Professional Documents
Culture Documents
Manual Service JLG 4013 CE English
Manual Service JLG 4013 CE English
Models
3507, 3508,
3509, 3512,
3513, 4007,
4008, 4009,
4012, 4013
P/N - 3121852
Revised
April 20, 2007
EFFECTIVITY PAGE
June 16, 2003 - A - Original Issue Of Manual
January 20, 2006 - B - Complete Revision Of Manual
April 20, 2007 - C - Revised pages 5.3, 5.5, 5.10, 6.3, 6.5, 6.7, 8.8, & 8.20
3121852
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
EFFECTIVITY PAGE
-b
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
SECTION CONTENTS
Section
Subject
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Page
1.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
1.2
1.2
1.2
1.3
1.3
1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
2.1
2.2
2.3
2.4
2.5
2.6
2.2
2.3
2.6
2.8
2.9
2.10
...........................................................
3.1
3.2
3.3
3.3
3.7
3.8
3.9
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Section 3
Boom
3.1
3.2
3.3
3.4
3.5
3.6
4.1
4.2
4.3
4.4
4.5
4.2
4.3
4.3
4.8
4.9
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
5.1
5.2
5.3
5.4
5.5
5.6
5.7
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.2
5.3
5.3
5.9
5.10
5.11
5.12
Section
Subject
Page
Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
6.2
6.3
6.4
6.5
6.6
6.1
6.2
6.3
6.3
6.3
6.3
6.7
Section 7
Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2
7.4
7.4
7.4
7.6
7.6
7.8
7.9
7.9
7.12
7.13
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.2
8.3
8.3
8.4
8.5
8.8
8.9
8.11
8.16
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
ii
9.3
9.4
9.4
9.4
9.7
9.17
9.20
9.21
9.22
9.24
9.26
9.27
9.33
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 1
Safety Practices
Contents
PARAGRAPH
1.1
1.2
1.3
1.4
1.5
1.6
1.7
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.1
Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1
Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.2
Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.3
General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.4
Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
1.2
1.2
1.2
1.2
1.3
1.3
1.3
1.3
1.3
1.4
1.4
1.4
1.1
Safety Practices
1.1
INTRODUCTION
1.2
1.2
DISCLAIMER
1.3
1.4
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Safety Practices
1.5
SAFETY INFORMATION
1.6
1.6.1
1.5.1
DANGER
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
SAFETY INSTRUCTIONS
Personal Hazards
1.6.2
Equipment Hazards
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
1.3
Safety Practices
1.6.3
General Hazards
1.6.4
Operational Hazards
1.7
SAFETY DECALS
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 2
General Information and Specifications
Contents
PARAGRAPH
2.1
2.2
2.3
2.4
2.5
2.6
TITLE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
2.2
2.3
2.3
2.4
2.5
2.6
2.6
2.6
2.6
2.7
2.7
2.8
2.9
2.9
2.9
2.9
2.10
2.10
2.11
2.1
2.1
MZ1780
2.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
40
48
32
40
32
36
24
32
20
28
1.5000
1.3750
1.2500
1.1250
1.0000
0.8750
0.7500
0.6250
0.5625
0.5000
0.4375
0.3750
0.3125
IN
0.2500
0.1900
0.1640
0.1380
0.1120
IN
BOLT
DIA.
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
SQ. IN.
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
SQ. IN.
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
LB.
380
420
580
610
900
940
1120
1285
2020
2320
LB.
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
FT-LB
8
9
16
18
30
31
43
49
96
120
IN-LB
263
TENSILE
CLAMP DRY OR
STRESS
LOAD LOCTITE
AREA
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
FT-LB
6
7
12
13
22
23
32
36
75
86
IN-LB
LUB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
FT-LB
IN-LB
LOCTITE
262
TORQUE
1-1/2
1-3/8
1-1/4
1-1/8
7/8
3/4
5/8
9/16
1/2
7/16
3/8
5/16
1/4
10
SIZE
THDS.
PER
INCH
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
FT-LB
105
135
IN-LB
LOCTITE
242 OR
271
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
LB.
540
600
820
920
1260
1320
1580
1800
2860
3280
LB.
CLAMP
LOAD
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
1280
1440
1820
2000
2380
2720
3160
3560
FT-LB
12
13
23
25
41
43
60
68
144
168
IN-LB.
DRY OR
LOCTITE
263
18
20
35
35
55
60
80
90
110
130
170
180
280
320
460
500
680
740
960
1080
1360
1500
1780
2040
2360
2660
FT-LB
9
10
17
19
31
32
45
51
108
120
IN-LB
LUB
22
25
40
45
63
70
96
108
139
154
180
204
301
336
485
534
687
796
1030
1155
1453
1610
1907
2165
2530
2844
FT-LB
IN-LB
LOCTITE
262
TORQUE
30
30
50
55
80
90
120
130
165
190
240
265
420
465
660
725
990
1100
1400
1575
2000
2200
2625
3000
3475
3925
FT-LB
160
185
IN-LB
LOCTITE
242 OR
271
5240
5800
7750
8780
10630
11870
14190
15990
18200
20300
22600
25600
33400
37300
46200
50900
60600
66300
76300
85600
96900
107300
115500
131500
140500
158000
LB.
3180
3640
LB.
25
27
45
50
70
75
110
115
155
165
210
220
365
400
585
635
865
915
1240
1380
1750
1880
2320
2440
3040
3270
FT-LB
160
168
IN-LB
PATCH
28
30
50
55
77
82
120
127
170
182
231
242
400
440
645
700
950
1000
1365
1520
1925
2070
2550
2685
3345
3600
FT-LB
168
178
IN-LB
PATCH
TORQUE
CLAMP WITHOUT WITH
LOAD LOC-WEL LOC-WEL
2.2.1
2.2
TORQUES
ASTM Fastener Torque Chart (English)
2.3
2.4
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
40
48
32
40
32
36
24
32
20
28
1.5000
1.3750
1.2500
1.1250
1.0000
0.8750
0.7500
0.6250
0.5625
0.5000
0.4375
0.3750
0.3125
IN
0.2500
0.1900
0.1640
0.1380
0.1120
SQ. IN.
IN
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
SQ. IN.
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
TENSILE
STRESS
AREA
BOLT
DIA.
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
LB.
380
420
580
610
900
940
1120
1285
2020
2320
LB.
CLAMP
LOAD
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
N, m
.8
1.0
1.8
2.0
3.4
3.4
5
6
11
14
DRY OR
LOCTITE
263
N, m
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
N, m
.8
.8
1.4
1.6
2.4
2.6
3.6
4
8
10
N, m
LUB
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
N, m
N, m
LOCTITE
262
TORQUE
1-1/2
1-3/8
1-1/4
1-1/8
7/8
3/4
5/8
9/16
1/2
7/16
3/8
5/16
1/4
10
SIZE
THDS.
PER
INCH
26
28
47
54
75
81
115
136
163
183
224
258
386
447
644
705
915
997
1139
1254
1593
1763
2068
2373
2745
3118
N, m
12
15
LOCTITE
242 OR
271
N, m
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
LB.
540
600
820
920
1260
1320
1580
1800
2860
3280
LB.
CLAMP
LOAD
34
34
61
68
95
108
149
163
203
230
298
325
515
569
813
895
1220
1356
1735
1952
2468
2712
3227
3688
4284
4827
N, m
1.4
1.5
2.6
2.8
4.6
5
7
8
16
19
DRY OR
LOCTITE
263
N, m
24
27
47
47
75
81
108
122
149
176
230
244
380
434
624
678
922
1003
1302
1464
1844
2034
2413
2766
3200
3606
N, m
1.0
1.0
2.0
2.2
3.4
3.6
5
6
12
14
N, m
LUB
30
34
54
61
85
95
130
146
188
209
244
277
408
456
658
724
931
1079
1396
1566
1970
2183
2586
2935
3430
3856
N, m
N, m
LOCTITE
262
TORQUE
41
41
68
75
108
122
163
183
224
258
325
359
569
630
895
983
1342
1491
1898
2135
2712
2983
3559
4067
4711
5322
N, m
18
21
LOCTITE
242 OR
271
N, m
5240
5800
7750
8780
10630
11870
14190
15990
18200
20300
22600
25600
33400
37300
46200
50900
60600
66300
76300
85600
96900
107300
115500
131500
140500
158000
LB.
3180
3640
LB.
CLAMP
LOAD
34
37
61
68
95
102
149
156
210
224
285
298
495
542
793
861
1173
1241
1681
1871
2373
2549
3145
3308
4122
4433
N, m
18
19
38
41
68
75
104
111
163
172
230
247
313
328
542
597
874
949
1288
1356
1851
2061
2610
2807
3457
3640
4535
4881
N, m
19
20
TORQUE
WITHOUT
WITH
LOC-WEL LOC-WEL
PATCH
PATCH
N, m
N, m
2.2.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
SIZE
PITCH
TORQUE
TENSILE
STRESS
AREA
CLAMP
LOAD
sq. mm
TORQUE
DRY OR
LOCTITE
263
LUB
LOCTITE
262
LOCTITE
242 OR
271
KN
N, m
N, m
N, m
N, m
CLAMP
LOAD
DRY OR
LOCTITE
263
LUB
LOCTITE
262
LOCTITE
242 OR
271
KN
N, m
N, m
N, m
N, m
.5
5.03
2.19
1.3
1.0
1.2
1.4
3.13
1.9
1.4
1.5
2.1
3.5
.6
6.78
2.95
2.1
1.6
1.9
2.3
4.22
3.0
2.2
2.4
3.3
.7
8.78
3.82
3.1
2.3
2.8
3.4
5.47
4.4
3.3
3.5
4.8
.8
14.2
6.18
6.2
4.6
5.6
6.8
8.85
8.9
6.6
7.1
9.7
20.1
8.74
11
7.9
9.4
12
12.5
15
11
12
17
28.9
12.6
18
13
16
19
18
25
19
20
28
1.25
36.6
15.9
25
19
23
28
22.8
37
27
29
40
10
1.5
58.0
25.2
50
38
45
55
36.1
72
54
58
79
12
1.75
84.3
36.7
88
66
79
97
52.5
126
95
101
139
14
115
50.0
140
105
126
154
71.6
200
150
160
220
16
157
68.3
219
164
197
241
97.8
313
235
250
344
18
2.5
192
83.5
301
226
271
331
119.5
430
323
344
473
20
2.5
245
106.5
426
320
383
469
152.5
610
458
488
671
22
2.5
303
132.0
581
436
523
639
189.0
832
624
665
915
24
353
153.5
737
553
663
811
220.0
1060
792
845
1170
27
459
199.5
1080
810
970
1130
286.0
1540
1160
1240
1690
30
3.5
561
244.0
1460
1100
1320
1530
349.5
2100
1570
1680
2310
33
3.5
694
302.0
1990
1490
1790
2090
432.5
2600
2140
2280
2860
36
817
355.0
2560
1920
2300
2690
509.0
3660
2750
2930
4020
42
4.5
1120
487.0
4090
3070
3680
4290
698.0
5860
4400
4690
6440
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.5
2.3
SPECIFICATIONS
2.3.1
Travel Speeds
First Gear
Second Gear
Third Gear
2.3.2
Note: Machine with no load, engine at full throttle, hydraulic oil above 130 F (54 C) minimum, engine at operating
temperature.
Function
8M
9M
12M
13M
Boom Extend
11,60
11,60
13,30
14,03
16,88
Boom Retract
9,83
9,83
11,27
12,48
15,02
Boom Lift
8,28
9,43
14,0
12,32
14,00
Boom Lower
5,63
6,41
9,65
8,49
9,65
Attachment Tilt UP
9,78
9,78
9,78
9,78
9,78
4,50
4,50
4,50
4,50
4,50
Outrigger - UP
N/A
N/A
N/A
2,93
2,93
Outrigger DOWN
N/A
N/A
N/A
2,19
2,19
Sway
11,0
11,0
11,0
11,0
11,0
2.3.3
Electrical System
Note: Refer to Section 9.4, Fuses and Relays, for more information.
Battery:
Type, Rating
Quantity
Reserve Capacity
Group/Series
DIN 600,38
Alternator
14V, 70 Amps
Starter
2.6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Note: Engine manufacturer's maximum high idle setting is lockwired and sealed. DO NOT disturb this setting.
a. Before S/N 1160000358
Description
Naturally Aspirated
Turbo
Engine Make/Model
Perkins 1004-42
Perkins 1004-40T
Low Idle
High Idle
Horsepower
Fuel Delivery
Fuel Injection
Fuel Injection
Air Cleaner
Naturally Aspirated
Turbo
Engine Make/Model
Perkins 1104C-44
Perkins - 1004-40T
Low Idle
High Idle
Horsepower
Fuel Delivery
Fuel Injection
Fuel Injection
Air Cleaner
2.3.5
Tires
405/70-20 MPT01 AG
405/70-24 MPT01 AG
405/70-24 MPT01 AG
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.7
2.4
Fuel Tank
Capacity
Type of Fuel
Cooling System
System Capacity
Type of Fluid
Axles
Differential Housing Capacity - Front
Type of Fluid
Hydraulic System
System Capacity
2.8
Type of Fluid
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.5
MAINTENANCE SCHEDULES
2.5.1
2.5.2
50
EVERY
10
Drain Fuel/
Water
Separator
Check Engine
Coolant Level
Check
Battery
Follow Lubrication
Schedule
EVERY
Check Fuel
Level
Check Tire
Pressure
Air Filter
Restriction
Indicator
Check Brake
Fluid Level
Check
Transmission
Oil Level
Test Load
Moment
Indicator
Check Engine
Oil Level
1st
50
LB/FT
Change
Axle Oil
Change Wheel
End Oil
Change Engine
Oil & Filter
Change
Transmission
Oil & Filter
250
Check Hydraulic
Oil Level
Change Engine
Oil and
Filter
Check Axle
Oil Level
Check Boom
Bearing
Pads
Check Transfer
Case Oil Level
Air Filter
Vacuator
Valve
Check Wheel
End Oil Levels
Check
Fan Belt
EVERY
(Nm)
500
Check Wheel
Lug Nut
Torque
LB/FT
(Nm)
MZ1670
Change Fuel
Filter
Check Wheel
Lug Nut
Torque
MZ1680
2.5.3
EVERY
1000
Change
Transmission
Oil & Filter
Change
Transfer Case
Oil
Change
Axle Oil
Change Wheel
End Oil
EVERY
1500
Change
Engine Coolant
Change
Hydraulic
Fluid & Filters
Change
Hydraulic Tank
Breather
Change
Brake Fluid
MZ1690
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.9
2.6
LUBRICATION SCHEDULES
2.6.1
EVERY
Mystik Tetrimoly
(NLGI 2 GC-LB)
MZ1700
2.10
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
EVERY
Mystik Tetrimoly
(NLGI 2 GC-LB)
50
MZ1710
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.11
2.12
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 3
Boom
Contents
PARAGRAPH
3.1
3.2
3.3
3.4
3.5
3.6
TITLE
PAGE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
3.1
Boom
3.1
First Boom
Section
Pivot Pin
Second Boom
Section
Third
Boom Section
Extend/Retract
Cylinder
Access
Panel
First Boom
Section
Pivot Pin
Tilt Cylinder
Quick Switch
Extend/Retract
Cylinder
Access
Panel
Second Boom
Section
Tilt Cylinder
Quick Switch
3.2
MZ1480
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Boom
3.2
3.2.1
BOOM SYSTEM
Boom System Description
3.3
3.3.1
Boom Removal
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
3.3
Boom
a. If the boom is going to be disassembled after
removal:
3.3.2
3. Pull the second and third boom sections out from the
first boom section (6).
MZ1740
3.3.3
2
3
MZ1720
3.4
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Boom
sling under the boom head. Carefully slide the
innermost boom section into the next section. Leave
15 cm to 20 cm (6 to 8) of the innermost boom
section out to be able to install wear pads on the
front of the next boom section.
MZ1730
3.3.4
1. Install the bottom rear wear pads (8) and bolts onto
the innermost boom section. Apply Loctite #242
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).
3.3.5
1. Install the bottom rear wear pads (9) and bolts onto
the second boom section. Apply Loctite #242 and
torque to 90 Nm (66 lb-ft). Install the bottom rear left
and right side wear pads, backing plate and bolts (do
not shim or tighten bolts). Install top rear wear pads,
backing plates and bolts (do not shim or tighten
bolts).
2. Grease the inside of the first boom section on areas
where the third boom section wear pads will slide.
8
MZ1750
3.5
Boom
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.
9
MZ1730
3.3.6
Boom Installation
Boom
3.4
11
3.4.1
Inspect all wear pads for wear. If the angle indicators (10)
on the ends of the wear pads are visible, the wear pads
can be reused. If the pads show uneven wear (front to
back), they should be replaced. Replace pads as a set if
worn or damaged.
10
10
MA2070
3.4.2
MAH0870
12
MU4080
3.4.3
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
3.7
Boom
3.5
3.5.1
3.5.2
MAH0980
3.5.3
3.5.4
3.5.5
19
18
13
14
3.8
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Boom
3.6
TROUBLESHOOTING
Problem
1. Boom will not extend or
retract
Cause
Remedy
1. Insufficient lubrication.
2. Worn bearing(s).
4. Replace bearing.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
3.9
Boom
Problem
6. Rapid boom pad wear.
3.10
Cause
Remedy
3. Contaminated, corroded or
rusted wear pad sliding
surfaces.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 4
Cab and Covers
Contents
PARAGRAPH
4.1
4.2
4.3
4.4
4.5
TITLE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
4.2
4.3
4.3
4.3
4.3
4.4
4.5
4.6
4.6
4.7
4.7
4.7
4.8
4.9
4.1
4.1
Air Louvers
Brake Fluid
Reservoir
Instrument
Panel
Air Louvers
Level
Indicator
Fuel Gauge
Load Moment
Indicator
Engine Temp Gauge
Control Console
Ignition Switch
Air Louvers
Steering Column
Adjuster
Joystick
Continuous Hydraulic
Powered Operation
Auxiliary Switch
Air Louvers
MZ0040
4.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
WARNING:
4.2
4.2.1
OPERATORS CAB
Serial Number Decal
4.3
4.3.1
CAB COMPONENTS
Steering Column and Orbitrol Valve
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
4.3
6
4
5
8
1
7
4.3.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
11
10
MZ0230
MZ0460
4.3.3
4.5
5. Install the bottom cover and secure using two lenshead capscrews.
4.3.5
Parking Brake
4.3.4
MZ1490
4.6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
4.3.6
4.3.7
4.3.8
12
Heater/Defroster System
MZ0480
4.7
4.4
CAB REMOVAL
4.8
13
MZ0640
4.5
CAB INSTALLATION
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
4.10
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH
5.1
5.2
5.3
5.4
5.5
5.6
5.7
TITLE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
5.2
5.3
5.3
5.3
5.3
5.3
5.3
5.4
5.6
5.9
5.9
5.9
5.9
5.9
5.9
5.10
5.10
5.11
5.11
5.11
5.12
5.1
5.1
Rear Axle
Assembly
Steering
Cylinder
(Rear)
Transmission Drop
Box
Steering
Cylinder
(Front)
Drive Shafts
MZ1510
Front Axle
Assembly
5.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.2
GENERAL INFORMATION
5.3.3
WARNING:
5.3
5.3.1
AXLE ASSEMBLIES
Axle Serial Number Plate
5.3.2
Axle Specifications
5.3.4
Axle Maintenance
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.3
Axle Removal
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a parking brake
mechanism and a limited-slip feature; the rear axle has
neither. The following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly.
Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on the outrigger
solenoids and other electrical components. If using a
steam cleaner, seal all openings before steam cleaning.
IMPORTANT: Clear the work area of all debris,
unnecessary personnel, etc. Allow sufficient space to
raise the machine and to remove the axle.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
5. If the axle will be disassembled after removal, place
a suitable receptacle under the axle (1) and wheel
hubs drain plugs (2). Remove the drain plugs and
allow the axle oil to drain into the receptacle.
Transfer the used axle oil into a suitable covered
container, and label the container as "Used Oil".
Dispose of used oil at an approved recycling facility.
2
MZ1520
MZ1030
5.4
15. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the machine
while removing the axle. Balance the axle and
prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
MZ1030
5.5
Problem
1. Excessive axle noise while
driving.
5.6
Cause
Remedy
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Problem
4. Oil leaking from axle
(differential housing and/or
axle housings).
Cause
Remedy
2. Tighten fittings.
2. Replace o-ring.
1. Tighten fittings.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.7
Problem
7. Axle overheating.
5.8
Cause
Remedy
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.4
5.4.1
DRIVE SHAFTS
Drive Shaft Inspection and Service
5.4.2
5.4.3
To Axle
5.4.4
5.4.5
5.5
WARNING:
Risk of death or
serious personal injury. 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.
5.10
MAH0890
5.5.1
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.6
5.6.1
BRAKES
Brake Disk Inspection.
WARNING:
Tread arrows must
point forward
10
9
4,5 mm
2
6
4
OY1220
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.11
MZ1030
5.7
5.12
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 6
Transmission:
Contents
PARAGRAPH
6.1
6.2
6.3
6.4
6.5
6.6
TITLE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
6.2
6.3
6.3
6.3
6.3
6.3
6.3
6.4
6.5
6.5
6.6
6.7
6.7
6.1
Transmission:
6.1
TRANSMISSION ASSEMBLY
COMPONENT TERMINOLOGY
Torque Convertor
Dipstick and Fill Tube
Oil Filter
Output Shaft
(front)
Breather
Output Shaft
(rear)
Breather
6.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Transmission:
WARNING:
6.2
TRANSMISSION DESCRIPTION
6.3
6.4
6.4.1
TRANSMISSION SPECIFICATIONS
Transmission Maintenance
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
6.4.2
6.5
TRANSMISSION REPLACEMENT
6.3
Transmission:
6.5.1
Transmission Removal
WARNING:
1
2
MZ1380
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Transmission:
28. Remove any external transmission components as
required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings.
29. Remove the transmission oil filter (3) and dispose of
properly. Clean the filter mounting surface. Cover or
cap the oil filter mount.
3
6.5.3
Transmission Installation
MZ0680
6.5.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
6.5
Transmission:
Operation & Safety Manual. DO NOT overfill.
Reinstall the dipstick when finished.
17. Install the belly pan under the engine.
18. Install the engine cover.
19. Install the battery and reconnect the positive (+) and
negative (-) cables.
20. Close and secure the engine cover.
6.5.4
In General:
1. Check the transmission oil level and add oil as
required.
2. Install a new transmission filter.
3. Check the torque on the drive shaft yoke capscrews.
4. Wear suitable eye protection. When an overhauled
or repaired transmission is installed, thoroughly
clean the oil cooler lines to and from the
transmission.
5. Drain and flush the entire system.
MZ0680
10. Run the engine for two minutes at idle to help prime
the torque convertor and the transmission oil lines.
CAUTION:
DO NOT exceed
11,4 bar (165 psi) when back flushing the oil
cooler. Applying too much pressure may
damage the oil cooler/radiator.
6.6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Transmission:
6.6
TROUBLESHOOTING
6.6.1
Transmission Troubleshooting
Problem
1. Transmission will not engage
or will not shift properly.
Cause
Remedy
6. Replace o-rings.
8. Replace couplings.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
6.7
Transmission:
Problem
2. Low or no pump flow or
pressure.
4. Lack of power.
6.8
Cause
Remedy
5. Transmission overheating.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Transmission:
Problem
5. Transmission overheating
(oil above 120 C (248 F)).
Cause
Remedy
2. Clogged radiator.
4. Excessive roading.
4. Internal damage.
6. Tighten capscrews.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
6.9
Transmission:
Problem
7. Oil leaking from transmission.
6.10
Cause
Remedy
3. Tighten fittings.
5. Tighten capscrews to 46 Nm
(34 lb-ft).
9. Housing damaged.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 7
Engine: Perkins 1104-42 & 1104-42T
Contents
PARAGRAPH
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.11
TITLE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1
Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.2
Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1
Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3
Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . .
Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.1
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.2
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.3
After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.1
Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8.2
Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.1
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.2
Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . .
7.9.3
Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.1
Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.2
Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
7.2
7.2
7.3
7.4
7.4
7.4
7.4
7.4
7.5
7.6
7.6
7.6
7.7
7.8
7.8
7.9
7.9
7.9
7.9
7.9
7.10
7.11
7.12
7.12
7.12
7.13
7.1
7.1
7.1.1
INTRODUCTION
Disclaimer and Scope
7.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Component Terminology
Fuel Filter
Oil Filter
Thermostat
Alternator
Turbocharger
(optional)
Starter
MZ0070
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.3
7.2
7.3
SPECIFICATIONS AND
MAINTENANCE INFORMATION
7.4
7.4.1
7.4.2
a. Thermostat Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and steering wheel, stating that the machine
should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Disconnect the battery negative (-) cable from the
battery negative (-) terminal.
5. Slowly turn the radiator cap (1) to the first stop and
allow any pressure to escape. Remove the radiator
cap.
6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain plug (2) and slowly remove to allow the coolant
to drain. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
replaced. Replace the radiator drain plug.
1
Thermostat Replacement
7.4
MZ0080
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9
5
7.4.3
4
8
7.5
15. Remove the four nuts and four washers from the
radiator mounts (9).
7.6
7.6.1
FUEL SYSTEM
Diesel Fuel
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
13
12
10. Lift the empty fuel tank from between the frame rails.
b. Disassembly
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed
and reused on the new replacement tank.
MZ0100
10
7.6.2
Fuel Tank
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.7
7.7.1
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 damage.
2. Plug all openings except one elbow fitting. Install the
elbow fitting, and apply approximately 7-10 kPa
(1-1.5 psi) of air pressure through the elbow. Check
the tank for leaks by applying a soap solution to the
exterior and look for bubbles to appear at the
cracked or damaged area.
f.
7.7.2
7.6.3
7.8
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.8.2
7.8
WARNING:
7.8.1
7.9
ENGINE REPLACEMENT
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.9.1
Engine Removal
MZ0950
7.9.2
22. At the rear right engine mount (15), remove the bolt
and washer. Repeat for the rear left engine mount.
7.10
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Engine Installation
12. Install and tighten the jam nuts on the throttle cable
at the throttle cable mount.
13. Connect the throttle cable at the engine throttle lever.
14. Connect the fuel inlet line to the fuel filter head.
15. Connect the fuel return line to the fuel filter head.
16. Connect all the labeled wire harness connections on
the engine.
17. Install the hood latch plate. Align the mark on the
plate to help with hood adjustment.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.11
7.10.2
7.10
7.10.1
16
MZ0580
7.12
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.11
TROUBLESHOOTING
Trouble
1, 2, 3, 4
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring
8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust
11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Knocking
9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running
7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration
13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
4, 38, 41
Overheating
11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Poor Compression
11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
10, 11, 12
Key to Possible Causes
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
7.14
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 8
Hydraulic System
Contents
PARAGRAPH
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
TITLE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
8.2
8.3
8.3
8.4
8.4
8.4
8.5
8.8
8.8
8.8
8.8
8.9
8.9
8.9
8.10
8.11
8.11
8.13
8.14
8.14
8.14
8.15
8.16
8.16
8.17
8.18
8.18
8.18
8.19
8.19
8.19
8.20
8.1
Hydraulic System
8.1
HYDRAULIC COMPONENT
TERMINOLOGY
Tilt Cylinder
Extend/Retract
Cylinder
(inside boom)
Hydraulic Fluid
Reservoir
Lift/lower
Cylinder
Compensation
Cylinder
Hydraulic Filter
ERS Control
Panel
Main Pump
Outrigger Cylinders
(12 & 13M only)
8.2
Steering
Cylinder
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Hydraulic System
8.2
SAFETY INFORMATION
WARNING:
8.3
Description
Approximate
Weight
Price and
Availability
10 lbs.
Consult Factory
7 lbs.
Consult Factory
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.3
Hydraulic System
8.4
HYDRAULIC CIRCUITS
8.4.1
8.4.2
MZ1270
MZ1310
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
DN 10
30
bar
25 l/min
25 l/min
STABILIZER RIGHT
3.5 bar
STABILIZER LEFT
DN 10
DN 10
DN 10
100/50
10 m
LPS 160R1X/
LD7-643/01
5 l/min
SWAY
7100
DN 10
3 bar
DN 10
DN 32
DN 40
60
EF
CF
L1
LD
280
DN 12
DN 16
110/63
DN 10
DN 10
130/200 l/min
DN 16
110 bar/4:1
LS
90/56
175 bar
235 bar
EXTEND/RETRACT 12/13 M
EXTEND/RETRACT
9597
280
COMPENSATION
2x90/45
A10VO60DFR1
Q=132 l/min
p=250 bar
n=2200 1/min
dp=25 bar
65/100 l/min
TILT
AUXILIARY
65 l/min
9598
280
DN 10
TILT
7003
300 bar/4:1
140/70
DN 50
AUXILIARY
DN 6
125/60
DN 10
DN 10
125/60
0.3 bar
DN 12
FRONT AXLE
DN 12
DN 25
DN 12
DN 20
LS
130 l/min
LIFT/LOWER
7006
0931
DN 10
DN 10
CF LX
OSPF 200 LS
110 bar/4:1
100/60
1.0
20 bar
EXTEND/RETRACT 7-9 M
4WE6G
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PVSP
REAR AXLE
SWAY
300 bar/4:1
= 12 V
VOLTAGE
5 bar
DN 16
160/90
BRAKES
DN 16
DN 8
DN 8
LIFT/LOWER
FRONT AXLE
8.5
DN 8
STABILIZER
Hydraulic System
HYDRAULIC SCHEMATICS
STANDARD MACHINE
MZ1630
8.5
REAR AXLE
DN 10
DN 6
DN 10
30
bar
25 l/min
STABILIZER RIGHT
0.3 bar
25 l/min
DN 10
3.5 bar
STABILIZER LEFT
DN 10
DN 10
100/50
10 m
LPS 160R1X/
LD7-643/01
5 l/min
SWAY
DN 10
3 bar
DN 10
DN 32
DN 40
EF
60
AUXILIARY
65 l/min
7003
DN 12
DN 25
CF
300 bar/4:1
140/70
DN 50
TILT
9598
280
DN 10
L1
LD
280
A1
B
B1
DN 16
110/63
DN 10
DN 10
130/200 l/min
DN 16
110 bar/4:1
LS
90/56
175 bar
235 bar
7006
0931
A2
LS
130 l/min
P
T
DN 10
DN 10
CF LX
OSPF 200 LS
B2
110 bar/4:1
100/60
1.0
20 bar
EXTEND/RETRACT 7-9 M
LIFT/LOWER
EXTEND/RETRACT 12/13 M
EXTEND/RETRACT
9597
280
COMPENSATION
2x90/45
A10VO60DFR1
Q=132 l/min
p=250 bar
n=2200 1/min
dp=25 bar
65/100 l/min
TILT
DN 12
125/60
FRONT AXLE
125/60
DN 6
BASKET ROTATOR
DN 10
DN 10
SWAY
REAR AXLE
DN 12
DN 20
4WE6G
PVSP
1.2
250
A2
B2
IN
A1
A1
OUT
P T
DN 16
5 bar
BRAKES
160/90
B1
MOTOR
DN 8
DN 8
DN 16
300 bar/4:1
LIFT/LOWER
FRONT AXLE
DN 12
8.6
DN 8
STABILIZER
Hydraulic System
MZ1640
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
REAR AXLE
DN 10
DN 6
DN 10
30
bar
25 l/min
STABILIZER RIGHT
25 l/min
DN 10
STABILIZER LEFT
DN 10
DN 10
3.5 bar
10 m
3 bar
DN 10
LPS 160R1X/
LD7-643/01
60
EF
L1
LD
280
A1
B
B1
DN 16
110/63
DN 10
DN 10
DN 16
110 bar/4:1
LS
90/56
175 bar
235 bar
A2
LS
130 l/min
DN 10
DN 10
CF LX
OSPF 200 LS
B2
LIFT/LOWER
7006
0931
110 bar/4:1
100/60
1.0
20 bar
EXTEND/RETRACT 7-9 M
PVSP
DN 8
DN 8
5 bar
1.2
250
A2
B2
IN
A1
A1
OUT
P T
DN 16
160/90
B1
MOTOR
BRAKES
DN 16
300 bar/4:1
LIFT/LOWER
FRONT AXLE
EXTEND/RETRACT 12/13 M
EXTEND/RETRACT
130/200 l/min
9597
280
2x90/45
COMPENSATION
A10VO60DFR1
Q=132 l/min
p=250 bar
n=2200 1/min
dp=25 bar
TILT
9598
280
65/100 l/min
CF
DN 10
65 l/min
7003
AUXILIARY
300 bar/4:1
140/70
5 l/min
DN 12
SWAY
DN 10
DN 12
DN 25
100/50
DN 50
TILT
DN 6
DN 12
125/60
DN 32
DN 40
DN 12
BASKET ROTATOR
FRONT AXLE
125/60
0.3 bar
DN 20
DN 10
DN 10
SWAY
REAR AXLE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
4WE6G
DN 8
STABILIZER
Hydraulic System
SVI
RVI
MZ1650
8.7
REAR AXLE
DN 10
DN 6
Hydraulic System
8.6
HYDRAULIC RESERVOIR
8.6.2
8.6.3
MZ0130
8.6.1
8.8
Hydraulic System
c. Cleaning and Drying
8.7
8.7.1
8.7.2
Aeration
Cavitation
Contamination
Excessive Heat
Over-Pressurization
Improper Fluid
e. Reservoir Installation
1. Lift the hydraulic oil reservoir into place and install
the six bolts, washers and nuts.
2. Uncap and connect the suction hose and return
hose. Tighten both clamps.
3. Uncap and connect the four small return hoses to
the fittings on the hydraulic oil reservoir.
4. Install the hydraulic fluid level sight-glass using
special designed and drilled capscrews and gaskets.
MZ1660
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.9
Hydraulic System
8.7.3
Pump Replacement
a. Pump Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Disconnect the battery negative (-) cable from the
battery negative (-) terminal.
5. Relieve any trapped pressure in the hydraulic
system by using the lever (supplied in the tool box)
or a 9mm wrench and move the double nut on the
side of the actuator module on each valve section
back and forth.
6. Thoroughly clean the pump and surrounding area,
including all hoses and fittings before proceeding.
Note: Cap all hoses as you remove them to prevent
unnecessary fluid spillage.
7. Remove the four bolts and four lockwashers
securing the flange halves to the pump. Remove the
inlet hose and o-ring.
Note: Before removing any fittings from the pump, note
their orientation to ensure correct installation.
8. Remove the four bolts and four lockwashers
securing the flange halves to the pump. Remove the
outlet hose and o-ring.
9. Disconnect the case drain hose from the fitting.
Disconnect the load sense line.
10. Remove the two bolts and two lockwashers securing
the pump to the transmission. Remove the gasket
located between the transmission and the pump.
Wipe up any hydraulic oil spillage.
Note: DO NOT disassemble the implement pump. The
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than an authorized
dealer could void the warranty.
8.10
b. Pump Installation
1. While the pump is still on the bench, install all
fittings, except the outlet hose fitting, orienting them
as noted during removal.
2. Apply Loctite 573 on the metal seal of the pump
and place into position on the transmission. Align the
pump shaft with the internal transmission gear, so
that the machined teeth mesh together.
3. Align the bolt holes with the pump mount holes.
Secure the pump to the transmission with the two
bolts and washers. Torque to 115 Nm (85 lb-ft).
4. If necessary, slide the T-bolt band clamp onto the
pump inlet hose. Secure the hoses to the hydraulic
reservoir outlet connection with the T-bolt band
clamp.
5. Place a new oiled o-ring into position over the pump
opening. Secure the inlet hose with two flange
halves, four lockwashers and four bolts.
6. Connect the load sense line to the fitting.
7. Place a new, oiled o-ring into position over the pump
opening. Secure the outlet hose with two flange
halves, four lockwashers and four bolts.
8. Prime the pump by filling the case drain port with
fresh, filtered hydraulic oil from a clean container
before installing the case drain connector and hoses.
9. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.
10. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
11. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
12. Connect the battery negative (-) cable to the battery
negative (-) terminal.
13. Close and secure the engine cover.
c. Pump Test
Refer to Section 8.4.2, Adjusting Hydraulic Pressure.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Hydraulic System
8.8
8.8.1
13
11
10
3
2
5 SECTION VALVE
4 SECTION VALVE
13
12
11
10
9
6 SECTION VALVE
5 SECTION VALVE
MZ1770
5
4
3
2
6 SECTION VALVE
6
5
4
3
2
7 SECTION VALVE
1
MZ1480
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.11
Hydraulic System
9. Support the valve and remove the four bolts securing
the main control valve bracket to the frame.
10. Remove the main control valve and bracket from the
frame and remove the four bolts holding the
mounting bracket to the valve.
b. Main Control Valve Disassembly
1. To disassemble the individual sections of the main
control valve, remove the nuts and from the end of
the tie rod. Pull the tie rods out through the sections.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
IMPORTANT: DO NOT adjust any of the relief valve
assemblies! Tampering with a relief valve will irrevocably
alter pressure in the affected circuit, requiring recalibration
or a new relief valve.
VALVE SECTION
END SECTION
INLET MODULE
MZ1500
f.
Hydraulic System
4. Use new oiled o-rings as required. Uncap and
connect all hoses, clamps, etc. to the main control
valve.
5. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.
6. Connect the battery negative (-) cable to the battery
negative (-) terminal.
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
10. Close and secure the engine cover.
g. Main Control Valve Test
Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section
8.4.1, Checking Function Pressures.
8.8.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.13
Hydraulic System
6. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
moving the machine or operating any hydraulic
functions.
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
Note: Check for leaks, and repair as required before
continuing. Add hydraulic fluid to the reservoir as
needed.
8. Close and secure the engine cover.
8.8.3
8.8.5
Brake Test
8.8.4
8.14
MZ0380
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Hydraulic System
8. Remove the steer select manifold with the attached
steer select valve (2) from the machine. Wipe up any
hydraulic fluid spillage in, on, near and around the
machine.
b. Steer Select Valve and Manifold Disassembly,
Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve from the manifold by
removing the four socket head capscrews. Discard
the four o-rings.
3. Remove the solenoid valves and cartridges from the
steer select housing.
4. Clean all components with a suitable cleaner before
inspection.
5. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
6. Inspect internal passageways of the steer select
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an ultrasmooth, polished finish, or components are
damaged in any way, replace the manifold or
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
surfaces within the secondary function manifold.
8.8.6
5
MZ1760
Hydraulic System
4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
8.9
8.9.1
HYDRAULIC CYLINDERS
General Cylinder Removal
Instructions
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Hydraulic System
8.9.2
WARNING:
Significant pressure
may be trapped inside the cylinder. Exercise
caution when removing a counterbalance valve
or a pilot-operated check valve from a cylinder.
Escaping hydraulic fluid under pressure can
penetrate the skin, causing death or serious
injury.
3
4
9. Remove the piston head (4) from the rod (5) and
carefully slide the head gland (6) off the end of the
rod.
2
6
MAH0160
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
10. Remove all seals, back-up rings and o-rings (2) from
the piston head and all seals, back-up rings and orings from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
DO NOT attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
catalog for ordering information.
8.17
Hydraulic System
8.9.3
8.9.4
Cylinder Inspection
1
2
3
4
8.9.5
2
6
MAH0160
8.18
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Hydraulic System
8.9.6
8.9.7
Attach a 345 bar (5000 psi) gauge to the test port on the
main control valve to check the system pressure.
Note: If a hydraulic cylinder pressure is greater than the
main control valve pressure, increase the main control
valve pressure by adjusting the main relief. Generally,
one half turn clockwise will be adequate to check an
individual circuit. Activate the circuit and if pressure is
obtained, turn the main relief counter clockwise one half
turn. Recheck the main relief setting and adjust if
necessary.
8.9.8
Steering Cylinders
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.19
Hydraulic System
8.9.9
a. Lift Cylinder
Machine
Piston
Head
Set Screw
N/A
N/A
N/A
2550-2600 Nm
(1881-1917 lb-ft)
775-825 Nm
(571-608 lb-ft)
20-25 Nm
(15-19 lb-ft)
2490-2540 Nm
(1837-1873 lb-ft)
950-1000 Nm
(701-738 lb-ft)
20-25 Nm
(15-19 lb-ft)
2490-2540 Nm
1837-1873 lb-ft)
950-1000 Nm
(701-738 lb-ft)
20-25 Nm
(15-19 lb-ft)
2490-2540 Nm
950-1000 Nm
(701-738 lb-ft)
20-25 Nm
(15-19 lb-ft)
b. Extend/Retract Cylinder
Machine
Piston
Head
Plug
Set Screw
N/A
N/A
N/A
N/A
1290-1340 Nm
(951-988 lb-ft)
400-450 Nm
(295-332 lb-ft)
N/A
20-25 Nm
(15-19 lb-ft)
1290-1340 Nm
(951-988 lb-ft)
400-450 Nm
(295-332 lb-ft)
N/A
20-25 Nm
(15-19 lb-ft)
1070-1120 Nm
(789-826 lb-ft)
480-530 Nm
(354-391 lb-ft) (rear)
380-430 Nm
(280-317 lb-ft) (front)
50-55 Nm
(37-41 lb-ft)
20-25 Nm
(15-19 lb-ft)
1070-1120 Nm
(789-826 lb-ft)
480-530 Nm
(354-391 lb-ft) (rear)
380-430 Nm
(280-317 lb-ft) (front)
50-55 Nm
(37-41 lb-ft)
20-25 Nm
(15-19 lb-ft)
8.20
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Hydraulic System
c. Tilt Cylinder
Machine
Piston
Head
Nut
Set Screw
800 Nm
(590 lb-ft)
1200 Nm
(885 lb-ft)
130 Nm
(96 lb-ft)
N/A
2850-2900 Nm
(2102-2139 lb-ft)
775-825 Nm
(572-608 lb-ft)
N/A
20-25 Nm
(15-19 lb-ft)
Piston
Head
Nut
Set Screw
N/A
N/A
800 Nm
(590 lb-ft)
N/A
850-900 Nm
(627-664 lb-ft)
380-430 Nm
(280-317 lb-ft)
N/A
20-25 Nm
(15-19 lb-ft)
d. Compensation Cylinder
Machine
e. Sway Cylinder
Machine
Piston
Head
Plug
Nut
Set Screw
600 Nm
(443 lb-ft)
800 Nm
(590 lb-ft)
150 Nm
(111 lb-ft)
100 Nm
(74 lb-ft)
N/A
1050-1100 Nm
(774-811 lb-ft)
400-450 Nm
(295-332 lb-ft)
N/A
N/A
20-25 Nm
(15-19 lb-ft)
f.
Outrigger Cylinder
Machine
Piston
Head
Plug
Nut
700 Nm
(516 lb-ft)
1000 Nm
(737 lb-ft)
150 Nm
(111 lb-ft)
100 Nm
(74 lb-ft)
1300-1350 Nm
(959-995 lb-ft)
625-675 Nm
(461-498 lb-ft)
N/A
N/A
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.21
Hydraulic System
g. Attachment Lock
Machine
Piston
Nut
Set Screw
N/A
N/A
45 Nm
(33 lb-ft)
70-80 Nm
(52-59 lb-ft)
75-85 Nm
(55-63 lb-ft)
N/A
8.22
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Section 9
Electrical System
Contents
PARAGRAPH
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
TITLE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
PAGE
9.3
9.3
9.4
9.4
9.4
9.4
9.4
9.5
9.7
9.7
9.8
9.9
9.10
9.11
9.12
9.13
9.17
9.17
9.18
9.19
9.20
9.20
9.21
9.21
9.22
9.22
9.22
9.23
9.24
9.24
9.25
9.25
9.26
9.26
9.27
9.27
9.27
9.28
9.1
Electrical System
9.13
9.2
9.12.4
Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.5
Transmission Mounted Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.6
Engine Coolant Temperature Sender/Switch . . . . . . . . . . . . . . . . . . . . . .
9.12.7
Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.8
Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.9
Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12.10 Fuel Level Indicator and Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . .
Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.13.1
Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.28
9.29
9.29
9.30
9.30
9.31
9.32
9.33
9.33
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
9.1
ELECTRICAL COMPONENT
TERMINOLOGY
9.1.1
Joystick
Power Control
Module
Display Panel
47
Transmission
Control Lever
Heater/AC Controls
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.3
Electrical System
9.2
SPECIFICATIONS
9.4
9.3
9.4.1
Cab
SERVICE WARNING
CAUTION:
MZ1070
9.4.2
MZ0520
Engine Compartment
4
7
5
6
MZ0540
9.4
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
9.4.3
K1
K5
X1
F01
F02
F03
F04
F05
F06
F07
F08
F09
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
X21
K2
X4
X5
X2
X3
X6
X7
X8
X9
X11
X10
X12
X13
X14
X16
X17
X18
X19
X22
X23
K3
K4
K6
X15
X25
MZ1560
Fuse/Relay
Function
Amp Rating
F1
15
F2
Cab Heater
15
F3
7.5
F4
7.5
F5
7.5
F6
7.5
F7
7.5
F8
7.5
F9
15
F10
15
F11
ESX Battery
25
F12
Key Switch
30
F13
Spare
15
F14
10
F15
Ignition
15
F16
Rear Wiper
20
F17
Front Wiper
20
F18
15
F19
15
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.5
Electrical System
9.6
F20
PVG Clip
10
F21
Air Conditioning
25
F22
Radio
F23
Transmission
10
F24
7.5
X1
X2
X3
X4
X5
Cab Harness
X6
Cab Harness
X7
Cab Harness
X8
Cab Harness
X9
X10
X11
Engine Harness
X12
X13
X14
X15
Joystick Connector
X16
X17
ESX Harness
X18
ESX Harness
X19
ESX Harness
X21
X22
X23
X25
X26
K1
K2
K3
Flasher
K4
Wiper Relay
K5
K6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
FUEL
LEVEL
GAGE
COOLANT
TEMP
GAGE
AUX
POWER
SOCKET
M8 GROUND
STUDS ON
CAB FIREWALL
AIR RIDE
SEAT
(OPT)
BRAKE LTS/
DECLUTCH
PRESSURE
SWITCH
M
5 BAR
OFF
HEATER
BLOWER MOTOR
ON
1
2
G
+
-
G
+
-
1
2
1
2
1
2
3
4
1
2
3
4
5
EMPTY
58
58
116
160
GND
110
160
GND
300 (BAT)
GND
GND
GND
189
GND
54
54A
136H
GND
136M
136L
GND
EMPTY
53
53A
31B (BAT)
115
GND
M
C
H
B
CABIN
1
1
3
RESERVED
SWITCH
2
BOOM LIGHTS
SWITCH
CHASSIS SWAY
SWITCH
BEACON LIGHT
SWITCH
REAR WIPER
SWITCH
DRIVING LIGHTS
SWITCH
1
58
ALTERNATOR
INDICATOR
1
1
2
LOAD CELL
LOAD CELL
MZ1090
FLASH
0
1
2
3
0
1
2
3
TURN
SIDE
HIGH
LOW
LEFT
FRONT
DRIVING
LIGHT
KEY
SWITCH
TURN SIGNAL
AND WIPER
LEVER
HAZARD
SWITCH
LOAD MOMENT
INDICATOR
VCC
F1
F2
PWR JOYSTICK
GND
CAN H
CAN L
185
186
HI
DIMMER
WASH
L H
WIPER
DISPLAY
BAT
BAT
IGN
IGN
HEAT
HEAT
HEAT
STRT
TURN
HORN
SGN OUT
IGN
GND
R
30
L
49
30B
49A
15
58
31
1
2
3
4
5
6
7
1
2
3
4
5
6
7
30
30
15
15
19
19
17
50A
1
2
3
4
1
2
3
4
5
6
LO
1
2
3
4
R
30
L
49
49
49A
15
58
GND
71A
158
56
56B
56A
123
EMPTY
53
L
R
EMPTY
49
160
53A
30
30
15
15
19
19
19
50
GND
CAN L
CAN H
152 (PWR)
EMPTY
56BL
56AL
58LV
LV
GND
143
181
184
GND
EMPTY
10
JOYSTICK
X15
1 2 3 4 5 6
10
10
10
10
10
10
1 2 3 4 5 6 7 8 9 10
GND
145
GND
144
58
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
139
140
58
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
10
8
9
10
TO PCB
GND
CAB HARNESS
X8
GND
180
GND
182
8
10
157
157A
TRAILER?
INDICATOR
1
56
CAB HARNESS
X7
GND
135
135
58
58
156
156A
58
FLASHER
INDICATOR
1
CAB HARNESS
X6
173
GND
GND
GND
GND
HI BEAM
INDICATOR
1
160
160
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
61
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
84
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
GND
1 2 3 4
83
9.7
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
136M
136L
189
EMPTY
EMPTY
FRONT
WIPER MOTOR
1
2
3
4
5
6
7
8
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
170/171
176
176
136L
136M
136H
300
185
186
EMPTY
EMPTY
58
143
144
145
135
135
56A
83
84
61
160
58
184
180
181
182
EMPTY
110
116
PARK BRAKE
SWITCH
FNR/GEAR SHIFTER
TO PCB
1
2
3
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
159A
172
173
56
58
EMPTY
156
156A
157
157A
136
170
171
172
173
EMPTY
159A
139
140
160
EMPTY
54
54A
115
EMPTY
189
EMPTY
136L
136M
136H
53
53A
31B
56AL
56BL
58LV
LV
EMPTY
GND
160
L
R
49
EMPTY
53A
53
123
71A
158
56
56A
56B
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
56A
30
30
30
15
15
15
19
19
50
R
30
L
49
49A
15
58
EMPTY
EMPTY
136
136H
GND
CAN L
CAN H
152
1
2
3
4
X23
FNR/GEAR SHIFTER HARNESS
Electrical System
9.5.2
TO PCB
X1
PCB PWR AND GND HARNESS
M8 GROUND STUD(S)
ON CAB FIREWALL
POSITIVE CABLE
TO BATTERY +
1 2 3 4 5 6 7 8 9 10
(BRN-GND)
(BRN-GND)
(BRN-GND)
(BRN-GND)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
GND
GND
GND
GND
GND
123
110
111
EMPTY
120
112
114
118
61
113
EMPTY
50
76
90
19
EMPTY
EMPTY
159
NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -
50mm BLK
STARTER
50mm RED
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
30A
30A
30C
30B
50A
30
30B
50A
ALTERNATOR
30A
30A
113
61
B+
W G
D+
ENGINE OIL
PRESSURE
SWITCH
111
110
112
110 C
118
GND
1
2
3 BAR
76
GND
HYD FILTER
PRESSURE
SWITCH
FUEL (NON TURBO HAS SINGLE
SOLENOID CONNECTION, NO GND)
1
2
114
GND
AIR FILTER
RESTRICTION
SWITCH
120
TRANSMISSION
OIL TEMP
SWITCH
30C
501A
501A
50
7.5
501
502
30
502
503
19
GND
503
ENGINE
GLOWPLUGS
1
2
EMPTY
501
500
76
GND
GLOWPLUGS
FUSE
SLO-BLO 50A
LIFT PUMP
FUSE
ATO 7.5A
GLOWPLUGS
RELAY
87
86
85
500
GND
9.8
CLT TEMP
SENDER
COOLANT
TEMP
SWITCH
COLD START
TEMP
SWITCH
90
76
GND
STARTER
RELAY
87
86
85
50
GND
M
4 87a
3 30
5 87
1 86
2 85
LIFT
PUMP
LIFT PUMP
RELAY
123
GND
FRONT
W/WASHER
PUMP
159
GND
REAR
W/WASHER
PUMP
(OPT)
MZ1120
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
Printed Circuit Board Electrical Schematic
9.5.3
5 watt
K5
30
87a
K2
30
87a
K3
FLASHER
K4
TO JOYSTICK
X15
WIPER RLY
30
87a
K6
TO OPTIONS HARNESS
X9
30
87a
D7
R9
R8
R7
8.2K
8.2K
1.8K
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
D8
D9
R10 2.2K
GND
163
114
161
X17/5
164
118
MT
120
112
145
MT
MT
MT
MT
115
MT
146
MT
61
111
MT
MT
MT
167
169
143
144
113
166
MT
130
122
58
54A
MT
19
CAN LOW
CAN HIGH
RXD
TXD
GND
GND
GND
15
GND
30
30
30
30
30
30
174
MT
217
MT
129/176
50
216
218
MT
181
MT
MT
50
GND
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
9.9
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
R220 ohm
MZ1110
X17
TO ESX HARNESS
X18
TO ESX HARNESS
TO CAB HARNESS
X8
7.5A
X19
TO ESX HARNESS
TO CAB HARNESS
X7
10A
F24
X21
CAN DIAGNOSTIC
CONNECTOR ON PCB
TO CAB HARNESS
X6
F23
X25
RS232 DIAGNOSTIC
CONNECTOR ON PCB
X14
TO OPTIONAL
TRAILER(ING) HARNESS
25A
TO FNR SHIFTER
X23
10A
F21
F20
1 2 3 4 5 6 7 8 9 10
15A
1 2 3 4 5 6
15A
F19
1 2 3 4 5 6 7 8 9 10
20A
F18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
20A
F17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
15A
F16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
10A
F15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
15A
F14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
30A
F13
1 2 3 4
25A
F12
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
15A
F11
1 2 3 4 5 6 7 8 9 10
F10
MT
MT
163
164
MT
MT
218
MT
169
119
177
MT
135
185
186
300
MT
MT
15A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
F9
MT
MT
MT
MT
MT
MT
216
217
122
MT
7.5A
1
2
3
4
5
6
7
8
9
10
F8
179
178
126
127
129
130
128
MT
MT
MT
7.5A
1
2
3
4
5
6
7
8
9
10
7.5A
F7
MT
56BR
MT
56AR
MT
58RV
MT
RV
167
119
146
147
71A
MT
MT
MT
MT
MT
F6
GROUND
D1
30
87a
KEY (PWR) RLY
85
86
87
K1
85
86
87
7.5A
155
301
171
172
173
131
132
134
133
140
49
49a
31
C2
F4
PWR
GND
CANH
CANL
MT
MT
85
86
87
5A
F22
7.5A
F5
15A
176
176
136L
136M
136H
300
185
186
MT
MT
R6 270
143
144
145
135
135
56A
83
84
61
160
58
184
180
181
182
MT
110
116
7.5A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
123
110
111
MT
120
112
114
118
61
113
MT
50
76
90
19
19
MT
159
R3 2.2K
56
58
NM
NM
MT
156
156A
157
157A
136
170
171
172
173
MT
159A
139
140
85
86
87
+12 VDC
R4 2.2K
MT
54
54A
115
MT
189
MT
136L
136M
136H
53
53A
31B
56AL
56BL
58LV
LV
MT
15A
F3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
R2 2.2K
160
L
R
49
MT
53A
53
123
71A
158
56
56A
56B
MT
MT
MT
MT
MT
85
86
87
58LH
58RH
LH
RH
54LH
54RH
174L
174R
124
116
X26
TILT SENSOR (NOT USED)
R5 2.2K
30
30
30
15
15
15
19
19
50
R
30
L
49
49A
15
58
MT
MT
F2
MT
MT
MT
1-P7
2-P6
FW-P2
RV-P3
MT
MT
12V-P8
MT
MT
HI-P5
12V-P1
MT
MT
MT
MT
R1 2.2K
GND
CANL
CANH
152
F1
Electrical System
A/C
CLUTCH
RELAY
(OPT)
F25
IN-LINE
FUSE
(OPT)
7.5
85
86
87
30
87a
155 (IGN)
GND
171 (IGN)
GND
173
172
GND
301
140
GND
132
GND
131
GND
134
GND
133
GND
189
A/C SWITCH
(OPT)
10
1
3
5
7
9
GND
M H
189A
189
TO CAB HARNESS
189
155 (IGN)
189
191
190
189A
189A
189A
189A
GND
189A
189
189
189
189
1
2
1
2
3
1
2
3
4
1
2
3
4
5
6
7
8
1
2
A/C
TEMP
SWITCH
(OPT)
1
2
53A
31
53
31B
A/C
CHARGE
SWITCH
(OPT)
A/C
FAN
(OPT)
A/C
COMPRESSOR
CLUTCH
(OPT)
SPEAKERS
(OPT)
RADIO
(OPT)
2
4
6
8
2
4
6
8
10
1
3
5
7
9
M8 GROUND STUD(S)
ON CAB FIREWALL
ESX HARNESS
X16.1
TO FRONT CHASSIS
HARNESS
ESX HARNESS
X18
TO PCB
ESX HARNESS
X19
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
ESX HARNESS
X17
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
TO PCB
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
GND
1 2 3 4 5 6 7 8 9 10
GND
15
GND
30
30
30
30
30
30
174
EMPTY
217
EMPTY
129 &176
50
216
218
EMPTY
181
EMPTY
EMPTY
50
GND
GND
EMPTY
EMPTY
167
169
143
144
113
166
EMPTY
130
122
58
54A
EMPTY
19
CAN LOW
CAN HIGH
RXD
TXD
GND
GND
GND
GND
201
200
202
203
204
205
206
207
208
EMPTY
191
GND
163
114
161
X17/5
164
118
EMPTY
120
112
145
EMPTY
EMPTY
EMPTY
EMPTY
115
EMPTY
146
EMPTY
61
111
EMPTY
191
189
190
155
301
171
172
173
131
132
134
133
140
GND
GND
GND
GND
207
218
200
208
30
30
30
30
30
GND
30
EMPTY
EMPTY
EMPTY
EMPTY
204
203
202
201
EMPTY
206
217
176
54A
111
143
167
145
122
129
113
EMPTY
114
181
118
120
15
CAN HIGH
CAN LOW
50
216
163
19
205
58
146
61
EMPTY
115
169
144
130
166
EMPTY
EMPTY
161
164
X17/5
112
TXD
RXD
174
EMPTY
GND
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
MZ1100
AI/2
D+
+WIRE1
-WIRE1
DO(2.5A)/3
DO(2.5A)/1
8.5VEXT
BB1/6
BB1/4
BB1/2
DI/16
DI/14
DI/12
DI/10
DI/8
DI/6
DI/4
DI/2
BB2/2
BB2/6
AI/7
AI/5
AI/3
AI/1
TXD
RXD
DO(2.5A)/4
DO(2.5A)/2
AGND
XGND2
XGND2
XGND1
XGND1
DO/5
DO(4A)/3
DO(4A)/2
DO(4A)/1
Ub
Ub
Ub
Ub
Ub
GND
Ue
+WIRE2
BB2/5
BB2/4
BB2/3
DO/4
DO/3
DO/2
DO/1
BB2/1
BB1/5
BB1/3
BB1/1
DI/15
DI/13
DI/11
DI/9
DI/7
DI/5
DI/3
DI/1
-WIRE2
AI/8
AI/6
AI/4
ESX CONTROLLER
GND
GND
GND
GND
RT O/R VLV (SAUER)
AUX HYD SELECT
PVG VLV PWR (SAUER)
LT O/R VLV (SAUER)
12V
12V
12V
12V
12V
GND
12V
(UNUSED)
(UNUSED)
(UNUSED)
(UNUSED)
AUX HYD VLV (SAUER)
TILT VLV (SAUER)
TELE VLV (SAUER)
LIFT VLV (SAUER)
(UNUSED)
SWAY LEFT VLV (DO)
AW STEER VLV (DO)
FWD/REV PWR (DO)
DCLUTCH PSI SW
ENG OIL PSI SW
(4 SECT TELE SW)
FRT AXLE PROX
SWAY LT SW
HYD PSI SW
NEUTRAL SW
ALT W SPEED (RPM)
(UNUSED)
AIR FILTER SW
LOAD MOMENT SW
HYD FILT PSI SW
TRANS TEMP SW
12V IGNITION
1. CAN HIGH
1. CAN LOW
STRT INTLK RLY
CRAB STEER VLV
8.5 V EXT SUPPLY
ENG PREHEAT SW (DI)
SWAY RIGHT VLV (DO)
(PARK LIGHT SW) (DI)
(O/R PSI)
ALT D+ CHARGE
(UNUSED)
PARK BRAKE SW
REAR AXLE PROX
SWAY RT SW
REVERSE SW
TURBINE SNSR (RPM)
(UNUSED)
(UNUSED)
(TILT SENSOR)
BOOM ANG SNSR
TRANS GEAR SEL
ENG TEMP SW
RS232 TX
RS232 RX
BACKUP LTS
(UNUSED)
ANALOG GND
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.10
189A
Electrical System
Front & Rear Chassis Harness Electrical Schematic
9.5.5
LICENSE
LIGHT
REVERSE
ALARM
FUEL
SNDR
TO PCB
X13
REAR CHASSIS HARNESS
M8 GROUND STUD(S)
ON CAB FIREWALL
TO ESX HARNESS
X16.1
FRONT CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10
TO PCB
X22
FRONT CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10
TO PCB
X16
FRONT CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10
TO PCB
X10
FRONT CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
TRANSMISSION
TURB
SPEED
SENSOR
178
179
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
128
GND
1 2 3 4 5 6 7 8 9 10
177
218
300
GND
GND
GND
LT O/R
130
GND
TO PCB
X12
REAR CHASSIS HARNESS
1
2
3
4
5
6
RT O/R
129
GND
STOP
EMPTY
218
300
GND
EMPTY
GND
SWAY
127
GND
TURN
EMPTY
135
GND
GND
BACK
1
2
3
4
5
1
2
AUX
126
GND
EMPTY
EMPTY
163
164
EMPTY
EMPTY
218
EMPTY
169
119
177
EMPTY
135
185
186
300
EMPTY
EMPTY
POSITIVE CABLE
TO STARTER SOLENOID
TILT
200 (PWR)
208 (SGN)
GND
58LH
58RH
LH
RH
54LH
54RH
174L
174R
124
116
NEGATIVE CABLE
TO STARTER (BODY)
TELE
200 (PWR)
207 (SGN)
GND
1 2
EMPTY
116
GND
1
2
3
(GRN)
LIFT
205 (RIGHT)
206 (LEFT)
GND
201
200
202
203
204
205
206
207
208
EMPTY
200 (PWR)
204 (SGN)
GND
179
178
126
127
129
130
128
EMPTY
EMPTY
EMPTY
200 (PWR)
203 (SGN)
GND
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
216
217
122
EMPTY
200 (PWR)
202 (SGN)
GND
EMPTY
56BR
EMPTY
56AR
EMPTY
58RV
EMPTY
RV
167
119
146
147
71A
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
200 (PWR)
201 (SGN)
GND
STOP
1 2 3 4 5 6 7
GND
163
164
119
EMPTY
GND
169
185
186
135
GND
135
GND
BATTERY DISCONNECT
SWITCH (OPT)
GND
CHASSIS GROUND
GND
TURN
124
GND
BACK
1 2 3 4 5 6 7
1
2
3
1
2
3
4
1
2
12 VDC
BATTERY
58LH
BOOM
ANGLE
SENSOR
2ND AUX
HYD CONN
SEL VLV
ON BOOM
(OPT)
REAR
AXLE
PROXIMITY
SWITCH
REAR
AXLE
LOAD
CELL
BOOM
LIGHTS
(OPT)
GND
58RH
174R
RH
54RH
EMPTY
EMPTY
EMPTY
56BR
56AR
58RV
RV
GND
71A
GND
217
GND
216
GND
122
GND
119
EMPTY
GND
167
1
2
3
4
5
6
1
2
1
2
1
2
1
2
3
4
146
147
GND
GND
EMPTY
HORN
CHASSIS
FRAME
FRONT
AXLE
PROXIMITY
SWITCH
HYDRAULIC
PRESSURE
SWITCH
ALL WHEEL
STEER
MODE
VALVE
CRAB
MZ1130
RIGHT
FRONT
DRIVING
LIGHT
TO
LEFT & RIGHT
OUTRIGGER
PRESSURE
SWITCH HARNESS
CONNECTOR
(NOT USED)
10 BAR
1
2
3
4
5
LOW
HIGH
SIDE
TURN
9.11
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
GND
58LH
174L
LH
54LH
EMPTY
EMPTY
X122
X121
H112
H104
X100
X101
25
25
11
11
26
26
11
X122
X121
87a
25
85
10
H100 H103
H105 H102
X124
X123
P100
H101
H100
ON
BASKET MODE
READY
X122
K115
P012 3
BASKET KEY
SWITCH
S101
2
STOP
H103
H100
H102
H105
H108
S103
H116
H104
S101
H106
S104
H107
H108
H101
H106
X123
DASHBOARD
P100
X124
30
58 15
50a
S100
19 17
10
10
10
X123
1
H101
X121
34
33
GRD
7
8
10
X121
X121
X121
WIRE
35
X122
32
13
GRD
CONN. PIN
X121
4
2
3
X121
X121
X121
X121
WIRE
12
CONN. PIN
7
8
X123
X123
X123
X123
X123
X123
X123
X123
CONN. PIN
21
21
21
GRD
WIRE
X124
X124
X124
X124
CONN. PIN
A101
87
H107
42
30 BASKET MODE
READY LAMP
RELAY
3mm^ 2
33
43
INSTRUMENTS CONNECTORS
X102
24
3.0 mm^ 2
3.0 mm^ 2
3mm^ 2
GRD
21
WIRE
21
21
21
H102
ERS MODE
LAMP
X121
32
31
FOOT
SWITCH
32
PREHEAT
LAMP
S102
D100
15
14
14
15
16
16
15
14
UP
16
CELL #4
CELL #3
NC
NO
NC
K100
D104
17
J8
A+
TOP VIEW
X137
17
X104
17
87a
87
30
RR
85
86
11
11
A#2
RL
CELL #2
A100
J6
X136
12
LSS MODULE
12
A-
K101
LSS POWER
RELAY
CELL #1
J7
J2 BLACK
2
A#3
BOTTOM VIEW
S103
ERS JOYSTICK
OUT
DOWN
NO
85
NO
IN
87
30
86
NC
NO
H103
NC
87a
FOOT SWITCH
LAMP
10
X122
D101
30
34
FOOTSWITCH LAMP -BK 7
LIFT DN ERS -BK 18
40
37
41
OPERATE
38
EMERGENCY
STOP
3.0 mm^ 2
39
FR
2
-
J5
J1 GREY
FL
6
DO2
6
5
DO1
H104
OVERLOAD
LAMP
X121
D102
12
12
12
WARNING
BUZZER
38
E100
D103
13
13
13
WAIT
LAMP
85
H112
FAULT
LAMP
H105
87
30
X122
35
X121
87a
86
K116
WAIT LAMP
RELAY
18
18
18
FUEL
GAUGE
P100
X123
X123
4
H106
ENGINE OIL
LAMP
X124
X124
X123
F100 (15A)
H108
BATTERY
CHARGE
LAMP
H107
WATER
TEMPERATURE
LAMP
86
ON
HORN
OFF
22
22
23
21
23
S104
HORN SWITCH
23
BASKET CAN LO
-BK-0.8 mm
21
22
24
24
WH
20
19
X122
20
CAN L
CAN H
GND
PWR
F2
F1
VCC
19
X121
BR
BL
BK
X138
BASKET CAN HI
-RD-0.8 mm
9.12
19
20
A101
JOYSTICK
ITT AJ3
9.5.6
58
15
19/17
50a
Electrical System
Basket Dash Board Box -Platform Machines Only
MZ1810
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
HORN -BK 5
X113
X102
X116
26
X103
25
X116
85
87
25
24
87a
27
X19-1
1
3
5
7
9
11
13
15
17
19
21
2
4
6
8
10
12
14
16
18
20
22
X119
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
18
24
X19
K103
BASKET
KEY PW
RELAY
ESX READY
3.0 mm^ 2
30
36
3.0 mm^ 2
3.0 mm^ 2
3.0 mm^ 2
21
11
1
2
3
4
14
X05-1
24 12
1
2
3
4
22
X05
37
60
37
A01 PIN 28 see sch. 003
86
X119
A1
A2
71
2
4
6
8
10
12
14
16
18
1
3
5
7
9
11
13
15
17
X06
K114
26
STARTER
LOCK
RELAY
31
30
29
3.0 mm^ 2
2
4
6
8
10
12
14
16
18
X11
1
3
5
7
9
11
13
15
17
30
2
4
6
8
10
12
14
16
18
1
3
5
7
9
11
13
15
17
X06-1
21
24 12
1
3
5
7
9
11
13
15
17
S01
30
58 15
2
4
6
8
10
12
14
16
18
X11-1
P012 3
Wire X06/4
originally
connected to
S01/6 (15)
moved to S01/10
(58)
27
22
19 17
A1
A2
11
14
21
59
27
29
50a
X114
K102
ESX/DISPLAY
IGNITION
RELAY
10
10
10
21
21
21
X106
A2 14
A1
11
12
24
22
21
X119
K104
CABIN
IGNITION
RELAY
X120
D105.1
X119
X120
D105.2
S109
STOP
OPERATE
CABIN EMERGENCY
STOP SWITCH
47
3.0 mm^ 2
39
X120
11
A2 14
A1
12
24
44
D105.9
X134
K105-1
BASKET
IGNITION
RELAY 1
H109
BASKET MODE
READY LED
10
22
21
X114
11
11
11
24
12
A1
11
A2 14
X120
2
4
6
8
10
12
14
16
18
22
21
X119
1
3
5
7
9
11
13
15
17
X03
K105-2
BASKET
IGNITION
RELAY 2
X120
D105.3
40
D105.8
F101 (15A)
11
A214
A1
48
24
2
4
6
8
10
12
14
16
18
X03-1
12
1
3
5
7
9
11
13
15
17
22
21
X107
X105
K106
FUEL
LEVEL
RELAY
41
P2 FUEL INDICATOR SIGNAL
3.0 mm^ 2
LEFT
STABILIZER
PROXIMITY
SENSOR
PNP
11
B100
X117
X103
42
BR BL BK
A1
A2 14
24
18
12
X108
K107
S108
34
22
45
1
RIGHT
STABILIZER
PROXIMITY
SENSOR
11
14
X118
A2
A1
B101
BR BL BK
PNP
LEFT
STABILIZER
RELAY
43
21
LEFT
STABILIZER
PRESSURE
SWITCH
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
xx bar
24
21
K108
10
S109
1
B+
B3
BK GN
RIGHT
STABILIZER
RELAY
X109
35
22
RIGHT
STABILIZER
PRESSURE
SWITCH
12
WH
32
2
LOAD
21
30
29
27
TO SCHEME 003
B102
9.5.7
xx bar
Electrical System
MZ1820
9.13
38
GND
GND
GND
GND
RT O/R VLV (SAUER)
AUX HYD SELECT
PVG VLV PWR (SAUER)
LT O/R VLV (SAUER)
12V
12V
12V
12V
12V
GND
12V
BASKET CAN +*
STB PRESS. SW
BASKET FAULTS* (DO)
FOOTSW LAMP* (DO)
AUX HYD VLV (SAUER)
TILT VLV (SAUER)
TELE VLV (SAUER)
LIFT VLV (SAUER)
ESX READY
SWAY LEFT VLV (DO)
AW STEER VLV (DO)
FWD/REV PWR (DO)
DCLUTCH PSI SW
ENG OIL PSI SW
FOOTSWITCH SGN*
FRT AXLE PROX
SWAY LT SW
HYD PSI SW
NEUTRAL SW
ALT W SPEED (RPM)
BASKET CAN -*
AIR FILTER SW
LOAD MOMENT SW
HYD FILT PSI SW
TRANS TEMP SW
12V IGNITION
1. CAN HIGH
1. CAN LOW
STRT INTLK RLY
CRAB STEER VLV
8.5 V EXT SUPPLY
ENG PREHEAT SW (DI)
SWAY RIGHT VLV (DO)
(UNUSED)
LSS SIGNAL*
ALT D+ CHARGE
BASKET CONNECTED*
PARK BRAKE SW
REAR AXLE PROX
SWAY RT SW
REVERSE SW
TURBINE SNSR (RPM)
(UNUSED)
BOOM EXT (DI) (AUST)
BASKET/CAB MODE*
BOOM ANG SNSR
TRANS GEAR SEL
ENG TEMP SW
RS232 TX
RS232 RX
BACKUP LTS
DUMP VALVE*
ANALOG GND
XGND2
XGND2
XGND1
XGND1
DO/5
DO(4A)/3
DO(4A)/2
DO(4A)/1
Ub
Ub
Ub
Ub
Ub
GND
Ue
+WIRE2
BB2/5
BB2/4
BB2/3
DO/4
DO/3
DO/2
DO/1
BB2/1
BB1/5
BB1/3
BB1/1
DI/15
DI/13
DI/11
DI/9
DI/7
DI/5
DI/3
DI/1
-WIRE2
AI/8
AI/6
AI/4
AI/2
D+
+WIRE1
-WIRE1
DO(2.5A)/3
DO(2.5A)/1
8.5VEXT
BB1/6
BB1/4
BB1/2
DI/16
DI/14
DI/12
DI/10
DI/8
DI/6
DI/4
DI/2
BB2/2
BB2/6
AI/7
AI/5
AI/3
AI/1
TXD
RXD
DO(2.5A)/4
DO(2.5A)/2
AGND
A01
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
21
1
X102
X114
X103
2
4
6
8
10
12
14
16
18
X07
A1
A2
1
3
5
7
9
11
13
15
17
49
14
12
24
22
21
2
4
6
8
10
12
14
16
18
X07-1
1
3
5
7
9
11
13
15
17
K109
HORN
RELAY
50
11
4
X114
6
BAT CHARGE LAMP -BK 6
5
WATER TEMP LAMP -BK 5
30
2
4
6
8
10
12
14
16
18
20
22
1
3
5
7
9
11
13
15
17
19
21
X17
X120
X120
4
D105.5
X119
D105.4
X119
51
29
X120
D105.6
X119
2
4
6
8
10
12
14
16
18
20
22
X17-1
X125
R100.1
X112
1
1
3
5
7
9
11
13
15
17
19
21
2.2K
55
27
53
52
X125
R100.2
X112
58
54
A01 PIN 19
2.2K
A01 PIN 9
9.14
A1
A2
11
14
ESX CONTROLLER
12
24
22
21
K110
BASKET
MODE
RELAY
11
A2 14
A1
24
12
22
21
21
30
29
27
TO SCHEME 004
K111
CABIN MODE
RELAY
Electrical System
MZ1830
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
A01 PIN 23
HORN -BK 1
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.15
MZ1840
X110
ESX CASE
21
30
29
27
X103
SEE SCHEME 002-C8
9
35
X102
X114
X110
18
18
SEE SCHEME 002-B2 & C7
18
X114
1
3
4
X139
B100
26 27
22
1 2 3
BR BL BK
PNP
X114
(AUSTRALIA ONLY)
BOOM
EXTENSION
PROXIMITY
SWITCH
BASKET GROUND
X110
10
1
3
5
7
9
11
13
15
17
19
21
X18
2
4
6
8
10
12
14
16
18
20
22
2
4
6
8
10
12
14
16
18
20
22
X18-1
1
3
5
7
9
11
13
15
17
19
21
X114
3
X110
2
X115
24
BASKET CAN HI
-RD-0.8 mm
22
23
22
22
23
23
X110
BASKET CAN LO
-GR-0.8 mm
X110
X114
13
13
13
X110
6
X114
19
X110
19
19
X110
33
33
TO SCHEME 005
21
33
27
30
29
Electrical System
X102
X114
X103
17
17
17
16
16
16
15
15
15
33
30
14
14
14
12
12
12
X120
D105.7
X119
20
20
20
Y100 B
P->A
X130
ERS LIFT UP
VENTIL
Y100 A
P->B
1.5 mm^ 2
X129
F102 (10A)
56
33
57
Y101 B
P->A
X131
X111
10
Y101 A
P->B
ERS TELESCOPE IN
VENTIL
X132
X128
X135
X135
H110
OVERLOAD
LED
30
8
12
E101
BUZZER
WARNING
33
X126
X127
57
5
D106.1
D106.2
D106.3
D106.4
K112
X135
X135
ERS
ENABLING
LED
H111
10
ERS ENABLING
SWITCH
S105
ON
OFF
S106
H113
UP
DOWN
ERS LIGHTED
SWITCH LIFT
M100
X127
ERS ELECTRIC
PUMP
56
21
61
17
16
15
14
67
15
68
16
69
17
70
D106.7
D106.10
D106.8
D106.9
S107
H114
IN
OUT
D106.12
D106.11
BATTERY
D106.5
D106.6
64
6
ERS LIGHTED
SWITCH TELESCOPE
62
35 mm^ 2
X126
85
RELAY
ENABLING
ERS PUMP
K113
30
87 87a
86
57
66
X133
33
29
Y102
DUMP VALVE
VENTIL
X141
30
PRESSURE LIMITING
VALVE
(POWER FOR MAX PRESSURE)
1.5 mm^ 2
Y103
(AUSTRALIAN ONLY)
X140
X142
1.5 mm^ 2
1.5 mm^ 2
27
35 mm^ 2
35 mm^ 2
63
12
14
9.16
+
Electrical System
MZ1850
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
65
Electrical System
9.6
CIRCUIT BREAKDOWNS
9.6.1
CAB HARNESS
KEY SWITCH
CAB HARNESS
HAZARD SWITCH
R 30 L 49 30B49A 15 58 31
LOAD MOMENT SW
HYD FILT PSI SW
TRANS TEMP SW
12V IGNITION
1. CAN HIGH
1. CAN LOW
STRT INTLK RLY
CRAB STEER VLV
8.5 V EXT SUPPLY
ENG PREHEAT SW (DI)
SWAY RIGHT VLV (DO)
(PARK LIGHT SW) (DI)
(O/R PSI)
ALT D+ CHARGE
(UNUSED)
PARK BRAKE SW
REAR AXLE PROX
SWAY RT SW
REVERSE SW
TURBINE SNSR (RPM)
(UNUSED)
(UNUSED)
(TILT SENSOR)
BOOM ANG SNSR
TRANS GEAR SEL
ENG TEMP SW
RS232 TX
RS232 RX
BACKUP LTS
(UNUSED)
ANALOG GND
AI/2
D+
+WIRE1
-WIRE1
DO(2.5A)/3
DO(2.5A)/1
8.5VEXT
BB1/6
BB1/4
BB1/2
DI/16
DI/14
DI/12
DI/10
DI/8
DI/6
DI/4
DI/2
BB2/2
BB2/6
AI/7
AI/5
AI/3
AI/1
TXD
RXD
DO(2.5A)/4
DO(2.5A)/2
AGND
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
NM
30
30
30
30
30
30
X19
TO PCB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
3030 30
30
NM
30
30
30
30
30
30
WIPER
L H
PCB
X8 TO CAB HARNESS
MT
TURN
158
X19
TO ESX HARNESS
K4
K4
XGND2
XGND2
XGND1
XGND1
DO/5
DO(4A)/3
DO(4A)/2
DO(4A)/1
Ub
Ub
Ub
Ub
Ub
GND
Ue
+WIRE2
BB2/5
BB2/4
BB2/3
DO/4
DO/3
DO/2
DO/1
BB2/1
BB1/5
BB1/3
BB1/1
DI/15
DI/13
DI/11
DI/9
DI/7
DI/5
DI/3
DI/1
-WIRE2
AI/8
AI/6
AI/4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X7 TO CAB HARNESS
K5
+12 VDC
87a
30
87
86
85
85
86
87
GND
GND
GND
GND
RT O/R VLV (SAUER)
AUX HYD SELECT
PVG VLV PWR (SAUER)
LT O/R VLV (SAUER)
12V
12V
12V
12V
12V
GND
12V
(UNUSED)
(UNUSED)
(UNUSED)
(UNUSED)
AUX HYD VLV (SAUER)
TILT VLV (SAUER)
TELE VLV (SAUER)
LIFT VLV (SAUER)
(UNUSED)
SWAY LEFT VLV (DO)
AW STEER VLV (DO)
FWD/REV PWR (DO)
DCLUTCH PSI SW
ENG OIL PSI SW
(4 SECT TELE SW)
FRT AXLE PROX
SWAY LT SW
HYD PSI SW
NEUTRAL SW
ALT W SPEED (RPM)
(UNUSED)
AIR FILTER SW
X6 TO CAB HARNESS
TO PCB
30
87a
ESX CONTROLLER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X7
TO PCB
TO PCB X6
87a
30
87
86
85
87a
30
87
86
301
X1 TO BATTERY
X9
1 2 3 4 5 6 7 8 9 10
X1
TO PCB
NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -
50mm BLK
300 (BAT)
1 2 3
1 2
AUX
POWER
SOCKET
30
STARTER
RELAY
ALTERNATOR
B+
W G
D+
30C
501A
50
7.5
501
502
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
1 2 3 4 5 6 7 8 9 10
X4 TO PCB
1 2 3 4 5 6
30A
30A
X13 TO PCB
87
86
85
501
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18
X4
300
301
30B
502
300
X13
1 2 3 4 5
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
30A
30A
30C
30B
50A
501A
X9 TO PCB
300
STARTER
50mm RED
TO OPTIONS HARNESS
1 2 3 4 5 6 7 8 9 10
POSITIVE CABLE
TO BATTERY +
K1 85
300
WIPER
WIPERRLY
RLY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
ESX HARNESS
EMPTY
30 30 30
TO PCB
CAB HARNESS
158
30
58
X2
1 2 3 4 5 6 7
10
FLASH
30 30 15 15 19 19 17 50A
WASH
HORN
BAT
LO
BAT
HI
DIMMER
0
1
2
3
0
1
2
3
30
87
86
85
4 87a
3 30
5 87
1 86
2 85
GLOWPLUGS
FUSE
SLO-BLO 50A
LIFT PUMP
FUSE
ATO 7.5A
GLOWPLUGS
RELAY
LIFT PUMP
RELAY
MZ1300
9.17
Electrical System
Start Circuit
CAB HARNESS
0
1
2
3
STRT
HEAT
0
1
2
3
KEY SWITCH
IGN
129
IGN
NEUTRAL SW
176
HEAT
DI/3
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
BAT
ESX HARNESS
68
67
HEAT
ESX CONTROLLER
BAT
9.6.2
30 30 15 15 19 19 17 50A
FNR/GEAR SHIFTER
R
176
176
50
30 30 30
50
50
X6
85
86
87
176
TO CAB HARNESS
F12
8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
30 30 30
176
30A
1
2
3
4
5
6
7
8
9
TO FNR SHIFTER
X23
10
11
12
13
14
15
16
17
18
K2
12V-P1
30
87a
+12 VDC
50
TO ENGINE HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
X4 TO PCB
X6
TO PCB
X19
1
2
3
4
1
2
3
4
TO PCB
X11
TO PCB
X23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8 9 10
PCB PWR AND GND HARNESS
TO PCB X11
X1 TO PCB
ENGINE HARNESS
POSITIVE CABLE
TO BATTERY +
(RED-PWR)
50
NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -
TO CAB ASSEMBLY
50mm BLK
50mm RED
STARTER
(RED-PWR)
30A
30A
30B
50A
30B
50A
50
GND
30A
30A
30
STARTER
87
86
85
RELAY
ALTERNATOR
B+
W G
D+
MZ1290
9.18
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
9.6.3
Charging Circuit
18
61
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
TO ESX HARNESS
X17
61
PCB
ESX CONTROLLER
113
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
ALTERNATOR
INDICATOR
X18
113
TO ESX HARNESS
61
61
113
PCB
X11
TO ENGINE HARNESS
X3
TO INST PANEL HARNESS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
160
61
TO BATTERY
X3
INST PANEL HARNESS
DASH PANEL
1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
ENGINE HARNESS
TO PCB
X11
ENGINE HARNESS
61
113
POSITIVE CABLE
TO BATTERY +
NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -
50mm BLK
50mm RED
STARTER
M
30A
30A
30A
30A
113
61
ALTERNATOR
B+
W G
D+
MZ1280
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.19
Electrical System
9.7
9.7.1
Starter
The starter (1) is located on the left side of the engine (the
right side of the machine).
MZ0150
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
f.
Starter Installation
9.8
CHARGING CIRCUIT
9.8.1
Alternator
a. Alternator Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
5. Loosen both alternator (2) mounting bolts and pivot
alternator in.
6. With the fan belt now being loose, remove the belt
from the engine.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.21
Electrical System
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 tighten completely at this time.
9.9.2
The LMI sensor (3) is bolted on the top right of the rear
axle.
3
9.9
9.9.1
ELECTRICAL SYSTEM
COMPONENTS
Load Moment Indicator
All five LEDs will light (three green, yellow & red)
and the warning buzzer sounds as the machine
reaches its forward stability limitations.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
4. Leave the machine undisturbed for a minimum of 2
hours before moving. DO NOT lift any load for a
minimum of 12 hours.
5. The transducer and area around it can be painted 2
hours after installation.
6. Plug the electrical connector into the sensor
assembly.
7. Connect the battery negative (-) cable to the battery
negative (-) terminal.
8. Close and secure the engine cover.
c. Load Moment Sensor Calibration
Calibration of the load moment sensor requires the
setting up of two reference points. 0% and 100% SWL.
During calibration the machine must be level, brakes off,
steering straight ahead and ignition turned on. Access to
the calibration mode requires the use of the magnetic
"key".
Acquiring the calibration mode
For the first calibration at installation:
When first installed and powered up, the display will show
error condition number 4 (red LED and 3rd green LED),
indicating that calibration is required. PRESS and hold
the TEST button, and place the magnet in position level
with and just to the right of the TEST button. The correct
position is indicated when the sounder stops and all LEDs
stay on. KEEP HOLDING THE TEST BUTTON AND
MAGNET IN PLACE until the display changes again to
show the red LED only. This indicates that the system is
now in calibrating mode, and waiting for the first
reference point.
RELEASE the TEST button and remove the magnet. The
display will emit short intermittent beeps to remind the
operator that calibration is in progress.
Note: If either the button or magnet is released too early
the display will revert to the uncalibrated condition
number 4.
9.9.3
Back-up Alarm
a. Disassembly
DO NOT disassemble the back-up alarm. Replace a
defective or faulty alarm with a new part.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.23
Electrical System
b. Inspection and Replacement
Inspect the wiring harness connector and alarm terminals
for continuity and shorting. Test the alarm by turning the
ignition key switch to the RUN position and shifting the
transmission control lever into the REVERSE position.
The alarm should sound.
9.10
9.10.1
WINDOW WIPER/WASHER
a. Removal
Note: It may be necessary to remove several hydraulic
hoses from under the dash in order to remove and install
the wiper motor housing.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
5. Remove the lower dash panel.
6. Disconnect the right side defroster hose from dash
panel hose connector.
IMPORTANT: DO NOT start the engine with the hoses
not connected to their proper fittings.
7. Disconnect the cab harness connectors from the
wiper motor.
MAH0910
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
9.10.2
a. Removal
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom,
place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel, stating that the
machine should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Disconnect the battery negative (-) cable at the
battery negative (-) terminal.
5. Remove the wiper arm from the wiper motor (5)
shaft.
9.10.3
7. From inside the cab, pull the wiper motor away from
the rear window.
b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.
c. Installation and Testing
1. Hold wiper motor up toward cab rear window and
install the cab harness connectors. Refit the
headliner.
2. With the help of an assistant, insert the wiper motor
through the roof hole and have the assistant thread
the hex nuts onto the wiper motor shaft and the
wiper motor. Insure that the motor housing is facing
the front of the cab.
MZ0190
MAH0920
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.25
Electrical System
b. Disassembly
DO NOT disassemble the pumps. The pump is not
serviceable. Replace pumps if found to be defective.
c. Cleaning and Drying
Without submerging the pumps, clean the pumps and
reservoir with an approved solvent and dry with a clean,
lint-free cloth.
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.
c. Installation and Testing
1. Check that the variable speed fan control is in the
OFF position.
9.11
9.11.1
9.26
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
9.12
9.12.1
MZ0200
9.12.2
MZ0450
9.27
Electrical System
c. Main Control Valve Solenoid Installation
9.12.4
9.12.3
MZ0650
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
9.12.5
9.12.6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.29
Electrical System
9.12.7
9.12.8
11
9.30
MZ1320
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
c. Boom Angle Sensor Installation
1. Install the sensor assembly to the sensor seat and
tighten both bolts.
2. Install the rod end to the sensor arm and tighten nut.
If the upper value is outside the range of 550850, a value of 800 is taken over.
5. If either the lower value (100) or the upper value
(800) is shown, the boom angle rod may need
adjusted.
9.12.9
Software-version
Learning
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.31
Electrical System
c. Inspection and Replacement
OFF
RUN
START
Wire #15
Wire #50
9.12.10
9.32
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Electrical System
9.13
9.13.1
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
9.33
Electrical System
9.34
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
JLG EQS
Z.I. De Beaulieu
47400 Fuillet
France
Phone: (33) 553 848 584
Fax: (33) 553 848 588
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: (48) 914 320 245
Fax: (48) 914 358 200
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal, Barcelona
Spain
Phone: (34) 937 724 700
Fax: (34) 937 711 762