Service Manual User Manual

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An Oshkosh Corporation Company

Service Manual

Models

3614RS

4017RS

31200940

Original

May 7, 2014

Summary of content (204 pages)

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Service Manual Models 3614RS 4017RS 31200940 Original May 7, 2014 An Oshkosh Corporation Company
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EFFECTIVITY PAGE May 7, 2014 - A - Original Issue Of Manual 31200940 3614RS, 4017RS i
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READ THIS FIRST Modifications Modifications to this machine may affect compliance with Industry Standards and/or Governmental Regulations. Any modification must be approved by JLG. Machine Configuration Two configurations of each machine are included in this manual. Determine if machine is equipped with Ultra Low Sulfur Fuel Decal (1) as indicated below.
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SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Page 1-1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section Section 4 Cab Subject Page ....................................................................... 4-1 Operator Cab Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section Subject Section 8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 Page 8-1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section iv Subject Page 3614RS, 4017RS
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Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 3614RS, 4017RS TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Practices 1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS 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. Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.
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Safety Practices 1.6 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 1.7 Following are general safety statements to consider before performing maintenance procedures on the telehandler.
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Safety Practices 1.7.3 General Hazards 1.7.4 Operational Hazards SOLVENTS: Only use approved solvents that are known to be safe for use. ENGINE: Stop the engine before performing any service unless specifically instructed otherwise. HOUSEKEEPING: Keep the work area and operator cab clean, and remove all hazards (debris, oil, tools, etc.). VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.
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Safety Practices DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion. PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result. LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.
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Safety Practices This Page Intentionally Left Blank 1-6 3614RS, 4017RS
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Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3614RS, 4017RS TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.
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General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION 2.2 THREAD LOCKING COMPOUND JLG P/N Loctite® ND Industries Description 0100011 242TM Vibra-TITETM121 Medium Strength (Blue) 1001095650 243TM Vibra-TITETM122 Medium Strength (Blue) 0100019 271TM Vibra-TITETM140 High Strength (Red) 0100071 262TM Vibra-TITETM131 Medium - High Strength (Red) Loctite® 243TM can be substituted in place of Loctite® 242TM.
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General Information and Specifications 2.3 TORQUE CHARTS 2.3.1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Stress Area Clamp Load Torque (Dry) Torque Lubricated Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) IN-LB [N.m] Torque (Loctite® 262TM or Vibra-TITETM 131) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 0.1120 0.00604 380 8 0.9 6 0.7 48 0.1120 0.00661 420 9 1.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Stress Area Clamp Load In Sq In LB 0.1120 0.00604 Size TPI Bolt Dia 4 40 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Torque (Dry or Loctite® 263) K=0.20 IN-LB [N.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Tensile Stress Area Torque (Dry) K=0.17 Size TPI Bolt Dia In Sq In LB IN-LB 4 40 0.1120 0.00604 380 7 0.8 48 0.1120 0.00661 420 8 0.9 6 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Clamp Load [N.m] 32 0.1380 0.00909 580 14 1.5 40 0.1380 0.01015 610 14 1.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Stress Area Clamp Load In Sq In LB 0.1120 0.00604 Size TPI Bolt Dia 4 40 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Torque (Dry or Loctite® 263) K=0.17 IN-LB [N.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAP SCREWS Tensile Stress Area Clamp Load See Note 4 LB Size TPI Bolt Dia In Sq In 4 40 0.1120 0.00604 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Torque (Dry) K=0.17 IN-LB [N.m] Torque (Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) or Precoat® 85 K=0.
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General Information and Specifications 2.3.1 SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAP SCREWS Tensile Stress Area Clamp Load See Note 4 In Sq In LB 0.1120 0.00604 Size TPI Bolt Dia 4 40 48 0.1120 0.00661 6 32 0.1380 0.00909 40 0.1380 0.01015 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 1 3/8 1 1/2 Torque (Dry) K=0.17 IN-LB [N.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Stress Area Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) Torque (Lube) Torque Torque TM or 271TM TM TM (Loctite® 242 (Loctite® 262 or 271 TM or Vibra-TITE 111 or Vibra-TITETM 131) or 141) Size Pitch Sq mm KN [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size Pitch 3 0.5 Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.20 Torque (Lube or Loctite® TM 242 or 271TM or Vibra-TITETM 111 or 140) K=0.18 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Sq mm KN [N.m] [N.m] [N.m] 5.03 3.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Tensile Stress Area Clamp Load See Note 4 Torque (Dry or Loctite® 263TM) K=0.17 Torque (Lube or Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.16 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 Size Pitch Sq mm KN [N.m] [N.m] [N.m] 3 0.5 5.03 2.19 1.1 1.1 1.0 3.5 0.6 6.78 2.95 1.
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General Information and Specifications 2.3.2 Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size Pitch 3 0.5 Clamp Load See Tensile Stress Area Note 4 Sq mm KN 5.03 3.13 Torque (Dry or Loctite® 263TM) K=0.17 Torque (Lube or Loctite® 242TM or 271TM or Vibra-TITETM 111 or 140) K=0.18 Torque (Loctite® 262TM or Vibra-TITETM 131) K=0.15 [N.m] [N.
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General Information and Specifications 2.3.3 Hydraulic Hose Torque Chart Note: By definition the “Flats Method“ will contain some variance. Flats Method: 1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 4 Nm (3 lb-ft). 2. Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it’s connecting to. 3.
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General Information and Specifications 2.4 SPECIFICATIONS 2.4.1 Travel Speeds TRANSMISSION APPROXIMATE SPEED First Gear 5 kph (3 mph) Second Gear 12 kph (7 mph) Third Gear 25 kph (15 mph) 2.4.2 Hydraulic Cylinder Performance Note: Machine with no attachment or load, engine at full throttle, hydraulic oil above 54° C (130° F) minimum, engine at operating temperature. FUNCTION APPROXIMATE TIMES (seconds) 3614RS 4017RS Boom Extend (Boom Level) 14.6 23.4 Boom Retract (Boom Level) 11.7 20.
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General Information and Specifications 2.4.3 Electrical System Battery Type, Rating 12 V, Negative (-) Ground, Tapered Top Post, Maintenance Free Quantity 1 Cranking Performance 1 - 830 Cold Cranking Amps @ -18° C (0° F) Group/Series BCI Group 31 Alternator 14V, 120 Amps Starter 12V,4 KW 2.4.4 Engine Performance Specifications Description TCD 3.
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General Information and Specifications 2.4.6 Tires Note: Wheel lug nut torque is 430-470 Nm (317-347 lb-ft) Note: Pressures for foam filled tires are for initial fill ONLY. a. 3614RS Tire Type Minimum Ply/ Star Rating Fill Type TR01 16 Ply Pneumatic 4,1 Bar (59 psi) L-2 12 Ply Pneumatic 4,0 Bar (58 psi) Liquid Filled 4,0 Bar (58 psi) 400/80-24 Power CL N/A Pneumatic 4,0 Bar (58 psi) 370/75-28 DuraForce MH 14 Ply Pneumatic 5,25 Bar (76 psi) Size 15.5/80-24 15.5-25 Pressure a.
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General Information and Specifications 2.5 FLUIDS, LUBRICANTS AND CAPACITIES Engine Crankcase Oil Capacity with Filter Change 8,0 liter (8.5 quart) Type of Oil -10°C to 40°C (14° to 104°F) SAE 15W-40 -15°C to 40°C (5° to 104°F) SAE 10W-40 -30°C to 30°C (-22° to 86°F) SAE 5W-40 Specification If Equipped For ULS API CJ-4 Plus If Equipped For LS API CI-4 Plus Fuel Tank Capacity 150 liter (39.
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General Information and Specifications Hydraulic System System Capacity 145 liter (38.3 gallon) Reservoir Capacity to Full Mark 90 liter (23.8 gallon) Auxiliary Hydraulic Circuit Max Flow 80 lpm (21.1 gpm) Type of Oil Mobilfluid 424 Hydraulic Oil Axles Differential Housing Capacity 3614RS Front Axle 7,3 liter (7.7 quart) Rear Axle 7,5 liter (7.9 quart) 4017RS Front Axle 6,8 liter (7.2 quart) Rear Axle 7,5 liter (7.9 quart) Wheel End Capacity 3614RS 1,4 liter (1.
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General Information and Specifications 2.6 2.6.
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General Information and Specifications 2.6.
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General Information and Specifications 2.6.
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General Information and Specifications 2.6.
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General Information and Specifications 2.6.5 6000 & 12000 Hour EVERY 6000 or 3 Years Add Engine Coolant Extender EVERY 12000 or 6 Years Change Engine Coolant OAM3522 Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine Operation & Maintenance Manual for additional information.
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General Information and Specifications 2.7 2.7.
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General Information and Specifications 2.7.
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General Information and Specifications This Page Intentionally Left Blank 2-26 3614RS, 4017RS
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Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3614RS, 4017RS TITLE Boom System Component Terminology - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance - 3614RS . .
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Boom 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3-2 Hose Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.1 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11.2 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY - 3614RS The following illustrations identify the components that are referred to throughout this section.
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Boom 3.2 3.2.1 BOOM SYSTEM - 3614RS Boom System Operation The 3614RS three section boom consists of the first, second and third assemblies with first and second section extend chains, and a single first and second section retract chain. As the extend/retract cylinder, which is anchored at the top rear of the first boom section, and the top front of the second boom section begins to extend, it pushes the second boom section out of the first boom section.
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Boom 3.3.1 Boom Removal While the boom sections can be separated from each other on the machine, it is much safer, more efficient and more cost effective to remove the complete boom assembly from the machine and place it on suitable supports for separation. Work can then progress at a normal working height. 3.3.2 Second, Third Boom Section Removal 1. Verify the boom assembly is setting on stable, secure and suitable supports.
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Boom 13. Remove the circlip and pin (8) from the retract chain (9) at the rear of the third boom section. Lay the retract chain over the rear edge of the first boom section. 5 6 7 5 MZ7080 Note: Before removing the extend chains, measure the distance between the face of the jam nut to the end of the chain clevis. This measurement will be used when reassembling the boom. 10. Disconnect both tilt hoses and (if equipped) both auxiliary hoses (5) at the bottom of the first boom section.
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Boom 3.3.3 Third Boom Section Removal 14 13 11 15 MZ7190 2. Loosen and remove the mounting bolt (13) and bracket (14) securing the extend chain clevis (15). MZ7160 1. Pull the tilt hoses and (if equipped) the auxiliary hoses from the rear of the third boom section. Note: The bracket (11) holding the tilt hoses and (if equipped) auxiliary hoses will still secure the tilt hoses and (if equipped) auxiliary hoses when the top rear wear pads are removed. 16 MZ7150 3.
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Boom 3.3.4 Third Boom Section Installation Note: During reassembly use Loctite® 243TM on all bolt threads. 3 Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear Pads.” You may have to final adjust the wear pads after the boom assembly is installed on the machine and hydraulic power is available. 4 Note: Coat the interior of all bushings and bores with Mystik Tetrimoly Grease XD#2 prior to the installation of pins and bushings.
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Boom 3.3.5 Second and Third Boom Section Installation 1. Place the first boom section on suitable supports. 5 6 7 MZ7220 2. From the rear of the boom, feed the tilt hoses (5) and (if equipped) auxiliary hoses (6) to the proper tube connections on the bottom of the first boom section. MZ7130 9. Install the wear pads, spacers and shims at the front of the first boom section (7). 3. Tighten and torque the tilt hoses and (if equipped) auxiliary hoses. Verify the hoses are aligned square to the boom. 4.
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Boom 14 10 11 15 MZ7230 MZ7080 11. Install the retract chain (10) at the front of the first boom section. Install the lock nut and jam nut. Do Not Tighten at this time. 12. Install the extend chain (11) at the front of the first boom section. Install the lock nut and jam nut. Do Not Tighten at this time. 14. Install the tilt cylinder in the boom head, install the mounting pin and keeper bolt, locking the mounting pin and tilt cylinder (14) into position. 15.
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Boom 18 19 17 21 20 21 18 21 21 MZ7240 3. Using suitable slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bores with the boom assembly pivot bores. Install shims, boom pivot pins and lock bolt (21). MZ7090 18. Properly support the extend/retract cylinder (17) using a hoist or crane and lower into place. 19. Install each mounting pin (18) in the extend/retract cylinder. 4.
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Boom 3.4 3.4.1 BOOM CHAIN REMOVAL/INSTALLATION - 3614RS Retract Chain Removal The removal of the retract chain can be accomplished with out the complete tear down of the boom sections. 1. Remove any attachment from the quick coupler assembly. Refer to Operation & Safety Manual. 4 2. Park the machine on a hard, level surface, fully retract the boom, level the boom assembly, place the transmission in (N) NEUTRAL, engage the park brake and shut the engine OFF. 5 1 6 3.
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Boom 2. Park the machine on a hard, level surface, fully retract the boom, level the boom assembly, place the transmission in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. Note: Removal of the retract chain from the rear of the third boom section may be required to access the extend chain clevis assembly. 9. Loosen and remove the mounting bolt (3) and bracket (4) securing the extend chain clevis (5). 4.
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Boom 3.5 TILT AND AUXILIARY CIRCUIT HOSE REMOVAL/INSTALLATION - 3614RS Hoses that need replaced and are still in one piece can be removed and replaced without removing sections of the boom. 3.5.1 Tilt/Auxiliary Hose Removal 5 MZ7200 4. Loosen and remove the clamps (5) securing the tilt hoses and (if equipped) auxiliary hoses at the rear of the third boom section. 1 5. From the rear of the boom, pull the tilt hoses from between the first and second boom sections. 2 6.
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Boom 3.6 EXTEND/RETRACT CYLINDER REMOVAL/ INSTALLATION - 3614RS The extend/retract cylinder hydraulically extends and retracts the third boom section. Seal kits for the extend/retract cylinders are available from the local JLG dealer. 3.6.1 3.6.2 Extend/Retract Cylinder Installation 1. Install the extend/retract cylinder (6) onto the top of the boom assembly. 2. Install one mounting pin (9) at each end of the extend/ retract cylinder and secure with retaining ring. 3.
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Boom A MZ7820 4. Adjust the boom chains to obtain dimension (A) 175,0-190,0mm (6.9-7.4 in). Note: Ensure that there is a minimum of one full thread of the clevis showing beyond the lock nut. 5. Start the machine and slowly extend and retract the boom three times. 6. Retract the extend/retract cylinder completely. Turn OFF engine 7. Repeat step 4 and 5 if necessary. 8. Tighten the extend/retract chain lock nuts (10 & 11) to 120 Nm (86 lb-ft) against the adjusting nut.
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Boom 3.8 BOOM SYSTEM COMPONENT TERMINOLOGY - 4017RS 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.
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Boom 3.9 BOOM SYSTEM - 4017RS 3.9.1 Boom System Operation The four section boom consists of the first, second, third and fourth assemblies with double third section extend chains, a single fourth section extend chain, a single third and fourth section retract chains. 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.
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Boom 3.10.1 Boom Removal While the boom sections can be separated from each other on the machine, it is much safer, more efficient and more cost- effective to remove the complete boom assembly from the machine and place it on suitable supports for separation. Work can then progress at a normal working height. 3.10.2 Second, Third and Fourth Boom Section Removal 1. Verify the boom assembly is setting on stable, secure and suitable supports.
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Boom 7 6 12 5 MZ7280 Note: Before removing the extend chains, measure the distance between the face of the jam nut to the end of the chain clevis. This measurement will be used when reassembling the boom. 10. Loosen and remove the lock nut and jam nut (5) on the retract chain at the front of the first boom section. 11. Loosen and remove the lock nuts and jam nuts (6) on the extend chains at the front of the first boom section. MZ7300 14.
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Boom 3.10.3 Third and Fourth Boom Section Removal 1. Verify the boom assembly is setting on stable, secure and suitable supports. 17 16 15 15 MZ7310 13 14 13 Note: Removal of the retract chain roller from the rear of the second boom section may be required to access the extend chain clevis assemblies. 2. Loosen and remove the mounting bolts (13) and bracket (14) securing each extend chain clevises (15). 3. Fasten a rope/wire to each extend chain clevis. MZ7320 4.
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Boom 10. Inspect hardware, wear pads, mounting points, chains and other components visible with the second boom section. Replace any item if damaged. (Refer to Section 3.15, “Boom Extend and Retract Chains - 3614RS & 4017RS,” and Section 3.16.1, “Wear Pad Inspection.”) 24 11. It is recommended that if any chain or hose is damaged that ALL chains or hoses are replaced. 3.10.4 Fourth Boom Section Removal 1. Verify the boom assembly is setting on stable, secure and suitable supports.
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Boom 3.10.5 26 Fourth Boom Section Removal Only Note: Removal and installation of the hose carrier can also be performed by removing only the fourth boom section if required. 27 29 MZ7360 28 10. Remove the extend chain (26) from top of fourth boom section. Clean and inspect chain. Replace if damaged. 30 MZ8370 11. Inspect the boom and welds. Consult your local authorized service distributor if structural damage is detected. 1.
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Boom 3.10.7 Fourth Boom Section Installation Only 1. 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.
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Boom 4. With the sling still under boom head install the bottom front wear pads and backing plates on the third boom section. Lower the fourth boom section and install the top front and side wear pads and backing plates on the third boom section. Do not shim or tighten bolts at this time. 3.10.9 Third and Fourth Boom Section Installation 1. Install the extend chains on the bottom inside of second boom section. Lay the extend chain the length of second boom section.
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Boom Note: Grease wear pads, bores and pins during assembly. 3.10.10 Second, Third and Fourth Boom Section Installation 10 11 12 MZ7610 1. Install the retract chain (12) to bottom front inside of the first boom section. Install the lock nut and jam nut. Lay the retract chain over the rear of the first boom section. 13 MZ7320 14 7. Install the extend chain (10) to the top front of the second boom section (11). Install the lock nut and jam nut. 8.
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Boom 4. Using a suitable sling, balance the second, third and fourth boom sections 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 sections onto a suitable support and reset sling under the boom head of the fourth boom section. Carefully slide the second, third and fourth boom sections into the first boom section.
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Boom 3.10.11 Note: Grease Tilt cylinder barrel end bore and pin before installing. 12. Remove the plugs from the fittings on the Tilt cylinder and the caps from the Tilt hoses from the hose carrier. Install both Tilt hoses (23). Torque as required. 13. If equipped, remove the plugs from the Auxiliary fittings and the caps from the Auxiliary hoses from the hose carrier. Install both Auxiliary hoses (24). Torque as required. Complete Boom Installation 1.
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Boom 3.11 HOSE CARRIER ASSEMBLY 3.11.2 Note: Removal and installation of the hose carrier can also be performed by removing only the fourth boom section if required. 3.11.1 Hose Carrier Removal 1. Place a sling around the center of the hose carrier to be able to balance the hose carrier while being installed. 2. Carefully slide the hose carrier (5) halfway into the fourth boom section. 3. Remove the sling and push the hose carrier assembly the remainder of way into the fourth boom section. 1.
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Boom 3.12.2 Tilt/Auxiliary Hose Installation 1. Fasten the rope/wire left in the boom from the hose removal to each end of the new hose at the rear of boom. 2. Slowly pull the rope/wire from below the first boom section until the hose end is visible at the tube connections. 3. Unfasten the rope/wire from each end of the hose. 35 36 4. Uncap and connect the hoses to the previously labeled tubes under the first boom section. Refer to Section 2.3.3, “Hydraulic Hose Torque Chart,” for proper hose torque.
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Boom 5. Loosen and remove upper clamp (40) securing both Tilt hoses (37) and (if equipped) both Auxiliary hoses (38). 3.13 BOOM CHAIN REMOVAL/INSTALLATION - 4017RS The removal of the extend and/or retract chain can only be accomplished with the complete tear down of the boom. 3.14 37 38 3.14.1 BOOM SECTIONS ADJUSTMENT 4017RS Chain Adjustments The chains are adjusted by tightening and/or backing off the adjusting nuts at the threaded end of the chains.
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Boom 11. The distance between the extend chains and the each boom section should measure 140-145 mm (5.5-5.7 in). 12. Loosen the locknuts on the extend chains and adjust if necessary. Tighten locknuts to 120 Nm (86 lb-ft). 3 13. Start the machine and cycle the extend/retract cylinder to verify the boom extends and retracts properly. MZ7870 4 1 2 1. Loosen the locknuts on the extend and retract chains. 2.
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Boom BOOM EXTEND AND RETRACT CHAINS - 3614RS & 4017RS 3.15 3.15.1 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. 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.
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Boom 3.15.3 Edge Wear Inspection Guidelines - 4017RS 1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission in (N) NEUTRAL, engage the park brake switch. 2 1 MZ1463 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%. Measure and compare to a normal link plate height by measuring a portion of chain that does not run over the sheave.
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Boom Distorted or Battered Link Plates 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. 85 a.
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Boom 3.15.4 Cracked Plates Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is 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 (1) are a result of repeated cyclic loading beyond the chain’s endurance limit.
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Boom 3.15.5 Chain Lubrication After inspection and before being returned to service, chains must be lubricated with Multipurpose Grease-NLGI Grade 2. 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.
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Boom 3.17 each side. QUICK COUPLER Note: The following procedures covers all styles of quick couplers. 3.17.1 Quick Coupler Removal 1. Lower attachment to ground, tilt forward to access coupler pin, set park brake and turn off engine. 2. If equipped with a hydraulic quick coupler device, refer to Operation & Safety Manual. 5 MZ7660 • Maintain a total boom section clearance of 0,5-1,5mm (0.020 to 0.060 in) between the wear pad and the next boom section (5).
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Boom 5. If equipped, reconnect the hydraulic attachment hoses to the quick disconnect fittings on the left side of the boom head. 3.18 3.19 WARNING FORKS Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately. A raised boom can fall if a hydraulic component is removed. Remove any load, retract the boom and install the boom prop or a suitable supporting stand before working under a raised boom. 3.
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Boom 6. Start the engine and SLOWLY lower the boom until there is a clearance of 6 mm (0.25 in) between the end of the boom prop and the lift/lower cylinder rod end (21). NOTICE EQUIPMENT DAMAGE. DO NOT operate with the boom prop in place. Damage to the boom prop and/or the lift/ lower cylinder could occur. 7. Shut OFF engine. b. Prop Removal 1. If needed, start machine and slowly raise the boom until the boom prop is clear of the lift/lower rod end. 2.
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Boom 3.20.2 Lowering Procedure 8. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine. a. Retract the boom as follows: b. Lower the boom as follows: 1. Remove the cover at the rear corner of the cab. 2. Place a suitable receptacle under the main control valve. 1. Place a suitable receptacle under the main control valve. 2. Label and disconnect the lift/lower cylinder hoses (6 & 7) from the main control valve. Install plugs in hoses to prevent fluid loss.
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Boom 3.21 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Problem 1. Boom will not extend or retract Possible Causes Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/retract hydraulic system not operating properly. 2. Refer to Section 8.5, “Hydraulic Circuits.” 3. Faulty extend/retract cylinder. 3.
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Boom Problem 6. Drooping chain, or jerky boom extend or retract functions. 7. Excessive Lift/Lower cylinder pivot pin noise and/or wear. 8. Rapid boom pad wear. 9. Auxiliary hydraulics will not operate. 3614RS, 4017RS Possible Causes Remedy 1. Chain(s) tension not properly adjusted. 1. Adjust chain(s). 2. Chain(s) stretched or binding. 2. Replace chains as needed. Refer to Section 3.7, “Boom Sections Adjustment - 3614RS.” 3. Wear pads loose, contaminated, excessively worn or damaged. 3.
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Boom Problem 10. Excessive chain wear. 3-44 Possible Causes Remedy 1. Improper chain adjustment. 1. Adjust to correct tension. Refer to Section 3.15, “Boom Extend and Retract Chains - 3614RS & 4017RS.”- Replace chains as needed. 2. Chain sheave(s) not properly lubricated. 2. Lubricate chain sheave. Refer to Section 2.6, “Service and Maintenance Schedules.” 3. Chain sheave(s) not rotating freely. 3. Lubricate chain sheave. Refer to Section 2.6, “Service and Maintenance Schedules.
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Section 4 Cab Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 3614RS, 4017RS TITLE Operator Cab Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2 Serial Number Plate. . . . .
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Cab 4.1 OPERATOR CAB COMPONENT TERMINOLOGY To understand safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with names and locations of major assemblies of machine cab. The following illustration identifies components that are referred to throughout this section.
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Cab 4.2 OPERATOR CAB WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.2.1 Operator Cab Safety WARNING The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary. ROPS/ FOPS must be properly installed using fasteners of correct size, grade, and torqued to their specified value. 4.3 CAB COMPONENTS 4.3.
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Cab 4.3.2 Steering Column/Orbitrol Valve 7. Label, disconnect and cap hydraulic hoses attached to orbitrol valve (1). a. Steering Column and Orbitrol Valve Removal 1. Park machine on a firm, level surface, level machine fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage park brake and shut engine OFF. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel. 8. Remove steering wheel (2). Refer to Section 4.3.1, “Steering Wheel.” 9.
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Cab 4.3.3 Service Brake a. Brake Valve Removal Refer to Section 8.9.2, “Service Brake Valve,” for removal information. b. Brake Valve Installation 7 Refer to Section 8.9.2, “Service Brake Valve,” for installation information. 4.3.4 Electronic Throttle Pedal a. Throttle Pedal Removal 1. Park machine on a firm, level surface, level machine fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage park brake and shut engine OFF. MZ7790 2.
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Cab 4.3.5 Joystick Assembly b. Joystick Assembly Installation 1. Connect previously labeled electrical connectors to joystick. a. Joystick Assembly Removal 1. Park machine on a firm, level surface, level machine fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage park brake and shut engine OFF. 2. Secure joystick assembly to cab using hardware removed earlier. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel. 4. Test joystick functions. 3.
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Cab 5 4 5 MZ7850 9. Remove heater cover (4) inside cab. MZ7840 11. Label and disconnect electrical connections. UPPER COVER 12. Label and remove hoses connected to heater. 13. If equipped, label and disconnect air conditioning hoses attached to heater assembly. 14. Remove bolts (5) securing heater assembly to cab. Remove heater assembly. b. Heater Assembly Installation 1. Position heater assembly to original orientation to cab. Secure with previously removed hardware. 2.
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Cab 4.3.8 Air Conditioning (if Equipped) If the air conditioning system requires servicing, contact the local JLG dealer or certified air conditioning service center. Refer to Section 2.5, “Fluids, Lubricants and Capacities,” for refrigerant type and capacity. 4.4 3 2 CAB REMOVAL WARNING The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necessary.
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Cab 4 18. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift cab and remove it from frame. Readjust position of sling as needed to help balance cab during removal. 4 19. When cab is completely clear of machine, carefully lower it to ground. Block up or support cab so it does not move or fall. 20. Assure that no personnel enter cab while it is being removed from machine. 21. Inspect and replace machine parts that are exposed with cab removed.
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Cab 4.5 CAB INSTALLATION 1. Block all four wheels to help prevent machine from moving. Assure that there is sufficient overhead and side clearance for cab installation. 2. Attach a sling with a minimum lifting capacity of 363 kg (800 lb) through lifting eyes of cab. 3. Use a hoist or overhead crane and sling attached to cab. Carefully begin to align cab with mounting holes in frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as cab is positioned.
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Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5.8 5.9 5.10 5.11 3614RS, 4017RS TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Replacement. . . . .
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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.
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Axles, Drive Shafts, Wheels and Tires WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 5.2 AXLE SERIAL NUMBER Front and rear axle serial number plate is located on the inside of each axle on right side of the center section. Information on the serial number plate is required in correspondence regarding the axle.
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Axles, Drive Shafts, Wheels and Tires Note: The wheel and tire assemblies must be re-installed later with the directional tread pattern “arrows” facing in the direction of forward travel. 14. Remove the drive shaft assembly. Refer to Section 5.9.3, “Drive Shaft Removal.” MZ7620 15. On front axle, remove capscrew and locknuts securing lower position cylinder-mount pin to the front cylinder. Tap the cylinder mount pin out, and move the cylinder to prevent it from interfering with axle removal. 16.
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Axles, Drive Shafts, Wheels and Tires 13. 3614RS Front Axle Only - Connect park brake cable. 23. Start engine. Turn steering wheel several times lock to lock, operate frame tilt function several times in both directions and check function of brakes. Check for hydraulic leaks, and tighten or repair as necessary. 4 3 22. Check hydraulic reservoir oil level. 24. Install fender assembly. Torque as required. 25. Properly connect battery. 26. Close and secure engine cover. MZ7620 1 14.
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Axles, Drive Shafts, Wheels and Tires 5.6 PARK BRAKE ADJUSTMENT - 3614RS 1. Park the machine on a slight grade, fully retract boom, level the boom, place transmission in (N) NEUTRAL, set the parking brake. The machine should not move. If the machine moves, adjust the park brake. 2. Apply service brake and disengage the park brake. 2 1 MM 60 MAM4100 3. Depress the release lever (1) and push the park brake lever (2) down. 4.
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Axles, Drive Shafts, Wheels and Tires 5.8 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING Problem 1. Excessive axle noise while driving. 2. Intermittent noise when traveling. 3. Vibration or intermittent noise when traveling. 3614RS, 4017RS Possible Causes Remedy 1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.5, “Fluids, Lubricants and Capacities.” 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 2.
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Axles, Drive Shafts, Wheels and Tires 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 Possible Causes Remedy 1. Drain and/or inspection plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft). 2. Hose fittings loose. 2. Tighten fittings. 3.
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Axles, Drive Shafts, Wheels and Tires 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. 3614RS, 4017RS Possible Causes Remedy 1. Oil level too high. 1. Fill oil to correct level. Refer to Section 2.5, “Fluids, Lubricants and Capacities.” 2.
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Axles, Drive Shafts, Wheels and Tires 5.9 5.9.1 DRIVE SHAFTS Drive Shaft Inspection 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 or damaged drive shafts and cross and bearing assemblies may cause an excessive amount of vibration or noise.
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Axles, Drive Shafts, Wheels and Tires 5.10 WHEELS AND TIRES WARNING Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. machine onto support and to remove wheel and tire assembly. 5. Lower machine onto support. 6. Remove lug nuts and washers in alternating pattern. 7. Remove wheel and tire assembly from machine. 5.10.
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Axles, Drive Shafts, Wheels and Tires 4. Tighten lug nuts in an alternating pattern as indicated in previous figure. Torque to 340-380 Nm (251-280 lb-ft) FRONT VIEW 5. Remove machine from supports. 6. Remove Do Not Operate Tag from ignition key switch and steering wheel. 5.11 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted after exhausting all other options. Make every effort to repair machine and move it under its own power. 5.11.1 3614RS Only 1. Fully retract the boom.
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Axles, Drive Shafts, Wheels and Tires a. Manually Releasing the Park Brake WARNING 5 5 5 5 Use a vehicle of sufficient capacity to tow the machine. Tow vehicle must be capable of providing braking for both vehicle and machine. 7. Clear area of any unnecessary personnel. 8. Have an operator seated in machine operator cab. 9. Remove blocks from all four wheels. 10. Disengage machine park brake. MZ1020 11. Tow machine to a secure location. Note: Tow machine at a very slow speed. 12.
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Axles, Drive Shafts, Wheels and Tires 6. Clear area of any unnecessary personnel. 7. Have an operator seated in machine operator cab. FRONT VIEW 8. Remove blocks from all four wheels. 9. Disengage machine park brake. 10. Tow machine to a secure location. Note: Tow machine at a very slow speed. 11. After towing is complete, engage park brake. 12. Block all four wheels. 13. Reinstall front and rear drive shafts. Refer to Section 5.9, “Drive Shafts.” 14. Repair machine as necessary.
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Section 6 Transmission Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 6.6 3614RS, 4017RS TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Replacement. . . . . . . . . . . . . . . . . . . . . . .
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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.
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Transmission 6.4 WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the transmission. Refer to the local JLG dealer and the applicable Transmission Service Manual for assistance with comprehensive transmission diagnosis, repair and component replacement. 6.
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Transmission 6.4.2 Transmission Installation WARNING NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling. 3 Note: Apply Loctite® 243TM to all transmission bolts before installation. 2 MZ7140 1. Use a suitable hoist or overhead crane, secure transmission with a lifting strap or chain to transmission lifting bracket. 12. Remove access cover (2) from the engine bell housing (3).
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Transmission 6.4.3 6.4.4 After Transmission Service or Replacement Transmission Torque Converter Stall Test 1. Start the machine and bring engine to normal operating temperature. In general: Engine - 75° ± 5° C (167° ± 40° F) 1. Disconnect and clean all transmission hoses. When possible, remove transmission lines from machine for cleaning. 2. Properly clean transmission oil cooler. Hydraulic Oil - 60° ± 5° C (140° ± 40° F) Torque Converter - 80° ± 5° C (176° ± 40° F) 2.
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Transmission This Page Intentionally Left Blank 6-6 3614RS, 4017RS
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Section 7 Engine Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 3614RS, 4017RS TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Engine 7.1 7.1.1 INTRODUCTION Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
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Engine 7.3.1 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.
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Engine 7.4 ENGINE COOLING SYSTEM 1 7.4.1 Surge Tank Cap A 1 Bar (14.5 psi) cap is used on the surge tank. 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 engine seems to take a long time to warm up, thermostat may be stuck in the open position and requires replacement.
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Engine 7.4.3 Radiator Assembly Replacement Before considering radiator assembly replacement for other than obvious damage, conduct a cooling system pressure test check coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator. • If engine runs hot, check temperature of upper radiator hose. • If hose is not hot, thermostat may be stuck in closed position.
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Engine b. Radiator Assembly Installation 9 6 7 1. Place radiator assembly in engine compartment at the original orientation. Secure with the previously used hardware. 8 2. Uncap and connect previously labeled hoses to radiator, transmission cooler and oil cooler. 3. Fill hydraulic oil reservoir. Refer to Section 8.7.2, “Hydraulic Oil Reservoir Filling.” 4. Fill transmission. Refer to Section 2.5, “Fluids, Lubricants and Capacities.” 5. Open surge tank cap and fill the radiator completely with coolant.
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Engine 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 7.6.1 FUEL SYSTEM 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. 2.
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Engine b. Disassembly Fuel tank is a one-piece unit and cannot be disassembled. Fuel level indicator can be removed and reused on new replacement tank. Dispose of old tank according to local regulations concerning hazardous materials disposal. c. Cleaning and Drying If contaminated fuel or foreign material is in the tank, tank can usually be cleaned. To clean the fuel tank: 1. Have a dry chemical (Class B) fire extinguisher near work area. 2.
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Engine 7.7 ENGINE EXHAUST SYSTEM Note: Emission Sensitive Exhaust. Assembly must be replaced exactly as removed. Contact your local JLG dealer before removing the muffler system. 6 7.7.1 7 Exhaust System Removal—ULS 3 9 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel. 3. Open engine cover.
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Engine 7.7.3 Exhaust System Removal—LS 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage parking brake, and shut engine OFF. 7 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel. 3. Open engine cover. Allow system fluids to cool. 4. Properly disconnect battery. 8 MZ7440 1 5. Remove belly pan (1). 6 4 9 10 5 3 MZ7480 9. Loosen and remove exhaust pipe clamps (6) 2 3 10.
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Engine 7.7.4 Exhaust System Installation—LS Note: Keep all clamps loosened until entire exhaust system is in place. 1. Install exhaust pipe (3) to muffler and secure with clamp (10). 2. Install muffler and secure with hardware removed earlier. Do not tighten hangars. 3. Install the tail pipe (5) to the exhaust pipe (3) and secure to frame with previously used clamps (2 & 4). Do Not Tighten. 4. Install exhaust pipe (8) to muffler with clamps (6). Do Not Tighten. 5.
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Engine 7.8 AIR CLEANER ASSEMBLY 7.8.2 Air Cleaner Assembly Installation 1. Install the air cleaner assembly (14) to the air cleaner mounting plate and secure with the previously used hardware. NOTICE NEVER run the engine with only the inner safety element installed. Note: Refer to the appropriate machine Operation & Safety Manual for the correct element change procedure. 2. Place the loosened clamp (12) over the air intake elbow (13) and install elbow on the air cleaner assembly. Tighten clamp. 3.
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Engine 7.9 7.9.1 ENGINE REPLACEMENT Engine/Transmission Removal Note: The radiator assembly must be removed from the machine before engine/transmission removal. Refer to Section 7.4.3, “Radiator Assembly Replacement.” Several additional components must be removed before engine/transmission removal. They will be addressed in the following procedures. 1.
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Engine 16. Remove exhaust pipe from exhaust manifold. Refer to Section 7.7, “Engine Exhaust System.” 7.9.3 Note: Emission Sensitive Exhaust. Assembly must be replaced exactly as removed. Engine disassembly, internal inspection, service, repair and assembly procedures are covered in the Engine Service Manual. Several special engine service tools are required to properly service the engine. Contact the local Caterpillar dealer for further information. 17. Remove air cleaner assembly. Refer to Section 7.
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Engine 14. Install heater and cooling hoses to engine and tighten clamps (if equipped). 7.10 TROUBLESHOOTING 15. Install hood (1), end covers (2) and belly pan from engine compartment and adjust if necessary. Refer to Section 7.3, “Specifications and Maintenance Information,” for detailed engine service information. 16. Install and properly connect battery(s). 17.
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Engine This Page Intentionally Left Blank 7-16 3614RS, 4017RS
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Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 3614RS, 4017RS TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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Hydraulic System 8.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual. 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.
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Hydraulic System 8.5 HYDRAULIC CIRCUITS This section covers the hydraulic circuits and includes listings for all hydraulic function pressures, where and how to check those pressures and a hydraulic schematic. Electrical and hydraulic functions are often related. Verify that the electrical components of the circuit are functioning properly whenever troubleshooting the hydraulic circuit. Always check the following before beginning to troubleshoot a circuit that is not functioning correctly. 1.
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Hydraulic System d. Pressure Specifications Hydraulic Circuit Test Port Procedure Adjustment Location Pressure Range N/A 175-185 Bar (2538-2683 PSI) 1 Steer Pressure LS1 (A) Connect gauge to LS1 port, select 2 wheel steer, run engine at high idle, turn steering wheel one direction to lock. Hold and check pressure. Note: Do not operate any other function while checking pressure. 2 Load Sense LS1 (A) Connect gauge to LS1 port, level boom and bottom boom retract.
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8-6 A B C D E F G H LS T T2 P 14 BAR 2 MM 8 COOLING CAPACITY APPROX 270W AT LOW IDLE ADDITIONAL 10W PER 100 RPM 270 BAR B1 5µ BETA RATIO: 1000 BYPASS OPENS AT: 3.5 BAR BLOCKAGE INDICATED AT 2.5 BAR RETURN FILTER BOOM RAISE/LOWER A1 MEDIA: 3µ AIR FILTER 7 PUMP PTO RATIO TO ENGINE 1.
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3614RS, 4017RS A B C D E F LS T T2 P 14 BAR 2 MM 8 COOLING CAPACITY APPROX 270W AT LOW IDLE ADDITIONAL 10W PER 100 RPM 270 BAR B1 5µ BETA RATIO: 1000 BYPASS OPENS AT: 3.5 BAR BLOCKAGE INDICATED AT 2.5 BAR RETURN FILTER BOOM RAISE/LOWER A1 COOLER BYPASS V2 V1 MEDIA: 3µ AIR FILTER 7 PUMP PTO RATIO TO ENGINE 1.
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Hydraulic System 8.7 HYDRAULIC RESERVOIR 8.7.2 Hydraulic Oil Reservoir Filling 1. Be sure the reservoir is clean and free of all debris. 1 5 3 2. Install a new hydraulic oil filter. 4 3. Fill the reservoir with oil until oil level is visible in the gauge window (3). Refer to Section 2.5, “Fluids, Lubricants and Capacities.” 4. Properly connect the battery. 6 6 2 5. Close and secure the engine cover. The hydraulic reservoir (1) is located under the cab. 6.
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Hydraulic System d. Inspection b. Disassembly Dispose of the old reservoir according to local regulations concerning hazardous materials disposal. 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 7-10 kPa (1-1.5 psi) of air pressure through the elbow.
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Hydraulic System 8.8 ENGINE IMPLEMENT PUMP b. Pump Installation 1. Apply Loctite® 243TM to all mounting bolts. 8.8.1 Pump Replacement 2. If the adapter plate was removed, place into position with a new, oiled o-ring on the engine. Secure with the previously used hardware. a. Pump Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission in (N) NEUTRAL, engage the park brake and shut the engine OFF. 3.
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Hydraulic System 8.9 CONTROL VALVES 8.9.1 fittings to allow any trapped pressure in the hydraulic system to escape. Main Control Valve The main control valve is mounted at the rear of the cab. 2 10. Wipe up any hydraulic fluid spillage in, on, near and around the machine and the work area. 11. Support the valve and remove the four bolts securing the main control valve to the frame. Remove the main control valve. b. Main Control Valve Disassembly 3 4 5 1 1.
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Hydraulic System e. Main Control Valve Assembly 9. Wipe up any hydraulic fluid spillage in, on, near and around the machine, work area and tools. 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. 10. Install main control valve cover. Assemble each Valve Section 12. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. 1.
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Hydraulic System 8.9.2 Service Brake Valve b. Service Brake Valve Installation 1. Install the service brake valve to its original orientation in the cab. Secure with the previously used hardware. a. Service Brake Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Install the service brake pedal. 2.
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Hydraulic System 8.9.4 4017RS Service Brake Test 1. Install a digital or a 70 bar (1000 psi) gauge to the test port on the brake valve (behind the front cover of the cab). 2. Start the machine and apply pressure to the service brake pedal. A maximum pressure of 44 bar (638 psi) should be achieved. 2 3. If further testing is required, refer to Section 8.5.1, “Hydraulic Pressures.” 2 8.9.
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Hydraulic System a. Outrigger/Stabilizer Valve Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, raise and support the boom, place the transmission in (N) NEUTRAL, engage the park brake, lower each outrigger and shut the engine OFF. c. Outrigger/Stabilizer Valve Installation 1. Install the outrigger/stabilizer valve to the frame using the previously removed nuts and washers. 2. Connect all the hydraulic hoses, fittings, solenoid wire terminal leads, etc.
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Hydraulic System a. Damper Removal 1. Remove any attachment from the machine. Park the machine on a firm level surface and fully retract the boom. Raise the boom to allow sufficient work space around the frame to allow the damper to be removed. Support the boom. Place the travel select lever in (N) NEUTRAL, engage the park brake, shut the engine OFF and chock wheels. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel. 3. Open the engine cover.
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Hydraulic System Use the following steps to properly pre-charge each damper: 13 14 14. Turn the gas valve/bleed valve (12) all the way in and remove the schrader adapter (11) from the valve on the damper. 9 8 13. When the correct pressure is reached, back the “T” handle (10) on the damper fill kit all the way out (counter-clockwise). Bleed the pressure from the hose by turning the gas valve/bleed valve out to relieve the pressure. 15. Reassemble the protective cap onto the gas valve on the damper.
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Hydraulic System 8.9.11 Steer Select Valve 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 solenoids from the spool. Discard the o-rings. 3. Clean all components with a suitable cleaner before inspection. 4. 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.
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Hydraulic System 9. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. d. Steering Test Refer to Section 8.5.1, “Hydraulic Pressures.” 1. Conduct a pressure check of the steering hydraulic circuit. 2. Check each steering mode for proper function. 8.10 8.10.1 HYDRAULIC CYLINDERS General Cylinder Removal Instructions 1. Remove any attachment from the machine. Park the machine on a firm level surface and fully retract the boom.
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Hydraulic System 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.
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Hydraulic System 7. Screw the head gland into the cylinder barrel and tighten with a spanner wrench. Refer to Section 8.10.4, “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.
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Hydraulic System 8.10.4 Cylinder Torque Specifications a. Lift/Lower Cylinder Model Head 3614 RS 1500 Nm (1106 lb-ft) 4017RS 480 Nm (354 lb-ft) Piston V1 Plug V2 Plug CB Valve 2000 Nm (1475 lb-ft) 85 Nm (63 lb-ft) 85 Nm (63 lb-ft) N/A b. Extend/Retract Cylinder c.
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Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 3614RS, 4017RS TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Electrical System 9.10 9.11 9.12 9.13 9-2 Load Stability Indicator (LSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.2 LSI Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.3 LSI System Calibration . . . . . . . .
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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.
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Electrical System 9.2 SPECIFICATIONS 9.4 Electrical system specifications are listed in Section 2, “General Information and Specifications.” 9.3 POWER DISTRIBUTION BOARD Power distribution board is located in cab. For access, remove screws securing the small side panel to cab. SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual.
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Electrical System Fuse/Relay Function Amp Rating F8 Lights Battery 1 15 F9 Lights Battery 2 15 F10 Key Battery 15 F11 Forward Worklights 15 F12 Rear Worklights 15 F13 Glow Out 15 F14 AC Power 30 F15 Option Power 1 15 F16 Option Power 2 15 F17 Option Power 3 (Cab AC Switch) 15 F18 Option Power 4 (Stabilizers Deploy) 15 F19 Beacon 15 F20 Brake Lights Power 15 F21 Rear Wiper 20 F22 Front Wiper 20 F23 Power Socket 15 F24 Fan 20 F25 ECM Power 30 F26 Key
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A B C D E F G TO ENGINE THROTTLE PEDAL 308-2 IVS PWR X W V U 1 X368 037 PED GND BLK A 307 PED SIG B 308 PED PWR C 309 IVS SIG D 337 TRANS TEMP E 525-2 ALT D+ F 525-1 ALT D+ G 710 CAN HI 6 RED 0.75mm² H 711 CAN LO 6 BLK 0.
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3614RS, 4017RS 9-7 MZ7930F A B C 10 11 12 6 7 8 9 4 5 XK2 1 2 3 INDIC D2 D1 1 615 COND FAN 2mm² 613-2 COND RL WHT 056-2 GND BLK 228 COND PWR YEL 2mm² 056 GND BLK 231 FLASH RLY IGNT YEL X285-4 415 SW LT 401 FOG LT 419-3 LH TURN 1.5mm² 401 FOG LT S123 208 FOG LT PWR YEL S125 S124 415-2 SW LT 028-4 GND BLK 418-3 RH TURN 1.5 mm² 420 BRK LT SW WHT1.5 mm² WHT 323 SEAT SW1 02-CAB 1-[8,H] S126 S127 207 PWR SKT 1.5 mm² 218 R WIPE PWR YEL 1.5mm² 415-3 SW LT 227 F WIPER YEL 1.
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9-8 3614RS, 4017RS MZ7980F A B C D TO PCB SHT.6 210 KEY 1 YEL 1 31 26 27 28 29 30 21 22 23 24 25 17 18 19 20 12 13 14 15 16 11 1 3 401 LH FOG LT 400 REV ALARM 402 REV LT 408 LH TAIL LT 404 LICENCE LT 407 STOP LT 406 LH TURN LT 403 RH TAIL LT 405 RH TURN LT 412 LH LOW BEAM LT 413 LH HI BEAM LT 416 RH LOW BEAM LT 417 RH HI BEAM LT 523 P BRK 323 SEAT SW1 219 SEAT SW2 1 mm² GND BLK GND BLK GND BLK 1.5mm² GND BLK 1.5mm² GND BLK 1.5mm² BLK GND 1.5mm² BLK GND 1.
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3614RS, 4017RS 9-9 MZ7950F A B C D 1 1 TO GLOW RLY 102 GLOW PWR RED 4AWG 1 RL896-2 X897 100A 1 X898 1 IP05 TO PCB 1 101 CAB PWR RED 4AWG X773 1 X110 1 X374 101 CAB PWR RED 4AWG X04 150A X03 1 1 IP02 102 GLOW PWR RED 4AWG 2 GENERIC BATTERY M 2 EC599 1 GENERIC EC599-B+ 1 RED 100 2/0AWG EC599-B1 BLK 001 2/0AWG 1 STARTER 1 BT600+ BT600- SWITCH BATTERY DISCONNECT MS604-A-1 1 BLK 001 2/0AWG BLK 002 2/0AWG 1 MS604-B-1 FRAME ENGINE BAY BLK 002 2/0AWG 1 X605 BLK 005 2/0AW
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A B C 1 2 3 6 1 2 3 1 COND FAN PWR 2 AC PWR AC PWR LIGHTS BAT 2 TX C2 49 RX STABS DEP LH 49a AC TEMP SWITCH O/P STABS DEP RH KEY 1 1 2 3 12 11 10 9 8 7 6 5 4 3 2 1 X285-3.
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A B C D E F G H D2.2 D2.1 BLK 735 TWISTED PAIR 5 - 1.5mm² 360 OIL PRESS 0.75mm² 359 BST PRESS 0.75mm² 358 BST PRESS 0.75mm² 047 GLOW RLY SW BLK 0.75mm² 357 OIL PRESS 0.75mm² 356 COOL TEMP 0.75mm² 355 BST PRESS 0.75mm² 354 RAIL PRESS 0.75mm² 353 RAIL PRESS 0.75mm² 351 BST PRESS 0.75mm² 336 GLOW OUT 0.75mm² BLK 745 TWISTED PAIR 10 - 1.5mm² WHT 744 TWISTED PAIR 10 + 1.5mm² 352 RAIL PRESS 0.75mm² TWISTED PAIR 9 - SHLD 0.75mm² GRN 743 TWISTED PAIR 9 - 0.
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A B C 12 13 14 15 CLEARSKY MODULE 056-5 GND BLK SWITCH, PRES 1 - + LEFT STABILIZER SWITCH,PROX 748 CAN HI 17 RED 0.
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Electrical System 9.6 ENGINE START CIRCUIT 9.6.1 Starter 3. If starter only “clicks” it may indicate that battery is discharged, or that there is a loose or corroded battery cable connection. Check battery state of charge and battery condition first, then check cables and cable connections. 4. For additional information on starting circuit, refer to Section 9.5, “Electrical System Schematics.” c. Starter Removal Remove starter only if it fails. To remove starter: 1.
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Electrical System 5. Remove Do Not Operate Tag from ignition key switch and steering wheel. 9.6.2 Charging Circuit 4. Properly disconnect battery. 5. Install a drive ratchet into square hole in serpentine belt tensioner bracket. Note Belt routing for future serpentine belt installation. 6. While lifting automatic belt tensioner away from belt, remove fan serpentine belt. Note: Record how alternator is installed to ensure correct installation later. 2 7.
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Electrical System 9.7 9.7.1 WIPER/WASHER WIPER MOTOR b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. Front Windshield Wiper Motor c. a. Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission in the (N) NEUTRAL, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel.
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Electrical System 9.7.2 Rear Window Wiper Motor 8. Remove wiper linkage (9). 9. Loosen and remove hardware (10) holding wiper motor assembly to window. a. Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel. 3. Open engine cover. Allow system fluids to cool.
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Electrical System 9.7.3 Roof Window Wiper Motor b. Disassembly DO NOT disassemble the motor. The motor is not serviceable. Replace motor if found to be defective. a. Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage parking brake, and shut engine OFF. 2. Place a Do Not Operate Tag on both ignition key switch and steering wheel. c. Inspection and Replacement Inspect motor terminals for continuity.
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Electrical System 9.7.4 Washer Tank b. Disassembly The washer motor and reservoir (5) is located in cab underneath the dash. It is labeled as a unit and cannot be serviced separately. DO NOT disassemble the pump. The pump is not serviceable. Replace pump if found to be defective. c. a. Removal Installation and Testing 1. Connect windshield washer hoses to washer tank. 1.
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Electrical System 9.8 9.8.1 SOLENOIDS, SENSORS AND SENDERS Transmission Solenoid Valves 7 6 MZ8180 Note: If the transmission is not shifting properly, the transmission shifter, wiring harness or transmission shift solenoids (6) should be checked in order to determine which component is defective.
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Electrical System 9.8.3 Transmission Mounted Speed Sensor 9.8.4 10 Engine Coolant Temperature Sensor 9 8 9 MZ8200 Transmission speed sensor (8) is located on the side of the transmission bell housing. a. Transmission Mounted Speed Sensor Removal 1. Park machine on a firm, level surface, level machine, fully retract boom, lower boom, place transmission in (N) NEUTRAL, engage park brake and shut engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel.
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Electrical System 5. Check for proper coolant level. 6. Start engine, allow it to reach operating temperature and observe operator instrument cluster for warning indication. If sensor is not defective, the problem could be elsewhere; possibly in a shorted wire, improperrunning engine, improper or low coolant, obstructed or faulty radiator, coolant pump, loose fan belt, defective instrument display, etc. 7. Close and secure engine cover. 8.
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Electrical System 9.8.7 Boom Angle Sensor The boom angle sensor is located at the top left inside rear of the boom. a. Boom Angle Sensor Removal 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine cover.
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Electrical System 9. If necessary, remove the sensor bracket. 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. If necessary, install the sensor bracket. 2. Install the sensor assembly to the sensor seat and tighten both bolts. 3. Install the rod end to the sensor arm and tighten nut. 4.
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Electrical System b. Disassembly 5. Install the lower dash panel. DO NOT disassemble the ignition key switch. Replace a defective switch with a new part. 6. Properly connect the battery. c. 8. Start engine to verify proper operation of the ignition switch. Inspection and Replacement To determine the proper operation of the ignition key switch, using the following chart, test the wires on the back of the switch for continuity with an ohmmeter. P 0 7. Close and secure the engine cover. 9.
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Electrical System 9.10 LOAD STABILITY INDICATOR (LSI) 9.10.1 WARNING Load Stability Indicator TIP OVER HAZARD. If the green, orange and red LEDs flash and warning buzzer sounds, retract and lower boom immediately. Determine cause and correct before continued use. WARNING TIP OVER HAZARD. The LSI considers only longitudinal stability limitations, observe all operating parameters. Failure to follow operating parameters of the telehandler could damage the equipment and/or cause tip over.
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Electrical System 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the engine cover. Allow the engine to cool. 5. Properly disconnect the battery. 6. Disconnect the LSI electrical connector. 9 7. Loosen, remove and discard the two bolts holding the LSI assembly to the rear axle. 8. Remove and discard the sensor assembly. b. LSI Sensor Installation 1.
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Electrical System 9.10.3 LSI System Calibration a. Standard Calibration To calibrate the LSI, certain conditions must be met: • The sensor must be installed according to Section 9.10.2, “LSI Sensor.” • The machine control system must be powered on for at least 10 minutes before calibration. 9. Lower boom until level. If equipped, fully raise outriggers. Pressing the LMI Override button may be required to lower the boom. 10. Attach the previously removed standard carriage, forks and weight. 11.
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Electrical System 5. Lower the outriggers, place test weight on ground, apply park brake and shut engine OFF. Do Not move machine. b. Field Calibration To calibrate the LSI, certain conditions must be met: • The sensor must be installed according to Section 9.10.2, “LSI Sensor.” Field Calibration Procedure: • The test weight matches the model being calibrated in the table shown on page 9-52. • The calibration shall be conducted with standard carriage and forks attached to the machine.
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Electrical System sounds and the LEDs will flash and perform a sequence until all are flashing. 9. Perform the LSI- CAN Check PT to finalize the calibration. Refer to Section 9.10.4, “LSI-CAN Check PT.” 9.10.5 500 Hour - LSI UGM Calibration Check 1. The machine must be on a level surface, wheels steered straight and park brake ON. 2. Start machine Note: The following procedure MUST BE performed to finalize the LSI System Calibration. 3.
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Electrical System 9.11 HAND HELD ANALYZER The hand held analyzer can be used in place of the cab display panel. 1 2 3 4 5 6 MZ6040 1. Cable Connector. 2. Analyzer Display Screen. 3. Escape Key: To return home or access previous menu. 4. Enter Key: Stores and selects Top Level, Sub Level and Items Menus. 5. Up/Down Arrow Keys: Change adjustable values. 6. Left and Right Arrow Keys: Used to move between Top Level, Sub Levels and Item Menus. 9.11.
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3614RS, 4017RS MARKET : ANSI MODEL: 4017RS DATALOG: RENTAL: XXXH XXM DATALOG: ERASE RENTAL? TELESCOPE ACTUAL: 0mA FORK TILT INPUT : 0% FORK TILT COMMANDED: 0mA FORK TILT ACTUAL: 0mA AUX. HYDRAULICS INPUT : 0% AUX. HYDRAULICS COMMANDED: 0mA AUX. HYDRAULICS ACTUAL: 0mA CONTINUOUS AUX.
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9-32 STAB RAMP: STEP SIZE: XXXmA STAB RAMP: STEP TIME: XXXms TELESCOPE X-AXIS MIN OUT: XXXmA TELESCOPE X-AXIS MAX OUT: XXXmA TELESCOPE ROLLER ACCEL IN: X.Xs TELESCOPE ROLLER DECEL IN: X.Xs TELESCOPE ROLLER ACCEL OUT : X.Xs TELESCOPE ROLLER DECEL OUT : X.
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3614RS, 4017RS MENU: OPERATOR TOOLS MENU: CALIBRATIONS PRESS ENTER TO SET CHECKPOINT. SET PARK BRAKE SHIFT TO SECOND GEAR WARNING: DRIVE WILL BE ENGAGED FORWARD TO START NEUTRAL TO PAUSE PARK BRAKE TEST COMPLETE PARK BRAKE TEST FAILED PRESS ENTER AT LOWEST POSITION. BOOM ANGLE: CALIBRATING LIFT UP. PRESS ENTER AT TOP.
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Electrical System 9.12 FAULT CODES Active faults and fault memory will be displayed at the operator level of access. Active faults will also be displayed as a blink code at the controller on-board LED. The 25 previous faults are logged in fault memory, which can be accessed by choosing ENTER while viewing active fault messages. 9.12.
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Electrical System 9.13 MACHINE FAULT CODES 9.13.1 Help Comment (00X) Message Fault Code EVERYTHING OK 001 9.13.2 Indicators Other Actions Taken Trigger for Fault Latch Until The system detects no problems exist. Power Up (21X) Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until POWER CYCLE 211 - - Power was cycled ON.
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Electrical System 9.13.
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Electrical System BOOM ANGLE SENSOR – NOT CALIBRATED 2343 5000Ms Boom angle sensor reading is +99° Lift Up and Down is de-rated to 60% (Constant Data) The UGM detects that a valid boom angle sensor calibration has not been performed The Boom Angle Sensor Calibration procedure is performed successfully BOOM ANGLE SENSOR – OUT OF RANGE HIGH 2344 5000Ms Boom angle sensor reading is +99° Lift Up and Down is de-rated to 60% (Constant Data) UGM J7-4 Boom Angle Sensor analog input is more than 4.
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Electrical System CABIN JOYSTICK – RIGHT ROLLER FAULT CABIN JOYSTICK – STABILIZER BUTTON FAULT CABIN JOYSTICK – NEUTRALIZER BUTTON FAULT CABIN JOYSTICK – FNR SWITCH FAULT OPERATING MODE INTERLOCK – OPERATOR PRESENCE 9-38 2351 2352 2329 23115 23120 Continuously Right Roller shall be prevented (Auxiliary Hydraulics) Cabin joystick transmits a DM1 (SPN:FMI) with 0Xf040:E2, 0Xf041:E2, or 0Xf042:E2 Cabin joystick transmits Error (1:0) for the Auxiliary Roller Neutral, Backward, or Forward position
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Electrical System 9.13.
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Electrical System MAIN LIFT DOWN VALVE – SHORT TO GROUND 33185 Continuously Lift Up is prevented Lift Down is prevented UGM J3-2 Lift Return is disabled Short to ground is detected on UGM J2-22 Power cycled MAIN TELESCOPE OUT VALVE – OPEN CIRCUIT 33186 5000Ms Telescope Out is prevented Open-circuit is detected on UGM J235 Power cycled Continuously Telescope Out is prevented Telescope In is prevented UGM J3-4 Telescope Return is disabled Short to battery is detected on UGM J2-34 or UGM J2-35
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Electrical System AUXILIARY FUNCTION-B VALVE – OPEN CIRCUIT 33199 5000Ms Auxiliary Function-B is prevented Continuous Auxiliary Hydraulics is prevented Auxiliary Release is prevented Open-circuit is detected on UGM J220 Power cycled Short to ground is detected on UGM J2-20 Power cycled AUXILIARY FUNCTION-B VALVE – SHORT TO GROUND 33200 Continuously Auxiliary Function-A is prevented Auxiliary Function-B is prevented UGM J3-14 Aux Return is disabled Continuous Auxiliary Hydraulics is prevented Aux
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Electrical System RIGHT STABILIZER UP VALVE – SHORT TO BATTERY 33232 Continuously Stabilizers are prevented Frame Level is prevented Short to battery is detected on UGM J2-3 Power cycled RIGHT STABILIZER UP VALVE – SHORT TO GROUND 33233 5000Ms Stabilizers are prevented Short to ground is detected on UGM J2-3 Power cycled FRAME LEVEL LEFT VALVE – OPEN CIRCUIT 33234 5000Ms Frame Level Left is prevented Open circuit is detected on UGM J27 Power cycled FRAME LEVEL LEFT VALVE – SHORT TO BATTER
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Electrical System TRANSMISSION FORWARD COIL – OPEN CIRCUIT TRANSMISSION FORWARD COIL – SHORT TO BATTERY TRANSMISSION FORWARD COIL – SHORT TO GROUND 33252 33253 33254 Continuously Deactivate output J2-33 Transmission Forward Coil. Flash the “Gear Selection” and the “Drive Direction” symbols on the LCD of the cabin’s display at 1.25Hz.
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Electrical System Deactivate output J1-20 TRANSMISSION 2ND GEAR COIL – SHORT TO BATTERY 33265 Continuously Transmission 2NDt Gear Coil. Flash the “Gear Selection” and the “Drive Direction” symbols on the LCD of the cabin’s display at 1.25Hz. Direction Selection shall be Neutral when Calibration’s TRANS SERVICE is NO Short to battery is detected on UGM J1-20 Power cycled Short to ground is detected on UGM J1-20 Power cycled Deactivate output J1-20 Transmission 2ND Gear Coil.
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Electrical System – Actual auxiliary function A / B (UGM J3-14) & commanded current disagree by >125Ma when command is >250 Ma for 1000Ms Actual auxiliary A / B current < 225Ma and PWM is >40% for 100ms Power cycled 5000Ms – Open circuit is detected on UGM J11 Power cycled 33211 5000Ms – Short to battery is detected on UGM J1-1 Power cycled 33212 5000Ms – Short to ground is detected on UGM J1-1 Power cycled AUXILIARY HYDRAULICS – CURRENT FEEDBACK READING TOO LOW 33291 5000Ms REVERSE ALA
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Electrical System 9.13.6 Engine (43X) Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ENGINE 43XXX - - - - – Engine running > 3,000Ms and UGM J4-7 Alternator D+ digital input is low UGM J4-7 Alternator D+ is high for 3,000Ms ALTERNATOR CHARGING FAILURE 9.13.
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Electrical System 9.13.8 Transmission & Drive System (46X) Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TRANSMISSION & DRIVE SYSTEM 46XXX - - - - Continuously – UGM J1-21 Transmission Temperature is grounded for a period of 3 seconds or more. Please put persistence timer in constant data. UGM J1-21 is not grounded Continuously Deactivate and inhibit output J2-33 Transmission Forward. Deactivate and inhibit output J2-32 Transmission Reverse.
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Electrical System 9.13.
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Electrical System 9.13.
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Electrical System MACHINE CONFIGURATION OUT OF RANGE – CHECK ALL SETTINGS CABIN JOYSTICK – INTERNAL FAILURE EEPROM VALUE – OUT OF RANGE GROUND MODULE VLOW FET FAILURE 9949 9976 9978 9986 Hydraulic functions are prevented Engine Start is prevented ECM Power is de-energized to shutdown engine UGM detects a parameter range issue with Machine Setup Machine Setup is properly configured; Power cycled Continuously Hydraulic functions are prevented Direction selection shall be neutral (If FNR configure
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31200940 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 2 65811111 Fax: +61 2 65813058 JLG Latino Americana Ltda.