JLG 4017 Parts Manual

An Oshkosh Corporation Company

Illustrated Parts Manual

Model

4017

3121859

Revised

March 31, 2014

EFFECTIVITY PAGE

October 22, 2004 - A - Original Issue Of Manual

April 8, 2005 - B - Revised Manual

November 23, 2005 - C - Revised Manual

January 2, 2007 - D - Revised Manual

April 25, 2008 - E - Revised Manual

July 15, 2009 - F - Revised Manual

April 20, 2012 - G - Revised Manual

March 31, 2014 - H - Revised Manual

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EFFECTIVITY PAGE

4017 3121859-ii

FIGURE NO. TITLE PAGE NO.

SECTION 1 –

FRAME & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1 Frame Shrouding & Attaching Parts, Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Frame Shrouding & Attaching Parts, Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-3 Axle & Fender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-4 Outrigger Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-5 Outrigger Mounting with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1-6 Outrigger Mounting Equipped W/LMIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

1-7 Hood Installation with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

SECTION 2 –

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1 First Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Bearings, Pads, Spacers & Shims, (First Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2-3 Second Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-4 Bearings, Pads, Spacers & Shims, (Second Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-5 Third Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-6 Bearings, Pads, Spacer & Shims, (Third Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-7 Fourth Boom Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-8 Bearings, Pads, Spacers & Shims, (Fourth Boom Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-9 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

SECTION 3 –

ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3 Four In One Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4 Fork Mounted Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-5 Truss Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-6 Side Shift Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-7 Fork Positioning Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-8 Fork Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-9 Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-10 Platform Assembly, Adapter & Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-11 Platform Assembly, Base & Railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-12 Platform Assembly, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-13 Platform Assembly, Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-14 Concrete Ladle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-15 Crane Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-16 Adjustable Boom Truss (Australia) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

SECTION 4 –

ENGINE & ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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4-2 Perkins Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3 Fuel Tank & Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-4 Cooling System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-5 Air Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-6 Muffler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-7 AC Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-8 Four Speed Transmission - Converter Housing Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-9 Four Speed Transmission - Case and Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-10 Four Speed Transmission - Torque Converter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-11 Four Speed Transmission - Gear Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-12 Four Speed Transmission - Pump Drive Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-13 Four Speed Transmission - Charging Pump Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-14 Four Speed Transmission - Reverse Idler Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4-15 Four Speed Transmission - Forward and Reverse Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4-16 Four Speed Transmission - 3rd Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

4-17 Four Speed Transmission - First and Second Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4-18 Four Speed Transmission - Output Shaft Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

4-19 Four Speed Transmission - Electric Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

4-20 Four Speed Transmission - Drive Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

4-21 Four Speed Transmission - Drop Box Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

SECTION 5 –

DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-1 Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 Front Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-3 Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4 Front Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-5 Front Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-6 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

5-7 Rear Axle - Central Housing & Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-8 Rear Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-9 Rear Axle - Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

5-10 Rear Axle - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-11 Tire & Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

SECTION 6 –

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Cab Interior Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-3 Cab Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4 Cab Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-5 Wiper System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-6 Driver Seat Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-7 Driver Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-8 Air Circulation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

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6-9 Air Conditioning Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

SECTION 7 –

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-1 Steering Column & Attaching Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2 Joystick Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 Accelerator Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

SECTION 8 –

HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8-1 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8-2 Steering Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8-3 Service/Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8-4 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-5 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-6 Tilt & Tilt Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8-7 Auxiliary Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8-8 Boom Hydraulics Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8-9 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8-10 Stabilizer Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8-11 Hydraulic Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

8-12 Boom Hydraulics with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30

8-13 Boom Hydraulics Installation with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32

8-14 Drive Pump to Main Valve with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

SECTION 9 –

HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-1 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9-2 Crowd Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9-3 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9-4 Compensation Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9-5 Sway Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

9-6 Stabilizer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

9-7 Fork Locking Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24

9-8 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28

9-9 Engine Drive Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33

9-10 Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35

9-11 Return Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37

9-12 Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39

9-13 ERS Control Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41

SECTION 10 –

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

10-1 Head Light/Tail Light Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

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10-2 Electrical Installation, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10-3 Electrical Installation, Gear & Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10-4 Electrical Installation, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10-5 Electrical Installation, Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

10-6 Electrical System, Rear of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14

10-7 Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

10-8 Electrical Installation, Cab with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

10-9 Electrical Installation on Boom with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

10-10 Sensor Assembly with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

10-11 Electric System with Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

10-12 Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

10-13 LMIS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34

10-14 LMIS Audible Tower/Beacon Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38

10-15 LMIS Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40

10-16 Stabilizer Harness Equipped W/LMIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42

SECTION 11 –

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-1 Frame & Boom Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11-2 Cab Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

SECTION 12 –

OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12-1 Drivers Seat Installation, Air Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12-2 Drivers Seat, Air Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12-3 Front Cab Glass Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12-4 Trailer Coupling Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

12-5 Site Hitch Assembly Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10

12-6 Draw Bar Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

12-7 Battery Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14

12-8 Ground Wire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16

12-9 7-Pin Trailer Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

SECTION 13 –

RECOMMENDED SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

SECTION 14 – PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

4017 3121859vi

SECTION 1

FRAME & ATTACHING PARTS

3121859 4017

FRAME & ATTACHING PARTS

PZ4440

14 a

14 b

61 81

BEFORE S/N 1160000742

Figure 1-1 Frame Shrouding & Attaching Parts, Right Side

4017 31218591-2

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Attaching Parts, Right Side

Item Part Number Qty. Description Rev.

1 0274487 1 ENGINE COVER, (includes items 2 thru 14) G 2 8000801 1 LOCK 3 4811700 3 FLAT WASHER, 6X1mm 4 3290607 3 HEX LOCKNUT, 6X1mm 5 8000382 1 HOOD LOCK 6 4806433 2 HOOD HINGE 7 4811900 8 FLAT WASHER, 8mm 8 0760810 8 HEX HD CAPSCREW, 8-1.25X20mm, GR 8.8

9 5220800 2 RIPP NUT, 8mm-48 10 8000420 1 GAS SPRING 11 0761010 2 HEX HD CAPSCREW, 10-1.50X20mm, GR 8.8 12 4812000 2 FLAT WASHER, 10mm 13 0903224 1 BRACKET 14 2014226 AR TRIM, (a = 2.10m; b = 1.65m) 15 4340994 1 MIRROR MOUNT 16 0760812 2 HEX HD CAPSCREW, 8-1.25X25mm, GR 8.8 18 2 10” MIRROR, (Before S/N 1160000742), (no longer available, order 3140007)

3140007 2 RECTANGULAR MIRROR, (S/N 1160000742 & After) 20 3290807 2 HEX LOCKNUT, 8mm-1.25, (Before S/N 1160000742) 21 1321140 2 CLAMP, (Before S/N 1160000742) 22 4811900 2 FLAT WASHER, 8mm, (Before S/N 1160000742) 23 0760810 2 HEX HD CAPSCREW, 8-1.25X20mm, GR 8.8, (Before S/N 1160000742) 24 4812000 5 FLAT WASHER, 10mm 25 0761012 2 HEX HD CAPSCREW, 10-1.50X25mm, GR 8.8 26 0701024 1 HEX HD CAPSCREW, 10-1.50X80mm, GR 8.8 27 8000704 1 STEEL PIPE 28 8001626 1 PLATE 29 5201012 2 RIPP BOLT, 10-48X25mm 30 8008721 12 PLASTIC CAP 31 3380538 1 PROTECTING PANEL ASSY, (includes items 32 thru 34) 32 4811600 2 FLAT WASHER, 5mm 33 0700507 2 HEX HD CAPSCREW, 5X8X14mm, GR 8.8 34 3380534 1 OIL DRAIN PANEL 35 1898686 AR TRIM 36 5211702 14 RIPP WASHER, M6 37 0760608 8 HEX HD CAPSCREW, 6-1.00X16mm, GR 8.8 38 0760612 6 HEX HD CAPSCREW, 6-1.00X25mm, GR 8.8 39 2966421 6 NUT HOLDER 40 8002423 1 HOLDER 41 4805896 1 ANGLE 42 8004879 1 RADIATOR GUARD PLATE 43 2360693 1 FRAME 44 8002263 1 REAR COVER ASSY, (includes items 45 thru 60 and 82) H 45 3290801 2 HEX NUT, 8mmX1.25 46 909304 0.12m TRIM 47 8003293 1 PIN 48 0760808 2 HEX HD CAPSCREW, 8-1.25X16mm, GR 8.8 49 5211902 4 RIPP WASHER, 8mm 50 3300497 1 RIPP NUT, 12X1mm

3121859 4017 1-3

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Attaching Parts, Right Side (Continued)

Item Part Number Qty. Description Rev.

51 8007430 1 HOLDER 52 8004882 1 ROTARY LATCH LOCK 53 1398385 2 SCREW, M6X40mm 54 3290605 8 HEX LOCKNUT, 6mm 55 5211702 4 RIPP WASHER, 6mm 56 8006105 2 HINGE 57 8006242 4 SCREW, M6X40mm 58 0630576 4 FLAT HD CAPSCREW, M6X20mm 59 5200605 2 RIPP BOLT, 6-36X10mm 60 8006491 1 PUSH BUTTON HANDLE

Ref KEY, (same key used for ignition), (see Figure 10-4 for details)

61 0274108 1 AIR DUCT INSTALLATION, (without A/C), (includes items 62 thru 81) E

0274125 1 AIR DUCT INSTALLATION, (with A/C), (includes items 62 thru 81) D 62 4806477 1 ANGLE 63 5200810 2 RIPP BOLT, 8-48X20mm 65 5201010 4 RIPP BOLT, 10-48X20mm 66 5221000 4 RIPP NUT, 10mm 67 8007467 1 HOLDER 68 0761008 1 HEX HD CAPSCREW, 10-1.50X16mm, GR 8.8 69 8003294 1 LOCK 70 4803394 1 FLAP 71 4806568 1 JOINT 72 4802837 1 VENTILATOR 73 3820019 22 POP RIVET 74 8003295 1 LOCKING HOOK 75 1898686 AR TRIM 76 3960927 AR TRIM 77 4010405 4 MACHINE SCREW 78 3290405 4 HEX NUT, 4mm 79 4811400 4 FLAT WASHER, 4mm 80 935113 AR TRIM 81 8006452 1 RADIATOR MOUNTING SEAT, (without A/C)

4806604 1 RADIATOR MOUNTING SEAT, (with A/C) 82 4812100 1 FLAT WASHER, 12mm

4017 31218591-4

FRAME & ATTACHING PARTS

Figure 1-1 Frame Shrouding & Attaching Parts, Right Side (Continued)

Item Part Number Qty. Description Rev.

3121859 4017 1-5

FRAME & ATTACHING PARTS

21, 46

43 44 46 49

41 42 45 47 48 50

Figure 1-2 Frame Shrouding & Attaching Parts, Left Side

4017 31218591-6

FRAME & ATTACHING PARTS

Figure 1-2 Frame Shrouding & Attaching Parts, Left Side

Item Part Number Qty. Description Rev.

1 4812500 16 FLAT WASHER, 20mm 2 0702037 8 HEX HD CAPSCREW, 20-2.5X200mm, GR 8.8 3 8008962 1 COUNTERWEIGHT, (right), (Before S/N 1160002169)

8005316 1 COUNTERWEIGHT, (right), (S/N 1160002169 & After) 4 Ref FRAME, (see Figure 1-1 for details) 5 3292007 8 HEX LOCKNUT, M20 6 8009883 2 PROTECTING CAP 7 8008961 1 COUNTERWEIGHT, (left), (Before S/N 1160002169)

8005315 1 COUNTERWEIGHT, (left), (S/N 1160002169 & After) 8 Ref CAB, (see Figure 6-1 for details) 9 80383311 1 STAIR TREAD

10 3291007 8 HEX LOCKNUT, M10X1.5 11 4812000 4 FLAT WASHER, 10mm 12 4240168 2 STEP STRAP 13 3575424 4 STRAP COVER PLATE 14 0701015 8 HEX HD CAPSCREW, 1.25-7X4, GR 8.8 15 5200608 6 RIPP BOLT, 6-36X16mm 16 3380567 1 CAB BOTTOM SHIELD 17 3960927 .722m TRIM 18 1898686 1.6m TRIM 19 3575579 1 COVER PLATE 20 0761008 2 HEX HD CAPSCREW, 10-1.5X16mm, GR 8.8 21 8001935 1 TOOL BOX ASSY, (includes items 22 thru 32) G 22 8008701 1 LOCK

8008049 1 KEY 23 914210 AR RUBBER SEAL 24 1001097296 1 GAS SPRING 26 5220800 2 RIPP NUT, 8mm 27 8002319 1 TOOL BOX 28 5220600 6 RIPP NUT, M6 30 8002332 1 HINGE 31 5200608 3 RIPP BOLT, 6-36X16mm 32 3380559 1 TOOL BOX COVER 33 5220800 3 RIPP NUT, 8mm 34 5211900 3 RIPP WASHER, 8mm 35 0760810 3 HEX HD CAPSCREW, 8-1.25X25mm 36 8004888 1 LIFTING SUPPORT SYSTEM, (includes items 37 thru 39) 37 909304 AR TRIM 38 1784861 2 GASKET 39 443630 2 WING SCREW 40 0240064 1 WRENCH, (not shown), (stored in tool box) 41 4821460 6 WEIGHT, 12X75X385mm 42 4821461 3 WEIGHT, 12X90X565mm 43 4821462 10 WEIGHT, 12X180X450mm 44 3291005 2 HEX LOCKNUT, 10mm-1.50 45 3291207 2 HEX LOCKNUT, 12mm-1.75 46 5212000 4 RIPP WASHER, 10mm 47 4812100 2 FLAT WASHER, 12mm 48 4740550 2 FENDER WASHER, 12mm

3121859 4017 1-7

FRAME & ATTACHING PARTS

Figure 1-2 Frame Shrouding & Attaching Parts, Left Side (Continued)

Item Part Number Qty. Description Rev.

49 0701032 2 HEX HD CAPSCREW, 10X150mm, GR 8.8 50 0701232 2 HEX HD CAPSCREW, 12X150mm, GR 8.8

4017 31218591-8

FRAME & ATTACHING PARTS

Figure 1-2 Frame Shrouding & Attaching Parts, Left Side (Continued)

Item Part Number Qty. Description Rev.

3121859 4017 1-9

FRAME & ATTACHING PARTS

201

202

102

110

105

104

109

103

106

101

124

123

120

Figure 1-3 Axle & Fender Installation

4017 31218591-10

FRAME & ATTACHING PARTS

Figure 1-3 Axle & Fender Installation

Item Part Number Qty. Description Rev.

0273827 Ref FRAME INSTALLATION, (includes items 1 thru 17) G

1 Ref FRAME, (see Figure 1-1 for details) 2 Ref FRONT AXLE, (see Figure 5-1 for details) 3 Ref REAR AXLE, (see Figure 5-6 for details) 4 0630574 8 HEX HD CAPSCREW, 20-1.5X130mm 5 3300478 8 WHEEL NUT, M20X1.5

8007736 1 FENDER INSTALLATION, (includes items 101 thru 124) F

101 8010525 2 FENDER SUPPORT, (left)

8010526 2 FENDER SUPPORT, (right)

102 8010519 4 FENDER 103 8010524 4 SUPPORT PLATE 104 0700818 16 HEX HD CAPSCREW, 0.875-9X8.00 105 4811900 16 FLAT WASHER, 8mm 106 5220800 20 RIPP NUT, 8mm 109 8006580 8 HOLDER 110 328027 4 MUSHROOM HD BOLT 120 4804522 2 FENDER ASSY, RIGHT, (includes items 101 thru 110) 121 4804511 2 FENDER ASSY, LEFT, (includes items 101 thru 110) 123 4740532 16 FLAT WASHER 124 0630571 16 HEX HD CAPSCREW 201 Ref TIRE & WHEEL ASSY, (see Figure 5-11 for details) 202 2478782 40 FLANGED BALL NUT

3121859 4017 1-11

FRAME & ATTACHING PARTS

Figure 1-4 Outrigger Mounting

4017 31218591-12

FRAME & ATTACHING PARTS

Figure 1-4 Outrigger Mounting

Item Part Number Qty. Description Rev.

0273828 1 STABILIZER INSTALLATION, (includes items 1 thru 8) C

1 4210014 2 STABILIZER MOUNT ASSY

0440309 4 BEARING

2160016 3 GREASE FITTING

2 4210010 2 STABILIZER PAD 3 3423125 2 STABILIZER PIN 4 3423127 2 STABILIZER CYLINDER PIN 5 3423129 2 STABILIZER CYLINDER PIN 6 Ref STABILIZER CYLINDER, (see Figure 9-6 for details) 8 0761210 6 HEX HD CAPSCREW, 12-1.75X20mm

3121859 4017 1-13

FRAME & ATTACHING PARTS

5 8

9 11

PZ2250

Figure 1-5 Outrigger Mounting with Platform

4017 31218591-14

FRAME & ATTACHING PARTS

Figure 1-5 Outrigger Mounting with Platform

Item Part Number Qty. Description Rev.

0274919 1 STABILIZER INSTALLATION, (PLATFORM) E

1 4210014 2 STABILIZER MOUNT AS 2 4210010 2 STABILIZER PAD 3 3423125 2 STABILIZER PIN 4 Ref STABILIZER CYLINDER PIN, (see Figure 9-6 for details) 5 Ref STABILIZER PAD PIN, (see Figure 9-6 for details) 6 Ref STABILIZER CYLINDER, (see Figure 9-6 for details) 8 0761210 6 HEX HD CAPSCREW, M12X20

9 0760608 4 HEX HD CAPSCREW, M6X16 10 0903341 1 SUPPORT BRACKET, LH 11 0903342 2 STRIKER BRACKET 12 0903368 1 SUPPORT BRACKET, RH 13 3291001 4 HEX NUT, M10X1.5 14 4000017 2 PROXIMITY SENSOR 15 2141102 2 FITTING, ELBOW 16 2143602 2 FITTING 17 1001092224 2 FITTING 18 4360661 2 PRESSURE SWITCH

3121859 4017 1-15

FRAME & ATTACHING PARTS

PAP181

3 8

1 3 8

X106

X107

5 7 8

B08 X33

Figure 1-6 Outrigger Mounting Equipped W/LMIS

4017 31218591-16

FRAME & ATTACHING PARTS

Figure 1-6 Outrigger Mounting Equipped W/LMIS

Item Part Number Qty. Description Rev.

1001106403 1 STABILIZER INSTALLATION EQUIPPED WITH LMIS, (includes items 1 thru 9) A 1 0760606 4 HEX HD CAPSCREW, 6X12mm 2 0903341 1 SUPPORT BRACKET, LH 3 0903342 2 STRIKER BRACKET 4 0903368 1 SUPPORT BRACKET, RH 5 3291001 4 HEX NUT, M10X1.5 6 4000017 2 PROXIMITY SENSOR 7 4812000 4 WASHER, 10mm 8 1001095650 AR LOCTITE, #243 9 Ref HARNESS, STABILIZER, (see Figure 10-16 for details)

3121859 4017 1-17

FRAME & ATTACHING PARTS

14 15

12 13

PZ2260

101

107 108

103

105 106

113

109 110 111 112

102

107 108

104

109 110 111 112

113

105 106

202

203

204

201

Figure 1-7 Hood Installation with Platform

4017 31218591-18

FRAME & ATTACHING PARTS

Figure 1-7 Hood Installation with Platform

Item Part Number Qty. Description Rev.

0275102 1 HOOD INSTALLATION, PLATFORM, (includes items 1 thru 15) A 1 Ref HOOD AS, (see Figure 1-1 for details) 2 Ref REAR COVER AS, (see Figure 1-1 for details) 3 8000782 1 CAB BOTTOM SHIELD AS, (includes items 201 thru 204) D, 5 4 Ref HEADLIGHT INSTALLATION, (see Figure 10-1 for details) 5 8001626 1 PLATE 6 5201012 2 RIPP BOLT, 10X25mm 7 Ref FLANGED BALL NUT, (see Figure 1-3 for details) 8 Ref PLASTIC CAP, (see Figure 1-1 for details) 9 0275101 1 REAR LAMP BRACKET AS, (includes items 101 thru 113) B

10 1321620 1 CLAMP 11 0903380 1 CLAMP SUPPORT BRACKET 12 0760812 2 HEX HD CAPSCREW, 8X25 13 5220800 2 RIPP NUT, 8mm 14 5221200 2 RIPP NUT, 12mm

15 4032123 2 SOCKET HD CAPSCREW, M12X100 101 0903440 1 REAR LAMP BRACKET, LH 102 0903502 1 REAR LAMP BRACKET, RH 103 8001991 1 TAILLIGHT, LH 104 8001989 1 TAILLIGHT, RH 105 4811900 4 WASHER 106 3290807 4 HEX LOCK NUT, M8X1.25 107 5212000 4 RIPP WASHER, 10mm 108 0761012 4 HEX HD CAPSCREW 109 1356294 4 WASHER, 13mm 110 0701219 2 HEX HD CAPSCREW 111 3291207 2 HEX LOCK NUT, M12X1.75 112 8009517 2 BUFFER 113 8009226 2 PLATE 201 3380567 1 SHIELD 202 5200608 6 RIPP BOLT, M6X16 203 1898686 1.6M STRAP 204 3960927 0.72M RUBBER SEAL

3121859 4017 1-19

FRAME & ATTACHING PARTS

This Page Intentionally Left Blank

4017 31218591-20

SECTION 2

BOOM

3121859 4017

BOOM

22 54

PAP085

101

103

102

104

105

107

3 55

Figure 2-1 First Boom Section

4017 31218592-2

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