JLG 4017 Service Manual

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An Oshkosh Corporation Company

Model

4017

3121858

Revised

September 3, 2010

Service Manual

EFFECTIV IT Y 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

EFFECTIV IT Y PAGE

4017 3121858-ii

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

4017

 JLG Industries, Inc.

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

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

1.1 INTRODUCTION

This service manual provides general directions for accomplishing servic e and re pai r proc edu res. Fo ll owi ng 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 appro ved safe ty p r actices, 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 opera tion, maintenance, or testing. When additi onal 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 for ward 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 DISCLAIMER

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.

1.3 OPERATOR & 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.

1.4 ACCIDENT 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.

1.2

4017

Safety Practices

1.5 SAFETY 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.

1.5.1 Safety 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.

1.6 SAFETY 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

1.6.1 Personal 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.

1.6.2 Equipment 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.

proceeding.

4017

1.3

Safety Practices

1.6.3 General 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: Imme diately clean, dress and report all inj uries (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.

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specificall y instr uc ted othe rw is e.

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 b e on a hard leve l surfa ce, wit h th e wh eel s 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 loosenin g any hydr aul ic 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 pr ope r 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

1.7 EMERGENCY EXIT REAR WINDOW

MZ1400

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.

Safety Practices

1.8 SAFETY 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 T orques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

MZ1462

2.1 REPLACEMENT 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.

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

2.2 TORQUES

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

SAE GRADE 5 BOLTS &

GRADE 2 NUTS

SAE GRADE 8 BOLTS & GRADE 8 NUTS

& SOCKET HEAD CAP SCREWS

UNBRAKO 1960 SERIES

SOCKET HEAD

SIZE

THDS.

PER

INCH

BOLT

DIA.

TENSILE

STRESS

AREA

CLAMP

LOAD

TORQUE

CLAMP

LOAD

TORQUE

CLAMP

LOAD

TORQUE

DRY OR

LOCTITE

263

LUB

LOCT ITE

262

LOCTITE

242 OR

271

DRY OR

LOCTITE

263

LUB

LOCTITE

262

LOCTITE

242 OR

271

WITHOUT

LOC-WEL

PATCH

WITH

LOC-WEL

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

0.1120

0.00604 380 8 6 — — 540 12 9 — — — — —

48 0.00661 420 9 7 — — 600 13 10 — — — — —632

0.1380

0.00909 580 16 12 — — 820 23 17 — — — — —

40 0.01015 610 18 13 — — 920 25 19 — — — — —832

0.1640

0.01400 900 30 22 — — 1260 41 31 — — — — —

36 0.01474 940 31 23 — — 1320 43 32 — — — — —1024

0.1900

0.01750 1120 43 32 — — 1580 60 45 — — — — —

32 0.02000 1285 49 36 — — 1800 68 51 — — — — —

1/4

0.2500

0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168

28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178

5/16

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

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

0.4375

0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77

20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82

1/2

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

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

5/8

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

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

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

1.0000

0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950

12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000

1-1/8

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

1-1/4

1.2500

0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925

12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070

1-3/8

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

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

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

2.2.1 ASTM Fastener Torque Chart (English)

General Information and Specifications

4017

2.3

General Information and Specifications

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS

SAE GRADE 5 BOLTS &

GRADE 2 NUTS

SAE GRADE 8 BOLTS & GRADE 8 NUTS

& SOCKET HEAD CAP SCREWS

UNBRAKO 1960 SERIES

SOCKET HEAD

SIZE

THDS.

PER

INCH

BOLT

DIA.

TENSILE

STRESS

AREA

CLAMP

LOAD

TORQUE

CLAMP

LOAD

TORQUE

CLAMP

LOAD

TORQUE

DRY OR

LOCTITE

263

LUB

LOCTITE

262

LOCTITE

242 OR

271

DRY OR

LOCTITE

263

LUB

LOCTITE

262

LOCTITE

242 OR

271

WITHOUT

LOC-WEL

PATCH

WITH

LOC-WEL

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

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

2.2.2 ASTM Fastener Torque Chart (Metric)

2.4

4017

General Information and Specifications

METRIC CLASS 8.8 METRIC CLASS 10.9

2.2.3 Metric Fastener Torque Chart

VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY

CLASS 8.8 METRIC BOLTS &

CLASS 8 METRIC NUTS

TORQUE

LUB

LOCTITE

262

LOCTITE

242 OR

271

CLAMP

SIZE PITCH

TENSILE

STRESS

AREA

CLAMP

LOAD

DRY OR

LOCTITE

263

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

81.2536.615.92519232822.837272940

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

CLASS 10.9 METRIC BOLTS &

CLASS 10 METRIC NUTS

LOAD

DRY OR

LOCT ITE

263

LUB

TORQUE

LOCTITE

262

LOCTITE

242 OR

271

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

4017

2.5

General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel 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)

2.3.2 Engine 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 Pr im ar y and Safety

Elements

2.3.3 Hydraulic 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

Opti on al Tir e Size 405/70-24 14PR MPT-01 TBL Opti o nal Tire Air P ressu re (Mi n i mum) 450 kPa (65 psi)

2.3.5 Axles

Dana Spicer

Model

212-531 FRONT 1:20.667 0280173

212-190-002 REAR 1:20.667 4803383

Axle JLG P/N

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

2.4 FLUIDS, 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

4017

Tractor Hydraulic Fluid (ISO 46)

2.9

General Information and Specifications

OZ0300

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Axle Oil

Change Wheel

End Oil

Check Boom

Chain Tension

Change Engine

Oil & Filter

Change

Transmission

Oil & Filter

Air Filter

Restriction

Indicator

Check Fuel

Level

Check Engine

Oil Level

Check Tire

Pressure

EVERY

Check Brake

Fluid Level

Check

Transmission

Oil Level

Test Load

Moment

Indicator

Check Hydraulic

Oil Level

OZ0320

500

EVERY

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Fuel

Filter

EVERY

Drain Fuel/

Water

Separator

Check Engine

Coolant Level

Check Battery

Follow Lubrication

Schedule

250

EVERY

Check Axle

Oil Level

Check Wheel

End Oil Levels

Air Filter Vacuator

Valve

Check

Fan Belt

Check Boom

Chain

Tension

Check Boom

Bearing

Pads

Check Transfer Case Oil Level

Change Engine

Oil and

Filter

2.5 SERVICE AND MAINTENANCE SCHEDULES

2.5.1 8 & 1st 50 Hour Maintenance Schedule

2.5.2 50, 250 & 500 Hour Maintenance Schedule

2.10

4017

General Information and Specifications

OZO891

1500

EVERY

Change

Engine Coolant

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

Change

Brake Fluid

1000

EVERY

Change

Axle Oil

Change Wheel

End Oil

Change

Transmission

Oil & Filter

Change

Transfer Case

Oil

Check Boom

Chain

(4017 only)

Mystik T e trimo ly

(NLGI 2 GC-LB)

Mystik Tetrimoly

(NLGI 2 GC-LB)

2.5.3 1000 & 1500 Hour Maintenance Schedule

2.6 LUBRICATION SCHEDULES

2.6.2 50 Hour Lube Schedule

2.6.1 8 Hour Lube Schedule

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

MZ0800

MZ0810

MZ0830

Extend/Retract

Cylinder

First Boom

Section

Auxiliary

Quick

Connects

Tilt Cylinder

Second Boom

Section

Third Boom

Section

Fourth Boom

Section

Hose Carrier

Extend Chains

(two pair)

Bottom View

Quick Switch Assembly

Rear View

Retract Chains

(three)

3.1 BOOM 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.

3.2

4017

Boom

MZ0420

EXT/RET

LIFT

TILT

AUX

SWAY

L. O/R

R. O/R

FRONT OF

MACHINE

3.2 BOOM SYSTEM

3.2.1 Boom 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.

3.3.1 Boom 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.

3.3 BOOM 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, understa nd and follow thes e instructions.

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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.

3.3

Boom

MZ0820

(before being turned over)

MZ0740

(after being turned over)

MZ0750

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.

3.3.2 Second, Third & Fourth Boom Sectio n 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.

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.

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.

3.4

4017

Boom

MZ0790

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.

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 t h e b ot to m le f t an d right sides of t h e first section boom. Do not remove the clev ises

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.

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 i f stru ctural 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.

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3.5

Boom

MZ0760

3.3.3 Third & Fourth Boom Section Removal

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.

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.

5. Remove the lock bolts, keeper and pin from both 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.

3.3.4 Fourth 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

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6. Inspect the boom and welds. Consult the local JLG

MZ0770

MZ0780

di s t r i b u t o r or th e JLG Ser vice D epart ment i f s tructur al damage is detected.

7. 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.”)

Boom

3.3.5 Hose Carrier Removal

1. Loosen and remove both auxiliary hoses in the boom head.Plug the auxiliary hose ends to prevent dirt and debris from entering hydraulic system.

2. With fourth boom section setting on suitable supports loosen and remove the si x bol ts (th ree pe r side) on the fourth boom section.

3. Pull the hose carrier (3) halfway out of fourth boom section by hand and set on a suitable support. Place a sling around the center of the hose carrier to be able to balance the hose carrier while being removed.Carefully slide the hose carrier the remainder of the way out of the fourth boom section and set down on suitable supports.

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

3.3.6 Hose Carrier Installatio n

1. Install the hose carrier into the fourth boom section. Using a suitable sling, place the sling under the center of the hose carrier and guide the front of hose carrier into the rear of the fourth boom section. Set the rear of the hose carrier on a suitable support. Remove the sling and slide the remainder of the hose carrier into the fourth boom section by hand.

2. Apply Loctite 242 the bolts through the three holes on each side of the fourth boom section. Install the front two bolts first. Install the middle two next. Then the rear two bolts last. Torque to all six bolts to 90 Nm (66 lb-ft).

to the hose carrier bolts. Install

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3.7

Boom

MZ0770

MZ0980

Third Boom Section

3.3.7 Fourth Boom Section Installation

1. Apply Loctite 242® to the wear pad mounting bolts. Install the bottom rear wear pads, washers and bolts. Torque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install top rear wear pads, backing plates and bolts (front bolts are drilled and tapped for grease fittings. Do not shim or tighten bolts). Install both extend chains (1) on bottom rear of fourth boom section. Lay extend chains the length of fourth boom section.

2. Grease the inside third boom section on area’s where the fourth boom section wear pads will slide.

4. With the sling still under boom head, apply Loctite

to the wear pad mounting bolts and install the

242 top wear pads, washers and bolts in the front of the third boom section. Torque to 90 Nm (66 lb-ft). Lower

the fourth boom section, apply Loctite 242

to the wear pad mounting bolts and install bottom wear pads, backing plates, shims and bolts in the front of the third boom section. Torque to 90 Nm (66 lb-ft).

Apply Loctite 242

to the wear pad mounting bolts and install both left side and right side front wear pads, backing plates, shims and bolts in the front of the third boom section. Torque to 90 Nm (66 lb-ft).

Note: Grease wear pads, inside sheaves, bores and pins during assembly.

5. Apply Loctite 242

to the sheave mounting bolts, Install the sheave (2), pin, lock plate and bolts at the bottom front of the third boom section. T orque bolts to 90 Nm (66 lb-ft ). Grease the sheave using the grease fitting in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly. Pull both extend cha ins from t he fourth boom section around the front and over the sheave. Install both chain clevises, pins and clips.

3. Using a suitable sling, balance t he fourth boom section and carefully slide 914 mm to 1219 mm (3 ft to 4 ft) into the front of the third boom section. Set the fourth boom section head onto suitable support and reset sling under the boom head of the fourth boom section. Carefully slide the fourth boom section into the third boom section. Leave 1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom section out to be able to install wear pads in front of the third boom section.

3.8

6. Retract the fourth boom section the remainder of the way into the third boom section and install the wear pads at the rear of third and fourth boom sections.

7. Apply Loctite 242

to the wear pad mounting bolts and install the bottom left and right side wear pads, backing plates, shims and bolts. Shim the top wear pads on the rear of the fourth boom section. Shim the top left and right wear pads on the rear of the fourth boom section. Torque bolts to 90 Nm (66 lb-ft). Torque grease fitting bolts to 45 Nm (33 lb-ft).

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Boom

MZ1000

Second Boom Section

(front)

MZ1010

Retract Chain

Clevises

Third Boom Section

(rear)

3.3.8 Third & Fourth Boom Section Installation

1. At the rear of the third boom section apply Loctite

2. Grease the inside second boom section on area’s

3. Install retract chain, pin and clip to bottom front

Note: Keep the retract chain centered on bottom of the third boom section while installing the third boom section into the second boom section.

4. Using a suitable sling, balance the third and fourth

5. With the sling still under boom head, Apply Loctite

to the wear pad mounting bolts and install the

242 bottom rear wear pads, washers and bolts. T orque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install the top rear wear pads, backing plates and bolts (front bolts are drilled and tapped for grease fittings. do not shim or tighten bolts). Install both extend chains on the bottom rear of the third boom section. Lay extend chains the length of third boom section.

where the third boom section wear pads will slide.

inside of the second boom section.

boom section and carefully slide 914mm-1219mm (3 ft - 4 ft) into the front of the second boom section. Set the third and fourth boom section onto a suitable support and reset the sling under the boom head of the fourth boom section. Carefully slide the third and fourth boom section into the second boom section. Leave 152mm-203mm (6 in - 8 in) of the third boom section out to be able to install the wear pads in the front of the second boom section

to the wear pad mounting bolts and install the

242 top wear pads, washers and bolts in the front of the second boom section. Torque to 90 Nm (66 lb-ft). Lower the third and fourth boom section and apply

Loctite 24 2

to the wear pad mounting bolts and install bottom wear pads, backing plates, shims, and the allenhead cap bolts in the front of the second boom section. Torque to 90 Nm (66 lb-ft). Install both left side and right side front wear pads, backing plates, shims and bolts in the front of the second boom section. Torque to 90 Nm (66 lb-ft).

Pull both exten d ch ai ns f rom th e t hir d bo om sect ion around the front and over the sheaves. Install both chain clevises , p ins and c lips (3).

7. Apply Loctite 242

to the wear pad mounting bolts and install the bottom left and right side wear pads, backing plates, shims and bolts.Shim the top wear pads on the rear of the third boom section. Shim the top left and right wear pads on the rear of the third boom section.Torque bolts to 90 Nm (66 lb-ft). Torque grease fitting bolts to 45 Nm (33 lb-ft).

8. Install the retract chain sheave (4), pin, keeper and bolts to bottom rear of third boom section. Apply

Loctite 242

and torque to 90 Nm (66 lb-ft). Grease the sheaves using the grease fitting in the pin. Spin the sheaves by hand to ensure the sheaves spin freely on the pin and to distribute grease evenly.

Note: Grease wear pads, inside sheaves, bores and pins during assembly.

6. Install both sheaves (2), pins, lock plat es and bolt s at the bottom front of the second boom section. Apply

Loctite 242 Grease the sheaves using the grease fitting in the

and torque bolts to 90 Nm (66 lb-ft).

pin. Spin the sheaves by hand to ensure the sheaves spin freely on the pin and to distribute grease evenly .

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3.9

Boom

MZ1140

Second Boom Section

(rear)

MZ1190

First Boom Section

(front view)

9. Install both retract chain sheaves (1), pin, keeper and bolts to bottom rear of second boom section. Apply Loctite 242 Grease the sheaves using the grease fitting in the pin. Spin the sheaves by hand to ensure the sheaves spin freely on the pin and to distribute grease evenly.

and torque to 90 Nm (66 lb-ft).

3.3.9 Second, Third & Fourth Boom Section Installation

IMPORTANT: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.

1. Appl y L octi te 242 the rear of the second boom section install the bottom rear wear pads, washers and bolts. T orque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install top rear wear pads, backing plates and bolts (front bolts are drilled and tapped for grease fittings. do not shim or tighten bolts).

to the wear pad mounting bolts.At

3.10

2. Grease the inside first boom section on area’s where the second boom section wear pads will slide.

3. Install the retract chains (2), pins and clips to bottom front inside of the first boom section.

4. Install both tilt hoses (3) and both auxiliary hoses (4) to the tubes mounted at the bottom front of the first boom section. Make sure both sets of hoses are run through the opening at the bottom front of the first boom section and run down the inside center of the boom section

Note: Keep the retract chains, tilt and auxiliary hoses centered in the first boom section while installing the second boom section into the first boom section.

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5. Using a suitable sling, balance the second, third and

MZ1200

Hose Carrier Mounting

Bolts (2)

Tilt Hoses

Auxiliary Hoses

fourth boom section and carefully slide 914 mm - 1219 mm (3 ft - 4 ft) into the front of the first boom section. Set the second, third and fourth boom section onto a suitable support and reset sling under the boom head of the fourth boom section. Carefully slide the second, third and fourth boom section into the first boom section. Leave 152 mm 203 mm (6 in - 8 in) of the second boom section out to be able to install wear pads in front of the first boom section.

6. With sling still under boom head, Apply Loctite 242 to the wear pad mounting bolts. Install the top wear pads, washers and bolts in the front of the first boom section. Torque to 90 Nm (66 lb-ft). Lower the second, third and fourth boom section and apply

Loctite 24 2

to the wear pad mounting bolts, Install bottom wear pads, backing plates, shims, and bolts in the front of the first boom section. Torque to 90 Nm (66 lb-ft). Install both left side and right side front wear pads, backing plates, shims and bolts in the front of the second boom section. Torque to 90 Nm (66 lb-ft).

Note: Shim ALL side wear pads as needed to maintain a minimum gap (1.6 mm - 1/16 in) the horizontal direction or a snug fit. The number of shims can vary at each shim point.

7. Install the bottom left and right side wear pads, backing plates, shims and bolts at the rear of the second boom section.Shim the top wear pads on the rear of the second boom section. Shim the top left and right wear pads on the rear of the second boom

section. Apply Loctite 242

and torque bolts to 90

Nm (66 lb-ft).

Boom

8. Retract the second, third and fourth boom sections the remainder of the way into the first boom section.

9. Attach the retract chain (5), pin and clip to the clevis at the rear of the fourth boom section.

10. Attach the retract chains (6), pins and clips to the clevises at the rear of the third boom section.

Note: Installing the clevis pins in the third boom section can only be done when the first boom section and the second boom section access holes are aligned.

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3.11

Boom

MZ0790

MZ1210

11. Attach both extend chain clevises (1) through the holes in the bottom front of the first boom section. Install the washers, adjustment nut and jam nut to the clevises.

12. Attach both extend chain clevises (1) through the holes in the bottom front of the second boom section. Install the washers, adjustment nut and jam nut to the clevises.

Note: Adjust all four extend chains (2) using the measurement taken in the beginning of the tear down procedure. Depending on the extent of the parts being replaced, the above measurement is to be used as a starting point ONLY.

13. Pull the rear of the hose carrier over the rear of the fourth boom section and set onto the rear of the third boom section. Using the two bolts, washers and nuts, bolt the rear of the hose carrier to the rear of

the third boom section. Apply Loctite 242

and

torque the two bolts to 90 Nm (66 lb-ft).

14. Remove the caps from the fittings on the hose carrier bulkhead and the plugs from the tilt and auxiliary hoses. Install all four hoses and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

15. Remove the caps from the auxiliary hoses in the boomed and install the auxiliary hoses from the front of the hose carrier to the auxiliary bulkhead. Tighten each hose wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats. Bolt the auxiliary hose bulkhead to the side of the boom head and torque the two bolts to 90 Nm (66 lb-ft).

16. Using a suitable sling through the rod end of the tilt cylinder, lower the tilt cylinder into boomhead. Align the tilt cylinder barrel end bore with the boomhead bore and install the tilt cylinder pin and retaining clip.

Note: Grease tilt cylinder barrel end bore and pin before installing.

17. Remove the caps from the fittings on the tilt cylinder and the plugs from the tilt hoses from the hose carrier. Install both tilt hoses and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

18. Using suitable slings, lift complete boom off supports and set on level ground. It will be necessary to place a block under the rear of the boom to keep the tilt and auxiliary tubes from being damaged

19. Turn the boom over being careful not to damage the tilt and auxiliary tubes mounted on the side and rear of boom.

20. After boom is turned upright, place a suitable support under the rear of the boom.

21. Attach a sling around a balance point on the extend/ retract cylinder and carefully set on top of the first boom section.

Note: Grease extend/retract cylinder barrel end bore and rod end bore and pins before installing.

22. Align the extend/retract cylinder barrel end (3) with bore at rear of the first boom section. Install the pin and retaining clip (4).

23. Align the extend/retract cylinder rod end (3) with bore at front of the second boom section. Install the pin and retaining clip (4).

24. Install extend/retract cylinder support (5). Apply

Loctite 242

and torque bolts to 90 Nm (66 lb-ft).

3.12

4017

Boom

MZ1230

MZ1240

MZ1250

3.3.10 Boom Installation

1. Park the machine on a hard, level surface. Make sure park brake is set, key is removed from the ignition and “DO NOT OPERATE” tag is placed in clear view in the cab.

Note: Raising the boom up or down with the sling maybe necessary so the boom, compensation and lift/ lower cylinder bores can be aligned for easier pin installation.

Note: Grease the boom pivot bore, compensation cylinder rod ends, lift/lower cylinder rod end and pins before installing.

5. Remove the caps from extend/retract cylinder fittings and plugs from extend/retract cylinder hoses. Attach each hose to the extend/retract cylinder fittings (9) and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

6. Remove the caps from both tilt tubes (10) and auxiliary tubes (11) and plugs from both tilt hoses and both auxiliary hoses. Attach both sets of hoses to the tilt tubes and the auxiliary tubes and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

7. Connect 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.

8. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic fluid level in the reservoir; add fluid if required.

2. Using suitable slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bore with the boom assembly pivot bore.

Install boom pivot pin (6). Apply Loctite 242

and

torque lock bolt to 90 Nm (66 lb-ft).

3. With the sling still in place, install both compensation cylinders, pins and lock bolts (7). Apply Loctite 242

and torque to 90 Nm (66 lb-ft).

4. With the sling still in place, install the rod end of the lift/lower cylinder, pin and lock bolt (8). Apply Loctite

and torque to 90 Nm (66 lb-ft).

242

9. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

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3.13

Boom

3.4 BOOM EXTEND AND RETRACT

CHAINS

3.4.1 Boom Chain Inspection

WARNING: Worn pins, stretched or

cracked links or corrosive environments can cause chain failure. A chain failure could result in uncontrolled boom movement, loss of load or machine instability, and could cause death or serious injury and/or property damage.

Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. The retract chains need to be exposed and inspected every 1000 hours of operation. Refer to the Service Manual for the proper procedure. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operating conditions and require more frequent inspection intervals.

Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosiv e or highl y corr os ive industrial atmospheres, in addition to abrasive exposures such as sand and grit. Some effects can be as follows:

• Moisture - Corrosive rusting reduces chain strength by pitting and cracking.

• Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation.

• Chemical Solutions or Vapors - Corrosive attack on the chain components and/or the mechanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time.

• Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins and plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye.

Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain.

• High velocity movement of load, followed by sudden, abrupt stops.

• Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain.

• Attempting to “inch” loads which are beyond the rated capacity of the vehicle.

The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted.

The boom chain’s normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3%. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulatio

3.4.2 Inspection Guidelines

1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission control lever in (N) NEUTRAL, engage the park br ake switch.

2. Fully extend the boom until the extend chain is taut. Shut the engine off.

3. The extend chains will be visible for inspection with the vehicle in this state.

4. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

5. Inspect the retract chains every 1000 hours of operation. Refer to the Service Manual for proper procedure.

6. Inspect the chains for the following conditions:

Edge Wear

Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. This can be compared to a normal link plate height by measuring a portion of chain that does not run over the sheave.

3.14

a. Extend Chains (fourth to third section)

The extend chains between the fourth and third boom sections measures 18 mm (.713 in) (1). If the measurement of the worn chain is less than 17 mm (.677 in) (2), the chain should be replaced.

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b. Extend Chains (third to second section)

MZ1463

MZ1464

MZ1465

6 7

The extend chains between the third and second boom sections measures 29,6 mm (1.2 in) (1). If the measurement of the worn chain is less than 28,6 mm (1.1 in) (2), the chain should be replaced.

Elongation

Boom

It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading. The ends of the chains, near the clevis terminal, will not have flexed as frequently, if at all, as nearer the middle of the chains.

a. Extend Chains (fourth to third section)

When the original length (3) of 305 mm (12.00 in) per foot of extend chain between the fourth and third boom sections has elongated from wear to a length (4) of 313 mm (12.36 in), the chain should be discarded and replaced.

Measure across a span of 16 pins at the center of the extend chain. Measure from pin center to pin center. Because the retract chain is inside the boom you will not be able to measure the chain.

The maximum measurement allowed is 313 mm(12.36 in). If the measurement is more than 313 mm (12.36 in), the chain should be replaced.

b. Extend Chains (third to second section)

When the original length (3) of 317 mm (12.5 in) per foot of extend chain between the third and second boom sections has elongated from wear to a length (4) of 325 mm (12.8 in), the chain should be discarded and replaced.

Measure across a span of 10 pins at the center of the extend chain. Measure from pin center to pin center. Because the retract chain is inside the boom you will not be able to measure the chain.

The maximum measurement allowed is 325 mm(12.8 in). If the measurement is more than 325 mm (12.8 in), the chain should be replaced.

Turning or Protruding Pins

Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.

Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (5). Chain with rotated/displaced heads (6) or abnormal pin protrusion (7) should be replaced immediately .

DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored.

Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected.

4017

3.15

Boom

MZ1466

MZ1467

MZ1468

MZ1469

MZ1470

MZ1471

Distorted or Battered Link Plates

Distorted or battered link plates (8) on a leaf chain can cause tight joints and prevent flexing.

Cracked Plates

Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety.

It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.

The types of cracks are:

• Fatigue Cracking Fatigue cracks (9) are a result of repeated cyclic loading beyond the chain’s endurance limit.

• Stress Corrosion Cracking - The

outside link plates are particularly susceptible to stress corrosion cracking (10).

• Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress.

Other Modes of Failure

• Tight Joints

- All joints in the chain should flex freely. Tight joints (3) resist flexing. If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain.

3.4.3 Expose Chains for Inspection

c. Extend Chains

1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position.

2. Lower both outriggers completely

3. Fully extend the boom until both extend chains are taut. Shut the engine OFF.

The extend chains will be visible for inspection with the machine in this state.

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

If during the inspection, any chain is found to be damaged or stretched, the chain must recommended that when any chain is replac ed, that all the chains and clevises be replaced at the same time.

d. Retract Chains

The three retract chains are only partially visible through the rear of the boom with all the sections retracted. It is possible to see a section of the retract chain as the boom is slowly extended. If there is ANY question that one or all the retract chains are damaged, the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary.

be replaced. It is

• Ultimate Strength Failure These types of failures are caused by overloads far in excess of the design load. Either fractured plates (1) or

Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis’ be replaced at the same time.

enlarged holes (2) can occur. If either of these failures occurs, the chain should be replaced immediately.

3.16

4017

Boom

797mm

31.378”

499mm

19.645”

229mm

9.016”

37mm

1.45”

20mm

.787”

e. Removing Extend and Retract Chains

The four extend chains and the three retract chains can only be removed during a complete boom teardown.

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

If during the inspection, any chain is found to be damaged or stretched, the chain must

be replaced. It is recommended that when any chain is replaced, that all the chains and clevis’ be replaced at the same time.

3.4.4 Chain Lubrication

After inspection and before being returned to service, chains must be lubricated with a quality chain lubricant (“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or equivalent).

The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links.

To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces.

Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation.

3.5 BOOM SECTION SEPARATION ADJUSTMENT

The second, third and fourth boom sections are set to dimensions between each section. The first and second boom sections are connected by the extend/retract cylinder which has no adjustment.

The third and fourth boom sections can be adjusted by loosening or tightening the extend chains and the retract chains.

1. Fully retract the boom and raise the boom to a horizontal position. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

2. Measure the distance between the boom sections (1). If adjustments are needed, extend the boom out 0,91 m to 1,2 m (3 ft to 4 ft). Shut off machine.

3. Loosen the locknuts on the extend chains and the retract chains and adjust as needed.

a. To increase the separation distance: Loosen the

retract chains locknut on the rear of the third or fourth boom sections one or two turns and tighten the extend chain loc knuts on the first and second boom sections equally the same numbe r of turns. A minimum of one full thread on the clevis must protrude beyond the locknut.

Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often.

Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. It is important that a reputable lubrication specialist, a JLG Distributor or the vehicle distributor be consulted for guidance.

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b. To decrease the separation distance: Loosen the

extend chain locknuts at the front of the first or second boom sections equally one or two turns and tighten the retract chains locknut the same number of turns. A minimum of one full thread on the clevis must protrude beyond the locknut.

3.17

Boom

MZ1220

120mm - 4.75in

180mm - 7in

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

5. If the measurements are within the tolerance, tighten the locknuts on the chain clevises. If more adjustment is needed, refer to paragraph a. or b. and repeat procedure until the proper boom section dimensions is achieved.

6. With the boom sections within the proper tole ra nce, start the machine, lower the outriggers if necessary and extend the boom to maximum extension.

7. Shut the machine off and measure the distance between the top of both extend chains and the bottom of the second and third boom sections at the center of each boom section.

8. The distance (2) between the top of the extend chains and the bottom of the second boom section should be approximately 180 mm (7 in). The distance (2) between the top of the extend chains and the bottom of the third boom section should be approximately 120 mm (4.75 in).

Note: If the second boom section to the third boom section separation distance cannot be achieved, contact the local JLG distributor or the JLG Service Department.

3.6 HOSE CARRIER ASSEMBLY

3.6.1 Hose Carrier Assembly Removal

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

2. Park the machine on a hard, level surface. Be sure there is enough room in front and rear of the machine to extend the boom sections and to be able to removed the hose carrier from the rear of the boom assembly.

3. Fully extend the boom and raise the boom to a horizontal position. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

4. Retract the boom until the rear hose carrier mounting bolts on the fourth boom section are accessible through each side of the third boom section access holes. Shut off the machine and remove the bolts.

5. Start the machine and retract the boom until the middle set of hose carrier bolts on the fourth boom section are accessible through the third boom section access holes. Shut the engine OFF and remove the bolts.

6. Start the engine and retract the boom until the front set of hose carrier bolts on the fourth boom section are just in front of the front of the third boom section. Shut the engine OFF and remove the bolts.

7. Start the engine and slowly retract the boom sections completely.

8. Shut the engine OFF and place an Accident Prevention Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

9. Relieve any trapped pressure in the tilt hydraulic system by using the handle provided or a 9mm wrench and move the double nut on the side of the main control valve tilt section back and forth. Repeat on the auxiliary valve section.

10. Locate the two hos es att ach ed to th e ba rr el o f t he tilt cylinder inside the boomhead.

11. Label and remove the hoses from the elbow fittings on the tilt cylinder (1). Plug the hose ends and cap the elbow fittings on the tilt cylinder to prevent dirt and debris from entering the hydraulic system.

3.18

4017

12. Label and remove the two auxiliary hydraulic hoses

MZ0900

Hose

Carrier

MZ0920

MZ0910

Access Hole on Each

Side of the Third

Section Boom

(2) from the bulkhead fittings inside the boomhead.

Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system.

13. At the rear of the boom, label and remove the tilt cylinder hoses and the auxiliary hoses from the hose carrier bulkhead. Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system.

14. From the top rear of the hose carrier, remove both bolts (3) holding the hose carrier (4) to the third boom section.

15. Remove both left and right side wear pad bolts and both left and right bottom wear pad bolts from the rear of the fourth boom section to be able to remove the hose carrier.

16. Pull the hose carrier halfway out of the rear of the boom, set on a suitable support. Using a sling around the hose carrier, balance the hose carrier and pull the remainder of the way out. Set the hose carrier on the ground or on suitable supports.

Boom

Note: If the machine or the boom has to be moved, replace all the bolts that were removed from the wear pads on the rear of the fourth boom section BEFORE the machine is started and/or the boom is retracted or extended.

3.6.2 Hose Carrier Assembly Replacement

1. Carefully lay the new hose carrier assembly out flat on a hard surface.

2. Make sure the boom is level and that the front two hose carrier holes (5) in the fourth boom section are accessible just in front of the front of the third boom section.

3. Using a sling around the center of the hose carrier, lift and carefully place the front of the hose carrier part way into the rear of the boom. Set the rear of the hose carrier down on a suitable support. Reposition the sling and lift the rear of the hose carrier and slide it the remainder of the way into the boom.

4017

3.19

Boom

4. 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 bottom wear pads and bolts. torque the side wear pads to 50 Nm (37 lb-ft) and the bottom wear pads to 90 Nm (66 lb-ft).

5. Align the front two threaded holes on the hose carrier with the front two holes (5) on each side of the fourth boom section and install both bolts. Apply

Loctite

242 and hand tighten only.

6. Fasten the rear of the hose carrier (3) to the top rear of the third boom section. Apply Loctite

242 and

torque both bolts to 90 Nm (66 lb-ft).

7. Start the machine and extend the boom out until the middle set of holes (6) in the fourth boom section align with access holes at the front sides of the third boom section. Shut off machine.

8. Align the middle two threaded holes on the hose carrier with the middle two holes on the fourth boom

section and install both bolts. Apply Loctite

242 and

hand tighten only.

9. Start the machine and extend the boom out until the rear set of holes (7) in the fourth boom section align with access holes on each side of the third boom section. Shut off machine.

10. Align the rear two threaded holes on the hose carrier with the rear two holes on the fourth boom section

and install both bolts. Apply Loctite

242 and torque

to 90 Nm (66 lb-ft).

11. Torque the middle two and front two hose carrier bolts to 90 Nm (66 lb-ft).

12. Start the machine and retract the boom completely.Shut the machine off.

13. Relieve any trapped pressure in the tilt hydraulic system by using the handle provided or a 9mm wrench and move the double nut on the side of the main control valve tilt section back and forth. Repeat on the auxiliary valve section.

14. Attach both tilt cylinder hoses from the hose carrier to the tilt cylinder and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

15. Attach both auxiliary hoses from the hose carrier to the auxiliary fittings on the bulkhead and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

16. Bolt the auxiliary bulkhead onto the side of the boom

head. Apply Loctite

242 and torque to 50 Nm (37 lb-

ft).

17. At the rear of the boom, attach both tilt cylinder hoses to the tilt hose carrier bulkhead fittings and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

18. At the rear of the boom, attach both auxiliary hoses to the auxiliary hose carrier bulkhead fittings and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

19. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic fluid level in the reservoir; add fluid if required.

3.20

4017

Boom

Ma2070

MZ0840

Fourth Section Boom

3.7 BOOM WEAR PADS

There are a total of 50 wear pads installed on the first, second, third and fourth boom sections. 10 wear pads are attached to the first boom section, 16 to the second boom section, 16 to the third boom section and 8 to the fourth boom section.

Note: All shims are used to maintain a minimum gap between the wear pad and the boom surface.

3.7.1 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicators on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.

3.7.2 Boom Wear Pad Replacement

When replacing a wear pad on the boom, replace both wear pads on that side of the boom; e.g.: replace top front left and top front right wear pads at the same time.

Usually, shimming will remain the same when installing new wear pads. Some wear pads are secured to the boom using different bolts and washers. Keep bolts and washers with the same wear pad that is being replaced. When installing new wear pads, apply Loctite wear pad mounting bolts and torque to required specifications.

#242 to all

a. Fourth Section Boom

Coat all wear pad bolts with Loctite 242

before installation. All fourth section boom wear pads are mounted on the rear outside of the fourth section boom.

Use shims under the upper rear wear pads and under the side wear pads as required to maintain a minimum gap of

1.6 mm (1/16 in) between the wear pad and the boom surface. Shims are available in two thicknesses, 2.0 mm and 4.0 mm.

b. Third Section Boom

Coat all wear pad bolts with Loctite 242

before installation.

The wear pads on the inside front and outside rear of the third boom section can be replaced by removing the bolts securing them to the top, sides and bottom of the boom.

When removing pads, move the boom sections as needed to gain access for removal and installation of wear pads. Mark or otherwise label each pad, spacer/ shim and hardware set for ease of installation later. Top wear pads are secured to the boom with washers and bolts; side wear pads are secured with washers and bolts.

4017

3.21

Boom

MZ0850

Third Section Boom

MZ0860

Second Section Boom

Use shims under the upper rear wear pads, under the bottom front wear pads and under the side wear pads as required, to maintain a minimum gap of 1.6 mm (1/16 in) between the wear pad and boom surface.

c. Second Boom Section

Coat all wear pad bolts with Loctite 242

before

installation. The wear pads on the inside front and outside rear of the

second boom section can be replaced by removing the bolts securing them to the top, sides and bottom of the boom.

d. First Boom Section

Coat all wear pad bolts with Loctite 242

before

installation. All first boom section wear pads are mounted on the

inside front of the first boom section. Remove the bottom wear pads before removing the top wear pads. Lower the gooseneck to the ground until the second boom section raises up, providing clearance for removing the bottom pads. Fill the grease pockets of the top rear boom wear pads with multi-purpose grease.

Use shims under the bottom front and under the side wear pads as required to maintain a minimum gap of

1.6 mm (1/16 in) between the wear pad and boom surface.

3.22

4017

3.7.3 Boom Wear Pad Lubrication

MZ0870

First Section Boom

MAH0980

The boom has been factory lubr icated for pr oper wear pa d break-in and will normally require minor further lubrication. However, after replacing any wear pad(s), or after prolonged periods of inoperation, light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.

Boom

3.8 QUICK SWITCH ASSEMBLY

This machine is equipped with a quick switch system for easy attachment changes.

3.8.1 Connecting with a Mechanical Quick

Switch Device

1. Retract quick switch device to provide clearance. Check to be sure lock pin (1) and retainer pin (2) is out.

2. Align attachment pin (3) with recess in attachment (4).

3. Engage quick switch device.

4. Shut off engine. Exit cab and insert lick pin and secure with retainer pin.

5. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.8.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.”

3.8.2 Connecting with a Hydraulic Quick Switch Device

1. Retract quick switch device to provide clearance. Check to be sure lock pin is disengaged.

2. Align attachment pin (3) with recess in attachment (4). Raise boom slightly to engage attachment pin in recess.

3. Engage quick switch device.

4. Press the button (5) and at the same time, move the joystick to engage or to disengage the quick switch device.

4017

5. Raise the boom to eye level and visually check that the quick switch pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

6. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.8.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.”

3.23

Boom

3.8.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment

1. Lower attachment to ground. Set the park brake, shut off engine and turn key back to the “ON” position.

2. Relieve pressure in the hydraulic system by actuating the joystick.

3. Connect the quick-disconnect fittings.

4. Start the engine.

3.8.4 Quick Switch Removal

1. Remove the lock bolt (5) holding the tilt cylinder rod end to the quick switch assembly. Remove the tilt cylinder pin.

2. Support the qui ck swit ch assem bly. Remove the four bolts and covers (6) from each end of the quick switch assembly. Remove the pin from the quick switch assembly from either side.

3. Inspect the above pin for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired, the pin must be replaced.

3.8.5 Quick Switch Installation

1. Assemble the quick switch to the boom head. Line up the quick switch between the mounts on the boom head. The quick switch should be centered in the boom head.

2. Coat the quick switch pivot pin with an anti-seize compound. Insert the quick switch pivot pin through the quick switch and boom head. Replace the end covers and four bolts (6) to each end of the quick switch.

3. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin. Align the tilt cylinder pin and screw in the locking bolt (5). Torque as required.

3.24

4017

3.9 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that occur during operation of the boom.

Boom Troubleshooting

Problem Cause Remedy

Boom

1. Boom will not extend or retract.

2. Boom shifts to right or left when extending.

3. Excessive boom pivot pin noise and/or wear.

4. Excessive compensation cylinder pivot pin noise and/ or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Exte nd/Retract hydraulic system not operating properly.

3. Faulty extend/retract cylinder.

4. Broken chains or anchors.

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication.

2. Worn bushing(s).

1. Insufficient lubrication.

2. Worn bushing(s).

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8.4, “Hydraulic Circuits.”

3. Repair cylinder, Refer to Section

8.8.1, “General Cylinder Removal Instructions.”

4. Replace chains as needed.

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.7.2, “Boom Wear Pad Replacement.”

1. Lubricate at regular intervals. (Refer to Section 2.5.3, 2.6. “Lubrication Schedules.”)

2. Replace bushing(s) and lubricate at regular intervals

1. Lubricate at regular intervals. (Refer to Section 2.5.3, 2.6. “Lubrication Schedules.”.) Replace worn pins as needed.

2. Replace bushing(s) and lubricate at regular intervals.

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3.25

Boom

Boom Troubleshooting (Continued)

Problem Cause Remedy

5. Dropping chain, or jerky boom extend or retract functions.

6. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes

1. Chain(s) tension not properly adjusted.

2. Chain(s) stretched or binding.

3. Wear pads loose, contaminated, excessively worn or damaged.

4. Contaminated, corroded or rusted wear pad sliding surfaces.

5. Extend/Retract hydraulic system not operating properly.

6. Damaged boom section.

and/or connection leaks .

2. Lift/Lower hydraulic system not operating properly.

3. Faulty Lift cylinder.

4. Seized boom pivot pin bushing.

1. Adjust chain(s).

2. Replace chains as needed. Refer to Section 3.5, “Boom Section Separation Adjustment.”

3. Replace wear pad. Refer to Section 3.7.2, “Boom Wear Pad Replacement.”

4. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

5. Refer to Section 8.4, “Hydraulic Circuits.”

6. Replace the damaged boom section. Refer to Section 3.3, “Boom Assembly Maintenance.”

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8.4, “Hydraulic Circuits.”

3. Repair cylinder. Refer toSection

8.8.1, “General Cylinder Removal Instructions.”

4. Replace bushing.

7. Excessive Lift/Lower cylinder pivot pin noise and/or wear.

3.26

1. Insufficient lubrication.

2. Worn self-aligning bushing(s).

1. Lubricate at regular interva ls. Refer to Section 2.5, “Service and Maintenance Schedules.” Replace worn pins as needed. Refer to Section 8.8.1, “General Cylinder Removal Instructions.”

2. Replace bushing(s) and lubricate at regular intervals. (Refer to appropriate owners manual for lubrication points.)

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Boom Troubleshooting (Continued)

Problem Cause Remedy

Boom

9. Rapid boom pad wear. 1. Incorrect wear pad gap.

2. Rapid cycle times with heavy loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

10. Auxiliary hydraulics will not operate.

11. Excessive chain wear. 1. Imprope r chain adjustment.

1. Auxiliary hydraulic system not operating properly.

2. Chain sheave(s) not properly lubricated.

3. Chain sheave(s) not rotating freely.

4. Improper chain lubrication.

1. Check wear pad gaps and correct as needed. Refer to Section 3.7.2, “Boom W ear Pad Replacement.”

2. Reduce cycle times.

3. Remove contamin ation and/or corrosion from wear pad sliding surfaces an d lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

4. Clean equipment frequently.

1. Refer to Section 8.4, “Hydraulic Circuits.”

1. Adjust to correct tension. Refer to Section 3.4.1, “Boom Chain Inspection.”- Replace chains as needed.

2. Lubricate chain sheave. (Refer to Section 2.5, “Service and Maintenance Schedules.”

3. Lubricate chain sheave. Refer to Section 2.5, “Service and Maintenance Schedules.” Repair or replace chain sheave(s) as needed.

4. Lubricate at regular intervals. (Refer to Section 2.5, “Service and Maintenance Schedules.” Replace chains as needed.

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3.27

Boom

This Page Intentionally Left Blank

3.28

4017

Section 4

Cab and Covers

Contents

PARAGRAPH TITLE PAGE

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3.1 Steering Column and Orbitrol Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.3.3 Throttle Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

4.3.4 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

4.3.5 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

4.3.6 Heater/Defroster System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

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4.1

Cab and Covers

Air

Louvers

Air

Louvers

Instrument

Panel

Level

Indicator

Fuel

Gauge

Load Moment

Indicator

Engine Temp

Gauge

Control Console

Hazard Flashers

Ignition Switch

Air Louvers

Joystick

Continuous Hydraulic

Powered Operation Auxiliary Switch Air Louvers

12V Receptacle

Heater & AC

Controls

Round Air Vents

Brake Fluid

Reservoir

Transmission Control Lever

Wiper, Lights & Turn

Signal Lever

Steering Column

Adjuster

Service Brake

Pedal

Accelerator

Pedal

Park Brake Lever

MZ0040

4.1 OPERATOR’S CAB AND COVERS 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 names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.

4.2

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4.2 OPERATOR’S CAB

MZ0620

4.2.1 Cab Safety

WARNING: The protection offered by

this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/ FOPS must be properly installed using fasteners of correct size and grade, and torqued to their specified value.

4.2.2 Serial Number Decal

The cab serial number decal is located on the left side of the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.

Cab and Covers

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

a. Orbitrol Valve Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control leve r in the (N) NEUT RAL position, engage the park brake and turn the engine OFF.

2. Place an Accident Prevention T ag on the ignition key switch, stating that the machine should not be operated.

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

4. Remove the battery negative (-) cable from the battery negative terminal.

5. Remove the lower dash panel.

6. Label, disconnect and cap the four hoses (1) from the side of the steering valve (2). Cap the fittings on the steering valve. Label, disconnect and plug the load sense hose (3) at the front of the steering valve. Cap the fitting on the steering valve.

7. Remove the steering wheel (4), disconnect and remove the display panel (5), disconnect and remove the accessory lever (6) and transmission control lever (7), loosen and remove the locking bolt (8) for the steering column adjustment, loosen and remove both steering column pivot bolts and nuts.

8. Remove the steering assembly (9) through the dash panel opening.

9. Support the stee ring valve, and remove the four hexhead capscrews and four lockw ash ers.

Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective.

b. Orbitrol Valve Installation

1. Secure the steering valve to the steering column with four hex-flange capscrews and four lockwashers. Torque capscrews to 18 Nm (13 lb-ft).

2. Install the steering valve through the dash panel opening. Position steering valve in the cab, with the “LS” port pointing forward (a way from th e operato r).

3. Install b oth steerin g column pivot bolt s and nuts, insta ll the locking bolt f or t he st eerin g colu mn adj ustm ent, install the accessory lever and transmission control lever and connect the harness conn ector, install the display panel and connect the harness connector, install the steering wheel assembly . Torque the steerin g wheel nut to 25 Nm (18 lb-ft).

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4.3

Cab and Covers

MZ0230

Note: ALWAYS use new o-rings when servicing the machine.

4. Install new o-rings into the fitti ngs. Lubricate the o-ring s with clean hydraulic oil.

5. Connect the load sense hose to the “LS” port at the top of the steering valve.

6. Connect the four previously labeled hoses to the appropriate ports.

7. Connect the battery negative (-) cable or cables at the battery negative (-) terminal.

8. Carefully examine all connections one last time before engine start-up. Rectify any faulty conditions.

9. Start the engine and check t he op erat ion o f steer ing system. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

10. Install the lower dash panel.

11. Close and secure the engine cover.

6. Remove the circlip, flat washer , and the return spring securing the service brake pedal to the cab.

7. Remove the clip/pin from the brake plunger fork link.

8. Remove the service brake pedal from the cab.

d. Service Brake Pedal Installation

c. Steering Test

Conduct a pressure check of the steering hydraulic circuits at the main control valve. Refer to Section 8.4.1, “Hydraulic Pressures.”

4.3.2 Service Brake Pedal

a. Brake Valve Removal

Refe r to Sectio n 8.7.2, “Se rvice Brak e Valve, ” for re moval information.

b. Brake Valve Installation

Refer to Section 8.7.2, “Service Brake Valve,” for installation information.

c. Service Brake Pedal Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF.

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

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

4. Remove the battery negative (-) cable from the battery negative (-) terminal.

5. Remove the lower dash panel.

1. Position the service brake pedal in its mounting location within the cab.

2. Install the brake peda l being carefu l to repositio n the brake plunger yoke. Install the return spr ing, washer and clip. Install clip/pin in brake plunger fork link.

3. Adjust the brake pedal as needed.

4. Install and secu re th e low er dash cover.

5. Connect the battery negative (-) cable or cables to the battery negative (-) terminal.

6. Close and secure the engine cover.

4.3.3 Throttle Pedal

a. Throttle Pedal Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF.

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

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

4. Disconnect the battery negative (-) cable at the battery negative (-) terminal.

5. Remove three capscrews securing the throttle pedal assembly to the cab floor.

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6. Remove the hex jam nut and flat washer securing

MZ0460

MZ0470

the throttle cable to the throttle pedal assembly.

7. Remove the clip/pin from the fork link.

8. Remove the throttle pe da l a ssemb ly from the cab.

b. Throttle Pedal Installation

1. Install the hex jam nut and flat washer onto the end of the throttle cable. Secure the cable to the throttle pedal. Secure the cable to the throttle pedal, with the clip/pin.

2. Align the throttle pedal assembly with its mount holes in the cab floor.

3. Install three capscrews securing the throttle pedal assembly to the cab floor. Torque the capscrews to 12 Nm (9 lb-ft).

4. Connect the battery negative (-) cable to the battery negative (-) terminal.

5. Close and secure the engine cover.

c. Throttle Adjustment

1. From within the cab, lightly depress the accelerator pedal to the full-t hrottle position. As needed, adjust the limit-stop sc rew (1) until it touches the pedal. Tighten the locknut to 13,6-14,1 Nm (120-125 lb-in).

Cab and Covers

IMPORTANT: During the full throttle check:

• DO NOT operate any hydraulic function.

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in (N) NEUTRAL.

2. Check the engine rpm at full throttle. If the rpm is not 2200 +/- 50 rpm, readjust the throttle limit-stop screw at the throttle pedal within the cab.

4.3.4 Joystick Assembly

a. Joystick Assembly Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and turn the ignition OFF.

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

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

4. Remove the battery negative (-) cable from the battery negative (-) terminal.

5. Remove two capscrews. Remove the bottom cover.Disconnect the electrical connections and remove the four self-tapping screws from the bottom of the joystick assembly.

6. Remove the joystick assembly.

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4.5

Cab and Covers

b. Joystick Assembly Installation

1. Set the joystick assembly (1) into the armrest support.

2. Install the four self-tapping screws. Connect the electrical connections.

3. Test the boom extend/retract and boom lift/lower joystick function:

a. Move the joystick handle rearward, activating the

boom lift function. The boom should RISE.

b. Move the joystick handle forward, activating the

boom lower function. The boom should LOWER.

c. Move the joystick handle to the right, activating

the boom extend function. The boom should EXTEND.

d. Move the joystick handle to the left, activating the

boom retract function. The boom should RETRACT.

4. Install the bottom cover and secure using two lenshead capscrews.

5. Close and secure the engine cover.

Refer to Section 9.13, “Joystick,” for complete joystick functions.

4.3.6 Heater/Defroster System

a. Heater Assembly Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF.

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

3. Open the engine cover. Allow the system fluids to cool. Draining the cooling system while the engine block is hot can cause cracks in the engine block.

4. Remove the battery negative (-) cable from the battery negative (-) terminal.

5. Remove the eight bolts holding the engine belly pan and remove the belly pan.

6. Refer to Section 7.4, “Engine Cooling System,” for proper coolant draining.

7. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility.

Note: Label all hoses to ensure correct installation.

8. Remove the six ripp bolts and remove the cab bottom shield.

9. Label, disconnect and cap the two heater hoses.

10. Remove the heat duct hoses from back side of the heating unit assembly.

11. Carefully lower the heater assembly (2) by hand. Label and disconnect the wiring harness connections at the blower.

12. Remove the heater assembly.

4.3.5 Windshield Wiper Assembly

Refer to Section 9.9, “Window Wiper/Washer Windshield Wiper Motor,” for removal and installation information.

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b. Heater Assembly Installation

MZ0480

1. Connect the wir i ng ha rne ss co nn ect io ns to the blower.

2. Lift the heater assembly to the bottom of the cab floor, and secure with four ripp bolts, six lockwashers and six nuts. Connect the hoses to the heater. Secure with two hose clamps.

3. Fill the cooling system completely with a 50/50 mixture of ethylene glycol and water, allowing time for the coolant to fill the engine block. The cooling system capacity is lis ted in Section 2.4, “Fluids, Lubricants and Capaciti es.”

4. Connect the battery negative (-) cable to the battery negative (-) terminal.

IMPORTANT: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.

5. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.

6. Replace the cab bottom shield.

7. Replace the belly pan.

8. Close and secure the engine cover.

Cab and Covers

4.4 CAB REMOVAL

IMPORTANT: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.

Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact the JL G distributor or the JLG Service Department with any questions about the suitability or condition of a cab.

IMPORTANT: Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine.

1. Park the machine on a f irm, level surface. Allow sufficient overhead and side clearance for cab removal. Lower the boom, retract the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF.

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

3. Remove the battery negative (-) cable from the battery negative (-) terminal.

4. Remove the eight bolts holding the engine belly pan and remove the belly pan.

5. Refer to Section 7.4, “Engine Cooling System,” for proper coolant draining.

6. Transfer the coolant to a container with a cover, and label as “Used Antifreeze.” Dispose of the used coolant at an approved recycling facility.

7. Working under the cab, loosen and remove the six ripp bolts, remove the cab bottom shield.

Note: Label all hoses to ensure correct installation.

8. Loosen the hose clamps and disconnect the heater hoses.

9. Remove the lens-head screws and remove the console panel below the right side window to access the wire harness connections, the right rear side panel and the left rear cup holder panel to access the two rear cab mount bolts. Also remove the rubber floor mat to access the front two cab mount bolts

10. Disconnect the cab-to-wiring harness connectors at the circuit board. Push the harness connectors through the opening at the right front corner of the cab.

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4.7

Cab and Covers

MZ0660

MZ0640

Note: Record the location, and label all hoses to ensure correct installation.

11. Working under the cab, label and disconnect the hydraulic hoses at the cab fittings. Plug the hoses and cap the fittings.

12. Disconnect the throttle cable from under the cab.

13. Install two lifting eye bolts (1) with a suitable lifting capacity in the existing threaded holes at the top corners of the windshield.

14. Remove the four cab-to-frame bolts, f lat wa s hers a nd nuts (2).

15. Remove the mirrors and all other cab components as needed, if not previously removed.

16. Use a hoist or overhead crane and sling attached to the cab, carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.

17. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the frame.

18. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall over. Assure that no personnel enter the cab while it is being removed from the machine.

19. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

20. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

4.5 CAB INSTALLATION

1. Block all four wheels to help prevent the machine from moving. Assure t hat ther e is suf ficien t overhe ad and side clearance for cab installation.

2. Install two lifting eye bolts with a suitable lifting capacity in the existing threaded holes by the top corners of the windshield.

3. Use a hoist or overhead crane and sling attached to the two lifting eyes, carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation.

4. Install the four bolts through the cab/frame mounts and install the four washers and nuts. Remove the sling and both lifting eye bolts. Tighten and torque the four mounting bolts to 651 Nm (480 lb-ft).

5. Secure the throttle cable to the hydraulic hoses using wire ties.

6. Install the throttle cable on the throttle cable bracket, attach the clip/pin through the fork link.

7. Working under the cab, uncap and connect the hydraulic hoses at the cab fittings.

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8. Route any hoses through the opening at the right front corner of the cab.

9. Route the wiring harness connectors through the opening at the right front corner of the cab and up into the side console.

10. Connect the cab-to-wir i ng har ness conne ctors. 1 1. Install the right side console panel, the right rear side

panel, the left rear cup holder panel and the rubber floor mat.

12. Working under the cab, connect the coolant hoses to the heater hoses. Secure with two hose clamps.

13. Fill the cooling system completely with a 50/50 mixture of ethylene glycol and water, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, “Fluids, Lubricants and Capacities.”

14. Connect the battery negative (-) cable to the battery negative (-) terminal.

15. Carefully examine all cab components, fasteners, etc., one last time before engine start-up. Rectify any faulty conditions.

16. Start the engine and check the operat ion of all controls. Check for hydraulic fluid leaks. Check the hydraulic fluid level in the tank and add fluid as required.

17. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.

18. Replace engine belly pan.

19. Replace cab bottom cover.

20. Close and secure the engine cover.

Cab and Covers

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4.9

Cab and Covers

This Page Intentionally Left Blank

4.10

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Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.2 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.3 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.4 Axle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.1 Axle Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3.6 Axle Assembly and Drive Shaft T roubleshooting . . . . . . . . . . . . . . . . . . . 5.7

5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.4.4 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

5.5.1 Removing Wheel and Tire Assembly from machine. . . . . . . . . . . . . . . . . 5.12

5.5.2 Installing Wheel and Tire Assembly onto machine. . . . . . . . . . . . . . . . . . 5.12

5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

5.6.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

5.7 T owing a Disabled machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14

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5.1

Axles, Drive Shafts, Wheels and Tires

MZ0590

Front Axle

Assembly

Front Steering

Cylinder

Front Drive Shaft

Rear Drive Shaft

Rear Steering

Cylinder

Rear Axle Assembly

Transmission

Drop Box

Front Axle Wheel Hubs (2)

Rear Axle Wheel

Hubs (2)

Sway Cylinder

5.1 AXLE, DRIVE SHAFT AND WHEEL 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 names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.

5.2

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Axles, Drive Shafts, Wheels and Tires

MZ1050

5.2 GENERAL INFORMATION

IMPORTANT: T o help ensure optimum performance, the drive shaft assembli es are speciall y balanc ed as a un it at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts manua l for order ing inform ation.

Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear. Always replace elastic locknuts and any damaged, worn, cracked, seiz ed or otherw is e improp er parts that could affect the safe and proper functioning of the machine, axles and drive shafts.

5.3 AXLE ASSEMBLIES

5.3.1 Axle Service and Troubleshooting

This section provides an easy reference guide covering the most common problems that may occur during operation of the axles.

5.3.2 Axle Serial Number Plate

The front and rear axle serial number plate (1) is located on a mounting pad on the front side of the center section of each axle. Information on the serial number plate is required in correspondence regarding the axle.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

5.3.3 Axle Specifications

General axle specifications are found in Section 2, “General Information and Specifi cat ion s.” Axle (differential housing) fluid information is found in Section

2.4, “Fluids, Lubricants and Capacities.” Wheel end fluid information is found in Section 2.4, “Fluids, Lubricants and Capacities.”

5.3.4 Axle Maintenance

Note: Detailed axle service instructions (covering the

axle, differential, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are available by contacting your local JLG distributor for a copy of the Dana-Spicer Axle Repair Manual (P/N 31200162).

Note: Several special axle service tools are required to properly service the axle assemblies. Contact your local Dana-Spicer Service Cente r for orde ring information.

IMPORT ANT: When replacing a fastener, replace it with one of equal or higher grade and quality. Torque fasteners to the specified value for the application.

IMPORT ANT: The use of replacement parts provided by other than the original manufacturer is not recommende d, as such use may cause axle failure and af fe ct machine safety.

• Some service operations require the use of tools specifically designed for the purpose. Use the special tools when and as recommended.

• DO NOT pound, beat or hammer on end yokes and flanges to remove or to install them. Damage to axle component s can occur . Remove and install end yokes and flanges by following the recommended procedures in the appropriate Dana axle service manual.

• DO NOT attempt carrier and differential removal and installation, and differential and pinion disassembly and assembly, without thoroughly understanding the instructions in the appropriate Dana publications.

• Before disassembling any parts inside the carrier, remove the entire axle assembly from the machine and securely support it with the pinion facing up in an appropriate stand or rack.

• DO NOT reuse oil or grease seals.

CLEANING: Clean parts with machined or ground surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the

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5.3

Axles, Drive Shafts, Wheels and Tires

MZ1030

MZ1060

lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces.

DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, lightly coat components with oil or a rust-preventive chemical to help protect them from corrosion. If storing components for a prolonged period, wrap them in wax paper.

PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the machine far enough to cause the drivetrain components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity.

SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necessary.

IMPORTANT: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission cont rol lever in the (N) NEUTRAL, engage the park brake, straighten all wheels and shut the engine OFF.

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

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

4. Remove the battery negative (-) cable from the battery negative (-) terminal.

5. If the axle will be disassembled after removal, place a suitable receptacle under the axle (1) and wheel hubs (2) drain plugs. Remove the drain plugs and allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility.

Note: Use a suitable puller for bearing removal. Clean, inspect and lubricate all bearings just prior to reassembly. If replacement of a damaged bearing cup or cone is necessary, replace the cup and cone as a set.

5.3.5 Axle Removal

WARNING: An improperly suppor te d

machine can fall, causing death or severe personal injury. Safely raise and adequately support the machine so that it will remain stable and in place before attempting to remove an axle.

The front and rear axle assemblies differ in that the front axle assembly is equipped with a park brake mechanism and a limited-slip feature; the rear axle has neither. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly.

Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machi ne . Avoi d spraying water or cleaning solution on the stabilizer solenoids and other electrical components. If using a steam cleaner, seal all openings before steam cleaning.

6. Label, disconnect and cap the steering and brake lines at the axle. Wipe up any spilled oil.

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Axles, Drive Shafts, Wheels and Tires

7. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine will remain in place during axle removal before proceeding.

8. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal.

9. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine.

10. Mark and remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.5.1, “Removing Wheel and Tire Assembly from machine.”)

11. Remove the drive shaft assemblies. (Refer to Section

5.4.3, “Drive Shaft Removal.”)

12. On the front axle remove the capscrew and locknuts securing the sway cylinder rod end pin to the front axle. Tap the cylinder mount pin out, and move the sway cylinder to prevent it from interfering with axle removal.

13. Remove the four bolts and locknuts securing the axle to the frame.

14. Remove the axles from the machine using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axle. Balance the axle and prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand.

c. Axle Installation

The front and rear axle assemblies differ in that the front axle assembly is equipped with a park brake mechanism and limited-slip feature; the rear axle has neither. The steps below outline a typical axle installation procedure, suitable for eit her th e f ron t or t he rea r a xle assem bly.

1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine.

2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ens ure that the machine will remain in place during axle installation.

3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Kee p the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure.

4. Position the axle under the frame, and align the axle housings with the holes in the frame.

5. Install the four axle bolts and nuts. Tighten and torque to 550 - 600 Nm (406 - 443 lb-ft).

6. Move the sway cylinder into position on the axle cylinder anchor. Insert a mount pin through the cylinder rod and cylinder anchor. Secure the sway cylinder-mount pin with one capscrew and a new locknut.

7. Apply multi-purpose grease through the self-tapping lube fitting to lubricate the self-align bearing and the cylinder-mount pin.

8. Install the drive shaft assemblies. (Refer to Section

5.4.4, “Drive Shaft Installation.”)

9. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaft yoke on the axle in the same plane as the yoke on the transmission.

10. Install and tighten the three axle oil drain plugs, loosen and remove the axle oil fill plug (1). Fill the axle through the axle fill plug until the oil level is even with the oil check level plugs (2).

4017

5.5

Axles, Drive Shafts, Wheels and Tires

MZ1030

MZ1040

11. Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.

12. Rotate wheel hubs 90 degrees so the drain plug becomes the fill plug (3). Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.

21. Close and secure the engine cover.

13. Install the wheel and tire assemblies. (Refer to Section 5.5.2, “Installing Wheel and Tire Assembly onto machine.”)

14. Carefully remove the jack, hoist or overhead crane and sling supporting the axle.

15. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground.

16. Remove the blocks from the front and rear of both tires on the other axle.

Note: ALWAYS use new o-rings when servicing the machine.

17. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.

18. Uncap and connect the steering and brake lines at their axle fittings.

19. Check the hydraulic reservoir oil level.

20. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt function several times in both directions and check the function of the brakes. Check for hydraulic leaks, and tighten o r repair as necessary.

5.6

4017

Axles, Drive Shafts, Wheels and Tires

5.3.6 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

1. Oil level too low.

2. Axle and/or wheel end housings filled with inco rrect oil or oil level low.

3. Incorrect alignment of ring and pinion gears.

4. Incorrect pinion (input) shaft bearing preload.

5. Worn or damaged bearings.

6. Worn or broken gear teeth.

7. Cont amination in the axle.

8. Axle housing damaged.

1. Fill oil to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

2. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424® ISO Grade

46. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

3. Correct alignment by adding or removing shims as needed.

4. Correct bearing preload by adding or removing shims as needed.

5. Replace bearings as needed.

6. Replace gears as needed.

7. Drain axle and/or wheel end housings and fill to correct level with Mobilfluid 424® ISO Grade

46. (Refer toSection 2.4, “Fluids, Lubricants and Capacities.”)

8. Replace damaged parts.

2. Intermittent noise when traveling.

3. Vibration or intermittent noise when traveling.

1. Universal joint(s) worn or damaged.

2. Differential ring and/or pinion gears damaged.

1. Drive shaft universal joint assembly(ies) incor rec tly tightened.

2. Drive shaft universal joint(s) worn or damaged.

3. Drive shaft(s) damaged/ unbalanced.

1. Repair or replace universal joints as needed.

2. Determine cause and repair as needed.

1. Tighten capscrews to correct torque.

2. Repair or replace universal joints as needed.

3. Replace drive shaft(s) as needed.

4017

5.7

Axles, Drive Shafts, Wheels and Tires

5.3.6 Axle Assembly and Drive Shaft Troubleshooting (Continued)

Problem Cause Remedy

4. Oil leaking from axle (differential housing and/or axle housings).

1. Drain and/or inspection plugs loose and/or o-rings damaged or missing.

2. Hose fittings loose.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surfaces.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft).

2. Tighten fittings.

3. Replace seal and/or joint coupling fork shaft (axle shaft).

4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Dana-Spicer Repair Manuals.

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 390 Nm (288 lb-ft).

7. Replace housing(s) as needed.

5. Oil leaking from wheel end housing (planet carrier).

6. Oil leaking from steering cylinder.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose.

5. Housing (planet carri er) dama ged.

1. Hose fittings loose.

2. Steering cylinder o-rings and/or seals worn or damaged.

3. Piston rod seal worn or damaged.

4. Cylinder tube damaged.

1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft).

2. Replace o-ring.

3. Replace seal and/or fork joint shaft.

4. Tighten housing capscrews to 55 Nm (41 lb-ft).

5. Replace housing (planet carrier).

1. Tighten fittings.

2. Replace o-rings and seals.

3. Replace piston rod seal.

4. Replace cylinder tube.

5.8

4017

Axles, Drive Shafts, Wheels and Tires

5.3.6 Axle Assembly and Drive Shaft Troubleshooting (Continued)

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high.

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

8. High steering effort required. 1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

3. Worn or dam aged swivel bearings.

9. Slow steering response. 1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally.

10. Excessive noise when brakes are engaged.

1. Brake discs worn.

2. Brake discs damaged.

1. Fill oil to correct level with Mobilfluid 424® ISO Grade 46. (Refer toSection 2.4, “Fluids, Lubricants and Capacities.”)

2. Drain axle and fill to correct level with Mobilflu id 424® ISO Gra de

46. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Correct bearing preload by adding or removing shims as needed.

3. Replace swivel bearings as needed.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Repair or replace steering cylinder as needed.

1. Check brake discs for wear. (Refer to Section 5.6, “Brakes.”)

2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not operating properly.

2. Brake piston o-rings and seals damaged (leaking).

12. Brakes will not hold the machine or braking power reduced.

4017

1. Brake discs worn.

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Replace o-rings and seals.

1. Check brake discs for wear. (Refer to Section 5.6, “Brakes.”)

2. Refer to Section 8.4, “Hydraulic Circuits.”

3. Replace o-rings and seals.

5.9

Axles, Drive Shafts, Wheels and Tires

1. Yoke shaft (1)

2. Cross (2)

3. Yoke Flange (1)

4. Needle bearings and cap (8)

5. Snap ring (8)

6. Grease fitting (1)

7. Dust cap (1)

8. Washer (1)

9. Felt seal (1)

10. Slip yoke (1)

5.4 DRIVE SHAFTS

5.4.1 Drive Shaft Inspection and Service

Whenever servicing the machine, conduct a visual inspection of the drive shafts and cross and bearing assemblies (u niversal joints, or U -joints). A few mome nts spent doing th is ca n he lp pre ven t f urt h er pr ob lem s an d down time later.

Inspect areas where the drive shaft flange yokes and slip yokes mount to the drive shafts. Attempt to turn each drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise.

Individually inspect each cross the needle bearings and cap for signs of wear or for missing parts.

Note: Replace the cross and bearings as a complete assembly if any parts are worn or missing. If all parts of the cross and bearing assemblies are in good condition, pack the bearing caps with a premium grade of multipurpose wheel-bearing grease. Reattach the bearing cap to the cross, assuring that all needle bearings are present. Then, reassemble the cros s and bearing assembly into the drive shaft yoke.

1. Replace the felt seal if worn or damaged.

2. Replace the entire drive shaft assembly if any flange yoke, slip yoke or drive shaft tube is severely dented or damaged.

3. Cross assemblies should flex and be free from excessive binding. A slight amount of drag or resistance is desirable on a new cross and bearing assembly. Excessive looseness causes unbalance.

5.10

4017

Axles, Drive Shafts, Wheels and Tires

Mt0350

To Axle

To Transmission

5.4.2 Drive Shaft Maintenance

Refer to Section 2.6, “Lubrication Schedules,” for information regarding the lubrication of the grease fittings on the drive shafts.

5.4.3 Drive Shaft Removal

IMPORTANT: T o help ensure optimum performance, the drive shaft assembli es are speciall y balanc ed as a un it at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Ref er to the a ppropriate parts manual fo r or d erin g i nfo r mat ion.

Note: The drive shaft assemblies are balanced assemblies. Mark the yoke and axle, transmission, transfer case, and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

a. Transmission-to-Axle Drive Shaft

1. Level the m achin e, re trac t the boom, lowe r t he b oom, place the transmission control lever in the (N) NEUTRAL, engage the park brake switch and shut the engine OFF.

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

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

4. Remove the battery negative (-) ground cable from the battery negative (-) terminal.

5. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that th es e compo ne nts can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

6. Remove t he four capscrew s and t wo stra ps securi ng the bearing cross to the transmission output shaft flange.

7. Remove t he four capscrew s and t wo stra ps securi ng the bearing crosses to the axle.

8. Remove the front drive shaft assembly.

9. Repeat the above procedure on the rear drive shaft.

5.4.4 Drive Shaft Installation

IMPORT ANT: T o help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent or damaged. Refer to the appropriate parts man ual for order ing infor mation.

a. Transmission-to-Axle Drive Shafts

1. Raise the drive shaft assembly into position. The slip-yoke end of the drive shaft mounts toward the axle. If reinstalling a drive shaft previously removed, align the flan ge yoke s ac cord in g to the alignment marks made during removal.

IMPORT ANT: Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

2. Install the four capscrews and two straps securing the bearing crosses to the transmission. Torque the capscrews to 81 Nm (60 lb-ft).

3. Install the four capscrews and two straps securing the bearing crosses to the axle. Torque the capscrews to 81 Nm (60 lb-ft).

4. Repeat the above procedure on the rear drive shaft.

5. Connect the battery negative (-) cable at the battery negative (-) terminal.

6. Close and secure the engine cover.

4017

5.11

Axles, Drive Shafts, Wheels and Tires

Mh3300

5.5 WHEELS AND TIRES

5.5.1 Removing Wheel and Tire Assembly from machine

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, enga ge the park brake, straighten all whee ls and shut the engine OFF.

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

3. Remove the battery negative (-) cable from the battery negative (-) terminal.

4. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.

5. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly.

6. Lower the machine onto the support.

7. Remove lug nuts and lug washers in an alternating pattern.

8. Remove the wheel and tire assembly from the machine.

5.5.2 Installing Wheel and Tire Assembly onto machine

IMPORTANT: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.

1. Position wheel onto studs on wheel end of axle.

2. Install wheel lug washers.

3. Install lug nuts and tighten in an alternating pattern. Torque to 583 to 637 Nm (430 to 470 lb-ft).

4. Raise the machine, remove the supports and lower machine to the ground.

5. Connect the battery negative (-) cable at the battery negative (-) terminal.

6. Close and secure the engine cover.

5.12

4017

Axles, Drive Shafts, Wheels and Tires

OH2690

1000

MT2840

MZ1030

5.6 BRAKES

5.6.1 Brake Disk Inspection.

Check the brake disks for wear every 1,000 hours of operation or yearly.

If the brake disks require service due to wear, the axle should be checked,

serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

a. Front and Rear Axles

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake, straighten all wheels and shut the engine OFF.

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

3. Remove the battery negative (-) cable from the battery negative (-) terminal.

7. Using a feeler gauge, check the gap (1) between the brake disks. if the gap (2) is less than 4,5 mm (0.18 in), replace the brake disks.

Note: If the brake disks are worn beyond their tolerance, the brake disk must be replaced on both sides of the axle at the same time.

WARNING: BLOCK ALL FOUR

WHEELS. Failure to do so could result in death or serious injury from machine r oll-away

4. Block all four wheels to help prevent the machine from moving after the park brake is disabled.

5. Remove the oil-level plug on each side of the axle.

6. Have an assistant sit in the cab and apply the brakes, keeping pressur e appl ie d.

8. Repeat steps 3 and 4 for the other side of the axle.

9. Fill the axle with Mobilfluid 424® ISO Grade 46 through the axle fill hole (3) until the oil level is even with both axle level holes (4).

10. Fill axle slowly, the oil has to run across the differential. Allow time for the oil to run across the differential. Axle level is correct when oil is up to both level plugs. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

4017

5.13

Axles, Drive Shafts, Wheels and Tires

MZ1020

Top View

5.7 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power, before using the emergency towing procedures outlined belo w.

IMPORTANT: Block the wheels of the machine BEFORE attempting to release the park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable.

5.7.2 Manually Resetting the Park Brake

IMPORTANT: Block the wheels of the machine BEFORE attempting to reset the machine’s park brake. Once the park brake is reset the machine’s park brake AND service brakes are operable.

1. Loosen the jam nuts on all four manual brake release bolts.

2. Turn all four manual brake release bolts OUT a quarter turn at a time to the dimension recorded before starting the towing procedure.

3. Tighten the jam nuts on all four manual brake release bolts.

4. After repairs to the machine have been made, start the machine and check the park brake and service brakes for proper function.

5.7.1 Manually Releasing the Park Brake

1. Measure the distance from the bolt head to the face of the jam nut on all four of the manual brake release bolts (1) located on each side of the front axle center section (two per side). Record the measurements.

2. Loosen the jam nuts on the four manual brake release bolts

3. Turn all four release bolts in equally with a wrench or socket BY HAND a quarter turn at a time up to approximately 19 mm (.750 in) or until resistance is felt. T ighten the jam nuts.

Note: Turning the release bolts in to far could warp the brake discs. DO NOT over tighten.

IMPORTANT: After the machine has been towed to a secure location, reactivate the park brake. Carefully follow the procedures from start to finish. Consult your local JLG distributor or the JLG Service Department if you are unsure about any part of the procedure, or for specific instructions concerning your particular situation.

5.14

4017

Section 6

Transmission:

Contents

PARAGRAPH TITLE PAGE

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

6.4.1 Transmission General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5.2 Transmission Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.6 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.6.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

6.6.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.5

6.6.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

6.6.4 After Transmission Service or Replacement. . . . . . . . . . . . . . . . . . . . . . . 6.6

6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

6.7.1 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

4017

6.1

Transmission:

MZ0670

Transmission Drop Box

Flex Plate Assembly

Oil Filter

Dipstick and Fill Tube

Shift Solenoids

Torque Converter

Output Shaft

(front)

Output Shaft

(rear)

Breather

Drop Box Oil Level

Sight Gauge

Oil Fill Plug

6.1 TRANSMISSION ASSEMBL Y 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 names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.

6.2

4017

Transmission:

6.2 TRANSMISSION DESCRIPTION

Instructions in this section p erta in mai nly to ge ne ral specifications, towing, m ainte nan ce i nf ormat ion , and transmission removal and installatio n pro ce dures .

Note: Instructions in this section pertain mainly to genera l specifications, towing, m ainte nan ce i nf ormat ion , and transmission removal and installatio n pro ce dures . For internal transmission service instructi ons and detailed spe ci fi ca t ions contact your local JLG distributor for a copy of the Dana-Spicer Transmission Repair Manual (P/N 31200163).

6.3 TRANSMISSION SERIAL NUMBER

The transmission serial number plate is located on the front of the transmission case below the converter housing. Information specified on the serial number plate includes the transmission model number, the transmission serial numbe r and other data . Informati on on the serial number plate is required in correspondence regarding the transmission.

6.4 TRANSMISSION SPECIFICATIONS

6.4.1 Transmission General Specifications

General transmission specifications are found in Section

2.4, “Fluids, Lubricants and Capacit ies.” Performance criteria is based on full throttle engine

speed unless otherwise specified or not applicable.

6.5 TRANSMISSION MAINTENANCE

6.5.1 Transmission Maintenance

Cleanliness is of extreme importance. Before attempting any repairs, thoroughly clean the exterior of the transmission to help prevent dirt from entering while performing maintenance checks and procedures.

Section 6.5.2, “Transmission Maintenance Schedule,” provides a suggested maintenance schedule with references to pertinent procedures and instructions in this manual. To help prevent transmission problems before they occur, follow the maintenance schedule.

6.5.2 Transmission Maintenance Schedule

Complete transmission maintenance information is located in the appropriate Operator & Safety Manual.

• At ten hour intervals, check the transmission oil level.

• When the machine completes its first 50 hours of use, change the transmission oil and filter.

• At 1,000 hour intervals, change the transmission oil and filter.

Periodically, depending on operating conditions and other factors, back flush the transmission oil cooler, which is located in or behind the radiator. ALWAYS back flush the transmission oil cooler after removing the transmission for repair or replaceme nt.

The transmission oil cooler outlet hose, routed to the lower oil cooler fitting, is located on the top of the transmission. The transmission oil cooler inlet hose, routed to the upper oil cooler fitting, is located on the top of the transmission. (Refer to Section 7.4.3, “Radiator/Oil Cooler and Replacement.”)

Disconnect and back flush the oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil and compressed air until all foreign material is removed. If necessary, remove the radiator or oil cooler from the machine, and clean the oil cooler circuit using oil, compressed air and steam.

IMPORTANT: DO NOT use flushing com pounds for cleaning purposes.

6.6 TRANSMISSION REPLACEMENT

Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period.

IMPORTANT: To help ensure safety and optimum performance, replace the transmission if it is damaged. Refer to the appropriate parts manual for ordering information.

Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other elect rica l com pon ents .

4017

6.3

Transmission:

MZ1380

MZ1330

6.6.1 T ransmission Removal

WARNING: Risk of severe personal

injury. NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling.

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF.

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

3. Open the engine cover and allow the system fluids to cool.

4. Remove engine cover.

5. Remove belly pan from under engine.

6. Drain the hydraulic oil reservoir . Refer to Section 8.5, “Hydraulic Reservoir.”

7. Disconnect both battery cables and remove the battery.

8. Thoroughly clean the transmission and surrounding area, including all hoses and fittings, before proceeding.

9. Place a suitable receptacle under the transmission drain plug. Remove the transmission drain plug (1), and allow the transmission oil to drain into the receptacle. Repeat drain procedure with the drop box (2).

10. Transfer the used transmission oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission and drop box drain plug.

11. Remove the drive shafts. Refer to Section 5.4.3, “Drive Shaft Removal.”

12. Remove air cleaner unit and intake tubes.

13. Remove the hydraulic pu m p. Re fe r to Sec ti o n 8. 6 . 3, “Pump Replacement.”

14. Label and disconnect the transmission temperature switch connector and sh ift sol en oid wiring harness connectors.

15. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission. The transmission oil cooler outlet hose, routed to the lower radiator fitting, is located on the top of the transmission. The transmission oil cooler inlet hose, routed to the upper radiator fitting, is located on top of the transmission.

16. Remove the access plug from side of the engine bell housing. This will allow access to remove the eight bolts holding the flex plate to the engine flywheel.

17. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Remove them one at a time.

18. Wipe up any spilled hydraulic and transmission oil.

19. Connect a lifting strap or chain to the lifting eye at the top of the transmission, and to a suitable hoist or overhead crane. Operate the hoist or crane to remove slack from the chain , but DO N OT raise the transmission at this time.

20. Place blocks under rear of engine for support BEFORE transmission mounts are removed

21. Place blocks under the transmission to help support it during removal.

22. Remove both rear transmission mount bolts and lockwashers securing the transmission mount to the frame.

6.4

4017

Transmission:

MZ0680

23. Remove the ten bolts and washers holding the transmission to the engine.

24. Remove the four capscrews and four lockwashers securing each rear transmission mount to the transmission.

25. Remove the two tra nsm issi on mo unts from the machine.

26. Inspect the rubber mounts. Replace the mounts if damaged.

27. Carefully remove the tr ansmission f rom the machi ne. Avoid causing damage to the transmission or surrounding parts.

28. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so that it will not move or fall.

29. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmissi on ope nin gs .

30. Remove the transmission oil filter (1) and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount.

31. If transmission oil is suspect of contamination or torque converter is damaged, remove the converter and flex plate from the transmission.

32. Remove the six bolts and washers holding the converter to the flex plate.

6.6.2 T ransmission Inspection and Internal Repair

The converter is now ready for inspection and/or further service. If replacing the entire transmission, transfer the transmission temperature switch to the replacement transmission. The gear shift solenoids are included with a new transmission.

For internal service, refer to the Dana Spicer Transmission Repair Manual (P/N 31200163).

6.6.3 Transmission Installation

1. Install both the rear transmission mounts on the transmission. Torque capscrews to120 Nm (88 lb-ft).

2. Install two guide studs near the top of the bell housing holes.

3. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis.

4. Align the torque converter, align the transmission bolt holes with the two studs in the bell housing. Install the eight bolts and washers and torque to 63 Nm (46 lb-ft). Remove the two alignment studs and install and torque the last two transmission mounting bolts.

5. Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers. Apply Loctite bolts and torque to 210 N m (155 lb- ft).

6. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Install them one at a time. Torque to 35-39 Nm (26-29 lb-ft). Replace access plug.

7. Remove the hoist or overhead crane and sling.

8. Connect the transmission temperature switch connector and shift solenoid wiring harness connectors.

9. Secure the wiring harness to the transmission housing.

10. Uncap and connect the transmission oil cooler inlet and outlet hoses at the tran smission.

1 1. Install the hydraulic pump. Refer to Section 8.6.3,

“Pump Replacement.”

12. Install drive shafts. Refer to Section 5.4.4, “Drive Shaft Installation.”

13. Install air cleaner and tubing.

14. Clean the transmission oil filter mounting surface.

242 threadlock to the transmission moun t

4017

6.5

Transmission:

MZ0680

15. Apply a thin film of clean Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46) to the new transmission filter gasket. Install the new filter and torque to 27-34 Nm (20-25 lb-ft).

16. Transmission oil may be added through the dipstick tube (1). Remove the dipstick and add approximately

11,4 liters (3 Gallons) of Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46). Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operator & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.

17. Transmission Transfer Case (Drop Box) oil may be added through the fill plug (2). Remove the fill plug and add approximately 1,4 liters (1.5 Quart) of

Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46). Check the oil level at sight gauge (3) directly below the fill plug.

18. Install the engine cover and belly pan.

19. Install and connect the battery cables on the battery.

6.6.4 After Transmission Service or Replacement

In general:

1. Check the transmission oil level and add oil as required.

2. Install a new transmission filter.

3. Check the torque on the drive shaft yoke capscrews.

4. Wear suitable eye protection. When an overhauled or repaired transmission is installed, thoroughly clean the oil cooler lines to and from the transmission.

5. Drain and flush the entire system.

6. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning.

7. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.

8. Back flush the transmission oil cooler portion of the radiator or the oil cooler (located behind the radiator) with oil and compressed air until all foreign material is removed. Flushing in the direction of normal oil flow does not adequately clean the cooler. If needed, remove the radiator or oil cooler from the machine.

9. Reassemble all components and fill the transmission

with clean, fresh Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46) through the dipstick tube opening (1). Remove the dipstick and fill with approximately

11,4 liters (3 gallons) of Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46). Check the level by taking intermittent dipstick readings as outlined in the appropriate Operator & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.

10. Transmission Transfer Case (Drop Box) oil may be added through the fill plug (2). Remove the fill plug and add approximately 1,4 liters (1.5 Quart) of

Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46). Check the oil level at sight gauge (3) directly below the fill plug.

11. Run the engine for two minute s at idle to help prime the torque converter and the transmission oil lines.

12. Recheck the level of the fluid in the transmission with the engine running at idle.

13. Add Mobilfluid 424

Tractor Hydraulic Fluid (ISO 46) as necessary to bring the fluid level up until it reaches the FULL mark on the dipstick. Recheck the oil level when it reaches operating temperature 83-94° C (180-200° F).

14. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.

6.6

4017

6.7 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission.

Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period.

6.7.1 Transmission Troubleshooting

The transmission should be checked, serviced and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

Problem Cause Remedy

Transmission:

1. Transmission will not engage or will not shift properly.

2. Low or no pump flow or pressure.

1. Oil level too high or low.

2. Transmission control lever not functioning properly and/or a fault in the wiring harness.

3. Transmission valve body solenoids not functioning properly.

4. Pilot-operated shift valves not operating properly.

5. Pump output pres sure low.

6. Clutch piston o-rings damaged.

7. Clutch discs worn or damaged.

8. Coupling shafts or gear teeth damaged.

1. Low oil level.

2. T ransmission fille d with incorrect oil, or oil contaminated.

3. Pump suction pipe screen clogged.

4. Central shaft damaged.

5. Pump worn or damaged.

1. Fill transmission to correct level. (Refer to the appropriate Operator & Safety Manual.)

2. Refer to Section 9.5.1, “Cab Harness Electric al Schematic.”

3. Refer to Section 9.5.1, “Cab Harness Electric al Schematic.”

4. Clean the valve spool and housing. Replace return spring as needed.

5. Refer to Section 6.7.1, “Transmission Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”

6. Replace o-rings.

7. Replace clutch discs.

8. Replace couplings.

1. Fill transmission to correct level. (Refer to the appropriate Operator & Safety Manual.)

2. Drain transmission and fill to correct level. (Refer to Section

2.4, “Fluids, Lubricants and Capacities.”)

3. Clean, repair and/or replace suction pipe.

4. Replace central shaft.

5. Repair or replace pump assembly.

4017

6.7

Transmission:

6.7.1 T ransmission Tro ubleshooting (Continued)

Problem Cause Remedy

3. Low clutch pressure. 1. Incorrect oil level.

2. Main pr es su re v al ve s t uc k op e n.

3. Broken or worn coupling shaft or piston o-rings.

4. Pressure reducing valve stuck open.

4. Lack of power. 1. Park or service brake dragging.

2. Low engine rpm causes converter stall.

3. Pump output pressure is low.

4. Clutch discs worn or damaged.

5. Transmission overheating.

1. Fill tran smission t o correct lev el. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Clean the valve spool and housing.

3. Replace co upling and/or o-ring s.

4. Clean the valve spool and housing.

1. Refer to Section 8.4, “Hydraulic Circuits.”

2. Adjust the engine rpm to specifications. Refer to Perkins Service Manual.

3. Refer to Section 6.7.1, “Transmission Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”

4. Replace clutch discs.

5. Refer to Section 6.7.1, “Transmission Troubleshooting,” Problem 5. “Transmission overheating, oil above 120° C (248° F).”

5. Transmission overheating, oil above 120° C (248° F).

6.8

1. Low oil level.

2. Clogged radiator.

3. Transmission filled with incorrect oil, or oil contaminated.

4. Excessive “roading.”

5. Restriction in oil cooler hoses.

6. Pump worn or damaged.

7. Engine thermostat stuck.

1. Fill tran smission t o correct lev el. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Remove debris from the radiator.

3. Drain transmission and fill to correct level. Refer to Section

2.4, “Fluids, Lubricants and Capacities.”

4. Stop and idle the engine.

5. Replace cooler hoses.

6. Repair or replace pump assembly.

7. Replace engine thermostat. Refer to Section 7.4.2, “Thermostat Replacement.”

4017

6.7.1 Transmission Troubleshooting (Continued)

Problem Cause Remedy

Transmission:

6. Grinding or “clunking” noise from transmission.

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil

1. Oil level too low.

2. T ransmission fille d with incorrect oil.

3. Incorrect clutch engagement.

4. Internal damage.

5. Broken diaphragm (flex plate).

6. Loose diaphragm (flex plate) mounting capscrews.

level).

2. Drain plug loose and/or o-rings damaged or missing.

3. Hose fittings loose.

4. Oil leaking at valve bodies (possible valve body gaskets damaged or missing and/or mounting capscrews not tight).

5. Housing capscrews loose.

6. Oil leaking at pump (possible pump-to-housing o-rings missing or damaged, and/or pump mounting capscrews not tight).

7. Oil leaking at converter bell (possible converter leak and/or input shaft seal damage).

8. Oil leaking at output shaft (output shaft seal damaged).

9. Housing damaged.

1. Fill oil to correct level. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Drain transmission and fill to correct level. Refer to Section

2.4, “Fluids, Lubricants and Capacities.”

3. Refer to Section 9.11.3, “Transmission Solenoid Valves.”

4. Repair or replace parts as needed.

5. Replace diaphragm (flex plate). Refer to Section 6.6.1, “Transmission Removal.”

6. Tighten capscrews.

1. Remove drain plug and drain oil as needed, until oil is at correct level. Refer to Section 2.4, “Fluids, Lubricants and Capacities.” Replace o-rings as needed and tighten plugs to 35 Nm (26 lb-ft).

2. Replace o-rings as needed and tighten plug to 35 Nm (26 lb-ft).

3. Tighten fittings.

4. Replace gaskets and/or tighten capscrews to 9,5 Nm (84 lb-in).

5. Tighten capscrews to 46 Nm (34 lb-ft).

6. Replace o-rings and/or tighten capscrews to 115 Nm (85 lb-ft).

7. Replace converter and/or input shaft seal.

8. Replace output shaft seal.

9. Replace housing as needed.

4017

6.9

Transmission:

This Page Intentionally Left Blank

6.10

4017

Section 7

Engine: Perkins 1004-40T

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.1.2 Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

7.2 Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4.3 Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

7.7.1 Exhaust System Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.8.2 Air Cleaner Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.9 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.9.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7.11

7.9.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

7.10 Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

7.10.1 Drive Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

7.10.2 Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

4017

7.1

Engine: Perkins 1004-40T

7.1 INTRODUCTION

7.1.1 Disclaimer and Scope

These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to the local Perkins Engine Distributor and the applicable Perkins Engine Service Manual for assistance with comprehensive engine diagnosis, repair and component replacement. A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 60° C (140° F). Extended light-load operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.

7.2

4017

7.1.2 Component Terminology

MZ0070

Fuel Filter

Oil Filter

Alternator

Starter

Thermostat

Turbocharger

Fuel Injection

Pump

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.

Engine: Perkins 1004-40T

4017

7.3

Engine: Perkins 1004-40T

MZ0080

7.2 ENGINE SERIAL NUMBER

The Perkins 1004-40T serial number Is stamped on a plate which is secured to the engine block, near the fuel injector pump. Information contained in the serial number is required in correspondence with the engine manufacturer.

7.3 SPECIFICATIONS AND MAINTENANCE INFORMATION

For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specification s . ”

Note: Detailed Perkins engine se rvic e ins tru ct io ns (covering disassembly, inspection, internal repair, assembly, adjustment and troubleshooting information) are provided in the appropriate Perkins engine service manual.

7.4 ENGINE COOLING SYSTEM

7.4.1 Radiator Pressure Cap

For a 99° C (210° F) system, use a .9 kPa (13 psi) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine.

a. Thermostat Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in NEUTRAL (N), engage the park brake and shut off the engine.

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

3. Open the engine cover. Allow the system fluids to cool. Draining the cooling system while the engine is hot can cause cracks in the engine block.

4. Remove the negative (-) battery cable from the battery negative (-) terminal.

5. Slowly turn the radiator cap (1) to the first stop and allow any pressure to escape. Remove the radiator cap.

6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug (2) and slowly remove to allow the coolant to drain. Drain approximately two liters (2 quarts) of coolant. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Reinstall and tighten the drain plug.

7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the coolant level, fan belt tension and instrument cluster temperature indicator.

• If the engine seems to take a long time to warm up, the thermostat may be stuck in the open position and requires replacement.

• If the engine runs hot, check the temperature of the upper radiator hose.

• If the hose is not hot, the thermostat may be stuck in the closed position.

• If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage.

7. Remove the two capscrews securing the thermostat housing to the engine.

8. Remove the thermostat housing, old gasket and thermostat. Clean all gasket surfaces. DO NOT let any debris into the thermostat opening.

IMPORTANT: ALWAYS use the correct thermostat and install a new ga sk et. NEVER operate the engine without a thermostat, or engine damage will result.

7.4

4017

b. Thermostat Installation

1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the two capscrews. Torque to 24 Nm (18 lb-ft).

2. Connect the negative (-) battery cable to the battery negative (-) terminal.

3. Open the radiator cap, and fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system.

4. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary.

5. Close and secure the engine cover.

7.4.3 Radiator/Oil Cooler and Replacement

Engine: Perkins 1004-40T

Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator.

• If the engine runs hot, check the temperature of the upper radiator hose.

• If the hose is not hot, the thermostat may be stuck in the closed position.

• If the engine has overheated, performance may suffer, indicating ot her da mag e i ncluding a le akin g cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage.

a. Radiator/Oil Cooler Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in NEUTRAL (N), engage the park brake and shut off the engine.

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

3. Open the engine cover. Allow the system fluids to cool. Draining the cooling system while the engine is

6. Remove the radiator guard cover (3) and the lower engine protective cover.

7. Disconne ct an d pl ug th e ho ses to th e o ver f lo w bot t le . Remove the three bolts holding the overflow bottle bracket and remove the overflow bottle.

8. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap.

9. Place a suitable container beneath the radiator drain.

10. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug (4) and slowly remove to allow the coolant to drain. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Replace the radiator drain plug.

11. Loosen the radiator clamp on the top radiator hose (5). Work the hose off the radiator. Position the hose out of the way to allow radiator removal, or remove the hose from the engine. Inspect the hose, and replace if necessary.

hot can cause cracks in the engine block.

4. Remove the negative (-) battery cable from the battery negative (-) terminal.

5. Remove engine cover to ease removal of radiator/oil cooler.

4017

7.5

Engine: Perkins 1004-40T

12. Loosen clamp on the lower radiator hose (6). Work the hose off the radiator. Position the hose out of the way to allow radiator removal, or remove the hose from the engine. Inspect the hose, and replace if necessary.

13. Disconnect and plug the transmission inlet (7) and outlet hoses (8) and cap the fittings on the oil cooler. Remove the clamp holding the top transmission cooler hose and the three bolts holding the fan screen.

14. Remove the four nuts and four washers from the four radiator mounts (9 ).

15. Connect a lifting strap to the radiator/oil cooler and carefully lift the radiator/oil cooler out of the engine bay.

Note: If applicable the radiator can be removed with the radiator frame. Remove the five bolts holding the radiator frame to the machine frame and remove the radiator and radiator frame as one unit.

b. Radiator/Oil Cooler Installation

Note: AL WAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening.

1. Install the isolator mounts to the bottom of the radiator. Insert radiator through the machine frame mounts and install the washers and new elastic locknuts.

2. At the top of the radiator, install the isolator mounts. Install the washers and new elastic locknuts on the back side of the weldment.

3. At the lower radiator return hose, and with the clamp installed over the hose, work the hose onto the radiator, and tighten the clamp.

4. Uncap and connect transmission inlet and outlet hoses to the radiator.

5. At the upper radiator hose, and with the clamp installed over the hose, work the hose onto the radiator, and tighten the clamp.

6. Install the radiator overflow bottle and reconnect the overflow hoses.

7. Open the radiator cap and fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system.

8. Connect the negative (-) battery cable to the battery negative (-) terminal.

9. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary.

10. Install the engine belly pan.

11. Install, close and secure the engine cover.

7.5 ENGINE ELECTRICAL SYSTEM

The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9.5, “Electrical System Schematics.”

7.6 FUEL SYSTEM

7.6.1 Diesel Fuel

Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair.

Note: Use only diesel fuel designed for diesel engines. Some heating fuels contain harmful chemicals that can seriously affect engine efficiency and performance.

IMPORTANT: Due to the precise to lerances of diesel injection systems, keep the fuel clean, and free of dirt and water. Dirt and water in the fuel syste m ca n cau se severe damage to both the injection pump and the injection nozzles. Use ASTM #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smoking.

Inform the owner/operator of the machine to use #2 diesel fuel, unless ambient temperatures are below 0° C (32° F). When temperatures are below 0° C (32° F), a blend of #1 diesel and #2 diesel fuels (known as “winterized” #2 diesel) may be used.

Note: #1 diesel fuel may be used, however, fuel economy will be reduced.

Use a low-sulfur content fuel with a cloud point (the temperature at which wax crystals form in diesel fuel) at least 10° below the lowest expected fuel temperature. The viscosity of the fuel must be kept above 1.3 centistrokes to provide adequate fuel system lubrication.

Note: When using diesel fuel with a sulfur content below

1.3 percent, the filter change interval must be reduced by

7.6

4017

Engine: Perkins 1004-40T

MZ0100

75 hours. The use of fuel with a sulfur content above

1.3 percent is not recommended.

5. Remove fuel tank drain plug (1), and drain fuel into an approved and suitable container. Dispose of fuel properly.

6. Loosen and remove the strap (2) over the fuel tank and disconnect the fuel supply hose (3) and return line hose (4) from tank.

7. Disconnect fuel level sender electrical connectors from the fuel level sender (5).

8. Remove screws securing fuel sender to the tank. Remove fuel sender from tank.

9. Lift the empty fuel tank from between the frame rails.

b. Disassembly

The fuel tank is a one-piece unit and cannot be disassembled. The fuel le vel indicator can be removed and reused on the new replacement tank.

c. Cleaning and Drying

If contaminated fuel or foreign material is in the tank, the tank can usually be cleaned.

7.6.2 Fuel Tank

Note: The fuel tank is a one piece unit. It is located at the rear of the machine, between the frame. If it i s determined that the fuel tank must be removed, the fuel must be drained before tank removal. Always dispose of fuel properly.

a. Fuel Tank Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in NEUTRAL (N), engage the park brake and shut off the engine.

2. Install the safety support on the lift/lower cylinder rod.

Note: The support is located at the left front corner of the frame.

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

4. Remove the negative (-) battery cable from the battery negative (-) terminal.

Note: If replacing the tank, remove all internal and external components from the old tank, and retain for use on the replacement tank.

Note: Have a dry chemical (Class B) fire extinguisher near the work area.

To clean the fuel tank:

1. Have a dry chemical (Class B) fire extinguisher near the work area.

2. Remove the fuel or oil tank drain plug, and safely drain any fuel into a suitable container. Dispose of fuel properly.

3. Clean the fuel tank with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly.

4. Add a diesel fuel emulsifying agent to the tank. Refer to the manufacturer’s instructions for the correct emulsifying agent-to-water mixture ratio. Refill the tank with water, and agitate the mixture for 10 minutes. Drain the tank completely. Dispose of contaminated water properly.

5. Refill the fuel tank with water until it overflows. Completely flush the tank with water. Empty the fuel tank, and allow it to dry completely.

d. Assembly

The fuel level ind icat or can be removed a nd r eus ed on th e new r eplacement tank. Dispose of the old tank according to local regulations concerning hazardous materials disposal regulations.

Note: If a leak is suspected in the fuel tank, contact a JLG Distributor.

4017

7.7

Engine: Perkins 1004-40T

MZ0110

e. Inspection

1. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other damage.

2. With the fuel tank removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately, 07-1 kPa (1-1.5 psi) of air pressure through the elbow. Check the reservo ir f or le aks by ap p ly in g a so ap so l ut i on t o the exterior and look for bubbles to appear at the cracked or damaged area.

f. Fuel Tank Installation

1. Set fuel tank between frame rails.

2. Install the fuel tank strap over the fuel tank.

3. Install the fuel sender with new gasket into the fuel tank and secure with screws. DO NOT overtighten.

4. Connect the fuel supply hose and return line hose to the tank. Secure with clamps.

5. Install the wire harness connections to the fuel sender.

Note: AL WAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening.

6. Fill the fuel tank according to specifications.Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

7. Check fuel tank for leaks.

8. Connect the negative (-) battery cable to the negative battery terminal.

9. Close and secure the engine cover.

7.6.3 After Fuel System Service

7.7.1 Exhaust System Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in NEUTRAL (N), engage the park brake and shut off the engine.

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

3. Open the engine hood. Allow the system fluids to cool.

4. Remove the ne gative (-) battery cable f rom the negative (-) battery terminal.

5. Remove the engine belly pan.

6. Loosen and remove the three nuts from the exhaust pipe at the exhaust manifold.

Note: Replace the three nuts and the three exhaust manifold studs if damaged.

7. Disconnect and remove the clamp attaching the exhaust pipe to the frame under the engine.

8. Disconnect and remove the clamp connecting the muffler and the exhaust pipe.

9. Disconnect and remove the clamp connecting the tail pipe to the muffler and remove the tail pipe.

10. Loosen and remove the two bolts at the front and one bolt at the rear of the muffler, and remove the muffler.

7.7.2 Exhaust System Installation

Note: Keep all clamps loosened until entire exhaust system is in place.

1. Drain and flush the fuel tank if it was contaminated.

2. Vent air from the fuel system in accordance with the instructions found in the appropriate Perkins Engine Service Manual.

3. Fill the fuel tank with fresh, clean d iesel fuel as required.

7.7 ENGINE EXHAUST SYSTEM

WARNING: Exhaust fumes contain

carbon monoxide, a colorless, odorless gas which is fatal when inhaled in a confined area. Avoid breathing exhaust fumes, and prevent engine operation from becoming a cause of toxic emissions. Exhaust system components reach high temperatures and can cause severe burns. DO NOT come into contact with hot exhaust system components.

7.8

1. Install the exhaust pipe with a new seal to the exhaust manifold.

Note: Replace the three nuts and the three exhaust manifold studs if damaged.

2. Install the exhaust pipe clamp under the engine.

4017

Engine: Perkins 1004-40T

MZ0120

3. Install the muffler to the exhaust pipe and bolt the muffler to the side of the frame.

4. Install the clamp securing the muffler to the exhaust pipe.

5. Install the clamp securing the muffler to the tail pipe.

6. Adjust the muffler, exhaust and tail pipes for proper clearance then tighten all clamps.

7. Connect the negative (-) battery cable to the negative (-) battery terminal.

8. Start engine and check for exhaust leaks at all exhaust connections. Adjust or repair as needed.

9. Install the belly pan.

7.8 AIR CLEANER ASSEMBLY

CAUTION: NEVER run the engine with

only the inner safety element installed.

IMPORTANT: Refer to the appropriate Operator & Safety Manual for your machine for the correct element change procedure.

6. Remove the two capscrews and ripp nuts securing the air cleaner mounting bracket to the air cleaner mounting plate. Remove the air cleaner assembly.

7.8.2 Air Cleaner Assembly Installation

Note: Apply Loctite® 242 threadlock to the capscrew threads before installati on.

1. With the air cleaner assembly attached, install the air cleaner mounting bracket using capscrews and ripp nuts.

2. Place the loosened clamps over the air intake elbow along with the reducing insert and the reinforcement ring, and install elbow on the air cleaner assembly.

3. Place the loosened clamps over the air outlet elbow and install elbow on the air cleaner assembly.

4. Connect low pressure indicator wire connection.

5. Adjust and tighten both clamps before starting the machine.

6. Close and secure the engine cover.

7.9 ENGINE REPLACEMENT

7.8.1 Air Cleaner Assembly Removal

1. Open the engine cover.

2. Disconnect low pressure indicator wire connection.

3. Remove the clamp securing the air intake elbow to the air cleaner assembly. Lift the air intake elbow off the air cleaner.

4. The reducing insert and the reinforcement ring should be removed along with the air intake tube.

5. Remove the clamp securing the air outlet elbow. Lift the air outlet elbow off the air cleaner.

7.9.1 Engine Removal

Note: The radiator and oil cooler must be removed from the machine before engine removal. Refer to Section

7.4, “Engine Cooling System.” Several additional components must be removed before engine removal. They will be addressed in the follow ing procedures.

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in NEUTRAL (N), engage the park brake and shut off the engine.

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

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

Note: ALWAYS replace elastic locknuts with new elastic locknuts to help ensure proper fastening.

4. Remove the engine cover, radiator guard plate and the engine belly pan.

5. Remove the radiator overflow bottle and hoses.

6. Refer to Section 7.4.3, “Radiator/Oil Cooler and Replacement,” to remove the radiator/oil cooler.

7. Loosen the clamps on each heater hose on the engine. Plug the heater hoses if necessary.

4017

7.9

Engine: Perkins 1004-40T

MZ0940

MZ0950

Note: The engine harness is routed and attached to the engine using hold-down clamps and plastic wire ties at various places on the engine. Before removing engine, ensure that the harness has been completely separated (disconnected) from the engine. Move the harness clear of the engine, and with the help of an observer, ensure that engine clears the harness during removal.

8. Label and disconnect all wire har ness connect ion s o n the engine.

9. Unbolt and remove the hood latch plate. Mark the plate to help with hood adjustment when being reinstalled.

10. Unbolt the return hydraulic oil filter plate and leave in place.

11. Disconnect the fuel inlet line at the fuel filter head. Install a plug in the end of fuel inlet line.

12. Disconnect the fuel return line from the fuel filter head. Install a plug in the end of fuel return line.

13. Mark the location of the throttle cable (1) at the throttle cable mount (2). Loosen jam nuts and remove.

14. Disconnect the throttle cable at the engine throttle pedal.

15. Remove the three nuts holding the exhaust pipe to the exhaust manifold. Remove the exhaust pipe from the exhaust manifold.

16. Loosen the clamps on the sleeve reducer at the engine and on the air suction pipe.

17. Disconnect the wire connection at the low air pressure indicator.

18. Loosen and remove the three bolts on the air cleaner mount plate, then remove the complete air cleaner assembly.

19. Remove the access plug from side of the engine bell housing. This will allow access to remove the eight bolts holding the flex plate to the engine flywheel.

20. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Remove them one at a time.

21. At the front right engine mount (3) remove the bolt and washer. Repeat for the front left engine mount.

7.10

4017

22. Place a support or jack under the transmission to

MZ0960

hold the transmission in place while engine is being removed.

23. Attach a l i f t ing cha i n t o t h e f r o nt and r e a r engine lift brackets (4).

24. Remove the ten bolts holding the transmission to the engine. Slightly lift and pull the engine forward to clear the transmission. Slowly lift and pull the engine out of the machine. Have an assistant ensure that the engine clears all frame components during removal.

25. Place engine on a flat, level surface.

7.9.2 Engine Disassembly, Inspection and

Service

Engine disassembly, internal inspection, service, repair and assembly procedures are covered in the Perkins 1004-40T service manual. Contact the local Perkins parts distributor for further information.

Note: If the engine is being replaced, there may be external components that will be required to be transfe rred from the original engine to the replacement engine depending upon who you purchase the new engine from and the configuration of your replacement engine. Refer to the appropriate Perkins user manual fo r detailed p rocedures that cover the transfer of original engine components to the replacement engine.

Engine: Perkins 1004-40T

7.9.3 Engine Installation

1. Attach a lifting chain to the front and rear engine lift brackets (4), and lift engine clear of the ground.

Note: Apply Loctite bracket capscrew threads before installation.

Note: The engine harness is routed and attached at various places on the engine using hold-down clamps and plastic wire ties. Before installing engine and with the help of an observer, ensure that engine clears the harness during installation.

2. Inspect the front engine mounting bracket isolator. Replace isolator if cracked or worn.

3. Install two guide studs in the bell housing holes.

4. Lift the engine and slowly push and lower into the engine bay. Have an assistant ensure that the engine clears all frame, hose and harness components during engine installation. Position engine brackets over the front frame mounts.

5. Push the engine back towards the transmiss io n aligning the guide studs and the torque converter shaft with the corresponding holes.

6. Push the engine against the transmission and install eight of the ten bolts and washers. Remove both guide studs and replace with the remaining two bolts and washers. Tighten bolts.

7. Torque the ten (10) transmission bolts to 63 Nm (46 lb-ft) AFTER engine is lowered and secured with the front motor mount bolts installed and torque.

8. Remove the support from under the transmission and lower the engine the remainder of the way onto the frame. Align the motor mount holes and install the bolts. Apply Loctite mount bolts and torque to 210 Nm (155 lb-ft).

9. Turn the engine over slowly by hand and align each of the eight flex plate bolts through the access hole in the bell housing. Install them one at a time. DO NOT fully tighten until all of the capscrews and locknuts are in place.

10. Torque to 35-39 Nm (26-29 lb-ft). Replace access plug.

11. Install the exhaust pipe to the exhaust manifold. Refer to Section 7.7.2, “Exhaust System Installation.”

12. Install the complete air cleaner assembly. Refer to Section 7.8.2, “Air Cleaner Assembly Installation.”

13. Install and tighten the jam nuts on the throttle cable at the throttle cable mount.

14. Connect the throttle cable at the engine throttle lever.

242 threadlock to the engine m ount

242 threadlock to the motor

4017

7.11

Engine: Perkins 1004-40T

MZ0970

15. Connect the fuel inlet line to the fuel filter head.

16. Connect the fuel return line to the fuel filter head.

17. Connect all the labeled wire harness connections on the engine.

18. Install the hood latch plate. Align the mark on the plate to help with hood adjustment.

19. Secure the return hydraulic oil filter plate to the frame.

20. Install both heater hoses to the engine and tighten clamps.

21. Install the complete radiator assembly (1) and tighten the four bolts

22. Install the hose clamp on the bottom radiator hose and work onto the engine. Tighten the clamp.

23. Install the hose clamp on the top radiator hose and work onto the engine. Tighten the clamp.

24. Connect the transmission inlet and outlet hoses on the oil cooler (2). Install the clamp holding the top transmission cooler hose and the three bolts holding the fan screen.

28. Check that all hydraulic system, electrical system, cooling system, fuel system, and exhaust system connections are correct and connected tightly

29. From within the cab, lightly depress the throttle pedal to full-throttle position. As needed, adjust the limitstop screw until it to uc he s the pe da l. Tighten the locknut to 13,6-14,1 Nm (120-125 lb-in).

Note: Have an assistant stand by with a Class B fire extinguisher.

30. Run engine to normal o perating te mperatu re then shut of f the engine. While the engine is cooling, check for leaks.

31. Allow the engine to cool. Check the radiator coolant level, and top off with a 50/50 mixture of ethylene glycol and water. Replace the radiator cap.

32. Check for leaks from the engine, main hydraulic pump and lines, transmission, hydraulic reservoir and fuel tank. Check the levels of all fluids and lubricants. Fill as required.

IMPORTANT: During the full throttle check:

• DO NOT operate any hydraulic function.

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in NEUTRAL (N).

33. Obtain and connect an appropriate engine analyzer or tachometer. Check the engine rpm at full throttle. If the rpm is not 2200 +/- 50 rpm, readjust the throttle limit-stop screw at the throttle pedal within the cab.

34. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level.

35. Check for proper operation of all components.

36. Turn the engine OFF.

37. Install the engine belly pan.

38. Close and secure the engine cover.

25. Install and adjust the engine cover .

26. Connect the negative (-) battery cable to the battery negative terminal.

27. Open the radiator cap and fill the radiator completely with a 50/50 mixture of ethylene glycol and water. Replace and tighten the radiator cap. Add coolant to the overflow bottle until the bottle is 1/4 to 1/2 full. This overfilling will compensate for any air trapped in the cooling system.

7.12

4017

Engine: Perkins 1004-40T

MZ0580

Drive Plate

Assembly

Drive Plates

Ring

7.10 ENGINE DRIVE PLATE

7.10.1 Drive Plate Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

Note: In order to remove the engine drive plates, the engine and transmission must be separated.

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

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

4. Remove the battery negative (-) cable from the battery negative terminal.

5. Refer to Section 6.6.1, “Transmission Removal,”or Section 7.9.1, 7.9.1. “Engine Removal.”

2. Mount the drive plate/converter assembly to the transmission.

3. Refer to Section 6.6.3, “Transmission Installation,”or Section 7.9.3, “Engine Installation,” for the remainder of the installation.

4. Connect the battery negative (-) cable to the battery negative terminal.

5. Close and secure the engine cover.

6. Remove the eight bolts holding the drive plates to the flywheel.

7. With the drive plates and torque converter removed, loosen and remove the six bolts and six lock washers holding the three drive plates to the torque converter.

8. Replace all three drive plates if damaged.

7.10.2 Drive Plate Installation

1. Install the three new drive plates on the torque converter and torque the six bolts with lock washers to 35-39 Nm (26-29 lb-ft).

4017

7.13

Engine: Perkins 1004-40T

7.11 TROUBLESHOOTING

T rouble Possible Causes (see key, below)

Low Cranking Power Will Not Start Difficult Starting Lack of Power Misfiring Excessive Fuel Consumption Black Exhaust Blue/White Exhaust Low Oil Pressure Knocking Erratic Running Vibration High Oil Pressure Overheating Excessive Crankcase Pressure Poor Compression Starts and Stops

1, 2, 3, 4 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62 4, 36, 37, 38, 39, 40, 42, 43, 44, 58 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49 4, 38, 41 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57 25, 31, 33, 34, 45, 55, 60 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59 10, 11, 12

Key to Possible Causes

1. Battery charge low

2. Bad electrical connection

3. Faulty starter motor

4. Incorrect grade of lubricating oil

5. Low cranking speed

6. Fuel tank empty

7. Faulty stop control operation

8. Fuel inlet restricted

9. Faulty fuel lift pump

10. Clogged fuel filter

11. Restricted air cleaner

12. Air in fuel system

13. Faulty fuel injection pump

14. Faulty fuel injectors or incorrect type

15. Incorrect use of cold start equipment

16. Faulty cold start equipment

17. Broken fuel injection pump drive

18. Incorrect fuel pump timing

19. Incorrect valve timing

20. Poor compression

21. Blocked fuel tank vent

22. Incorrect grade of fuel

23. Sticking throttle or restricted movement

24. Exhaust pipe restric tio n

25. Leaking cylinder head gasket

26. Overheating

27. Cold running

28. Incorrect tappet adju st men t

29. Sticking valves

30. Incorrect high pressure pipes

31. Worn cylinder bores

32. Pitted valves and seats

33. Broken, worn or sticking piston ring(s)

34. Worn valve stems and guides

35. Restricted air cleaner

36. Worn or damaged bearings

37. Insufficient oil in sump

38. Inaccurate gauge

39. Oil pump worn

40. Pressure relief valve sticking open

41. Pressure relief valve sticking closed

42. Broken relief valve spring

43. Faulty suction pipe

44. Restricted oil filter

45. Piston seizure/pick up

46. Incorrect piston heigh t

47. Damaged fan

48. Faulty engine mounting

49. Incorrectly aligned flywheel housing or incorrectly aligned flywheel

50. Faulty thermostat

51. Restriction in water jacket

52. Loose fan belt

53. Restricted radiator

54. Faulty water pump

55. Restricted breather pipe

56. Damaged valve stem oil deflectors (if fitted)

57. Coolant level too low

58. Blocked sump strainer

59. Broken valve spring

60. Exhauster or vacuum pip e leak

61. Turbo impeller damaged or dirty

62. Turbo lubricating oil seal leak

63. Induction system lea ks

7.14

4017

JLG 4017 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 INTRODUCTION

1.2 DISCLAIMER

1.3 OPERATOR & SAFETY MANUAL

1.4 ACCIDENT PREVENTION TAGS

1.5 SAFETY INFORMATION

1.5.1 Safety Alert System and Signal Words

1.6 SAFETY INSTRUCTIONS

1.6.1 Personal Hazards

1.6.2 Equipment Hazards

1.6.3 General Hazards

1.6.4 Operational Hazards

1.7 EMERGENCY EXIT REAR WINDOW

1.8 SAFETY DECALS

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

2.2 TORQUES

2.2.1 ASTM Fastener Torque Chart (English)

2.2.2 ASTM Fastener Torque Chart (Metric)

2.2.3 Metric Fastener Torque Chart

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

2.3.2 Engine Performance Specifications

2.3.3 Hydraulic Cylinder Performance

2.3.4 Tires

2.3.5 Axles

2.3.6 Electrical System

2.4 FLUIDS, LUBRICANTS AND CAPACITIES

2.5 SERVICE AND MAINTENANCE SCHEDULES

2.5.1 8 & 1st 50 Hour Maintenance Schedule

2.5.2 50, 250 & 500 Hour Maintenance Schedule

2.5.3 1000 & 1500 Hour Maintenance Schedule

2.6 LUBRICATION SCHEDULES

2.6.2 50 Hour Lube Schedule

2.6.1 8 Hour Lube Schedule

3.1 BOOM SYSTEM COMPONENT TERMINOLOGY

3.2 BOOM SYSTEM

3.2.1 Boom System Operation

3.3.1 Boom Removal

3.3 BOOM ASSEMBLY MAINTENANCE

3.3.2 Second, Third & Fourth Boom Sectio n Removal

3.3.3 Third & Fourth Boom Section Removal

3.3.4 Fourth Boom Section Removal

3.3.5 Hose Carrier Removal

3.3.6 Hose Carrier Installatio n

3.3.7 Fourth Boom Section Installation

3.3.8 Third & Fourth Boom Section Installation

3.3.9 Second, Third & Fourth Boom Section Installation

3.3.10 Boom Installation

3.4.1 Boom Chain Inspection

3.4.2 Inspection Guidelines

3.4.3 Expose Chains for Inspection

3.4.4 Chain Lubrication

3.5 BOOM SECTION SEPARATION ADJUSTMENT

3.6 HOSE CARRIER ASSEMBLY

3.6.1 Hose Carrier Assembly Removal

3.6.2 Hose Carrier Assembly Replacement

3.7 BOOM WEAR PADS

3.7.1 Wear Pad Inspection

3.7.2 Boom Wear Pad Replacement

3.7.3 Boom Wear Pad Lubrication

3.8 QUICK SWITCH ASSEMBLY

3.8.2 Connecting with a Hydraulic Quick Switch Device

3.8.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment

3.8.4 Quick Switch Removal

3.8.5 Quick Switch Installation

3.9 TROUBLESHOOTING

4.1 OPERATOR’S CAB AND COVERS COMPONENT TERMINOLOGY

4.2 OPERATOR’S CAB

4.2.1 Cab Safety

4.2.2 Serial Number Decal

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

4.3.2 Service Brake Pedal

4.3.3 Throttle Pedal

4.3.4 Joystick Assembly

4.3.6 Heater/Defroster System

4.3.5 Windshield Wiper Assembly