Jlg 4017 Service Manual- Manuals

1.1 4017 Section 1 Safety Practices Contents PARAGRAPH TITLE PAGE 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 1.3 Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Safety Practices 1.2 4017 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 ...

1.3 4017 Safety Practices 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 ...

1.5 4017 Safety Practices 1.7 EMERGENCY EXIT REAR WINDOW The rear window in the enclosed cab can be used as an emergency exit by removing the latch pin (1) located on the window latch. Once the latch pin is removed, the window is free to swing open. 1.8 SAFETY DECALS Check that all safety decals are...

Safety Practices 1.6 4017 This Page Intentionally Left Blank

General Information and Specifications 2.2 4017 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 as indicated in the figure below. IMPORTANT: The replacement of...

2.3 4017 General Information and Specifications 2.2 TORQUES 2.2.1 ASTM Fastener Torque Chart (English) VAL UES F OR ZI N C PL A T ED / YEL LOW CHROM A TE F ASTEN ERS ON LY UN PL A T ED CAP SCREW S SA E G R A D E 5 BO LT S & GRA D E 2 N U TS S A E GRADE 8 BOL T S & GRA D E 8 N U TS & S O ...

2.5 4017 General Information and Specifications 2.2.3 Metric Fastener Torque Chart VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY CLASS 8.8 METRIC BOLTS & CLASS 8 METRIC NUTS CLASS 10.9 METRIC BOLTS & CLASS 10 METRIC NUTS SIZE PITCH TENSILE STRESS AREA CLAMP LOAD TORQUE CLAMP LOAD T...

General Information and Specifications 2.6 4017 2.3 SPECIFICATIONS 2.3.1 Travel Speeds 2.3.2 Engine Performance Specifications Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting . 2.3.3 Hydraulic Cylinder Performance Description First Gear 5,...

2.7 4017 General Information and Specifications 2.3.4 Tires 2.3.5 Axles Description Wheel Lug Nut Torque 550-600 Nm (405-445 lb-ft) Standard Tire Size 405/70-24 14PR MPT-04 TBL Standard Tire Air Pressure (Minimum) 450 kPa (65 psi) Optional Tires Optional Tire Size 405/70-24 14PR MPT-01 TBL Optional ...

General Information and Specifications 2.8 4017 2.3.6 Electrical System Battery: Type, Rating 12 VDC, Negative (-) Ground, Maintenance Free Quantity 1 Reserve Capacity 1,000 Cold Cranking Amps @ 0° F (-18° C) Group/Series Series 31 Alternator 12V, 85 Amps Fuses - Standard Blade Style: 5 Amps Radio 7...

General Information and Specifications 2.10 4017 2.5 SERVICE AND MAINTENANCE SCHEDULES 2.5.1 8 & 1st 50 Hour Maintenance Schedule 2.5.2 50, 250 & 500 Hour Maintenance Schedule OZ0300 Check Wheel Lug Nut Torque LB/FT (N m) Change Axle Oil Change Wheel End Oil 50 1 st Check Boom Chain Tension ...

2.11 4017 General Information and Specifications 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 OZO891 1500 EVERY Change Engine Coolant Change Hydraulic Fluid & Filters Change Hydraulic Tank Breather Change Brake F...

Boom 3.2 4017 3.1 BOOM SYSTEM 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 name and location of the major assemblies of the boom system. The following illustration iden...

3.3 4017 Boom 3.2 BOOM SYSTEM 3.2.1 Boom System Operation The four section boom consists of the first, second, third and fourth assemblies with double third and fourth section extend chains, a double third section retract chains and a single fourth section retract chain. As the extend/retract cylind...

3.7 4017 Boom 6. Inspect the boom and welds. Consult the local JLG distributor or the JLG Service Department if structural damage is detected. 7. Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the first boom section. Replace any item if damaged. (Refer ...

Boom 3.8 4017 3.3.7 Fourth Boom Section Installation 1. Apply Loctite 242 ® to the wear pad mounting bolts. Install the bottom rear wear pads, washers and bolts. Torque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts)....

3.9 4017 Boom 3.3.8 Third & Fourth Boom Section Installation 1. At the rear of the third boom section apply Loctite 242 ® to the wear pad mounting bolts and install the bottom rear wear pads, washers and bolts. Torque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, ba...

Boom 3.10 4017 9. Install both retract chain sheaves (1), pin, keeper and bolts to bottom rear of second boom section. Apply Loctite 242 ® and torque to 90 Nm (66 lb-ft). Grease the sheaves using the grease fitting in the pin. Spin the sheaves by hand to ensure the sheaves spin freely on the pin and...

3.11 4017 Boom 5. Using a suitable sling, balance the second, third and fourth boom section 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 section onto a suitable support and reset sling under the boom head of the fo...

3.15 4017 Boom 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. Elongation It is important to measure the chain ...

Boom 3.16 4017 Distorted or Battered Link Plates Distorted or battered link plates (8) on a leaf chain can cause tight joints and prevent flexing. 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 discove...

3.17 4017 Boom e. Removing Extend and Retract Chains The four extend chains and the three retract chains can only be removed during a complete boom teardown. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the cha...

Boom 3.18 4017 4. Start the machine and extend and retract the boom sections two or three times. Fully retract the boom and measure the distance between the boom sections. 5. If the measurements are within the tolerance, tighten the locknuts on the chain clevises. If more adjustment is needed, refer...

3.19 4017 Boom 12. Label and remove the two auxiliary hydraulic hoses (2) from the bulkhead fittings inside the boomhead. Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system. 13. At the rear of the boom, label and remove the tilt cylinder ho...

3.21 4017 Boom 3.7 BOOM WEAR PADS There are a total of 50 wear pads installed on the first, second, third and fourth boom sections. 10 wear pads are attached to the first boom section, 16 to the second boom section, 16 to the third boom section and 8 to the fourth boom section. Note: All shims are u...

Boom 3.22 4017 Use shims under the upper rear wear pads, under the bottom front wear pads and under the side wear pads as required, to maintain a minimum gap of 1.6 mm (1/16 in) between the wear pad and boom surface. c. Second Boom Section Coat all wear pad bolts with Loctite 242 ® before installati...

3.23 4017 Boom 3.7.3 Boom Wear Pad 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, light lubrication of the boom wear surfaces with ...

3.25 4017 Boom 3.9 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Boom Troubleshooting Problem Cause Remedy 1. Boom will not extend or retract. 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking....

Boom 3.26 4017 5. Dropping chain, or jerky boom extend or retract functions. 1. Chain(s) tension not properly adjusted. 2. Chain(s) stretched or binding. 3. Wear pads loose, contaminated, excessively worn or damaged. 4. Contaminated, corroded or rusted wear pad sliding surfaces. 5. Extend/Retract hy...

3.27 4017 Boom 9. Rapid boom pad wear. 1. Incorrect wear pad gap. 2. Rapid cycle times with heavy loads. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 4. Operating in extremely dusty/ abrasive conditions. 1. Check wear pad gaps and correct as needed. Refer to Section 3.7.2, “Boom We...

Cab and Covers 4.2 4017 4.1 OPERATOR’S CAB AND COVERS 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 machine cab and co...

4.3 4017 Cab and Covers 4.2 OPERATOR’S CAB 4.2.1 Cab Safety 4.2.2 Serial Number Decal The cab serial number decal is located on the left side of the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this ...

Cab and Covers 4.4 4017 Note: ALWAYS use new o-rings when servicing the machine. 4. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil. 5. Connect the load sense hose to the “LS” port at the top of the steering valve. 6. Connect the four previously labeled hoses to...

4.5 4017 Cab and Covers 6. Remove the hex jam nut and flat washer securing the throttle cable to the throttle pedal assembly. 7. Remove the clip/pin from the fork link. 8. Remove the throttle pedal assembly from the cab. b. Throttle Pedal Installation 1. Install the hex jam nut and flat washer onto ...

Cab and Covers 4.6 4017 b. Joystick Assembly Installation 1. Set the joystick assembly (1) into the armrest support. 2. Install the four self-tapping screws. Connect the electrical connections. 3. Test the boom extend/retract and boom lift/lower joystick function: a. Move the joystick handle rearwar...

4.7 4017 Cab and Covers b. Heater Assembly Installation 1. Connect the wiring harness connections to the blower. 2. Lift the heater assembly to the bottom of the cab floor, and secure with four ripp bolts, six lockwashers and six nuts. Connect the hoses to the heater. Secure with two hose clamps. 3....

Cab and Covers 4.8 4017 Note: Record the location, and label all hoses to ensure correct installation. 11. Working under the cab, label and disconnect the hydraulic hoses at the cab fittings. Plug the hoses and cap the fittings. 12. Disconnect the throttle cable from under the cab. 13. Install two l...

5.1 4017 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 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

5.3 4017 Axles, Drive Shafts, Wheels and Tires 5.2 GENERAL INFORMATION IMPORTANT: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are...

Axles, Drive Shafts, Wheels and Tires 5.4 4017 lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces. DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces du...

5.7 4017 Axles, Drive Shafts, Wheels and Tires 5.3.6 Axle Assembly and Drive Shaft Troubleshooting Problem Cause Remedy 1. Excessive axle noise while driving. 1. Oil level too low. 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 3. Incorrect alignment of ring and pinion...

Axles, Drive Shafts, Wheels and Tires 5.8 4017 4. Oil leaking from axle (differential housing and/or axle housings). 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 2. Hose fittings loose. 3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces. ...

Axles, Drive Shafts, Wheels and Tires 5.10 4017 5.4 DRIVE SHAFTS 5.4.1 Drive Shaft Inspection and Service Whenever servicing the machine, conduct a visual inspection of the drive shafts and cross and bearing assemblies (universal joints, or U-joints). A few moments spent doing this can help prevent ...

Axles, Drive Shafts, Wheels and Tires 5.12 4017 5.5 WHEELS AND TIRES 5.5.1 Removing Wheel and Tire Assembly from machine 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake, straighten al...

5.13 4017 Axles, Drive Shafts, Wheels and Tires 5.6 BRAKES 5.6.1 Brake Disk Inspection. Check the brake disks for wear every 1,000 hours of operation or yearly. If the brake disks require service due to wear, the axle should be checked, serviced and repaired only by experienced service technicians w...

Axles, Drive Shafts, Wheels and Tires 5.14 4017 5.7 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power, before using the emergency towing procedure...

6.1 4017 Section 6 Transmission: Contents PARAGRAPH TITLE PAGE 6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6.2 6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 6.3 Transmission Ser...

6.3 4017 Transmission: 6.2 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance information, and transmission removal and installation procedures. Note: Instructions in this section pertain mainly to general specifications, towing, maint...

Transmission: 6.4 4017 6.6.1 Transmission Removal 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place an Accident Prevention Tag on both the ignition key...

6.5 4017 Transmission: 23. Remove the ten bolts and washers holding the transmission to the engine. 24. Remove the four capscrews and four lockwashers securing each rear transmission mount to the transmission. 25. Remove the two transmission mounts from the machine. 26. Inspect the rubber mounts. Re...

6.7 4017 Transmission: 6.7 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that may occur during operation of the transmission. Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period. The transmi...

6.9 4017 Transmission: 6. Grinding or “clunking” noise from transmission. 1. Oil level too low. 2. Transmission filled with incorrect oil. 3. Incorrect clutch engagement. 4. Internal damage. 5. Broken diaphragm (flex plate). 6. Loose diaphragm (flex plate) mounting capscrews. 1. Fill oil to correct ...

7.1 4017 Section 7 Engine: Perkins 1004-40T Contents PARAGRAPH TITLE PAGE 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Engine: Perkins 1004-40T 7.2 4017 7.1 INTRODUCTION 7.1.1 Disclaimer and Scope These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to the local Perkins Engine Distributor and the applicable Perkins Engine Service Manual for assistance ...

7.3 4017 Engine: Perkins 1004-40T 7.1.2 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 engine components. The following illustration identifies...

Engine: Perkins 1004-40T 7.4 4017 7.2 ENGINE SERIAL NUMBER The Perkins 1004-40T serial number Is stamped on a plate which is secured to the engine block, near the fuel injector pump. Information contained in the serial number is required in correspondence with the engine manufacturer. 7.3 SPECIFICAT...

7.5 4017 Engine: Perkins 1004-40T b. Thermostat Installation 1. Install the engine thermostat, thermostat gasket and thermostat housing. Secure with the two capscrews. Torque to 24 Nm (18 lb-ft). 2. Connect the negative (-) battery cable to the battery negative (-) terminal. 3. Open the radiator cap...

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 inle...

7.7 4017 Engine: Perkins 1004-40T 75 hours. The use of fuel with a sulfur content above 1.3 percent is not recommended. 7.6.2 Fuel Tank Note: The fuel tank is a one piece unit. It is located at the rear of the machine, between the frame. If it is determined that the fuel tank must be removed, the fu...

Engine: Perkins 1004-40T 7.8 4017 e. Inspection 1. Inspect the fuel tank thoroughly for any cracks, slices, leaks or other damage. 2. With the fuel tank removed from the machine, plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately, 07-1 kPa (1-1.5 psi) of a...

7.9 4017 Engine: Perkins 1004-40T 3. Install the muffler to the exhaust pipe and bolt the muffler to the side of the frame. 4. Install the clamp securing the muffler to the exhaust pipe. 5. Install the clamp securing the muffler to the tail pipe. 6. Adjust the muffler, exhaust and tail pipes for pro...

7.11 4017 Engine: Perkins 1004-40T 22. Place a support or jack under the transmission to hold the transmission in place while engine is being removed. 23. Attach a lifting chain to the front and rear engine lift brackets (4). 24. Remove the ten bolts holding the transmission to the engine. Slightly ...

7.13 4017 Engine: Perkins 1004-40T 7.10 ENGINE DRIVE PLATE 7.10.1 Drive Plate Removal 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. Note: In order to remove the...

Hydraulic System 8.2 4017 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustratio...

8.3 4017 Hydraulic System 8.2 SAFETY INFORMATION Petroleum-based hydraulic fluids are used in this machine. The temperature of hydraulic fluid increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic fluid presents a fire hazard, especially when an ignition s...

Hydraulic System 8.4 4017 8.4 HYDRAULIC CIRCUITS This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, where and how to check those pressures and a hydraulic schematic. Electrical and hydraulic functions are often related. Verify that the electrical c...

8.5 4017 Hydraulic System b. Adjusting Hydraulic Pressure There is only one adjustment to set the main hydraulic pressure. 1. Park the machine on a firm, level surface. Engage the park brake, place the transmission control lever in (N) NEUTRAL, level the boom and turn the engine OFF. Remove the cap ...

8.7 4017 Hydraulic System 8.5 HYDRAULIC RESERVOIR The hydraulic oil reservoir is a one piece unit. It is located under the rear of the machine cab. Occasionally, fluid may seep, leak or be more forcefully expelled from the breather when system pressure exceeds the rating of the filter head or breath...

Hydraulic System 8.8 4017 c. Cleaning and Drying If contaminated hydraulic oil or foreign material is in the tank, the tank can usually be cleaned. Note: If a leak is suspected in the hydraulic oil reservoir, contact JLG Service Department. To clean the hydraulic oil reservoir: 1. Have a dry chemica...

Hydraulic System 8.10 4017 8.7 CONTROL VALVES 8.7.1 Main Control Valve The main control valve is mounted on the frame in the engine compartment. The main control valve assembly (1) consists of seven working sections with their own valve assemblies, each providing a specific hydraulic function. The s...

Hydraulic System 8.12 4017 b. Main Control Valve Disassembly This section covers disassembly of each valve section of the main control valve. The main control valve assembly consists of seven working sections with their own valve assemblies, each providing a specific hydraulic function. The section ...

8.13 4017 Hydraulic System f. Main Control Valve Installation 1. Loosely install the four main control valve mounting bolts through bracket on the inside frame rail of the engine bay. 2. Install the main control valve onto the bracket, aligning the bolts with the holes in the end sections of the mai...

Hydraulic System 8.14 4017 b. Service Brake Valve Installation 1. Install the service brake valve with the four lockwashers and four capscrews to mount the brake valve to the steering column support. 2. Align the yoke on the brake valve with the brake pedal arm. Insert the pin and clip into place be...

8.15 4017 Hydraulic System 5. Label or otherwise mark the hydraulic hoses on each side and bottom of the park brake valve. Disconnect and cap all hoses, fittings, etc. 6. Remove the two capscrews, and two lockwashers mounting the park brake valve to the left side of the seat base. Note: DO NOT disas...

Hydraulic System 8.16 4017 4. Label or otherwise mark the hydraulic hoses and the electrical plugs connected to the steering select valve. Disconnect and cap all hoses, fittings, solenoid wire terminal leads, etc. 5. Remove the two bolts holding the steer select valve to the mounting plate on the fr...

8.17 4017 Hydraulic System 5. Attach a suitable sling to an appropriate lifting device and to the cylinder. Make sure the device used can actually support the cylinder. 6. Remove the lock bolt and/or any retaining clips securing the cylinder pins. Remove the cylinder pins. 7. Remove the cylinder. 8....

Hydraulic System 8.18 4017 b. Cylinder Cleaning Instructions 1. Discard all seals, back-up rings and o-rings. Replace with new items from seal kit to ensure proper cylinder function. 2. Clean all metal parts with an approved cleaning solvent such as trichlorethylene. Carefully clean cavities, groove...

8.19 4017 Hydraulic System individual circuit. Activate the circuit and if pressure is obtained turn the main relief counter clockwise one half turn. Re-check the main relief setting and adjust if necessary. 8.8.3 Steering Cylinders The steer cylinder (1) is attached to each axle center housing. The...

Electrical System 9.2 4017 9.11 Solenoids and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 9.11.1 Fuel Shut-off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 9.11.2 Main Control Valve Solenoids ...

Electrical System 9.4 4017 9.2 SERVICE WARNINGS 9.2.1 Electronics 9.3 SPECIFICATIONS Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.4 FUSES AND RELAYS 9.4.1 Fuse and Relay Locations a. Cab For access to the fuse and relay panel, remove the four ...

9.5 4017 Electrical System 9.4.2 Connector Legend, Relays & Fuses Connector Legend No. Type X1 PCB Power & GND Harness X2 Instrument Panel Harness X3 Instrument Panel Harness X4 Instrument Panel Harness X5 Cab Harness X6 Cab Harness X7 Cab Harness X8 Cab Harness X9 Worklight, Radio, Rear Wip...

Electrical System 9.6 4017 9.4.3 Fuse and Relay Replacement Shut off the engine and disconnect the negative (-) battery cable at the negative (-) battery terminal before checking the electrical system fuses or relays. a. Fuse Block Fuse or Relay Replacement Remove a suspect fuse or relay (Refer to S...

9.7 4017 Electrical System 9.5 ELECTRICAL SYSTEM SCHEMATICS 9.5.1 Cab Harness Electrical Schematic MZ1090 3 12 4 4 2 13 17 10 7 56 89 12 11 13 15 14 16 18 12 6 12345 9 78 11 1014 13 15 17 16 18 2 135 41 8 12 6871 0 91 1 15 1314 1617 11 13246 579 81 01 4 1213 16 15 1718 11 13 2 46579 81 01 4 1213 16 ...

Electrical System 9.12 4017 9.6 CIRCUIT BREAKDOWNS 9.6.1 Constant Power Circuit from Battery 85 8786 30 GLOWPLUGS RELAY GLOWPLUGS FUSE SLO-BLO 50A LIFT PUMP FUSE ATO 7.5A 85 8786 30 LIFT PUMP RELAY 9 10 7 1 3 2 5 4 6 8 PCB TO CAB HARNESS X7 15 16 17 18 7 8 9 1011 12 13 14 1 2 3 4 5 6 2 23 13 5 3 4 6...

9.15 4017 Electrical System 9.7 ENGINE START CIRCUIT 9.7.1 Starter The starter (1) is located on the left side of the engine (the right side of the machine). a. Testing the Starter on the Engine If the starter does not engage when the ignition key switch is turned, check the following: 1. The main f...

Electrical System 9.16 4017 9.8 CHARGING CIRCUIT If the engine alternator charging warning indicator illuminates, perform the following checks: 1. Check the all battery cable connections at the battery, and verify that they are clean and tight. 2. Check the external alternator wiring and connections...

9.17 4017 Electrical System b. Alternator Installation 1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper (longer) mounting hardware through the alternator mount. Thread the longer capscrew into the alternator front mount. DO NOT tighten comp...

Electrical System 9.18 4017 d. Installation and Testing 1. Install all required hardware to the motor assembly. 2. Align motor with the mounting holes and bolt the motor to the mounting bracket. 3. Connect the wiper linkage to the wiper motor shaft. Note: Align the wiper linkage arm with the flat on...

9.19 4017 Electrical System b. Disassembly DO NOT disassemble the switch. The switch is not serviceable. Replace switch if found to be defective. c. Installation and Testing 1. Connect the windshield washer switch to the cab harness connector. 2. Position the switch over the rectangular switch bezel...

Electrical System 9.20 4017 1. Open engine cover. Allow engine to cool. 2. Disconnect the negative (-) battery cable at the negative (-) battery terminal. 3. Remove the four screws from the cab heater and fan control panel. 4. Pull the control panel out from the dash panel and disconnect the variabl...

9.21 4017 Electrical System 9.11.2 Main Control Valve Solenoids a. Main Control Valve Solenoid Removal 1. Open engine cover. Allow engine to cool. 1. Clean area around valve solenoid to be removed. 2. Disconnect the negative (-) battery cable at the negative (-) battery terminal. 3. Disconnect the w...

9.25 4017 Electrical System 9.11.10 Load Moment Indicator The Load Moment Indicator (1) provides a visual indication for stability limitations. If the LMI senses that the machine is becoming unstable, an audible and visual alarm will begin to sound and the boom lower, boom extension and outriggers f...

Electrical System 9.26 4017 Note: If either the button or magnet is released too early the display will revert to the uncalibrated condition number 4. THE SYSTEM ALLOWS FIVE MINUTES for each part of the calibration procedure to be completed. If a part of the calibration procedure is not completed wi...

9.27 4017 Electrical System 9.12 DISPLAY MONITOR AND GAUGES 9.12.1 Digital Display "Main Screen" The Digital Display unit (1) monitors all functions of the machine. Refer to the Operator & Safety Manual for detailed information. a. Removal 1. Open engine cover. Allow engine to cool. 2. D...

Electrical System 9.28 4017 9.13 JOYSTICK Note: For information on the removal and replacement of the joystick, refer to Section 4.3.4, “Joystick Assembly.” 9.14 DASH SWITCHES Note: For information on the front windshield wiper, rear window wiper and washer systems, refer to Section 9.9, “Window Wip...

JLG Worldwide Locations An Oshkosh Corporation Company JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: +61 265 811 111Fax: +61 265 810 122 JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazilPhone: +55 193 295 0407...