Document Outline

• 3121858_C_JLG_4017_Service
  • Effectivity
  • Table of Contents
    • 1.1 Introduction 1.2
    • 1.2 Disclaimer 1.2
    • 1.3 Operator & Safety Manual 1.2
    • 1.4 Accident Prevention Tags 1.2
    • 1.5 Safety Information 1.3
    • 1.6 Safety Instructions 1.3
    • 1.7 Emergency Exit Rear Window 1.5
    • 1.8 Safety Decals 1.5
  • Section 1 Safety Practices
    • 1.1 Introduction
    • 1.2 Disclaimer
    • 1.3 Operator & Safety Manual
    • 1.4 Accident Prevention Tags
    • 1.5 Safety Information
      • 1.5.1 Safety Alert System and Signal Words
    • 1.6 Safety Instructions
      • 1.6.1 Personal Hazards
      • 1.6.2 Equipment Hazards
      • 1.6.3 General Hazards
      • 1.6.4 Operational Hazards
    • 1.7 Emergency Exit Rear Window
    • 1.8 Safety Decals
  • Section 2 General Information and Specifications
    • 2.1 Replacement Parts and Warranty Information
    • 2.2 Torques
      • 2.2.1 ASTM Fastener Torque Chart (English)
      • 2.2.2 ASTM Fastener Torque Chart (Metric)
      • 2.2.3 Metric Fastener Torque Chart
    • 2.3 Specifications
      • 2.3.1 Travel Speeds
      • 2.3.2 Engine Performance Specifications
      • 2.3.3 Hydraulic Cylinder Performance
      • 2.3.4 Tires
      • 2.3.5 Axles
      • 2.3.6 Electrical System
    • 2.4 Fluids, Lubricants and Capacities
    • 2.5 Service and Maintenance Schedules
      • 2.5.1 8 & 1st 50 Hour Maintenance Schedule
      • 2.5.2 50, 250 & 500 Hour Maintenance Schedule
      • 2.5.3 1000 & 1500 Hour Maintenance Schedule
    • 2.6 Lubrication Schedules
      • 2.6.1 8 Hour Lube Schedule
      • 2.6.2 50 Hour Lube Schedule
  • Section 3 Boom
    • 3.1 Boom System Component Terminology
    • 3.2 Boom System
      • 3.2.1 Boom System Operation
    • 3.3 Boom Assembly Maintenance
      • 3.3.1 Boom Removal
      • 3.3.2 Second, Third & Fourth Boom Section Removal
      • 3.3.3 Third & Fourth Boom Section Removal
      • 3.3.4 Fourth Boom Section Removal
      • 3.3.5 Hose Carrier Removal
      • 3.3.6 Hose Carrier Installation
      • 3.3.7 Fourth Boom Section Installation
      • 3.3.8 Third & Fourth Boom Section Installation
      • 3.3.9 Second, Third & Fourth Boom Section Installation
      • 3.3.10 Boom Installation
    • 3.4 Boom Extend and Retract Chains
      • 3.4.1 Boom Chain Inspection
      • 3.4.2 Inspection Guidelines
      • 3.4.3 Expose Chains for Inspection
      • 3.4.4 Chain Lubrication
    • 3.5 Boom Section Separation Adjustment
    • 3.6 Hose Carrier Assembly
      • 3.6.1 Hose Carrier Assembly Removal
      • 3.6.2 Hose Carrier Assembly Replacement
    • 3.7 Boom Wear Pads
      • 3.7.1 Wear Pad Inspection
      • 3.7.2 Boom Wear Pad Replacement
      • 3.7.3 Boom Wear Pad Lubrication
    • 3.8 Quick Switch Assembly
      • 3.8.1 Connecting with a Mechanical Quick Switch Device
      • 3.8.2 Connecting with a Hydraulic Quick Switch Device
      • 3.8.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment
      • 3.8.4 Quick Switch Removal
      • 3.8.5 Quick Switch Installation
    • 3.9 Troubleshooting
  • Section 4 Cab and Covers
    • 4.1 Operator’s Cab and Covers Component Terminology
    • 4.2 Operator’s Cab
      • 4.2.1 Cab Safety
      • 4.2.2 Serial Number Decal
    • 4.3 Cab Components
      • 4.3.1 Steering Column and Orbitrol Valve
      • 4.3.2 Service Brake Pedal
      • 4.3.3 Throttle Pedal
      • 4.3.4 Joystick Assembly
      • 4.3.5 Windshield Wiper Assembly
      • 4.3.6 Heater/Defroster System
    • 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 General Information
    • 5.3 Axle Assemblies
      • 5.3.1 Axle Service and Troubleshooting
      • 5.3.2 Axle Serial Number Plate
      • 5.3.3 Axle Specifications
      • 5.3.4 Axle Maintenance
      • 5.3.5 Axle Removal
      • 5.3.6 Axle Assembly and Drive Shaft Troubleshooting
    • 5.4 Drive Shafts
      • 5.4.1 Drive Shaft Inspection and Service
      • 5.4.2 Drive Shaft Maintenance
      • 5.4.3 Drive Shaft Removal
      • 5.4.4 Drive Shaft Installation
    • 5.5 Wheels and Tires
      • 5.5.1 Removing Wheel and Tire Assembly from machine
      • 5.5.2 Installing Wheel and Tire Assembly onto machine
    • 5.6 Brakes
      • 5.6.1 Brake Disk Inspection.
    • 5.7 Towing a Disabled machine
      • 5.7.1 Manually Releasing the Park Brake
      • 5.7.2 Manually Resetting the Park Brake
  • Section 6 Transmission:
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Transmission Description
    • 6.3 Transmission Serial Number
    • 6.4 Transmission Specifications
      • 6.4.1 Transmission General Specifications
    • 6.5 Transmission Maintenance
      • 6.5.1 Transmission Maintenance
      • 6.5.2 Transmission Maintenance Schedule
    • 6.6 Transmission Replacement
      • 6.6.1 Transmission Removal
      • 6.6.2 Transmission Inspection and Internal Repair
      • 6.6.3 Transmission Installation
      • 6.6.4 After Transmission Service or Replacement
    • 6.7 Troubleshooting
      • 6.7.1 Transmission Troubleshooting
  • Section 7 Engine: Perkins 1004-40T
    • 7.1 Introduction
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Component Terminology
    • 7.2 Engine Serial Number
    • 7.3 Specifications and Maintenance Information
    • 7.4 Engine Cooling System
      • 7.4.1 Radiator Pressure Cap
      • 7.4.2 Thermostat Replacement
      • 7.4.3 Radiator/Oil Cooler and 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
      • 7.7.2 Exhaust System Installation
    • 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 Removal
      • 7.9.2 Engine Disassembly, Inspection and Service
      • 7.9.3 Engine Installation
    • 7.10 Engine Drive Plate
      • 7.10.1 Drive Plate Removal
      • 7.10.2 Drive Plate Installation
    • 7.11 Troubleshooting
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 Hydraulic Pressure Diagnosis
    • 8.4 Hydraulic Circuits
      • 8.4.1 Hydraulic Pressures
      • 8.4.2 Hydraulic Schematic
    • 8.5 Hydraulic Reservoir
      • 8.5.1 Hydraulic Oil Reservoir Draining
      • 8.5.2 Hydraulic Oil Reservoir Filling
      • 8.5.3 Hydraulic Oil Reservoir Removal
    • 8.6 Engine Implement Pump
      • 8.6.1 Pump Description
      • 8.6.2 Pump Failure Analysis
      • 8.6.3 Pump Replacement
    • 8.7 Control Valves
      • 8.7.1 Main Control Valve
      • 8.7.2 Service Brake Valve
      • 8.7.3 Park Brake Valve
      • 8.7.4 Steering Orbitrol Valve
      • 8.7.5 Steer Select Valve
    • 8.8 Hydraulic Cylinders
      • 8.8.1 General Cylinder Removal Instructions
      • 8.8.2 Cylinder Pressure Checking
      • 8.8.3 Steering Cylinders
      • 8.8.4 Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
      • 9.1.1 General Overview (Cab Harness)
    • 9.2 Service Warnings
      • 9.2.1 Electronics
    • 9.3 Specifications
    • 9.4 Fuses and Relays
      • 9.4.1 Fuse and Relay Locations
      • 9.4.2 Connector Legend, Relays & Fuses
      • 9.4.3 Fuse and Relay Replacement
    • 9.5 Electrical System Schematics
      • 9.5.1 Cab Harness Electrical Schematic
      • 9.5.2 Engine Harness Electrical Schematic
      • 9.5.3 Printed Circuit Board Electrical Schematic
      • 9.5.4 ESX Harness and Options Electrical Schematic
      • 9.5.5 Front & Rear Chassis Harness Electrical Schematic
    • 9.6 Circuit Breakdowns
      • 9.6.1 Constant Power Circuit from Battery
      • 9.6.2 Start Circuit
      • 9.6.3 Charging Circuit
    • 9.7 Engine Start Circuit
      • 9.7.1 Starter
    • 9.8 Charging Circuit
      • 9.8.1 Alternator
    • 9.9 Window Wiper/Washer Windshield Wiper Motor
      • 9.9.1 Rear Window Wiper Motor
      • 9.9.2 Rear Wiper/Rear Window Washer Switch
      • 9.9.3 Windshield/Rear Window Washer Reservoir and Pump
    • 9.10 Cab Heater and Fan
      • 9.10.1 Cab Heater Controls
    • 9.11 Solenoids and Senders
      • 9.11.1 Fuel Shut-off Solenoid
      • 9.11.2 Main Control Valve Solenoids
      • 9.11.3 Transmission Solenoid Valves
      • 9.11.4 Transmission Temperature Sender
      • 9.11.5 Transmission Mounted Speed Sensor
      • 9.11.6 Engine Coolant Temperature Sender
      • 9.11.7 Engine Oil Pressure Sender
      • 9.11.8 Fuel Level Sender
      • 9.11.9 Boom Angle Sensor
      • 9.11.10 Load Moment Indicator
      • 9.11.11 Load Moment Sensor
      • 9.11.12 Front and Rear Axle Proximity Sensors
    • 9.12 Display Monitor and Gauges
      • 9.12.1 Digital Display "Main Screen"
      • 9.12.2 Analog Gauges
    • 9.13 Joystick
    • 9.14 Dash Switches
      • 9.14.1 Ignition Key Switch
      • 9.14.2 Dash Switches
    • 9.15 Transmission Control Lever / Accessory Control Lever
      • 9.15.1 Control Lever Replacement