Jlg 4017 Service Manual User Manual

An Oshkosh Corporation CompanyService ManualModel40173121858RevisedSeptember 3, 2010

Safety Practices1.4 40171.6.3 General HazardsSOLVENTS: Only use approved solvents that are known to be safe for use.HOUSEKEEPING: Keep the work area a

Engine: Perkins 1004-40T7.14 40177.11 TROUBLESHOOTINGTrouble Possible Causes (see key, below)Low Cranking PowerWill Not StartDifficult StartingLack o

8.14017Section 8Hydraulic SystemContentsPARAGRAPH TITLE PAGE8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System8.2 40178.1 HYDRAULIC COMPONENT TERMINOLOGYTo understand the safety, operation and service information presented in this section, it i

8.34017Hydraulic System8.2 SAFETY INFORMATIONPetroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases d

Hydraulic System8.4 40178.4 HYDRAULIC CIRCUITSThis section covers the hydraulic circuits and includes listings for all hydraulic function pressures, w

8.54017Hydraulic Systemb. Adjusting Hydraulic PressureThere is only one adjustment to set the main hydraulic pressure.1. Park the machine on a firm, l

Hydraulic System8.6 40178.4.2 Hydraulic SchematicTENSION = 12VFRONT AXLEREAR AXLEDN 40DN 50DN 32DN 20DN 6DN 10TPAB5 barDN 12DN 8DN 8DN 10DN 8DN 10DN 1

8.74017Hydraulic System8.5 HYDRAULIC RESERVOIRThe hydraulic oil reservoir is a one piece unit. It is located under the rear of the machine cab. Occasi

Hydraulic System8.8 4017c. Cleaning and DryingIf contaminated hydraulic oil or foreign material is in the tank, the tank can usually be cleaned. Note:

8.94017Hydraulic System6. Drain the hydraulic oil reservoir. Refer to Section 8.5.1, “Hydraulic Oil Reservoir Draining.”7. Thoroughly clean the pump (

1.54017Safety Practices1.7 EMERGENCY EXIT REAR WINDOW The rear window in the enclosed cab can be used as an emergency exit by removing the latch pin (

Hydraulic System8.10 40178.7 CONTROL VALVES8.7.1 Main Control ValveThe main control valve is mounted on the frame in the engine compartment.The main c

8.114017Hydraulic SystemMZ0320Left OutriggerRight OutriggerFrame SwayAuxiliaryTiltCrowdLiftHandle used to bleed off excess pressure in each valve sect

Hydraulic System8.12 4017b. Main Control Valve DisassemblyThis section covers disassembly of each valve section of the main control valve. The main co

8.134017Hydraulic Systemf. Main Control Valve Installation1. Loosely install the four main control valve mounting bolts through bracket on the inside

Hydraulic System8.14 4017b. Service Brake Valve Installation1. Install the service brake valve with the four lockwashers and four capscrews to mount t

8.154017Hydraulic System5. Label or otherwise mark the hydraulic hoses on each side and bottom of the park brake valve. Disconnect and cap all hoses,

Hydraulic System8.16 40174. Label or otherwise mark the hydraulic hoses and the electrical plugs connected to the steering select valve. Disconnect an

8.174017Hydraulic System5. Attach a suitable sling to an appropriate lifting device and to the cylinder. Make sure the device used can actually suppor

Hydraulic System8.18 4017b. Cylinder Cleaning Instructions1. Discard all seals, back-up rings and o-rings. Replace with new items from seal kit to ens

8.194017Hydraulic Systemindividual circuit. Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn. Re-

Safety Practices1.6 4017This Page Intentionally Left Blank

Hydraulic System8.20 4017This Page Intentionally Left Blank

9.14017Section 9Electrical SystemContentsPARAGRAPH TITLE PAGE9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System9.2 40179.11 Solenoids and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.209.1

9.34017Electrical System9.1 ELECTRICAL COMPONENT TERMINOLOGYTo understand the safety, operation, and service information presented in this section, it

Electrical System9.4 40179.2 SERVICE WARNINGS9.2.1 Electronics9.3 SPECIFICATIONSElectrical system specifications are listed in Section 2, “General Inf

9.54017Electrical System9.4.2 Connector Legend, Relays & FusesConnector LegendNo. TypeX1 PCB Power & GND HarnessX2 Instrument Panel HarnessX3

Electrical System9.6 40179.4.3 Fuse and Relay ReplacementShut off the engine and disconnect the negative (-) battery cable at the negative (-) battery

9.74017Electrical System9.5 ELECTRICAL SYSTEM SCHEMATICS9.5.1 Cab Harness Electrical SchematicMZ1090312 4 4213 1710756 89 1211 1 3 1514 16 18 12612345

Electrical System9.8 40179.5.2 Engine Harness Electrical Schematic2176GND85878630GLOWPLUGSRELAYGLOWPLUGSFUSESLO-BLO 50ALIFT PUMPFUSEATO 7.5AMLIFTPUMP5

9.94017Electrical System9.5.3 Printed Circuit Board Electrical SchematicMZ1110KEY (PWR) RLY STRT INTLK RLYWORK LTS RLY FLASHER WIPER RLY FUEL SOL RLYX

2.14017Section 2General Information and SpecificationsPARAGRAPH TITLE PAGE2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . .

Electrical System9.10 40179.5.4 ESX Harness and Options Electrical SchematicMZ1100ON CAB FIREWALLM8 GROUND STUD(S)GNDX17ESX HARNESSX16.1TO FRONT CHASS

9.114017Electrical System9.5.5 Front & Rear Chassis Harness Electrical SchematicMZ1130HORNREVERSEALARMVALV ESTEERMODEALL WHEELCRAB12 VDCBATTERYGND

Electrical System9.12 40179.6 CIRCUIT BREAKDOWNS9.6.1 Constant Power Circuit from Battery85878630GLOWPLUGSRELAYGLOWPLUGSFUSESLO-BLO 50ALIFT PUMPFUSEAT

9.134017Electrical System9.6.2 Start CircuitMZ1290FNR/GEAR SHIFTER78356412948675 231RFN123414321614151312111018171223135346710891112181415161719202122

Electrical System9.14 40179.6.3 Charging CircuitPCBPRINTED CIRCUIT BOARD160DASH PANELX11ENGINE HARNESSTO PCBNEGATIVE CABLETO BATTERY DISCONNECTOR BATT

9.154017Electrical System9.7 ENGINE START CIRCUIT9.7.1 StarterThe starter (1) is located on the left side of the engine (the right side of the machine

Electrical System9.16 40179.8 CHARGING CIRCUITIf the engine alternator charging warning indicator illuminates, perform the following checks:1. Check t

9.174017Electrical Systemb. Alternator Installation1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert

Electrical System9.18 4017d. Installation and Testing1. Install all required hardware to the motor assembly. 2. Align motor with the mounting holes an

9.194017Electrical Systemb. DisassemblyDO NOT disassemble the switch. The switch is not serviceable. Replace switch if found to be defective.c. Instal

General Information and Specifications2.2 40172.1 REPLACEMENT PARTS AND WARRANTY INFORMATIONBefore ordering parts or initiating service inquiries, mak

Electrical System9.20 40171. Open engine cover. Allow engine to cool.2. Disconnect the negative (-) battery cable at the negative (-) battery terminal

9.214017Electrical System9.11.2 Main Control Valve Solenoidsa. Main Control Valve Solenoid Removal1. Open engine cover. Allow engine to cool.1. Clean

Electrical System9.22 40179.11.4 Transmission Temperature SenderThe transmission temperature sender is located at the bottom right side of the transmi

9.234017Electrical System4. Start the engine, allow it to reach operating temperature and observe the operator’s instrument cluster for warning indica

Electrical System9.24 40179.11.9 Boom Angle Sensor The boom angle sensor (1) is located at the top left inside rear of the machine. a. Boom Angle Sens

9.254017Electrical System9.11.10 Load Moment IndicatorThe Load Moment Indicator (1) provides a visual indication for stability limitations. If the LMI

Electrical System9.26 4017Note: If either the button or magnet is released too early the display will revert to the uncalibrated condition number 4.T

9.274017Electrical System9.12 DISPLAY MONITOR AND GAUGES9.12.1 Digital Display "Main Screen"The Digital Display unit (1) monitors all functi

Electrical System9.28 40179.13 JOYSTICK Note: For information on the removal and replacement of the joystick, refer to Section 4.3.4, “Joystick Assem

9.294017Electrical Systemd. Switch Installation1. Connect the switch to the cab harness connector.2. Position the switch over the rectangular switch b

2.34017General Information and Specifications2.2 TORQUES2.2.1 ASTM Fastener Torque Chart (English)VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS O

Electrical System9.30 4017This Page Intentionally Left Blank

JLG Worldwide LocationsAn Oshkosh Corporation CompanyJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: +

General Information and Specifications2.4 40172.2.2 ASTM Fastener Torque Chart (Metric) VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY U

2.54017General Information and Specifications2.2.3 Metric Fastener Torque ChartVALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLYCLASS 8.8 METRIC

General Information and Specifications2.6 40172.3 SPECIFICATIONS2.3.1 Travel Speeds2.3.2 Engine Performance SpecificationsNote: Engine manufacturer&

2.74017General Information and Specifications2.3.4 Tires2.3.5 AxlesDescriptionWheel Lug Nut Torque 550-600 Nm (405-445 lb-ft)Standard Tire Size 405/70

General Information and Specifications2.8 40172.3.6 Electrical SystemBattery:Type, Rating 12 VDC, Negative (-) Ground, Maintenance FreeQuantity 1Reser

2.94017General Information and Specifications2.4 FLUIDS, LUBRICANTS AND CAPACITIESEngine Crankcase OilCapacity w/Filter Change 8,5 liters (9 quarts)Fi

General Information and Specifications2.10 40172.5 SERVICE AND MAINTENANCE SCHEDULES2.5.1 8 & 1st 50 Hour Maintenance Schedule2.5.2 50, 250 &

2.114017General Information and Specifications2.5.3 1000 & 1500 Hour Maintenance Schedule2.6 LUBRICATION SCHEDULES2.6.1 8 Hour Lube Schedule2.6.2

General Information and Specifications2.12 4017This Page Intentionally Left Blank

3.14017Section 3BoomContentsPARAGRAPH TITLE PAGE3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Boom3.2 40173.1 BOOM SYSTEM COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in this section, it is nece

3.34017Boom3.2 BOOM SYSTEM 3.2.1 Boom System OperationThe four section boom consists of the first, second, third and fourth assemblies with double thi

Boom3.4 40179. Support the extend/retract cylinder and remove the clip and pin from rod end of extend/retract cylinder. Remove the clip and pin from b

3.54017Boom3. Use a suitable sling around the third section boom to take any pressure off of wear pads to make pad removal easier.Note: Before removi

EFFECTIVITY PAGE31261858 4017 iJune 10, 2005 - A - Original Issue Of ManualJanuary 6, 2006 - B - Revision Of ManualSeptember 3, 2010 - C - Revised pag

Boom3.6 40173.3.3 Third & Fourth Boom Section Removal 1. With the three boom sections setting on suitable supports remove bolts, keeper and pin fr

3.74017Boom6. Inspect the boom and welds. Consult the local JLG distributor or the JLG Service Department if structural damage is detected.7. Inspect

Boom3.8 40173.3.7 Fourth Boom Section Installation 1. Apply Loctite 242® to the wear pad mounting bolts. Install the bottom rear wear pads, washers an

3.94017Boom3.3.8 Third & Fourth Boom Section Installation1. At the rear of the third boom section apply Loctite 242® to the wear pad mounting bolt

Boom3.10 40179. Install both retract chain sheaves (1), pin, keeper and bolts to bottom rear of second boom section. Apply Loctite 242® and torque to

3.114017Boom5. Using a suitable sling, balance the second, third and fourth boom section and carefully slide 914 mm - 1219 mm (3 ft - 4 ft) into the f

Boom3.12 401711. Attach both extend chain clevises (1) through the holes in the bottom front of the first boom section. Install the washers, adjustmen

3.134017Boom3.3.10 Boom InstallationIMPORTANT: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep th

Boom3.14 40173.4 BOOM EXTEND AND RETRACT CHAINS3.4.1 Boom Chain Inspection Under normal operating conditions the boom chains will need to be inspected

3.154017Boomb. Extend Chains (third to second section)The extend chains between the third and second boom sections measures 29,6 mm (1.2 in) (1). If t

EFFECTIVITY PAGE4017 3121858-ii

Boom3.16 4017Distorted or Battered Link PlatesDistorted or battered link plates (8) on a leaf chain can cause tight joints and prevent flexing.Cracked

3.174017Boome. Removing Extend and Retract ChainsThe four extend chains and the three retract chains can only be removed during a complete boom teardo

Boom3.18 40174. Start the machine and extend and retract the boom sections two or three times. Fully retract the boom and measure the distance between

3.194017Boom12. Label and remove the two auxiliary hydraulic hoses (2) from the bulkhead fittings inside the boomhead. Plug the hose ends and cap the

Boom3.20 40174. Apply Loctite® 242 to the wear pad mounting bolts and install both left and right side wear pads and bolts and both left and right bot

3.214017Boom3.7 BOOM WEAR PADSThere are a total of 50 wear pads installed on the first, second, third and fourth boom sections. 10 wear pads are attac

Boom3.22 4017Use shims under the upper rear wear pads, under the bottom front wear pads and under the side wear pads as required, to maintain a minimu

3.234017Boom3.7.3 Boom Wear Pad LubricationThe boom has been factory lubricated for proper wear pad break-in and will normally require minor further l

Boom3.24 40173.8.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment1. Lower attachment to ground. Set the park brake, shut off engine

3.254017Boom3.9 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that occur during operation of the boom

SECTION CONTENTSSection Subject Page JLG Industries, Inc.4017iSection 1Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom3.26 40175. Dropping chain, or jerky boom extend or retract functions.1. Chain(s) tension not properly adjusted. 2. Chain(s) stretched or binding.

3.274017Boom9. Rapid boom pad wear. 1. Incorrect wear pad gap.2. Rapid cycle times with heavy loads.3. Contaminated, corroded or rusted wear pad slidi

Boom3.28 4017This Page Intentionally Left Blank

4.14017Section 4Cab and CoversContentsPARAGRAPH TITLE PAGE4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . .

Cab and Covers4.2 40174.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in

4.34017Cab and Covers4.2 OPERATOR’S CAB4.2.1 Cab Safety 4.2.2 Serial Number DecalThe cab serial number decal is located on the left side of the cab, b

Cab and Covers4.4 4017Note: ALWAYS use new o-rings when servicing the machine.4. Install new o-rings into the fittings. Lubricate the o-rings with cl

4.54017Cab and Covers6. Remove the hex jam nut and flat washer securing the throttle cable to the throttle pedal assembly.7. Remove the clip/pin from

Cab and Covers4.6 4017b. Joystick Assembly Installation1. Set the joystick assembly (1) into the armrest support.2. Install the four self-tapping scre

4.74017Cab and Coversb. Heater Assembly Installation1. Connect the wiring harness connections to the blower.2. Lift the heater assembly to the bottom

Section Subject Pageii4017Section 6Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab and Covers4.8 4017Note: Record the location, and label all hoses to ensure correct installation.11. Working under the cab, label and disconnect t

4.94017Cab and Covers8. Route any hoses through the opening at the right front corner of the cab.9. Route the wiring harness connectors through the op

Cab and Covers4.10 4017This Page Intentionally Left Blank

5.14017Section 5Axles, Drive Shafts, Wheels and TiresContentsPARAGRAPH TITLE PAGE5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . .

Axles, Drive Shafts, Wheels and Tires5.2 40175.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance

5.34017Axles, Drive Shafts, Wheels and Tires5.2 GENERAL INFORMATIONIMPORTANT: To help ensure optimum performance, the drive shaft assemblies are spec

Axles, Drive Shafts, Wheels and Tires5.4 4017lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces.DRYING: Use cl

5.54017Axles, Drive Shafts, Wheels and Tires7. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine w

Axles, Drive Shafts, Wheels and Tires5.6 401711. Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.12. Rotate w

5.74017Axles, Drive Shafts, Wheels and Tires5.3.6 Axle Assembly and Drive Shaft TroubleshootingProblem Cause Remedy1. Excessive axle noise while drivi

1.14017Section 1Safety PracticesContentsPARAGRAPH TITLE PAGE1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axles, Drive Shafts, Wheels and Tires5.8 40174. Oil leaking from axle (differential housing and/or axle housings).1. Drain and/or inspection plugs loo

5.94017Axles, Drive Shafts, Wheels and Tires7. Axle overheating. 1. Oil level too high.2. Axle and/or wheel end housings filled with incorrect oil or

Axles, Drive Shafts, Wheels and Tires5.10 40175.4 DRIVE SHAFTS5.4.1 Drive Shaft Inspection and ServiceWhenever servicing the machine, conduct a visual

5.114017Axles, Drive Shafts, Wheels and Tires5.4.2 Drive Shaft MaintenanceRefer to Section 2.6, “Lubrication Schedules,” for information regarding the

Axles, Drive Shafts, Wheels and Tires5.12 40175.5 WHEELS AND TIRES5.5.1 Removing Wheel and Tire Assembly from machine1. Park the machine on a firm, le

5.134017Axles, Drive Shafts, Wheels and Tires5.6 BRAKES5.6.1 Brake Disk Inspection.Check the brake disks for wear every 1,000 hours of operation or ye

Axles, Drive Shafts, Wheels and Tires5.14 40175.7 TOWING A DISABLED MACHINETowing a disabled machine should only be attempted as a last resort, after

6.14017Section 6Transmission: ContentsPARAGRAPH TITLE PAGE6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . .

Transmission:6.2 40176.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGYTo understand the safety, operation and maintenance information presented in this

6.34017Transmission:6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance informatio

Safety Practices1.2 40171.1 INTRODUCTIONThis service manual provides general directions for accomplishing service and repair procedures. Following the

Transmission:6.4 40176.6.1 Transmission Removal1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmi

6.54017Transmission:23. Remove the ten bolts and washers holding the transmission to the engine.24. Remove the four capscrews and four lockwashers sec

Transmission:6.6 401715. Apply a thin film of clean Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46) to the new transmission filter gasket. Install th

6.74017Transmission:6.7 TROUBLESHOOTINGThis section provides an easy reference guide covering the most common problems that may occur during operation

Transmission:6.8 40173. Low clutch pressure. 1. Incorrect oil level.2. Main pressure valve stuck open.3. Broken or worn coupling shaft or piston o-rin

6.94017Transmission:6. Grinding or “clunking” noise from transmission.1. Oil level too low.2. Transmission filled with incorrect oil.3. Incorrect clut

Transmission:6.10 4017This Page Intentionally Left Blank

7.14017Section 7Engine: Perkins 1004-40TContentsPARAGRAPH TITLE PAGE7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine: Perkins 1004-40T7.2 40177.1 INTRODUCTION7.1.1 Disclaimer and ScopeThese instructions cover only the routine maintenance, removal, installation

7.34017Engine: Perkins 1004-40T7.1.2 Component TerminologyTo understand the safety, operation and maintenance information presented in this section, i

1.34017Safety Practices1.5 SAFETY INFORMATIONTo avoid possible death or injury, carefully read, understand and comply with all safety messages.In the

Engine: Perkins 1004-40T7.4 40177.2 ENGINE SERIAL NUMBERThe Perkins 1004-40T serial number Is stamped on a plate which is secured to the engine block,

7.54017Engine: Perkins 1004-40Tb. Thermostat Installation1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the t

Engine: Perkins 1004-40T7.6 401712. Loosen clamp on the lower radiator hose (6). Work the hose off the radiator. Position the hose out of the way to a

7.74017Engine: Perkins 1004-40T75 hours. The use of fuel with a sulfur content above 1.3 percent is not recommended.7.6.2 Fuel Tank Note: The fuel ta

Engine: Perkins 1004-40T7.8 4017e. Inspection1. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other damage. 2. With the fuel tank

7.94017Engine: Perkins 1004-40T3. Install the muffler to the exhaust pipe and bolt the muffler to the side of the frame.4. Install the clamp securing

Engine: Perkins 1004-40T7.10 4017Note: The engine harness is routed and attached to the engine using hold-down clamps and plastic wire ties at variou

7.114017Engine: Perkins 1004-40T22. Place a support or jack under the transmission to hold the transmission in place while engine is being removed.23.

Engine: Perkins 1004-40T7.12 401715. Connect the fuel inlet line to the fuel filter head.16. Connect the fuel return line to the fuel filter head.17.

7.134017Engine: Perkins 1004-40T7.10 ENGINE DRIVE PLATE7.10.1 Drive Plate Removal1. Park the machine on a firm, level surface, fully retract the boom,