Document Outline

• 31200940_A_3614RS 4017RS_JLG_Service
  • Effectivity Page
  • Table of Contents
  • Section 1 Safety Practices
    • 1.1 Introduction
    • 1.2 Disclaimer
    • 1.3 Operation & Safety Manual
    • 1.4 Do Not Operate Tags
    • 1.5 Safety Information
    • 1.6 Safety Alert System and Signal Words
    • 1.7 Safety Instructions
      • 1.7.1 Personal Hazards
      • 1.7.2 Equipment Hazards
      • 1.7.3 General Hazards
      • 1.7.4 Operational Hazards
    • 1.8 Safety Decals
  • Section 2 General Information and Specifications
    • 2.1 Replacement Parts and Warranty Information
    • 2.2 Thread Locking Compound
    • 2.3 Torque Charts
      • 2.3.1 SAE Fastener Torque Chart
      • 2.3.2 Metric Fastener Torque Chart
      • 2.3.3 Hydraulic Hose Torque Chart
    • 2.4 Specifications
      • 2.4.1 Travel Speeds
      • 2.4.2 Hydraulic Cylinder Performance
      • 2.4.3 Electrical System
      • 2.4.4 Engine Performance Specifications
      • 2.4.5 Transmission Performance Specifications
      • 2.4.6 Tires
    • 2.5 Fluids, Lubricants and Capacities
    • 2.6 Service and Maintenance Schedules
      • 2.6.1 10 & 1st 50 Hour
      • 2.6.2 50 & 1st 250 Hour
      • 2.6.3 250 & 500 Hour
      • 2.6.4 1000 & 3000 Hour
      • 2.6.5 6000 & 12000 Hour
    • 2.7 Lubrication Schedule
      • 2.7.1 3614RS
      • 2.7.2 4017RS
  • Section 3 Boom
    • 3.1 Boom System Component Terminology - 3614RS
    • 3.2 Boom System - 3614RS
      • 3.2.1 Boom System Operation
    • 3.3 Boom Assembly Maintenance - 3614RS
      • 3.3.1 Boom Removal
      • 3.3.2 Second, Third Boom Section Removal
      • 3.3.3 Third Boom Section Removal
      • 3.3.4 Third Boom Section Installation
      • 3.3.5 Second and Third Boom Section Installation
      • 3.3.6 Complete Boom Installation
    • 3.4 Boom Chain Removal/Installation - 3614RS
      • 3.4.1 Retract Chain Removal
      • 3.4.2 Retract Chain Installation
      • 3.4.3 Extend Chain Removal
      • 3.4.4 Extend Chain Installation
    • 3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - 3614RS
      • 3.5.1 Tilt/Auxiliary Hose Removal
      • 3.5.2 Tilt/Auxiliary Hose Installation
    • 3.6 Extend/Retract Cylinder Removal/ Installation - 3614RS
      • 3.6.1 Extend/Retract Cylinder Removal
      • 3.6.2 Extend/Retract Cylinder Installation
    • 3.7 Boom Sections Adjustment - 3614RS
      • 3.7.1 Chain Adjustments
    • 3.8 Boom System Component Terminology - 4017RS
    • 3.9 Boom System - 4017RS
      • 3.9.1 Boom System Operation
    • 3.10 Boom Assembly Maintenance - 4017RS
      • 3.10.1 Boom Removal
      • 3.10.2 Second, Third and Fourth Boom Section Removal
      • 3.10.3 Third and Fourth Boom Section Removal
      • 3.10.4 Fourth Boom Section Removal
      • 3.10.5 Fourth Boom Section Removal Only
      • 3.10.6 Hose Carrier Removal/Installation
      • 3.10.7 Fourth Boom Section Installation Only
      • 3.10.8 Fourth Boom Section Installation
      • 3.10.9 Third and Fourth Boom Section Installation
      • 3.10.10 Second, Third and Fourth Boom Section Installation
      • 3.10.11 Complete Boom Installation
    • 3.11 Hose Carrier Assembly
      • 3.11.1 Hose Carrier Removal
      • 3.11.2 Hose Carrier Installation
    • 3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - 4017RS
      • 3.12.1 Tilt/Auxiliary Hose Removal
      • 3.12.2 Tilt/Auxiliary Hose Installation
      • 3.12.3 Carrier Tilt/Auxiliary Hose Removal
      • 3.12.4 Carrier Tilt/Auxiliary Hose Installation
    • 3.13 Boom Chain Removal/Installation - 4017RS
    • 3.14 Boom Sections Adjustment - 4017RS
      • 3.14.1 Chain Adjustments
    • 3.15 Boom Extend and Retract Chains - 3614RS & 4017RS
      • 3.15.1 Boom Chain Inspection
      • 3.15.2 Inspection Guidelines - 3614RS
      • 3.15.3 Inspection Guidelines - 4017RS
      • 3.15.4 Expose Chains for Inspection
      • 3.15.5 Chain Lubrication
    • 3.16 Boom Wear Pads
      • 3.16.1 Wear Pad Inspection
      • 3.16.2 Boom Wear Pad Installation/Lubrication
    • 3.17 Quick Coupler
      • 3.17.1 Quick Coupler Removal
      • 3.17.2 Quick Coupler Installation
    • 3.18 Forks
    • 3.19 Boom Prop (If Equipped)
      • 3.19.1 Installation and Removal Procedures
    • 3.20 Emergency Boom Lowering Procedure
      • 3.20.1 Equipment and Supplies Required
      • 3.20.2 Lowering Procedure
    • 3.21 Troubleshooting
  • Section 4 Cab
    • 4.1 Operator Cab Component Terminology
    • 4.2 Operator Cab
      • 4.2.1 Operator Cab Safety
      • 4.2.2 Serial Number Plate
    • 4.3 Cab Components
      • 4.3.1 Steering Wheel
      • 4.3.2 Steering Column/Orbitrol Valve
      • 4.3.3 Service Brake
      • 4.3.4 Electronic Throttle Pedal
      • 4.3.5 Joystick Assembly
      • 4.3.6 Window Wiper Assembly
      • 4.3.7 Heater/Air Conditioning System (if Equipped)
      • 4.3.8 Air Conditioning (if Equipped)
    • 4.4 Cab Removal
    • 4.5 Cab Installation
  • Section 5 Axles, Drive Shafts, Wheels and Tires
    • 5.1 Axle, Drive Shaft and Wheel Component Terminology
    • 5.2 Axle Serial Number
    • 5.3 Axle Specifications and Maintenance Information
    • 5.4 Axle Replacement
      • 5.4.1 Axle Removal
      • 5.4.2 Axle Installation
    • 5.5 Brake Inspection
    • 5.6 Park Brake adjustment - 3614RS
    • 5.7 Steering Angle Adjustment
    • 5.8 Axle Assembly and Drive Shaft Troubleshooting
    • 5.9 Drive Shafts
      • 5.9.1 Drive Shaft Inspection
      • 5.9.2 Drive Shaft Maintenance
      • 5.9.3 Drive Shaft Removal
      • 5.9.4 Drive Shaft Cleaning and Drying
      • 5.9.5 Drive Shaft Installation
    • 5.10 Wheels and Tires
      • 5.10.1 Removing Wheel and Tire Assembly from Machine
      • 5.10.2 Installing Wheel and Tire Assembly onto Machine
    • 5.11 Towing a Disabled Machine
      • 5.11.1 3614RS Only
      • 5.11.2 4017RS Only
      • 5.11.3 Manually Resetting the Park Brake
  • Section 6 Transmission
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Transmission Serial Number
    • 6.3 Specifications and Maintenance Information
    • 6.4 Transmission Replacement
      • 6.4.1 Transmission Removal
      • 6.4.2 Transmission Installation
      • 6.4.3 After Transmission Service or Replacement
      • 6.4.4 Transmission Torque Converter Stall Test
    • 6.5 Torque Convertor Diaphragm
      • 6.5.1 Torque Convertor Diaphragm Removal/ Installation
    • 6.6 Troubleshooting
  • Section 7 Engine
    • 7.1 Introduction
      • 7.1.1 Disclaimer and Scope
    • 7.2 Engine Serial Number
    • 7.3 Specifications and Maintenance Information
      • 7.3.1 Component Terminology
    • 7.4 Engine Cooling System
      • 7.4.1 Surge Tank Cap
      • 7.4.2 Thermostat Replacement
      • 7.4.3 Radiator Assembly Replacement
    • 7.5 Engine Electrical System
    • 7.6 Fuel System
      • 7.6.1 Diesel Fuel
      • 7.6.2 Fuel Tank
      • 7.6.3 After Fuel System Service
    • 7.7 Engine Exhaust System
      • 7.7.1 Exhaust System Removal—ULS
      • 7.7.2 Exhaust System Installation—ULS
      • 7.7.3 Exhaust System Removal—LS
      • 7.7.4 Exhaust System Installation—LS
    • 7.8 Air Cleaner Assembly
      • 7.8.1 Air Cleaner Assembly Removal
      • 7.8.2 Air Cleaner Assembly Installation
    • 7.9 Engine Replacement
      • 7.9.1 Engine/Transmission Removal
      • 7.9.2 Transmission Removal/Installation
      • 7.9.3 Engine Disassembly, Inspection and Service
      • 7.9.4 Engine/Transmission Installation
    • 7.10 Troubleshooting
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 Specifications
    • 8.4 Hydraulic Pressure Diagnosis
      • 8.4.1 Pressure Checks and Adjustments
    • 8.5 Hydraulic Circuits
      • 8.5.1 Hydraulic Pressures
    • 8.6 Hydraulic Schematics
      • 8.6.1 3614RS
      • 8.6.2 4017RS
    • 8.7 Hydraulic Reservoir
      • 8.7.1 Hydraulic Oil Reservoir Draining
      • 8.7.2 Hydraulic Oil Reservoir Filling
      • 8.7.3 Hydraulic Oil Reservoir Removal/ Installation
    • 8.8 Engine Implement Pump
      • 8.8.1 Pump Replacement
    • 8.9 Control Valves
      • 8.9.1 Main Control Valve
      • 8.9.2 Service Brake Valve
      • 8.9.3 Service Brake Bleeding
      • 8.9.4 Service Brake Test
      • 8.9.5 Steering Orbitrol Valve
      • 8.9.6 Outrigger/Stabilizer Valve and Brake Damper
      • 8.9.7 Brake Damper
      • 8.9.8 Brake Damper Charging
      • 8.9.9 Pre-Charging Damper
      • 8.9.10 Checking Pre-Charge
      • 8.9.11 Steer Select Valve
    • 8.10 Hydraulic Cylinders
      • 8.10.1 General Cylinder Removal Instructions
      • 8.10.2 Cylinder Pressure Checking
      • 8.10.3 Steering Cylinders
      • 8.10.4 Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
      • 9.1.1 General Overview
    • 9.2 Specifications
    • 9.3 Safety Information
    • 9.4 Power Distribution Board
    • 9.5 Electrical System Schematics
      • 9.5.1 Cab Harness Electrical Schematic 1 of 2
      • 9.5.2 Cab Harness Electrical Schematic 2 of 2
      • 9.5.3 Frame
      • 9.5.4 Battery
      • 9.5.5 Power Distribution Board
      • 9.5.6 Engine
      • 9.5.7 Option Harnesses
    • 9.6 Engine Start Circuit
      • 9.6.1 Starter
      • 9.6.2 Charging Circuit
      • 9.6.3 Alternator
    • 9.7 Wiper/Washer Wiper Motor
      • 9.7.1 Front Windshield Wiper Motor
      • 9.7.2 Rear Window Wiper Motor
      • 9.7.3 Roof Window Wiper Motor
      • 9.7.4 Washer Tank
    • 9.8 Solenoids, Sensors and Senders
      • 9.8.1 Transmission Solenoid Valves
      • 9.8.2 Transmission Oil Temperature Switch
      • 9.8.3 Transmission Mounted Speed Sensor
      • 9.8.4 Engine Coolant Temperature Sensor
      • 9.8.5 Fuel Level Sender
      • 9.8.6 Boom Retract Sensor
      • 9.8.7 Boom Angle Sensor
      • 9.8.8 Back-up Alarm
    • 9.9 Dash Switches
      • 9.9.1 Ignition Key Switch
      • 9.9.2 Dash Switches
    • 9.10 Load Stability Indicator (LSI)
      • 9.10.1 Load Stability Indicator
      • 9.10.2 LSI Sensor
      • 9.10.3 LSI System Calibration
      • 9.10.4 LSI-CAN Check PT
      • 9.10.5 500 Hour - LSI UGM Calibration Check
    • 9.11 Hand Held Analyzer
      • 9.11.1 Analyzer Usage
      • 9.11.2 Analyzer Software Version V6.3
    • 9.12 Fault Codes
      • 9.12.1 Indicator Cross Reference Table
    • 9.13 Machine Fault Codes
      • 9.13.1 Help Comment (00X)
      • 9.13.2 Power Up (21X)
      • 9.13.3 Cabin Controls (23X)
      • 9.13.4 Function Prevented (25X)
      • 9.13.5 Output Drivers (33X)
      • 9.13.6 Engine (43X)
      • 9.13.7 Battery Supply (44X)
      • 9.13.8 Transmission & Drive System (46X)
      • 9.13.9 Communications (66X)
      • 9.13.10 Load Moment (85X)
      • 9.13.11 Hardware (99X)