Jlg 4017RS Service Manual manuals

Jlg 4017RS Service Manual User Manual (204 pages)

Brand: Jlg | Category: Special machinery | Size: 25.76 MB |

English

Table of contents

Service Manual

1

EFFECTIVITY PAGE

3

READ THIS FIRST

4

SECTION CONTENTS

5

Section Subject Page

6

Section 1

9

1.1 INTRODUCTION

10

1.2 DISCLAIMER

10

1.4 DO NOT OPERATE TAGS

10

1.5 SAFETY INFORMATION

10

1.7 SAFETY INSTRUCTIONS

11

Safety Practices

12

1.7.3 General Hazards

12

1.7.4 Operational Hazards

12

1.8 SAFETY DECALS

13

Section 2

15

2.2 THREAD LOCKING COMPOUND

16

2.3 TORQUE CHARTS

17

SOCKET HEAD CAP SCREWS

21

Flats Method:

27

2.4 SPECIFICATIONS

28

2.4.3 Electrical System

29

2.4.6 Tires

30

2.6 SERVICE AND MAINTENANCE

33

SCHEDULES

33

2.6.2 50 & 1st 250 Hour

34

LB/FT (Nm)

35

2.6.4 1000 & 3000 Hour

36

2.6.5 6000 & 12000 Hour

37

2.7 LUBRICATION SCHEDULE

38

2.7.2 4017RS

39

Section 3

41

3.1 BOOM SYSTEM COMPONENT

43

TERMINOLOGY - 3614RS

43

3.2 BOOM SYSTEM - 3614RS

44

3.3.1 Boom Removal

45

Installation

49

- 3614RS

52

REMOVAL/INSTALLATION - 3614RS

54

INSTALLATION - 3614RS

55

3.8 BOOM SYSTEM COMPONENT

57

TERMINOLOGY - 4017RS

57

3.9 BOOM SYSTEM - 4017RS

58

3.10.1 Boom Removal

59

3.11 HOSE CARRIER ASSEMBLY

69

HOSE REMOVAL/INSTALLATION

69

- 4017RS

71

BOOM EXTEND AND RETRACT

73

CHAINS - 3614RS & 4017RS

73

3.16 BOOM WEAR PADS

77

3.17 QUICK COUPLER

78

3.18 FORKS

79

3.19 BOOM PROP (IF EQUIPPED)

79

3.20 EMERGENCY BOOM LOWERING

80

PROCEDURE

80

VIEW FROM REAR OF CAB

81

3.21 TROUBLESHOOTING

82

Section 4

85

4.1 OPERATOR CAB COMPONENT

86

4.2 OPERATOR CAB

87

4.3 CAB COMPONENTS

87

4.3.3 Service Brake

89

4.3.5 Joystick Assembly

90

4.3.6 Window Wiper Assembly

90

(if Equipped)

90

UPPER COVER

91

LOWER COVER

91

4.4 CAB REMOVAL

92

4.5 CAB INSTALLATION

94

Section 5

95

5.2 AXLE SERIAL NUMBER

97

5.3 AXLE SPECIFICATIONS AND

97

MAINTENANCE INFORMATION

97

5.4 AXLE REPLACEMENT

97

5.4.2 Axle Installation

98

5.5 BRAKE INSPECTION

99

5.7 STEERING ANGLE ADJUSTMENT

100

3614RS, 4017RS

101

TO TRANSMISSION

104

5.10 WHEELS AND TIRES

105

5.11.1 3614RS Only

106

5.11.2 4017RS Only

107

Section 6

109

Transmission

109

6.1 TRANSMISSION ASSEMBLY

110

COMPONENT TERMINOLOGY

110

INFORMATION

111

6.4 TRANSMISSION REPLACEMENT

111

6.6 TROUBLESHOOTING

113

Section 7

115

7.1 INTRODUCTION

116

7.2 ENGINE SERIAL NUMBER

116

7.3.1 Component Terminology

117

7.4 ENGINE COOLING SYSTEM

118

7.5 ENGINE ELECTRICAL SYSTEM

121

7.6 FUEL SYSTEM

121

7.7 ENGINE EXHAUST SYSTEM

123

7.8 AIR CLEANER ASSEMBLY

126

7.9 ENGINE REPLACEMENT

127

7.10 TROUBLESHOOTING

129

Section 8

131

Hydraulic System

131

8.1 HYDRAULIC COMPONENT

132

TERMINOLOGY

132

8.2 SAFETY INFORMATION

133

8.3 SPECIFICATIONS

133

8.5 HYDRAULIC CIRCUITS

134

COUPLING

136

8.6.2 4017RS

137

8.7 HYDRAULIC RESERVOIR

138

8.8 ENGINE IMPLEMENT PUMP

140

8.9 CONTROL VALVES

141

8.9.2 Service Brake Valve

143

8.9.3 Service Brake Bleeding

143

8.9.4 Service Brake Test

144

8.9.5 Steering Orbitrol Valve

144

8.9.7 Brake Damper

145

8.9.8 Brake Damper Charging

146

8.9.9 Pre-Charging Damper

146

8.9.10 Checking Pre-Charge

147

8.9.11 Steer Select Valve

148

8.10 HYDRAULIC CYLINDERS

149

8.10.3 Steering Cylinders

151

Section 9

153

Electrical System

153

9.1 ELECTRICAL COMPONENT

155

9.2 SPECIFICATIONS

156

9.3 SAFETY INFORMATION

156

9.4 POWER DISTRIBUTION BOARD

156

113-1 FLASH BAT RED

159

227-1 F WIPE PWR RED 1.5mm²

159

9.5.3 Frame

160

9.5.4 Battery

161

9.5.6 Engine

163

9.6 ENGINE START CIRCUIT

165

9.6.2 Charging Circuit

166

9.6.3 Alternator

166

9.7 WIPER/WASHER WIPER MOTOR

167

9.7.2 Rear Window Wiper Motor

168

9.7.3 Roof Window Wiper Motor

169

9.7.4 Washer Tank

170

MZ6 084

172

9.8.5 Fuel Level Sender

173

9.8.6 Boom Retract Sensor

173

9.8.7 Boom Angle Sensor

174

9.9 DASH SWITCHES

175

9.10.2 LSI Sensor

177

9.10.3 LSI System Calibration

179

9.10.4 LSI-CAN Check PT

181

9.11 HAND HELD ANALYZER

182

(SHEET 3 of 3)

185

1127 RPM

186

9.13 MACHINE FAULT CODES

187

9.13.3 Cabin Controls (23X)

188

9.13.5 Output Drivers (33X)

191

9.13.6 Engine (43X)

198

9.13.7 Battery Supply (44X)

198

9.13.9 Communications (66X)

200

9.13.10 Load Moment (85X)

201

9.13.11 Hardware (99X)

201

31200940

204

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