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This service manual PDF download for the 4017 JLG Boom Lift / Telescopic Handler has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
TABLE OF CONTENTS :
Section 1 Safety Practices
1.1 Introduction
1.2 Disclaimer
1.3 Operator & Safety Manual
1.4 Accident Prevention Tags
1.5 Safety Information
1.6 Safety Instructions
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
2.3 Specifications
2.4 Fluids, Lubricants and Capacities
2.5 Service and Maintenance Schedules
2.6 Lubrication Schedules
Section 3 Boom
3.1 Boom System Component Terminology
3.2 Boom System
3.3 Boom Assembly Maintenance
3.4 Boom Extend and Retract Chains
3.5 Boom Section Separation Adjustment
3.6 Hose Carrier Assembly
3.7 Boom Wear Pads
3.8 Quick Switch Assembly
3.9 Troubleshooting
Section 4 Cab and Covers
4.1 Operator’s Cab and Covers Component Terminology
4.2 Operator’s Cab
4.3 Cab Components
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
5.4 Drive Shafts
5.5 Wheels and Tires
5.6 Brakes
5.7 Towing a Disabled machine
Section 6 Transmission:
6.1 Transmission Assembly Component Terminology
6.2 Transmission Description
6.3 Transmission Serial Number
6.4 Transmission Specifications
6.5 Transmission Maintenance
6.6 Transmission Replacement
6.7 Troubleshooting
Section 7 Engine: Perkins 1004-40T
7.1 Introduction
7.2 Engine Serial Number
7.3 Specifications and Maintenance Information
7.4 Engine Cooling System
7.5 Engine Electrical System
7.6 Fuel System
7.7 Engine Exhaust System
7.8 Air Cleaner Assembly
7.9 Engine Replacement
7.10 Engine Drive Plate
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
8.5 Hydraulic Reservoir
8.6 Engine Implement Pump
8.7 Control Valves
8.8 Hydraulic Cylinders
Section 9 Electrical System
9.1 Electrical Component Terminology
9.2 Service Warnings
9.3 Specifications
9.4 Fuses and Relays
9.5 Electrical System Schematics
9.6 Circuit Breakdowns
9.7 Engine Start Circuit
9.8 Charging Circuit
9.9 Window Wiper/Washer Windshield Wiper Motor
9.10 Cab Heater and Fan
9.11 Solenoids and Senders
9.12 Display Monitor and Gauges
9.13 Joystick
9.14 Dash Switches
9.15 Transmission Control Lever / Accessory Control Lever
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3121858
Total Pages : 152
This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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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
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