Service Manual

Model
4017

P/N - 3121858

Revised
January 6, 2006
 EFFECTIVITY PAGE

June 10, 2005 - A - Original Issue Of Manual

January 6, 2006 - B - Revision Of Manual

31261858 4017 i
 EFFECTIVITY PAGE

-ii 4017 3121858

 SECTION CONTENTS
Section Subject Page

Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
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 2
General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Section 3
Boom ........................................................... 3.1
3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.4 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.5 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.6 Hose Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.7 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.8 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
3.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
Section 4
Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Section 5
Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13

 JLG Industries, Inc.

4017 i
Section Subject Page

5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14

Section 6
Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Section 7
Engine: Perkins 1004-40T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Section 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.6 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
Section 9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.1 Electrical Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.6 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.7 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.11 Solenoids and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.13 Joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.14 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28

ii 4017
Section Subject Page

9.15 Transmission Control Lever / Accessory Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . 9.29

4017 iii
Section Subject Page

iv 4017
 Section 1
Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operator & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Accident Prevention Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.7 Emergency Exit Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.8 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

4017 1.1
 Safety Practices
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 all locally approved safety practices,
procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor
provide directions for meeting every possible contingency
during operation, maintenance, or testing. When additional
information is desired consult the local JLG distributor.
Many factors contribute to unsafe conditions: carelessness,
fatigue, overload, inattentiveness, unfamiliarity, even
drugs and alcohol, among others. For optimal safety,
encourage everyone to think, and to act, safely.
Appropriate service methods and proper repair
procedures are essential for the safety of the individual
doing the work, for the safety of the operator, and for the
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
operator’s seat looking in a forward direction.
Supplementary information is available from JLG in the
form of Service Bulletins, Service Campaigns, Service
Training Schools, the JLG website, other literature, and
through updates to the manual itself.
1.2
1.2 DISCLAIMER
All information in this manual is based on the latest
product information available at the time of publication.
JLG reserves the right to make changes and
improvements to its products, and to discontinue the
manufacture of any product, at its discretion at any time
without public notice or obligation.
1.3 OPERATOR & SAFETY MANUAL
The mechanic must not operate the machine until the
Operator & Safety Manual has been read & understood,
training has been accomplished and operation of the
machine has been completed under the supervision of an
experienced and qualified operator.
An Operator & Safety Manual is supplied with each
machine and must be kept in the cab. In the event that the
Operator & Safety Manual is missing, consult the local
JLG distributor before proceeding.
1.4 ACCIDENT PREVENTION TAGS
Place Accident Prevention Tags on the ignition key
switch and the steering wheel before attempting to
perform any service or maintenance. Remove key and
disconnect battery leads.
4017

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 emergency
telephone numbers (fire department, ambulance, rescue
squad/paramedics, police department, etc.) nearby. If
working alone, check with another person routinely to
help assure personal safety.
1.5.1 Safety Alert System and Signal Words
DANGER
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
4017
Safety Practices
1.6 SAFETY INSTRUCTIONS
Following are general safety statements to consider before
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and
procedures are located throughout this manual and are
listed prior to any work instructions to provide safety
information before the potential of a hazard occurs.
For all safety messages, carefully read, understand and
follow the instructions before proceeding.
1.6.1 Personal Hazards
PERSONAL SAFETY GEAR: Wear all the protective
clothing and personal safety gear necessary to perform
the job safely. This might include heavy gloves, safety
glasses or goggles, filter mask or respirator, safety shoes
or a hard hat.
LIFTING: NEVER lift a heavy object without the help of at
least one assistant or a suitable sling and hoist.
1.6.2 Equipment Hazards
LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working order, and
is properly attached.
NEVER stand or otherwise become positioned under a
suspended load or under raised equipment. The load or
equipment could fall or tip.
DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.
1.3
 Safety Practices

1.6.3 General Hazards appropriate container and dispose of in accordance with

prevailing environmental regulations.
SOLVENTS: Only use approved solvents that are known
to be safe for use. RADIATOR CAP: Always wear steam-resistant, heat
protective gloves when opening the radiator cap. Cover
HOUSEKEEPING: Keep the work area and operator’s
the cap with a clean, thick cloth and turn slowly to the first
cab clean, and remove all hazards (debris, oil, tools, etc.).
stop to relieve pressure.
FIRST AID: Immediately clean, dress and report all injuries
FLUID FLAMABILTITY: DO NOT service the fuel or
(cuts, abrasions, burns, etc.), no matter how minor the
hydraulic systems near an open flame, sparks or smoking
injury may seem. Know the location of a First Aid Kit, and
materials.
know how to use it.
NEVER drain or store fluids in an open container. Engine
CLEANLINESS: Wear eye protection, and clean all
fuel and hydraulic fluid are flammable and can cause a
components with a high-pressure or steam cleaner
fire and/or explosion.
before attempting service.
DO NOT mix gasoline or alcohol with diesel fuel. The
When removing hydraulic components, plug hose ends
mixture can cause an explosion.
and connections to prevent excess leakage and
contamination. Place a suitable catch basin beneath the PRESSURE TESTING: When conducting any test, only
machine to capture fluid run-off. use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
Check and obey all Federal, State and/or Local
manner, and make changes or repairs as indicated by the
regulations regarding waste storage, disposal and
test procedure to achieve the desired result.
recycling.
LEAVING MACHINE: Lower the forks or attachment to
1.6.4 Operational Hazards the ground before leaving the machine.

ENGINE: Stop the engine before performing any service TIRES: Always keep tires inflated to the proper pressure
unless specifically instructed otherwise. to help prevent tipover. DO NOT over-inflate tires.

VENTILATION: Avoid prolonged engine operation in NEVER use mismatched tire types, sizes or ply ratings.
enclosed areas without adequate ventilation. Always use matched sets according to machine
specifications.
SOFT SURFACES AND SLOPES: NEVER work on a
machine that is parked on a soft surface or slope. The BATTERY: DO NOT charge a frozen battery.Charging a
machine must be on a hard level surface, with the wheels frozen battery may cause it to explode. Allow the battery
blocked before performing any service. to thaw before jump-starting or connecting a battery
charger.
FLUID TEMPERATURE: NEVER work on a machine
when the engine, cooling or hydraulic systems are hot.
Hot components and fluids can cause severe burns.
Allow systems to cool before proceeding.
FLUID PRESSURE: Before loosening any hydraulic or
diesel fuel component, hose or tube, turn the engine
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use
a piece of cardboard or wood instead. If injured, seek
medical attention immediately. Diesel fluid leaking under
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an

1.4 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.

MZ1400

1.8 SAFETY DECALS

Check that all safety decals are present and readable on
the machine. Refer to the Operator & Safety Manual
supplied with machine for information.

4017 1.5
 Safety Practices

This Page Intentionally Left Blank

1.6 4017
 Section 2
General Information and Specifications

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.1 ASTM Fastener Torque Chart (English) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.2.2 ASTM Fastener Torque Chart (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.2.3 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.2 Engine Performance Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.3 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.3.4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.3.5 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.3.6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.5 Service and Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.5.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.5.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.6.1 8 Hour Lube Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.6.2 50 Hour Lube Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

4017 2.1
 General Information and Specifications

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.

35

MZ1462

IMPORTANT: The replacement of any part on this

machine with any other than JLG authorized
replacement parts can adversely affect the performance,
durability, or safety of the machine, and will void the
warranty. JLG disclaims liability for any claims or
damages, whether regarding property damage, personal
injury or death arising out of the use of unauthorized
replacement parts.
A warranty registration form must be filled out by the JLG
distributor, signed by the purchaser and returned to JLG
when the machine is sold and/or put into use.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed. To
guarantee full warranty service, verify that the distributor
has returned the business reply card of the warranty
registration form to JLG.

2.2 4017
 2.2

4017
2.2.1
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
STRESS LOCTITE LOCTITE
TORQUES

SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. IN-LB IN-LB IN-LB IN-LB LB. IN-LB. IN-LB IN-LB IN-LB LB. IN-LB IN-LB
40 0.00604 380 8 6 — — 540 12 9 — — — — —
4 0.1120
48 0.00661 420 9 7 — — 600 13 10 — — — — —
32 0.00909 580 16 12 — — 820 23 17 — — — — —
6 0.1380
40 0.01015 610 18 13 — — 920 25 19 — — — — —
32 0.01400 900 30 22 — — 1260 41 31 — — — — —
8 0.1640
36 0.01474 940 31 23 — — 1320 43 32 — — — — —
24 0.01750 1120 43 32 — — 1580 60 45 — — — — —
10 0.1900
32 0.02000 1285 49 36 — — 1800 68 51 — — — — —
20 0.0318 2020 96 75 — 105 2860 144 108 — 160 3180 160 168
1/4 0.2500
28 0.0364 2320 120 86 — 135 3280 168 120 — 185 3640 168 178
IN SQ. IN. LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB FT-LB FT-LB LB. FT-LB FT-LB
18 0.0524 3340 17 13 16 19 4720 25 18 22 30 5240 25 28
5/16 0.3125
24 0.0580 3700 19 14 17 21 5220 25 20 25 30 5800 27 30
16 0.0775 4940 30 23 28 35 7000 45 35 40 50 7750 45 50
ASTM Fastener Torque Chart (English)

3/8 0.3750
24 0.0878 5600 35 25 32 40 7900 50 35 45 55 8780 50 55
14 0.1063 6800 50 35 45 55 9550 70 55 63 80 10630 70 77
7/16 0.4375
20 0.1187 7550 55 40 50 60 10700 80 60 70 90 11870 75 82
13 0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120
1/2 0.5000
20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127
12 0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170
9/16 0.5625
18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182
11 0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231
5/8 0.6250
18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242
10 0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400
3/4 0.7500
16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440
9 0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645
7/8 0.8750
14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700
8 0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950
1 1.0000
12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000
7 0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365
1-1/8 1.1250
12 0.8560 47500 880 660 802 925 77000 1440 1080 1155 1575 85600 1380 1520
7 0.9690 53800 1120 840 1009 1175 87200 1820 1360 1453 2000 96900 1750 1925
1-1/4 1.2500
12 1.0730 59600 1240 920 1118 1300 96600 2000 1500 1610 2200 107300 1880 2070
6 1.1550 64100 1460 1100 1322 1525 104000 2380 1780 1907 2625 115500 2320 2550
1-3/8 1.3750
12 1.3150 73000 1680 1260 1506 1750 118100 2720 2040 2165 3000 131500 2440 2685
6 1.4050 78000 1940 1460 1755 2025 126500 3160 2360 2530 3475 140500 3040 3345
1-1/2 1.5000
12 1.5800 87700 2200 1640 1974 2300 142200 3560 2660 2844 3925 158000 3270 3600
General Information and Specifications

Note: These torque values do not apply to cadmium plated fasteners.

2.3
2.4
2.2.2
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
STRESS LOCTITE LOCTITE
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
40 0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —
4 0.1120
48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —
32 0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —
6 0.1380
40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — —
32 0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —
8 0.1640
36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — —
24 0.01750 1120 5 3.6 — — 1580 7 5 — — — — —
10 0.1900
32 0.02000 1285 6 4 — — 1800 8 6 — — — — —
20 0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19
1/4 0.2500
28 0.0364 2320 14 10 — 15 3280 19 14 — 21 3640 19 20
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
18 0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38
5/16 0.3125
24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41
16 0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68
3/8 0.3750
24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75
ASTM Fastener Torque Chart (Metric)
General Information and Specifications

14 0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104

7/16 0.4375
20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111
13 0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163
1/2 0.5000
20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172
12 0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230
9/16 0.5625
18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247
11 0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313
5/8 0.6250
18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328
10 0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542
3/4 0.7500
16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597
9 0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874
7/8 0.8750
14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949
8 0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288
1 1.0000
12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356
7 0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851
1-1/8 1.1250
12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061
7 0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610
1-1/4 1.2500
12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807
6 1.1550 64100 1979 1491 1792 2068 104000 3227 2413 2586 3559 115500 3145 3457
1-3/8 1.3750
12 1.3150 73000 2278 1708 2042 2373 118100 3688 2766 2935 4067 131500 3308 3640
6 1.4050 78000 2630 1979 2379 2745 126500 4284 3200 3430 4711 140500 4122 4535
1-1/2 1.5000
12 1.5800 87700 2983 2224 2676 3118 142200 4827 3606 3856 5322 158000 4433 4881

Note: These torque values do not apply to cadmium plated fasteners.

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 10.9 METRIC BOLTS &
CLASS 8 METRIC NUTS CLASS 10 METRIC NUTS
TORQUE TORQUE
TENSILE
CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE
STRESS LOCTITE LOCTITE
SIZE PITCH LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR
AREA 262 262
263 271 263 271
sq. mm KN N, m N, m N, m N, m KN N, m N, m N, m N, m
3 .5 5.03 2.19 1.3 1.0 1.2 1.4 3.13 1.9 1.4 1.5 2.1
3.5 .6 6.78 2.95 2.1 1.6 1.9 2.3 4.22 3.0 2.2 2.4 3.3
4 .7 8.78 3.82 3.1 2.3 2.8 3.4 5.47 4.4 3.3 3.5 4.8
5 .8 14.2 6.18 6.2 4.6 5.6 6.8 8.85 8.9 6.6 7.1 9.7
6 1 20.1 8.74 11 7.9 9.4 12 12.5 15 11 12 17
7 1 28.9 12.6 18 13 16 19 18 25 19 20 28
8 1.25 36.6 15.9 25 19 23 28 22.8 37 27 29 40
10 1.5 58.0 25.2 50 38 45 55 36.1 72 54 58 79
12 1.75 84.3 36.7 88 66 79 97 52.5 126 95 101 139
14 2 115 50.0 140 105 126 154 71.6 200 150 160 220
16 2 157 68.3 219 164 197 241 97.8 313 235 250 344
18 2.5 192 83.5 301 226 271 331 119.5 430 323 344 473
20 2.5 245 106.5 426 320 383 469 152.5 610 458 488 671
22 2.5 303 132.0 581 436 523 639 189.0 832 624 665 915
24 3 353 153.5 737 553 663 811 220.0 1060 792 845 1170
27 3 459 199.5 1080 810 970 1130 286.0 1540 1160 1240 1690
30 3.5 561 244.0 1460 1100 1320 1530 349.5 2100 1570 1680 2310
33 3.5 694 302.0 1990 1490 1790 2090 432.5 2600 2140 2280 2860
36 4 817 355.0 2560 1920 2300 2690 509.0 3660 2750 2930 4020
42 4.5 1120 487.0 4090 3070 3680 4290 698.0 5860 4400 4690 6440

Note: These torque values do not apply to cadmium plated fasteners.

METRIC CLASS 8.8 METRIC CLASS 10.9

4017 2.5
 General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

Description
First Gear 5,2 km/h (3.2 mph)
Second Gear 11 km/h (6.9 mph)
Third Gear 22,5 km/h (14 mph)
Fourth Gear 35 km/h (21.7 mph)

2.3.2 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

Description
Engine Make/Model Perkins 1004-40T
Low Idle 925 ±50 rpm
High Idle 2200 ±50 rpm
Horsepower 99.5 BHP / 74.5 kW @ 2200 rpm
Fuel Delivery Fuel Injection
Air Cleaner Dry Type, Replaceable Primary and Safety
Elements

2.3.3 Hydraulic Cylinder Performance

Function Approximate Times (seconds)

Extend Cylinder Extend 23.0
Extend Cylinder Retract 18.0
Lift Retracted 15.5
Lower Retracted 10.0
Attachment Tilt - UP 4.5
Attachment Tilt - DOWN 9.8
Outrigger - Left and Right, DOWN 8.7
Outrigger - Left and Right, UP 6.4

2.6 4017
 General Information and Specifications

2.3.4 Tires

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 Tire Air Pressure (Minimum) 450 kPa (65 psi)

2.3.5 Axles

Dana Spicer Axle JLG P/N

Model

212-531 FRONT 1:20.667 0280173

212-190-002 REAR 1:20.667 4803383

4017 2.7
 General Information and Specifications

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
7.5 Amps Headlights and Tail Lights, ESX Ignition and Sensors
10 Amps Brake Lights, Cold Start, Beacon
15 Amps Rear Work Lights, Cab Heater, Aux Power Socket,
Battery Ind. Light, Dome Light, Spare, Ignition, Front
Work Lights, Boom Work Lights,
20 Amps Rear Wiper, Front Wiper
25 Amps ESX Battery, Air Conditioning
30 Amps Key Switch
Relays:
Key (power) K1
Start Interlock K2
Flasher K3
Wiper K4
Work Lights K5
Fuel Solenoid K6
Relays in Engine Compartment:
Starter
Lift pump
Glow Plug
Inline Fuse:
Lift Pump and Glow Plug

2.8 4017
 General Information and Specifications

2.4 FLUIDS, LUBRICANTS AND

CAPACITIES

Engine Crankcase Oil

Capacity w/Filter Change 8,5 liters (9 quarts)
Filter Capacity 1,0 liter (0.26 quarts)
Type of Oil 15W-40 CE/SE
Fuel Filters
Primary Fuel Filter Capacity Approx. 1,0 liter (0.26 quarts)
Fuel Filter Capacity 0,6 liters (0.16 quarts)
Fuel Tank
Capacity 140 liters (37 gallons)
Type of Fuel U.S.A. #2 Diesel
Cooling System
System Capacity w/o Heater 19,7 liters (20.8 quarts)
Type of Fluid 50/50 mix of ethylene glycol & water
Transmission Fluid
Capacity w/filter change 12,9 liter (13.6 quarts)
Filter Capacity 1,4 liters (1.5 quarts)
Type of Fluid Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
Transmission Transfer Case (Drop Box)
Capacity 1,4 liter (1.5 quarts)
Type of Fluid Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
Axles
Differential Housing Capacity - Front 6,9 liters (1.3 quarts)
Differential Housing Capacity - Rear 6,9 liters (1.3 quarts)
Wheel End Capacity 1,25 liters (1.3 quarts)
Type of Fluid Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
Brakes
Master Cylinder Capacity 0,7 liters (0.7 quarts)
Type of Fluid ATF Dexron II
Hydraulic System
System Capacity 246 liters (65 gallons)
Reservoir Capacity to FULL Mark 160 liters (42.3 gallons)
Type of Fluid Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)

4017 2.9
 General Information and Specifications

2.5 SERVICE AND MAINTENANCE 2.5.2 50, 250 & 500 Hour Maintenance
SCHEDULES Schedule

2.5.1 8 & 1st 50 Hour Maintenance Schedule

EVERY
50
EVERY
8
Drain Fuel/ Check Engine Check Follow Lubrication
Water Coolant Level Battery Schedule
Separator

Check Fuel
Level
Check Tire
Pressure
Air Filter
Restriction
Check Engine
Oil Level
Check Hydraulic
Oil Level
EVERY
Indicator
250

Check Brake Check Test Load

Fluid Level Transmission Moment Change Engine Check Axle Check Wheel Air Filter Check
Oil Level Indicator Oil and Oil Level End Oil Levels Vacuator Fan Belt
Filter Valve

1st
50
Check Boom Check Boom Check Transfer
Chain Bearing Case Oil Level
LB/F
T (N
m) Tension Pads

Change
Axle Oil
Change Wheel
End Oil
Change Engine
Oil & Filter
Change
Transmission
Check Wheel
Lug Nut
EVERY
Oil & Filter Torque
500
LB/F
T (N
m)

Check Boom
Chain Tension Change Fuel Check Wheel
Filter Lug Nut
Torque
OZ0300
OZ0320

2.10 4017
 General Information and Specifications

2.5.3 1000 & 1500 Hour Maintenance 2.6.2 50 Hour Lube Schedule
Schedule

Mystik Tetrimoly
(NLGI 2 GC-LB)

EVERY
1000

Change Change Change Change Wheel Check Boom

Transmission Transfer Case Axle Oil End Oil Chain
Oil & Filter Oil (4017 only)

EVERY
1500

Change Change Change Change

Engine Coolant Hydraulic Hydraulic Tank Brake Fluid
Fluid & Filters Breather
OZO891

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lube Schedule

Mystik Tetrimoly
(NLGI 2 GC-LB)

4017 2.11
 General Information and Specifications

2.12 4017
 Section 3
Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Boom System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3.2 Second, Third & Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . 3.4
3.3.3 Third & Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.3.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.3.5 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.3.6 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.3.7 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.3.8 Third & Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.3.9 Second, Third & Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . 3.10
3.3.10 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.4 Boom Extend and Retract Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.4.1 Boom Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.5 Boom Section Separation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.6 Hose Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.6.1 Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
3.6.2 Hose Carrier Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
3.7 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.7.1 Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.7.2 Boom Wear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.7.3 Boom Wear Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
3.8 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
3.8.1 Connecting with a Mechanical Quick Switch Device. . . . . . . . . . . . . . . . . 3.23
3.8.2 Connecting with a Hydraulic Quick Switch Device . . . . . . . . . . . . . . . . . . 3.23
3.8.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment . . . 3.24
3.8.4 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
3.8.5 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
3.9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

4017 3.1
 Boom

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 identifies the components that are
referred to throughout this section.

Hose Carrier
Fourth Boom
Section
Third Boom
Section
Second Boom
Auxiliary Section
Quick Retract Chains
Connects (three)

Extend/Retract
Cylinder

MZ0830
Rear View
Tilt Cylinder

Quick Switch Assembly

Extend Chains
(two pair)
First Boom
Section

MZ0800

Bottom View
MZ0810

3.2 4017

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 cylinder, which is anchored at the
front of the second boom section, and the rear of the first
boom section begins to extend, it forces the second boom
section out of the first boom section.
The first, second, third and fourth boom sections are
connected by extend and retract chains. These chains
are routed around sheaves on the second and third boom
sections. As the second and third boom sections are
forced out, the extend chain pulls the fourth boom section
out of the third boom section.
As hydraulic pressure is applied to the retract port on the
extend/retract cylinder, the second boom section is pulled
back into the first boom section, and the retract chain
pulls the third and fourth boom sections back into the
second boom section.
This mechanical linkage formed by the chains and
supporting hardware, extends and retracts the third and
fourth boom sections at the same rate.
The first boom section does not extend or retract, but lifts
and lowers via action of the lift cylinder.
3.3 BOOM ASSEMBLY MAINTENANCE
The boom assembly consists of the first, second, third
and fourth boom sections and supporting hardware.
IMPORTANT: Before removing the boom, the carriage
or any other attachment must be removed from the quick
switch assembly.
These instructions must be completed in sequence. The
second, third and fourth boom sections are removed from
the first boom section.The third and fourth boom sections
are removed from the second boom section.The fourth
boom section is removed from the third boom section.
Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
undertaken. Read, understand and follow these
instructions.
4017
Boom
3.3.1 Boom Removal
1. Remove any attachment from the quick switch
assembly. (Refer to Section 3.8.1, “Connecting with
a Mechanical Quick Switch Device.”)
2. Set the quick attach assembly in a vertical position
and set on a hard level surface. Refer to Section
3.8.4, “Quick Switch Removal,” for disassembly
instructions.
3. Park the machine on a firm, level surface. Be sure
there is enough room in front of the machine to allow
the boom sections to be removed. Fully retract the
boom then raise the boom to access the rod end pin
of lift cylinder. Place the transmission control lever in
(N) NEUTRAL, engage the park brake and shut the
engine OFF.
4. Open the engine cover. Allow the system fluids to
cool.
5. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
1
L. O/R
R. O/R
SWAY
AUX
TILT
EXT/RET
LIFT
F
MARON
CH T O
INE F
MZ0420
6. Relieve any trapped pressure in the tilt hydraulic
system by installing the handle (1) (located in the
toolbox) or using an 9mm wrench and move the
double nut on the side of the actuator module on the
tilt valve section back and forth. Repeat on the
auxiliary valve section and on the extend/retract
valve section.
7. Disconnect, label and cap both hoses from the
extend/retract cylinder, tilt hoses and both auxiliary
hoses from tubes at left rear corner of first boom
section to prevent dirt and debris from entering
hydraulic system.
8. Remove the extend/retract cylinder support at the
top front of the first boom section.
3.3
 Boom

9. Support the extend/retract cylinder and remove the

clip and pin from rod end of extend/retract cylinder.
2
Remove the clip and pin from barrel end of extend/
retract cylinder and remove the extend/retract (after being turned over)
cylinder.
10. Disconnect the boom angle indicator rod from switch
at the inside left rear corner of the main boom
section and frame. Refer to Section 9.11.9, “Boom
Angle Sensor,” for adjustment information.
11. Support the front of the boom by placing a sling
behind the boom head. Support the lift/lower cylinder
and remove the lock bolt and then the rod end pin.
Lower the lift/lower cylinder onto the frame rails.
12. Remove the lock bolt and pin from compensation
cylinder on each side of first boom section. Remove MZ0740

the lock bolt and pivot pin from rear of first boom
section.
13. Lower the boom to a level position and place a
suitable support under the boom head. Reposition
the slings to each end of the boom.
14. Lift the complete boom (1) off machine and set on
level ground or supports being careful not to damage
the tubes on the left side of boom.
3.3.2 Second, Third & Fourth Boom Section
Removal
1. Set the complete boom on level ground and by
repositioning the slings turn boom over on to the top
side. Set the complete boom (2) on suitable stands
to begin tear down.
Note: With the complete boom setting upside down, the
removal and replacing of each boom section, tilt cylinder,
hoses, extend and retract chains and hose carrier are
made much easier.
2. At the boom head attach a sling through rod end of
tilt cylinder. Remove both hoses from tilt cylinder.
Plug the hose ends and cap the tilt cylinder fittings to
prevent dirt and debris from entering the hydraulic
system. Remove the clip from barrel end of tilt
cylinder pin. Remove the tilt cylinder pin and lift the
tilt cylinder out of the boomhead.

1 3
(before being turned over)
MZ0820

Note: In the following sections the individual boom

sections are removed as follows:
1. Remove second, third and fourth boom sections as
one unit from the first boom section.
2. Remove third and fourth boom sections as one unit
from the second boom section.
3. Remove fourth boom section from the third boom
section.
4. Remove hose carrier from fourth boom section. MZ0750

3.4 4017
 Boom

3. Use a suitable sling around the third section boom to 10. Pull the third boom section out 152 mm to 203 mm
take any pressure off of wear pads to make pad (6 in to 8 in) to be able to access the wear pad bolts
removal easier. on the rear of the second section boom. Remove the
top left and right side wear pads, backing plates and
Note: Before removing the extend chains, measure the
shims (one on each side) from the second boom
distance (1) between the face of the jam nut to the end of
section. Loosen the bottom rear wear pad bolts and
the chain clevis on all four extend chains. This
remove the shims from the second boom section to
measurement will be used when reassembling the
gain the necessary clearance to be able to remove
boom.
the second boom section from the first boom
section. Tag each pad, backing plate, shim and bolts
from each location.
11. Using a sling around the front of the second boom
section, lift and slide the three boom sections 3/4 of
the way out of the first boom section. Set the boom
head down on a suitable support, then center the
MZ0790 sling to be able to balance the three boom sections
being removed. Carefully pull the three boom
1 1 sections (3) the remainder of the way out of the first
boom section and set the three boom sections down
on suitable supports.
4. At the bottom front of the first section boom remove
12. Remove the clip and pin holding each retract chain
the jam nuts and nuts and washers from the two
from the inside of the first boom section. Clean and
extend chain clevises. Remove clips and pins from
inspect chains. Replace if damaged.
the two clevises and remove clevis from each chain.
13. Unscrew the tilt and auxiliary hoses from tubes at
5. At the bottom front of the second section boom
bottom front of first boom section. Plug the tilt and
remove the jam nuts and nuts and washers from the
auxiliary hoses and cap the tubes to prevent dirt and
two extend chain clevises. Remove clips and pins
debris from entering hydraulic system. Clean and
from the two clevises and remove clevis from each
inspect the hoses. Replace if damaged.
chain.
14. Inspect the boom and welds. Consult the local JLG
6. At the rear of boom, loosen and unscrew both tilt
distributor or the JLG Service Department if structural
hoses and both auxiliary hoses from bulkhead on
damage is detected.
hose carrier. Plug the hose ends and cap the
bulkhead fittings to prevent dirt and debris from 15. Inspect hoses, hardware, wear pads, mounting
entering the hydraulic system. points, chains and other components visible with the
first boom section. Replace any item if damaged.
7. Remove the clip and pin from both retract chain
(Refer to Section 3.4.1, 3.4.1. “Boom Chain
clevises that are attached to the rear of the third
Inspection,” and Section 3.7.1, 3.7.1. “Wear Pad
section boom. The pins can be removed through the
Inspection.”)
access holes at the bottom left and right sides of the
first section boom. Do not remove the clevises Note: It is recommended that if any chain or hose is
8. Remove the clip and pin from the retract chain clevis damaged that ALL chains or hoses are replaced.
that is attached to the rear of the fourth boom
section. Do not remove the clevis.
9. Pull the second section boom out
152 mm to 203 mm (6 in to 8 in) to be able to loosen
and remove all the bolts and remove all the wear
pads, backing plates and shims from the front inside
of the first section boom. Tag each pad, backing
plate, shim and bolts from each location.

4017 3.5
 Boom
3.3.3 Third & Fourth Boom Section Removal
1. With the three boom sections setting on suitable
supports remove bolts, keeper and pin from both
sheaves on the bottom front of the second boom
section. Remove sheaves. Remove all the wear
pads, backing plates and shims from the front inside
of the second boom section. Tag each pad, backing
plate, shim and bolts from each location.
2. Remove the bolts, keeper and pin from center
sheave on the bottom rear of the third boom section.
Remove the sheave.
3. Remove the top left and right side rear wear pads,
backing plates and shims (one on each side) from
the third boom section. Loosen the bottom rear wear
pad bolts and remove the shims from the third boom
section to gain the necessary clearance to remove
the third boom section from the second boom
section. Tag each pad, backing plate, shim and bolts
from each location.
1 backing plates and shims from the front inside of the
MZ0760
4. Place a sling around the front of the third boom
section. Lift and slid the two boom sections 3/4 of the
way out of the second boom section.Set the boom
head down on a suitable support, then center the
sling to be able to balance the two boom sections
being removed. Carefully pull the two boom sections
(1) the remainder of the way out of the second boom
section and set the two boom sections down on
suitable supports.
3.6
5. Remove the lock bolts, keeper and pin from both
sheaves at bottom rear of the second section boom.
Remove the sheave’s.
6. Remove the clip and pin holding retract chain from
bottom front of second boom section. Clean and
inspect chain. Replace if damaged.
7. Inspect the boom and welds. Consult the local JLG
distributor or the JLG Service Department if structural
damage is detected.
8. Inspect hoses, hardware, wear pads, mounting
points, chains and other components visible with the
first boom section. Replace any item if damaged.
(Refer to Section 3.4.1, 3.4.1. “Boom Chain
Inspection,” and Section 3.7.1, 3.7.1. “Wear Pad
Inspection.”)
Note: It is recommended that if any chain or hose is
damaged that ALL chains or hoses are replaced.
3.3.4 Fourth Boom Section Removal
1. With the two boom sections setting on suitable
supports remove the bolts, keeper and pin from
sheave on the front of the third boom section.
Remove the sheaves. Remove all the wear pads,
third boom section. Tag each pad, backing plate,
shim and bolts from each location.
2. Remove the top left and right side rear wear pads,
backing plates and shims (one on each side) from
the fourth boom section. Loosen the bottom rear
wear pad bolts and remove the shims from the fourth
boom section to gain the necessary clearance to be
able to remove the fourth boom section from the
third boom section.Tag each pad, backing plate,
shim and bolts from each location.
3. Loosen and remove the two bolts holding the rear of
the catrack to the top of the third boom section. Lift
and push rear of hose carrier into the fourth boom
section.
4. Place a sling around the front of the fourth boom
section (2). Lift and slid the fourth boom section 3/4
of the way out of the third boom section. Set the
boom head down on a suitable support, then center
the sling to be able to balance the fourth boom
section being removed. Carefully pull the fourth
boom section the remainder of the way out of the
third boom section and set the fourth boom section
down on suitable supports.
5. Remove the clip and pin holding both extend chains
from bottom of third and fourth boom sections. Clean
and inspect chains. Replace if damaged.
4017
 Boom

3.3.5 Hose Carrier Removal

1. Loosen and remove both auxiliary hoses in the
boom head.Plug the auxiliary hose ends to prevent
dirt and debris from entering hydraulic system.
2 2. With fourth boom section setting on suitable
supports loosen and remove the six bolts (three per
side) on the fourth boom section.
3. Pull the hose carrier (3) halfway out of fourth boom
section by hand and set on a suitable support. Place
a sling around the center of the hose carrier to be
able to balance the hose carrier while being
removed.Carefully slide the hose carrier the
remainder of the way out of the fourth boom section
and set down on suitable supports.

MZ0770

6. Inspect the boom and welds. Consult the local JLG 3

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 to Section 3.4.1, 3.4.1. “Boom Chain
Inspection,” and Section 3.7.1, 3.7.1. “Wear Pad
Inspection.”)
Note: It is recommended that if any chain or hose is
damaged that ALL chains or hoses are replaced. MZ0780

3.3.6 Hose Carrier Installation

1. Install the hose carrier into the fourth boom section.
Using a suitable sling, place the sling under the
center of the hose carrier and guide the front of hose
carrier into the rear of the fourth boom section. Set
the rear of the hose carrier on a suitable support.
Remove the sling and slide the remainder of the
hose carrier into the fourth boom section by hand.
2. Apply Loctite 242® to the hose carrier bolts. Install
the bolts through the three holes on each side of the
fourth boom section. Install the front two bolts first.
Install the middle two next. Then the rear two bolts
last. Torque to all six bolts to 90 Nm (66 lb-ft).

4017 3.7
 Boom
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). Install top rear wear pads,
backing plates and bolts (front bolts are drilled and
tapped for grease fittings. Do not shim or tighten
bolts). Install both extend chains (1) on bottom rear
of fourth boom section. Lay extend chains the length
of fourth boom section.
2. Grease the inside third boom section on area’s
where the fourth boom section wear pads will slide.
1 90 Nm (66 lb-ft). Grease the sheave using the grease
MZ0770
3. Using a suitable sling, balance the fourth boom
section and carefully slide 914 mm to 1219 mm
(3 ft to 4 ft) into the front of the third boom section.
Set the fourth boom section head onto suitable
support and reset sling under the boom head of the
fourth boom section. Carefully slide the fourth boom
section into the third boom section. Leave
1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom
section out to be able to install wear pads in front of
the third boom section.
3.8
4. With the sling still under boom head, apply Loctite
242® to the wear pad mounting bolts and install the
top wear pads, washers and bolts in the front of the
third boom section. Torque to 90 Nm (66 lb-ft). Lower
the fourth boom section, apply Loctite 242® to the
wear pad mounting bolts and install bottom wear
pads, backing plates, shims and bolts in the front of
the third boom section. Torque to 90 Nm (66 lb-ft).
Apply Loctite 242® to the wear pad mounting bolts
and install both left side and right side front wear
pads, backing plates, shims and bolts in the front of
the third boom section. Torque to 90 Nm (66 lb-ft).
Note: Grease wear pads, inside sheaves, bores and
pins during assembly.
5. Apply Loctite 242® to the sheave mounting bolts,
Install the sheave (2), pin, lock plate and bolts at the
bottom front of the third boom section. Torque bolts to
fitting in the pin. Spin the sheave by hand to ensure
the sheave spins freely on the pin and to distribute
grease evenly. Pull both extend chains from the fourth
boom section around the front and over the sheave.
Install both chain clevises, pins and clips.
MZ0980
Third Boom Section
6. Retract the fourth boom section the remainder of the
way into the third boom section and install the wear
pads at the rear of third and fourth boom sections.
7. Apply Loctite 242® to the wear pad mounting bolts
and install the bottom left and right side wear pads,
backing plates, shims and bolts. Shim the top wear
pads on the rear of the fourth boom section. Shim
the top left and right wear pads on the rear of the
fourth boom section. Torque bolts to 90 Nm (66 lb-ft).
Torque grease fitting bolts to 45 Nm (33 lb-ft).
4017
 Boom

3.3.8 Third & Fourth Boom Section Pull both extend chains from the third boom section
Installation around the front and over the sheaves. Install both
chain clevises, pins and clips (3).
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 2
side wear pads, backing plate and bolts (do not shim
or tighten bolts). Install the top rear wear pads,
backing plates and bolts (front bolts are drilled and
tapped for grease fittings. do not shim or tighten
bolts). Install both extend chains on the bottom rear
of the third boom section. Lay extend chains the
length of third boom section.
MZ1000
2. Grease the inside second boom section on area’s
where the third boom section wear pads will slide. Second Boom Section
(front)
3. Install retract chain, pin and clip to bottom front
inside of the second boom section. 7. Apply Loctite 242® to the wear pad mounting bolts
and install the bottom left and right side wear pads,
Note: Keep the retract chain centered on bottom of the
backing plates, shims and bolts.Shim the top wear
third boom section while installing the third boom section
pads on the rear of the third boom section. Shim the
into the second boom section.
top left and right wear pads on the rear of the third
4. Using a suitable sling, balance the third and fourth boom section.Torque bolts to 90 Nm (66 lb-ft).
boom section and carefully slide 914mm-1219mm Torque grease fitting bolts to 45 Nm (33 lb-ft).
(3 ft - 4 ft) into the front of the second boom section. 8. Install the retract chain sheave (4), pin, keeper and
Set the third and fourth boom section onto a suitable bolts to bottom rear of third boom section. Apply
support and reset the sling under the boom head of Loctite 242® and torque to 90 Nm (66 lb-ft). Grease
the fourth boom section. Carefully slide the third and the sheaves using the grease fitting in the pin. Spin
fourth boom section into the second boom section. the sheaves by hand to ensure the sheaves spin
Leave 152mm-203mm (6 in - 8 in) of the third boom freely on the pin and to distribute grease evenly.
section out to be able to install the wear pads in the
front of the second boom section
Retract Chain
5. With the sling still under boom head, Apply Loctite Clevises
242® to the wear pad mounting bolts and install the 3
top wear pads, washers and bolts in the front of the
second boom section. Torque to 90 Nm (66 lb-ft).
Lower the third and fourth boom section and apply 4
Loctite 242® to the wear pad mounting bolts and
install bottom wear pads, backing plates, shims, and
the allenhead cap bolts in the front of the second
boom section. Torque to 90 Nm (66 lb-ft). Install both
MZ1010
left side and right side front wear pads, backing
plates, shims and bolts in the front of the second Third Boom Section
boom section. Torque to 90 Nm (66 lb-ft). (rear)

Note: Grease wear pads, inside sheaves, bores and

pins during assembly.
6. Install both sheaves (2), pins, lock plates and bolts at
the bottom front of the second boom section. Apply
Loctite 242® and torque bolts 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 to distribute grease evenly.

4017 3.9
 Boom

3.3.9 Second, Third & Fourth Boom Section

1
Installation
IMPORTANT: Light lubrication of the boom wear
surfaces with a factory authorized grease is
recommended to keep the boom wear surfaces
lubricated properly. Light lubrication of the boom wear
surfaces is also recommended when the machine is
stored, to help prevent rusting.
1. Apply Loctite 242® to the wear pad mounting bolts.At
the rear of the second boom section install the
MZ1140
bottom rear wear pads, washers and bolts. Torque to
90 Nm (66 lb-ft). Install the bottom rear left and right
Second Boom Section
side wear pads, backing plate and bolts (do not shim
(rear)
or tighten bolts). Install top rear wear pads, backing
plates and bolts (front bolts are drilled and tapped for
grease fittings. do not shim or tighten bolts).
9. Install both retract chain sheaves (1), pin, keeper 2
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 to distribute grease evenly.

3 4

MZ1190

First Boom Section

(front view)

2. Grease the inside first boom section on area’s where

the second boom section wear pads will slide.
3. Install the retract chains (2), pins and clips to bottom
front inside of the first boom section.
4. Install both tilt hoses (3) and both auxiliary hoses (4)
to the tubes mounted at the bottom front of the first
boom section. Make sure both sets of hoses are run
through the opening at the bottom front of the first
boom section and run down the inside center of the
boom section
Note: Keep the retract chains, tilt and auxiliary hoses
centered in the first boom section while installing the
second boom section into the first boom section.

3.10 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 fourth boom section.
Carefully slide the second, third and fourth boom 6
section into the first boom section. Leave 152 mm -
203 mm
(6 in - 8 in) of the second boom section out to be
able to install wear pads in front of the first boom Tilt Hoses
section.
Auxiliary Hoses
6. With sling still under boom head, Apply Loctite 242® 5
to the wear pad mounting bolts. Install the top wear
pads, washers and bolts in the front of the first boom
section. Torque to 90 Nm (66 lb-ft). Lower the
second, third and fourth boom section and apply
Loctite 242® to the wear pad mounting bolts, Install
bottom wear pads, backing plates, shims, and bolts
in the front of the first boom section. Torque to
90 Nm (66 lb-ft). Install both left side and right side
front wear pads, backing plates, shims and bolts in MZ1200

the front of the second boom section. Torque to

90 Nm (66 lb-ft).
Note: Shim ALL side wear pads as needed to maintain
a minimum gap (1.6 mm - 1/16 in) the horizontal
direction or a snug fit. The number of shims can vary at
each shim point.
7. Install the bottom left and right side wear pads,
backing plates, shims and bolts at the rear of the
second boom section.Shim the top wear pads on the
rear of the second boom section. Shim the top left
and right wear pads on the rear of the second boom
section. Apply Loctite 242® and torque bolts to 90
Nm (66 lb-ft).
Hose Carrier Mounting
Bolts (2)
8. Retract the second, third and fourth boom sections
the remainder of the way into the first boom section.
9. Attach the retract chain (5), pin and clip to the clevis
at the rear of the fourth boom section.
10. Attach the retract chains (6), pins and clips to the
clevises at the rear of the third boom section.
Note: Installing the clevis pins in the third boom section
can only be done when the first boom section and the
second boom section access holes are aligned.

4017 3.11
 Boom
11. Attach both extend chain clevises (1) through the
holes in the bottom front of the first boom section.
Install the washers, adjustment nut and jam nut to
the clevises.
12. Attach both extend chain clevises (1) through the
holes in the bottom front of the second boom
section. Install the washers, adjustment nut and jam
nut to the clevises.
2 and set on level ground. It will be necessary to place
MZ0790
1 Note: Grease extend/retract cylinder barrel end bore
Note: Adjust all four extend chains (2) using the
measurement taken in the beginning of the tear down
procedure. Depending on the extent of the parts being
replaced, the above measurement is to be used as a
starting point ONLY.
13. Pull the rear of the hose carrier over the rear of the
fourth boom section and set onto the rear of the third
boom section. Using the two bolts, washers and
nuts, bolt the rear of the hose carrier to the rear of
the third boom section. Apply Loctite 242® and
torque the two bolts to 90 Nm (66 lb-ft).
14. Remove the caps from the fittings on the hose
carrier bulkhead and the plugs from the tilt and
auxiliary hoses. Install all four hoses and tighten until
wrench-tight. Mark the hose fitting then tighten each
hose firmly 1 to 1 1/2 flats.
15. Remove the caps from the auxiliary hoses in the
boomed and install the auxiliary hoses from the front
of the hose carrier to the auxiliary bulkhead. Tighten
each hose wrench-tight. Mark the hose fitting then
tighten each hose firmly 1 to 1 1/2 flats. Bolt the
auxiliary hose bulkhead to the side of the boom head
and torque the two bolts to 90 Nm (66 lb-ft).
16. Using a suitable sling through the rod end of the tilt
cylinder, lower the tilt cylinder into boomhead. Align
the tilt cylinder barrel end bore with the boomhead
bore and install the tilt cylinder pin and retaining clip.
3.12
Note: Grease tilt cylinder barrel end bore and pin before
installing.
17. Remove the caps from the fittings on the tilt cylinder
and the plugs from the tilt hoses from the hose
carrier. Install both tilt hoses and tighten until
wrench-tight. Mark the hose fitting then tighten each
hose firmly 1 to 1 1/2 flats.
18. Using suitable slings, lift complete boom off supports
a block under the rear of the boom to keep the tilt
and auxiliary tubes from being damaged
19. Turn the boom over being careful not to damage the
tilt and auxiliary tubes mounted on the side and rear
of boom.
20. After boom is turned upright, place a suitable
support under the rear of the boom.
21. Attach a sling around a balance point on the extend/
retract cylinder and carefully set on top of the first
boom section.
and rod end bore and pins before installing.
22. Align the extend/retract cylinder barrel end (3) with
bore at rear of the first boom section. Install the pin
and retaining clip (4).
23. Align the extend/retract cylinder rod end (3) with
bore at front of the second boom section. Install the
pin and retaining clip (4).
24. Install extend/retract cylinder support (5). Apply
Loctite 242® and torque bolts to 90 Nm (66 lb-ft).
5
4
3
4
MZ1210
4017

3.3.10 Boom Installation
IMPORTANT: Light lubrication of the boom wear
surfaces with a factory authorized grease is
recommended to keep the boom wear surfaces
lubricated properly. Light lubrication of the boom wear
surfaces is also recommended when the machine is
stored, to help prevent rusting.
1. Park the machine on a hard, level surface. Make
sure park brake is set, key is removed from the
ignition and “DO NOT OPERATE” tag is placed in
clear view in the cab.
7
6 6. Remove the caps from both tilt tubes (10) and
7
MZ1230
2. Using suitable slings, balance the boom assembly,
lift and carefully guide the boom into place. Align the
frame pivot bore with the boom assembly pivot bore.
Install boom pivot pin (6). Apply Loctite 242® and
torque lock bolt to 90 Nm (66 lb-ft).
3. With the sling still in place, install both compensation
cylinders, pins and lock bolts (7). Apply Loctite 242®
and torque to 90 Nm (66 lb-ft).
4. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt (8). Apply Loctite
242® and torque to 90 Nm (66 lb-ft).
8 MZ1240
4017
Boom
Note: Raising the boom up or down with the sling
maybe necessary so the boom, compensation and lift/
lower cylinder bores can be aligned for easier pin
installation.
Note: Grease the boom pivot bore, compensation
cylinder rod ends, lift/lower cylinder rod end and pins
before installing.
5. Remove the caps from extend/retract cylinder fittings
and plugs from extend/retract cylinder hoses. Attach
each hose to the extend/retract cylinder fittings (9)
and tighten until wrench-tight. Mark the hose fitting
then tighten each hose firmly 1 to 1 1/2 flats.
auxiliary tubes (11) and plugs from both tilt hoses
and both auxiliary hoses. Attach both sets of hoses
to the tilt tubes and the auxiliary tubes and tighten
until wrench-tight. Mark the hose fitting then tighten
each hose firmly 1 to 1 1/2 flats.
7. Connect the boom angle indicator rod from switch at
the inside left rear corner of the main boom section
and frame. Refer to Section 9.11.9, “Boom Angle
Sensor,” for adjustment information.
8. Start the engine and operate all boom functions
several times. Check for leaks, and check the
hydraulic fluid level in the reservoir; add fluid if
required.
9
11
10
MZ1250
9. Clean up all debris, hydraulic fluid, etc., in, on, near
and around the machine.
3.13
 Boom
3.4 BOOM EXTEND AND RETRACT
CHAINS
3.4.1 Boom Chain Inspection
WARNING: Worn pins, stretched or
cracked links or corrosive environments can
cause chain failure. A chain failure could result
in uncontrolled boom movement, loss of load
or machine instability, and could cause death
or serious injury and/or property damage.
Under normal operating conditions the boom chains will
need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every
1000 hours of operation. Refer to the Service Manual for
the proper procedure. Environmental conditions and
dynamic impulse/shock loads can drastically affect
normal operating conditions and require more frequent
inspection intervals.
Environments in which material handling vehicles
operate can vary widely from outdoor moisture to
temperature to mildly corrosive or highly corrosive
industrial atmospheres, in addition to abrasive
exposures such as sand and grit. Some effects can be
as follows:
• Moisture - Corrosive rusting reduces chain
strength by pitting and cracking.
• Temperature - Low temperature reduces chain
strength by embrittlement. Going in and out of
cold storage results in moisture from
condensation.
• Chemical Solutions or Vapors - Corrosive attack
on the chain components and/or the mechanical
connections between the chain components.
Cracking can be (and often is) microscopic.
Going from microscopic cracking to complete
failure can be either abrupt or may require an
extended period of time.
• Abrasives - Accelerated wearing and scoring of
the articulating members of the chain (pins and
plates), with a corresponding reduction in chain
strength. Due to the inaccessibility of the bearing
surfaces (pin surfaces and plate apertures),
wear and scoring are not readily noticeable to
the naked eye.
3.14
Following are some examples of dynamic shock loading
which can impose abnormal loads above the endurance
limit of a leaf chain.
• High velocity movement of load, followed by
sudden, abrupt stops.
• Carrying loads in suspension over irregular
surfaces such as railroad tracks, potholes, and
rough terrain.
• Attempting to “inch” loads which are beyond the
rated capacity of the vehicle.
The above load cycles and environmental conditions
make it impossible to predict chain life. It is therefore
necessary to conduct frequent inspections until
replacement life can be predicted.
The boom chain’s normal life expectancy can be
expressed as a maximum percent of elongation. This is
generally 3%. As the chain flexes back and forth over the
sheave, the bearing joints (pins and inside link plates)
gradually incur wear due to articulatio
3.4.2 Inspection Guidelines
1. Park the machine on a firm, level surface, raise the
boom to a horizontal (level) position, place the
transmission control lever in (N) NEUTRAL, engage
the park brake switch.
2. Fully extend the boom until the extend chain is taut.
Shut the engine off.
3. The extend chains will be visible for inspection with
the vehicle in this state.
4. While doing the chain inspection, check all chain
clevis ends for distortion or cracking and sheaves for
bearing wear or grooving from the chain.
5. Inspect the retract chains every 1000 hours of
operation. Refer to the Service Manual for proper
procedure.
6. Inspect the chains for the following conditions:
Edge Wear
Check the chain for wear on the link plate edges
caused by running back and forth over the sheave.
The maximum reduction of material should not
exceed 5%. This can be compared to a normal link
plate height by measuring a portion of chain that
does not run over the sheave.
a. Extend Chains (fourth to third section)
The extend chains between the fourth and third
boom sections measures 18 mm (.713 in) (1). If the
measurement of the worn chain is less than 17 mm
(.677 in) (2), the chain should be replaced.
4017
 Boom

b. Extend Chains (third to second section)

3
The extend chains between the third and second
boom sections measures 29,6 mm (1.2 in) (1). If the 4
measurement of the worn chain is less than
28,6 mm (1.1 in) (2), the chain should be replaced.

2 1

MZ1463

Elongation
It is important to measure the chain in the section
that moves over the sheaves because it receives the
most frequent articulation. Measuring the chain near
its clevis terminals could give an inaccurate reading.
The ends of the chains, near the clevis terminal, will
not have flexed as frequently, if at all, as nearer the
middle of the chains.
MZ1464
Turning or Protruding Pins
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces
between pin and link plates. When chain is allowed
to operate in this condition, a pin or series of pins,
can begin to twist out of a chain, resulting in failure.

a. Extend Chains (fourth to third section)
When the original length (3) of 305 mm (12.00 in)
per foot of extend chain between the fourth and third
boom sections has elongated from wear to a length
(4) of 313 mm (12.36 in), the chain should be
discarded and replaced.
Measure across a span of 16 pins at the center of
the extend chain. Measure from pin center to pin
center. Because the retract chain is inside the boom
you will not be able to measure the chain.
The maximum measurement allowed is
313 mm(12.36 in). If the measurement is more than
313 mm (12.36 in), the chain should be replaced.
Examine the pin head rivets to determine if the
“VEE” flats are still in correct alignment (5). Chain
with rotated/displaced heads (6) or abnormal pin
protrusion (7) should be replaced immediately.
DO NOT attempt to repair the chain by welding or
driving the pin(s) back into the chain. Once the press
fit integrity between outside plates and pins has
been altered, it cannot be restored.
Any wear pattern on the pin heads or the sides of the
link plates indicates misalignment in the system.
This condition damages the chain as well as
increases frictional loading and should be corrected.

b. Extend Chains (third to second section)

When the original length (3) of 317 mm (12.5 in) per 6
5
foot of extend chain between the third and second
boom sections has elongated from wear to a length 7
(4) of 325 mm (12.8 in), the chain should be MZ1465
discarded and replaced.
Measure across a span of 10 pins at the center of
the extend chain. Measure from pin center to pin
center. Because the retract chain is inside the boom
you will not be able to measure the chain.
The maximum measurement allowed is
325 mm(12.8 in). If the measurement is more than
325 mm (12.8 in), the chain should be replaced.

4017 3.15
 Boom

Distorted or Battered Link Plates • Tight Joints

- All joints in
Distorted or battered link plates (8) on a leaf chain can
the chain
cause tight joints and prevent flexing. should flex
freely. Tight
3 MZ1471
joints (3)
88
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or
bent pins, replace the chain.

MZ1466 3.4.3 Expose Chains for Inspection

Cracked Plates c. Extend Chains

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 discovered, the chain
should be replaced in its entirety.
It is important, however to determine the cause of
the crack before installing a new chain so the
condition does not repeat itself.
The types of cracks are:
• Fatigue Cracking -
Fatigue cracks (9) are a
result of repeated
cyclic loading beyond MZ1467
the chain’s endurance
limit.
• Stress Corrosion
Cracking - The
outside link plates 10
are particularly
susceptible to stress
corrosion cracking (10).
• Corrosion Fatigue Cracking - Corrosion
fatigue cracks are very similar to fatigue
cracks in appearance. Corrosion fatigue is the
combined action of an aggressive
environment and cyclic stress.
Other Modes of Failure
• Ultimate Strength Failure -
These types of failures are
caused by overloads far in 1 replace both the chain and the clevis. It is recommended
excess of the design load.
Either fractured plates (1) or 2
enlarged holes (2) can
occur. If either of these
failures occurs, the chain
should be replaced immediately.
1. Park the machine on a firm, level surface. Place the
transmission control lever in (N) NEUTRAL, engage
the park brake switch and raise the boom to a
horizontal (level) position.
2. Lower both outriggers completely
3. Fully extend the boom until both extend chains are
taut. Shut the engine OFF.
The extend chains will be visible for inspection with the
machine in this state.
9 While doing the chain inspection, check all chain clevis
ends for distortion or cracking and sheaves for bearing
wear or grooving from the chain.
If during the inspection, any chain is found to be damaged
or stretched, the chain must be replaced. It is
recommended that when any chain is replaced, that all
the chains and clevises be replaced at the same time.
MZ1468
d. Retract Chains
The three retract chains are only partially visible through
the rear of the boom with all the sections retracted. It is
possible to see a section of the retract chain as the boom
is slowly extended. If there is ANY question that one or all
the retract chains are damaged, the boom should be
removed and disassembled with the retract chains being
inspected and replaced if necessary.
Note: DO NOT attempt to repair a chain. Replace a
stretched or damaged chain with a new part. Always
MZ1469 that when any chain is replaced, that all chains and
clevis’ be replaced at the same time.
MZ1470

3.16 4017

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 chain.
If during the inspection, any chain is found to be damaged
or stretched, the chain must be replaced. It is
recommended that when any chain is replaced, that all
the chains and clevis’ be replaced at the same time.
3.4.4 Chain Lubrication
After inspection and before being returned to service,
chains must be lubricated with a quality chain lubricant
(“LUBRIPLATE” Chain & Cable Fluid, “LPS3” or
equivalent).
The lubricant must penetrate the chain joint to prevent
wear. Applying lubricant to the external surfaces will
prevent rust, but the chains should be articulated to
make sure the lubricant penetrates to the working
surfaces between the pins and links.
To prepare the chain for lubrication, the chain plates
should be brushed with a stiff brush or wire brush to
clear the space between the plates so that lubricant can
penetrate to the working surfaces.
Lubricant may be applied with a narrow paint brush or
directly poured on, but the chain should be well flooded
with lubricant and the boom should be extended and
retracted to be sure that the lubricant penetrates to the
working surfaces. All surplus lubricant should be wiped
away from the external surfaces. DO NOT use a solvent
for this wiping operation.
Regular application of lubricant is necessary to make
sure that all working surfaces are adequately lubricated.
In extremely dusty conditions, it may be necessary to
lubricate the chains more often.
Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special
consideration. It is important that a reputable lubrication
specialist, a JLG Distributor or the vehicle distributor be
consulted for guidance.
4017
Boom
3.5 BOOM SECTION SEPARATION
ADJUSTMENT
The second, third and fourth boom sections are set to
dimensions between each section. The first and second
boom sections are connected by the extend/retract
cylinder which has no adjustment.
The third and fourth boom sections can be adjusted by
loosening or tightening the extend chains and the retract
chains.
1. Fully retract the boom and raise the boom to a
horizontal position. Place the transmission control
lever in (N) NEUTRAL, engage the park brake
switch.
2. Measure the distance between the boom sections
(1). If adjustments are needed, extend the boom out
0,91 m to 1,2 m (3 ft to 4 ft). Shut off machine.
3. Loosen the locknuts on the extend chains and the
retract chains and adjust as needed.
a. To increase the separation distance: Loosen the
retract chains locknut on the rear of the third or
fourth boom sections one or two turns and
tighten the extend chain locknuts on the first and
second boom sections equally the same number
of turns. A minimum of one full thread on the
clevis must protrude beyond the locknut.
1
797mm
31.378”
499mm
19.645”
229mm
9.016”
20mm
37mm
1.45” .787”
b. To decrease the separation distance: Loosen the
extend chain locknuts at the front of the first or
second boom sections equally one or two turns
and tighten the retract chains locknut the same
number of turns. A minimum of one full thread
on the clevis must protrude beyond the locknut.
3.17
 Boom
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 to paragraph a. or b. and
repeat procedure until the proper boom section
dimensions is achieved.
6. With the boom sections within the proper tolerance,
start the machine, lower the outriggers if necessary
and extend the boom to maximum extension.
7. Shut the machine off and measure the distance
between the top of both extend chains and the
bottom of the second and third boom sections at the
center of each boom section.
8. The distance (2) between the top of the extend
chains and the bottom of the second boom section
should be approximately 180 mm (7 in). The
distance (2) between the top of the extend chains
and the bottom of the third boom section should be
approximately 120 mm (4.75 in).
2 section are accessible through the third boom
120mm - 4.75in 180mm - 7in
MZ1220
Note: If the second boom section to the third boom
section separation distance cannot be achieved, contact
the local JLG distributor or the JLG Service Department.
3.18
3.6 HOSE CARRIER ASSEMBLY
3.6.1 Hose Carrier Assembly Removal
1. Remove any attachment from the quick switch
assembly. (Refer to Section 3.8.1, “Connecting with
a Mechanical Quick Switch Device.”)
2. Park the machine on a hard, level surface. Be sure
there is enough room in front and rear of the
machine to extend the boom sections and to be able
to removed the hose carrier from the rear of the
boom assembly.
3. Fully extend the boom and raise the boom to a
horizontal position. Place the transmission control
lever in (N) NEUTRAL, engage the park brake
switch.
4. Retract the boom until the rear hose carrier
mounting bolts on the fourth boom section are
accessible through each side of the third boom
section access holes. Shut off the machine and
remove the bolts.
5. Start the machine and retract the boom until the
middle set of hose carrier bolts on the fourth boom
section access holes. Shut the engine OFF and
remove the bolts.
6. Start the engine and retract the boom until the front
set of hose carrier bolts on the fourth boom section
are just in front of the front of the third boom section.
Shut the engine OFF and remove the bolts.
7. Start the engine and slowly retract the boom
sections completely.
8. Shut the engine OFF and place an Accident
Prevention Tag on both the ignition key switch and
the steering wheel, stating that the machine should
not be operated.
9. Relieve any trapped pressure in the tilt hydraulic
system by using the handle provided or a 9mm
wrench and move the double nut on the side of the
main control valve tilt section back and forth. Repeat
on the auxiliary valve section.
10. Locate the two hoses attached to the barrel of the tilt
cylinder inside the boomhead.
11. Label and remove the hoses from the elbow fittings
on the tilt cylinder (1). Plug the hose ends and cap
the elbow fittings on the tilt cylinder to prevent dirt
and debris from entering the hydraulic system.
4017

2 3
Hose
Carrier
MZ0900
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 hoses and the auxiliary hoses from the hose
carrier bulkhead. Plug the hose ends and cap the
bulkhead fittings to prevent dirt and debris from
entering the hydraulic system.
14. From the top rear of the hose carrier, remove both
bolts (3) holding the hose carrier (4) to the third
boom section.
15. Remove both left and right side wear pad bolts and
both left and right bottom wear pad bolts from the
rear of the fourth boom section to be able to remove
the hose carrier.
16. Pull the hose carrier halfway out of the rear of the
boom, set on a suitable support. Using a sling
around the hose carrier, balance the hose carrier
and pull the remainder of the way out. Set the hose
carrier on the ground or on suitable supports.
5
4017
Boom
MZ0920
4
Note: If the machine or the boom has to be moved,
replace all the bolts that were removed from the wear
pads on the rear of the fourth boom section BEFORE the
machine is started and/or the boom is retracted or
extended.
3.6.2 Hose Carrier Assembly Replacement
1. Carefully lay the new hose carrier assembly out flat
on a hard surface.
2. Make sure the boom is level and that the front two
hose carrier holes (5) in the fourth boom section are
accessible just in front of the front of the third boom
section.
3. Using a sling around the center of the hose carrier,
lift and carefully place the front of the hose carrier
part way into the rear of the boom. Set the rear of the
hose carrier down on a suitable support. Reposition
the sling and lift the rear of the hose carrier and slide
it the remainder of the way into the boom.
6 7
Access Hole on Each
Side of the Third
Section Boom
MZ0910
3.19
 Boom

4. Apply Loctite® 242 to the wear pad mounting bolts 17. At the rear of the boom, attach both tilt cylinder
and install both left and right side wear pads and hoses to the tilt hose carrier bulkhead fittings and
bolts and both left and right bottom wear pads and tighten until wrench-tight. Mark the hose fitting then
bolts. torque the side wear pads to 50 Nm (37 lb-ft) tighten each hose firmly 1 to 1 1/2 flats.
and the bottom wear pads to 90 Nm (66 lb-ft). 18. At the rear of the boom, attach both auxiliary hoses
5. Align the front two threaded holes on the hose to the auxiliary hose carrier bulkhead fittings and
carrier with the front two holes (5) on each side of tighten until wrench-tight. Mark the hose fitting then
the fourth boom section and install both bolts. Apply tighten each hose firmly 1 to 1 1/2 flats.
Loctite® 242 and hand tighten only. 19. Start the engine and operate all boom functions
6. Fasten the rear of the hose carrier (3) to the top rear several times. Check for leaks, and check the
of the third boom section. Apply Loctite® 242 and hydraulic fluid level in the reservoir; add fluid if
torque both bolts to 90 Nm (66 lb-ft). required.
7. Start the machine and extend the boom out until the
middle set of holes (6) in the fourth boom section
align with access holes at the front sides of the third
boom section. Shut off machine.
8. Align the middle two threaded holes on the hose
carrier with the middle two holes on the fourth boom
section and install both bolts. Apply Loctite® 242 and
hand tighten only.
9. Start the machine and extend the boom out until the
rear set of holes (7) in the fourth boom section align
with access holes on each side of the third boom
section. Shut off machine.
10. Align the rear two threaded holes on the hose carrier
with the rear two holes on the fourth boom section
and install both bolts. Apply Loctite® 242 and torque
to 90 Nm (66 lb-ft).
11. Torque the middle two and front two hose carrier
bolts to 90 Nm (66 lb-ft).
12. Start the machine and retract the boom
completely.Shut the machine off.
13. Relieve any trapped pressure in the tilt hydraulic
system by using the handle provided or a 9mm
wrench and move the double nut on the side of the
main control valve tilt section back and forth. Repeat
on the auxiliary valve section.
14. Attach both tilt cylinder hoses from the hose carrier
to the tilt cylinder and tighten until wrench-tight. Mark
the hose fitting then tighten each hose firmly
1 to 1 1/2 flats.
15. Attach both auxiliary hoses from the hose carrier to
the auxiliary fittings on the bulkhead and tighten until
wrench-tight. Mark the hose fitting then tighten each
hose firmly 1 to 1 1/2 flats.
16. Bolt the auxiliary bulkhead onto the side of the boom
head. Apply Loctite® 242 and torque to 50 Nm (37 lb-
ft).

3.20 4017

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 used to maintain a minimum gap
between the wear pad and the boom surface.
3.7.1 Wear Pad Inspection
Inspect all wear pads for wear. If the angle indicators on
the ends of the wear pads are visible, the wear pads can
be reused. If the pads show uneven wear (front to back),
they should be replaced. Replace pads as a set if worn or
damaged.
Ma2070
3.7.2 Boom Wear Pad Replacement
When replacing a wear pad on the boom, replace both
wear pads on that side of the boom; e.g.: replace top front
left and top front right wear pads at the same time.
Usually, shimming will remain the same when installing
new wear pads. Some wear pads are secured to the
boom using different bolts and washers. Keep bolts and
washers with the same wear pad that is being replaced.
When installing new wear pads, apply Loctite® #242 to all
wear pad mounting bolts and torque to required
specifications.
4017
Boom
a. Fourth Section Boom
Coat all wear pad bolts with Loctite 242® before
installation.
All fourth section boom wear pads are mounted on the
rear outside of the fourth section boom.
Fourth Section Boom
MZ0840
Use shims under the upper rear 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 the boom
surface. Shims are available in two thicknesses, 2.0 mm
and 4.0 mm.
b. Third Section Boom
Coat all wear pad bolts with Loctite 242® before
installation.
The wear pads on the inside front and outside rear of the
third boom section can be replaced by removing the bolts
securing them to the top, sides and bottom of the boom.
When removing pads, move the boom sections as
needed to gain access for removal and installation of
wear pads. Mark or otherwise label each pad, spacer/
shim and hardware set for ease of installation later. Top
wear pads are secured to the boom with washers and
bolts; side wear pads are secured with washers and
bolts.
3.21
 Boom
Third Section Boom
MZ0850
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
installation.
The wear pads on the inside front and outside rear of the
second boom section can be replaced by removing the
bolts securing them to the top, sides and bottom of the
boom.
When removing pads, move the boom sections as
needed to gain access for removal and installation of
wear pads. Mark or otherwise label each pad, spacer/
shim and hardware set for ease of installation later. Top
wear pads are secured to the boom with washers and
bolts; side wear pads are secured with washers and
bolts.
3.22
Second Section Boom
MZ0860
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 the boom surface.
d. First Boom Section
Coat all wear pad bolts with Loctite 242® before
installation.
All first boom section wear pads are mounted on the
inside front of the first boom section. Remove the bottom
wear pads before removing the top wear pads. Lower the
gooseneck to the ground until the second boom section
raises up, providing clearance for removing the bottom
pads. Fill the grease pockets of the top rear boom wear
pads with multi-purpose grease.
Use shims under the bottom front 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.
4017

First Section Boom
1
13
2 3
MZ0870
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 a factory authorized grease
is recommended to keep the boom wear surfaces
lubricated properly. Light lubrication of the boom wear
surfaces is also recommended when the machine is
stored, to help prevent rusting.
4017
Boom
3.8 QUICK SWITCH ASSEMBLY
This machine is equipped with a quick switch system for
easy attachment changes.
3.8.1 Connecting with a Mechanical Quick
Switch Device
1. Retract quick switch device to provide clearance.
Check to be sure lock pin (1) and retainer pin (2) is
out.
2. Align attachment pin (3) with recess in
attachment (4).
3. Engage quick switch device.
4. Shut off engine. Exit cab and insert lick pin and
secure with retainer pin.
5. If attachment is equipped, connect auxiliary
hydraulic hoses. See Section 3.8.3, “Connecting with
a Quick Switch to a Hydraulic Operated Attachment.”
3.8.2 Connecting with a Hydraulic Quick
Switch Device
1. Retract quick switch device to provide clearance.
Check to be sure lock pin is disengaged.
2. Align attachment pin (3) with recess in
attachment (4). Raise boom slightly to engage
attachment pin in recess.
3. Engage quick switch device.
4. Press the button (5) and at the same time, move the
joystick to engage or to disengage the quick switch
device.
MAH0980
5. Raise the boom to eye level and visually check that
the quick switch pin protrudes through the hole. If the
pin does not protrude through the hole, place the
attachment on the ground and return to step 2.
6. If attachment is equipped, connect auxiliary
hydraulic hoses. See Section 3.8.3, “Connecting with
a Quick Switch to a Hydraulic Operated Attachment.”
3.23
 Boom

3.8.3 Connecting with a Quick Switch to a

Hydraulic Operated Attachment
1. Lower attachment to ground. Set the park brake,
shut off engine and turn key back to the “ON”
position.
2. Relieve pressure in the hydraulic system by
actuating the joystick.
3. Connect the quick-disconnect fittings.
4. Start the engine.

3.8.4 Quick Switch Removal

1. Remove the lock bolt (5) holding the tilt cylinder rod
end to the quick switch assembly. Remove the tilt
cylinder pin.
2. Support the quick switch assembly. Remove the four
bolts and covers (6) from each end of the quick
switch assembly. Remove the pin from the quick
switch assembly from either side.
3. Inspect the above pin for nicks or surface corrosion.
Use fine emery cloth to fix minor nicks or corrosion.
If damaged or if it cannot be repaired, the pin must
be replaced.

3.8.5 Quick Switch Installation

1. Assemble the quick switch to the boom head. Line
up the quick switch between the mounts on the
boom head. The quick switch should be centered in
the boom head.
2. Coat the quick switch pivot pin with an anti-seize
compound. Insert the quick switch pivot pin through
the quick switch and boom head. Replace the end
covers and four bolts (6) to each end of the quick
switch.
3. Align the quick switch with the tilt cylinder rod end
and insert the tilt cylinder pin. Align the tilt cylinder
pin and screw in the locking bolt (5). Torque as
required.
4
3

1
2

3.24 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 1. Broken hydraulic hose(s) or
retract. tube(s) and/or connections
leaking.
2. Extend/Retract hydraulic system
not operating properly.
3. Faulty extend/retract cylinder.
4. Broken chains or anchors.
1. Locate break, replace hose(s)
or tube(s), tighten connections.
2. Refer to Section 8.4, “Hydraulic
Circuits.”
3. Repair cylinder, Refer to Section
8.8.1, “General Cylinder
Removal Instructions.”
4. Replace chains as needed.

1. Boom shifts to right or left
when extending.
1. Boom pivot pin improperly
shimmed.
2. Incorrect wear pad gap or
shimming, or wear pads
excessively worn.
1. Re-shim the boom to a minimum
gap with shims distributed
evenly on both sides of the
boom pivot pin.
2. Shim wear pads to correct gap.
Replace wear pads as needed.
Refer to Section 3.7.2, “Boom
Wear Pad Replacement.”

4. Excessive boom pivot pin 1. Insufficient lubrication. 1. Lubricate at regular intervals.

noise and/or wear. (Refer to Section 2.5.3, 2.6.
“Lubrication Schedules.”)
2. Replace bushing(s) and
2. Worn bushing(s). lubricate at regular intervals

1. Excessive compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/ (Refer to Section 2.5.3, 2.6.
or wear. “Lubrication Schedules.”.)
Replace worn pins as needed.
2. Worn bushing(s). 2. Replace bushing(s) and
lubricate at regular intervals.

4017 3.25
 Boom
Boom Troubleshooting (Continued)
Problem
6. Dropping chain, or jerky
boom extend or retract
functions.
7. Boom will not raise or lower.
8. Excessive Lift/Lower cylinder
pivot pin noise and/or wear.
3.26
Cause
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 hydraulic system
not operating properly.
6. Damaged boom section.
1. Broken hydraulic hoses or tubes
and/or connection leaks.
2. Lift/Lower hydraulic system not
operating properly.
3. Faulty Lift cylinder.
4. Seized boom pivot pin bushing.
1. Insufficient lubrication.
2. Worn self-aligning bushing(s).
Remedy
1. Adjust chain(s).
2. Replace chains as needed.
Refer to Section 3.5, “Boom
Section Separation Adjustment.”
3. Replace wear pad. Refer to
Section 3.7.2, “Boom Wear Pad
Replacement.”
4. Remove contamination and/or
corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Refer to Section 8.4, “Hydraulic
Circuits.”
6. Replace the damaged boom
section. Refer to Section 3.3,
“Boom Assembly Maintenance.”
1. Locate break, replace hose(s)
or tube(s), tighten connections.
2. Refer to Section 8.4, “Hydraulic
Circuits.”
3. Repair cylinder. Refer toSection
8.8.1, “General Cylinder
Removal Instructions.”
4. Replace bushing.
1. Lubricate at regular intervals.
Refer to Section 2.5, “Service
and Maintenance Schedules.”
Replace worn pins as needed.
Refer to Section 8.8.1, “General
Cylinder Removal Instructions.”
2. Replace bushing(s) and
lubricate at regular intervals.
(Refer to appropriate owners
manual for lubrication points.)
4017

Boom Troubleshooting (Continued)
Problem
9. Rapid boom pad wear.
10. Auxiliary hydraulics will not
operate.
11. Excessive chain wear.
4017
Cause
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. Auxiliary hydraulic system not
operating properly.
1. Improper chain adjustment.
2. Chain sheave(s) not properly
lubricated.
3. Chain sheave(s) not rotating
freely.
4. Improper chain lubrication.
Boom
Remedy
1. Check wear pad gaps and
correct as needed. Refer to
Section 3.7.2, “Boom Wear Pad
Replacement.”
2. Reduce cycle times.
3. Remove contamination and/or
corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be
reconditioned, replace the boom
section(s).
4. Clean equipment frequently.
1. Refer to Section 8, “Hydraulic
System.”
1. Adjust to correct tension. Refer
to Section 3.4.1, “Boom Chain
Inspection.”- Replace chains as
needed.
2. Lubricate chain sheave. (Refer
to Section 2.5, “Service and
Maintenance Schedules.”
3. Lubricate chain sheave. Refer to
Section 2.5, “Service and
Maintenance Schedules.”
Repair or replace chain
sheave(s) as needed.
4. Lubricate at regular intervals.
(Refer to Section 2.5, “Service
and Maintenance Schedules.”
Replace chains as needed.
3.27
 Boom

This Page Intentionally Left Blank

3.28 4017
 Section 4
Cab and Covers

Contents

PARAGRAPH TITLE PAGE

4.1 Operator’s Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . 4.2
4.2 Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.1 Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.2 Serial Number Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.3.2 Service Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.3 Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3.4 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4.3.5 Windshield Wiper Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.3.6 Heater/Defroster System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4 Cab Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.5 Cab Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

4017 4.1
 Cab and Covers

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
covers. The following illustration identifies the
components that are referred to throughout this section.

Air Instrument Air Level Fuel

Louvers Panel Louvers Indicator Gauge
Load Moment
Brake Fluid Indicator
Reservoir Engine Temp
Gauge
Control Console
Round Air Vents
Hazard Flashers
Transmission
Control Lever
Ignition Switch
Wiper, Lights & Turn
Signal Lever Air Louvers

Steering Column
Adjuster Joystick
Continuous Hydraulic
Powered Operation
Auxiliary Switch
Service Brake Air Louvers
Pedal
Accelerator
Pedal
12V Receptacle
Park Brake Lever
Heater & AC
Controls

Round Air Vents

MZ0040

4.2 4017
 Cab and Covers

4.2 OPERATOR’S CAB

4
6
4.2.1 Cab Safety

WARNING: The protection offered by

5

this ROPS/FOPS will be impaired if subjected

to any modification or structural damage, at 8
which time replacement is necessary. ROPS/
9
FOPS must be properly installed using
fasteners of correct size and grade, and
torqued to their specified value. 1

7
4.2.2 Serial Number Decal 3
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
2
cab serial number and other data. Write this information
down in a convenient location to use in cab
correspondence.

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

MZ0620

a. Orbitrol Valve 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
position, engage the park brake and turn the engine
OFF.
2. Place an Accident Prevention Tag on the ignition key
switch, stating that the machine should not be
operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the battery negative (-) cable from the
battery negative terminal.
5. Remove the lower dash panel.
6. Label, disconnect and cap the four hoses (1) from
the side of the steering valve (2). Cap the fittings on
the steering valve. Label, disconnect and plug the
load sense hose (3) at the front of the steering valve.
Cap the fitting on the steering valve.
7. Remove the steering wheel (4), disconnect and
remove the display panel (5), disconnect and
remove the accessory lever (6) and transmission
control lever (7), loosen and remove the locking bolt
(8) for the steering column adjustment, loosen and
remove both steering column pivot bolts and nuts.
8. Remove the steering assembly (9) through the dash
panel opening.
9. Support the steering valve, and remove the four hex-
head capscrews and four lockwashers.
Note: DO NOT disassemble the orbitrol valve. The
orbitrol valve is not serviceable and must be replaced in
its entirety, if defective.
b. Orbitrol Valve Installation
1. Secure the steering valve to the steering column
with four hex-flange capscrews and four
lockwashers. Torque capscrews to 18 Nm (13 lb-ft).
2. Install the steering valve through the dash panel
opening. Position steering valve in the cab, with the
“LS” port pointing forward (away from the operator).
3. Install both steering column pivot bolts and nuts, install
the locking bolt for the steering column adjustment,
install the accessory lever and transmission control
lever and connect the harness connector, install the
display panel and connect the harness connector,
install the steering wheel assembly. Torque the steering
wheel nut to
25 Nm (18 lb-ft).

4017 4.3
 Cab and Covers

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 the
appropriate ports.
7. Connect the battery negative (-) cable or cables at
the battery negative (-) terminal.
8. Carefully examine all connections one last time
MZ0230
before engine start-up. Rectify any faulty conditions.
9. Start the engine and check the operation of steering
6. Remove the circlip, flat washer, and the return spring
system. Check for hydraulic fluid leaks. Check the
securing the service brake pedal to the cab.
hydraulic fluid level in the tank and add fluid as
required. 7. Remove the clip/pin from the brake plunger fork link.
10. Install the lower dash panel. 8. Remove the service brake pedal from the cab.
11. Close and secure the engine cover.
d. Service Brake Pedal Installation
c. Steering Test 1. Position the service brake pedal in its mounting
location within the cab.
Conduct a pressure check of the steering hydraulic
circuits at the main control valve. Refer to Section 8.4.1, 2. Install the brake pedal being careful to reposition the
“Hydraulic Pressures.” brake plunger yoke. Install the return spring, washer and
clip. Install clip/pin in brake plunger fork link.
4.3.2 Service Brake Pedal 3. Adjust the brake pedal as needed.
4. Install and secure the lower dash cover.
a. Brake Valve Removal
5. Connect the battery negative (-) cable or cables to
Refer to Section 8.7.2, “Service Brake Valve,” for removal the battery negative (-) terminal.
information.
6. Close and secure the engine cover.
b. Brake Valve Installation
4.3.3 Throttle Pedal
Refer to Section 8.7.2, “Service Brake Valve,” for
installation information. a. Throttle Pedal Removal

c. Service Brake Pedal Removal 1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
1. Park the machine on a firm, level surface, fully transmission control lever in the (N) NEUTRAL,
retract the boom, lower the boom, place the engage the park brake and shut the engine OFF.
transmission control lever in the (N) NEUTRAL,
2. Place an Accident Prevention Tag on both the
engage the park brake and shut the engine OFF.
ignition key switch and steering wheel, stating that
2. Place an Accident Prevention Tag on both the the machine should not be operated.
ignition key switch and steering wheel, stating that
3. Open the engine cover. Allow the system fluids to
the machine should not be operated.
cool.
3. Open the engine cover. Allow the system fluids to
4. Disconnect the battery negative (-) cable at the
cool.
battery negative (-) terminal.
4. Remove the battery negative (-) cable from the
5. Remove three capscrews securing the throttle pedal
battery negative (-) terminal.
assembly to the cab floor.
5. Remove the lower dash panel.

4.4 4017

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
MZ0460
1. Install the hex jam nut and flat washer onto the end
of the throttle cable. Secure the cable to the throttle
pedal. Secure the cable to the throttle pedal, with the
clip/pin.
2. Align the throttle pedal assembly with its mount
holes in the cab floor.
3. Install three capscrews securing the throttle pedal
assembly to the cab floor. Torque the capscrews to
12 Nm (9 lb-ft).
4. Connect the battery negative (-) cable to the battery
negative (-) terminal.
5. Close and secure the engine cover.
c. Throttle Adjustment
1. From within the cab, lightly depress the accelerator
pedal to the full-throttle position. As needed, adjust the
limit-stop screw (1) until it touches the pedal. Tighten
the locknut to 13,6-14,1 Nm (120-125 lb-in).
4017
Cab and Covers
1
MZ0470
IMPORTANT: During the full throttle check:
• DO NOT operate any hydraulic function.
• DO NOT steer or apply any pressure to the steer-
ing wheel.
• Keep the transmission in (N) NEUTRAL.
2. Check the engine rpm at full throttle. If the rpm is not
2200 +/- 50 rpm, readjust the throttle limit-stop screw
at the throttle pedal within the cab.
4.3.4 Joystick Assembly
a. Joystick Assembly 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 turn the ignition OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the battery negative (-) cable from the
battery negative (-) terminal.
5. Remove two capscrews. Remove the bottom
cover.Disconnect the electrical connections and
remove the four self-tapping screws from the bottom
of the joystick assembly.
6. Remove the joystick assembly.
4.5
 Cab and Covers
1 a. Heater Assembly Removal
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 rearward, activating the
boom lift function. The boom should RISE.
b. Move the joystick handle forward, activating the
boom lower function. The boom should LOWER.
c. Move the joystick handle to the right, activating
the boom extend function. The boom should
EXTEND.
d. Move the joystick handle to the left, activating the
boom retract function. The boom should
RETRACT.
4. Install the bottom cover and secure using two lens-
head capscrews.
5. Close and secure the engine cover.
Refer to Section 9.13, “Joystick,” for complete joystick
functions.
4.3.5 Windshield Wiper Assembly
Refer to Section 9.9, “Window Wiper/Washer Windshield
Wiper Motor,” for removal and installation information.
4.6
4.3.6 Heater/Defroster System
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 switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool. Draining the cooling system while the engine
block is hot can cause cracks in the engine block.
4. Remove the battery negative (-) cable from the
battery negative (-) terminal.
5. Remove the eight bolts holding the engine belly pan
and remove the belly pan.
6. Refer to Section 7.4, “Engine Cooling System,” for
proper coolant draining.
7. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
Note: Label all hoses to ensure correct installation.
8. Remove the six ripp bolts and remove the cab
bottom shield.
9. Label, disconnect and cap the two heater hoses.
10. Remove the heat duct hoses from back side of the
heating unit assembly.
11. Carefully lower the heater assembly (2) by hand.
Label and disconnect the wiring harness
connections at the blower.
12. Remove the heater assembly.
4017

2
MZ0480
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. Fill the cooling system completely with a 50/50
mixture of ethylene glycol and water, allowing time
for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.4, “Fluids,
Lubricants and Capacities.”
4. Connect the battery negative (-) cable to the battery
negative (-) terminal.
IMPORTANT: When the engine is initially started, run it
briefly at low idle and check the machine for any visual
sign of fluid leakage. STOP the engine immediately if
any leakage is noted, and make any necessary repairs
before continuing.
5. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
6. Replace the cab bottom shield.
7. Replace the belly pan.
8. Close and secure the engine cover.
4017
Cab and Covers
4.4 CAB REMOVAL
IMPORTANT: To help ensure safety and optimum
performance, replace the cab if it is damaged. Refer to
the appropriate parts manual for ordering information.
Inspect the cab, its welds and mounts. If modification,
damage, a cracked weld and/or fatigued metal is
discovered, replace the cab. Contact the JLG distributor or
the JLG Service Department with any questions about
the suitability or condition of a cab.
IMPORTANT: Remove and label cab components as
needed before removing the cab from the machine.
Label, disconnect and cap hydraulic hoses. Transfer cab
parts to the replacement cab after the replacement cab
is securely mounted on the machine.
1. Park the machine on a firm, level surface. Allow
sufficient overhead and side clearance for cab
removal. Lower the boom, retract the boom, place
the transmission control lever in the (N) NEUTRAL,
engage the park brake and shut the engine OFF.
2. Open the engine cover. Allow the system fluids to
cool.
3. Remove the battery negative (-) cable from the
battery negative (-) terminal.
4. Remove the eight bolts holding the engine belly pan
and remove the belly pan.
5. Refer to Section 7.4, “Engine Cooling System,” for
proper coolant draining.
6. Transfer the coolant to a container with a cover, and
label as “Used Antifreeze.” Dispose of the used
coolant at an approved recycling facility.
7. Working under the cab, loosen and remove the six
ripp bolts, remove the cab bottom shield.
Note: Label all hoses to ensure correct installation.
8. Loosen the hose clamps and disconnect the heater
hoses.
9. Remove the lens-head screws and remove the
console panel below the right side window to access
the wire harness connections, the right rear side
panel and the left rear cup holder panel to access
the two rear cab mount bolts. Also remove the
rubber floor mat to access the front two cab mount
bolts
10. Disconnect the cab-to-wiring harness connectors at
the circuit board. Push the harness connectors
through the opening at the right front corner of the
cab.
4.7
 Cab and Covers

1 14. Remove the four cab-to-frame bolts, flat washers and

MZ0660
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.
2
MZ0640
13. Install two lifting eye bolts (1) with a suitable lifting
capacity in the existing threaded holes at the top
corners of the windshield.
nuts (2).
15. Remove the mirrors and all other cab components
as needed, if not previously removed.
16. Use a hoist or overhead crane and sling attached to
the cab, carefully begin to lift the cab. Stop and
check that all wiring, hydraulic hoses and fasteners
are disconnected or removed.
17. When all wiring, hydraulic hoses and fasteners are
disconnected or removed, carefully and slowly lift the
cab and remove it from the frame.
18. When the cab is completely clear of the machine,
carefully lower it to the ground. Block up or support
the cab so that it does not move or fall over. Assure
that no personnel enter the cab while it is being
removed from the machine.
19. Inspect the condition of the fittings, clamps, hydraulic
hoses, etc. Replace parts as indicated by their
condition.
20. Inspect and replace other machine parts that are
exposed with the cab removed. Repair or replace as
required.
4.5 CAB INSTALLATION
1. Block all four wheels to help prevent the machine
from moving. Assure that there is sufficient overhead
and side clearance for cab installation.
2. Install two lifting eye bolts with a suitable lifting
capacity in the existing threaded holes by the top
corners of the windshield.
3. Use a hoist or overhead crane and sling attached to
the two lifting eyes, carefully begin to align the cab
with the mounting holes in the frame. Stop and
check that wiring, hydraulic hoses, cables, etc., will
not be pinched or damaged as the cab is positioned.
Readjust the position of the sling as needed to help
balance the cab during installation.
4. Install the four bolts through the cab/frame mounts
and install the four washers and nuts. Remove the
sling and both lifting eye bolts. Tighten and torque the
four mounting bolts to 651 Nm (480 lb-ft).
5. Secure the throttle cable to the hydraulic hoses
using wire ties.
6. Install the throttle cable on the throttle cable bracket,
attach the clip/pin through the fork link.
7. Working under the cab, uncap and connect the
hydraulic hoses at the cab fittings.

4.8 4017
 Cab and Covers

8. Route any hoses through the opening at the right

front corner of the cab.
9. Route the wiring harness connectors through the
opening at the right front corner of the cab and up
into the side console.
10. Connect the cab-to-wiring harness connectors.
11. Install the right side console panel, the right rear side
panel, the left rear cup holder panel and the rubber
floor mat.
12. Working under the cab, connect the coolant hoses to
the heater hoses. Secure with two hose clamps.
13. Fill the cooling system completely with a 50/50 mixture
of ethylene glycol and water, allowing time for the
coolant to fill the engine block. The cooling system
capacity is listed in Section 2.4, “Fluids, Lubricants
and Capacities.”
14. Connect the battery negative (-) cable to the battery
negative (-) terminal.
15. Carefully examine all cab components, fasteners,
etc., one last time before engine start-up. Rectify any
faulty conditions.
16. Start the engine and check the operation of all controls.
Check for hydraulic fluid leaks. Check the hydraulic
fluid level in the tank and add fluid as required.
IMPORTANT: When the engine is initially started, run it
briefly at low idle and check the machine for any visual
sign of fluid leakage. STOP the engine immediately if
any leakage is noted, and make any necessary repairs
before continuing.
17. Wait for the engine to cool and check the coolant
level. Add coolant to the overflow bottle as required
to bring the coolant to the proper level.
18. Replace engine belly pan.
19. Replace cab bottom cover.
20. Close and secure the engine cover.

4017 4.9
 Cab and Covers

4.10 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
5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.2 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.3 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.4 Axle Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.1 Axle Service and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.3.6 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . 5.7
5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.4.4 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5.5.1 Removing Wheel and Tire Assembly from machine. . . . . . . . . . . . . . . . . 5.12
5.5.2 Installing Wheel and Tire Assembly onto machine . . . . . . . . . . . . . . . . . . 5.12
5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.6.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5.7 Towing a Disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14

4017 5.1
 Axles, Drive Shafts, Wheels and Tires

5.1 AXLE, DRIVE SHAFT AND WHEEL

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 axles, drive shafts,
wheels and tires. The following illustration identifies the
components that are referred to throughout this section.

Sway Cylinder

Rear Steering
Cylinder

Transmission
Drop Box

Rear Axle
Assembly
Front Steering
Cylinder Rear Axle Wheel
Rear Drive Shaft
Hubs (2)

Front Drive Shaft

Front Axle
Assembly Front Axle Wheel Hubs (2) MZ0590

5.2 4017

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 bent or damaged. Refer to the
appropriate parts manual for ordering information.
Before performing any inspection, maintenance or
service operation, thoroughly clean the unit. The axles
and drive shafts should be checked and repaired only by
experienced service technicians who are aware of all
safety instructions and particular component features.
Use suitable products to thoroughly clean all
disassembled mechanical parts to help prevent personal
injury to the worker and prevent damage to the parts.
Carefully inspect the integrity of all moving parts
(bearings, yokes, tubes, gears, shafts, etc.) and fasteners
(nuts, bolts, washers, etc.) as they are subject to major
stress and wear. Always replace elastic locknuts and any
damaged, worn, cracked, seized or otherwise improper
parts that could affect the safe and proper functioning of
the machine, axles and drive shafts.
5.3 AXLE ASSEMBLIES
5.3.1 Axle Service and Troubleshooting
This section provides an easy reference guide covering
the most common problems that may occur during
operation of the axles.
5.3.2 Axle Serial Number Plate
The front and rear axle serial number plate (1) is located
on a mounting pad on the front side of the center section
of each axle. Information on the serial number plate is
required in correspondence regarding the axle.
1 sembly and assembly, without thoroughly under-
MZ1050
Supply information from the axle serial number plate
when communicating about an axle assembly or axle
components.
4017
Axles, Drive Shafts, Wheels and Tires
5.3.3 Axle Specifications
General axle specifications are found in Section 2,
“General Information and Specifications.” Axle
(differential housing) fluid information is found in Section
2.4, “Fluids, Lubricants and Capacities.” Wheel end fluid
information is found in Section 2.4, “Fluids, Lubricants
and Capacities.”
5.3.4 Axle Maintenance
Note: Detailed axle service instructions (covering the
axle, differential, brakes and wheel-end safety, repair,
disassembly, reassembly, adjustment and
troubleshooting information) are available by contacting
your local JLG distributor for a copy of the Dana-Spicer
Axle Repair Manual (P/N 31200162).
Note: Several special axle service tools are required to
properly service the axle assemblies. Contact your local
Dana-Spicer Service Center for ordering information.
IMPORTANT: When replacing a fastener, replace it with
one of equal or higher grade and quality. Torque
fasteners to the specified value for the application.
IMPORTANT: The use of replacement parts provided by
other than the original manufacturer is not recommended, as
such use may cause axle failure and affect machine safety.
• Some service operations require the use of tools
specifically designed for the purpose. Use the
special tools when and as recommended.
• DO NOT pound, beat or hammer on end yokes
and flanges to remove or to install them. Damage
to axle components can occur. Remove and install
end yokes and flanges by following the recom-
mended procedures in the appropriate Dana axle
service manual.
• DO NOT attempt carrier and differential removal
and installation, and differential and pinion disas-
standing the instructions in the appropriate Dana
publications.
• Before disassembling any parts inside the car-
rier, remove the entire axle assembly from the
machine and securely support it with the pinion
facing up in an appropriate stand or rack.
• DO NOT reuse oil or grease seals.
CLEANING: Clean parts with machined or ground
surfaces (such as gears, bearings and shafts) with
emulsion cleaners or petroleum-based cleaners. DO
NOT steam clean internal components and the interior of
the planetary hub and axle housing. Water can cause
corrosion of critical parts. Rust contamination in the
5.3
 Axles, Drive Shafts, Wheels and Tires

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
due to lack of lubrication. After drying, lightly coat
components with oil or a rust-preventive chemical to help
protect them from corrosion. If storing components for a
prolonged period, wrap them in wax paper.
PERIODIC OPERATION REQUIREMENT: Every two
weeks, drive the machine far enough to cause the drive-
train components to make several complete revolutions.
This will help ensure that internal components receive
lubrication to minimize deterioration caused by
environmental factors such as high humidity.
SUBMERSION: If the machine has been exposed to
water deep enough to cover the hubs, disassemble the
wheel ends and inspect for water damage and
contamination. If the carrier housing was submerged in
water, especially if the water level was above the vent
tube (breather), drain the axle and inspect internal parts
for water damage and contamination. Before assembling
and refilling the unit with the specified lubricant(s), clean,
examine and replace damaged parts as necessary.
Note: Use a suitable puller for bearing removal. Clean,
inspect and lubricate all bearings just prior to
reassembly. If replacement of a damaged bearing cup or
cone is necessary, replace the cup and cone as a set.
IMPORTANT: Clear the work area of all debris,
unnecessary personnel, etc. Allow sufficient space to
raise the machine and to remove the axle.
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 all wheels and
shut the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the battery negative (-) cable from the
battery negative (-) terminal.
5. If the axle will be disassembled after removal, place
a suitable receptacle under the axle (1) and wheel
hubs (2) drain plugs. Remove the drain plugs and
allow the axle oil to drain into the receptacle.
Transfer the used axle oil into a suitable covered
container, and label the container as “Used Oil.”
Dispose of used oil at an approved recycling facility.

5.3.5 Axle Removal

WARNING: An improperly supported

MZ1030

machine can fall, causing death or severe

1
personal injury. Safely raise and adequately
support the machine so that it will remain
stable and in place before attempting to remove
an axle.

The front and rear axle assemblies differ in that the front
axle assembly is equipped with a park brake mechanism
and a limited-slip feature; the rear axle has neither. The
following steps outline a typical axle removal
procedure, suitable for either the front or the rear axle
assembly.
Cleanliness is extremely important. Before attempting to 2
remove the axle, thoroughly clean the machine. Avoid MZ1060

spraying water or cleaning solution on the stabilizer

solenoids and other electrical components. If using a 6. Label, disconnect and cap the steering and brake
steam cleaner, seal all openings before steam cleaning. lines at the axle. Wipe up any spilled oil.

5.4 4017

7. Block the front and rear of both tires on the axle that
is not being removed. Ensure that the machine will
remain in place during axle removal before
proceeding.
8. Raise the machine using a suitable jack or hoist.
Place suitable supports under both sides of the
frame and lower the machine onto the supports.
Ensure that the machine will remain in place during
axle removal.
9. Support the axle that is being removed with a suitable
jack, hoist or overhead crane and sling. DO NOT
raise the axle or the machine.
10. Mark and remove both wheel and tire assemblies
from the axle that is being removed. (Refer to
Section 5.5.1, “Removing Wheel and Tire Assembly
from machine.”)
11. Remove the drive shaft assemblies. (Refer to Section
5.4.3, “Drive Shaft Removal.”)
12. On the front axle remove the capscrew and locknuts
securing the sway cylinder rod end pin to the front
axle. Tap the cylinder mount pin out, and move the
sway cylinder to prevent it from interfering with axle
removal.
13. Remove the four bolts and locknuts securing the
axle to the frame.
14. Remove the axles from the machine using the jack,
hoist or overhead crane and sling supporting the
axle. DO NOT raise or otherwise disturb the machine
while removing the axle. Balance the axle and
prevent it from tipping, turning or falling while
removing it from beneath the machine. Place the
axle on a suitable support or holding stand.
4017
Axles, Drive Shafts, Wheels and Tires
c. Axle Installation
The front and rear axle assemblies differ in that the front
axle assembly is equipped with a park brake mechanism
and limited-slip feature; the rear axle has neither. The
steps below outline a typical axle installation procedure,
suitable for either the front or the rear axle assembly.
1. Before proceeding, ensure that the machine will
remain in place during axle installation. Block the
front and rear of both tires on the axle that is already
installed on the machine.
2. If applicable, raise the machine using a suitable jack
or hoist. Place suitable supports beneath the frame
and lower the machine onto the supports, allowing
enough room for axle installation. Ensure that the
machine will remain in place during axle installation.
3. Using a suitable jack, hoist or overhead crane and
sling, remove the axle from its support or holding
stand. Balance the axle and prevent it from tipping,
turning or falling while positioning it beneath the
machine. DO NOT raise or otherwise disturb the
machine while installing the axle. Keep the axle
supported and balanced on the jack, hoist or
overhead crane and sling throughout the installation
procedure.
4. Position the axle under the frame, and align the axle
housings with the holes in the frame.
5. Install the four axle bolts and nuts. Tighten and
torque to 550 - 600 Nm (406 - 443 lb-ft).
6. Move the sway cylinder into position on the axle
cylinder anchor. Insert a mount pin through the
cylinder rod and cylinder anchor. Secure the sway
cylinder-mount pin with one capscrew and a new
locknut.
7. Apply multi-purpose grease through the self-tapping
lube fitting to lubricate the self-align bearing and the
cylinder-mount pin.
8. Install the drive shaft assemblies. (Refer to Section
5.4.4, “Drive Shaft Installation.”)
9. If reinstalling an axle previously removed from the
machine, position the driveshaft yoke on the axle
according to the alignment marks made earlier. If
installing a new axle, note the position of the
driveshaft yoke at the transmission. Align the
driveshaft yoke on the axle in the same plane as the
yoke on the transmission.
10. Install and tighten the three axle oil drain plugs,
loosen and remove the axle oil fill plug (1). Fill the
axle through the axle fill plug until the oil level is even
with the oil check level plugs (2).
5.5
 Axles, Drive Shafts, Wheels and Tires

11. Refer to Section 2.4, “Fluids, Lubricants and 21. Close and secure the engine cover.
Capacities,” for proper oil and capacities.
1

MZ1030

12. Rotate wheel hubs 90 degrees so the drain plug

becomes the fill plug (3). Refer to Section 2.4,
“Fluids, Lubricants and Capacities,” for proper oil and
capacities.

MZ1040

13. Install the wheel and tire assemblies. (Refer to

Section 5.5.2, “Installing Wheel and Tire Assembly
onto machine.”)
14. Carefully remove the jack, hoist or overhead crane
and sling supporting the axle.
15. Carefully raise the machine using a suitable jack or
hoist. Remove the supports from beneath the frame
and lower the machine to the ground.
16. Remove the blocks from the front and rear of both
tires on the other axle.
Note: ALWAYS use new o-rings when servicing the
machine.
17. Install new o-rings into the fittings. Lubricate the
o-rings with clean hydraulic oil.
18. Uncap and connect the steering and brake lines at
their axle fittings.
19. Check the hydraulic reservoir oil level.
20. Start the engine. Turn the steering wheel several
times lock to lock, operate the frame tilt function
several times in both directions and check the
function of the brakes. Check for hydraulic leaks, and
tighten or repair as necessary.

5.6 4017
 Axles, Drive Shafts, Wheels and Tires
5.3.6 Axle Assembly and Drive Shaft Troubleshooting
Problem Cause
1. Excessive axle noise while 1. Oil level too low.
driving.
2. Axle and/or wheel end housings
filled with incorrect oil or oil level
low.
3. Incorrect alignment of ring and
pinion gears.
4. Incorrect pinion (input) shaft
bearing preload.
5. Worn or damaged bearings.
6. Worn or broken gear teeth.
7. Contamination in the axle.
8. Axle housing damaged.
2. Intermittent noise when 1. Universal joint(s) worn or
traveling. damaged.
2. Differential ring and/or pinion
gears damaged.
3. Vibration or intermittent noise 1. Drive shaft universal joint
when traveling. assembly(ies) incorrectly
tightened.
2. Drive shaft universal joint(s)
worn or damaged.
3. Drive shaft(s) damaged/
unbalanced.
4017
Remedy
1. Fill oil to correct level. (Refer to
Section 2.4, “Fluids, Lubricants
and Capacities.”)
2. Drain axle and/or wheel end
housings and fill to correct level
with Mobilfluid 424® ISO Grade
46. (Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”)
3. Correct alignment by adding or
removing shims as needed.
4. Correct bearing preload by
adding or removing shims as
needed.
5. Replace bearings as needed.
6. Replace gears as needed.
7. Drain axle and/or wheel end
housings and fill to correct level
with Mobilfluid 424® ISO Grade
46. (Refer toSection 2.4, “Fluids,
Lubricants and Capacities.”)
8. Replace damaged parts.
1. Repair or replace universal
joints as needed.
2. Determine cause and repair as
needed.
1. Tighten capscrews to correct
torque.
2. Repair or replace universal
joints as needed.
3. Replace drive shaft(s) as
needed.
5.7
 Axles, Drive Shafts, Wheels and Tires
5.3.6 Axle Assembly and Drive Shaft Troubleshooting (Continued)
Problem
4. Oil leaking from axle
(differential housing and/or
axle housings).
5. Oil leaking from wheel end
housing (planet carrier).
6. Oil leaking from steering
cylinder.
5.8
Cause
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.
4. Input shaft multi-seal ring
damaged or missing and/or
worn or damaged pinion (input)
shaft sealing surfaces.
5. Axle casing to brake housing
and/or brake housing to
differential assembly o-rings
and/or seals worn or damaged.
6. Axle housing mounting nuts and
capscrews loose.
7. Differential and/or axle
housing(s) damaged.
1. Oil level plugs loose and/or
o-rings damaged or missing.
2. O-ring between hub and
housing (planet carrier)
damaged or missing.
3. Shaft seal damaged or missing
and/or worn or damaged shaft
sealing surfaces.
4. Housing capscrews loose.
5. Housing (planet carrier) damaged.
1. Hose fittings loose.
2. Steering cylinder o-rings and/or
seals worn or damaged.
3. Piston rod seal worn or
damaged.
4. Cylinder tube damaged.
Remedy
1. Replace o-rings as needed and
tighten plugs to 130 Nm
(96 lb-ft).
2. Tighten fittings.
3. Replace seal and/or joint
coupling fork shaft (axle shaft).
4. Replace multi-seal ring and/or
input shaft. Adjust ring and
pinion alignment and bearing
preload as described in the
Dana-Spicer Repair Manuals.
5. Replace o-rings and seals.
6. Tighten housing nuts and
capscrews to 390 Nm
(288 lb-ft).
7. Replace housing(s) as needed.
1. Replace o-rings as needed and
tighten plugs to 130 Nm
(96 lb-ft).
2. Replace o-ring.
3. Replace seal and/or fork joint
shaft.
4. Tighten housing capscrews to
55 Nm (41 lb-ft).
5. Replace housing (planet carrier).
1. Tighten fittings.
2. Replace o-rings and seals.
3. Replace piston rod seal.
4. Replace cylinder tube.
4017

5.3.6 Axle Assembly and Drive Shaft Troubleshooting (Continued)
Problem
7. Axle overheating.
8. High steering effort required.
9. Slow steering response.
10. Excessive noise when brakes
are engaged.
11. Brakes will not engage.
12. Brakes will not hold the
machine or braking power
reduced.
4017
Axles, Drive Shafts, Wheels and Tires
Cause
1. Oil level too high.
2. Axle and/or wheel end housings
filled with incorrect oil or oil
contaminated or oil level low.
1. Steering (hydraulic) system not
operating properly.
2. Excessive joint housing swivel
bearing preload.
3. Worn or damaged swivel
bearings.
1. Steering (hydraulic) system not
operating properly.
2. Steering cylinder leaking
internally.
1. Brake discs worn.
2. Brake discs damaged.
1. Brake (hydraulic) system not
operating properly.
2. Brake piston o-rings and seals
damaged (leaking).
1. Brake discs worn.
2. Brake (hydraulic) system not
operating properly.
3. Brake piston o-rings and seals
damaged (leaking).
Remedy
1. Fill oil to correct level with
Mobilfluid 424® ISO Grade 46.
(Refer toSection 2.4, “Fluids,
Lubricants and Capacities.”)
2. Drain axle and fill to correct level
with Mobilfluid 424® ISO Grade
46. (Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.”)
1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Correct bearing preload by
adding or removing shims as
needed.
3. Replace swivel bearings as
needed.
1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Repair or replace steering
cylinder as needed.
1. Check brake discs for wear.
(Refer to Section 5.6, “Brakes.”)
2. Replace brake discs.
1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Replace o-rings and seals.
1. Check brake discs for wear.
(Refer to Section 5.6, “Brakes.”)
2. Refer to Section 8.4, “Hydraulic
Circuits.”
3. Replace o-rings and seals.
5.9
 Axles, Drive Shafts, Wheels and Tires

5.4 DRIVE SHAFTS

2
5.4.1 Drive Shaft Inspection and Service
Whenever servicing the machine, conduct a visual 1 3
inspection of the drive shafts and cross and bearing
assemblies (universal joints, or U-joints). A few moments 4
spent doing this can help prevent further problems and
5
down time later.
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each
drive shaft in both directions. Look for excessive
looseness, missing parts, cracks or other damage. Worn 6
or damaged drive shafts and cross and bearing
assemblies may cause an excessive amount of vibration
or noise. 7
Individually inspect each cross the needle bearings and 8
9
cap for signs of wear or for missing parts.
2
Note: Replace the cross and bearings as a complete 10
assembly if any parts are worn or missing. If all parts of 4
the cross and bearing assemblies are in good condition,
pack the bearing caps with a premium grade of multi- 5
purpose wheel-bearing grease. Reattach the bearing 1. Yoke shaft (1) 6. Grease fitting (1)
cap to the cross, assuring that all needle bearings are 2. Cross (2) 7. Dust cap (1)
present. Then, reassemble the cross and bearing 3. Yoke Flange (1) 8. Washer (1)
assembly into the drive shaft yoke. 4. Needle bearings 9. Felt seal (1)
1. Replace the felt seal if worn or damaged. and cap (8) 10. Slip yoke (1)
5. Snap ring (8)
2. Replace the entire drive shaft assembly if any flange
yoke, slip yoke or drive shaft tube is severely dented
or damaged.
3. Cross assemblies should flex and be free from
excessive binding. A slight amount of drag or
resistance is desirable on a new cross and bearing
assembly. Excessive looseness causes unbalance.

5.10 4017
 Axles, Drive Shafts, Wheels and Tires

5.4.2 Drive Shaft Maintenance IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at
Refer to Section 2.6, “Lubrication Schedules,” for
the factory. When servicing any flange yoke, slip yoke or
information regarding the lubrication of the grease fittings
drive shaft tube, order a complete assembly if
on the drive shafts.
components are bent or damaged. Refer to the
appropriate parts manual for ordering information.
5.4.3 Drive Shaft Removal
IMPORTANT: To help ensure optimum performance, the a. Transmission-to-Axle Drive Shafts
drive shaft assemblies are specially balanced as a unit at 1. Raise the drive shaft assembly into position. The
the factory. When servicing any flange yoke, slip yoke or slip-yoke end of the drive shaft mounts toward the
drive shaft tube, order a complete assembly if axle. If reinstalling a drive shaft previously removed,
components are bent or damaged. Refer to the appropriate align the flange yokes according to the alignment
parts manual for ordering information. marks made during removal.
Note: The drive shaft assemblies are balanced IMPORTANT: Yokes at both ends of the drive shaft must
assemblies. Mark the yoke and axle, transmission, be in the same plane to help prevent excessive vibration.
transfer case, and the shaft and slip yoke so that these 2. Install the four capscrews and two straps securing
components can be returned to their original positions the bearing crosses to the transmission. Torque the
when reinstalled. Yokes at both ends of the drive shaft capscrews to 81 Nm (60 lb-ft).
must be in the same plane to help prevent excessive
vibration. 3. Install the four capscrews and two straps securing
the bearing crosses to the axle. Torque the
a. Transmission-to-Axle Drive Shaft capscrews to 81 Nm (60 lb-ft).
4. Repeat the above procedure on the rear drive shaft.
1. Level the machine, retract the boom, lower the boom,
place the transmission control lever in the (N)
NEUTRAL, engage the park brake switch and shut To Transmission
the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the battery negative (-) ground cable from
the battery negative (-) terminal.
5. The drive shaft assembly is a balanced assembly.
Mark the yoke and axle, transmission and the shaft Mt0350

and slip yoke so that these components can be

returned to their original positions when reinstalled. To Axle
Yokes at both ends of the drive shaft must be in the
same plane to help prevent excessive vibration.
6. Remove the four capscrews and two straps securing 5. Connect the battery negative (-) cable at the battery
the bearing cross to the transmission output shaft negative (-) terminal.
flange. 6. Close and secure the engine cover.
7. Remove the four capscrews and two straps securing
the bearing crosses to the axle.
8. Remove the front drive shaft assembly.
9. Repeat the above procedure on the rear drive shaft.

5.4.4 Drive Shaft Installation

4017 5.11
 Axles, Drive Shafts, Wheels and Tires

5.5 WHEELS AND TIRES 5.5.2 Installing Wheel and Tire Assembly
onto machine
5.5.1 Removing Wheel and Tire Assembly IMPORTANT: The wheel and tire assemblies must be
from machine installed with the directional tread pattern “arrows” facing
in the direction of forward travel.
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 all wheels and shut
the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the machine should not be operated.
3. Remove the battery negative (-) cable from the
battery negative (-) terminal.
4. Loosen but DO NOT remove the lug nuts on the
wheel and tire assembly to be removed.
5. Place a suitable jack under the axle pad closest to
the wheel being removed. Raise the machine and
position a suitable support beneath the axle. Allow
sufficient room to lower the machine onto the
support and to remove the wheel and tire assembly. Mh3300

6. Lower the machine onto the support.

1. Position wheel onto studs on wheel end of axle.
7. Remove lug nuts and lug washers in an alternating
2. Install wheel lug washers.
pattern.
3. Install lug nuts and tighten in an alternating pattern.
8. Remove the wheel and tire assembly from the
Torque to 583 to 637 Nm (430 to 470 lb-ft).
machine.
4. Raise the machine, remove the supports and lower
machine to the ground.
5. Connect the battery negative (-) cable at the battery
negative (-) terminal.
6. Close and secure the engine cover.

5.12 4017
 Axles, Drive Shafts, Wheels and Tires

5.6 BRAKES 7. Using a feeler gauge, check the gap (1) between the
brake disks. if the gap (2) is less than
4,5 mm (0.18 in), replace the brake disks.
5.6.1 Brake Disk Inspection.
Check the brake disks for wear every
1,000 hours of operation or yearly.
1000
If the brake disks require service due to
OH2690 wear, the axle should be checked,
serviced and repaired only by
experienced service technicians who are aware of all
safety instructions and particular component features.

a. Front and Rear Axles

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 all wheels and shut
the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the machine should not be operated.
3. Remove the battery negative (-) cable from the
battery negative (-) terminal.
WARNING: BLOCK ALL FOUR
WHEELS. Failure to do so could result in death
or serious injury from machine roll-away
4. Block all four wheels to help prevent the machine
from moving after the park brake is disabled.
5. Remove the oil-level plug on each side of the axle.
6. Have an assistant sit in the cab and apply the
brakes, keeping pressure applied.
1
MT2840
2
Note: If the brake disks are worn beyond their tolerance,
the brake disk must be replaced on both sides of the axle
at the same time.
8. Repeat steps 3 and 4 for the other side of the axle.
9. Fill the axle with Mobilfluid 424® ISO Grade 46
through the axle fill hole (3) until the oil level is even
with both axle level holes (4).
10. Fill axle slowly, the oil has to run across the
differential. Allow time for the oil to run across the
differential. Axle level is correct when oil is up to both
level plugs. Refer to Section 2.4, “Fluids, Lubricants
and Capacities.”

MZ1030

4017 5.13
 Axles, Drive Shafts, Wheels and Tires

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
procedures outlined below.
IMPORTANT: Block the wheels of the machine
BEFORE attempting to release the park brake. Once
the park brake is released the machine’s park brake
AND service brakes are inoperable.
1
IMPORTANT: After the machine has been towed to a
secure location, reactivate the park brake. Carefully
follow the procedures from start to finish. Consult your
local JLG distributor or the JLG Service Department if
you are unsure about any part of the procedure, or for
specific instructions concerning your particular situation.
5.7.2 Manually Resetting the Park Brake
IMPORTANT: Block the wheels of the machine
BEFORE attempting to reset the machine’s park
brake. Once the park brake is reset the machine’s
park brake AND service brakes are operable.
1. Loosen the jam nuts on all four manual brake
release bolts.
2. Turn all four manual brake release bolts OUT a
quarter turn at a time to the dimension recorded
before starting the towing procedure.
3. Tighten the jam nuts on all four manual brake
release bolts.
4. After repairs to the machine have been made, start
the machine and check the park brake and service
brakes for proper function.

MZ1020

Top View

5.7.1 Manually Releasing the Park Brake

1. Measure the distance from the bolt head to the face
of the jam nut on all four of the manual brake release
bolts (1) located on each side of the front axle center
section (two per side). Record the measurements.
2. Loosen the jam nuts on the four manual brake
release bolts
3. Turn all four release bolts in equally with a wrench or
socket BY HAND a quarter turn at a time up to
approximately
19 mm (.750 in) or until resistance is felt. Tighten the
jam nuts.
Note: Turning the release bolts in to far could warp the
brake discs. DO NOT over tighten.

5.14 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 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.4.1 Transmission General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.5.2 Transmission Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.6.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.6.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6.5
6.6.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
6.6.4 After Transmission Service or Replacement . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
6.7.1 Transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

4017 6.1
 Transmission:

6.1 TRANSMISSION ASSEMBLY

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 transmission.
The following illustration identifies the components that
are referred to throughout this section.

Torque Converter Dipstick and Fill Tube

Output Shaft
(front) Oil Filter

Breather

Output Shaft
(rear) Breather

Drop Box Oil Level

Sight Gauge
Transmission Drop Box
Shift Solenoids
MZ0670
Flex Plate Assembly

6.2 4017

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, maintenance information, and
transmission removal and installation procedures. For
internal transmission service instructions and detailed
specifications contact your local JLG distributor for a copy
of the Dana-Spicer Transmission Repair Manual
(P/N 31200163).
6.3 TRANSMISSION SERIAL NUMBER
The transmission serial number plate is located on the
front of the transmission case below the converter
housing. Information specified on the serial number plate
includes the transmission model number, the
transmission serial number and other data. Information
on the serial number plate is required in correspondence
regarding the transmission.
6.4 TRANSMISSION SPECIFICATIONS
6.4.1 Transmission General Specifications
General transmission specifications are found in Section
2.4, “Fluids, Lubricants and Capacities.”
Performance criteria is based on full throttle engine
speed unless otherwise specified or not applicable.
6.5 TRANSMISSION MAINTENANCE
6.5.1 Transmission Maintenance
Cleanliness is of extreme importance. Before attempting
any repairs, thoroughly clean the exterior of the
transmission to help prevent dirt from entering while
performing maintenance checks and procedures.
Section 6.5.2, “Transmission Maintenance Schedule,”
provides a suggested maintenance schedule with
references to pertinent procedures and instructions in this
manual. To help prevent transmission problems before
they occur, follow the maintenance schedule.
4017
Transmission:
6.5.2 Transmission Maintenance Schedule
Complete transmission maintenance information is
located in the appropriate Operator & Safety Manual.
• At ten hour intervals, check the transmission oil
level.
• When the machine completes its first 50 hours of
use, change the transmission oil and filter.
• At 1,000 hour intervals, change the transmission
oil and filter.
Periodically, depending on operating conditions and
other factors, back flush the transmission oil cooler,
which is located in or behind the radiator. ALWAYS back
flush the transmission oil cooler after removing the
transmission for repair or replacement.
The transmission oil cooler outlet hose, routed to the
lower oil cooler fitting, is located on the top of the
transmission. The transmission oil cooler inlet hose,
routed to the upper oil cooler fitting, is located on the top
of the transmission. (Refer to Section 7.4.3, “Radiator/Oil
Cooler and Replacement.”)
Disconnect and back flush the oil cooler portion of the
radiator or the oil cooler (located behind the radiator) with
oil and compressed air until all foreign material is
removed. If necessary, remove the radiator or oil cooler
from the machine, and clean the oil cooler circuit using oil,
compressed air and steam.
IMPORTANT: DO NOT use flushing compounds for
cleaning purposes.
6.6 TRANSMISSION REPLACEMENT
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
IMPORTANT: To help ensure safety and optimum
performance, replace the transmission if it is damaged.
Refer to the appropriate parts manual for ordering
information.
Cleanliness is of extreme importance. Before attempting
to remove the transmission, thoroughly clean the exterior
of the transmission to help prevent dirt from entering
during the replacement process. Avoid spraying water or
cleaning solution onto or near the transmission shift
solenoids and other electrical components.
6.3
 Transmission:

6.6.1 Transmission Removal

WARNING: Risk of severe personal

injury. NEVER lift a transmission alone; enlist
the help of at least one assistant or use a
suitable hoist or overhead crane and sling.

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 switch and steering wheel, stating that
the machine should not be operated.
3. Open the engine cover and allow the system fluids to
cool.
4. Remove engine cover.
5. Remove belly pan from under engine.
6. Drain the hydraulic oil reservoir. Refer to Section 8.5,
“Hydraulic Reservoir.”
7. Disconnect both battery cables and remove the
battery.
MZ1380
1 of the eight flex plate bolts to be accessed. Remove
2 them one at a time.
8. Thoroughly clean the transmission and surrounding
area, including all hoses and fittings, before
proceeding.
9. Place a suitable receptacle under the transmission
drain plug. Remove the transmission drain plug (1),
and allow the transmission oil to drain into the
receptacle. Repeat drain procedure with the drop
box (2).
10. Transfer the used transmission oil into a suitable,
covered container, and label the container as “Used
Oil.” Dispose of used oil at an approved recycling
facility. Clean and reinstall the transmission and drop
box drain plug.
MZ1330
11. Remove the drive shafts. Refer to Section 5.4.3,
“Drive Shaft Removal.”
12. Remove air cleaner unit and intake tubes.
13. Remove the hydraulic pump. Refer to Section 8.6.3,
“Pump Replacement.”
14. Label and disconnect the transmission temperature
switch connector and shift solenoid wiring harness
connectors.
15. Label, disconnect and cap the transmission oil
cooler inlet and outlet hoses at the transmission. The
transmission oil cooler outlet hose, routed to the
lower radiator fitting, is located on the top of the
transmission. The transmission oil cooler inlet hose,
routed to the upper radiator fitting, is located on top
of the transmission.
16. Remove the access plug from side of the engine bell
housing. This will allow access to remove the eight
bolts holding the flex plate to the engine flywheel.
17. Turn the engine over slowly by hand and align each
18. Wipe up any spilled hydraulic and transmission oil.
19. Connect a lifting strap or chain to the lifting eye at
the top of the transmission, and to a suitable hoist or
overhead crane. Operate the hoist or crane to
remove slack from the chain, but DO NOT raise the
transmission at this time.
20. Place blocks under rear of engine for support
BEFORE transmission mounts are removed
21. Place blocks under the transmission to help support
it during removal.
22. Remove both rear transmission mount bolts and
lockwashers securing the transmission mount to the
frame.

6.4 4017

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. Replace the mounts if
damaged.
27. Carefully remove the transmission from the machine.
Avoid causing damage to the transmission or
surrounding parts.
28. Lift the transmission clear of the machine, and lower
it onto suitable supports or secure it to a stand built
especially for transmission or engine service. Secure
the transmission so that it will not move or fall.
29. Remove any external transmission components as
required, including the transmission temperature
switch, and inlet and outlet cooler hose fittings.
Cover all transmission openings.
30. Remove the transmission oil filter (3) and dispose of
properly. Clean the filter mounting surface. Cover or
cap the oil filter mount.
3 mounting bolts.
MZ0680
31. If transmission oil is suspect of contamination or
torque converter is damaged, remove the converter
and flex plate from the transmission.
32. Remove the six bolts and washers holding the
converter to the flex plate.
4017
Transmission:
6.6.2 Transmission Inspection and Internal
Repair
The converter is now ready for inspection and/or further
service.
If replacing the entire transmission, transfer the
transmission temperature switch to the replacement
transmission. The gear shift solenoids are included with a
new transmission.
For internal service, refer to the Dana Spicer Transmission
Repair Manual (P/N 31200163).
6.6.3 Transmission Installation
1. Install both the rear transmission mounts on the
transmission. Torque capscrews to120 Nm
(88 lb-ft).
2. Install two guide studs near the top of the bell
housing holes.
3. Use a hoist or overhead crane and sling attached to
the lifting eye at the top of the transmission. Raise
and position the transmission within the chassis.
4. Align the torque converter, align the transmission
bolt holes with the two studs in the bell housing.
Install the eight bolts and washers and torque to
63 Nm (46 lb-ft). Remove the two alignment studs
and install and torque the last two transmission
5. Install the two rear transmission mounting bolts on
the frame with two capscrews and two lockwashers.
Apply Loctite® 242 threadlock to the transmission mount
bolts and torque to 210 Nm (155 lb-ft).
6. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Install
them one at a time. Torque to 35-39 Nm (26-29 lb-ft).
Replace access plug.
7. Remove the hoist or overhead crane and sling.
8. Connect the transmission temperature switch
connector and shift solenoid wiring harness
connectors.
9. Secure the wiring harness to the transmission
housing.
10. Uncap and connect the transmission oil cooler inlet
and outlet hoses at the transmission.
11. Install the hydraulic pump. Refer to Section 8.6.3,
“Pump Replacement.”
12. Install drive shafts. Refer to Section 5.4.4, “Drive
Shaft Installation.”
13. Install air cleaner and tubing.
14. Clean the transmission oil filter mounting surface.
6.5
 Transmission:

15. Apply a thin film of clean Mobilfluid 424® Tractor
Hydraulic Fluid (ISO 46) to the new transmission
filter gasket. Install the new filter and torque to 27-34
Nm (20-25 lb-ft).
16. Transmission oil may be added through the dipstick
tube (1). Remove the dipstick and add approximately
11,4 liters (3 Gallons) of Mobilfluid 424® Tractor
Hydraulic Fluid (ISO 46). Check the oil level by
taking intermittent dipstick readings as outlined in
the appropriate Operator & Safety Manual. DO NOT
overfill. Reinstall the dipstick when finished.
17. Install the engine cover and belly pan.
18. Install and connect the battery cables on the battery.
9. Reassemble all components and fill the transmission
with clean, fresh Mobilfluid 424® Tractor Hydraulic
Fluid (ISO 46) through the dipstick tube opening.
Remove the dipstick and fill with approximately
11,4 liters (3 gallons) of Mobilfluid 424® Tractor
Hydraulic Fluid (ISO 46). Check the level by taking
intermittent dipstick readings as outlined in the
appropriate Operator & Safety Manual. DO NOT
overfill. Reinstall the dipstick when finished.
1

6.6.4 After Transmission Service or

Replacement
In general:
1. Check the transmission oil level and add oil as
required.
2. Install a new transmission filter.
3. Check the torque on the drive shaft yoke capscrews.
4. Wear suitable eye protection. When an overhauled
or repaired transmission is installed, thoroughly
clean the oil cooler lines to and from the transmission.
5. Drain and flush the entire system.
MZ0680
6. Disconnect and clean all transmission cooler hoses.
When possible, remove transmission lines from the
10. Run the engine for two minutes at idle to help prime the
machine for cleaning.
torque converter and the transmission oil lines.
7. Thoroughly clean transmission filter screens and
11. Recheck the level of the fluid in the transmission with
cases, and replace transmission filter elements.
the engine running at idle.

CAUTION: DO NOT exceed 11,4 bar 12. Add Mobilfluid 424® Tractor Hydraulic Fluid (ISO 46)
as necessary to bring the fluid level up until it
(165 psi) when back flushing the oil cooler.
Applying too much pressure may damage the reaches the FULL mark on the dipstick. Recheck the
oil cooler/radiator. oil level when it reaches operating temperature
83-94° C (180-200° F).
8. Back flush the transmission oil cooler portion of the 13. Recheck all drain plugs, lines, connections, etc., for
radiator or the oil cooler (located behind the radiator) leaks, and tighten where necessary.
with oil and compressed air until all foreign material
is removed. Flushing in the direction of normal oil
flow does not adequately clean the cooler. If needed,
remove the radiator or oil cooler from the machine.
IMPORTANT: DO NOT use flushing compounds for
cleaning purposes.

6.6 4017

6.7 TROUBLESHOOTING
The transmission should be checked, serviced and
This section provides an easy reference guide covering repaired only by experienced service technicians who are
the most common problems that may occur during aware of all safety instructions and particular component
operation of the transmission. features.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
6.7.1 Transmission Troubleshooting
Problem Cause
1. Transmission will not engage 1. Oil level too high or low.
or will not shift properly.
2. Transmission control lever not
functioning properly and/or a
fault in the wiring harness.
3. Transmission valve body
solenoids not functioning
properly.
4. Pilot-operated shift valves not
operating properly.
5. Pump output pressure low.
6. Clutch piston o-rings damaged.
7. Clutch discs worn or damaged.
8. Coupling shafts or gear teeth
damaged.
2. Low or no pump flow or 1. Low oil level.
pressure.
2. Transmission filled with incorrect
oil, or oil contaminated.
3. Pump suction pipe screen
clogged.
4. Central shaft damaged.
5. Pump worn or damaged.
4017
Transmission:
Remedy
1. Fill transmission to correct level.
(Refer to the appropriate
Operator & Safety Manual.)
2. Refer to Section 9.5.1, “Cab
Harness Electrical Schematic.”
3. Refer to Section 9.5.1, “Cab
Harness Electrical Schematic.”
4. Clean the valve spool and
housing. Replace return spring
as needed.
5. Refer to Section 6.7.1,
“Transmission Troubleshooting,”
Problem 2. “Low or no pump
flow or pressure.”
6. Replace o-rings.
7. Replace clutch discs.
8. Replace couplings.
1. Fill transmission to correct level.
(Refer to the appropriate
Operator & Safety Manual.)
2. Drain transmission and fill to
correct level. (Refer to Section
2.4, “Fluids, Lubricants and
Capacities.”)
3. Clean, repair and/or replace
suction pipe.
4. Replace central shaft.
5. Repair or replace pump
assembly.
6.7
 Transmission:
6.7.1 Transmission Troubleshooting (Continued)
Problem Cause
3. Low clutch pressure. 1. Incorrect oil level.
2. Main pressure valve stuck open.
3. Broken or worn coupling shaft or
piston o-rings.
4. Pressure reducing valve stuck
open.
4. Lack of power. 1. Park or service brake dragging.
2. Low engine rpm causes
converter stall.
3. Pump output pressure is low.
4. Clutch discs worn or damaged.
5. Transmission overheating.
5. Transmission overheating, 1. Low oil level.
oil above 120° C (248° F).
2. Clogged radiator.
3. Transmission filled with incorrect
oil, or oil contaminated.
4. Excessive “roading.”
5. Restriction in oil cooler hoses.
6. Pump worn or damaged.
7. Engine thermostat stuck.
6.8
Remedy
1. Fill transmission to correct level.
Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”
2. Clean the valve spool and
housing.
3. Replace coupling and/or o-rings.
4. Clean the valve spool and
housing.
1. Refer to Section 8.4, “Hydraulic
Circuits.”
2. Adjust the engine rpm to
specifications. Refer to Perkins
Service Manual.
3. Refer to Section 6.7.1,
“Transmission Troubleshooting,”
Problem 2. “Low or no pump
flow or pressure.”
4. Replace clutch discs.
5. Refer to Section 6.7.1,
“Transmission Troubleshooting,”
Problem 5. “Transmission
overheating, oil above 120° C
(248° F).”
1. Fill transmission to correct level.
Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”
2. Remove debris from the
radiator.
3. Drain transmission and fill to
correct level. Refer to Section
2.4, “Fluids, Lubricants and
Capacities.”
4. Stop and idle the engine.
5. Replace cooler hoses.
6. Repair or replace pump
assembly.
7. Replace engine thermostat.
Refer to Section 7.4.2,
“Thermostat Replacement.”
4017

6.7.1 Transmission Troubleshooting (Continued)
Problem Cause
6. Grinding or “clunking” noise 1. Oil level too low.
from transmission.
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.
7. Oil leaking from transmission. 1. Oil leaking from vent (high oil
level).
2. Drain plug loose and/or o-rings
damaged or missing.
3. Hose fittings loose.
4. Oil leaking at valve bodies
(possible valve body gaskets
damaged or missing and/or
mounting capscrews not tight).
5. Housing capscrews loose.
6. Oil leaking at pump (possible
pump-to-housing o-rings
missing or damaged, and/or
pump mounting capscrews not
tight).
7. Oil leaking at converter bell
(possible converter leak and/or
input shaft seal damage).
8. Oil leaking at output shaft
(output shaft seal damaged).
9. Housing damaged.
4017
Transmission:
Remedy
1. Fill oil to correct level. Refer to
Section 2.4, “Fluids, Lubricants
and Capacities.”
2. Drain transmission and fill to
correct level. Refer to Section
2.4, “Fluids, Lubricants and
Capacities.”
3. Refer to Section 9.11.3,
“Transmission Solenoid Valves.”
4. Repair or replace parts as
needed.
5. Replace diaphragm (flex plate).
Refer to Section 6.6.1,
“Transmission Removal.”
6. Tighten capscrews.
1. Remove drain plug and drain oil
as needed, until oil is at correct
level. Refer to Section 2.4,
“Fluids, Lubricants and
Capacities.” Replace o-rings as
needed and tighten plugs to 35
Nm (26 lb-ft).
2. Replace o-rings as needed and
tighten plug to 35 Nm (26 lb-ft).
3. Tighten fittings.
4. Replace gaskets and/or tighten
capscrews to 9,5 Nm (84 lb-in).
5. Tighten capscrews to 46 Nm
(34 lb-ft).
6. Replace o-rings and/or tighten
capscrews to 115 Nm (85 lb-ft).
7. Replace converter and/or input
shaft seal.
8. Replace output shaft seal.
9. Replace housing as needed.
6.9
 Transmission:

This Page Intentionally Left Blank

6.10 4017
 Section 7
Engine: Perkins 1004-40T

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.4.3 Radiator/Oil Cooler and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.7.1 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.7.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.8.1 Air Cleaner Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
7.9.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7.11
7.9.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
7.10 Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
7.10.1 Drive Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
7.10.2 Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

4017 7.1
 Engine: Perkins 1004-40T

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
with comprehensive engine diagnosis, repair and
component replacement. A gradual running-in (break-in)
of a new engine is not necessary. Full load can be applied
to a new engine as soon as the engine is put into service
and the coolant temperature is at least 60° C (140° F).
Extended light-load operation during the early life of the
engine is not recommended. DO NOT run the engine at
high, no-load speeds. DO NOT apply an overload to the
engine.

7.2 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 the components that are referred to
throughout this section.

Fuel Injection
Pump

Fuel Filter

Oil Filter

Thermostat

Alternator

Turbocharger

Starter

MZ0070

4017 7.3
 Engine: Perkins 1004-40T
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 SPECIFICATIONS AND
MAINTENANCE INFORMATION
For engine, coolant and oil specifications, and
maintenance information, refer to Section 2, “General
Information and Specifications.”
Note: Detailed Perkins engine service instructions
(covering disassembly, inspection, internal repair,
assembly, adjustment and troubleshooting information)
are provided in the appropriate Perkins engine service
manual.
7.4 ENGINE COOLING SYSTEM
7.4.1 Radiator Pressure Cap
For a 99° C (210° F) system, use a .9 kPa (13 psi) radiator
cap. An incorrect or malfunctioning cap can result in the
loss of coolant and a hot-running engine.
7.4.2 Thermostat Replacement
Before considering thermostat replacement, check the
coolant level, fan belt tension and instrument cluster
temperature indicator.
• If the engine seems to take a long time to warm
up, the thermostat may be stuck in the open posi-
tion and requires replacement.
• If the engine runs hot, check the temperature of
the upper radiator hose.
• If the hose is not hot, the thermostat may be
stuck in the closed position.
• If the engine has overheated, performance may
suffer, indicating other damage including a leak-
ing cylinder head gasket, cracked cylinder head
or block, and/or other internal engine damage.
7.4
a. Thermostat Removal
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in NEUTRAL (N), engage
the park brake and shut off the engine.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool. Draining the cooling system while the engine is
hot can cause cracks in the engine block.
4. Remove the negative (-) battery cable from the
battery negative (-) terminal.
5. Slowly turn the radiator cap (1) to the first stop and
allow any pressure to escape. Remove the radiator
cap.
6. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain plug (2) and slowly remove to allow the coolant
to drain. Drain approximately two liters (2 quarts) of
coolant. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
replaced. Reinstall and tighten the drain plug.
1
2 MZ0080
7. Remove the two capscrews securing the thermostat
housing to the engine.
8. Remove the thermostat housing, old gasket and
thermostat. Clean all gasket surfaces. DO NOT let
any debris into the thermostat opening.
IMPORTANT: ALWAYS use the correct thermostat and
install a new gasket. NEVER operate the engine without
a thermostat, or engine damage will result.
4017
 Engine: Perkins 1004-40T

b. Thermostat Installation
1. Install the engine thermostat, thermostat gasket and 9
5
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. 7
3. 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 3
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.
4. 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, 6
as necessary.
5. Close and secure the engine cover.

7.4.3 Radiator/Oil Cooler and Replacement 8

Before considering radiator or oil cooler replacement for
other than obvious damage, conduct a cooling system
pressure test check the coolant specific gravity, coolant
level, fan belt tension and dash panel temperature
indicator.
• If the engine runs hot, check the temperature of
the upper radiator hose.
• If the hose is not hot, the thermostat may be
stuck in the closed position.
• If the engine has overheated, performance may
suffer, indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
4
6. Remove the radiator guard cover (3) and the lower
engine protective cover.
7. Disconnect and plug the hoses to the overflow bottle.
Remove the three bolts holding the overflow bottle
bracket and remove the overflow bottle.
8. Slowly turn the radiator cap to the first stop and allow
any pressure to escape. Remove the radiator cap.
9. Place a suitable container beneath the radiator
drain.

a. Radiator/Oil Cooler Removal
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in NEUTRAL (N), engage
the park brake and shut off the engine.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool. Draining the cooling system while the engine is
hot can cause cracks in the engine block.
4. Remove the negative (-) battery cable from the
battery negative (-) terminal.
5. Remove engine cover to ease removal of radiator/oil
cooler.
10. Place a funnel at the base of the radiator to channel
the drained coolant into the container. Loosen the
drain plug (4) and slowly remove to allow the coolant
to drain. Transfer the coolant into a properly labeled
container. Dispose of properly if coolant needs to be
replaced. Replace the radiator drain plug.
11. Loosen the radiator clamp on the top radiator hose
(5). 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.

4017 7.5
 Engine: Perkins 1004-40T
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.
7.6
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
4017

75 hours. The use of fuel with a sulfur content above
1.3 percent is not recommended.
5
3 8. Remove screws securing fuel sender to the tank.
4
2
MZ0100
1 If contaminated fuel or foreign material is in the tank, the
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 fuel must be
drained before tank removal. Always dispose of fuel
properly.
a. Fuel Tank Removal
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in NEUTRAL (N), engage
the park brake and shut off the engine.
2. Install the safety support on the lift/lower cylinder
rod.
Note: The support is located at the left front corner of
the frame.
3. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
4. Remove the negative (-) battery cable from the
battery negative (-) terminal.
Note: If replacing the tank, remove all internal and
external components from the old tank, and retain for
use on the replacement tank.
Note: Have a dry chemical (Class B) fire extinguisher
near the work area.
4017
Engine: Perkins 1004-40T
5. Remove fuel tank drain plug (1), and drain fuel into
an approved and suitable container. Dispose of fuel
properly.
6. Loosen and remove the strap (2) over the fuel tank
and disconnect the fuel supply hose (3) and return
line hose (4) from tank.
7. Disconnect fuel level sender electrical connectors
from the fuel level sender (5).
Remove fuel sender from tank.
9. Lift the empty fuel tank from between the frame rails.
b. Disassembly
The fuel tank is a one-piece unit and cannot be
disassembled. The fuel level indicator can be removed and
reused on the new replacement tank.
c. Cleaning and Drying
tank can usually be cleaned.
To clean the fuel tank:
1. Have a dry chemical (Class B) fire extinguisher near
the work area.
2. Remove the fuel or oil tank drain plug, and safely
drain any fuel into a suitable container. Dispose of
fuel properly.
3. Clean the fuel tank with a high-pressure washer, or
flush the tank with hot water for five minutes and
drain the water. Dispose of contaminated water
properly.
4. Add a diesel fuel emulsifying agent to the tank. Refer
to the manufacturer’s instructions for the correct
emulsifying agent-to-water mixture ratio. Refill the
tank with water, and agitate the mixture for 10
minutes. Drain the tank completely. Dispose of
contaminated water properly.
5. Refill the fuel tank with water until it overflows.
Completely flush the tank with water. Empty the fuel
tank, and allow it to dry completely.
d. Assembly
The fuel level indicator can be removed and reused on the
new replacement tank. Dispose of the old tank according
to local regulations concerning hazardous materials
disposal regulations.
Note: If a leak is suspected in the fuel tank, contact a
JLG Distributor.
7.7
 Engine: Perkins 1004-40T
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 air pressure through the elbow. Check
the reservoir for leaks by applying a soap solution to
the exterior and look for bubbles to appear at the
cracked or damaged area.
f. Fuel Tank Installation
1. Set fuel tank between frame rails.
2. Install the fuel tank strap over the fuel tank.
3. Install the fuel sender with new gasket into the fuel
tank and secure with screws. DO NOT overtighten.
4. Connect the fuel supply hose and return line hose to
the tank. Secure with clamps.
5. Install the wire harness connections to the fuel
sender.
Note: ALWAYS replace elastic locknuts with new elastic
locknuts to help ensure proper fastening.
6. Fill the fuel tank according to specifications.Refer to
Section 2.4, “Fluids, Lubricants and Capacities.”
7. Check fuel tank for leaks.
8. Connect the negative (-) battery cable to the
negative battery terminal.
9. Close and secure the engine cover.
7.6.3 After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Perkins Engine
Service Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required.
7.7 ENGINE EXHAUST SYSTEM
WARNING: Exhaust fumes contain
carbon monoxide, a colorless, odorless gas
which is fatal when inhaled in a confined area.
Avoid breathing exhaust fumes, and prevent
engine operation from becoming a cause of
toxic emissions. Exhaust system components
reach high temperatures and can cause
severe burns. DO NOT come into contact with
hot exhaust system components.
7.8
7.7.1 Exhaust System Removal
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in NEUTRAL (N), engage
the park brake and shut off the engine.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine hood. Allow the system fluids to
cool.
4. Remove the negative (-) battery cable from the negative
(-) battery terminal.
5. Remove the engine belly pan.
6. Loosen and remove the three nuts from the exhaust
pipe at the exhaust manifold.
Note: Replace the three nuts and the three exhaust
manifold studs if damaged.
7. Disconnect and remove the clamp attaching the
exhaust pipe to the frame under the engine.
8. Disconnect and remove the clamp connecting the
muffler and the exhaust pipe.
9. Disconnect and remove the clamp connecting the
tail pipe to the muffler and remove the tail pipe.
10. Loosen and remove the two bolts at the front and
one bolt at the rear of the muffler, and remove the
muffler.
7.7.2 Exhaust System Installation
Note: Keep all clamps loosened until entire exhaust
system is in place.
MZ0110
1. Install the exhaust pipe with a new seal to the
exhaust manifold.
Note: Replace the three nuts and the three exhaust
manifold studs if damaged.
2. Install the exhaust pipe clamp under the engine.
4017

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 proper
clearance then tighten all clamps.
7. Connect the negative (-) battery cable to the negative (-)
battery terminal.
8. Start engine and check for exhaust leaks at all
exhaust connections. Adjust or repair as needed.
9. Install the belly pan.
7.8 AIR CLEANER ASSEMBLY
CAUTION: NEVER run the engine with
only the inner safety element installed.
IMPORTANT: Refer to the appropriate Operator &
Safety Manual for your machine for the correct element
change procedure.
7.8.1 Air Cleaner Assembly Removal
1. Open the engine cover.
2. Disconnect low pressure indicator wire connection.
3. Remove the clamp securing the air intake elbow to
the air cleaner assembly. Lift the air intake elbow off
the air cleaner.
4. The reducing insert and the reinforcement ring
should be removed along with the air intake tube.
MZ0120
5. Remove the clamp securing the air outlet elbow. Lift
the air outlet elbow off the air cleaner.
4017
Engine: Perkins 1004-40T
6. Remove the two capscrews and ripp nuts securing
the air cleaner mounting bracket to the air cleaner
mounting plate. Remove the air cleaner assembly.
7.8.2 Air Cleaner Assembly Installation
Note: Apply Loctite® 242 threadlock to the capscrew
threads before installation.
1. With the air cleaner assembly attached, install the air
cleaner mounting bracket using capscrews and ripp
nuts.
2. Place the loosened clamps over the air intake elbow
along with the reducing insert and the reinforcement
ring, and install elbow on the air cleaner assembly.
3. Place the loosened clamps over the air outlet elbow
and install elbow on the air cleaner assembly.
4. Connect low pressure indicator wire connection.
5. Adjust and tighten both clamps before starting the
machine.
6. Close and secure the engine cover.
7.9 ENGINE REPLACEMENT
7.9.1 Engine Removal
Note: The radiator and oil cooler must be removed from
the machine before engine removal. Refer to Section
7.4, “Engine Cooling System.” Several additional
components must be removed before engine removal.
They will be addressed in the following procedures.
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in NEUTRAL (N), engage
the park brake and shut off the engine.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
Note: ALWAYS replace elastic locknuts with new elastic
locknuts to help ensure proper fastening.
4. Remove the engine cover, radiator guard plate and
the engine belly pan.
5. Remove the radiator overflow bottle and hoses.
6. Refer to Section 7.4.3, “Radiator/Oil Cooler and
Replacement,” to remove the radiator/oil cooler.
7. Loosen the clamps on each heater hose on the
engine. Plug the heater hoses if necessary.
7.9
 Engine: Perkins 1004-40T

Note: The engine harness is routed and attached to the

engine using hold-down clamps and plastic wire ties at
various places on the engine. Before removing engine,
ensure that the harness has been completely separated 3
(disconnected) from the engine. Move the harness clear
of the engine, and with the help of an observer, ensure
that engine clears the harness during removal.
8. Label and disconnect all wire harness connections on
the engine.
1

MZ0950

11. Disconnect the fuel inlet line at the fuel filter head.
Install a plug in the end of fuel inlet line.
2
12. Disconnect the fuel return line from the fuel filter
MZ0940
head. Install a plug in the end of fuel return line.
13. Mark the location of the throttle cable (1) at the
9. Unbolt and remove the hood latch plate. Mark the throttle cable mount (2). Loosen jam nuts and remove.
plate to help with hood adjustment when being
14. Disconnect the throttle cable at the engine throttle
reinstalled.
pedal.
10. Unbolt the return hydraulic oil filter plate and leave in
15. Remove the three nuts holding the exhaust pipe to
place.
the exhaust manifold. Remove the exhaust pipe from
the exhaust manifold.
16. Loosen the clamps on the sleeve reducer at the
engine and on the air suction pipe.
17. Disconnect the wire connection at the low air
pressure indicator.
18. Loosen and remove the three bolts on the air cleaner
mount plate, then remove the complete air cleaner
assembly.
19. Remove the access plug from side of the engine bell
housing. This will allow access to remove the eight
bolts holding the flex plate to the engine flywheel.
20. Turn the engine over slowly by hand and align each
of the eight flex plate bolts to be accessed. Remove
them one at a time.
21. At the front right engine mount (3) remove the bolt
and washer. Repeat for the front left engine mount.

7.10 4017

4
MZ0960
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 lift and pull the engine forward to clear
the transmission. Slowly lift and pull the engine out of
the machine. Have an assistant ensure that the
engine clears all frame components during removal.
25. Place engine on a flat, level surface.
7.9.2 Engine Disassembly, Inspection and
Service
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Perkins
1004-40T service manual. Contact the local Perkins parts
distributor for further information.
Note: If the engine is being replaced, there may be external
components that will be required to be transferred from the
original engine to the replacement engine depending upon
who you purchase the new engine from and the
configuration of your replacement engine. Refer to the
appropriate Perkins user manual for detailed procedures
that cover the transfer of original engine components to the
replacement engine.
4017
Engine: Perkins 1004-40T
7.9.3 Engine Installation
1. Attach a lifting chain to the front and rear engine lift
brackets (4), and lift engine clear of the ground.
Note: Apply Loctite® 242 threadlock to the engine mount
bracket capscrew threads before installation.
Note: The engine harness is routed and attached at
various places on the engine using hold-down clamps
and plastic wire ties. Before installing engine and with
the help of an observer, ensure that engine clears the
harness during installation.
2. Inspect the front engine mounting bracket isolator.
Replace isolator if cracked or worn.
3. Install two guide studs in the bell housing holes.
4. Lift the engine and slowly push and lower into the
engine bay. Have an assistant ensure that the
engine clears all frame, hose and harness
components during engine installation. Position
engine brackets over the front frame mounts.
5. Push the engine back towards the transmission
aligning the guide studs and the torque converter
shaft with the corresponding holes.
6. Push the engine against the transmission and install
eight of the ten bolts and washers. Remove both
guide studs and replace with the remaining two bolts
and washers. Tighten bolts.
7. Torque the ten (10) transmission bolts to 63 Nm (46
lb-ft) AFTER engine is lowered and secured with the
front motor mount bolts installed and torque.
8. Remove the support from under the transmission
and lower the engine the remainder of the way onto
the frame. Align the motor mount holes and install
the bolts. Apply Loctite® 242 threadlock to the motor
mount bolts and torque to 210 Nm (155 lb-ft).
9. Turn the engine over slowly by hand and align each
of the eight flex plate bolts through the access hole
in the bell housing. Install them one at a time. DO
NOT fully tighten until all of the capscrews and
locknuts are in place.
10. Torque to 35-39 Nm (26-29 lb-ft). Replace access
plug.
11. Install the exhaust pipe to the exhaust manifold.
Refer to Section 7.7.2, “Exhaust System Installation.”
12. Install the complete air cleaner assembly. Refer to
Section 7.8.2, “Air Cleaner Assembly Installation.”
13. Install and tighten the jam nuts on the throttle cable
at the throttle cable mount.
14. Connect the throttle cable at the engine throttle lever.
15. Connect the fuel inlet line to the fuel filter head.
7.11
 Engine: Perkins 1004-40T
16. Connect the fuel return line to the fuel filter head.
17. Connect all the labeled wire harness connections on
the engine.
18. Install the hood latch plate. Align the mark on the
plate to help with hood adjustment.
19. Secure the return hydraulic oil filter plate to the
frame.
20. Install both heater hoses to the engine and tighten
clamps.
21. Install the complete radiator assembly (1) and
tighten the four bolts
22. Install the hose clamp on the bottom radiator hose
and work onto the engine. Tighten the clamp.
23. Install the hose clamp on the top radiator hose and
work onto the engine. Tighten the clamp.
24. Connect the transmission inlet and outlet hoses on
the oil cooler (2). Install the clamp holding the top
transmission cooler hose and the three bolts holding
the fan screen.
1 • DO NOT operate any hydraulic function.
2 • DO NOT steer or apply any pressure to the steer-
MZ0970
25. Install and adjust the engine cover.
26. Connect the negative (-) battery cable to the battery
negative terminal.
27. 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.
7.12
28. Check that all hydraulic system, electrical system,
cooling system, fuel system, and exhaust system
connections are correct and connected tightly
29. From within the cab, lightly depress the throttle pedal
to full-throttle position. As needed, adjust the limit-
stop screw until it touches the pedal. Tighten the
locknut to 13,6-14,1 Nm (120-125 lb-in).
Note: Have an assistant stand by with a Class B fire
extinguisher.
30. Run engine to normal operating temperature then shut
off the engine. While the engine is cooling, check for
leaks.
31. Allow the engine to cool. Check the radiator coolant
level, and top off with a 50/50 mixture of ethylene
glycol and water. Replace the radiator cap.
32. Check for leaks from the engine, main hydraulic pump
and lines, transmission, hydraulic reservoir and fuel
tank. Check the levels of all fluids and lubricants. Fill
as required.
IMPORTANT: During the full throttle check:
ing wheel.
• Keep the transmission in NEUTRAL (N).
33. Obtain and connect an appropriate engine analyzer
or tachometer. Check the engine rpm at full throttle.
If the rpm is not 2200 +/- 50 rpm, readjust the throttle
limit-stop screw at the throttle pedal within the cab.
34. Purge the hydraulic system of air by operating all
boom functions through their entire range of motion
several times. Check the hydraulic oil level.
35. Check for proper operation of all components.
36. Turn the engine OFF.
37. Install the engine belly pan.
38. Close and secure the engine cover.
4017
 Engine: Perkins 1004-40T

7.10 ENGINE DRIVE PLATE 2. Mount the drive plate/converter assembly to the
transmission.
7.10.1 Drive Plate Removal 3. Refer to Section 6.6.3, “Transmission Installation,”or
Section 7.9.3, “Engine Installation,” for the remainder
1. Park the machine on a firm, level surface, fully of the installation.
retract the boom, lower the boom, place the
transmission control lever in (N) NEUTRAL, engage 4. Connect the battery negative (-) cable to the battery
the park brake and shut the engine OFF. negative terminal.
5. Close and secure the engine cover.
Note: In order to remove the engine drive plates, the
engine and transmission must be separated.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the battery negative (-) cable from the
battery negative terminal.
5. Refer to Section 6.6.1, “Transmission Removal,”or
Section 7.9.1, 7.9.1. “Engine Removal.”

Drive Plate
Assembly

Drive Plates

Ring

MZ0580

6. Remove the eight bolts holding the drive plates to

the flywheel.
7. With the drive plates and torque converter removed,
loosen and remove the six bolts and six lock
washers holding the three drive plates to the torque
converter.
8. Replace all three drive plates if damaged.

7.10.2 Drive Plate Installation

1. Install the three new drive plates on the torque
converter and torque the six bolts with lock washers
to 35-39 Nm (26-29 lb-ft).

4017 7.13
 Engine: Perkins 1004-40T

7.11 TROUBLESHOOTING

Trouble Possible Causes (see key, below)

Low Cranking Power 1, 2, 3, 4
Will Not Start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33
Difficult Starting 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 24, 29, 31, 32, 33, 61, 63
Lack of Power 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 31, 32, 33, 61, 63
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32
Excessive Fuel Consumption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63
Black Exhaust 11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33, 61, 63
Blue/White Exhaust 4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 35, 45, 56, 62
Low Oil Pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58
Knocking 9, 14, 16, 18, 19, 22, 26, 28, 29, 31, 33, 35, 36, 45, 46, 59
Erratic Running 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45, 47, 48, 49
High Oil Pressure 4, 38, 41
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57
Excessive Crankcase Pressure 25, 31, 33, 34, 45, 55, 60
Poor Compression 11, 19, 25, 28, 29, 31, 32, 33, 34, 46, 59
Starts and Stops 10, 11, 12

Key to Possible Causes

1. Battery charge low 21. Blocked fuel tank vent 43. Faulty suction pipe
2. Bad electrical connection 22. Incorrect grade of fuel 44. Restricted oil filter
3. Faulty starter motor 23. Sticking throttle or 45. Piston seizure/pick up
4. Incorrect grade of restricted movement 46. Incorrect piston height
lubricating oil 24. Exhaust pipe restriction 47. Damaged fan
5. Low cranking speed 25. Leaking cylinder head gasket 48. Faulty engine mounting
6. Fuel tank empty 26. Overheating 49. Incorrectly aligned flywheel
7. Faulty stop control operation 27. Cold running housing or incorrectly aligned
8. Fuel inlet restricted 28. Incorrect tappet adjustment flywheel
9. Faulty fuel lift pump 29. Sticking valves 50. Faulty thermostat
10. Clogged fuel filter 30. Incorrect high pressure pipes 51. Restriction in water jacket
11. Restricted air cleaner 31. Worn cylinder bores 52. Loose fan belt
12. Air in fuel system 32. Pitted valves and seats 53. Restricted radiator
13. Faulty fuel injection pump 33. Broken, worn or sticking 54. Faulty water pump
14. Faulty fuel injectors or piston ring(s) 55. Restricted breather pipe
incorrect type 34. Worn valve stems and guides 56. Damaged valve stem oil
15. Incorrect use of cold start 35. Restricted air cleaner deflectors (if fitted)
equipment 36. Worn or damaged bearings 57. Coolant level too low
16. Faulty cold start equipment 37. Insufficient oil in sump 58. Blocked sump strainer
17. Broken fuel injection 38. Inaccurate gauge 59. Broken valve spring
pump drive 39. Oil pump worn 60. Exhauster or vacuum pipe leak
18. Incorrect fuel pump timing 40. Pressure relief valve sticking open 61. Turbo impeller damaged or dirty
19. Incorrect valve timing 41. Pressure relief valve sticking closed 62. Turbo lubricating oil seal leak
20. Poor compression 42. Broken relief valve spring 63. Induction system leaks

7.14 4017
 Section 8
Hydraulic System

Contents

PARAGRAPH TITLE PAGE

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.4.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.4.2 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
8.5 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.5.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.6 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.1 Pump Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.2 Pump Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.6.3 Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.7 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.7.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.7.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8.7.3 Park Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
8.7.4 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
8.7.5 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
8.8 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.8.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8.8.2 Cylinder Pressure Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
8.8.3 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
......................................................... 8.19

4017 8.1
 Hydraulic System

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 illustration identifies the components that are
referred to throughout this section.

* Brake Valve, Steering

Orbitorl Valve, and Park
Brake Valve are located in
the cab.
Crowd Cylinder

Tilt Cylinder
Compensation
Cylinders

Lift Cylinder

Hydraulic
Main Filter Fill
Control Oil
Cooler Cap
Valve

Main
Pump
Steering
Frame Sway Cylinder
Cylinder (Rear)

Hydraulic
Reservoir
Steer Select
Valve
Steering (inside left frame rail) MZ1260

Outrigger Cylinders Cylinder

(Front)

8.2 4017
 Hydraulic System

8.2 SAFETY INFORMATION 8.3 HYDRAULIC PRESSURE DIAGNOSIS

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 source is present.
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully
examine any deterioration and determine whether any
further use of the component would constitute a hazard.
If in doubt, replace the component.
JLG Parts Department has a kit available to use for
hydraulic system maintenance and troubleshooting: the
JLG Pressure Test Kit. The kit is contained in a durable
polyethylene carrying case for demanding field service
conditions.
Pressure Test Kit
The hydraulic pressure test kit is used to pressure test the
various hydraulic components in the hydraulic system.
The kit includes:

WARNING: Relieve hydraulic pressure

• Gauges for testing high and low pressure circuits
• Fittings, couplers and hoses
before servicing any hydraulic component.
Escaping hydraulic fluid under pressure can
penetrate the skin causing death or serious injury.

Note: Residual pressure may remain in hydraulic

cylinders, hoses, valve bodies, components, etc. If the
hydraulic lines going to or coming from a component are
taut, slowly and cautiously relieve (“bleed off”) pressure
using the handle provided in the tool kit.
Note: Whenever you disconnect a hydraulic line,
coupler, fitting or other component, slowly and cautiously
loosen the part involved. A hissing sound or slow
seepage of hydraulic fluid may occur in most cases. After
the hissing sound has ceased, continue removing the
part. Any escaping oil should be directed into an
appropriate container. Cap or otherwise block off the part
to prevent further fluid seepage.
MZ1460

Hydraulic system maintenance will, at times, require that

the engine be operated. Always follow safety precautions. Contact your JLG Parts Department for ordering
A major cause of hydraulic component failure is information.
contamination. Keeping the hydraulic fluid as clean as Part Description Approximate Price and
possible will help avoid downtime and repairs. Sand, grit Number Weight Availability
and other contaminants can damage the finely machined 80904003 Hydraulic Pressure Test Kit 10 lbs. Consult Factory
surfaces within hydraulic components. If operating in an
exceptionally dirty environment, change filters and
inspect the fluid more often. When servicing the system,
cap or plug hydraulic fittings, hoses and tube assemblies.
Plug all cylinder ports, valves and the hydraulic reservoir,
and pump openings until installation occurs. Protect
threads from contamination and damage.
Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.5, “Electrical System
Schematics,” in this manual.

4017 8.3
 Hydraulic System

8.4 HYDRAULIC CIRCUITS 8.4.1 Hydraulic Pressures

This section covers the hydraulic circuits and includes a. Checking Function Pressures
listings for all hydraulic function pressures, where and
All hydraulic system function pressures can be checked
how to check those pressures and a hydraulic schematic.
at one location. A digital pressure gauge is
Electrical and hydraulic functions are often related. Verify recommended.
that the electrical components of the circuit are
1. Start the machine and warm the hydraulic system to
functioning properly whenever troubleshooting the
operating temperature.
hydraulic circuit.
2. Shut off the machine and install a digital or a 345 bar
Always check the following before beginning to
(5000 psi) gauge to the test port located at the top
troubleshoot a circuit that is not functioning correctly.
right corner of the main control valve (1).
1. Check the hydraulic oil level in the reservoir. Oil level
should be to the middle of the sight glass with all
cylinders retracted. 1

2. Check hoses, tubes, fittings and other hydraulic

components for leaks, bends, kinks, interference, etc.
3. Check for air in the hydraulic system. Erratic machine
performance and/or spongy cylinder operation are
signs of air in the hydraulic system.

WARNING: Hydraulic oil leaking under

MZ1310

pressure can penetrate the skin and cause Note: See Section 8.7.1, “Main Control Valve,” for
severe personal injury. DO NOT use your hand complete valve breakdown.
or any part of your body to check for hydraulic
leaks. When checking for hydraulic leaks, wear 3. Start the machine, run the engine at full throttle and
safety glasses and gloves to help provide bottom the boom in function.
protection from spraying hydraulic oil. Use a Note: It is possible to see maximum system pressure by
piece of cardboard or paper to search for activating and bottoming any of the hydraulic functions.
leaks.
4. With the engine running at full throttle and the
4. If air in the hydraulic system is suspected, you will hydraulic function bottomed, the gauge should read
hear air leakage when hydraulic fittings are loosened 250 bar (3625 psi) +/- 5 bar (70 psi).
and see air bubbles in the hydraulic fluid.
5. Loose fittings, faulty o-rings or seals, trapped oil,
leaks, system opened for service, etc., can cause air
in the system. Determine what is causing air to enter
the system and correct it. Bleed air from the system.

8.4 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 on the bottom relief (2) on the
pilot valve at the main hydraulic pump located at the
rear of the engine.

Engine

MZ1270
2

2. Start the machine and loosen the jam nut on the

relief and using an allen wrench; turn the relief
clockwise to increase pressure or counter-clockwise
to decrease pressure. Set the pressure to 250 bar
(3625 psi) +/- 5 bar (70 psi) at full throttle.
3. Tighten the jam nut and recheck the pressure at full
throttle. If the reading is within specification, shut the
machine off, install the safety cap and remove the
gauge from the test port.
4. If the proper pressure cannot be set, refer toSection
8.4.2, “Hydraulic Schematic,” and/or Section 9.5,
“Electrical System Schematics,” to help trouble shoot
and correct the problem.

4017 8.5
 4017
STABILIZERS
FORKS BOOM LIFT
130/65 130/65 BOOM EXTENSION
FRAME 140/70 160/90
350 bar/4:1
LEVELLING 130/80

MZ1080
100/50
AUXILIARY
300 bar/4:1
M
350 bar/4.2:1
COMPENSATION 300 bar/4:1
C2 1
C2 C1 C1
2x90/45
2
1 2 1 2
DN 10
DN 10 A B DN 16
V2 V1 V2 V1
DN 10 DN 10 DN 16
DN 12

350 bar/4.2:1 DN 8
350 bar/4.2:1
DN 10 DN 16
DN 12
DN 12

DN 10 DN 16
DN 12

DN 10 C
A B A B A B A B A B A B A B CF LX
P T
DN 8
B DN 8 DN 8
PARK BRAKE
280 280 20 - 25 bar VALVE
M
280
B B B B B B B

DN 8
BRAKE LIGHT
SWITCH

DN 8
5 bar
7003 9598 9597 7006
0931
A A A A A A A
7101 7101 7105 7003 9598 9597 0931 1.0
7006
BRAKES

REAR AXLE
FRONT AXLE
PVSP
LIFT P
LH STABILIZER RH STABILIZER FRAME LEV. AUXILIARY TILT EXTENSION T LS P
25 l/min 25 l/min 5 l/min 65 l/min 65/100 l/min 130/200 l/min 130 l/min

DN 12
L R
DN 10 235 bar

DN 32
P A DN 10

DN 6
X T B
Hydraulic Schematic

DN 10
DN 25
3 bar

4WE6G
DN 10 DN 10

REAR AXLE
Hydraulic System

FRONT AXLE
3.5 bar
LS
10 µm
B
175 bar OSPF 200 LS
P T
60 A10VO60DFR1
Q=132 l/min
p=250 bar
n=2200 1/min
dp=25 bar
S L1 L

DN 40

DN 20
DN 50

DN 10
TENSION = 12V

8.4.2

8.6

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 breather. If the return filter becomes
plugged, the return hydraulic oil will bypass the filter when
pressure reaches 1,7 kPa (25 psi) and return to the
reservoir unfiltered.
Carefully examine fluid seepage or leaks from the
hydraulic reservoir to determine the exact cause. Clean
the reservoir and note where any seepage occurs.
MZ0130
8.5.1 Hydraulic Oil Reservoir Draining
1. Park the machine on a firm, level surface, fully
retract and lower the boom, place the transmission
control lever in (N) NEUTRAL, engage the park
brake and shut the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the hydraulic fluid to
cool.
4. Remove the drain plug at the bottom of the hydraulic
oil reservoir.
5. Transfer the used hydraulic oil into a suitable,
covered container, and label as "Used Oil". Dispose
of used oil at an approved recycling facility. Clean
and reinstall the drain plug.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
8.5.2 Hydraulic Oil Reservoir Filling
1. Be sure reservoir is clean and free of all debris.
2. Install a new hydraulic oil filter.
4017
Hydraulic System
3. Fill the reservoir with Mobilfluid 424® Tractor
Hydraulic Fluid (ISO 46). Refer to Section 2.4,
“Fluids, Lubricants and Capacities.”
4. Start the machine. Run the engine to normal
operating temperature. Operate all hydraulic
functions to remove any trapped air in the system.
8.5.3 Hydraulic Oil Reservoir Removal
If it is determined that the hydraulic oil reservoir must be
removed, the hydraulic oil must be drained before
reservoir is removed. Always dispose of oil properly.
a. Reservoir Removal
1. Park the machine on a firm level surface, fully retract
the boom, lower the boom, place the transmission
control lever in NEUTRAL (N), engage the park
brake and shut the engine off.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluid to
cool.
4. Remove the negative (-) battery cable from the
battery negative terminal.
5. Refer to Section 8.5.1, “Hydraulic Oil Reservoir
Draining,” for draining procedure.
6. Remove and cap the four return hoses on the
hydraulic oil reservoir.
7. Loosen the clamps and remove and plug the suction
and return hoses on the hydraulic oil reservoir.
8. Plug and cap the fittings on the hydraulic oil
reservoir.
9. Support the hydraulic oil reservoir from the bottom
and remove the six bolts and nuts.
10. Carefully lower the reservoir to the ground.
b. Disassembly
The hydraulic oil reservoir is a one-piece unit and cannot
be disassembled. The hydraulic oil level sight- glass and
hydraulic oil filler cap can be removed and reused on the
new replacement reservoir. Dispose of the old reservoir
according to local regulations concerning hazardous
materials disposal.
8.7
 Hydraulic System
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 chemical (Class B) fire extinguisher near
the work area.
2. Clean the hydraulic oil reservoir with a high-pressure
washer, or flush the tank with hot water for five
minutes and drain the water. Dispose of
contaminated water properly.
d. Inspection
Note: If a leak is suspected in the fuel or hydraulic oil tank,
contact JLG Service Department.
1. Inspect the hydraulic oil reservoir thoroughly for any
cracks, slices, leaks or other damage.
2. With the hydraulic oil reservoir removed from the
machine, plug all openings except one elbow fitting.
Install the elbow fitting, and apply approximately
.06-1 bar (1-1.5 psi) of air pressure through the
elbow. Check the reservoir for leaks by applying a
soap solution to the exterior and look for bubbles to
appear at the cracked or damaged area.
e. Assembly
The hydraulic oil reservoir is a one piece-unit and cannot
be disassembled. The hydraulic oil level sight-glass and
hydraulic oil filler cap can be removed and reused on the
new replacement tank. Dispose of the old tank according
to local regulations concerning hazardous materials
disposal regulations.
f. Hydraulic Oil Tank Installation
1. Lift the hydraulic oil reservoir into place and install
the six bolts, washers and nuts.
2. Uncap and connect the suction hose and return
hose. Tighten both clamps.
3. Uncap and connect the four small return hoses to
the fittings on the hydraulic oil reservoir.
4. Install the hydraulic fluid level sight-glass using
special designed and drilled capscrews and gaskets.
5. Install hydraulic filler neck components and secure.
6. Fill the hydraulic oil reservoir according to
specifications. Refer to Section 2.4, “Fluids,
Lubricants and Capacities.”
7. Check the hydraulic oil reservoir for leaks.
8.8
8. Connect the negative (-) battery cable to the
negative battery terminal.
9. Close and secure the engine cover.
8.6 ENGINE IMPLEMENT PUMP
8.6.1 Pump Description
For internal service instructions contact your local JLG
distributor.
8.6.2 Pump Failure Analysis
The pump is the “heart” of the hydraulic system, and
whenever there is a problem in the system, the pump
often is blamed. However, pump failure is seldom due to
failure of pump components. Pump failure usually
indicates another problem in the hydraulic system.
According to pump manufacturer statistics, 90-95 percent
of pump failures are due to one or more of the following
causes:
• Aeration
• Cavitation
• Contamination
• Excessive Heat
• Over-Pressurization
• Improper Fluid
In the event of pump failure, investigate further to
determine the cause of the problem.
8.6.3 Pump Replacement
a. Pump Removal
1. Park the machine on a firm, level surface, lower the
boom to the ground, place the transmission control
lever in (N) NEUTRAL, engage the park brake and
shut the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the negative (-) battery cable from the
battery negative terminal.
5. Relieve any trapped pressure in the hydraulic
system by using the lever (supplied in the tool box)
or a 9mm wrench and move the double nut on the
side of the actuator module on each valve section
back and forth
4017

6. Drain the hydraulic oil reservoir. Refer to Section
8.5.1, “Hydraulic Oil Reservoir Draining.”
7. Thoroughly clean the pump (1) and surrounding
area, including all hoses and fittings before
proceeding.
Note: Cap all hoses as you remove them to prevent
unnecessary fluid spillage.
8. Remove the four bolts and four lockwashers
securing the flange halves to the pump. Remove the
inlet hose and o-ring.
1
MZ0280
Note: Before removing any fittings from the pump, note
their orientation to ensure correct installation.
9. Remove the four bolts and four lockwashers
securing the flange halves to the pump. Remove the
outlet hose and o-ring.
10. Disconnect the case drain hose from the fitting.
Disconnect the load sense line.
11. Remove the two bolts and two lockwashers securing
the pump to the transmission. Remove the gasket
located between the transmission and the pump.
Wipe up any hydraulic oil spillage.
Note: DO NOT disassemble the operating pump. The
pump is pre-set from the manufacturer. Any adjustments
or repairs performed by anyone other than an authorized
dealer could void the warranty.
b. Pump Installation
1. While the pump is still on the bench, install all
fittings, except the outlet hose fitting, orientating
them as noted during removal.
4017
Hydraulic System
2. Place the pump and a new gasket into position on
the transmission. Align the pump shaft with the
internal transmission gear, so that the machined
teeth mesh together.
3. Align the bolt holes with the pump mount holes.
Secure the pump to the transmission with the two
bolts and washers.
4. If necessary, slide the T-bolt band clamp onto the pump
inlet hose. Uncap and secure the hose to the hydraulic
reservoir outlet connection with the T-bolt band clamp.
5. Place a new oiled o-ring into position over the pump
opening. Uncap and secure the inlet hose with two
flange halves, four lockwashers and four bolts.
6. Connect the load sense line to the fitting.
7. Place a new, oiled o-ring into position over the pump
opening. Uncap and secure the outlet hose with two
flange halves, four lockwashers and four bolts.
8. Fill the hydraulic reservoir with clean, filtered
hydraulic oil.
9. Prime the pump by filling the case drain port with fresh,
filtered hydraulic oil from a clean container before
installing the case drain connector and hose.
10. Check all routing of hoses and tubing for sharp
bends or interference with any rotating members. All
tube and hose clamps must be tight.
11. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
WARNING: Hydraulic oil leaking under
pressure can penetrate the skin and cause
severe personal injury. DO NOT use your hand
or any part of your body to check for hydraulic
leaks. When checking for hydraulic leaks, wear
safety glasses and gloves to help provide
protection from spraying hydraulic oil. Use a
piece of cardboard or paper to search for
leaks.
12. Inspect for leaks and check all fluid levels. The
hydraulic reservoir oil level must be to the middle of
the sight gauge.
c. Pump Test
Refer to Section 8.4.1, “Hydraulic Pressures.”
1. Check the system functions.
8.9
 Hydraulic System

8.7 CONTROL VALVES 1. Park the machine on a firm, level surface, lower the
boom to the ground, place the transmission control
lever in (N) NEUTRAL, engage the park brake and
8.7.1 Main Control Valve shut the engine OFF.
The main control valve is mounted on the frame in the 2. Place an Accident Prevention Tag on both the
engine compartment. ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the hydraulic fluid to
cool.
1 4. Disconnect the positive (+) and negative (-) battery
cables from the battery terminals and remove the
battery.
5. With the engine OFF, relieve any trapped pressure in
the hydraulic system by using the lever (supplied in
the tool box) or a 9mm wrench and move the double
nut on the side of the actuator module on each valve
section back and forth.
6. Thoroughly clean the main control valve and
surrounding area, including all hoses and fittings,
before proceeding.
7. Place a suitable container to catch hydraulic fluid
MZ0290 drainage beneath the frame.
8. Label or otherwise mark, disconnect, cap or plug all
the hydraulic hoses, tubes and wires at the main
The main control valve assembly (1) consists of seven
control valve.
working sections with their own valve assemblies, each
providing a specific hydraulic function. The section 9. Wipe up any hydraulic fluid spillage in, on, near and
assemblies from left to right are the outrigger (left), around the machine and the work area.
outrigger (right), frame sway, auxiliary, tilt, crowd (boom 10. Support the valve and remove the four bolts securing
in/out), and lift sections. the main control valve bracket to the frame.
All the main control valve functions are electronically 11. Remove the main control valve and bracket from the
controlled through the joystick. frame and remove the four bolts holding the
mounting bracket to the valve.
a. Main Control Valve Removal

MZ1340

8.10 4017
 Hydraulic System

Handle used to bleed off excess pressure in each

valve section. A 9mm wrench can also be used.
Left Outrigger

Right Outrigger

Frame Sway

Auxiliary

Bleed-off Handle is
clamped to this shaft

Tilt

Crowd

Lift

MZ0320

4017 8.11
 Hydraulic System
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 assemblies from left to right are the end
section, outrigger (left), outrigger (right), frame sway,
auxiliary, tilt, extend/retract, inlet, lift and load sense
sections.
1
MZ0310
1. To disassemble the individual sections of the main
control valve, remove the nuts from one end of the
tie rods. Pull the tie rods (1) out through the sections.
2. Disassemble each section assembly as required.
Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
IMPORTANT: DO NOT adjust any of the relief valve
assemblies! Tampering with a relief valve will irrevocably
alter pressure in the affected circuit, requiring recalibration
or a new relief valve.
Disassemble each Valve Section
1. Carefully separate the load sense outlet section from the
lift/lower section.
2. Remove the o-rings from between the two sections.
3. Carefully separate each remaining sections, being
careful not to lose the load sense shuttle ball.
4. Remove both end caps from each end of the valve
sections then remove each control spool.
5. Remove any check valves, compensator valves,
anti-cavitation valves or shock valves from individual
valve section if equipped.
6. Keep all parts being removed from individual valve
sections tagged and kept together.
8.12
c. Main Control Valve Parts Cleaning
Clean all components with a suitable cleaner, such as
triclorethylene, before continuing. Blow dry.
d. Main Control Valve Parts Inspection
Inspect all parts and internal passageways for wear,
damage, etc. If inner surfaces of any component DO NOT
display an ultra-smooth, polished finish, or are damaged
in any way, replace the damaged part. Often, dirty
hydraulic fluid causes failure of internal seals, damage to
the polished surfaces within the component, and wear of
and/or harm to other parts.
e. Main Control Valve Assembly
This section covers the assembly of the individual
sections of the main control valve.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
Assemble each Valve Section
1. Reassemble any check valves, compensator valves,
anti-cavitation valves or shock valves from each
individual valve sections if equipped.
2. Install the control spool being careful not to nick or
scratch the valve section bore or the control spool.
3. Install the end caps on each end of the valve section.
Assemble the Main Control Valve.
1. Place all three tie rods with the washers and nuts
through the end main control valve section.
2. Stand the end main control valve section on end.
3. Install the proper o-rings and load sense shuttle on
the inner face of the end main control valve section.
Align the left outrigger control valve section over the
three tie rods and slide onto the end main control
valve section.
4. Using the proper o-rings and load sense shuttle,
repeat step three for the right outrigger control valve
section, the frame sway valve section, the auxiliary
valve section, the tilt valve section, the extend/retract
valve section, the inlet/outlet valve section, the raise/
lower valve section and last the inlet end valve
section.
5. Install the three washers and nuts on the tie rods
and torque to 22 Nm (195 lb-in).
4017

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 main control valve. Slide the main control
valve into position, and tighten all bolts.
3. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a
clean container, before attaching the hoses.
4. Use new oiled o-rings as required. Uncap and
connect all hoses, clamps, etc. to the main control
valve.
5. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all tube and hose
clamps.
6. Connect the positive (+) and negative (-) battery
cables to the battery terminals and remove the
battery.
7. Start the engine and run at approximately one-third
to one-half throttle for about one minute without
moving the machine or operating any hydraulic
functions.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
9. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
10. Close and secure engine cover.
g. Main Control Valve Test
Conduct a pressure check of the hydraulic system in its
entirety. Adjust pressure(s) as required. Refer to Section
8.4.1, “Hydraulic Pressures.”
4017
Hydraulic System
8.7.2 Service Brake Valve
The service brake valve (2) is secured with four
capscrews and lockwashers at the lower left dash.
The service brakes themselves are part of the axles (the park
brake is part of the front axle only). Refer to Section 5.3, “Axle
Assemblies,” for further information.
2
MZ0330
a. Service Brake Valve Removal
1. Park the machine on a firm, level surface, lower
boom, place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the system fluids to
cool.
4. Remove the lower dash panel.
5. Label or otherwise mark the hydraulic hoses on the
side of the service brake valve. Disconnect and cap
all hoses, fittings, etc.
6. Disconnect the pin holding the yoke to the brake
pedal arm.
7. Remove the four capscrews, four nuts and four
lockwashers mounting the service brake valve to the
steering column support.
Note: DO NOT disassemble the service brake valve.
The service brake valve is not serviceable and must be
replaced in its entirety, if defective.
8.13
 Hydraulic System

b. Service Brake Valve Installation 3. DO NOT open the brake bleeder without holding the
tubing firmly on the bleeder. There is pressure at the
1. Install the service brake valve with the four
brakes. Carefully open the bleeder with a 12 mm
lockwashers and four capscrews to mount the brake
wrench. Have the assistant depress the brake pedal.
valve to the steering column support.
Close the brake bleeder when air bubbles no longer
2. Align the yoke on the brake valve with the brake appear in the oil. Release the brake pedal. Remove
pedal arm. Insert the pin and clip into place being the tubing from the brake bleeder.
sure there is a small amount of play between the
4. Repeat Steps 2 and 3 for the right front brake.
pedal and the plunger.
5. Repeat Steps 2,3 and 4 for the rear axle brakes.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and 6. Install a vacuum pump on the brake reservoir and
operation. Lubricate seals and o-rings with clean remove the remainder of the trapped air from the
hydraulic oil. brake system.
7. Check brake fluid level and add if necessary using
3. Use new oiled o-rings as required. Uncap and
ATF fluid.
reattach and secure all valves, hoses, clamps, etc.
8. Conduct a pressure and function check of the
4. Check the routing of all hoses, and tubing for sharp
service brake. Refer to Section 8.4.1, “Hydraulic
bends or interference with any rotating members,
Pressures.”
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.
8.7.3 Park Brake Valve
5. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without The park brake valve (1) is secured with two capscrews
moving the machine or operating any hydraulic and lockwashers at the left side of the seat base.
functions. The park brake is part of the front axle only. Refer to Section
6. Inspect the service brake valve and connections for 5.3, “Axle Assemblies,” for further information.
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8. Close and secure the engine cover.
c. Brake Test
Carefully bleed the brake lines as soon as the brake valve
1
is installed in the machine. Air in the system will not allow
the brakes to apply properly. There are four brake
bleeder locations on the front axle. The outside bleeders MZ0350

are for the park brake, the inside bleeders are for the
service brakes. There are two service brake bleeders on
the rear axle. Work with an assistant to perform this
procedure.
1. Place the transmission control lever in (N)
NEUTRAL, engage the park brake, and start the
engine.
2. Remove the plastic cap from the left front brake
bleeder. Attach one end of a length of transparent
tubing over the brake bleeder. Place the other end of
this tubing in a suitable transparent container that is
partially filled with hydraulic oil. The end of the tubing
must be below the oil level in the container.
a. Park Brake Removal
1. Park the machine on a firm, level surface, lower
boom, place the transmission control lever in (N)
NEUTRAL, engage the park brake and shut the
engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine cover. Allow the hydraulic fluid to
cool.
4. Loosen and remove the three bolts and washers
holding the park brake valve cover. Remove the
cover.

8.14 4017

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 disassemble the park brake valve. The
park brake valve is not serviceable and must be replaced
in its entirety, if defective.
b. Park Brake Valve Installation
1. Install the park brake valve with the two lockwashers
and two capscrews to mount the park brake valve to
the left side of the seat base.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
2. Use new oiled o-rings as required. Uncap and
reattach and secure the three hoses.
3. Check the routing of all hoses for sharp bends or
interference with any rotating members, and install
tie wraps and/or protective conduit as required.
4. Start the engine and run at approximately one-third
to one-half throttle for about one minute, without
moving the machine or operating any hydraulic
functions.
5. Inspect the park brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8.7.4 Steering Orbitrol Valve
The steering orbitrol valve (2) is located at the base of the
steering wheel shaft, concealed by the lower dash cover.
The valve is not serviceable and must be replaced in its
entirety if defective. For detailed information refer to
Section 4.3.1, “Steering Column and Orbitrol Valve.”
2
MZ0370
4017
Hydraulic System
8.7.5 Steer Select Valve
The machine can be used in the front-wheel, four-wheel
or crab steering mode. The steer select valve (3) controls
the direction of hydraulic fluid flow to the steering cylinder
mounted on each axle. The steer select valve is attached
to a mounting plate inside the frame near the left front
corner of the cab.
3
MZ0380
Verify the correct operation of the steer select valve
solenoids before considering replacement of the valve.
Refer to Section 9.5, “Electrical System Schematics,” and
Section 9.12.1, “Digital Display "Main Screen".” The
housing of the steer select valve is not serviceable and
must be replaced if defective.
a. Steer Select Manifold and Valve Removal
1. Park the machine on a firm, level surface, fully
retract the boom, raise the boom, place the
transmission control lever in (N) NEUTRAL, engage
the park brake and shut the engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
WARNING: DO NOT get under a raised
boom unless the boom is blocked up. Always
block the boom before doing any servicing that
requires the boom to be up. Unexpected lowering
of the boom may cause death or serious injury.
3. Open the engine cover. Allow the system fluids to
cool.
8.15
 Hydraulic System
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 frame.
6. Remove the steer select manifold with the attached
steer select valve from the machine. Wipe up any
hydraulic fluid spillage in, on, near and around the
machine.
b. Steer Select Manifold and Valve Disassembly,
Cleaning, Inspection and Assembly
1. Place the steer select assembly on a suitable work
surface.
2. Separate the steer select valve from the manifold by
removing the four socket head capscrews. Discard
the four o-rings.
3. Remove the solenoid valves and cartridges from the
steer select housing.
4. Clean all components with a suitable cleaner before
inspection.
5. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination.
6. Inspect internal passageways of the steer select
manifold and valve for wear, damage, etc. If inner
surfaces of the manifold DO NOT display an ultra-
smooth, polished finish, or components are
damaged in any way, replace the manifold or
appropriate part. Often, dirty hydraulic fluid causes
failure of internal seals and damage to the polished
surfaces within the secondary function manifold.
Note: ALWAYS replace seals, o-rings, gaskets, etc.,
with new parts to help ensure proper sealing and
operation. Lubricate seals and o-rings with clean
hydraulic oil.
7. Install the solenoid valves and cartridges in the steer
select housing.
8. Attach the steer select valve to the manifold using
four new, oiled o-rings and the four socket head
capscrews.
c. Steer Select Valve and Manifold Installation
1. Install the steer select valve to the mounting plate
under the left front side of the frame using the two
bolts.
8.16
2. Uncap and reattach all the hydraulic hoses, fittings,
solenoid wire terminal leads, etc., to the steer select
valve
3. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating
members, and install tie wraps and/or protective
conduit as required. Tighten all hose clamps.
4. Start the engine and run at approximately 1/3-1/2
throttle for about one minute without moving the
machine or operating any hydraulic functions.
5. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
6. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
d. Steering Test
Refer to Section 8.4.1, “Hydraulic Pressures.”
1. Conduct a pressure check of the steering hydraulic
circuit.
2. Check each steering mode for proper function.
8.8 HYDRAULIC CYLINDERS
8.8.1 General Cylinder Removal
Instructions
1. Remove any attachment from the machine. Park the
machine on a firm level surface and fully retract the
boom. Allow sufficient work space around the
hydraulic cylinder being removed. Support the boom
if the lift/lower cylinder is being removed. Place the
transmission control lever in (N) NEUTRAL, engage
the park brake, shut the engine OFF and chock
wheels.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
WARNING: DO NOT get under a raised
boom unless the boom is blocked up. Always
block the boom before doing any servicing that
requires the boom to be up. Unexpected lowering
of the boom may cause death or serious injury.
3. Open the engine cover. Allow the system fluids to
cool.
4. Label, disconnect and cap or plug hydraulic hoses
and cylinder ports in relation to the cylinder.
4017

MZ0400
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. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
a. General Cylinder Disassembly
1. Clean the cylinder with a suitable cleaner before
disassembly. Remove all dirt, debris and grease
from the cylinder.
2. Clamp the barrel end of the cylinder in a soft-jawed
vise or other acceptable holding equipment if
possible.
WARNING: Significant pressure may be
trapped inside the cylinder. Exercise caution when
removing a counterbalance valve or a pilot-
operated check valve from a cylinder. Escaping
hydraulic fluid under pressure can penetrate the
skin, causing death or serious injury.
IMPORTANT: Avoid using excessive force when
clamping the cylinder in a vise. Apply only enough force
to hold the cylinder securely. Excessive force can
damage the cylinder tube.
3. If applicable, remove the counterbalance valve from
the side of the cylinder barrel.
IMPORTANT: DO NOT tamper with or attempt to adjust
the counterbalance valve cartridge. If adjustment or
replacement is necessary, replace the counterbalance
valve with a new part.
4. Extend the rod as required to allow access to the
base of the cylinder.
4017
Hydraulic System
IMPORTANT: Protect the finish of the rod at all times.
Damage to the surface of the rod can cause seal failure.
5. Using a pin spanner wrench, unscrew the head
gland from the tube. A considerable amount of force
will be needed to remove the head gland. Carefully
slide the head gland down along the rod toward the
rod eye, away from the cylinder barrel.
IMPORTANT: When sliding the rod and piston assembly
out of the barrel, prevent the threaded end of the barrel
from damaging the piston. Keep the rod centered within
the barrel to help prevent binding.
6. Carefully pull the rod assembly along with the head
gland out of the cylinder barrel.
7. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
8. Remove the set screw from the piston head.
Note: It may be necessary to apply heat to break the
bond of the sealant between the piston and the rod
before the piston can be removed.
Some cylinder parts are sealed with a special organic
sealant and locking compound. Before attempting to
disassemble these parts, remove any accessible seals
from the area of the bonded parts. Wipe off any hydraulic
oil, then heat the part(s) uniformly to break the bond. A
temperature of 149-204° C (300-400° F) will destroy the
bond. Avoid overheating, or the parts may become
distorted or damaged. Apply sufficient torque for removal
while the parts are still hot. The sealant often leaves a
white, powdery residue on threads and other parts, which
must be removed by brushing with a soft brass wire brush
prior to reassembly.
9. Remove the piston head from the rod and carefully
slide the head gland off the end of the rod.
10. Remove all seals, back-up rings and o-rings from the
piston head and all seals, back-up rings and o-rings
from the head gland.
Note: The head gland bearing will need to be inspected
to determine if replacement is necessary.
DO NOT attempt to salvage cylinder seals, sealing rings
or o-rings. ALWAYS use a new, complete seal kit when
rebuilding hydraulic components. Consult the parts
catalog for ordering information.
8.17
 Hydraulic System
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, grooves, threads, etc.
Note: If a white powdery residue is present on threads
or parts, it can be removed by using a soft brass wire
brush. Wipe clean with Loctite Cleaner prior to
reassembly.
c. Cylinder Inspection
1. Inspect internal surfaces and all parts for wear,
damage, etc. If the inner surface of the cylinder
barrel does not display a smooth finish, or is scored
or damaged in any way, replace the barrel.
2. Remove light scratches on the piston, head gland,
rod or inner surface of the cylinder barrel with a 400-
600 grit emery cloth. Use the emery cloth in a rotary
motion to polish out and blend the scratch(es) into
the surrounding surface.
3. Check the piston rod assembly for run-out. If the rod
is bent, it must be replaced.
d. General Cylinder Assembly Instructions
1. Use the proper tools for specific installation tasks.
Clean tools are required for installation.
2. Install new seals, back-up rings and o-rings on the
piston and new seals, back-up rings, o-rings and
bearing on the head gland.
Note: The extend/retract cylinder has a spacer that
MUST be installed over the rod AFTER the head gland
and BEFORE the piston head.
3. Fasten the rod eye in a soft-jawed vise, and place a
padded support under and near the threaded end of
the rod to prevent any damage to the rod.
IMPORTANT: Protect the finish on the cylinder rod at all
times. Damage to the surface of the rod can cause seal
failure.
4. Lubricate and slide the head gland over the cylinder
rod. Install the piston head on to the end of the
cylinder rod. Loctite and install the set screw in the
piston head. Refer to Section , “,” for torque
specifications for the piston head and the set screw.
8.18
IMPORTANT: Avoid using excess force when clamping
the cylinder barrel in a vise. Apply only enough force to
hold the cylinder barrel securely. Excessive force can
damage the cylinder barrel.
5. Place the cylinder barrel in a soft-jawed vise or other
acceptable holding devise.
IMPORTANT: When sliding the rod and piston assembly
into the cylinder barrel, prevent the threaded end of the
cylinder barrel from damaging the piston head. Keep the
cylinder rod centered within the barrel to prevent binding.
6. Carefully insert the cylinder rod assembly into the
cylinder barrel.
7. Screw the head gland into the cylinder barrel and
tighten with a spanner wrench. Refer to Section
8.8.4, “Cylinder Torque Specifications,” for torque
specifications for the head gland.
8. If applicable, install new counter balance valve into
block on the cylinder barrel.
e. General Cylinder Installation
1. Grease the bushings at the ends of the hydraulic
cylinder. Using an appropriate sling, lift the cylinder
into it’s mounting position.
2. Align cylinder bushing and install pin, lock bolt or
retaining clip.
3. Connect the hydraulic hoses in relation to the labels
or markings made during removal.
4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full
mark with Mobilfluid 424® ISO Grade 46.
5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
both directions allowing cylinder to fill with hydraulic
oil.
6. Inspect for leaks and check level of hydraulic fluid in
reservoir. Add hydraulic fluid if needed. Shut the
engine OFF.
7. Wipe up any hydraulic fluid spillage in, on, near and
around the machine, work area and tools.
8.8.2 Cylinder Pressure Checking
Attach a 345 bar (5000 psi) gauge to the test port on the
main control valve to check the system pressure. Refer to
Section 8.4.1, “Hydraulic Pressures,” for the circuit
pressure setting.
Note: If a hydraulic cylinder pressure is greater than the
main control valve pressure, increase the main control
valve pressure by adjusting the main relief. Generally,
one half turn clockwise will be adequate to check an
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 steer cylinder is covered in the appropriate
manufacturer’s axle literature

Axle Center Section

8.8.4 Cylinder Torque Specifications

Description Piston Head Cylinder Gland

Lift Cylinder 2490-2540 Nm (1837-1873 lb-ft) 950-1000 Nm (700-738 lb-ft)
Extend/Retract 2160-2210 Nm (1593-1630 lb-ft) 625-675 Nm (461-498 lb-ft)
Cylinder
Tilt Cylinder 2850-2900 Nm (2102-2139 lb-ft) 775-825 Nm (572-608 lb-ft)
Compensation 850-900 Nm (627-664 lb-ft) 380-430 Nm (280-317 lb-ft)
Cylinder
Sway Cylinder 1050-1100 Nm (774-811 lb-ft) 400-450 Nm (295-332 lb-ft)
Outrigger Cylinder 1300-1350 Nm (959-996 lb-ft) 625-675 Nm (461-498 lb-ft)

Note: All set screws for the piston heads are torqued to 20-25 Nm (177-221 lb-in) using Loctite 648®.
Note: All cylinder glands are torqued using DELO ML® 5249.
Note: All bearings in the cylinder glands use Loctite 648®.

4017 8.19
 Hydraulic System

8.20 4017
 Section 9
Electrical System

Contents

PARAGRAPH TITLE PAGE

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.1.1 General Overview (Cab Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9.2 Service Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.2.1 Electronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4.1 Fuse and Relay Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
9.4.2 Connector Legend, Relays & Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
9.4.3 Fuse and Relay Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5.1 Cab Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
9.5.2 Engine Harness Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
9.5.3 Printed Circuit Board Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 9.9
9.5.4 ESX Harness and Options Electrical Schematic. . . . . . . . . . . . . . . . . . . . 9.10
9.5.5 Front & Rear Chassis Harness Electrical Schematic . . . . . . . . . . . . . . . . 9.11
9.6 Circuit Breakdowns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.6.1 Constant Power Circuit from Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
9.6.2 Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
9.6.3 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
9.8 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.8.1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
9.9 Window Wiper/Washer Windshield Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
9.9.1 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.9.2 Rear Wiper/Rear Window Washer Switch. . . . . . . . . . . . . . . . . . . . . . . . . 9.18
9.9.3 Windshield/Rear Window Washer Reservoir and Pump . . . . . . . . . . . . . . 9.19
9.10 Cab Heater and Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
9.10.1 Cab Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19

4017 9.1
 Electrical System

9.11 Solenoids and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

9.11.1 Fuel Shut-off Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
9.11.2 Main Control Valve Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.11.3 Transmission Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9.11.4 Transmission Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.11.5 Transmission Mounted Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
9.11.7 Engine Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.11.8 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9.11.9 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
9.11.10 Load Moment Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.11.11 Load Moment Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
9.11.12 Front and Rear Axle Proximity Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.12 Display Monitor and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.12.1 Digital Display "Main Screen" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.12.2 Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9.13 Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.14 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.14.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.14.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
9.15 Transmission Control Lever / Accessory Control Lever . . . . . . . . . . . . . . . . . . . 9.29
9.15.1 Control Lever Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29

9.2 4017
 Electrical System

9.1 ELECTRICAL 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 electrical components of the machine. The
following illustration identifies the components that are
referred to throughout this section.

9.1.1 General Overview (Cab Harness)

(X03) (X04)
(X02)
(X10) (X189)
(X05) (M08)

(X08)
(X22)
(X07)
(X18) (S04)

(X16)
ESX (X06)

(X23) (X17)
(X15)
(X19) (X24)
(X16.1)
(X07) (A03)
(H02)
(H01)

(H04) (S11)

(S03) (X20)

(S01) (S12)
(S14) (S02)
(S30)

(X06)

(A7.1)
P01 (A7.2)
P02
C

80 100
(A01)
0 4/4
40 120

(M03) (S07)
(X27)

(M02)
(X11)

(X13)
X12/X13
(X01)
X10/X16/X22 X11 (X12)

X01

A01------------- ESX
A03------------- DISPLAY S12------------- SWITCH HEATER FAN, (in UNIT FOR HEAT ONLY; in AIR CONDITIONING UNIT INSTALLATION)
A7.1, 7.2------ LMI S14------------- SWITCH WARNING BEACON
H01------------- HIGH BEAM PILOT LIGHT S15------------- SWITCH 2.AUXILIARY HYDRAULIC, (in 2. AUXILIARY HYDRAULIC KIT)}
H02------------- DIRECTION INDICATOR PILOT LIGHT S17------------- SWITCH AUXILIARY HYDRAULIC CONTINUOUS OPERATION, (in 1. AUXILIARY HYDRAULIC KIT)
H03------------- INDICATOR PILOT LIGHT TRAILER, (In HYDRAULIC HITCH KIT) S18------------- SWITCH LEVELING
H04------------- CHARGING WARNING LIGHT) S27------------- SWITCH WORK FLASHER BOOM (in WORKLIGHT BOOM KIT)
M02-------------HEATER FAN, (in UNIT FOR HEAT ONLY; in AIR CONDITIONING UNIT INSTALLATION) S30------------- SWITCH AIR CONDITIONING (in AIR CONDITIONING KIT)
M03-------------WIPER FRONT X01------------- POWER SUPPLY
M08-------------AIR SUSPENSION SEAT OPTION X02-04--------- CABLE INSTRUMENT PANEL
P01------------- TEMPERATURE DISPLAY ENGINE X05-08--------- CABLE STEAR COLUMN CABIN BOTTOM
P02------------- FUEL GAUGE X10,16, 16.1,22--CABLE FRONT END GEAR UNIT
S01------------- SWITCH IGNITION X11------------- CABLE ENGINE
S02------------- WARNING FLASHER SWITCH X12, 13-------- CABLE REAR
S03------------- DRIVING LIGHTS SWITCH X15------------- JOYSTICK
S04------------- SIGNAL and WIPER CONTROL X16.1, 17-19- CABLE ESX
S07------------- SWITCH PARKING BRAKE X20------------- 12V POWER OUTLET IN CABIN
S09------------- SWITCH WORK LIGHTS FRONT, (in WORK LIGHT FRONT KIT) X23, 24-------- CABLE FNR GEAR SHIFT CONTROL
S10------------- SWITCH WORK LIGHTS REAR, (in WORK LIGHTS REAR KIT) X27------------- LEFT DRIVING LIGHT MZ0510
S11------------- SWITCH WIPER REAR X189----------- AIR CONDITIONING OPTION

4017 9.3
 Electrical System

9.2 SERVICE WARNINGS 9.4 FUSES AND RELAYS

9.2.1 Electronics 9.4.1 Fuse and Relay Locations

CAUTION: When doing welding a. Cab

anywhere on the machine disconnect the wire
harness from the ESX Control Module
mounted under the operators seat and
disconnect both cables from the battery and
clamp both cables together.
For access to the fuse and relay panel, remove the four
screws securing the right side console access panel to
the cab. The fuses and sealed 12-volt relays are mounted
under the right side console access panel. The fuse and
relay panels are part of the cab harness.

ESX Control Module

Fuse Cover

MZ0520 MZ1070

9.3 SPECIFICATIONS b. Engine Compartment

Electrical system specifications are listed in Section 2,
“General Information and Specifications.”
The fuse and relay bar is located on the frame directly
above the engine. To remove the relays from inside the
engine compartment, remove the mounting screws and
washers. When re-installing the relays torque the
mounting hardware to 7 - 12,5 Nm (62 - 110 lb -in).

Lift Pump & Glow Plug

Fuses

Lift Pump
Relay
(Included W/
Cable) Starter Relay

Glow Plug
Relay MZ0540

9.4 4017
 Electrical System

9.4.2 Connector Legend, Relays & Fuses Fuses

No. Amp Type
Connector Legend F1 15A Rear Work Lights
No. Type F2 15A Cab Heater
X1 PCB Power & GND Harness F3 7.5A Left Headlight - Low
F4 7.5A Right Headlight - Low
X2 Instrument Panel Harness
F5 7.5A Left Headlight - High
X3 Instrument Panel Harness
F6 7.5A Right Headlight - High
X4 Instrument Panel Harness F7 7.5A Left Tail & Side Lights
X5 Cab Harness F8 7.5A Right Tail & Side Lights, Display
X6 Cab Harness F9 15A Auxiliary Power Socket
X7 Cab Harness F10 15A Battery Indicator Light
X8 Cab Harness F11 25A ESX Battery
F12 30A Key Switch
X9 Worklight, Radio, Rear Wiper Harness
F13 15A Spare
X10 Front Chassis Harness F14 10A Brake Lights, Cold Start, Beacon
X11 Engine Harness F15 15A Ignition
X12 Rear Chassis Harness F16 20A Rear Wiper
X13 Rear Chassis Harness F17 20A Front Wiper
X14 Optional Trailer(ing) Harness F18 15A Front Work Lights
F19 15A Boom Work Lights
X15 Joystick Connector
F20 Not Used
X16 Front Chassis Harness
F21 25A Air Conditioning
X17 ESX Harness F22 5A Radio
X18 ESX Harness F23 10A Transmission
X19 ESX Harness F24 7.5A ESX Ignition & Sensors
X21 CAN Diagnostic Connector
X22 Front Chassis Harness
X23 F-N-R & Gear Shifter Harness
X25 RS232 Diagnostic Connector
X26 Tilt Sensor - Not Used

Relays
K1 Key (Power) Relay
K2 Start Interlock Relay
K3 Flasher
K4 Wiper Relay
K5 Work Light Relay
K6 Fuel Solenoid Relay

Engine Compartment Relays & Fuse

Lift Pump Relay
Glow Plug Relay
Starter Relay
Lift Pump & Glow Plug Fuses

4017 9.5
 Electrical System

X26
K2
START X2 X3 X4 X5
INTERLOCK
RELAY
F01
F02
K1
KEY F03
(POWER) F04
RELAY X6 X7 X8
F05
F06
K3
F07 FLASHER
F08
F09
F10
F11
X9 X11 X10
F12
F13
F14 K4
F15 WIPER
F16 RELAY
K5 F17
WORK X12 X13 X14
F18
LIGHTS
RELAY F19
F20
F21
F22 K6
F23 FUEL X17
SOLENOID X16 X18
F24 RELAY

X1

X21 X15 X19 X22 X23

X25

MZ0550

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 Section 9.4.1,
“Fuse and Relay Locations,”for locations of fuses and
relays) from the fuse and relay panel by pulling the fuse
or relay straight out and away. ALWAYS install the
correct amp rated fuse or relay.

b. Engine Compartment Relay Replacement

Label and disconnect the wire leads and remove the bolts
holding the relay to the bracket. ALWAYS install the
correct amp rated relay.

c. After Fuse or Relay Service

Connect the negative (-) battery cable to the negative (-)
battery terminal.

9.6 4017
 9.7
Electrical System

CABIN
HEATER FAN SWITCH HI BEAM FLASHER TRAILER? ALTERNATOR DRIVING LIGHTS FRT WORK LIGHTS REAR WORK LIGHTS REAR WIPER BEACON LIGHT CHASSIS SWAY BOOM LIGHTS RESERVED AUX HYD SELECT CONT AUX HYD
SEE SHEET 2 FOR OPT WIRING INDICATOR INDICATOR INDICATOR INDICATOR SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH (OPT) SWITCH (OPT)

MZ1090
1 2 1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
M H
3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4 3 4
L B
5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6
C
7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8
9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10
GND

GND
136M

136H
136L

56A
136

160

160

GND
83

84

61

56

173

139
140

GND

GND

GND

GND

GND

GND
58

58

145

144

135
135

180

182
GND

GND

GND

58

58
156A

157A

159A
160

156

157

172
173
58

58

58
VCC
F1
F2
PWR JOYSTICK
GND

170/171
CAN H
CAN L
185 1 LOAD CELL
186 2 LOAD CELL
58
LOAD MOMENT
FUEL G
116 181 1 SGN OUT INDICATOR
LEVEL 160 184
GAGE + 2 IGN
-
GND GND 3 GND
EMPTY 4
58
COOLANT G
110
TEMP 160
GAGE +
-
GND R R
30 30
L L
300 (BAT) 49
AUX 1 49
POWER 2
GND 49 30B
HAZARD
SOCKET 49A 49A
SWITCH
15 15
58 58
GND 31
GND
M8 GROUND
STUDS ON
CAB FIREWALL GND 71A 1 HORN
158 2
56 3 DIMMER
56B
AIR RIDE 189 4 LO HI FLASH
1 56A
SEAT M 2
GND
123
5
(OPT) 6
EMPTY 7
WASH
TURN SIGNAL
53 1
AND WIPER
BRAKE LTS/ 5 BAR 54 L LEVER
ELECTRICAL SYSTEM SCHEMATICS

2
DECLUTCH 54A R TURN WIPER
PRESSURE 3
SWITCH EMPTY 4 L R L H
49
136H 5
1 160
GND 6
2 53A
HEATER M 3
136M 7
Cab Harness Electrical Schematic

BLOWER MOTOR 136L

4
30 BAT
GND 30
1 30 BAT
EMPTY 30
2 15 IGN
FRONT
WIPER MOTOR
M 3
53
15
15
IGN
0
1
2
53A 15 3 KEY
4 19 HEAT
31B (BAT) 19 SWITCH
5 19 19
HEAT 0
1
19 17
HEAT 2
3
50 50A
STRT
PARK BRAKE 1
115
SWITCH 2
GND
OFF ON
GND 1
N
CAN L 2
R F
1 CAN H 3
DISPLAY
2 152 (PWR)
FNR/GEAR SHIFTER

4
3
1 4
EMPTY
2
3 5
4
1
6
2 7
3
4 8 EMPTY LOW
1
56BL 2
56AL 3 HIGH LEFT
58LV FRONT
EMPTY 4 DRIVING
1 LV LIGHT
EMPTY 5 SIDE
2 GND
3
EMPTY 6
4 143 TURN
5
FNR/GEAR SHIFTER HARNESS 6

EMPTY
EMPTY

EMPTY

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY
EMPTY

EMPTY
EMPTY
CAN H
7

CAN L
GND

136M

136M
136H

136H
56AL
56BL

156A

157A

159A
58LV
136L

136L
49A

53A

71A

56A
56B

54A

53A
31B

56A
EMPTY

189

152

160

123

158

189

156

157

136
170
171
172
173

139
140

143
144
145
135
135

160

184
180
181
182

176
176

300
185
186
115

110
116
LV
30
30
30
15
15
15
19
19
50

30

49

15
58

49

53

56

54

53

56
58

83
84
61

58
R

R
L

L
8
TO PCB 9
EMPTY
X23
10
11
EMPTY
12
EMPTY
13
14 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6
15
EMPTY
EMPTY CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS CAB HARNESS INST PANEL HARNESS INST PANEL HARNESS INST PANEL HARNESS JOYSTICK
16 X5 X6 X7 X8 X2 X3 X4 X15
17
EMPTY
EMPTY TO A/C OPT
9.5.1 18 HARNESS TO PCB

4017
9.5
 Electrical System

9.5.2 Engine Harness Electrical Schematic

TO CAB ASSEMBLY
TO PCB TO PCB
X11 X1
POSITIVE CABLE
ENGINE HARNESS M8 GROUND STUD(S) PCB PWR AND GND HARNESS
TO BATTERY +
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ON CAB FIREWALL 1 2 3 4 5 6 7 8 9 10

NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -

(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(RED-PWR)
(BRN-GND)
(BRN-GND)
(BRN-GND)
(BRN-GND)
EMPTY

EMPTY

EMPTY
EMPTY

GND

GND
GND
GND
GND
123

120

159
110

112
114
118

113
111

61

50
76
90
19

50mm BLK

50mm RED STARTER

(RED-PWR)
(RED-PWR)
(RED-PWR) M
(RED-PWR)
(RED-PWR)
(RED-PWR)
30A
30A
30C
30B
50A

30B 30
50A 87 STARTER
50 86 RELAY
GND 85

30A ALTERNATOR
30A B+
113 W G
61 D+

111 ENGINE OIL

PRESSURE
SWITCH

110
CLT TEMP
SENDER
112 110 C COOLANT
TEMP
SWITCH

90 COLD START
TEMP
SWITCH

118 3 BAR HYD FILTER

GND PRESSURE
SWITCH

76 76
1 1 FUEL (NON TURBO HAS SINGLE
GND GND
2 2 SOLENOID CONNECTION, NO GND)

114 AIR FILTER

GND RESTRICTION
SWITCH

120 TRANSMISSION
OIL TEMP
30C SWITCH
501A
501A GLOWPLUGS
7.5 50 FUSE
501 SLO-BLO 50A
502 LIFT PUMP
FUSE
ATO 7.5A
502 30
503 87 GLOWPLUGS
19 86 RELAY
GND 85

503 1 ENGINE
GLOWPLUGS

500 1 LIFT
GND 2 M PUMP

EMPTY 4 87a
501 3 30
500 5 87 LIFT PUMP
76 1 86
RELAY
GND 2 85

123 FRONT
GND M W/WASHER
PUMP

REAR
159 W/WASHER
GND M PUMP
(OPT) MZ1120

9.8 4017
 9.9
Electrical System

TO REAR CHASSIS HARNESS TO FNR SHIFTER TO CAB HARNESS (DISPLAY) TO CAB HARNESS TO CAB HARNESS TO CAB HARNESS TO INST PANEL HARNESS TO INST PANEL HARNESS TO INST PANEL HARNESS TO JOYSTICK TO OPTIONS HARNESS
X12 X23 X5 X6 X7 X8 X2 X3 X4 X15 X9 D7 R7 1.8K
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10

MZ1110
D8 R8 8.2K
D9 R9 8.2K
CANH

CANH
PWR
CANL

CANL
GND

GND
58RH

54RH

136M

136M
58LH

54LH

174R

136H

136H
56AL
56BL

156A

157A

159A
58LV

NM
NM
174L

136L

136L
RH

MT
MT
MT

MT
MT

MT
MT

MT
MT
MT
MT

MT
MT

MT

MT
MT
MT
MT
MT

MT

MT

MT

MT

MT

MT

MT

MT
MT

MT
MT
49A

53A

71A

56A
56B

54A

53A
31B

56A
124

152

160

123

158

189

156

157

136
170
171
172
173

139
140

143
144
145
135
135

160

184
180
181
182

176
176

300
185
186

155
301
171
172
173
131
132
134
133
140
FW-P2
LH

116

115

110
116
LV
12V-P8

12V-P1

30
30
30
15
15
15
19
19
50

30

49

15
58

49

53

56

54

53

56
58

83
84
61

58
RV-P3

R
L

L
HI-P5
1-P7
2-P6

R10 2.2K
GND 1
163 2
114 3
161 4
X17/5 5
164 6
1 MT 118
MT 7
2 MT 8
163 120

TO ESX HARNESS
3 9
4 164 112
MT 10
TO REAR CHASSIS HARNESS

5 145 11
MT

X17
6 MT 12
7 218 MT
MT 13
8 MT 14
9 169 MT 15
X13

10 119 115
177 16
11 MT 17
MT
12 146 18
135
13 MT 19
185
14 61 20
186
15 111 21
300
16 MT 22
MT
17 MT
18
MT 1
MT 2
1 MT
167
TO FRT CHASSIS HARNESS TO FRT CHASSIS HARNESS

MT 3
2 169
MT 4
3 143
MT 5
4 144
MT 6
5 113
X16

MT 7
6 166
216 8
7 MT

TO ESX HARNESS
217 9
8 130
122 10
9 122
MT 11

X18
10 58 12
54A 13
MT 14
1 179
19 15
2 178
CAN LOW 16
3 126
CAN HIGH 17
4 127
RXD 18
5 129
TXD
X22

130 19
6 GND
128 20
7 GND
MT 21
8 GND
MT 22
9
10 MT
15
Printed Circuit Board Electrical Schematic

1
GND 2
1 MT
30 3
2 56BR
30 4
3 MT
30 5
4 56AR
30 6
5 MT
30
TO FRT CHASSIS HARNESS

58RV 7
6 30
MT 8
7 174

TO ESX HARNESS
RV 9
8 MT
167 10
9 217
X10

119 11

X19
10 MT
146 12
11 129/176
147 13
12 50
71A 14
13 216
MT 15
14 218
MT 16
15 MT
MT 17
16 181
MT 18
17 MT
MT 19
18 MT 20
50 21
GND 22
1 123
2 110
3 111
MT 1

CONNECTOR ON PCB
4
120 2

CAN DIAGNOSTIC
5
112 3
TO ENGINE HARNESS

6
114 4
7

X21
118 5
8
61 6
9
7
X11

10 113
MT 8
11
50 9
12
13 76
14 90
19 1

CONNECTOR ON PCB
15
19 2

RS232 DIAGNOSTIC
16
MT 3
17
159 4
18

X25
5
6
GROUND 7
TO GROUND AND BATTERY

1
8
2
9
3
4
5
+12 VDC
1
X1

TRAILER(ING) HARNESS
6
2
7
3

TO OPTIONAL
8 D1 4
9
R1 2.2K

R5 2.2K

R2 2.2K

R4 2.2K

R3 2.2K

R6 270

X14
5
10
6
7
8
9

15A
15A
7.5A
7.5A
7.5A
7.5A

15A
15A
25A
30A
15A
10A
15A
20A
20A
15A
15A
10A
25A

10A
10

7.5A
7.5A

7.5A
5A

R220 ohm
5 watt
F10

F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F11
F1
F2
F3
F4
F5
F6
F7
F8
F9
K1 K5 K2 K3 K4 K6

85
86
87
30

85
86
87
30

85
86
87
30

85
86
87
30

85
86
87
30
87a

87a

87a

87a

87a
X26

49a

C2
49

31
TILT SENSOR (NOT USED)
KEY (PWR) RLY WORK LTS RLY STRT INTLK RLY FLASHER WIPER RLY FUEL SOL RLY
9.5.3

4017
 4017
TO CAB HARNESS A/C SWITCH A/C FAN SWITCH
HEATER FAN SWITCH
(OPT) (OPT)
SEE SHEET 1 FOR STD WIRING M8 GROUND STUD(S)
A/C OPT HARNESS ON CAB FIREWALL

MZ1100
1 2 1 2
M H 3 4 3 4
L B 5 6 5 6
C 7 8 7 8
9 10 9 10
GND

GND
GND

GND

GND
189A

189A
189

189

189

191
189
190

191

ESX CONTROLLER
GND 68 GND XGND2
GND 67 GND XGND2
GND GND XGND1
GND 66
XGND1
85 GND 65 GND
A/C 207 DO/5
86 189A 64 RT O/R VLV (SAUER)
CLUTCH 218 DO(4A)/3
87 189 63 AUX HYD SELECT
RELAY 200 DO(4A)/2
30 189 62 PVG VLV PWR (SAUER)
(OPT) 208 LT O/R VLV (SAUER) DO(4A)/1
87a 61
30 12V Ub
30 60
Ub
189 59 12V
30 12V Ub
F25 30 58
12V Ub
IN-LINE 30 57
56 12V Ub
FUSE 7.5 GND GND
(OPT) 189 55 GND
30 54 12V Ue
A/C EMPTY 53 (UNUSED) +WIRE2
TEMP 1
189A EMPTY 52 (UNUSED) BB2/5
SWITCH 2
189A EMPTY 51 (UNUSED) BB2/4
(OPT) EMPTY 50 (UNUSED) BB2/3
204 49 AUX HYD VLV (SAUER) DO/4
A/C 203 TILT VLV (SAUER) DO/3
CHARGE 189A 48
1 202 TELE VLV (SAUER) DO/2
SWITCH 189A 47
2 201 46 LIFT VLV (SAUER) DO/1
(OPT) EMPTY (UNUSED) BB2/1
45
A/C 1
191 206 44 SWAY LEFT VLV (DO) BB1/5
FAN M 2
190 217 43 AW STEER VLV (DO) BB1/3
(OPT) 176 42 FWD/REV PWR (DO) BB1/1
54A 41 DCLUTCH PSI SW DI/15
111 40 ENG OIL PSI SW DI/13
A/C 143
ESX Harness and Options Electrical Schematic

(4 SECT TELE SW) DI/11

COMPRESSOR 189 39
167 38 FRT AXLE PROX DI/9
CLUTCH 145 SWAY LT SW DI/7
37
(OPT) 122 HYD PSI SW DI/5
36
129 35 NEUTRAL SW DI/3
113 34 ALT W SPEED (RPM) DI/1
EMPTY 33 (UNUSED) -WIRE2
SPEAKERS 114 32 AIR FILTER SW AI/8
(OPT) 181 31 LOAD MOMENT SW AI/6
118 30 HYD FILT PSI SW AI/4
120 29 TRANS TEMP SW AI/2
1 15 28 12V IGNITION D+
2 CAN HIGH 27 1. CAN HIGH +WIRE1
3 CAN LOW
155 (IGN) 26 1. CAN LOW -WIRE1
4 50 25 STRT INTLK RLY DO(2.5A)/3
RADIO 5 216
(OPT) 24 CRAB STEER VLV DO(2.5A)/1
6 163
155 (IGN) 23 8.5 V EXT SUPPLY 8.5VEXT
7 19
GND 22 ENG PREHEAT SW (DI) BB1/6
8 205 21 SWAY RIGHT VLV (DO) BB1/4
58
53A 171 (IGN) 20 (PARK LIGHT SW) (DI) BB1/2
1 146
31 GND 19 (O/R PSI) DI/16
2 61
REAR WIPER MOTOR
(OPT)
M 53 3
173
EMPTY
18 ALT D+ CHARGE DI/14
31B 172 17 (UNUSED) DI/12
4 115 16 PARK BRAKE SW DI/10
1
169 15 REAR AXLE PROX DI/8
2
GND 144 14 SWAY RT SW DI/6
INTERIOR DOME LIGHT 301 130
(OPT) 3 13 REVERSE SW DI/4
166 12 TURBINE SNSR (RPM) DI/2
EMPTY
140 11 (UNUSED) BB2/2
BEACON LIGHT EMPTY
GND 10 (UNUSED) BB2/6
(OPT) 161 9 (TILT SENSOR) AI/7
164 8 BOOM ANG SNSR AI/5
132 X17/5 7 TRANS GEAR SEL AI/3
RT FRONT WORKLIGHT GND 112
(OPT) 6 ENG TEMP SW AI/1
TXD 5 RS232 TX TXD
RXD
131 4 RS232 RX RXD
LT FRONT WORKLIGHT 174
GND 3 BACKUP LTS DO(2.5A)/4
(OPT) EMPTY 2 (UNUSED) DO(2.5A)/2
GND 1 ANALOG GND AGND
134
LT REAR WORKLIGHT GND
(OPT)
Electrical System

133
RT REAR WORKLIGHT GND
(OPT)

CAN LOW
CAN HIGH
EMPTY

EMPTY
EMPTY
EMPTY
EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY
EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY

EMPTY
EMPTY
129 &176
GND

GND
GND
GND

GND

GND
RXD
TXD
X17/5

54A
155
301
171
172
173
131
132
134
133
140

163

161

164

120

145

146

201
200
202
203
204
205
206
207
208

167
169
143
144

166

130
122

174

217

216
218

181
114

118

112

115

113
111
61

58

19

15

30
30
30
30
30
30

50

50
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
WKLT, RADIO, R WIPER HARNESS ESX HARNESS ESX HARNESS ESX HARNESS
ESX HARNESS
X9 X17 X18 X19
X16.1
(OPTION)
TO PCB TO FRONT CHASSIS TO PCB
HARNESS
9.5.4

9.10
 9.11
Electrical System

LICENSE REVERSE
~1/0 AWG BLK
FUEL
LEFT REAR DRIVING LIGHT RIGHT REAR DRIVING LIGHT

MZ1130
LIGHT ALARM SNDR
TAIL BACK TURN STOP TAIL BACK TURN STOP TO PCB TO PCB TO PCB TO PCB TO PCB TO ESX HARNESS
X12 X13 X10 X16 X22 X16.1
REAR CHASSIS HARNESS REAR CHASSIS HARNESS M8 GROUND STUD(S) FRONT CHASSIS HARNESS FRONT CHASSIS HARNESS FRONT CHASSIS HARNESS FRONT CHASSIS HARNESS
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ON CAB FIREWALL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2
EMPTY
EMPTY

EMPTY

EMPTY

EMPTY
EMPTY
EMPTY

EMPTY
EMPTY

EMPTY

EMPTY

EMPTY

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY

EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY

EMPTY

EMPTY
EMPTY
EMPTY

EMPTY
GND

GND

56BR

56AR
58RH

54RH

58RV
58LH

54LH

174R
174L
RH

186
300

71A
RV
124

163
164

218

169

177

135
185

167

146
147

216
217
122

179
178
126
127
129
130
128

201
200
202
203
204
205
206
207
208
LH

116

119

119
HORN
GND

GND

GND
58LH

124

116
EMPTY
EMPTY
EMPTY

EMPTY

71A
GND

GND
58RH

54RH
58LH

54LH

174R
174L

RH
LH

GND
CHASSIS
FRAME
217 1 ALL WHEEL
GND 2 STEER
216 MODE
1 VALVE
GND 2 CRAB
122 1
10 BAR HYDRAULIC
GND 2 PRESSURE
SWITCH
119 1 FRONT
GND EMPTY AXLE
Front & Rear Chassis Harness Electrical Schematic

1 2
BOOM 163 GND PROXIMITY
2 3
ANGLE 164 167 SWITCH
3 4
SENSOR
TO
EMPTY 1
177 146 1 LEFT & RIGHT
1 1
218 2
218 147 2 OUTRIGGER
2ND AUX
2 2
300 3
300 GND 3 PRESSURE
HYD CONN 3 GND GND GND
SEL VLV 3 4 4 SWITCH HARNESS
(GRN) 4
EMPTY 5
GND EMPTY 5 CONNECTOR
ON BOOM EMPTY EMPTY GND GND
(OPT) 5 6 (NOT USED)
REAR 1
119
EMPTY EMPTY LOW
AXLE 2 1
PROXIMITY 3
GND 56BR 2
169 56AR HIGH RIGHT
SWITCH 4 3
58RV FRONT
4
REAR RV DRIVING
185 5 SIDE LIGHT
AXLE 1 GND
2
186 6
LOAD
CELL TURN
135 1
135
GND 2
GND
BOOM
LIGHTS
(OPT) 135
GND
~1/0 AWG RED POSITIVE CABLE
TO STARTER SOLENOID
BATTERY DISCONNECT
SWITCH (OPT)
~1/0 AWG BLK ~1/0 AWG BLK NEGATIVE CABLE
TO STARTER (BODY)
+ -
12 VDC
BATTERY
CHASSIS GROUND

205 (RIGHT)
200 (PWR)

200 (PWR)

200 (PWR)

200 (PWR)

200 (PWR)

200 (PWR)
201 (SGN)

202 (SGN)

203 (SGN)

204 (SGN)

207 (SGN)

208 (SGN)
206 (LEFT)
GND

GND

GND

GND

GND

GND

GND

GND

GND

GND

GND

GND
126

127

129

130

128

178
179
2 1 2
1 2 3 1 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 1 2 1 2 1 2
TURB
LIFT TELE TILT AUX SWAY RT O/R LT O/R 1 2 F R S SPEED
SENSOR
DANFOSS CONTROL VALVE TRANSMISSION
9.5.5

4017
 Electrical System

9.6 CIRCUIT BREAKDOWNS

9.6.1 Constant Power Circuit from Battery

CAB HARNESS
KEY SWITCH CAB HARNESS
HAZARD SWITCH
TURN SIGNAL AND WIPER LEVER

0
1
2
3

0
1
2
3

FLASH

L H
WASH
HORN

WIPER
INST PANEL HARNESS

DIMMER
HI
DRIVING LIGHTSSWITCH BAT BAT

R
LO

TURN

L
1 2
3 4
30 30 15 15 19 19 17 50A R 30 L 49 30B49A 15 58 31
5 6
1 2 3 4 5 6 7
7 8

9 10

CAB HARNESS
158
58 30
EMPTY

X2 TO PCB 30 30 30 TO PCB X6 TO PCB X7 X TO PCB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

ESX HARNESS PCB

X2 TO INST PANEL HARNESS X6 TO CAB HARNESS X7 TO CAB HARNESS X8 TO CAB HARNESS
ESX CONTROLLER 3030 30
GND XGND2 68 30
XGND2 67 NM NM 158 MT
GND
GND XGND1
66
GND XGND1
65
RT O/R VLV (SAUER) DO/5
64
AUX HYD SELECT DO(4A)/3
63
DO(4A)/2
PVG VLV PWR (SAUER) 62 1
DO(4A)/1
LT O/R VLV (SAUER) 2
12V Ub
61
30 3
30
60
12V Ub
59
30 4 30
12V Ub
58
30 5 30
30 30
87a
Ub 87a
12V 57 6
30
30
30

RLY
Ub 30

WIPERRLY
12V 56 7
GND GND 55 30 8 30 87
87

WIPER
12V Ue 54 F9 F10 F11 F12 F13 86
9 86
(UNUSED) +WIRE2 53 10 F17
85
K4 85

K4
(UNUSED) BB2/5
(UNUSED) BB2/4
52
X19 11 X19
51 12 15A 30A 25A 15A 15A
(UNUSED) BB2/3 50 TO PCB 13 TO ESX HARNESS 20A
87a

WORK LTS RLY

AUX HYD VLV (SAUER) DO/4 49 30
14
TILT VLV (SAUER) DO/3 48 15 87
TELE VLV (SAUER) DO/2 47 16 86
LIFT VLV (SAUER) DO/1 46 17 85
(UNUSED) BB2/1 45 18 K5
SWAY LEFT VLV (DO) BB1/5 44 19
AW STEER VLV (DO) BB1/3 43 20 +12 VDC 87a
FWD/REV PWR (DO) BB1/1 42 21

KEY (PWR) RLY

DCLUTCH PSI SW DI/15 30
41 22
ENG OIL PSI SW DI/13 40 87
(4 SECT TELE SW) DI/11 39 86
FRT AXLE PROX DI/9 38
SWAY LT SW DI/7 37
K1 85
300
HYD PSI SW DI/5 36 X1 TO BATTERY 301 300
NEUTRAL SW DI/3 35
ALT W SPEED (RPM) DI/1 34
X9 TO OPTIONS HARNESS TO REAR CHASSIS HARNESS X13 X4 TO INST PANEL HARNESS
(UNUSED) -WIRE2 33
AIR FILTER SW AI/8 32
LOAD MOMENT SW AI/6 31
HYD FILT PSI SW AI/4 30 1 2 3 4 5 6 7 8 9 10
29
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1516 17 18 1 2 3 4 5 6 7 8 9 10
TRANS TEMP SW AI/2
12V IGNITION D+ 28
27
1. CAN HIGH +WIRE1
POSITIVE CABLE X13 TO PCB X4 TO PCB
1. CAN LOW -WIRE1 26
X1 X9 TO PCB
STRT INTLK RLY DO(2.5A)/3 25 TO BATTERY +
CRAB STEER VLV DO(2.5A)/1 24 TO PCB NEGATIVE CABLE 300
8.5 V EXT SUPPLY 8.5VEXT 23
ENG PREHEAT SW (DI) BB1/6 22 TO BATTERY DISCONNECT 301 1 2 3 4 5 6
SWAY RIGHT VLV (DO) BB1/4 21 OR BATTERY - 50mm BLK 300 (BAT)
(PARK LIGHT SW) (DI) BB1/2 20
(O/R PSI) DI/16 19 300
ALT D+ CHARGE DI/14 18
50mm RED STARTER
17
1 2 3 1 2
(UNUSED) DI/12
1 2 3 4 5
PARK BRAKE SW DI/10 16
(RED-PWR)
REAR AXLE PROX DI/8 15
SWAY RT SW DI/6 14 (RED-PWR)
REVERSE SW DI/4 13 (RED-PWR) M 2
TURBINE SNSR (RPM) DI/2 12
11
(RED-PWR)
(UNUSED) BB2/2
(UNUSED) BB2/6 10 (RED-PWR) AUX
(TILT SENSOR) AI/7 9 (RED-PWR) WORK LGHTS, RADIO, R WIPER
POWER
SOCKET
2ND AUX SEL VLV
BOOM ANG SNSR AI/5 8
7
30A HARNESS (OPTION) HYD CONN ON BOOM (OPT)
TRANS GEAR SEL AI/3 INST PANEL HARNESS
ENG TEMP SW AI/1 6 30A
RS232 TX TXD 5 30C REAR CHASSIS HARNESS
RS232 RX RXD 4
BACKUP LTS DO(2.5A)/4 3 30B
(UNUSED) DO(2.5A)/2 2
50A
ANALOG GND AGND 1

30B 30
87 STARTER
86 RELAY
85

30A ALTERNATOR
30A B+
W G
D+

30C
501A
GLOWPLUGS
501A 7.5 50 FUSE
SLO-BLO 50A
501 LIFT PUMP
FUSE
502 ATO 7.5A
30
502
87 GLOWPLUGS
86 RELAY
85

4 87a
501 3 30
5 87 LIFT PUMP
1 86
RELAY
2 85
MZ1300
PCB AND PWR HARNESS

9.12 4017
 Electrical System

9.6.2 Start Circuit

ESX HARNESS
68
ESX CONTROLLER 67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43 176
BB1/1 FWD/REV PWR (DO) 42
41
40
39
38
37
36
DI/3
129
NEUTRAL SW 35
34
CAB HARNESS
33
KEY SWITCH
32
31
30
29
28
27
0
1
2
3

0
1
2
3

26
STRT INTLK RLY 25
24
23
22
HEAT
HEAT
HEAT
STRT
BAT
BAT
IGN
IGN

21
20
19
18
17 30 30 15 15 19 19 17 50A
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
INST PANEL HARNESS
1 FNR/GEAR SHIFTER

R
50 176 176

N
30 30 30

4
3
2
1
4
3
2
1

F
TO PCB X6 X4 TO PCB
TO PCB X19

8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

TO ESX HARNESS X19 30 30 30 50 X6 TO CAB HARNESS 176 176 X4 TO INST PANEL HARNESS
50 1
2
3
4
5
6
F12 30A TO FNR SHIFTER 7
X23 8
9
10
K2
85 11
STRT INTLK RLY

86 12
87 12V-P1
13
30 14
87a 15
+12 VDC TO PCB
16 X23

50 17
X1 TO GROUND AND BATTERY 18
TO ENGINE HARNESS X11
FNR/GEAR SHIFTER HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10

PCB PWR AND GND HARNESS

TO PCB X11 ENGINE HARNESS X1 TO PCB
POSITIVE CABLE
TO BATTERY +
(RED-PWR)

50

NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -

TO CAB ASSEMBLY

50mm BLK

50mm RED STARTER

(RED-PWR)
30A
30A

30B
50A

30B 30
50A STARTER
87
50 RELAY
86
GND 85

ALTERNATOR
30A
30A
B+
W G
D+

MZ1290

4017 9.13
 Electrical System

9.6.3 Charging Circuit

PRINTED CIRCUIT BOARD

1
2 TO ESX HARNESS
3
4
5
6
7
8
9
10
11 X17
12
13
14
15
16
17
18
61 19 61
DI/14 ALT D+ CHARGE 18 20
21
22

PCB
22
21
20
19
18
ESX CONTROLLER 17
16
15
14
13
ALTERNATOR
12 X18
11 INDICATOR
10 1 2
9
8
113 7 113
DI/1 ALT W SPEED (RPM) 34
6
5
4
3
2 1
1 TO ESX HARNESS 2 160
3
4
5
6
7
8
61 61
9
10 TO BATTERY
11
12
13
X3 14
X3
PCB
TO INST PANEL HARNESS 15 INST PANEL HARNESS
X11 16
TO ENGINE HARNESS 17
61 113 18

DASH PANEL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

ENGINE HARNESS
TO PCB
X11 61 113
ENGINE HARNESS POSITIVE CABLE
TO BATTERY +
NEGATIVE CABLE
TO BATTERY DISCONNECT
OR BATTERY -

50mm BLK

50mm RED STARTER

30A
30A

30A ALTERNATOR
30A B+
113 W G
61 D+

MZ1280

9.14 4017

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).
1
MZ0150
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 fuse may be blown, requiring replacement.
Check for the cause of the blown fuse.
2. There may be a defect in the ignition key switch,
ignition wiring or starter solenoid.
3. Check battery condition. Clean the battery posts and
the connectors at each end of the battery cables.
4. Check for broken wiring and damaged insulation on
the wiring. Replace all broken or damaged wiring.
5. Check all connections at the starter solenoid, key
switch and wiring harness plugs. Clean and tighten
all connections.
6. If the starter still does not operate after these checks
have been performed, check the starting circuit.
b. Starter Circuit Checks
1. Check wires and connections for looseness,
corrosion, damage, etc.
4017
Electrical System
2. If a “whirring” noise is heard but the engine does not
turn over, the starter is spinning but not engaging the
flywheel. The starter drive or solenoid that pushes
the drive forward to engage the flywheel may be
defective. Missing or damaged teeth on the flywheel
can also prevent the starter from cranking the
engine.
3. If the starter only “clicks” it may indicate that the
battery is discharged, or that there is a loose or
corroded battery cable connection. Check the
battery state of charge and battery condition first,
then check the cables and cable connections.
4. For additional information on the starting circuit, refer
to Section 9.5, “Electrical System Schematics.”
c. Starter Removal
Remove the starter only if it fails. To remove the starter:
1. Open the engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove the wires from the solenoid stud. Remove
the positive (+) battery cable from the starter. Label
and disconnect the wire from the starter solenoid
housing stud. Record how the wires are installed to
ensure correct installation later.
4. Loosen, but DO NOT remove, the three fasteners
securing the starter to the flywheel housing. Support
the starter securely, as it is relatively heavy and will
fall if not supported.
5. Support the starter and remove the fasteners
securing the starter to the engine. Remove the
negative (-) ground cable from its starter mounting
bolt.
6. Remove the starter from the machine.
d. Starter Installation
1. Position the starter in its mounting opening on the
flywheel housing. Position the ground cable over the
correct starter mounting bolt. Secure the starter with
the three fasteners. Torque fasteners to 43 Nm
(32 lb -ft).
2. Connect the positive (+) battery cable to the upper
solenoid stud. Install the wires to the upper solenoid
stud, and secure with lock washer and nut. Torque
nuts to 43 Nm (32 lb -ft).
3. Connect the wire to the solenoid mounting stud.
4. Connect the negative (-) battery cable to the negative
(-) battery terminal.
9.15
 Electrical System

9.8 CHARGING CIRCUIT 9.8.1 Alternator

CAUTION:
a. Alternator Removal
When doing welding
anywhere on the machine disconnect the wire 1. Open the engine cover.
harness from the ESX Control Module 2. Disconnect the negative (-) battery cable at the
mounted under the operators seat and negative (-) battery terminal.
disconnect both cables from the battery and 3. Loosen both alternator (1) mounting bolts and pivot
clamp both cables together. alternator in.
If the engine alternator charging warning indicator 4. With the fan belt now being loose, remove the belt
illuminates, perform the following checks: from the engine.
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, and verify that they are in good
condition.
3. Check the fan belt condition and tension. (Refer to
the Perkins Service Manual.)Verify that the
alternator mounting hardware is tight.
4. Run the engine and check the alternator for noise. A
loose drive pulley, loose mounting hardware, worn or
dirty internal alternator bearings, a defective stator
or defective diodes can cause noise. Replace a worn
or defective alternator. 1
5. For additional information on the charging circuit
refer to Section 9.5, “Electrical System Schematics.”

MZ0150

Note: Record how the alternator is installed to ensure

correct installation later.
5. Label and disconnect the B+, D+,W and ground wire
leads.
6. Remove the lower mounting capscrew (3) securing
the alternator to the lower mounting hole on the
engine.
7. While supporting the alternator with one hand,
remove the upper (longer) mounting capscrew (4)
from the upper alternator mount. Remove the
alternator from the machine.

9.16 4017
 Electrical System

b. Alternator Installation 9.9 WINDOW WIPER/WASHER

WINDSHIELD WIPER MOTOR

4 a. Removal
Note: It may be necessary to remove several hydraulic
hoses from under the dash in order to remove and install
the wiper motor housing. (Refer to Section 4.3.1,
“Steering Column and Orbitrol Valve.”)
1. Open engine cover.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove the lower access panel below the
instrument panel.
3
4. Disconnect the right side defroster hose from dash
MA61902 panel hose connector.
5. Disconnect the cab harness connectors from the
1. Position the alternator and align with the upper wiper motor.
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
completely at this time.
2. Align the lower alternator mount hole with the lower
mounting bracket on the engine, and insert the lower
mounting capscrew. DO NOT tighten completely at
this time.
3. Install the fan belt, adjust the alternator for proper
belt tension and belt alignment. (Refer to the
appropriate Perkins Service Manual.) Tighten the
lower capscrew and upper capscrew securely.
4. Connect the B+, D+,W and ground wire leads. MAH0910

5. Connect the negative (-) battery cable to the negative

(-) battery terminal.
6. Remove the linkage attached to the wiper motor.
6. Close and secure engine cover.
7. Loosen and remove the four bolt holding the wiper
motor to the mounting bracket.
Note: Retain all hardware removed from the wiper
assembly for possible reuse on the replacement motor.
8. Remove the motor from the inside of the cab.

b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.

c. Inspection and Replacement

Inspect the motor terminals for continuity. Replace motor
if continuity is not found.

4017 9.17
 Electrical System
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 the
motor shaft to ensure wiper stroke covers window area,
and it does not swipe past the glass area.
4. Connect the cab harness connectors to windshield
wiper motor connectors.
5. Connect the negative (-) battery cable to the negative
(-) battery terminal.
6. Turn ignition key switch to the RUN position, and
operate windshield wiper in both LOW and HIGH
speeds to ensure proper operation and that correct
wiper travel is achieved. Turn ignition key switch
OFF.
7. Install right side defroster hose to the dash panel
hose connector.
8. If previously removed, install hydraulic hoses under
the dash. (Refer to Section 4.3.1, “Steering Column
and Orbitrol Valve.”)
9. Install the lower dash panel.
10. Close and secure engine cover.
9.9.1 Rear Window Wiper Motor
MAH0920
a. Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove the wiper arm from the wiper motor shaft.
4. Remove the nut on the wiper motor shaft and on the
wiper motor.
9.18
5. From inside the cab, pull the wiper motor away from
the rear window.
6. Label and disconnect the cab harness connectors
from the wiper motor.
b. Disassembly
DO NOT disassemble the motor. The motor is not
serviceable. Replace motor if found to be defective.
c. Installation and Testing
1. Hold wiper motor up toward cab rear window and
install the cab harness connectors.
2. With the help of an assistant, insert the wiper motor
through the window hole and have the assistant
thread the hex nuts onto the wiper motor shaft and
the wiper motor. Insure that the motor housing is
facing the front of the cab.
3. Install the wiper arm onto the wiper motor shaft.
4. Connect the negative (-) battery cable to the negative
(-) battery terminal.
5. Turn ignition key switch to the RUN position and turn
the rear wiper switch to the ON position. Ensure
wiper stays on the window through a full stroke. Turn
the rear wiper switch to the OFF position.
6. Engage the washer switch and ensure washer fluid
is sprayed on the rear window. Turn the ignition key
switch to the OFF position.
7. Close and secure engine cover.
9.9.2 Rear Wiper/Rear Window Washer
Switch
Rear Wiper/
Rear
Washer
Switch
a. Removal
1. Refer to Section 9.14.2, “Dash Switches,” for
removal information
4017
 Electrical System

b. Disassembly 5. Rotate the washer reservoir, label and remove the

cab harness connectors from the washer reservoir
DO NOT disassemble the switch. The switch is not
connectors.
serviceable. Replace switch if found to be defective.
6. Remove the windshield washer hoses from the
c. Installation and Testing reservoir.

1. Connect the windshield washer switch to the cab b. Disassembly

harness connector.
2. Position the switch over the rectangular switch bezel
and snap into position.
3. Connect the negative (-) battery cable to the negative
(-) battery terminal.
4. Check the washer reservoir for fluid; fill if needed.
5. Turn the ignition key switch to the RUN position and
test the windshield washer functions. Verify that fluid
is being pumped to both the front and rear
windshields.
9.9.3 Windshield/Rear Window Washer
Reservoir and Pump
The windshield washer motor and reservoir is located in
the engine compartment as a unit and cannot be serviced
separately.
a. Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove the nuts and the lock washers from the
washer mounting bolts.
4. Pull the washer reservoir out and away from the
mounting bracket.
DO NOT disassemble the pump. The pump is not
serviceable. Replace pump if found to be defective.
c. Installation and Testing
1. Connect the windshield washer hoses to the
reservoir.
2. Connect the cab wiring harness connectors to the
reservoir connectors.
3. Install the reservoir tank onto the mounting bracket.
4. Install the lock washers and nuts and secure.
5. Fill the washer fluid reservoir with washer fluid.
6. Connect the negative (-) battery cable to the negative
(-) battery terminal.
7. Turn the ignition key switch to the RUN position and
press the washer switch. Verify that fluid is sprayed
on both the windshield and rear glass.
8. Close and secure engine cover.
9.10 CAB HEATER AND FAN
9.10.1 Cab Heater Controls
Note: If the suspect component is found to be within the
heater box, the heater box must be removed as a
complete unit and replaced. For additional information
on the removal and installation of the heater box, refer to
Section 4.3.6, “Heater/Defroster System.”

a. Cab Heater Controls Removal

Fan
Speed

MZ0190 Temperature
Control

4017 9.19
 Electrical System
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 variable speed fan control cab
harness connector and disconnect the temperature
cable.
5. Remove the control from the panel.
b. Disassembly
DO NOT disassemble the cab heater and fan controls.
The controls are not serviceable. Replace controls if
found to be defective.
c. Installation and Testing
1. Check that the variable speed fan control is in the
OFF position.
2. Install the temperature control cable to the back of
the control.
3. Install the hex locknut on the shaft and tighten.
4. Connect the cab harness connector to the variable
speed fan control.
5. Install the screws securing the control panel to the
dash panel.
6. Connect the negative (-) battery cable to the negative
(-) battery terminal.
7. Turn the ignition key to the ON position and check
the fan speeds. If further repair is needed, refer to
Section 9.5, “Electrical System Schematics.”
8. Start the machine and allow engine to warm to
operating temperature. Check heat control at
different levels.
9. Close and secure engine cover.
9.20
9.11 SOLENOIDS AND SENDERS
9.11.1 Fuel Shut-off Solenoid
1
MZ0200
a. Fuel Shut-off Solenoid Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Disconnect the wiring connector at the fuel shut-off
solenoid lead.
4. Remove the fuel shut-off solenoid (1) from the fuel
injector pump.
b. Fuel Shut-off Solenoid Disassembly
DO NOT disassemble a fuel shut-off solenoid. Replace a
defective fuel shut-off solenoid with a new part.
c. Fuel Shut-off Solenoid Inspection and
Replacement
Use a 12-volt DC source and ground to test the solenoid.
Energize the solenoid, and watch for the plunger to
retract. If the plunger does not retract, replace the fuel
shut-off solenoid with a new solenoid.
d. Fuel Shut-off Solenoid Installation
1. Clean the exterior of the fuel injector pump.
2. Install the fuel shut-off solenoid on the fuel injection
pump. Do Not Over Tighten.
3. Connect the wiring connector at the fuel shut-off
solenoid lead.
4. Connect the negative (-) battery cable to the negative
(-) battery terminal.
5. Start the engine. If the engine starts, the fuel shut-off
solenoid is functioning. If the engine fails to start, the
fuel shut-off run solenoid may have a poor ground
connection. Visually check the wiring at the fuel
shut-off solenoid leads and/or check for continuity
with a voltmeter as required.
6. Check for fuel and/or oil leakage around the solenoid.
7. Close and secure engine cover.
4017
 Electrical System

9.11.2 Main Control Valve Solenoids 9.11.3 Transmission Solenoid Valves

2
MZ0450
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 wiring connector at the valve
solenoid lead
4. Loosen and remove the four allenhead mounting
screws.
5. Remove the valve solenoid (2) being careful not to
lose or damage any o-rings. Note the location of any
orifices, check valves and o-rings if equipped.
The transmission should be checked, serviced and
repaired only by experienced service technicians who are
aware of all safety instructions and particular component
features.
Note: If the transmission is not shifting properly, the
transmission control lever, wiring harness or
transmission shift solenoids (3) should be checked in
order to determine which component is defective.
Specific information to determine which travel position
and corresponding component is not responding can be
found in the detailed transmission service instructions
(covering repair, disassembly, reassembly and
adjustment information) are provided in the Dana-Spicer
T12000 Transmission Repair Manual, PN-0120 and can
be obtained by calling your local Dana Spicer Service
Center.
Note: Contact the JLG Service Department if internal
transmission repair is required during the warranty
period.
4

b. Main Control Valve Solenoid Disassembly

DO NOT disassemble a valve solenoid. Replace a
defective valve solenoid with a new solenoid.

c. Main Control Valve Solenoid Installation

1. Install the valve solenoid using new o-rings and
tighten the allenhead screws. Do Not Over Tighten.
2. Connect the wire connector to the valve solenoid
3. Start the machine and slowly move joystick to
engage function. If further trouble shooting is
required, refer to Section 9.5, “Electrical System
Schematics,” or Section 8.4.2, “Hydraulic
Schematic.”
4. Close and secure engine cover.

3
MZ0650

4017 9.21
 Electrical System
9.11.4 Transmission Temperature Sender
The transmission temperature sender is located at the
bottom right side of the transmission housing.
a. Transmission Temperature Sender Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Unplug the transmission temperature sender
connector from the wiring harness connector.
4. The sender is threaded into the transmission
housing. Remove the sender.
b. Transmission Temperature Sender Inspection and
Replacement
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sender with a new part.
c. Transmission Temperature Sender Installation and
Testing
1. Thread the transmission temperature sender into the
transmission housing snugly, then connect the sender
connector to the wiring harness connector.
2. Connect the negative (-) battery cable to the negative
(-) battery terminal.
3. Check for proper fluid level.
4. Start the engine, allow it to reach operating
temperature and observe the operator’s display
cluster for warning indication. If the sender is not
defective, the problem could be elsewhere; possibly
in a shorted wire, damaged transmission, improper
or low fluid, etc.
5. Close and secure engine cover.
9.11.5 Transmission Mounted Speed Sensor
a. Transmission Mounted Speed Sensor Removal
1. Open engine cover. Allow engine to cool.
2. The transmission speed sensor (4) is located at the
left side of the transmission below the transmission
filter.
3. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
4. Unplug the speed sensor sender connector from the
wiring harness connector.
5. Loosen the screw holding the clamp and remove the
sensor, clamp and o-ring.
9.22
b. Transmission Mounted Speed Sensor Inspection
and Replacement
Inspect the sensor and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sensor with a new sensor.
c. Transmission Mounted Speed Sensor Installation
and Testing
1. Install new o-ring on speed sensor, install sensor in
transmission, install clamp on sensor, bolt down
clamp, turn arrow on sensor 45 degrees from clamp
bolt and torque to 8-10 Nm (70-88 lb-in).
2. Connect the sensor plug to the wire harness.
3. Connect the negative (-) battery cable to the negative
(-) battery terminal.
4. Open cover. Allow engine to cool.
9.11.6 Engine Coolant Temperature Sender
a. Engine Coolant Temperature Sender Removal
1. The engine coolant sender / switch is located by the
alternator.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Unplug the engine coolant temperature sender /
switch connector from the wiring harness connector.
4. The sender / switch is threaded into the engine
block. Remove the sender.
b. Engine Coolant Temperature Sender / Switch
Inspection and Replacement
Inspect the sender / switch and the wiring harness
connector terminals for continuity. Replace a defective or
faulty sender with a new sender.
c. Engine Coolant Temperature Sender Installation
and Testing
1. Thread the engine coolant temperature sender into
the engine block snugly, then connect the sender
connector to the wiring harness connector.
2. Connect the negative (-) battery cable to the negative
(-) battery terminal.
3. Check for proper coolant level.
4017

4. Start the engine, allow it to reach operating
temperature and observe the operator’s instrument
cluster for warning indication. If the sender is not
defective, the problem could be elsewhere; possibly
in a shorted wire, improper-running engine, improper
or low coolant, obstructed or faulty radiator, coolant
pump, loose fan belt, defective instrument display,
etc.
5. Close and secure engine cover.
9.11.7 Engine Oil Pressure Sender
The engine oil pressure sender is located below the
injector pump.
a. Engine Oil Pressure Sender Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Unplug the engine oil pressure sender connector
from the wiring harness connector.
4. The sender is threaded into the engine block.
Remove the sender.
b. Engine Oil Pressure Sender Inspection and
Replacement
Inspect the sender and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sender with a new sender.
c. Engine Oil Pressure Sender Installation and
Testing
1. Thread the engine oil pressure sender into the
engine block snugly, then connect the sender
connector to the wiring harness connector.
2. Connect the negative (-) battery cable to the negative
(-) battery terminal.
3. Check for proper oil level.
4. Start the engine, and observe the operator’s display
for warning indication. If the sender is not defective,
the problem could be elsewhere; possibly in a
shorted wire, improper-running engine, low oil,
obstructed or faulty oil pump, defective instrument
display.
5. Close and secure engine cover.
4017
Electrical System
9.11.8 Fuel Level Sender
a. Fuel Level Indicator Testing
1. The fuel level sender wiring harness leads can be
accessed from the top of the fuel tank. Disconnect
the fuel level sender wiring harness leads. With the
help of an assistant, touch both harness leads
together.
2. From the operator’s cab, have the assistant turn the
ignition key switch to the RUN position. DO NOT
start the engine. Observe the fuel level indicator
needle on the operator’s instrument cluster. The
reading must be at the FULL mark.
3. Turn the ignition key switch to the OFF position. The
fuel level indicator needle should return to the
EMPTY position.
b. Fuel Level Circuit Tests
If the fuel level sender is suspected of giving a false
reading, perform the following checks:
1. If the fuel level indicator needle does not move,
check the fuel tank for fuel.
2. Check for loose or defective wiring, faulty ground
connections, and corrosion on the fuel tank sender
and wiring lead.
3. If the fuel level indicator needle does not move after
the ignition key switch is turned to the RUN position,
use a test lamp to determine whether current is
flowing from the ignition switch to the fuel level
sender.
4. If the fuel level indicator does not move and a faulty
or defective fuel level sender in the fuel tank has
been ruled out, and in addition, wiring and
connectors have been checked and ruled out, the
fuel level indicator is defective and must be replaced.
5. Check that the ignition terminal has current and that
the fuse in the fuse panel is not blown.
6. Check for broken, shorted, frayed, disconnected or
damaged wiring between the fuel level indicator
wiring at the cab, fuse and relay panel, ignition key
switch, and from the fuel level sender on the fuel
tank through the wiring in the cab.
7. Check the fuel level sender. A defective fuel level
sender in the fuel tank may also prevent the fuel
level indicator from moving. Refer to Section 9.5,
“Electrical System Schematics,” for further
information.
9.23
 Electrical System

9.11.9 Boom Angle Sensor d. Boom Angle Sensor Adjustment

The boom angle sensor (1) is located at the top left inside 1. Access Level 2 can be reached by pressing buttons
rear of the machine. C and OK at the same time.
2. Access level 2 consists of the following menu-items:

1 • Anti theft device

256.5 mm (10 in)
MZ1320
a. Boom Angle Sensor Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Disconnect the boom angle sensor electrical
connector.
4. Loosen and remove the nut holding the rod
assembly to the sensor arm.
5. Loosen and remove the two bolts holding the sensor
to the sensor seat.
6. Remove the sensor assembly.
b. Boom Angle Sensor Inspection and Replacement
Inspect the sensor and the wiring harness connector
terminals for continuity. Replace a defective or faulty
sensor with a new sensor.
c. Boom Angle Sensor Installation
1. Install the sensor assembly to the sensor seat and
tighten both bolts.
2. Install the rod end to the sensor arm and tighten nut.
3. Measure and set rod length to 256.5 mm. (10 in) if
needed.
4. Plug the electrical connector into the sensor
assembly.
5. Connect the negative (-) battery cable to the negative
(-) battery terminal.
6. Close and secure engine cover.
9.24
• Software-Version
• Learning
3. The following submenus can be found in the
Learning menu.
• Boom
• Vehicle Speed
4. After choosing boom the analog values of the boom
angle sensor for the upper and lower limit positions
get determined and taken over.
The range detection of the analog values for the
boom must be performed for the boom angle sensor
in order to allow a precise calculation of the boom
angle.
Firstly, the upper analog value is learned. When the
boom is moved upwards (joystick Y-axis moved to
the back) one can see the analog value gets higher.
At the upper limit position of the boom the value gets
confirmed by pressing the OK button and the learning
of the lower limit position can be started. When the
boom is moved downwards (joystick Y-axis moved to
the front) the value decreases. At the lower limit
position the value needs to be confirmed with the OK
button and one comes back to the Learning menu.
Conditions for the value range:
• If the lower value is outside the range of 70-330, a
value of 100 is taken over.
• If the upper value is outside the range of 550-850, a
value of 800 is taken over.
5. If either the lower value (100) or the upper value
(800) is shown, the boom angle rod may need
adjusted.
4017

9.11.10 Load Moment Indicator
1
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 functions will be prohibited.
Depending on the circumstance, the LMI can be
overridden by pressing the "overload shut-off" button on
the display panel.
Note: The Load Moment Indicator is NOT a serviceable
item. The Load Moment Indicator must be inspected
and/or replaced by a qualified dealer or JLG technician
9.11.11 Load Moment Sensor
The Load Moment Sensor (2) is bolted on the top right of
the rear axle.
2
a. Load Moment Sensor Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Disconnect the LMI electrical connector.
4. Loosen and remove the two bolts holding the Load
Moment Sensor to the rear axle.
5. Remove the sensor assembly.
4017
Electrical System
b. Load Moment Sensor Installation
1. Clean the bare metal with a degreasing solution and
allow to dry.
2. Apply a thin film of Loctite® 638 adhesive to the flat
metal surface of the transducer, ensuring the
adhesive is spread evenly over the entire surface.
3. Fit the transducer, ensuring the lead exits in the
corner direction. If the existing bolts are not
available, use M10 x 40 mm bolts with a minimum
tensile strength of 10.9. No washers are used.
Note: It is important to prevent distortion of the sensor
element, therefore tighten the bolts alternately a small
amount at a time, until a value of 70 Nm (50 lb-ft) is
achieved.
4. Leave the machine undisturbed for a minimum of
2 hours before moving. DO NOT lift any load for a
minimum of 12 hours.
5. The transducer and area around it can be painted
2 hours after installation.
6. Plug the electrical connector into the sensor
assembly.
7. Connect the negative (-) battery cable to the negative
(-) battery terminal.
8. Close and secure engine cover.
c. Load Moment Sensor Calibration
Calibration of the load moment sensor requires the
setting up of two reference points. 0% and 100% SWL.
During calibration the machine must be level, brakes off,
steering straight ahead and ignition turned on. Access to
the calibration mode requires the use of a magnetic "key".
• Acquiring the calibration mode
1. For the first calibration at installation:
When first installed and powered up, the display will
show error condition number 4 (red LED and 3rd
green LED), indicating that calibration is required.
PRESS and hold the TEST button, and place the
magnet in position level with and just to the right of
the TEST button. The correct position is indicated
when the sounder stops and all LEDs stay on.
KEEP HOLDING THE TEST BUTTON AND
MAGNET IN PLACE until the display changes again
to show the red LED only. This indicates that the
system is now in calibration mode, and waiting for the
first reference point.
RELEASE the TEST button and remove the magnet-
the display will emit short intermittent beeps to
remind the operator that calibration is in progress.
9.25
 Electrical System

Note: If either the button or magnet is released too early 9.11.12 Front and Rear Axle Proximity
the display will revert to the uncalibrated condition Sensors
number 4.
The sensors used on each axle allow the steering to be
THE SYSTEM ALLOWS FIVE MINUTES for each changed to one of three different settings. The sensors
part of the calibration procedure to be completed. If a will not allow the change to be completed unless both
part of the calibration procedure is not completed axles are in the central location.
within the five minutes allowed the system will Each sensor is mounted in the center of each steer
automatically revert to the uncalibrated error cylinder.
condition number 4.
IF THE IGNITION IS SWITCHED OFF during first a. Removal
calibration the system will remain in the uncalibrated
1. Open engine cover. Allow engine to cool.
condition.
2. Disconnect the negative (-) battery cable at the
2. For any subsequent calibration:
negative (-) battery terminal.
PRESS and hold the TEST button, and place the
3. Unplug the axle proximity sensor from the wiring
magnet in position level with and just to the right of
harness.
the TEST button. The display will show all LEDs
flashing and sounder on. The correct position is 4. Remove the three bolts holding the sensor to the
indicated when the sounder stops and all LEDs stay steering cylinder barrel.
on.
b. Disassembly
• Calibration Procedure
1. Inspect the sensor and the wiring harness connector
1. Set 0%
terminals for continuity. Replace a defective or faulty
ARRANGE the machine on level ground in the 0% sensor with a new sensor.
calibration position, (ie boom is retracted, forks
lowered but not resting on the ground, and no load on c. Installation and Testing
the forks).
1. Install the three bolts holding the sensor to the
PRESS the TEST button ONCE. The system will give
steering cylinder barrel.
a single, short beep indicating that the 0% point is
set. The display will change to show the red and 2. Connect the axle proximity sensor to the wiring
amber LEDs lit (with continuing intermittent beeps), harness.
indicating that the system is ready and waiting for the 3. Connect the negative (-) battery cable to the negative
100% reference. (-) battery terminal.
Note: If a long beep is emitted from the sounder during 4. Close and secure engine cover.
calibration, this indicates a fault condition - see below. 5. Start the machine, select a steering mode, turn the
2. Set 100% steering wheel until the display unit shows the
steering has been "locked" into the selected mode.
PICK up the calibrated (maximum capacity) 100%
load and extend the boom to the pre-determined,
normal 100% point.
PRESS the TEST button ONCE to set the 100%
reference.
The display will now change back to normal
operation, and show 100%, (ie all green and amber
LEDs lit and flashing).
System calibration has now been completed. No
further action is required.

9.26 4017

9.12 DISPLAY MONITOR AND GAUGES
9.12.1 Digital Display "Main Screen"
CAUTION: The Digital Display Panel
can only be accessed for modification or
repair by a qualified JLG technician.
The Digital Display unit (1) monitors all functions of the
machine. Refer to the Operator & Safety Manual for
detailed information.
C OK
! 2
1
MZ0010
a. Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove the steering wheel assembly and the
transmission control lever.
4. Loosen the pinch bolt on the bracket holding the
display unit to the steering column. Slide the display
unit/bracket over the steering column and unplug the
wiring harness from the unit.
b. Disassembly
1. DO NOT disassemble the unit. The display unit is not
serviceable. Replacement of the digital display
should be replaced by a qualified JLG technician if
the unit is found to be defective
c. Installation and Testing
1. Slide the display unit/bracket over the steering
column, align the display unit and tighten the pinch
bolt.
4017
Electrical System
2. Reinstall the transmission control lever and steering
wheel assembly.
3. Connect the negative (-) battery cable to the negative
(-) battery terminal.
4. Close and secure engine cover.
5. The digital display unit MUST be recalibrated
BEFORE the machine is put back into service.
9.12.2 Analog Gauges
The machine is equipped with a analog engine coolant
temperature gauge (2) and a fuel level gauge (3). The
engine coolant temperature also is displayed on the
display "Main Screen".
3
80 100 0 4/4
40 120
MZ0500
a. Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove the lower dash panel, unplug connectors
from the gauge, remove the two nuts and lock
washers along with the gauge bracket.
4. Pull the gauge out from the front of the dash.
b. Disassembly
DO NOT disassemble the gauge. The gauge is not
serviceable. Replace the gauge if found to be defective.
c. Installation and Testing
1. Install the gauge in the dash. Install the gauge
bracket, lock washers and nuts. Connect the wire
connections.
2. Connect the negative (-) battery cable to the negative
(-) battery terminal.
3. Turn the ignition to the ON position to check the fuel
level. If gauge is not reading properly refer to Section
9.11.8, “Fuel Level Sender.”
4. Start the machine and allow the engine to warm to
check the engine water temperature.
5. Close and secure engine cover.
9.27
 Electrical System
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 Wiper/Washer Windshield Wiper Motor.”
9.14.1 Ignition Key Switch
a. Ignition Switch Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. Remove lower access panel.
4. Remove the hex nut securing the ignition key switch
to the dash.
5. Reach up and under the dash to work the ignition
switch and wiring out of the mounting hole.
6. Disconnect the ignition switch connectors from the
cab harness connectors, and remove the switch
from the machine.
b. Disassembly
DO NOT disassemble the ignition switch. Replace a
defective switch with a new part.
c. Inspection and Replacement
To determine the proper operation of the ignition key
switch, using the following charts, test the wires on the
back of the switch for continuity with an ohmmeter.
Test the ignition key switch for continuity, by checking
from the ignition (#30) wire to each of the following wires
in each switch position. Continuity (X) should be present
as indicated in the following chart:
Switch Position
Test from #30 wire to: OFF RUN START
Wire #50 X
Test the ignition key switch for continuity, by checking
from the ignition (#30) wire to each of the following wires
in each switch position. Continuity (X) should be present
as indicated in the following chart:
9.28
Switch Position
Test from #30 wire to: OFF RUN START
Wire #15 X X
Wire #50 X
If all wires do not show proper continuity, replace the
ignition switch.
d. Ignition Switch Installation
1. Connect the ignition key switch to the cab harness
connectors.
2. Reach up and under the dash to work the ignition
switch into the ignition switch-mounting hole on the
lower right side of the dash.
3. Align the ignition switch so that when it is in the OFF
position, the key slot is positioned vertically (straight up
and down). Install the hex nut securing the ignition
switch to the dash. DO NOT overtighten.
4. Install the lower access panel.
5. Connect the negative (-) battery cable to the negative
(-) battery terminal.
6. Close and secure engine cover.
Note: If further information is needed, refer to Section
9.5, “Electrical System Schematics.”
9.14.2 Dash Switches
a. Switch Removal
1. Open engine cover. Allow engine to cool.
2. Disconnect the negative (-) battery cable at the
negative (-) battery terminal.
3. There are three frames with three switches in each
frame.
4. Pull the frame out of the dash, disconnect the
harness connector to the switch in question and
push the switch out of the frame.
b. Disassembly
DO NOT disassemble the dash switch. Replace a
defective switch with a new part.
c. Inspection and Replacement
Inspect the switch terminals for continuity in both the
engaged and disengaged positions. Replace a defective
or faulty switch with a new switch.
4017
 Electrical System

d. Switch Installation 9.15 Transmission Control Lever / Accessory

1. Connect the switch to the cab harness connector. Control Lever
2. Position the switch over the rectangular switch bezel
and snap into position. 9.15.1 Control Lever Replacement
3. Connect the negative (-) battery cable to the negative The transmission control lever (10) is on the left side of
(-) battery terminal. the steering column. The accessory control lever (11) is
4. Start the machine and check the replaced switch for on the right side of the steering column.
proper function.
11
5. Close and secure engine cover.

6 7 8

2 9 10

3 12 MZ1461

5 a. Lever Removal
4
1. Open engine cover. Allow engine to cool.
1. Head Light Switch 2. Disconnect the negative (-) battery cable at the
2. Work Light Switches negative (-) battery terminal.
3. Rear Wiper/Washer Switch 3. Loosen and remove the two allenhead screws (12).
4. Machine Sway Switch 4. Disconnect the wiring harness connector from the
lever base and remove.
5. Rotating Beacon Switch (optional)
6. High Beam Indicator b. Disassembly
7. Battery Charge Indicator DO NOT disassemble the control lever. Replace a
8. Turn Signal Indicator defective lever with a new lever.
9. Trailer Turn Signal Indicator (optional)
c. Inspection and Replacement
Inspect the switch terminals for continuity. Replace a
defective or faulty lever with a new lever.

d. Lever Installation
1. Connect the wire harness connector to the lever
base.
2. Install both allenhead screws into the accessory
control lever base and tighten the two screws into
the transmission control lever base.
3. Connect the negative (-) battery cable at the negative
(-) battery terminal.
4. Start the machine and check the functions of the
replaced lever.
5. Close and secure engine cover.

4017 9.29
 Electrical System

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9.30 4017
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia) JLG Industries (UK)
P.O. Box 5119 Unit 12, Southside
11 Bolwarra Road Bredbury Park Industrial Estate
Port Macquarie Bredbury
N.S.W. 2444 Stockport
Australia SK6 2sP
Phone: (61) 2 65 811111 England
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Latino Americana Ltda. JLG Europe B.V.
Rua Eng. Carlos Stevenson, Jupiterstraat 234
80-Suite 71 2132 HJ Foofddorp
13092-310 Campinas-SP The Netherlands
Brazil Phone: (31) 23 565 5665
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd.
Kilmartin Place, Unit 1, 24 Industrial Complex
Tannochside Park Herman Street
Uddingston G71 5PH Meadowdale
Scotland Germiston
Phone: (44) 1 698 811005 South Africa
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334
Fax: (27) 11 453 1342
JLG Deutschland GmbH JLG Industries (Italia)
Max Planck Strasse 21 Via Po. 22
D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Bei Bremen Italy
Germany Phone: (39) 02 9359 5210
Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Fax: (49) 421 693 5035
JLG Industries (Norge AS) JLG Polska
Sofeimyrveien 12 UI. Krolewska
N-1412 Sofienyr 00-060 Warsawa
Norway Poland
Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Plataformas Elevadoras JLG Industries (Sweden)
JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 175 27 Jarfalla
08755Castellbisbal Sweden
Spain Phone: (46) 8 506 59500
Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (34) 93 77 11762