
CYLINDER
TILT CYLINDER
EXTEND/RETRACT
CYLINDER
(INSIDE BOOM)
OUTRIGGER CYLINDERS
(12, 13 & 17M ONLY)
STEERING
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
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-3
Hydraulic System
This section covers the hydraulic circuits and includes a. Checking Pressures
listings for all hydraulic function pressures, where and
1. Start the machine and warm the hydraulic system to
how to check those pressures.
operating temperature.
Electrical and hydraulic functions are often related. Verify
2. Shut off the machine and install a digital or a 345 bar
that the electrical components of the circuit are
(5000 psi) gauge to the appropriate test port.
functioning properly whenever troubleshooting the
hydraulic circuit. 3. Start the machine, run the engine and follow
procedures in Section 8.4.1, c. “Pressure
Always check the following before beginning to
Specifications.”
troubleshoot a circuit that is not functioning correctly.
1. Check the hydraulic oil level in the reservoir. Oil level b. Adjusting Hydraulic Pressure
should be at the middle of the sight glass with all
cylinders retracted. 1. Shut the machine off. Remove the cap on the relief
(if necessary).
2. Check hoses, tubes, fittings and other hydraulic
components for leaks, bends, kinks, interference, 2. Start the machine and loosen the jam nut on the
etc. relief. Turn the relief clockwise to increase pressure
or counter-clockwise to decrease pressure. Set to
3. Check for air in the hydraulic system. Erratic the correct pressure.
machine performance and/or spongy cylinder
operation are signs of air in the hydraulic system. 3. Tighten the jam nut and recheck the pressure at full
throttle. If the reading is within specification, shut the
If air in the hydraulic system is suspected, you will machine off, install the safety cap and remove the
hear air leakage when hydraulic fittings are loosened gauge from the test port.
and see air bubbles in the hydraulic oil. 4. If the proper pressure cannot be set, use the
accompanying hydraulic schematic and/or the
Loose fittings, faulty o-rings or seals, trapped oil, electrical schematic to help troubleshoot and correct
leaks, system opened for service, etc., can cause air the problem.
in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.
8-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
c. Pressure Specifications
M 2
Pr
1
MZ2320
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-5
Hydraulic System
8-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-7
Hydraulic System
8-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-9
Hydraulic System
8.5.3 8M, 9M, 12M & 13M - Frame Level (if equipped)
8M & 9M
8-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
8.5.4 17M
Before S/N 1160005851 excluding 1160005819
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-11
Hydraulic System
8-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-13
Hydraulic System
8-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-15
Hydraulic System
8-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
a. Reservoir Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
MZ0130
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
8.6.1 Hydraulic Oil Reservoir Draining 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
1. Park the machine on a firm, level surface, level the machine should not be operated.
machine, fully retract the boom, lower the boom,
3. Open the engine cover. Allow the system fluids to
place the transmission control lever in
cool.
(N) NEUTRAL, engage the park brake and shut the
engine OFF. 4. Properly disconnect the battery.
2. Place a Do Not Operate Tag on both the ignition key 5. Drain the hydraulic oil reservoir. Refer to Section
switch and the steering wheel, stating that the 8.6.1, “Hydraulic Oil Reservoir Draining.”
machine should not be operated. 6. Loosen the clamps and remove and cap the suction
3. Open the engine cover. Allow the system fluids to and return hoses on the hydraulic oil reservoir.
cool. 7. Plug and cap the fittings on the hydraulic oil
4. Properly disconnect the battery. reservoir.
5. Open the filler cap on the hydraulic oil reservoir. 8. Support the hydraulic oil reservoir from the bottom
Remove the drain plug at the bottom of the hydraulic and remove the six bolts, washers and nuts.
oil reservoir. 9. Carefully lower the reservoir to the ground.
6. Transfer the used hydraulic oil into a suitable,
covered container, and label as "Used Oil". Dispose b. Disassembly
of used oil at an approved recycling facility. Clean The hydraulic oil reservoir is a one-piece unit and cannot
and reinstall the drain plug. be disassembled. The hydraulic oil level sight-glass and
7. Wipe up any hydraulic oil spillage in, on, near and hydraulic oil filler cap can be removed and reused on the
around the machine and the work area. new replacement reservoir. Dispose of the old reservoir
according to local regulations concerning hazardous
materials disposal.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-17
Hydraulic System
d. Inspection
Note: If a leak is suspected in the hydraulic oil reservoir,
contact JLG Service Department.
1. Inspect the hydraulic oil reservoir thoroughly for any
cracks, slices, leaks or other damage. MZ1950
2. With the hydraulic oil reservoir removed from the The implement pump (1) is the “heart” of the hydraulic
machine, plug all openings except one elbow fitting. system, and whenever there is a problem in the system,
Install the elbow fitting, and apply approximately the pump often is blamed. However, implement pump
0,06-0,10 bar (1-1.5 psi) of air pressure through the failure is seldom due to failure of pump components.
elbow. Check the reservoir for leaks by applying a Pump failure usually indicates another problem in the
soap solution to the exterior and look for bubbles to hydraulic system.
appear at the cracked or damaged area. According to pump manufacturer statistics, 90-95 percent
of pump failures are due to one or more of the following
e. Reservoir Installation causes:
1. Lift the hydraulic oil reservoir into place and install • Aeration
the six bolts, washers and nuts. • Cavitation
2. Uncap and connect the suction hose and return • Contamination
hose. Tighten both clamps. • Excessive Heat
3. Uncap and connect the four small return hoses to • Over-Pressurization
the fittings on the hydraulic oil reservoir. • Improper oil
4. Install the hydraulic oil level sight-glass using special In the event of pump failure, investigate further to
designed and drilled capscrews and gaskets. determine the cause of the problem.
5. Install hydraulic filter neck components and secure.
6. Fill the hydraulic oil reservoir according to
specifications. Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”
7. Check the hydraulic oil reservoir for leaks.
8. Properly connect the battery.
9. Close and secure the engine cover.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel.
8-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
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
MZ2530
2
5. Thoroughly clean the auxiliary pump (2) and
surrounding area, including all hoses and fittings,
before proceeding.
MZ2080
6. Place a suitable container to catch hydraulic oil
drainage beneath the frame. The main control valve assembly consists of working
sections with their own valve assemblies, each providing
7. Label, disconnect and cap the hydraulic hoses
a specific hydraulic function. Those functions are:
attached to the auxiliary pump. Slowly turn hose
lift/lower (3), extend/retract (4), tilt (5) and auxiliary (6).
fittings to allow any trapped pressure in the hydraulic
system to escape. Call all fittings to prevent dirt and
a. Main Control Valve Removal
debris from entering the hydraulic system.
8. Wipe up any hydraulic oil spillage in, on, near and 1. Park the machine on a firm, level surface, level the
around the machine and work area. machine, fully retract the boom, lower the boom,
place the transmission control lever in
9. Label and disconnect the electrical connections to (N) NEUTRAL, engage the park brake and shut the
the auxiliary pump. engine OFF.
10. Support the valve and remove the bolts securing the 2. Place a Do Not Operate Tag on both the ignition key
pump to the engine pod. switch and the steering wheel, stating that the
11. Remove the pump. machine should not be operated.
8-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
3. Open the engine cover. Allow the system fluids to d. Main Control Valve Parts Inspection
cool.
Inspect all parts and internal passageways for wear,
4. Properly disconnect the battery. damage, etc. If inner surfaces of any component DO NOT
5. Thoroughly clean the main control valve and display an ultra-smooth, polished finish, or are damaged
surrounding area, including all hoses and fittings, in any way, replace the damaged part. Often, dirty
before proceeding. hydraulic oil causes failure of internal seals, damage to
the polished surfaces within the component, and wear of
6. Place a suitable container to catch hydraulic oil
and/or harm to other parts.
drainage beneath the frame.
7. Label, disconnect and cap all the hydraulic hoses, e. Main Control Valve Assembly
tubes and wires at the main control valve. Slowly
turn hose fittings to allow any trapped pressure in Note: ALWAYS replace seals, o-rings, gaskets, etc.,
the hydraulic system to escape. with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
8. Wipe up any hydraulic oil spillage in, on, near and hydraulic oil.
around the machine and the work area.
9. Support the valve and remove the four bolts Assemble each Valve Section
securing the main control valve bracket to the frame.
1. Reassemble any check valves, compensator valves,
10. Remove the main control valve and bracket from the anti-cavitation valves or shock valves from each
frame and remove the four bolts holding the individual valve sections if equipped.
mounting bracket to the valve.
2. Install the end caps on each end of the valve
section.
b. Main Control Valve Disassembly
1. To disassemble the individual sections of the main Assemble the Main Control Valve.
control valve, remove the nuts from one end of the
1. Place all three tie rods with the nuts through the end
tie rods. Pull the tie rods out through the sections.
main control valve section.
2. Disassemble each section assembly as required.
2. Stand the end main control valve section on end.
Some sections include a pre-adjusted relief valve that
3. Install the proper o-rings and load sense shuttle on
regulates pressure in a specific circuit.
the inner face of the end main control valve section.
Note: DO NOT adjust any of the relief valve assemblies. Align the next valve section over the three tie rods
Tampering with a relief valve will irrevocably alter and slide onto the end main control valve section.
pressure in the affected circuit, requiring recalibration or a 4. Using the proper o-rings and load sense shuttle,
new relief valve. repeat step three for the remaining valve sections
and lastly the inlet end valve section.
Disassemble each Valve Section
5. Install the nuts on the tie rods.
1. Carefully separate the load sense outlet section (7) from
the next section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining section.
4. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual 7
valve section if equipped.
5. Keep all parts being removed from individual valve
sections tagged and kept together.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-21
Hydraulic System
8-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
Note: ALWAYS replace seals, o-rings, gaskets, etc., Close the brake bleeder when air bubbles no longer
with new parts to help ensure proper sealing and appear in the oil. Release the brake pedal. remove
operation. Lubricate seals and o-rings with clean the tubing from the brake bleeder.
hydraulic oil. 4. Repeat Steps 2 and 3 for the remaining brake
3. Use new oiled o-rings as required. Reattach and bleeders.
secure all valves, hoses, clamps, etc. 5. Install a vacuum pump on the brake reservoir and
4. Check the routing of all hoses, and tubing for sharp remove the remainder of the trapped air from the
bends or interference with any rotating members, brake system.
and install tie wraps and/or protective conduit as 6. Check brake fluid level and add if necessary using
required. Tighten all tube and hose clamps. ATF fluid.
5. Properly connect the battery. 7. Conduct a pressure and function check of the
6. Start the engine and run at approximately one-third service brake. Refer to Section 8.3, “Hydraulic
to one-half throttle for about one minute, without Pressure Diagnosis.”
moving the machine or operating any hydraulic
functions. 8.9.4 Steering Orbitrol Valve
7. Bleed air from the brake circuit. Refer to Section Refer to Section 4.3.1, “Steering Column and Orbitrol
8.9.3, “Brake Test.” Valve,” for details.
8. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic oil in the 8.9.5 Steer Select Valve
reservoir. Shut the engine OFF. The machine can be used in the front-wheel, four-wheel
Note: Check for leaks, and repair as required before or crab steering mode. The steer select valve controls the
continuing. Add hydraulic oil to the reservoir as needed. direction of hydraulic oil flow to the steering cylinder
mounted on each axle. The steer select valve is attached
9. Close and secure the engine cover. to a mounting plate inside the frame near the left front
10. Remove the Do Not Operate Tags from both the corner of the cab.
ignition key switch and the steering wheel. Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve.
8.9.3 Brake Test The housing of the steer select valve is not serviceable
Carefully bleed the brake lines as soon as the brake valve and must be replaced if defective.
is installed in the machine. Air in the system will not allow
the brakes to apply properly. Work with an assistant to a. Steer Select Manifold and Valve Removal
perform this procedure. 1. Park the machine on a firm, level surface, fully
Note: 17M machines have an extra set of bleeders on retract the boom, lower the boom, place the
the front axle. The outside set is for the park brakes and transmission control lever in (N) NEUTRAL, engage
the inside set is for the service brakes. Be sure to bleed the park brake and shut the engine OFF.
the correct circuit. 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
1. Place the transmission control lever in (N)
machine should not be operated.
NEUTRAL, engage the park brake, and start the
engine. 3. Open the engine cover. Allow the system fluids to
cool.
2. Remove the plastic cap from the front brake bleeder.
Attach one end of a length of transparent tubing over 4. Properly disconnect the battery.
the brake bleeder. Place the other end of this tubing 5. Label, disconnect and cap all hydraulic hoses and
in a suitable transparent container that is partially fittings connected to the steering select valve.
filled with hydraulic oil. The end of the tubing must
6. Disconnect all wire terminal leads attached to the
be below the oil level in the container.
steering select valve.
3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is a pressure at
the brakes. Carefully open the bleeder with a
wrench. Have the assistant depress the brake pedal.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-23
Hydraulic System
7. Remove the two bolts holding the steer select valve Note: ALWAYS replace seals, o-rings, gaskets, etc.,
to the mounting plate on the frame. with new parts to help ensure proper sealing and
17M Frame Shown
operation. Lubricate seals and o-rings with clean
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
four new, oiled o-rings and the four socket head
capscrews.
8-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
MZ2410
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-25
Hydraulic System
f. Leveling Valve Installation 6. Label, disconnect and cap hydraulic hoses and
cylinder ports in relation to the cylinder.
1. Install the leveling valve into the engine
compartment and secure with the previously used 7. Attach a suitable sling to an appropriate lifting device
hardware. to the cylinder. Make sure the device used can
actually support the cylinder.
2. Prime the leveling valve by filling the inlet openings
with fresh, filtered hydraulic oil from a clean 8. Remove the lock bolt and/or any retaining clips
container, before attaching the hoses. securing the cylinder pins. Remove the cylinder pins.
3. Use new oiled o-rings as required. Uncap and 9. Remove the cylinder.
connect all hoses, clamps, etc. to the leveling valve. 10. Wipe up any hydraulic oil spillage in, on, near or
4. Check the routing of all hoses, wiring and tubing for around the machine.
sharp bends or interference with any rotating
members, and install tie wraps and/or protective 8.10.2 General Cylinder Disassembly
conduit as required. Tighten all tube and hose 1. Clean the cylinder with a suitable cleaner before
clamps. disassembly. Remove all dirt, debris and grease
5. Properly connect the battery. from the cylinder.
6. Start the engine and run at approximately one-third 2. Clamp the barrel end of the cylinder in a soft-jawed
to one-half throttle for about one minute without vise or other acceptable holding equipment if
moving the machine or operating any hydraulic possible.
functions.
7. Inspect for leaks and check the level of the hydraulic
oil in the reservoir. Shut the engine OFF.
WARNING
8. Wipe up any hydraulic oil spillage in, on, near and Significant pressure may be trapped inside the
around the machine, work area and tools. cylinder. Exercise caution when removing a
counterbalance valve or a pilot-operated check valve
9. Close and secure the engine cover.
from a cylinder.
10. Remove the Do Not Operate Tags from both the
ignition key switch and the steering wheel. Note: Avoid using excessive force when clamping the
cylinder in a vise. Apply only enough force to hold the
8.10 HYDRAULIC CYLINDERS cylinder securely. Excessive force can damage the
cylinder tube.
8.10.1 General Cylinder Removal 3. If applicable, remove the counterbalance valve from
Instructions the side of the cylinder barrel.
1. Remove any attachment from the machine. Park the Note: DO NOT tamper with or attempt to adjust the
machine on a firm, level surface, allowing sufficient counterbalance valve cartridge. If adjustment is
workspace. Level the machine, place the transmission necessary, replace the counterbalance valve with a new
control lever in (N) NEUTRAL, engage the park brake, part.
shut the engine OFF and block the wheels. 4. Extend the rod (5) to allow access to the base of the
2. Place a Do Not Operate Tag on both the ignition key cylinder.
switch and the steering wheel, stating that the Note: Protect the finish on the rod at all times. Damage
machine should not be operated. to the surface of the rod can cause seal failure.
3. Open the engine cover. Allow the system fluids to
5. Using a pin spanner wrench, unscrew the head
cool.
gland (6) from the barrel (1). A considerable amount
4. Properly disconnect the battery. of force will be necessary to remove the head gland.
5. Relieve any trapped pressure in the hydraulic Carefully slide the head gland down along the rod
system by using the handle or wrench (located in the toward the rod eye end, away from the cylinder
toolbox) and move the double nut on the side of the barrel.
actuator module on the valve section back and forth.
8-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
Note: When sliding the rod and piston assembly out of 10. Remove all seals, back-up rings and o-rings (2) from
the tube, prevent the threaded end of the tube from the piston head and all seals, back-up rings and o-
damaging the piston. Keep the rod centered within the rings from the head gland.
tube to help prevent binding.
Note: The head gland bearing will need to be inspected
1 to determine if replacement is necessary.
2
DO NOT attempt to salvage cylinder seals, sealing rings
3 or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
4 catalog for ordering information.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8-27
Hydraulic System
4. Lubricate and slide the head gland (6) over the 9. Remove the Do Not Operate Tags from both the
cylinder rod (5). Install the piston head (4) on to the ignition key switch and the steering wheel.
end of the cylinder rod. Apply Loctite® 243TM to the
setscrew (3) and install in the piston head. Refer to 8.10.7 Cylinder Pressure Checking
Section 8.10.9, “Hydraulic Cylinder Torque
Attach a 345 bar (5000 psi) gauge to the test port on the
Specifications,” for tightening guidelines for the
main control valve to check the system pressure.
piston head and the set screw.
Note: If a hydraulic cylinder pressure is greater than the
Note: Avoid using excessive force when clamping the
main control valve pressure, increase the main control
cylinder barrel in a vise. Apply only enough force to hold
valve pressure by adjusting the main relief. Generally,
the cylinder barrel securely. Excessive force can
one half turn clockwise will be adequate to check an
damage the cylinder barrel.
individual circuit. Activate the circuit and if pressure is
5. Place the cylinder barrel (1) in a soft-jawed vise or obtained, turn the main relief counter clockwise one half
other acceptable holding equipment if possible. turn. Recheck the main relief setting and adjust if
necessary.
Note: When sliding the rod and piston assembly into the
cylinder barrel, prevent the threaded end of the cylinder
barrel from damaging the piston head. Keep the cylinder
8.10.8 Steering Cylinders
rod centered within the barrel to prevent binding. The steering cylinders (7) are attached to each axle
center housing. The steer cylinders are covered in the
6. Carefully insert the cylinder rod assembly into the
appropriate manufacturer’s axle literature.
tube.
7. Screw the head gland (6) into the cylinder barrel (1)
and tighten with a spanner wrench. Refer to Section
7
8.10.9, “Hydraulic Cylinder Torque Specifications,”
for tightening guidelines for the head gland.
8. If applicable, thread the new counterbalance valve
into the block on the cylinder barrel.
8-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Hydraulic System
a. Lift/Lower Cylinder
b. Extend/Retract Cylinder
c. Tilt Cylinder
d. Compensation Cylinder
f. Outrigger Cylinder
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
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-1
Electrical System
9-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
LOAD
STABILITY
INDICATOR JOYSTICK
POWER
DISTRIBUTION
DISPLAY BOARD
PANEL
TRANSMISSION
SOLENOID VALVES
ALTERNATOR
UGM
CONTROLLER
STARTER
BATTERY
MZ2370
MZ2380
IGNITION KEY
SWITCH
BOOM ANGLE
SENSOR
LOAD STABILITY
SENSOR
(ON AXLE)
MZ2360
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-3
Electrical System
9-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Function Description
Change Anti Theft Allows the owner to change the Anti Theft Code
Code
Perform Hardware Allows the owner to restore machine data (anti theft code, engine hours, machine
Exchange personalities, etc.) in the event that the machine controller or display/cluster gauge has
been replaced
Confirm Machine Allows the owner to turn off the Service Required Warning lamp when service is
Service performed
Review Service History Allows the owner to see the last 15 times the Service Required Warning lamp was reset
Set Service Interval Allows the owner to modify the default service interval of 100 hours
Cabin Joystick Allows the owner to change/swap operation of the joystick Telescope and Fork Tilt
Telescope: X-Axis/ functions.
Roller NOTE: This change requires the installation of a new joystick operation decal in the cab.
Contact your local authorized distributor.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-5
Electrical System
9.4.2 Personalities
9.4.3 Calibrations
Function Description
Boom Angle Allows the owner to calibrate the boom angle sensor if it is replaced. Refer to Section 9.14.7,
“Boom Angle Sensor.”
9-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
6. Scroll to and select the proper screen for hardware 2. Press the "C" and "OK" buttons on the dash
exchange. The screen will show either simultaneously to enter the analyzer mode.
"DISPLAY -> UGM" or "UGM -> DISPLAY". The new 3. Scroll to "Access level code". Enter the code
component should be listed second. "33271" to go into access level 2.
4. Scroll to and select the "Operator Tools" screen.
5. Scroll to and select the "Set Service Interval" screen.
6. Enter a new service interval.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-7
Electrical System
MZ2100
9-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
MZ2090
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-9
Electrical System
9-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-11
Electrical System
9-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
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
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-15
Electrical System
9-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-17
Electrical System
9-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-19
Electrical System
9-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-21
Electrical System
SOCKET
FLASHER
LIGHTS BAT 1
LIGHTS BAT 2
KEY BAT
SPARE BAT
XF XH
XA XD
5 4 3 2 1 1 2 6 2 4 13
PCB PWR
XA
SOCKET
KEY BAT
EMPTY
LIGHTS BAT 1
LIGHTS BAT 2
HAZARD
SWITCH
X8
S3 1
1 2
3 6
DRIVING LIGHTS
SWITCH 2 5 1
EMERG STOP
S12 1 4 FLASH BAT SWITCH AUX POWER
3 6 8 7 (PLATFORM ONLY)
SOCKET
2
2 5
FLASH BAT
X18
KEY BAT A
30
KEY BAT A
8 7 30 0P
1
15 2
X17
15 3
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
58 0P
1
58
2
3
56a
53c
56b
49a
53a
KEY
56
30
53
15
H
R
L
19 0P SWITCH
19 1
2
17 3
17
TURN/ 0P
WIPER 50 1
SWITCH 2
50
3
PCB PWR
PCB PWR
PCB PWR
PCB PWR
XA1 30
AUXILIARY
PCB PWR
PCB PWR
PCB PWR
PCB PWR
POWER
87
UNIT
86 RELAY
(PLATFORM ONLY)
X110
+ -
12 VDC
BATTERY
STARTER
PCB PWR
PCB PWR
PCB PWR X36
M
PCB PWR
STRT PWR
PHEAT PWR
ALT BAT X38
ALT BAT
30
STRT PWR
STARTER
87
RELAY
86
85
MZ2260
9-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
3 10 13 4 5 6 7 8 9 10 11 12 12 4 4 5 6 8 16 20 30 3
STRT RLY
BRK LT SW
APU ENABLE
GLOWPLUGS
CLUTCH LOCK
PREHEAT
CLUTCH
KEY IGN
NEUT
P BRK
KEY STRT
KEY 1B
FUEL PMP
IGNITION
IGNITION
IGNITION
IGNITION
KEY IGN
KEY IGN
KEY IGN
FUEL VLV
KEY BAT A
S1 7
APU ENABLE 3 2 1 8
SWITCH KEY 1B
(PLATFORM ONLY)
APU
S5 7
CLUTCH LOCK
SWITCH
(POWERSHIFT ONLY)
3 2 8
KEY 1B
CLUTCH
X10
1
KEY 1B
BRAKE BRK LT
2 EMERG STOP
PEDAL
SWITCH 3 SWITCH
CLUTCH (PLATFORM ONLY)
4 X18
2 KEY BAT A
30
1 KEY BAT A
30 0P
1 KEY 1B 1
PARK BRAKE X13 KEY IGN
OFF 2 P BRK 15 2
SWITCH KEY IGN
ON 15 3
X13B
KEY 1B 58 0P
1
P BRK 1
2 58
2
3 3 KEY
PREHEAT
X14 19 0P SWITCH
KEY 1B PREHEAT A 1
FWD PWR
1 19
2
STRT RLY
NEUT F PREHEAT A
2 17
REV N NEUT 3
SHIFTER 3
17
SWITCH
I R
4 0P
KEY STRT
II I
5 50 1
II 2
6 50
III III
7
3
FUEL PMP
IV IV
8
nc
9 FUEL VLV GLOWPLUGS
CAB HARNESS
8 20 36 37
STRT RLY
X3
+ -
12 VDC
BATTERY
STARTER
GLOWPLUGS
50
PHEAT PWR
FUEL VLV
X43
COLD START
TEMP
M
FUSE X46
SWITCH
STRT PWR
85 STARTER
87
X48 X49 RELAY
PHEAT STRT RLY 86
1 1
ENGINE
GLOWPLUGS 2 M FUEL
PUMP
85
MZ2270
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-23
Electrical System
9.9 ENGINE START CIRCUIT can also prevent the starter from cranking the
engine.
9.9.1 Starter 3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit,
refer to Section 9.8.2, “Start Circuit.”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
2. Open the engine cover. Allow the engine to cool.
1 3. Properly disconnect the battery.
4. Remove the wires from the solenoid stud. Remove
MZ0150 the positive (+) battery cable from the starter. Label
and disconnect the wire from the starter solenoid
The starter (1) is located on the left side of the engine (the housing stud. Record how the wires are installed to
right side of the machine). ensure correct installation later.
5. Loosen, but DO NOT remove the three fasteners
a. Testing the Starter on the Engine
securing the starter to the flywheel housing. Support
If the starter does not engage when the ignition key the starter securely, as it is relatively heavy and will
switch is turned, check the following: fall if not supported.
1. The main fuse may be blown, requiring replacement. 6. Support the starter and remove the fasteners
Check for the cause of the blown fuse. securing the starter to the engine. Remove the
2. There may be a defect in the ignition key switch, negative (-) ground cable from its starter mounting
ignition wiring or starter solenoid. bolt.
3. Check battery condition. Clean the battery posts and 7. Remove the starter from the machine.
the connectors at each end of the battery cables.
d. Starter Cleaning and Drying
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring. 1. While the starter is being removed, wipe away any
grease or dirt that has accumulated around the
5. Check all connections at the starter solenoid, key
starter mounting opening.
switch and wiring harness plugs. Clean and tighten
all connections. 2. If reinstalling the starter, clean the exterior of the
starter with an approved solvent. DO NOT submerse
6. If the starter still does not operate after these checks
the starter or allow the solvent to contact the starter
have been performed, check the starting circuit.
bushings.
b. Starter Circuit Checks 3. Dry the starter with a clean, lint-free cloth.
9-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
3. Check the fan belt condition and tension. 5. Loosen both alternator (2) mounting bolts and pivot
4. Verify that the alternator mounting hardware is tight. alternator in.
5. Run the engine and check the alternator for noise. A 6. With the fan belt now being loose, remove the belt
loose drive pulley, loose mounting hardware, worn or from the engine.
dirty internal alternator bearings, a defective stator Note: Record how the alternator is installed to ensure
or defective diodes can cause noise. Replace a worn correct installation later.
or defective alternator.
7. Label and disconnect the wire leads attached to the
alternator.
8. Remove the lower mounting capscrew securing the
alternator to the lower mounting hole on the engine.
9. While supporting the alternator with one hand,
remove the upper (longer) mounting hardware from
the upper alternator mount. Remove the alternator
from the machine.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-25
Electrical System
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 5
serviceable. Replace motor if found to be defective.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-27
Electrical System
6. Pull the washer reservoir (6) out and away from the a. Cab Heater Controls Removal
mounting studs.
1. Park the machine on a firm, level surface, level the
7. Rotate the washer reservoir, label and remove the machine, fully retract the boom, lower the boom,
cab harness connectors from the washer reservoir place the transmission control lever in (N)
connectors. NEUTRAL, engage the park brake and shut the
8. Remove the windshield washer hoses from the engine OFF.
reservoir. 2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
b. Disassembly machine should not be operated.
DO NOT disassemble the pumps. The pump is not 3. Open the engine cover. Allow the engine to cool.
serviceable. Replace pumps if found to be defective.
4. Properly disconnect the battery.
9-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
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.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-29
Electrical System
9.14.2 Transmission Temperature Switch defective, the problem could be elsewhere; possibly
in a shorted wire, damaged transmission, improper
or low fluid, etc.
5. Close and secure the engine cover.
6. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
9 MZ2150
9-30 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
c. Transmission Mounted Speed Sensor 2. Place a Do Not Operate Tag on both the ignition key
Installation and Testing switch and the steering wheel, stating that the
machine should not be operated.
1. Install new o-ring on speed sensor, install sensor in
transmission, install clamp on sensor, bolt down 3. Open the engine cover. Allow the engine to cool.
clamp, turn arrow on sensor 45 degrees from clamp 4. Properly disconnect the battery.
bolt and torque to 8-10 Nm (70-88 lb-in).
5. Unplug the engine coolant temperature sender/
2. Connect the sensor plug to the wire harness. switch connector from the wiring harness connector.
3. Properly connect the battery. 6. The sender/switch is threaded into the engine block.
4. Close and secure the engine cover. Remove the sender.
5. Remove the Do Not Operate Tag from the ignition
b. Engine Coolant Temperature Sender/Switch
key switch and the steering wheel.
Inspection and Replacement
d. Transmission Mounted Speed Sensor Calibration Inspect the sender/switch and the wiring harness
connector terminals for continuity. Replace a defective or
A JLG Analyzer is required to perform this calibration.
faulty sender/switch with a new part.
There is also an embedded JLG Analyzer in the cab
display. To access the JLG Analyzer, press and hold the
c. Engine Coolant Temperature Sender/Switch
C and OK buttons on the keypad simultaneously until the
Installation and Testing
JLG Analyzer Help Menu screen appears on the display.
1. Go to the Access Level menu and enter a password 1. Thread the engine coolant temperature sender into
of 33271. the engine block snugly, then connect the sender/
switch connector to the wiring harness connector.
2. Go to the Calibrations menu, select Vehicle Speed
and press the Enter button (OK button on the 2. Properly connect the battery.
embedded Analyzer). 3. Check for proper coolant level.
3. Follow the instructions on the Analyzer. The 4. Start the engine, allow it to reach operating
machine must be driven over a 50 meter straight line temperature and observe the operator instrument
course. cluster for warning indication. If the sender/switch is
• The machine cab be driven in any gear and at not defective, the problem could be elsewhere;
any speed. possibly in a shorted wire, improper-running engine,
improper or low coolant, obstructed or faulty radiator,
• The Analyzer will prompt the operator to press coolant pump, loose fan belt, defective instrument
Enter or OK when starting the 50 meter drive. display, etc.
• Drive the machine 50 meters and stop. When the 5. Close and secure the engine cover.
50 meter point is reached, press the Enter or OK
button as appropriate. 6. Remove the Do Not Operate Tag from the ignition
key switch and the steering wheel.
4. If the calibration fails, check the Help menu for
possible faults. 9.14.5 Ignition Key Switch
9.14.4 Engine Coolant Temperature Sender/ a. Ignition Key Switch Removal
Switch
1. Park the machine on a firm, level surface, level the
The engine coolant temperature sender/switch is located machine, fully retract the boom, lower the boom,
by the alternator. place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
a. Engine Coolant Temperature Sender/Switch engine OFF.
Removal
2. Place a Do Not Operate Tag on both the ignition key
1. Park the machine on a firm, level surface, level the switch and the steering wheel, stating that the
machine, fully retract the boom, lower the boom, machine should not be operated.
place the transmission control lever in (N)
3. Open the engine cover. Allow the engine to cool.
NEUTRAL, engage the park brake and shut the
engine OFF. 4. Properly disconnect the battery.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-31
Electrical System
9-32 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
been ruled out and in addition, wiring and 4. Properly disconnect the battery.
connectors have been checked and ruled out, the 5. Disconnect the boom angle sensor electrical
fuel level indicator is defective and must be connector.
replaced.
6. If equipped, remove the safety spring (12).
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown. 7. Loosen and remove the nut holding the rod
assembly to the sensor arm.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator 8. Loosen and remove the two bolts holding the sensor
wiring at the cab, fuse and relay panel, ignition key to the sensor seat.
switch and from the fuel level sender on the fuel tank 9. Remove the sensor assembly.
through the wiring in the cab.
7. Check the fuel level sender. The resistance of the b. Boom Angle Sensor Inspection and Replacement
fuel level sender is <7 ohms for a full tank of fuel, Inspect the sensor and the wiring harness connector
108-128 ohms for 1/2 tank and 315-345 ohms for an terminals for continuity. Replace a defective or faulty
empty tank. A defective fuel level sender in the fuel sensor with a new sensor.
tank may also prevent the fuel level indicator from
moving. c. Boom Angle Sensor Installation
9.14.7 Boom Angle Sensor 1. Install the sensor assembly to the sensor seat and
tighten both bolts.
12
2. Install the rod end to the sensor arm and tighten nut.
11
3. If equipped, install the safety spring (12).
4. Measure and set rod length (13) to 212 ±0,5 mm if
needed on 8, 9, 12 & 13M Non-Platform equipped
machines. Set the rod length to 211,6 ±0,5 mm on
17M machines and to 226 ±0,5 mm on Platform
equipped 13M machines.
13
5. Plug the electrical connector into the sensor
assembly.
Note: At this point, the boom angle sensor will need to
be calibrated by an authorized service technician.
6. Properly connect the battery.
MZ2540
7. Close and secure the engine cover.
Note: The boom angle sensor (11) is located at the top 8. Remove the Do Not Operate Tag from the ignition
left inside rear of the machine. key switch and the steering wheel.
Note: After installation, the sensor will need to be
calibrated by an authorized service technician. 9.14.8 Boom Retracted Sensor
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-33
Electrical System
9-34 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Test LSI (8) at the beginning of each work shift. b. LSI Sensor Installation
1. Fully retract and level the boom, with no load. Do not 1. Ensure threads of both bolt holes are clean and free
raise the boom during this test. from rust, water and debris.
2. Level frame using level in cab. 2. Clean the bare metal with a degreasing agent,
3. Press the test button (8) on the LSI display. This will Loctite® 7063TM.
cause all LEDs to flash on and an audible warning to 3. Remove any excess degreasing agent and allow to
sound. This indicates that the system is functioning dry.
properly. If the test gives a different result, the
system is not functioning properly and the machine 4. Apply a thin film of Loctite® 330TM adhesive to the flat
must be removed from service and repaired before metal surface of the sensor, ensuring the adhesive is
continued operation. spread evenly over the entire surface.
5. Apply a layer of Loctite® 7386TM to the mounting
9.15.2 LSI Sensor surface of the axle, ensuring the activator is spread
evenly over the entire surface.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-35
Electrical System
1. With ignition key in OFF position, press and hold • The test weight matches the model being calibrated
in the table shown on page 9-39.
TEST button on LSI display and turn ignition key to
engine START position. Release the ignition key • The calibration shall be conducted with standard
when engine start is achieved, but continue to hold carriage and forks attached to the machine.
TEST button on LSI display until the led power • If the machine is equipped with outriggers, they shall
indicator on LSI display begins to flash remain up for the calibration procedure.
(approximately 2 seconds). Release TEST key
within 2 seconds of power led flashing. • The machine must be on a level surface with the
wheels steered straight and park brake OFF. Drive
2. The lower green led of the scale should be on the machine forward over a distance of at least 2 m
constant. Position the machine with empty (6.5 ft) before entering a calibration point.
attachment with boom level and fully retracted, forks
• The calibration must be completed within 30 minutes
level (not contacting ground).
after starting procedure.
3. Press the TEST button on the LSI display and
release. The lower green led should flash for
approximately 8 seconds while the calibration point
is read. Following a successful calibration of the first
point, the buzzer will sound for 2 seconds, the green
led will be turned off, and the top red led will be on
constant.
4. Position the machine (using weight on the
attachment) such that the rear axle weight in the
following table is achieved
9-36 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Field Calibration Procedure: 4. Retract the boom and place the test weight on the
ground. Disengage the weight and fully retract the
Note: If the test weight is not known, follow steps 1 & 2.
lower the boom.
Model Test Weight (W) Xtip (1) Xcal (2) 5. Ensure the boom is level and fully retracted, the
2100 kg 2300 mm 1620 mm forks are level and not contacting the ground. Apply
3508PS the park brake and shut engine OFF.
(4630 lb) (90 in) (64 in)
2000 kg 3030 mm 2060 mm 6. With the ignition key in OFF position, press and hold
3509PS TEST button on LSI display and turn ignition key to
(4409 lb) (119 in) (81 in)
engine START position. Release the ignition key
500 kg 2985 mm 2100 mm
3512PS when engine start is achieved, but continue to hold
(1102 lb) (117 in) (83 in)
TEST button on LSI display until the LED power
500 kg 3275 mm 2310 mm indicator on LSI display begins to flash
3513PS
(1102 lb) (129 in) (91 in) (approximately 2 seconds).
4008PS, 2100 kg 3107 mm 2372 mm 7. Release TEST key within 2 seconds of power LED
40.8 (4630 lb) (122 in) (93 in) flashing. The lower green LED of the scale should
4009PS, 2000 kg 3700 mm 2840 mm be on constant.
40.9 (4409 lb) (146 in) (112 in) 8. Press the TEST button on the LSI display and
700 kg 3145 mm 2340 mm release. The lower green LED should flash for
4012PS approximately 8 seconds while the calibration point
(1543 lb) (124 in) (92 in)
is read. Following successful calibration of the first
700 kg 3535 mm 2655 mm
4013PS point, the buzzer will sound for 2 seconds, the green
(1543 lb) (139 in) (105 in)
LED will be turned off, and the top red LED will be on
500 kg 2715 mm 2070 mm constant.
4017PS
(1102 lb) (107 in) (81 in) 2
1 A B C
A B C D
1
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-37
Electrical System
11. Press the TEST button on the LSI display and 9.16 LOAD STABILITY INDICATOR (LSI) -
release. The top red LED should flash for 8, 9, 12 & 13M S/N 1160005993 & After
approximately 8 seconds while the calibration point
including 1160005949 & 1160005950
is read. Following successful calibration of the
second point, the buzzer will be on constant, the red 17M S/N 1160005937 & After
LED will be turned off, and the green power LED will excluding 1160005952, 1160005960,
be on constant. 1160005963, 1160005966 &
12. Disengage the test weight and fully retract the boom. 1160005978
Turn the ignition key to OFF. LSI is now calibrated.
13. Verify proper operation of the LSI System:
• Start the machine with no load, fully retract and level
WARNING
the boom. Do Not raise the boom. TIP OVER HAZARD. The LSI considers only
longitudinal stability limitations, observe all operating
• Level the machine.
parameters. Failure to follow operating parameters of
• Press the test button on the LSI display. All LEDs will the telehandler could damage the equipment and/or
flash and the audible warning will sound. cause tip over.
• The system is functioning properly.
9.16.1 Load Stability Indicator
Note: The Load Stability Indicator is NOT a serviceable
item. The LSI must be inspected and/or replaced by a
qualified dealer or a JLG technician.
14
12
10 11
13
9
MZ6120
9-38 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
• In some instances the LSI system may slow down or 9.16.2 LSI Sensor
stop boom functions if operated close to forward
stability limitations. When LEDs begin to flash,
function can not be operated. Retract boom and/or 15
return the joystick to neutral position for a short
period to allow system to reset and LEDs to stop
flashing before proceeding with operation.
Passive Mode (8 & 9M)
• The orange LED (14) illuminates when either of the
following occurs:
• The boom is fully retracted.
• The park brake is not applied and transmission
control lever is in the forward or reverse position.
• When approching forward stability limitations, visual The LSI sensor (15) is bolted on the top right of the rear
and audible indication is provided and the automatic axle.
function cut-out and /or slow down feature is Note: If the rear axle is removed or replaced, the LSI
disabled. Sensor must be installed AFTER the rear axle is installed
• Travel in accordance with the requirements set forth and setting on all four wheels.
in Section 1 - General Safety Practices.
• When placing a load, ensure axles are not fully a. LSI Sensor Removal
steered in either direction. 1. Remove any fork carrier or attachment from the
machine.
WARNING 2. Park the machine on a firm, level surface, level the
machine, fully retract the boom, fully raise the boom,
TIP OVER HAZARD. If the green, orange and red place the transmission control lever in (N)
LEDs flash and warning buzzer sounds, retract and NEUTRAL, engage the park brake and shut the
lower boom immediately. Determine cause and engine OFF.
correct before continued use.
3. Place a Do Not Operate Tag on both the ignition key
• Test the LSI at the beginning of each work shift. switch and the steering wheel, stating that the
machine should not be operated.
1.Fully retract and level the boom, with no load. Do
not raise the boom during this test. 4. Open the engine cover. Allow the engine to cool.
2.Level frame using level in cab. 5. Properly disconnect the battery.
3.Press the system check button (13) on the LSI 6. Disconnect the LSI electrical connector.
display. This will cause all LEDs to flash on and an 7. Loosen, remove and discard the two bolts holding
audible warning to sound. This indicates that the the LSI assembly to the rear axle.
system is functioning properly. If the test gives a
8. Remove and discard the sensor assembly.
different result, the system is not functioning
properly and the machine must be removed from
b. LSI Sensor Installation
service and repaired before continued operation.
1. Ensure threads of both bolt holes are clean and free
from rust, water and debris.
2. Clean the bare metal with a degreasing agent,
Loctite® 7063TM.
3. Remove any excess degreasing agent and allow to
dry.
4. Apply a thin film of Loctite® 638TM adhesive to the flat
metal surface of the sensor, ensuring the adhesive is
spread evenly over the entire surface.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-39
Electrical System
Note: Follow all adhesive manufacturer’s • The calibration must be completed within 30 minutes
recommendations including storage life. after starting procedure.
5. Fit the sensor, ensuring the lead exits in the corner Calibration Procedure:
direction. Secure with two bolts - Socket HD 1. Start and position the machine to perform the
Capscrew M10x35x1.5, Grade 12.9. calibration procedure.
Note: It is important to prevent distortion of the sensor 2. Remove the standard carriage, fork and weight
element, therefore tighten each bolt finger tight. assembly.
Alternately tighten each bolt to 35 Nm (26 lb-ft) and 3. Fully retract the boom and if equipped, lower the
finally to 70-80 Nm (52-59 lb-ft). outriggers. Shut the machine OFF.
6. Permanently mark position of bolt head and sensor 4. With ignition key in OFF position, press and hold
body. SYSTEM CHECK button on LSI display and turn
7. Leave the machine undisturbed for a minimum of 6 ignition key to engine START position. Release the
hours before moving. ignition key when engine start is achieved, but
continue to hold SYSTEM CHECK button on LSI
8. Plug the electrical connector into the sensor
display until the orange LED on LSI display goes out
assembly.
and buzzer sounds (approximately 3 seconds).
9. Properly connect the battery. Release SYSTEM CHECK button.
10. Close and secure the engine cover. 5. The LEDs will perform a rolling sequence. When
11. Remove the Do Not Operate Tag from the ignition only the third green LED illuminates, press the
key switch and the steering wheel. SYSTEM CHECK button.
12. Calibrate the LSI system, refer to Section 9.16.3, 6. The first green LED then illuminates. With no
“LSI System Calibration.” attachment, outriggers down and boom retracted, lift
boom to maximum boom angle.
9.16.3 LSI System Calibration 7. Press the SYSTEM CHECK button on the LSI
display and release. The first 3 green LEDs will
a. Standard Calibration illuminate. The third then second green LEDs will go
To calibrate the LSI, certain conditions must be met: out as the calibration point is recorded.
8. The first green LED goes out and buzzer sounds
• The sensor must be installed according to Section
9.15.2, “LSI Sensor.” then the red LED illuminates.
9. Lower boom until level. If equipped, fully raise
• The machine control system must be powered on for
outriggers. Pressing the LMI Override button may be
at least 10 minutes before calibration.
required to lower the boom.
• The operator must remain in the cab.
10. Attach the previously removed standard carriage,
• The calibration shall be conducted with the standard forks and weight.
carriage and forks attached and weights as
necessary (a range of 60 - 80% of maximum weight 11. Slowly extend the boom until the rear axle weight in
capacity. the following table is achieved.
9-40 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
b. Field Calibration A B C
To calibrate the LSI, certain conditions must be met: 3508PS, 4008PS, 3509PS & 4009PS
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-41
Electrical System
4. The machine must be on a level surface with the 7. With the boom horizontal, slowly extend the boom to
wheels steered straight and park brake OFF. Drive the distance of Xcal (2). The proper calibration
the machine forward over a distance of at least 2 m weight is now on the rear axle and the LSI can now
(6.5 ft) before entering a calibration point. be calibrated.
5. Place test weight on ground, apply park brake and 8. Press the SYSTEM CHECK button on the LSI
shut engine OFF. Do Not move machine. display and release. As the calibration point is
Field Calibration Procedure: recorded, buzzer sounds and the LEDs will flash and
perform a sequence until all are flashing.
Note: The following procedure must be completed
9. Turn the ignition key to OFF. LSI is now calibrated.
within 30 minutes of starting the procedure.
10. Perform the LSI-CAN CHECK PT. Refer to Section
1. With ignition key in OFF position, press and hold 9.16.4, “LSI - CAN CHECK PT.”
SYSTEM CHECK button on LSI display and turn
ignition key to engine START position. Release the Note: The following procedure MUST be performed
ignition key when engine start is achieved, but before the calibration is finalized.
continue to hold SYSTEM CHECK button on LSI
display until the orange LED on LSI display goes out 9.16.4 LSI - CAN CHECK PT
and buzzer sounds (approximately 3 seconds). With the LSI calibrated, the UGM also need it’s “LSI_CAN
Release SYSTEM CHECK button. CHECK PT” calibrated and verified.
2. The LEDs will perform a sequence. When only the 1. Start the machine.
third green LED illuminates, press the SYSTEM
CHECK button. 2. Press the “C” and “OK” buttons simultaneously on
the keypad or the analyzer.
3. The first green LED then illuminates. With no
attachment and boom retracted, lift boom fully. 3. Go to “ACCESS LEVEL 3” and press “OK”.
4. Press the SYSTEM CHECK button on the LSI 4. Enter the proper access code and press “OK”.
display and release. The first 3 green LEDs will 5. "ACCESS LEVEL 2" is now visible.
illuminate. The third then second green LEDs will go 6. Go to "CALIBRATION" menu, press "OK".
out as the calibration point is recorded.
7. Scroll to "LSI_CAN CHECK PT", use the arrow keys
5. The first green LED goes out and buzzer sounds to change "NO" to "YES".
then the red LED illuminates.
8. “SET LSI_CAN SYSTEM CHECK POINT?”, use the
6. Lower boom and without moving the machine, pick arrow keys to change “NO” to “YES”.
up the proper test weight (W) listed in the table on
page 9.40. Pressing the LMI Override button may be 9. Follow the screen instructions:
required to lower the boom. a. “Remove Weights and Attachments”, press “OK”.
2 b. “TELESCOPE IN and FULLY LIFT UP”, press
“OK”.
c. “STOP, WAIT ONE MINUTE”, press “OK”.
A B C
d. “PRESS ENTER TO SET CHECK POINT”, press
"OK".
3508PS, 4008PS, 3509PS & 4009PS
e. Screen defaults back to Calibrations Menu.
A B C D
9-42 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
9.16.5 500 Hour - LSI UGM Calibration Check 9.17 HAND HELD ANALYZER
1. Start machine
The hand held analyzer can be used in place of the cab
2. Press the “C” and “OK” buttons simultaneously on display panel.
the keypad or the analyzer.
3. Go to “ACCESS LEVEL 2 or 1” and press “OK”.
4. Enter the proper access code and press “OK”.
1
5. Go to “OPERATOR TOOLS” menu, press “OK”.
6. Scroll to “LSI_CAN SYSTEM CHECK”.
7. “PERFORM LSI_CAN SYSTEM CHECK?”, use the
arrow keys to change “NO” to “YES”.
8. Follow the screen instructions as follows: 2
a. “Remove Weights and Attachments”, press “OK”. 3 4
b. “TELESCOPE IN and FULLY LIFT UP”, press
“OK”.
c. “STOP, WAIT ONE MINUTE”, press “OK”.
5 6
d. “PRESS ENTER TO START TEST”
e. “PASS or “FAIL”, press “ESC”. Must receive a
“PASS”.
f. “LSI CAN SYSTEM CHECK”, press “ESC” to
return to menu. MZ6040
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-43
9-44
9.17.2
- Not ACCESSABLE
MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PERSONALITIES MAIN LIFT BUCKET LIFT PLATFORM LIFT TELESCOPE BUCKET TELESCOPE PLAT. TELESCOPE FORK TILT BUCKET TILT PLATFORM LEVEL PLATFORM ROTATE STABILIZERS FRAME LEVEL AUX. FUNCTION1 AUX. FUNCTION2 AUX. MOMENTARY
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2: AUX. MOMENTARY:
ACCEL UP: x.x S ACCEL UP: x.x S ACCEL UP: x.x S ACCEL IN: x.x S ACCEL UP: x.x S ACCEL IN: x.x S ACCEL UP: x.x S ACCEL UP: x.x S ACCEL UP: x.x S ACCEL LEFT: x.x S ACCEL UP: x.x S ACCEL LEFT: x.x S ACCEL COIL A: x.x S ACCEL COIL A: x.x S COIL A: xxxx mA
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2: AUX. MOMENTARY:
DECEL UP: x.x S DECEL UP: x.x S DECEL UP: x.x S DECEL IN: x.x S DECEL UP: x.x S DECEL IN: x.x S DECEL UP: x.x S DECEL UP: x.x S DECEL UP: x.x S DECEL LEFT: x.x S DECEL UP: x.x S DECEL LEFT: x.x S DECEL COIL A: x.x S DECEL COIL A: x.x S COIL B: xxxx mA
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL OUT: x.x S ACCEL DOWN: x.x S ACCEL OUT: x.x S ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL DOWN: x.x S ACCEL RIGHT: x.x S ACCEL DOWN: x.x S ACCEL RIGHT: x.x S ACCEL COIL B: x.x S ACCEL COIL B: x.x S
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL OUT: x.x S DECEL DOWN: x.x S DECEL OUT: x.x S DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL DOWN: x.x S DECEL RIGHT: x.x S DECEL DOWN: x.x S DECEL RIGHT: x.x S DECEL COIL B: x.x S DECEL COIL B: x.x S
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MIN UP: xxx mA MIN UP: xxx mA MIN UP: xxx mA MIN IN: xxx mA MIN UP: xxx mA MIN IN: xxx mA MIN UP: xxx mA MIN UP: xxx mA MIN UP: xxx mA MIN LEFT: xxx mA MIN UP: xxx mA MIN LEFT: xxx mA MIN COIL A: xxx mA MIN COIL A: xxx mA
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MAX UP: xxxx mA MAX UP: xxxx mA MAX UP: xxxx mA MAX IN: xxxx MA MAX UP: xxxx mA MAX IN: xxxx mA MAX UP: xxxx mA MAX UP: xxxx mA MAX UP: xxxx mA MAX LEFT: xxxx mA MAX UP: xxxx mA MAX LEFT: xxxx mA MAX COIL A: xxxx mA MAX COIL A: xxxx mA
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MIN DOWN: xxx mA MIN DOWN: xxx mA MIN DOWN: xxx mA MIN OUT: xxx mA MIN DOWN: xxx mA MIN OUT: xxx mA MIN DOWN: xxx mA MIN DOWN: xxx mA MIN DOWN: xxx mA MIN RIGHT: xxx mA MIN DOWN: xxx mA MIN RIGHT: xxx mA MIN COIL B: xxx mA MIN COIL B: xxx mA
MAIN LIFT: BUCKET LIFT: PLATFORM LIFT: TELESCOPE: BUCKET TELE: PLAT. TELESCOPE: FORK TILT: BUCKET TILT: PLATFORM LEVEL: PLATFORM ROTATE: STABILIZERS: FRAME LEVEL: AUX. FUNCTION1: AUX. FUNCTION2:
MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX OUT: xxxx mA MAX DOWN: xxxx mA MAX OUT: xxxx mA MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX DOWN: xxxx mA MAX RIGHT: xxxx mA MAX DOWN: xxxx mA MAX RIGHT: xxxx mA MAX COIL B: xxxx mA MAX COIL B: xxxx mA
CALIBRATE TILT CALIBRATE BOOM PLATFORM TYPE: PERFORM PARK SET LSI-CAN
SENSOR? ANGLE SENSOR? 450 - EXTENDABLE BRAKE TEST? CHECK POINT: NO
MENU: CHANGE PERFORM HARDWARE CONFIRM MACHINE REVIEW SET SERVICE VEHICLE SPEED TEMPERATURE: OIL PRESSURE: CABIN JOYSTICK: STEER MODE: PERFORM LSI-CAN
OPERATOR TOOLS ANTI-THEFT CODE? EXCHANGE: NO SERVICE? SERVICE HISTORY? INTERVAL: 100H UNITS: KPH CELCIUS BAR TELESCOPE: X-AXIS AUTOMATIC SYSTEM CHECK? YES
ENTER CURRENT TRANSFER FROM: SERVICE COMPLETE SERVICE HISTORY VEHICLE SPEED TEMPERATURE: OIL PRESSURE: CABIN JOYSTICK: STEER MODE: REMOVE WEIGHTS
CODE: 0000 DISPLAY à UGM YES: ENTER, NO: ESC 1: XXXX HOURS UNITS: MPH FAHRENHEIT PSI TELESCOPE: ROLLER MANUAL AND ATTACHMENTS.
MAM2831-3.5
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
- Not ACCESSABLE
Note: The layout shows all possible analyzer screens. Please note, some screens may not be available depending upon machine configuration.
MENU: MODEL: MARKET: ENGINE CONTROL: TRANSMISSION: LOAD MONITORING: PLATFORM OPTION: HYDRAULIC QUICK AUX. FUNCTION BOOM RETRACTED BOOM EXTENSION LOAD SENSING: BOOM RIDE: BOOM FLOAT:
MACHINE SETUP UNKNOWN CE MECHANICAL POWERSYNCHRO LSI-CAN DISABLED CONNECT: NO SELECT: NO SWITCH: NO SWITCH: NO NONE NO NO
MODEL: MARKET: ENGINE CONTROL: LOAD MONITORING: PLATFORM OPTION: HYDRAULIC QUICK AUX. FUNCTION BOOM RETRACTED BOOM EXTENSION LOAD SENSING: BOOM RIDE: BOOM FLOAT:
TH336 ANSI ELECTRONIC LMI ENABLED CONNECT: YES SELECT: YES SWITCH: YES SWITCH: YES WARN ONLY YES YES
MODEL:
TH407
MODEL:
TH414
MODEL:
TH514
MODEL:
TH417
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
DIAGNOSTICS DRIVE / STEER CABIN JOYSTICK CABIN FUNCTIONS PLATFORM STABILIZERS FRAME LEVEL ENGINE SYSTEM LOAD MOMENT BOOM RIDE BOOM FLOAT PLATFORM LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
DRIVE DIRECTION CABIN JOYSTICK: RESPONSE CURVE: MAIN LIFT STABILIZER FRAME LEVEL OPERATING STATE: GROUND MODULE LOAD MOMENT BOOM RIDE BOOM FLOAT PLATFORM LOAD CAN1 STATISTICS: CALIBRATION DATA DATALOG: ON-TIME GROUND MODULE
INPUT: FORWARD X – AXIS: 0 % TELEHANDLER INPUT: XXX% INPUT: XXX% LEFT INPUT: LOW ENGINE STOPPED VOLTAGE: XX.XV STATUS: STABLE SWITCH: LOW SWITCH: LOW STATE: OK RX/SEC: X LIFT CAL1: XXX XXXXXXH XXM SOFTWARE: PX.X
GEAR SELECTION CABIN JOYSTICK: MAIN LIFT MAIN LIFT LEFT STABILIZER FRAME LEVEL ENGINE PREHEAT PLATFORM MODULE LOAD MOMENT BOOM RIDE BOOM FLOAT PLATFORM LOAD CAN1 STATISTICS: CALIBRATION DATA DATALOG: ENGINE GROUND MODULE
INPUT: 2 X – AXIS: NEUTRAL INPUT: XXX% COMMANDED: XXXXMA UP COIL: OFF RIGHT INPUT: LOW SWITCH: OPEN VOLTAGE: XX.XV OVERRIDE: NO STATUS: OFF SWITCH: OFF ACTUAL: XXX.X KG TX/SEC: X LIFT CAL2: XXX XXXXXXH XXM CNST. DATA: PX.X
DIRECTION / GEAR CABIN JOYSTICK: MAIN LIFT MAIN LIFT LEFT STABILIZER FRAME LEVEL AIR FILTER AMBIENT LOAD MOMENT %: PLATFORM LOAD CAN1 STATISTICS: DATALOG: DRIVE GROUND MODULE
ACTUAL: FORWARD / 2 Y – AXIS: 0 % COMMANDED: XXXXMA ACTUAL: XXXXMA DOWN COIL: OFF LEFT COIL: OFF SWITCH: OPEN TEMPERATURE: XXXC XX.X GROSS: XXX.X KG BUS OFF: X XXXXXXH XXM HARDWARE: REV X
DESIRED STEER CABIN JOYSTICK: MAIN LIFT TELESCOPE RIGHT STABILIZER FRAME LEVEL BATTERY VOLTAGE: STATION CONTROL: MOMENT CELL1 RAW PLATFORM LOAD CAN1 STATISTICS: DATALOG: LIFT GROUND MODULE
MODE: 2 - WHEEL Y – AXIS: NEUTRAL ACTUAL: XXXXMA INPUT: XXX% UP COIL: OFF RIGHT COIL: OFF XX.XV CABIN VALUE: XXXXXX OFFSET: XXXXXX PASSIVE: X XXXXXXH XXM S/N: XXXXXX
CURRENT STEER CABIN JOYSTICK: TELESCOPE TELESCOPE RIGHT STABILIZER FRAME LEVEL COOLANT OPERATING MODE: MOMENT CELL2 RAW PLATFORM LOAD CAN1 STATISTICS: DATALOG: TELE. GROUND MODULE
MODE: 2 - WHEEL L – ROLLER: 0 % INPUT: XXX% COMMANDED: XXXXMA DOWN COIL: OFF COMMANDED: XXXXMA TEMPERATURE: XXXC CABIN MODE VALUE: XXXXXX CELL 1: XXX.X KG MSG ERROR: XXXX XXXXXXH XXM P/N: XXXXXXXXXX
STEER PRESSURE CABIN JOYSTICK: TELESCOPE TELESCOPE STABILIZER SPEED CONTROL OIL PRESSURE: RESPONSE CURVE: PLATFORM LOAD CAN2 STATISTICS: DATALOG: AUX. PLATFORM MODULE
SWITCH: OPEN L – ROLLER: NEUTRAL COMMANDED: XXXXMA ACTUAL: XXXXMA COMMANDED: XXXXMA ACTUAL: XXXXMA XXXX PSI TELEHANDLER CELL 2: XXX.X KG RX/SEC: X XXXXXXH XXM SOFTWARE: PX.X
STEER PRESSURE CABIN JOYSTICK: TELESCOPE LEVEL UP SPEED CONTROL JOYSTICK LOCK AMBIENT PLATFORM STATUS: PLATFORM LOAD CAN2 STATISTICS: DATALOG: PLATFORM PLATFORM MODULE
STATUS: OK R – ROLLER: 0% ACTUAL: XXXXMA SWITCH: OPEN ACTUAL: XXXXMA ENGAGED: NO TEMPERATURE: XXXC NOT ATTACHED CELL 3: XXX.X KG TX/SEC: X XXXXXXH XXM HARDWARE: REV X
SERVICE BRAKE CABIN JOYSTICK: FORK TILT LEVEL DOWN JOYSTICK LOCK FRAME LEVEL FUEL LEVEL J1-21 PLATFORM PLATFORM LOAD CAN2 STATISTICS: DATALOG: PLATFORM MODULE
SWITCH: CLOSED R – ROLLER: NEUTRAL INPUT: XXX% SWITCH: OPEN ENGAGED: NO OPERATION: OK SENSOR: FULL ATTACHED: HIGH CELL 4: XXX.XKG BUS OFF: X MAX TEMP: XXC S/N: XXXXXX
SERVICE BRAKE CABIN JOYSTICK: FORK TILT PLATFORM LEVEL STABILIZER ENGINE SPEED FUNCTION ENABLE CAN2 STATISTICS: DATALOG: PLATFORM MODULE
STATUS: OFF S1 BUTTON: OFF COMMANDED: XXXXMA COMMANDED: XXXXMA OPERATION: OK ACTUAL: XXXX RPM GROUND: OPEN PASSIVE: X MIN TEMP: XXC P/N: XXXXXXXXXX
TRANSMISSION OIL CABIN JOYSTICK: FORK TILT PLATFORM LEVEL STABILIZER INPUT FUNCTION ENABLE CAN2 STATISTICS: DATALOG: CABIN JOYSTICK
TEMP.: XXX.X C TRIGGER: OFF ACTUAL: XXXXMA ACTUAL: XXXXMA 1 DEPLOYED: NO PLATFORM: CLOSED MSG ERROR: XXXX MAX VOLTS: XX.XV SOFTWARE: PX.X
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
CABIN JOYSTICK: AUX. HYDRAULICS ROTATE LEFT STABILIZER INPUT BOOM ANGLE: DATALOG: CABIN DISPLAY
S – ROCKER: LOW INPUT: XXX% SWITCH: OPEN 2 DEPLOYED: NO XX.X DEGREES RENTAL: XXXXH XXM SOFTWARE: PX.X
CABIN JOYSTICK: AUX. HYDRAULICS ROTATE RIGHT BOOM ANGLE RAW: DATALOG: LSS MODULE
T – ROCKER: LOW COMMANDED: XXXXMA SWITCH: OPEN COUNTS: XXXXXX ANTI-THEFT: 0000 SOFTWARE: PX.X
CHASSIS TILT:
X – AXIS: XX.X DEG
Electrical System
CHASSIS TILT:
Y – AXIS: XX.X DEG
HYDRAULIC FILTER
SWITCH: CLOSED
MAM2841-3.5
9-45
Electrical System
15&16 14
13 12
11
10 9 7 2 3 1 5 4 MAM1420
9-46 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
POWER UP 21XXX
FUNCTION ENABLE 214 1 Ignore and inhibit all function If both J7-15 of the UGM and J7-8 Power cycled.
INPUTS – INVALID requests from the platform station. of the platform module are
SIGNAL STATES Output J2-19 Function Enable simultaneously HIGH or LOW for a
Relay of the platform module will be period of 1 second after the
deactivated. Function Enable Relay power-up
Output J2-26 Engage Starter will check have been successfully
be deactivated and inhibited from completed or J7-15 is HIGH and
the platform. J7-8 is LOW after the Function
Enable Relay power-up check have
been successfully completed and
the PLATFORM STATION is active
and a valid PLATFORM MODE
exists.
JOYSTICK AXES 215 1 Ignore command signals from the At system power-up, if the one of A CAN
NOT IN NEUTRAL joystick regarding the X axis and Y the two axes are not in the neutral message is
POSITION AT axis. position, the UGM will report and received
POWER UP log a “JOYSTICK AXES NOT IN indicating the
NEUTRAL POSITION AT X axis and Y
POWER-UP” fault. axis are in the
neutral
position.
JOYSTICK ROLLER 216 1 Ignore command signals from the At system power-up, if the roller is A CAN
NOT IN NEUTRAL joystick regarding the roller. not in the neutral position on JLG message is
POSITION AT models only. received
POWER UP indicating the
roller is in the
neutral
position.
JOYSTICK S1 217 1 Ignore command signals from the At system power-up, if the S1 button A CAN
BUTTON ACTIVE AT joystick S1 button that was active is activated. message is
POWER UP during the power-up. received
indicating the
joystick S1
button is not
activated.
JOYSTICK S2 218 1 Ignore command signals from the At system power-up, if the S2 button A CAN
BUTTON ACTIVE AT joystick S2 button that was active is activated on JLG models only. message is
POWER UP during the power-up. received
indicating the
joystick S2
button is not
activated.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-47
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
JOYSTICK S3 219 1 Ignore command signals from the At system power-up, if the S3 button A CAN
BUTTON ACTIVE AT joystick S3 button that was active is activated on JLG models only. message is
POWER UP during the power-up. received
indicating the
joystick S3
button is not
activated.
JOYSTICK S4 2110 1 Ignore command signals from the At system power-up, if the S4 button A CAN
BUTTON ACTIVE AT joystick S4 button that was active is activated on JLG models only. message is
POWER UP during the power-up. received
indicating the
joystick S4
button is not
activated.
ENGINE START 2111 1 The engine start signal will be If a LOW on J1-14 of the platform Power cycled.
PREVENTED – ignored. module and the PLATFORM
PLATFORM START J2-26 Engage Starter will be STATION is active at system power
SWITCH HIGH AT deactivated and inhibited. up.
POWER UP
PLATFORM ROTATE 2112 1 Ignore platform rotate left function If the PLATFORM STATION is The input
LEFT PREVENTED request. active and a platform is configured goes LOW for
– INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform rotate left input at
system power up.
PLATFORM ROTATE 2113 1 Ignore platform rotate right function If the PLATFORM STATION is The input
RIGHT PREVENTED request. active and a platform is configured goes LOW for
– INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform rotate right input at
system power up.
PLATFORM LEVEL 2114 1 Ignore platform level up function If the PLATFORM STATION is The input
UP PREVENTED – request. active and a platform is configured goes LOW for
INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform level up input at system
power up.
PLATFORM LEVEL 2115 1 Ignore platform level down function If the PLATFORM STATION is The input
DOWN PREVENTED request. active and a platform is configured goes LOW for
– INPUT HIGH AT as ENABLED and a platform is a period of at
POWER UP detected as attached and a HIGH is least 1
detected at the platform station on second.
the platform level down input at
system power up.
9-48 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
APU SWITCH INPUT 2116 1 Still allow APU function request. If a platform is configured as The input
INVALID – INPUT If J7-4 Boom Angle reading is less ENABLED and the UGM detects goes LOW for
HIGH AT POWER than 10° and the J3-8 Boom J4-16 Auxiliary Power Unit (APU) a period of at
UP Retracted input is HIGH, cutout the Enable is HIGH at system power up. least 1
Main Lift Up and Telescope Out second.
functions.
PLATFORM 2117 1 Ignore platform lift and telescope If the PLATFORM STATION is Joystick is
JOYSTICK NOT IN function requests from the platform active and a platform is configured detected to be
NEUTRAL joystick. as ENABLED and a platform is in neutral
POSITION AT detected as attached and the position.
POWER UP platform joystick is not detected to
be in the neutral position at system
power up.
ENGINE 2118 1 Ignore engine pre-heat function If the UGM detects J4-20 Engine The input
PRE-HEAT request. Pre-Heat or the platform module goes LOW for
PREVENTED – input J1-23 Engine Pre-heat is a period of at
INPUT HIGH AT HIGH at system power up. least 1
POWER UP second.
FRAME LEVEL 2119 1 Deactivate and inhibit J2-5 Frame If J4-17 Frame Leveling Right is Power cycled.
RIGHT INPUT – Level Right Valve. HIGH at power up.
INVALID SIGNAL Deactivate and inhibit J2-7 Frame
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve (if applicable) as it relates to
frame leveling functions only.
FRAME LEVEL 2120 1 Deactivate and inhibit J2-5 Frame If J4-9 Frame Leveling Left is HIGH Power cycled.
LEFT INPUT – Level Right Valve. at power up.
INVALID SIGNAL Deactivate and inhibit J2-7 Frame
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve (if applicable) as it relates to
frame leveling functions only.
HYDRAULIC QUICK 2121 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature is Power cycled.
CONNECT INPUT – Quick Connect Valve. configured in the MACHINE SETUP
INVALID Ignore hydraulic quick connect menu and J7-35 Hydraulic Quick
SIGNAL function requests. Connect ON is HIGH at power up or
Deactivate output J2-9 Auxiliary J3-10 Hydraulic Quick Connect
Function-A Valve until the cabin’s OFF is LOW at power up or J7-35
joystick is in the neutral position matches the state of input J3-10 for
and the S4 switch is OFF and J1-23 0.5 seconds.
is confirmed to be deactivated.
Deactivate output J2-20 Auxiliary
Function-B Valve until the cabin’s
joystick is in the neutral position
and the S4 switch is OFF and J1-23
is confirmed to be deactivated.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-49
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
CONTINUOUS 2122 1 Inhibit operation of the Continuous The UGM has detected the The input
AUXILIARY Auxiliary Hydraulics feature/logic. Continuous Auxiliary Hydraulics goes LOW for
HYDRAULICS switch is HIGH at system power up. a period of at
SWITCH HIGH AT least 1
POWER UP second.
JOYSTICK 2123 1 Ignore command signals from the At system power-up, if the joystick A CAN
TRIGGER SWITCH joystick trigger switch that was trigger switch is activated on CAT message is
ACTIVE AT POWER active during the power-up. models only. received
UP indicating the
joystick
trigger switch
is not
activated.
JOYSTICK LEFT 2124 1 Ignore command signals from the At system power-up, if the left roller Latch fault
ROLLER NOT IN joystick regarding the left roller. of the joystick is not in the neutral until a joystick
THE NEUTRAL position on CAT models only. CAN message
POSITION AT is received
POWER UP indicating the
roller is in the
neutral
position.
JOYSTICK RIGHT 2125 1 Ignore command signals from the At system power-up, if the right Latch fault
ROLLER NOT IN joystick regarding the right roller. roller of the joystick is not in the until a joystick
THE NEUTRAL neutral position on CAT models CAN message
POSITION AT only. is received
POWER UP indicating the
roller is in the
neutral
position.
BOOM RIDE 2130 1 Ignore signal from the Boom Ride At system power-up, the Boom Boom Ride
ENABLE SWITCH Enable Switch. Ride/Boom Float module has Enable Switch
NOT IN THE OFF detected the Boom Ride Enable is detected in
POSITION AT Switch is engaged. its OFF
POWER UP position.
PLATFORM 22XXX
CONTROLS
PLATFORM LEVEL – 2225 1 Not acknowledge either platform If the UGM receives CAN2 Power cycled.
CONFLICTING level function request messages. messages that indicate both J1-9
INPUT SIGNALS and J1-10 inputs to the platform
controller are HIGH together.
PLATFORM ROTATE 2226 1 Not acknowledge either platform If the UGM receives CAN2 Power cycled.
– CONFLICTING rotate function request messages. messages that indicate both J1-7
INPUT SIGNALS and J1-8 inputs to the platform
controller are HIGH together.
9-50 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
FUNCTION ENABLE 2227 1 The requested function will be If the PLATFORM STATION is The hydraulic
INTERLOCK – ignored. active and a platform is configured function
ENABLE SWITCH as ENABLED and a platform is request is no
NOT SELECTED detected as attached and a longer active.
FIRST hydraulic function request is detect
at the platform station before the
function enable signal was
received.
FUNCTION ENABLE 2228 1 Turn OFF the functions enabled If the PLATFORM STATION is The function
INTERLOCK – NOT indicator at the platform station. active and a platform is configured enable switch
SELECTED IN TIME Ignore all function requests from as ENABLED and a platform is is released.
the platform station while the detected as attached and if a
FUNCTIONS ENABLED state is function request is not received
active. within the 7 second period from the
time the FUNCTION ENABLE state
is activated.
ENGINE START 2229 1 The engine start signal will be When the PLATFORM STATION is The function
PREVENTED – ignored. J2-26 Engage Starter will active and the engine start signal is enable switch
FUNCTION ENABLE be deactivated and inhibited. detected at the platform and the is released.
SWITCH ENGAGED UGM detects the function enable
switch is engaged.
PLATFORM 2230 1 Hydraulic functions The platform module detects the Power cycle.
JOYSTICK – OUT (Lift and Telescope) associated to input voltage for dual-axis joystick is
OF RANGE HIGH the dual-axis platform joystick are out of range on the high side and
inhibited. reports the issue to the UGM.
PLATFORM 2231 1 Hydraulic functions The platform module detects center Power cycle.
JOYSTICK – (Lift and Telescope) associated to tap dual-axis joystick voltage is out
CENTER TAP BAD the dual-axis platform joystick are of range and reports the issue to
inhibited. the UGM.
FUNCTION ENABLE 2233 1 Deactivate and inhibit platform J7-2 of the platform module is HIGH Power cycle.
RELAY – INVALID module output J2-19 Function and J2-4 Function Enable Integrity
SIGNAL Enable Relay. Signal does not change states from
Deactivate and inhibit UGM output HIGH to LOW during the power-up
J2-26 Engage Starter. test sequence.
Suppress the “FUNCTION
ENABLE INPUTS – INVALID
SIGNAL STATES” fault.
GROUND 23XXX
CONTROLS
OPERATING MODE 239 1 J2-26 Engage Starter output will be The PLATFORM STATION is active A valid drive
INTERLOCK – deactivated and engine start will and CABIN MODE was the last direction of
SHIFTER NOT IN not be permitted if the PLATFORM valid operating mode and a platform Neutral exists
NEUTRAL STATION is active and CABIN is detected as attached and the (J4-4 is the
MODE was the last valid operating drive direction inputs are not only HIGH
mode. detected as follows: (J4-4 Neutral- shifter input).
Changeover to PLATFORM MODE HIGH, J7-22 Forward-LOW, J4-18
will not be permitted. LOW).
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-51
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
PLATFORM OPTION 2311 1 The UGM will also disregard all If the PLATFORM ATTACHED Power cycle.
NOT commands from the platform option has not been configured in
CONFIGURED station. the MACHINE SETUP menu and a
The UGM will use the platform platform attached state is detected
attached response curves. or the UGM detects a HIGH on J7-1
or J7-2.
STABILIZERS NOT 2312 1 The UGM will ignore all stabilizer If the S1 button on the cabin’s The S1
CONFIGURED function requests from the joystick. joystick is activated and the button on the
STABILIZERS option has not been cabin joystick
configured in the MACHINE SETUP is released.
menu and STABILIZERS are a
configurable for the selected
MODEL.
FRAME LEVEL NOT 2313 1 The UGM will ignore all frame level If J4-17 Frame Leveling Right or J4-17 or J4-9
CONFIGURED function requests on UGM inputs J4-9 Frame Leveling Left inputs are goes LOW.
J4-17 and J4-9. HIGH and the FRAME LEVEL
option has not been configured in
the MACHINE SETUP menu.
OPERATING 2314 1 The directional symbol “N” will be If UGM inputs J7-3 Ground Mode Power cycle.
STATION displayed in the operator’s cabin and J7-2 Platform Mode both are
SELECTION display LCD. HIGH during operation.
INVALID The transmission will be
commanded to neutral and drive
will not be permitted.
Immediately deactivate and inhibit
all hydraulic function operation.
9-52 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
OPERATING MODE 2315 1, 15 J2-26 Engage Starter output will be The PLATFORM STATION is active J7-7 and J7-
INTERLOCK - deactivated and engine start will and one or both inputs J7-7 and 20 become
STABILIZERS NOT not be permitted if the PLATFORM J7-20 are LOW. HIGH.
DEPLOYED STATION is active and CABIN
MODE was the last valid operating
mode.
Changeover to PLATFORM MODE
will not be permitted. If PLAFORM
MODE is already the valid
operating state and the UGM has
not detected any chassis tilt
condition, then inhibit the Lift
function until the Boom Retracted
switch is HIGH. Once the Boom
Retracted switch is HIGH, the UGM
will permit the Lift Down
Function to operate and inhibit the
Telescope Out function. Once the
UGM detects the boom angle is
below 10°, the Telescope Out
function will be permitted and the
Lift function permitted up to a boom
angle of 10°. If the UGM detects a
chassis tilt condition with a tilt
sensor angle reading of ABSO-
LUTE TRIP POINT 1 or higher but
less than ABSOLUTE TRIP POINT
2, the above retrieval sequence will
be permitted at derated function
speeds. If the UGM detects a
chassis tilt condition with a tilt
sensor angle reading of
ABSOLUTE TRIP POINT 2 or
higher, Telescope Out will be
immediately inhibited.
OPERATING MODE 2316 1 J2-26 Engage Starter output will be The PLATFORM STATION is active The UGM
INTERLOCK - PLAT- deactivated and engine start will and the UGM has not detected the detects the
FORM NOT not be permitted if the PLATFORM platform electrically attached. platform as
ATTACHED STATION is active and CABIN electrically
MODE was the last valid operating attached.
mode.
Changeover to PLATFORM MODE
will not be permitted. If
PLATFORM MODE is the last valid
operating mode, the UGM will
assume the platform is attached.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-53
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
OPERATING MODE 2317 1, 16 J2-26 Engage Starter output will be The PLATFORM STATION is active The UGM
INTERLOCK - deactivated and engine start will and the UGM has detected the detects the
CHASSIS NOT not be permitted if the PLATFORM machine’s chassis is not sufficiently machine’s
LEVEL STATION is active and CABIN level for platform operation. chassis tilt
MODE was the last valid operating level is within
mode. range.
Changeover to PLATFORM MODE
will not be permitted. If
PLATFORM MODE is already the
valid operating state and a chassis
tilted condition occurs from a tilt
sensor angle reading of
ABSOLUTE TRIP POINT 1or
higher but less than ABSOLUTE
TRIP POINT 2, the Lift and
Telescope function speeds will be
derated if an ENGINE RUNNING
condition exists and APU operation
will be permitted if an ENGINE
STOPPED condition exists. If
PLATFORM MODE is already the
valid operating state and a chassis
tilted condition occurs from a tilt
sensor angle reading of
ABSOLUTE TRIP POINT 2 or
higher, telescope out will be
inhibited.
OPERATING MODE 2318 1 J2-26 Engage Starter output will be CABIN MODE was the last valid The UGM has
INTERLOCK - deactivated and engine start will operating mode and the PLAFORM detected the
BOOM ANGLE TOO not be permitted if the PLATFORM STATION is currently active and the boom angle is
HIGH STATION is active and CABIN UGM has detected the boom angle 10°.
MODE was the last valid operating is 10°.
mode. PLATFORM MODE was the last
Changeover to PLATFORM MODE valid operating mode and the
will not be permitted. CABIN
Changeover to CABIN MODE will STATION is currently active and the
not be permitted. UGM has detected the boom angle
is 10°.
OPERATING MODE 2319 1 J2-26 Engage Starter output will be CABIN MODE was the last valid The UGM has
INTERLOCK - deactivated and engine start will operating mode and the PLAFORM detected J3-8
BOOM NOT FULLY not be permitted if the PLATFORM STATION is currently active and the Boom
RETRACTED STATION is active and CABIN UGM has detected J3-8 Boom Retracted is
MODE was the last valid operating Retracted is LOW. HIGH.
mode. PLATFORM MODE was the last
Changeover to PLATFORM MODE valid operating mode and the
will not be permitted. CABIN
Changeover to CABIN MODE will STATION is currently active and the
not be permitted. UGM has detected J3-8 Boom
Retracted is LOW.
9-54 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
OPERATING MODE 2320 1 J2-26 Engage Starter output will be The PLATFORM STATION or J4-5 Park
INTERLOCK - PARK deactivated and engine start will CABIN STATION is active and the Brake is HIGH
BRAKE NOT SET not be permitted if the PLATFORM UGM has detected J4-5 Park Brake (set).
STATION is active and CABIN is LOW (not set) during a MODE
MODE was the last valid operating changeover situation or during
mode. PLATFORM MODE.
Changeover to PLATFORM MODE
will not be permitted.
Changeover to CABIN MODE will
not be permitted.
All hydraulic function requests from
the platform station will be ignored.
ERRATIC 2321 1 The platform will be considered The UGM detects three signal Power cycled.
PLATFORM attached. transitions on J1-21 within a 5
ATTACHED Display the platform attached second period.
SIGNAL screen on the cabin’s LCD.
CONFLICTING 2322 1 Deactivate and inhibit J2-5 Frame J4-17 Frame Leveling Right and Power cycled.
FRAME LEVEL Level Right Valve. J4-9 Frame Leveling Left inputs are
SIGNALS Deactivate and inhibit J2-7 Frame both HIGH simultaneously.
Level Left Valve.
Deactivate and inhibit J1-3
Stabilizer and Frame Level Speed
Valve (if applicable) as it relates to
frame leveling functions only.
CABIN JOYSTICK – 2323 1 X-axis function requests will be The cabin joystick detects a fault on Power cycled.
X AXIS FAULT ignored by the UGM. the X-axis of the joystick.
CABIN JOYSTICK – 2324 1 Y-axis function requests will be The cabin joystick detects a fault on Power cycled.
Y AXIS FAULT ignored by the UGM. the Y-axis of the joystick.
CABIN JOYSTICK – 2325 1 Roller function requests will be The JLG cabin joystick detects a Power cycled.
ROLLER FAULT ignored by the UGM. fault with the roller on the joystick.
CABIN JOYSTICK – 2326 1 S1 button function requests will be The cabin joystick detects a fault Power cycled.
S1 BUTTON FAULT ignored by the UGM. with the S1 button on the joystick.
CABIN JOYSTICK – 2327 1 S2 button function requests will be The JLG cabin joystick detects a Power cycled.
S2 BUTTON FAULT ignored by the UGM. fault with the S2 button on the
joystick.
CABIN JOYSTICK – 2328 1 S3 button function requests will be The JLG cabin joystick detects a Power cycled.
S3 BUTTON FAULT ignored by the UGM. fault with the S3 button on the
joystick.
CABIN JOYSTICK – 2329 1 S4 button function requests will be The JLG cabin joystick detects a Power cycled.
S4 BUTTON FAULT ignored by the UGM. fault with the S4 button on the
joystick.
CABIN JOYSTICK – 2330 1 S switch function requests will be The cabin joystick detects a fault Power cycled.
S SWITCH FAULT ignored by the UGM. with the S switch.
CABIN JOYSTICK – 2331 1 T switch function requests will be The cabin joystick detects a fault Power cycled.
T SWITCH FAULT ignored by the UGM. with the T switch.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-55
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
ALL WHEEL STEER 2333 1 Not recognize any steer mode J4-35 All Wheel Steer input is HIGH Power cycled.
INPUT – INVALID requests on input J4-35 All Wheel at power up or for a period of 7
SIGNAL Steer. seconds or longer.
Flash the All-Wheel Steer Mode
Indicator at a frequency of 5 Hz.
CRAB STEER 2334 1 Not recognize any steer mode J4-34 Crab Steer input is HIGH at Power cycled.
INPUT – INVALID requests on input J4-34 Crab Steer. power up or for a period of 7
SIGNAL Flash the Crab Steer Mode seconds or longer.
Indicator at a frequency of 5 Hz.
JOYSTICK LOCK 2335 1 Deactivate the Joystick Lock J7-11 Joystick Lock input is HIGH at Power cycled.
INPUT – INVALID feature if the CABIN STATION is power up or for a period of 7
SIGNAL active. seconds or longer.
Activate J4-1 Joystick Function
Indicator to flash at a frequency of 5
Hz.
LOAD MOMENT 2336 1 Disregard a HIGH on input J4-33. J4-33 Load Moment Shutoff input is Power cycled.
SHUTOFF INPUT – If the CABIN STATION is active, HIGH at power up or for a period of
INVALID SIGNAL monitor and immediately react to 40 seconds or longer.
the signal at J4-10; otherwise,
disregard the signal at J4-10.
If the CABIN STATION is active,
flash J4-26 Load Moment Shutoff
Indicator at a frequency of 5Hz;
otherwise, activate J4-26.
If the CABIN STATION is active, set
the Load Moment Shutoff state to
active; otherwise, set the Load
Moment Shutoff state to inactive.
BUCKET MODE 2337 1 Discard the fork tilt response J4-19 Bucket Mode input is HIGH at Power cycled.
INPUT – INVALID curves for bucket mode. power up or for a period of 7
SIGNAL Activate J4-13 Bucket Mode seconds or longer.
Indicator to flash at a frequency of
5 Hz.
Apply the proper fork tilt response
curves for the new active mode
when the cabin’s joystick X and Y
and roller(s) axes are in neutral.
2–WHEEL STEER 2338 1 Not recognize any steer mode J3-9 2-Wheel Steer input is HIGH at Power cycled.
INPUT – INVALID requests on input J3-9 2-Wheel power up or for a period of 7
SIGNAL Steer. seconds or longer.
Flash the 2-Wheel Steer Mode
Indicator at a frequency of 5 Hz.
KEYPAD OK 2339 1 Disregard all signal changes until The UGM detects the keypad OK Power cycled.
BUTTON – INVALID switch state transitions to LOW. button is HIGH at power up or for a
SIGNAL period of 7 seconds or longer.
9-56 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
KEYPAD CANCEL 2340 1 Disregard all signal changes until The UGM detects the keypad Power cycled.
BUTTON – INVALID switch state transitions to LOW. CANCEL button is HIGH at power
SIGNAL up or for a period of 7 seconds or
longer.
KEYPAD UP 2341 1 Disregard all signal changes until The UGM detects the keypad UP Power cycled.
BUTTON – INVALID switch state transitions to LOW. button is HIGH at power up or for a
SIGNAL period of 7 seconds or longer.
KEYPAD DOWN 2342 1 Disregard all signal changes until The UGM detects the keypad Power cycled.
BUTTON – INVALID switch state transitions to LOW. DOWN button is HIGH at power up
SIGNAL or for a period of 7 seconds or
longer.
BOOM ANGLE 2343 1 Assign a fixed boom angle value of The UGM detects no calibration has A valid boom
SENSOR – NOT 99×, as other functions will then been completed. angle sensor
CALIBRATED fault to safe conditions. calibration is
Display the fixed boom angle value completed.
of ‘99’ on the operator’s cabin
display.
Derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.
Ignore all hydraulic function
requests from the platform module.
BOOM ANGLE 2344 1 Display the fixed boom angle value During operation or calibration, the Power cycled.
SENSOR – OUT OF of ‘99’ on the operator’s cabin UGM detects a value at this input of
RANGE HIGH display. more than 4.4V.
Temporarily assign a fixed boom
angle value of 99×.
If a calibration is in progress, fail
boom angle sensor calibration
(“CALIBRATION: SENSOR
FAULT”).
Derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.
Ignore all hydraulic function
requests from the platform module.
BOOM ANGLE 2345 1 Display the fixed boom angle value During operation or calibration, the Power cycled.
SENSOR – OUT OF of ‘99’ on the operator’s cabin UGM detects a value at this input of
RANGE LOW display. less than 0.6V.
Temporarily assign a fixed boom
angle value of 99×.
If a calibration is in progress, fail
boom angle sensor calibration
(“CALIBRATION: SENSOR
FAULT”).
Derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.
²Ignore all hydraulic function
requests from the platform module.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-57
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
BOOM ANGLE 2346 1 Display the fixed boom angle value J2-11 Main Lift Up Valve or J2-22 Power cycled.
SENSOR – NOT of ‘99’ on the operator’s cabin Main Lift Down Valve are active
RESPONDING display. operating at a current of at least 900
Temporarily assign a fixed boom mA for a period of 4 seconds with
angle value of 99×. an ENGINE RUNNING condition
Disallow boom angle sensor and no appreciable change set at
calibration (“BOOM ANGLE: 0.5 degrees (adjustable in
CALIBRATION FAIL”). Constant Data) in the value at this
Ignore all hydraulic function input. (Note, this fault will not be
requests from the platform module. report during boom angle sensor
Deactivate and inhibit the Lift Up calibration.)
output if the platform is detected as
attached or PLATFORM MODE is
the current active mode; otherwise,
derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.
9-58 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
SYSTEM 2347 1 Deactivate and inhibit all joystick The UGM has detected one of the Joystick
INTERLOCK – SET functionality. following conditions: inputs are in
JOYSTICK INPUTS The hydraulic quick connect switch the
TO NEUTRAL is activated when any of the other neutral
auxiliary hydraulics functions is position.
active.
If the joystick roller(s) and/or X-axis
and/or Y-axis are not in the neutral
or centered position when the
hydraulic quick connect switch is
released.
When the hydraulic quick connect
switch is activated and the S4
button activation is not the next
detected operator action.
If the joystick roller(s) and/or X-axis
and/or Y-axis are not in the neutral
or centered position when the ‘S’
switch activation cause the Auxiliary
Hydraulics Release feature to
engage.
If the Auxiliary Hydraulics Release
feature is active and the platform
becomes detected as attached.
When the hydraulic quick connect
switch is activated and the S4
button activated, but then released.
When the Quick Connect feature is
active and the S4 button is
released.
If the platform is detected as
attached with bucket mode active.
If the roller(s) and/or X-axis and/or
Y-axis are not in the neutral or
centered position or one of the
S1-S4 buttons are engaged or the
trigger switch is engaged and the
Joystick Lock feature is enabled.
The S4 button is engaged when the
joystick roller and/or X-axis and/or
Y-axis are not in the neutral or
centered position.
The Auxiliary Hydraulics Release
feature will suppress this fault when
active.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-59
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
CABIN JOYSTICK – 2350 1 Left roller function requests will be The CAT cabin joystick detects a Power cycled.
LEFT ROLLER ignored by the UGM. fault with the left roller on the
FAULT joystick.
CABIN JOYSTICK – 2351 1 Right roller function requests will be The CAT cabin joystick detects a Power cycled.
RIGHT ROLLER ignored by the UGM. fault with the right roller on the
FAULT joystick.
CABIN JOYSTICK – 2352 1 Trigger switch requests will be The CAT cabin joystick detects a Power cycled.
TRIGGER SWITCH ignored by the UGM. fault with the trigger switch on the
FAULT joystick.
BOOM ANGLE 2353 1 Display the fixed boom angle value The UGM or platform module has Power cycled.
SENSOR – of ‘99’ on the operator’s cabin detected one of the following
INTERNAL FAILURE display. internal failures of the CAN based
Temporarily assign a fixed boom boom angle sensor:
angle value of 99×. A difference of more than 7 counts
Disallow boom angle sensor (2.5°) for 1 second between the 2
calibration (“BOOM ANGLE: angle readings.
CALIBRATION FAIL”). A CAN bus message indicating a
Ignore all hydraulic function boom angle value out of range of
requests from the platform module. the calibration, i.e. more than 250
Deactivate and inhibit the Lift Up counts.
output if the platform is detected as
attached or PLATFORM MODE is
the current active mode; otherwise,
derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.
OPERATING 2354 1 J2-26 Engage Starter output will be The platform module has detected J1-1 of the
INTERLOCK – deactivated and engine start will J1-1 of the platform module is LOW platform
ATTACHMENT not be permitted if the PLATFORM and the PLATFORM STATION is module goes
COUPLING PIN NOT STATION is active and CABIN active and a platform is detected as HIGH for a
ENGAGED MODE was the last valid operating attached and CAN communications period of 3
mode. exist between the UGM and plat- seconds.
Changeover to PLATFORM MODE form module.
will not be permitted.
If the PLATFORM MODE is the
valid operating mode, Lift and
Telescope functions will be derated
to the LIFT UP DERATE and TELE
DERATE values in Constant Data.
OPERATING 2384 1 J2-26 Engage Starter output will be The PLATFORM STATION is active The UGM
INTERLOCK – deactivated and engine start will and a MARKET configuration of detects the
PLATFORM NOT not be permitted if the PLATFORM AUSTRAILIA exists and the UGM platform as
COUPLED STATION is active and CABIN has not detected the platform coupled for 2
MODE was the last valid operating coupled signal on input J3-13 seconds.
mode. (LOW).
Changeover to PLATFORM MODE
will not be permitted. If
PLATFORM MODE is the last valid
operating mode, the UGM will
assume the platform is attached.
9-60 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
ERRATIC 2385 1 The platform will be considered The UGM detects three signal Power cycled.
PLATFORM coupled. transitions on J3-13 within a 5
COUPLED SIGNAL second period.
LOSS OF 2386 1 N/A The CABIN STATION is active and Power cycled.
PLATFORM a MARKET configuration of
COUPLED SIGNAL AUSTRALIA exists and J3-13
Platform Coupled input is LOW and
J1-21 Platform Attached input is
LOW or valid platform module CAN
bus messages are being
continuously received by the UGM
or “ERRACTIC PLATFORM
ATTACHED SIGNAL” fault exists.
FUNCTION 25XXX
PREVENTED
MODEL CHANGED 259 1 Deactivate and inhibit all hydraulic The MODEL selection on the Power cycled.
– HYDRAULICS function operation. Analyzer was changed from its
SUSPENDED – J2-26 Engage Starter output will be previous setting.
CYCLE EMS deactivated and engine start will
not be permitted.
FUNCTIONS 2520 1 Deactivate and inhibit all hydraulic The Constant Data code version is Proper
LOCKED OUT – function operation. not up to date / compatible with the Constant
CONSTANT DATA J2-26 Engage Starter output will be current machine Application code. Version is
VERSION deactivated and engine start will loaded and
IMPROPER not be permitted. power is
cycled.
ENGINE START 2525 1 J2-26 Engage Starter output will be The CABIN STATION is active and J4-5 Park
PREVENTED – deactivated and engine start will J4-8 Engine Start input is HIGH and Brake is HIGH
PARK BRAKE NOT not be permitted. J4-5 Park Brake is LOW (not set). (set).
SET
BOOM EXTENDED 2526 1 N/A J7-8 Boom Extension Limit input is Power cycled.
SWITCH – LOW, the feature is enabled in the
CONFLICTING MACHINE SETUP menu, and the
STATE J3-8 Boom Retracted input is HIGH.
EXCESSIVE BOOM 2527 1 Not activate outputs J2-9 Auxiliary If hydraulic quick connect feature is J7-35
ANGLE FOR Function-A Valve or J2-20 Auxiliary configured in the MACHINE SETUP Hydraulic
HYDRAULIC QUICK Function-B Valve. menu and the boom angle sensor Quick
CONNECT reading is 10° and the boom angle Connect ON
OPERATION sensor has successfully completed is LOW and
a calibration and a hydraulic quick J3-10
connect function request is Hydraulic
detected. Quick
Connect OFF
is HIGH.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-61
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
PLATFORM 2528 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature is J7-35
ATTACHED - Quick Connect. configured in the MACHINE SETUP Hydraulic
HYDRAULIC QUICK Ignore auxiliary hydraulic requests menu and the platform attached Quick
CONNECT CUTOUT when the S4 button is engaged on conditions have been met and Connect ON
the cabin’s joystick. J7-35 is HIGH and J3-10 is LOW is LOW and
and the CABIN STATION is active. J3-10
Hydraulic
Quick
Connect OFF
is HIGH.
ENGINE START 2529 1 J2-26 Engage Starter output is If the drive direction signal is not in Shift lever is in
PREVENTED – inhibited. neutral (i.e. – J7-22 Forward HIGH neutral
SHIFT LEVER NOT and/or J4-18 Reverse HIGH). position.
IN NEUTRAL
PLATFORM 2533 1 Report the condition to the UGM. The platform option is configured The UGM and
ATTACHED ANGLE Deactivate platform module output and a platform is detected as platform
LIMIT EXCEEDED J2-19 Function Enable Relay attached and the platform module is module
(which deactivates the dump valve) detecting the “PLATFORM confirm the
with any Main Lift Up hydraulic ATTACHED BOOM ANGLE boom angle
request from the platform station. OVERSHOOT POINT” has been sensor
The UGM will inhibit activation of reached and faults 2343, 2353, and reading is less
J2-11 Main Lift Up Valve. 6621 are not active. than the
“PLATFORM
ATTACHED
BOOM
ANGLE CUT-
OUT POINT”
for at least 1
second.
BOOM EXTENSION 2557 1 Illuminate the vehicle system dis- If a platform is detected as attached Power cycled.
LIMIT SWITCHES – tress indicator in the cabin’s display. and AM J1-4 is LOW and J7-8 is
CONFLICTING Activate the buzzer for a period of 5 HIGH or Visa Versa for more than
STATES seconds in the cabin’s display. 500ms when a telescope function is
Illuminate the vehicle system active.
distress indicator at the platform
station.
Activate the buzzer for a period of 5
seconds at the platform station.
Illuminate the Envelope Control
indicator at the platform station. If a
prohibited function is engaged, the
Envelope Control indicator will
instead flash at a 10Hz rate.
J2-35 Main Telescope Out Valve
will be inhibited.
J2-22 Main Lift Down Valve will be
inhibited; allow Telescope In
function until a J3-8 Boom
Retracted input state changes
occurs from LOW to HIGH. Only
permit J2-22 Main Lift Down once
J3-8 state change has been seen
as HIGH.
9-62 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
TELESCOPE 2558 1 Illuminate the vehicle system If a platform is detected as attached Power cycled.
POSITION distress indicator in the cabin’s and both AM J1-4 and J7-8 are
SWITCHES – display. LOW and the J3-8 Boom Retracted
CONFLICTING Activate the buzzer for a period of 5 input is HIGH.
STATES seconds in the cabin’s display.
Illuminate the vehicle system
distress indicator at the platform
station.
Activate the buzzer for a period of 5
seconds at the platform station.
BOOM RETRACTED 2560 1 Consider any information on input The UGM has detected one of the Power cycled.
SENSOR FAULTY – J3-8 Boom Retracted invalid. following failures of the boom
SENSING INVALID Set the system as if the boom is retracted sensor when configured
always extended. for LSI-CAN or LSI-CAN + LMI:
With no telescope functions active,
a boom retracted sensor state
changes occur.
With Telescope In active, a boom
retracted sensor transition of HIGH
to LOW occurs.
With Telescope Out active, a boom
retracted sensor transition of LOW
to HIGH occurs.
With Telescope Out active, the
boom retracted sensor has not
HIGH for a period of 5 seconds with
at least 950mA commanded on the
function AND the Load Moment
Warning Point has been met or
exceeded.
MAIN LIFT UP 33181 1 Deactivate output J2-11 Main Lift The UGM detects an open circuit at Power cycled.
VALVE – Up Valve. this output or the UGM detects a
OPEN CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag to
determine if this fault condition is
the reason for the fault.
MAIN LIFT VALVES 33182 1 Deactivate output J2-11 Main Lift The UGM detects a short to battery Power cycled.
– SHORT TO Up Valve. at this output.
BATTERY Deactivate output J2-22 Main Lift
Down Valve.
Decouple/disable current feedback
input J3-2 Lift Return (Disables Lift
Up and Down).
MAIN LIFT UP 33183 1 Deactivate output J2-11 Main Lift The UGM detects a short to ground Power cycled.
VALVE – SHORT TO Up Valve. at this output or the UGM detects a
GROUND Decouple/disable current feedback CURRENT FEEDBACK LOST
input J3-2 Lift Return (Disables Lift condition and sets an internal flag to
Up and Down). determine if this fault condition is
the reason for the fault.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-63
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
MAIN LIFT DOWN 33184 1 Deactivate output J2-22 Main Lift The UGM detects an open circuit at Power cycled.
VALVE – Down Valve. this output or the UGM detects a
OPEN CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag to
determine if this fault condition is
the reason for the fault.
MAIN LIFT DOWN 33185 1 Deactivate output J2-22 Main Lift The UGM detects a short to ground Power cycled.
VALVE – Down Valve. at this output or the UGM detects a
SHORT TO Decouple/disable current feedback CURRENT FEEDBACK LOST
GROUND input J3-2 Lift Return (Disables Lift condition and sets an internal flag to
Up and Down). determine if this fault condition is
the reason for the fault.
MAIN TELESCOPE 33186 1 Deactivate output J2-35 Main The UGM detects an open circuit at Power cycled.
OUT VALVE – OPEN Telescope Out Valve. this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag to
determine if this fault condition is
the reason why.
MAIN TELESCOPE 33187 1 Deactivate output J2-35 Main The UGM detects a short to battery Power cycled.
VALVES – SHORT Telescope Out Valve. at this output.
TO BATTERY Deactivate output J2-34 Main
Telescope In Valve.
Decouple/disable current feedback
input J3-4 Telescope Return
(Disables Telescope Out and In).
MAIN TELESCOPE 33188 1 Deactivate output J2-35 Main The UGM detects a short to ground Power cycled.
OUT VALVE – Telescope Out Valve. at this output or the UGM detects a
SHORT TO Decouple/disable current feedback CURRENT FEEDBACK LOST
GROUND input J3-4 Telescope Return condition and sets an internal flag to
(Disables Telescope Out and In). determine if this fault condition is
the reason for the fault.
MAIN TELESCOPE 33189 1 Deactivate output J2-34 Main The UGM detects an open circuit at Power cycled.
IN VALVE – OPEN Telescope In Valve. this output or the UGM detects a
CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag to
determine if this fault condition is
the reason for the fault.
MAIN TELESCOPE 33190 1 Deactivate output J2-34 Main The UGM detects a short to ground Power cycled.
IN VALVE – SHORT Telescope In Valve. at this output or the UGM detects a
TO GROUND Decouple/disable current feedback CURRENT FEEDBACK LOST
input J3-4 Telescope Return condition and sets an internal flag to
(Disables Telescope Out and In). determine if this fault condition is
the reason for the fault.
FORK TILT UP 33191 1 Deactivate output J2-8 Fork Tilt Up The UGM detects an open circuit at Power cycled.
VALVE – Valve. this output or the UGM detects a
OPEN CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag to
determine if this fault condition is
the reason for the fault.
9-64 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
FORK TILT VALVES 33192 1 Deactivate output J2-8 Fork Tilt Up The UGM detects a short to battery Power cycled.
– SHORT TO Valve. at this output.
BATTERY Deactivate output J2-19 Fork Tilt
Down Valve.
Decouple/disable current feedback
input J3-6 Tilt Return (Disables
Fork Tilt Up and Down).
FORK TILT UP 33193 1 Deactivate output J2-8 Fork Tilt Up The UGM detects a short to ground Power cycled.
VALVE – SHORT TO Valve. at this output or the UGM detects a
GROUND Decouple/disable current feedback CURRENT FEEDBACK LOST
input J3-6 Tilt Return (Disables condition and sets an internal flag to
Fork Tilt Up and Down). determine if this fault condition is
the reason for the fault.
FORK TILT DOWN 33194 1 Deactivate output J2-19 Fork Tilt The UGM detects an open circuit at Power cycled.
VALVE – Down Valve. this output or the UGM detects a
OPEN CIRCUIT CURRENT FEEDBACK LOST
condition and sets an internal flag to
determine if this fault condition is
the reason for the fault.
FORK TILT DOWN 33195 1 Deactivate output J2-19 Fork Tilt The UGM detects a short to ground Power cycled.
VALVE – SHORT TO Down Valve. at this output or the UGM detects a
GROUND Decouple/disable current feedback CURRENT FEEDBACK LOST
input J3-6 Tilt Return (Disables condition and sets an internal flag to
Fork Tilt Up and Down). determine if this fault condition is
the reason for the fault.
AUXILIARY FUNC- 33196 1 Deactivate output J2-9 Auxiliary The UGM detects an open circuit at Power cycled.
TION-A VALVE – Function-A Valve. this output or the UGM detects a
OPEN CIRCUIT Deactivate and inhibit the CURRENT FEEDBACK LOST
Continuous Auxiliary Hydraulics condition and sets an internal flag to
feature. determine if this fault condition is
Turn OFF the Continuous Auxiliary the reason for the fault.
Hydraulics indicator.
AUXILIARY 33197 1 Deactivate output J2-9 Auxiliary The UGM detects a short to battery Power cycled.
FUNCTIO-A/B Function-A Valve. at this output.
VALVES – SHORT Decouple/disable current feedback
TO BATTERY input J3-14 Aux Return (Disables
Auxiliary Function-A and
Function-B).
Deactivate and inhibit the
Continuous Auxiliary Hydraulics
feature.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-65
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
AUXILIARY 33198 1 Deactivate output J2-9 Auxiliary The UGM detects a short to ground Power cycled.
FUNCTION-A Function-A Valve. at this output or the UGM detects a
VALVE– SHORT TO Decouple/disable current feedback CURRENT FEEDBACK LOST
GROUND input J3-14 Aux Return (Disables condition and sets an internal flag to
Auxiliary Function-A and determine if this fault condition is
Function-B). the reason for the fault.
Deactivate and inhibit the
Continuous Auxiliary Hydraulics
feature.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.
AUXILIARY 33199 1 Deactivate output J2-20 Auxiliary The UGM detects an open circuit at Power cycled.
FUNCTION-B VALVE Function-B Valve. this output or the UGM detects a
– OPEN CIRCUIT Deactivate and inhibit the CURRENT FEEDBACK LOST
Continuous Auxiliary Hydraulics condition and sets an internal flag to
feature. determine if this fault condition is
Turn OFF the Continuous Auxiliary the reason for the fault.
Hydraulics indicator.
AUXILIARY 33200 1 Deactivate output J2-20 Auxiliary The UGM detects a short to ground Power cycled.
FUNCTION-B VALVE Function-B Valve. at this output or the UGM detects a
– SHORT TO Decouple/disable current feedback CURRENT FEEDBACK LOST
GROUND input J3-14 Aux Return (Disables condition and sets an internal flag to
Auxiliary Function-A and determine if this fault condition is
Function-B). the reason for the fault.
Deactivate and inhibit the
Continuous Auxiliary Hydraulics
feature.
Turn OFF the Continuous Auxiliary
Hydraulics indicator.
STABILIZER/FRAME 33201 1 Deactivate output J1-3 Stabilizer The UGM is not configured for a Power cycled.
LEVEL SPEED and Frame Level Speed Valve. 3508, 3509, 4008, or 4009 and the
VALVE – UGM detects an open circuit at this
OPEN CIRCUIT output or the UGM detects a
CURRENT FEEDBACK LOST
condition and sets an internal flag to
determine if this fault condition is
the reason for the fault.
STABILIZER/FRAME 33202 1 Deactivate output J1-3 Stabilizer The UGM is not configured for a Power cycled.
LEVEL SPEED and Frame Level Speed Valve. 3508, 3509, 4008, or 4009 and the
VALVE – SHORT TO Decouple/disable current feedback UGM detects a short to battery at
BATTERY input J3-5 Stabilizer – Frame Level this output.
Return (Disables Stabilizers and
Frame Leveling functions).
STABILIZER/FRAME 33203 1 Deactivate output J1-3 Stabilizer The UGM is not configured for a Power cycled.
LEVEL SPEED and Frame Level Speed Valve. 3508, 3509, 4008, or 4009 and the
VALVE – SHORT TO Decouple/disable current feedback UGM detects a short to ground at
GROUND input J3-5 Stabilizer – Frame Level this output or the UGM detects a
Return (Disables Stabilizers and CURRENT FEEDBACK LOST
Frame Leveling functions). condition and sets an internal flag to
determine if this fault condition is
the reason for the fault.
9-66 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
HYDRAULIC QUICK 33204 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature is Power cycled.
CONNECT SELECT Quick Connect Select. configured in the MACHINE SETUP
– OPEN CIRCUIT menu and the UGM detects an
open circuit at this output.
HYDRAULIC QUICK 33205 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature is Power cycled.
CONNECT SELECT Quick Connect Select. configured in the MACHINE SETUP
– SHORT TO Deactivate output J2-9 Auxiliary menu and the UGM detects a short
BATTERY Function-A Valve. to battery at this output.
Deactivate output J2-20 Auxiliary
Function-B Valve.
HYDRAULIC QUICK 33206 1 Deactivate output J1-23 Hydraulic If hydraulic quick connect feature is Power cycled.
CONNECT SELECT Quick Connect Select. configured in the MACHINE SETUP
– SHORT TO Deactivate output J2-9 Auxiliary menu and the UGM detects a short
GROUND Function-A Valve. to ground at this output.
Deactivate output J2-20 Auxiliary
Function-B Valve.
HORN – 33207 1 Deactivate output J2-2 Horn. The UGM detects an open circuit at Power cycled.
OPEN CIRCUIT this output.
HORN – SHORT TO 33208 1 Deactivate output J2-2 Horn. The UGM detects a short to battery Power cycled.
BATTERY at this output.
HORN – SHORT TO 33209 1 Deactivate output J2-2 Horn. The UGM detects a short to ground Power cycled.
GROUND at this output.
REVERSE ALARM 33210 1 Deactivate output J1-1 Reverse The UGM detects an open circuit at Power cycled.
AND LIGHTS – Alarm and Lights. this output.
OPEN CIRCUIT
REVERSE ALARM 33211 1 Deactivate output J1-1 Reverse The UGM detects a short to battery Power cycled.
AND LIGHTS – Alarm and Lights. at this output.
SHORT TO
BATTERY
REVERSE ALARM 33212 1 Deactivate output J1-1 Reverse The UGM detects a short to ground Power cycled.
AND LIGHTS – Alarm and Lights. at this output.
SHORT TO
GROUND
DUMP VALVE – 33213 1 Deactivate output J2-13 Dump The platform option is configured Power cycled.
OPEN CIRCUIT Valve. and the UGM detects an open
circuit at this output.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-67
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
DUMP VALVE – 33214 1 Deactivate output J2-13 Dump The platform option is configured Power cycled.
SHORT TO Valve. and the UGM detects a short to
BATTERY Deactivate output J2-3 Right battery at this output.
Stabilizer Up Valve.
Deactivate output J2-5 Frame Level
Right Valve.
Deactivate output J2-7 Frame Level
Left Valve.
Deactivate output J2-8 Fork Tilt Up
Valve.
Deactivate output J2-9 Auxiliary
Function-A Valve.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-11 Main Lift
Up Valve.
Deactivate output J2-15 Right
Stabilizer Down Valve.
Deactivate output J2-19 Fork Tilt
Down Valve.
Deactivate output J2-20 Auxiliary
Function-B Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate output J2-22 Main Lift
Down Valve.
Deactivate output J2-34 Main
Telescope In Valve.
Deactivate output J2-35 Main
Telescope Out Valve.
Deactivate output J1-3 Stabilizer
and Frame Level Speed Valve
(if applicable).
DUMP VALVE – 33215 1 Deactivate output J2-13 Dump The platform option is configured Power cycled.
SHORT TO Valve. and the UGM detects a short to
GROUND ground at this output.
AUXILIARY 33216 1 Deactivate output J2-1 Auxiliary The CAT brand is configured for the Power cycled.
FUNCTION SELECT Function Select. UGM, the PLATFORM STATION is
– OPEN CIRCUIT not active, and the UGM detects an
open circuit at this output.
AUXILIARY 33217 1 Deactivate output J2-1 Auxiliary The CAT brand is configured for the Power cycled.
FUNCTION SELECT Function Select. UGM and the UGM detects a short
– SHORT TO Deactivate output J2-9 Auxiliary to battery at this output.
BATTERY Function-A Valve.
Deactivate output J2-20 Auxiliary
Function-B Valve.
AUXILIARY 33218 1 Deactivate output J2-1 Auxiliary The CAT brand is configured for the Power cycled.
FUNCTION SELECT Function Select. UGM and the UGM detects a short
– SHORT TO Deactivate output J2-9 Auxiliary to ground at this output.
GROUND Function-A Valve.
Deactivate output J2-20 Auxiliary
Function-B Valve.
9-68 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
AUXILIARY 33219 1 Deactivate output J2-1 Auxiliary The JLG brand is configured for the Power cycled.
ELECTRICS – OPEN Electrics. UGM, the PLATFORM STATION is
CIRCUIT not active, and the UGM detects an
open circuit at this output.
AUXILIARY 33220 1 Deactivate output J2-1 Auxiliary The JLG brand is configured for the Power cycled.
ELECTRICS – Electrics. UGM and the UGM detects a short
SHORT TO to battery at this output.
BATTERY
AUXILIARY 33221 1 Deactivate output J2-1 Auxiliary The JLG brand is configured for the Power cycled.
ELECTRICS – Electrics. UGM and the PLATFORM STATION
SHORT TO is not active and the UGM detects a
GROUND short to ground at this output.
LEFT STABILIZER 33222 1 Deactivate output J2-15 Right The stabilizers are configured in the Power cycled.
DOWN VALVE – Stabilizer Down Valve. MACHINE SETUP menu and the
OPEN CIRCUIT Deactivate output J2-21 Left UGM detects an open circuit at this
Stabilizer Down Valve. output.
LEFT STABILIZER 33223 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
DOWN VALVE – Stabilizer Up Valve. MACHINE SETUP menu and the
SHORT TO Deactivate output J2-15 Right UGM detects a short to battery at
BATTERY Stabilizer Down Valve. this output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output J1-3,
(Frame Leveling and Stabilizers will
be cutout).
LEFT STABILIZER 33224 1 Deactivate output J2-15 Right The stabilizers are configured in the Power cycled.
DOWN VALVE – Stabilizer Down Valve. MACHINE SETUP menu and the
SHORT TO Deactivate output J2-21 Left UGM detects a short to ground at
GROUND Stabilizer Down Valve. this output.
LEFT STABILIZER 33225 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
UP VALVE – OPEN Stabilizer Up Valve. MACHINE SETUP menu and the
CIRCUIT Deactivate output J2-15 Right UGM detects an open circuit at this
Stabilizer Down Valve. output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
LEFT STABILIZER 33226 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
UP VALVE – SHORT Stabilizer Up Valve. MACHINE SETUP menu and the
TO BATTERY Deactivate output J2-15 Right UGM detects a short to battery at
Stabilizer Down Valve. this output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output
J1-3, (Frame Leveling and
Stabilizers will be cutout).
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-69
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
LEFT STABILIZER 33227 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
UP VALVE – SHORT Stabilizer Up Valve. MACHINE SETUP menu and the
TO GROUND Deactivate output J2-15 Right UGM detects a short to ground at
Stabilizer Down Valve. this output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
RIGHT STABILIZER 33228 1 Deactivate output J2-15 Right The stabilizers are configured in the Power cycled.
DOWN VALVE – Stabilizer Down Valve. MACHINE SETUP menu and the
OPEN CIRCUIT Deactivate output J2-21 Left UGM detects an open circuit at this
Stabilizer Down Valve. output.
RIGHT STABILIZER 33229 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
DOWN VALVE – Stabilizer Up Valve. MACHINE SETUP menu and the
SHORT TO Deactivate output J2-15 Right UGM detects a short to battery at
BATTERY Stabilizer Down Valve. this output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output J1-3
(Frame Leveling and Stabilizers will
be cutout).
RIGHT STABILIZER 33230 1 Deactivate output J2-15 Right The stabilizers are configured in the Power cycled.
DOWN VALVE – Stabilizer Down Valve. MACHINE SETUP menu and the
SHORT TO Deactivate output J2-21 Left UGM detects a short to ground at
GROUND Stabilizer Down Valve. this output.
RIGHT STABILIZER 33231 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
UP VALVE – OPEN Stabilizer Up Valve. MACHINE SETUP menu and the
CIRCUIT Deactivate output J2-15 Right UGM detects an open circuit at this
Stabilizer Down Valve. output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
RIGHT STABILIZER 33232 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
UP VALVE – SHORT Stabilizer Up Valve. MACHINE SETUP menu and the
TO BATTERY Deactivate output J2-15 Right UGM detects a short to battery at
Stabilizer Down Valve. this output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate and inhibit output
(Frame Leveling and Stabilizers will
be cutout).
9-70 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
RIGHT STABILIZER 33233 1 Deactivate output J2-3 Right The stabilizers are configured in the Power cycled.
UP VALVE – SHORT Stabilizer Up Valve. MACHINE SETUP menu and the
TO GROUND Deactivate output J2-15 Right UGM detects a short to ground at
Stabilizer Down Valve. this output.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
FRAME LEVEL 33234 1 Deactivate output J2-7. Frame leveling is configured in the Power cycled.
LEFT VALVE – MACHINE SETUP menu and the
OPEN CIRCUIT UGM detects an open circuit at this
output.
FRAME LEVEL 33235 1 Deactivate output J2-7. Frame leveling is configured in the Power cycled.
LEFT VALVE – Deactivate and inhibit output J1-3 MACHINE SETUP menu and the
SHORT TO Frame Leveling and Stabilizers UGM detects a short to battery at
BATTERY Speed Valve (if applicable). this output.
FRAME LEVEL 33236 1 Deactivate output J2-7. Frame leveling is configured in the Power cycled.
LEFT VALVE – MACHINE SETUP menu and the
SHORT TO UGM detects a short to ground at
GROUND this output.
FRAME LEVEL 33237 1 Deactivate output J2-5. Frame leveling is configured in the Power cycled.
RIGHT VALVE – MACHINE SETUP menu and the
OPEN CIRCUIT UGM detects an open circuit at this
output.
FRAME LEVEL 33238 1 Deactivate output J2-5. Frame leveling is configured in the Power cycled.
RIGHT VALVE – Deactivate and inhibit output J1-3 MACHINE SETUP menu and the
SHORT TO Frame Leveling and Stabilizers UGM detects a short to battery at
BATTERY Speed Valve (if applicable). this output.
FRAME LEVEL 33239 1 Deactivate output J2-5. Frame leveling is configured in the Power cycled.
RIGHT VALVE – MACHINE SETUP menu and the
SHORT TO UGM detects a short to ground at
GROUND this output.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-71
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
9-72 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-73
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
ENGINE FUEL 33267 1 Deactivate output J2-31 Engine The UGM detects an open circuit at Power cycled.
RELAY – Fuel Relay. this output.
OPEN CIRCUIT Deactivate and inhibit output J2-26
Engage Starter.
9-74 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
ENGINE FUEL 33268 1 Deactivate output J2-31 Engine The UGM detects a short to battery Power cycled.
RELAY – SHORT TO Fuel Relay. at this output.
BATTERY Deactivate and inhibit output J2-26
Engage Starter.
ENGINE FUEL 33269 1 Deactivate output J2-31 Engine The UGM detects a short to ground Power cycled.
RELAY – SHORT TO Fuel Relay. at this output.
GROUND Deactivate and inhibit output J2-26
Engage Starter.
CRAB STEER 33270 1 Deactivate output J2-16 Crab Steer The UGM detects an open circuit at Power cycled.
VALVE – Valve. this output.
OPEN CIRCUIT Try to complete any pending steer
mode changes.
Display the “Steer Valve Failure”
screen on the LCD of the cabin’s
display.
CRAB STEER 33271 1 Deactivate output J2-16 Crab Steer The UGM detects a short to battery Power cycled.
VALVE – SHORT TO Valve. at this output.
BATTERY Try to complete any pending steer
mode changes and prohibit any
new steer mode requests.
Display the “Steer Valve Failure”
screen on the LCD of the cabin’s
display.
CRAB STEER 33272 1 Deactivate output J2-16 Crab Steer The UGM detects a short to ground Power cycled.
VALVE – SHORT TO Valve. at this output.
GROUND Try to complete any pending steer
mode changes.
Display the “Steer Valve Failure”
screen on the LCD of the cabin’s
display.
ALL WHEEL STEER 33273 1 Deactivate output J2-4 All Wheel The UGM detects an open circuit at Power cycled.
VALVE – Steer Valve. this output.
OPEN CIRCUIT Try to complete any pending steer
mode changes.
Display the “Steer Valve Failure”
screen on the LCD of the cabin’s
display.
ALL WHEEL STEER 33274 1 Deactivate output J2-4 All Wheel The UGM detects a short to battery Power cycled.
VALVE – SHORT TO Steer Valve. at this output.
BATTERY Try to complete any pending steer
mode changes and prohibit any
new steer mode requests.
Display the “Steer Valve Failure”
screen on the LCD of the cabin’s
display.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-75
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
ALL WHEEL STEER 33275 1 Deactivate output J2-4 All Wheel The UGM detects a short to ground Power cycled.
VALVE – SHORT TO Steer Valve. at this output.
GROUND Try to complete any pending steer
mode changes.
Display the “Steer Valve Failure”
screen on the LCD of the cabin’s
display.
APU PUMP RELAY – 33276 1 Inhibit operation of J1-13 APU The platform option is configured Power cycled.
OPEN CIRCUIT Pump Relay. and the UGM detects an open
circuit at this output.
APU PUMP RELAY – 33277 1 Inhibit operation of J1-13 APU The platform option is configured Power cycled.
SHORT TO Pump Relay. and the UGM detects a short to
BATTERY battery at this output.
APU PUMP RELAY – 33278 1 Inhibit operation of J1-13 APU The platform option is configured Power cycled.
SHORT TO Pump Relay. and the UGM detects a short to
GROUND ground at this output.
GLOWPLUGS – 33279 1, 2 Deactivate output J1-12 Glow- The UGM detects an open circuit at Power cycled.
OPEN CIRCUIT plugs. this output.
GLOWPLUGS – 33280 1, 2 Deactivate output J1-12 Glow- The UGM detects a short to battery Power cycled.
SHORT TO plugs. at this output.
BATTERY
GLOWPLUGS - 33281 1, 2 Deactivate output J1-12 Glow- The UGM detects a short to ground Power cycled.
SHORT TO plugs. at this output.
GROUND
ENGAGE STARTER 33282 1 Deactivate output J2-26 Engage The UGM detects an open circuit at Power cycled.
OUTPUT – OPEN Starter. this output.
CIRCUIT
ENGAGE STARTER 33283 1 Deactivate output J2-26 Engage The UGM detects a short to battery Power cycled.
OUTPUT – SHORT Starter. at this output.
TO BATTERY Activate output J2-31 Fuel Enable
Signal.
ENGAGE STARTER 33284 1 Deactivate output J2-26 Engage The UGM detects a short to ground Power cycled.
OUTPUT – SHORT Starter. at this output.
TO GROUND
ALTERNATOR 33285 1, 2, 10 J1-32 Alternator Excitation output J1-32-Alternator Excite (and thus Power cycled.
EXCITATION LINE – will be deactivated. J4-7 Alternator D+) is HIGH for a
SHORT TO period of 2 seconds or more and an
BATTERY ENGINE STOPPED state is
detected.
FRONT MOTOR – 33286 1 N/A The UGM detects the actual current Power cycled.
CURRENT has deviated more than 250 mA
FEEDBACK from the commanded current for
READING TOO LOW more than 1 second.
9-76 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
LIFT – CURRENT 33287 1 Do not detect or report the BOOM The UGM detects the actual current Power cycled.
FEEDBACK ANGLE SENSOR – NOT has deviated more than 250 mA
READING TOO LOW RESPONDING fault. from the commanded current for
more than 1 second.
TELESCOPE – 33288 1 N/A The UGM detects the actual current Power cycled.
CURRENT has deviated more than 250 mA
FEEDBACK from the commanded current for
READING TOO LOW more than 1 second.
STABILIZERS/ 33289 1 N/A The UGM detects the actual current Power cycled.
FRAME LEVEL – has deviated more than 250 mA
CURRENT from the commanded current for
FEEDBACK more than 1 second.
READING TOO LOW
FORK TILT – 33290 1 N/A The UGM detects the actual current Power cycled.
CURRENT has deviated more than 250 mA
FEEDBACK from the commanded current for
READING TOO LOW more than 1 second.
AUXILIARY 33291 1 N/A The UGM detects the actual current Power cycled.
HYDRAULICS – has deviated more than 250 mA
CURRENT from the commanded current for
FEEDBACK more than 1 second.
READING TOO LOW
FRONT MOTOR 33292 1 Deactivate output J1-6 Front Motor The UGM detects an open circuit at Power cycled.
SWIVEL ANGLE – Swivel. this output.
OPEN CIRCUIT
FRONT MOTOR 33293 1 Deactivate output J1-6 Front Motor The UGM detects a short to battery Power cycled.
SWIVEL ANGLE – Swivel. at this output.
SHORT TO
BATTERY
FRONT MOTOR 33294 1 Deactivate output J1-6 Front Motor The UGM detects a short to ground Power cycled.
SWIVEL ANGLE – Swivel. at this output.
SHORT TO
GROUND
REAR AUXILIARY 33326 1 Deactivate output J2-23 Rear If the rear auxiliary hydraulics Power cycled.
HYDRAULICS Auxiliary Hydraulics Valve. feature is configured in the
VALVE – MACHINE SETUP menu and the
OPEN CIRCUIT UGM detects an open circuit at this
output.
REAR AUXILIARY 33327 1 Deactivate output J2-23 Rear If the rear auxiliary hydraulics Power cycled.
HYDRAULICS Auxiliary Hydraulics Valve. feature is configured in the
VALVE – SHORT TO Deactivate output J2-9 Auxiliary MACHINE SETUP menu and the
BATTERY Function-A Valve. UGM detects a short to battery at
Deactivate output J2-20 Auxiliary this output.
Function-B Valve.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-77
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
REAR AUXILIARY 33328 1 Deactivate output J2-23 Rear If the rear auxiliary hydraulics Power cycled.
HYDRAULICS Auxiliary Hydraulics Valve. feature is configured in the
VALVE – SHORT TO Deactivate output J2-9 Auxiliary MACHINE SETUP menu and the
GROUND Function-A Valve until input J7-23 UGM detects a short to ground at
is LOW. this output.
Deactivate output J2-20 Auxiliary
Function-B Valve until input J7-23
is LOW.
BOOM RIDE VALVE 33369 1 The Boom Ride feature will be If the Boom Ride feature is Power cycled.
– SHORT TO deactivated and inhibited. configured and the Boom Ride/
BATTERY OR OPEN Boom Float Module detects a short
CIRCUIT to battery or open circuit at this
output.
BOOM RIDE VALVE 33338 1 The Boom Ride feature will be If the Boom Ride feature is Power cycled.
– SHORT TO deactivated and inhibited. configured and the Boom Ride/
GROUND Boom Float Module detects a short
to ground at this output.
BOOM FLOAT 33370 1 The Boom Float feature will be If the Boom Float feature is Power cycled.
VALVE – SHORT TO deactivated and inhibited. configured and the Boom Ride/
BATTERY OR OPEN The Boom Ride feature will be Boom Float Module detects a short
CIRCUIT deactivated and inhibited. to battery or open circuit at this
J2-11 Main Lift Up Valve will be output.
inhibited.
BOOM FLOAT 33341 1 The Boom Float feature will be If the Boom Float feature is Power cycled.
VALVE – SHORT TO deactivated and inhibited. configured and the Boom Ride/
GROUND J2-11 Main Lift Up Valve will be Boom Float Module detects a short
inhibited. to ground at this output.
BOOM TANK VALVE 33371 1 The Boom Ride feature will be If the Boom Ride or Boom Float Power cycled.
– SHORT TO deactivated and inhibited. feature is configured and the Boom
BATTERY OR OPEN The Boom Float feature will be Ride/Boom Float Module detects a
CIRCUIT deactivated and inhibited. short to battery or open circuit at
J2-11 Main Lift Up Valve will be this output.
inhibited.
BOOM TANK VALVE 33344 1 The Boom Ride feature will be If the Boom Ride or Boom Float Power cycled.
– SHORT TO deactivated and inhibited. feature is configured and the Boom
GROUND The Boom Float feature will be Ride/Boom Float Module detects a
deactivated and inhibited. short to ground at this output.
ENGINE 43XXX
9-78 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
ENGINE TROUBLE 437 1, 2, 3* (ECM will determine the proper The ECM detects a fault condition Power cycled
CODE: (SPN):(FMI) action to take.) (not defined in this SRD).
* - The UGM will illuminate just the
engine warning fault indicator if the
DM1 message indicates a warning
or derate condition. The UGM will
illuminate the engine warning and
engine critical fault indicators if the
DM1 message indicates a critical
(shutdown) condition. In the event a
transfer protocol message is
received with multiple faults, a fault
indicating a critical (shutdown) fault
will receive priority when the UGM
determines what indicators to turn
ON.
WRONG ENGINE 4314 1, 2 J2-26 Engage Starter will be The ENGINE CONTROL Power cycled.
SELECTED – ECM deactivated and inhibited. configuration is MECHANICAL and
DETECTED the UGM detects CAN messages
from an ECM.
HIGH ENGINE 4316 1, 2, 12 (For ECM controlled engines, the MECHANICAL: The engine coolant MECHANIAL:
COOLANT ECM may also derate the engine.) temperature reaches 113×C or The engine
TEMPERATURE more for a period of at least 10 coolant
WARNING seconds and an ENGINE temperature
RUNNING state exists. reaches
ELECTRONIC: The ECM detects 110×C.
the engine coolant temperature has ELETRONIC:
reached 113×C or more, the ECM The ECM no
will transmit a J1939 CAN bus DM1 longer
message, or use the J1939 Transfer transmits the
Protocol in the event multiple condition as
engine faults exist, on CAN1 to an active fault.
communicate an engine coolant
temperature warning (SPN:FMI
110:15 or 110:16).
HIGH ENGINE 4317 1, 2, 3, 12 (For ECM controlled engines, the MECHANCIAL: The engine coolant MECHANIAL:
COOLANT ECM may also derate the engine.) temperature reaches 118×C or The engine
TEMPERATURE more for a period of at least 10 coolant
CRITICAL seconds and an ENGINE temperature
RUNNING state exists. reaches
ELECTRONIC: The engine coolant 115×C.
temperature reaches 118×C or ELETRONIC:
more, the ECM will transmit a J1939 The ECM no
CAN bus DM1 message, or use the longer
J1939 Transfer Protocol in the event transmits the
multiple engine faults exist, on condition as
CAN1 to communicate an engine an active fault.
coolant temperature critical
(SPN:FMI 110:0).
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-79
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
LOW ENGINE OIL 4318 1, 2, 9 N/A The ECM detects the engine oil Power cycled.
PRESSURE pressure is getting low, the ECM will
WARNING transmit a J1939 CAN bus DM1
message, or use the J1939 Transfer
Protocol in the event multiple
engine faults exist, on CAN1 to
communicate low engine oil
pressure (SPN:FMI 100:17 or
100:18).
LOW ENGINE OIL 4319 1, 2, 3, 9 N/A MECHANICAL: The UGM detects Power cycled.
PRESSURE input J12-8 Engine Oil Pressure is
CRITICAL LOW for 3 seconds and an ENGINE
RUNNING state exists for a period
of 5 seconds.
ELECTRONIC: The engine oil
pressure reaches its critical low oil
pressure value, which is based on
engine speed, the ECM will transmit
a J1939 CAN bus DM1 message, or
use the J1939 Transfer Protocol in
the event multiple engine faults
exist, on CAN1 at a rate of 1 second
to communicate low engine oil
pressure (SPN:FMI 100:1).
AIR FILTER 4321 1, 2, 7 N/A J1-34 Air Filter Restriction input is J1-34 Air
RESTRICTION LOW and an ENGINE RUNNING Filter
state exists for a period of 3 Restriction
seconds or more or 10 seconds input is HIGH
after a system power up. for 1 second.
LOSS OF ENGINE 4322 1, 2 Deactivate J2-26 Engage Starter. MECHANICAL: J4-7 Alternator D+ Power cycled.
SPEED SIGNAL Ignore the above-mentioned is HIGH and J12-8 is HIGH and no
interlock for disabling the impulses are received at J1-16
Continuous Auxiliary Hydraulics Engine Speed.
function when engine speed is 600 ELECTRONIC: The TCM or ECM
RPM. will report the fault using J1939
Ignore the prevent engine stall CAN protocol to the UGM.
logic.
CONFLICTING 4324 1, 2 N/A J4-8 Engine Start has been Power cycled.
OPERATING engaged during the active power
ENGINE STATE cycle, an ENGINE STOPPED
condition exists, and one of the
three ENGINE RUNNING
conditions is true
9-80 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
BATTERY VOLTAGE 441 1 Inhibit all output drivers except The UGM or platform module has Power cycled.
TOO LOW – engine start. detected the battery voltage is at or (Replace/fix
SYSTEM below 9V. battery.)
SHUTDOWN
BATTERY VOLTAGE 442 1 Inhibit all output drivers. The UGM or platform module has Power cycled.
TOO HIGH – detected the battery voltage is at or (Fix supply
SYSTEM above 16V. voltage.)
SHUTDOWN
LSS BATTERY 443 1 UGM assumes a platform The LSS module detects its supply Power cycled.
VOLTAGE TOO overloaded condition. voltage is too high and reports the (Fix supply
HIGH issue to the UGM. voltage.)
LSS BATTERY 444 1 UGM assumes a platform The LSS module detects its supply Power cycled.
VOLTAGE TOO LOW overloaded condition. voltage is too low and reports the (Replace/fix
issue to the UGM. battery.)
BATTERY VOLTAGE 445 1 J1-12 Glow-plugs will be inhibited. The UGM has detected the battery The UGM
LOW voltage below 11V for a period of 3 detects the
seconds or more and an ENGINE battery
RUNNING state exists. voltage higher
than 11V for a
period of 10
seconds or
power cycled.
REFERENCE 447 1 Inhibit all hydraulic functions. The UGM has detected its Power cycled.
VOLTAGE OUT OF reference voltage is too high or low.
RANGE – GROUND
HIGH 461 1, 11 N/A UGM input J3-11 Transmission Oil Power cycled.
TRANSMISSION OIL Temperature is LOW when a
TEMPERATURE TRANSMISSION configuration of
CRITICAL POWERSHIFT or
POWERSYNCRO is selected.
CONFLICTING 462 1 Command an ‘N’ in the cabin’s A HIGH signal is detected on more Only input
DRIVE DIRECTION display. than one of drive direction inputs J4-4 Neutral is
SIGNALS Broadcast the TC1 J1939 CAN (J4-4 Neutral / J7-22 Forward / HIGH.
message on CAN1 to command the J4-18 Reverse) at the same time for
TCM to the neutral gear selection if a period of 3 seconds or more.
MODELS: TH336, TH337, TH406,
TH407, TH414, TH417, TH515 are
configured.
Deactivate and inhibit output J2-33
Transmission Forward.
Deactivate and inhibit output J2-32
Transmission Reverse.
Deactivate and inhibit output J1-1
Reversing Alarm and Lights.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-81
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
DRIVE DIRECTION 463 1 Command an ‘N’ in the cabin’s J4-4 Neutral and J7-22 Forward and Only input
SIGNAL LOST display. J4-18 Reverse are simultaneously J4-4 Neutral is
Broadcast the TC1 J1939 CAN LOW for a period of 3 seconds or HIGH.
message on CAN1 to command the more
TCM to the neutral gear selection if
MODELS: TH336, TH337, TH406,
TH407, TH414, TH417, TH515 are
configured.
Deactivate and inhibit output J2-33
Transmission Forward.
Deactivate and inhibit output J2-32
Transmission Reverse.
Deactivate and inhibit output J1-1
Reversing Alarm and Lights.
CONFLICTING 464 1 Maintain the output of the last valid If more than one of the gear J4-5 Park
GEAR SELECTION gear selected or 3rd Gear if the fault selection inputs, J4-21 1st Gear / Brake is HIGH
SIGNALS is present at startup for J4-11 2nd Gear / J4-22 3rd Gear / and issue
POWERSHIFT and J4-23 4th Gear, are HIGH cleared or
POWERSYNCRO transmissions or simultaneously for a period of 3 power cycled.
2nd Gear if the fault is present at seconds.
startup for a HYDROSTATIC
transmission. Transmission drive
direction signals will still be
acknowledged in this case.
Flash last valid gear selection or
flash 3rd Gear if the fault is present
at startup for POWERSHIFT and
POWERSYNCRO transmissions or
2nd Gear if the fault is present at
startup for a HYDROSTATIC
transmission on the LCD of the
cabin’s display.
GEAR SELECTION 465 1 Maintain the output of the last valid If J4-21 1st Gear and J4-11 2nd J4-5 Park
SIGNAL LOST gear selected or 3rd Gear if the fault Gear and J4-22 3rd Gear and J4-23 Brake is HIGH
is present at startup for 4th Gear are simultaneously LOW and issue
POWERSHIFT and for a period of 3 seconds or more. cleared or
POWERSYNCRO transmissions or power cycled.
2nd Gear if the fault is present at
startup for a HYDROSTATIC
transmission. Transmission drive
direction signals will still be
acknowledged in this case.
Flash last valid gear selection or
flash 3rd Gear if the fault is present
at startup for POWERSHIFT and
POWERSYNCRO transmissions or
2nd Gear if the fault is present at
startup for a HYDROSTATIC
transmission on the LCD of the
cabin’s display.
9-82 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
INVALID 466 1 Deactivate output J1-20 J4-22 3rd Gear or J4-23 4th Gear The
TRANSMISSION Transmission D / 2 Coil. are LOW and a TRANSMISSION configuration
CONFIGURATION Deactivate output J1-7 selection of HYDROSTATIC is is corrected
Transmission E / 1 Coil. configured. and power is
Deactivate output J2-33 cycled.
Transmission A / Forward Coil.
Deactivate output J2-32
Transmission B / Reverse Coil.
Deactivate output J1-10
Transmission C Coil.
Deactivate output J2-5 Frame
Leveling Right Valve.
Deactivate output J2-7 Frame
Leveling Left Valve.
Deactivate output J2-3 Right
Stabilizer Up Valve.
Deactivate output J2-15 Right
Stabilizer Down Valve.
Deactivate output J2-10 Left
Stabilizer Up Valve.
Deactivate output J2-21 Left
Stabilizer Down Valve.
Deactivate output J2-13 Dump
Valve.
Deactivate output J1-3 Stabilizer
and Frame Level Speed Valve
(if applicable).
Deactivate output J2-11 Main Lift
Up Valve.
Deactivate output J2-22 Main Lift
Down Valve.
Deactivate output J2-35 Main
Telescope Out Valve.
Deactivate output J2-34 Main
Telescope In Valve.
Deactivate output J2-8 Fork Tilt Up
Valve.
Deactivate output J2-19 Fork Tilt
Down Valve.
Deactivate output J2-9 Auxiliary
Hydraulics 1 Valve.
Deactivate output J2-20 Auxiliary
Hydraulics 2 Valve.
TRANSMISSION 467 1 (TCM will determine the proper The TCM detects a fault condition Power cycled
TROUBLE CODE: action to take.) (not defined in this SRD).
(SPN):(FMI) Flash the current drive direction
and gear selection on the cabin’s
display.
VEHICLE SPEED 468 1 Broadcast a proprietary B CAN VEHICLE SPEED is configured in Power cycled.
SENSOR – NOT message on CAN1 to display a the MACHINE SETUP menu and
RESPONDING value of ‘99’ on the cabin’s LCD the transmission is not in neutral
display. and the service brake is not
Disable the drive direction interlock engaged and the park brake is not
and allow drive direction to be engaged and Engine RPM is 1200
changed at any point in time. RPM and no VEHICLE SPEED
Boom Ride feature will be inhibited signal is measured for a period 3
if configured. seconds or more.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-83
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
COMMUNICATIONS 66XXX
CANBUS FAILURE – 662 1 Disregard any CAN messages with The PLATFORM OPTION is Power cycled.
PLATFORM the platform module source configured as ENABLED and a
MODULE addresses. platform is detected as attached
and the UGM does not detect the
platform module on the CAN bus for
a period of 250msec.
CANBUS FAILURE – 663 1, 14 Deactivate and inhibit the Lift Up The PLATFORM STATION is active Power cycled.
LOAD SENSING output. and the PLATFORM OPTION is
SYSTEM MODULE Deactivate and inhibit the Lift Down configured as ENABLED and a
output. platform is detected as attached
Deactivate and inhibit the and the LOAD SENSING menu
Telescope Out output. screen is not configured as NONE
Deactivate and inhibit the and the UGM does not detect the
Telescope In output. LSS module on the CAN bus.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
Disregard any CAN messages with
platform module source addresses.
CANBUS FAILURE – 666 1, 3 Deactivate and inhibit output J2-26 The ENGINE CONTROL menu is Power cycled.
ENGINE Engage Starter. configured as ELECTRONIC and
CONTROLLER the UGM does not detect the ECM
on the CAN bus.
CANBUS FAILURE – 6613 1 N/A The UGM detects more than 500 Power cycled.
EXCESSIVE Bus Off or more than 500 Bus
CANBUS ERRORS Passive conditions during a power
cycle or the UGM detects more than
22 Bus Off or more than 22 Bus
Passive conditions during a period
of 1 second.
CANBUS FAILURE – 6616 1 Only transmit messages that keep The UGM does not detect the TCM Power cycled.
TRANSMISSION the transmission in neutral. on the CAN bus when a
CONTROLLER POWERSYNCRO transmission is
configured and an ENGINE
STOPPED or ENGINE RUNNING
state exists for a period of one
second.
9-84 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
CANBUS FAILURE – 6617 1 Disregard any CAN messages with The UGM does not detect the Valid CAN bus
CABIN JOYSTICK the cabin joystick source cabin’s joystick on the CAN bus for communica-
addresses. a period of 250msec and an tion is
Deactivate and inhibit all hydraulic ENGINE STOPPED or ENGINE re-estab-
functions. RUNNING state exists for a period lished with the
of one second. joystick.
CANBUS FAILURE – 6618 1 The UGM does not detect the Power cycled.
CABIN DISPLAY cabin’s display on the CAN bus.
CANBUS FAILURE – 6619 1 N/A The UGM has detected an unknown Power cycled.
UNKNOWN module reporting a DM1 or transfer
TROUBLE CODE: protocol message.
(SPN):(FMI)
CANBUS FAILURE – 6621 1 Display the fixed boom angle value The UGM or platform module has Power cycled.
BOOM ANGLE of ‘99’ on the operator’s cabin lost communications with the Boom
SENSOR display. Angle Sensor.
Temporarily assign a fixed boom
angle value of 99×.
Disallow boom angle sensor
calibration (“BOOM ANGLE:
CALIBRATION FAIL”).
Ignore any hydraulic function
requests from the platform station.
Deactivate and inhibit the Lift Up
output if the platform is detected as
attached or PLATFORM MODE is
the current active mode; otherwise,
derate the MAX LIFT UP in the
PERSONALITIES menu screen by
the LIFT UP DERATE value in the
Constant Data tables.
CANBUS FAILURE - 6622 1 CAN Communications has been Valid CAN bus
TCU MODULE lost with the TCU module for 30 communica-
seconds or more. Only reported if tions is
the telematics machine re-estab-
configuration digit is enabled. lished with the
telematics
module
CANBUS FAILURE - 6623 1 CAN Communications has been Valid CAN bus
GATEWAY MODULE lost with the gateway module for 30 communica-
seconds or more. Only reported if tions is
the telematics machine re-estab-
configuration digit is enabled. lished with the
gateway
module
CANBUS FAILURE - 6629 1 If this fault has been detected, the Power cycled.
TELEMATICS CAN- CANBUS FAILURE TCU
BUS LOADING TOO COMUNICATIONS LOST fault will
HIGH be suppressed.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-85
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
CANBUS FAILURE – 6631 1 If active, deactivate and then inhibit The UGM has lost communications Power cycled.
BOOM RIDE/BOOM operation of Boom Ride Valve, with the Boom Ride/Boom Float
FLOAT MODULE Boom Float Valve, and Boom Tank (Accessory) Module.
Valve.
CANBUS FAILURE - 6637 1 The UGM has lost communications Power cycled.
BOOM EXTENSION with the Accessory Module.
LIMIT MODULE
CANBUS FAILURE - 6638 1 If active, the control system will The UGM has lost communications Power cycled.
LSI respond as if the Load Moment with the LSI system for 1000
Cutout % parameter has been milliseconds.
reached (regardless of the state of
input J4-10) and react accordingly
depending on the MARKET
configuration.
CHASSIS TILT 813 1 The UGM will not permit The PLAFORM OPTION is Successful tilt
SENSOR NOT PLATFORM MODE operation. configured as ENABLED and the calibration has
CALIBRATED UGM detects its on-board tilt sensor been com-
has not been calibrated. pleted.
CHASSIS TILT 814 1 The UGM will not permit The PLAFORM OPTION is Power cycle.
SENSOR OUT OF PLATFORM MODE operation. configured as ENABLED and the (Replace
RANGE UGM detects a platform is attached board)
and the UGM detects the tilt sensor
reading is more than 19° for 4
seconds and the PLATFORM
STATION is active or the CABIN
STATION is active with one or more
stabilizer deployed.
CHASSIS TILT 815 1 The UGM will not permit The PLATFORM OPTION is Power cycle.
SENSOR PLATFORM MODE operation. configured as ENABLED and the (Replace
DISAGREEMENT UGM detects a platform is attached board)
and the UGM detects the machine
is driving and a 3° difference
between tilt sensor for 5 seconds or
the UGM detects the machine is not
driving and a 1° difference between
tilt sensor for 2 seconds.
9-86 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
LSS CELL #1 821 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active and
Deactivate and inhibit the Lift Down the PLATFORM OPTION is
output. ENABLED and a platform is
Deactivate and inhibit the detected as attached and the LSS
Telescope Out output. module is reporting a error with
Deactivate and inhibit the regard to load cell #1.
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
LSS CELL #2 822 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active and
Deactivate and inhibit the Lift Down the PLATFORM OPTION is
output. ENABLED and a platform is
Deactivate and inhibit the detected as attached and the LSS
Telescope Out output. module is reporting a error with
Deactivate and inhibit the regard to load cell #2.
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-87
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
LSS CELL #3 823 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active and
Deactivate and inhibit the Lift Down the PLATFORM OPTION is
output. ENABLED and a platform is
Deactivate and inhibit the detected as attached and the LSS
Telescope Out output. module is reporting a error with
Deactivate and inhibit the regard to load cell #3.
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
LSS CELL #4 824 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the Power cycled.
ERROR output. PLATFORM STATION is active and
Deactivate and inhibit the Lift Down the PLATFORM OPTION is
output. ENABLED and a platform is
Deactivate and inhibit the detected as attached and the LSS
Telescope Out output. module is reporting a error with
Deactivate and inhibit the regard to load cell #4.
Telescope In output.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
9-88 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
LSS HAS NOT BEEN 825 1, 14 Deactivate and inhibit the Lift Up The UGM has detected the A valid
CALIBRATED output. PLATFORM STATION is active and calibration of
Deactivate and inhibit the Lift Down the PLATFORM OPTION is the LSS
output. ENABLED and a platform is module is
Deactivate and inhibit the detected as attached and the LSS completed or
Telescope Out output. module calibration has not been the LOAD
Deactivate and inhibit the completed. SENSING
Telescope In output. menu screen
Deactivate and inhibit the Platform is configured
Rotate Left output. to NONE and
Deactivate and inhibit the Platform power is
Rotate Right output. cycled.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
PLATFORM FUNC- 829 1, 14 Deactivate and inhibit the Lift Up When the UGM or platform module When a rated
TIONS CUTOUT – output. detects an overloaded platform load of less
PLATFORM Deactivate and inhibit the Lift Down condition at 110% rated load and than 110% is
OVERLOADED output. the PLATFORM STATION is detected for a
Deactivate and inhibit the selected and a platform is detected period of at
Telescope Out output. as attached and the LOAD least 3
Deactivate and inhibit the SENSING menu screen is seconds. (The
Telescope In output. configured as PLATFORM system will
Deactivate and inhibit the Platform CUTOUT. then re-enable
Rotate Left output. J2-19
Deactivate and inhibit the Platform Function
Rotate Right output. Enable Relay
Deactivate and inhibit the Platform and verify the
Level Up output. platform
Deactivate and inhibit the Platform function
Level Down output. enable switch
Deactivate platform module output is not
J2-19 Function Enable Relay when engaged
platform module detects condition if before
the UGM fails to report the operation is
condition in 1 second. allowed.)
Display the platform overloaded
screen on the cabin’s LCD.
LSI NOT 8514 1 Set CAN message bit to permit LSI Within 1500ms of system power The LSI
CALIBRATED System display control of its alarm. ON, the UGM reads a CAN System CAN
message from the LSI System message
indicating calibration has not which
occurred. indicates the
calibration
mode status
changes to
OFF.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-89
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
LSI DETECTED BUT 8515 1 Inhibit all hydraulic functions. The UGM has detected the CAN Use analyzer
NOT CONFIGURED Set CAN message bit to permit LSI bus LSI system is present on the and correct
System display control of its alarm. machine; however it has not been parameter
configured properly in the that is
MACHINE SETUP - LOAD improperly
MOMENT menu selection. configured.
LSI LOAD CELL A – 8516 1 If active, the control system will The LSI System has detected that Power cycle.
OUT OF RANGE respond as if the Load Moment Load Cell A is out of range and is
Cutout % parameter has been providing a CAN bus message
reached and react accordingly notification to the UGM.
depending on the MARKET
configuration.
Set CAN message bit to permit LSI
System display control of its alarm.
LSI LOAD CELL B – 8517 1 If active, the control system will The LSI System has detected that Power cycle.
OUT OF RANGE respond as if the Load Moment Load Cell B is out of range and is
Cutout % parameter has been providing a CAN bus message
reached and react accordingly notification to the UGM.
depending on the MARKET
configuration.
Set CAN message bit to permit LSI
System display control of its alarm.
LSI CUTOUT 8518 1 If active, the control system will The LSI System has detected that Power cycle.
OUTPUT – SHORT respond as if the Load Moment its 100% Cutout digital output has
TO BATTERY OR Cutout % parameter has been an short to battery or open circuit
OPEN CIRCUIT reached and react accordingly condition and is providing a CAN
depending on the MARKET bus message notification to the
configuration. UGM.
Set CAN message bit to permit LSI
System display control of its alarm.
LSI OUT OF 8519 1 If active, the control system will The UGM LSI-CAN system check The LSI-CAN
CALIBRATION respond as if the Load Moment has been performed and the actual system check
Cutout % parameter has been load cell raw counts are not within is performed
reached and react accordingly +/- 10 counts of the logged and is
depending on the MARKET calibrated counts. completed
configuration. with a pass
Set CAN message bit to permit LSI condition.
System display control of its alarm.
STEERING 86XXX
LOW STEERING 8638 1, 8 N/A J1-35 Steering Pressure is HIGH for Until steer
PRESSURE a period of 3 seconds or more and pressure is
an ENGINE RUNNING state must re-estab-
be detected for at least 5 seconds. lished (i.e.
J1-35 is LOW
for a period of
3 seconds).
HARDWARE 99XXX
9-90 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
EEPROM FAILURE – 998 1 Suspend all hydraulic function, The UGM has detected an anomaly Power cycle.
CHECK ALL engine, and transmission in EEPROM. (Replace
SETTINGS operation. board)
FUNCTION 9910 1 Suspend all hydraulic function, The UGM has detected the platform Reprogram
LOCKED OUT – engine, and transmission operation module software major revision # is board and
PLATFORM from platform station only. (CABIN not compatible. power cycle.
MODULE STATION operation is permitted.) (Replace
SOFTWARE board)
VERSION
IMPROPER
FUNCTION 9911 1 Suspend all hydraulic functions, The UGM has detected the LSS Reprogram
LOCKED OUT – LSS prevent engine start, and module software revision # is not board and
MODULE transmission operation from compatible (if major version is 7, power cycle.
SOFTWARE platform station only. (CABIN then minor will be checked to be 17 (Replace
VERSION STATION operation is permitted.) or higher; otherwise major version board)
IMPROPER higher than 7 will pass).
CHASSIS TILT 9915 1 The UGM will not permit PLAT- The PLATFORM OPTION is Power cycle.
SENSOR NOT GAIN FORM MODE operation. configured as ENABLED and the (Replace
CALIBRATED UGM detects the tilt gain values board)
necessary for calculating chassis
have been lost.
GROUND MODULE 9921 1 Suspend all hydraulics. The UGM detects a internal Power cycle.
FAILURE – HIGH hardware failure on J2-1, J2-13,
SIDE DRIVER and/or J1-23.
CUTOUT FAULTY
FUNCTIONS 9924 1 The UGM will not permit engine The UGM detects the MACHINE The
LOCKED OUT – start. SETUP menu has never been MACHINE
MACHINE NOT The UGM will not permit any entered, which is noted by the SETUP menu
CONFIGURED hydraulic function operation. MODEL menu screen being has been
configured to “????????????????” accessed and
(i.e. it is the first time the board was power is
powered ON). cycled.
CURRENT FEED- 9944 1 The UGM will not permit engine The UGM has detected the current Power cycle.
BACK GAINS OUT start. feedback gain calibrations have (Replace
OF RANGE The UGM will not permit any been lost. board)
hydraulic function operation.
3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9-91
Electrical System
Message Fault Indicators Other Actions Taken Trigger for Fault Latch Until
Code
CURRENT FEED- 9945 1 The UGM will not permit engine The UGM has detected the current Power cycle.
BACK CALIBRATION start. feedback calibration checksum is (Replace
CHECKSUM The UGM will not permit any incorrect. board)
INCORRECT hydraulic function operation.
CABIN DISPLAY 9946 1 N/A The UGM was not able to write/ Power cycle.
EEPROM WRITE reprogram the cabin display’s
FAILURE EEPROM.
HARDWARE 9947 1 Enter analyzer mode and take the The UGM has detected a data Complete a
EXCHANGE user directly to the “PERFORM mismatch between itself and the hardware
REQUIRED HARDWARE EXCHANGE?” menu. cabin’s display. exchange and
cycle power.
PLATFORM 9948 1 The UGM will not permit engine The platform module has detected Power cycle.
MODULE start from the platform. the cleaning current FET has failed.
HARDWARE The UGM will not permit any
FAILURE hydraulic function operation from
the platform.
MACHINE 9949 1 Suspend all hydraulic function, The UGM has detected an anomaly Use analyzer
CONFIGURATION engine, and transmission in the EEPROM. and correct
OUT OF RANGE – operation. parameter
CHECK ALL that is out of
SETTINGS range.
CABIN JOYSTICK - 9976 1 The UGM will not permit any The ITT cabin joystick reports has Power cycle.
INTERNAL FAILURE hydraulic function operation. an internal problem. (Reference ITT
SRD)
LSS CORRUPT 9977 1 Deactivate and inhibit the Lift Up At power-up or immediately Power cycle
EEPROM output. thereafter, if the PLATFORM
Deactivate and inhibit the Lift Down STATION is active and the platform
output. module and UGM will check the
Deactivate and inhibit the consistency of the redundantly
Telescope Out output. stored Platform Unloaded Weight
Deactivate and inhibit the and the Platform Maximum Allowed
Telescope In output. Load values.
Deactivate and inhibit the Platform
Rotate Left output.
Deactivate and inhibit the Platform
Rotate Right output.
Deactivate and inhibit the Platform
Level Up output.
Deactivate and inhibit the Platform
Level Down output.
Deactivate platform module output
J2-19 Function Enable Relay.
Display the platform overloaded
screen on the cabin’s LCD.
EEPROM VALUE – 9978 1 Suspend all hydraulic function and The UGM has detected an anomaly Use analyzer
OUT OF RANGE engine operation, and command in the EEPROM. and correct
the transmission to neutral. 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 Indicators Other Actions Taken Trigger for Fault Latch Until
Code
GROUND MODULE 9986 1 Suspend all hydraulic function and The UGM has detected an anomaly Power cycle.
VLOW FET FAILURE engine operation, and command in a mosfet. (Replace
the transmission to neutral. board)
FUNCTIONS 99151 1 If active, the control system will The UGM has detected the LSI Power cycle.
LOCKED OUT – LSI respond as if the Load Moment module software revision # is not (Install proper
SOFTWARE Cutout % parameter has been compatible [(Major version 0, minor LSI)
VERSION reached and react accordingly 11) OR (Major version 1).
IMPROPER depending on the MARKET
configuration.
Set CAN message bit to permit LSI
System display control of its alarm.
LSI FAULTY – 99152 1 If active, the control system will The LSI System has detected a Power cycle.
SYSTEM FLASH respond as if the Load Moment checksum error with its system (Replace LSI)
CRC ERROR Cutout % parameter has been flash and is reporting the issue on a
reached and react accordingly CAN bus message to UGM.
depending on the MARKET
configuration.
Set CAN message bit to permit LSI
System display control of its alarm.
LSI FAULTY – DATA 99153 1 If active, the control system will The LSI System has detected a Power cycle.
FLASH CRC ERROR respond as if the Load Moment checksum error with its data flash (Replace LSI)
Cutout % parameter has been and is reporting the issue on a CAN
reached and react accordingly bus message to UGM.
depending on the MARKET
configuration.
Set CAN message bit to permit LSI
System display control of its alarm.
LSI FAULTY – LOAD 99154 1 If active, the control system will The LSI System has detected a Power cycle.
CELLS A AND B respond as if the Load Moment unacceptable variance in the (Recalibrate
DISAGREEMENT Cutout % parameter has been readings between Load Cell A and or replace LSI
reached and react accordingly Load Cell B and is reporting the sensor)
depending on the MARKET issue on a CAN bus message to
configuration. UGM.
Set CAN message bit to permit LSI
System display control of its alarm.
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
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