JLG 4017 Service Manual

Service Manual

Model

4017

3121858

Revised

September 3, 2010

An Oshkosh Corporation Company

EFFECTIVITY PAGE

June 10, 2005 - A - Original Issue Of Manual

January 6, 2006 - B - Revision Of Manual

September 3, 2010 - C - Revised pages 2.8, 3.25 thru 3.27, 6.5 & 6.6

31261858

4017

i

EFFECTIVITY PAGE

-ii

4017

3121858

SECTION CONTENTS

Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.1
1.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.2	Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.3	Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.4	Accident Prevention Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.2
1.5	Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
1.6	Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
1.7	Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.5
1.8	Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.5
Section 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.1
2.1	Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.2
2.2	Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.3
2.3	Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.6
2.4	Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.9
2.5	Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.10
2.6	Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.11
Section 3
Boom . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.1
3.1	Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.2
3.2	Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
3.3	Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
3.4	Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.14
3.5	Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.17
3.6	Hose Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.18
3.7	Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.21
3.8	Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.23
3.9	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.25
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		4.1
4.1	Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . .	4.2
4.2	Operator’s Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.3
4.3	Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.3
4.4	Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.7
4.5	Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4.8
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		5.1
5.1	Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . .	5.2
5.2	General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.3
5.3	Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.3
5.4	Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.10
5.5	Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.12
5.6	Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.13
5.7	Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5.14
	JLG Industries, Inc.
4017		i

Section Subject Page

Section 6
Transmission:	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.1
6.1	Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.2
6.2	Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.3	Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.4	Transmission Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.5	Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.6	Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.3
6.7	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6.7
Section 7
Engine: Perkins 1004-40T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		7.1
7.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.2
7.2	Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.4
7.3	Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.4
7.4	Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.4
7.5	Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.6
7.6	Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.6
7.7	Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.8
7.8	Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.9
7.9	Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.9
7.10	Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.13
7.11	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7.14
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		8.1
8.1	Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.2
8.2	Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.3
8.3	Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.3
8.4	Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.4
8.5	Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.7
8.6	Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.8
8.7	Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.10
8.8	Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8.16
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		9.1
9.1	Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.3
9.2	Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.4
9.3	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.4
9.4	Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.4
9.5	Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.7
9.6	Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.12
9.7	Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.15
9.8	Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.16
9.9	Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.17
9.10	Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.19
9.11	Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.20
9.12	Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.27
9.13	Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.28
9.14	Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9.28
9.15	Transmission Control Lever / Accessory Control Lever . . . . . . . . . . . . . . . . . . . . . . . . .	9.29

ii

4017

Section 1

Safety Practices

Contents

PARAGRAPH		TITLE	PAGE
1.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.2
1.3	Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.2
1.4	Accident Prevention Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.2
1.5	Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.3
	1.5.1	Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
1.6	Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.3
	1.6.1	Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
	1.6.2	Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.3
	1.6.4	Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1.4
1.7	Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.5
1.8	Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1.5

4017

1.1

Safety Practices

1.1INTRODUCTION

This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local JLG distributor.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.

Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.

1.2

1.2DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3OPERATOR & SAFETY MANUAL

The mechanic must not operate the machine until the Operator & Safety Manual has been read & understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operator & Safety Manual is supplied with each machine and must be kept in the cab. In the event that the Operator & Safety Manual is missing, consult the local JLG distributor before proceeding.

1.4ACCIDENT PREVENTION TAGS

Place Accident Prevention Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

4017

Safety Practices

1.5SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.5.1Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

4017

1.6SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions before proceeding.

1.6.1Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

1.3

Safety Practices

1.6.3General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

1.6.4Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an

appropriate container and dispose of in accordance with prevailing environmental regulations.

RADIATOR CAP: Always wear steam-resistant, heat protective gloves when opening the radiator cap. Cover the cap with a clean, thick cloth and turn slowly to the first stop to relieve pressure.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.4

4017

Safety Practices

1.7EMERGENCY EXIT REAR WINDOW

The rear window in the enclosed cab can be used as an emergency exit by removing the latch pin (1) located on the window latch. Once the latch pin is removed, the window is free to swing open.

1

MZ1400

1.8SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operator & Safety Manual supplied with machine for information.

4017

1.5

Safety Practices

This Page Intentionally Left Blank

1.6

4017

Section 2

General Information and Specifications

PARAGRAPH		TITLE	PAGE
2.1	Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.2
2.2	Torques.	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.3
	2.2.1	ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . .	2.3
	2.2.2	ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.4
	2.2.3	Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.5
2.3	Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.6
	2.3.1	Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.6
	2.3.2	Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.6
	2.3.3	Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.6
	2.3.4	Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.7
	2.3.5	Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.7
	2.3.6	Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.8
2.4	Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.9
2.5	Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.10
	2.5.1	8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . .	2.10
	2.5.2	50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . .	2.10
	2.5.3	1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . .	2.11
2.6	Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2.11
	2.6.1	8 Hour Lube Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.11
	2.6.2	50 Hour Lube Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2.11

4017

2.1

General Information and Specifications

2.1REPLACEMENT PARTS AND WARRANTY INFORMATION

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure below.

35

MZ1462

1

IMPORTANT: The replacement of any part on this machine with any other than JLG authorized replacement parts can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.

2.2

4017

4017																			1.2.2	2.2
						VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY										UNPLATED CAP SCREWS				TORQUES
						SAE GRADE 5 BOLTS &					SAE GRADE 8 BOLTS & GRADE 8 NUTS					UNBRAKO 1960 SERIES			FastenerASTM
						GRADE 2 NUTS						& SOCKET HEAD CAP SCREWS				SOCKET HEAD
			BOLT	TENSILE	CLAMP		TORQUE				CLAMP		TORQUE			CLAMP	TORQUE
		THDS.				DRY OR			LOCTITE	LOCTITE		DRY OR		LOCTITE	LOCTITE		WITHOUT	WITH
	SIZE	PER	DIA.	STRESS	LOAD	LOCTITE	LUB			242 OR	LOAD	LOCTITE	LUB		242 OR	LOAD	LOC-WEL	LOC-WEL
				AREA					262					262
		INCH				263				271		263			271		PATCH	PATCH
			IN	SQ. IN.	LB.	IN-LB	IN-LB		IN-LB	IN-LB	LB.	IN-LB.	IN-LB	IN-LB	IN-LB	LB.	IN-LB	IN-LB
	4	40	0.1120	0.00604	380	8	6		—	—	540	12	9	—	—	—	—	—
		48		0.00661	420	9	7		—	—	600	13	10	—	—	—	—	—	Torque
	8	32	0.1640	0.00909	580	16	12		—	—	820	23	17	—	—	—	—	—
	6	40	0.1380	0.01015	610	18	13		—	—	920	25	19	—	—	—	—	—
		32		0.01400	900	30	22		—	—	1260	41	31	—	—	—	—	—
		36		0.01474	940	31	23		—	—	1320	43	32	—	—	—	—	—	Chart
		20		0.0318	2020	96	75		—	105	2860	144	108	—	160	3180	160	168
	10	24	0.1900	0.01750	1120	43	32		—	—	1580	60	45	—	—	—	—	—
		32		0.02000	1285	49	36		—	—	1800	68	51	—	—	—	—	—
	1/4		0.2500
		28		0.0364	2320	120	86		—	135	3280	168	120	—	185	3640	168	178	(English)
	5/16	18	0.3125	0.0524	3340	17	13		16	19	4720	25	18	22	30	5240	25	28
		24		0.0580	3700	19	14		17	21	5220	25	20	25	30	5800	27	30
	3/8	16	0.3750	0.0775	4940	30	23		28	35	7000	45	35	40	50	7750	45	50
		24		0.0878	5600	35	25		32	40	7900	50	35	45	55	8780	50	55
	7/16	14	0.4375	0.1063	6800	50	35		45	55	9550	70	55	63	80	10630	70	77				General
		20		0.1187	7550	55	40		50	60	10700	80	60	70	90	11870	75	82
	1/2	13	0.5000	0.1419	9050	75	55		68	85	12750	110	80	96	120	14190	110	120
		20		0.1599	10700	90	65		80	100	14400	120	90	108	130	15990	115	127
	9/16	12	0.5625	0.1820	11600	110	80		98	120	16400	150	110	139	165	18200	155	170
		18		0.2030	12950	120	90		109	135	18250	170	130	154	190	20300	165	182				Information
	5/8	11	0.6250	0.2260	14400	150	110		135	165	20350	220	170	180	240	22600	210	231
		18		0.2560	16300	170	130		153	190	23000	240	180	204	265	25600	220	242
	3/4	10	0.7500	0.3340	21300	260	200		240	285	30100	380	280	301	420	33400	365	400
		16		0.3730	23800	300	220		268	330	33600	420	320	336	465	37300	400	440
	7/8	9	0.8750	0.4620	29400	430	320		386	475	41600	600	460	485	660	46200	585	645
		14		0.5090	32400	470	350		425	520	45800	660	500	534	725	50900	635	700
	1	8	1.0000	0.6060	38600	640	480		579	675	51500	900	680	687	990	60600	865	950				and
		12		0.6630	42200	700	530		633	735	59700	1000	740	796	1100	66300	915	1000
	1-1/8	7	1.1250	0.7630	42300	800	600		714	840	68700	1280	960	1030	1400	76300	1240	1365
		12		0.8560	47500	880	660		802	925	77000	1440	1080	1155	1575	85600	1380	1520				Specifications
	ote:	These torque values		do not apply to cadmium plated			fasteners.		1009	1175	87200	1820	1360	1453	2000	96900	1750	1925
	1-1/4	7	1.2500	0.9690	53800	1120	840
		12		1.0730	59600	1240	920		1118	1300	96600	2000	1500	1610	2200	107300	1880	2070
	1-3/8	6	1.3750	1.1550	64100	1460	1100		1322	1525	104000	2380	1780	1907	2625	115500	2320	2550
		12		1.3150	73000	1680	1260		1506	1750	118100	2720	2040	2165	3000	131500	2440	2685
	1-1/2	6	1.5000	1.4050	78000	1940	1460		1755	2025	126500	3160	2360	2530	3475	140500	3040	3345
		12		1.5800	87700	2200	1640		1974	2300	142200	3560	2660	2844	3925	158000	3270	3600
3.2

4.2

2.2

2.

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

UNPLATED CAP SCREWS

SAE GRADE 5 BOLTS &

SAE GRADE 8 BOLTS & GRADE 8 NUTS

UNBRAKO 1960 SERIES

GRADE 2 NUTS

& SOCKET HEAD CAP SCREWS

SOCKET HEAD

TorqueFastenerASTM

andInformationGeneral

TENSILE

TORQUE

TORQUE

TORQUE

THDS.

BOLT

CLAMP

DRY OR

LOCTITE

CLAMP

DRY OR

LOCTITE

CLAMP

WITHOUT

WITH

STRESS

LOCTITE

LOCTITE

SIZE

PER

DIA.

LOAD

LOCTITE

LUB

242 OR

LOAD

LOCTITE

LUB

242 OR

LOAD

LOC-WEL

LOC-WEL

AREA

262

262

INCH

263

271

263

271

PATCH

PATCH

IN

SQ. IN.

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

(Metric)Chart

Specifications

IN

SQ. IN.

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

N, m

N, m

LB.

N, m

N, m

Note: These torque values do not apply to cadmium plated fasteners.

4017

General Information and Specifications

2.2.3Metric Fastener Torque Chart

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

				CLASS 8.8 METRIC BOLTS &					CLASS 10.9 METRIC BOLTS &
				CLASS 8 METRIC NUTS					CLASS 10 METRIC NUTS
		TENSILE			TORQUE					TORQUE
			CLAMP	DRY OR			LOCTITE	CLAMP	DRY OR				LOCTITE
		STRESS				LOCTITE					LOCTITE
SIZE	PITCH		LOAD		LUB			LOAD		LUB
		AREA		LOCTITE			242 OR		LOCTITE				242 OR
						262					262
				263			271		263				271
		sq. mm	KN	N, m	N, m	N, m	N, m	KN	N, m	N, m	N, m		N, m
3	.5	5.03	2.19	1.3	1.0	1.2	1.4	3.13	1.9	1.4	1.5		2.1
3.5	.6	6.78	2.95	2.1	1.6	1.9	2.3	4.22	3.0	2.2	2.4		3.3
4	.7	8.78	3.82	3.1	2.3	2.8	3.4	5.47	4.4	3.3	3.5		4.8
5	.8	14.2	6.18	6.2	4.6	5.6	6.8	8.85	8.9	6.6	7.1		9.7
6	1	20.1	8.74	11	7.9	9.4	12	12.5	15	11	12		17
7	1	28.9	12.6	18	13	16	19	18	25	19	20		28
8	1.25	36.6	15.9	25	19	23	28	22.8	37	27	29		40
10	1.5	58.0	25.2	50	38	45	55	36.1	72	54	58		79
12	1.75	84.3	36.7	88	66	79	97	52.5	126	95	101		139
14	2	115	50.0	140	105	126	154	71.6	200	150	160		220
16	2	157	68.3	219	164	197	241	97.8	313	235	250		344
18	2.5	192	83.5	301	226	271	331	119.5	430	323	344		473
20	2.5	245	106.5	426	320	383	469	152.5	610	458	488		671
22	2.5	303	132.0	581	436	523	639	189.0	832	624	665		915
24	3	353	153.5	737	553	663	811	220.0	1060	792	845		1170
27	3	459	199.5	1080	810	970	1130	286.0	1540	1160	1240		1690
30	3.5	561	244.0	1460	1100	1320	1530	349.5	2100	1570	1680		2310
33	3.5	694	302.0	1990	1490	1790	2090	432.5	2600	2140	2280		2860
36	4	817	355.0	2560	1920	2300	2690	509.0	3660	2750	2930		4020
42	4.5	1120	487.0	4090	3070	3680	4290	698.0	5860	4400	4690		6440

Note: These torque values do not apply to cadmium plated fasteners.

METRIC CLASS 8.8 METRIC CLASS 10.9

4017

2.5

General Information and Specifications

2.3SPECIFICATIONS

2.3.1Travel Speeds

	Description
First Gear		5,2 km/h (3.2 mph)
Second Gear		11 km/h (6.9 mph)
Third Gear		22,5 km/h (14 mph)
Fourth Gear		35 km/h (21.7 mph)

2.3.2Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

	Description
Engine Make/Model		Perkins 1004-40T
Low Idle		925 ±50 rpm
High Idle		2200 ±50 rpm
Horsepower		99.5 BHP / 74.5 kW @ 2200 rpm
Fuel Delivery		Fuel Injection
Air Cleaner		Dry Type, Replaceable Primary and Safety
		Elements

2.3.3Hydraulic Cylinder Performance

Function	Approximate Times (seconds)
Extend Cylinder Extend	23.0
Extend Cylinder Retract	18.0
Lift Retracted	15.5
Lower Retracted	10.0
Attachment Tilt - UP	4.5
Attachment Tilt - DOWN	9.8
Outrigger - Left and Right, DOWN	8.7
Outrigger - Left and Right, UP	6.4

2.6

4017

		General Information and Specifications
2.3.4	Tires
	Description
Wheel Lug Nut Torque		550-600 Nm (405-445 lb-ft)
Standard Tire Size		405/70-24 14PR MPT-04 TBL
Standard Tire Air Pressure (Minimum)		450 kPa (65 psi)
Optional Tires
Optional Tire Size		405/70-24 14PR MPT-01 TBL
Optional Tire Air Pressure (Minimum)		450 kPa (65 psi)

2.3.5Axles

Dana Spicer	Axle	JLG P/N
Model
212-531	FRONT 1:20.667	0280173
212-190-002	REAR 1:20.667	4803383

4017

2.7

General Information and Specifications

2.3.6	Electrical System
Battery:
Type, Rating		12 VDC, Negative (-) Ground, Maintenance Free
Quantity		1
Reserve Capacity		1,000 Cold Cranking Amps @ 0° F (-18° C)
Group/Series		Series 31
Alternator		12V, 85 Amps
Fuses - Standard Blade Style:
5 Amps		Radio
7.5 Amps		Headlights and Tail Lights, ESX Ignition and Sensors
10 Amps		Brake Lights, Cold Start, Beacon
15 Amps		Rear Work Lights, Cab Heater, Aux Power Socket,
		Battery Ind. Light, Dome Light, Spare, Ignition, Front
		Work Lights, Boom Work Lights,
20 Amps		Rear Wiper, Front Wiper
25 Amps		ESX Battery, Air Conditioning
30 Amps		Key Switch
Relays:
Key (power)		K1
Start Interlock		K2
Flasher		K3
Wiper		K4
Work Lights		K5
Fuel Solenoid		K6
Relays in Engine Compartment:
Starter
Lift pump
Glow Plug
Inline Fuse:
Lift Pump and Glow Plug

2.8

4017

General Information and Specifications

2.4FLUIDS, LUBRICANTS AND CAPACITIES

Engine Crankcase Oil
Capacity w/Filter Change	8,5 liters (9 quarts)
Filter Capacity	1,0 liter (0.26 quarts)
Type of Oil	15W-40 CE/SE
Fuel Filters
Primary Fuel Filter Capacity	Approx. 1,0 liter (0.26 quarts)
Fuel Filter Capacity	0,6 liters (0.16 quarts)
Fuel Tank
Capacity	140 liters (37 gallons)
Type of Fuel	U.S.A. #2 Diesel
Cooling System
System Capacity w/o Heater	19,7 liters (20.8 quarts)
Type of Fluid	50/50 mix of ethylene glycol & water
Transmission Fluid
Capacity w/filter change	12,9 liter (13.6 quarts)
Filter Capacity	1,4 liters (1.5 quarts)
Type of Fluid	Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
Transmission Transfer Case (Drop Box)
Capacity	1,4 liter (1.5 quarts)
Type of Fluid	Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
Axles
Differential Housing Capacity - Front	6,9 liters (1.3 quarts)
Differential Housing Capacity - Rear	6,9 liters (1.3 quarts)
Wheel End Capacity	1,25 liters (1.3 quarts)
Type of Fluid	Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
Brakes
Master Cylinder Capacity	0,7 liters (0.7 quarts)
Type of Fluid	ATF Dexron II
Hydraulic System
System Capacity	246 liters (65 gallons)
Reservoir Capacity to FULL Mark	160 liters (42.3 gallons)
Type of Fluid	Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
4017	2.9

General Information and Specifications

2.5	SERVICE AND MAINTENANCE	2.5.2	50, 250 & 500 Hour Maintenance
	SCHEDULES		Schedule
2.5.1	8 & 1st 50 Hour Maintenance Schedule
			EVERY
			50

EVERY

8

Check Fuel

Check Tire

Air Filter

Level

Pressure

Restriction

Indicator

Check Engine	Check Hydraulic
Oil Level	Oil Level

Check Brake		Check		Test Load
Fluid Level		Transmission		Moment
		Oil Level		Indicator

1st

50

Change

Axle Oil

Check Boom

Chain Tension

Change Wheel	Change Engine
End Oil	Oil & Filter

Change

Transmission

Oil & Filter

LB/FT

(Nm)

Check Wheel

Lug Nut

Torque

OZ0300

Drain Fuel/	Check Engine	Check	Follow Lubrication
Water	Coolant Level	Battery	Schedule
Separator

Change Engine

Oil and

Filter

Check Boom

Chain

Tension

EVERY

250

Check Axle

Oil Level

Check Boom

Bearing

Pads

Check Wheel

End Oil Levels

Check Transfer

Case Oil Level

Air Filter	Check
Vacuator	Fan Belt
Valve

EVERY

500

	LB/FT
	(Nm)
Change Fuel	Check Wheel
Filter	Lug Nut
	Torque

OZ0320

2.10

4017

			General		Information and Specifications
2.5.3		1000 & 1500 Hour Maintenance	2.6.2	50	Hour Lube Schedule
		Schedule

Change

Transmission

Oil & Filter

Change

Engine Coolant

Change

Transfer Case

Oil

Change

Hydraulic

Fluid & Filters

EVERY

1000

Change	Change Wheel
Axle Oil	End Oil

EVERY

1500

Change	Change
Hydraulic Tank	Brake Fluid
Breather

Mystik Tetrimoly

(NLGI 2 GC-LB)

Check Boom

Chain

(4017 only)

OZO891

2.6LUBRICATION SCHEDULES

2.6.18 Hour Lube Schedule

Mystik Tetrimoly

(NLGI 2 GC-LB)

4017

2.11

General Information and Specifications

This Page Intentionally Left Blank

2.12

4017

Section 3

Boom

Contents

PARAGRAPH		TITLE	PAGE
3.1	Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.2
3.2	Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.3
	3.2.1	Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
3.3	Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.3
	3.3.1	Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.3
	3.3.2	Second, Third & Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . .	3.4
	3.3.3	Third & Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .	3.6
	3.3.4	Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.6
	3.3.5	Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.7
	3.3.6	Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.7
	3.3.7	Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.8
	3.3.8	Third & Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . .	3.9
	3.3.9	Second, Third & Fourth Boom Section Installation . . . . . . . . . . . . . . . . . .	3.10
	3.3.10	Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.13
3.4	Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.14
	3.4.1	Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.14
3.5	Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.17
3.6	Hose Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.18
	3.6.1	Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.18
	3.6.2	Hose Carrier Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.19
3.7	Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.21
	3.7.1	Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.21
	3.7.2	Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.21
	3.7.3	Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.23
3.8	Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.23
	3.8.1	Connecting with a Mechanical Quick Switch Device. . . . . . . . . . . . . . . . .	3.23
	3.8.2	Connecting with a Hydraulic Quick Switch Device . . . . . . . . . . . . . . . . . .	3.23
	3.8.3	Connecting with a Quick Switch to a Hydraulic Operated Attachment . . .	3.24
	3.8.4	Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.24
	3.8.5	Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3.24
3.9	Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3.25

4017

3.1

Boom

3.1BOOM SYSTEM COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.

			Hose Carrier
		Fourth Boom
		Section
		Third Boom
		Section
	Auxiliary	Second Boom
		Section	Retract Chains
	Quick
	Connects		(three)
			Extend/Retract
			Cylinder
			MZ0830
			Rear View
		Tilt Cylinder
	Quick Switch Assembly

Extend Chains

(two pair)

First Boom

Section

MZ0800

Bottom View

MZ0810

3.2

4017

3.2BOOM SYSTEM

3.2.1Boom System Operation

The four section boom consists of the first, second, third and fourth assemblies with double third and fourth section extend chains, a double third section retract chains and a single fourth section retract chain.

As the extend/retract cylinder, which is anchored at the front of the second boom section, and the rear of the first boom section begins to extend, it forces the second boom section out of the first boom section.

The first, second, third and fourth boom sections are connected by extend and retract chains. These chains are routed around sheaves on the second and third boom sections. As the second and third boom sections are forced out, the extend chain pulls the fourth boom section out of the third boom section.

As hydraulic pressure is applied to the retract port on the extend/retract cylinder, the second boom section is pulled back into the first boom section, and the retract chain pulls the third and fourth boom sections back into the second boom section.

This mechanical linkage formed by the chains and supporting hardware, extends and retracts the third and fourth boom sections at the same rate.

The first boom section does not extend or retract, but lifts and lowers via action of the lift cylinder.

3.3BOOM ASSEMBLY MAINTENANCE

The boom assembly consists of the first, second, third and fourth boom sections and supporting hardware.

IMPORTANT: Before removing the boom, the carriage or any other attachment must be removed from the quick switch assembly.

These instructions must be completed in sequence. The second, third and fourth boom sections are removed from the first boom section.The third and fourth boom sections are removed from the second boom section.The fourth boom section is removed from the third boom section.

Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.

Boom

3.3.1Boom Removal

1.Remove any attachment from the quick switch assembly. (Refer to Section 3.8.1, “Connecting with a Mechanical Quick Switch Device.”)

2.Set the quick attach assembly in a vertical position and set on a hard level surface. Refer to Section 3.8.4, “Quick Switch Removal,” for disassembly instructions.

3.Park the machine on a firm, level surface. Be sure there is enough room in front of the machine to allow the boom sections to be removed. Fully retract the boom then raise the boom to access the rod end pin of lift cylinder. Place the transmission control lever in

(N) NEUTRAL, engage the park brake and shut the engine OFF.

4.Open the engine cover. Allow the system fluids to cool.

5.Place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

	1
L.O/R R.O/R SWAY AUX TILT EXT/RET	LIFT
FRONT OF
MA
CHINE	MZ0420

6.Relieve any trapped pressure in the tilt hydraulic system by installing the handle (1) (located in the toolbox) or using an 9mm wrench and move the double nut on the side of the actuator module on the tilt valve section back and forth. Repeat on the auxiliary valve section and on the extend/retract valve section.

7.Disconnect, label and cap both hoses from the extend/retract cylinder, tilt hoses and both auxiliary hoses from tubes at left rear corner of first boom section to prevent dirt and debris from entering hydraulic system.

8.Remove the extend/retract cylinder support at the top front of the first boom section.

4017

3.3

Boom

9.Support the extend/retract cylinder and remove the clip and pin from rod end of extend/retract cylinder. Remove the clip and pin from barrel end of extend/ retract cylinder and remove the extend/retract cylinder.

10.Disconnect the boom angle indicator rod from switch at the inside left rear corner of the main boom section and frame. Refer to Section 9.11.9, “Boom Angle Sensor,” for adjustment information.

11.Support the front of the boom by placing a sling behind the boom head. Support the lift/lower cylinder and remove the lock bolt and then the rod end pin. Lower the lift/lower cylinder onto the frame rails.

12.Remove the lock bolt and pin from compensation cylinder on each side of first boom section. Remove the lock bolt and pivot pin from rear of first boom section.

13.Lower the boom to a level position and place a suitable support under the boom head. Reposition the slings to each end of the boom.

14.Lift the complete boom (1) off machine and set on level ground or supports being careful not to damage the tubes on the left side of boom.

1

(before being turned over)

MZ0820

2

(after being turned over)

MZ0740

3.3.2Second, Third & Fourth Boom Section Removal

1.Set the complete boom on level ground and by repositioning the slings turn boom over on to the top side. Set the complete boom (2) on suitable stands to begin tear down.

Note: With the complete boom setting upside down, the removal and replacing of each boom section, tilt cylinder, hoses, extend and retract chains and hose carrier are made much easier.

2.At the boom head attach a sling through rod end of tilt cylinder. Remove both hoses from tilt cylinder. Plug the hose ends and cap the tilt cylinder fittings to prevent dirt and debris from entering the hydraulic system. Remove the clip from barrel end of tilt cylinder pin. Remove the tilt cylinder pin and lift the tilt cylinder out of the boomhead.

3

Note: In the following sections the individual boom sections are removed as follows:

1.Remove second, third and fourth boom sections as one unit from the first boom section.

2.Remove third and fourth boom sections as one unit from the second boom section.

3.Remove fourth boom section from the third boom section.

4.Remove hose carrier from fourth boom section.

3.4

MZ0750

4017

Boom

3.Use a suitable sling around the third section boom to take any pressure off of wear pads to make pad removal easier.

Note: Before removing the extend chains, measure the distance (1) between the face of the jam nut to the end of the chain clevis on all four extend chains. This measurement will be used when reassembling the boom.

	MZ0790
1	1

4.At the bottom front of the first section boom remove the jam nuts and nuts and washers from the two extend chain clevises. Remove clips and pins from the two clevises and remove clevis from each chain.

5.At the bottom front of the second section boom remove the jam nuts and nuts and washers from the two extend chain clevises. Remove clips and pins from the two clevises and remove clevis from each chain.

6.At the rear of boom, loosen and unscrew both tilt hoses and both auxiliary hoses from bulkhead on hose carrier. Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system.

7.Remove the clip and pin from both retract chain clevises that are attached to the rear of the third section boom. The pins can be removed through the access holes at the bottom left and right sides of the first section boom. Do not remove the clevises

8.Remove the clip and pin from the retract chain clevis that is attached to the rear of the fourth boom section. Do not remove the clevis.

9.Pull the second section boom out

152 mm to 203 mm (6 in to 8 in) to be able to loosen and remove all the bolts and remove all the wear pads, backing plates and shims from the front inside of the first section boom. Tag each pad, backing plate, shim and bolts from each location.

4017

10.Pull the third boom section out 152 mm to 203 mm (6 in to 8 in) to be able to access the wear pad bolts on the rear of the second section boom. Remove the top left and right side wear pads, backing plates and shims (one on each side) from the second boom section. Loosen the bottom rear wear pad bolts and remove the shims from the second boom section to gain the necessary clearance to be able to remove the second boom section from the first boom section. Tag each pad, backing plate, shim and bolts from each location.

11.Using a sling around the front of the second boom section, lift and slide the three boom sections 3/4 of the way out of the first boom section. Set the boom head down on a suitable support, then center the sling to be able to balance the three boom sections being removed. Carefully pull the three boom sections (3) the remainder of the way out of the first boom section and set the three boom sections down on suitable supports.

12.Remove the clip and pin holding each retract chain from the inside of the first boom section. Clean and inspect chains. Replace if damaged.

13.Unscrew the tilt and auxiliary hoses from tubes at bottom front of first boom section. Plug the tilt and auxiliary hoses and cap the tubes to prevent dirt and debris from entering hydraulic system. Clean and inspect the hoses. Replace if damaged.

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

15.Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the first boom section. Replace any item if damaged. (Refer to Section 3.4.1, 3.4.1. “Boom Chain Inspection,” and Section 3.7.1, 3.7.1. “Wear Pad Inspection.”)

Note: It is recommended that if any chain or hose is damaged that ALL chains or hoses are replaced.

3.5

Boom

3.3.3Third & Fourth Boom Section Removal 5. Remove the lock bolts, keeper and pin from both

1.With the three boom sections setting on suitable supports remove bolts, keeper and pin from both sheaves on the bottom front of the second boom section. Remove sheaves. Remove all the wear pads, backing plates and shims from the front inside of the second boom section. Tag each pad, backing plate, shim and bolts from each location.

2.Remove the bolts, keeper and pin from center sheave on the bottom rear of the third boom section. Remove the sheave.

3.Remove the top left and right side rear wear pads, backing plates and shims (one on each side) from the third boom section. Loosen the bottom rear wear pad bolts and remove the shims from the third boom section to gain the necessary clearance to remove the third boom section from the second boom section. Tag each pad, backing plate, shim and bolts from each location.

1

MZ0760

4.Place a sling around the front of the third boom section. Lift and slid the two boom sections 3/4 of the way out of the second boom section.Set the boom head down on a suitable support, then center the sling to be able to balance the two boom sections being removed. Carefully pull the two boom sections

(1) the remainder of the way out of the second boom section and set the two boom sections down on suitable supports.

sheaves at bottom rear of the second section boom. Remove the sheave’s.

6.Remove the clip and pin holding retract chain from bottom front of second boom section. Clean and inspect chain. Replace if damaged.

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

8.Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the first boom section. Replace any item if damaged. (Refer to Section 3.4.1, 3.4.1. “Boom Chain Inspection,” and Section 3.7.1, 3.7.1. “Wear Pad Inspection.”)

Note: It is recommended that if any chain or hose is damaged that ALL chains or hoses are replaced.

3.3.4Fourth Boom Section Removal

1.With the two boom sections setting on suitable supports remove the bolts, keeper and pin from sheave on the front of the third boom section.

Remove the sheaves. Remove all the wear pads, backing plates and shims from the front inside of the third boom section. Tag each pad, backing plate, shim and bolts from each location.

2.Remove the top left and right side rear wear pads, backing plates and shims (one on each side) from the fourth boom section. Loosen the bottom rear wear pad bolts and remove the shims from the fourth boom section to gain the necessary clearance to be able to remove the fourth boom section from the third boom section.Tag each pad, backing plate, shim and bolts from each location.

3.Loosen and remove the two bolts holding the rear of the catrack to the top of the third boom section. Lift and push rear of hose carrier into the fourth boom section.

4.Place a sling around the front of the fourth boom section (2). Lift and slid the fourth boom section 3/4 of the way out of the third boom section. Set the boom head down on a suitable support, then center the sling to be able to balance the fourth boom section being removed. Carefully pull the fourth boom section the remainder of the way out of the third boom section and set the fourth boom section down on suitable supports.

5.Remove the clip and pin holding both extend chains from bottom of third and fourth boom sections. Clean and inspect chains. Replace if damaged.

3.6

4017