Jlg 4013PS Service Manual- Manuals

Section Subject Page iii 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Section 9Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.1 Electrical Component Terminology . . . . . . . . ...

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

1-1 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2 Disclaimer . . . . . ...

Safety Practices 1-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 1.1 INTRODUCTION This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reli...

1-3 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Safety Practices 1.6 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedu...

Safety Practices 1-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 pressure can explode. Hydraulic oil and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury. Relieve all pressure before disconne...

General Information and Specifications 2-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION For reference when ordering replacement parts or making service inquiries about the machine, the machine serial number is requi...

2-3 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 General Information and Specifications 2.2 TORQUE CHARTS 2.2.1 SAE Fastener Torque Chart REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND Description 0100011 242 TM Vibra-TITE TM 121 Medium Strength (Blue) 0100019 2...

2-5 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 48...

General Information and Specifications 2-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2.2.1 SAE Fastener Torque Chart (Continued) Size TPI Bolt Dia Tensile Stress Area Clamp Load See Note 4 In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 48...

2-7 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 General Information and Specifications 2.2.2 Metric Fastener Torque Chart Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263 TM ) Torque (Lub) Sq mm KN [N.m] [N.m] [N.m] [N.m] 3 0.5 5.03 2.19 1....

2-9 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Size PITCH Tensile Stress Area Clamp Load See Note 4 K = .17 K = .16 K = .15 Sq mm kN [N.m] [N.m] [N.m] 3 0.5 5.03 3.5 0.6 6.78...

General Information and Specifications 2-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2.2.3 Hydraulic Hose Torque Chart Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is n...

2-11 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 General Information and Specifications 2.3 SPECIFICATIONS 2.3.1 Travel Speeds 2.3.2 Hydraulic Cylinder Performance Specifications Note: Machine with no load, engine at full throttle, hydraulic oil above 130° F (5...

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

2-15 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 General Information and Specifications 2.5 MAINTENANCE SCHEDULES 2.5.1 8 & 1st 50 Hour Maintenance Schedule 2.5.2 50, 250 & 500 Hour Maintenance Schedule 2.5.3 1000 & 1500 Hour Maintenance Schedule MZ...

General Information and Specifications 2-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2.6 LUBRICATION SCHEDULES 2.6.1 8 Hour Lubrication Schedule 8, 9, 12 & 13M EVERY 8 O Z22 6 0

General Information and Specifications 2-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 This Page Intentionally Left Blank

Boom 3-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3.10 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 3.10.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Boom 3-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3.2 BOOM SYSTEM - TWO AND THREE SECTION BOOM 3.2.1 Boom System Description The boom operates via an interchange among the electrical, hydraulic and mechanical systems. Components involved include the joystick...

Boom 3-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3.7 BOOM EXTEND AND RETRACT CHAINS FOUR SECTION BOOM 3.7.1 Boom Chain Inspection Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. The retract chains n...

3-19 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Boom b. Extend Chains (third to second section) The extend chains between the third and second boom sections measures 29,6 mm (1.2 in) (1). If the measurement of the worn chain is less than 28,6 mm (1.1 in) (2), ...

Boom 3-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Distorted or Battered Link Plates Distorted or battered link plates (8) on a leaf chain can cause tight joints and prevent flexing. Cracked Plates Inspect the chains very carefully, front and back as well as...

3-21 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Boom e. Removing Extend and Retract Chains The four extend chains and the three retract chains can only be removed during a complete boom teardown. While doing the chain inspection, check all chain clevis ends fo...

3-25 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Boom 3.10 BOOM WEAR PADS The wear pads on this machine are flat rectangular wear pads with metal inserts. A total of 13 wear pads are installed on the boom sections of the 8 & 9M machines. A total of 26 wear ...

Boom 3-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 • Torque wear pad bolts after shimming is completed. • Lubricate the face and pockets of each wear pad after being installed. Boom Section Wear Pad Pathway Lubrication: • Clean and lightly grease all wear pa...

3-27 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Boom 3.11.4 Quick Switch Removal 1. Support the quick switch assembly. Remove the lock bolt (11) holding the tilt cylinder rod end pin (12) to the quick switch assembly. Remove the tilt cylinder pin. 2. Support t...

Boom 3-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 3.13 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Problem Cause Remedy 1. Boom will not extend or retract 1. Broken...

3-29 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Boom 6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication.” 2. Rapid cycle times with heavy loads. 2. Re...

Cab and Covers 4-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar wi...

4-3 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Cab and Covers 4.2 OPERATOR CAB 4.2.1 Serial Number Decal The cab serial number decal is located inside the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the...

Cab and Covers 4-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7. Start the engine and check the operation of steering system. Check for hydraulic oil leaks. Check the hydraulic oil level in the tank and add oil as required. Wipe up any spilled oil. 8. Install ...

4-5 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Cab and Covers 6. Remove the throttle pedal return spring (6). 7. Disconnect the throttle control cable (7) from the throttle lever. 8. Remove the retaining ring from the throttle pedal pivot pin. Slide the thrott...

Cab and Covers 4-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 b. Joystick Assembly Installation 1. Set the joystick assembly into the armrest support. 2. Install the four self-tapping screws. Connect the electrical connections. 3. Properly connect the battery....

4-7 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Cab and Covers 4.3.6 Parking Brake (17M) a. Park Brake Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) N...

Cab and Covers 4-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4.3.9 Heater/Defroster System a. Heater Assembly 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...

4-9 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Cab and Covers 9. Replace the belly pan. 10. Close and secure the engine cover. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 4.3.10 Cab Heater/Air Conditioning Contr...

Cab and Covers 4-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4. Properly disconnect the battery. 5. Remove the belly pan. 6. Drain the engine radiator. Refer to Section 7.4.3, “Radiator/Oil Cooler and Coolant Heater Replacement.” 7. Working under the cab, re...

4-11 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 as needed, if not previously removed. 18. Use a hoist or overhead crane and sling attached to the cab, carefully begin to lift the cab. Stop and ...

5-1 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH TITLE PAGE 5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . 5-2 5.2 General Information . . . . . . ....

5-3 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Axles, Drive Shafts, Wheels and Tires 5.2 GENERAL INFORMATION Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, s...

Axles, Drive Shafts, Wheels and Tires 5-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem Cause Remedy 1. Excessive axle noise while driving. 1. Oil level too low. 1. Fill oil to correct level. Refer to Se...

5-9 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Axles, Drive Shafts, Wheels and Tires 5.4 DRIVE SHAFTS 5.4.1 Drive Shaft Inspection and Service Whenever servicing the machine, conduct a visual inspection of the drive shaft and cross and bearing assembly (univer...

Axles, Drive Shafts, Wheels and Tires 5-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5.5 WHEELS AND TIRES JLG recommends a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering informat...

5-11 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Axles, Drive Shafts, Wheels and Tires 5.5.2 Installing Wheel and Tire Assembly onto Machine Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the directio...

Axles, Drive Shafts, Wheels and Tires 5-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 5.7 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine...

6-1 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Section 6 Transmission: Contents PARAGRAPH TITLE PAGE 6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2 Transmission Description . . . . . . . . . . . . . . . . ...

6-3 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Transmission: 6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance information, and transmission removal and installation procedures. For internal...

Transmission: 6-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 6.5.1 Transmission 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 the (N) NEUTRAL, engage the...

6-5 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Transmission: 27. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so that it wil...

6-7 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Transmission: 6.6 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the JLG Service Department if in...

Transmission: 6-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 2. Low or no pump flow or pressure. 1. Low oil level. 1. Fill transmission to correct level with Mobilfluid 424 ® ISO Grade 46. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”) 2. Transmi...

7-1 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Section 7 Engine: Perkins 1104-42 & 1104-42T Contents PARAGRAPH TITLE PAGE 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.1...

Engine: Perkins 1104-42 & 1104-42T 7-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7.1 INTRODUCTION 7.1.1 Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, saf...

7-3 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Engine: Perkins 1104-42 & 1104-42T 7.1.2 Component Terminology To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar ...

Engine: Perkins 1104-42 & 1104-42T 7-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7.2 ENGINE SERIAL NUMBER The Perkins serial number is stamped on a plate which is secured to the engine block, near the fuel injector pump. Information contained in the seria...

7-5 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Engine: Perkins 1104-42 & 1104-42T b. Thermostat Installation 1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the two capscrews. Torque to 24 Nm (18 lb-ft). 2. Properly ...

Engine: Perkins 1104-42 & 1104-42T 7-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 15. Remove the air conditioner condenser (if equipped) from the radiator assembly. 16. Carefully lift the radiator/oil cooler out of the engine bay. Note: If applicable the r...

7-7 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Engine: Perkins 1104-42 & 1104-42T 7.6.2 Fuel Tank Note: The fuel tank is a one piece unit. It is located at the rear of the machine, between the frame. If it is determined that the fuel tank must be removed, ...

Engine: Perkins 1104-42 & 1104-42T 7-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 e. Inspection Note: If a leak is suspected in the fuel tank, contact your local JLG distributor. 1. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other da...

7-9 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 clearance then tighten all clamps. 7. Properly connect the battery. 8. Start engine and check for exhaust leaks at al...

7-11 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Engine: Perkins 1104-42 & 1104-42T 7.9.3 Engine Installation 1. Attach a lifting chain to the front and rear engine lift brackets, and lift engine clear of the ground. Note: Apply Loctite ® 243 TM threadlock ...

Engine: Perkins 1104-42 & 1104-42T 7-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 • DO NOT steer or apply any pressure to the steering wheel. • Keep the transmission in (N) NEUTRAL. 32. Obtain and connect an appropriate engine analyzer or tachometer. Chec...

Hydraulic System 8-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and ...

8-3 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System 8.2 SAFETY INFORMATION Petroleum-based hydraulic oils are used in this machine. The temperature of hydraulic oil increases during the operation of various hydraulic functions. A heated petroleum-b...

Hydraulic System 8-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8.4 HYDRAULIC CIRCUITS This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, where and how to check those pressures. Electrical and hydraulic funct...

8-5 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System c. Pressure Specifications Hydraulic Circuit Test Port Procedure Adjustment Location Pressure Range Implement M Connect gauge to M port, run engine at low idle, bottom out boom retract function. H...

Hydraulic System 8-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8.5 HYDRAULIC SCHEMATICS 8.5.1 8M, 9M, 12M & 13M (w/o trailer brakes) Before S/N 1160005851 excluding 1160005819

8-17 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System 8.6 HYDRAULIC RESERVOIR The hydraulic reservoir is a one piece unit. It is located under the rear of the machine cab. Occasionally, oil may seep, leak or be more forcefully expelled from the brea...

Hydraulic System 8-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 c. Cleaning and Drying If contaminated hydraulic oil or foreign material is in the tank, the tank can usually be cleaned. To clean the hydraulic oil reservoir: 1. Have a dry chemical (Class B) fi...

Hydraulic System 8-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 8.8 AUXILIARY PUMP (PLATFORM EQUIPPED MODELS ONLY) 8.8.1 Auxiliary Pump Description The auxiliary pump works as a safety back up for the platform in case of engine stalling. The pump will allow t...

8-21 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, b...

Hydraulic System 8-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 f. Main Control Valve Installation 1. Loosely install the four main control valve mounting bolts through bracket on the inside rail of the engine bay. 2. Install the main control valve onto the b...

8-23 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 3. Use new oiled o-rings as r...

Hydraulic System 8-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 7. Remove the two bolts holding the steer select valve to the mounting plate on the frame. 8. Remove the steer select manifold with the attached steer select valve (9) from the machine. Wipe up a...

8-25 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Label, disconnect and cap all hydraulic hoses (1) and fittings connected to the leveling valve. 6...

Hydraulic System 8-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 f. Leveling Valve Installation 1. Install the leveling valve into the engine compartment and secure with the previously used hardware. 2. Prime the leveling valve by filling the inlet openings wi...

8-27 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System Note: When sliding the rod and piston assembly out of the tube, prevent the threaded end of the tube from damaging the piston. Keep the rod centered within the tube to help prevent binding. 6. Ca...

Hydraulic System 8-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 4. Lubricate and slide the head gland (6) over the cylinder rod (5). Install the piston head (4) on to the end of the cylinder rod. Apply Loctite ® 243 TM to the setscrew (3) and install in the p...

8-29 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Hydraulic System 8.10.9 Hydraulic Cylinder Torque Specifications a. Lift/Lower Cylinder b. Extend/Retract Cylinder c. Tilt Cylinder d. Compensation Cylinder e. Frame Level Cylinder f. Outrigger Cylinder Machine P...

Electrical System 9-2 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9.12 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 9.12.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . ....

Electrical System 9-4 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9.3 PLATFORM INTERLOCK CHECKS To check the platform interlock, turn the ignition key to position I and be sure the following are set: • Park brake is applied • Transmission control lever is in th...

9-5 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System 9.4 SOFTWARE LEVEL 2 ACCESSIBILITY The following parameters can be altered in the 2nd level of access to the machine’s software. 9.4.1 Operator Tools Function Description Change Anti Theft Code A...

9-7 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System 9.5 OPERATOR TOOLS 9.5.1 Resetting the Anti Theft Code To reset the anti theft code: 1. Turn the engine to the ON position. 2. Press the "C" and "OK" buttons on the dash simultane...

Electrical System 9-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9.5.6 Cabin Joystick Telescope: X-Axis/Roller To change the joystick telescope function on the joystick: 1. Turn the engine to the ON position. 2. Press the "C" and "OK" buttons o...

9-11 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System 9.7 ELECTRICAL SYSTEM SCHEMATICS For more detailed schematics, contact your local authorized service distributor. 9.7.1 Cab Harness Electrical Schematic Before S/N 1160005993 excluding 116000594...

Electrical System 9-22 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9.8 CIRCUIT BREAKDOWNS 9.8.1 Constant Power Circuit from Battery MZ22 6 0 PCB PWR PCB PWR PCB PWR PCB PWR PCB PWR XA1 POWER CONTROL BOARD M STARTER 1 2 3 4 XA1 PCB PWR PCB PWR PCB PWR PCB PWR PC...

Electrical System 9-24 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9.9 ENGINE START CIRCUIT 9.9.1 Starter The starter (1) is located on the left side of the engine (the right side of the machine). a. Testing the Starter on the Engine If the starter does not eng...

9-25 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System f. Starter Installation 1. Position the starter in its mounting opening on the flywheel housing. Position the ground cable over the correct starter mounting bolt. Secure the starter with fastene...

Electrical System 9-26 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 b. Alternator Installation 1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper mounting hardware through the alternator mount. DO NOT tig...

9-27 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. c. Inspection and Replacement Inspect the motor terminals for continuity. Repla...

Electrical System 9-28 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9.12.3 Windshield Washer Reservoir and Pump The windshield washer motor and reservoir is located in the engine compartment as a unit and cannot be serviced separately. a. Removal 1. Park the mac...

9-29 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...

9-33 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System been ruled out and in addition, wiring and connectors have been checked and ruled out, the fuel level indicator is defective and must be replaced. 5. Check that the ignition terminal has current...

9-35 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. 1. Fully retract and level the boom, with no load. Do not raise the boom during this test. 2. Level frame using level in cab. 3. Press the test ...

9-37 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System Field Calibration Procedure: Note: If the test weight is not known, follow steps 1 & 2. 1. With the estimated test weight on the forks, start the machine and extend the boom horizontally unt...

9-43 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Electrical System 9.16.5 500 Hour - LSI UGM Calibration Check 1. Start machine 2. Press the “C” and “OK” buttons simultaneously on the keypad or the analyzer. 3. Go to “ACCESS LEVEL 2 or 1” and press “OK”. 4. Ent...

Electrical System 9-46 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 9.18 FAULT CODES Active faults and fault memory will be displayed at the operator level of access. Active faults will also be displayed as a blink code at the controller on-board LED. The 16 pre...

JLG Worldwide Locations An Oshkosh Corporation Company www.jlg.com 31200206 JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: +61 265 811 111Fax: +61 265 810 122 JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazilPh...