JLG 4009 Manuals

Manuals and User Guides for JLG 4009. We have 3 JLG 4009 manuals available for free PDF download: Supplemental Repair Manual, Service Manual, Operator's Manual

JLG 4009 Service Manual (136 pages)

Brand: JLG | Category: Construction Equipment | Size: 13 MB

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
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
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

JLG 4009 Supplemental Repair Manual (180 pages)

Drive Axle

Brand: JLG | Category: Lifting Systems | Size: 7 MB

Table of Contents
5
Introduction

9
Specifications

11
- Definition of Viewpoints
  11
- Data Plate
  11
- Conversion Tables
  12
- Torque Specifications
  13
  - Coarse Pitch
    13
  - Fine Pitch
    13
  - Wheel Nut Tightening Torques
    14
- Maintenance
  15
  - Maintenance Points
    15
  - Maintenance Intervals
    16
  - Adjustment and Checks
    16
  - Lubricant & Sealant Specifications
    17
Safety Precautions

19
Checking Wear and Replacing the Braking Discs

21
- Exploded View
  21
- Disassembly
  22
- Assembly
  24
- Special Tools
  26
Complete Steering Case

27
- Exploded View
  27
- Disassembly
  28
- Assembly
  29
Double U-Joint

31
- Exploded View
  31
- Disassembly
  32
- Assembly
  33
- Special Tools
  35
Planetary Reduction Gear

37
- Exploded View
  37
- Disassembly
  38
- Assembly
  42
- Special Tools
  46
Steering Cylinder

49
- Exploded View
  49
- Optical Sensor and Magnetic Sensor
  50
- Disassembly
  51
- Assembly
  54
- Special Tools
  60
Differential Unit

63
- Exploded View
  63
- Disassembly
  64
- Assembly
  66
- Special Tools
  68
Bevel Pinion

69
- Exploded View
  69
- Disassembly
  70
- Assembly
  73
- Special Tools
  79
Manual Emergency Relase

85
- Exploded View
  85
- Release
  86
- Adjust
  87
Mechanical Parking Brake

89
- Exploded View
  89
- Disassembly
  90
- Assembly
  92
External Hydraulic Negative Brake

95
- Exploded View
  95
- Disassembly
  96
- Assembly
  97
External Hydraulic Negative Brake with Quick Release

99
- Exploded View
  99
- Disassembly
  100
- Assembly
  102
Incoming Drum Brake

105
- Exploded View
  105
- Disassembly
  106
- Assembly
  108
- Special Tools
  110
4" Incoming Brake (2 and 3 Function Versions)

113
- Exploded View
  113
- Disassembly
  114
- Assembly
  118
- Special Tools
  124
Normal Differential Unit

127
- Exploded View
  127
- Disassembly
  128
- Assembly
  130
- Special Tools
  133
Limited Slip Differential Unit (25% and 45%)

135
- Exploded View
  135
- Disassembly
  136
- Assembly
  139
- Special Tools
  142
Hydraulic Differential Lock

145
- Exploded View
  145
- Disassembly
  146
- Assembly
  149
- Special Tools
  151
Hydraulic Negative Brake

153
- Exploded View
  153
- Disassembly
  154
- Assembly
  157
Incorporated Reduction Gear and Pinion 602

163
- Exploded View
  163
- Disassembly
  164
- Assembly
  168
- Special Tools
  171

JLG 4009 Operator's Manual (132 pages)

Brand: JLG | Category: Boom Lifts | Size: 5 MB

Read this First

4
Table of Contents

11
Section 1 - General Safety Practices

11
- General Precautions
  11
- Hazard Classification System
  11
  - Safety Alert System and Safety Signal Words
    11
- Operation Safety
  12
  - Electrical Hazards
    12
  - Tip over Hazard
    13
  - Travel Hazard
    16
  - Load Falling Hazard
    17
  - Lifting Personnel
    18
  - Driving Hazards on Slopes
    20
  - Pinch Points and Crush Hazards
    21
  - Fall Hazard
    23
  - Chemical Hazards
    24
Section 2 - Pre-Operation and Controls

25
- Pre-Operation Checks and Inspection
  25
  - Walk-Around Inspection
    26
- Safety Decals
  28
- Operator Cab
  31
- Controls
  32
  - Instrument Panel
    34
  - Display Screen
    36
  - Anti Theft Device
    39
  - Ignition
    40
  - Park Brake
    41
  - Parking Procedure
    41
  - Transmission Control
    42
  - Wiper, Lights and Turn Signal Control Lever
    44
  - Steering Column Adjuster
    45
  - Joystick
    46
  - Load Moment Indicator (LMI)
    50
  - Control and Indicator Console
    51
  - Heater and Air Conditioner (Optional) Controls
    52
Table of Contents

53
- Steer Modes
  53
- Operator Seat
  54
  - Adjustments
    54
  - Seat Belt
    55
- Mirrors and Windows
  56
  - Cab Door Window
    56
  - Rear Window
    56
  - Mirrors
    57
- Hood
  58
Section 3 - Operation

59
- Warm-Up and Operational Checks
  59
- Engine
  60
  - Starting the Engine
    60
  - Battery Boosted Starting
    61
  - Normal Engine Operation
    62
  - Shut-Down Procedure
    62
- Operating with a Load
  63
  - Lift Load Safely
    63
  - Before Picking up a Load
    63
  - Transporting the Load
    64
  - Leveling Procedure
    64
  - Placing the Load
    65
  - Disengaging the Load
    65
- Road Operation
  66
- Loading and Securing for Transport
  67
Section 4 - Attachments and Hitch Options

69
- Approved Attachments
  69
- Unapproved Attachments
  69
- Telehandler/Attachment/Fork Capacity
  70
- Use of the Capacity Chart
  71
  - Capacity Indicator Locations
    71
  - Sample Capacity Chart
    72
  - Example
    74
- Attachment Installation
  75
- Adjusting/Moving Forks
  79
- Attachment Operation
  79
  - Carriage W/Forks
    80
  - Truss Boom
    81
  - Side Shift Carriage
    82
  - Bucket
    84
  - Fork Extension
    86
  - Fork Hook
    88
  - Adjustable Truss Boom
    89
- Hitch Options
  90
  - Mechanical Hitch
    90
  - Hydraulic Hitch
    91
Section 5 - Emergency Procedures

93
- Towing a Disabled Product
  93
  - Moving Short Distances
    93
  - Moving Longer Distances
    93
- Emergency Lowering of Boom
  94
  - Electronic Control Unit Failure
    95
  - Engine Failure
    96
- Cab Emergency Exit
  98
Section 6 - Lubrication and Maintenance

99
- Introduction
  99
  - Clothing and Safety Gear
    99
- General Maintenance Instructions
  100
- Service and Maintenance Schedules
  101
- Lubrication Schedules
  104
  - Hour Lubrication Schedule
    104
- Operator Maintenance Instructions
  106
  - Fuel System
    106
  - Air Intake System
    108
  - Engine Oil
    110
  - Brake System
    111
  - Hydraulic Oil
    112
  - Tires
    113
  - Transmission Oil
    114
  - Engine Cooling System
    115
  - Battery
    116
Table of Contents

117
Section 7 - Additional Checks

117
- Load Moment Indicator Test
  117
Section 8 - Specifications

119
- Product Specifications
  119
  - Fluid and Lubrication Capacities
    119
  - Tires
    120
  - Performance
    121
  - Dimensions
    123
  - Noise Emission Level
    124
  - Telehandler Vibration
    124
Index

125

JLG Categories

Boom Lifts Lifting Systems Scissor Lifts Construction Equipment Work Light

More JLG Manuals

JLG 4009 Manuals

JLG 4009 Service Manual (136 pages)

Table of Contents

Section

Section 2 General Information and Specifications

Section 3 Boom

Section 5 Axles, Drive Shafts, Wheels and Tires

Paragraph

Transmission

Section 7 Engine: Perkins 1104-42 & 1104-42T

Section 8 Hydraulic System

Section 9 Electrical System

Electrical Component Terminology

Electrical System Schematics

Specifications

Service Warning

Fuses and Relays

Engine Start Circuit

Charging Circuit

Electrical System

Electrical System Components

Display Monitor and Gauges

JLG 4009 Supplemental Repair Manual (180 pages)

Table of Contents

Introduction

Specifications

Safety Precautions

Checking Wear and Replacing the Braking Discs

Complete Steering Case

Double U-Joint

Planetary Reduction Gear

Steering Cylinder

Differential Unit

Bevel Pinion

Manual Emergency Relase

Mechanical Parking Brake

External Hydraulic Negative Brake

External Hydraulic Negative Brake with Quick Release

Incoming Drum Brake

4" Incoming Brake (2 and 3 Function Versions)

Normal Differential Unit

Limited Slip Differential Unit (25% and 45%)

Hydraulic Differential Lock

Hydraulic Negative Brake

Incorporated Reduction Gear and Pinion 602

JLG 4009 Operator's Manual (132 pages)

Table of Contents

Read this First

Table of Contents

Section 1 - General Safety Practices

Section 2 - Pre-Operation and Controls

Table of Contents

Section 3 - Operation

Section 4 - Attachments and Hitch Options

Section 5 - Emergency Procedures

Section 6 - Lubrication and Maintenance

Table of Contents

Section 7 - Additional Checks

Section 8 - Specifications

Index

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