JLG 3508PS - 4017PS, 40.8, 40.9 Telehandlers Service Manual (CE)

JLG 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 Telehandlers Service Manual (CE)
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This service manual PDF download for the 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 JLG Boom Lift / Telehandlers 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 3508PS
JLG Lift 3509PS
JLG Lift 3512PS
JLG Lift 3513PS
JLG Lift 4008PS
JLG Lift 4009PS
JLG Lift 4012PS
JLG Lift 4013PS
JLG Lift 4017PS
JLG Lift Agrovector 40.8
JLG Lift Agrovector 40.9


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 Torque Charts
        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 - Two and Three Section Boom
        3.2 Boom System - Two and Three Section Boom
        3.3 Boom Assembly Maintenance - Two and Three Section Boom
        3.4 Boom System Component Terminology - Four Section Boom
        3.5 Boom System - Four Section Boom
        3.6 Boom Assembly Maintenance - Four Section Boom
        3.7 Boom Extend and Retract Chains Four Section Boom
        3.8 Boom Section Separation Adjustment - Four Section Boom
        3.9 Hose Carrier Assembly - Four Section Boom
        3.10 Boom Wear Pads
        3.11 Quick Switch Assembly
        3.12 Forks
        3.13 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
        4.2 Operator 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 Auxiliary Pump (Platform Equipped Models Only)
        8.9 Valves and Manifolds
        8.10 Hydraulic Cylinders
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Platform Interlock Checks
        9.4 Software Level 2 Accessibility
        9.5 Operator Tools
        9.6 Fuses and Relays
        9.7 Electrical System Schematics
        9.8 Circuit Breakdowns
        9.9 Engine Start Circuit
        9.10 Charging Circuit
        9.11 Electrical System Components
        9.12 Window Wiper/Washer
        9.13 Cab Heater and Fan
        9.14 Switches, Solenoids, Sensors and Senders
        9.15 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
        9.16 Load Stability Indicator (LSI) - 8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950 17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978
        9.17 Hand Held Analyzer
        9.18 Fault Codes


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200206
Total Pages : 236


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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31200206_C_8, 9, 12, 13, 17M PS, 40.8, 40.9_JLG_Service
    Effectivity
    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 Torque Charts
            2.2.1 SAE Fastener Torque Chart
            2.2.2 Metric Fastener Torque Chart
            2.2.3 Hydraulic Hose Torque Chart
        2.3 Specifications
            2.3.1 Travel Speeds
            2.3.2 Hydraulic Cylinder Performance Specifications
            2.3.3 Platform Hydraulic Performance Specifications
            2.3.4 Electrical System
            2.3.5 Engine Performance Specifications
            2.3.6 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 - Two and Three Section Boom
        3.2 Boom System - Two and Three Section Boom
            3.2.1 Boom System Description
        3.3 Boom Assembly Maintenance - Two and Three Section Boom
            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 (8 & 9M)
            3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (8 & 9M)
            3.3.5 Second Section Boom Installation (12 & 13M)
            3.3.6 Boom Installation
        3.4 Boom System Component Terminology - Four Section Boom
        3.5 Boom System - Four Section Boom
            3.5.1 Boom System Operation
        3.6 Boom Assembly Maintenance - Four Section Boom
            3.6.1 Boom Removal
            3.6.2 Second, Third and Fourth Boom Section Removal
            3.6.3 Third and Fourth Boom Section Removal
            3.6.4 Fourth Boom Section Removal
            3.6.5 Hose Carrier Removal
            3.6.6 Hose Carrier Installation
            3.6.7 Fourth Boom Section Installation
            3.6.8 Third and Fourth Boom Section Installation
            3.6.9 Second, Third and Fourth Boom Section Installation
            3.6.10 Boom Installation
        3.7 Boom Extend and Retract Chains Four Section Boom
            3.7.1 Boom Chain Inspection
            3.7.2 Inspection Guidelines
            3.7.3 Expose Chains for Inspection
            3.7.4 Chain Lubrication
        3.8 Boom Section Separation Adjustment - Four Section Boom
        3.9 Hose Carrier Assembly - Four Section Boom
            3.9.1 Hose Carrier Assembly Removal
            3.9.2 Hose Carrier Assembly Replacement
        3.10 Boom Wear Pads
            3.10.1 Wear Pad Inspection
            3.10.2 Wear Pad Installation and Lubrication
        3.11 Quick Switch Assembly
            3.11.1 Connecting with a Mechanical Quick Switch Device
            3.11.2 Connecting with a Hydraulic Quick Switch Device
            3.11.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment
            3.11.4 Quick Switch Removal
            3.11.5 Quick Switch Installation
        3.12 Forks
        3.13 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
        4.2 Operator 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 (8, 9, 12 & 13M)
            4.3.6 Parking Brake (17M)
            4.3.7 Windshield Wiper Assembly
            4.3.8 Windshield Washer Assembly
            4.3.9 Heater/Defroster System
            4.3.10 Cab Heater/Air Conditioning Controls
        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 Installation
            5.3.7 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
            5.7.1 Towing (8, 9, 12 & 13M)
            5.7.2 Manually Releasing the Park Brake (17M)
            5.7.3 Manually Resetting the Park Brake (17M)
            
    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
        
    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 Hydraulic Pressures
        8.5 Hydraulic Schematics
            8.5.1 8M, 9M, 12M & 13M (w/o trailer brakes)
            8.5.2 8M, 9M, 12M & 13M (w/ trailer brakes)
            8.5.3 8M, 9M, 12M & 13M - Frame Level (if equipped)
            8.5.4 17M
            8.5.5 13M (if equipped for platform)
            8.5.6 17M (if equipped for platform)
        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 Auxiliary Pump (Platform Equipped Models Only)
            8.8.1 Auxiliary Pump Description
            8.8.2 Auxiliary Pump Replacement
        8.9 Valves and Manifolds
            8.9.1 Main Control Valve
            8.9.2 Service Brake Valve
            8.9.3 Brake Test
            8.9.4 Steering Orbitrol Valve
            8.9.5 Steer Select Valve
            8.9.6 Leveling Valve
        8.10 Hydraulic Cylinders
            8.10.1 General Cylinder Removal Instructions
            8.10.2 General Cylinder Disassembly
            8.10.3 Cylinder Cleaning Instructions
            8.10.4 Cylinder Inspection
            8.10.5 General Cylinder Assembly
            8.10.6 General Cylinder Installation
            8.10.7 Cylinder Pressure Checking
            8.10.8 Steering Cylinders
            8.10.9 Hydraulic Cylinder Torque Specifications
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Platform Interlock Checks
        9.4 Software Level 2 Accessibility
            9.4.1 Operator Tools
            9.4.2 Personalities
            9.4.3 Calibrations
        9.5 Operator Tools
            9.5.1 Resetting the Anti Theft Code
            9.5.2 Hardware Exchange
            9.5.3 Confirm Machine Service
            9.5.4 Review Service History
            9.5.5 Set Service Interval
            9.5.6 Cabin Joystick Telescope: X-Axis/ Roller
        9.6 Fuses and Relays
            9.6.1 Cab
            9.6.2 Engine Compartment
            9.6.3 Power Distribution Board
        9.7 Electrical System Schematics
            9.7.1 Cab Harness Electrical Schematic
            9.7.2 Cabin Roof Harness Electrical Schematic
            9.7.3 Power Distribution Electrical Schematic
            9.7.4 Chassis and Boom Harness Electrical Schematic
            9.7.5 Engine Harness Electrical Schematic
            9.7.6 Platform Electrical Schematic
            9.7.7 Platform Cab Harness Schematic (if equipped)
        9.8 Circuit Breakdowns
            9.8.1 Constant Power Circuit from Battery
            9.8.2 Start Circuit
        9.9 Engine Start Circuit
            9.9.1 Starter
        9.10 Charging Circuit
            9.10.1 Alternator
        9.11 Electrical System Components
            9.11.1 Back-up Alarm
        9.12 Window Wiper/Washer
            9.12.1 Windshield Wiper Motor
            9.12.2 Rear Window Wiper Motor
            9.12.3 Windshield Washer Reservoir and Pump
        9.13 Cab Heater and Fan
            9.13.1 Cab Heater Controls
        9.14 Switches, Solenoids, Sensors and Senders
            9.14.1 Transmission Solenoid Valves
            9.14.2 Transmission Temperature Switch
            9.14.3 Transmission Mounted Speed Sensor (if equipped)
            9.14.4 Engine Coolant Temperature Sender/ Switch
            9.14.5 Ignition Key Switch
            9.14.6 Fuel Level Indicator and Fuel Level Sender
            9.14.7 Boom Angle Sensor
            9.14.8 Boom Retracted Sensor
        9.15 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
            9.15.1 Load Stability Indicator
            9.15.2 LSI Sensor
            9.15.3 LSI System Calibration
        9.16 Load Stability Indicator (LSI) - 8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950 17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963, 1160005966 & 1160005978
            9.16.1 Load Stability Indicator
            9.16.2 LSI Sensor
            9.16.3 LSI System Calibration
            9.16.4 LSI - CAN CHECK PT
            9.16.5 500 Hour - LSI UGM Calibration Check
        9.17 Hand Held Analyzer
            9.17.1 Analyzer Usage
            9.17.2 Analyzer Software Version 3.5 (Sheet 1 of 2)
        9.18 Fault Codes
            9.18.1 Indicator Cross Reference Table
            9.18.2 Fault Code Table
            
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