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JLG
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3509
JLG 3509 Service Manual
136 pages
Manual
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Ser
vice Manual
Models
3507, 3508,
3509, 3512,
3513, 4007,
4008, 4009,
4012, 4013
P/
N -
31
218
5
2
Rev
i
sed
April 20,
2007
Courtesy of Crane.Market
2
Table of Contents
Section
5
Table of Contents
5
Safety Practices
8
Introduction
8
Disclaimer
8
Operation & Safety Manual
8
Do Not Operate Tags
8
Safety Information
9
Safety Instructions
9
Safety Alert System and Signal Words
9
Personal Hazards
9
Equipment Hazards
9
Safety Decals
10
General Hazards
10
Operational Hazards
10
Section 2 General Information and Specifications
11
Replacement Parts and Warranty Information
12
Specifications
16
Travel Speeds
16
Hydraulic Cylinder Performance Specifications
16
Electrical System
16
Engine Performance Specifications
17
Tires
17
Fluids, Lubricants and Capacities
18
Maintenance Schedules
19
1St 50 Hour Maintenance Schedule
19
500 Hour Maintenance Schedule
19
Lubrication Schedules
20
Section 3 Boom
23
Boom System Component Terminology
24
Boom Assembly Maintenance
25
Boom System Description
25
Boom Removal
25
Second Section Boom Removal (12 & 13M)
26
Third Section Boom Removal (12 & 13M) Second Section Boom Removal (7, 8 & 9M)
26
Third Section Boom Installation (12 & 13M) Second Section Boom Installation (7, 8 & 9M)
27
Second Section Boom Installation (12 & 13M)
27
Boom Installation
28
Boom System
25
Boom Wear Pads
29
Wear Pad Inspection
29
Boom Wear Pad Replacement
29
Boom Wear Pad Lubrication
29
Quick Switch Assembly
30
Connecting with a Mechanical Quick Switch Device
30
Connecting with a Hydraulic Quick Switch Device
30
Connecting with a Quick Switch to a Hydraulic Operated Attachment
30
Quick Switch Removal
30
Quick Switch Installation
30
Troubleshooting
31
Cab and Covers
33
Operator's Cab and Covers Component Terminology
34
Operator's Cab
35
Cab Components
35
Cab Removal
40
Cab Installation
41
Section 5 Axles, Drive Shafts, Wheels and Tires
43
Paragraph
44
Axle, Drive Shaft and Wheel Component Terminology
44
General Information
45
Axle Assemblies
45
Axle Serial Number Plate
45
Axle Specifications
45
Axle Internal Service
45
Axle Maintenance
45
Axle Removal
46
Axle Assembly and Drive Shaft Troubleshooting
48
Drive Shafts
51
Drive Shaft Inspection and Service
51
Drive Shaft Maintenance
51
Drive Shaft Removal
51
Drive Shaft Cleaning and Drying
51
Drive Shaft Installation
51
Wheels and Tires
52
Removing Wheel and Tire Assembly from Machine
52
Brakes
53
Installing Wheel and Tire Assembly Onto Machine
53
Brake Disk Inspection
53
Towing a Disabled Machine
54
Transmission
55
Transmission Assembly Component Terminology
56
Transmission Description
57
Transmission Serial Number
57
Transmission Specifications
57
Transmission Replacement
57
Troubleshooting
61
Section 7 Engine: Perkins 1104-42 & 1104-42T
65
Introduction
66
Disclaimer and Scope
66
Component Terminology
67
Engine Cooling System
68
Radiator Pressure Cap
68
Thermostat Replacement
68
Radiator/Oil Cooler and Coolant Heater Replacement
69
Engine Serial Number
68
Specifications and Maintenance Information
68
Engine Electrical System
70
Fuel System
70
Diesel Fuel
70
Fuel Tank
71
Engine Exhaust System
72
After Fuel System Service
72
Air Cleaner Assembly
73
Engine Replacement
73
Air Cleaner Assembly Removal
73
Air Cleaner Assembly Installation
73
Engine Removal
73
Engine Disassembly, Inspection and Service
74
Engine Installation
75
Engine Drive Plate
76
Drive Plate Removal
76
Drive Plate Installation
76
Troubleshooting
77
Section 8 Hydraulic System
79
Hydraulic Component Terminology
80
Hydraulic Pressure Diagnosis
81
Safety Information
81
Hydraulic Circuits
82
Checking Function Pressures
82
Adjusting Hydraulic Pressure
82
Hydraulic Schematics
82
Hydraulic Reservoir
86
Hydraulic Oil Reservoir Draining
86
Hydraulic Oil Reservoir Filling
86
Hydraulic Oil Reservoir Removal/Installation
86
Hydraulic System Pump
87
Pump Description
87
Pump Failure Analysis
87
Pump Replacement
88
Valves and Manifolds
89
Main Control Valve
89
Service Brake Valve
91
Brake Test
92
Steering Orbitrol Valve
92
Steer Select Valve
92
ERS Control Valve Assembly
93
Hydraulic Cylinders
94
General Cylinder Removal Instructions
94
General Cylinder Disassembly
95
Cylinder Cleaning Instructions
96
Cylinder Inspection
96
General Cylinder Assembly
96
General Cylinder Installation
97
Cylinder Pressure Checking
97
Steering Cylinders
97
Hydraulic Cylinder Torque Specifications
98
Section 9 Electrical System
101
Electrical Component Terminology
103
General Overview (Cab Harness)
103
Electrical System Schematics
104
Engine Harness Electrical Schematic
108
Circuit Breakdowns
117
Charging Circuit
119
Specifications
104
Service Warning
104
Fuses and Relays
104
Cab
104
Engine Compartment
104
Engine Start Circuit
120
Starter
120
Charging Circuit
121
Alternator
121
Electrical System
122
Window Wiper/Washer
124
Cab Heater and Fan
126
Switches, Solenoids and Senders
127
Transmission Temperature Sender
128
Transmission Mounted Speed Sensor
129
Engine Coolant Temperature Sender/Switch
129
Engine Oil Pressure Sender
130
Boom Angle Sensor
130
Ignition Key Switch
131
Fuel Level Indicator and Fuel Level Sender
132
Electrical System Components
122
Load Moment Indicator
122
Load Moment Sensor
122
Display Monitor and Gauges
133
Analog Gauges
133
Other manuals for JLG 3509
Operator's Manual
132 pages
Supplemental Repair Manual
180 pages
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JLG 3509 Specifications
General
Model
3509
Width
1.22 m
Capacity
227 kg
Rated Capacity
227 kg
Operating Weight
6, 900 lb (3, 130 kg)
Weight
6, 900 lb (3, 130 kg)
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