JLG 4017RS Parts Manual
31200939 3614RS, 4017RS 3
4 3614RS, 4017RS 31200939
31200939 3614RS, 4017RS 5
TABLE OF CONTENTS
SECTION 1 - FRAME & ATTACHING PARTS ................................................................................................................................... 13
FIGURE 1-1. FRAME INSTALLATION - 3614RS .......................................................................................................................... 14
FIGURE 1-2. FRAME INSTALLATION - 4017RS ........................................................................................................................... 16
FIGURE 1-3. ENCLOSURE GROUP INSTALLATION ................................................................................................................... 18
FIGURE 1-4. MIRROR INSTALLATION - 3614RS ......................................................................................................................... 20
FIGURE 1-5. MIRROR INSTALLATION - 4017RS ......................................................................................................................... 22
FIGURE 1-6. MIRROR ASSEMBLY ............................................................................................................................................... 24
FIGURE 1-7. BOOM PROP INSTALLATION ................................................................................................................................. 26
FIGURE 1-8. WHEEL CHOCK INSTALLATION ............................................................................................................................. 28
FIGURE 1-9. COUNTERWEIGHT INSTALLATION - 3614RS ....................................................................................................... 30
FIGURE 1-10. COUNTERWEIGHT INSTALLATION - 4017RS ..................................................................................................... 32
FIGURE 1-11. HOOD ASSEMBLY ................................................................................................................................................. 34
FIGURE 1-12. SOUND SUPPRESSION INSTALLATION .............................................................................................................. 36
FIGURE 1-13. CHASSIS COVER PLATE INSTALLATION - 3614RS ............................................................................................ 38
FIGURE 1-14. CHASSIS COVER PLATE INSTALLATION - 4017RS ............................................................................................ 40
FIGURE 1-15. LICENSE PLATE INSTALLATION .......................................................................................................................... 42
FIGURE 1-16. RETRIEVAL HITCH ................................................................................................................................................ 44
FIGURE 1-17. HYDRAULIC TANK INSTALLATION ...................................................................................................................... 46
SECTION 2 - BOOM .......................................................................................................................................................................... 49
FIGURE 2-1. BOOM INSTALLATION - 3614RS (NO AUXILIARY HYDRAULICS) ........................................................................ 50
FIGURE 2-2. BOOM INSTALLATION - 3614RS (AUXILIARY HYDRAULICS) .............................................................................. 52
FIGURE 2-3. BOOM INSTALLATION - 4017RS (NO AUXILIARY HYDRAULICS) ........................................................................ 54
FIGURE 2-4. BOOM INSTALLATION - 4017RS (AUXILIARY HYDRAULICS) .............................................................................. 56
FIGURE 2-5. BOOM ASSEMBLY - 3614RS (NO AUXILIARY HYDRAULICS) .............................................................................. 58
FIGURE 2-6. BOOM ASSEMBLY - 3614RS (AUXILIARY HYDRAULICS) ..................................................................................... 60
FIGURE 2-7. BOOM ASSEMBLY - 4017RS (NO AUXILIARY HYDRAULICS) .............................................................................. 62
FIGURE 2-8. BOOM ASSEMBLY - 4017RS (AUXILIARY HYDRAULICS) ..................................................................................... 64
FIGURE 2-9. EXTEND CHAIN ASSEMBLY - 3614RS ................................................................................................................... 66
FIGURE 2-10. EXTEND CHAIN ASSEMBLY (1) - 4017RS ............................................................................................................ 68
FIGURE 2-11. EXTEND CHAIN ASSEMBLY (2) - 4017RS ............................................................................................................ 70
FIGURE 2-12. RETRACT CHAIN ASSEMBLY - 3614RS ............................................................................................................... 72
FIGURE 2-13. RETRACT CHAIN ASSEMBLY (1) - 4017RS ......................................................................................................... 74
FIGURE 2-14. RETRACT CHAIN ASSEMBLY (2) - 4017RS ......................................................................................................... 76
FIGURE 2-15. COVER PLATE INSTALLATION - 3614RS ............................................................................................................ 78
FIGURE 2-16. COVER PLATE INSTALLATION - 4017RS ............................................................................................................ 80
FIGURE 2-17. FIRST BOOM SECTION - 3614RS ......................................................................................................................... 82
FIGURE 2-18. FIRST BOOM SECTION - 4017RS ......................................................................................................................... 84
FIGURE 2-19. SECOND BOOM SECTION - 3614RS .................................................................................................................... 86
FIGURE 2-20. SECOND BOOM SECTION - 4017RS .................................................................................................................... 88
FIGURE 2-21. THIRD BOOM SECTION - 3614RS ........................................................................................................................ 90
FIGURE 2-22. THIRD BOOM SECTION - 4017RS ........................................................................................................................ 92
FIGURE 2-23. FOURTH BOOM SECTION - 4017RS .................................................................................................................... 94
FIGURE 2-24. HOSE SUPPORT ASSEMBLY - 4017RS ............................................................................................................... 96
FIGURE 2-25. MANUAL QUICK ATTACH ..................................................................................................................................... 98
FIGURE 2-26. HYDRAULICS INSTALLATION - 3614RS (NO AUXILIARY HYDRAULICS) ........................................................ 100
FIGURE 2-27. HYDRAULICS INSTALLATION - 3614RS (AUXILIARY HYDRAULICS) .............................................................. 102
FIGURE 2-28. HYDRAULICS INSTALLATION - 4017RS ............................................................................................................ 104
FIGURE 2-29. HYDRAULICS ASSEMBLY - 4017RS ................................................................................................................... 106
FIGURE 2-30. HYDRAULICS INSTALLATION - 4017RS (AUXILIARY HYDRAULICS) .............................................................. 108
SECTION 3 - ATTACHMENTS ........................................................................................................................................................ 111
FIGURE 3-1. CARRIAGE ............................................................................................................................................................. 112
FIGURE 3-2. FORKS .................................................................................................................................................................... 114
FIGURE 3-3. BUCKET ................................................................................................................................................................. 116
FIGURE 3-4. MULTI-PURPOSE BUCKET ................................................................................................................................... 118
FIGURE 3-5. TRUSS BOOM ........................................................................................................................................................ 120
SECTION 4 - ENGINE & ATTACHING PARTS ............................................................................................................................... 123
FIGURE 4-1. ENGINE AND TRANSMISSION INSTALLATION (ULS) ......................................................................................... 124
FIGURE 4-2. ENGINE AND TRANSMISSION INSTALLATION (LS) ........................................................................................... 126
FIGURE 4-3. ENGINE MOUNTING INSTALLATION ................................................................................................................... 128
31200939 3614RS, 4017RS 7
TABLE OF CONTENTS
FIGURE 4-4. HYDRAULIC PUMP INSTALLATION ...................................................................................................................... 130
FIGURE 4-5. TURBO SHIELD INSTALLATION ............................................................................................................................ 132
FIGURE 4-6. FUEL LINES INSTALLATION .................................................................................................................................. 134
FIGURE 4-7. FUEL TANK INSTALLATION .................................................................................................................................. 136
FIGURE 4-8. FUEL TANK ............................................................................................................................................................. 138
FIGURE 4-9. COOLING SYSTEM INSTALLATION ...................................................................................................................... 140
FIGURE 4-10. EXPANSION TANK ASSEMBLY ........................................................................................................................... 142
FIGURE 4-11. RADIATOR ASSEMBLY ........................................................................................................................................ 144
FIGURE 4-12. TRANSMISSION COOLING INSTALLATION ....................................................................................................... 146
FIGURE 4-13. HEATER LINES INSTALLATION .......................................................................................................................... 148
FIGURE 4-14. AIR SYSTEM INSTALLATION .............................................................................................................................. 150
FIGURE 4-15. AIR FILTER ASSEMBLY ....................................................................................................................................... 152
FIGURE 4-16. AIR INTAKE FILTER ............................................................................................................................................. 154
FIGURE 4-17. EXHAUST SYSTEM INSTALLATION (ULS) ......................................................................................................... 156
FIGURE 4-18. EXHAUST SYSTEM INSTALLATION (LS) ............................................................................................................ 158
SECTION 5 - DRIVETRAIN .............................................................................................................................................................. 161
FIGURE 5-1. AXLE INSTALLATION - 3614RS ............................................................................................................................. 162
FIGURE 5-2. AXLE INSTALLATION (NO FOAM FILL) - 4017RS ................................................................................................. 164
FIGURE 5-3. AXLE INSTALLATION (FOAM FILL) - 4017RS ....................................................................................................... 166
FIGURE 5-4. DRIVE SHAFT INSTALLATION - 3614RS .............................................................................................................. 168
FIGURE 5-5. DRIVE SHAFT INSTALLATION - 4017RS .............................................................................................................. 170
FIGURE 5-6. FRONT AXLE - 3614RS .......................................................................................................................................... 172
FIGURE 5-7. FRONT AXLE, CENTRAL HOUSING - 3614RS ...................................................................................................... 174
FIGURE 5-8. FRONT AXLE, DIFFERENTIAL - 3614RS ............................................................................................................... 176
FIGURE 5-9. FRONT AXLE, HUB REDUCTION - 3614RS .......................................................................................................... 178
FIGURE 5-10. FRONT AXLE, BRAKES - 3614RS ....................................................................................................................... 182
FIGURE 5-11. FRONT AXLE, STEERING - 3614RS .................................................................................................................... 184
FIGURE 5-12. FRONT AXLE, TRUNION - 3614RS ...................................................................................................................... 186
FIGURE 5-13. FRONT AXLE - 4017RS ........................................................................................................................................ 188
FIGURE 5-14. FRONT AXLE, CENTRAL HOUSING - 4017RS .................................................................................................... 190
FIGURE 5-15. FRONT AXLE, DIFFERENTIAL - 4017RS ............................................................................................................. 192
FIGURE 5-16. FRONT AXLE, HUB REDUCTION - 4017RS ........................................................................................................ 194
FIGURE 5-17. FRONT AXLE, BRAKES - 4017RS ....................................................................................................................... 198
FIGURE 5-18. FRONT AXLE, STEERING - 4017RS .................................................................................................................... 200
FIGURE 5-19. FRONT AXLE, TRUNION - 4017RS ...................................................................................................................... 202
FIGURE 5-20. REAR AXLE - 3614RS, 4017RS (NO FOAM FILL) ............................................................................................... 204
FIGURE 5-21. REAR AXLE, CENTRAL HOUSING - 3614RS, 4017RS (NO FOAM FILL) ........................................................... 206
FIGURE 5-22. REAR AXLE, DIFFERENTIAL - 3614RS, 4017RS (NO FOAM FILL) .................................................................... 208
FIGURE 5-23. REAR AXLE, HUB REDUCTION - 3614RS, 4017RS (NO FOAM FILL)................................................................ 210
FIGURE 5-24. REAR AXLE, BRAKES - 3614RS, 4017RS (NO FOAM FILL) ............................................................................... 214
FIGURE 5-25. REAR AXLE, STEERING - 3614RS, 4017RS (NO FOAM FILL) ........................................................................... 216
FIGURE 5-26. REAR AXLE, TRUNION - 3614RS, 4017RS (NO FOAM FILL) ............................................................................. 218
FIGURE 5-27. REAR AXLE - 4017RS (FOAM FILL)..................................................................................................................... 220
FIGURE 5-28. REAR AXLE, CENTRAL HOUSING - 4017RS (FOAM FILL) ................................................................................ 222
FIGURE 5-29. REAR AXLE, DIFFERENTIAL - 4017RS (FOAM FILL) ......................................................................................... 224
FIGURE 5-30. REAR AXLE, HUB REDUCTION - 4017RS (FOAM FILL) ..................................................................................... 226
FIGURE 5-31. REAR AXLE, BRAKES - 4017RS (FOAM FILL) .................................................................................................... 230
FIGURE 5-32. REAR AXLE, STEERING - 4017RS (FOAM FILL) ................................................................................................ 232
FIGURE 5-33. REAR AXLE, TRUNION - 4017RS (FOAM FILL) .................................................................................................. 234
FIGURE 5-34. POWERSHIFT TRANSMISSION .......................................................................................................................... 236
FIGURE 5-35. POWERSHIFT TRANSMISSION, CONVERTER HOUSING ................................................................................ 238
FIGURE 5-36. POWERSHIFT TRANSMISSION, TRANSMISSION PLATE ................................................................................. 240
FIGURE 5-37. POWERSHIFT TRANSMISSION, TORQUE CONVERTER .................................................................................. 242
FIGURE 5-38. POWERSHIFT TRANSMISSION, GEAR GROUP ................................................................................................ 244
FIGURE 5-39. POWERSHIFT TRANSMISSION, PUMP DRIVE .................................................................................................. 246
FIGURE 5-40. POWERSHIFT TRANSMISSION, CHARGE PUMP .............................................................................................. 248
FIGURE 5-41. POWERSHIFT TRANSMISSION, REVERSE IDLER ............................................................................................ 250
FIGURE 5-42. POWERSHIFT TRANSMISSION, FORWARD & REVERSE SHAFT .................................................................... 252
FIGURE 5-43. POWERSHIFT TRANSMISSION, 3RD SHAFT ..................................................................................................... 254
FIGURE 5-44. POWERSHIFT TRANSMISSION, 1ST & 2ND SHAFT .......................................................................................... 256
FIGURE 5-45. POWERSHIFT TRANSMISSION, OUTPUT SHAFT ............................................................................................. 258
FIGURE 5-46. POWERSHIFT TRANSMISSION, DROP BOX ...................................................................................................... 260
FIGURE 5-47. POWERSHIFT TRANSMISSION, CONTROL ....................................................................................................... 262
FIGURE 5-48. POWERSHIFT TRANSMISSION, MODULATION VALVE .................................................................................... 264
FIGURE 5-49. POWERSHIFT TRANSMISSION, DRIVE PLATE ................................................................................................. 266
8 3614RS, 4017RS 31200939
TABLE OF CONTENTS
FIGURE 5-50. TIRE WHEEL SET, MITAS 15.5/80-24 - 3614RS ................................................................................................. 268
FIGURE 5-51. RH MITAS WHEEL - 3614RS ............................................................................................................................... 270
FIGURE 5-52. LH MITAS WHEEL - 3614RS ................................................................................................................................ 272
FIGURE 5-53. TIRE WHEEL SET, MITAS 14.00-24 - 4017RS .................................................................................................... 274
FIGURE 5-54. RH MITAS WHEEL - 4017RS ............................................................................................................................... 276
FIGURE 5-55. LH MITAS WHEEL - 4017RS ................................................................................................................................ 278
FIGURE 5-56. TIRE WHEEL SET, GOODYEAR 15.5-25 SGL - 3614RS .................................................................................... 280
FIGURE 5-57. RH GOODYEAR WHEEL - 3614RS ..................................................................................................................... 282
FIGURE 5-58. LH GOODYEAR WHEEL - 3614RS ...................................................................................................................... 284
FIGURE 5-59. TIRE WHEEL SET, GOODYEAR 14.00-24 - 4017RS .......................................................................................... 286
FIGURE 5-60. RH GOODYEAR WHEEL - 4017RS ..................................................................................................................... 288
FIGURE 5-61. LH GOODYEAR WHEEL - 4017RS ...................................................................................................................... 290
FIGURE 5-62. TIRE WHEEL SET, MICHELIN 400/80-24 POWER CL - 3614RS ........................................................................ 292
FIGURE 5-63. RH MICHELIN WHEEL - 3614RS ......................................................................................................................... 294
FIGURE 5-64. LH MICHELIN WHEEL - 3614RS.......................................................................................................................... 296
FIGURE 5-65. TIRE WHEEL SET, MICHELIN - 4017RS ............................................................................................................. 298
FIGURE 5-66. MICHELIN WHEEL - 4017RS ............................................................................................................................... 300
FIGURE 5-67. TIRE WHEEL SET, FIRESTONE 370/75-28 - 3614RS ......................................................................................... 302
FIGURE 5-68. FIRESTONE WHEEL - 3614RS ............................................................................................................................ 304
FIGURE 5-69. TIRE WHEEL SET, FIRESTONE 400/75-28 16 PLY - 4017RS ............................................................................ 306
FIGURE 5-70. FIRESTONE WHEEL - 4017RS ............................................................................................................................ 308
FIGURE 5-71. FOAM FILLED WHEEL SET - 3614RS ................................................................................................................. 310
FIGURE 5-72. RH FOAM WHEEL - 3614RS ................................................................................................................................ 312
FIGURE 5-73. LH FOAM WHEEL - 3614RS ................................................................................................................................ 314
FIGURE 5-74. FOAM FILLED WHEEL SET - 4017RS ................................................................................................................. 316
FIGURE 5-75. RH FOAM WHEEL - 4017RS ................................................................................................................................ 318
FIGURE 5-76. LH FOAM WHEEL - 4017RS ................................................................................................................................ 320
SECTION 6 - CAB ............................................................................................................................................................................ 323
FIGURE 6-1. CAB INSTALLATION (FNR LEVER) ....................................................................................................................... 324
FIGURE 6-2. CAB INSTALLATION (NO FNR LEVER) ................................................................................................................ 326
FIGURE 6-3. CAB (FNR LEVER) ................................................................................................................................................. 328
FIGURE 6-4. CAB (NO FNR LEVER) ........................................................................................................................................... 330
FIGURE 6-5. CAB ASSEMBLY .................................................................................................................................................... 332
FIGURE 6-6. CAB......................................................................................................................................................................... 334
FIGURE 6-7. FUEL DOOR INSTALLATION ................................................................................................................................. 336
FIGURE 6-8. DOOR STRAP INSTALLATION .............................................................................................................................. 338
FIGURE 6-9. INTERIOR MIRROR ............................................................................................................................................... 340
FIGURE 6-10. MIRROR INSTALLATION ..................................................................................................................................... 342
FIGURE 6-11. TRIM INSTALLATION ........................................................................................................................................... 344
FIGURE 6-12. COVER PANEL INSTALLATION .......................................................................................................................... 346
FIGURE 6-13. GASKET INSTALLATION ..................................................................................................................................... 348
FIGURE 6-14. FRONT COVER ASSEMBLY ................................................................................................................................ 350
FIGURE 6-15. HEADLINER INSTALLATION ............................................................................................................................... 352
FIGURE 6-16. FRONT PANEL INSTALLATION........................................................................................................................... 354
FIGURE 6-17. REAR COVER PANEL INSTALLATION ............................................................................................................... 356
FIGURE 6-18. REAR WINDOW INSTALLATION ......................................................................................................................... 358
FIGURE 6-19. REAR WINDOW ................................................................................................................................................... 360
FIGURE 6-20. CAB DOOR INSTALLATION ................................................................................................................................ 362
FIGURE 6-21. WINDOW ASSEMBLY .......................................................................................................................................... 364
FIGURE 6-22. DOOR ASSEMBLY ............................................................................................................................................... 366
FIGURE 6-23. VINYL SEAT INSTALLATION ............................................................................................................................... 368
FIGURE 6-24. VINYL SEAT ......................................................................................................................................................... 370
FIGURE 6-25. CLOTH SEAT INSTALLATION ............................................................................................................................. 372
FIGURE 6-26. CLOTH SEAT ....................................................................................................................................................... 374
FIGURE 6-27. WIPER TANK INSTALLATION ............................................................................................................................. 376
FIGURE 6-28. FRONT WIPER INSTALLATION........................................................................................................................... 378
FIGURE 6-29. ROOF WIPER INSTALLATION ............................................................................................................................ 380
FIGURE 6-30. HEATER INSTALLATION ..................................................................................................................................... 382
FIGURE 6-31. CAB HEATER ....................................................................................................................................................... 384
FIGURE 6-32. AIR CONDITIONING INSTALLATION .................................................................................................................. 386
FIGURE 6-33. HEATER (NO A/C) ................................................................................................................................................ 390
FIGURE 6-34. HEATER (A/C) ...................................................................................................................................................... 392
SECTION 7 - CONTROLS ............................................................................................................................................................... 395
31200939 3614RS, 4017RS 9
TABLE OF CONTENTS
FIGURE 7-1. BRAKE PEDAL INSTALLATION ............................................................................................................................. 396
FIGURE 7-2. BRAKE PEDAL ASSEMBLY ................................................................................................................................... 398
FIGURE 7-3. ACCELERATOR PEDAL INSTALLATION ............................................................................................................... 400
FIGURE 7-4. ACCELERATOR PEDAL ......................................................................................................................................... 402
FIGURE 7-5. STEER COLUMN INSTALLATION (FNR LEVER) .................................................................................................. 404
FIGURE 7-6. STEERING COLUMN (FNR LEVER) ...................................................................................................................... 406
FIGURE 7-7. STEERING COLUMN INSTALLATION (NO FNR LEVER) ...................................................................................... 408
FIGURE 7-8. STEERING COLUMN ASSEMBLY (NO FNR LEVER) ............................................................................................ 410
FIGURE 7-9. STEERING WHEEL................................................................................................................................................. 412
FIGURE 7-10. MECHANICAL HANDBRAKE INSTALLATION - 3614RS ..................................................................................... 414
FIGURE 7-11. HYDRAULIC HANDBRAKE INSTALLATION - 4017RS ........................................................................................ 416
FIGURE 7-12. JOYSTICK INSTALLATION (FNR LEVER) ........................................................................................................... 418
FIGURE 7-13. JOYSTICK INSTALLATION (NO FNR LEVER) ..................................................................................................... 420
FIGURE 7-14. JOYSTICK INSTALLATION (AUX, FNR LEVER) .................................................................................................. 422
FIGURE 7-15. JOYSTICK INSTALLATION (AUX, NO FNR LEVER)............................................................................................ 424
FIGURE 7-16. JOYSTICK (FNR LEVER) ...................................................................................................................................... 426
FIGURE 7-17. JOYSTICK (NO FNR LEVER) ............................................................................................................................... 428
FIGURE 7-18. JOYSTICK (AUX, FNR LEVER) ............................................................................................................................ 430
FIGURE 7-19. JOYSTICK (AUX, NO FNR LEVER) ...................................................................................................................... 432
SECTION 8 - HYDRAULIC CIRCUITS ............................................................................................................................................. 435
FIGURE 8-1. SUPPLY LINES INSTALLATION - 3614RS ............................................................................................................. 436
FIGURE 8-2. SUPPLY LINES INSTALLATION - 4017RS ............................................................................................................. 438
FIGURE 8-3. PUMP LINES INSTALLATION - 3614RS (NO AUXILIARY HYDRAULICS) ............................................................ 440
FIGURE 8-4. PUMP LINES INSTALLATION - 3614RS (AUXILIARY HYDRAULICS) .................................................................. 442
FIGURE 8-5. PUMP LINES INSTALLATION - 4017RS (NO AUXILIARY HYDRAULICS) ............................................................ 444
FIGURE 8-6. PUMP LINES INSTALLATION - 4017RS (AUXILIARY HYDRAULICS) .................................................................. 446
FIGURE 8-7. STEERING INSTALLATION - 3614RS .................................................................................................................... 448
FIGURE 8-8. STEERING INSTALLATION - 4017RS .................................................................................................................... 450
FIGURE 8-9. UPPER BRAKE LINES INSTALLATION - 3614RS ................................................................................................. 452
FIGURE 8-10. UPPER BRAKE LINES INSTALLATION - 4017RS ............................................................................................... 454
FIGURE 8-11. LOWER BRAKE LINES INSTALLATION - 3614RS .............................................................................................. 456
FIGURE 8-12. LOWER BRAKE LINES INSTALLATION - 4017RS .............................................................................................. 458
FIGURE 8-13. IMPLEMENT LINES INSTALLATION - 3614RS (NO AUX HYDRAULICS) ........................................................... 460
FIGURE 8-14. IMPLEMENT LINES INSTALLATION - 3614RS (AUXILIARY HYDRAULICS) ...................................................... 462
FIGURE 8-15. IMPLEMENT LINES INSTALLATION - 4017RS (NO AUX HYDRAULICS) ........................................................... 464
FIGURE 8-16. IMPLEMENT LINES INSTALLATION - 4017RS (AUXILIARY HYDRAULICS) ...................................................... 466
FIGURE 8-17. LEVELING AND OUTRIGGERS INSTALLATION - 3614RS ................................................................................. 468
FIGURE 8-18. LEVELING AND OUTRIGGERS INSTALLATION - 4017RS ................................................................................. 470
FIGURE 8-19. OUTRIGGER LEG ASSEMBLY ............................................................................................................................ 472
FIGURE 8-20. BREATHER INSTALLATION ................................................................................................................................. 474
SECTION 9 - HYDRAULIC COMPONENTS .................................................................................................................................... 477
FIGURE 9-1. LIFT CYLINDER - 3614RS ...................................................................................................................................... 478
FIGURE 9-2. LIFT CYLINDER - 4017RS ...................................................................................................................................... 480
FIGURE 9-3. EXTEND/RETRACT CYLINDER - 3614RS ............................................................................................................. 482
FIGURE 9-4. EXTEND/RETRACT CYLINDER - 4017RS ............................................................................................................. 484
FIGURE 9-5. TILT CYLINDER ...................................................................................................................................................... 486
FIGURE 9-6. COMPENSATION CYLINDER ................................................................................................................................ 488
FIGURE 9-7. FRAME LEVEL CYLINDER - 3614RS ..................................................................................................................... 490
FIGURE 9-8. FRAME LEVEL CYLINDER - 4017RS ..................................................................................................................... 492
FIGURE 9-9. OUTRIGGER CYLINDER ........................................................................................................................................ 494
FIGURE 9-10. MAIN CONTROL VALVE (NO AUXILIARY HYDRAULICS) .................................................................................. 496
FIGURE 9-11. MAIN CONTROL VALVE (AUXILIARY HYDRAULICS)......................................................................................... 500
FIGURE 9-12. STEERING SELECT VALVE ................................................................................................................................. 504
FIGURE 9-13. COUNTERBALANCE VALVE ................................................................................................................................ 506
FIGURE 9-14. OUTRIGGER VALVE ............................................................................................................................................ 508
FIGURE 9-15. GEAR PUMP ......................................................................................................................................................... 510
FIGURE 9-16. HYDRAULIC TANK ............................................................................................................................................... 512
FIGURE 9-17. HYDRAULIC PARK BRAKE RELEASE VALVE .................................................................................................... 514
FIGURE 9-18. HYDRAULIC OIL FILTER ...................................................................................................................................... 516
SECTION 10 - ELECTRICAL ............................................................................................................................................................ 519
FIGURE 10-1. ENGINE ELECTRICAL INSTALLATION ............................................................................................................... 520
10 3614RS, 4017RS 31200939
TABLE OF CONTENTS
FIGURE 10-2. 200 AMP RELAY................................................................................................................................................... 522
FIGURE 10-3. BATTERY INSTALLATION ................................................................................................................................... 524
FIGURE 10-4. CAB ELECTRICAL INSTALLATION ..................................................................................................................... 526
FIGURE 10-5. UGM CONTROL ................................................................................................................................................... 528
FIGURE 10-6. PCB ELECTRICAL ASSEMBLY ........................................................................................................................... 530
FIGURE 10-7. PC BOARD ........................................................................................................................................................... 532
FIGURE 10-8. LSI INSTALLATION .............................................................................................................................................. 534
FIGURE 10-9. RADIO INSTALLATION ........................................................................................................................................ 536
FIGURE 10-10. CAB EARTH INSTALLATION ............................................................................................................................. 538
FIGURE 10-11. HORN INSTALLATION ....................................................................................................................................... 540
FIGURE 10-12. BOOM ANGLE SENSOR INSTALLATION - 3614RS ......................................................................................... 542
FIGURE 10-13. BOOM ANGLE SENSOR INSTALLATION - 4017RS ......................................................................................... 544
FIGURE 10-14. BOOM RETRACT SENSOR INSTALLATION - 3614RS ..................................................................................... 546
FIGURE 10-15. BOOM RETRACT SENSOR INSTALLATION - 4017RS ..................................................................................... 548
FIGURE 10-16. LSI SENSOR INSTALLATION ............................................................................................................................ 550
FIGURE 10-17. BACK-UP ALARM INSTALLATION .................................................................................................................... 552
FIGURE 10-18. CHASSIS HARNESS INSTALLATION - 3614RS ............................................................................................... 554
FIGURE 10-19. CHASSIS HARNESS INSTALLATION - 4017RS ............................................................................................... 556
FIGURE 10-20. DASH ELECTRICAL INSTALLATION ................................................................................................................. 558
FIGURE 10-21. CAB WORKLIGHTS INSTALLATION (NO HAC) ................................................................................................ 560
FIGURE 10-22. CAB WORKLIGHTS INSTALLATION (HAC) ...................................................................................................... 562
FIGURE 10-23. DRIVING LIGHTS INSTALLATION (GERMANY AND CE) ................................................................................. 564
FIGURE 10-24. DRIVING LIGHTS INSTALLATION (UK AND IRELAND) ................................................................................... 566
FIGURE 10-25. BEACON INSTALLATION .................................................................................................................................. 568
FIGURE 10-26. OUTRIGGERS DEPLOYED INSTALLATION - 4017RS ..................................................................................... 570
FIGURE 10-27. ENGINE HARNESS ............................................................................................................................................ 572
FIGURE 10-28. CHASSIS HARNESS .......................................................................................................................................... 578
FIGURE 10-29. CAB HARNESS .................................................................................................................................................. 584
FIGURE 10-30. CAB POWER HARNESS .................................................................................................................................... 592
FIGURE 10-31. RADIO HARNESS .............................................................................................................................................. 594
FIGURE 10-32. WORKLIGHTS HARNESS .................................................................................................................................. 596
FIGURE 10-33. LIGHT EXTENSION HARNESS.......................................................................................................................... 598
FIGURE 10-34. BEACON HARNESS ........................................................................................................................................... 600
FIGURE 10-35. OUTRIGGERS DEPLOYED CHASSIS HARNESS - 4017RS ............................................................................ 602
FIGURE 10-36. OUTRIGGERS DEPLOYED CAB HARNESS - 4017RS ..................................................................................... 604
FIGURE 10-37. ROOF WIPER HARNESS ................................................................................................................................... 606
FIGURE 10-38. HAC CAB HARNESS .......................................................................................................................................... 608
FIGURE 10-39. HAC CHASSIS HARNESS ................................................................................................................................. 610
SECTION 11 - DECALS ................................................................................................................................................................... 613
FIGURE 11-1. DECAL LOCATION INSTALLATION (ULS) .......................................................................................................... 614
FIGURE 11-2. DECAL LOCATION INSTALLATION (LS) ............................................................................................................. 616
FIGURE 11-3. JOYSTICK DECAL INSTALLATION, BUCKET ..................................................................................................... 618
FIGURE 11-4. JOYSTICK DECAL INSTALLATION, FORK ......................................................................................................... 620
FIGURE 11-5. BOOM DECAL INSTALLATION ............................................................................................................................ 622
FIGURE 11-6. DECAL INSTALLATION, RUSSIA ........................................................................................................................ 624
FIGURE 11-7. SOUND PLATE INSTALLATION .......................................................................................................................... 626
FIGURE 11-8. LOAD CHART, 3614RS ........................................................................................................................................ 628
FIGURE 11-9. LOAD CHART, 4017RS ........................................................................................................................................ 630
FIGURE 11-10. REFLECTOR INSTALLATION ............................................................................................................................ 632
FIGURE 11-11. 25KPH SPEED DECAL INSTALLATION ............................................................................................................ 634
FIGURE 11-12. JLG DECAL INSTALLATION, 3614RS ............................................................................................................... 636
FIGURE 11-13. JLG DECAL INSTALLATION, 4017RS ............................................................................................................... 638
FIGURE 11-14. CONSTRUCTION INSTALLATION (UK/IRELAND) ............................................................................................ 640
FIGURE 11-15. CONSTRUCTION INSTALLATION (CE) ............................................................................................................ 642
FIGURE 11-16. CONSTRUCTION INSTALLATION (FRANCE) ................................................................................................... 644
SECTION 12 - RECOMMENDED SPARE PARTS .......................................................................................................................... 647
FIGURE 12-1. RECOMMENDED SPARE PARTS ....................................................................................................................... 648
PART NUMBER INDEX ................................................................................................................................................................... 651
31200939 3614RS, 4017RS 11
SECTION 1 - FRAME & ATTACHING PARTS
SECTION 1 - FRAME & ATTACHING PARTS
31200939 3614RS, 4017RS 13
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-1. FRAME INSTALLATION - 3614RS
14 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001146014
Ref
Frame Installation - 3614RS
A 1 1001091126
4
Plug 2
N.S.S.
1
Weldment, Frame
FIGURE 1-1. FRAME INSTALLATION - 3614RS
31200939 3614RS, 4017RS 15
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-2. FRAME INSTALLATION - 4017RS
16 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001146017
Ref
Frame Installation - 4017RS
A 1 1001091126
4
Plug 2
N.S.S.
1
Weldment, Frame
FIGURE 1-2. FRAME INSTALLATION - 4017RS
31200939 3614RS, 4017RS 17
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-3. ENCLOSURE GROUP INSTALLATION
18 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001145381
Ref
Enclosure Group Installation
C 1 0760812
12
Bolt, M8X25
2 0761012
11
Bolt, M10X25
3 0761014
6
Bolt, M10X30
4 4811902
14
Washer, M8
5 4812002
17
Washer, M10
6 1001154688
1
Plate, Latch
7 1001145307
1
Plate, Belly Pan
8 1001145312
1
Panel, Front
9 1001145313
1
Panel, Side
10
1001149046
1
Panel, Rear
12
0761614
4
Bolt, M16X30
14
3290801
2
Nut, M8X1.25
15
4806433
2
Hinge, Hood
16
1001092256
4
Washer, M17
17
1001112426
1
Spring, Hood
18
1001150144
1
Assembly, Hood (See Hood Assembly for Details)
19
1001150624
1
Bracket, Hood
20
1001095650
AR
Compound, Locking
FIGURE 1-3. ENCLOSURE GROUP INSTALLATION
31200939 3614RS, 4017RS 19
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-4. MIRROR INSTALLATION - 3614RS
20 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001144111
Ref
Mirror Installation - 3614RS
1 0761012
3
Bolt, M10X25
2 4812000
3
Washer, M10
3 1001008436
1
Mirror, (See MIRROR ASSEMBLY for Breakdown)
4 1001096913
1
Cap, Lamp Bracket
5 1001142726
1
Mirror, Convex
6 1001144430
1
Bracket, Mirror
7 1001095650
AR
Compound, Locking
FIGURE 1-4. MIRROR INSTALLATION - 3614RS
31200939 3614RS, 4017RS 21
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-5. MIRROR INSTALLATION - 4017RS
22 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001171098
Ref
Mirror Installation - 4017RS
1 0761012
3
Bolt, M10X25
2 4812000
3
Washer, M10
3 1001008436
1
Assembly, Mirror (See MIRROR ASSEMBLY for Breakdown)
4 1001095650
AR
Compound, Locking
5 1001096913
1
Cap, Lamp Bracket
6 1001142724
1
Mirror, Convex
7 1001142726
1
Mirror Convex
8 1001144430
1
Bracket, Mirror
FIGURE 1-5. MIRROR INSTALLATION - 4017RS
31200939 3614RS, 4017RS 23
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-6. MIRROR ASSEMBLY
24 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001008436
1
Mirror Assembly
B 1 1001008475
2
Lockwasher, M12
2 1001009062
2
Washer 3
1001010838
2
Bolt
FIGURE 1-6. MIRROR ASSEMBLY
31200939 3614RS, 4017RS 25
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-7. BOOM PROP INSTALLATION
26 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001164211
Ref
Boom Prop Installation
A 1 0761214
2
Bolt, M12X30
2 3291201
2
Nut, M12X1.75
3 1001095650
AR
Compound, Locking
4 1001101458
2
Bolt, Wing M8X40
5 1001101628
2
Bracket, Boom Prop Mount
6 1001164018
1
Bracket, Boom Prop
FIGURE 1-7. BOOM PROP INSTALLATION
31200939 3614RS, 4017RS 27
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-8. WHEEL CHOCK INSTALLATION
28 3614RS, 4017RS 31200939
SECTION 1 - FRAME & ATTACHING PARTS
ITEM
PART NUMBER
QTY
DESCRIPTION
REV
1001157868
Ref
Wheel Chock Installation
A 1 0760812
4
Bolt, M8X25
2 806253
1
Wedge 3
806264
1
Holder, Wedge
4 4811900
4
Washer, M8
FIGURE 1-8. WHEEL CHOCK INSTALLATION
31200939 3614RS, 4017RS 29
SECTION 1 - FRAME & ATTACHING PARTS
FIGURE 1-9. COUNTERWEIGHT INSTALLATION - 3614RS
30 3614RS, 4017RS 31200939
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