JLG 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 Telehandler Service Manual (CE)

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This service manual PDF download for the 3507, 3508, 3509, 3512, 3513, 4007, 4008, 4009, 4012, 4013 JLG Telehandler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG Lift 3507
JLG Lift 3508
JLG Lift 3509
JLG Lift 3512
JLG Lift 3513
JLG Lift 4007
JLG Lift 4008
JLG Lift 4009
JLG Lift 4012
JLG Lift 4013


TABLE OF CONTENTS :

    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
        1.6 Safety Instructions
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torques
        2.3 Specifications
        2.4 Fluids, Lubricants and Capacities
        2.5 Maintenance Schedules
        2.6 Lubrication Schedules
            
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System
        3.3 Boom Assembly Maintenance
        3.4 Boom Wear Pads
        3.5 Quick Switch Assembly
        3.6 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
        4.3 Cab Components
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
        5.4 Drive Shafts
        5.5 Wheels and Tires
        5.6 Brakes
        5.7 Towing A Disabled Machine
        
    Section 6 Transmission:
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Description
        6.3 Transmission Serial Number
        6.4 Transmission Specifications
        6.5 Transmission Replacement
        6.6 Troubleshooting
            
    Section 7 Engine: Perkins 1104-42 & 1104-42T
        7.1 Introduction
        7.2 Engine Serial Number
        7.3 Specifications and Maintenance Information
        7.4 Engine Cooling System
        7.5 Engine Electrical System
        7.6 Fuel System
        7.7 Engine Exhaust System
        7.8 Air Cleaner Assembly
        7.9 Engine Replacement
        7.10 Engine Drive Plate
        7.11 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
        8.4 Hydraulic Circuits
        8.5 Hydraulic Schematics
        8.6 Hydraulic Reservoir
        8.7 Hydraulic System Pump
        8.8 Valves and Manifolds
        8.9 Hydraulic Cylinders
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Service Warning
        9.4 Fuses and Relays
        9.5 Electrical System Schematics
        9.6 Circuit Breakdowns
        9.7 Engine Start Circuit
        9.8 Charging Circuit
        9.9 Electrical System Components
        9.10 Window Wiper/Washer
        9.11 Cab Heater and Fan
        9.12 Switches, Solenoids and Senders
        9.13 Display Monitor and Gauges


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121852
Total Pages : 136


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3121852_C_7, 8, 9, 12, 13M_JLG_Service
    Table of Contents
    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
            1.5.1 Safety Alert System and Signal Words
        1.6 Safety Instructions
            1.6.1 Personal Hazards
            1.6.2 Equipment Hazards
            1.6.3 General Hazards
            1.6.4 Operational Hazards
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torques
            2.2.1 ASTM Fastener Torque Chart (English)
            2.2.2 ASTM Fastener Torque Chart (Metric)
            2.2.3 Metric Fastener Torque Chart
        2.3 Specifications
            2.3.1 Travel Speeds
            2.3.2 Hydraulic Cylinder Performance Specifications
            2.3.3 Electrical System
            2.3.4 Engine Performance Specifications
            2.3.5 Tires
        2.4 Fluids, Lubricants and Capacities
        2.5 Maintenance Schedules
            2.5.1 8 & 1st 50 Hour Maintenance Schedule
            2.5.2 50, 250 & 500 Hour Maintenance Schedule
            2.5.3 1000 & 1500 Hour Maintenance Schedule
        2.6 Lubrication Schedules
            2.6.1 8 Hour Lubrication Schedule
            2.6.2 50 Hour Lubrication Schedule
            
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Boom System
            3.2.1 Boom System Description
        3.3 Boom Assembly Maintenance
            3.3.1 Boom Removal
            3.3.2 Second Section Boom Removal (12 & 13M)
            3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (7, 8 & 9M)
            3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (7, 8 & 9M)
            3.3.5 Second Section Boom Installation (12 & 13M)
            3.3.6 Boom Installation
        3.4 Boom Wear Pads
            3.4.1 Wear Pad Inspection
            3.4.2 Boom Wear Pad Replacement
            3.4.3 Boom Wear Pad Lubrication
        3.5 Quick Switch Assembly
            3.5.1 Connecting with a Mechanical Quick Switch Device
            3.5.2 Connecting with a Hydraulic Quick Switch Device
            3.5.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment
            3.5.4 Quick Switch Removal
            3.5.5 Quick Switch Installation
        3.6 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator’s Cab and Covers Component Terminology
        4.2 Operator’s Cab
            4.2.1 Serial Number Decal
        4.3 Cab Components
            4.3.1 Steering Column and Orbitrol Valve
            4.3.2 Service Brake Pedal and Valve
            4.3.3 Throttle Pedal Replacement
            4.3.4 Joystick Assembly Replacement
            4.3.5 Parking Brake
            4.3.6 Windshield Wiper Assembly
            4.3.7 Windshield Washer Assembly
            4.3.8 Heater/Defroster System
        4.4 Cab Removal
        4.5 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 General Information
        5.3 Axle Assemblies
            5.3.1 Axle Serial Number Plate
            5.3.2 Axle Specifications
            5.3.3 Axle Internal Service
            5.3.4 Axle Maintenance
            5.3.5 Axle Removal
            5.3.6 Axle Assembly and Drive Shaft Troubleshooting
        5.4 Drive Shafts
            5.4.1 Drive Shaft Inspection and Service
            5.4.2 Drive Shaft Maintenance
            5.4.3 Drive Shaft Removal
            5.4.4 Drive Shaft Cleaning and Drying
            5.4.5 Drive Shaft Installation
        5.5 Wheels and Tires
            5.5.1 Removing Wheel and Tire Assembly from Machine
            5.5.2 Installing Wheel and Tire Assembly onto Machine
        5.6 Brakes
            5.6.1 Brake Disk Inspection.
        5.7 Towing A Disabled Machine
        
    Section 6 Transmission:
        6.1 Transmission Assembly Component Terminology
        6.2 Transmission Description
        6.3 Transmission Serial Number
        6.4 Transmission Specifications
            6.4.1 Transmission Maintenance
            6.4.2 Transmission Maintenance Schedule
        6.5 Transmission Replacement
            6.5.1 Transmission Removal
            6.5.2 Transmission Inspection and Internal Repair
            6.5.3 Transmission Installation
            6.5.4 After Transmission Service or Replacement
        6.6 Troubleshooting
            6.6.1 Transmission Troubleshooting
            
    Section 7 Engine: Perkins 1104-42 & 1104-42T
        7.1 Introduction
            7.1.1 Disclaimer and Scope
            7.1.2 Component Terminology
        7.2 Engine Serial Number
        7.3 Specifications and Maintenance Information
        7.4 Engine Cooling System
            7.4.1 Radiator Pressure Cap
            7.4.2 Thermostat Replacement
            7.4.3 Radiator/Oil Cooler and Coolant Heater Replacement
        7.5 Engine Electrical System
        7.6 Fuel System
            7.6.1 Diesel Fuel
            7.6.2 Fuel Tank
            7.6.3 After Fuel System Service
        7.7 Engine Exhaust System
            7.7.1 Exhaust System Removal
            7.7.2 Exhaust System Installation
        7.8 Air Cleaner Assembly
            7.8.1 Air Cleaner Assembly Removal
            7.8.2 Air Cleaner Assembly Installation
        7.9 Engine Replacement
            7.9.1 Engine Removal
            7.9.2 Engine Disassembly, Inspection and Service
            7.9.3 Engine Installation
        7.10 Engine Drive Plate
            7.10.1 Drive Plate Removal
            7.10.2 Drive Plate Installation
        7.11 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 Hydraulic Pressure Diagnosis
        8.4 Hydraulic Circuits
            8.4.1 Checking Function Pressures
            8.4.2 Adjusting Hydraulic Pressure
        8.5 Hydraulic Schematics
        8.6 Hydraulic Reservoir
            8.6.1 Hydraulic Oil Reservoir Draining
            8.6.2 Hydraulic Oil Reservoir Filling
            8.6.3 Hydraulic Oil Reservoir Removal/ Installation
        8.7 Hydraulic System Pump
            8.7.1 Pump Description
            8.7.2 Pump Failure Analysis
            8.7.3 Pump Replacement
        8.8 Valves and Manifolds
            8.8.1 Main Control Valve
            8.8.2 Service Brake Valve
            8.8.3 Brake Test
            8.8.4 Steering Orbitrol Valve
            8.8.5 Steer Select Valve
            8.8.6 ERS Control Valve Assembly
        8.9 Hydraulic Cylinders
            8.9.1 General Cylinder Removal Instructions
            8.9.2 General Cylinder Disassembly
            8.9.3 Cylinder Cleaning Instructions
            8.9.4 Cylinder Inspection
            8.9.5 General Cylinder Assembly
            8.9.6 General Cylinder Installation
            8.9.7 Cylinder Pressure Checking
            8.9.8 Steering Cylinders
            8.9.9 Hydraulic Cylinder Torque Specifications
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
            9.1.1 General Overview (Cab Harness)
        9.2 Specifications
        9.3 Service Warning
        9.4 Fuses and Relays
            9.4.1 Cab
            9.4.2 Engine Compartment
            9.4.3 Power Control Board
        9.5 Electrical System Schematics
            9.5.1 Cab Harness Electrical Schematic
            9.5.2 Engine Harness Electrical Schematic
            9.5.3 Printed Circuit Board Electrical Schematic
            9.5.4 ESX Harness and Options Electrical Schematic
            9.5.5 Front & Rear Chassis Harness Electrical Schematic
            9.5.6 Basket Dash Board Box -Platform Machines Only
            9.5.7 Cab Harness - Platform Machines Only
        9.6 Circuit Breakdowns
            9.6.1 Constant Power Circuit from Battery
            9.6.2 Start Circuit
            9.6.3 Charging Circuit
        9.7 Engine Start Circuit
            9.7.1 Starter
        9.8 Charging Circuit
            9.8.1 Alternator
        9.9 Electrical System Components
            9.9.1 Load Moment Indicator
            9.9.2 Load Moment Sensor
            9.9.3 Back-up Alarm
        9.10 Window Wiper/Washer
            9.10.1 Windshield Wiper Motor
            9.10.2 Rear Window Wiper Motor
            9.10.3 Windshield Washer Reservoir and Pump
        9.11 Cab Heater and Fan
            9.11.1 Cab Heater Controls
        9.12 Switches, Solenoids and Senders
            9.12.1 Fuel Shut-off Solenoid
            9.12.2 Main Control Valve Solenoids
            9.12.3 Transmission Solenoid Valves
            9.12.4 Transmission Temperature Sender
            9.12.5 Transmission Mounted Speed Sensor
            9.12.6 Engine Coolant Temperature Sender/ Switch
            9.12.7 Engine Oil Pressure Sender
            9.12.8 Boom Angle Sensor
            9.12.9 Ignition Key Switch
            9.12.10 Fuel Level Indicator and Fuel Level Sender
        9.13 Display Monitor and Gauges
            9.13.1 Analog Gauges
            
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