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JLG 3507, Service Manual

The "Rousseau 3507 Owner's Manual" is available for free download at manualshive.com. This comprehensive manual provides step-by-step instructions and in-depth information on operating and maintaining the Rousseau 3507. Get easy access to this essential manual today and unlock the full potential of your product.

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ectr

ica
l System

9.1
2

 

3507,

 3508

, 3509,

 3512,

 3513,

 4007,

 4008,

 4009,

 4012,

 4013

9.

5.

6

B

asket

 Dash Boar

d Bo

x -Pl

a

tf

orm 

Mac

h

ines Onl

y

11

26

25

9

10

21

14

3

217

16

15

12

7

13

8

18

4

1

6

5

2

4

2

3

2

2

2

0

19

10

8

9

7

6

2

5

2

6

11

5

3

4

1

2

2

4

2

5

11

30

17

19

3

1 2

15

58

50a

P 0

39

10

9

21

3

214

15

16

17

A#2

41

A#3

A+

2

1

J2 BLACK

A-

12

11

-

+

2

1

DO2

DO1

6

5

40

7

12

13

38

2

1

3

4

8

18

4

1

5

6

2

4

22

2

3

19

2

0

10

9

21

3

214

15

16

17

12

7

13

31

32

NC

NO

C

OUT

UP

NC

NO

NO

C

DOWN

NC

NO

C

C

NC

18

8

4

1

5

6

2

2

2

3

19

2

0

19/17

BASKET MODE

READY

9

33

86

87a

85

BASKET MODE

30

RELAY

READY LAMP

87

2

1

1

1

2

EMERGENCY

STOP

58
15

50a

30

6

30

LAMP

LSS OVER ERS

5

ERS MODE

10

34

1

86

30

RELAY

87a

87

85

35

37

1

4

86

87a

87

LSS POWER

85

30

RELAY

38

BUZZER

WARNING

87a

3

3

2

WH

86

85

87

RELAY

WAIT LAMP

GAUGE

FUEL

7

HORN SWITCH

BL

BR

BK

HORN

5

3

JOYSTICK

32

21

BASKET DASH BOARD BOX

ENGINE OIL

LAMP

LAMP

WATER

CHARGE

LAMP

TEMPERATURE

1

21

8

2

1

3

2

1

3

4

4

5

6

7

8

8

4

6

2

4

ON

+

-

BATTERY

1

2

3

4

1

2

11

12

6

2

1

5

J1 GREY

RR

RL

FL

FR

J8

J7

J5

J6

42

43

IN

MZ1810

BASKET

 CAN HI

-BK-0.8 mm

BASKET

 IGNITION -BK 25

FOOTSWITCH SIGNAL

 -BK 6

FOOTSWITCH LAMP

 -BK 7

LSS 

ALARM SIGNAL

 -BK 16

FUEL

 LEVEL

 SIGNAL

 -BK 12

W

A

TER 

TEMP

 LAMP

 -BK 9

BA

T

 CHARGE LAMP

 -BK 10

BASKET

 CAN LO

-RD-0.8 mm

BASKET

 CONN SIGNAL

 -BK 23

LSS PWR BY

 ERS GROUND CMD

BASKET

 KEY

 PWR - OR-3.0 mm^ 2

BASKET

 GROUND - BL-3.0 mm^ 2

BASKET

 MODE READY

 -BK 15

BASKET

 ST

AR

T

 -BK 14

S104

S103

X122

X102

H103

H116

H100

H101

H107

X121

H102

H104

H105

A101

S101

H108

P100

H106

X123

X124

PREHEA

T

 -BK 13

LIFT

 DN ERS -BK 18

LIFT

 UP

 ERS -BK 19

TELE OUT

 ERS -BK 20

TELE IN ERS -BK 21

FAUL

T

 LAMP

 -BK 17

LSS SIGNAL

 -BK 1

1

LSS MODULE

ESX READY

 -BK 22

ENG OIL

 LAMP

 -BK 8

HORN -BK 5

X122

DASHBOARD

H103

H100

H112

X121

X101

H102

-

H105

H104

INSTRUMENTS CONNECTORS

X100

S100

BASKET KEY

SWITCH

S102

SWITCH

FOOT

A100

X104

ERS JOYSTICK

S103

H100

X122

K115

S101

F100 (15A)

X122

LAMP

LAMP

H102

H103

H104

LAMP

H105

X121

FOOT SWITCH

X122

X123

K100

D101

D100

OVERLOAD

FAULT

X121

X121

K101

E100

D102

D103

LAMP

H112

X121

X124

WAIT

K116

P100

X123

S104

ITT AJ3

A101

H101

PREHEAT

LAMP

H106

H107

H108

X124

D104

-BK 24

X122

X124

H101

X123

H107

H108

H106

X123

X123

+

-

S

3.0 mm^ 2

3.0 mm^ 2

3.0 mm^ 2

X138

X137

X136

TOP VIEW

CELL #3

CELL #4

CELL #1

CELL #2

3mm^ 2

3mm^ 2

UNDIMENSIONED CABLE 1 mm?2
IF NOT DIFFERENT STATED NUMBER
OF WIRE IS THE SAME OF X100 PIN
CONNECTED
GROUND WIRES BLUE COLOURED

BOTTOM VIEW

P100

INSTRUMENTS CONNECTION TABLE

X121

1

12

CONN. PIN

WIRE

X121

2

-

X121

3

GRD

X121

4

13

CONN. PIN

WIRE

X123

X123

1

2

GRD

9

X123

X123

4

3

5

21

X123

X123

X123

5

6

7

4

21

6

X123

8

21

CONN. PIN

WIRE

X124

X124

X124

X124

4

3

2

1

2

1

GRD

8

21

X121

5

32

X122

6

35

-

7

X121

X121

8

GRD

33

9

X121

X121

10

34

CONN. PIN

WIRE

STOP

OPERATE

2

OFF

ON

CAN H

CAN L

F1

GND

PWR

F2

VCC

Courtesy of Crane.Market 

Summary of Contents for 3507

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: ...Courtesy of Crane Market ...

Page 3: ...3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 a 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 Courtesy of Crane Market ...

Page 4: ...EFFECTIVITY PAGE 3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 b Courtesy of Crane Market ...

Page 5: ... 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...

Page 6: ...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...

Page 7: ...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 Courtesy of Crane Market ...

Page 8: ... references to 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 1 2 DISCLAIMER All information in this manual is based on the latest product info...

Page 9: ...re 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 goggl...

Page 10: ...erious 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 cont...

Page 11: ...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 ...

Page 12: ...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 returne...

Page 13: ... 7550 55 40 50 60 10700 80 60 70 90 11870 75 82 1 2 13 0 5000 0 1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120 20 0 1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127 9 16 12 0 5625 0 1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170 18 0 2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182 5 8 11 0 6250 0 2260 14400 150 110 135 165 20350 220 170 180 240 22600 ...

Page 14: ...1870 102 111 1 2 13 0 5000 0 1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163 20 0 1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172 9 16 12 0 5625 0 1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230 18 0 2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247 5 8 11 0 6250 0 2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313 18 0 2560 16300 2...

Page 15: ...2 17 7 1 28 9 12 6 18 13 16 19 18 25 19 20 28 8 1 25 36 6 15 9 25 19 23 28 22 8 37 27 29 40 10 1 5 58 0 25 2 50 38 45 55 36 1 72 54 58 79 12 1 75 84 3 36 7 88 66 79 97 52 5 126 95 101 139 14 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 2...

Page 16: ...ourth Gear Turbo Only 35 km h 21 7 mph 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 UP 9 78 9 78 9 78 9 78 9 78 Attachment Tilt DOWN 4 50 4 50 4 50 4 50 4 50 Outrigger UP N A N A N A 2 93 2 93 Outrigger DOWN N A N A N A 2 19 ...

Page 17: ...uel Injection Fuel Injection Air Cleaner Dry Type Replaceable Primary and Safety Elements Dry Type Replaceable Primary and Safety Elements 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 ...

Page 18: ...allons 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 F...

Page 19: ... Fluid Level Check Transmission Oil Level Test Load Moment Indicator Check Hydraulic Oil Level MZ1680 500 EVERY Check Wheel Lug Nut Torque LB FT Nm Change Fuel Filter 50 EVERY Drain Fuel Water Separator Check Engine Coolant Level Check Battery Follow Lubrication Schedule 250 EVERY Check Axle Oil Level Check Wheel End Oil Levels Air Filter Vacuator Valve Check Fan Belt Check Boom Bearing Pads Check...

Page 20: ...ormation and Specifications 2 10 3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 2 6 LUBRICATION SCHEDULES 2 6 1 8 Hour Lubrication Schedule MZ1700 8 EVERY Mystik Tetrimoly NLGI 2 GC LB Courtesy of Crane Market ...

Page 21: ...2 11 3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 General Information and Specifications 2 6 2 50 Hour Lubrication Schedule MZ1710 50 EVERY Mystik Tetrimoly NLGI 2 GC LB Courtesy of Crane Market ...

Page 22: ...General Information and Specifications 2 12 3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 This Page Intentionally Left Blank Courtesy of Crane Market ...

Page 23: ...nstallation 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 Switc...

Page 24: ...ocations of the major assemblies of the boom system The following illustration identifies the components that are referred to throughout this section MZ1480 Second Boom Section First Boom Section Pivot Pin Extend Retract Cylinder Tilt Cylinder Access Panel Quick Switch Access Panel Quick Switch Second Boom Section Extend Retract Cylinder Pivot Pin First Boom Section Third Boom Section Three Sectio...

Page 25: ...ine 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 ...

Page 26: ...st 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 3 3 2 Second Section Boom Removal 12 13M 1 With the boom ...

Page 27: ...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 ...

Page 28: ...h 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 sl...

Page 29: ... washers When installing new wear pads apply Loctite 242 to all wear pad 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 Use sh...

Page 30: ...c hoses See Section 3 5 3 Connecting with a Quick Switch to a Hydraulic Operated Attachment 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 Qu...

Page 31: ... Boom shifts to right or left when extending 1 Boom side wear pads improperly shimmed or worn 1 Shim wear pads to correct gap Replace wear pads as needed Refer to Section 3 4 2 Boom Wear Pad Replacement 4 Excessive pivot pin noise and or wear 1 Insufficient lubrication 1 Lubricate at regular intervals Refer to Section 2 6 Lubrication Schedules Replace worn pins as needed 2 Worn bearing s 2 Replace...

Page 32: ...ntaminated corroded or rusted wear pad sliding surfaces 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 Operating in extremely dusty abrasive conditions 4 Clean equipment frequently 7 Auxiliary hydraulics will not operate 1 Auxiliary hydraulic system not operating properly 1 Refer to Section 8...

Page 33: ...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 Courtesy of Crane Mark...

Page 34: ... identifies the components that are referred to throughout this section Air Louvers Air Louvers Instrument Panel Level Indicator Fuel Gauge Load Moment Indicator Engine Temp Gauge Control Console Hazard Flashers Ignition Switch Air Louvers Joystick Continuous Hydraulic Powered Operation Auxiliary Switch Air Louvers 12V Receptacle Heater AC Controls Round Air Vents Round Air Vents Brake Fluid Reser...

Page 35: ... 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 acc...

Page 36: ...art the engine and check the operation of steering system Check for hydraulic fluid leaks Check the hydraulic fluid level in the tank and add fluid as required Wipe up any spilled oil 9 Install the lower dash panel 10 Close and secure the engine cover 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 Hydraul...

Page 37: ...ion 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 6 Remove the hex jam nut and flat washer securing the throttle cable to the throttle pedal a...

Page 38: ...joystick assembly into the armrest support 2 Install the four self tapping screws Connect the electrical connections 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 L...

Page 39: ...indshield 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 2 Place a Do Not Operate Tag on both the ignition key switch and the ste...

Page 40: ...ement 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 coo...

Page 41: ...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...

Page 42: ...Cab and Covers 4 10 3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 This Page Intentionally Left Blank Courtesy of Crane Market ...

Page 43: ...intenance 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 ...

Page 44: ...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 MZ1510 Rear Axle Assembly Steering Cylinder Front Front Axle Assembly Steering Cylinder Rear Drive Shafts Transmission Drop Box Courtes...

Page 45: ...nformation are provided in the Dana Spicer Maintenance and Repair Manual P N 31200162 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 contamina...

Page 46: ...a suitable covered container and label the container as Used Oil Dispose of used oil at an approved recycling facility 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...

Page 47: ...ply 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 posi...

Page 48: ...ing 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 8 Axle housing damaged 8 Replace damaged parts 2 Intermittent noise when traveling 1...

Page 49: ... Replace o rings and seals 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 housing s damaged 7 Replace housing s as needed 5 Oil leaking from wheel end housing planet carrier 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 ...

Page 50: ...r damaged swivel bearings 3 Replace swivel bearings as needed 9 Slow steering response 1 Steering hydraulic system not operating properly 1 Refer to Section 8 9 8 Steering Cylinders 2 Steering cylinder leaking internally 2 Repair or replace steering cylinder as needed 10 Excessive noise when brakes are engaged 1 Brake discs worn 1 Check brake discs for wear Refer to Section 5 6 Brakes 2 Brake disc...

Page 51: ...y 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 ...

Page 52: ...lation 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 arr...

Page 53: ...1 Brake Disk Inspection a Front and Rear Axles 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 di...

Page 54: ...ities 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 ...

Page 55: ...umber 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 Courte...

Page 56: ...e 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 MZ0670 Output Shaft front Torque Convertor Dipstick and Fill Tube Breather Output Shaft rear Drop Box Oil Level Sight Gauge Breather Transmission Drop Box Flex Plate Assembly Shift Solenoids Oil Fi...

Page 57: ...rvals 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 f...

Page 58: ...ator 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 fl...

Page 59: ...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 moun...

Page 60: ... 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 9 Reassemble all components and fill the transmission with clean fresh Mobilfluid 424 ISO Grade 46 through t...

Page 61: ...vel 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 2 Refer toSection 9 5 1 Cab Harness Electrical Schematic 3 Transmission valve body solenoids not functioning properly 3 Refer to ...

Page 62: ...t 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 piston o rings 3 Replace coupling and or 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 Hydrauli...

Page 63: ... damaged 6 Repair or replace pump assembly 7 Engine thermostat stuck 7 Replace engine thermostat Refer to Section 7 4 2 Thermostat Replacement 6 Grinding or clunking noise from transmission 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 ...

Page 64: ... valve bodies possible valve body gaskets damaged or missing and or mounting capscrews not tight 4 Replace gaskets and or tighten capscrews to 9 5 Nm 7 lb ft 5 Housing capscrews loose 5 Tighten capscrews to 46 Nm 34 lb ft 6 Oil leaking at pump possible pump to housing o rings missing or damaged and or pump mounting capscrews not tight 6 Replace o rings and or tighten capscrews to 115 Nm 85 lb ft 7...

Page 65: ...il 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 Inspe...

Page 66: ...gulations 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 servic...

Page 67: ...formation 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 MZ0070 Turbocharger optional Fuel Injection Pump Oil Filter Thermostat Fuel Filter Alternator Starter Courtesy of Crane Market ...

Page 68: ...s 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 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 leve...

Page 69: ...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 ...

Page 70: ...ed 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...

Page 71: ...all 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 ...

Page 72: ...tem 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 ...

Page 73: ...w 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 ...

Page 74: ... 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 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 transmi...

Page 75: ...ter 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 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 Sectio...

Page 76: ...ngine 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 Note In order to remove the engine drive plates the engine and transmission must be separated 5 Refer to Section 6 5 1 Transmission Remova...

Page 77: ...el 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 restrict...

Page 78: ...Engine Perkins 1104 42 1104 42T 7 14 3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 This Page Intentionally Left Blank Courtesy of Crane Market ...

Page 79: ...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...

Page 80: ...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 Extend Retract Cylinder inside boom Lift lower Cylinder Compensation Cylinder Tilt Cylinder Hydraulic Filter Main Pump Steering Cylinder Main Control Valve Outrigger Cylinders 12 13M only Hydraulic Fluid Reservoir ERS Co...

Page 81: ...nents 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 elect...

Page 82: ... 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 3 Start the machine run the engine at full throttle and bottom the boom in function Note It is possible to see maximum system pressure by activating and bottoming any of the hydraulic fu...

Page 83: ... 4WE6G 125 60 STABILIZER 125 60 100 50 SWAY AUXILIARY 90 56 EXTEND RETRACT 12 13 M 110 63 110 bar 4 1 LIFT LOWER 160 90 T P 300 bar 4 1 DN 12 DN 10 DN 10 DN 10 DN 10 FRONT AXLE REAR AXLE BRAKES A10VO60DFR1 Q 132 l min p 250 bar n 2200 1 min S L1 L B X 60 dp 25 bar 0 3 bar 3 5 bar 10 µm 3 bar LS P L R T OSPF 200 LS 175 bar 235 bar COMPENSATION 2x90 45 140 70 TILT 300 bar 4 1 100 60 EXTEND RETRACT 7...

Page 84: ... 125 60 100 50 SWAY BASKET ROTATOR 90 56 EXTEND RETRACT 12 13 M 110 63 110 bar 4 1 LIFT LOWER 160 90 T P 300 bar 4 1 DN 12 DN 10 DN 10 DN 10 DN 10 FRONT AXLE REAR AXLE BRAKES A10VO60DFR1 Q 132 l min p 250 bar n 2200 1 min S L1 L B X 60 dp 25 bar 0 3 bar 3 5 bar 10 µm 3 bar LS P L R T OSPF 200 LS 175 bar 235 bar COMPENSATION 2x90 45 140 70 TILT 300 bar 4 1 100 60 EXTEND RETRACT 7 9 M A B 110 bar 4 ...

Page 85: ... 50 SWAY BASKET ROTATOR 90 56 EXTEND RETRACT 12 13 M 110 63 110 bar 4 1 LIFT LOWER 160 90 T P 300 bar 4 1 DN 12 DN 10 DN 10 DN 10 DN 10 FRONT AXLE REAR AXLE BRAKES A10VO60DFR1 Q 132 l min p 250 bar n 2200 1 min S L1 L B X 60 dp 25 bar 0 3 bar 3 5 bar 10 µm 3 bar LS P L R T OSPF 200 LS 175 bar 235 bar COMPENSATION 2x90 45 140 70 TILT 300 bar 4 1 100 60 EXTEND RETRACT 7 9 M A B 110 bar 4 1 A B A B A...

Page 86: ...servoir 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 t...

Page 87: ... 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 ...

Page 88: ...y 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 gea...

Page 89: ...ake 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 actuat...

Page 90: ... 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 ...

Page 91: ...rol 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 hy...

Page 92: ... 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 an...

Page 93: ...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 ...

Page 94: ...osition 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...

Page 95: ...added 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 re...

Page 96: ...T 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 Insta...

Page 97: ... 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 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 mai...

Page 98: ... 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 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 400 450 Nm 295 332 lb ft N A 20 25 Nm 15 1...

Page 99: ... Nm 590 lb ft N A 7 8M S N 1160000569 After 9M S N 1160000875 After 12M S N 1160000765 After 13M S N 1160000863 After 850 900 Nm 627 664 lb ft 380 430 Nm 280 317 lb ft N A 20 25 Nm 15 19 lb ft 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 600 Nm 443 lb ft 800 Nm 590 lb ft 150 Nm 111 lb ft 100 Nm 74 lb ...

Page 100: ...t Set Screw 7 8M Before S N 1160000569 9M Before S N 1160000875 12M Before S N 1160000765 13M Before S N 1160000863 N A N A 45 Nm 33 lb ft 7 8M S N 1160000569 After 9M S N 1160000875 After 12M S N 1160000765 After 13M S N 1160000863 After 70 80 Nm 52 59 lb ft 75 85 Nm 55 63 lb ft N A Courtesy of Crane Market ...

Page 101: ...asket Dash Board Box Platform Machines Only 9 12 9 5 7 Cab Harness Platform Machines Only 9 13 9 6 Circuit Breakdowns 9 17 9 6 1 Constant Power Circuit from Battery 9 17 9 6 2 Start Circuit 9 18 9 6 3 Charging Circuit 9 19 9 7 Engine Start Circuit 9 20 9 7 1 Starter 9 20 9 8 Charging Circuit 9 21 9 8 1 Alternator 9 21 9 9 Electrical System Components 9 22 9 9 1 Load Moment Indicator 9 22 9 9 2 Loa...

Page 102: ...ission Mounted Speed Sensor 9 29 9 12 6 Engine Coolant Temperature Sender Switch 9 29 9 12 7 Engine Oil Pressure Sender 9 30 9 12 8 Boom Angle Sensor 9 30 9 12 9 Ignition Key Switch 9 31 9 12 10 Fuel Level Indicator and Fuel Level Sender 9 32 9 13 Display Monitor and Gauges 9 33 9 13 1 Analog Gauges 9 33 Courtesy of Crane Market ...

Page 103: ... the operator mechanic be familiar with the name and location of the electrical components of the machine The following illustration identifies the components that are referred to throughout this section 9 1 1 General Overview Cab Harness 47 MZ1800 Power Control Module Control Indicator Console Gauges Display Panel Joystick ESX Control Module Heater AC Controls Transmission Control Lever Courtesy ...

Page 104: ...bar is located on the frame directly above the engine The fuse and relay bar contains the lift pump and glow plug fuses 4 starter relay 5 glow plug relay 6 and lift pump relay 7 To remove the relays from inside the engine compartment remove the mounting screws and washers When re installing the relays torque the mounting hardware to 7 12 5 Nm 62 110 lb in Note On machines before S N 1160000358 the...

Page 105: ...ght Tail and Side Lights Display 7 5 F9 Aux Pwr Socket 15 F10 Battery Ind Light Dome Light 15 F11 ESX Battery 25 F12 Key Switch 30 F13 Spare 15 F14 Brake Lights Cold Start Beacon 10 F15 Ignition 15 F16 Rear Wiper 20 F17 Front Wiper 20 F18 Front Work Lights 15 F19 Boom Work Lights 15 MZ1560 X26 K1 K5 X1 X21 X25 X15 K6 K4 K3 K2 X2 X6 X9 X12 X16 X19 X3 X7 X11 X13 X17 X22 X4 X5 X8 X10 X14 X18 X23 F01 ...

Page 106: ...9 Worklight Radio Rear Wiper Harness X10 Front Chassis Harness X11 Engine Harness X12 Rear Chassis Harness X13 Rear Chassis Harness X14 Optional Trailer ing Harness X15 Joystick Connector X16 Front Chassis Harness X17 ESX Harness X18 ESX Harness X19 ESX Harness X21 CAN Diagnostic Connector X22 Front Chassis Harness X23 F N R and Gear Shifter Harness X25 RS232 Diagnostic Connector X26 Tilt Sensor n...

Page 107: ... HARNESS X2 EMPTY 56 58 157 156A 156 136 157A 170 140 173 172 171 159A EMPTY 139 INST PANEL HARNESS X3 135 143 135 145 144 84 83 56A 160 61 58 116 181 180 184 EMPTY 182 110 X23 FNR GEAR SHIFTER HARNESS EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY EMPTY 136L 176 176 185 300 136M 136H EMPTY 186 INST PANEL HARNESS X4 EMPTY EMPTY EMPTY EMPTY EMPTY TO PCB EMPTY SWITCH PARK BRAKE 58LV GND LV LIGHT DRIVING FRONT ...

Page 108: ... GND GND PUMP FRONT W WASHER ALTERNATOR ENGINE OIL SWITCH PRESSURE POSITIVE CABLE TO BATTERY NEGATIVE CABLE TO BATTERY DISCONNECT OR BATTERY 50mm BLK 50mm RED CLT TEMP SENDER COOLANT SWITCH TEMP COLD START TEMP SWITCH HYD FILTER SWITCH PRESSURE FUEL SOLENOID AIR FILTER RESTRICTION SWITCH TRANSMISSION OIL TEMP SWITCH ENGINE GLOWPLUGS W WASHER PUMP REAR 111 110 112 90 118 GND 76 GND 114 GND 120 503 ...

Page 109: ...0 MT MT 50 GND 166 113 144 143 169 167 MT MT MT 130 GND GND RXD GND TXD CAN LOW CAN HIGH 19 MT 58 122 54A 120 MT MT 111 61 MT 146 MT MT MT 145 112 164 MT 118 X17 5 161 GND 114 163 115 MT 58LH 58RH LH RH 54LH 54RH 174L 174R 124 116 MT MT MT 1 P7 2 P6 FW P2 RV P3 MT MT 12V P8 MT MT HI P5 12V P1 MT MT MT MT GND CANL CANH 152 30 30 30 15 15 15 19 19 50 R 30 L 49 49A 15 58 MT MT 160 L R 49 MT 53A 53 12...

Page 110: ...A 31 53 31B 189 A C OPT HARNESS TO CAB HARNESS ESX CONTROLLER 1 2 4 3 17 11 6 5 7 9 8 10 14 12 13 16 15 18 6 1 2 4 3 5 9 7 8 10 21 20 19 22 12 1 2 4 3 5 7 6 8 10 9 11 18 15 13 14 17 16 20 19 21 22 1 8 5 3 2 4 6 7 10 9 11 13 12 14 21 18 16 15 17 19 20 22 1 2 23 13 5 3 4 6 7 10 8 9 11 12 18 14 15 16 17 19 20 21 22 28 24 25 26 27 31 29 30 32 33 36 34 35 37 38 41 39 40 42 43 54 49 46 44 45 47 48 50 51...

Page 111: ...IGHT TO EMPTY GND GND 147 146 EMPTY EMPTY EMPTY EMPTY RIGHT FRONT DRIVING LIGHT EMPTY EMPTY 56BR EMPTY 56AR 146 RV 58RV EMPTY 167 119 147 71A EMPTY EMPTY EMPTY EMPTY EMPTY 216 EMPTY 217 EMPTY 122 127 178 179 126 128 129 130 EMPTY EMPTY EMPTY 203 200 201 202 206 204 205 207 EMPTY 208 EMPTY EMPTY EMPTY EMPTY EMPTY GND 71A GND 122 GND 58RV 56AR 56BR RV EMPTY GND 200 PWR 201 SGN 202 SGN 200 PWR GND 20...

Page 112: ...R BY ERS GROUND CMD BASKET KEY PWR OR 3 0 mm 2 BASKET GROUND BL 3 0 mm 2 BASKET MODE READY BK 15 BASKET START BK 14 S104 S103 X122 X102 H103 H116 H100 H101 H107 X121 H102 H104 H105 A101 S101 H108 P100 H106 X123 X124 PREHEAT BK 13 LIFT DN ERS BK 18 LIFT UP ERS BK 19 TELE OUT ERS BK 20 TELE IN ERS BK 21 FAULT LAMP BK 17 LSS SIGNAL BK 11 LSS MODULE ESX READY BK 22 ENG OIL LAMP BK 8 HORN BK 5 X122 DAS...

Page 113: ...AY 45 42 41 43 29 30 21 TO SCHEME 003 27 A03 DISPLAY PWR PIN 4 B01 FUEL SENSOR SIGNAL P2 FUEL INDICATOR SIGNAL A01 PIN 28 see sch 003 21 21 21 21 21 11 A1 14 A2 21 24 12 22 18 8 8 SEE SCHEME 004 C2 11 13 15 7 5 9 3 17 13 14 18 16 14 15 18 17 16 12 4 6 8 10 1 2 12 11 4 6 8 7 5 10 9 1 2 3 24 60 38 59 44 48 RELAY STARTER LOCK 9 9 30 0 P 2 1 3 15 58 50a 17 19 Wire X06 4 originally connected to S01 6 1...

Page 114: ...4 3 5 10 8 7 9 12 11 13 ENG TEMP SW RS232 RX ANALOG GND BACKUP LTS DUMP VALVE RS232 TX BOOM EXT DI AUST UNUSED TURBINE SNSR RPM BOOM ANG SNSR BASKET CAB MODE TRANS GEAR SEL REVERSE SW 18 16 15 17 20 19 22 21 24 23 26 25 27 28 30 29 ENG PREHEAT SW DI UNUSED BASKET CONNECTED ALT D CHARGE PARK BRAKE SW REAR AXLE PROX SWAY RIGHT VLV DO LSS SIGNAL HYD FILT PSI SW TRANS TEMP SW 12V IGNITION 1 CAN HIGH 1...

Page 115: ... 1 2 3 22 23 19 13 33 21 30 29 FROM SCHEME 003 27 33 CABIN ELECTRICAL BOX 21 29 30 TO SCHEME 005 27 2 3 SEE SCHEME 002 B2 C7 18 2 3 22 23 13 19 33 8 A01 PIN 52 see sch 003 9 35 SEE SCHEME 002 C8 3 1 4 PNP BR BL BK 3 2 1 SEE SCHEME 002 B2 E1 22 28 A01 PIN 10 see sch 003 10 26 27 MZ1840 RD 0 8 mm GR 0 8 mm BASKET CAN LO BASKET CAN HI BASKET CONN SIGNAL BK 19 FOOTSWITCH SIGNAL BK 2 FOOTSWITCH LAMP BK...

Page 116: ...2 63 64 57 66 65 67 68 70 69 33 33 17 16 15 14 12 56 8 7 10 9 57 10 1 2 30 30 MZ1850 LSS ALARM SIGNAL BK 12 LIFT DN ERS BK 14 LSS POWER BY ERS GROUND CMD BK 20 LIFT UP ERS BK 15 TELE OUT ERS BK 16 TELE IN ERS BK 17 X102 M100 VENTIL DUMP VALVE X114 Y100 A Y100 B Y101 A Y101 B K112 X103 D106 9 D106 1 D106 4 D106 3 D106 2 D106 8 Y102 D106 11 D106 12 D106 10 D106 6 D106 7 D106 5 F102 10A H110 LED OVER...

Page 117: ...S M 85 87 86 30 D G B W 10 20 22 21 15 19 18 17 16 14 13 12 11 9 8 7 6 5 2 4 3 1 87 85 86 30 87a 85 86 30 87 87a 86 85 30 87 87a 15 16 17 18 7 8 9 10 11 12 13 14 1 2 3 4 5 6 87a 30 87 86 85 15 16 17 18 7 8 9 10 11 12 13 14 1 2 3 4 5 6 6 5 4 3 2 1 14 13 12 11 10 9 8 7 18 17 16 15 1 BACKUP LTS ANALOG GND TRANS GEAR SEL RS232 TX ENG TEMP SW TILT SENSOR BOOM ANG SNSR REAR AXLE PROX REVERSE SW TURBINE ...

Page 118: ...0A POSITIVE CABLE TO BATTERY NEGATIVE CABLE TO BATTERY DISCONNECT OR BATTERY 12 VDC TO GROUND AND BATTERY X1 TO CAB HARNESS X6 30 30 30 50 TO INST PANEL HARNESS X4 176 176 TO FNR SHIFTER X23 12V P1 STRT INTLK RLY K2 50 TO ENGINE HARNESS X11 X23 FNR GEAR SHIFTER HARNESS TO PCB X19 TO ESX HARNESS 50 X19 ESX HARNESS 129 176 ESX CONTROLLER TO PCB CAB HARNESS X6 30 30 30 50 176 176 INST PANEL HARNESS X...

Page 119: ... 30A 113 61 30A 30A POSITIVE CABLE TO BATTERY M D G B W MZ1280 TO BATTERY 61 113 X18 113 TO ESX HARNESS TO ESX HARNESS 61 X17 TO INST PANEL HARNESS X3 61 ESX CONTROLLER 61 113 INST PANEL HARNESS X3 61 ALTERNATOR INDICATOR 11 12 1 2 3 10 5 4 6 8 7 9 14 13 15 17 16 18 15 16 17 18 7 8 9 10 11 12 13 14 1 2 3 4 5 6 12 14 13 10 11 22 20 21 17 18 19 15 16 5 8 9 6 7 3 4 1 2 7 10 9 8 2 6 5 4 3 1 18 19 20 1...

Page 120: ... cable connection Check the battery state of charge and battery condition first then check the cables and cable connections 4 For additional information on the starting circuit refer to Section 9 6 2 Start Circuit c Starter Removal Remove the starter only if it fails To remove the starter 1 Open the engine cover Allow the engine to cool 2 Disconnect the battery negative cable at the battery negati...

Page 121: ...e fan belt condition and tension 4 Verify that the alternator mounting hardware is tight 5 Run the engine and check the alternator for noise A loose drive pulley loose mounting hardware worn or dirty internal alternator bearings a defective stator or defective diodes can cause noise Replace a worn or defective alternator 9 8 1 Alternator a Alternator Removal 1 Park the machine on a firm level surf...

Page 122: ...le warning to sound This indicates that the system is functioning properly If the test gives a different result the system is not functioning properly and the machine must be removed from service and repaired before continued operation Note The Load Moment Indicator is NOT a serviceable item The Load Moment Indicator must be inspected and or replaced by a qualified dealer or a JLG technician 9 9 2...

Page 123: ... revert to the uncalibrated error condition number 4 IF THE IGNITION IS SWITCH OFF during first calibration the system will remain in the uncalibrated condition For any subsequent calibration PRESS and hold the TEST button and place the magnet in position level with and just to the right of the TEST button The display will show all LEDs flashing and sounder on The correct position is indicated whe...

Page 124: ...ness connectors from the wiper motor 8 Remove the linkage attached to the wiper motor 4 9 Loosen and remove the four bolts holding the wiper motor to the mounting bracket Note Retain all hardware removed from the wiper assembly for possible reuse on the replacement motor housing 10 Remove the motor from the inside of the cab b Disassembly DO NOT disassemble the motor The motor is not serviceable R...

Page 125: ...tor housing is facing the front of the cab 3 Install the wiper arm onto the wiper motor shaft 4 Connect the battery negative cable to the battery negative terminal 5 Turn ignition key switch to the RUN position and turn the rear wiper switch to the ON position Ensure wiper stays on the window through a full stroke Turn the rear wiper switch to the OFF position 6 Engage the washer switch and ensure...

Page 126: ...ace level the machine fully retract the boom lower the boom place the transmission control lever in N NEUTRAL engage the park brake and shut the engine OFF 2 Place a Do Not Operate Tag on both the ignition key switch and the steering wheel stating that the machine should not be operated 3 Open the engine cover Allow the engine to cool 4 Disconnect the battery negative cable at the battery negative...

Page 127: ...uel injection pump Do not over tighten 3 Connect the wiring connector at the fuel shut off solenoid lead 4 Connect the battery negative cable at the battery negative terminal 5 Start the engine If the engine starts the fuel shut off solenoid is functioning If the engine fails to start the fuel shut off solenoid may have a poor ground connection Visually check the wiring at the fuel shut off soleno...

Page 128: ...perature Sender The transmission temperature sender is located at the bottom right side of the transmission housing a Transmission Temperature Sender 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 igniti...

Page 129: ... Switch The engine coolant temperature sender switch is located by the alternator a Engine Coolant Temperature Sender Switch 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 ste...

Page 130: ...egative cable to the battery negative terminal 3 Check for proper oil level 4 Start the engine and observe the operator s display for warning indication If the sender is not defective the problem could be elsewhere possibly in a a shorted wire improper running engine low oil obstructed or faulty oil pump defective instrument display 5 Close and secure the engine cover 9 12 8 Boom Angle Sensor The ...

Page 131: ...ning of the lower limit position can be started When the boom is moved downwards joystick Y axis moved to the front the value decreases At the lower limit position the value needs to be confirmed with the OK button and one comes back to the Learning menu Conditions for the value range If the lower value is outside the range of 70 330 a value of 100 is taken over If the upper value is outside the r...

Page 132: ... the ignition key switch to the OFF position The fuel level indicator needle should return to the EMPTY position b Fuel Level Circuit Tests If the fuel level indicator is suspected of giving a false reading perform the following checks 1 If the fuel level indicator needle does not move check the fuel tank for fuel 2 Check for loose or defective wiring faulty ground connections or corrosion on the ...

Page 133: ...he engine to cool 4 Disconnect the battery negative cable at the battery negative terminal 5 Remove the lower dash panel unplug connectors from the gauge remove the two nuts and lock washers along with the gauge bracket 6 Pull the gauge out from the front of the dash b Disassembly DO NOT disassemble the gauge The gauge is not serviceable Replace the gauge if found to be defective c Installation an...

Page 134: ...Electrical System 9 34 3507 3508 3509 3512 3513 4007 4008 4009 4012 4013 This Page Intentionally Left Blank Courtesy of Crane Market ...

Page 135: ...Courtesy of Crane Market ...

Page 136: ...ne 49 421 693 500 Fax 49 421 693 5035 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong Phone 852 2639 5783 Fax 852 2639 5797 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 029 359 5210 Fax 39 029 359 5845 JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands Phone 31 235 655 665 Fax 31 235 572 493 JLG Polska UI K...

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