JLG 4017 Service Manual - Manual (Page 92)

Engine: Perkins 1004-40T
7.6 4017
12. Loosen clamp on the lower radiator hose (6). Work
the hose off the radiator. Position the hose out of the
way to allow radiator removal, or remove the hose
from the engine. Inspect the hose, and replace if
necessary.
13. Disconnect and plug the transmission inlet (7) and
outlet hoses (8) and cap the fittings on the oil cooler.
Remove the clamp holding the top transmission
cooler hose and the three bolts holding the fan
screen.
14. Remove the four nuts and four washers from the four
radiator mounts (9).
15. Connect a lifting strap to the radiator/oil cooler and
carefully lift the radiator/oil cooler out of the engine
bay.
Note: If applicable the radiator can be removed with the
radiator frame. Remove the five bolts holding the radiator
frame to the machine frame and remove the radiator and
radiator frame as one unit.
b. Radiator/Oil Cooler Installation
Note: ALWAYS replace elastic locknuts with new elastic
locknuts to help ensure proper fastening.
1. Install the isolator mounts to the bottom of the
radiator. Insert radiator through the machine frame
mounts and install the washers and new elastic
locknuts.
2. At the top of the radiator, install the isolator mounts.
Install the washers and new elastic locknuts on the
back side of the weldment.
3. At the lower radiator return hose, and with the clamp
installed over the hose, work the hose onto the
radiator, and tighten the clamp.
4. Uncap and connect transmission inlet and outlet
hoses to the radiator.
5. At the upper radiator hose, and with the clamp
installed over the hose, work the hose onto the
radiator, and tighten the clamp.
6. Install the radiator overflow bottle and reconnect the
overflow hoses.
7. Open the radiator cap and fill the radiator completely
with a 50/50 mixture of ethylene glycol and water.
Replace and tighten the radiator cap. Add coolant to
the overflow bottle until the bottle is
1/4 to 1/2 full. This overfilling will compensate for any
air trapped in the cooling system.
8. Connect the negative (-) battery cable to the battery
negative (-) terminal.
9. Run the engine to operating temperature. Visually
check for leaks with the engine running. Check the
coolant level in the overflow bottle and fill, or drain,
as necessary.
10. Install the engine belly pan.
11. Install, close and secure the engine cover.
7.5 ENGINE ELECTRICAL SYSTEM
The engine electrical system, including the starter,
alternator and primary wiring, is described in Section 9.5,
“Electrical System Schematics.”
7.6 FUEL SYSTEM
7.6.1 Diesel Fuel
Fuel represents a major portion of machine operating
costs and therefore must be used efficiently. ALWAYS
use a premium brand of high-quality, clean diesel fuel.
Low cost, inferior fuel can lead to poor performance and
expensive engine repair.
Note: Use only diesel fuel designed for diesel engines.
Some heating fuels contain harmful chemicals that can
seriously affect engine efficiency and performance.
IMPORTANT: Due to the precise tolerances of diesel
injection systems, keep the fuel clean, and free of dirt
and water. Dirt and water in the fuel system can cause
severe damage to both the injection pump and the
injection nozzles. Use ASTM #2 diesel fuel with a
minimum Cetane rating of 40. #2 diesel fuel gives the
best economy and performance under most operating
conditions. Fuels with Cetane numbers higher than 40
may be needed in high altitudes or extremely low
ambient temperatures to help prevent misfiring and
excessive smoking.
Inform the owner/operator of the machine to use #2
diesel fuel, unless ambient temperatures are below 0° C
(32° F). When temperatures are below 0° C (32° F), a
blend of #1 diesel and #2 diesel fuels (known as
“winterized” #2 diesel) may be used.
Note: #1 diesel fuel may be used, however, fuel
economy will be reduced.
Use a low-sulfur content fuel with a cloud point (the
temperature at which wax crystals form in diesel fuel) at
least 10° below the lowest expected fuel temperature.
The viscosity of the fuel must be kept above 1.3
centistrokes to provide adequate fuel system lubrication.
Note: When using diesel fuel with a sulfur content below
1.3 percent, the filter change interval must be reduced by