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JLG 3507, 3509, 3508, 4008, 4007 Service Manual

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Page 1
Service Manual
Models 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009,
4012, 4013
P/N - 3121852
Revised
April 20, 2007
Courtesy of Crane.Market
Page 2
Page 3
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 a
Page 4
EFFECTIVITY PAGE
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013-b
Page 5
SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Section 3
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.4 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.5 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
2004 JLG Industries, Inc.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
i
Page 6
Section Subject Page
Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7
Section 7
Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4
8.5 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.8 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.9 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3 Service Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
9.9 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.10 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.11 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.12 Switches, Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.13 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
ii
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 7
Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
1.1
Page 8
Safety Practices
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 reliability.
Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local JLG distributor.
Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.
Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.
All references to
1.2 DISCLAIMER
All information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.
1.3 OPERATION & SAFETY MANUAL
The mechanic must not operate the machine until the Operation & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.
An Operation & Safety Manual is supplied with each machine and must be kept in the cab. In the event that the Operation & Safety Manual is missing, consult the local
JLG distributor before proceeding.
1.4 DO NOT OPERATE TAGS
Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.
1.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 9
Safety Practices
1.5 SAFETY INFORMATION
To avoid possible death or injury, carefully read, understand and comply with all safety messages.
In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.
1.5.1 Safety Alert System and Signal Words
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.
1.6 SAFETY INSTRUCTIONS
Following are general safety statements to consider performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs.
For all safety messages, carefully read, understand and follow the instructions
before
proceeding.
1.6.1 Personal Hazards
PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.
LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.
1.6.2 Equipment Hazards
LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.
NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.
DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.
before
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
1.3
Page 10
Safety Practices
1.6.3 General Hazards
SOLVENTS: Only use approved solvents that are known to be safe for use.
HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).
FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.
CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.
When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.
Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.
1.6.4 Operational Hazards
ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.
VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.
SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.
FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.
FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.
Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an
appropriate container and dispose of in accordance with prevailing environmental regulations.
RADIATOR CAP: Always wear steam-resistant, heat protective gloves when opening the radiator cap. Cover the cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure.
FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.
NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.
PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.
LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.
TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.
NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.
MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.
BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.
1.7 SAFETY DECALS
Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.
1.4
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 11
Section 2
General Information and Specifications
Contents
PARAGRAPH TITLE PAGE
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.1 ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.2 ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.3 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2.6
2.3.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.4 Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.3.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6.1 8 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6.2 50 Hour Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.1
Page 12
General Information and Specifications
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 required to help assure the provision of correct parts and information. Before ordering parts or initiating service inquiries, make note of the serial number located on the serial number plate (1).
MZ1780
1
IMPORTANT: The replacement of any part on this machine with any other than a JLG authorized replacement part can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.
A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.
Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.
2.2
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 13
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS &
GRADE 2 NUTS
TENSILE
PER
BOLT
DIA.
STRESS
AREA
THDS.
SIZE
INCH
IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB
40
4
6
8
10
1/4
0.1120
48 0.00661 420 9 7 — — 600 13 10 — — — — — 32
0.1380
40 0.01015 610 18 13 — — 920 25 19 — — — — — 32
0.1640
36 0.01474 940 31 23 — — 1320 43 32 — — — — — 24
0.1900
32 0.02000 1285 49 36 — — 1800 68 51 — — — — — 20
0.2500
28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178
0.00604 380 8 6 — — 540 12 9 — — — — —
0.00909 580 16 12 — — 820 23 17 — — — — —
0.01400 900 30 22 — — 1260 41 31 — — — — —
0.01750 1120 43 32 — — 1580 60 45 — — — — —
0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168
IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
18
0.3125
24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30 16
0.3750
24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55 14
0.4375
20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82 13
0.5000
20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127 12
0.5625
18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182 11
0.6250
18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242 10
0.7500
16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440
9
0.8750
14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700
8
1.0000
12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000
7
1.1250
12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520
7
1.2500
12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070
6
1.3750
12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685
6
1.5000
12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600
0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28
0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50
0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77
0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120
0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170
0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231
0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400
0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645
0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950
0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365
0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925
1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550
1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345
Note: These torque values do not apply to cadmium plated fasteners.
CLAMP
LOAD
DRY OR
LOCTITE
263
TORQUE
LUB
LOCTITE
262
LOCTITE
242 OR
271
SAE GRADE 8 BOLTS & GRADE 8 NUTS
& SOCKET HEAD CAP SCREWS
TORQUE
CLAMP
LOAD
DRY OR
LOCTITE
263
LUB
LOCTITE
262
LOCTITE
242 OR
271
UNBRAKO 1960 SERIES
SOCKET HEAD
TORQUE
CLAMP
LOAD
WITHOUT LOC-WEL
PATCH
WITH
LOC-WEL
PATCH
2.2.1 ASTM Fastener Torque Chart (English)
2.2 TORQUES
General Information and Specifications
2.3
Page 14
2.4
2.2.2 ASTM Fastener Torque Chart (Metric)
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS &
GRADE 2 NUTS
TORQUE
LUB
SIZE
THDS.
PER
INCH
BOLT
DIA.
TENSILE
STRESS
AREA
CLAMP
LOAD
DRY OR
LOCTITE
263
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
40
4
6
8
10
1/4
0.1120
48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — — 32
0.1380
40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — — 32
0.1640
36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — — 24
0.1900
32 0.02000 1285 6 4 — — 1800 8 6 — — — — — 20
0.2500
28 0.0364 2320 14 10 — 15 3280 19 14 — 21 3640 19 20
0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —
0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —
0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —
0.01750 1120 5 3.6 — — 1580 7 5 — — — — —
0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
18
0.3125
24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41 16
0.3750
24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75 14
0.4375
20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111 13
0.5000
20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172 12
0.5625
18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247 11
0.6250
18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328 10
0.7500
16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597
9
0.8750
14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949
8
1.0000
12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356
7
1.1250
12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061
7
1.2500
12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807
6
1.3750
12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640
6
1.5000
12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881
0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38
0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68
0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104
0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163
0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230
0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313
0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542
0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874
0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288
0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851
0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610
1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457
1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535
Note: These torque values do not apply to cadmium plated fasteners.
LOCTITE
262
LOCTITE
242 OR
271
SAE GRADE 8 BOLTS & GRADE 8 NUTS
& SOCKET HEAD CAP SCREWS
LUB
TORQUE
LOCTITE
262
CLAMP
LOAD
DRY OR
LOCTITE
263
LOCTITE
242 OR
271
UNBRAKO 1960 SERIES
SOCKET HEAD
CLAMP
LOAD
TORQUE
WITHOUT LOC-WEL
PATCH
WITH
LOC-WEL
PATCH
General Information and Specifications
Page 15
General Information and Specifications
9
2.2.3 Metric Fastener Torque Chart
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY
CLASS 8.8 METRIC BOLTS &
CLASS 8 METRIC NUTS
TORQUE
LUB
LOCTITE
262
LOCTITE
242 OR
271
CLAMP
SIZE PITCH
TENSILE
STRESS
AREA
CLAMP
LOAD
DRY OR
LOCTITE
263
sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m
3 .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
4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8
5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7
6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17
7 1 28.9 12.6 18 13 16 19 18 25 19 20 28
81.2536.615.92519232822.837272940
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 2 115 50.0 140 105 126 154 71.6 200 150 160 220
16 2 157 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 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170
27 3 459 199.5 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 4 817 355.0 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
CLASS 10.9 METRIC BOLTS &
CLASS 10 METRIC NUTS
LOAD
DRY OR
LOCTITE
263
LUB
TORQUE
LOCTITE
262
LOCTITE
242 OR
271
Note: These torque values do not apply to cadmium plated fasteners.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
METRIC CLASS 8.8METRIC CLASS 10.
2.5
Page 16
General Information and Specifications
2.3 SPECIFICATIONS
2.3.1 Travel Speeds
First Gear 5 km/h (3.1 mph)
Second Gear 10 km/h (6.2 mph)
Third Gear 25 km/h (15.5 mph)
Fourth Gear (Turbo Only) 35 km/h (21.7 mph)
2.3.2 Hydraulic Cylinder Performance Specifications
Note: Machine with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature.
Function Approximate Times (sec.)
7M 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 -
9,78 9,78 9,78 9,78 9,78
UP
Attachment Tilt -
4,50 4,50 4,50 4,50 4,50
DOWN
Outrigger - UP N/A N/A N/A 2,93 2,93
Outrigger -
N/A N/A N/A 2,19 2,19
DOWN
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 12V DC, Negative (-) Ground, Limited Maintenance,
Wet Charged
Quantity 1 (100 Ah) (C
Reserve Capacity CCA @ -18° C: 880 EN
20
)
Group/Series DIN 600,38
Alternator 14V, 70 Amps
Starter 12V, 3,0 KW Type EV (Gear Reduction)
2.6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 17
General Information and Specifications
2.3.4 Engine Performance Specifications
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 925 RPM ±50 RPM 925 RPM ±50 RPM
High Idle 2340 RPM ±50 RPM 2340 RPM ±50 RPM
Horsepower 80,4 BHP/60 KW @ 2200 rpm 99,9 BHP/74,5 KW @ 2200 rpm
Fuel Delivery Fuel Injection Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and
Safety Elements
Dry Type, Replaceable Primary and Safety Elements
b. S/N 1160000358 & After
Description Naturally Aspirated Turbo
Engine Make/Model Perkins 1104C-44 Perkins - 1004-40T
Low Idle 925 RPM ±50 RPM 925 RPM ±50 RPM
High Idle 2340 RPM ±50 RPM 2340 RPM ±50 RPM
Horsepower 80,4 BHP/60 KW @ 2200 rpm 99,9 BHP/74,5 KW @ 2200 rpm
Fuel Delivery Fuel Injection Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and
Safety Elements
Dry Type, Replaceable Primary and Safety Elements
2.3.5 Tires
Note: Standard wheel lug nut torque is 500 Nm (369 lb-ft).
a. 7M, 8M & 9M
Description Tire Air Pressure
16/70-20 MPT04 CONST 3,5 Bar (50 psi)
405/70-20 MPT01 AG 3,5 Bar (50 psi)
405/70-24 MPT01 AG 4,0 Bar (58 psi)
405/70-24 MPT04 CONST 4,0 Bar (58 psi)
b. 12M & 13M
Description Tire Air Pressure
405/70-24 MPT01 AG 4,0 Bar (58 psi)
405/70-24 MPT04 CONST 4,0 Bar (58 psi)
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.7
Page 18
General Information and Specifications
2.4 FLUIDS, LUBRICANTS AND CAPACITIES
Engine Crankcase Oil
Capacity w/Filter Change 8,5 liters (9 quarts)
Oil Type 15W-40 CE
Fuel Tank
Capacity 140 liters (37 gallons)
Type of Fuel U.S.A. #2 Diesel
Cooling System
System Capacity 19,7 liters (20.8 quarts)
Type of Fluid 50/50 mix of ethylene glycol & water
Axles
Differential Housing Capacity - Front 7,3 liters (7.8 quarts)
Wheel End Capacity 1,4 liters (1.5 quarts)
Type of Fluid Mobilfluid 424
®
(ISO 46)
Hydraulic System
System Capacity 246 liters (65 gallons)
Reservoir Capacity to FULL Mark 160 liters (42.3 gallons)
Type of Fluid Mobilfluid 424
®
(ISO 46)
2.8
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 19
General Information and Specifications
2.5 MAINTENANCE SCHEDULES
2.5.1 8 & 1st 50 Hour Maintenance Schedule
EVERY
10
Check Fuel
Level
Check Brake
Fluid Level
st
1
Check Tire
Pressure
Check
Transmission
Oil Level
Air Filter
Restriction
Indicator
Test Load
Moment
Indicator
Check Engine
Oil Level
Check Hydraulic
Oil Level
50
L
B/F
T (N
m)
Change
Axle Oil
Change Wheel
End Oil
Change Engine
Oil & Filter
Change
Transmission
Oil & Filter
Check Wheel
Lug Nut
Torque
MZ1670
2.5.2 50, 250 & 500 Hour Maintenance Schedule
EVERY
50
Drain Fuel/
Water
Separator
Check Engine Coolant Level
EVERY
Check
Battery
Follow Lubrication
Schedule
250
Change Engine
Oil and
Filter
Check Boom
Bearing
Pads
Check Axle
Oil Level
Check Transfer Case Oil Level
Check Wheel
End Oil Levels
EVERY
Air Filter
Vacuator
Valve
Check
Fan Belt
500
LB/FT (Nm)
Change Fuel
Filter
Check Wheel
Lug Nut
Torque
MZ1680
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
2.5.3 1000 & 1500 Hour Maintenance Schedule
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
2.9
Page 20
General Information and Specifications
2.6 LUBRICATION SCHEDULES
2.6.1 8 Hour Lubrication Schedule
EVERY
8
Mystik Tetrimoly
(NLGI 2 GC-LB)
2.10
MZ1700
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 21
2.6.2 50 Hour Lubrication Schedule
EVERY
50
General Information and Specifications
Mystik Tetrimoly
(NLGI 2 GC-LB)
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
MZ1710
2.11
Page 22
General Information and Specifications
This Page Intentionally Left Blank
2.12
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 23
Section 3
Boom
Contents
PARAGRAPH TITLE PAGE
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.2 Second Section Boom Removal (12 & 13M). . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (7, 8 &
9M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (7,
8 & 9M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.3.5 Second Section Boom Installation (12 & 13M) . . . . . . . . . . . . . . . . . . . . . 3.5
3.3.6 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.4 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.4.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.5 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.5.1 Connecting with a Mechanical Quick Switch Device. . . . . . . . . . . . . . . . . 3.8
3.5.2 Connecting with a Hydraulic Quick Switch Device . . . . . . . . . . . . . . . . . . 3.8
3.5.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment . . . 3.8
3.5.4 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.5.5 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
3.1
Page 24
Boom
3.1 BOOM SYSTEM COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.
Three Section Boom
Second Boom
Section
First Boom
Section
Pivot Pin
Access
Panel
Quick Switch
Access
Panel
Third
Boom Section
Tilt Cylinder
Second Boom
Section
Extend/Retract
Cylinder
First Boom
Section
Extend/Retract
Cylinder
Pivot Pin
Two Section Boom
3.2
Quick Switch
Tilt Cylinder
MZ1480
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 25
Boom
3.2 BOOM SYSTEM
3.2.1 Boom System Description
The boom operates via an interchange among the electrical, hydraulic and mechanical systems. Components involved include the joystick, tilt cylinder, extend/retract cylinder, lift/lower cylinder, compensation cylinder, electronic sensors, various pivots, supporting hardware and other components.
3.3 BOOM ASSEMBLY MAINTENANCE
IMPORTANT: Boom replacement must be completed in sequence, one boom section at a time, as described in these instructions.
Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.
3.3.1 Boom Removal
1. Remove any attachment from the quick switch assembly. Refer to Section 3.5.1, “Connecting with a Mechanical Quick Switch Device.”
Note: If replacing the innermost boom section, remove the quick switch assembly. Refer to Section 3.5.4, “Quick Switch Removal.”
2. Park the machine on a hard, level surface. Be sure there is enough room in front of the machine to allow the boom sections to be removed.
3. Fully retract the boom then raise the boom to access the rod end pin of the lift/lower cylinder. Place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
4. Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated.
5. Open the engine cover. Allow the system fluids to cool.
6. Disconnect the battery negative (-) cable from the battery negative (-) terminal.
7. Relieve any trapped pressure in the tilt hydraulic system by using the handle or wrench (located in the toolbox) and move the double nut on the side of the actuator module on the tilt valve section back and forth. Repeat on the auxiliary valve section and on the extend/retract section.
8. Label, disconnect and cap hydraulic hoses attached the hose rack at the left rear corner of the boom.
9. Disconnect the boom angle indicator rod from the switch at the inside left corner of the main boom section and frame. Refer to Section 9.12.8, “Boom Angle Sensor.”
10. Support the front of the boom by placing a sling behind the boom head. Support the lift/lower cylinder and remove the lock bolt and then the rod end pin. Lower the lift/lower cylinder onto the frame rails.
11. Lower the boom to a level position and place a suitable support under the boom head. Reposition the slings to each end of the boom.
12. Remove the lock bolt and pin from the compensation cylinder on each side of the first boom section. Remove the lock bolt and pivot pin from rear of first boom section.
13. Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the side of the first boom section.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
3.3
Page 26
Boom
a. If the boom is going to be disassembled after
removal:
1. Set the complete boom on level ground and by repositioning the slings, turn boom over on to the top side. Set the complete boom on suitable stands to begin teardown.
Note: With the complete boom setting upside down, the other boom section(s), tilt cylinder and hoses are made more accessible.
2. Remove the access panel from the boom head.
3. Label, disconnect and cap the hoses attached to the tilt cylinder and the hose rack on the side of the first boom section.
4. Attach a sling through the rod end of the tilt cylinder. Remove the clip from the barrel end of the tilt cylinder pin. Remove the tilt cylinder pin and lift the tilt cylinder out of the boom head.
5. Remove the hose clamp inside the innermost boom section.
6. Label, disconnect and cap the hoses attached to the extend/retract cylinder at the rear of the boom.
7. Pull the extend/retract, tilt and auxiliary hoses (1) out through the rear of the boom.
8. Remove the clip from the rear extend/retract cylinder pin (2).
9. On 12 & 13M machines, remove the 2 brackets that secure the extend/retract cylinder to the second boom section.
10. Use a sling around the innermost boom section to take any pressure off of the wear pads to make pad removal easier.
11. Use a sling to pull the remaining boom section(s) out far enough to gain access to the rod end of the extend/retract cylinder.
12. Remove the clip from the front extend/retract cylinder pin. Pull the extend/retract cylinder (3) out through the rear of the boom.
1
2
3
3.3.2 Second Section Boom Removal (12 & 13M)
1. With the boom sections sitting on suitable supports, use a sling around the third boom section (4) to take any pressure off of wear pads to make pad removal easier.
2. Remove the top, left and right side wear pads, backing plates and shims. Loosen the bottom wear pad bolts and remove the shims from the first boom section to gain the necessary clearance to remove the first boom section from the second boom section (5). Tag each pad, backing plate, shim and bolts from each location.
3. Pull the second and third boom sections out from the first boom section (6).
4
6
5
MZ1740
3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (7, 8 & 9M)
1. Remove the top left and right side wear pads, backing plates and shims. Loosen the bottom wear pad bolts and remove the shims from the innermost boom section to gain the necessary clearance to remove the last boom section (7). Tag each pad, backing plate, shim and bolts from each location.
2. Pull out the innermost boom section (7).
3. Remove the remaining wear pads.
3.4
MZ1720
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 27
7
MZ1730
3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (7, 8 & 9M)
1. Install the bottom rear wear pads (8) and bolts onto the innermost boom section. Apply Loctite 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).
®
#242
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.
4. With the boom head still supported, install the top wear pads, washers and bolts in the front of the larger boom section. Apply Loctite
®
#242 and torque to 90 Nm (66 lb-ft). Remove the boom head from supports and install the bottom wear pads, backing plates, shims and bolts in the front of the larger boom section. Apply Loctite
®
#242 and torque to 90 Nm (66 lb-ft). Install both left and right side front wear pads, backing plates, shims and bolts in the front of the larger boom section. Apply Loctite® #242 and torque to 50 Nm (37 lb-ft).
Note: Shim ALL side wear pads as needed to maintain a minimum gap in the horizontal direction or a tight fit. The number of shims can vary at each shim point except on the bottom wear pads.
IMPORTANT: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly.
5. Tighten all wear pads after ensuring the minimum gap requirements have been met. Refer to Section
3.4.1, “Wear Pad Inspection.”
3.3.5 Second Section Boom Installation (12 & 13M)
8
MZ1750
2. Grease the inside of the next boom section on areas where the innermost boom section wear pads will slide.
3. Using a suitable sling, balance the innermost boom section and carefully slide 1 m to 1,5 m (3’ to 4’) into the front of the next boom section. Set the innermost boom section head onto suitable supports and reset
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
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.
3. Using a suitable sling, balance the first and second boom sections and carefully slide 1 m to 1,5 m (3’ to 4’) into the front of the third boom section.Set the third boom section head onto suitable supports and reset sling under the boom head. Carefully slide the first and second boom sections into the first section. Leave 15 cm to 20 cm (6” to 8”) of the second boom section out to be able to install wear pads on the front of the first boom section.
3.5
Page 28
Boom
9
MZ1730
4. With the boom head still supported, install the top wear pads, washers and bolts in the front of the first boom section. Apply Loctite® #242 and torque to 90 Nm (66 lb-ft). Remove the boom head from supports and install the bottom wear pads, backing plates, shims and bolts in the front of the first boom section. Apply Loctite® #242 and torque to 90 Nm (66 lb-ft). Install both left and right side front wear pads, backing plates, shims and bolts in the front of the first boom section. Apply Loctite
®
#242 and
torque to 50 Nm (37 lb-ft).
Note: Shim ALL side wear pads as needed to maintain a minimum gap in the horizontal direction or a tight fit. The number of shims can vary at each shim point except on the bottom wear pads.
IMPORTANT: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly.
5. Tighten all wear pads after ensuring the minimum gap requirements have been met. Refer to Section
3.4.1, “Wear Pad Inspection.”
3.3.6 Boom Installation
1. Insert the extend/retract cylinder through the rear of the boom. Align the extend/retract rod end with the cylinder pin mounting hole on the last boom section. Install the extend/retract cylinder pin and retaining clip.
IMPORTANT: On 12 & 13M machines, install the two brackets the secure the extend/retract cylinder to the second boom section.
2. Align the extend/retract barrel end with the cylinder pin mounting hole on the first boom section. Install the extend/retract cylinder pin and retaining clip.
Note: Grease extend/retract cylinder barrel end bore and pin before installing.
3. Attach a sling through the rod end of the tilt cylinder and position the cylinder to its original mounting location. Install the tilt cylinder pins and retaining clips.
4. Insert the extend/retract, tilt and auxiliary hoses through the boom.
5. Uncap and connect the previously labeled hydraulic hoses to the appropriate locations on each cylinder.
6. Install the hose clamps inside the innermost boom section.
7. Using suitable slings, turn the boom over to its original orientation.
8. Rebalance the boom assembly with slings, lift and carefully guide the boom into place. Align the frame pivot bore with the boom pivot bore. Install the boom pivot pin. Apply Loctite
®
#242 and torque to 300 Nm
(221 lb-ft).
9. With the sling still in place, install both compensation cylinders, pins and lock bolts. Apply Loctite® #242 and torque to 120 Nm (88 lb-ft).
10. With the sling still in place, raise the boom enough to install the lift/lower pin and lock bolt. Apply Loctite® #242 and torque to 300 Nm (221 lb-ft).
Note: Raising the boom up or down with the sling maybe necessary so the boom, compensation and lift/ lower cylinder bores can be aligned for easier pin installation.
Note: Grease the boom pivot bore, compensation cylinder rod ends, lift/lower rod end and pins before installing.
11. Uncap and connect the previously labeled hydraulic hoses to the hose rack on the side of the first boom section.
12. Connect the boom angle indicator rod from switch at the inside left rear corner of the main boom section and frame. Refer to Section 9.12.8, “Boom Angle Sensor,” for adjustment information.
13. Connect the battery negative (-) cable to the battery negative (-) terminal.
14. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic fluid level in the reservoir; add fluid if required.
15. Install the access panel on the boom head.
16. Close and secure the engine cover.
3.6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 29
3.4 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 7, 8 & 9M machines.
A total of 26 wear pads are installed on the boom sections of the 12 & 13M machines.
3.4.1 Wear Pad Inspection
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
3.4.2 Boom Wear Pad Replacement
When replacing a wear pad on the boom, replace both wear pads on that side of the boom; e.g.: replace top front left and top front right wear pads at the same time.
Usually, shimming will remain the same when installing new wear pads. All wear pads are secured to the boom using different capscrews and washers. When installing new wear pads, apply Loctite mounting capscrews. Torque right and left side wear pads to 50 Nm (36 lb-ft) and torque top and bottom side wear pads to 90 Nm (66 lb-ft). Grease the new pads and surrounding area.
Note: The first shim next to a wear pad always needs to have the two hole configuration. The remaining pads (11) may have the large slot configuration.
®
#242 to all wear pad
10
MA2070
Boom
11
MAH0870
Use shims (11) under the wear pads as required to maintain a maximum gap of 1,5 mm (0.06") (12) between the wear pad on the front and sides of the boom. The gap at the rear of the boom should be no more than 3 mm (0.12”).
Shims are available in four thicknesses, 0,5mm (0.02'), 1 mm (0.04”), 1,5mm (0.06”) and 2,0mm (0.08”).
12
MU4080
3.4.3 Boom Wear Pad Lubrication
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
After replacing any wear pad(s), or after prolonged periods of inoperation, light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.
3.7
Page 30
Boom
3.5 QUICK SWITCH ASSEMBLY
This machine is equipped with a quick switch system for easy attachment changes.
3.5.1 Connecting with a Mechanical Quick Switch Device
1. Retract quick switch device to provide clearance. Check to be sure lock pin (13) and retainer pin (14) is out.
2. Align attachment pin (15) with recess in attachment (16). Raise boom slightly to engage attachment pin in recess.
3. Engage quick switch device.
4. Shut off engine. Exit cab and insert lick pin and secure with retainer pin.
5. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.5.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.”
3.5.2 Connecting with a Hydraulic Quick Switch Device
3.5.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment
1. Lower attachment to ground. Set parking brake, shut off engine and turn key back to the “ON” position.
2. Relieve pressure in the hydraulic system by actuating the joystick.
3. Connect the quick-disconnect fittings.
4. Start the engine.
3.5.4 Quick Switch Removal
1. Support the quick switch assembly. Remove the lock bolt (18) holding the tilt cylinder rod end to the quick switch assembly. Remove the tilt cylinder pin.
2. Support the quick switch assembly. Remove the four bolts and covers (19) from each end of the quick switch assembly. Remove the pin from the quick switch assembly from either side.
3. Inspect the above pin for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired, the pin must be replaced.
1. Retract quick switch device to provide clearance. Check to be sure lock pin is disengaged.
2. Align attachment pin (15) with recess in attachment (16). Raise boom slightly to engage attachment pin in recess.
3. Engage quick switch device.
4. Press the button (17) and at the same time, move the joystick to engage or to disengage the quick switch device.
17
MAH0980
5. Raise the boom to eye level and visually check that the quick switch pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.
6. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.5.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.”
3.5.5 Quick Switch Installation
1. Assemble the quick switch to the boom head. Line up the quick switch between the mounts on the boom head. The quick switch should be centered in the boom head.
2. Coat the quick switch pivot pin with an anti-seize compound. Insert the quick switch pivot pin through the quick switch and boom head. Replace the end covers and four bolts (19) to each end of the quick switch.
3. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin. Align the tilt cylinder pin and screw in the locking bolt (18). Torque as required.
16
15
19
18
3.8
13
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
14
Page 31
3.6 TROUBLESHOOTING
This section provides an easy reference guide covering the most common problems that occur during operation of the boom.
Problem Cause Remedy
Boom
1. Boom will not extend or retract
2. Boom will not fully extend. 1. Extend/retract hydraulic system
3. Boom shifts to right or left when extending.
4. Excessive pivot pin noise and/or wear.
1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.
2. Extend/retract hydraulic system not operating properly.
3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section
not operating properly.
1. Boom side wear pads improperly shimmed or worn.
1. Insufficient lubrication. 1. Lubricate at regular intervals.
2. Worn bearing(s). 2. Replace bearing(s) and
1. Locate break, replace hose(s) or tube(s), tighten connections.
2. Refer to Section 8, “Hydraulic System.”
8.9.4, “Cylinder Inspection.”
1. Refer to Section 8, “Hydraulic System.”
1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.4.2, “Boom Wear Pad Replacement.”
Refer to Section 2.6, “Lubrication Schedules.” Replace worn pins as needed.
lubricate at regular intervals Refer to Section 2.6, “Lubrication Schedules.”
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes and/or connection leaks.
2. Lift/lower hydraulic system not operating properly.
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section
4. Seized boom pivot pin bearing. 4. Replace bearing.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
1. Locate break, replace hose(s) or tube(s), tighten connections.
2. Refer to Section 8, “Hydraulic System.”
8.9.4, “Cylinder Inspection.”
3.9
Page 32
Boom
Problem Cause Remedy
6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and
correct as needed. Refer to Section 3.4.2, “Boom Wear Pad Replacement.”
7. Auxiliary hydraulics will not operate.
2. Rapid cycle times with heavy loads.
3. Contaminated, corroded or rusted wear pad sliding surfaces.
4. Operating in extremely dusty/ abrasive conditions.
1. Auxiliary hydraulic system not operating properly.
2. Reduce cycle times.
3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).
4. Clean equipment frequently.
1. Refer to Section 8, “Hydraulic System.”
3.10
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 33
Section 4
Cab and Covers
Contents
PARAGRAPH TITLE PAGE
4.1 Operator’s Cab and Covers Component Terminology. . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.1 Serial Number Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.2 Service Brake Pedal and Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.3 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.3.4 Joystick Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.5 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.6 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.3.7 Windshield Washer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.3.8 Heater/Defroster System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
4.1
Page 34
Cab and Covers
4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.
Brake Fluid
Reservoir
Round Air Vents
Transmission Control
Lever
Wiper, Lights & Turn Signal
Lever
Steering Column
Adjuster
Service Brake Pedal
Accelerator Pedal
Parking Brake Lever
Air Louvers
Instrument
Panel
Air Louvers
Level
Indicator
Fuel Gauge
Engine Temp Gauge
Load Moment
Indicator
Control Console
Hazard Flashers
Ignition Switch
Air Louvers
Joystick
Continuous Hydraulic
Powered Operation
Auxiliary Switch
Air Louvers
12V Receptacle
Heater & AC
Controls
4.2
Round Air Vents
MZ0040
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 35
Cab and Covers
WARNING: DO NOT service the
machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. Failure to follow the safety practices may result in death or serious injury.
4.2 OPERATOR’S CAB
4.2.1 Serial Number Decal
The cab serial number decal is located inside the cab, below the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.
4.3 CAB COMPONENTS
4.3.1 Steering Column and Orbitrol Valve
a. Orbitrol Valve 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 at the battery negative (-) terminal.
5. Remove the lower dash panel.
6. Label, disconnect and cap the four hoses (1) from the side of the steering valve (2). Cap the fittings on the steering valve. Label, disconnect and plug the load sense hose (3) at the front of the steering valve. Cap the fitting on the steering valve.
7. Remove the steering wheel (4), disconnect and remove the display panel bracket (5), disconnect and remove the accessory lever (6) and transmission control lever (7), loosen and remove the locking bolt (8) for the steering column adjustment, loosen and remove both steering column pivot bolts and nuts.
8. Support the steering valve, and remove the four hex- head capscrews and four lockwashers.
9. Remove the steering assembly (9) through the dash panel opening.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective.
4.3
Page 36
Cab and Covers
6
8
6. Connect the four previously labeled hoses to the appropriate ports.
7. Connect the battery negative (-) cable to the battery negative (-) terminal.
4
8. Start the engine and check the operation of steering system. Check for hydraulic fluid leaks. Check the
5
hydraulic fluid level in the tank and add fluid as required. Wipe up any spilled oil.
9. Install the lower dash panel.
9
10. Close and secure the engine cover.
1
3
2
MZ0620
7
b. Orbitrol Valve Installation
1. Secure the steering valve to the steering column with four hex-flange capscrews and four lockwashers. Torque capscrews to 35 Nm (25 lb-ft).
2. Install the steering valve through the dash panel opening. Position steering valve in the cab, with the "LS" port pointing forward (away from the operator).
3. Install both steering column pivot bolts and nuts, install the locking bolt for the steering column adjustment, install the wiper lever and transmission control lever and connect the harness connector, install the steering wheel assembly. Torque the steering wheel nut to 25 Nm (18 lb-ft).
c. Power Steering Test
Conduct a pressure check of the steering hydraulic circuits at the main control valve. Refer to Section 8.4.2, “Adjusting Hydraulic Pressure.”
4.3.2 Service Brake Pedal and Valve
a. Service Brake Valve Removal
Refer to Section 8.8.2, a. “Service Brake Valve Removal,” for removal information.
b. Service Brake Valve Installation
Refer to Section 8.8.2, b. “Service Brake Valve Installation,” for installation information.
c. Service Brake Pedal 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 at the battery negative (-) terminal.
5. Remove the lower dash panel.
Note: ALWAYS use new o-rings when servicing the machine.
4. Install new o-rings into the fittings. Lubricate the o- rings with clean hydraulic oil.
5. Connect the load sense hose to the "LS" port at the top of the steering valve.
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MZ0230
6. Remove the circlip, flat washer, and the return spring securing the service brake pedal to the cab.
7. Remove the clip/pin from the brake plunger fork link.
8. Remove the service brake pedal (10) from the cab.
d. Service Brake Pedal Installation
1. Position the service brake pedal in its mounting location within the cab.
2. Install the brake pedal being careful to reposition the brake plunger yoke. Install the return spring, washer and clip. Install clip/pin in brake plunger fork link.
3. Adjust the brake pedal as needed.
4. Install and secure the lower dash cover.
5. Connect the battery negative (-) cable to the battery negative (-) terminal.
6. Close and secure the engine cover.
4.3.3 Throttle Pedal Replacement
a. Throttle Pedal 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 engine to cool.
4. Disconnect the battery negative (-) cable at the battery negative (-) terminal.
5. Remove the three capscrews (11), three lockwashers securing the throttle pedal assembly to the cab floor.
Cab and Covers
6. Remove the hex jam nut and flat washer securing the throttle cable to the throttle pedal assembly.
7. Remove the clip/pin from the fork link.
8. Remove the throttle pedal assembly from the cab.
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MZ0460
b. Throttle Pedal Installation
1. Install the hex jam nut and flat washer onto the end of the throttle cable. Secure the cable to the throttle pedal. Secure with the cable clamp and two locknuts.
2. Align the throttle pedal assembly with its mount holes on the cab floor.
3. Install three capscrews securing the throttle pedal assembly to the cab floor. Torque the capscrews to 12 Nm (9 lb-ft).
4. Connect the battery negative (-) cable to the battery negative (-) terminal.
5. Close and secure the engine cover.
c. Throttle Adjustment
1. From within the cab, lightly depress the accelerator pedal to the full-throttle position. As needed, adjust the limit-stop screw until it touches the pedal. Tighten the locknut.
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MZ0470
IMPORTANT: During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steer- ing wheel.
• Keep the transmission in (N) NEUTRAL.
2. Check the engine rpm at full throttle. If the rpm is not 2340 ±50 rpm, readjust the throttle limit-stop screw at the throttle pedal within the cab.
3. Connect the battery negative (-) cable to the battery negative (-) terminal.
4. Test the boom joystick functions:
a. Move the joystick handle rearward, activating the
boom lift function. The boom should RISE.
b. Move the joystick handle forward, activating the
boom lower function. The boom should LOWER.
c. Move the joystick handle to the right, activating
the boom extend function. The boom should EXTEND.
d. Move the joystick handle to the left, activating the
boom retract function. The boom should RETRACT.
e. Move the joystick rocker switch forward activating
the boom extend function. The boom should EXTEND.
5. Install the bottom cover and secure using two lens- head capscrews.
6. Close and secure the engine cover.
4.3.5 Parking Brake
4.3.4 Joystick Assembly Replacement
a. Joystick 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 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 engine to cool.
4. Disconnect the battery negative (-) cable at the battery negative (-) terminal.
5. Remove the two capscrews. Remove the bottom cover. Disconnect the electrical connections and remove the four self-tapping screws from the bottom of the joystick assembly.
6. Remove the joystick assembly.
b. Joystick Assembly Installation
1. Set the joystick assembly into the armrest support.
2. Install the four self-tapping screws. Connect the electrical connections.
MZ1490
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) 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. Block the wheels.
4. Remove the cover from around the park brake lever.
5. Disconnect the park brake electrical connector switch.
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6. Remove the pin attached to the park brake cable from the park brake lever.
7. Remove the bolts holding the park brake lever to the mounting plate.
8. Loosen the nuts securing the park brake cable to the mounting plate.
9. Feed the cable end through the bottom of the cab.
10. If necessary, remove the cable clamp from under the cab.
Note: Record the routing of the park brake cable for later installation.
11. Remove the cable mounting hardware on the front axle to free the park brake cable.
b. Park Brake Installation
1. Install the park brake cable on the front axle.
2. Route the park brake cable using the previous routing path.
3. Feed the cable end through the bottom of the cab.
4. Secure the park brake lever to the mounting plate using the pre-existing mounting hardware.
5. Secure the park brake cable to the park brake lever with the pre-existing pin.
6. Connect the park brake electrical connector switch.
7. Test the park brake for proper functionality.
8. With the park brake applied, check the display panel for the proper indicator light.
9. Reinstall the cover around the park brake lever.
10. Unblock the wheels.
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. Remove the belly pan.
6. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap.
7. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug and slowly remove to allow the coolant to drain. Transfer the coolant into a suitable, covered container and label as "Used Coolant". Dispose of the used coolant at an approved recycling facility. Clean and reinstall the drain plug.
8. Remove the cab bottom shield.
9. Remove the cab floor mat to gain access to the heater assembly mounting bolts.
Note: Label all hoses to ensure correct installation.
10. Loosen the hose clamps and disconnect the two heater hoses.
11. Remove the heat duct hoses from the back side of the heating unit assembly.
12. Carefully lower the heater assembly (12) by hand. Label and disconnect the wiring harness connections at the blower.
13. Remove the heater assembly.
4.3.6 Windshield Wiper Assembly
Refer to Section 9.10.1, “Windshield Wiper Motor,” for removal and installation information.
4.3.7 Windshield Washer Assembly
Refer to Section 9.10.3, “Windshield Washer Reservoir and Pump,” for removal and installation information.
4.3.8 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 in (N) NEUTRAL, engage the park brake and shut the engine OFF.
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MZ0480
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b. Heater Assembly Installation
1. Connect the wiring harness connections to the blower.
2. Lift the heater assembly to the bottom of the cab floor, and secure with bolts, lockwashers and nuts.
3. Connect the previously labeled hoses to the heater. Secure with hose clamps.
4. Fill the cooling system completely with a 50/50 mixture of ethylene glycol and water, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, “Fluids, Lubricants and Capacities.”
5. Connect the battery negative (-) cable to the battery negative (-) terminal.
6. Start the engine and run at low idle. Check for any visual signs of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.
7. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.
8. Replace the cab bottom shield.
9. Replace the belly pan.
10. Close and secure the engine cover.
4.4 CAB REMOVAL
IMPORTANT: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.
Before performing any inspection, maintenance or service operation, thoroughly clean the machine. DO NOT spray water or cleaning solution in, on, near or around the operator’s dash panels and electrical components.
Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact your local JLG distributor with any questions about the suitability or condition of a cab.
IMPORTANT: Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine.
1. Park the machine on a firm, level surface, level the machine. Allow sufficient overhead and side clearance for cab removal. Fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.
2. Block the wheels.
3. Open the engine cover. Allow the system fluids to cool.
4. Disconnect the battery negative (-) cable from the battery negative (-) terminal.
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, remove the cab bottom shield.
8. Label, disconnect and cap the heater hoses.
9. Remove the lens-head screws in the cab and remove the console panel below the right side window to access the wire harness connections, the right rear side panel and the left rear cup holder panel to access the two rear cab mount bolts. Also remove the rubber floor mat to access the front two cab mount bolts.
10. Disconnect the cab-to-wiring harness connectors at the circuit board. Push the harness connectors through the opening at the right front corner of the cab.
11. Remove the park brake cover. Disconnect the park brake switch connector and park brake cable.
12. Working under the cab, label, disconnect and cap the hydraulic hoses at the cab fittings. Plug the hoses and cap the fittings.
13. Disconnect the throttle cable from under the cab.
14. Install two lifting eye bolts with a suitable lifting capacity in the existing threaded holes at the top corners of the windshield.
15. Secure the cab with a hoist or overhead crane and sling. Do not lift the cab at this time.
16. Remove the four cab-to-frame bolts (13), flat washers and nuts.
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 check that all wiring, hydraulic hoses and fasteners are disconnected or removed.
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19. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the frame.
20. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall over. Assure that no personnel enter the cab while it is being removed from the machine.
21. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.
22. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.
13
MZ0640
4.5 CAB INSTALLATION
1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation.
2. Attach a sling with suitable lifting capacity through the previously installed eye bolts on top of the cab.
3. Using a hoist or overhead crane and sling attached to the two lifting eyes, carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation.
4. Install the four bolts through the cab/frame mounts and install the four washers and nuts. Remove the sling and both lifting eye bolts. Tighten and torque the four mounting bolts to 150 Nm (110 lb-ft).
5. Secure the throttle cable to the hydraulic hoses using wire ties.
6. Install the throttle cable on the throttle cable bracket, attach the clip/pin through the fork link.
7. Working under the cab, uncap and connect the hydraulic hoses at the cab fittings.
8. Route any hoses through the opening at the right front corner of the cab.
9. Route the wiring harness connectors through the opening at the right front corner of the cab and up into the side console.
10. Connect the cab-to-wiring harness connectors.
11. Connect the park brake cable and switch connector to the park brake lever. Reinstall the park brake cover.
12. Install the right side console panel, the right rear side panel, the left rear cup holder panel and the rubber floor mat.
13. Working under the cab, connect the coolant hoses to the heater hoses. Secure with two hose clamps.
14. Fill the cooling system completely with a 50/50 mixture of ethylene glycol and water, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, “Fluids, Lubricants and Capacities.”
15. Connect the battery negative (-) cable to the battery negative (-) terminal.
16. Start the engine and check the operation of all controls. Check for hydraulic leaks. Check the hydraulic fluid level in the tank and add fluid as required.
IMPORTANT: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.
17. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.
18. Reinstall engine belly pan.
19. Reinstall the cab bottom shield.
20. Close and secure the engine cover.
21. Unblock the wheels.
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Section 5
Axles, Drive Shafts, Wheels and Tires
Contents
PARAGRAPH TITLE PAGE
5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.3 Axle Internal Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.3.6 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5.6
5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5.10
5.5.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . 5.11
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.6.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.7 Towing A Disabled Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
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5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
Rear Axle
Assembly
Steering Cylinder
(Rear)
Steering Cylinder
(Front)
Front Axle
Assembly
Transmission Drop
Box
Drive Shafts
MZ1510
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5.2 GENERAL INFORMATION
IMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent of damaged. Refer to the appropriate parts manual for ordering information.
Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.
Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear. Always replace elastic locknuts and any damaged, worn, cracked, seized or otherwise improper parts that could affect the safe and proper functioning of the machine, axles and drive shafts.
5.3 AXLE ASSEMBLIES
5.3.1 Axle Serial Number Plate
The front and rear axle serial number plate is located on a mounting pad on the front side of the center section of each axle. Information on the serial number plate is required in correspondence regarding the axle.
Supply information from the axle serial number plate when communicating about an axle assembly or axle components.
5.3.2 Axle Specifications
General axle specifications are found in Section 2.4, “Fluids, Lubricants and Capacities.”
5.3.3 Axle Internal Service
Detailed axle service instructions (covering the axle, differential, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the Dana Spicer Maintenance and Repair Manual (P/N 31200162).
WARNING: DO NOT service the
machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury.
5.3.4 Axle Maintenance
CLEANING: Clean parts with machined or ground
surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces.
DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, lightly coat components with oil or a rust-preventive chemical to help protect them from corrosion. If storing components for a prolonged period, wrap them in wax paper.
PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the machine far enough to cause the drive- train components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity.
SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necessary.
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Note: Use a suitable puller for bearing removal. Clean, inspect and lubricate all bearings just prior to reassembly. If replacement of a damaged bearing cup or
cone is necessary, replace the cup and cone as a set.
5.3
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0
5.3.5 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.
MZ103
1
2
MZ1520
6. Label, disconnect and cap the steering and brake lines at the axle. Wipe up any spilled oil.
7. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine will remain in place during axle removal before proceeding.
8. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal.
9. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine.
10. Mark and remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.5.1, “Removing Wheel and Tire Assembly from Machine.”)
11. Remove the drive shaft assembly. Refer to Section
5.4.3, “Drive Shaft Removal.”
12. On the front axle, remove the hardware securing the sway cylinder or bar (not necessary on machines with fixed axles before S/N 1160000798). Tap the mount pin out, and move the cylinder or bar to prevent it from interfering with axle removal.
13. Remove the park brake cable from the front axle.
14. Remove the bolts and locknuts securing the axle to the frame.
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.
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c. Axle Installation
The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and limited-slip feature; the rear axle has neither. The steps below outline a typical axle installation procedure, suitable for either the front or the rear axle assembly.
1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine.
2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure.
4. Position the axle under the frame, and align the axle housing with the holes in the frame.
5. Install the axle bolts and nuts. Tighten and torque the axle nuts near the pivoting bearings to 650 Nm (479 lb-ft) and the bolts in the front axle cylinder anchor plate to 550 Nm (405 lb-ft). On fixed axle machines before S/N 1160000798, tighten and torque the axle front axle nuts to 650 Nm (479 lb-ft) and the rear nuts to 550 Nm (405 lb-ft).
6. Move the cylinder into position on the axle cylinder anchor. Insert a cylinder-mount pin through the cylinder and cylinder anchor (not necessary on fixed axle machines before S/N 1160000798). Secure the cylinder-mount pin.
7. Apply a multi-purpose grease through the self- tapping lube fitting to lubricate the self-align bearing and the cylinder-mount pin.
8. Install the drive shaft assemblies. (Refer to Section
5.4.5, “Drive Shaft Installation.”)
9. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the yoke on the transmission.
10. Tighten the axle oil drain plug, loosen and remove the axle oil fill plug (3). Fill the axle through the axle fill plug until the oil level is even with the oil check level plugs (4). Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.
3
MZ103
4
11. Rotate wheel hubs 90 degrees so the drain plug becomes the fill plug. Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.
12. Install the wheel and tire assemblies. Refer to Section 5.5.2, “Installing Wheel and Tire Assembly onto Machine.”
Note: Be sure the directional tread pattern "arrows" of the tires are facing in the direction of forward travel.
13. Carefully remove the jack, hoist or overhead crane and sling supporting the axle.
14. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground.
Note: ALWAYS use new o-rings when servicing the machine.
15. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.
16. Uncap and connect the steering and brake lines at their axle fittings.
17. Install the park brake on the front axle.
18. Bleed brakes as necessary. Refer to Section 8.8.3, “Brake Test.”
19. Check the hydraulic reservoir oil level.
20. Unblock the wheels.
21. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt function several times in both directions and check the function of the brakes. Check for hydraulic leaks, and tighten or repair as necessary.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
22. Close and secure the engine cover.
5.5
Page 48
Axles, Drive Shafts, Wheels and Tires
5.3.6 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 Section 2.4, “Fluids, Lubricants and Capacities.”
2. Axle and/or wheel end housings
filled with incorrect oil or oil level low.
2. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424
®
ISO 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”
3. Incorrect alignment of ring and pinion gears.
4. Incorrect pinion (input) shaft bearing preload.
3. Correct alignment by adding or removing shims as needed.
4. Correct bearing preload by adding or removing shims as needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424® ISO 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”
2. Intermittent noise when traveling.
3. Vibration or intermittent noise when traveling.
8. Axle housing damaged. 8. Replace damaged parts.
1. Universal joint(s) worn or damaged.
2. Differential ring and/or pinion gears damaged.
1. Drive shaft universal joint assembly(ies) incorrectly
1. Repair or replace universal joints as needed.
2. Determine cause and repair as needed.
1. Tighten capscrews to correct torque.
tightened.
2. Drive shaft universal joint(s) worn or damaged.
3. Drive shaft(s) damaged/ unbalanced.
2. Repair or replace universal joints as needed.
3. Replace drive shaft(s) as needed.
5.6
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 49
Axles, Drive Shafts, Wheels and Tires
Problem Cause Remedy
4. Oil leaking from axle (differential housing and/or axle housings).
1. Drain and/or inspection plugs loose and/or o-rings damaged or missing.
1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft).
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or missing and/or worn or
3. Replace seal and/or joint coupling fork shaft (axle shaft).
damaged shaft sealing surfaces.
4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.
4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Dana Repair Manuals.
5. Axle casing to brake housing
5. Replace o-rings and seals.
and/or brake housing to differential assembly o-rings and/or seals worn or damaged.
6. Axle housing mounting nuts and capscrews loose.
6. Tighten housing nuts and capscrews to 390 Nm (288 lb-ft).
7. Differential and/or axle
7. Replace housing(s) as needed.
housing(s) damaged.
5. Oil leaking from wheel end housing (planet carrier).
6. Oil leaking from steering cylinder.
1. Oil level plugs loose and/or o-rings damaged or missing.
1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft).
2. O-ring between hub and
2. Replace o-ring.
housing (planet carrier) damaged or missing.
3. Shaft seal damaged or missing and/or worn or damaged shaft
3. Replace seal and/or fork joint shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews to 55 Nm (41 lb-ft).
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
1. Hose fittings loose. 1. Tighten fittings.
2. Steering cylinder o-rings and/or
2. Replace o-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or
3. Replace piston rod seal.
damaged.
4. Cylinder tube damaged. 4. Replace cylinder tube.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.7
Page 50
Axles, Drive Shafts, Wheels and Tires
Problem Cause Remedy
7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with
Mobilfluid 424® ISO 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”
2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.
3. Dragging park brake. 3. Adjust park brake cable as
8. High steering effort required. 1. Steering (hydraulic) system not operating properly.
2. Excessive joint housing swivel bearing preload.
3. Worn or damaged swivel bearings.
9. Slow steering response. 1. Steering (hydraulic) system not operating properly.
2. Steering cylinder leaking internally.
10. Excessive noise when brakes
1. Brake discs worn. 1. Check brake discs for wear.
are engaged.
2. Drain axle and fill to correct level
®
with Mobilfluid 424
ISO 46. Refer toSection 2.4, “Fluids, Lubricants and Capacities.”
needed.
1. Refer to Section 8.9.8, “Steering Cylinders.”
2. Correct bearing preload by adding or removing shims as needed.
3. Replace swivel bearings as needed.
1. Refer to Section 8.9.8, “Steering Cylinders.”
2. Repair or replace steering cylinder as needed.
Refer to Section 5.6, “Brakes.”
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not operating properly.
2. Brake piston o-rings and seals damaged (leaking).
12. Brakes will not hold the
1. Brake discs worn. 1. Check brake discs for wear.
machine or braking power reduced.
2. Brake (hydraulic) system not operating properly.
3. Brake piston o-rings and seals damaged (leaking).
5.8
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
1. Refer to Section 8.8.3, “Brake Te s t.”
2. Replace o-rings and seals.
Refer to Section 5.6, “Brakes.”
2. Refer to Section 8.8.3, “Brake Te s t.”
3. Replace o-rings and seals.
Page 51
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 (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later.
Inspect area where the drive shaft flange yoke and slip yoke mount to the drive shaft. Attempt to turn drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shaft and cross and bearing assembly may cause an excessive amount of vibration or noise.
5.4.2 Drive Shaft Maintenance
Refer to Section 2.6, “Lubrication Schedules,” for information regarding the lubrication of the grease fittings on the drive shafts.
5.4.3 Drive Shaft Removal
IMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts manual for ordering information.
Note: The drive shaft assemblies are balanced assemblies. Mark the yoke and axle, transmission, transfer case, and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.
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 engine to cool.
4. Disconnect the battery negative (-) cable at the battery negative (-) terminal.
5. Block the wheels.
6. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that these components can be
returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.
7. Remove the four capscrews and two straps securing the bearing cross to the transmission output shaft flange.
8. Remove the four capscrews and two straps securing the bearing crosses to the axle.
9. Remove the front drive shaft assembly.
10. Repeat the above procedure for the rear drive shaft.
To Transmission
To Axle
5.4.4 Drive Shaft Cleaning and Drying
1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry.
2. Remove any burrs or rough spots from all machined surfaces. Re-clean and dry as required.
5.4.5 Drive Shaft Installation
IMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts manual for ordering information.
1. Raise the drive shaft assembly into position. The slip-yoke end of the drive shaft mounts toward the axle. If reinstalling a drive shaft previously removed, align the flange yokes according to the alignment marks made during removal.
2. Install the four capscrews and two straps securing the bearing crosses to the transmission. Torque the capscrews to 38 Nm (28 lb-ft).
3. Install the four capscrews and two straps securing the bearing crosses to the axle. Torque the capscrews to 38 Nm (28 lb-ft).
4. Repeat the above procedure on the rear drive shaft.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.9
Page 52
Axles, Drive Shafts, Wheels and Tires
5. Connect the battery negative (-) cable at the battery negative (-) terminal.
6. Unblock the wheels.
7. Close and secure the engine cover.
5.5 WHEELS AND TIRES
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.
JLG recommends a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using a JLG approved replacement tire, JLG recommends that replacement tires have the following characteristics:
• Equal or greater ply/load rating and size of original.
• Tire tread contact width equal or greater than
original.
• Wheel diameter, width and offset dimensions equal to the original.
• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load).
The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability.
The tires are filled with air only when the machine leaves the factory. JLG does not recommend the use of hydrofill as a tire-fill substance because of possible environmental impact.
Large-bore valve stems are used to help expedite tire inflation and deflation. An inner tube may be used if a tire does not provide an airtight seal. Check tire inflation pressures when the tires are cold. When mounting a tire on the wheel, the tire must be mounted on the wheel respective of the directional tread pattern of the tire; this produces a left or right tire and wheel assembly.
The wheel and tire assemblies must be installed with the directional tread pattern “arrows” (4) facing in the direction of forward travel.
4
MAH0890
5.5.1 Removing Wheel and Tire Assembly from Machine
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. Loosen, but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.
4. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly.
5. Lower the machine onto the support.
6. Remove lug nuts and lug washers in an alternating pattern.
7. Remove the wheel and tire assembly from the machine.
5.10
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Page 53
Axles, Drive Shafts, Wheels and Tires
5.5.2 Installing Wheel and Tire Assembly onto Machine
IMPORTANT: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.
Tread “arrows” must
point forward
Install tires onto
wheels to rotate in
proper direction
5.6 BRAKES
5.6.1 Brake Disk Inspection.
a. Front and Rear Axles
WARNING: BLOCK ALL FOUR
WHEELS. Failure to do so could result in
death or serious injury from machine roll-away.
1. Block all four wheels to help prevent the machine from moving after the parking brake is disabled.
2. Remove the oil-level plug (7) on each side of the axle.
3. Have an assistant sit in the cab and apply the brakes, keeping pressure applied.
4. Using a feeler gauge, check the gap between the brake discs. If the gap is less than 4,5 mm (0.18"), replace the brake discs.
Note: If the brake discs are worn beyond their tolerance, the brake disc must be replaced on both sides of the axle at the same time.
MAH0460
1. Position wheel onto studs on wheel end of axle.
2. Install wheel lug washers.
3. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.
4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 500 Nm (367 lb-ft).
5
3
1
10
8
6
7
9
2
4
OY1220
5. Remove machine from supports.
4,5 mm
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5.11
Page 54
Axles, Drive Shafts, Wheels and Tires
6
MZ1030
7
5. Repeat steps 3 and 4 for the other side of the axle.
6. Fill the axle through the axle fill plug (6) until the oil level is even with the oil check level plugs (7). Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.
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, and move it under its own power, before using the emergency towing procedures outlined below.
1. Secure the machine to a suitable towing vehicle.
2. Release the park brake and set the transmission control lever in (N) NEUTRAL.
3. Tow the machine to a suitable repair facility.
4. After towing is complete, engage the park brake.
5.12
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 55
Section 6
Transmission:
Contents
PARAGRAPH TITLE PAGE
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.5.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.5
6.5.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.5.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
6.6.1 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
6.1
Page 56
Transmission:
6.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.
Output Shaft
(rear)
Tor que Convertor
Dipstick and Fill Tube
Oil Filter
Output Shaft
(front)
Breather
Breather
6.2
Drop Box Oil Level Sight
Gauge
MZ0670
Transmission Drop Box
Shift Solenoids
Flex Plate Assembly
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 57
WARNING: DO NOT service the
machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury.
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 service instructions and detailed specifications contact your local JLG distributor for a copy of the Dana Spicer Repair Manual (P/N 31200163).
6.3 TRANSMISSION SERIAL NUMBER
The transmission serial number plate is located on the front of the transmission case below the convertor housing. Information specified on the serial number plate includes the transmission model number, the transmission serial number and other data. Information on the serial number plate is required in correspondence regarding the transmission.
6.4 TRANSMISSION SPECIFICATIONS
6.4.1 Transmission Maintenance
Cleanliness is of extreme importance. Before attempting any repairs, thoroughly clean the exterior of the transmission to help prevent dirt from entering while performing maintenance checks and procedures.
Section 2.5, “Maintenance Schedules.” provides a suggested maintenance schedule with references to pertinent procedures and instructions in this manual. To help prevent transmission problems before they occur, follow the maintenance schedule.
Note: Lubrication and Maintenance chart decals are located inside the rear door of the machine or in the cab. These decals contain a general maintenance schedule that should be followed to maintain the machine in good operating condition. Refer to Section 2.6, “Lubrication Schedules.” The same schedule information is presented in the appropriate Operation & Safety Manual, with a detailed account of how to perform the procedures.
Transmission:
6.4.2 Transmission Maintenance Schedule
Complete transmission maintenance information is located in the appropriate Operation & Safety Manual.
• At ten hour intervals, check the transmission oil level. Refer to the appropriate Operation & Safety Manual.
• When the machine completes it’s first 50 hours of use, change the transmission filter and oil. Refer to the appropriate Operation & Safety Manual.
• At 1,000 hour intervals, change the transmission oil and filter. Refer to the appropriate Operation & Safety Manual.
Periodically, depending on operating conditions and other factors, back flush the transmission oil cooler, which is located in or behind the radiator. ALWAYS back flush the transmission oil cooler after removing the transmission for repair or replacement.
The transmission oil cooler outlet hose, routed to the lower oil cooler fitting, is located on the top of the transmission. The transmission oil cooler inlet hose, routed to the upper oil cooler fitting, is located on the top of the transmission (Refer to Section 7.4, “Engine Cooling System.”)
Disconnect and back flush the oil cooler portion of the radiator or the oil cooler with oil and compressed air until all foreign material is removed. If necessary, remove the radiator or oil cooler from the machine, and clean the oil cooler circuit using oil, compressed air and steam.
IMPORTANT: DO NOT use flushing compounds for cleaning purposes.
6.5 TRANSMISSION REPLACEMENT
Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period.
IMPORTANT: To help ensure safety and optimum performance, replace the transmission if it is damaged. Refer to the appropriate Parts Manual for ordering information.
Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other electrical components.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
6.3
Page 58
Transmission:
6.5.1 Transmission Removal
WARNING: Risk of severe personal
injury. NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling.
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF.
2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.
3. Open the engine cover. Allow the engine to cool.
4. Remove the engine cover to allow easier access to the transmission.
5. Remove the belly pan from under engine.
6. Disconnect the (+) positive and (-) negative battery cables and remove the battery.
7. Thoroughly clean the transmission and surrounding area, including all hoses and fittings, before proceeding.
8. Place a suitable receptacle under the transmission drain plug (1). Remove the transmission drain plug and allow the transmission oil to drain into the receptacle. Repeat drain procedure with the drop box (2).
1
2
9. Transfer the used transmission oil into a suitable, covered container, and label the container "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission drain plug.
10. Remove the drive shafts. Refer to Section 5.4.3, “Drive Shaft Removal.”
11. Remove the air cleaner unit and intake tubes.
MZ1380
12. Remove the hydraulic pump. Refer to Section 8.7.3, “Pump Replacement.”
13. Label and disconnect the transmission temperature switch connector and shift solenoid wiring harness connectors.
14. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission. The transmission oil cooler outlet hose, routed to the lower radiator fitting, is located on the top of the transmission. the transmission oil cooler inlet hose, routed to the upper radiator fitting, is located on top of the transmission.
15. Remove the access plug from the side of the engine bell housing. This will allow access to remove the eight bolts holding the flex plate to the engine flywheel.
16. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Remove them one at a time.
17. Wipe up any spilled hydraulic and transmission oil.
18. Connect a lifting strap or chain to the lifting eye at the top of the transmission, and to a suitable hoist or overhead crane. Operate the hoist or crane to remove slack from the chain, but DO NOT raise the transmission at this time.
19. Place blocks under the rear of engine for support BEFORE transmission mounts are removed.
20. Place blocks under the transmission to help support it during removal.
21. Remove both rear transmission mount bolts and lockwashers securing the transmission mount to the frame.
22. Remove the ten bolts and washers holding the transmission to the engine.
23. Remove the four capscrews and four lockwashers securing each rear transmission mount to the transmission.
24. Remove the two transmission mount from the machine.
25. Inspect the rubber mounts. Replace the mounts if damaged.
26. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts.
27. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so that it will not move or fall.
6.4
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 59
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
MZ0680
30. If transmission oil is suspected of contamination or torque convertor is damaged, remove the convertor and flex plate from the transmission.
31. Remove the six bolts and washers holding the convertor to the flex plate.
6.5.2 Transmission Inspection and Internal
Repair
If replacing the entire transmission, transfer the transmission temperature switch to the replacement transmission. The gear shift solenoids are included with a new transmission.
Detailed internal service instructions are provided in the Dana Spicer Repair Manual, which can be obtained by contacting your local JLG Distributor.
6.5.3 Transmission Installation
1. Install both the rear transmission mounts on the transmission. Torque capscrews to 120 Nm (88 lb-ft).
2. Install guide studs near the top of the bell housing holes and in the flex plate.
3. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis.
4. Align the torque convertor, align the transmission bolt holes with the guide studs in the bell housing and flex plate. Install the eight bolts and washers and torque to 63 Nm (46 lb-ft). Remove the alignment studs and install and torque the last two transmission mount bolts and torque to 63 Nm (46 lb-ft).
5. Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers. Apply Loctite® 242 threadlock to the transmission mount bolts and torque to 210 Nm (155 lb-ft).
6. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Install them one at a time. Torque to 35-39 Nm (26-29 lb-ft). Replace access plug.
7. Remove the hoist or overhead crane and sling.
8. Connect the transmission temperature switch connector and shift solenoid wiring harness connectors.
9. Secure the wiring harness to the transmission housing.
10. Uncap and connect the transmission oil cooler inlet and outlet hoses at the transmission.
11. Install the hydraulic pump. Refer to Section 8.7.3, “Pump Replacement.”
12. Install the transmission-to-axle drive shafts. Refer to Section 5.4.5, “Drive Shaft Installation.”
13. Install air cleaner and tubing.
14. Clean the transmission oil filter mounting surface.
15. Apply a thin film of clean Mobilfluid 424 Grade 46 to the new transmission filter gasket. Install the new filter and torque to 27-34 Nm (20-25 lb-ft).
16. Transmission oil may be added through the dipstick tube. Remove the dipstick and add approximately 11,4 liters (3 Gallons) of Mobilfluid 424 Grade 46. Check the oil level by taking intermittent dipstick readings as outlined in the appropriate
®
ISO
®
ISO
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
6.5
Page 60
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 After Transmission Service or
Replacement
Refer to the Dana Spicer Transmission Repair Manual which can be obtained by calling your local JLG Distributor.
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.
6. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning.
7. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.
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.
9. Reassemble all components and fill the transmission with clean, fresh Mobilfluid 424
®
ISO Grade 46 through the dipstick tube opening (4). Remove the dipstick and fill with approximately 11,4 liters (3 gallons) of Mobilfluid 424® ISO Grade 46. Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.
4
MZ0680
10. Run the engine for two minutes at idle to help prime the torque convertor and the transmission oil lines.
11. Recheck the level of the fluid in the transmission with the engine running at idle.
12. Add Mobilfluid 424
®
ISO Grade 46 as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick. Recheck the oil level when it reaches operating temperature 83-94°C (180-200°F).
13. Recheck all drain plugs, lines, connections, etc. for leaks, and tighten where necessary.
8. Back flush the transmission oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil and compressed air until all foreign material is removed. Flushing in the direction of normal oil flow does not adequately clean the cooler. If needed, remove the radiator or oil cooler from the machine.
IMPORTANT: DO NOT use flushing compounds for cleaning purposes.
6.6
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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 internal transmission repair is required during the warranty period.
The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.
6.6.1 Transmission Troubleshooting
Problem Cause Remedy
Transmission:
1. Transmission will not engage or will not shift properly.
1. Oil level too high or low. 1. Fill transmission to correct level with Mobilfluid 424® ISO Grade 46. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)
2. Transmission control lever not
functioning properly and/or a fault in the wiring harness.Transmission control lever not functioning properly and/or a fault in the wiring harness.
3. Transmission valve body
solenoids not functioning properly.
4. Pilot-operated shift valves not
operating properly.
5. Pump output pressure low. 5. Refer to Section 6.6.1,
2. Refer toSection 9.5.1, “Cab Harness Electrical Schematic.”
3. Refer to Section 9.5.1, “Cab Harness Electrical Schematic.”
4. Clean the valve spool and housing. Replace return spring as needed.
“Transmission Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”
6. Clutch piston o-rings damaged. 6. Replace o-rings.
7. Clutch discs worn or damaged. 7. Replace clutch discs.
8. Coupling shafts or gear teeth damaged.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8. Replace couplings.
6.7
Page 62
Transmission:
Problem Cause Remedy
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. Transmission filled with incorrect
oil, or oil contaminated.
2. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. (Refer to Section
2.4, “Fluids, Lubricants and Capacities.”)
3. Pump suction pipe screen clogged.
3. Clean, repair and/or replace suction pipe.
4. Central shaft damaged. 4. Replace central shaft.
5. Pump worn or damaged. 5. Repair or replace pump assembly.
3. Low clutch pressure. 1. Incorrect oil level. 1. Fill transmission to correct level with Mobilfluid 424
®
ISO Grade 46. Refer toSection 2.4, “Fluids, Lubricants and Capacities.”
2. Main pressure valve stuck open. 2. Clean the valve spool and housing.
®
3. Broken or worn coupling shaft or
3. Replace coupling and/or o-rings.
piston o-rings.
4. Pressure reducing valve stuck
open.
4. Clean the valve spool and housing.
4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.5, “Hydraulic Schematics.”
2. Low engine rpm causes converter stall.
2. Adjust the engine rpm to specifications. Refer to Dana- Spicer Service Manual.
3. Pump output pressure is low. 3. Refer to Section 6.6.1, “Transmission Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”
4. Clutch discs worn or damaged. 4. Replace clutch discs.
5. Transmission overheating. 5. Refer to Section 6.6.1, “Transmission Troubleshooting,” Problem 5. “Transmission overheating (oil above 120° C (248° F)).”
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Problem Cause Remedy
Transmission:
5. Transmission overheating (oil above 120° C (248° F)).
6. Grinding or “clunking” noise from transmission.
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. Clogged radiator. 2. Remove debris from the radiator.
3. Transmission filled with incorrect
oil, or oil contaminated.
3. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section
2.4, “Fluids, Lubricants and Capacities.”
4. Excessive “roading.” 4. Stop and idle the engine.
5. Restriction in oil cooler hoses. 5. Replace cooler hoses.
6. Pump worn or damaged. 6. Repair or replace pump assembly.
7. Engine thermostat stuck. 7. Replace engine thermostat. Refer to Section 7.4.2, “Thermostat Replacement.”
1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”
®
2. Transmission filled with incorrect
oil.
2. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section
2.4, “Fluids, Lubricants and Capacities.”
3. Incorrect clutch engagement. 3. Refer to Section 9.12.3, “Transmission Solenoid Valves.”
4. Internal damage. 4. Repair or replace parts as needed.
5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate). Refer to Section 6.5.1, “Transmission Removal.”
6. Loose diaphragm (flex plate)
6. Tighten capscrews.
mounting capscrews.
®
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Transmission:
Problem Cause Remedy
7. Oil leaking from transmission. 1. Oil leaking from vent (high oil
level).
2. Drain plug loose and/or o-rings damaged or missing.
3. Hose fittings loose. 3. Tighten fittings.
4. Oil leaking at valve bodies (possible valve body gaskets damaged or missing and/or mounting capscrews not tight).
5. Housing capscrews loose. 5. Tighten capscrews to 46 Nm
6. Oil leaking at pump (possible pump-to-housing o-rings missing or damaged, and/or pump mounting capscrews not tight).
1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.4, “Fluids, Lubricants and Capacities.” Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft).
2. Replace o-rings as needed and tighten plug to 35 Nm (26 lb-ft).
4. Replace gaskets and/or tighten capscrews to 9,5 Nm (7 lb-ft).
(34 lb-ft).
6. Replace o-rings and/or tighten capscrews to 115 Nm (85 lb-ft).
7. Oil leaking at converter bell (possible converter leak and/or
7. Replace converter and/or input shaft seal.
input shaft seal damage).
8. Oil leaking at output shaft
8. Replace output shaft seal.
(output shaft seal damaged).
9. Housing damaged. 9. Replace housing as needed.
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Section 7
Engine: Perkins 1104-42 & 1104-42T
Contents
PARAGRAPH TITLE PAGE
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.3 Radiator/Oil Cooler and Coolant Heater Replacement . . . . . . . . . . . . . . . 7.5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.8.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7.10
7.9.3 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.10.1 Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.10.2 Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
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Engine: Perkins 1104-42 & 1104-42T
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, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
IMPORTANT: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. For assistance with comprehensive engine diagnosis, repair and component replacement, contact your local Perkins Service partner.
A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 60° C (140° F). Extended light- load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.
7.2
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7.1.2 Component Terminology
To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.
Fuel Injection Pump
Engine: Perkins 1104-42 & 1104-42T
Fuel Filter
Oil Filter
Thermostat
Alternator
Turbocharger
(optional)
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Starter
MZ0070
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Engine: Perkins 1104-42 & 1104-42T
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 serial number is required in correspondence with the engine manufacturer.
7.3 SPECIFICATIONS AND MAINTENANCE INFORMATION
For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specifications.”
Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to your local Perkins Engine Distributor for assistance with comprehensive engine diagnosis, repair and component replacement.
7.4 ENGINE COOLING SYSTEM
7.4.1 Radiator Pressure Cap
For a 99° C (210° F) system, use a 90 kPa (13 psi) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine.
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
7.4.2 Thermostat Replacement
Before considering thermostat replacement, check the coolant level, fan belt tension and instrument cluster temperature indicator.
• If the engine seems to take a long time to warm up, the thermostat may be stuck in the open position and requires replacement.
• If the engine runs hot, check the temperature of the upper radiator hose.
• If the hose is not hot, the thermostat may be stuck in the closed position.
• If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage.
2
MZ0080
7. Remove the two capscrews securing the thermostat housing to the engine.
8. Remove the thermostat housing, old gasket and thermostat. Clean all gasket surfaces. DO NOT let any debris into the thermostat opening.
IMPORTANT: ALWAYS use the correct thermostat and install a new gasket. NEVER operate the engine without a thermostat, or engine damage will result.
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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. Connect the battery negative (-) cable to the battery negative (-) terminal.
3. Open the radiator cap, and fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system.
4. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary.
5. Close and secure the engine cover.
7.4.3 Radiator/Oil Cooler and Coolant Heater Replacement
Engine: Perkins 1104-42 & 1104-42T
9
5
7
3
6
Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator.
• If the engine runs hot, check the temperature of the upper radiator hose.
• If the hose is not hot, the thermostat may be stuck in the closed position.
• If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage.
a. Radiator/Oil Cooler 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. Remove the engine cover to ease removal of radiator/oil cooler.
4
8
6. If necessary, remove the windshield washer fluid reservoir.
7. On platform equipped 13M machines, remove the ERS control panel and bracket to gain access to radiator mounting points. Refer to Section 8.8.6, “ERS Control Valve Assembly.”
8. Remove the radiator guard cover (3) and the engine belly pan.
9. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap.
10. Place a suitable container beneath the radiator drain plug.
11. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug (4) 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.
12. Loosen the radiator clamp on the top radiator hose (5). Work the hose off the radiator. Position the hose out of the way to allow radiator removal, or
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Engine: Perkins 1104-42 & 1104-42T
remove the hose from the engine. Inspect the hose, and replace if necessary.
13. Loosen clamp on the radiator return hose (6). Work the hose off the radiator. Position the hose out of the way to allow radiator removal, or remove the hose from the engine. Inspect the hose, and replace if necessary.
14. Disconnect and plug the transmission inlet (7) and outlet hoses (8) and cap the fittings on the oil cooler. Remove the hose from the engine. Inspect the hose, and replace if necessary.
15. Remove the four nuts and four washers from the radiator mounts (9).
16. Carefully lift the radiator/oil cooler out of the engine bay.
Note: If applicable the radiator can be removed with the radiator frame. Remove the five bolts holding the radiator frame to the machine frame and remove the radiator and radiator frame as one unit.
b. Radiator/Oil Cooler Installation
1. Install the isolator mounts to the bottom of the radiator. Insert radiator through the machine frame mounts and install the washers and new locknuts.
2. At the top of the radiator, install the isolator mounts. Install the washers and new locknuts on the back side of the weldment.
3. Be sure the engine fan has clearance in regard to the radiator. Install the radiator guard cover.
4. At the lower radiator return hose, and with the clamp installed over the hose, work the hose onto the radiator and tighten the clamp.
5. Uncap and connect the transmission inlet and outlet hoses to the radiator.
6. At the upper radiator hose, and with the clamp installed over the hose, work the hose onto the radiator, and tighten the clamp.
7. Open the radiator cap and fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system.
8. On Platform equipped 13M machines, install the ERS control panel and bracket. Refer to Section
8.8.6, “ERS Control Valve Assembly.”
9. Connect the battery negative (-) cable to the battery negative (-) terminal.
10. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain as necessary.
11. Install the engine cover.
12. Install the belly pan.
13. Close and secure the engine cover.
7.5 ENGINE ELECTRICAL SYSTEM
The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9, “Electrical System.”
7.6 FUEL SYSTEM
7.6.1 Diesel Fuel
Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair.
Note: Use only diesel fuel designed for diesel engines. Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance.
IMPORTANT: Due to the precise tolerances of diesel injection systems, keep the fuel clean, and free of dirt and water. Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles. Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking.
Inform the owner/operator of the machine to use #2 diesel fuel, unless ambient temperatures are below 0° C (32° F). When temperatures are below 0° C (32° F), a blend of #1 diesel and #2 diesel fuels (known as “winterized” #2 diesel) may be used.
Note: #1 diesel fuel may be used, however, fuel economy will be reduced.
Use a low-sulfur content fuel with a cloud point (the temperature at which wax crystals form in diesel fuel) at least 10° below the lowest expected fuel temperature. The viscosity of the fuel must be kept above 1.3 centistrokes to provide adequate fuel system lubrication.
7.6
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Engine: Perkins 1104-42 & 1104-42T
Note: When using diesel fuel with a sulfur content below
1.3 percent, the filter change interval must be reduced by 75 hours. The use of fuel with a sulfur content above
1.3 percent is not recommended.
13
11
12
10
MZ0100
Note: If replacing the tank, remove all internal and external components from the old tank, and retain for use on the replacement tank.
Note: Have a dry chemical (Class B) fire extinguisher near the work area.
6. Remove fuel tank drain plug (10), and drain fuel into an approved and suitable container. Dispose of fuel properly. Reinstall the fuel tank drain plug and torque to 26 Nm (19 lb-ft).
7. Loosen and remove the strap over the fuel tank and disconnect the fuel supply hose (11) and return line hose (12) from tank.
8. Disconnect fuel level sender (13) electrical connectors from the fuel level sender.
9. Remove screws securing fuel sender to the tank. Remove fuel sender from tank.
10. Lift the empty fuel tank from between the frame rails.
b. Disassembly
The fuel tank is a one-piece unit and cannot be disassembled. The fuel level indicator can be removed and reused on the new replacement tank.
c. Cleaning and Drying
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, the fuel must be drained before tank removal. Always dispose of
fuel properly.
a. Fuel Tank Removal
1. Park the machine on a firm, level surface, level the machine, raise the boom to access the fuel tank, 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 engine to cool.
4. Remove the boom. Refer to Section 3.3.1, “Boom Removal.”
5. Disconnect the battery negative (-) cable at the battery negative (-) terminal.
If contaminated fuel or foreign material is in the tank, the tank can usually be cleaned.
Note: If a leak is suspected in the fuel tank, contact your local JLG distributor.
To clean the fuel tank:
1. Have a dry chemical (Class B) fire extinguisher near the work area.
2. Remove the fuel or oil tank drain plug, and safely drain any fuel into a suitable container. Dispose of fuel properly.
3. Clean the fuel tank with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly.
4. Add a diesel fuel emulsifying agent to the tank. Refer to the manufacturer’s instructions for the correct emulsifying agent-to-water mixture ratio. Refill the tank with water, and agitate the mixture for 10 minutes. Drain the tank completely. Dispose of contaminated water properly.
5. Refill the fuel tank with water until it overflows. Completely flush the tank with water. Empty the fuel tank, and allow it to dry completely.
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Engine: Perkins 1104-42 & 1104-42T
d. Assembly
The fuel level indicator can be removed and reused on the new replacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal.
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. Fuel Tank Installation
1. Set fuel tank between frame rails.
2. Install the fuel tank strap over the fuel tank.
3. Install the fuel sender with new gasket into the fuel tank and secure with screws. Tighten to 5 Nm (3.6 lb-ft). DO NOT overtighten.
4. Connect the fuel supply hose and return line hose to the tank. Secure with clamps and tighten to 25 Nm (18 lb-ft)
5. Install the wire harness connections to the fuel sender.
6. Fill the fuel tank according to specifications. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”
7. Check fuel tank for leaks.
8. Install the boom. Refer to Section 3.3.6, “Boom Installation.”
9. Connect the battery negative (-) cable to the battery negative (-) terminal.
10. Close and secure the engine cover.
7.6.3 After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the instructions found in the appropriate Operation & Safety Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required.
7.7 ENGINE EXHAUST SYSTEM
7.7.1 Exhaust System 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 engine to cool.
4. Disconnect the battery negative (-) cable from the battery negative (-) terminal.
5. Remove the belly pan.
6. Loosen and remove the mounting hardware for the exhaust pipe at the exhaust manifold. Replace the hardware if damaged.
7. Disconnect and remove the clamp attaching the exhaust pipe to the frame.
8. Disconnect and remove the clamp connecting the muffler to the exhaust pipe.
9. Disconnect and remove the clamp connecting the tail pipe to the muffler and remove the tail pipe.
10. Loosen and remove the two bolts at the front and one bolt at the rear of the muffler, and remove the muffler.
MZ0110
7.7.2 Exhaust System Installation
Note: Keep all clamps loosened until entire exhaust system is in place.
1. Install the exhaust pipe with a new seal to the exhaust manifold.
2. Install the exhaust pipe clamp under the engine.
3. Install the muffler to the exhaust pipe and bolt the muffler to the side of the frame.
4. Install the clamp securing the muffler to the exhaust pipe.
7.8
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Engine: Perkins 1104-42 & 1104-42T
5. Install the clamp securing the muffler to the tail pipe.
6. Adjust the muffler, exhaust and tail pipes for proper clearance then tighten all clamps.
7. Connect the battery negative (-) cable to the battery negative (-) terminal.
8. Start engine and check for exhaust leaks at all exhaust connections. Adjust or repair as needed.
9. Install the belly pan.
10. Close and secure the engine cover.
7.8 AIR CLEANER ASSEMBLY
WARNING: NEVER run the engine
with only the inner safety element installed.
IMPORTANT: Refer to the appropriate Operation & Safety Manual for the correct element change procedure.
7.8.1 Air Cleaner 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 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 engine to cool.
4. Disconnect the battery negative (-) cable at the battery negative (-) terminal.
5. Disconnect the low pressure indicator wire connection on the air cleaner.
6. Remove the clamp securing the air intake elbow to the air cleaner assembly. Lift the air intake elbow off the air cleaner.
7. The reducing insert and the reinforcement ring should be removed along with the air intake tube.
8. Remove the clamp securing the air outlet elbow. Lift the air outlet elbow off the air cleaner.
9. Remove the two capscrews and ripp nuts securing the air cleaner mounting bracket to the air cleaner mounting plate. Remove the air cleaner assembly.
7.8.2 Air Cleaner Assembly Installation
Note: Apply Loctite® 242 threadlock to the capscrew threads before installation.
1. With the air cleaner assembly attached, install the air cleaner mounting bracket using capscrews and ripp nuts.
2. Place the loosened clamps over the air intake elbow along with the reducing insert and the reinforcement ring, and install elbow on the air cleaner assembly.
3. Place the loosened clamps over the air outlet elbow and install elbow on the air cleaner assembly.
4. Connect low pressure indicator wire connection.
5. Adjust and tighten both clamps before starting the machine.
6. Connect the battery negative (-) cable at the battery negative (-) terminal.
7.9 ENGINE REPLACEMENT
7.9.1 Engine 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 engine to cool.
4. Disconnect the (+) positive and (-) negative battery cables and remove the battery.
5. Remove the engine cover, radiator guard plate and the engine belly pan.
6. On Platform equipped 13M machines, remove the ERS control and bracket. Refer to Section 8.8.6, “ERS Control Valve Assembly.”
7. Drain and remove the radiator assembly. Refer to Section 7.4.3, “Radiator/Oil Cooler and Coolant Heater Replacement.”
8. Remove the heater hoses attached to the engine.
Note: The engine harness is routed and attached to the engine using hold-down clamps and plastic wire ties at various places on the engine. Before removing engine, ensure that the harness has been completely separated (disconnected) from the engine. Move the harness clear of the engine, and with the help of an observer, ensure that engine clears the harness during removal.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.9
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Engine: Perkins 1104-42 & 1104-42T
9. Label and disconnect all wire harness connections on the engine.
10. Unbolt and remove the hood latch plate. Mark the plate to help with hood adjustment when being reinstalled.
11. Unbolt the return hydraulic oil filter plate and leave in place.
12. Disconnect and cap the fuel inlet line at the fuel filter head.
13. Disconnect and cap the fuel return line from the fuel filter head.
14. Mark the location of the throttle cable (14) at the throttle cable mount. Loosen jam nuts and remove.
14
MZ0940
15. Disconnect the throttle cable at the engine throttle lever.
16. Remove the exhaust pipe from the exhaust manifold. Refer to Section 7.7.1, “Exhaust System Removal.”
17. Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe.
18. Remove the air cleaner assembly. Refer to Section
7.8.1, “Air Cleaner Assembly Removal.”
19. Remove the access plug from side of the engine bell housing. This will allow access to remove the eight bolts holding the flex plate to the engine flywheel.
20. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Remove them one at a time.
21. Secure the engine with a lifting strap or chain from the appropriate lifting points. Use a suitable hoist or overhead crane.
22. At the rear right engine mount (15), remove the bolt and washer. Repeat for the rear left engine mount.
15
MZ0950
23. Place a support or jack under the transmission to hold the transmission in place while engine is being removed.
24. Remove the ten bolts holding the transmission to the engine. Slightly lift and pull the engine out of the machine. Have an assistant ensure that the engine clears all frame components during removal.
25. Place engine on a flat, level surface.
7.9.2 Engine Disassembly, Inspection and
Service
Engine disassembly, internal inspection, service, repair and assembly procedures are covered in the Perkins service manual. Several special engine service tools are required to properly service the engine. Contact your local Perkins Service partner for further information.
Note: If the engine is being replaced, there may be external components that will be required to be transferred from the original engine to the replacement engine depending upon who you purchase the new engine from and the configuration of your replacement engine. Refer to the appropriate Perkins user manual for detailed procedures that cover the transfer of original engine components to the replacement engine.
7.10
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Page 75
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® 242 threadlock to the engine mount bracket capscrew threads before installation.
2. Inspect the front engine mounting bracket isolator. Replace isolator if cracked or worn.
3. Install two guide studs in the bell housing holes.
4. Lift the engine and slowly push and lower into the engine bay. Have an assistant ensure that the engine clears all frame, hose and harness components during engine installation. Position engine brackets over the front frame mounts.
5. Push the engine towards the transmission aligning the guide studs and the torque converter shaft with the corresponding holes.
6. Push the engine against the transmission and install eight of the ten bolts and washers. Remove both guide studs and replace with the remaining two bolts and washers. Tighten bolts.
7. Torque the transmission bolts to 63 Nm (46 lb-ft) AFTER engine is lowered and secured with the front motor mount bolts installed and torqued.
8. Remove the support from under the transmission and lower the engine the remainder of the way onto the frame. Align the motor mount holes and install the bolts. Apply Loctite mount bolts and torque to 210 Nm (155 lb-ft).
9. Turn the engine over slowly by hand and align each of the eight flex plate bolts through the access plug in the bell housing. Install them one at a time. DO NOT fully tighten until all of the capscrews and locknuts are in place. Torque to 35-39 Nm (26-29 lb-ft). Replace access plug.
10. Install the exhaust pipe. Refer to Section 7.7.2, “Exhaust System Installation.”
11. Install the complete air cleaner assembly. Refer to Section 7.8.2, “Air Cleaner Assembly 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.
®
242 threadlock to the motor
18. Secure the return hydraulic oil filter plate to the frame.
19. Install both heater hoses to the engine and tighten clamps.
20. Install the complete radiator assembly. Refer to Section 7.4.3, “Radiator/Oil Cooler and Coolant Heater Replacement.”
21. Install the hose clamp on the bottom radiator hose and work onto the engine. Tighten the clamp.
22. Install the hose clamp on the top radiator hose and work onto the engine. Tighten the clamp.
23. Connect the transmission inlet and outlet hoses on the oil cooler. Install the clamp holding the top transmission cooler hose and the three bolts holding the fan screen.
24. On Platform equipped 13M machines, install the ERS control panel and bracket. Refer to Section
8.8.6, “ERS Control Valve Assembly.”
25. Install the engine cover and adjust.
26. Install the battery and reconnect the (+) positive and (-) negative cables.
27. Open the radiator cap and fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system.
28. Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are correct and connected tightly.
29. From within the cab, lightly depress the throttle pedal to full-throttle position. As needed, adjust the limit- stop screw until it touches the pedal. Tighten the locknut to 13,6-14,1 Nm (120-125 lb-in).
Note: Have an assistant stand by with a Class B fire extinguisher.
30. Start the engine and run to normal operating temperature then shut off the engine. While the engine is cooling, check for leaks.
31. Allow the engine to cool. Check the radiator coolant level, and top off with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap.
32. Check for leaks from the engine, main hydraulic pump and lines, transmission, hydraulic reservoir and fuel tank. Check the levels of all fluids and lubricants. Fill as required.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.11
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Engine: Perkins 1104-42 & 1104-42T
IMPORTANT: During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steer- ing wheel.
• Keep the transmission in (N) NEUTRAL.
33. Obtain and connect an appropriate engine analyzer or tachometer. Check the engine rpm at full throttle. If the rpm is not 2340 ±50 rpm, readjust the throttle limit-stop screw at the throttle pedal within the cab.
34. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level.
35. Check for proper operation of all components.
36. Turn the engine off.
37. Install the engine belly pan.
38. Close and secure the engine cover.
7.10 ENGINE DRIVE PLATE
7.10.1 Drive Plate 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 engine to cool.
4. Disconnect the battery negative (-) cable from the battery negative (-) terminal.
7.10.2 Drive Plate Installation
1. Install the three new drive plates on the torque converter and torque the six bolts with lock washers to 35-39 Nm (26-29 lb-ft).
2. Mount the drive plate/converter assembly to the transmission.
3. Refer to Section 6.5.3, “Transmission Installation,” or Section 7.9.3, “Engine Installation,” for the remainder of the installation.
4. Connect the battery negative (-) cable to the battery negative (-) terminal.
5. Close and secure the engine cover.
16
MZ0580
Note: In order to remove the engine drive plates, the engine and transmission must be separated.
5. Refer to Section 6.5.1, “Transmission Removal,” or Section 7.9.1, “Engine Removal.”
6. Remove the eight bolts holding the drive plates (16) to the flywheel.
7. With the drive plates and torque convertor removed, loosen and remove the six bolts and six lock washers holding the three drive plates to the torque converter.
8. Replace all three drive plates if damaged
7.12
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Engine: Perkins 1104-42 & 1104-42T
7.11 TROUBLESHOOTING
Trouble Possible Causes (see key, below)
Low Cranking Power
Will Not Start
Difficult Starting
Lack of Power
Misfiring
Excessive Fuel Consumption
Black Exhaust
Blue/White Exhaust
Low Oil Pressure
Knocking
Erratic Running
Vibration
High Oil Pressure
Overheating
Excessive Crankcase Pressure
Poor Compression
Starts and Stops
1, 2, 3, 4
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
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
11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
4, 36, 37, 38, 39, 40, 42, 43, 44, 58
9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
4, 38, 41
11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
25, 31, 33, 34, 45, 55, 60
11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
10, 11, 12
Key to Possible Causes
1. Battery charge low
2. Bad electrical connection
3. Faulty starter motor
4. Incorrect grade of lubricating oil
5. Low cranking speed
6. Fuel tank empty
7. Faulty stop control operation
8. Fuel inlet restricted
9. Faulty fuel lift pump
10. Clogged fuel filter
11. Restricted air cleaner
12. Air in fuel system
13. Faulty fuel injection pump
14. Faulty fuel injectors or incorrect type
15. Incorrect use of cold start equipment
16. Faulty cold start equipment
17. Broken fuel injection pump drive
18. Incorrect fuel pump timing
19. Incorrect valve timing
20. Poor compression
21. Blocked fuel tank vent
22. Incorrect grade of fuel
23. Sticking throttle or restricted movement
24. Exhaust pipe restriction
25. Leaking cylinder head gasket
26. Overheating
27. Cold running
28. Incorrect tappet adjustment
29. Sticking valves
30. Incorrect high pressure pipes
31. Worn cylinder bores
32. Pitted valves and seats
33. Broken, worn or sticking piston ring(s)
34. Worn valve stems and guides
35. Restricted air cleaner
36. Worn or damaged bearings
37. Insufficient oil in sump
38. Inaccurate gauge
39. Oil pump worn
40. Pressure relief valve sticking open
41. Pressure relief valve sticking closed
42. Broken relief valve spring
43. Faulty suction pipe
44. Restricted oil filter
45. Piston seizure/pick up
46. Incorrect piston height
47. Damaged fan
48. Faulty engine mounting
49. Incorrectly aligned flywheel housing or incorrectly aligned flywheel
50. Faulty thermostat
51. Restriction in water jacket
52. Loose fan belt
53. Restricted radiator
54. Faulty water pump
55. Restricted breather pipe
56. Damaged valve stem oil deflectors (if fitted)
57. Coolant level too low
58. Blocked sump strainer
59. Broken valve spring
60. Exhauster or vacuum pipe leak
61. Turbo impeller damaged or dirty
62. Turbo lubricating oil seal leak
63. Induction system leaks
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
7.13
Page 78
Engine: Perkins 1104-42 & 1104-42T
This Page Intentionally Left Blank
7.14
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 79
Section 8
Hydraulic System
Contents
PARAGRAPH TITLE PAGE
8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.4.1 Checking Function Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.4.2 Adjusting Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.1 Hydraulic Oil Reservoir Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.2 Hydraulic Oil Reservoir Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7 Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.7.1 Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.7.2 Pump Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
8.7.3 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8 Valves and Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.8.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8.8.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.8.3 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8.5 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.8.6 ERS Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
8.9 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.9.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.9.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
8.9.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.9.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.9.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.9.6 General Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.9.7 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.9.8 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.9.9 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
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8.1
Page 80
Hydraulic System
8.1 HYDRAULIC COMPONENT TERMINOLOGY
To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
Tilt Cylinder
Extend/Retract
Cylinder
(inside boom)
Hydraulic Filter
ERS Control
Panel
8.2
Lift/lower
Cylinder
Main Control Valve
Main Pump
Hydraulic Fluid
Reservoir
Outrigger Cylinders
(12 & 13M only)
Steering Cylinder
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Compensation
Cylinder
Page 81
Hydraulic System
8.2 SAFETY INFORMATION
WARNING: DO NOT service the
machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Failure to follow the safety practices may result in death or serious injury.
Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition source is present.
Accordingly, periodically inspect all hydraulic system components, hoses, tubes, lines, fittings, etc. Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard. If in doubt, replace the component.
Whenever you disconnect a hydraulic line, coupler, fitting or other component, slowly and cautiously loosen the part involved. A hissing sound or slow seepage of hydraulic fluid may occur in most cases. After the hissing sound has ceased, continue removing the part. Any escaping oil should be directed into an appropriate container. Cap or otherwise block off the part to prevent further fluid seepage.
Hydraulic system maintenance will, at times, require that the engine be operated. Always follow safety precautions.
A major cause of hydraulic component failure is contamination. Keeping the hydraulic fluid as clean as possible will help avoid downtime and repairs. Sand, grit and other contaminants can damage the finely machined surfaces within hydraulic components. If operating in an exceptionally dirty environment, change filters and inspect the fluid more often. When servicing the system, cap or plug hydraulic fittings, hoses and tube assemblies. Plug all cylinder ports, valves and the hydraulic reservoir, and pump openings until installation occurs. Protect threads from contamination and damage.
Some hydraulic functions are actuated by interfacing with electrical system components (switches, solenoids and sensors). When the hydraulic system is not functioning properly, check the electrical aspect of the malfunctioning circuit also.
8.3 HYDRAULIC PRESSURE DIAGNOSIS
JLG Parts Department has a kit available to use for hydraulic system maintenance and troubleshooting: the JLG Pressure Test Kit. The kit is in a durable polyethylene carrying case for demanding field service conditions.
Pressure Test Kit
The hydraulic pressure test kit is used to pressure test the various hydraulic components in the hydraulic system. The kit includes:
• Gauges for testing high and low pressure circuits
• Fittings, couplers and hoses
• Durable carrying case
Contact your local JLG distributor for ordering information.
Part
Number
70000652 Hydraulic Pressure Test Kit 10 lbs. Consult Factory
70000101 Digital Hydraulic Pressure
Description Approximate
Weight
7 lbs. Consult Factory
Te st K it
Price and
Availability
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.3
Page 82
Hydraulic System
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 functions are often related. Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit.
Always check the following before beginning to troubleshoot a circuit that is not functioning correctly.
1. Check the hydraulic oil level in the reservoir. Oil level should be at the middle of the sight glass with all cylinders retracted.
2. Check hoses, tubes, fittings and other hydraulic components for leaks, bends, kinks, interference, etc.
3. Check for air in the hydraulic system. Erratic machine performance and/or spongy cylinder operation are signs of air in the hydraulic system.
4. If air in the hydraulic system is suspected, you will hear air leakage when hydraulic fittings are loosened and see air bubbles in the hydraulic fluid.
5. Loose fittings, faulty o-rings or seals, trapped oil, leaks, system opened for service, etc., can cause air in the system. Determine what is causing air to enter the system and correct it. Bleed air from the system.
8.4.1 Checking Function Pressures
All hydraulic system function pressures can be checked at one location. A digital pressure gauge is recommended.
1. Start the machine and warm the hydraulic system to operating temperature.
2. Shut off the machine and install a digital or a 345 bar (5000 psi) gauge to the test port (1) located at the top right corner of the main control valve.
1
Note: It is possible to see maximum system pressure by activating and bottoming any of the hydraulic functions.
4. With the engine running at full throttle and the hydraulic function bottomed, the gauge should read 250 bar (3625 psi) ± 5 bar (70 psi).
8.4.2 Adjusting Hydraulic Pressure
There is only one adjustment to set the main hydraulic pressure.
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. Open the engine cover.
3. Remove the cap on the bottom relief on the pilot valve at the main hydraulic pump located at the end of the transmission.
2
MZ1270
4. Start the machine and loosen the jam nut on the relief and using an allen wrench; turn the relief clockwise to increase pressure or counter-clockwise to decrease pressure. Set the pressure to 250 bar (3625 psi) ± 5 bar (70 psi) at full throttle.
5. Tighten the jam nut and recheck the pressure at full throttle. If the reading is within specification, shut the machine off, install the safety cap and remove the gauge from the test port.
6. If the proper pressure cannot be set, refer to Section
8.5, “Hydraulic Schematics,” or Section 9.5, “Electrical System Schematics,” to help troubleshoot the problem.
MZ1310
3. Start the machine, run the engine at full throttle and bottom the boom in function.
8.4
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 83
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.5 HYDRAULIC SCHEMATICS
MZ1630
125/60
DN 10
DN 10
STABILIZER LEFT
STABILIZER
AB
B
A
P
5
T
0.3 bar
125/60
DN 10
STABILIZER RIGHT
30
bar
100/50
DN 10
AB
B
A
3.5 bar
SWAY
DN 10
DN 32
3 bar
10 µm
DN 40
DN 10
AB
B
A
7100
SWAY
LPS 160R1X/ LD7-643/01
AUXILIARY
DN 12
B
140/70
DN 12
AB
B
7003
A
AUXILIARY
65 l/min
EF
CF
2
P
DN 25
60
SL1L
300 bar/4:1
DN 50
TILT
P
P
T
T
280
B
9598
A
LD
DN 10
DN 12
A
DN 6
X
A10VO60DFR1 Q=132 l/min p=250 bar n=2200 1/min dp=25 bar
DN 20
COMPENSATION
2x90/45
DN 12
B
280
FRONT AXLE
EXTEND/RETRACT 12/13 M
110/63
DN 16
A
B
280
B
9597
A
130/200 l/min 130 l/min65/100 l/min25 l/min 5 l/min25 l/min
DN 10
DN 10
90/56
P
T
110 bar/4:1
DN 16
DN 10
M
B
A
LS
P
T
LR
235 bar
175 bar
P
T
DN 10
EXTEND/RETRACT 7-9 M
100/60
P
T
110 bar/4:1
AB
A
7006
0931
CF
B
LIFT/LOWEREXTEND/RETRACTTILT
P
A
DN 10
B
T
DN 10
LS
4WE6G
OSPF 200 LS
LIFT/LOWER
LX
20 bar
B
1.0
PVSP
P
REAR AXLE
DN 8
FRONT AXLE
DN 6
DN 10
160/90
P
P
T
T
300 bar/4:1
DN 16
DN 16
DN 8
5 bar
DN 8
BRAKES
STANDARD MACHINE
REAR AXLE
Hydraulic System
VOLTAGE
= 12 V
8.5
Page 84
8.6
8.5 Hydraulic Schematics (Continued)
Hydraulic System
BASKET ROTATOR
125/60
DN 10
STABILIZER
DN 10
AB
B
A
125/60
DN 10
100/50
DN 10
AB
B
A
SWAY
DN 10
DN 10
AB
B
A
DN 12
DN 12
AB
B
7003
A
140/70
TILT
EXTEND/RETRACT 12/13 M
90/56
COMPENSATION
2x90/45
P
P
T
T
300 bar/4:1
DN 10
DN 12
A
B
DN 12
280
280
B
9598
A
110/63
DN 16
A1
A
P
T
110 bar/4:1
DN 16
B1
B
280
M
B
9597
A
EXTEND/RETRACT 7-9 M
DN 10
A2
A
B
7006
0931
A
100/60
P
T
110 bar/4:1
AB
B2
CF
B
LIFT/LOWER
160/90
P
P
T
T
300 bar/4:1
DN 16
DN 16
LX
20 bar
B
1.0
DN 8
DN 8
DN 8
BRAKES
5 bar
SMART BASKET OPTION
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
MZ1640
SWAYSTABILIZER RIGHTSTABILIZER LEFT
LPS 160R1X/ LD7-643/01
DN 32
30
bar
P
5
T
0.3 bar
3 bar
10 µm
3.5 bar
DN 40
AUXILIARY
65 l/min
DN 25
B
60
EF
2
P
TILT
65/100 l/min25 l/min 5 l/min25 l/min
CF
LD
DN 6
X
SL1L
DN 50
FRONT AXLE
A10VO60DFR1 Q=132 l/min p=250 bar n=2200 1/min dp=25 bar
DN 20
EXTEND/RETRACT
130/200 l/min
DN 10
LS
T
LR
235 bar
DN 10
175 bar
P
P
LIFT/LOWER
130 l/min
LS
T
DN 10
P
A
B
T
4WE6G
OSPF 200 LS
DN 10
DN 10
P
REAR AXLE
PVSP
FRONT AXLE
PT
A1
B1
DN 6
OUT
DN 10
1.2
MOTOR
IN
REAR AXLE
A1
A2
B2
250
Page 85
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
125/60
DN 10
STABILIZER
DN 10
AB
B
A
125/60
DN 10
100/50
DN 10
AB
B
A
SWAY
DN 10
DN 10
AB
B
A
BASKET ROTATOR
DN 12
DN 12
AB
B
7003
A
140/70
8.5 Hydraulic Schematics (Continued)
TILT
COMPENSATION
2x90/45
P
P
T
T
300 bar/4:1
DN 10
DN 12
DN 12
A
B
280
280
B
9598
A
EXTEND/RETRACT 12/13 M
110/63
DN 16
A1
B1
A
B
280
B
9597
A
DN 16
90/56
P
T
110 bar/4:1
M
EXTEND/RETRACT 7-9 M
100/60
DN 10
A2
A
B
7006
0931
A
P
T
110 bar/4:1
AB
B2
LX
CF
B
LIFT/LOWER
20 bar
B
1.0
160/90
P
P
T
T
300 bar/4:1
DN 16
DN 16
DN 8
DN 8
5 bar
DN 8
BRAKES
AUSTRALIAN SMART BASKET OPTION
REAR AXLE
A1
A2
B2
250
Hydraulic System
MZ1650
SWAYSTABILIZER RIGHTSTABILIZER LEFT
LPS 160R1X/ LD7-643/01
DN 32
30
bar
P
5
T
0.3 bar
3 bar
10 µm
3.5 bar
DN 40
AUXILIARY
65 l/min
DN 25
B
60
EF
65/100 l/min25 l/min 5 l/min25 l/min
CF
2
LD
P
SL1L
DN 50
DN 6
X
A10VO60DFR1 Q=132 l/min p=250 bar n=2200 1/min dp=25 bar
DN 20
EXTEND/RETRACTTILT
FRONT AXLE
130/200 l/min
DN 10
LS
T
LR
235 bar
DN 10
175 bar
P
P
LIFT/LOWER
130 l/min
P
A
DN 10
B
T
DN 10
LS
4WE6G
OSPF 200 LS
T
DN 10
PVSP
P
A
SVI
RVI
B
REAR AXLE
FRONT AXLE
PT
A1
B1
DN 6
DN 10
OUT
1.2
MOTOR
IN
8.7
Page 86
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, fluid may seep, leak or be more forcefully expelled from the breather when system pressure exceeds the rating of the filter head or breather. If the return filter becomes plugged, the return hydraulic oil will bypass the filter when pressure reaches 1,7 bar (25 psi) and return to the reservoir unfiltered.
Carefully examine fluid seepage or leaks from the hydraulic reservoir to determine the exact cause. Clean the reservoir and note where any seepage occurs.
MZ0130
8.6.1 Hydraulic Oil Reservoir Draining
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. Open the filler cap on the hydraulic oil reservoir. Remove the drain plug at the bottom of the hydraulic oil reservoir.
6. Transfer the used hydraulic oil into a suitable, covered container, and label as "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the drain plug.
7. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area.
8.6.2 Hydraulic Oil Reservoir Filling
1. Be sure reservoir is clean and free of all debris.
2. Install a new hydraulic oil filter.
3. Fill the reservoir with Mobilfluid 424® ISO Grade 46 oil. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”
4. Connect the battery negative (-) cable to the battery negative (-) terminal.
5. Close and secure the engine cover.
8.6.3 Hydraulic Oil Reservoir Removal/ Installation
If it is determined that the hydraulic oil reservoir must be removed, the hydraulic oil must be drained before the reservoir is removed. Always dispose of hydraulic oil properly.
a. Reservoir Removal
1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (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. Drain the hydraulic oil reservoir. Refer to Section
8.6.1, “Hydraulic Oil Reservoir Draining.”
6. Loosen the clamps and remove and cap the suction and return hoses on the hydraulic oil reservoir.
7. Plug and cap the fittings on the hydraulic oil reservoir.
8. Support the hydraulic oil reservoir from the bottom and remove the six bolts, washers and nuts.
9. Carefully lower the reservoir to the ground.
b. Disassembly
The hydraulic oil reservoir is a one-piece unit and cannot be disassembled. The hydraulic oil level sight-glass and hydraulic oil filler cap can be removed and reused on the new replacement reservoir. Dispose of the old reservoir according to local regulations concerning hazardous materials disposal.
8.8
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 87
Hydraulic System
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) fire extinguisher near the work area.
2. Clean the hydraulic oil reservoir with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly.
d. Inspection
Note: If a leak is suspected in the hydraulic oil reservoir, contact JLG Service Department.
1. Inspect the hydraulic oil reservoir thoroughly for any cracks, slices, leaks or other damage.
2. With the hydraulic oil reservoir removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 0,06-0,10 bar (1-1.5 psi) of air pressure through the elbow. Check the reservoir for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area.
e. Reservoir Installation
8.7 HYDRAULIC SYSTEM PUMP
8.7.1 Pump Description
For internal service instructions contact your local JLG distributor.
8.7.2 Pump Failure Analysis
The implement pump is the “heart” of the hydraulic system, and whenever there is a problem in the system, the pump often is blamed. However, implement pump failure is seldom due to failure of pump components. Pump failure usually indicates another problem in the hydraulic system.
According to pump manufacturer statistics, 90-95 percent of pump failures are due to one or more of the following causes:
• Aeration
•Cavitation
• Contamination
• Excessive Heat
• Over-Pressurization
• Improper Fluid
In the event of pump failure, investigate further to determine the cause of the problem.
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.
5. Install hydraulic filter neck components and secure.
6. Fill the hydraulic oil reservoir according to specifications. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”
7. Check the hydraulic oil reservoir for leaks.
8. Connect the battery negative (-) cable to the battery negative (-) terminal.
9. Close and secure the engine cover.
1
MZ1660
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.9
Page 88
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.
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.”
8.10
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 89
Hydraulic System
8.8 VALVES AND MANIFOLDS
8.8.1 Main Control Valve
The main control valve is mounted on the side rail in the engine compartment.
4
3
2
4 SECTION VALVE
5
4
5 SECTION VALVE
7
5
6 SECTION VALVE
7
6
5
7 SECTION VALVE
The main control valve assembly consists of working sections with their own valve assemblies, each providing a specific hydraulic function. Those functions are: lift/lower (1), extend/retract (2), tilt (3), auxiliary (4), sway (5), outrigger right (6) and outrigger left (7).
1
3
2
1
4
3
2
1
4
3
2
1
MZ1480
Note: The 7M Agricultural Option has two separate options for the main control valve. The functions are: lift/lower (8), extend/retract (9), tilt (10), auxiliary (11), sway (12) and auxiliary rear (13).
13
11
10
9
5 SECTION VALVE
6 SECTION VALVE
13
12
11
8
10
9
8
MZ1770
a. Main Control Valve 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. With the engine OFF, 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.
5. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding.
6. Place a suitable container to catch hydraulic fluid drainage beneath the frame.
7. Label, disconnect and cap all the hydraulic hoses, tubes and wires at the main control valve.
8. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.11
Page 90
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
d. Main Control Valve Parts Inspection
Inspect all parts and internal passageways for wear, damage, etc. If inner surfaces of any component DO NOT display an ultra-smooth, polished finish, or are damaged in any way, replace the damaged part. Often, dirty hydraulic fluid causes failure of internal seals, damage to the polished surfaces within the component, and wear of and/or harm to other parts.
e. Main Control Valve Assembly
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.
Assemble each Valve Section
1. Reassemble any check valves, compensator valves, anti-cavitation valves or shock valves from individual valve sections if equipped.
2. Install the control spool being careful not to nick or scratch the valve section bore or the control spool.
3. Install the end caps on each end of the valve section.
INLET MODULE
MZ1500
Disassemble each Valve Section
1. Carefully separate the load sense outlet section from the extend/retract section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining section being careful not to lose the load sense shuttle ball.
4. Remove both end caps from each end of the valve sections then remove each control spool.
5. Remove any check valves, compensator valves, anti-cavitation valves or shock valves from each individual valve section if equipped.
6. Keep all parts being removed from individual valve sections tagged and kept together.
c. Main Control Valve Parts Cleaning
Clean all components with a suitable cleaner, such as trichlorethylene, before continuing. Blow dry.
Assemble the Main Control Valve.
1. Place all three tie rods with the washers and nuts through the end main control valve section.
2. Stand the end main control valve section on end.
3. Install proper o-rings and load sense shuttle on the inner face of the end main control valve section. Align the extend/retract section over the three tie rods and slide onto the end main control valve section.
4. Using proper o-rings and load sense shuttle, repeat step three for the remaining sections.
5. Install the washers and nuts on the tie rods and torque to 22 Nm (195 lb-in).
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 bracket, aligning the bolts with the holes in the end sections of the main control valve. Slide the main control valve into position, and tighten the bolts.
3. Prime the main control valve by filling the inlet openings with fresh, filtered hydraulic oil from a clean container, before attaching the hoses.
8.12
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 91
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 Service Brake Valve
The service brake valve is at the base of the steering column support, concealed by the lower dash cover.
The service brakes themselves are part of the axles (the park brake is part of the front axle only). Refer to Section 5, “Axles, Drive Shafts, Wheels and Tires,” for further information.
a. Service Brake Valve 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. Remove the necessary dash panels.
6. Label, disconnect and cap all hydraulic hoses and fittings on the side of the service brake valve (1).
7. Disconnect the pin holding the yoke to the brake pedal arm.
8. Remove the four capscrews, four nuts and four lockwashers mounting the service brake valve to the steering column support.
Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective.
b. Service Brake Valve Installation
1. Install the service brake valve with the lockwashers and capscrews to mount the brake valve to the steering column support.
2. Align the yoke on the brake valve with the brake pedal arm. Insert the pin and clip into place being sure there is a small amount of play between the pedal and the brake plunger.
1
MZ0330
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.
3. Use new oiled o-rings as required. Reattach and secure all valves, hoses, clamps, etc.
4. Check the routing of all hoses, and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps.
5. Connect the battery negative (-) cable to the battery negative (-) terminal.
8.13
Page 92
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 Brake Test
Carefully bleed the brake lines as soon as the brake valve is installed in the machine. Air in the system will not allow the brakes to apply properly. There are two brake bleeder locations on each axle. Work with an assistant to perform this procedure.
1. Place the transmission control lever in (N) NEUTRAL, engage the park brake, and start the engine.
2. Remove the plastic cap from the front brake bleeder. Attach one end of a length of transparent tubing over the brake bleeder. Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil. The end of the tubing must be
below the oil level in the container.
3. DO NOT open the brake bleeder without holding the tubing firmly on the bleeder. There is a pressure at the brakes. Carefully open the bleeder with a wrench. Have the assistant depress the brake pedal. Close the brake bleeder when air bubbles no longer appear in the oil. Release the brake pedal. remove the tubing from the brake bleeder.
4. Repeat Steps 2 and 3 for the remaining brake bleeders.
5. Install a vacuum pump on the brake reservoir and remove the remainder of the trapped air from the brake system.
6. Check brake fluid level and add if necessary using ATF fluid.
7. Conduct a pressure and function check of the service brake. Refer to Section 8.3, “Hydraulic Pressure Diagnosis.”
8.8.4 Steering Orbitrol Valve
Refer to Section 4.3.1, “Steering Column and Orbitrol Valve,” for details.
8.8.5 Steer Select Valve
The machine can be used in the front-wheel, four-wheel or crab steering mode. The steer select valve controls the direction of hydraulic fluid flow to the steering cylinder mounted on each axle. The steer select valve is attached to a mounting plate inside the frame near the left front corner of the cab.
Verify the correct operation of the steer select valve solenoids before considering replacement of the valve. The housing of the steer select valve is not serviceable and must be replaced if defective.
2
MZ0380
a. Steer Select Manifold and Valve Removal
1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NE UTRAL, 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. Label, disconnect and cap all hydraulic hoses and fittings connected to the steering select valve.
6. Disconnect all wire terminal leads attached to the steering select valve.
7. Remove the two bolts holding the steer select valve to the mounting plate on the frame.
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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 ultra- smooth, 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.
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.
5. Connect the battery negative (-) cable to the battery negative (-) terminal.
6. Start the engine and run at approximately 1/3-1/2 throttle for about one minute, without moving the machine or operating any hydraulic functions.
7. Inspect 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. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.
9. Close and secure the engine cover.
d. Steering Test
1. Conduct a pressure check of the steering hydraulic circuit at the test port on the implement pump. Refer to Section 8.4.2, “Adjusting Hydraulic Pressure.”
2. Check each steering mode for proper function.
8.8.6 ERS Control Valve Assembly
The ERS Control Panel is only included on 13M Platform machines. The control panel is located in the engine compartment.
3
4
7. Install the solenoid valves and cartridges in the steer select housing.
8. Attach the steer select valve to the manifold using four new, oiled o-rings and the four socket head capscrews.
c. Steer Select Manifold and Valve Installation
1. Install the steer select valve to the mounting plate under the left side of the frame using the two bolts.
2. Uncap and connect the previously labeled hydraulic hoses and fittings to the steer select valve.
3. Connect all previously labeled wire terminal leads to the steer select valve.
4. 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 hose clamps.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
5
MZ1760
a. ERS Control Valve 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 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.
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Hydraulic System
4. Disconnect the battery negative (-) cable at the battery negative (-) terminal.
5. Label and disconnect the electrical connections attached to the ERS control panel (3).
6. Remove the four bolts that attach the control panel face plate to the control panel body.
7. Remove the two capscrews that attach the control panel body to the control panel bracket (4).
8. Label, disconnect and cap all hydraulic hoses attached to the ERS control valve assembly.
9. Label, disconnect and cap the hydraulic hoses attached to the hydraulic filter (5).
10. On Australian Platform machines, label, disconnect and cap the hydraulic hoses attached to the 2 by 2 valve. Remove the two mounting capscrews securing the 2 by 2 valve. Remove the 2 by 2 valve from the engine compartment.
11. Remove the ERS control valve assembly mounting hardware. Remove the ERS control valve assembly from the engine compartment.
12. Remove the hydraulic filter from the engine compartment.
13. Loosen, but do not remove the two bolts on the left side of the main control valve bracket. Remove the two bolts in the center of the control valve bracket.
14. Slide the control valve assembly bracket to the left to release the bracket from the engine compartment.
b. ERS Control Valve Assembly Installation
1. Slide the control valve assembly bracket into position by guiding the bracket notches around the main control valve bracket mounting bolts.
2. Install the two bolts in the center of the control valve bracket. Tighten the two bolts on the main control valve bracket.
3. Install the hydraulic filter to its original position.
4. Position the ERS control valve assembly to its original orientation and secure with the same mounting hardware.
5. On Australian machines, secure the 2 by 2 valve to the control valve bracket. Uncap and reconnect the hydraulic hoses to the 2 by 2 valve.
6. Uncap and reconnect the hydraulic hoses to the hydraulic filter and the ERS control valve.
7. Install the ERS control panel to the control panel bracket with two capscrews.
8. Install the face plate to the control panel with four capscrews.
9. Connect the previously labeled electrical connections to the ERS control panel.
10. Connect the battery negative (-) cable to the battery negative (-) terminal.
11. Close and secure the engine cover.
8.9 HYDRAULIC CYLINDERS
8.9.1 General Cylinder Removal
Instructions
1. Remove any attachment from the machine. Park the machine on a firm, level surface, allowing sufficient workspace. Level the machine, place the transmission control lever in (N) NEUTRAL, engage the park brake, shut the engine OFF and block the wheels.
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. Relieve any trapped pressure in the hydraulic system by using the handle or wrench (located in the toolbox) and move the double nut on the side of the actuator module on the valve section back and forth.
5. Label, disconnect and cap hydraulic hoses and cylinder ports in relation to the cylinder.
6. Attach a suitable sling to an appropriate lifting device to the cylinder. Make sure the device used can actually support the cylinder.
7. Remove the lock bolt and/or any retaining clips securing the cylinder pins. Remove the cylinder pins.
8. Remove the cylinder.
9. Wipe up any hydraulic fluid spillage in, on, near or around the machine.
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Hydraulic System
8.9.2 General Cylinder Disassembly
1. Clean the cylinder with a suitable cleaner before disassembly. Remove all dirt, debris and grease from the cylinder.
2. Clamp the barrel end of the cylinder in a soft-jawed vise or other acceptable holding equipment if
possible.
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.
IMPORTANT: Avoid using excessive force when clamping the cylinder in a vise. Apply only enough force to hold the cylinder securely. Excessive force can damage the cylinder tube.
3. If applicable, remove the counterbalance valve from the side of the cylinder barrel.
1
2
3
4
1
2
6
MAH0160
5
4. Extend the rod (5) to allow access to the base of the cylinder.
IMPORTANT: Protect the finish on the rod at all times. Damage to the surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head gland (6) from the barrel (1). A considerable amount of force will be necessary to remove the head gland. Carefully slide the head gland down along the rod toward the rod eye end, away from the cylinder barrel.
IMPORTANT: 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. Carefully pull the rod assembly along with the head gland out of the cylinder barrel.
7. Fasten the rod end in a soft-jawed vise, and put a padded support under and near the threaded end of the rod to help prevent damage to the rod.
8. Remove the set screw (3) from the piston (4).
Note: It may be necessary to apply heat to break the bond of the sealant between the piston and the rod before the piston can be removed.
Some cylinder parts are sealed with a special organic sealant and locking compound. Before attempting to disassemble these parts, remove any accessible seals from the area of the bonded parts. Wipe off any hydraulic oil, then heat the part(s) uniformly to break the bond. A temperature of 149-204° C (300-400° F) will destroy the bond. Avoid overheating, or the parts may become distorted or damaged. Apply sufficient torque for removal while the parts are still hot. The sealant often leaves a white, powdery residue on threads and other parts, which must be removed by brushing with a soft brass wire brush prior to reassembly.
9. Remove the piston head (4) from the rod (5) and carefully slide the head gland (6) off the end of the rod.
10. Remove all seals, back-up rings and o-rings (2) from the piston head and all seals, back-up rings and o- rings from the head gland.
Note: The head gland bearing will need to be inspected to determine if replacement is necessary.
IMPORTANT: DO NOT tamper with or attempt to adjust the counterbalance valve cartridge. If adjustment is necessary, replace the counterbalance valve with a new part.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
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.
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Hydraulic System
8.9.3 Cylinder Cleaning Instructions
1. Discard all seals, back-up rings and o-rings. Replace with new items from complete seal kits to help ensure proper cylinder function.
2. Clean all metal parts with an approved cleaning solvent such as trichlorethylene. Carefully clean cavities, grooves, threads, etc.
Note: If a white powdery residue is present on threads and parts, it can be removed. Clean the residue away with a soft brass wire brush prior to reassembly, and wipe with loctite cleaner before reinstallation.
8.9.4 Cylinder Inspection
1. Inspect internal surfaces and all parts for wear, damage, etc. If the inner surface of the tube does not display a smooth finish, or is scored or damaged in any way, replace the tube.
2. Remove light scratches on the piston, rod or inner surface of the tube with a 400-600 grit emery cloth. Use the emery cloth in a rotary motion to polish out and blend the scratch(es) into the surrounding surface.
3. Check the piston rod assembly for run-out. If the rod is bent, it must be replaced.
force to hold the cylinder barrel securely. Excessive force can damage the cylinder barrel.
5. Place the cylinder barrel (1) in a soft-jawed vise or other acceptable holding equipment if possible.
IMPORTANT: When sliding the rod and piston assembly into the cylinder barrel, prevent the threaded end of the cylinder barrel from damaging the piston head. Keep the cylinder rod centered within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the tube.
7. Screw the head gland (6) into the cylinder barrel (1) and tighten with a spanner wrench. Refer to Section
8.9.9, “Hydraulic Cylinder Torque Specifications,” for tightening guidelines for the head gland.
8. If applicable, thread the new counterbalance valve into the block on the cylinder barrel.
1
2
3
4
8.9.5 General Cylinder Assembly
1. Use the proper tools for specific installation tasks. Clean tools are required for assembly.
2. Install new seals, back-up rings and o-rings (2) on the piston (4) and the head gland (6).
Note: The extend/retract cylinder has a spacer that MUST be installed over the rod AFTER the head gland and BEFORE the piston head.
3. Fasten the rod eye in a soft-jawed vise, and place a padded support under and near the threaded end of the rod (5) to prevent any damage to the rod.
IMPORTANT: Protect the finish on the rod at all times. Damage to the surface of the rod can cause seal failure.
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. Loctite and install the setscrew (3) in the piston head. Refer to Section
8.9.9, “Hydraulic Cylinder Torque Specifications,” for tightening guidelines for the piston head and the set screw.
IMPORTANT: Avoid using excessive force when clamping the cylinder barrel in a vise. Apply only enough
1
2
6
MAH0160
5
8.18
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Page 97
8.9.6 General Cylinder Installation
1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropriate sling, lift the cylinder into it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or retaining clip.
3. Connect the hydraulic hoses in relation to the labels or markings made during removal.
4. Before starting the machine, check fluid level of the hydraulic fluid reservoir and if necessary, fill to full mark with Mobilfluid 424
5. Start the machine and run at low idle for about one minute. Slowly activate hydraulic cylinder function in both directions allowing cylinder to fill with hydraulic oil.
6. Inspect for leaks and check level of hydraulic fluid in reservoir. Add hydraulic fluid if needed. Shut the engine OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools.
®
ISO Grade 46.
Hydraulic System
8.9.7 Cylinder Pressure Checking
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
The steering cylinders are attached to each axle center housing. The steer cylinders are covered in the appropriate Dana-Spicer axle literature.
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
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Hydraulic System
8.9.9 Hydraulic Cylinder Torque Specifications
a. Lift Cylinder
Machine Piston Head Set Screw
7 & 8M - Before S/N 1160000569 N/A N/A N/A
7 & 8M - S/N 1160000569 & After 2550-2600 Nm
(1881-1917 lb-ft)
775-825 Nm
(571-608 lb-ft)
20-25 Nm
(15-19 lb-ft)
9M - Before S/N 1160000875
9M- S/N 1160000875 & After 2490-2540 Nm
(1837-1873 lb-ft)
950-1000 Nm
(701-738 lb-ft)
20-25 Nm
(15-19 lb-ft)
12M - Before S/N 1160000765
12M - S/N 1160000765 & After 2490-2540 Nm
1837-1873 lb-ft)
950-1000 Nm
(701-738 lb-ft)
20-25 Nm
(15-19 lb-ft)
13M - Before S/N 1160000863
13M - S/N 1160000863 & After 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
7 & 8M - Before S/N 1160000569 N/A N/A N/A N/A
7 & 8M - S/N 1160000569 & After 1290-1340 Nm
(951-988 lb-ft)
400-450 Nm
(295-332 lb-ft)
N/A 20-25 Nm
(15-19 lb-ft)
9M - Before S/N 1160000875
9M - S/N 1160000875 & After 1290-1340 Nm
(951-988 lb-ft)
12M - Before S/N 1160000765
12M - S/N 1160000765 & After 1070-1120 Nm
(789-826 lb-ft)
13M - Before S/N 1160000863
13M - S/N 1160000863 & After 1070-1120 Nm
(789-826 lb-ft)
8.20
400-450 Nm
(295-332 lb-ft)
480-530 Nm
(354-391 lb-ft) (rear)
N/A 20-25 Nm
(15-19 lb-ft)
50-55 Nm
(37-41 lb-ft)
20-25 Nm
(15-19 lb-ft)
380-430 Nm
(280-317 lb-ft) (front)
480-530 Nm
(354-391 lb-ft) (rear)
50-55 Nm
(37-41 lb-ft)
20-25 Nm
(15-19 lb-ft)
380-430 Nm
(280-317 lb-ft) (front)
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
Page 99
c. Tilt Cylinder
Machine Piston Head Nut Set Screw
Hydraulic System
7 & 8M - Before S/N 1160000569 9M - Before S/N 1160000875 12M - Before S/N 1160000765 13M - Before S/N 1160000863
7 & 8M - S/N 1160000569 & After 9M - S/N 1160000875 & After 12M - S/N 1160000765 & After 13M - S/N 1160000863 & After
d. Compensation Cylinder
Machine Piston Head Nut Set Screw
7 & 8M - Before S/N 1160000569 9M - Before S/N 1160000875 12M - Before S/N 1160000765 13M - Before S/N 1160000863
7 & 8M - S/N 1160000569 & After 9M - S/N 1160000875 & After 12M - S/N 1160000765 & After 13M - S/N 1160000863 & After
e. Sway Cylinder
800 Nm
(590 lb-ft)
2850-2900 Nm
(2102-2139 lb-ft)
1200 Nm
(885 lb-ft)
775-825 Nm
(572-608 lb-ft)
N/A N/A 800 Nm
850-900 Nm
(627-664 lb-ft)
380-430 Nm
(280-317 lb-ft)
130 Nm
(96 lb-ft)
N/A 20-25 Nm
(15-19 lb-ft)
(590 lb-ft)
N/A 20-25 Nm
(15-19 lb-ft)
N/A
N/A
Machine Piston Head Plug Nut Set Screw
7 & 8M - Before S/N 1160000569 9M - Before S/N 1160000875 12M - Before S/N 1160000765 13M - Before S/N 1160000863
7 & 8M - S/N 1160000569 & After 9M - S/N 1160000875 & After 12M - S/N 1160000765 & After 13M - S/N 1160000863 & After
f. Outrigger Cylinder
Machine Piston Head Plug Nut
12M - Before S/N 1160000765 13M - Before S/N 1160000863
12M - S/N 1160000765 & After 13M - S/N 1160000863 & After
600 Nm
(443 lb-ft)
1050-1100 Nm
(774-811 lb-ft)
700 Nm
(516 lb-ft)
1300-1350 Nm
(959-995 lb-ft)
800 Nm
(590 lb-ft)
400-450 Nm
(295-332 lb-ft)
1000 Nm
(737 lb-ft)
625-675 Nm
(461-498 lb-ft)
150 Nm
(111 lb-ft)
100 Nm
(74 lb-ft)
N/A N/A 20-25 Nm
(15-19 lb-ft)
150 Nm
(111 lb-ft)
100 Nm (74 lb-ft)
N/A N/A
N/A
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
8.21
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Hydraulic System
g. Attachment Lock
Machine Piston Nut Set Screw
7 & 8M - Before S/N 1160000569 9M - Before S/N 1160000875 12M - Before S/N 1160000765 13M - Before S/N 1160000863
7 & 8M - S/N 1160000569 & After 9M - S/N 1160000875 & After 12M - S/N 1160000765 & After 13M - S/N 1160000863 & After
N/A N/A 45 Nm
70-80 Nm
(52-59 lb-ft)
75-85 Nm
(55-63 lb-ft)
(33 lb-ft)
N/A
8.22
3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013
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