Service Manual Models 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, Agrovector 40.8, 40.
EFFECTIVITY PAGE September 11, 2007 - A - Original Issue Of Manual April 4, 2008 - B - Revised pages 2.7, 2-8, 3.12, 3.27, 5.11, 7.3, 7.7, 7.8, 8.2, 8.9, 9.10, 9.28 and pages 9.30 thru 9.70. Added platform information. June 15, 2011 - C - Update all Loctite® 242TM, to Loctite® 243TM. Added models 40.8 & 40.9. Revised page numbering. Revised pages 1-3, 2-3 thru 2-9, 2-13, 8-6 thru 8-16, 9-11 thru 9-21 & 9-34 thru 9-45. 31200206 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.
EFFECTIVITY PAGE b 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Page 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . .
Section Subject Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Page 5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section Subject Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platform Interlock Checks . . .
Section iv Subject Page 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Practices 1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS 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. 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.
Safety Practices 1.6 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and 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.
Safety Practices pressure can explode. Hydraulic oil and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury. Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component.
Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION 1 MZ1780 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).
General Information and Specifications 2.2 2.2.1 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque (Dry) Tensile Clamp Load Stress Area Torque Lubricated Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque (Dry or Loctite® 263) K= 0.20 Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K=.18 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Magni Coating* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Loctite® Torque Loctite® 262™ 242™ or 271™ OR OR Vibra-TITE™ 131 Vibra-TITE™ 111 or 140 [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque Dry or Loctite® 263™ K = 0.20 Sq mm KN [N.m] Torque Lube OR Loctite® 242™ or 271™ OR Vibra-TITE™ 111 or 140 K= 0.18 Torque Loctite® 262™ OR Vibra-TITE™ 131 [N.m] [N.m] K=0.15 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.
General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Magni Coating* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Clamp Load See Note 4 Sq mm kN Torque Lube OR Loctite® Torque Torque Dry 242™ or 271™ Loctite® 262™ or OR OR Loctite® 263™ Vibra-TITE™ Vibra-TITE™ 131 111 or 140 K = .17 K = .16 K = .15 [N.m] [N.m] [N.m] 3 0.5 3.5 0.6 5.03 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.
General Information and Specifications 2.2.3 Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart Size ORFS JIC Flats Method 4 13 lb-ft (18 Nm) 13 lb-ft (18 Nm) 1.5 to 1.75 6 23 lb-ft (31 Nm) 23 lb-ft (31 Nm) 1 to 1.5 8 40 lb-ft (54 Nm) 40 lb-ft (54 Nm) 1.5 to 1.75 10 60 lb-ft (81 Nm) 60 lb-ft (81 Nm) 1.5 to 1.75 12 74 lb-ft (100 Nm) 85 lb-ft (115 Nm) 1.0 to 1.5 16 115 lb-ft (156 Nm) 115 lb-ft (156 Nm) 0.75 to 1.0 20 170 lb-ft (230 Nm) 170 lb-ft (230 Nm) 0.
General Information and Specifications 2.3 SPECIFICATIONS 2.3.1 Travel Speeds Function Speed First Gear 5 km/h (3.1 mph) Second Gear 10 km/h (6.2 mph) Third Gear 25 km/h (15.5 mph) Fourth Gear (Turbo Only) 35 km/h (21.7 mph) 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. Approximate Times (sec.
General Information and Specifications 2.3.4 Electrical System Note: Refer to Section 9.6, “Fuses and Relays,” for more information. Battery Type, Rating 12V DC, Negative (-) Ground, Limited Maintenance, Wet Charged Quantity 1 (100 Ah) (C20) Reserve Capacity CCA @ -18° C: 880 EN Group/Series DIN 600,38 Alternator 12V, 85 Amps Starter 12V, 3,2 KW Type EV (Gear Reduction) 2.3.5 Engine Performance Specifications Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed.
General Information and Specifications 2.4 FLUIDS, LUBRICANTS AND CAPACITIES Engine Crankcase Oil Capacity w/Filter Change 8,5 L (9 qt) Oil Type 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS 40.8 & 40.9 15W-40 CH DF Super ENGINE OIL 15W-40 Fuel Tank Capacity 140 L (37 gal) Type of Fuel #2 Diesel Cooling System System Capacity Type of Fluid 20 L (5 gal) 50/50 mix of ethylene glycol and water Hydraulic System System Capacity (8, 9M, 40.8 & 40.
General Information and Specifications Axles Differential Housing Capacity - Front 8,0 L (8.5 qt) Differential Housing Capacity - Rear 7,3 L (7.7 qt) Wheel End Capacity - Front 1,9 L (2.0 qt) Wheel End Capacity - Rear 1,4 L (1.5 qt) Type of Fluid 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS 40.8 & 40.9 Mobilfluid 424® (ISO 46) DF UTTO Tractor Hydraulic Fluid Brake System System Capacity 1,0 L (1.
General Information and Specifications 2.5 MAINTENANCE SCHEDULES 2.5.1 2.5.
General Information and Specifications 2.6 2.6.1 LUBRICATION SCHEDULES 8 Hour Lubrication Schedule 8, 9, 12 & 13M EVERY 8 OZ2260 2-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
General Information and Specifications 17M EVERY 8 OZ2430 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
General Information and Specifications 2.6.2 50 Hour Lubrication Schedule 8, 9, 12 & 13M EVERY 50 2x OZ2270 2-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
General Information and Specifications 17M EVERY 50 2X OZ2440 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
General Information and Specifications This Page Intentionally Left Blank 2-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 TITLE PAGE Boom System Component Terminology - Two and Three Section Boom . . . . . 3-3 Boom System - Two and Three Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Boom Assembly Maintenance - Two and Three Section Boom . . . . . . . . . . . . . 3-4 3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . .
Boom 3.10 3.11 3.12 3.13 3-2 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.
Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY - TWO AND THREE SECTION BOOM 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.
Boom 3.2 3.2.1 BOOM SYSTEM - TWO AND THREE SECTION BOOM 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.
Boom 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. 1 2 3 MZ1720 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). 2. Remove the top, left and right side wear pads, backing plates and shims.
Boom 3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (8 & 9M) 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. Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. 5.
Boom 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® 243TM 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® 243TM 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.
Boom 3.4 BOOM SYSTEM COMPONENT TERMINOLOGY - FOUR SECTION BOOM To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.
Boom 3.5 3.5.1 BOOM SYSTEM - FOUR SECTION BOOM Boom System Operation The four section boom consists of the first, second, third and fourth assemblies with double third and fourth section extend chains, a double third section retract chains and a single fourth section retract chain. As the extend/retract cylinder, which is anchored at the front of the second boom section, and the rear of the first boom section begins to extend, it forces the second boom section out of the first boom section.
Boom 13. Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the left side of boom. 3.6.2 Second, Third and Fourth Boom Section Removal 1 Note: Before removing the extend chains, measure the distance (2) between the face of the jam nut to the end of the chain clevis on all four extend chains. This measurement will be used when reassembling the boom. 4.
Boom 11. Using a sling around the front of the second boom section, lift and slide the three boom sections 75% of the way out of the first boom section. Set the boom head down on a suitable support, then center the sling to be able to balance the three boom sections being removed. Carefully pull the three boom sections the remainder of the way out of the first boom section and set the three boom sections down on suitable supports. 3 12.
Boom 3.6.4 Fourth Boom Section Removal 1. With the two boom sections setting on suitable supports remove the bolts, keeper and pin from sheave on the front of the third boom section. Remove the sheaves. Remove all wear pads, from the front inside of the third boom section. Label all parts for installation. 2. Remove the top left and right side rear wear pads on the fourth boom section.
Boom 3.6.7 Fourth Boom Section Installation 6 5. Apply Loctite® 243TM to the sheave mounting bolts, Install the sheave (7), pin, lock plate and bolts at the bottom front of the third boom section. Torque bolts to 90 Nm (66 lb-ft). Grease the sheave using the grease fitting in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly. Pull both extend chains from the fourth boom section around the front and over the sheave.
Boom 4. Using a suitable sling, balance the third and fourth boom sections and carefully slide 914 mm-1219 mm (3 ft - 4 ft) into the front of the second boom section. Set the third and fourth boom sections onto a suitable support and reset the sling under the boom head of the fourth boom section. Carefully slide the third and fourth boom sections into the second boom section.
Boom 2. Grease the inside first boom section on area’s where the second boom section wear pads will slide. 3 the front of the second boom section. Torque to 90 Nm (66 lb-ft). Note: Shim ALL side wear pads as needed to maintain a minimum gap (1.6 mm - 1/16 in) the horizontal direction or a snug fit. The number of shims can vary at each shim point. 4 5 7. Install the bottom left and right side wear pads, backing plates, shims and bolts at the rear of the second boom section.
Boom Note: Grease Tilt cylinder barrel end bore and pin before installing. 9 17. Using suitable slings, lift complete boom off supports and set on level ground. It will be necessary to place a block under the rear of the boom to keep the tilt and auxiliary tubes from being damaged MZ0790 8 11. Attach both extend chain clevises (8) through the holes in the bottom front of the first boom section. Install the washers, adjustment nut and jam nut to the clevises. 12.
Boom 3.6.10 Boom Installation Note: 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. 1. Park the machine on a hard, level surface. Make sure park brake is set, key is removed from the ignition and “Do Not Operate” tag is placed in clear view in the cab.
Boom 3.7 3.7.1 BOOM EXTEND AND RETRACT CHAINS FOUR SECTION BOOM Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain. • High velocity movement of load, followed by sudden, abrupt stops. Boom Chain Inspection • Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain. WARNING Worn pins, stretched or cracked links or corrosive environments can cause chain failure.
Boom b. Extend Chains (third to second section) 3 The extend chains between the third and second boom sections measures 29,6 mm (1.2 in) (1). If the measurement of the worn chain is less than 28,6 mm (1.1 in) (2), the chain should be replaced. 2 4 1 MZ1463 MZ1464 Elongation It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading.
Boom Distorted or Battered Link Plates Distorted or battered link plates (8) on a leaf chain can cause tight joints and prevent flexing. 88 MZ1466 • Tight Joints - All joints in the chain should flex freely. Tight 3 MZ1471 joints (3) resist flexing. If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain. 3.7.3 Expose Chains for Inspection c.
Boom e. Removing Extend and Retract Chains The four extend chains and the three retract chains can only be removed during a complete boom teardown. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain. If during the inspection, any chain is found to be damaged or stretched, the chain must be replaced. It is recommended that when any chain is replaced, that all the chains and clevis’ be replaced at the same time. 3.
Boom 4. Start the machine and extend and retract the boom sections two or three times. Fully retract the boom and measure the distance between the boom sections. 5. If the measurements are within the tolerance, tighten the locknuts on the chain clevises. If more adjustment is needed, repeat procedure until the proper boom section dimensions is achieved. 6. With the boom sections within the proper tolerance, start the machine, lower the outriggers if necessary and extend the boom to maximum extension. 7.
Boom 15. Remove both left and right side wear pad bolts and both left and right bottom wear pad bolts from the rear of the fourth boom section to be able to remove the hose carrier. 2 16. Pull the hose carrier halfway out of the rear of the boom, set on a suitable support. Using a sling around the hose carrier, balance the hose carrier and pull the remainder of the way out. Set the hose carrier on the ground or on suitable supports.
Boom 6 5 7 MZ0910 5. Align the front two threaded holes on the hose carrier with the front two holes (5) on each side of the fourth boom section and install both bolts. Apply Loctite®243TM and hand tighten only. 3 11. Torque the middle two and front two hose carrier bolts to 90 Nm (66 lb-ft). 12. Start the machine and retract the boom completely.Shut the machine off. 13.
Boom 3.10 BOOM WEAR PADS The wear pads on this machine are flat rectangular wear pads with metal inserts. • The number of shims can vary at each shim point. • The bottom wear pads must be shimmed equally on each side. 5 A total of 13 wear pads are installed on the boom sections of the 8 & 9M machines. A total of 26 wear pads are installed on the boom sections of the 12 & 13M machines. A total of 50 wear pads are installed on the boom sections of the 17M machines. 3.10.
Boom • Torque wear pad bolts after shimming is completed. • Lubricate the face and pockets of each wear pad after being installed. Boom Section Wear Pad Pathway Lubrication: • Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease. • Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease. 3.11 3.11.2 Connecting with a Hydraulic Quick Switch Device 1. Retract quick switch device to provide clearance. Check to be sure lock pin is disengaged. 2.
Boom 3.11.4 3.12 Quick Switch Removal FORKS Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately. Daily Inspection 11 3 12 6 7 5 13 1. Support the quick switch assembly. Remove the lock bolt (11) holding the tilt cylinder rod end pin (12) to the quick switch assembly. Remove the tilt cylinder pin. 2. Support the quick switch assembly.
Boom 3.13 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Problem 1. Boom will not extend or retract Cause Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/retract hydraulic system not operating properly. 2. Refer to Section 8, “Hydraulic System.” 3. Faulty extend/retract cylinder. 3. Repair cylinder.
Boom Problem 6. Rapid boom pad wear. 7. Auxiliary hydraulics will not operate. Cause Remedy 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication.” 2. Rapid cycle times with heavy loads. 2. Reduce cycle times. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate.
Boom This Page Intentionally Left Blank 3-30 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 TITLE Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.
Cab and Covers 4.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar 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.
Cab and Covers WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.2 4.2.1 2 4 OPERATOR CAB Serial Number Decal 3 The cab serial number decal is located inside the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence. 1 4.3 4.3.
Cab and Covers 7. Start the engine and check the operation of steering system. Check for hydraulic oil leaks. Check the hydraulic oil level in the tank and add oil as required. Wipe up any spilled oil. 5 8. Install the lower dash panel. 9. Close and secure the engine cover. 10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. c. Power Steering Test Conduct a pressure check of the steering hydraulic circuits at the main control valve. Refer to Section 8.4.
Cab and Covers 2. From within the cab, check the engine rpm at low idle. If the rpm is not 925 ±50 rpm, readjust the throttle cable adjustments. 3. Check the engine rpm at full throttle. If the rpm is not 2340 ±50 rpm, adjust the rubber-stop screw on the throttle pedal or the throttle cable adjustments. 7 Note: During the full throttle check: • DO NOT operate any hydraulic function. 6 • DO NOT steer or apply any pressure to the steering wheel. • Keep the transmission in (N) NEUTRAL. 4.
Cab and Covers b. Joystick Assembly Installation 1. Set the joystick assembly into the armrest support. 2. Install the four self-tapping screws. Connect the electrical connections. 3. Properly connect the battery. 2 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.
Cab and Covers 4.3.6 2. Uncap and connect the previously labeled hydraulic hoses to the park brake. Parking Brake (17M) a. Park Brake Removal 3. Connect the park brake electrical connector switch. 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.
Cab and Covers 4.3.9 Heater/Defroster System a. Heater Assembly Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 7 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. 6 4.
Cab and Covers 9. Replace the belly pan. c. Installation and Testing 10. Close and secure the engine cover. 11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 4.3.10 Cab Heater/Air Conditioning Controls a. Cab Heater Controls 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.
Cab and Covers 4. Properly disconnect the battery. 5. Remove the belly pan. 1 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.
Cab and Covers 17. Remove the mirrors and all other cab components as needed, if not previously removed. 18. Use a hoist or overhead crane and sling attached to the cab, carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed. 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.
Cab and Covers This Page Intentionally Left Blank 4-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5.7 TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . .
Axles, Drive Shafts, Wheels and Tires 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.
Axles, Drive Shafts, Wheels and Tires 5.2 GENERAL INFORMATION Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, 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.
Axles, Drive Shafts, Wheels and Tires 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.
Axles, Drive Shafts, Wheels and Tires 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.
Axles, Drive Shafts, Wheels and Tires 5.3.7 Axle Assembly and Drive Shaft Troubleshooting Problem 1. Excessive axle noise while driving. 2. Intermittent noise when traveling. 3. Vibration or intermittent noise when traveling. 5-6 Cause Remedy 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.
Axles, Drive Shafts, Wheels and Tires Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. Cause Remedy 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 damaged shaft sealing surfaces. 3.
Axles, Drive Shafts, Wheels and Tires Problem 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the machine or braking power reduced. 5-8 Cause Remedy 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.
Axles, Drive Shafts, Wheels and Tires 5.4 DRIVE SHAFTS To Transmission 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.
Axles, Drive Shafts, Wheels and Tires 5.5 WHEELS AND TIRES 5 WARNING Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. JLG recommends a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information.
Axles, Drive Shafts, Wheels and Tires 5.5.2 Installing Wheel and Tire Assembly onto Machine Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel. Tread "arrows" must point forward 5.6 5.6.1 BRAKES 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. 8 MZ1030 6 2. Remove the oil-level plug (6) on each side of the axle.
Axles, Drive Shafts, Wheels and Tires 5.7 TOWING A DISABLED MACHINE Note: Turning the release bolts in to far could warp the brake discs. DO NOT over tighten. Towing a disabled machine should only be attempted as 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. On 17M machines, the park brake is hydraulically operated.
Section 6 Transmission: Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 6.6 TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.
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.
Transmission: 6.4.2 WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance information, and transmission removal and installation procedures.
Transmission: 6.5.1 11. Remove the air cleaner unit and intake tubes. 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.
Transmission: 27. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so that it will not move or fall. 28. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmission openings. 3 6.5.3 Transmission Installation 1.
Transmission: 16. Remove the dipstick and add approximately 11,4 liters (3 Gallons) of hydraulic oil. Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished. 4 17. Remove the fill plug on the transfer case. Fill the transmission drop box. Refer to Section 2.4, “Fluids, Lubricants and Capacities.” Install and tighten drop box fill plug. 18. Install the belly pan under the engine. 19.
Transmission: 6.6 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features. Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period. Problem 1.
Transmission: Problem 2. Low or no pump flow or pressure. 3. Low clutch pressure. 4. Lack of power. 6-8 Cause Remedy 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 Section 2.4, “Fluids, Lubricants and Capacities.”) 3.
Transmission: Problem 5. Transmission overheating (oil above 120° C (248° F)). 6. Grinding or “clunking” noise from transmission. Cause Remedy 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.
Transmission: Problem 7. Oil leaking from transmission. 6-10 Cause Remedy 1. Oil leaking from vent (high oil level). 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. Drain plug loose and/or o-rings damaged or missing. 2. Replace o-rings as needed and tighten plug to 35 Nm (26 lb-ft). 3. Hose fittings loose. 3. Tighten fittings. 4.
Section 7 Engine: Perkins 1104-42 & 1104-42T Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . .
Engine: Perkins 1104-42 & 1104-42T 7.1 7.1.1 INTRODUCTION 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. A gradual running-in (break-in) of a new engine is not necessary.
Engine: Perkins 1104-42 & 1104-42T 7.1.2 Component Terminology To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.
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 a. Thermostat Removal 1.
Engine: Perkins 1104-42 & 1104-42T b. Thermostat Installation 1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the two capscrews. Torque to 24 Nm (18 lb-ft). 5. Remove the engine cover to ease removal of radiator/oil cooler. 6 2. Properly connect the battery. 3. Open the radiator cap, and fill the radiator completely with coolant. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full.
Engine: Perkins 1104-42 & 1104-42T 15. Remove the air conditioner condenser (if equipped) from the radiator assembly. 7.5 16. Carefully lift the radiator/oil cooler out of the engine bay. The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9, “Electrical System.” Note: If applicable the radiator can be removed with the radiator frame.
Engine: Perkins 1104-42 & 1104-42T 7.6.2 Fuel Tank Note: The fuel tank is a one piece unit. It is located at the rear of the machine, between the frame. If it is determined that the fuel tank must be removed, the fuel must be drained before tank removal. Always dispose of fuel properly. 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 hoses from the tank. 8.
Engine: Perkins 1104-42 & 1104-42T e. Inspection 7.7 Note: If a leak is suspected in the fuel tank, contact your local JLG distributor. 7.7.1 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.
Engine: Perkins 1104-42 & 1104-42T 6. Adjust the muffler, exhaust and tail pipes for proper clearance then tighten all clamps. 7. Properly connect the battery. 6. Remove the clamp securing the air intake boot (11) to the air cleaner assembly. Lift the air intake boot off the air cleaner. 8. Start engine and check for exhaust leaks at all exhaust connections. Adjust or repair as needed. 7. Remove the clamp securing the air outlet elbow (12). Lift the air outlet elbow off the air cleaner. 9.
Engine: Perkins 1104-42 & 1104-42T 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. 19. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed.
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® 243TM 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.
Engine: Perkins 1104-42 & 1104-42T • DO NOT steer or apply any pressure to the steering wheel. • Keep the transmission in (N) NEUTRAL. 32. Obtain and connect an appropriate engine analyzer or tachometer. 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. 15 33. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level.
Engine: Perkins 1104-42 & 1104-42T 7.
Engine: Perkins 1104-42 & 1104-42T This Page Intentionally Left Blank 7-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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. 8.3 HYDRAULIC PRESSURE DIAGNOSIS Kits are available to use for hydraulic system maintenance and troubleshooting. The kits are contained in a durable polyethylene carrying case for demanding field service conditions.
Hydraulic System 8.4 HYDRAULIC CIRCUITS 8.4.1 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.
Hydraulic System c. Pressure Specifications Hydraulic Circuit Test Port Procedure Adjustment Location Pressure Range Implement M Connect gauge to M port, run engine at low idle, bottom out boom retract function. Hold over relief and check pressure. 1 250 ±5 Bar (3626 ±73 psi) Pilot Pr Connect gauge to Pr port, run engine at low idle, bottom out boom retract function. Hold over relief and check pressure.
Hydraulic System 8.5 8.5.1 HYDRAULIC SCHEMATICS 8M, 9M, 12M & 13M (w/o trailer brakes) Before S/N 1160005851 excluding 1160005819 8-6 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System S/N 1160005851 & After including 1160005819 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System 8.5.2 8M, 9M, 12M & 13M (w/ trailer brakes) Before S/N 1160005851 excluding 1160005819 8-8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System S/N 1160005851 & After including 1160005819 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System 8M, 9M, 12M & 13M - Frame Level (if equipped) 12M, if equipped w/out frame 12M & 13M 8M & 9M 8.5.3 8-10 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System 8.5.4 17M Before S/N 1160005851 excluding 1160005819 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System S/N 1160005851 & After including 1160005819 8-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System 8.5.5 13M (if equipped for platform) Before S/N 1160005851 excluding 1160005819 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System S/N 1160005851 & After including 1160005819 8-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System 8.5.6 17M (if equipped for platform) Before S/N 1160005851 excluding 1160005819 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System S/N 1160005851 & After including 1160005819 8-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Hydraulic System 8.6 HYDRAULIC RESERVOIR 8.6.2 The hydraulic reservoir is a one piece unit. It is located under the rear of the machine cab. Occasionally, oil may seep, leak or be more forcefully expelled from the 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.
Hydraulic System c. Cleaning and Drying 8.7 If contaminated hydraulic oil or foreign material is in the tank, the tank can usually be cleaned. 8.7.1 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.
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. Properly disconnect the battery. 5.
Hydraulic System 8.8 8.8.1 AUXILIARY PUMP (PLATFORM EQUIPPED MODELS ONLY) Auxiliary Pump Description The auxiliary pump works as a safety back up for the platform in case of engine stalling. The pump will allow the platform to lower without the engine running. 8.8.2 Auxiliary Pump Replacement b. Auxiliary Pump Installation 1. Install the pump to its original orientation and secure in place with the previously used hardware. 2. Connect the previously labeled electrical connections to the pump. 3.
Hydraulic System 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding. 6. Place a suitable container to catch hydraulic oil drainage beneath the frame. 7. Label, disconnect and cap all the hydraulic hoses, tubes and wires at the main control valve. Slowly turn hose fittings to allow any trapped pressure in the hydraulic system to escape. 8.
Hydraulic System f. Main Control Valve Installation a. Service Brake Valve Removal 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.
Hydraulic System Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 3. Use new oiled o-rings as 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. Properly connect the battery.
Hydraulic System 7. Remove the two bolts holding the steer select valve to the mounting plate on the frame. 17M Frame Shown 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. 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.
Hydraulic System 3. Open the engine cover. Allow the system fluids to cool. 2 3 4. Properly disconnect the battery. 13M MACHINE SHOWN 1 MZ2410 4. Remove any coils (2) or retainers (3) from the individual valve section. 5. Keep all parts being removed from individual valve sections tagged and kept together. MZ2280 5. Label, disconnect and cap all hydraulic hoses (1) and fittings connected to the leveling valve. 6. Disconnect all wire terminal leads attached to the leveling valve. 7.
Hydraulic System f. Leveling Valve Installation 1. Install the leveling valve into the engine compartment and secure with the previously used hardware. 2. Prime the leveling valve by filling the inlet openings with fresh, filtered hydraulic oil from a clean container, before attaching the hoses. 3. Use new oiled o-rings as required. Uncap and connect all hoses, clamps, etc. to the leveling valve. 4.
Hydraulic System Note: When sliding the rod and piston assembly out of the tube, prevent the threaded end of the tube from damaging the piston. Keep the rod centered within the tube to help prevent binding. 1 2 10. Remove all seals, back-up rings and o-rings (2) from the piston head and all seals, back-up rings and orings from the head gland. Note: The head gland bearing will need to be inspected to determine if replacement is necessary. DO NOT attempt to salvage cylinder seals, sealing rings or o-rings.
Hydraulic System 4. Lubricate and slide the head gland (6) over the cylinder rod (5). Install the piston head (4) on to the end of the cylinder rod. Apply Loctite® 243TM to the setscrew (3) and install in the piston head. Refer to Section 8.10.9, “Hydraulic Cylinder Torque Specifications,” for tightening guidelines for the piston head and the set screw. Note: Avoid using excessive force when clamping the cylinder barrel in a vise. Apply only enough force to hold the cylinder barrel securely.
Hydraulic System 8.10.9 Hydraulic Cylinder Torque Specifications a. Lift/Lower Cylinder Machine Piston Head Set Screw 8M 2550-2600 Nm (1881-1917 lb-ft) 775-825 Nm (571-608 lb-ft) 20-25 Nm (15-19 lb-ft) 9, 12, 13 & 17M 2490-2540 Nm 1837-1873 lb-ft) 950-1000 Nm (701-738 lb-ft) 20-25 Nm (15-19 lb-ft) b.
Hydraulic System This Page Intentionally Left Blank 8-30 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Level 2 Accessibility . . . . . . . . . . . . . . . . . .
Electrical System 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9-2 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.1 Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . Cab Heater and Fan. . . . . . . .
Electrical System 9.1 ELECTRICAL COMPONENT TERMINOLOGY 9.2 Electrical system specifications are listed in Section 2, “General Information and Specifications.” 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 electrical components of the machine. The following illustration identifies the components that are referred to throughout this section.
Electrical System 9.3 PLATFORM INTERLOCK CHECKS To check the platform interlock, turn the ignition key to position I and be sure the following are set: • Park brake is applied • Transmission control lever is in the (N) NEUTRAL position • Machine outriggers are fully lowered • Machine is level WARNING While an assistant raises the boom. DO NOT leave the cab unattended. 6. Have an assistant raise the boom above 60 degrees in the platform. The boom should not raise above 60 degrees (Model 4017 only).
Electrical System 9.4 SOFTWARE LEVEL 2 ACCESSIBILITY The following parameters can be altered in the 2nd level of access to the machine’s software. 9.4.1 Operator Tools Function Description Change Anti Theft Code Allows the owner to change the Anti Theft Code Perform Hardware Exchange Allows the owner to restore machine data (anti theft code, engine hours, machine personalities, etc.
Electrical System 9.4.
Electrical System 9.5 OPERATOR TOOLS 9.5.3 Confirm Machine Service To log the machine service into the software: 9.5.1 Resetting the Anti Theft Code To reset the anti theft code: 1. Turn the engine to the ON position. 1. Turn the engine to the ON position. 2. Press the "C" and "OK" buttons on the dash simultaneously to enter the analyzer mode. 2. Press the "C" and "OK" buttons on the dash simultaneously to enter the analyzer mode. 3. Scroll to "Access level code".
Electrical System 9.5.6 Cabin Joystick Telescope: X-Axis/ Roller To change the joystick telescope function on the joystick: 9.6 9.6.1 FUSES AND RELAYS Cab 1. Turn the engine to the ON position. 2. Press the "C" and "OK" buttons on the dash simultaneously to enter the analyzer mode. 3. Scroll to "Access level code". Enter the code "33271" to go into access level 2. 1 4. Scroll to and select the "Operator Tools" screen. 2 5. Scroll to and select the "Cabin Joystick Telescope" screen. 6.
Electrical System 9.6.3 Power Distribution Board MZ2090 Fuse/Relay Function Amp Rating F1 Rt. Headlight Low 7.5 F2 Rear Wiper 15 F3 Rt. Headlight High 7.5 F4 Lt. Headlight Low 7.5 F5 Lt. Headlight High 7.5 F6 Fan 20 F7 Front Wiper 25 F8 A/C 7.5 F9 Key 2 15 F10 Key 1 15 F11 Radio 10 F12 Lights Bat 1 15 F13 Lights Bat 2 15 F14 Lt. Marker Lights 7.
Electrical System Fuse/Relay 9-10 Function Amp Rating F18 Flasher 15 F19 Rt. Marker Lights 7.
Electrical System 9.7 ELECTRICAL SYSTEM SCHEMATICS For more detailed schematics, contact your local authorized service distributor. 9.7.1 Cab Harness Electrical Schematic Before S/N 1160005993 excluding 1160005949 & 1160005950 (Sheet 1) 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System Before S/N 1160005993 excluding 1160005949 & 1160005950 (Sheet 1 - Continued) 9-12 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System S/N 1160005993 & After including 1160005949 & 1160005950 (Sheet 1) 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System S/N 1160005993 & After including 1160005949 & 1160005950 (Sheet 1 - Continued) 9-14 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System 9.7.2 Cabin Roof Harness Electrical Schematic (Sheet 2) 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System 9.7.3 Power Distribution Electrical Schematic (Sheet 3) 9-16 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System 9.7.4 Chassis and Boom Harness Electrical Schematic Before S/N 1160005993 excluding 1160005949 & 1160005950 (Sheet 4) 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System S/N 1160005993 & After including 1160005949 & 1160005950 (Sheet 4) 9-18 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System 9.7.5 Engine Harness Electrical Schematic (Sheet 5) 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System 9.7.6 Platform Electrical Schematic (Sheet 7) Note: Sheet 6 of 8 not included in electrical schematic intentionally. 9-20 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System 9.7.7 Platform Cab Harness Schematic (if equipped) (Sheet 8 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
Electrical System 9.8 9.8.
Electrical System Start Circuit CAB UGM POWER CONTROL BOARD 3 2 1 3 KEY IGN CLUTCH KEY STRT 8 16 20 30 PREHEAT 6 APU ENABLE 4 NEUT 5 P BRK 4 STRT RLY GLOWPLUGS KEY IGN IGNITION KEY IGN KEY IGN IGNITION 12 9 10 11 12 CONN.
Electrical System 9.9 9.9.1 ENGINE START CIRCUIT can also prevent the starter from cranking the engine. 3. If the starter only “clicks” it may indicate that the battery is discharged, or that there is a loose or corroded battery cable connection. Check the battery state of charge and battery condition first, then check the cables and cable connections. Starter 4. For additional information on the starting circuit, refer to Section 9.8.2, “Start Circuit.” c.
Electrical System f. Starter Installation 1. Position the starter in its mounting opening on the flywheel housing. Position the ground cable over the correct starter mounting bolt. Secure the starter with fasteners. Torque fasteners to 43 Nm (32 lb-ft). 2. Connect the positive (+) battery cable to the upper solenoid stud. Install the wires to the upper solenoid stud, and secure with lockwasher and nut. Torque nuts to 43 Nm (32 lb-ft). 3. Connect the wire to the solenoid mounting stud. 4.
Electrical System 9.12 b. Alternator Installation WINDOW WIPER/WASHER 1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper mounting hardware through the alternator mount. DO NOT tighten completely at this time. 9.12.1 2. Align the lower alternator mount hole with the lower mounting bracket on the engine. Insert the lower mounting capscrew. DO NOT tighten completely at this time.
Electrical System b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. 5 c. Inspection and Replacement Inspect the motor terminals for continuity. Replace motor if continuity is not found. MAH0920 d. Installation and Testing 1. Install all required hardware to the motor assembly. 5. Remove the wiper arm from the wiper motor (5) shaft. 2. Align motor with the mounting holes and bolt the motor to the mounting bracket. 6.
Electrical System 9.12.3 Windshield Washer Reservoir and Pump The windshield washer motor and reservoir is located in the engine compartment as a unit and cannot be serviced separately. c. Cleaning and Drying Without submerging the pumps, clean the pumps and reservoir with an approved solvent and dry with a clean, lint-free cloth. d. Inspection and Replacement a. Removal Inspect the electrical terminals for continuity. 1.
Electrical System 9.14 SWITCHES, SOLENOIDS, SENSORS AND SENDERS 9.14.1 Transmission Solenoid Valves 7 MZ2160 5. Remove the four screws (7) from the cab heater and fan control panel. 6. Pull the control panel out from the dash panel and disconnect the variable speed fan control cab harness connector and disconnect the temperature cable. 7. Remove the control from the panel. b. Disassembly DO NOT disassemble the cab heater and fan controls. The controls are not serviceable.
Electrical System 9.14.2 Transmission Temperature Switch defective, the problem could be elsewhere; possibly in a shorted wire, damaged transmission, improper or low fluid, etc. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. 9.14.3 9 Transmission Mounted Speed Sensor (if equipped) MZ2150 The transmission temperature switch (9) is located at the bottom right side of the transmission housing. 10 a.
Electrical System c. Transmission Mounted Speed Sensor Installation and Testing 1. Install new o-ring on speed sensor, install sensor in transmission, install clamp on sensor, bolt down clamp, turn arrow on sensor 45 degrees from clamp bolt and torque to 8-10 Nm (70-88 lb-in). 2. Connect the sensor plug to the wire harness. 3. Properly connect the battery. 4. Close and secure the engine cover. 5. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. d.
Electrical System 5. Remove the lower dash panel. d. Ignition Key Switch Installation 6. Remove the hex nut securing the ignition key switch to the dash. 1. Connect the ignition key switch to the cab harness connectors. 7. Reach up and under the dash to work the ignition switch and wiring out of the mounting hole. 2. Reach up and under the dash to work the ignition key switch into the ignition key switch mounting hole on the dash. 8.
Electrical System been ruled out and in addition, wiring and connectors have been checked and ruled out, the fuel level indicator is defective and must be replaced. 5. Check that the ignition terminal has current and that the fuse in the fuse panel is not blown. 6. Check for broken, shorted, frayed, disconnected or damaged wiring between the fuel level indicator wiring at the cab, fuse and relay panel, ignition key switch and from the fuel level sender on the fuel tank through the wiring in the cab. 7.
Electrical System 9.15 a. Boom Retracted Sensor Removal LOAD STABILITY INDICATOR (LSI) 8, 9, 12 & 13M Before S/N 1160005993 excluding 1160005949 & 1160005950 17M Before S/N 1160005937 including 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978 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.
Electrical System Test LSI (8) at the beginning of each work shift. b. LSI Sensor Installation 1. Fully retract and level the boom, with no load. Do not raise the boom during this test. 1. Ensure threads of both bolt holes are clean and free from rust, water and debris. 2. Level frame using level in cab. 2. Clean the bare metal with a degreasing agent, Loctite® 7063TM. 3. Press the test button (8) on the LSI display. This will cause all LEDs to flash on and an audible warning to sound.
Electrical System 9.15.3 LSI System Calibration . Model a. Standard Calibration To calibrate the LSI, certain conditions must be met: • The sensor must be installed at least 6 hours before beginning calibration. • The machine control system must be powered on for at least 10 minutes before calibration. • The calibration shall be conducted with the standard carriage and forks attached and weights as necessary.
Electrical System Field Calibration Procedure: Note: If the test weight is not known, follow steps 1 & 2. Model Test Weight (W) Xtip (1) Xcal (2) 3508PS 2100 kg (4630 lb) 2300 mm (90 in) 1620 mm (64 in) 3509PS 2000 kg (4409 lb) 3030 mm (119 in) 2060 mm (81 in) 3512PS 500 kg (1102 lb) 2985 mm (117 in) 2100 mm (83 in) 3513PS 500 kg (1102 lb) 3275 mm (129 in) 2310 mm (91 in) 4008PS, 40.8 2100 kg (4630 lb) 3107 mm (122 in) 2372 mm (93 in) 4009PS, 40.
Electrical System 11. Press the TEST button on the LSI display and release. The top red LED should flash for approximately 8 seconds while the calibration point is read. Following successful calibration of the second point, the buzzer will be on constant, the red LED will be turned off, and the green power LED will be on constant. 9.16 12. Disengage the test weight and fully retract the boom. Turn the ignition key to OFF. LSI is now calibrated.
Electrical System • In some instances the LSI system may slow down or stop boom functions if operated close to forward stability limitations. When LEDs begin to flash, function can not be operated. Retract boom and/or return the joystick to neutral position for a short period to allow system to reset and LEDs to stop flashing before proceeding with operation. 9.16.2 LSI Sensor 15 Passive Mode (8 & 9M) • The orange LED (14) illuminates when either of the following occurs: • The boom is fully retracted.
Electrical System • The calibration must be completed within 30 minutes after starting procedure. Note: Follow all adhesive manufacturer’s recommendations including storage life. 5. Fit the sensor, ensuring the lead exits in the corner direction. Secure with two bolts - Socket HD Capscrew M10x35x1.5, Grade 12.9. Note: It is important to prevent distortion of the sensor element, therefore tighten each bolt finger tight. Alternately tighten each bolt to 35 Nm (26 lb-ft) and finally to 70-80 Nm (52-59 lb-ft).
Electrical System Note: If the test weight is not known, follow steps 1 & 2. Model Weight on Rear Axle Model Test Weight (W) Xtip (1) Xcal (2) 3508PS 700 kg (1543 lb) 3508PS 4008PS, 40.8 800 kg (1764 lb) 2000 kg (4409 lb) 2468 mm (97 in) 1895 mm (75 in) 3509PS 800 kg (1764 lb) 3509PS 2000 kg (4409 lb) 2975 mm (117 in) 2343 mm (92 in) 4009PS, 40.
Electrical System 4. The machine must be on a level surface with the wheels steered straight and park brake OFF. Drive the machine forward over a distance of at least 2 m (6.5 ft) before entering a calibration point. 7. With the boom horizontal, slowly extend the boom to the distance of Xcal (2). The proper calibration weight is now on the rear axle and the LSI can now be calibrated. 5. Place test weight on ground, apply park brake and shut engine OFF. Do Not move machine. 8.
Electrical System 9.16.5 500 Hour - LSI UGM Calibration Check 1. Start machine 2. Press the “C” and “OK” buttons simultaneously on the keypad or the analyzer. 9.17 HAND HELD ANALYZER The hand held analyzer can be used in place of the cab display panel. 3. Go to “ACCESS LEVEL 2 or 1” and press “OK”. 4. Enter the proper access code and press “OK”. 5. Go to “OPERATOR TOOLS” menu, press “OK”. 1 6. Scroll to “LSI_CAN SYSTEM CHECK”. 7.
9-44 MENU: HELP: PRESS ENTER MENU: OPERATOR TOOLS MENU: CALIBRATIONS SOFT-LIFT ZONE: SET ANGLE %: xx % SOFT-LIFT %: SET DERATE: xxxx mA SOFT-LIFT ZONE: SET ANGLE %: xx % SOFT-LIFT %: SET DERATE: x.x S x.x S xxxx mA xxx mA x.x S PLATFORM LEVEL: DECEL UP: x.x S x.
MARKET: ANSI MARKET: AUSTRALIA MODEL: TH336 MODEL: TH337 ENGINE CONTROL: MECHANICAL BOOM RETRACTED SWITCH: CLOSED BOOM EXTENDED SWITCH: OPEN AM BOOM EXTENDED SWITCH: OPEN TRANSPORT MODE: IN TRANSPORT TELESCOPE STATUS: RETRACTED PLATFORM LEVEL ACTUAL: XXXXMA ROTATE LEFT SWITCH: OPEN ROTATE RIGHT SWITCH: OPEN PLATFORM ROTATE COMMANDED: XXXXMA PLATFORM ROTATE ACTUAL: XXXXMA HORN SWITCH: OPEN ENGINE PREHEAT SWITCH: OPEN COUPLING PIN ENGAGED: NO FORK TILT ACTUAL: XXXXMA AUX.
Electrical System 9.18 FAULT CODES Active faults and fault memory will be displayed at the operator level of access. Active faults will also be displayed as a blink code at the controller on-board LED. The 16 previous faults are logged in fault memory, which can be accessed by choosing ENTER while viewing active fault messages. 9.18.
Electrical System 9.18.2 Fault Code Table Message Fault Code HELP COMMENT 00XXX EVERYTHING OK 001 POWER UP Indicators Other Actions Taken Trigger for Fault Latch Until The system detects no problems exist. 21XXX POWER CYCLE 211 Power was cycled ON. FUNCTION ENABLE INPUTS – INVALID SIGNAL STATES 214 1 Ignore and inhibit all function requests from the platform station. Output J2-19 Function Enable Relay of the platform module will be deactivated.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until JOYSTICK S3 BUTTON ACTIVE AT POWER UP 219 1 Ignore command signals from the joystick S3 button that was active during the power-up. At system power-up, if the S3 button is activated on JLG models only. A CAN message is received indicating the joystick S3 button is not activated.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until APU SWITCH INPUT INVALID – INPUT HIGH AT POWER UP 2116 1 Still allow APU function request. If J7-4 Boom Angle reading is less than 10° and the J3-8 Boom Retracted input is HIGH, cutout the Main Lift Up and Telescope Out functions. If a platform is configured as ENABLED and the UGM detects J4-16 Auxiliary Power Unit (APU) Enable is HIGH at system power up.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CONTINUOUS AUXILIARY HYDRAULICS SWITCH HIGH AT POWER UP 2122 1 Inhibit operation of the Continuous Auxiliary Hydraulics feature/logic. The UGM has detected the Continuous Auxiliary Hydraulics switch is HIGH at system power up. The input goes LOW for a period of at least 1 second.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until FUNCTION ENABLE INTERLOCK – ENABLE SWITCH NOT SELECTED FIRST 2227 1 The requested function will be ignored. If the PLATFORM STATION is active and a platform is configured as ENABLED and a platform is detected as attached and a hydraulic function request is detect at the platform station before the function enable signal was received. The hydraulic function request is no longer active.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until PLATFORM OPTION NOT CONFIGURED 2311 1 The UGM will also disregard all commands from the platform station. The UGM will use the platform attached response curves. If the PLATFORM ATTACHED option has not been configured in the MACHINE SETUP menu and a platform attached state is detected or the UGM detects a HIGH on J7-1 or J7-2. Power cycle.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until OPERATING MODE INTERLOCK STABILIZERS NOT DEPLOYED 2315 1, 15 J2-26 Engage Starter output will be deactivated and engine start will not be permitted if the PLATFORM STATION is active and CABIN MODE was the last valid operating mode. Changeover to PLATFORM MODE will not be permitted.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until OPERATING MODE INTERLOCK CHASSIS NOT LEVEL 2317 1, 16 J2-26 Engage Starter output will be deactivated and engine start will not be permitted if the PLATFORM STATION is active and CABIN MODE was the last valid operating mode. Changeover to PLATFORM MODE will not be permitted.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until OPERATING MODE INTERLOCK - PARK BRAKE NOT SET 2320 1 J2-26 Engage Starter output will be deactivated and engine start will not be permitted if the PLATFORM STATION is active and CABIN MODE was the last valid operating mode. Changeover to PLATFORM MODE will not be permitted. Changeover to CABIN MODE will not be permitted. All hydraulic function requests from the platform station will be ignored.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until HYDRAULIC FILTER RESTRICTION 2332 1, 6 N/A J2-24 Hydraulic Filter Restriction input is HIGH for a period of 3 seconds or more after system power has been ON for at least 10 minutes. J2-24 Hydraulic Filter Restriction input is LOW for 1 second. ALL WHEEL STEER INPUT – INVALID SIGNAL 2333 1 Not recognize any steer mode requests on input J4-35 All Wheel Steer.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until KEYPAD CANCEL BUTTON – INVALID SIGNAL 2340 1 Disregard all signal changes until switch state transitions to LOW. The UGM detects the keypad CANCEL button is HIGH at power up or for a period of 7 seconds or longer. Power cycled. KEYPAD UP BUTTON – INVALID SIGNAL 2341 1 Disregard all signal changes until switch state transitions to LOW.
Electrical System Message BOOM ANGLE SENSOR – NOT RESPONDING 9-58 Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until 2346 1 Display the fixed boom angle value of ‘99’ on the operator’s cabin display. Temporarily assign a fixed boom angle value of 99×. Disallow boom angle sensor calibration (“BOOM ANGLE: CALIBRATION FAIL”). Ignore all hydraulic function requests from the platform module.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until SYSTEM INTERLOCK – SET JOYSTICK INPUTS TO NEUTRAL 2347 1 Deactivate and inhibit all joystick functionality. The UGM has detected one of the following conditions: The hydraulic quick connect switch is activated when any of the other auxiliary hydraulics functions is active.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CABIN JOYSTICK – LEFT ROLLER FAULT 2350 1 Left roller function requests will be ignored by the UGM. The CAT cabin joystick detects a fault with the left roller on the joystick. Power cycled. CABIN JOYSTICK – RIGHT ROLLER FAULT 2351 1 Right roller function requests will be ignored by the UGM. The CAT cabin joystick detects a fault with the right roller on the joystick. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ERRATIC PLATFORM COUPLED SIGNAL 2385 1 The platform will be considered coupled. The UGM detects three signal transitions on J3-13 within a 5 second period. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until PLATFORM ATTACHED HYDRAULIC QUICK CONNECT CUTOUT 2528 1 Deactivate output J1-23 Hydraulic Quick Connect. Ignore auxiliary hydraulic requests when the S4 button is engaged on the cabin’s joystick. If hydraulic quick connect feature is configured in the MACHINE SETUP menu and the platform attached conditions have been met and J7-35 is HIGH and J3-10 is LOW and the CABIN STATION is active.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TELESCOPE POSITION SWITCHES – CONFLICTING STATES 2558 1 Illuminate the vehicle system distress indicator in the cabin’s display. Activate the buzzer for a period of 5 seconds in the cabin’s display. Illuminate the vehicle system distress indicator at the platform station. Activate the buzzer for a period of 5 seconds at the platform station.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until MAIN LIFT DOWN VALVE – OPEN CIRCUIT 33184 1 Deactivate output J2-22 Main Lift Down Valve. The UGM detects an open circuit at this output or the UGM detects a CURRENT FEEDBACK LOST condition and sets an internal flag to determine if this fault condition is the reason for the fault. Power cycled. MAIN LIFT DOWN VALVE – SHORT TO GROUND 33185 1 Deactivate output J2-22 Main Lift Down Valve.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until FORK TILT VALVES – SHORT TO BATTERY 33192 1 Deactivate output J2-8 Fork Tilt Up Valve. Deactivate output J2-19 Fork Tilt Down Valve. Decouple/disable current feedback input J3-6 Tilt Return (Disables Fork Tilt Up and Down). The UGM detects a short to battery at this output. Power cycled. FORK TILT UP VALVE – SHORT TO GROUND 33193 1 Deactivate output J2-8 Fork Tilt Up Valve.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until AUXILIARY FUNCTION-A VALVE– SHORT TO GROUND 33198 1 Deactivate output J2-9 Auxiliary Function-A Valve. Decouple/disable current feedback input J3-14 Aux Return (Disables Auxiliary Function-A and Function-B). Deactivate and inhibit the Continuous Auxiliary Hydraulics feature. Turn OFF the Continuous Auxiliary Hydraulics indicator.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until HYDRAULIC QUICK CONNECT SELECT – OPEN CIRCUIT 33204 1 Deactivate output J1-23 Hydraulic Quick Connect Select. If hydraulic quick connect feature is configured in the MACHINE SETUP menu and the UGM detects an open circuit at this output. Power cycled. HYDRAULIC QUICK CONNECT SELECT – SHORT TO BATTERY 33205 1 Deactivate output J1-23 Hydraulic Quick Connect Select.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until DUMP VALVE – SHORT TO BATTERY 33214 1 Deactivate output J2-13 Dump Valve. Deactivate output J2-3 Right Stabilizer Up Valve. Deactivate output J2-5 Frame Level Right Valve. Deactivate output J2-7 Frame Level Left Valve. Deactivate output J2-8 Fork Tilt Up Valve. Deactivate output J2-9 Auxiliary Function-A Valve. Deactivate output J2-10 Left Stabilizer Up Valve.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until AUXILIARY ELECTRICS – OPEN CIRCUIT 33219 1 Deactivate output J2-1 Auxiliary Electrics. The JLG brand is configured for the UGM, the PLATFORM STATION is not active, and the UGM detects an open circuit at this output. Power cycled. AUXILIARY ELECTRICS – SHORT TO BATTERY 33220 1 Deactivate output J2-1 Auxiliary Electrics.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LEFT STABILIZER UP VALVE – SHORT TO GROUND 33227 1 Deactivate output J2-3 Right Stabilizer Up Valve. Deactivate output J2-15 Right Stabilizer Down Valve. Deactivate output J2-10 Left Stabilizer Up Valve. Deactivate output J2-21 Left Stabilizer Down Valve. The stabilizers are configured in the MACHINE SETUP menu and the UGM detects a short to ground at this output. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until RIGHT STABILIZER UP VALVE – SHORT TO GROUND 33233 1 Deactivate output J2-3 Right Stabilizer Up Valve. Deactivate output J2-15 Right Stabilizer Down Valve. Deactivate output J2-10 Left Stabilizer Up Valve. Deactivate output J2-21 Left Stabilizer Down Valve. The stabilizers are configured in the MACHINE SETUP menu and the UGM detects a short to ground at this output. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TRANSMISSION C COIL – SHORT TO GROUND 33242 1 Deactivate output J1-10 Transmission C Control Coil. 3rd, 2nd, and 1st will be the only available gear selections. Flash the “Gear Selection” symbol on the LCD of the cabin’s display. A TRANSMISSION configuration of POWERSHIFT is configured and a GEAR SELECTION of 4F/3R is configured and the UGM detects a short to ground at this output. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TRANSMISSION A COIL – SHORT TO GROUND 33251 1 Deactivate output J2-33 Transmission A Control Coil. Flash the “Gear Selection” and the “Drive Direction” symbols on the LCD of the cabin’s display. A TRANSMISSION configuration of POWERSHIFT is configured and the UGM detects a short to ground at this output. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TRANSMISSION 1 COIL – SHORT TO GROUND 33260 1 Deactivate output J1-7 Transmission 1 Coil. Deactivate and inhibit activation of J1-20 Transmission 2 Coil. Flash the “Gear Selection” symbol on the LCD of the cabin’s display. A TRANSMISSION configuration of HYDROSTATIC is configured and the UGM detects a short to ground at this output. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ENGINE FUEL RELAY – SHORT TO BATTERY 33268 1 Deactivate output J2-31 Engine Fuel Relay. Deactivate and inhibit output J2-26 Engage Starter. The UGM detects a short to battery at this output. Power cycled. ENGINE FUEL RELAY – SHORT TO GROUND 33269 1 Deactivate output J2-31 Engine Fuel Relay. Deactivate and inhibit output J2-26 Engage Starter. The UGM detects a short to ground at this output.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ALL WHEEL STEER VALVE – SHORT TO GROUND 33275 1 Deactivate output J2-4 All Wheel Steer Valve. Try to complete any pending steer mode changes. Display the “Steer Valve Failure” screen on the LCD of the cabin’s display. The UGM detects a short to ground at this output. Power cycled. APU PUMP RELAY – OPEN CIRCUIT 33276 1 Inhibit operation of J1-13 APU Pump Relay.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LIFT – CURRENT FEEDBACK READING TOO LOW 33287 1 Do not detect or report the BOOM ANGLE SENSOR – NOT RESPONDING fault. The UGM detects the actual current has deviated more than 250 mA from the commanded current for more than 1 second. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until REAR AUXILIARY HYDRAULICS VALVE – SHORT TO GROUND 33328 1 Deactivate output J2-23 Rear Auxiliary Hydraulics Valve. Deactivate output J2-9 Auxiliary Function-A Valve until input J7-23 is LOW. Deactivate output J2-20 Auxiliary Function-B Valve until input J7-23 is LOW. If the rear auxiliary hydraulics feature is configured in the MACHINE SETUP menu and the UGM detects a short to ground at this output.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ENGINE TROUBLE CODE: (SPN):(FMI) 437 1, 2, 3* (ECM will determine the proper action to take.) * - The UGM will illuminate just the engine warning fault indicator if the DM1 message indicates a warning or derate condition. The UGM will illuminate the engine warning and engine critical fault indicators if the DM1 message indicates a critical (shutdown) condition.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LOW ENGINE OIL PRESSURE WARNING 4318 1, 2, 9 N/A The ECM detects the engine oil pressure is getting low, the ECM will transmit a J1939 CAN bus DM1 message, or use the J1939 Transfer Protocol in the event multiple engine faults exist, on CAN1 to communicate low engine oil pressure (SPN:FMI 100:17 or 100:18). Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until BATTERY VOLTAGE TOO LOW – SYSTEM SHUTDOWN 441 1 Inhibit all output drivers except engine start. The UGM or platform module has detected the battery voltage is at or below 9V. Power cycled. (Replace/fix battery.) BATTERY VOLTAGE TOO HIGH – SYSTEM SHUTDOWN 442 1 Inhibit all output drivers. The UGM or platform module has detected the battery voltage is at or above 16V. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until DRIVE DIRECTION SIGNAL LOST 463 1 Command an ‘N’ in the cabin’s display. Broadcast the TC1 J1939 CAN message on CAN1 to command the TCM to the neutral gear selection if MODELS: TH336, TH337, TH406, TH407, TH414, TH417, TH515 are configured. Deactivate and inhibit output J2-33 Transmission Forward. Deactivate and inhibit output J2-32 Transmission Reverse.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until INVALID TRANSMISSION CONFIGURATION 466 1 Deactivate output J1-20 Transmission D / 2 Coil. Deactivate output J1-7 Transmission E / 1 Coil. Deactivate output J2-33 Transmission A / Forward Coil. Deactivate output J2-32 Transmission B / Reverse Coil. Deactivate output J1-10 Transmission C Coil. Deactivate output J2-5 Frame Leveling Right Valve. Deactivate output J2-7 Frame Leveling Left Valve.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until COMMUNICATIONS 66XXX CANBUS FAILURE – PLATFORM MODULE 662 1 Disregard any CAN messages with the platform module source addresses. The PLATFORM OPTION is configured as ENABLED and a platform is detected as attached and the UGM does not detect the platform module on the CAN bus for a period of 250msec. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CANBUS FAILURE – CABIN JOYSTICK 6617 1 Disregard any CAN messages with the cabin joystick source addresses. Deactivate and inhibit all hydraulic functions. The UGM does not detect the cabin’s joystick on the CAN bus for a period of 250msec and an ENGINE STOPPED or ENGINE RUNNING state exists for a period of one second. Valid CAN bus communication is re-established with the joystick.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CANBUS FAILURE – BOOM RIDE/BOOM FLOAT MODULE 6631 1 If active, deactivate and then inhibit operation of Boom Ride Valve, Boom Float Valve, and Boom Tank Valve. The UGM has lost communications with the Boom Ride/Boom Float (Accessory) Module. Power cycled. CANBUS FAILURE BOOM EXTENSION LIMIT MODULE 6637 1 The UGM has lost communications with the Accessory Module. Power cycled.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSS CELL #1 ERROR 821 1, 14 Deactivate and inhibit the Lift Up output. Deactivate and inhibit the Lift Down output. Deactivate and inhibit the Telescope Out output. Deactivate and inhibit the Telescope In output. Deactivate and inhibit the Platform Rotate Left output. Deactivate and inhibit the Platform Rotate Right output. Deactivate and inhibit the Platform Level Up output.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSS CELL #3 ERROR 823 1, 14 Deactivate and inhibit the Lift Up output. Deactivate and inhibit the Lift Down output. Deactivate and inhibit the Telescope Out output. Deactivate and inhibit the Telescope In output. Deactivate and inhibit the Platform Rotate Left output. Deactivate and inhibit the Platform Rotate Right output. Deactivate and inhibit the Platform Level Up output.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSS HAS NOT BEEN CALIBRATED 825 1, 14 Deactivate and inhibit the Lift Up output. Deactivate and inhibit the Lift Down output. Deactivate and inhibit the Telescope Out output. Deactivate and inhibit the Telescope In output. Deactivate and inhibit the Platform Rotate Left output. Deactivate and inhibit the Platform Rotate Right output. Deactivate and inhibit the Platform Level Up output.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSI DETECTED BUT NOT CONFIGURED 8515 1 Inhibit all hydraulic functions. Set CAN message bit to permit LSI System display control of its alarm. The UGM has detected the CAN bus LSI system is present on the machine; however it has not been configured properly in the MACHINE SETUP - LOAD MOMENT menu selection. Use analyzer and correct parameter that is improperly configured.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault LSS EEPROM ERROR 992 1 Power cycle. (Replace board) LSS INTERNAL ERROR – PIN EXCITATION 993 1 Power cycle. (Replace board) LSS INTERNAL ERROR – DRDY MISSING FROM A/D 994 1 Power cycle. (Replace board) EEPROM FAILURE – CHECK ALL SETTINGS 998 1 Suspend all hydraulic function, engine, and transmission operation. The UGM has detected an anomaly in EEPROM. Power cycle.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT 9945 1 The UGM will not permit engine start. The UGM will not permit any hydraulic function operation. The UGM has detected the current feedback calibration checksum is incorrect. Power cycle. (Replace board) CABIN DISPLAY EEPROM WRITE FAILURE 9946 1 N/A The UGM was not able to write/ reprogram the cabin display’s EEPROM. Power cycle.
Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until GROUND MODULE VLOW FET FAILURE 9986 1 Suspend all hydraulic function and engine operation, and command the transmission to neutral. The UGM has detected an anomaly in a mosfet. Power cycle.
Electrical System 9-94 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.
31200206 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda. Rua Eng.