JLG 4017RS Service Manual

An Oshkosh Corporation Company

Models

3614RS
4017RS

Service Manual

31200940

Original

May 7, 2014

May 7, 2014 - A - Original Issue Of Manual

EFFECTIVITY PAGE

31200940 3614RS, 4017RS

i

READ THIS FIRST

OZ4390

D

1001139654 A

S

15 mg/kg

1

Modifications

Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations.
Any modification must be approved by JLG.

Machine Configuration

Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur
Fuel Decal (1) as indicated below.

• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as
Ultra Low Sulfur (ULS) from this point forward.

•If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to
as Low Sulfur (LS) from this point forward.

ii

3614RS, 4017RS 31200940

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.5 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.6 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.7 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Boom System Component Terminology - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.2 Boom System - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom Assembly Maintenance - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Boom Chain Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6 Extend/Retract Cylinder Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3.7 Boom Sections Adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.8 Boom System Component Terminology - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3.9 Boom System - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.10 Boom Assembly Maintenance - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.11 Hose Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - 4017RS . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.13 Boom Chain Removal/Installation - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.14 Boom Sections Adjustment - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.15 Boom Extend and Retract Chains - 3614RS & 4017RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3.16 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.17 Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.18 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.19 Boom Prop (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.20 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.21 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

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Section Subject Page

Section 4

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Operator Cab Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4 Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6 Park Brake adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.7 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.8 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.9 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.10 Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Section 6

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Torque Convertor Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Section 7

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.4 Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.6 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

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3614RS, 4017RS

Section Subject Page

Section 8

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

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.4 Hydraulic Pressure Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.5 Hydraulic Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.6 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.8 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.9 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

8.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.3 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.4 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.5 Electrical System Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

9.6 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

9.7 Wiper/Washer Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

9.8 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

9.9 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

9.10 Load Stability Indicator (LSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

9.11 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30

9.12 Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

9.13 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35

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3614RS, 4017RS

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

3614RS, 4017RS

1-1

Safety Practices

1.1 INTRODUCTION

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

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

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

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 seat looking in
a forward direction.

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

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the
steering wheel before attempting to perform any service or
maintenance. Remove key and disconnect battery leads.

1.5 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.

1.2 DISCLAIMER

All information in this manual is based on the latest product
information available at the time of publication. The
manufacturer 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 OPERATION & SAFETY MANUAL

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

An Operation & Safety Manual is supplied with each machine
and must be kept in the manual holder located in the cab. In
the event that the Operation & Safety Manual is missing,
consult the local JLG dealer before proceeding.

1-2

3614RS, 4017RS

Safety Practices

1.6 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.

1.7 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

1.7.1 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.

1.7.2 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.

3614RS, 4017RS

1-3

Safety Practices

1.7.3 General Hazards

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

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

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

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

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

It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
machine is needed, ensure the machine is shut down before
pressure-washing. Should pressure-washing be utilized to
wash areas containing electrical/electronic components, JLG
recommends a maximum pressure of 52 bar (750 psi) at a
minimum distance of 30,5 cm (12 in) away from these
components. If electrical/electronic components are
sprayed, spraying must not be direct and for brief time
periods to avoid heavy saturation,

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

1.7.4 Operational Hazards

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

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

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

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

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

Refer to the engine manufacturers manual for specific details
concerning the fuel system.

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.

COOLANT SYSTEM CAP: The cooling system is under
pressure, and escaping coolant can cause severe burns and
eye injury. To prevent personal injury, NEVER remove the
coolant system cap while the cooling system is hot. Wear
safety glasses. Turn the coolant system cap to the first stop
and allow pressure to escape before removing the cap
completely. Failure to follow the safety practices could result
in death or serious injury.

Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.

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.

1-4

3614RS, 4017RS

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

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

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

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

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

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

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

Safety Practices

1.8 SAFETY DECALS

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

3614RS, 4017RS

1-5

Safety Practices

This Page Intentionally Left Blank

1-6

3614RS, 4017RS

Section 2

General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3.2 Metric Fastener Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.1 Travel Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.4.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.4.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.4.5 Transmission Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.4.6 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.5 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.6 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6.1 10 & 1st 50 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2.6.2 50 & 1st 250 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.6.3 250 & 500 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.6.4 1000 & 3000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2.6.5 6000 & 12000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.7 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2.7.1 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

2.7.2 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

3614RS, 4017RS

2-1

General Information and Specifications

ModelYea r:

100100YYYA

Model:

YearofManufacture:

ProductIdentificationNumber

SerialNumber

Nominalenginepower,kW:

Unladenmass:

Maximumcapacity:

Maximumcapacityat max.Height:

kg

kg

kg

JLGManufacturingEuropeBVBA

IndustrieterreinOud eBunders1034
Breitwaterstraat 12
3630Maasmechelen-Belgium

1001138666A

M 8340Z

1

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 on the frame behind the right
front tire.

Note: The replacement of any part on this machine with any
other than factory 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.

2.2 THREAD LOCKING COMPOUND

242
243
271
262

®

ND Industries Description

TM

TM

TM

TM

Vibra-TITETM121
Vibra-TITETM122
Vibra-TITETM140
Vibra-TITETM131

Medium Strength (Blue)
Medium Strength (Blue)

Medium - High Strength (Red)

High Strength (Red)

JLG P/N

Loctite

0100011

1001095650

0100019
0100071

Loct ite® 243TM can be substituted in place of Loctite® 242TM.
Vibra-TITE

TM

122 can be substituted in place of Vibra-TITETM 121.

A warranty registration form must be filled out by the local
JLG dealer.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed to
guarantee full warranty service.

2-2

3614RS, 4017RS

General Information and Specifications

2.3 TORQUE CHARTS

2.3.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

T o r q u e

Size TPI Bolt Dia

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

Tensile Stress

Area

In Sq In LB IN - L B [N.m] IN - L B [N.m] IN - L B [N.m] I N -L B [N.m]

In Sq In LB FT -LB [N.m] FT-L B [N.m] FT-LB [N.m] FT-LB [N.m]

Clamp

Load

T o rq u e

(Dry)

T o r q u e

Lubricated

(Loctite® 242

TM

Vibra-TITE

111 or 140)

or 271TM or

TM

To r q ue
(Loctite® 262
Vibra-TITE

TM

TM

131)

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

3614RS, 4017RS

2-3

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Size TPI Bolt Dia

In Sq In LB IN -LB [N.m] IN -LB [N.m] I N-L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 43 5

10 24 0.1900 0.01750 1580 60 7

32 0.1900 0.02000 1800 68 8

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

Tensile Stress

Area

Clamp Load

Torque

(D ry o r L oct it e® 2 63 )

K=0.20

(Loctite® 242

To r qu e

Vibra-TITE

K=0.18

TM

or 271TM or

TM

1 1 1 o r 1 4 0 )

Torque
(Loctite® 262
Vibra-TITE

K=0.15

TM

TM

131)

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

2-4

3614RS, 4017RS

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Size TPI Bolt Dia

In Sq In LB IN- LB [N.m] IN -LB [N.m] IN- LB [N.m]

4 40 0.1120 0.00604 380 7 0.8

48 0.1120 0.00661 420 8 0.9

6 32 0.1380 0.00909 580 14 1.5

40 0.1380 0.01015 610 14 1.6

8 32 0.1640 0.01400 900 25 2.8

36 0.1640 0.01474 940 26 2.9

10 24 0.1900 0.01750 1120 36 4.1

32 0.1900 0.02000 1285 42 4.7

1/4 20 0.2500 0.0318 2020 86 9.7 80 9

28 0.2500 0.0364 2320 99 11.1 95 11

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20

24 0.3125 0.0580 3700 15 20 15 21 15 20

3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34

24 0.3750 0.0878 5600 30 40 28 38 25 34

7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48

20 0.4375 0.1187 7550 45 60 44 60 40 54

1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75

20 0.5000 0.1599 10700 75 100 71 97 65 88

9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109

18 0.5625 0.2030 12950 105 145 97 132 90 122

5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156

18 0.6250 0.2560 16300 145 195 136 185 125 170

3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272

16 0.7500 0.3730 23800 255 345 238 324 225 306

7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435

14 0.8750 0.5090 32400 400 545 378 514 355 483

1 8 1.0000 0.6060 38600 545 740 515 700 480 653

12 1.0000 0.6630 42200 600 815 563 765 530 721

1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809

12 1.1250 0.8560 47500 755 1025 713 969 670 911

1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142

12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265

1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496

12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707

1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992

12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237

Tensile Stress

Area

Clamp Load

Torque

(Dry)

K=0.17

(Loctite® 242

To r qu e

Vibra-TITE

K=0.16

TM

or 271TM or

TM

1 1 1 o r 1 4 0 )

Torque
(Loctite® 262
Vibra-TITE

K=0.15

TM

TM

or

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

3614RS, 4017RS

2-5

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Size TPI Bolt Dia

In Sq In LB IN -LB [N.m] IN -LB [N.m] I N-L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474 1320 37 4

10 24 0.1900 0.01750 1580 51 6

32 0.1900 0.02000 1800 58 7

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

Torque

(D ry o r L oct it e® 2 63 )

K=0.17

(Loctite® 242

To r qu e

Vibra-TITE

K=0.16

TM

or 271TM or

TM

1 1 1 o r 1 4 0 )

Torque
(Loctite® 262
Vibra-TITE

K=0.15

TM

TM

131)

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

2-6

3614RS, 4017RS

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Magni Coating Fasteners (Ref 4150701)

SOCKET HEAD CAP SCREWS

To r qu e

Size TPI Bolt Dia

In Sq In LB I N-L B [N.m] IN -LB [N.m] I N-L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

See Note 4

Torque

(Dry) K=0.17

(Loctite® 242
Vibra-TITE

TM

or 271TM or

TM

111 or 140) or

Precoat® 85 K=0.16

Torque
(Loctite® 262
Vibra-TITE

K=0.15

TM

TM

or

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

3614RS, 4017RS

2-7

General Information and Specifications

2.3.1 SAE Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS

To r qu e

Size TPI Bolt Dia

In Sq In LB IN -LB [N.m] IN -LB [N.m] I N-L B [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

Tensile Stress

Area

Clamp Load

See Note 4

Torque

(Dry) K=0.17

(Loctite® 242
Vibra-TITE

TM

or 271TM or

TM

111 or 140) or

Precoat® 85 K=0.16

Torque
(Loctite® 262
Vibra-TITE

K=0.15

TM

TM

131)

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

2-8

3614RS, 4017RS

General Information and Specifications

2.3.2 Metric Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Size Pitch

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12

7128.9012.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290

Tensile Stress

Area

Sq mm KN [N.m] [N.m] [N.m]

Clamp Load

See Note 4

Torque

(Dry or Loctite® 263

)

Torque (Lube)

TM

T o r q ue

(Loctite® 262

or Vibra-TITE

TM

or 271TM

TM

131)

T o rq u e

(Loctite® 242

or Vibra-TITE

or 141)

TM

or 271TM

TM

111

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

3614RS, 4017RS

2-9

General Information and Specifications

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS,

CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

T o r q ue

Size Pitch Tensile Stress Area

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27

10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395

Clamp Load

See Note 4

Torque

(Dry or Loctite® 263

K=0.20

TM

)

(Lube or Loctite®

TM

242

or 271TM or

Vibra-TITE

TM

K=0.18

111 or 140)

To r qu e
(Loctite® 262
Vibra-TITE

K=0.15

TM

or

TM

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

2-10

3614RS, 4017RS

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS

Size Pitch Tensile Stress Area

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03

3.5 0.6 6.78
4 0.7 8.78
5 0.8 14.20
6 1 20.10
7 1 28.90
8 1.25 36.60

10 1.5 58.00
12 1.75 84.30
14 2 115
16 2 157
18 2.5 192
20 2.5 245
22 2.5 303
24 3 353
27 3 459
30 3.5 561
33 3.5 694
36 4 817
42 4.5 1120

Clamp Load

See Note 4

2.19 1.1 1.1 1.0

2.95 1.8 1.7 1.5

3.82 2.6 2.4 2.3

6.18 5.3 4.9 4.6

8.74 9 8.4 7.9

12.6 15 14 13

15.9 22 20 19

25.2 43 40 38

36.7 75 70 66

50.0 119 110 105

68.3 186 175 165

83.5 256 240 225

106.5 362 340 320

132.0 494 465 435

153.5 627 590 555

199.5 916 860 810

244.0 1245 1170 1100

302.0 1694 1595 1495

355.5 2176 2050 1920

487.0 3477 3275 3070

General Information and Specifications

Torque

(Dry or Loctite® 263

K=0.17

Torque

TM

(Lube or Loctite® 242

)

Vibra-TITE

271

TM

K=0.16

TM

or

111 or 140)

TM

or

T o r q ue
(Loctite® 262
Vibra-TITE

K=0.15

TM

TM

131)

or

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

3614RS, 4017RS

2-11

General Information and Specifications

2.3.2 Metric Fastener Torque Chart (Continued)

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS,

CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE*

T o r q ue

Size Pitch Tensile Stress Area

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395

Clamp Load See

Note 4

Torque

(Dry or Loctite® 263

K=0.17

TM

)

(Lube or Loctite®

TM

or 271TM or

242

Vibra-TITE

TM

K=0.18

111 or 140)

To r qu e
(Loctite® 262
Vibra-TITE

K=0.15

TM

or

TM

131)

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

3. * ASSEMBLY USES HARDENED WASHER

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

2-12

3614RS, 4017RS

2.3.3 Hydraulic Hose Torque Chart

Note: By definition the “Flats Method“ will contain some
variance.

Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand
tighten the swivel nut until no lateral movement of the
swivel nut can be detected. Average hand torque is 4
Nm (3 lb-ft).

2. Mark a dot on one of the swivel nut flats and another
dot in line on the hex of the adapter it’s connecting to.

3. Use the double wrench method while tightening to
avoid hose twist.

4. Tighten the connection 6.35 mm (0.25 in) or 1.5 flats.

5. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering
the dots indicating that the connection has been
properly tightened.

General Information and Specifications

3614RS, 4017RS

2-13

General Information and Specifications

2.4 SPECIFICATIONS

2.4.1 Travel Speeds

TRANSMISSION APPROXIMATE SPEED

First Gear 5 kph (3 mph)

Second Gear 12 kph (7 mph)

Third Gear 25 kph (15 mph)

2.4.2 Hydraulic Cylinder Performance

Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 54° C (130° F) minimum, engine at operating
temperature.

FUNCTION

Boom Extend (Boom Level) 14.6 23.4

Boom Retract (Boom Level) 11.7 20.0

Boom Lift 15.5 21.0

Boom Lower 13.3 16.8

Quick Coupler Raise 3.1 3.1

Quick Coupler Lower 2.7 2.8

Frame Level - Full Right to Left 7.1 8.0

Frame Level - Full Left to Right 10.8 12.1

Outrigger - Both Down 6.9 7.0

Outrigger - Both Up 6.2 6.0

Outrigger - Single Down 4.4 4.5

Outrigger - Single Up 4.6 4.6

APPROXIMATE TIMES (seconds)

3614RS 4017RS

2-14

3614RS, 4017RS

General Information and Specifications

2.4.3 Electrical System

Battery

Type, Rating 12 V, Negative (-) Ground, Tapered Top Post, Maintenance Free

Quantity 1

Cranking Performance 1 - 830 Cold Cranking Amps @ -18° C (0° F)

Group/Series BCI Group 31

Alternator 14V, 120 Amps

Starter 12V,4 KW

2.4.4 Engine Performance Specifications

Description TCD 3.6 L4

Engine Make/Model Deutz TCD

Displacement 3,6 liters (276 in³)

Low Idle 945-955 rpm

High Idle 2295-2345 rpm

Horsepower 74,4 kW (99,7 HP)@ 2200 rpm

Peak Torque 410 Nm (302 lb-ft) @ 1600 rpm

Fuel Delivery Fuel Injection

Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.4.5 Transmission Performance Specifications

Engine kW (Horsepower) Transmission Stall Speed

Deutz TCD 3.6 L4 74,4 (99.7) 3 Speed 2030 rpm 2050 rpm

3614RS, 4017RS

2-15

General Information and Specifications

2.4.6 Tires

Note: Wheel lug nut torque is 430-470 Nm (317-347 lb-ft)

Note: Pressures for foam filled tires are for initial fill ONLY.

a. 3614RS

Size Tire Type

15.5/80-24 TR01 16 Ply Pneumatic 4,1 Bar (59 psi)

15.5-25 L-2 12 Ply

400/80-24 Power CL N/A Pneumatic 4,0 Bar (58 psi)

370/75-28 DuraForce MH 14 Ply Pneumatic 5,25 Bar (76 psi)

a. 4017RS

Size Tire Type

14-24 TG02 16 Ply Pneumatic 4,25 Bar (62 psi)

14-24 SGG-2A 16 Ply

14-24 L2/G2 Radial Pneumatic 5,5 Bar (80 psi)

400/75-28 DuraForce MH 16 Ply Pneumatic 5,25 Bar (76 psi)

Minimum Ply/

Star Rating

Minimum Ply/

Star Rating

Fill Type Pressure

Pneumatic 4,0 Bar (58 psi)

Liquid Filled 4,0 Bar (58 psi)

Fill Type Pressure

Pneumatic 4,75 Bar (69 psi)

Liquid Filled 4,75 Bar (69 psi)

2-16

3614RS, 4017RS

General Information and Specifications

2.5 FLUIDS, LUBRICANTS AND CAPACITIES

Engine Crankcase Oil

Capacity with Filter Change 8,0 liter (8.5 quart)

Type of Oil

-10°C to 40°C (14° to 104°F) SAE 15W-40

-15°C to 40°C (5° to 104°F) SAE 10W-40

-30°C to 30°C (-22° to 86°F) SAE 5W-40

Specification

If Equipped For ULS API CJ-4 Plus

If Equipped For LS API CI-4 Plus

Fuel Tank

Capacity 150 liter (39.6 gallon)

Type of Fuel

Standard #2 Diesel

Cold Weather Blend of #1 and #2 Diesel

Specification

If Equipped For ULS Ultra Low Sulfur (S <

If Equipped For LS Low Sulfur (S <

Cooling System

System Capacity 19,0 liter (20 quart)

Type of Coolant

Standard 50/50 Ethylene Glycol & Water

Cold Weather 60/40 Ethylene Glycol & Water

Transmission System

Capacity with Filter Change 13,5 liter (14.3 qt)

Type of Oil

Standard Mobilfluid 424 Hydraulic Oil

Cold Weather Mobilfluid LT 75W-80

Transfer Case

Capacity 0.75 liter (0.79 qt)

Type of Oil

15 mg/kg)

500 mg/kg)

3614RS, 4017RS

Standard Mobilfluid 424 Hydraulic Oil

Cold Weather Mobilfluid LT 75W-80

2-17

General Information and Specifications

Hydraulic System

System Capacity 145 liter (38.3 gallon)

Reservoir Capacity to Full Mark 90 liter (23.8 gallon)

Auxiliary Hydraulic Circuit Max Flow 80 lpm (21.1 gpm)

Type of Oil Mobilfluid 424 Hydraulic Oil

Axles

Differential Housing Capacity

3614RS

Front Axle 7,3 liter (7.7 quart)

Rear Axle 7,5 liter (7.9 quart)

4017RS

Front Axle 6,8 liter (7.2 quart)

Rear Axle 7,5 liter (7.9 quart)

Wheel End Capacity

3614RS 1,4 liter (1.5 quart)

4017RS

Front Axle 2,0 liter (2.1 quart)

Rear Axle

If Equipped with Pneumatic Tires 1,4 liter (1.5 quart)

If Equipped with Foam Filled Tires 2,0 liter (2.1 quart)

Type of Oil

Shell LS 90

Fuchs Renogear Oil LSA SAE 90

Fuchs Titan Gear 85W-90 LS

Castrol LSC SAE 90

Mobil Lube SHC LS 75W-90 (Full Synthetic)

Mobil 1 SAE 75W-90 LS (E.P.)

Air Conditioning System (if equipped)

System Capacity 1,0 kg (2.2 lb)

Type of Refrigerant R-134a Tetrafluoroethane

Grease

Wear Pad, Cylinder & Axle Multipurpose Grease (NLGI Grade 2)

Boom Chain Schaffer 200S Silver Streak

2-18

3614RS, 4017RS

2.6 SERVICE AND MAINTENANCE

50

1

st

Check Axle

Differential Oil

Level

Check Wheel

End Oil Levels

Check Boom

Chain & Tension

Check Wheel

Lug Nut

Torque

Check

Transmission

Oil Level

Check Fuel

Level

10

EVERY

Check Engine
Coolant Level

Check Engine

Oil Level

Check Hydraulic

Oil Level

Check Tire

Condition &

Pressure

MZ8290

SCHEDULES

2.6.1 10 & 1st 50 Hour

General Information and Specifications

3614RS, 4017RS

2-19

General Information and Specifications

OB0440

Change

Transmission

Oil & Filter

Change

Transfer Case

Oil

250

1

st

Change Axle

Differential Oil

Change Wheel

End Oil

Check Air Filter

Lubrication

Schedule

50

EVERY

Drain Fuel/

Water

Separator

Check

Battery

Check Washer

Fluid Level

(if equipped)

Check Cab

Air Filter

2.6.2 50 & 1st 250 Hour

2-20

3614RS, 4017RS

2.6.3 250 & 500 Hour

OZ4260

Check Transfer
Case Oil Level

Check Wheel

End Oil Levels

250

EVERY

Check Axle

Differential Oil

Level

Check Boom

Wear Pads

Check Boom

Chain & Tension

Check

Fan Belt

500

EVERY

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Check LSI

Calibration

Change

Air Filter

Elements

Change Fuel

Filters

Change Engine

Oil and

Filter

Lubrication

Schedule

General Information and Specifications

3614RS, 4017RS

2-21

General Information and Specifications

OAM3771

Change

Belt

3000

EVERY

Change

Hydraulic

Fluid & Filters

1000

EVERY

Change

Transmission

Oil & Filter

Change Wheel

End Oil

Change

Transfer Case

Oil

Check

Air Intake

System

Change Axle

Differential Oil

2.6.4 1000 & 3000 Hour

2-22

3614RS, 4017RS

2.6.5 6000 & 12000 Hour

OAM3522

Add Engine

Coolant

Extender

6000

EVERY

or

3 Years

Change

Engine Coolant

12000

EVERY

or

6 Years

General Information and Specifications

Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine Operation & Maintenance Manual for
additional information.

3614RS, 4017RS

2-23

General Information and Specifications

OAM3780

2.7 LUBRICATION SCHEDULE

2.7.1 3614RS

2-24

3614RS, 4017RS

2.7.2 4017RS

OAM3790

General Information and Specifications

3614RS, 4017RS

2-25

General Information and Specifications

This Page Intentionally Left Blank

2-26

3614RS, 4017RS

Section 3

Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2 Boom System - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom Assembly Maintenance - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.3.2 Second, Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.3.3 Third Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.3.4 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.3.5 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.3.6 Complete Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.4 Boom Chain Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.4.1 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.4.2 Retract Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.4.3 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.4.4 Extend Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - 3614RS. . . . . . . . . . . . . . . . . . . . . 3-14

3.5.1 Tilt/Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.5.2 Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.6 Extend/Retract Cylinder Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.6.1 Extend/Retract Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.6.2 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.7 Boom Sections Adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.7.1 Chain Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.8 Boom System Component Terminology - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.9 Boom System - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.9.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.10 Boom Assembly Maintenance - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.10.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.10.2 Second, Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.10.3 Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.10.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.10.5 Fourth Boom Section Removal Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.10.6 Hose Carrier Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.10.7 Fourth Boom Section Installation Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.10.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3.10.9 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.10.10 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.10.11 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3614RS, 4017RS

3-1

Boom

3.11 Hose Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.11.1 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.11.2 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - 4017RS. . . . . . . . . . . . . 3-29

3.12.1 Tilt/Auxiliary Hose Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.12.2 Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3.12.3 Carrier Tilt/Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3.12.4 Carrier Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.13 Boom Chain Removal/Installation - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.14 Boom Sections Adjustment - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.14.1 Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3.15 Boom Extend and Retract Chains - 3614RS & 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.15.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.15.2 Inspection Guidelines - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.15.3 Inspection Guidelines - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3.15.4 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3.15.5 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.16 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.16.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.16.2 Boom Wear Pad Installation/Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.17 Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.17.1 Quick Coupler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.17.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.18 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.19 Boom Prop (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.19.1 Installation and Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.20 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.20.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.20.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-2

3614RS, 4017RS

3.1 BOOM SYSTEM COMPONENT

MZ7070

SECOND

BOOM

SECTION

THIRD

BOOM

SECTION

RETRACT CHAIN

(inside boom)

FIRST BOOM

SECTION

TILT CYLINDER

(inside Boom head)

EXTEND/RETRACT CYLINDER

EXTEND CHAINS

(inside boom)

AUXIL IARY

CONNECTIONS

(if equipped)

TERMINOLOGY - 3614RS

The following illustrations identify the components that are
referred to throughout this section.

Boom

3614RS, 4017RS

3-3

Boom

3.2 BOOM SYSTEM - 3614RS

3.2.1 Boom System Operation

The 3614RS three section boom consists of the first, second
and third assemblies with first and second section extend
chains, and a single first and second section retract chain.

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

The boom sections are connected by extend and retract
chains. These chains are routed around rollers on the front
and the rear of the second boom section. As the extend/
retract cylinder is forced out hydraulically, the third boom
section is pulled out by the extend chains.

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

This mechanical linkage formed by the chains and
supporting hardware, extends and retracts the third boom
section into the second boom section at the same rate.

The boom section lifts and lowers via action of the lift
cylinder.

3.3 BOOM ASSEMBLY MAINTENANCE ­3614RS

These instructions must be completed in sequence. The
second and third boom sections are removed from the first
boom section. The third boom section is removed from the
second boom section or the complete boom assembly can
be removed from the machine.

Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.The boom assembly consists of the first, second
and third section booms and supporting hardware.

Note: Before removing the boom or boom section, the carriage
or any other attachment must be removed from the quick
coupler.

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

During service of the boom, perform the following:

1. Check wear pads. (Refer to Section 3.16.1, “Wear Pad
Inspection.”)

2. Check chain rollers.

3. Apply grease at all lubrication points (grease fittings).
(Refer to Section 2.7, “Lubrication Schedule.”)

4. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.

Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.

3-4

WARNING

NEVER weld or drill the boom unless approved in writing

by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.

3614RS, 4017RS

Boom

MZ7090

1

4

2

4

3

3.3.1 Boom Removal

While the boom sections can be separated from each other
on the machine, it is much safer, more efficient and more cost

3.3.2 Second, Third Boom Section Removal

1. Verify the boom assembly is setting on stable, secure
and suitable supports.

effective to remove the complete boom assembly from the
machine and place it on suitable supports for separation.
Work can then progress at a normal working height.

Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 2721 kg (6000 lbs).

1. Remove any attachment from the quick coupler. Refer
to Operation & Safety Manual.

2. Remove the quick coupler assembly. Refer to Section

3.17.1, “Quick Coupler Removal.”

3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.

4. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

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

6. Properly disconnect the battery.

7. Close engine cover to access lift/lower cylinder pin and
the compensation cylinder pin.

8. Properly support the boom assembly using a hoist or
crane.

9. Remove boom angle sensor arm. Refer to Section 9.8.7,
“Boom Angle Sensor.”

10. Remove the pin from the rod end of the lift/lower
cylinder being careful not to drop the cylinder. Lower
the cylinder to a secure position.

11. Remove the pin from the rod end of the compensation
cylinder being careful not to drop the cylinder. Lower
the cylinder to a secure position.

12. Lower the boom assembly to level.

13. Place a sling around the first boom section at the
balance points.

14. Label, disconnect and cap all hydraulic hoses attached
to the tubes on the bottom of the boom. Cap all fittings
and openings to keep dirt and debris from entering the
hydraulic system.

15. Raise the boom assembly to allow the removal of the
boom assembly pivot pins.

16. Confirm that the boom assembly is balanced with the
sling and remove the boom assembly pivot pins.

17. Lift the boom assembly from the machine and lower

2. Properly support the extend/retract cylinder (1) using a
hoist or crane.

3. Label, disconnect and cap the extend/retract cylinder
hoses (2) from the extend/retract cylinder. Cap all
fittings and openings to prevent dirt and debris from
entering the hydraulic system.

4. Loosen and remove the extend/retract cylinder bracket
(3).

5. Remove one retaining ring from the mounting pin (4) at
each end of the extend/retract cylinder.

6. Remove each mounting pin and remove the extend/
retract cylinder and place in a secure location.

7. Label, disconnect and cap the tilt circuit hoses from the
tilt cylinder at the front of the third boom section. Label,
disconnect and cap the auxiliary circuit hoses from the
quick disconnect fittings at the front of the third boom
section. Cap all fittings and openings to prevent dirt and
debris from entering the hydraulic system.

8. Place a sling through the opening at the top of the
boom head and around the tilt cylinder and remove the
retaining rings and pin at the barrel end of the tilt
cylinder. Lower the tilt cylinder and place in a secure
location.

9. Loosen and remove the rear cover and door assembly
from the rear of the first boom section.

onto suitable supports.

3614RS, 4017RS

3-5

Boom

MZ7080

6

7

5

5

M 7120Z

9

8

MZ7130

10

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

10. Disconnect both tilt hoses and (if equipped) both
auxiliary hoses (5) at the bottom of the first boom
section.Plug the hose ends and cap the tube ends to
prevent dirt and debris from entering the hydraulic
system. Pull the disconnected hoses out from the rear of
the boom.

11. Loosen and remove the lock nut and jam nut (6) on the
retract chain at the front of the first boom section.

12. Loosen and remove the lock nut and jam nut (7) on the
extend chain at the front of the first boom section.

13. Remove the circlip and pin (8) from the retract chain (9)
at the rear of the third boom section. Lay the retract
chain over the rear edge of the first boom section.

14. Pull the second and third boom sections out of the first
boom section approximately 304mm (12 in) to access
the front first section wear pads.

15. Remove all wear pads, shims and backing plates from
the front inside of the first boom section(10). Label and
tag each set of wear pads being removed.

16. Pull the second and third boom sections out of the first
boom section. Relocate the lifting slings and slowly pull
the two boom sections clear of the first boom section.
Lower onto suitable supports.

17. Inspect the first boom and welds. Consult your local
authorized service distributor if structural damage is
detected.

18. 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 3.15, “Boom Extend and Retract Chains - 3614RS
& 4017RS,” and Section 3.16.1, “Wear Pad Inspection.”)

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

Note: After removing the second and third boom section the
retract chain is left laying on the inside of the first boom section
and can be removed, cleaned, inspected and replaced if

3-6

required.

3614RS, 4017RS

3.3.3 Third Boom Section Removal

MZ7160

11

MZ7200

12

MZ7190

13

14

15

M 7150Z

16

Boom

2. Loosen and remove the mounting bolt (13) and bracket
(14) securing the extend chain clevis (15).

1. Pull the tilt hoses and (if equipped) the auxiliary hoses
from the rear of the third boom section.

Note: The bracket (11) holding the tilt hoses and (if equipped)
auxiliary hoses will still secure the tilt hoses and (if equipped)
auxiliary hoses when the top rear wear pads are removed.

Note: Remove the individual brackets (12) securing the tilt
hoses and (if equipped) auxiliary hoses to the main mounting
bracket (11).

3. Remove all wear pads, shims and backing plates from
the front inside of the second boom section (16). Label
and tag each set of wear pads being removed.

4. Place a sling around the third boom section, lift and
slowly pull the third boom section approximately half
way out of the second boom section. Lower the third
boom section onto a suitable support.

5. Relocate the sling or using two slings for better stability,
balance the third boom section and slowly pull it out of
the second boom section being careful not to damage
the hydraulic hoses or chains. Lower the third boom
sections onto suitable supports.

3614RS, 4017RS

Note: After removing the third boom section the extend chain
is left laying on the inside of the second boom section and can
be removed, cleaned, inspected and replaced if required.

3-7

Boom

MZ7210

1

MZ7190

4

3

2

3.3.4 Third Boom Section Installation

Note: During reassembly use Loctite® 243TM on all bolt threads.

Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear

Pads.” You may have to final adjust the wear pads after the
boom assembly is installed on the machine and hydraulic
power is available.

Note: Coat the interior of all bushings and bores with Mystik
Tetrimoly Grease XD#2 prior to the installation of pins and
bushings. Wear pads and slide areas must be lubricated with
Mystik Tetrimoly Grease XD#2 or an equivalent.

1. Place the second boom section on suitable supports.

2. Lubricate the inside second boom section on areas
where the third boom section wear pads will slide.

3. Lubricate and place the extend chain in the center of
the second boom section.

4. Using a suitable sling, balance the third boom section
and carefully slide the 1m-1,2m (3 ft-4 ft) of the third
boom section into the front of the second boom
section.

5. Set the third boom section onto a suitable support and
reset the sling under the boom head of the third boom
section. Carefully slide the third boom section into the
second boom section.

6. Leave 152 mm-203 mm (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.

7. With the sling still under boom head, install the wear
pads and spacers in the front of the second boom
section.

9. Install the extend chain clevis (2), mounting bracket (3)
and secure with bolt (4).

8. Install the previously removed tilt hoses and
(if equipped) the auxiliary hoses mounting bracket (1).

3-8

3614RS, 4017RS

3.3.5 Second and Third Boom Section

MZ7220

5

6

MZ7130

7

M 7120Z

9

8

Installation

1. Place the first boom section on suitable supports.

2. From the rear of the boom, feed the tilt hoses (5) and (if
equipped) auxiliary hoses (6) to the proper tube
connections on the bottom of the first boom section.

3. Tighten and torque the tilt hoses and (if equipped)
auxiliary hoses. Verify the hoses are aligned square to
the boom.

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

5. Lubricate and place the retract chain in the center of the
second boom section with 254mm (10 in) extending
from the rear of the first boom section.

6. Using a suitable sling, balance the second and third
boom sections and carefully slide 0,9 m-1,22 m
(3 ft-4 ft) into the front of the first boom section.

7. Set the second and third boom sections onto a suitable
support and reset the sling under the boom head of the
third boom section.

8. Carefully slide the two boom sections into the first
boom section. Leave 152 mm-203 mm (6 in-8 in) in of
the two boom sections out to be able to install the wear
pad block and the wear pads in the front of the first
boom section.

Boom

9. Install the wear pads, spacers and shims at the front of
the first boom section (7).

10. Install the pin (8) and circlip securing the retract chain
(9) at the rear of the third boom section.

3614RS, 4017RS

3-9

Boom

MZ7080

10

11

M 7120Z

13

12

M 7230Z

14

15

MZ7200

16

11. Install the retract chain (10) at the front of the first
boom section. Install the lock nut and jam nut. Do Not
Tighten at this time.

12. Install the extend chain (11) at the front of the first
boom section. Install the lock nut and jam nut. Do Not
Tighten at this time.

13. Feed the tilt hoses (12) and (if equipped) auxiliary hoses
(13) through the top of the third boom section.

14. Install the tilt cylinder in the boom head, install the
mounting pin and keeper bolt, locking the mounting
pin and tilt cylinder (14) into position.

15. Connect the tilt cylinder hoses to the proper fittings on
the tilt cylinder.

16. If equipped, connect the auxiliary hoses to the proper
fittings (15) on the boom head.

17. Install the individual brackets (16) securing the tilt
hoses and (if equipped) auxiliary hoses to the main
mounting bracket.

3-10

3614RS, 4017RS

MZ7090

17

18

19

18

20

M 7240Z

21

21

21

21

18. Properly support the extend/retract cylinder (17) using
a hoist or crane and lower into place.

19. Install each mounting pin (18) in the extend/retract
cylinder.

20. Install one retaining ring to the mounting pin (18) at
each end of the extend/retract cylinder.

21. Remove caps and/or plugs from all fittings and
openings. Connect the extend/retract cylinder hoses
(19) to the extend/retract cylinder.

22. Install the extend/retract cylinder bracket (20).

3.3.6 Complete Boom Installation

Note: Lubrication of the boom wear surfaces with
Multipurpose Grease is recommended to keep the boom wear
surfaces lubricated properly. Lubrication of the boom wear
surfaces is also recommended when the machine is stored, to
help prevent rusting.

1. Park the machine on a hard, level surface, place the
transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

Note: Grease the boom pivot bores, compensating cylinder rod
end, lift/lower cylinder rod end and pins before installing.

Boom

3. Using suitable slings, balance the boom assembly, lift
and carefully guide the boom into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install shims, boom pivot pins and lock bolt (21).

4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.

5. With the sling still in place, install the rod end of the lift/
lower cylinder, pin and lock bolt. Apply

®

Loctite

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

6. Uncap and connect the previously labeled extend/
retract cylinder hoses to the extend/retract cylinder.

7. Uncap and connect the previously labeled tilt hoses and
(if equipped) auxiliary hoses to the appropriate cylinder.

8. Install the boom angle sensor arm. Refer to Section

9.8.7, “Boom Angle Sensor.”

9. Remove slings and/or supports from the boom
assembly.

10. Properly connect the battery.

11. Start the engine and operate all boom functions several
times to bleed any air out of the hydraulic system. Check
for fluid leaks. Check the hydraulic fluid level in the tank
and add fluid as required.

12. Lower the boom assembly and shut engine OFF.

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

14. Remove the Do Not Operate Tag from both the ignition
key switch and the steering wheel.

243TM and torque to 90 Nm (66 lb-ft).

3614RS, 4017RS

3-11

Boom

M 7250Z

3

1

2

1

M 7120Z

4

5

6

3.4 BOOM CHAIN REMOVAL/INSTALLATION

- 3614RS

3.4.1 Retract Chain Removal

The removal of the retract chain can be accomplished with
out the complete tear down of the boom sections.

1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Safety Manual.

2. Park the machine on a hard, level surface, fully retract
the boom, level the boom assembly, place the
transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.

3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

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

5. Loosen and remove the rear cover and door assembly
from the rear of the first boom section.

6. Properly disconnect the battery.

9. Remove the circlip and pin (4) securing the retract chain
clevis (5) at the rear of the third boom section.

10. Pull the retract chain (6) from between the first and
second boom sections from the rear of the boom
assembly.

11. Unfasten the rope/wire from the retract chain clevis.

7. Remove the extend chain lock nut, adjusting nut (1) and
roller assembly (2). Secure extend chain to access the
removal of the retract chain.

8. Remove the retract chain lock nut and adjusting nut (3).
Fasten a rope/wire to the end of the clevis to aid in
reinstallation.

3.4.2 Retract Chain Installation

1. Fasten the rope/wire left in the boom from the retract
chain removal to the new retract chain clevis and pull
the chain through the boom sections to the
approximate final position. Remove the rope/wire.

2. Install the retract chain, pin and circlip (4) at the rear of
the third boom section.

3. Install the retract chain roller assembly, lock nut and
adjusting nut (3) at the front of the first boom section
below the boom head.

4. Install the rear cover and door assembly to the rear of
the first boom section.

5. Properly connect the battery.

6. Close and secure the engine cover.

7. For chain adjustments see Section 3.7.1, “Chain
Adjustments.”

3.4.3 Extend Chain Removal

The removal of the extend chains can be accomplished with
out the complete tear down of the boom sections.

1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Safety Manual.

3-12

3614RS, 4017RS

Boom

M 7250Z

1

2

MZ7190

3

4

5

2. Park the machine on a hard, level surface, fully retract
the boom, level the boom assembly, place the
transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.

3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

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

5. Properly disconnect the battery.

6. Loosen and remove the rear cover and door assembly
from the rear of the first boom section.

7. Loosen the extend chain lock nut and adjusting nut (1)
from the extend chain at the bottom of the first boom
section.

8. Remove the cotter pin and pin (2) securing the extend
chain to the extend chain clevis. Fasten a rope/wire to
the end of the clevis to aid in reinstallation.

Note: Removal of the retract chain from the rear of the third
boom section may be required to access the extend chain clevis
assembly.

9. Loosen and remove the mounting bolt (3) and bracket
(4) securing the extend chain clevis (5).

10. Pull the extend chain from between the second and
third boom sections at the rear of the machine.

11. Unfasten the rope/wire from the extend chain.

3.4.4 Extend Chain Installation

1. Fasten the rope/wire left in the boom from the extend
chain removal to the new extend chain and pull the
chain through the boom sections to the approximate
final position. Remove the rope/wire.

2. Install the extend chain clevis bracket (4) and mounting
bolt (3) to the extend chain clevis at the rear of the third
boom section.

3. Install the pin and cotter pin (2) securing the extend
chain to the extend chain clevis at the front of the boom
assembly.

4. Install the extend chain lock nut and adjusting nut (1) at
the front of the first boom section.

5. Install the rear cover and door assembly to the rear of
the first boom section.

6. Properly connect the battery.

7. Close and secure the engine cover.

8. For chain adjustments see Section 3.7.1, “Chain
Adjustments.”

3614RS, 4017RS

3-13

Boom

M 7230Z

1

2

MZ7220

3

4

MZ7200

5

3.5 TILT AND AUXILIARY CIRCUIT HOSE REMOVAL/INSTALLATION - 3614RS

Hoses that need replaced and are still in one piece can be
removed and replaced without removing sections of the
boom.

3.5.1 Tilt/Auxiliary Hose Removal

4. Loosen and remove the clamps (5) securing the tilt
hoses and (if equipped) auxiliary hoses at the rear of the
third boom section.

5. From the rear of the boom, pull the tilt hoses from
between the first and second boom sections.

6. From the rear of the boom, pull the tilt hoses from
inside the third boom section.

7. Unfasten the rope/wire from each end of the hose
assembly.

1. Label, disconnect and cap both hoses from the tilt
cylinder (1) and (if equipped) auxiliary fittings (2) at the
front of the boom. Cap all fittings and openings to keep
dirt and debris from entering the hydraulic system.

2. Label, disconnect and cap both tilt hoses (3) attached to
the tubes on the bottom of the boom. If equipped,
label, disconnect and cap both auxiliary hoses (3)
attached to the tubes on the bottom of the boom.Cap
all fittings and openings to keep dirt and debris from
entering the hydraulic system.

3. Fasten a rope/wire to the hose end below the first boom
section.

3.5.2 Tilt/Auxiliary Hose Installation

1. Fasten the rope/wire left in the boom from the hose
removal to each end of the new hose at the rear of
boom.

2. Slowly pull the rope/wire from the boom head until the
hose end is visible at the boom head.

3. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube
connections.

4. Unfasten the rope/wire from each end of the hose.

5. Uncap and connect the hoses to the previously labeled
tubes under the first boom section. Refer to Section

2.3.3, “Hydraulic Hose Torque Chart,” for proper hose
torque.

6. Uncap and connect the hoses to the previously labeled
fittings at the tilt cylinder or the auxiliary fittings. Refer
to Section 2.3.3, “Hydraulic Hose Torque Chart,” for
proper hose torque.

7. Install and tighten the clamps holding the tilt hoses at
the rear of the third boom section.

8. Properly connect the battery.

3-14

3614RS, 4017RS

Boom

MZ7090

6

9

7

9

8

MZ7810

10

11

3.6 EXTEND/RETRACT CYLINDER REMOVAL/ INSTALLATION - 3614RS

The extend/retract cylinder hydraulically extends and
retracts the third boom section.
Seal kits for the extend/retract cylinders are available from
the local JLG dealer.

3.6.1 Extend/Retract Cylinder Removal

1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Safety Manual.

2. Park the machine on a hard, level surface, extend the
boom to gain access to the extend/retract cylinder pin
in the third boom section, level the boom assembly,
place the transmission in (N) NEUTRAL, engage the park
brake and shut the engine OFF.

3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

3.6.2 Extend/Retract Cylinder Installation

1. Install the extend/retract cylinder (6) onto the top of the
boom assembly.

2. Install one mounting pin (9) at each end of the extend/
retract cylinder and secure with retaining ring.

3. Uncap and connect the hoses (7) to the previously
labeled fittings at the extend/retract cylinder.

4. Instal the extend/retract cylinder bracket (8).

5. Properly connect the battery.

6. Start the machine and cycle the extend/retract cylinder
checking for leaks or any alignment problems.

3.7 BOOM SECTIONS ADJUSTMENT ­3614RS

3.7.1 Chain Adjustments

The chains are adjusted by tightening and/or backing off the
adjusting nuts at the threaded end of the chains. The
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed.

The chains are properly adjusted whenever the following
parameters are met.

1. Start the machine, level the boom and retract the
extend/retract cylinder completely. Turn OFF engine.

4. Properly support the extend/retract cylinder (6) using a
hoist or crane.

5. Label, disconnect and cap the extend/retract cylinder
hoses (7) from the extend/retract cylinder. Cap all
fittings and openings to prevent dirt and debris from
entering the hydraulic system.

6. Loosen and remove the extend/retract cylinder bracket

7. Remove one retaining ring from the mounting pin (9) at

(8).

2. At the bottom front of the boom section, adjust the
extend chain (10) and retract chain (11) to achieve the
proper boom measurements.

3. Loosen the jam nut on each chain clevis.

each end of the extend/retract cylinder.

8. Remove each mounting pin and remove the extend/
retract cylinder and place in a secure location.

3614RS, 4017RS

3-15

Boom

MZ7820

A

M 7830Z

D

B

C

4. Adjust the boom chains to obtain dimension (A)
175,0-190,0mm (6.9-7.4 in).

Note: Ensure that there is a minimum of one full thread of the
clevis showing beyond the lock nut.

5. Start the machine and slowly extend and retract the
boom three times.

6. Retract the extend/retract cylinder completely. Turn
OFF engine

7. Repeat step 4 and 5 if necessary.

8. Tighten the extend/retract chain lock nuts (10 & 11) to
120 Nm (86 lb-ft) against the adjusting nut.

Note: Ensure that there is a minimum of one full thread of the
clevis showing beyond the lock nut.

9. Start the machine and cycle the extend/retract cylinder
to verify the boom extends and retracts properly.

10. With the boom level, extend the boom completely and
retract 50,0mm (2.0 in).

11. Verify dimensions (B) 3900,0mm (153.5 in) and (C)
1950,0mm (76.8 in) are correct.

12. Verify the SAG dimension (D) is 160-165mm
(6.3-6.5 in).

13. Adjust extend chain (10) if required. Repeat steps 9, 10
and 11 if necessary.

3-16

3614RS, 4017RS

3.8 BOOM SYSTEM COMPONENT

M 7260Z

EXTEND/RETRACT CYLINDER

FIRST BOOM SECTION

AUXI LIARY

CONNE CTIONS

(if equipped)

TILT CYLINDER

SECOND BOOM SECTION

THIRD BOOM

SECTION

FOURTH BOOM SECTION

EXTEND CHAIN

(fourth boom section)

RETRACT CHAIN

(fourth boom section)

(not shown)

EXTEND CHAINS - 2

(third boom section)

(not shown)

RETRACT CHAIN

(third boom section)

(not shown)

TERMINOLOGY - 4017RS

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.

Boom

3614RS, 4017RS

3-17

Boom

3.9 BOOM SYSTEM - 4017RS

3.9.1 Boom System Operation

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

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 chains pull the third and fourth boom
sections out of the second 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 chains 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.

3.10 BOOM ASSEMBLY MAINTENANCE ­4017RS

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

Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.The boom assembly consists of the first, second
and third section booms and supporting hardware.

Note: Before removing the boom or boom section, the carriage
or any other attachment must be removed from the quick
coupler.

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

During service of the boom, perform the following:

1. Check wear pads. (Refer to Section 3.16.1, “Wear Pad
Inspection.”)

2. Check chain rollers.

3. Apply grease at all lubrication points (grease fittings).
(Refer to Section 2.7, “Lubrication Schedule.”)

4. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.

Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.

3-18

WARNING

NEVER weld or drill the boom unless approved in writing

by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.

3614RS, 4017RS

Boom

MZ7270

4

2

3

4

1

3.10.1 Boom Removal

While the boom sections can be separated from each other
on the machine, it is much safer, more efficient and more
cost- effective to remove the complete boom assembly from

3.10.2 Second, Third and Fourth Boom Section Removal

1. Verify the boom assembly is setting on stable, secure
and suitable supports.

the machine and place it on suitable supports for separation.
Work can then progress at a normal working height.

Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 6000 lbs.

1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Safety Manual.

2. Remove the quick coupler assembly. Refer to Section

3.17.1, “Quick Coupler Removal.”

3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.

4. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

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

6. Properly disconnect the battery.

7. Close engine cover to access lift/lower cylinder pin and
the compensation cylinder pin.

8. Properly support the boom assembly using a hoist or
crane.

9. Remove boom angle sensor arm. Refer to Section 9.8.7,
“Boom Angle Sensor.”

10. Remove the pin from the rod end of the lift/lower
cylinder being careful not to drop the cylinder. Lower
the cylinder to a secure position.

11. Remove the pin from the rod end of the compensation
cylinder being careful not to drop the cylinder. Lower
the cylinder to a secure position.

12. Lower the boom assembly to level.

13. Place a sling around the first boom section at the
balance points.

14. Label, disconnect and cap all hydraulic hoses attached
to the tubes on the bottom of the boom. Cap all fittings
and openings to keep dirt and debris from entering the
hydraulic system.

15. Raise the boom assembly to allow the removal of the
boom assembly pivot pins.

16. Confirm that the boom assembly is balanced with the
sling and remove the boom assembly pivot pins.

17. Lift the boom assembly from the machine and lower
onto suitable supports.

2. Properly support the extend/retract cylinder (1) using a
hoist or crane.

3. Label, disconnect and cap the extend/retract cylinder
hoses (2) from the extend/retract cylinder. Cap all
fittings and openings to prevent dirt and debris from
entering the hydraulic system.

4. Loosen and remove the extend/retract cylinder bracket
(3).

5. Remove one retaining ring from the mounting pin (4) at
each end of the extend/retract cylinder.

6. Remove each mounting pin and remove the extend/
retract cylinder and place in a secure location.

7. Label, disconnect and cap the tilt circuit hoses from the
tilt cylinder at the front of the third boom section. Label,
disconnect and cap the auxiliary circuit hoses from the
quick disconnect fittings at the front of the third boom
section. Cap all fittings and openings to prevent dirt and
debris from entering the hydraulic system.

8. Place a sling through the opening at the top of the
boom head and around the tilt cylinder and remove the
retaining rings and pin at the barrel end of the tilt
cylinder. Lower the tilt cylinder and place in a secure
location.

9. Loosen and remove the rear cover and door assembly
from the rear of the first boom section.

3614RS, 4017RS

3-19

Boom

M 7280Z

6

5

7

MZ7290

10

9

8

11

M 7300Z

12

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

10. Loosen and remove the lock nut and jam nut (5) on the
retract chain at the front of the first boom section.

11. Loosen and remove the lock nuts and jam nuts (6) on
the extend chains at the front of the first boom section.

12. At the rear of the boom, label, disconnect and cap both
Tilt hoses (8) and (if equipped) both Auxiliary hoses (9)
from the brackets attached to the third boom section.
Cap all fittings to prevent dirt and debris from entering
the hydraulic system.

13. Remove the clip and pin (10) from the retract chain
clevis that is attached to the rear of the third section
boom. Lay the retract chain (11) over the rear of the first
boom section.

3-20

14. Pull the second, third and fourth section booms out 152
mm to 203 mm (6 in to 8 in) and remove all the wear
pads, shims and backing plates from the front inside of
the first section boom (12). Label all parts for
installation.

15. Using a sling around the front of the second boom
section, lift and slide the three boom sections 75% 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 the
remainder of the way out of the first boom section and
set the three boom sections down on suitable supports.

16. Remove the retract chain from the inside of the first
boom section. Clean and inspect chains. Replace if
damaged.

17. Label, disconnect and cap the Tilt and (if equipped)
Auxiliary hydraulic hoses from tubes at bottom front of
first boom section. Plug all fittings to prevent dirt and
debris from entering hydraulic system. Clean and
inspect the hoses. Replace if damaged.

18. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.

19. 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 3.15, “Boom Extend and Retract Chains - 3614RS
& 4017RS,” and Section 3.16.1, “Wear Pad Inspection.”)

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

3614RS, 4017RS

3.10.3 Third and Fourth Boom Section Removal

MZ7310

13

15

13

14

15

MZ7320

17

16

1. Verify the boom assembly is setting on stable, secure
and suitable supports.

Boom

Note: Removal of the retract chain roller from the rear of the
second boom section may be required to access the extend
chain clevis assemblies.

2. Loosen and remove the mounting bolts (13) and
bracket (14) securing each extend chain clevises (15).

3. Fasten a rope/wire to each extend chain clevis.

4. At the top front of the second boom section (16),
remove the jam nuts and nuts and washers from the
extend chain clevis (17).

5. Pull the third boom section out 152 mm to 203 mm (6 in
to 8 in). Remove the top wear pads, shims and backing
plate from the second boom section. Label and tag each
set of wear pads being removed.

6. Remove the side wear pads, shims and backing plates
from either side of the rear of the second boom section.
Label and tag each set of wear pads being removed.

7. Place a sling around the front of the third boom section.
Lift and slide the two boom sections 75% 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 the remainder of
the way out of the second boom section and set the
two boom sections down on suitable supports.

8. Remove the extend chains from bottom of second
boom section. Clean and inspect chain. Replace if
damaged.

9. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.

3614RS, 4017RS

3-21

Boom

MZ7330

18

20

19

22

21

MZ7350

24

23

25

10. Inspect hardware, wear pads, mounting points, chains
and other components visible with the second boom
section. Replace any item if damaged. (Refer to Section

3.15, “Boom Extend and Retract Chains - 3614RS &
4017RS,” and Section 3.16.1, “Wear Pad Inspection.”)

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

3.10.4 Fourth Boom Section Removal

1. Verify the boom assembly is setting on stable, secure
and suitable supports.

2. At the rear of the boom, loosen and remove the hose
brackets (18) attached to the third boom section
securing tilt hoses (19) and (if equipped) the auxiliary
hoses (20). Label, disconnect and cap both Tilt hoses
and (if equipped) both Auxiliary hoses. Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.

3. Remove the clip and pin from the retract chain clevis
(21) that is attached to the rear of the fourth section
boom. Lay the retract chain over the rear of the third
boom section.

4. Remove the retract chain from top of third boom
section. Clean and inspect chain. Replace if damaged.

5. Loosen and remove the two bolts securing the hose
carrier (22) to the third boom section.

6. At the top front of the third boom section (23), Lay the
extend chain and clevis (24) over the front of the fourth
boom section.(25).

7. Remove the top wear pads, shims and backing plate
from the third boom section. Label and tag each set of
wear pads being removed.

8. Remove all wear pads, shims and backing plates from
the front of the third boom section. Label and tag each
set of wear pads being removed.

9. Place a sling around the front of the fourth boom
section. Lift and slide the two boom sections 75% 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 two boom sections 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.

3-22

3614RS, 4017RS

10. Remove the extend chain (26) from top of fourth boom

MZ7360

26

MZ8370

27

29

30

28

section. Clean and inspect chain. Replace if damaged.

11. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.

12. Inspect hardware, wear pads, mounting points, chains
and other components visible with the second boom
section. Replace any item if damaged. (Refer to Section

3.15, “Boom Extend and Retract Chains - 3614RS &
4017RS,” and Section 3.16.1, “Wear Pad Inspection.”)

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

Boom

3.10.5 Fourth Boom Section Removal Only

Note: Removal and installation of the hose carrier can also be
performed by removing only the fourth boom section if
required.

1. Disconnect the extend chain clevis (27) from the rear of
the fourth boom section.

2. At the rear of the boom, label, disconnect and cap both
Tilt hoses (28) and (if equipped) both Auxiliary hoses
(29) from the tubes attached to the third boom section.
Cap all fittings to prevent dirt and debris from entering
the hydraulic system.

3. Loosen and remove the two bolts securing the hose
carrier (30) to the third boom section.

4. Remove all wear pads, shims and backing plates from
the front of the third boom section. Label and tag each
set of wear pads being removed.

5. Place a sling around the front of the fourth boom
section. Lift and slide the two boom sections 75% 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 two boom sections 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.

3614RS, 4017RS

3.10.6 Hose Carrier Removal/Installation

Refer to Section 3.11, “Hose Carrier Assembly,” for detailed
hose carrier removal and installation.

3-23

Boom

MZ7360

1

3.10.7 Fourth Boom Section Installation Only

1. Using a suitable sling, balance the 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.

2. With the sling still under boom head install the bottom
front wear pads and backing plates on the third boom
section. Lower the fourth boom section and install the
top front and side wear pads and backing plates on the
third boom section. Tighten as required.

3. Install the two bolts securing the hose carrier (30) to the
third boom section.

4. At the rear of the boom, remove the caps from both Tilt
hoses (28) and (if equipped) both Auxiliary hoses (29).
Connect each hose to the previously labeled tubes
attached to the third boom section.

5. Connect the extend chain clevis (27) to the rear of the
fourth boom section.

3.10.8 Fourth Boom Section Installation

Note: During reassembly use Loctite® 243TM on all bolt threads.

Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear

Pads.” You may have to final adjust the wear pads after the
boom assembly is installed on the machine and hydraulic
power is available.

Note: Coat the interior of all bushings and sheaves with Mystik
Tetrimoly Grease XD#2 prior to the installation of pins and
bushings. Wear pads and slide areas must be lubricated with
Mystik Tetrimoly Grease XD#2 or an equivalent.

3-24

1. Install the extend chain (1) on the top rear of fourth
boom section. Lay the extend chain 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.

3. Using a suitable sling, balance the 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.

3614RS, 4017RS

Boom

MZ7330

2

4

3

6

5

MZ7310

8

7

8

9

7

4. With the sling still under boom head install the bottom
front wear pads and backing plates on the third boom
section. Lower the fourth boom section and install the
top front and side wear pads and backing plates on the
third boom section. Do not shim or tighten bolts at this
time.

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

5. Retract the fourth boom section the remainder of the
way into the third boom section.

6. Shim all wear pads on the front of the third boom
section. Torque bolts to 90 Nm (66 lb-ft).

3.10.9 Third and Fourth Boom Section Installation

1. Install the extend chains on the bottom inside of second
boom section. Lay the extend chain the length of
second boom section.

2. Grease the inside second boom section on areas where
the third boom section wear pads will slide.

3. Using a suitable sling, balance the third and fourth
boom sections and carefully slide 914 mm-1219 mm
(3 ft - 4 ft) into the front of the second boom section. Set
the third and fourth boom sections onto a suitable
support and reset the sling under the boom head of the

7. At the rear of the boom, install the hose brackets (2) to
the third boom section securing tilt hoses (3) and (if
equipped) the auxiliary hoses (4).

8. Remove caps on both Tilt hoses and (if equipped) both
Auxiliary hoses. Install hoses and torque as required.

9. Lay the retract chain (5) the length of third boom
section.

10. Install the pin and clip to the retract chain clevis (5) to
the top rear of the fourth section boom.

11. Install the two bolts securing the hose carrier (6) to the
third boom section. Torque as required.

fourth boom section. Carefully slide the third and fourth
boom sections into the second boom section. Leave 152
mm-203 mm (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.

4. With the sling still under third boom section, install the
bottom front wear pads and backing plates on the
second boom section. Lower the third boom section
and install the top front and side wear pads and backing
plates on the second boom section. Do not shim or
tighten bolts at this time.

Note: Installation of the retract chain roller from the rear of the
second boom section may be required if removed to access the
extend chain clevis assemblies.

5. Secure the extend chains to the each extend chain
clevises (7)

6. Install the mounting bolts (8) and bracket (9) securing
each extend chain clevises (7).

3614RS, 4017RS

3-25

Boom

MZ7320

10

11

M 7610Z

12

MZ7220

13

14

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

3.10.10 Second, Third and Fourth Boom Section Installation

1. Install the retract chain (12) to bottom front inside of
the first boom section. Install the lock nut and jam nut.
Lay the retract chain over the rear of the first boom
section.

7. Install the extend chain (10) to the top front of the
second boom section (11). Install the lock nut and jam
nut.

8. Shim all wear pads on the rear of the third boom section
and front of the second boom section. Torque bolts to
90 Nm (66 lb-ft).

2. Install the tilt hoses (13) and auxiliary hoses (14) to the
tubes mounted at the bottom front of the first boom
section. Verify both sets of hoses are run through the
opening at the bottom front of the first boom section
and parallel with the retract chain. Lay the tilt hoses and
auxiliary hoses over the rear of the first boom section.

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

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

3-26

3614RS, 4017RS

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

M 7610Z

15

MZ7290

17

19

18

16

20

21

22

24

23

fourth boom sections 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
sections onto a suitable support and reset sling under
the boom head of the fourth boom section. Carefully
slide the second, third and fourth boom sections 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.

5. With the sling still under the third boom section, install
the bottom front wear pads and backing plates on the
first boom section. Lower the third boom section and
install the top front and side wear pads and backing
plates on the first boom section. Do not shim or tighten
bolts at this time.

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

Note: Shim wear pads as needed to maintain an even gap of
0,5-1,5 mm (0.002-0.06 in) between the wear pads and the next
boom section. The number of shims can vary at each shim
point.

7. Shim all wear pads on the rear of the second boom
section and front of the first boom section. Torque as
required.

Boom

9. Attach the retract chain (16), pins and clips to the
clevises (17) at the rear of the second boom section.

Note: Adjust all extend chains 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.

10. Remove the caps from the Tilt hoses (18)(and if
equipped) Auxiliary hoses (19) and connect to the
appropriate fittings at the rear of the second boom
section. Torque as required.

8. Attach the extend chains (15) at the bottom front of the
first boom section. Install the lock nut and jam nut.

3614RS, 4017RS

11. Using a suitable sling around the barrel end of the Tilt
cylinder (20), raise the Tilt cylinder into boom head.
Align the Tilt cylinder barrel end bore with the boom
head bore (21) and install the Tilt cylinder pin and
mounting bolt and nut (22).

3-27

Boom

MZ7270

27

30

29

28

25

26

M 7590Z

31

31

31

31

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

12. Remove the plugs from the fittings on the Tilt cylinder
and the caps from the Tilt hoses from the hose carrier.
Install both Tilt hoses (23). Torque as required.

13. If equipped, remove the plugs from the Auxiliary fittings
and the caps from the Auxiliary hoses from the hose
carrier. Install both Auxiliary hoses (24). Torque as
required.

14. Attach a sling around a balance point on the Extend/
Retract cylinder (25) 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.

15. Align the Extend/Retract cylinder barrel end (26) with
bore at rear of the first boom section. Install the pin and
retaining clip (27).

16. Align the Extend/Retract cylinder rod end with bore at
front of the second boom section. Install the pin and
retaining clip (28).

17. Install Extend/Retract cylinder support (29). Torque as
required.

18. Uncap and connect the previously labeled extend/
retract cylinder hoses (30) to the extend/retract
cylinder.

Note: Torque extend and retract chains lock/jam nuts to 115­125Nm (85-92 lb-ft).

3.10.11 Complete Boom Installation

1. Park the machine on a hard, level surface, place the
transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

3. Using suitable slings, balance the boom assembly, lift
and carefully guide the boom into place. Align the
frame pivot bores with the boom assembly pivot bores.
Install shims, boom pivot pins and lock bolt (31).

4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.

5. With the sling still in place, install the rod end of the lift/
lower cylinder, pin and lock bolt.

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

6. Uncap and connect the previously labeled extend/
retract cylinder hoses to the extend/retract cylinder.

7. Uncap and connect the previously labeled tilt hoses and
(if equipped) auxiliary hoses to the appropriate cylinder.

8. Install the boom angle sensor arm. Refer to Section

9.8.7, “Boom Angle Sensor.”

9. Remove slings and/or supports from the boom
assembly.

10. Start the engine and operate all boom functions several
times to bleed any air out of the hydraulic system. Check
for fluid leaks. Check the hydraulic fluid level in the tank
and add fluid as required.

11. Lower the boom assembly and shut engine OFF.

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

3-28

3614RS, 4017RS

Boom

M 7371Z

4

3

2

5

1

3

6

7

3.11 HOSE CARRIER ASSEMBLY

Note: Removal and installation of the hose carrier can also be
performed by removing only the fourth boom section if
required.

3.11.1 Hose Carrier Removal

1. Refer to Section 3.10.4, “Fourth Boom Section
Removal,”for detailed removal instructions.

2. Set the forth boom section on level ground, reposition
the slings and slowly turn the boom section over.
Reposition the slings and set the boom section on
suitable supports.

3.11.2 Hose Carrier Installation

1. Place a sling around the center of the hose carrier to be
able to balance the hose carrier while being installed.

2. Carefully slide the hose carrier (5) halfway into the
fourth boom section.

3. Remove the sling and push the hose carrier assembly
the remainder of way into the fourth boom section.

®

4. Apply Loctite
mounting bolts.

5. Install the twelve bolts (six per side)(4) on the fourth
boom section.

6. Install the mounting bolts (3) securing the tilt hoses and
(if equipped) both auxiliary hoses brackets at the rear of
the fourth boom section.

7. Insert the tilt hoses (6)(and if equipped) auxiliary hoses
(7) into the hose carrier tray (2).

8. Install the hose carrier tray (2) into the fourth boom
section and secure the hose carrier tray with mounting
bolts (1).

9. Using slings, slowly turn the boom section over.
Reposition the slings and set the boom section on
suitable supports.

10. Refer to Section 3.10.8, “Fourth Boom Section
Installation,” for detailed installation instructions.

TM

243

to the previously removed

3. Loosen and remove the two bolts (1) securing the hose
carrier tray (2).

4. Pull the tray (2) from the rear of the fourth boom
section.

5. With fourth boom section setting on suitable supports
loosen and remove the each bolt (3) securing the tilt
hoses and (if equipped) both auxiliary hoses brackets at
the rear of the fourth boom section.

6. Loosen and remove the twelve bolts (six per side)(4) on
the fourth boom section.

7. Pull the hose carrier (5) 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.

8. Carefully slide the hose carrier (5) the remainder of the
way out of the fourth boom section and set down on
suitable supports.

9. Secure the tilt hoses (and if equipped) the auxiliary
hoses with nylon ties. Remove tilt and/or auxiliary hoses
if required.

3.12 BOTTOM TILT AND AUXILIARY CIRCUIT
HOSE REMOVAL/INSTALLATION ­4017RS

3.12.1 Tilt/Auxiliary Hose Removal

The following procedures can be performed without
disassembling the boom assembly.

1. Remove any attachment from the quick coupler
assembly. Refer to Operation & Safety Manual.

2. Remove the quick coupler assembly. Refer to Section

3.17.1, “Quick Coupler Removal.”

3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF.

4. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

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

6. Properly disconnect the battery.

3614RS, 4017RS

3-29

Boom

MZ7520

35

36

MZ7220

35

36

M 7530Z

37

38

39

40

7. Label, disconnect and cap both Tilt hoses (35) and (if
equipped) both Auxiliary hoses (36). Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.

3.12.2 Tilt/Auxiliary Hose Installation

1. Fasten the rope/wire left in the boom from the hose
removal to each end of the new hose at the rear of
boom.

2. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube
connections.

3. Unfasten the rope/wire from each end of the hose.

4. Uncap and connect the hoses to the previously labeled
tubes under the first boom section. Refer to Section

2.3.3, “Hydraulic Hose Torque Chart,” for proper hose
torque.

5. Uncap and connect the hoses to the previously labeled
fittings at the tilt cylinder or the auxiliary fittings. Refer
to Section 2.3.3, “Hydraulic Hose Torque Chart,” for
proper hose torque.

6. Properly connect the battery.

3.12.3 Carrier Tilt/Auxiliary Hose Removal

8. Label, disconnect and cap both Tilt hoses (35) attached
to the tubes on the bottom of the boom. If equipped,
label, disconnect and cap both Auxiliary hoses (36)
attached to the tubes on the bottom of the boom.Cap
all fittings and openings to keep dirt and debris from
entering the hydraulic system.

9. Fasten a rope/wire to the hose end below the first boom
section.

10. From the rear of the boom, pull the tilt hoses (and if

second boom sections.

11. Unfasten the rope/wire from the end of the hose

equipped) auxiliary hoses from between the first and

assembly.

3-30

1. Label, disconnect and cap both Tilt hoses (37) and (if
equipped) both Auxiliary hoses (38). Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.

2. Fasten a rope/wire to the end of each disconnected
hose.

3. Loosen and remove lower clamp (39) securing both Tilt
hoses (37) and (if equipped) both Auxiliary hoses (38).

4. Slowly pull each hose assembly halfway out of the rear
boom assembly.

3614RS, 4017RS

Boom

MZ7570

38

37

M 7860Z

AB

C

5. Loosen and remove upper clamp (40) securing both Tilt
hoses (37) and (if equipped) both Auxiliary hoses (38).

6. Label, disconnect and cap both Tilt hoses (37) and
(if equipped) both Auxiliary hoses (38). Cap all fittings to
prevent dirt and debris from entering the hydraulic
system.

7. Slowly pull each hose assembly the remainder of the
way out of the rear boom assembly.

8. Disconnect the rope/wire from each end of the hose
assemblies.

3.13 BOOM CHAIN REMOVAL/INSTALLATION

- 4017RS

The removal of the extend and/or retract chain can only be
accomplished with the complete tear down of the boom.

3.14 BOOM SECTIONS ADJUSTMENT ­4017RS

3.14.1 Chain Adjustments

The chains are adjusted by tightening and/or backing off the
adjusting nuts at the threaded end of the chains. The
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed.

Fully retract and level the boom.

3.12.4 Carrier Tilt/Auxiliary Hose Installation

1. Connect the previously removed rope/wire to the new
Tilt hoses (37) and (if equipped) both Auxiliary hoses
(38).

2. Carefully feed the hoses through the rear of the boom
assembly while pulling the wire/rope connected to the
hose from the front of the boom head.

3. Carefully feed the hoses through the rear of the boom
assembly while pulling the wire/rope connected to the
hose from the bottom rear of the boom assembly.

4. Remove any caps and connect each Tilt hoses (37) and
(if equipped) both Auxiliary hoses (38) to the previously
labeled connection. Torque as required.

5. At the rear of the boom, tighten the previously
loosened clamps (39) securing the Tilt hoses (37) and (if
equipped) both Auxiliary hoses (38).

The boom is properly adjusted whenever the following
parameters are met.

A. 127-137mm (4.9-5.4 in)
B. 180-190mm (7.08-7.48 in)
C. 45mm (1.77 in) (No Adjustment)

If adjustments are needed: Start the machine, level the
boom and extend the boom 0,91m to 1,2m
(3 ft to 4 ft). Turn OFF engine.

3614RS, 4017RS

3-31

Boom

MZ7870

3

1

4

2

MZ7990

5

6

1. Loosen the locknuts on the extend and retract chains.

2. Adjust extend chains (1) and retract chain (2) to ensure
a gap of (B) between the back of the second boom
section and the back of the third boom section.

3. Adjust extend chain (3) and retract chain (4) to ensure a
gap of (A) between the back of the third boom section
and the back of the fourth boom section.

4. Tighten the extend and retract chain lock nuts to 120
Nm (86 lb-ft) against the adjusting nut.

11. The distance between the extend chains and the each
boom section should measure 140-145 mm (5.5-5.7 in).

12. Loosen the locknuts on the extend chains and adjust if
necessary. Tighten locknuts to 120 Nm (86 lb-ft).

13. Start the machine and cycle the extend/retract cylinder
to verify the boom extends and retracts properly.

Note: Ensure that there is a minimum of one full thread of the
clevis showing beyond the lock nut.

5. Start the machine and slowly extend and retract the
boom three times.

6. Retract the extend/retract cylinder completely. Turn
OFF engine.

7. Verify boom section dimensions. Repeat steps 1 thru 3 if
necessary.

8. Start the machine, lower the out riggers if necessary and
extend the boom to maximum extension, then retract
51 to 76 mm (2 to 3 in). Shut machine off.

9. Measure the distance (5) between the top of extend
chain and the top of the third boom section.

10. Measure the distance (6) between the top of both
extend chains and the bottom of the second boom
section.

3-32

3614RS, 4017RS

Boom

3.15 BOOM EXTEND AND RETRACT

CHAINS - 3614RS & 4017RS

3.15.1 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.

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 corrosive or highly corrosive 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 articulation.

3.15.2 Inspection Guidelines - 3614RS

a. Retract Chain

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

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

3. The retract chain will be visible for inspection with the
vehicle in this state.

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

b. Extend Chains

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

2. Fully retract the boom. Shut the engine off.

3. Both extend chain clevises and pins will be visible for
inspection with the vehicle in this state.

4. Limited visual inspection of the extend chains is
possible. For complete extend chain inspection, the
extend chains must be removed from the boom. For
extend chain removal, refer to Section 3.4.3, “Extend
Chain Removal,” and Section 3.4.4, “Extend Chain
Installation.”

5. Inspect the extend and retract chains every 250 hours of
operation.

6. Inspect the chains for the following conditions:

3614RS, 4017RS

3-33

Boom

MZ1463

2

1

MY1360

3

4

MZ1463

1

2

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%.
Measure and compare to a normal link plate height by
measuring a portion of chain that does not run over the
sheave. If the measured plate height (1) is 5% less than
the normal plate height (2), discard and replace the
chain.

Elongation

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 the middle of the chains.

It is best to measure in 12 pin increments from pin
center to pin center. For example, if the links are
25 mm (1 in) from pin center to pin center, the distance
should be 305 mm (12 in). If the links are 19 mm (.75 in)
apart, the distance after 12 pins should be 229 mm (9
in).

3.15.3 Inspection Guidelines - 4017RS

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

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.

If the distance measured (3) is 3% greater than the
normal length (4), discard and replace the chain.

3-34

b. Extend Chains (third to second section)

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.

3614RS, 4017RS

Boom

MY1360

3

4

8

MZ1466

5

MZ1465

6

7

8

Elongation

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)

Distorted or Battered Link Plates

Distorted or battered link plates (5) on a leaf chain can cause
tight joints and prevent flexing.

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.

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.

Examine the pin head rivets to determine if the “VEE”
flats are still in correct alignment (6). Chain with rotated/
displaced heads (7) or abnormal pin protrusion (8)
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.

3614RS, 4017RS

3-35

Boom

MZ1467

1

MZ1468

2

MZ1469

MZ1470

3

4

MZ1471

5

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 (1) 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 (2).

• 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

• Ultimate Strength Failure -

These types of failures are
caused by overloads far in
excess of the design load.
Either fractured plates (3) or
enlarged holes (4) can occur. If
either of these failures occurs,
the chain should be replaced
immediately.

• Tight Joints ­All joints in
the chain
should flex
freely. Tight
joints (5)
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.

3.15.4 Expose Chains for Inspection

c. Retract Chain

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

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

The retract chain 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, if any chain is found to be damaged
or stretched, the chain must
that when any chain is replaced, that all the chains and
clevises be replaced at the same time.

d. Extend Chains

The extend 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 extend chain as the boom is slowly
extended. If there is ANY question that one or both extend
chains are damaged, the extend chains should be removed,
inspected and replaced if necessary.

Refer to Section 3.15, “Boom Extend and Retract Chains ­3614RS & 4017RS.”

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’
time.

be replaced. It is recommended

be replaced at the same

3-36

3614RS, 4017RS

Boom

M 7680Z

1

1

MAM1390

2

3

4

3.15.5 Chain Lubrication

After inspection and before being returned to service,
chains must be lubricated with Multipurpose Grease-NLGI
Grade 2.

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.

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. Refer to Section 2.6, “Service and
Maintenance Schedules,” and Section 2.7, “Lubrication
Schedule,” for detailed information.

Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special
consideration. Contact the JLG dealer for guidance.

3.16 BOOM WEAR PADS

The boom wear pads are flat rectangular plastic blocks with
metal inserts.

3.16.1 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicators (1) 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.

3.16.2 Boom Wear Pad Installation/Lubrication

The boom has been factory lubricated for proper wear pad
break-in and will normally require minor further lubrication.
However, after replacing any wear pad(s), or after prolonged
periods of inoperation, lubrication of the boom wear surfaces
with Multipurpose Grease is recommended to keep the
boom wear surfaces lubricated properly. Lubrication of the
boom wear surfaces is also recommended when the
machine is stored, to help prevent rusting.

The following wear pad procedure must be followed to
insure the proper wear pad installation:

• The wear pad inserts and mounting bolts MUST be
clean before mounting bolts are installed.

• Apply Loctite

®

243TM to all wear pad mounting bolts.

3614RS, 4017RS

• A spacer (2) with holes must be used before any shim
(3) is used.

• A shim (3) must inserted between the spacer (2) and
wear pad support plate, block or boom section (4).

• The number of shims can vary at each shim point.

• The bottom wear pads must be shimmed equally on

3-37

Boom

MZ7660

5

MY3620

A

B

MZ7690

6

8

7

8

9

each side.

• Maintain a total boom section clearance of
0,5-1,5mm (0.020 to 0.060 in) between the wear pad
and the next boom section (5).

3.17 QUICK COUPLER

Note: The following procedures covers all styles of quick
couplers.

3.17.1 Quick Coupler Removal

1. Lower attachment to ground, tilt forward to access
coupler pin, set park brake and turn off engine.

2. If equipped with a hydraulic quick coupler device, refer
to Operation & Safety Manual.

• The length of the wear pad bolt depends on the
number of shims, spacers and washers being used.

• The thickness of each threaded wear pad insert is 10mm
(0.393 in) (A).

• The bolt length should be determined by measuring
the distance from the face of the insert to the face of the
boom (B) including any spacer, shim(s) and washer(s).

• Bolt thread engagement in the wear pad insert should
not extend.

• One or two hardened washers are to be used on each
wear pad bolt except where noted otherwise.
DO NOT use more than two hardened washers.

3. Remove the bolts and lock bracket (6) holding the rod
end tilt cylinder pin to the quick coupler assembly.
Remove the rod end pin (7).

4. Support the quick coupler assembly. Remove the bolts
(8) and pin (9) from the quick coupler assembly.

5. Inspect the above pins 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.

• Use only one hardened washer if mounting bolts are
recessed.

• Wear Pad Bolt Torque:
M12 x 20, 95-105Nm - M12 x 25, 95-105Nm
M12 x 30, 95-105Nm - M12 x 35, 95-105Nm
M12 x 40, 95-105Nm - M12 x 80, 95-105Nm

• Lubricate the face and pockets of each wear pad after
being installed.

Boom Section Wear Pad Pathway Lubrication:

• Clean and lightly grease all wear pad pathways with
Multipurpose Grease.

• Clean and lightly grease the hose carrier guide bar
pathway with Multipurpose Grease.

3-38

3.17.2 Quick Coupler Installation

1. Apply Loctite® 243TM to all mounting bolts.

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

3. Coat the quick coupler pivot pin with Anti-Seize Lube.
Insert the quick coupler pivot pin (9) through the quick
coupler and boom head. Secure with the previously
removed bolts (8).

4. Align the quick coupler with the rod end tilt cylinder
and insert the coupler pin (7) and replace the lock
bracket and bolt assembly (6).

3614RS, 4017RS

Boom

MH6460

12

11

15

16

14

10

13

15

14

17

18

MAM4080

20

21

20

19

5. If equipped, reconnect the hydraulic attachment hoses
to the quick disconnect fittings on the left side of the
boom head.

3.18 FORKS

Forks should be cleaned and inspected prior to being
attached to carriage. If the following criteria is not met, forks
must be removed from service immediately.

3.19 BOOM PROP (IF EQUIPPED)

WARNING

A raised boom can fall if a hydraulic component is
removed. Remove any load, retract the boom and install
the boom prop or a suitable supporting stand before
working under a raised boom.

3.19.1 Installation and Removal Procedures

a. Prop Installation

1. Park the machine on a firm, level surface. Place the
transmission in (N) NEUTRAL, engage the park brake
switch.

2. Raise the boom to an angle of approximately 20
degrees. Stop engine.

3. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.

4. Before installing the boom prop, inspect the prop for
damage. Do not use if the prop is damaged or if the
locking pins are damaged or missing.

Daily Inspection

1. Inspect forks (10) for cracks, paying special attention to
heel (11) and mounting tubes (12).

2. Inspect forks for broken or bent tips (13) and twisted
blades (14) and shanks (15).

Yearly Inspection

1. Straightness of the upper face of blade (14) and the
front face of shank (15) should not exceed 0.5 percent of
the length of blade or height of shank.

2. Angle (16) between upper face of blade and front face
of shank should not exceed 93 degrees.

3. Thickness of blade (14) and shank (15) should not be
reduced to 90 percent of original thickness.

Note: Contact the local JLG dealer with the fork part number to
find the manufactured dimensions of the fork blade.

4. Ensure fork length (17) is adequate for intended loads.

5. Fork markings should be legible, re-stamp if required.

6. Compare fork tips (18) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent of
the length of the blade (17).

3614RS, 4017RS

5. Align lift cylinder prop (19) so the locking pins (20) are
on the bottom side of the lift/lower cylinder rod (21).
Install the boom prop (19) onto the lift/lower cylinder
(19). Install locking pins (20).

3-39

Boom

6. Start the engine and SLOWLY lower the boom until
there is a clearance of 6 mm (0.25 in) between the end
of the boom prop and the lift/lower cylinder rod end

(21).

NOTICE

EQUIPMENT DAMAGE. DO NOT operate with the boom
prop in place. Damage to the boom prop and/or the lift/
lower cylinder could occur.

7. Shut OFF engine.

b. Prop Removal

1. If needed, start machine and slowly raise the boom until
the boom prop is clear of the lift/lower rod end.

2. Remove the locking pins (20) and boom prop (19) from
the lift cylinder. Return the boom prop to the proper
location and secure.

3. Lower boom, shut engine OFF.

3.20 EMERGENCY BOOM LOWERING PROCEDURE

WARNING

To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting the
lift cylinder. If circumstances prevent retraction of the
extend/retract cylinder first, lower the lift cylinder the
minimum amount necessary and resume retraction of
the extend/retract cylinder as soon as possible.

3.20.1 Equipment and Supplies Required

Auxiliary Hydraulic Power Supply:

• Portable hydraulic unit or another machine with an
auxiliary hydraulic power supply with a capacity to
hold up to 35 L (9 gal) of hydraulic oil from the
machine during lowering process.

NOTICE

EQUIPMENT DAMAGE. Auxiliary Hydraulic Power
Supply hydraulic oil must be compatible with hydraulic
oil shown in Section 2.5, “Fluids, Lubricants and
Capacities.”

Hoses:

• Two Hydraulic Hoses - Approximately 3,0 m
(10 ft) each, with a minimum I.D. of
9,5 mm (0.375 in) and a minimum rating of
275,8 bar (4000 psi).

Fittings:

• Two -8 EO Caps

• Two -8 EO Plugs

Adaptors:

• Two -8 EO Adaptors

Note: Machine extend/retract and lift/lower hoses are -8 ORFS.
The adaptor size may vary depending on the hose ends of the
auxiliary hydraulic power supply.

3-40

3614RS, 4017RS

Boom

MZ7710

7

4

6

5

VIEW FROM REAR OF CAB

3.20.2 Lowering Procedure

a. Retract the boom as follows:

1. Remove the cover at the rear corner of the cab.

2. Place a suitable receptacle under the main control valve.

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

b. Lower the boom as follows:

1. Place a suitable receptacle under the main control valve.

2. Label and disconnect the lift/lower cylinder hoses
(6 & 7) from the main control valve. Install plugs in hoses
to prevent fluid loss. Cap all fittings and openings to
keep dirt and debris from entering the hydraulic system.

Note: Loss of hydraulic oil is limited to the amount trapped
within each hose.

3. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
and the hoses removed from the main control valve lift/
lower section of the affected machine. Hose (7) is the
supply (lower) and hose (6) is the return. Connect the
hoses in the proper order to ensure that the boom is
lowered, not raised.

4. Use the auxiliary power supply to lower the boom.

5. Loosen and remove the jumper hoses and reconnect
the lift/lower cylinder hoses.

6. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil.” Dispose
of used oil at an approved recycling facility.

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

8. Install the previously removed rear cover.

3. Label and disconnect the extend/retract cylinder hoses
(4 & 5) from the main control valve. Install plugs in hoses
to prevent fluid loss. Cap all fittings and openings to
keep dirt and debris from entering the hydraulic system.

Note: Loss of hydraulic oil is limited to the amount trapped
within each hose.

4. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
and the hoses removed from the main control valve
extend/retract section of the affected machine. Retract
hose (5) is the supply and extend hose (4) is the return.
Connect the hoses in the proper order to ensure that
the cylinder is retracted, not extended.

5. Use the auxiliary power supply to retract the extend/
retract cylinder.

6. Loosen and remove the jumper hoses and reconnect
the extend/retract cylinder hoses.

7. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil.” Dispose
of used oil at an approved recycling facility.

3614RS, 4017RS

3-41

Boom

3.21 TROUBLESHOOTING

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

Problem Possible Causes Remedy

1. Boom will not extend or retract 1. Broken hydraulic hose(s) or
tube(s) and/or connections
leaking.

2. Extend/retract hydraulic system
not operating properly.

3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section

2. Boom shifts to right or left when
extending.

3. Excessive pivot pin noise and/or
wear.

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

1. Boom side wear pads improperly
shimmed or worn.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn bearing(s). 2. Replace bearing(s) and lubricate

1. Insufficient lubrication. 1. Lubricate at regular intervals.

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

2. Refer to Section 8.5, “Hydraulic
Circuits.”

8.10.1, “General Cylinder Removal
Instructions.”

1. Shim wear pads to correct gap.
Replace wear pads as needed.
Refer to Section 3.16, “Boom Wear
Pads.”

Refer to Section 2.7, “Lubrication
Schedule.” Replace worn pins as
needed.

at regular intervals Refer to
Section 2.7, “Lubrication
Schedule.”

Refer to Section 2.7, “Lubrication
Schedule.” Replace worn pins as
needed.

2. Worn bushing(s). 2. Replace bushing(s) and lubricate

5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes
and/or connection leaks.

2. Lift/lower hydraulic system not
operating properly.

3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

4. Seized boom pivot pin bushing. 4. Replace bushing.

3-42

at regular intervals.

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

2. Refer to Section 8.5, “Hydraulic
Circuits.”

8.10.1, “General Cylinder Removal
Instructions.”

3614RS, 4017RS

Problem Possible Causes Remedy

Boom

6. Drooping chain, or jerky boom
extend or retract functions.

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

1. Chain(s) tension not properly
adjusted.

2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to

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. 6. Replace the damaged boom

1. Insufficient lubrication. 1. Lubricate at regular intervals.

1. Adjust chain(s).

Section 3.7, “Boom Sections
Adjustment - 3614RS.”

3. Replace wear pad. Refer to Section

3.16, “Boom Wear Pads.”

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 8.5, “Hydraulic
Circuits.”

section.

Refer to Section 2.6, “Service and
Maintenance Schedules.” Replace
worn pins as needed. Refer to
Section 8.10.1, “General Cylinder
Removal Instructions.”

2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate
at regular intervals. Refer to
Section 2.7, “Lubrication
Schedule.”

8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct
as needed. Refer to Section 3.16,
“Boom Wear Pads.”

9. Auxiliary hydraulics will not

operate.

2. Rapid cycle times with heavy
loads.

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

4. Operating in extremely dusty/
abrasive conditions.

1. Auxiliary hydraulic system not
operating properly.

2. Reduce cycle times.

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

4. Clean equipment frequently.

1. Refer to Section , “Running H/F 1.”

3614RS, 4017RS

3-43

Boom

Problem Possible Causes Remedy

10. Excessive chain wear. 1. Improper chain adjustment. 1. Adjust to correct tension. Refer to
Section 3.15, “Boom Extend and
Retract Chains - 3614RS &
4017RS.”- Replace chains as
needed.

2. Chain sheave(s) not properly
lubricated.

3. Chain sheave(s) not rotating
freely.

4. Improper chain lubrication. 4. Lubricate at regular intervals.

2. Lubricate chain sheave. Refer to
Section 2.6, “Service and
Maintenance Schedules.”

3. Lubricate chain sheave. Refer to
Section 2.6, “Service and
Maintenance Schedules.” Repair or
replace chain sheave(s) as needed.

Refer to Section 2.6, “Service and
Maintenance Schedules.” Replace
chains as needed.

3-44

3614RS, 4017RS

Section 4

Cab

Contents

PARAGRAPH TITLE PAGE

4.1 Operator Cab Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.2 Serial Number Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.2 Steering Column/Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.3 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.4 Electronic Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.5 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.6 Window Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.3.7 Heater/Air Conditioning System (if Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.8 Air Conditioning (if Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

3614RS, 4017RS

4-1

Cab

MZ0770

JOYSTICK

CAPACITY

CHART

STEERING WHEEL

FRAME LEVEL

INDICATOR

ACCESSORY CONTROL

LEVER

ACCELER ATOR

PEDAL

SERVICE BRAKE PEDAL

CONSO LE
SWITCHES

INSTRUMENT

CLUSTER

PAR K BRA KE

CONSOLE SWITCHES

CLIMATE

CONT ROLS

TRANSMISSION

CONTROL LEVER

STEERING

COLUM N

ADJUSTER

IGNITION

SWITCH

LSI INDICATOR

4.1 OPERATOR CAB COMPONENT TERMINOLOGY

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

4-2

3614RS, 4017RS

Cab

MAH0430

1

3

2

4.2 OPERATOR CAB

WARNING

DO NOT service the machine without following all safety

precautions as outlined in the “Safety Practices” section of
this manual.

4.2.1 Operator 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, grade, and torqued to their specified value.

WARNING

DO NOT weld, grind, drill, repair or modify the cab in any

way. Any modification or damage to cab structural
components requires cab replacement.

4.3 CAB COMPONENTS

4.3.1 Steering Wheel

a. Steering Wheel Removal

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

2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.

3. Open engine covers. Allow system fluids to cool.

4. Properly disconnect battery.

Refer to the appropriate parts manual for ordering
information.

4.2.2 Serial Number Plate

The cab serial number plate is located on the left side of the
cab, below 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.

5. Carefully pry center button (1) out of steering wheel.

6. Mark steering wheel and shaft to ensure proper
installation. Remove nut (2) securing the steering wheel
(3) to splined steering column shaft.

7. Use a steering wheel puller to remove steering wheel (3)
from splined shaft.

b. Steering Wheel Installation

1. Install steering wheel (3) onto splined steering column
shaft.

2. Secure steering wheel with nut (2).

3. Press center button (1) onto steering wheel.

4. Properly connect battery.

5. Close and secure engine covers.

6. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

3614RS, 4017RS

4-3

Cab

M 7770Z

UPPER COVER

LOWER COVER

MAM3930

1

2

4

3

5

6

4.3.2 Steering Column/Orbitrol Valve

a. Steering Column and Orbitrol Valve Removal

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

2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.

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

4. Properly disconnect battery.

5. Remove lower dash panel in cab.

6. Remove access covers from front of cab.

7. Label, disconnect and cap hydraulic hoses attached to
orbitrol valve (1).

8. Remove steering wheel (2). Refer to Section 4.3.1,
“Steering Wheel.”

9. Disconnect and remove the accessory control lever (3),
and if equipped, transmission control lever (4).
Disconnect control lever(s) harness from the main cab
harness.

10. Have an assistant hold the orbitrol valve from outside of
cab. Remove bolts (5) securing orbitrol valve to cab.

11. Remove the steering column (6) through the dash panel
opening.

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

b. Steering Column and Orbitrol Valve Installation

1. Install steering column to original orientation in cab.

2. Have an assistant hold orbitrol valve in original
orientation from outside cab. Install steering column to
valve with previously removed hardware.

3. Install accessory control lever, and if equipped,
transmission control lever. Connect control lever(s)
harness connector to main cab harness and install steering
wheel assembly.

4. Uncap and connect previously labeled hydraulic hoses
to orbitrol valve.

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

6. Properly connect battery.

7. Start engine and check operation of steering system.
Check for hydraulic fluid leaks. Check hydraulic fluid
level in tank and add fluid as required.

8. Install access covers to front of cab.

9. Install lower dash panel in cab.

10. Close and secure engine cover.

11. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

c. Steering Test

Conduct a pressure check of the steering hydraulic circuits at
the main control valve. Refer to Section 8.4.1, “Pressure
Checks and Adjustments.”

4-4

3614RS, 4017RS

4.3.3 Service Brake

M 7770Z

UPPER COVER

LOWER COVER

M 7790Z

7

a. Brake Valve Removal

Refer to Section 8.9.2, “Service Brake Valve,” for removal
information.

b. Brake Valve Installation

Refer to Section 8.9.2, “Service Brake Valve,” for installation
information.

4.3.4 Electronic Throttle Pedal

a. Throttle Pedal Removal

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

2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.

3. Open engine covers. Allow system fluids to cool.

4. Properly disconnect battery.

Cab

6. Remove hardware (7) securing pedal assembly.

7. Disconnect electrical connection to pedal assembly.

8. Remove throttle pedal assembly from cab.

5. Remove access covers from front of cab.

b. Throttle Pedal Installation

1. Position throttle pedal in its mounting location in cab.

2. Reconnect electrical connection to pedal assembly.

3. Secure throttle pedal into position with previously used
hardware (7).

4. Install protective covers.

5. Properly connect battery.

6. Close and secure engine cover.

7. Remove Do Not Operate Tag from ignition key switch
and the steering wheel.

3614RS, 4017RS

4-5

Cab

M 7800Z

3

4.3.5 Joystick Assembly

a. Joystick Assembly Removal

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

2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.

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

4. Properly disconnect battery.

b. Joystick Assembly Installation

1. Connect previously labeled electrical connectors
to joystick.

2. Secure joystick assembly to cab using hardware
removed earlier.

3. Properly connect battery.

4. Test joystick functions.

5. Close and secure engine cover.

6. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

4.3.6 Window Wiper Assembly

Refer to Section 9.7, “Wiper/Washer Wiper Motor,” for
removal and installation information.

4.3.7 Heater/Air Conditioning System (if Equipped)

Note: If machine is equipped with air conditioning,
DO NOT loosen or disconnect any air conditioning hoses until
the air conditioning system has been properly drained by the
local distributor or certified air conditioning service center.

5. Remove hardware securing joystick assembly (3).

6. Lift joystick from its mounting position.

7. Label and disconnect electrical connectors attached to
joystick.

8. Remove joystick assembly.

a. Heater Assembly Removal

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

2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.

3. Open engine covers. Allow system fluids to cool.

4. Properly disconnect battery.

5. Place a suitable container beneath radiator. Slowly turn
surge tank cap and allow any pressure to escape.
Remove surge tank cap.

6. Place a funnel at base of radiator to channel drained
coolant into container. Remove drain plug and allow
coolant to drain.

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

8. Tighten radiator drain plug.

4-6

3614RS, 4017RS

9. Remove heater cover (4) inside cab.

M 7850Z

4

M 7770Z

UPPER COVER

LOWER COVER

M 7840Z

5

5

Cab

11. Label and disconnect electrical connections.

12. Label and remove hoses connected to heater.

13. If equipped, label and disconnect air conditioning hoses
attached to heater assembly.

14. Remove bolts (5) securing heater assembly to cab.
Remove heater assembly.

10. Remove access covers from front of cab.

b. Heater Assembly Installation

1. Position heater assembly to original orientation to cab.
Secure with previously removed hardware.

2. Connect previously labeled electrical connections.

3. Connect previously labeled heater hoses to appropriate
locations.

4. If equipped, connect previously labeled air conditioning
hoses to appropriate locations.

5. Fill cooling system completely with coolant, allowing
time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.5, “Fluids,
Lubricants and Capacities.”

6. Properly connect battery.

7. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.

Note: STOP engine immediately if any leakage is noted, and
make any necessary repairs before continuing.

8. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.

9. Install protective covers.

10. Install heater cover inside cab.

11. Close and secure the engine cover.

12. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

3614RS, 4017RS

4-7

Cab

M 7840Z

2

3

M 7890Z

4.3.8 Air Conditioning (if Equipped)

If the air conditioning system requires servicing, contact the
local JLG dealer or certified air conditioning service center.
Refer to Section 2.5, “Fluids, Lubricants and Capacities,” for
refrigerant type and capacity.

4.4 CAB REMOVAL

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.

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

Inspect cab, its welds and mounts. If modification, damage, a
cracked weld and/or fatigued metal is discovered, replace
cab. Contact local JLG dealer with any questions about
suitability or condition of a cab.

9. Label, disconnect and cap all hydraulic hoses attached
to the steering orbitrol valve (2). Cap all fittings and
openings to keep dirt and debris from entering
hydraulic system.

10. Label, disconnect and cap all hydraulic hoses attached
to the brake assembly (3). Cap all fittings and openings
to keep dirt and debris from entering hydraulic system.

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

1. Park machine on a firm, level surface. Allow sufficient
overhead and side clearance for cab removal. Level
machine, fully retract boom, lower boom, place travel
select lever in (N) NEUTRAL position, engage park brake
and shut engine OFF.

2. Block all four wheels to help prevent machine from
moving. Assure that there is sufficient overhead and
side clearance for cab removal.

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

4. Properly disconnect battery.

5. Place a funnel at base of cooling system to channel
drained coolant into suitable container. Remove drain
plug and allow coolant to drain.

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

7. Replace and tighten drain plug.

8. Label and disconnect cab heater hoses. Refer to Section

4.3.7, “Heater/Air Conditioning System (if Equipped).”

11. Remove rear cab cover and securing hardware.

12. Disconnect cab ground strap.

13. Label and disconnect the cab harness connectors. Move
the harnesses clear of the cab to prevent damage
during cab removal.

4-8

3614RS, 4017RS

14. Install four lifting eye bolts with a minimum lifting

M 7910Z

4

4

M 7900Z

5

5

capacity of 363 kg (800 lb) in the existing lifting holes at
the top corners of the cab (4).

15. Use a hoist or overhead crane and sling with a minimum
lifting capacity of 363 kg (800 lb) attached to the four
eye bolts. DO NOT attempt to lift the cab at this point.

Cab

18. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift cab
and remove it from frame. Readjust position of sling as
needed to help balance cab during removal.

19. When cab is completely clear of machine, carefully
lower it to ground. Block up or support cab so it does
not move or fall.

20. Assure that no personnel enter cab while it is being
removed from machine.

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

16. Remove four bolts (5) securing cab to frame.

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

3614RS, 4017RS

4-9

Cab

4.5 CAB INSTALLATION

1. Block all four wheels to help prevent machine from
moving. Assure that there is sufficient overhead and
side clearance for cab installation.

2. Attach a sling with a minimum lifting capacity of
363 kg (800 lb) through lifting eyes of cab.

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

4. Install four cab to frame mount bolts, washers and nuts to
145–155 Nm (107–114 lb-ft).

5. Connect previously labeled cab harness connectors to
their appropriate locations.

6. Reconnect cab ground strap.

7. Uncap and reconnect previously labeled hydraulic
hoses to their appropriate locations.

8. Reconnect any remaining electrical connections to their
appropriate locations.

9. Reconnect heater hoses to cab heater. Refer to Section

4.3.7, “Heater/Air Conditioning System (if Equipped).”

10. Fill cooling system completely with coolant, allowing
time for coolant to fill engine block. Cooling system
capacity is listed in Section 2.5, “Fluids, Lubricants and
Capacities.”

11. Properly connect battery.

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

13. Start engine and check operation of all controls. Check for
hydraulic fluid leaks. Check hydraulic fluid level in tank
and add fluid as required.

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

14. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.

15. Install protective covers to front of cab.

16. Install the mirrors and all other cab components as
needed, if removed.

17. Install protective cover to rear of cab.

18. Unblock wheels.

19. Close and secure engine cover.

20. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

4-10

3614RS, 4017RS

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 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.1 Axle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6 Park Brake adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.8 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.9 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.9.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.9.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.9.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.9.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.9.5 Drive Shaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.10 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.10.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.10.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

3614RS, 4017RS

5-1

Axles, Drive Shafts, Wheels and Tires

MZ8360

FRONT AXLE

ASSEMBLY

FRONT STEERING

CYLINDER

REAR DRIVE SHAFT

REAR STEERING

CYLINDER

REAR AXLE
ASSEMBLY

TRANSMISSION

REAR AXLE WHEEL

HUBS

MZ8350

FRONT AXLE WHEEL

HUB

FRONT AXLE

ASSEMBLY

FRONT DRIVE SHAFT

FRONT DRIVE SHAFT

FRONT STEERING

CYLINDER

TRANSMISSION

REAR DRIVE SHAFT

REAR STEERING

CYLINDER

REAR AXLE WHEEL

HUBS

REAR AXLE
ASSEMBLY

3614RS

4017RS

FRONT AXLE WHEEL

HUB

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

3614RS, 4017RS

WARNING

DO NOT service the machine without following all safety

precautions as outlined in the “Safety Practices” section of
this manual.

Axles, Drive Shafts, Wheels and Tires

5.4 AXLE REPLACEMENT

5.4.1 Axle Removal

WARNING

5.2 AXLE SERIAL NUMBER

Front and rear axle serial number plate is located on the
inside of each axle on right side of the center section.
Information on the serial number plate is required in
correspondence regarding the axle.

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

5.3 AXLE SPECIFICATIONS AND MAINTENANCE INFORMATION

For axle, oil specifications and maintenance information,
refer to Section 2.5, “Fluids, Lubricants and Capacities.”

Detailed axle service instructions are provided in the
following publications:

• Axle Service Manual (P/N 31200162)

• Parts Manual (P/N 31200939)

An improperly supported machine can fall. 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 front axle
assembly is equipped with a parking brake mechanism and a
limited slip feature; rear axle has neither. The following steps
outline a typical axle removal procedure, suitable for either
front or rear axle assembly.

Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
spraying water or cleaning solution on electrical
components. If using a steam cleaner, seal all openings
before steam cleaning.

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

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

2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.

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

4. Properly disconnect battery.

5. Remove bolts securing fender assembly to axle.

3614RS, 4017RS

5-3

Axles, Drive Shafts, Wheels and Tires

M 7620Z

M 7630Z

2

1

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

7. Disconnect LSI sensor at the rear axle.

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

9. 3614RS Front Axle Only - Disconnect park brake cable.

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

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

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

13. Remove both the wheel and the tire assemblies
from the axle that is being removed. Refer to
Section 5.10.1, “Removing Wheel and Tire Assembly
from Machine.”

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

14. Remove the drive shaft assembly. Refer to Section 5.9.3,
“Drive Shaft Removal.”

15. On front axle, remove capscrew and locknuts securing
lower position cylinder-mount pin to the front cylinder.
Tap the cylinder mount pin out, and move the cylinder
to prevent it from interfering with axle removal.

16. Remove bolts and locknuts securing axle to frame.

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

5.4.2 Axle Installation

1. If applicable, raise 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.

2. Before proceeding, ensure machine will remain in place
during axle installation.

3. Block front and rear of both tires on axle that is already
installed on machine.

4. Using a suitable jack, hoist or overhead crane and sling,
remove axle from its support or holding stand. Balance
axle and prevent it from tipping, turning or falling while
positioning it beneath machine. DO NOT raise or
otherwise disturb machine while installing the axle.

5. Keep axle supported and balanced on the jack, hoist or
overhead crane and sling throughout the installation
procedure.

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

7. Apply Loctite

8. Install axle mounting bolts and nuts. Tighten and torque
as required.

9. Install the drive shaft assemblies. Refer to Section 5.9.5,
“Drive Shaft Installation.”

10. If reinstalling an axle previously removed from machine,
position driveshaft yoke on axle according to alignment
marks made earlier.

11. If installing a new axle, note position of driveshaft yoke
at transmission. Align driveshaft yoke on axle in same
plane as yoke on transmission.

12. Connect the steering and brake lines at axle.

®

262 to each mounting bolt.

5-4

3614RS, 4017RS

Axles, Drive Shafts, Wheels and Tires

M 7620Z

3

4

1

MT0220

2

13. 3614RS Front Axle Only - Connect park brake cable.

14. Tighten axle oil drain plugs (1), loosen and remove the
axle oil fill plug (3). Loosen and remove check fill plug
(4). Fill until oil level reaches bottom of check fill plug.
Refer to Section 2.5, “Fluids, Lubricants and Capacities,”
for proper oil and capacities.

22. Check hydraulic reservoir oil level.

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

24. Install fender assembly. Torque as required.

25. Properly connect battery.

26. Close and secure engine cover.

27. Remove Do Not Operate Tag from ignition key switch
and steering wheel.

Note: Service brake circuit will need to bled after axle
installation. Refer to Section 8.9.3, “Service Brake Bleeding.”

5.5 BRAKE INSPECTION

Detailed axle service instructions are provided in the Axle
Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information.”

15. Rotate wheel hubs 90 degrees so wheel hub drain plug
becomes the fill plug (2). Refer to Section 2.5, “Fluids,
Lubricants and Capacities,” for proper oil and capacities.

16. Install the wheel and tire assemblies. Refer to Section

5.10.2, “Installing Wheel and Tire Assembly onto
Machine.”

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

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

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

Note:

ALWAYS use new o-rings when servicing machine.

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

21. Uncap and connect steering and brake lines at their axle
fittings.

3614RS, 4017RS

5-5

Axles, Drive Shafts, Wheels and Tires

60MM

MAM4100

2

1

5.6 PARK BRAKE ADJUSTMENT - 3614RS

1. Park the machine on a slight grade, fully retract boom,
level the boom, place transmission in (N) NEUTRAL, set
the parking brake. The machine should not move. If the
machine moves, adjust the park brake.

2. Apply service brake and disengage the park brake.

3. Depress the release lever (1) and push the park brake
lever (2) down.

4. Adjust the park brake cable by turning the adjuster
knob (2) clockwise to increase park brake force. Turn the
adjuster knob counterclockwise to decrease park brake
force.

5. If park brake cannot be adjusted, refer to Section 5.3,
“Axle Specifications and Maintenance Information,” for
detailed axle information.

5.7 STEERING ANGLE ADJUSTMENT

Detailed axle service instructions are provided in the Axle
Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information.”

5-6

3614RS, 4017RS