JLG 3507 Service Manual
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JLG 3507 Service Manual

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See also: Operator's Manual
Service Manual
Models
3507, 3508,
3509, 3512,
3513, 4007,
4008, 4009,
4012, 4013
P/N - 3121852
Revised
April 20, 2007
Courtesy of Crane.Market

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Summary of Contents for JLG 3507

  • Page 1 Service Manual Models 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 P/N - 3121852 Revised April 20, 2007 Courtesy of Crane.Market...
  • Page 2 Courtesy of Crane.Market...
  • Page 3 January 20, 2006 - B - Complete Revision Of Manual April 20, 2007 - C - Revised pages 5.3, 5.5, 5.10, 6.3, 6.5, 6.7, 8.8, & 8.20 3121852 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 4 EFFECTIVITY PAGE 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 5: Table Of Contents

    Towing A Disabled Machine ..........5.12  2004 JLG Industries, Inc. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 6 Display Monitor and Gauges ..........9.33 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 7 Safety Decals ............3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013...

  • Page 8: Safety Practices

    Training Schools, the JLG website, other literature, and service or maintenance. Remove key and disconnect through updates to the manual itself. battery leads. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 9: Safety Information

    HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 10: Safety Decals

    Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 11 50 Hour Lubrication Schedule ........2.11 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 12: Replacement Parts And Warranty Information

    A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.
  • Page 13 VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD TORQUE TORQUE TORQUE TENSILE BOLT...
  • Page 14 VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD TORQUE TORQUE TORQUE TENSILE BOLT...
  • Page 15 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440 Note: These torque values do not apply to cadmium plated fasteners. METRIC CLASS 8.8 METRIC CLASS 10.9 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 16: Specifications

    1 (100 Ah) (C Reserve Capacity CCA @ -18° C: 880 EN Group/Series DIN 600,38 Alternator 14V, 70 Amps Starter 12V, 3,0 KW Type EV (Gear Reduction) 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 17: Engine Performance Specifications

    405/70-24 MPT04 CONST 4,0 Bar (58 psi) b. 12M & 13M Description Tire Air Pressure 405/70-24 MPT01 AG 4,0 Bar (58 psi) 405/70-24 MPT04 CONST 4,0 Bar (58 psi) 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 18: Fluids, Lubricants And Capacities

    (ISO 46) Hydraulic System System Capacity 246 liters (65 gallons) Reservoir Capacity to FULL Mark 160 liters (42.3 gallons) ® Type of Fluid Mobilfluid 424 (ISO 46) 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 19: Maintenance Schedules

    Transfer Case Axle Oil End Oil Oil & Filter EVERY 1500 Change Change Change Change Engine Coolant Hydraulic Hydraulic Tank Brake Fluid Fluid & Filters Breather MZ1690 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 20: Lubrication Schedules

    General Information and Specifications LUBRICATION SCHEDULES 2.6.1 8 Hour Lubrication Schedule Mystik Tetrimoly EVERY (NLGI 2 GC-LB) MZ1700 2.10 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 21 General Information and Specifications 2.6.2 50 Hour Lubrication Schedule Mystik Tetrimoly EVERY (NLGI 2 GC-LB) MZ1710 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 2.11 Courtesy of Crane.Market...
  • Page 22 General Information and Specifications This Page Intentionally Left Blank 2.12 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 23 Troubleshooting ........... 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013...

  • Page 24: Boom System Component Terminology

    Cylinder Access Panel First Boom Section Pivot Pin Tilt Cylinder Quick Switch Extend/Retract Cylinder Two Section Boom Access Panel Second Boom Section Tilt Cylinder MZ1480 Quick Switch 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 25: Boom System

    13. Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the side of the first boom section. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 26: Second Section Boom Removal (12 & 13M)

    (7). Tag each pad, backing plate, shim and bolts from each location. 2. Pull out the innermost boom section (7). 3. Remove the remaining wear pads. MZ1720 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 27: Third Section Boom Installation (12 & 13M) Second Section Boom Installation (7, 8 & 9M)

    1 m to 1,5 m (3’ to 4’) into the front of the next boom section. Set the innermost boom section head onto suitable supports and reset 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 28: Boom Installation

    15. Install the access panel on the boom head. pin mounting hole on the first boom section. Install 16. Close and secure the engine cover. the extend/retract cylinder pin and retaining clip. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 29: Boom Wear Pads

    Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 30: Quick Switch Assembly

    2. 6. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.5.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.” 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 31: Troubleshooting

    2. Refer to Section 8, “Hydraulic operating properly. System.” 3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section 8.9.4, “Cylinder Inspection.” 4. Seized boom pivot pin bearing. 4. Replace bearing. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 32 4. Clean equipment frequently. abrasive conditions. 7. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8, “Hydraulic operate. operating properly. System.” 3.10 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 33: Cab And Covers

    Cab Installation ........... . 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013...

  • Page 34: Operator's Cab And Covers Component Terminology

    Adjuster Continuous Hydraulic Powered Operation Auxiliary Switch Air Louvers Service Brake Pedal Accelerator Pedal 12V Receptacle Parking Brake Lever Heater & AC Controls Round Air Vents MZ0040 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 35: Operator's Cab

    9. Remove the steering assembly (9) through the dash panel opening. Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 36 4. Install new o-rings into the fittings. Lubricate the o- rings with clean hydraulic oil. 5. Connect the load sense hose to the "LS" port at the top of the steering valve. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 37 4. Disconnect the battery negative (-) cable at the battery negative (-) terminal. 5. Remove the three capscrews (11), three lockwashers securing the throttle pedal assembly to the cab floor. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 38 4. Remove the cover from around the park brake lever. 2. Install the four self-tapping screws. Connect the 5. Disconnect the park brake electrical connector electrical connections. switch. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 39 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, MZ0480 place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 40: Cab Removal

    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. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 41: Cab Installation

    19. Reinstall the cab bottom shield. Readjust the position of the sling as needed to help 20. Close and secure the engine cover. balance the cab during installation. 21. Unblock the wheels. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 42 Cab and Covers This Page Intentionally Left Blank 4.10 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 43 Towing A Disabled Machine......... . 5.12 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 44: Axle, Drive Shaft And Wheel Component Terminology

    The following illustration identifies the components that are referred to throughout this section. Rear Axle Assembly Steering Cylinder (Rear) Transmission Drop Steering Cylinder (Front) Drive Shafts MZ1510 Front Axle Assembly 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 45: General Information

    If replacement of a damaged bearing cup or cone is necessary, replace the cup and cone as a set. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 46: Axle Removal

    Balance the axle and prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 47 Check for hydraulic leaks, and tighten or repair as necessary. driveshaft yoke at the transmission. Align the 22. Close and secure the engine cover. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 48: Axle Assembly And Drive Shaft Troubleshooting

    2. Drive shaft universal joint(s) 2. Repair or replace universal worn or damaged. joints as needed. 3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as unbalanced. needed. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 49 2. Replace o-rings and seals. seals worn or damaged. 3. Piston rod seal worn or 3. Replace piston rod seal. damaged. 4. Cylinder tube damaged. 4. Replace cylinder tube. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 50 2. Brake (hydraulic) system not 2. Refer to Section 8.8.3, “Brake operating properly. Test.” 3. Brake piston o-rings and seals 3. Replace o-rings and seals. damaged (leaking). 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 51: Drive Shafts

    Mark the yoke and axle, transmission and the shaft 4. Repeat the above procedure on the rear drive shaft. and slip yoke so that these components can be 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 52: Wheels And Tires

    The wheel and tire assemblies must be installed with the pattern. directional tread pattern “arrows” (4) facing in the direction of forward travel. 7. Remove the wheel and tire assembly from the machine. 5.10 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 53: Brakes

    4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 500 Nm (367 lb-ft). 4,5 mm OY1220 5. Remove machine from supports. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 5.11 Courtesy of Crane.Market...

  • Page 54: Towing A Disabled Machine

    2. Release the park brake and set the transmission control lever in (N) NEUTRAL. 3. Tow the machine to a suitable repair facility. 4. After towing is complete, engage the park brake. 5.12 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 55: Transmission

    Transmission Troubleshooting ........3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013...

  • Page 56: Transmission Assembly Component Terminology

    Dipstick and Fill Tube Oil Filter Output Shaft (front) Breather Output Shaft (rear) Breather Drop Box Oil Level Sight Gauge MZ0670 Transmission Drop Box Shift Solenoids Flex Plate Assembly 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 57: Transmission Description

    Operation & Safety Manual, with a cleaning solution onto or near the transmission shift detailed account of how to perform the procedures. solenoids and other electrical components. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 58 Secure “Drive Shaft Removal.” the transmission so that it will not move or fall. 11. Remove the air cleaner unit and intake tubes. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 59 Remove the dipstick and add approximately ® 11,4 liters (3 Gallons) of Mobilfluid 424 Grade 46. Check the oil level by taking intermittent dipstick readings as outlined in the appropriate 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 60 If needed, remove the radiator or oil cooler from the machine. IMPORTANT: DO NOT use flushing compounds for cleaning purposes. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 61: Troubleshooting

    6. Clutch piston o-rings damaged. 6. Replace o-rings. 7. Clutch discs worn or damaged. 7. Replace clutch discs. 8. Coupling shafts or gear teeth 8. Replace couplings. damaged. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 62 4. Clutch discs worn or damaged. 4. Replace clutch discs. 5. Transmission overheating. 5. Refer to Section 6.6.1, “Transmission Troubleshooting,” Problem 5. “Transmission overheating (oil above 120° C (248° F)).” 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 63 5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate). Refer to Section 6.5.1, “Transmission Removal.” 6. Loose diaphragm (flex plate) 6. Tighten capscrews. mounting capscrews. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 64 8. Oil leaking at output shaft 8. Replace output shaft seal. (output shaft seal damaged). 9. Housing damaged. 9. Replace housing as needed. 6.10 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 65 Troubleshooting ........... 7.13 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 66: Introduction

    IMPORTANT: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. For assistance with comprehensive engine diagnosis, repair and component replacement, contact your local Perkins Service partner. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 67: Component Terminology

    The following illustration identifies the components that are referred to throughout this section. Fuel Injection Pump Fuel Filter Oil Filter Thermostat Alternator Turbocharger (optional) Starter MZ0070 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 68: Engine Serial Number

    IMPORTANT: ALWAYS use the correct thermostat and block, and/or other internal engine damage. install a new gasket. NEVER operate the engine without a thermostat, or engine damage will result. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 69: Radiator/Oil Cooler And Coolant Heater Replacement

    (5). Work the hose off the radiator. Position the 5. Remove the engine cover to ease removal of hose out of the way to allow radiator removal, or radiator/oil cooler. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 70: Engine Electrical System

    The viscosity of the fuel must be kept above 1.3 9. Connect the battery negative (-) cable to the battery centistrokes to provide adequate fuel system lubrication. negative (-) terminal. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 71: Fuel Tank

    5. Refill the fuel tank with water until it overflows. battery negative (-) terminal. Completely flush the tank with water. Empty the fuel tank, and allow it to dry completely. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 72: Engine Exhaust System

    3. Fill the fuel tank with fresh, clean diesel fuel as required. muffler to the side of the frame. 4. Install the clamp securing the muffler to the exhaust pipe. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 73: Air Cleaner Assembly

    (disconnected) from the engine. Move the harness clear of the engine, and with the help of an observer, ensure that engine clears the harness during removal. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 74: Engine Disassembly, Inspection And Service

    22. At the rear right engine mount (15), remove the bolt and washer. Repeat for the rear left engine mount. 7.10 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 75: Engine Installation

    Check the levels of all fluids and the engine. lubricants. Fill as required. 17. Install the hood latch plate. Align the mark on the plate to help with hood adjustment. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 7.11 Courtesy of Crane.Market...

  • Page 76: Engine Drive Plate

    8. Replace all three drive plates if damaged 7.12 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 77: Troubleshooting

    19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak 20. Poor compression 42. Broken relief valve spring 63. Induction system leaks 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 7.13 Courtesy of Crane.Market...
  • Page 78 Engine: Perkins 1104-42 & 1104-42T This Page Intentionally Left Blank 7.14 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 79 Hydraulic Cylinder Torque Specifications ......8.20 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 80: Hydraulic Component Terminology

    (inside boom) Compensation Hydraulic Fluid Cylinder Reservoir Lift/lower Cylinder Hydraulic Filter Main Pump ERS Control Panel Outrigger Cylinders (12 & 13M only) Steering Cylinder Main Control Valve 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 81: Safety Information

    Some hydraulic functions are actuated by interfacing with electrical system components (switches, solenoids and sensors). When the hydraulic system is not functioning properly, check the electrical aspect of the malfunctioning circuit also. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 82: Hydraulic Circuits

    8.5, “Hydraulic Schematics,” or Section 9.5, “Electrical System Schematics,” to help troubleshoot the problem. MZ1310 3. Start the machine, run the engine at full throttle and bottom the boom in function. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 83 SWAY STABILIZER EXTEND/RETRACT 7-9 M TILT EXTEND/RETRACT 12/13 M LIFT/LOWER AUXILIARY 125/60 125/60 160/90 90/56 140/70 100/50 COMPENSATION 100/60 2x90/45 110/63 110 bar/4:1 300 bar/4:1 DN 10 110 bar/4:1 300 bar/4:1 DN 10 DN 16 DN 10 DN 10 DN 16 DN 10 DN 16 DN 10...
  • Page 84 BASKET ROTATOR SWAY EXTEND/RETRACT 7-9 M STABILIZER EXTEND/RETRACT 12/13 M TILT LIFT/LOWER 125/60 125/60 160/90 90/56 140/70 100/50 100/60 COMPENSATION 2x90/45 110/63 110 bar/4:1 300 bar/4:1 DN 10 300 bar/4:1 110 bar/4:1 DN 10 DN 16 DN 10 DN 10 DN 16 DN 10 DN 16...
  • Page 85 BASKET ROTATOR STABILIZER EXTEND/RETRACT 12/13 M EXTEND/RETRACT 7-9 M SWAY TILT LIFT/LOWER 125/60 125/60 160/90 90/56 140/70 100/50 COMPENSATION 100/60 2x90/45 110/63 110 bar/4:1 300 bar/4:1 DN 10 300 bar/4:1 110 bar/4:1 DN 10 DN 16 DN 10 DN 10 DN 16 DN 10 DN 16...

  • Page 86: Hydraulic Reservoir

    7. Wipe up any hydraulic fluid spillage in, on, near and new replacement reservoir. Dispose of the old reservoir around the machine and the work area. according to local regulations concerning hazardous materials disposal. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 87: Hydraulic System Pump

    7. Check the hydraulic oil reservoir for leaks. 8. Connect the battery negative (-) cable to the battery MZ1660 negative (-) terminal. 9. Close and secure the engine cover. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 88: Pump Replacement

    Any adjustments c. Pump Test or repairs performed by anyone other than an authorized dealer could void the warranty. Refer to Section 8.4.2, “Adjusting Hydraulic Pressure.” 8.10 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 89: Valves And Manifolds

    8. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 8.11 Courtesy of Crane.Market...
  • Page 90 Clean all components with a suitable cleaner, such as clean container, before attaching the hoses. trichlorethylene, before continuing. Blow dry. 8.12 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 91: Service Brake Valve

    Tighten all tube and hose clamps. 5. Connect the battery negative (-) cable to the battery MZ0330 negative (-) terminal. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 8.13 Courtesy of Crane.Market...

  • Page 92: Brake Test

    7. Remove the two bolts holding the steer select valve Refer to Section 4.3.1, “Steering Column and Orbitrol to the mounting plate on the frame. Valve,” for details. 8.14 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 93: Ers Control Valve Assembly

    3. Open the engine cover. Allow the system fluids to members, and install tie wraps and/or protective cool. conduit as required. Tighten all hose clamps. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 8.15 Courtesy of Crane.Market...

  • Page 94: Hydraulic Cylinders

    7. Install the ERS control panel to the control panel bracket with two capscrews. 8. Install the face plate to the control panel with four capscrews. 8.16 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 95: General Cylinder Disassembly

    If adjustment is rebuilding hydraulic components. Consult the parts necessary, replace the counterbalance valve with a new catalog for ordering information. part. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 8.17 Courtesy of Crane.Market...

  • Page 96: Cylinder Cleaning Instructions

    IMPORTANT: Avoid using excessive force when clamping the cylinder barrel in a vise. Apply only enough 8.18 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 97: General Cylinder Installation

    Recheck the main relief setting and adjust if necessary. 8.9.8 Steering Cylinders The steering cylinders are attached to each axle center housing. The steer cylinders are covered in the appropriate Dana-Spicer axle literature. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 8.19 Courtesy of Crane.Market...

  • Page 98: Hydraulic Cylinder Torque Specifications

    13M - S/N 1160000863 & After 1070-1120 Nm 480-530 Nm 50-55 Nm 20-25 Nm (789-826 lb-ft) (354-391 lb-ft) (rear) (37-41 lb-ft) (15-19 lb-ft) 380-430 Nm (280-317 lb-ft) (front) 8.20 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 99 (737 lb-ft) (111 lb-ft) (74 lb-ft) 12M - S/N 1160000765 & After 1300-1350 Nm 625-675 Nm 13M - S/N 1160000863 & After (959-995 lb-ft) (461-498 lb-ft) 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 8.21 Courtesy of Crane.Market...
  • Page 100 70-80 Nm 75-85 Nm 9M - S/N 1160000875 & After (52-59 lb-ft) (55-63 lb-ft) 12M - S/N 1160000765 & After 13M - S/N 1160000863 & After 8.22 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 101 Transmission Solenoid Valves........9.28 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 102 Analog Gauges ..........9.33 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 103: Electrical Component Terminology

    9.1.1 General Overview (Cab Harness) Joystick Power Control Module Display Panel Control & Indicator Console Transmission Control Lever Heater/AC Controls ESX Control Module Gauges MZ1800 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 104: Specifications

    MZ0540 Note: On machines before S/N 1160000358, the fuse and relay bar is not present. Only the starter relay is mounted on the frame above the engine. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 105 Aux Pwr Socket Battery Ind Light, Dome Light ESX Battery Key Switch Spare Brake Lights, Cold Start, Beacon Ignition Rear Wiper Front Wiper Front Work Lights Boom Work Lights 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 106 Front Chassis Harness F-N-R and Gear Shifter Harness RS232 Diagnostic Connector Tilt Sensor-not used Key (Power) Relay Start Interlock Relay Flasher Wiper Relay Work Lights Relay Fuel Solenoid Relay 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 107 CABIN HEATER FAN SWITCH HI BEAM FLASHER TRAILER? ALTERNATOR DRIVING LIGHTS FRT WORK LIGHTS REAR WORK LIGHTS REAR WIPER BEACON LIGHT CHASSIS SWAY BOOM LIGHTS RESERVED AUX HYD SELECT CONT AUX HYD SEE SHEET 2 FOR OPT WIRING INDICATOR INDICATOR INDICATOR INDICATOR SWITCH...

  • Page 108: Engine Harness Electrical Schematic

    GLOWPLUGS FUSE SLO-BLO 50A LIFT PUMP FUSE ATO 7.5A GLOWPLUGS RELAY ENGINE GLOWPLUGS LIFT PUMP EMPTY LIFT PUMP RELAY FRONT W/WASHER PUMP REAR W/WASHER PUMP MZ1120 (OPT) 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 109 TO REAR CHASSIS HARNESS TO FNR SHIFTER TO CAB HARNESS (DISPLAY) TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO INST PANEL HARNESS TO INST PANEL HARNESS TO INST PANEL HARNESS TO JOYSTICK TO OPTIONS HARNESS 1.8K 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14...
  • Page 110 A/C SWITCH A/C FAN SWITCH TO CAB HARNESS HEATER FAN SWITCH (OPT) (OPT) SEE SHEET 1 FOR STD WIRING M8 GROUND STUD(S) A/C OPT HARNESS ON CAB FIREWALL ESX CONTROLLER XGND2 XGND2 XGND1 XGND1 DO/5 189A RT O/R VLV (SAUER) DO(4A)/3 CLUTCH AUX HYD SELECT...
  • Page 111 ~1/0 AWG BLK LICENSE REVERSE FUEL LEFT REAR DRIVING LIGHT RIGHT REAR DRIVING LIGHT LIGHT ALARM SNDR TO PCB TO PCB TO PCB TO ESX HARNESS TAIL BACK TURN STOP TAIL BACK TURN STOP TO PCB TO PCB X16.1 REAR CHASSIS HARNESS REAR CHASSIS HARNESS M8 GROUND STUD(S) FRONT CHASSIS HARNESS...
  • Page 112 BASKET DASH BOARD BOX 19/17 X123 X124 X123 F100 (15A) PREHEAT EMERGENCY WATER BATTERY LAMP ENGINE OIL TEMPERATURE CHARGE STOP LAMP LAMP LAMP D100 D101 D104 H101 OPERATE H106 H107 H108 X123 X123 D102 D103 STOP HORN S101 BASKET MODE X138 LSS OVER ERS LSS POWER...
  • Page 113 CABIN ELECTRICAL BOX TO SCHEME 003 3.0 mm^ 2 X120 X120 X119 X119 X119 F101 (15A) D105.1 D105.2 D105.3 D105.8 D105.9 X119 X119 X120 X120 X120 BASKET ESX/DISPLAY CABIN BASKET BASKET FUEL LEFT RIGHT STARTER KEY PW IGNITION IGNITION IGNITION IGNITION LEVEL STABILIZER...
  • Page 114 CABIN ELECTRICAL BOX FROM SCHEME 002 TO SCHEME 004 ESX CONTROLLER BABYBOARD 1=TYPE A P/N 25021 BABYBOARD 2=TYPE A P/N 3911 XGND2 X119 X119 X119 X112 X112 XGND2 XGND1 2.2K 2.2K XGND1 D105.4 D105.5 D105.6 R100.1 R100.2 RT O/R VLV (SAUER) DO/5 X120 X120...
  • Page 115 SEE SCHEME 002-C8 A01 PIN 52 see sch. 003 ESX READY -BK 18 SEE SCHEME 002-B2 & C7 A01 PIN 45 see sch. 003 FOOTSWITCH SIGNAL -BK 2 BASKET GROUND SEE SCHEME 002-B2 & E1 BOOM EXTENTION LIMIT SIGNAL -BK 22 A01 PIN 10 see sch.
  • Page 116 CABIN ELECTRICAL BOX ERS GROUND CMD BOX FROM SCHEME 004 X111 1.5 mm^ 2 1.5 mm^ 2 ERS LIGHTED X135 ERS LIGHTED SWITCH TELESCOPE SWITCH LIFT F102 (10A) DOWN X141 X142 H111 ERS GROUND CMD FUSE ENABLING X135 S106 S107 S105 H113 H114...

  • Page 117: Circuit Breakdowns

    ANALOG GND AGND STARTER RELAY ALTERNATOR 501A GLOWPLUGS 501A FUSE SLO-BLO 50A LIFT PUMP FUSE ATO 7.5A GLOWPLUGS RELAY LIFT PUMP RELAY MZ1300 PCB AND PWR HARNESS 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.17 Courtesy of Crane.Market...
  • Page 118 TO PCB X11 ENGINE HARNESS POSITIVE CABLE TO BATTERY + NEGATIVE CABLE TO BATTERY DISCONNECT OR BATTERY - 50mm BLK STARTER 50mm RED (RED-PWR) STARTER RELAY ALTERNATOR MZ1290 9.18 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 119: Charging Circuit

    ENGINE HARNESS TO PCB POSITIVE CABLE ENGINE HARNESS TO BATTERY + NEGATIVE CABLE TO BATTERY DISCONNECT OR BATTERY - 50mm BLK STARTER 50mm RED ALTERNATOR MZ1280 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.19 Courtesy of Crane.Market...

  • Page 120: Engine Start Circuit

    The starter drive or solenoid that pushes the drive forward to engage the flywheel may be 9.20 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 121: Charging Circuit

    9. While supporting the alternator with one hand, remove the upper (longer) mounting hardware from the upper alternator mount. Remove the alternator from the machine. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.21 Courtesy of Crane.Market...

  • Page 122: Electrical System Components

    70 Nm (50 lb-ft) is item. The Load Moment Indicator must be inspected achieved. and/or replaced by a qualified dealer or a JLG technician. 9.22 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 123 Disassembly the system will remain in the uncalibrated condition. DO NOT disassemble the back-up alarm. Replace a defective or faulty alarm with a new part. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.23 Courtesy of Crane.Market...

  • Page 124: Window Wiper/Washer

    9. Install the lower dash panel. 10. Close and secure the engine cover. MAH0910 8. Remove the linkage attached to the wiper motor (4). 9.24 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 125 3. Install the wiper arm onto the wiper motor shaft. connectors. 4. Connect the battery negative (-) cable to the 8. Remove the windshield washer hoses from the battery negative (-) terminal. reservoir. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.25 Courtesy of Crane.Market...

  • Page 126: Cab Heater And Fan

    2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover. Allow the engine to cool. 9.26 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 127: Switches, Solenoids And Senders

    2. Install the fuel shut-off solenoid on the fuel injection pump. Do not over tighten. 3. Connect the wiring connector at the fuel shut-off solenoid lead. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.27 Courtesy of Crane.Market...

  • Page 128: Transmission Temperature Sender

    Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period. 9.28 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 129: Transmission Mounted Speed Sensor

    9.12.6 Engine Coolant Temperature Sender/ display, etc. Switch 5. Close and secure the engine cover. The engine coolant temperature sender/switch is located by the alternator. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.29 Courtesy of Crane.Market...

  • Page 130: Engine Oil Pressure Sender

    5. Close and secure the engine cover. Inspect the sensor and the wiring harness connector terminals for continuity. Replace a defective or faulty sensor with a new sensor. 9.30 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 131: Ignition Key Switch

    OK button and one comes back to the Learning menu. Conditions for the value range: • If the lower value is outside the range of 70-330, a value of 100 is taken over. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.31 Courtesy of Crane.Market...

  • Page 132: Fuel Level Indicator And Fuel Level Sender

    3. Turn the ignition key switch to the OFF position. The fuel level indicator needle should return to the EMPTY position. 9.32 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...

  • Page 133: Display Monitor And Gauges

    4. Start the machine and allow the engine to warm to check the engine water temperature. 5. Close and secure the engine cover. 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 9.33 Courtesy of Crane.Market...
  • Page 134 Electrical System This Page Intentionally Left Blank 9.34 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Courtesy of Crane.Market...
  • Page 135 Courtesy of Crane.Market...
  • Page 136 McConnellsburg PA. 17233-9533 Phone: (717) 485-5161 Customer Support Toll Free: (877) 554-5438 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) JLG EQS P.O. Box 5119 Rua Eng. Carlos Stevenson, Unit 4 & 5 Z.I.

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