B 3614RS 4017RS JLG Service English

Service Manual
Models
3614RS
4017RS
SN E160000141 to Present
including E160000120, E160000126,
1160008774, 1160008775 & 1160008777
31211333
April 17, 2019 - Rev B
An Oshkosh Corporation Company

EFFECTIVITY PAGE
DATE REVISION DESCRIPTION

September 28, 2018 A Original Issue of Manual
April 17, 2019 B Revised pages 2-3, 2-5, 2-6, 4-11, 7-9 thru 7-12, 9-50 thru 9-56, 9-69 thru 9-217.
Added pages 7-13 & 7-14, 9-20 thru 9-27, 9-240 thru 9-250.
3614RS, 4017RS 31211333 i

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.
• If equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Ultra
Low Sulfur (ULS) from this point forward.
• If not equipped with the Ultra Low Sulfur decal, all specific references to this machine configuration will be referred to as Low
Sulfur (LS) from this point forward.
S 15 mg/kg
1 D
1001139654 A
OZ4390
ii 31211333 3614RS, 4017RS

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices ......................................................................................................................... 1-1
1.1 Introduction ........................................................................................................................................................... 1-2
1.2 Disclaimer ................................................................................................................................................................ 1-2
1.3 Operation & Safety Manual ............................................................................................................................... 1-2
1.4 Do Not Operate Tags ........................................................................................................................................... 1-2
1.5 Safety Information ............................................................................................................................................... 1-2
1.6 Safety Instructions ................................................................................................................................................ 1-3
1.7 Safety Decals .......................................................................................................................................................... 1-4
Section 2
General Information and Specifications ................................................................................. 2-1
2.1 Replacement Parts and Warranty Information .......................................................................................... 2-3
2.2 Specifications ......................................................................................................................................................... 2-4
2.3 Fluids and Lubricant Capacities ...................................................................................................................... 2-8
2.4 Service and Maintenance Schedules ............................................................................................................. 2-11
2.5 Lubrication Schedule .......................................................................................................................................... 2-14
2.6 Thread Locking Compound .............................................................................................................................. 2-16
2.7 Torque Charts ........................................................................................................................................................ 2-17
2.8 Hydraulic Connection Assembly and Torque Specification ................................................................. 2-27
Section 3
Boom .............................................................................................................................. 3-1
3.1 Boom System Component Terminology - 3614RS ................................................................................... 3-3
3.2 Boom System - 3614RS ....................................................................................................................................... 3-4
3.3 Boom Assembly Maintenance - 3614RS ....................................................................................................... 3-4
3.4 Boom Chain Removal/Installation - 3614RS ............................................................................................... 3-12
3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - 3614RS ............................................................. 3-14
3.6 Extend/Retract Cylinder Removal/Installation - 3614RS ........................................................................ 3-15
3.7 Boom Sections Adjustment - 3614RS ............................................................................................................ 3-16
3.8 Boom System Component Terminology - 4017RS ................................................................................... 3-17
3.9 Boom System - 4017RS ....................................................................................................................................... 3-18
3.10 Boom Assembly Maintenance - 4017RS ....................................................................................................... 3-18
3.11 Hose Carrier Assembly ........................................................................................................................................ 3-30
3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - 4017RS ............................................. 3-31
3.13 Boom Chain Removal/Installation - 4017RS ............................................................................................... 3-33
3.14 Boom Sections Adjustment - 4017RS ............................................................................................................ 3-33
3.15 Boom Extend and Retract Chains - 3614RS & 4017RS ............................................................................. 3-34
3.16 Boom Wear Pads ................................................................................................................................................... 3-38
3.17 Quick Coupler ........................................................................................................................................................ 3-39
3.18 Forks .......................................................................................................................................................................... 3-40
3.19 Boom Prop (if equipped) ................................................................................................................................... 3-40
3.20 Emergency Boom Lowering Procedure ....................................................................................................... 3-41
3.21 Troubleshooting ................................................................................................................................................... 3-43
3614RS, 4017RS 31211333 i

Section 4
Cab .............................................................................................................................. 4-1
4.1 Operator Cab Component Terminology ..................................................................................................... 4-2
4.2 Operator Cab ......................................................................................................................................................... 4-3
4.3 Cab Components ................................................................................................................................................. 4-3
4.4 Cab Removal .......................................................................................................................................................... 4-11
4.5 Cab Installation ..................................................................................................................................................... 4-13
Section 5
Axles, Drive Shafts, Wheels and Tires ...................................................................................... 5-1
5.1 Axle, Drive Shaft and Wheel Component Terminology ......................................................................... 5-2
5.2 Axle Serial Number .............................................................................................................................................. 5-4
5.3 Axle Specifications and Maintenance Information .................................................................................. 5-4
5.4 Axle Replacement ................................................................................................................................................ 5-4
5.5 Brake Inspection ................................................................................................................................................... 5-7
5.6 Park Brake adjustment - 3614RS ..................................................................................................................... 5-7
5.7 Steering Angle Adjustment .............................................................................................................................. 5-7
5.8 Axle Assembly and Drive Shaft Troubleshooting ..................................................................................... 5-8
5.9 Drive Shafts ............................................................................................................................................................. 5-11
5.10 Wheels and Tires ................................................................................................................................................... 5-12
5.11 Towing a Disabled Machine ............................................................................................................................. 5-13
Section 6
Transmission ............................................................................................................................. 6-1
6.1 Transmission Assembly Component Terminology .................................................................................. 6-2
6.2 Transmission Serial Number ............................................................................................................................. 6-3
6.3 Specifications and Maintenance Information ............................................................................................ 6-3
6.4 Transmission Replacement ............................................................................................................................... 6-3
6.5 Torque Converter Flex Plate ............................................................................................................................. 6-7
Section 7
Engine .............................................................................................................................. 7-1
7.1 Introduction ........................................................................................................................................................... 7-2
7.2 Engine Serial Number ......................................................................................................................................... 7-4
7.3 Specifications and Maintenance Information ............................................................................................ 7-4
7.4 Engine Cooling System ...................................................................................................................................... 7-4
7.5 Engine Electrical System .................................................................................................................................... 7-7
7.6 Fuel System ............................................................................................................................................................ 7-7
7.7 Engine Exhaust System ...................................................................................................................................... 7-9
7.8 Air Cleaner Assembly .......................................................................................................................................... 7-16
7.9 Engine Replacement .......................................................................................................................................... 7-17
ii 31211333 3614RS, 4017RS

Section 8
Hydraulic System ...................................................................................................................... 8-1
8.1 Hydraulic Component Terminology .............................................................................................................. 8-2
8.3 Specifications ......................................................................................................................................................... 8-4
8.4 Hydraulic Pressure Diagnosis ........................................................................................................................... 8-4
8.5 Hydraulic Circuits .................................................................................................................................................. 8-5
8.6 Hydraulic Schematics .......................................................................................................................................... 8-7
8.7 Hydraulic Reservoir .............................................................................................................................................. 8-11
8.8 Engine Implement Pump .................................................................................................................................. 8-13
8.9 Control Valves ........................................................................................................................................................ 8-14
8.10 Hydraulic Cylinders .............................................................................................................................................. 8-23
Section 9
Electrical System ....................................................................................................................... 9-1
9.1 Electrical Component Terminology ............................................................................................................... 9-4
9.2 Specifications ......................................................................................................................................................... 9-5
9.4 Power Distribution Board .................................................................................................................................. 9-5
9.5 Electrical System Schematics ........................................................................................................................... 9-13
9.6 Dielectric Grease Application ........................................................................................................................... 9-28
9.7 Engine Start Circuit .............................................................................................................................................. 9-31
9.8 Battery ...................................................................................................................................................................... 9-33
9.9 Wiper/Washer Wiper Motor .............................................................................................................................. 9-34
9.10 Solenoids, Sensors and Senders ...................................................................................................................... 9-38
9.11 Dash Switches ........................................................................................................................................................ 9-43
9.12 Load Stability Indicator (LSI) (IF EQUIPPED) ................................................................................................ 9-45
9.13 Machine Data ......................................................................................................................................................... 9-48
9.14 Analyzer Software Accessibility ....................................................................................................................... 9-57
9.15 Fault Codes ............................................................................................................................................................. 9-68
9.16 Machine Fault Codes ........................................................................................................................................... 9-69
9.17 Engine Diagnostic ................................................................................................................................................ 9-218
3614RS, 4017RS 31211333 iii

iv 31211333 3614RS, 4017RS

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.1 Personal Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.2 Equipment Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
3614RS, 4017RS 31211333 1-1

Safety Practices
1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

This service manual provides general directions for Place Do Not Operate Tags on the ignition key switch and the
accomplishing service and repair procedures. Following the steering wheel before attempting to perform any service or
procedures in this manual will help assure safety and maintenance. Remove key and disconnect battery leads.
equipment reliability.
Read, understand and follow the information in this manual, 1.5 SAFETY INFORMATION
and obey all locally approved safety practices, procedures,
rules, codes, regulations and laws. To avoid possible death or injury, carefully read, understand
and comply with all safety messages.
These instructions cannot cover all details or variations in the
equipment, procedures, or processes described, nor provide In the event of an accident, know where to obtain medical
directions for meeting every possible contingency during assistance and how to use a first aid kit and fire extinguisher/
operation, maintenance, or testing. When additional fire suppression system. Keep emergency telephone
information is desired consult the local JLG dealer. numbers (fire department, ambulance, rescue squad/
paramedics, police department, etc.) nearby. If working
Many factors contribute to unsafe conditions: carelessness, alone, check with another person routinely to help assure
fatigue, overload, inattentiveness, unfamiliarity, even drugs personal safety.
and alcohol, among others. For optimal safety, encourage
everyone to think, and to act, safely.
1.5.1 Safety Alert System and Signal Words
Appropriate service methods and proper repair procedures
are essential for the safety of the individual doing the work,
for the safety of the operator, and for the safe, reliable
operation of the machine. All references to the right side, left
DANGER
side, front and rear are given from the operator seat looking in
a forward direction. DANGER indicates an imminently hazardous situation
Supplementary information is available from the which, if not avoided, will result in death or serious injury.
manufacturer in the form of Service Bulletins, Service
Campaigns, Service Training Schools, the service website,
other literature, and through updates to the manual itself. WARNING
1.2 DISCLAIMER
WARNING indicates a potentially hazardous situation which,
All information in this manual is based on the latest product if not avoided, could result in death or serious injury.
information available at the time of publication. The
manufacturer reserves the right to make changes and
improvements to its products, and to discontinue the CAUTION
manufacture of any product, at its discretion at any time
without public notice or obligation.
CAUTION indicates a potentially hazardous situation which,
1.3 OPERATION & SAFETY MANUAL if not avoided, may result in minor or moderate injury.
The mechanic must not operate the machine until the

Operation & Safety Manual has been read and understood,
training has been accomplished and operation of the
machine has been completed under the supervision of an
experienced and qualified operator.
An Operation & Safety Manual is supplied with each machine
and must be kept in the manual holder located in the cab. In
the event that the Operation & Safety Manual is missing,
consult the local JLG dealer before proceeding.
1-2 31211333 3614RS, 4017RS

Safety Practices
1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be
Following are general safety statements to consider before
safe for use.
performing maintenance procedures on the telehandler.
Additional statements related to specific tasks and HOUSEKEEPING: Keep the work area and operator cab clean,
procedures are located throughout this manual and are and remove all hazards (debris, oil, tools, etc.).
listed prior to any work instructions to provide safety FIRST AID: Immediately clean, dress and report all injuries
information before the potential of a hazard occurs. (cuts, abrasions, burns, etc.), no matter how minor the injury
For all safety messages, carefully read, understand and follow may seem. Know the location of a First Aid Kit, and know how
the instructions before proceeding. to use it.
CLEANLINESS: Wear eye protection, and clean all
1.6.1 Personal Hazards components with a high pressure or steam cleaner before
PERSONAL SAFETY GEAR: Wear all the protective clothing attempting service.
and personal safety gear necessary to perform the job safely. When removing hydraulic components, plug hose ends and
This might include heavy gloves, safety glasses or goggles, connections to prevent excess leakage and contamination.
filter mask or respirator, safety shoes or a hard hat. Place a suitable catch basin beneath the machine to capture
LIFTING: NEVER lift a heavy object without the help of at fluid run off.
least one assistant or a suitable sling and hoist. It is good practice to avoid pressure-washing electrical/
electronic components. In the event pressure-washing the
1.6.2 Equipment Hazards machine is needed, ensure the machine is shut down before
pressure-washing. Should pressure-washing be utilized to
LIFTING OF EQUIPMENT: Before using any lifting equipment
wash areas containing electrical/electronic components, JLG
(chains, slings, brackets, hooks, etc.), verify that it is of the
recommends a maximum pressure of 52 bar (750 psi) at a
proper capacity, in good working order, and is properly
minimum distance of 30,5 cm (12 in) away from these
attached.
components. If electrical/electronic components are
NEVER stand or otherwise become positioned under a sprayed, spraying must not be direct and for brief time
suspended load or under raised equipment. The load or periods to avoid heavy saturation,
equipment could fall or tip.
Check and obey all Federal, State and/or Local regulations
DO NOT use a hoist, jack or jack stands only to support regarding waste storage, disposal and recycling.
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job; keep
tools clean and in good working order, and use special
service tools only as recommended.
3614RS, 4017RS 31211333 1-3

Safety Practices
1.6.4 Operational Hazards FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic
systems near an open flame, sparks or smoking materials.
ENGINE: Stop the engine before performing any service
unless specifically instructed otherwise. NEVER drain or store fluids in an open container. Engine fuel
and hydraulic fluid are flammable and can cause a fire and/or
VENTILATION: Avoid prolonged engine operation in
explosion.
enclosed areas without adequate ventilation.
DO NOT mix gasoline or alcohol with diesel fuel. The mixture
SOFT SURFACES AND SLOPES: NEVER work on a machine
can cause an explosion.
that is parked on a soft surface or slope. The machine must be
on a hard level surface, with the wheels blocked before PRESSURE TESTING: When conducting any test, only use test
performing any service. equipment that is correctly calibrated and in good condition.
Use the correct equipment in the proper manner, and make
FLUID TEMPERATURE: NEVER work on a machine when the
changes or repairs as indicated by the test procedure to
engine, cooling or hydraulic systems are hot. Hot
achieve the desired result.
components and fluids can cause severe burns. Allow
systems to cool before proceeding. LEAVING MACHINE: Lower the forks or attachment to the
ground before leaving the machine.
FLUID PRESSURE: Before loosening any hydraulic or diesel
fuel component, hose or tube, turn the engine OFF. Wear TIRES: Always keep tires inflated to the proper pressure to
heavy, protective gloves and eye protection. NEVER check help prevent tipover. DO NOT over inflate tires.
for leaks using any part of your body; use a piece of NEVER use mismatched tire types, sizes or ply ratings.
cardboard or wood instead. If injured, seek medical attention Always use matched sets according to machine
immediately. Diesel fluid leaking under pressure can specifications.
explode. Hydraulic fluid and diesel fuel leaking under
MAJOR COMPONENTS: Never alter, remove, or substitute any
pressure can penetrate the skin, cause infection, gangrene
items such as counterweights, tires, batteries or other items
and other serious personal injury.
that may reduce or affect the overall weight or stability of the
Engine fuel lines are pressurized. DO NOT attempt repairs machine.
unless specific training has been completed.
BATTERY: DO NOT charge a frozen battery.Charging a frozen
Refer to the engine manufacturers manual for specific details
battery may cause it to explode. Allow the battery to thaw
concerning the fuel system.
before jump starting or connecting a battery charger.
Relieve all pressure before disconnecting any component,
part, line or hose. Slowly loosen parts and allow release of 1.7 SAFETY DECALS
residual pressure before removing any part or component.
Before starting the engine or applying pressure, use Check that all safety decals are present and readable on the
components, parts, hoses and pipes that are in good machine. Refer to the Operation & Safety Manual supplied
condition, connected properly and are tightened to the with machine for information.
proper torque. Capture fluid in an appropriate container and
dispose of in accordance with prevailing environmental
regulations.
COOLANT SYSTEM CAP: The cooling system is under
pressure, and escaping coolant can cause severe burns and
eye injury. To prevent personal injury, NEVER remove the
coolant system cap while the cooling system is hot. Wear
safety glasses. Turn the coolant system cap to the first stop
and allow pressure to escape before removing the cap
completely. Failure to follow the safety practices could result
in death or serious injury.
Properly disconnect battery(s) prior to service the fuel or
hydraulic systems.
1-4 31211333 3614RS, 4017RS

Section 2
General Information and Specifications
Contents

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.2 Hydraulic Cylinder Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2.3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.5 Transmission Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.6 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3 Fluids and Lubricant Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.1 Fluids (if equipped for ULS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.2 Fluids (if equipped for LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.4 Service and Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.1 Every 10 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.2 First 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.3 Every 50 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.4.4 First 250 Hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.5 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.6 Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.4.7 Every 1000 Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4.8 Every 3000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4.9 Every 6000 Hours or 4 years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.5 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5.1 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.5.2 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.6 Thread Locking Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.7 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.7.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.7.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
3614RS, 4017RS 31211333 2-1

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-27

2.8.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections 2-29
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections. 2-31
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.8.5 Assembly Instructions for 45° SAE Flare Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings. . . . . . . . . . . . . . . . . . . 2-37
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) . . 2-39
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings . . . . . . . . . . . . . . . . 2-53
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends . . . . . . . . . 2-61
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings . . . . . . . . . . . . . . . . 2-63
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62) . . . . . . . . . . . . . . 2-71
2.8.14 Double Wrench Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2.8.15 FFWR and TFFT Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
2.8.16 Adjustable Stud End Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
2.8.17 O-ring Installation (Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
2-2 31211333 3614RS, 4017RS

2.1 REPLACEMENT PARTS AND WARRANTY

INFORMATION
1
MAE34840
Before ordering parts or initiating service inquiries, make

note of the machine serial number. The machine serial
number plate (1) is located on the frame behind the right
front tire.
Note: The replacement of any part on this machine with any
other than factory authorized replacement parts can adversely
affect the performance, durability, or safety of the machine,
and will void the warranty. JLG disclaims liability for any claims
or damages, whether regarding property damage, personal
injury or death arising out of the use of unauthorized
replacement parts.
A warranty registration form must be filled out by the local
JLG dealer.
Registration activates the warranty period and helps to
assure that warranty claims are promptly processed to
guarantee full warranty service.
3614RS, 4017RS 31211333 2-3

2.2 SPECIFICATIONS
2.2.1 Travel Speeds
APPROXIMATE MAXIMUM SPEED

TRANSMISSION
74,4 kW 55,0 kW
First Gear 5 kph (3 mph) 5 kph (3 mph)
Second Gear 12 kph (7 mph) 9.5 kph (6 mph)
Third Gear 25 kph (15 mph) 19.3 kph (12 mph)
2.2.2 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.
APPROXIMATE TIMES (seconds)

FUNCTION
3614RS 4017RS
Boom Extend (Boom Level) 14.6 23.4
Boom Retract (Boom Level) 11.7 20.0
Boom Lift 15.0 21.0
Boom Lower 12.0 15.0
Quick Coupler Raise 3.1 3.1
Quick Coupler Lower 2.7 2.8
Frame Level - Full Right to Left 11.0 13.0
Frame Level - Full Left to Right 11.0 13.0
Outrigger - Both Down 6.9 7.0
Outrigger - Both Up 6.2 6.0
Outrigger - Single Down 4.4 4.5
Outrigger - Single Up 4.6 4.6
2-4 31211333 3614RS, 4017RS

2.2.3 Electrical System
Description Standard
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
2.2.4 Engine Performance Specifications
a. Prior to SN E160000342, excluding E160000328 thru E160000332 & E160000336
Specifications
Description
74,4 kW 55,0 kW
Engine Make/Model Deutz TCD 3.6 L4 Deutz TCD 3.6 L4
Displacement 3,6 liters (276 in³) 3,6 liters (276 in³)
Low Idle 945-955 rpm 945-955 rpm
High Idle 2295-2345 rpm 2295-2345 rpm
Horsepower 74,4 kW (99.7 HP) @ 2200 rpm 55,4 kW (74.3 HP) @ 2200 rpm
Peak Torque 410 Nm (302 lb-ft) @ 1600 rpm 390 Nm (288 lb-ft) @ 1300 rpm
Fuel Delivery Fuel Injection Fuel Injection
Dry Type, Replaceable Primary and Safety Dry Type, Replaceable Primary and Safety
Air Cleaner
Elements Elements
3614RS, 4017RS 31211333 2-5

b. SN E160000342 to present, including E160000328 thru E160000332 & E160000336
Specifications
Description
74,4 kW 55,0 kW
Engine Make/Model Deutz TCD 3.6 L4 Deutz TCD 3.6 L4
Displacement 3,6 liters (276 in³) 3,6 liters (276 in³)
Low Idle 945-955 rpm 945-955 rpm
High Idle 2295-2345 rpm 2295-2345 rpm
Horsepower 74,4 kW (99.7 HP) @ 2200 rpm 55,4 kW (74.3 HP) @ 2200 rpm
Peak Torque 410 Nm (302 lb-ft) @ 1600 rpm 405Nm (299 lb-ft) @ 1300 rpm
Fuel Delivery Fuel Injection Fuel Injection
Dry Type, Replaceable Primary and Safety Dry Type, Replaceable Primary and Safety
Air Cleaner
Elements Elements
2.2.5 Transmission Performance Specifications
Engine kW (Horsepower) Transmission Stall Speed

Deutz TCD 3.6 L4 74,4 (99.7) 3 Speed 2030 rpm 2050 rpm
Deutz TCD 3.6 L4 55,4 (74.3) 3 Speed 1930 rpm 1950 rpm
2.2.6 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
Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
15.5/80-24 TR01 16 Ply Pneumatic 4,1 Bar (59 psi)
Pneumatic 4,0 Bar (58 psi)
15.5-25 L-2 12 Ply
Foam 186 kg (410 lb)
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)
2-6 31211333 3614RS, 4017RS

b. 4017RS
Minimum Ply/
Size Tire Type Fill Type Pressure
Star Rating
14-24 TG02 16 Ply Pneumatic 4,25 Bar (62 psi)
Pneumatic 4,75 Bar (69 psi)
14-24 SGG-2A 16 Ply
Foam 245 kg (540lb)
14-24 L2/G2 Radial Pneumatic 5,5 Bar (80 psi)
400/75-28 DuraForce MH 16 Ply Pneumatic 5,25 Bar (76 psi)
3614RS, 4017RS 31211333 2-7

2.3 FLUIDS AND LUBRICANT CAPACITIES
2.3.1 Fluids (if equipped for ULS)

Ambient Temperature Range
Compartment or
Type and Classification Viscosities °F °C
System
Min Max Min Max
Deutz Specification SAE 15W-40 14 120 -10 49
Engine Crankcase DQC III-10 LA SAE 10W-40 5 120 -15 49
DQC IV-10 LA SAE 5W-40 -22 104 -30 40
Transmission and Transfer Mobilfluid 424 10W-30 0 104 -20 40
Case Mobilfluid LT 75W-80 -40 0 -40 -20
SAE140 50 122 10 50
80W-140
14 122 -10 50
85W-140
SAE90
Axle Differential and API GL5 with 32 104 0 40
SAE90LS
Wheel End LS Additives
80W-90
-4 104 -20 40
85W-90
75W-90 -40 104 -40 40
75W -40 50 -40 10
Mobilfluid 424 10W-30 0 104 -20 40
Hydraulic System
Exxon Univis HVI -40 0 -40 -20
Cylinder, Boom Wear
Pad and Boom Chain Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Lubricant
Axle Grease Extreme Pressure Grease NLGI Grade 2EP 5 122 -15 50
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Ultra Low Sulfur
Fuel
ASTM D975 Grade 1-D (S < 15 mg/kg)
(Maximum B5 Biodiesel)
Brake Fluid (if equipped
Mobil ATF 220 -40 122 -40 50
with 55 kW engine)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane
2-8 31211333 3614RS, 4017RS

2.3.2 Fluids (if equipped for LS)

Ambient Temperature Range
Compartment or System Type and Classification Viscosities °F °C
Min Max Min Max
Deutz Specification SAE 15W-40 14 120 -10 49
Engine Crankcase DQC III-10 SAE 10W-40 5 120 -15 49
DQC IV-10 SAE 5W-40 -22 104 -30 40
Transmission and Transfer Mobilfluid 424 10W-30 0 104 -20 40
Case Mobilfluid LT 75W-80 -40 0 -40 -20
SAE140 50 122 10 50
80W-140
14 122 -10 50
85W-140
SAE90
Axle Differential and API GL5 with 32 104 0 40
SAE90LS
Wheel End LS Additives
80W-90
-4 104 -20 40
85W-90
75W-90 -40 104 -40 40
75W -40 50 -40 10
Mobilfluid 424 10W-30 0 104 -20 40
Hydraulic System
Exxon Univis HVI -40 0 -40 -20
Cylinder, Boom Wear
Pad and Boom Chain Multipurpose Grease NLGI Grade 2 -22 104 -30 40
Lubricant
Axle Grease Extreme Pressure Grease NLGI Grade 2EP 5 122 -15 50
Ethylene Glycol 50/50 Mix Standard
Engine Coolant
and Water 60/40 Mix Cold Weather
EN590
ASTM D975 Grade 2-D Low Sulfur
Fuel
ASTM D975 Grade 1-D (S < 500 mg/kg)
(Maximum B5 Biodiesel)
Air Conditioning Refrigerant R-134-a Tetrafluoroethane
3614RS, 4017RS 31211333 2-9

2.3.3 Capacities
Engine Crankcase Oil

Capacity with Filter Change 8,0 liter (8.5 quart)
Fuel Tank
Capacity 150 liter (39.6 gallon)
Cooling System
System Capacity 19,0 liter (20 quart)
Transmission System
Capacity with Filter Change 13,5 liter (14.3 qt)
Transfer Case
Capacity 0,75 liter (0.79 qt)
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)
Axles
Differential Housing Capacity
3614RS
Front Axle 7,3 liter (7.7 quart)
Rear Axle 7,5 liter (7.9 quart)
4017RS
Rear Axle 7,5 liter (7.9 quart)
Wheel End Capacity
3614RS 1,4 liter (1.5 quart)
4017RS
Rear Axle
If Equipped with Pneumatic Tires 1,4 liter (1.5 quart)
If Equipped with Foam Filled Tires 2,1 liter (2.2 quart)
Air Conditioning System (if equipped)
System Capacity 1,0 kg (2.2 lb)
2-10 31211333 3614RS, 4017RS

2.4 SERVICE AND MAINTENANCE

SCHEDULES
2.4.1 Every 10 Hours
OC0880 OC0910 OC0920 OC0890 OC0970 OC0930
Check Fuel Level Check Engine Oil Check Hydraulic Check Tire Check Engine Check
Level Oil Level Condition & Coolant Level Transmission Oil
Pressure Level
OF0620
Check
LSI System
2.4.2 First 50 Hours
OC1110 OC1130 MAE19460 OC0990
Check Axle Check Wheel End Check Boom Chain Check Wheel Lug
Differential Oil Oil Level & Tension Nut Torque
Level
OC0960 OC0950 MAE19470 OC1150 OC1020 MAE8060
Drain Fuel/Water Check Air Filter Lubrication Check Check Washer Check cab Air Filter
Separator Schedule Battery Fluid Level
(if equipped)
3614RS, 4017RS 31211333 2-11

2.4.4 First 250 Hours
OC1070 OC1060 OC1040 OC1050
Check Change Transfer Change Axle Change Wheel End

Transmission Oil & Case Oil Differential Oil Oil
Filter
OC1100 MAE19480 OC1110 OC1130 MAE19490 MAE19460
Check Transfer Check Fan Belt Check Axle Check Wheel End Check Boom Wear Check Boom Chain
Case Oil Level Differential Oil Oil Level Pads & Tension
Level
OC1220 OC1140 MAE19620 OC0990 MAE19470

MAE19590
Change Fuel Filter Change Engine Oil Change Air Filter Check Wheel Lug Lubrication Check LSI
and Filter Elements Nut Torque Schedule Calibration
2-12 31211333 3614RS, 4017RS

2.4.7 Every 1000 Hour
OC1070 OC1060 OC1230 OC1040 OC1050
Change Change Transfer Change Hydraulic Change Axle Change Wheel End
Transmission Oil & Case Oil Fluid & Filter Differential Oil Oil
Filter
OC1160
Change Belt
2.4.9 Every 6000 Hours or 4 years
OC1240
Change Engine
Coolant
Note: If hour and year intervals are listed, use the interval that occurs first. Refer to Engine Operation & Maintenance Manual for
additional information.
3614RS, 4017RS 31211333 2-13

2.5 LUBRICATION SCHEDULE
2.5.1 3614RS
OAM3780
2-14 31211333 3614RS, 4017RS

2.5.2 4017RS
OAM3790
3614RS, 4017RS 31211333 2-15

2.6 THREAD LOCKING COMPOUND
JLG PN Loctite ND Industries Description

0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue)
1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue)
0100019 271™ Vibra-TITE™ 140 High Strength (Red)
0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red)
Loctite® 243™ can be substituted in place of Loctite® 242™. Vibra-TITE™ 122 can be substituted in place of Vibra-TITE™ 121.
2-16 31211333 3614RS, 4017RS

2.7 TORQUE CHARTS
2.7.1 SAE Fastener Torque Chart

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Tensile Stress Clamp Torque Torque (Loctite® 242™ or 271™ or
Size TPI Bolt Dia (Loctite® 262™ or
Area Load (Dry) Lubricated Vibra-TITE™
111 or 140) Vibra-TITE™ 131)
In Sq In LB IN-LB [N.m] IN-LB [N.m] 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 1.0 7 0.8
6 32 0.1380 0.00909 580 16 1.8 12 1.4
40 0.1380 0.01015 610 18 2.0 13 1.5
8 32 0.1640 0.01400 900 30 3.4 22 2.5
36 0.1640 0.01474 940 31 3.5 23 2.6
10 24 0.1900 0.01750 1120 43 4.8 32 3.5
32 0.1900 0.02000 1285 49 5.5 36 4
1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12
28 0.2500 0.0364 2320 120 13.5 86 10 135 15
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22
24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23
3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38
24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43
7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61
20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68
1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92
20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108
9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133
18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148
5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183
18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207
3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325
16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363
7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523
14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576
1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785
12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858
1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968
12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087
1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368
12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516
1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792
12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042
1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379
12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
3614RS, 4017RS 31211333 2-17

2.7.1 SAE Fastener Torque Chart (Continued)
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Tensile Stress (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
Area Vibra-TITE™ 111 or 140) Vibra-TITE™ 131)
K=0.20
K=0.18 K=0.15
In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 43 5
10 24 0.1900 0.01750 1580 60 7
32 0.1900 0.02000 1800 68 8
1/4 20 0.2500 0.0318 2860 143 16 129 15
28 0.2500 0.0364 3280 164 19 148 17
In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]
5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25
24 0.3125 0.0580 5220 25 35 25 35 20 25
3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50
24 0.3750 0.0878 7900 50 70 45 60 35 50
7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70
20 0.4375 0.1187 10700 80 110 70 95 60 80
1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110
20 0.5000 0.1599 14400 120 165 110 150 90 120
9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155
18 0.5625 0.2030 18250 170 230 155 210 130 175
5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220
18 0.6250 0.2560 23000 240 325 215 290 180 245
3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380
16 0.7500 0.3730 33600 420 570 380 515 315 430
7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620
14 0.8750 0.5090 45800 670 910 600 815 500 680
1 8 1.0000 0.6060 51500 860 1170 770 1045 645 875
12 1.0000 0.6630 59700 995 1355 895 1215 745 1015
1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310
12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475
1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855
12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055
1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430
12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760
1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225
12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS. 5000059K
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%.
3. * ASSEMBLY USES HARDENED WASHER.
2-18 31211333 3614RS, 4017RS

Values for Magni Coating Fasteners (Ref 4150701)

SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque Torque
Torque
Size TPI Bolt Dia Clamp Load (Dry)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604 380 7 0.8
48 0.1120 0.00661 420 8 0.9
6 32 0.1380 0.00909 580 14 1.5
40 0.1380 0.01015 610 14 1.6
8 32 0.1640 0.01400 900 25 2.8
36 0.1640 0.01474 940 26 2.9
10 24 0.1900 0.01750 1120 36 4.1
32 0.1900 0.02000 1285 42 4.7
1/4 20 0.2500 0.0318 2020 86 9.7 80 9
28 0.2500 0.0364 2320 99 11.1 95 11
5/16 18 0.3125 0.0524 3340 15 20 14 19 15 20
24 0.3125 0.0580 3700 15 20 15 21 15 20
3/8 16 0.3750 0.0775 4940 25 35 25 34 25 34
24 0.3750 0.0878 5600 30 40 28 38 25 34
7/16 14 0.4375 0.1063 6800 40 55 40 54 35 48
20 0.4375 0.1187 7550 45 60 44 60 40 54
1/2 13 0.5000 0.1419 9050 65 90 60 82 55 75
20 0.5000 0.1599 10700 75 100 71 97 65 88
9/16 12 0.5625 0.1820 11600 90 120 87 118 80 109
18 0.5625 0.2030 12950 105 145 97 132 90 122
5/8 11 0.6250 0.2260 14400 130 175 120 163 115 156
18 0.6250 0.2560 16300 145 195 136 185 125 170
3/4 10 0.7500 0.3340 21300 225 305 213 290 200 272
16 0.7500 0.3730 23800 255 345 238 324 225 306
7/8 9 0.8750 0.4620 29400 365 495 343 466 320 435
14 0.8750 0.5090 32400 400 545 378 514 355 483
1 8 1.0000 0.6060 38600 545 740 515 700 480 653
12 1.0000 0.6630 42200 600 815 563 765 530 721
1 1/8 7 1.1250 0.7630 42300 675 920 635 863 595 809
12 1.1250 0.8560 47500 755 1025 713 969 670 911
1 1/4 7 1.2500 0.9690 53800 955 1300 897 1219 840 1142
12 1.2500 1.0730 59600 1055 1435 993 1351 930 1265
1 3/8 6 1.3750 1.1550 64100 1250 1700 1175 1598 1100 1496
12 1.3750 1.3150 73000 1420 1930 1338 1820 1255 1707
1 1/2 6 1.5000 1.4050 78000 1660 2260 1560 2122 1465 1992
12 1.5000 1.5800 87700 1865 2535 1754 2385 1645 2237
3614RS, 4017RS 31211333 2-19


SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Torque Torque
Torque
Size TPI Bolt Dia Clamp Load (Dry or Loctite® 263)
K=0.17
K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474 1320 37 4
10 24 0.1900 0.01750 1580 51 6
32 0.1900 0.02000 1800 58 7
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
2-20 31211333 3614RS, 4017RS


SOCKET HEAD CAP SCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS.
IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
3614RS, 4017RS 31211333 2-21

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)*

SOCKET HEAD CAP SCREWS
Torque Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or (Loctite® 262™ or
Size TPI Bolt Dia
Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™ 131)
Precoat® 85 K=0.16 K=0.15
4 40 0.1120 0.00604
48 0.1120 0.00661
6 32 0.1380 0.00909
40 0.1380 0.01015
8 32 0.1640 0.01400
36 0.1640 0.01474
10 24 0.1900 0.01750
32 0.1900 0.02000
1/4 20 0.2500 0.0318 2860 122 14 114 13
28 0.2500 0.0364 3280 139 16 131 15
5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25
24 0.3125 0.0580 5220 25 35 20 25 20 25
3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50
24 0.3750 0.0878 7900 40 55 40 55 35 50
7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70
20 0.4375 0.1187 10700 65 90 60 80 60 80
1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110
20 0.5000 0.1599 14400 100 135 95 130 90 120
9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155
18 0.5625 0.2030 18250 145 195 135 185 130 175
5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220
18 0.6250 0.2560 23000 205 280 190 260 180 245
3/4 10 0.7500 0.3340 30100 320 435 300 415 280 380
16 0.7500 0.3730 33600 355 485 335 455 315 430
7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620
14 0.8750 0.5090 45800 570 775 535 730 500 680
1 8 1.0000 0.6060 51500 730 995 685 930 645 875
12 1.0000 0.6630 59700 845 1150 795 1080 745 1015
1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310
12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475
1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855
12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055
1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430
12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760
1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225
12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625
2-22 31211333 3614RS, 4017RS

2.7.2 Metric Fastener Torque Chart

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Tensile Stress Clamp Load Torque (Loctite® 242™ or 271™ or
Size Pitch Torque (Lube) (Loctite® 262™ or 271™ or
Area See Note 4 (Dry or Loctite® 263™) Vibra-TITE™ 111
Vibra-TITE™ 131)
or 141)
Sq mm KN [N.m] [N.m] [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 2.3
4 0.7 8.78 3.82 3.1 2.3 2.8 3.4
5 0.8 14.20 6.18 6.2 4.6 5.6 6.8
6 1 20.10 8.74 11 7.9 9.4 12
7 1 28.90 12.6 18 13 16 19
8 1.25 36.60 15.9 26 19 23 28
10 1.5 58.00 25.2 50 38 45 55
12 1.75 84.30 36.7 88 66 79 97
14 2 115 50.0 140 105 126 154
16 2 157 68.3 219 164 197 241
18 2.5 192 83.5 301 226 271 331
20 2.5 245 106.5 426 320 383 469
22 2.5 303 132.0 581 436 523 639
24 3 353 153.5 737 553 663 811
27 3 459 199.5 1080 810 970 1130
30 3.5 561 244.0 1460 1100 1320 1530
33 3.5 694 302.0 1990 1490 1790 2090
36 4 817 355.5 2560 1920 2300 2690
42 4.5 1120 487.0 4090 3070 3680 4290
3614RS, 4017RS 31211333 2-23

2.7.2 Metric Fastener Torque Chart (Continued)

CLASS 10.9 METRIC (HEX HEAD) BOLTS,
CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Torque
Torque
Torque (Lube or Loctite®
Clamp Load (Loctite® 262™ or
Size Pitch Tensile Stress Area (Dry or Loctite® 263™) 242™ or 271™ or
See Note 4 Vibra-TITE™ 131)
K=0.20 Vibra-TITE™ 111 or 140)
K=0.15
K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5
7 1 28.90 18.0 25 23 19
8 1.25 36.60 22.8 37 33 27
10 1.5 58.00 36.1 70 65 55
12 1.75 84.30 52.5 125 115 95
14 2 115 71.6 200 180 150
16 2 157 97.8 315 280 235
18 2.5 192 119.5 430 385 325
20 2.5 245 152.5 610 550 460
22 2.5 303 189.0 830 750 625
24 3 353 222.0 1065 960 800
27 3 459 286.0 1545 1390 1160
30 3.5 561 349.5 2095 1885 1575
33 3.5 694 432.5 2855 2570 2140
36 4 817 509.0 3665 3300 2750
42 4.5 1120 698.0 5865 5275 4395
2-24 31211333 3614RS, 4017RS

Values for Magni Coated Fasteners (Ref 4150701)*

CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS
Torque
Torque
Torque (Lube or Loctite® 242™ or (Loctite® 262™ or
Clamp Load
Size Pitch Tensile Stress Area (Dry or Loctite® 263™) 271™ or
See Note 4 Vibra-TITE™ 131)
K=0.17 Vibra-TITE™ 111 or 140) K=0.15
K=0.16
3 0.5 5.03 2.19 1.1 1.1 1.0
3.5 0.6 6.78 2.95 1.8 1.7 1.5
4 0.7 8.78 3.82 2.6 2.4 2.3
5 0.8 14.20 6.18 5.3 4.9 4.6
6 1 20.10 8.74 9 8.4 7.9
7 1 28.90 12.6 15 14 13
8 1.25 36.60 15.9 22 20 19
10 1.5 58.00 25.2 43 40 38
12 1.75 84.30 36.7 75 70 66
14 2 115 50.0 119 110 105
16 2 157 68.3 186 175 165
18 2.5 192 83.5 256 240 225
20 2.5 245 106.5 362 340 320
22 2.5 303 132.0 494 465 435
24 3 353 153.5 627 590 555
27 3 459 199.5 916 860 810
30 3.5 561 244.0 1245 1170 1100
33 3.5 694 302.0 1694 1595 1495
36 4 817 355.5 2176 2050 1920
42 4.5 1120 487.0 3477 3275 3070
3614RS, 4017RS 31211333 2-25

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*
Torque
(Lube or Loctite® Torque
Torque
Tensile Stress Clamp Load See (Loctite® 262™ or
Size Pitch (Dry or Loctite® 263™) 242™ or 271™ or
Area Note 4 Vibra-TITE™ 131)
K=0.17 Vibra-TITE™ 111 or 140) K=0.15
K=0.18
3 0.5 5.03 3.13
3.5 0.6 6.78 4.22
4 0.7 8.78 5.47
5 0.8 14.20 8.85
6 1 20.10 12.5 13 12 11
7 1 28.90 18.0 21 20 19
8 1.25 36.60 22.8 31 29 27
10 1.5 58.00 36.1 61 58 55
12 1.75 84.30 52.5 105 100 95
14 2 115 71.6 170 160 150
16 2 157 97.8 265 250 235
18 2.5 192 119.5 365 345 325
20 2.5 245 152.5 520 490 460
22 2.5 303 189.0 705 665 625
24 3 353 222.0 905 850 800
27 3 459 286.0 1315 1235 1160
30 3.5 561 349.5 1780 1680 1575
33 3.5 694 432.5 2425 2285 2140
36 4 817 509.0 3115 2930 2750
42 4.5 1120 698.0 4985 4690 4395
2-26 31211333 3614RS, 4017RS

2.8 HYDRAULIC CONNECTION ASSEMBLY SAE - 45° flare per SAE J512
AND TORQUE SPECIFICATION
2.8.1 Definitions
a. Tapered Thread Types
NPTF - National tapered fuel (dry seal) per SAE J476/J512

MAE9030
ORFS - O-ring face seal per SAE J1453
MAE9000 MAE9040
MBTL - Metric flareless bite type fitting, pressure rating L

BSPT - British standard pipe tapered per ISO7-1
(medium) per ISO 8434, DIN 2353
MBTS - Metric flareless bite type fitting, pressure rating S (high)
per ISO 8434, DIN 2353
MAE9050
MAE9010
BH - Bulkhead connection – JIC, ORFS, MBTL, or MBTS types

b. Straight Thread Types, Tube and Hose Connections
JIC - 37° flare per SAE J514
MAE9060
MAE9020
3614RS, 4017RS 31211333 2-27

c. Straight Thread Types, Port Connections d. Flange Connection Types

FL61 - Code 61 flange per SAE J518, ISO 6162
ORB - O-ring boss per SAE J1926, ISO 11926
FL62 - Code 62 flange per SAE J518, ISO 6162
MPP - Metric pipe parallel o-ring boss per SAE J2244,
ISO 6149, DIN 3852
MAE9090
MAE9070
e. Tightening Methods
MFF - Metric flat face port per ISO 9974-1 Torque - Application of a twisting force to the applicable
connection by use of a precise measurement instrument
BSPP - British standard parallel pipe per ISO 1179-1, (i.e. torque wrench).
DIN 3852-2
Finger Tight (Hand Tight) - The point where the connector
will no longer thread onto the mating part when tightened
by hand or fingers. Finger Tight is relative to user strength
and will have some variance. The average torque applied by
this method is 4 Nm (3 ft-lbs).
TFFT - Turns From Finger Tight; Application of a preload to a
connection by first tightening the connection by
hand (fingers) and applying an additional rotation counted
by a defined number of turns by use of a tool.
FFWR (Flat method) - Flats From Wrench Resistance;
Application of a preload to a connection by tightening to
the point of initial wrench resistance and turning the nut a
described number of flats. A flat is one side of the hexagonal
tube nut and equates to 1/6 of a turn.
f. Assembly and Torque Specifications

MAE9080
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the
connector being installed.
g. General Tube Type Fitting Assembly Instructions

1. Take precautions to ensure that fittings and mating
components are not damaged during storage, handling
or assembly. Nicks and scratches in sealing surfaces can
create a path for leaks which could lead to component
contamination and/or failure.
2. When making a connection to tubing, compression or
flare, inspect the tube in the area of the fitting
attachment to ensure that the tube has not been
damaged.
2-28 31211333 3614RS, 4017RS

3. The assembly process is one of the leading causes for 6. Refer to the appropriate section in this manual for more
contamination in air and hydraulic systems. specific instructions and procedures for each type of
Contamination can prevent proper tightening of fittings fitting connection.
and adapters from occurring.
a. Avoid using dirty or oily rags when handling fittings. 2.8.2 Assembly Instructions for American
Standard Pipe Thread Tapered
b. If fittings are disassembled, they should be cleaned
and inspected for damage. Replace fittings as
Connections
necessary before reinstalling. 1. Inspect components to ensure male and female port
c. Sealing compounds should be applied where threads are free of rust, splits, dirt, foreign matter, or
specified; however, care should be taken not to burrs.
introduce sealant into the system. 2. Apply a suitable thread sealant, such as Loctite 567, to
d. Avoid applying sealant to the area of the threads the male pipe threads if not already applied. Ensure the
where the sealant will be forced into the system. first 1 to 2 threads are uncovered to prevent system
This is generally the first two threads of a fitting. contamination.
e. Sealant should only be applied to the male threads. 3. Assemble connection hand tight.
f. Straight thread fittings do not require sealants. 4. Mark fittings, male and female
O-rings or washers are provided for sealing.
g. When replacing or installing an o-ring, care is to be
taken while transferring the o-ring over the threads
as it may become nicked or torn. When replacing an NOTICE
o-ring on a fitting, the use of a thread protector is
recommended. Over tightening may cause deformation of the pipe
fitting and damage to the joining fitting, flange or
h. When installing fittings with o-rings, lubrication
component may occur.
shall be used to prevent scuffing or tearing of the
o-ring. Refer to Section 2.8.17, “O-ring Installation
(Replacement)”, for procedure.
4. Take care to identify the material of parts to apply the
correct torque values. NOTICE
a. Verify the material designation in the table headings
Never back off (loosen) pipe threaded connectors to
b. If specifications are given only for steel fittings and achieve alignment. Meet the minimum required turns
components, the values for alternate materials shall and use the last turn for alignment.
be as follows:
Aluminum and Brass - reduce steel values by 35% 5. Rotate male fitting the number of turns as per below
Stainless Steel - Use the upper limit for steel. mentioned table. Refer to Section 2.8.15, “FFWR and
5. To achieve the specified torque, the torque wrench is to TFFT Methods”, for procedure.
be held perpendicular to the axis of rotation.
Note: TFFT values provided in below mentioned table are
applicable for the following material configurations:
a. Steel fittings with steel mating components
b. Steel fittings with aluminum or brass mating
components
c. Aluminum or brass fittings with steel mating
components
d. Aluminum or brass fittings with aluminum or brass
mating components.
MAE9100
3614RS, 4017RS 31211333 2-29

a. NPTF Pipe Thread
MAE9110
TYPE/FITTING IDENTIFICATION
Turns From Finger Tight
Thread Size ØA*
Material Dash Size (TFFT)**
(UNF) (in) (mm)
2 1/8 - 27 0.40 10.24 2 to 3
4 1/4 - 18 0.54 13.61 2 to 3
STEEL, ALUMINUM, OR 6 3/8 - 18 0.67 17.05 2 to 3
BRASS FITTINGS
8 1/2 - 14 0.84 21.22 2 to 3
WITH STEEL,
ALUMINUM, OR 12 3/4 - 14 1.05 26.56 2 to 3
BRASS
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5
MATING
COMPONENTS 20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5
24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.
2-30 31211333 3614RS, 4017RS

2.8.3 Assembly Instructions for British

Standard Pipe Thread Tapered
Connections
1. Inspect components to ensure male and female port
NOTICE
threads are free of rust, splits, dirt, foreign matter, or Never back off (loosen) pipe threaded connectors to
burrs. achieve alignment. Meet the minimum required turns
2. Apply a suitable thread sealant, such as Loctite 567, to and use the last turn for alignment.
the male pipe threads if not already applied. Ensure the 5. Rotate male fitting the number of turns as per below
first 1 to 2 threads are uncovered to prevent system mention table.
contamination.
Note: TFFT values provided in below table are applicable for
3. Assemble connection hand tight.
the following material configurations:
4. Mark fittings, male and female.
a. Steel fittings with steel mating components
NOTICE b. Steel fittings with aluminum or brass mating

components
c. Aluminum or brass fittings with steel mating
Over tightening may cause deformation of the pipe
components
fitting and damage to the joining fitting, flange or
component may occur. d. Aluminum or brass fittings with aluminum or brass
mating components.
a. BSPT Pipe Thread
MAE9120
Turns From Finger Tight
Thread Size ØA* (TFFT)**
Material Dash Size
(BSPT) (in) (mm)
2 1/8 - 28 0.38 9.73 2 to 3
4 1/4 - 19 0.52 13.16 2 to 3
STEEL, ALUMINUM, OR
BRASS FITTINGS 6 3/8 - 19 0.66 16.66 2 to 3
WITH STEEL, 8 1/2 - 14 0.83 20.96 2 to 3
ALUMINUM, OR 12 3/4 - 14 1.04 26.44 2 to 3
BRASS 16 1 - 11 1.31 33.25 1.5 to 2.5
MATING
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
COMPONENTS
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
NOTE: * ØA thread dimension for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for TFFT procedure requirements.
3614RS, 4017RS 31211333 2-31

This page left blank intentionally
2-32 31211333 3614RS, 4017RS

2.8.4 Assembly Instructions for 37° (JIC) Flare 2. Align tube to fitting and start threads by hand.
Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
NOTICE
surface is smooth, free of rust, weld and brazing splatter, The torque method should NOT be used on lubricated or
splits, dirt, foreign matter, or burrs. If necessary, replace oily fittings. No lubrication or sealant is required. The
fitting or adapter. lubrication would cause increased clamping force and
cause fitting damage.
NOTICE 3. Torque assembly to value listed in below mentioned
table while using the Double Wrench Method.
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint Note: Torque values provided in below table are segregated
eventually leading to leakage. based on the material configuration of the connection.
a. 37° Flare (JIC) Thread - Steel
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --

3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2
STEEL FITTINGS
WITH STEEL 8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4
MATING
10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2
THREADS
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
NOTE: * ØA and ØB thread dimensions for reference only.

** Refer to Section 2.8.15, “FFWR and TFFT Methods”, for FFWR procedure requirements.
3614RS, 4017RS 31211333 2-33

b. 37° Flare (JIC) Thread - Aluminum Brass
MAE9130
TYPE/FITTING IDENTIFICATION Flats From

Thread ØA* ØB* [Ft-Lb] [Nm] Wrench
Dash Size Resistance
Material Size (F.F.W.R)**
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --

3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2
ALUMINUM/BRASS 6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2

FITTINGS OR
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4
ALUMINUM/BRASS
MATING 10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2
THREADS 14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1

2-34 31211333 3614RS, 4017RS

2.8.5 Assembly Instructions for 45° SAE Flare

Fittings
1. Inspect the flare for obvious visual squareness and
concentricity issues with the tube OD. Ensure that
surface is smooth, free of rust, weld and brazing splatter,
splits, dirt, foreign matter, or burrs. If necessary, replace
fitting or adapter.
NOTICE
DO NOT force a misaligned or short hose/tube into
alignment. It puts undesirable strain onto the joint
eventually leading to leakage.
2. Align tube to fitting.

3. Tighten fitting by hand until hand tight.
NOTICE
The torque method should NOT be used on lubricated or
oily fittings. No lubrication or sealant is required. The
lubrication would cause increased clamping force and
Torque fitting to value listed in below table while using the

Double Wrench Method outlined in this section.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
‘Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following material
configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
3614RS, 4017RS 31211333 2-35

a. 45° Flare (SAE)
MAE9140
STEEL
TYPE/FITTING IDENTIFICATION TORQUE

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19

STEEL FITTINGS
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
WITH STEEL MATING
COMPONENTS; 8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
UN-LUBRICATED
THREADS 10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
ALUMINUM BRASS

Thread ØA* ØB* [Ft-Lb] [Nm]
Dash Size
Material Size
ALUMINUM/BRASS 4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12

FITTINGS OR 6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20
ALUMINUM/BRASS
MATING 8 3/4-16 0.69 17.50 0.75 19.10 27 29 30 37 39 41
COMPONENTS;
UN-LUBRICATED 10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
THREADS
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83
2-36 31211333 3614RS, 4017RS

2.8.6 Assembly Instructions for O-Ring Face

Seal (ORFS) Fittings
1. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement)”, for
procedure.
2. Ensure that surface is smooth, free of rust, weld and
brazing splatter, splits, dirt, foreign matter, or burrs. If
necessary, replace fitting or adapter.
NOTICE
Care to be taken when lubricating o-ring. Avoid adding
oil to the threaded connection of the fitting. The
3. Pre-lubricate the o-ring with hydraulic oil.

4. Place the tube assembly against the fitting body so that
the flat face comes in contact with the o-ring. Hand
thread the nut onto the fitting body.
5. Torque nut to value listed in below mentioned table
while using the Double Wrench Method. Refer to
Section 2.8.15, “FFWR and TFFT Methods”, for procedure
if using the FFWR method.
Note: Torque values provided in below table are segregated
based on the material configuration of the connection.
Aluminum/brass fittings or aluminum/brass mating
components’ indicate either the following
material configurations:
a. Steel fittings with aluminum or brass mating
components
b. Aluminum or brass fittings with steel mating
components
c. Aluminum or brass fittings with aluminum or brass
mating components.
3614RS, 4017RS 31211333 2-37

a. O-ring Face Seal (ORFS)
MAE9150
STEEL

Thread
Dash ØA* ØB* [Ft-Lb] [Nm] Tube Swivel &
Material Size
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
STEEL FITTINGS 8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4
WITH 10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4
STEEL MATING
12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
COMPONENTS;
UN-LUBRICATED 16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4

ALUMINUM/BRASS
FLATS FROM
WRENCH
RESISTANCE
(F.F.W.R)**
Thread
ØA* ØB* [Ft-Lb] [Nm]
Dash Size Tube Swivel &
Material
Size Nuts Hose Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4

6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
ALUMINUM/BRASS 8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4
FITTINGS OR
ALUMINUM/BRASS 10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4
MATING 12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
COMPONENT;
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
UN-LUBRICATED
THREADS 20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

2-38 31211333 3614RS, 4017RS

2.8.7 Assembly Instructions for DIN 24° Flare

Bite Type Fittings (MBTL and MBTS)
NOTICE
A non-square tube end can cause improperly seated
fittings and leakage.
6. Inspect the components to ensure free of
contamination, external damage, rust, splits, dirt,
foreign matter, or burrs. Ensure tube end is visibly
square. If necessary, replace fitting or tube.
7. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
8. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
9. Push the tube end into the coupling body.
10. Slide collet into position and tighten until finger tight.
Mark nut and tube in the finger-tight position. Tighten
nut to the number of flats listed while using the Double
Wrench Method. The tube must not turn with the nut.
3614RS, 4017RS 31211333 2-39

a. DIN 24° CONE (MBTL & MBTS)
MAE9160
DIN 24° CONE FLARELESS BITE FITTING

(WITH OR WITHOUT O-RING)
Tube Thread Torque Flats From
ØA* ØB* C* ØD*
O.D. M Size [Ft-Lb] [Nm] Wrench
Material Type
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75
FFWR is the recommended method of
10 M16 x 1.5 14.50 16.00 7.00 10.20 fitting assembly. 1.5 to 1.75
DIN 12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
Torque values are application specific
24° CONE 15 M22 x 1.5 20.50 22.00 7.00 15.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
BITE (MBTL) 18 M26 x 1.5 24.50 26.00 7.50 18.20 characteristic of the connection. 1.5 to 1.75
FITTING 22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
Consult Engineering on the
28 M36 x 2 33.90 36.00 7.50 28.20 generation of torque values for the 1.5 to 1.75
particular application.
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75
42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
STEEL Tube Thread Torque Flats From

ØA* ØB* C* ØD*
FITTINGS WITH O.D. M Size [Ft-Lb] [Nm] Wrench
Type
STEEL MATING Resistance
COMPONENTS (mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75

FFWR is the recommended method of
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75
fitting assembly.
10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
DIN 12 M20 x 1.5 18.50 20.00 7.50 12.20 Torque values are application specific 1.5 to 1.75
24° CONE 14 M22 x 1.5 20.50 22.00 8.00 14.20 due to variability in the fitting supplier, 1.5 to 1.75
FLARELESS coating, lubrication, and other physical
16 M24 x 1.5 22.50 24.00 8.50 16.20 characteristics of the connection. 1.5 to 1.75
BITE (MBTS)
FITTING 20 M30 x 2 27.90 30.00 10.50 20.20 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 Consult Engineering on the 1.5 to 1.75
generation of torque values for the
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
particular application.
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
NOTE: * ØA, ØB,C, & ØD thread dimensions for reference only.

2-40 31211333 3614RS, 4017RS

2.8.8 Assembly Instructions for Bulkhead (BH)

Fittings
1. Ensure that threads and surface are free of rust, weld
and brazing splatter, splits, burrs or other foreign
material. If necessary, replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
5. Torque nut onto fitting while using the Double Wrench
Method.
3614RS, 4017RS 31211333 2-41

a. Bulkhead Fittings (BH) - INCH
MAE9170
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Thread Torque
Dash Size
Material Type [Ft-Lb] [Nm]
Size
(UNF) Min Nom Max Min Nom Max
4 9/16-18 15 16 17 20 22 23
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
O-RING FACE 10 1-14 85 90 94 115 122 127
SEAL (ORFS)
12 1 3/16-12 135 142 149 183 193 202
BULKHEAD
FITTING 14 1 5/16-12 170 179 187 230 243 254
16 1 7/16-12 200 210 220 271 285 298
20 1 11/16-12 245 258 270 332 350 366
24 2-12 270 284 297 366 385 403
Thread Torque
Dash Size
Type [Ft-Lb] [Nm]
Size
STEEL (UNF) Min Nom Max Min Nom Max
FITTINGS 3 3/8-24 8 9 9 11 12 12
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
6 9/16-18 25 27 28 34 37 38
8 3/4-16 50 53 55 68 72 75
37° FLARE (JLIC) 10 7/8-14 85 90 94 115 122 127
BULKHEAD
12 1 1/16-12 135 142 149 183 193 202
FITTING
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
2-42 31211333 3614RS, 4017RS

b. Bulkhead Fittings (BH) - METRIC
MAE9180
FASTENING JAM NUT

FOR BULKHEAD CONNECTORS
Connecting Thread Torque
Material Type Tube O.D. M Size [Ft-Lb] [Nm]
(mm) (metric) Min Nom Max Min Nom Max
6 M12 x 1.5 14 15 16 19 20 22
8 M14 x 1.5 17 18 19 23 24 26
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
DIN 24° CONE
FLARELESS BITE 15 M22 x 1.5 44 47 50 60 64 68
(MBTL) BULKHEAD 18 M26 x 1.5 70 75 80 95 102 108
FITTING
22 M30 x 2 115 120 125 156 163 169
28 M36 x 2 150 157 164 203 213 222
35 M45 x 2 155 162 169 210 220 229
42 M52 x 2 220 230 240 298 312 325
Connecting Thread Torque
STEEL Tube O.D. M Size
Type [Ft-Lb] [Nm]
FITTINGS
(mm) (metric) Min Nom Max Min Nom Max
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
10 M18 x 1.5 35 23 24 47 31 33
12 M20 x 1.5 40 35 37 54 47 50
DIN 24° CONE
FLARELESS BITE 14 M22 x 1.5 44 47 50 60 64 68
(MBTS) BULKHEAD 16 M24 x 1.5 70 75 80 95 102 108
FITTING 20 M30 x 2 115 120 125 156 163 169
25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
3614RS, 4017RS 31211333 2-43

2-44 31211333 3614RS, 4017RS

2.8.9 Assembly Instructions for O-Ring Boss

(ORB) Fittings
1. Inspect components to ensure that male and female
port threads are free of rust, splits, dirt, foreign matter,
or burrs.
2. Ensure proper o-ring is installed. If o-ring is missing
install per o-ring Installation (replacement). Refer to
Section 2.8.17, “O-ring Installation (Replacement)”, for
procedure.
NOTICE

4. For non-adjustable and plugs, thread the fitting by hand
until contact.
5. For adjustable fittings, refer to Section 2.8.16,
“Adjustable Stud End Assembly”, for proper assembly.
6. Torque the fitting or nut to value while using the
Double Wrench Method.
a. The table headings identify the straight thread
o-ring port and the type on the other side of the
fitting. The torque will be applied to the straight
thread o-ring port.
b. Torque values are segregated based on the material
configuration of the connection. ‘Aluminum/brass
fittings or aluminum/brass mating components’
indicate either the following material
configurations:
• Steel fittings with aluminum or brass mating
components
• Aluminum or brass fittings with steel mating
components
• Aluminum or brass fittings with aluminum or brass
mating components.
7. Inspect to ensure the o-ring is not pinched and the
washer is seated flat on the counter bore of the port.
3614RS, 4017RS 31211333 2-45

a. O-ring Boss (ORB) - Table 1 of 6
MAE9190
HEX TYPE PLUGS & STUD ENDS

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
Material Dash Size Size [Ft-Lb] [Nm]
(UNF) (in) (mm) Min Nom Max Min Nom Max
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
NOTE: 1. * ØA thread OD dimension for reference only.

2. Removal torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
2-46 31211333 3614RS, 4017RS

b. O-ring Boss (ORB) - Table 2 of 6
MAE9190
STUD ENDS
WITH (ORFS) OR S ERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

3614RS, 4017RS 31211333 2-47

c. O-ring Boss (ORB) - Table 3 of 6
MAE9210
ADJUSTABLE STUD END

WITH 37° (JIC) OR L SERIES DIN (MBTL) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
5 1/2-20 0.50 12.70 23 25 26 32 34 35
STEEL FITTINGS 6 9/16-18 0.56 14.28 29 31 32 40 42 43
WITH STEEL 8 3/4-16 0.75 19.10 52 55 57 70 75 77
MATING
10 7/8-14 0.87 22.22 85 90 94 115 122 127
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13
4 7/16-20 0.44 11.11 14 15 16 19 20 22
5 1/2-20 0.50 12.70 15 16 17 20 22 23
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 19 20 21 26 27 28
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 34 36 37 46 49 50
MATING 10 7/8-14 0.87 22.22 55 58 61 75 79 83
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-48 31211333 3614RS, 4017RS

d. O-ring Boss (ORB) - Table 4 of 6
MAE9220
ADJUSTABLE STUD END

WITH (ORFS) OR S SERIES DIN (MBTS) OPPOSITE END
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45
STEEL FITTINGS 6 9/16-18 0.56 14.28 35 37 39 46 50 53
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 -- -- -- -- -- --
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 20 21 21 27 28 28
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 23 24 24 31 33 33
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

3614RS, 4017RS 31211333 2-49

e. O-ring Boss (ORB) - Table 5 of 6
MAE9230
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
4 7/16-20 0.44 11.11 10 11 11 14 15 15
5 1/2-20 0.50 12.70 14 15 16 19 20 22
STEEL FITTINGS 6 9/16-18 0.56 14.28 34 36 38 46 49 52
WITH STEEL 8 3/4-16 0.75 19.10 60 63 66 80 85 89
MATING
10 7/8-14 0.87 22.22 100 105 110 135 142 149
COMPONENTS;
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
THREADS 14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
Thread Torque
ØA*
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5
4 7/16-20 0.44 11.11 6 7 7 8 9 9
5 1/2-20 0.50 12.70 9 10 10 12 14 14
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 22 24 25 30 33 34
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 39 41 43 53 56 58
MATING 10 7/8-14 0.87 22.22 65 69 72 88 94 98
COMPONENTS; 12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10 114 120 126 155 163 171
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363

2-50 31211333 3614RS, 4017RS

f. O-ring Boss (ORB) - Table 6 of 6
MAE9240
ZERO LEAK GOLD®

HOLLOW HEX PLUGS
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
6 9/16-18 0.56 14.28 11 12 13 15 16 18
STEEL FITTINGS WITH
STEEL MATING 8 3/4-16 0.75 19.10 28 30 32 38 41 43
COMPONENTS; 10 7/8-14 0.87 22.22 46 48 50 62 65 68
UN-LUBRICATED 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
THREADS
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50
Thread Torque
ØA*
2 5/16-24 0.31 7.93 2 3 4 3 4 5
3 3/8-24 0.37 9.52 3 4 5 4 5 7
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
ALUMINUM/BRASS 6 9/16-18 0.56 14.28 11 12 13 15 16 18
FITTINGS OR
ALUMINUM/BRASS 8 3/4-16 0.75 19.10 28 30 32 38 41 43
MATING 10 7/8-14 0.87 22.22 46 48 50 62 65 68
COMPONENTS; 12 1 1/16-12 1.06 27.00 51 54 57 69 73 77
UN-LUBRICATED
THREADS 14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on
Caterpillar applications.
20 1 5/8-12 1.63 41.30
Consult specific service procedure if
24 1 7/8-12 1.87 47.60 encountered.
32 2 1/2-12 2.50 63.50

3614RS, 4017RS 31211333 2-51

2-52 31211333 3614RS, 4017RS

2.8.10 Assembly Instructions for Adjustable

Port End Metric Fittings
threads and surfaces are free of rust, splits, dirt, foreign
matter, or burrs.
2. If o-ring is not pre-installed, install proper size, taking
care not to damage it. Refer to Section 2.8.17, “O-ring
Installation (Replacement)”, for procedure.
NOTICE

4. For non-adjustable fittings and plugs, thread the fitting
by hand until contact.
a. The table headings identify the Metric port and the
type on the other side of the fitting. The torque will
be applied to the Metric port.
configurations:
components
components
mating components.
3614RS, 4017RS 31211333 2-53

a. Metric Flat Face Port (MFF) L Series - Table 1 of 3
MAE9260
MAE9250
FORM A (SEALING WASHER) FORM B (CUTTING FACE)

TYPE/FITTING STUD ENDS STUD ENDS
IDENTIFICATION WITH 37° (JIC) or L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
OPPOSITE END OPPOSITE END
Thread Connecting Torque Torque
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
STEEL FITTINGS
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
WITH STEEL
MATING M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153
UN-LUBRICATED
M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
THREADS
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
Material M Size Tube O.D

[Ft-Lb] [Nm] [Ft-Lb] [Nm]
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
ALUMINUM/BRASS
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
FITTINGS OR M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
ALUMINUM/BRASS M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
MATING
COMPONENTS; M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
UN-LUBRICATED M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
THREADS
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
2-54 31211333 3614RS, 4017RS

b. Metric Flat Face Port (MFF) L Series - Table 2 of 3
MAE9280
MAE9270

IDENTIFICATION WITH 37° (JIC) OR L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)

M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
STEEL FITTINGS
WITH STEEL M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
MATING M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
COMPONENTS; M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99
UN-LUBRICATED M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
THREADS
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

(UNF) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
BRASS FITTINGS
OR ALUMINUM/ M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
BRASS M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
MATING M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
COMPONENTS; M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
3614RS, 4017RS 31211333 2-55

c. Metric Flat Face Port (MFF) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

BANJO FITTINGS FORM E (EOLASTIC
TYPE/FITTING FITTINGS
WITH L SERIES DIN (MBTL) SEALING RING)
IDENTIFICATION WITH L SERIES DIN (MBTL)
OPPOSITE END HOLLOW HEX PLUGS
OPPOSITE END
Thread Connecting Torque Torque Torque
Material M Size Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
STEEL FITTINGS
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
WITH STEEL
MATING M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
UN-LUBRICATED
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
ALUMINUM/ M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
BRASS FITTINGS
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
OR ALUMINUM/
BRASS M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
MATING M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
COMPONENTS;
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98
UN-LUBRICATED
THREADS M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
2-56 31211333 3614RS, 4017RS

d. Metric Flat Face Port (MFF) S Series - Table 1 of 3
MAE9320 MAE9330

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

Material M Size Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
STEEL FITTINGS
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121
WITH STEEL
MATING M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
COMPONENTS; M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187
UN-LUBRICATED
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297
THREADS
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770

M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
BRASS FITTINGS
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
OR ALUMINUM/
BRASS M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
MATING M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
COMPONENTS;
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
3614RS, 4017RS 31211333 2-57

e. Metric Flat Face Port (MFF) S Series - Table 2 of 3
MAE9350
MAE9340

IDENTIFICATION WITH (ORFS) OR S SERIES DIN (MBTS) WITH (ORFS) OR S SERIES DIN (MBTS)

M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
STEEL FITTINGS
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
WITH STEEL
MATING M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137
COMPONENTS; M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
UN-LUBRICATED
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594

M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
ALUMINUM/ M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
BRASS FITTINGS
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
OR ALUMINUM/
BRASS M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
MATING M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
COMPONENTS;
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
2-58 31211333 3614RS, 4017RS

f. Metric Flat Face Port (MFF) S Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION WITH S SERIES DIN (MBTS)
OPPOSITE END

M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
STEEL FITTINGS
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
WITH STEEL
MATING M18x1.5 15 81 85 89 110 115 121 92 97 101 125 132 137 59 62 65 80 84 88
COMPONENTS; M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
UN-LUBRICATED
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
THREADS
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --

M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
ALUMINUM/
BRASS M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
FITTINGS OR M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
ALUMINUM/ M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
BRASS
MATING M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
COMPONENTS; M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --
UN-LUBRICATED M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
THREADS
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
3614RS, 4017RS 31211333 2-59

2-60 31211333 3614RS, 4017RS

2.8.11 Assembly Instructions for Metric ISO

6149 Port Assembly Stud Ends
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement)”.
NOTICE

a. The table headings identify the Metric port and the
be applied to the Metric port.
configurations:
components
components
mating components.
3614RS, 4017RS 31211333 2-61

a. Metric Pipe Parallel O-Ring Boss (MPP)
MAE9370 MAE9380
MAE9360
TYPE/FITTING STUD ENDS WITH 37° (JIC) OR L SERIES STUD ENDS WITH (ORFS) OR S SERIES
IDENTIFICATION DIN (MBTL) OPPOSITE END DIN (MBTS) OPPOSITE END

M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16 16 15 16 17 20 22 23
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
STEEL FITTINGS M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
WITH STEEL M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
MATING
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110
COMPONENTS;
UN-LUBRICATED M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
THREADS M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
ALUMINUM/ M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
BRASS FITTINGS M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
OR ALUMINUM/ M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
BRASS
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
MATING
COMPONENTS; M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
UN-LUBRICATED M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
THREADS M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
2-62 31211333 3614RS, 4017RS

2.8.12 Assembly Instructions for Adjustable

Port End (BSPP) Fittings
matter, or burrs.
2. If o-ring is not pre installed, install proper size, taking
Installation (Replacement)”, for instructions.
NOTICE

a. The table headings identify the BSPP port and the
be applied to the BSPP port.
configurations:
components
components
mating components.
3614RS, 4017RS 31211333 2-63

a. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
MAE9390 MAE9400
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING STUD ENDS WITH 37° (JIC) or STUD ENDS
IDENTIFICATION L SERIES DIN (MBTL) WITH 37° (JIC) OR L SERIES DIN (MBTL)
Torque Torque
Connecting
BSPP
Tube O.D.
Material Thread [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
MATING G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153
COMPONENTS; G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
UN-LUBRICATED G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198
THREADS G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
Connecting Torque Torque

BSPP
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
BRASS
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
MATING
COMPONENTS; G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
UN-LUBRICATED G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
THREADS G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
NOTE: ** Non typical for Straight Male Stud Fittings, reference only.
2-64 31211333 3614RS, 4017RS

b. British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
MAE9410 MAE9420
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH 37° (JIC) OR STUD ENDS WITH 37° (JIC) OR
IDENTIFICATION
L SERIES DIN (MBTL) OPPOSITE END L SERIES DIN (MBTL) OPPOSITE END

BSPP
G Size
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
STEEL FITTINGS G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
WITH STEEL G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
MATING G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
UN-LUBRICATED G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
THREADS G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
ALUMINUM/ G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
BRASS FITTINGS G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
OR ALUMINUM/ G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
BRASS
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
MATING
COMPONENTS; G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
UN-LUBRICATED G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
THREADS G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
3614RS, 4017RS 31211333 2-65

c. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9310
MAE9290 MAE9300
HIGH PRESSURE BANJO

TYPE/FITTING FITTINGS WITH
WITH S SERIES DIN (MBTS) SEALING RING)
IDENTIFICATION S SERIES DIN (MBTS)
OPPOSITE END
Torque Torque Torque
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
(mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
WITH STEEL
MATING G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
COMPONENTS; G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
UN-LUBRICATED
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
THREADS
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
BSPP Connecting
Material Thread Tube O.D [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
ALUMINUM/
BRASS G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
FITTINGS OR G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
ALUMINUM/ G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
BRASS
MATING G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
COMPONENTS; G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99
UN-LUBRICATED G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
THREADS
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321
2-66 31211333 3614RS, 4017RS

d. British Standard Parallel Pipe Port (BSPP) S Series - Table 1 of 3
MAE9430 MAE9440
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)

TYPE/FITTING
STUD ENDS WITH (ORFS) OR STUD ENDS WITH (ORFS) OR
IDENTIFICATION
S SERIES DIN (MBTS) OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END
BSPP Connecting Torque Torque

G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
STEEL FITTINGS
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
WITH STEEL
MATING G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165
COMPONENTS; G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
UN-LUBRICATED
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297
THREADS
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Connecting Torque Torque
G Size (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
ALUMINUM/ G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
BRASS FITTINGS
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
OR ALUMINUM/
BRASS G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
MATING G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
COMPONENTS;
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
UN-LUBRICATED
THREADS G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500
3614RS, 4017RS 31211333 2-67

e. British Standard Parallel Pipe Port (BSPP) S Series - Table 2 of 3
MAE9460
MAE9450
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING

TYPE/FITTING STUD ENDS AND HEX TYPE PLUGS RING) STUD ENDS & ADJUSTABLE
IDENTIFICATION WITH (ORFS) or S SERIES DIN (MBTS) STUD ENDS WITH (ORFS) OR
OPPOSITE END S SERIES DIN (MBTS) OPPOSITE END

BSPP
G Size
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
STEEL FITTINGS
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
WITH STEEL
MATING G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99
COMPONENTS; G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
UN-LUBRICATED
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
THREADS
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594

BSPP
G Size
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
ALUMINUM/ G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
BRASS FITTINGS
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
OR ALUMINUM/
BRASS G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
MATING G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
COMPONENTS;
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
UN-LUBRICATED
THREADS G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386
NOTE: * Typical for Straight Male Stud Fittings

***Typical for Adjustable Fittings.
2-68 31211333 3614RS, 4017RS

f. British Standard Parallel Pipe Port (BSPP) L Series - Table 3 of 3
MAE9290 MAE9300
MAE9470
BANJO FITTINGS HIGH PRESSURE BANJO

TYPE/FITTING JIS/BSPP O-RING
WITH S SERIES DIN (MBTS) FITTINGS WITH S SERIES
IDENTIFICATION ONLY
OPPOSITE END DIN (MBTS) OPPOSITE END

BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77 Fitting type not typically
STEEL FITTINGS
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 specified on Caterpillar
WITH STEEL
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133 applications.
MATING
COMPONENTS; G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133 Refer to the specific
UN-LUBRICATED
G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure
THREADS
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353 in this Service Manual.
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770
BSPP Connecting
Material Thread Tube O.D. [Ft-Lb] [Nm] [Ft-Lb] [Nm] [Ft-Lb] [Nm]
G Size
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
ALUMINUM/ G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50 Fitting type not typically
BRASS FITTINGS
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 specified on Caterpillar
OR ALUMINUM/
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87 applications.
BRASS
MATING G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87 Refer to the
COMPONENTS;
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 specific procedure in
UN-LUBRICATED
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229 this Service Manual.
THREADS
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499
3614RS, 4017RS 31211333 2-69

2-70 31211333 3614RS, 4017RS

2.8.13 Assembly Instructions for Flange

Connections (FL61 and FL62)
1. Ensure sealing surfaces are free of rust, splits, scratches,
dirt, foreign matter, or burrs.
2. Pre-lubricate the O-ring with hydraulic oil.
3. Position flange and clamp halves.
4. Place lock washers on bolt and bolt through clamp
halves.
5. Tighten all bolts by hand.
6. Torque bolts in diagonal sequence in two or more
increments to the torque listed.
3614RS, 4017RS 31211333 2-71

a. Flange Code (FL61 & FL62) - Inch Fasteners
MAE9480
STEEL 4-BOLT FLANGE SAE J518
(INCH FASTENERS)
Fastener Torque for Fastener Torque for
Inch Bolt Flanges Equipped with Flanges Equipped with
Flange Flange
A* Thread GRADE 5 Screws GRADE 8 Screws
Type SAE Size
Size
Dash [Ft-Lb] [Nm] [Ft-Lb] [Nm]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
CODE 61 24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
SPLIT
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
FLANGE
(FL61) 40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
Inch Bolt Fastener Torque for Flanges Fastener Torque for Flanges
Flange Flange Equipped with GRADE 5 Screws Equipped with GRADE 8 Screws
A* Thread
Type SAE Size
Size
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 3/8-16 -- -- -- -- -- -- 44 46 49 60 63 66
CODE 62 16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101
SPLIT
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
FLANGE
(FL62) 20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
NOTE: * A dimension for reference only.
2-72 31211333 3614RS, 4017RS

b. Flange Code (FL61 & FL62) - Metric Fasteners
MAE9480
TYPE/FITTING STEEL 4-BOLT FLANGE SAE J518

IDENTIFICATION (INCH FASTENERS)
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE CLASS 8.8 Screws CLASS 10.9 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.50 38.10
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
CODE 61 24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
SPLIT
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
FLANGE
(FL61) 40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
Inch Fastener Torque for Fastener Torque for
Bolt Flanges Equipped with Flanges Equipped with
Flange Flange Size A* Thread
Type SAE GRADE 5 Screws GRADE 8 Screws
Size
Size (in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77
CODE 62 16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
SPLIT
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
FLANGE
(FL62) 20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
NOTE: * A dimension for reference only.
3614RS, 4017RS 31211333 2-73

2.8.14 Double Wrench Method

To prevent undesired hose or connector rotation, two
wrenches must be used; one torque wrench and one
back- up wrench. If two wrenches are not used,
inadvertent component rotation may occur which
absorbs torque and causes improper joint load and leads
to leaks. For hose connections, the ‘layline’ printed on the
hose is a good indicator of proper hose installation. A
twisted lay-line usually indicates the hose is twisted.
Double Wrench Method to Prevent Hose Twist
MAE9490
2-74 31211333 3614RS, 4017RS

2.8.15 FFWR and TFFT Methods 2.8.16 Adjustable Stud End Assembly
1. FFWR (Flats from Wrench Resistance Method) For Adjustable Stud End Connections; the following
a. Tighten the swivel nut to the mating fitting until no assembly steps are to be performed:
lateral movement of the swivel nut can be detected; a. Lubricate the o-ring with a light coat of hydraulic oil.
finger tight condition.
b. Position #1 – The o-ring should be located in the
b. Mark a dot on one of the swivel hex nut flats and groove adjacent to the face of the back-up washer.
another dot in line on the connecting tube adapter. The washer and o-ring should be positioned at the
c. Use the double wrench method per Appendix A, extreme top end of the groove as shown.
turn the swivel nut to tighten. The nut is to be c. Position #2 – Position the locknut to just touch the
rotated clockwise the number of hex flats. back-up washer as shown. The locknut in this
d. After the connection has been properly tightened, position will eliminate potential back up washer.
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has 2.8.17 O-ring Installation (Replacement)
been properly tightened.
Care must be taken when installing o-rings over threads dur-
ing replacement or installation. O-rings could become
FFWR Method
nicked or torn. A damaged o-ring could lead to leakage
problems.
1. Inspect o-ring for tears or nicks. If any are found replace
o-ring.
2. Ensure proper o-ring to be installed. Many o-rings look
the same but are of different material, different
hardness, or are slightly different diameters or widths.
3. Use a thread protector when replacing o-rings on
MAE9500
fittings.
4. In ORB; ensure o-ring is properly seated in groove. On
2. TFFT (Turns from Finger Tight Method)
straight threads, ensure o-ring is seated all the way past
a. Tighten the swivel nut to the mating fitting until no the threads prior to installation.
lateral movement of the swivel nut can be detected;
finger tight condition. 5. Inspect o-ring for any visible nicks or tears. Replace if
b. Mark a dot on one of the swivel hex nut flats and found.
another dot in line on the connecting tube adapter.
c. Use the double wrench method per Appendix A,
turn the swivel nut to tighten. The nut is to be
rotated clockwise the number of turns.
d. After the connection has been properly tightened,
mark a straight line across the connecting parts, not
covering the dots, to indicate the connection has
been properly tightened.
3614RS, 4017RS 31211333 2-75

2-76 31211333 3614RS, 4017RS

Section 3
Boom
Contents

3.1 Boom System Component Terminology - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2 Boom System - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Boom Assembly Maintenance - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3.2 Second, Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.3 Third Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.3.4 Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3.5 Second and Third Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.6 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4 Boom Chain Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.1 Retract Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.2 Retract Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4.3 Extend Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.4.4 Extend Chain Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5 Tilt and Auxiliary Circuit Hose Removal/Installation - 3614RS. . . . . . . . . . . . . . . . . . . . . 3-14
3.5.1 Tilt/Auxiliary Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5.2 Tilt/Auxiliary Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6 Extend/Retract Cylinder Removal/Installation - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.1 Extend/Retract Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.6.2 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7 Boom Sections Adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.7.1 Chain Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.8 Boom System Component Terminology - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.9 Boom System - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.9.1 Boom System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10 Boom Assembly Maintenance - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.10.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3.10.2 Second, Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.10.3 Third and Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.10.4 Fourth Boom Section Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.10.5 Fourth Boom Section Removal Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3.10.6 Hose Carrier Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.7 Fourth Boom Section Installation Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.8 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3.10.9 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3.10.10 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.10.11 Complete Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3614RS, 4017RS 31211333 3-1

Boom
3.11 Hose Carrier Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3.11.1 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.11.2 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.12 Bottom Tilt and Auxiliary Circuit Hose Removal/Installation - 4017RS . . . . . . . . . . . . . 3-31
3.12.1 Tilt Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.12.2 Tilt Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.12.3 Carrier Tilt Hose Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.12.4 Carrier Tilt Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
3.13 Boom Chain Removal/Installation - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.14 Boom Sections Adjustment - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.14.1 Chain Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3.15 Boom Extend and Retract Chains - 3614RS & 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.2 Inspection Guidelines - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.15.3 Inspection Guidelines - 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.15.4 Expose Chains for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
3.15.5 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.16 Boom Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.16.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.16.2 Boom Wear Pad Installation/Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.17 Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.17.1 Quick Coupler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.17.2 Quick Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.18 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.19 Boom Prop (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.19.1 Installation and Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.20 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.20.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
3.20.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3-2 31211333 3614RS, 4017RS

Boom
3.1 BOOM SYSTEM COMPONENT

TERMINOLOGY - 3614RS
The following illustrations identify the components that are
referred to throughout this section.
EXTEND/RETRACT
CYLINDER
RETRACT CHAIN
(INSIDE BOOM)
EXTEND CHAINS
(INSIDE BOOM)
THIRD BOOM
SECTION
FIRST BOOM
SECTION
SECOND BOOM
SECTION
AUXILIARY
CONNECTIONS
(IF EQUIPPED)
TILT CYLINDER
(INSIDE BOOM HEAD)
MZ7070
3614RS, 4017RS 31211333 3-3

Boom
3.2 BOOM SYSTEM - 3614RS 3.3 BOOM ASSEMBLY MAINTENANCE -

3614RS
3.2.1 Boom System Operation
These instructions must be completed in sequence. The
The three section boom consists of the first, second and third second and third boom sections are removed from the first
assemblies with first and second section extend chains, and boom section. The third boom section is removed from the
a single first and second section retract chain. second boom section or the complete boom assembly can
As the extend/retract cylinder, which is anchored at the top be removed from the machine.
rear of the first boom section, and the top front of the second Before beginning, conduct a visual inspection of the
boom section begins to extend, it pushes the second boom machine and work area, and review the task about to be
section out of the first boom section. undertaken. Read, understand and follow these
The boom sections are connected by extend and retract instructions.The boom assembly consists of the first, second
chains. These chains are routed around rollers on the front and third section booms and supporting hardware.
and the rear of the second boom section. As the extend/ Note: Before removing the boom or boom section, the carriage
retract cylinder is forced out hydraulically, the third boom or any other attachment must be removed from the quick
section is pulled out by the extend chains. coupler.
As hydraulic pressure is applied to the retract port on the
Before beginning, conduct a visual inspection of the
extend/retract cylinder, the retract chain pulls the third boom
machine and work area, and review the task about to be
section back into the second boom section as the extend/
undertaken. Read, understand and follow these instructions.
retract cylinder pulls the second boom section into the first
boom section. During service of the boom, perform the following:
This mechanical linkage formed by the chains and 1. Check wear pads.
supporting hardware, extends and retracts the third boom (Refer to Section 3.16.1, “Wear Pad Inspection”)
section into the second boom section at the same rate. 2. Check chain rollers.
The boom section lifts and lowers via action of the lift 3. Apply grease at all lubrication points (grease fittings).
cylinder. (Refer to Section 2.5, “Lubrication Schedule”)
4. Check for proper operation by operating all boom
functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.
WARNING
NEVER weld or drill the boom unless approved in writing
by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.
3-4 31211333 3614RS, 4017RS

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.
Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 2721 kg (6000 lbs). 1
1. Remove any attachment from the quick coupler. Refer
to Operation & Safety Manual.
2. Remove the quick coupler assembly. Refer to 1
Section 3.17.1, “Quick Coupler Removal”.
3. Park the machine on a hard, level surface, fully retract
the boom, raise the boom assembly to access lift/lower
cylinder pin and the compensation cylinder pin, place 1
the transmission in (N) NEUTRAL, engage the park brake 1 MAE34610
and shut the engine OFF.
11. Remove the shims, boom pivot pins and lock bolts from
4. Place a Do Not Operate Tag on both the ignition key the rod end of the compensation cylinder being careful
switch and the steering wheel. not to drop the cylinder. Lower the cylinder to a secure
5. Open the engine cover. Allow the system fluids to cool. position.
6. Properly disconnect the battery. Refer Section 9.8, 12. Lower the boom assembly to level.
“Battery”, for procedure. 13. Place a sling around the first boom section at the
7. Close engine cover to access lift/lower cylinder pin and balance points.
the compensation cylinder pin. 14. Label, disconnect and cap all hydraulic hoses attached
8. Properly support the boom assembly using a hoist or to the tubes on the bottom of the boom. Cap all fittings
crane. and openings to keep dirt and debris from entering the
hydraulic system.
9. Remove boom angle sensor arm. Refer to Section 9.10.7,
“Boom Angle Sensor”. 15. Raise the boom assembly to allow the removal of the
boom assembly pivot pins.
10. Remove the pin from the rod end of the lift/lower
cylinder being careful not to drop the cylinder. Lower 16. Confirm that the boom assembly is balanced with the
the cylinder to a secure position. sling and remove the boom assembly pivot pins (1).
17. Lift the boom assembly from the machine and lower
onto suitable supports.
3614RS, 4017RS 31211333 3-5

Boom
3.3.2 Second, Third Boom Section Removal

1. Verify the boom assembly is setting on stable, secure
and suitable supports.
3
2 6 9
8
4
5
MAE35090
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.
MZ7090
10. Disconnect both tilt hoses (6) and (if equipped) both
2. Properly support the extend/retract cylinder (2) using a auxiliary hoses (7) (if equipped) at the bottom of the
hoist or crane. first boom section. Plug the hose ends and cap the tube
3. Label, disconnect and cap the extend/retract cylinder ends to prevent dirt and debris from entering the
hoses (3) from the extend/retract cylinder. Cap all hydraulic system. Pull the disconnected hoses out from
fittings and openings to prevent dirt and debris from the rear of the boom.
entering the hydraulic system. 11. Loosen and remove the lock nut and jam nut (8) on the
4. Loosen and remove the extend/retract cylinder retract chain at the front of the first boom section.
bracket (4). 12. Loosen and remove the lock nut and jam nut (9) on the
5. Remove one retaining ring from the mounting pin (5) at extend chain at the front of the first boom section.
each end of the extend/retract cylinder.
6. Remove each mounting pin and remove the
extend/retract cylinder and place in a secure location.
7. Label, disconnect and cap the tilt circuit hoses from the
tilt cylinder at the front of the third boom section. Label,
disconnect and cap the auxiliary circuit hoses from the
quick disconnect fittings at the front of the third boom
section. Cap all fittings and openings to prevent dirt and
debris from entering the hydraulic system.
8. Place a sling through the opening at the top of the
boom head and around the tilt cylinder and remove the 10
retaining rings and pin at the barrel end of the tilt
cylinder. Lower the tilt cylinder and place in a secure
location.
9. Loosen and remove the rear cover and door assembly
from the rear of the first boom section. 11 MZ7120
3-6 31211333 3614RS, 4017RS

Boom
13. Remove the circlip and pin (10) from the retract 3.3.3 Third Boom Section Removal
chain (11) at the rear of the third boom section. Lay the
retract chain over the rear edge of the first boom 13
section.
12
MZ7130 MZ7160
14. Pull the second and third boom sections out of the first 1. Pull the tilt hoses and the auxiliary hoses (if equipped)
boom section approximately 304 mm (12 in) to access from the rear of the third boom section.
the front first section wear pads.
Note: The bracket (13) holding the tilt hoses and auxiliary
15. Remove all wear pads, shims and backing plates from hoses (if equipped) will still secure the tilt hoses and auxiliary
the front inside of the first boom section (12). Label and hoses (if equipped) when the top rear wear pads are removed.
tag each set of wear pads being removed.
16. Pull the second and third boom sections out of the first
boom section. Relocate the lifting slings and slowly pull
the two boom sections clear of the first boom section.
Lower onto suitable supports.
17. Inspect the first boom and welds. Consult your local
authorized service distributor if structural damage is
detected.
18. Inspect hoses, hardware, wear pads, mounting points,
chains and other components visible with the first 14
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”)
Note: It is recommended that if any chain or hose is damaged MZ7200
that ALL chains or hoses are replaced.
Note: After removing the second and third boom section the Note: Remove the individual brackets (14) securing the tilt
retract chain is left laying on the inside of the first boom section hoses and auxiliary hoses (if equipped) to the main mounting
and can be removed, cleaned, inspected and replaced if bracket (13).
required.
3614RS, 4017RS 31211333 3-7

Boom
3.3.4 Third Boom Section Installation

Note: During reassembly use Loctite® 243TM on all bolt threads.
Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear
16 Pads”. You may have to final adjust the wear pads after the
boom assembly is installed on the machine and hydraulic
15 power is available.
Note: Coat the interior of all bushings and bores with Lithium
Grease prior to the installation of pins and bushings. Wear pads
and slide areas must be lubricated with Lithium Grease or an
equivalent.
1. Place the second boom section on suitable supports.
2. Lubricate the inside second boom section on areas
17 MZ7190
where the third boom section wear pads will slide.
2. Loosen and remove the mounting bolt (15) and 3. Lubricate and place the extend chain in the center of
bracket (16) securing the extend chain clevis (17). the second boom section.
4. Using a suitable sling, balance the third boom section
and carefully slide the 1 m - 1,2 m (3 ft - 4 ft) of the third
boom section into the front of the second boom
section.
5. Set the third boom section onto a suitable support and
reset the sling under the boom head of the third boom
section. Carefully slide the third boom section into the
second boom section.
6. Leave 152 mm - 203 mm (6 in - 8 in) of the third boom
section out to be able to install the wear pads in the
front of the second boom section.
7. With the sling still under boom head, install the wear
18 pads and spacers in the front of the second boom
section.
MZ7150
3. Remove all wear pads, shims and backing plates from

the front inside of the second boom section (18). Label
and tag each set of wear pads being removed.
4. Place a sling around the third boom section, lift and
slowly pull the third boom section approximately half 13
way out of the second boom section. Lower the third
boom section onto a suitable support.
5. Relocate the sling or using two slings for better stability,
balance the third boom section and slowly pull it out of
the second boom section being careful not to damage
the hydraulic hoses or chains. Lower the third boom
sections onto suitable supports.
MZ7210
Note: After removing the third boom section the extend chain
is left laying on the inside of the second boom section and can 8. Install the previously removed tilt hoses and
be removed, cleaned, inspected and replaced if required. (if equipped) the auxiliary hoses mounting bracket (13).
3-8 31211333 3614RS, 4017RS

Boom
6. Using a suitable sling, balance the second and third

boom sections and carefully slide 0,9 m - 1,22 m
(3 ft - 4 ft) into the front of the first boom section.
16 7. Set the second and third boom sections onto a suitable
support and reset the sling under the boom head of the
third boom section.
15
8. Carefully slide the two boom sections into the first
boom section. Leave 152 mm - 203 mm (6 in - 8 in) in of
the two boom sections out to be able to install the wear
pad block and the wear pads in the front of the first
boom section.
17 MZ7190
9. Install the extend chain clevis (17), mounting

bracket (16) and secure with bolt (15).
3.3.5 Second and Third Boom Section

Installation
1. Place the first boom section on suitable supports.
6
12
MZ7130
7 9. Install the wear pads, spacers and shims at the front of

the first boom section (12).
MAE35080
2. From the rear of the boom, feed the tilt hoses (6) and
auxiliary hoses (7) (if equipped) to the proper tube
connections on the bottom of the first boom section.
3. Tighten and torque the tilt hoses and auxiliary hoses (if 10
equipped). Verify the hoses are aligned square to the
boom.
4. Lubricate the inside first boom section on area’s where
the second boom section wear pads will slide.
5. Lubricate and place the retract chain in the center of the 11 MZ7120
second boom section with 254 mm (10 in) extending
from the rear of the first boom section. 10. Install the pin (10) and circlip securing the retract
chain (11) at the rear of the third boom section.
3614RS, 4017RS 31211333 3-9

Boom
19
9
8
20
MZ7230
MAE35090
14. Install the tilt cylinder in the boom head, install the
11. Install the retract chain at the front of the first boom mounting pin and keeper bolt, locking the mounting
section. Install the lock nut and jam nut (8). Do Not pin and tilt cylinder (19) into position.
Tighten at this time. 15. Connect the tilt cylinder hoses to the proper fittings on
12. Install the extend chain at the front of the first boom the tilt cylinder.
section. Install the lock nut and jam nut (9). Do Not 16. If equipped, connect the auxiliary hoses to the proper
Tighten at this time. fittings (20) on the boom head.
14
MZ7200
17. Install the individual brackets (14) securing the tilt

MZ7120 hoses and auxiliary hoses (if equipped) to the main
mounting bracket.
13. Feed the tilt hoses (6) and auxiliary hoses (7)
(if equipped) through the top of the third boom section.
3-10 31211333 3614RS, 4017RS

Boom
3.3.6 Complete Boom Installation

Note: Lubrication of the boom wear surfaces with
Multipurpose Grease is recommended to keep the boom wear
5 surfaces lubricated properly. Lubrication of the boom wear
3 surfaces is also recommended when the machine is stored, to
2 help prevent rusting.
1. Park the machine on a hard, level surface, place the
transmission in (N) NEUTRAL, engage the park brake
4
2. Place a Do Not Operate Tag on both the ignition key
switch and the steering wheel.
5
Note: Grease the boom pivot bores, compensating cylinder rod
end, lift/lower cylinder rod end and pins before installing.
MZ7090
18. Properly support the extend/retract cylinder (2) using a

hoist or crane and lower into place.
1
19. Install each mounting pin (5) in the extend/retract
cylinder.
20. Install one retaining ring to the mounting pin (5) at each
end of the extend/retract cylinder. 1
21. Remove caps and/or plugs from all fittings and

openings. Connect the extend/retract cylinder
hoses (3) to the extend/retract cylinder. 1
22. Install the extend/retract cylinder bracket (4). 1 MAE34610
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 (1).
4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.
5. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt. Apply
Loctite® 243TM and torque to 90 Nm (66 lb-ft).
Note: Raising the boom up or down with the sling may be
necessary so the boom, compensating and lift/lower cylinder
bores can be aligned for easier pin installation.
6. Uncap and connect the previously labeled extend/
retract cylinder hoses to the extend/retract cylinder.
7. Uncap and connect the previously labeled tilt hoses and
auxiliary hoses (if equipped) to the appropriate cylinder.
3614RS, 4017RS 31211333 3-11

Boom
8. Install the boom angle sensor arm. Refer to 3.4 BOOM CHAIN REMOVAL/INSTALLATION
Section 9.10.7, “Boom Angle Sensor”, for procedure. - 3614RS
9. Remove slings and/or supports from the boom
assembly.
3.4.1 Retract Chain Removal
10. Properly connect the battery. Refer Section 9.8,
The removal of the retract chain can be accomplished with
“Battery”, for procedure.
out the complete tear down of the boom sections.
11. Start the engine and operate all boom functions several
1. Remove any attachment from the quick coupler
times to bleed any air out of the hydraulic system. Check
assembly. Refer to Operation & Safety Manual.
for fluid leaks. Check the hydraulic fluid level in the tank
and add fluid as required. 2. Park the machine on a hard, level surface, fully retract
the boom, level the boom assembly, place the
12. Lower the boom assembly and shut engine OFF.
13. Clean up all debris, hydraulic fluid, etc., in, on, near and and shut the engine OFF.
around the machine.
14. Remove the Do Not Operate Tag from both the ignition switch and the steering wheel.
key switch and the steering wheel.
4. Open the engine cover. Allow the system fluids to cool.
from the rear of the first boom section.
6. Properly disconnect the battery. Refer Section 9.8,
MZ7250
1
7. Remove the extend chain lock nut, adjusting nut (1) and
roller assembly (2). Secure extend chain to access the
removal of the retract chain.
8. Remove the retract chain lock nut and adjusting nut (3).
Fasten a rope/wire to the end of the clevis to aid in
reinstallation.
3-12 31211333 3614RS, 4017RS

Boom
3.4.3 Extend Chain Removal

The removal of the extend chains can be accomplished with
out the complete tear down of the boom sections.
the boom, level the boom assembly, place the
4 and shut the engine OFF.
5 3. Place a Do Not Operate Tag on both the ignition key
6 switch and the steering wheel.
MZ7120 from the rear of the first boom section.
9. Remove the circlip and pin (4) securing the retract chain
clevis (5) at the rear of the third boom section.
10. Pull the retract chain (6) from between the first and
second boom sections from the rear of the boom
assembly.
11. Unfasten the rope/wire from the retract chain clevis.
3.4.2 Retract Chain Installation

1. Fasten the rope/wire left in the boom from the retract
chain removal to the new retract chain clevis and pull 8
the chain through the boom sections to the
approximate final position. Remove the rope/wire.
2. Install the retract chain, pin and circlip (4) at the rear of 7
the third boom section.
3. Install the retract chain roller assembly, lock nut and MZ7250
adjusting nut (3) at the front of the first boom section 7. Loosen the extend chain lock nut and adjusting nut (7)
below the boom head. from the extend chain at the bottom of the first boom
4. Install the rear cover and door assembly to the rear of section.
the first boom section. 8. Remove the cotter pin and pin (8) securing the extend
5. Properly connect the battery. Refer Section 9.8, chain to the extend chain clevis. Fasten a rope/wire to
“Battery”, for procedure. the end of the clevis to aid in reinstallation.
6. Close and secure the engine cover.
7. For chain adjustments see Section 3.7.1, “Chain
Adjustments”.
3614RS, 4017RS 31211333 3-13

Boom
3.5 TILT AND AUXILIARY CIRCUIT HOSE

REMOVAL/INSTALLATION - 3614RS
10 Hoses that need replaced and are still in one piece can be
removed and replaced without removing sections of the
boom.
9
3.5.1 Tilt/Auxiliary Hose Removal
11 MZ7190
1
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 (9) and 2
bracket (10) securing the extend chain clevis (11).
10. Pull the extend chain from between the second and
third boom sections at the rear of the machine.
11. Unfasten the rope/wire from the extend chain. MZ7230
3.4.4 Extend Chain Installation 1. Label, disconnect and cap both hoses from the tilt
cylinder (1) and auxiliary fittings (2) (if equipped) at the
1. Fasten the rope/wire left in the boom from the extend
front of the boom. Cap all fittings and openings to keep
chain removal to the new extend chain and pull the
dirt and debris from entering the hydraulic system.
chain through the boom sections to the approximate
final position. Remove the rope/wire.
2. Install the extend chain clevis bracket (10) and
mounting bolt (9) to the extend chain clevis at the rear
of the third boom section.
3. Install the pin and cotter pin (8) securing the extend
chain to the extend chain clevis at the front of the boom
assembly. 3
4. Install the extend chain lock nut and adjusting nut (7) at
the front of the first boom section. 4
5. Install the rear cover and door assembly to the rear of
the first boom section.
8. For chain adjustments refer Section 3.7.1, “Chain
Adjustments”. MAE35080
2. Label, disconnect and cap both tilt hoses (3) attached to

the tubes on the bottom of the boom. If equipped,
label, disconnect and cap both auxiliary hoses (4)
attached to the tubes on the bottom of the boom. Cap
3-14 31211333 3614RS, 4017RS

Boom
all fittings and openings to keep dirt and debris from 3.6 EXTEND/RETRACT CYLINDER REMOVAL/
entering the hydraulic system. INSTALLATION - 3614RS
3. Fasten a rope/wire to the hose end below the first boom
section. 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 Extend/Retract Cylinder Removal

2. Park the machine on a hard, level surface, extend the
boom to gain access to the extend/retract cylinder pin
5 in the third boom section, level the boom assembly,
place the transmission in (N) NEUTRAL, engage the park
brake and shut the engine OFF.
MZ7200 switch and the steering wheel.
4. Loosen and remove the clamps (5) securing the tilt

hoses and auxiliary hoses (if equipped) at the rear of the
third boom section. 4
5. From the rear of the boom, pull the tilt hoses from 2
between the first and second boom sections. 1
6. From the rear of the boom, pull the tilt hoses from
inside the third boom section.
7. Unfasten the rope/wire from each end of the hose 3
assembly.
3.5.2 Tilt/Auxiliary Hose Installation 4

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 the boom head until the
hose end is visible at the boom head.
3. Slowly pull the rope/wire from below the first boom
section until the hose end is visible at the tube MZ7090
connections. 4. Properly support the extend/retract cylinder (1) using a

4. Unfasten the rope/wire from each end of the hose. hoist or crane.
5. Uncap and connect the hoses to the previously labeled 5. Label, disconnect and cap the extend/retract cylinder
tubes under the first boom section. Refer to Section 2.2, hoses (2) from the extend/retract cylinder. Cap all
“Specifications”, for proper hose torque. fittings and openings to prevent dirt and debris from
6. Uncap and connect the hoses to the previously labeled entering the hydraulic system.
fittings at the tilt cylinder or the auxiliary fittings. Refer 6. Loosen and remove the extend/retract cylinder
to Section 2.2, “Specifications”, for proper hose torque. bracket (3).
7. Install and tighten the clamps holding the tilt hoses at 7. Remove one retaining ring from the mounting pin (4) at
the rear of the third boom section. each end of the extend/retract cylinder.
8. Properly connect the battery. Refer Section 9.8, 8. Remove each mounting pin and remove the extend/
“Battery”, for procedure. retract cylinder and place in a secure location.
3614RS, 4017RS 31211333 3-15

Boom
3.6.2 Extend/Retract Cylinder Installation

A
1. Install the extend/retract cylinder (1) onto the top of the
boom assembly.
2. Install one mounting pin (4) at each end of the
extend/retract cylinder and secure with retaining ring.
3. Uncap and connect the hoses (2) to the previously
labeled fittings at the extend/retract cylinder.
4. Instal the extend/retract cylinder bracket (3).
6. Start the machine and cycle the extend/retract cylinder
checking for leaks or any alignment problems.
MZ7820
3.7 BOOM SECTIONS ADJUSTMENT - 4. Adjust the boom chains to obtain dimension (A)
3614RS 175,0 - 190,0mm (6.9 - 7.4 in).
Note: Ensure that there is a minimum of one full thread of the
3.7.1 Chain Adjustments clevis showing beyond the lock nut.
The chains are adjusted by tightening and/or backing off the 5. Start the machine and slowly extend and retract the
adjusting nuts at the threaded end of the chains. The boom three times.
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed. 6. Retract the extend/retract cylinder completely. Turn
OFF engine
The chains are properly adjusted whenever the following
parameters are met. 7. Repeat step 4 and 5 if necessary.
1. Start the machine, level the boom and retract the 8. Tighten the extend/retract chain lock nuts (10 and 11)
extend/retract cylinder completely. Turn OFF engine. to 120 Nm (86 lb-ft) against the adjusting nut.
clevis showing beyond the lock nut.
9. Start the machine and cycle the extend/retract cylinder
to verify the boom extends and retracts properly.
2
D
C
B
MZ7830
10. With the boom level, extend the boom completely and
1 MZ7810 retract 50,0 mm (2.0 in).
2. At the bottom front of the boom section, adjust the 11. Verify dimensions (B) 375,0 mm (147.6 in) and (C)
extend chain (1) and retract chain (2) to achieve the 1875,0 mm (73.8 in) are correct.
proper boom measurements.
12. Verify the SAG dimension (D) is
3. Loosen the jam nut on each chain clevis. 160 mm - 165 mm (6.3 in - 6.5 in).
13. Adjust extend chain (1) if required. Repeat steps 9, 10
and 11 if necessary.
3-16 31211333 3614RS, 4017RS

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.
EXTEND/RETRACT CYLINDER
RETRACT CHAIN
(FOURTH BOOM SECTION)
(INSIDE BOOM)
EXTEND CHAIN
(FOURTH BOOM FIRST BOOM
SECTION) SECTION
RETRACT CHAIN
FOURTH BOOM (THIRD BOOM SECTION)
SECTION (INSIDE BOOM)
EXTEND CHAINS
(THIRD BOOM SECTION)
(INSIDE BOOM)
SECOND BOOM
SECTION
THIRD BOOM
SECTION
MAE21500
TILT CYLINDER
3614RS, 4017RS 31211333 3-17

Boom
3.9 BOOM SYSTEM - 4017RS 3.10 BOOM ASSEMBLY MAINTENANCE -

4017RS
3.9.1 Boom System Operation
These instructions must be completed in sequence. The
The four section boom consists of the first, second, third and second, third and fourth boom sections are removed from
fourth assemblies with double third section extend chains, a the first boom section.The third and fourth boom sections
single fourth section extend chain, a single third and fourth are removed from the second boom section.The fourth
section retract chains. boom section is removed from the third boom section.
As the extend/retract cylinder, which is anchored at the front Before beginning, conduct a visual inspection of the
of the second boom section, and the rear of the first boom machine and work area, and review the task about to be
section begins to extend, it forces the second boom section undertaken. Read, understand and follow these
out of the first boom section. instructions.The boom assembly consists of the first, second
The first, second, third and fourth boom sections are and third section booms and supporting hardware.
connected by extend and retract chains. These chains are Note: Before removing the boom or boom section, the carriage
routed around sheaves on the second and third boom or any other attachment must be removed from the quick
sections. As the second and third boom sections are forced coupler.
out, the extend chains pull the third and fourth boom
sections out of the second boom section. Before beginning, conduct a visual inspection of the
machine and work area, and review the task about to be
As hydraulic pressure is applied to the retract port on the
undertaken. Read, understand and follow these instructions.
extend/retract cylinder, the second boom section is pulled
back into the first boom section, and the retract chains pulls During service of the boom, perform the following:
the third and fourth boom sections back into the second 1. Check wear pads.
boom section. (Refer to Section 3.16.1, “Wear Pad Inspection”)
This mechanical linkage formed by the chains and 2. Check chain rollers.
supporting hardware, extends and retracts the third and
3. Apply grease at all lubrication points (grease fittings).
fourth boom sections at the same rate.
(Refer to Section 2.5, “Lubrication Schedule”)
The first boom section does not extend or retract, but lifts
4. Check for proper operation by operating all boom
and lowers via action of the lift cylinder.
functions through their full ranges of motion several
times.
Depending on your particular circumstance, the following
procedures explain the removal/installation of individual
boom sections or removal/installation of the complete
boom.
WARNING
NEVER weld or drill the boom unless approved in writing
by JLG. The structural integrity of the boom will be
impaired if subjected to any repair involving welding or
drilling.
3-18 31211333 3614RS, 4017RS

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.
Note: When removing a complete boom assembly use a hoist
or crane with a minimum lift capacity of 6000 lbs. 1

2. Remove the quick coupler assembly. Refer to
Section 3.17.1, “Quick Coupler Removal”. 1
cylinder pin and the compensation cylinder pin, place 1
1 MAE21520
the transmission in (N) NEUTRAL, engage the park brake
and shut the engine OFF. 11. Remove the shims, boom pivot pins and lock bolts from
the rod end of the compensation cylinder being careful
not to drop the cylinder. Lower the cylinder to a secure
position.
12. Lower the boom assembly to level.
13. Place a sling around the first boom section at the
balance points.
7. Close engine cover to access lift/lower cylinder pin and
14. Label, disconnect and cap all hydraulic hoses attached
the compensation cylinder pin.
to the tubes on the bottom of the boom. Cap all fittings
8. Properly support the boom assembly using a hoist or and openings to keep dirt and debris from entering the
crane. hydraulic system.
9. Remove boom angle sensor arm. Refer to Section 9.10.7, 15. Raise the boom assembly to allow the removal of the
“Boom Angle Sensor”. boom assembly pivot pins (1).
10. Remove the pin from the rod end of the lift/lower 16. Confirm that the boom assembly is balanced with the
cylinder being careful not to drop the cylinder. Lower sling and remove the boom assembly pivot pins.
the cylinder to a secure position.
17. Lift the boom assembly from the machine and lower
onto suitable supports.
3614RS, 4017RS 31211333 3-19

Boom
3.10.2 Second, Third and Fourth Boom Section

Removal
3
7
2 8
5
6
4
MAE21720
MAE21510
7. Label, disconnect and cap the tilt circuit hoses (6) from
2. Properly support the extend/retract cylinder (2) using a the tilt cylinder (7) at the front of the forth boom
hoist or crane. section. Cap all fittings and openings to prevent dirt and
3. Label, disconnect and cap the extend/retract cylinder debris from entering the hydraulic system.
hoses (3) from the extend/retract cylinder. Cap all 8. Place a sling through the opening at the top of the
fittings and openings to prevent dirt and debris from boom head and around the tilt cylinder and remove the
entering the hydraulic system. retaining rings and pin (8) at the barrel end of the tilt
4. Loosen and remove the extend/retract cylinder cylinder. Lower the tilt cylinder and place in a secure
bracket (4). location.
5. Remove one retaining ring from the mounting pins (5) 9. Loosen and remove the rear cover and door assembly
at each end of the extend/retract cylinder (2). from the rear of the first boom section.
6. Remove each mounting pin and remove the

extend/retract cylinder (2) and place in a secure
location.
10
9
11
MAE21530
Note: Before removing the extend chains, measure and note

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.
3-20 31211333 3614RS, 4017RS

Boom
10. Loosen and remove the lock nut and jam nut (9) on the
retract chain at the front of the first boom section.
11. Loosen and remove the lock nuts and jam nuts (10) on
the extend chains at the front of the first boom section.
12. Label, disconnect and cap the tilt hoses (11) from tubes
at bottom front of first boom section. Plug all fittings to
prevent dirt and debris from entering hydraulic system.
Clean and inspect the hoses. Replace if damaged.
15
MAE21650
16. Pull the second, third and fourth section booms out
152 - 203 mm (6 - 8 in) and remove all the wear pads,
shims and backing plates from the front inside of the
first section boom (15). Label all parts for installation.
12 17. Place a sling around the front of the second boom
13 section, lift and slide the three boom section 3/4 of the
MAE21540 way out of the first boom section. Set the boom head
14
down on a suitable support, then center the sling to be
13. At the rear of the boom, label, disconnect and cap tilt able to balance the three boom sections being
hoses (12) from the bracket attached to the third boom removed. Carefully pull the three boom sections the
section. Cap all fittings to prevent dirt and debris from remainder of the way out of the first boom section and
entering the hydraulic system. set the two boom sections down on suitable supports.
14. Pull tilt hoses (12) through the rear of the first boom 18. Remove the retract chain from the inside of the first
section. boom section. Clean and inspect chains. Replace if
15. Remove the clip and pin (13) from the retract chain damaged.
clevis that is attached to the rear of the third section 19. Inspect the boom and welds. Consult your local
boom. Lay the retract chain (14) over the rear of the first authorized service distributor if structural damage is
boom section. detected.
20. Inspect hoses, hardware, wear pads, mounting points,
chains and other components visible with the first
boom section. Replace any item if damaged. (Refer to
& 4017RS” and Section 3.16.1, “Wear Pad Inspection”).
Note: It is recommended that if any chain or hose is damaged
3614RS, 4017RS 31211333 3-21

Boom
3.10.3 Third and Fourth Boom Section Removal

and suitable supports. 20
19
18
18
MAE21660
4. At the top front of the second boom section (19),

16 17 remove the jam nuts and nuts and washers from the
MAE21550
16
extend chain clevis (20).
Note: Removal of the retract chain roller from the rear of the
5. Pull the third and fourth boom section out
second boom section may be required to access the extend
152 - 203 mm (6 - 8 in). Remove the top wear pads,
chain clevis assemblies.
shims and backing plate from the second boom section.
2. Loosen and remove the mounting bolts (16) and Label and tag each set of wear pads being removed.
bracket (17) securing each extend chain clevises (18). 6. Remove the side wear pads, shims and backing plates
3. Fasten a rope/wire to each extend chain clevis. from either side of the rear of the second boom section.
Label and tag each set of wear pads being removed.
7. Place a sling around the front of the third boom section,
lift and slide the two boom section 3/4 of the way out of
the second boom section. Set the boom head down on
a suitable support, then center the sling to be able to
balance the two boom sections being removed.
Carefully pull the two boom sections the remainder of
the way out of the second boom section and set the
two boom sections down on suitable supports.
8. Remove the extend chains from bottom of second
boom section. Clean and inspect chain. Replace if
damaged.
9. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is
detected.
3-22 31211333 3614RS, 4017RS

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 26
& 4017RS” and Section 3.16.1, “Wear Pad Inspection”).
Note: It is recommended that if any chain or hose is damaged
3.10.4 Fourth Boom Section Removal 25

27
23
MAE21670
6. At the top front of the third boom section (25), lay the
extend chain and clevis (26) over the front of the fourth
boom section (27).
7. Remove the top wear pads, shims and backing plate
from the third boom section. Label and tag each set of
21 wear pads being removed.
8. Remove all wear pads, shims and backing plates from
the front of the third boom section. Label and tag each
set of wear pads being removed.
MAE21560 9. Place a sling around the front of the fourth boom
24 22 section, lift and slide the fourth boom section 3/4 of the
way out of the third boom section. Set the boom head
2. At the rear of the boom, loosen and remove the tilt hose
bracket (21) attached to the third boom section
able to balance the fourth boom section being
securing tilt hoses (22). Label, disconnect and cap tilt
removed. Carefully pull the fourth boom section the
hoses. Cap all fittings to prevent dirt and debris from
remainder of the way out of the third boom section and
entering the hydraulic system.
set the fourth boom section down on suitable supports.
3. Remove the clip and pin from the retract chain
clevis (23) that is attached to the rear of the fourth
section boom. Lay the retract chain over the rear of the
third boom section.
4. Remove the retract chain from top of third boom
section. Clean and inspect chain. Replace if damaged.
5. Loosen and remove the two bolts securing the hose
carrier (24) to the third boom section.
3614RS, 4017RS 31211333 3-23

Boom
3.10.5 Fourth Boom Section Removal Only

28
Note: Removal and installation of the hose carrier can also be
performed by removing only the fourth boom section if
required.
29
MAE21570 30
10. Remove the extend chain (28) from top of fourth boom
section. Clean and inspect chain. Replace if damaged.
31 MAE21580
11. Inspect the boom and welds. Consult your local
authorized service distributor if structural damage is 1. Disconnect the extend chain clevis (29) from the rear of
detected. the fourth boom section.
12. Inspect hardware, wear pads, mounting points, chains 2. At the rear of the boom, label, disconnect and cap tilt
and other components visible with the second boom hoses (30) from the tubes attached to the third boom
section. Replace any item if damaged. (Refer to section. Cap all fittings to prevent dirt and debris from
Section 3.15, “Boom Extend and Retract Chains - 3614RS entering the hydraulic system.
& 4017RS” and Section 3.16.1, “Wear Pad Inspection”). 3. Loosen and remove the two bolts securing the hose
Note: It is recommended that if any chain or hose is damaged carrier (31) to the third boom section.
that ALL chains or hoses are replaced. 4. Remove all wear pads, shims and backing plates from
the front of the third boom section. Label and tag each
set of wear pads being removed.
5. Place a sling around the front of the fourth boom
section, lift and slide the three boom sections 3/4 of the
way out of the fourth boom section. Set the boom head
able to balance the fourth boom section being
removed. Carefully pull the fourth boom section the
remainder of the way out of the three boom sections
and set the fourth boom section down on suitable
supports.
3-24 31211333 3614RS, 4017RS

Boom
3.10.6 Hose Carrier Removal/Installation 3.10.8 Fourth Boom Section Installation

Refer to Section 3.11, “Hose Carrier Assembly”, for detailed Note: During reassembly use Loctite® 243™ on all bolt threads.
hose carrier removal and installation.
Note: Shim all wear pads. Refer to Section 3.16, “Boom Wear
Pads”. You may have to final adjust the wear pads after the
3.10.7 Fourth Boom Section Installation Only
boom assembly is installed on the machine and hydraulic
1. Using a suitable sling, balance the fourth boom section power is available.
and carefully slide 914 - 1219 mm (3 - 4 ft) into the front
Note: Coat the interior of all bushings and sheaves with
of the third boom section. Set the fourth boom section
Lithium Grease prior to the installation of pins and bushings.
head onto suitable support and reset sling under the
Wear pads and slide areas must be lubricated with Mystik
boom head of the fourth boom section. Carefully slide
Tetrimoly Grease XD#2 or an equivalent.
the fourth boom section into the third boom section.
28
Leave 1829 - 2438 mm (6 - 8 ft) of the fourth boom
section out to be able to install wear pads in front of the
third boom section.
2. 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. Tighten as required.
3. Install the two bolts securing the hose carrier (31) to the
third boom section.
4. At the rear of the boom, remove the caps from both tilt
hoses (30). Connect each hose to the previously labeled
tubes attached to the third boom section.
5. Connect the extend chain clevis (29) to the rear of the
fourth boom section.
MAE21570
1. Install the extend chain (28) on the top rear of fourth

boom section. Lay the extend chain the length of fourth
boom section.
2. Grease the inside third boom section on area’s where
the fourth boom section wear pads will slide.
3. Using a suitable sling, balance the fourth boom section
and carefully slide 914 - 1219 mm (3 - 4 ft) into the front
of the third boom section. Set the fourth boom section
head onto suitable support and reset sling under the
boom head of the fourth boom section. Carefully slide
the fourth boom section into the third boom section.
Leave 1829 - 2438 mm (6 - 8 ft) of the fourth boom
section out to be able to install wear pads in front of the
third boom section.
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.
3614RS, 4017RS 31211333 3-25

Boom
Note: Grease wear pads, bores and pins during assembly. 3.10.9 Third and Fourth Boom Section
5. Retract the fourth boom section the remainder of the
Installation
way into the third boom section. 1. Install the extend chains on the bottom inside of second
6. Shim all wear pads on the front of the third boom boom section. Lay the extend chain the length of
section. Torque bolts to 90 Nm (66 lb-ft). second boom section.
23
18
18
21
16 17
MAE21550
MAE21560
16
24 22 2. Grease the inside second boom section on areas where
the third boom section wear pads will slide.
7. At the rear of the boom, install the hose bracket (21) to
the third boom section securing tilt hoses (22). 3. Using a suitable sling, balance the third and fourth
boom sections and carefully slide 914 - 1219 mm
8. Remove caps on tilt hoses. Install hoses and torque as
(3 - 4 ft) into the front of the second boom section. Set
required.
the third and fourth boom sections onto a suitable
9. Lay the retract chain (23) the length of third boom support and reset the sling under the boom head of the
section. fourth boom section. Carefully slide the third and fourth
10. Install the pin and clip to the retract chain clevis to the boom sections into the second boom section. Leave
top rear of the fourth section boom. 152 - 203 mm (6 - 8 in) of the third boom section out to
be able to install the wear pads in the front of the
11. Install the two bolts securing the hose carrier (24) to the
second boom section.
third boom section. Torque as required.
4. With the sling still under third boom section, install the
bottom front wear pads and backing plates on the
second boom section. Lower the third boom section
and install the top front and side wear pads and backing
plates on the second boom section. Do not shim or
tighten bolts at this time.
Note: Installation of the retract chain roller from the rear of the
second boom section may be required if removed to access the
extend chain clevis assemblies.
5. Secure the extend chains to the each extend chain
clevises (18).
3-26 31211333 3614RS, 4017RS

Boom
6. Install the mounting bolts (16) and bracket (17) 3.10.10 Second, Third and Fourth Boom Section
securing each extend chain clevises (18). Installation
Note: Grease wear pads, bores and pins during assembly.
20
10
9
11
MAE21530
19
1. Install the retract chain to bottom front inside of the first
boom section. Install the lock nut and jam nut (9). Lay the
retract chain over the rear of the first boom section.
2. Install the tilt hoses (11) to the tubes mounted at the
bottom front of the first boom section. Verify both sets
of hoses are run through the opening at the bottom
front of the first boom section and parallel with the
retract chain. Lay the tilt hoses over the rear of the first
boom section.
MAE21660
Note: Keep the retract chain and tilt hoses centered in the first
7. Install the extend chain (20) to the top front of the boom section while installing the second boom section into the
second boom section (19). Install the lock nut and jam first boom section.
nut. 3. Grease the inside first boom section on area’s where the
8. Shim all wear pads on the rear of the third boom section second boom section wear pads will slide.
and front of the second boom section. Torque bolts to 4. Using a suitable sling, balance the second, third and
90 Nm (66 lb-ft). fourth boom sections and carefully slide
914 - 1219 mm (3 - 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. Leave 152 - 203 mm (6 - 8 in) of the
second boom section out to be able to install wear pads
in front of the first boom section.
5. With the sling still under the third boom section, install
the bottom front wear pads and backing plates on the
first boom section. Lower the third boom section and
install the top front and side wear pads and backing
plates on the first boom section. Do not shim or tighten
bolts at this time.
3614RS, 4017RS 31211333 3-27

Boom
6. Retract the second, third and fourth boom sections the

remainder of the way into the first boom section.
Note: Shim wear pads as needed to maintain an even gap of
0,5 - 1,5 mm (0.002 - 0.06 in) between the wear pads and the
next boom section. The number of shims can vary at each shim
point.
7. Shim all wear pads on the rear of the second boom
section and front of the first boom section. Torque as 7
8
required.
8. Attach the extend chains at the bottom front of the first
6
boom section. Install the lock nut and jam nut.
MAE21720
11. Using a suitable sling around the barrel end of the tilt
cylinder (7), raise the tilt cylinder into boom head. Align
the tilt cylinder barrel end bore with the boom head
bore and install the tilt cylinder pin and mounting bolt
and nut (8).
Note: Grease Tilt cylinder barrel end bore and pin before
12 installing.
13
MAE21540
12. Remove the plugs from the fittings on the tilt cylinder
14 and the caps from the Tilt hoses from the hose carrier.
9. Attach the retract chain (14), pins and clips to the Install both tilt hoses (6). Torque as required.
clevises (13) at the rear of the second boom section.
Note: Adjust all extend chains using the measurement taken in
the beginning of the tear down procedure. Depending on the
3
extent of the parts being replaced, the above measurement is to
be used as a starting point ONLY. 2
10. Remove the caps from the tilt hoses (12) and connect to 5
the appropriate fittings at the rear of the second boom
section. Torque as required. 4
MAE21510
3-28 31211333 3614RS, 4017RS

Boom
13. Attach a sling around a balance point on the Note: Raising the boom up or down with the sling may be
extend/retract cylinder (2) and carefully set on top of necessary so the boom, compensating and lift/lower cylinder
the first boom section. bores can be aligned for easier pin installation.
Note: Grease Extend/Retract cylinder barrel end bore and rod 6. Uncap and connect the previously labeled
end bore and pins before installing. extend/retract cylinder hoses to the extend/retract
cylinder.
14. Align the Extend/Retract cylinder barrel end with bore
at rear of the first boom section. Install the pin and 7. Uncap and connect the previously labeled tilt hoses and
retaining clip (5). (if equipped) auxiliary hoses to the appropriate cylinder.
15. Align the Extend/Retract cylinder rod end with bore at 8. Install the boom angle sensor arm. Refer to
front of the second boom section. Install the pin and Section 9.10.7, “Boom Angle Sensor”.
retaining clip (5). 9. Remove slings and/or supports from the boom
16. Install Extend/Retract cylinder support (4). Torque as assembly.
required. 10. Start the engine and operate all boom functions several
17. Uncap and connect the previously labeled extend/ times to bleed any air out of the hydraulic system. Check
retract cylinder hoses (3) to the extend/retract for fluid leaks. Check the hydraulic fluid level in the tank
cylinder.Torque extend and retract chains lock/jam nuts to and add fluid as required.
115 - 125 Nm (85 - 92 lb-ft). 11. Lower the boom assembly and shut engine OFF.
12. Clean up all debris, hydraulic fluid, etc., in, on, near and
3.10.11 Complete Boom Installation around the machine.
1. Park the machine on a hard, level surface, place the
1 MAE21520
1
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 (1).
4. With the sling still in place, install the compensating
cylinder, pin and lock bolts.
5. With the sling still in place, install the rod end of the
lift/lower cylinder, pin and lock bolt.
3614RS, 4017RS 31211333 3-29

Boom
3.11 HOSE CARRIER ASSEMBLY 3.11.2 Hose Carrier Installation

1. Place a sling around the center of the hose carrier to be
Note: Removal and installation of the hose carrier can also be
able to balance the hose carrier while being installed.
performed by removing only the fourth boom section if
required. 2. Carefully slide the hose carrier (5) halfway into the
fourth boom section.
3.11.1 Hose Carrier Removal 3. Remove the sling and push the hose carrier assembly
1. Refer to Section 3.10.4, “Fourth Boom Section Removal”, the remainder of way into the fourth boom section.
for detailed removal instructions. 4. Apply Loctite® 243™ to the previously removed
2. Set the forth boom section on level ground, reposition mounting bolts.
the slings and slowly turn the boom section over. 5. Install the twelve bolts (six per side) (4) on the fourth
Reposition the slings and set the boom section on boom section.
suitable supports. 6. Install the mounting bolts (3) securing the tilt hoses
brackets at the rear of the fourth boom section.
1 7. Insert the tilt hoses (6) into the hose carrier tray (2).
8. Install the hose carrier tray (2) into the fourth boom
2
section and secure the hose carrier tray with mounting
bolts (1).
9. Using slings, slowly turn the boom section over.
6 Reposition the slings and set the boom section on
suitable supports.
10. Refer to Section 3.10.8, “Fourth Boom Section
Installation”, for detailed installation instructions.
3 3
MAE21620
5
3. Loosen and remove the two bolts (1) securing the hose
carrier tray (2).
4. Pull the tray (2) from the rear of the fourth boom
section.
5. With fourth boom section setting on suitable supports
loosen and remove the each bolt (3) securing the tilt
hoses brackets at the rear of the fourth boom section.
6. Loosen and remove the twelve bolts (six per side) (4) on
the fourth boom section.
7. Pull the hose carrier (5) halfway out of fourth boom
section by hand and set on a suitable support. Place a
sling around the center of the hose carrier to be able to
balance the hose carrier while being removed.
8. Carefully slide the hose carrier (5) the remainder of the
way out of the fourth boom section and set down on
suitable supports.
9. Secure the tilt hoses with nylon ties. Remove tilt hoses.
3-30 31211333 3614RS, 4017RS

Boom
3.12 BOTTOM TILT AND AUXILIARY CIRCUIT

HOSE REMOVAL/INSTALLATION -
4017RS
1
3.12.1 Tilt Hose Removal
The following procedures can be performed without
disassembling the boom assembly.
assembly. Refer to Operation & Maintenance Manual.
2. Remove the quick coupler assembly. Refer to
Section 3.17.1, “Quick Coupler Removal”.
cylinder pin and the compensation cylinder pin, place
MAE21690
and shut the engine OFF. 8. Label, disconnect and cap both tilt hoses (1) attached to
4. Place a Do Not Operate Tag on both the ignition key the tubes on the bottom of the boom. Cap all fittings
switch and the steering wheel. and openings to keep dirt and debris from entering the
hydraulic system.
9. Fasten a rope/wire to the hose end below the first boom
6. Properly disconnect the battery. Refer to Section 9.8,
section.
10. From the rear of the boom, pull the tilt hoses from
between the first and second boom sections.
11. Unfasten the rope/wire from the end of the hose
assembly.
3.12.2 Tilt 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.
4. Uncap and connect the hoses to the previously labeled
1
tubes under the first boom section. Refer to
Section 2.2, “Specifications”, for proper hose torque.
MAE21680 5. Uncap and connect the hoses to the previously labeled
7. Label, disconnect and cap tilt hoses (1). Cap all fittings fittings at the tilt cylinder. Refer to Section 2.2,
to prevent dirt and debris from entering the hydraulic “Specifications”, for proper hose torque.
system. 6. Properly connect the battery. Refer to Section 9.8,
3614RS, 4017RS 31211333 3-31

Boom
3.12.3 Carrier Tilt Hose Removal
4
3
MAE21700
6. Label, disconnect and cap both tilt hoses (2). Cap all
fittings to prevent dirt and debris from entering the
hydraulic system.
7. Slowly pull each hose assembly the remainder of the
way out of the rear boom assembly.
MAE21710
3 2 8. Disconnect the rope/wire from each end of the hose
assemblies.
1. Label, disconnect and cap tilt hoses (2). Cap all fittings
to prevent dirt and debris from entering the hydraulic
system. 3.12.4 Carrier Tilt Hose Installation
2. Fasten a rope/wire to the end of each disconnected 1. Connect the previously removed rope/wire to the new
hose. tilt hoses (3) and both auxiliary hoses (4) (if equipped).
3. Loosen and remove lower clamp (3) securing tilt 2. Carefully feed the hoses through the rear of the boom
hoses (2). assembly while pulling the wire/rope connected to the
hose from the front of the boom head.
4. Slowly pull each hose assembly halfway out of the rear
boom assembly. 3. Carefully feed the hoses through the rear of the boom
assembly while pulling the wire/rope connected to the
5. Loosen and remove upper clamp (4) securing tilt
hose from the bottom rear of the boom assembly.
hoses (3).
4. Remove any caps and connect each tilt hoses (3) and
both auxiliary hoses (4) (if equipped) to the previously
labeled connection. Torque as required.
5. At the rear of the boom, tighten the previously
loosened clamps (5 and 6) securing the tilt hoses (3)
and both auxiliary hoses (4) (if equipped).
3-32 31211333 3614RS, 4017RS

Boom
3.13 BOOM CHAIN REMOVAL/INSTALLATION

- 4017RS
3
The removal of the extend and/or retract chain can only be
accomplished with the complete tear down of the boom.
3.14 BOOM SECTIONS ADJUSTMENT -

4017RS
3.14.1 Chain Adjustments MZ7870

4
The chains are adjusted by tightening and/or backing off the 1 2
adjusting nuts at the threaded end of the chains. The 1. Loosen the locknuts on the extend and retract chains.
opposite chain adjusting nut usually must be loosened
whenever this procedure is performed. Fully retract and level 2. Adjust extend chains (1) and retract chain (2) to ensure
the boom. a gap of (B) between the back of the second boom
section and the back of the third boom section.
AA B B
3. Adjust extend chain (3) and retract chain (4) to ensure a
gap of (A) between the back of the third boom section
CC
and the back of the fourth boom section.
4. Tighten the extend and retract chain lock nuts to
120 Nm (86 lb-ft) against the adjusting nut.
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. Verify boom section dimensions. Repeat steps 1 thru 3 if
necessary.
8. Start the machine, lower the out riggers if necessary and
extend the boom to maximum extension, then retract
51 mm to 76 mm (2 to 3 in). Shut machine off.
MAE35060
5
The boom is properly adjusted whenever the following
parameters are met.
A. 210 mm -230 mm (8.3 - 9.0 in)
B. 145mm -165 mm (5.71 - 6.50 in)
C. 45 mm (1.77 in) (No Adjustment)
If adjustments are needed: Start the machine, level the
boom and extend the boom 0,91 mm - 1,2m (3 ft - 4 ft).
Turn OFF engine.
MZ7990
6
9. Measure the distance (5) between the top of extend
chain and the top of the third boom section.
10. Measure the distance (6) between the top of both
extend chains and the bottom of the second boom
section.
3614RS, 4017RS 31211333 3-33

Boom
11. The distance between the extend chains and the each Following are some examples of dynamic shock loading
boom section should measure which can impose abnormal loads above the endurance limit
140 mm - 145 mm (5,5 in - 5,7 in). of a leaf chain.
12. Loosen the locknuts on the extend chains and adjust if • High velocity movement of load, followed by
necessary. Tighten locknuts to 120 Nm (86 lb-ft). sudden, abrupt stops.
13. Start the machine and cycle the extend/retract cylinder • Carrying loads in suspension over irregular surfaces
to verify the boom extends and retracts properly. such as railroad tracks, potholes, and rough terrain.
• Attempting to “inch” loads which are beyond the
3.15 BOOM EXTEND AND RETRACT rated capacity of the vehicle.
CHAINS - 3614RS & 4017RS The above load cycles and environmental conditions make it
impossible to predict chain life. It is therefore necessary to
3.15.1 Boom Chain Inspection conduct frequent inspections until replacement life can be
predicted.
The boom chain’s normal life expectancy can be expressed
WARNING as a maximum percent of elongation. This is generally 3%.
As the chain flexes back and forth over the sheave, the
Worn pins, stretched or cracked links or corrosive bearing joints (pins and inside link plates) gradually incur
environments can cause chain failure. A chain failure wear due to articulation.
could result in uncontrolled boom movement, loss of
load or machine instability. 3.15.2 Inspection Guidelines - 3614RS
Under normal operating conditions the boom chains will
a. Retract Chain
need to be inspected every 250 hours of operation. The
retract chains need to be exposed and inspected every 1. Park the machine on a firm, level surface, raise the boom
1000 hours of operation. Refer to the Service Manual for the to a horizontal (level) position, place the transmission in
proper procedure. Environmental conditions and dynamic (N) NEUTRAL, engage the park brake switch.
impulse/shock loads can drastically affect normal operating
conditions and require more frequent inspection intervals. 2. Fully extend the boom until the retract chain is taut.
Shut the engine off.
Environments in which material handling vehicles operate
can vary widely from outdoor moisture to temperature to 3. The retract chain will be visible for inspection with the
mildly corrosive or highly corrosive industrial atmospheres, vehicle in this state.
in addition to abrasive exposures such as sand and grit. 4. While doing the chain inspection, check all chain clevis
Some effects can be as follows: ends, pins for distortion or cracking and sheaves for
• Moisture - Corrosive rusting reduces chain strength bearing wear or grooving from the chain.
by pitting and cracking.
• Temperature - Low temperature reduces chain b. Extend Chains
strength by embrittlement. Going in and out of 1. Park the machine on a firm, level surface, raise the boom
cold storage results in moisture from condensation. to a horizontal (level) position, place the transmission in
• Chemical Solutions or Vapors - Corrosive attack on (N) NEUTRAL, engage the park brake switch.
the chain components and/or the mechanical 2. Fully retract the boom. Shut the engine off.
connections between the chain components.
Cracking can be (and often is) microscopic. Going 3. Both extend chain clevises and pins will be visible for
from microscopic cracking to complete failure can inspection with the vehicle in this state.
be either abrupt or may require an extended period 4. Limited visual inspection of the extend chains is
of time. possible. For complete extend chain inspection, the
• Abrasives - Accelerated wearing and scoring of the extend chains must be removed from the boom. For
articulating members of the chain (pins and plates), extend chain removal, refer to Section 3.4.3, “Extend
with a corresponding reduction in chain strength. Chain Removal” and Section 3.4.4, “Extend Chain
Due to the inaccessibility of the bearing surfaces Installation”.
(pin surfaces and plate apertures), wear and scoring
are not readily noticeable to the naked eye. 5. Inspect the extend and retract chains every 250 hours of
operation.
3-34 31211333 3614RS, 4017RS

Boom
6. Inspect the chains for the following conditions: 3.15.3 Inspection Guidelines - 4017RS
Edge Wear 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. Fully extend the boom until the extend chain is taut.
1 2 Shut the engine off.
3. The extend chains will be visible for inspection with the
vehicle in this state.
MZ1463
4. While doing the chain inspection, check all chain clevis
ends for distortion or cracking and sheaves for bearing
Check the chain for wear on the link plate edges caused wear or grooving from the chain.
by running back and forth over the sheave. The
maximum reduction of material should not exceed 5%. 5. Inspect the retract chains every 1000 hours of
Measure and compare to a normal link plate height by operation. Refer to the Service Manual for proper
measuring a portion of chain that does not run over the procedure.
sheave. If the measured plate height (1) is 5% less than 6. Inspect the chains for the following conditions:
the normal plate height (2), discard and replace the
chain. Edge Wear
Elongation Check the chain for wear on the link plate edges caused
by running back and forth over the sheave. The
It is important to measure the chain in the section that maximum reduction of material should not exceed 5%.
moves over the sheaves because it receives the most This can be compared to a normal link plate height by
frequent articulation. Measuring the chain near its clevis measuring a portion of chain that does not run over the
terminals could give an inaccurate reading. The ends of sheave.
the chains, near the clevis terminal, will not have flexed
as frequently, if at all, as the middle of the chains. a. Extend Chains (fourth to third section)
It is best to measure in 12 pin increments from pin
The extend chains between the fourth and third boom
center to pin center. For example, if the links are
sections measures 18 mm (.713 in) (1). If the
25 mm (1 in) from pin center to pin center, the distance
measurement of the worn chain is less than
should be 305 mm (12 in). If the links are 19 mm (.75 in)
17 mm (.677 in) (2), the chain should be replaced.
apart, the distance after 12 pins should be
229 mm (9 in).
b. Extend Chains (third to second section)
4
3
2 1
MZ1463
The extend chains between the third and second boom

sections measures 29,6 mm (1.2 in) (1). If the
measurement of the worn chain is less than
28,6 mm (1.1 in) (2), the chain should be replaced.
MY1360
If the distance measured (3) is 3% greater than the

normal length (4), discard and replace the chain.
3614RS, 4017RS 31211333 3-35

Boom
Elongation Distorted or Battered Link Plates

It is important to measure the chain in the section that
moves over the sheaves because it receives the most 85
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.
a. Extend Chains (fourth to third section)

MZ1466
4
3
Distorted or battered link plates (5) on a leaf chain can cause
tight joints and prevent flexing.
Turning or Protruding Pins
Highly loaded chain, operating with inadequate
lubrication can generate abnormal frictional forces
between pin and link plates. When chain is allowed to
operate in this condition, a pin or series of pins, can
begin to twist out of a chain, resulting in failure.
7
MY1360
6
When the original length (3) of 305 mm (12.00 in) per 8
foot of extend chain between the fourth and third
MZ1465
boom sections has elongated from wear to a length (4)
of 313 mm (12.36 in), the chain should be discarded and
replaced. Examine the pin head rivets to determine if the “VEE”
flats are still in correct alignment (6). Chain with
Measure across a span of 16 pins at the center of the rotated/displaced heads (7) or abnormal pin
extend chain. Measure from pin center to pin center. protrusion (8) should be replaced immediately.
Because the retract chain is inside the boom you will not
be able to measure the chain. DO NOT attempt to repair the chain by welding or
driving the pin(s) back into the chain. Once the press fit
The maximum measurement allowed is 313 mm(12.36 integrity between outside plates and pins has been
in). If the measurement is more than 313 mm (12.36 in), altered, it cannot be restored.
the chain should be replaced.
Any wear pattern on the pin heads or the sides of the
link plates indicates misalignment in the system. This
b. Extend Chains (third to second section)
condition damages the chain as well as increases
When the original length (3) of 317 mm (12.5 in) per frictional loading and should be corrected.
foot of extend chain between the third and second
boom sections has elongated from wear to a length (4)
of 325 mm (12.8 in), the chain should be discarded and
replaced.
Measure across a span of 10 pins at the center of the
extend chain. Measure from pin center to pin center.
Because the retract chain is inside the boom you will not
be able to measure the chain.
The maximum measurement allowed is
325 mm(12.8 in). If the measurement is more than
325 mm (12.8 in), the chain should be replaced.
3-36 31211333 3614RS, 4017RS

Boom
Cracked Plates 3.15.4 Expose Chains for Inspection

Inspect the chains very carefully, front and back as well
as side to side, for any evidence of cracked plates. If any c. Retract Chain
one crack is discovered, the chain should be replaced in 1. Park the machine on a firm, level surface. Place the
its entirety. transmission in (N) NEUTRAL, engage the park brake
It is important, however to determine the cause of the switch and raise the boom to a horizontal (level)
crack before installing a new chain so the condition position.
does not repeat itself. 2. Fully extend the boom until the retract chain is taut.
The types of cracks are: Shut the engine OFF.
• Fatigue Cracking - The retract chain will be visible for inspection with the
Fatigue cracks (1) are a machine in this state.
1
result of repeated cyclic While doing the chain inspection, check all chain clevis ends
loading beyond the MZ1467 for distortion or cracking and sheaves for bearing wear or
chain’s endurance limit.
grooving from the chain.
• Stress Corrosion If during the inspection, if any chain is found to be damaged
Cracking - The outside
or stretched, the chain must be replaced. It is recommended
link plates are
particularly 2 MZ1468
that when any chain is replaced, that all the chains and
susceptible to stress clevises be replaced at the same time.
corrosion cracking (2).
d. Extend Chains
• Corrosion Fatigue Cracking - Corrosion fatigue
cracks are very similar to fatigue cracks in The extend chains are only partially visible through the rear
appearance. Corrosion fatigue is the combined of the boom with all the sections retracted. It is possible to
action of an aggressive environment and cyclic see a section of the extend chain as the boom is slowly
stress. extended. If there is ANY question that one or both extend
Other Modes of Failure chains are damaged, the extend chains should be removed,
inspected and replaced if necessary.
• Ultimate Strength Failure -
These types of failures are Refer to Section 3.15, “Boom Extend and Retract Chains -
caused by overloads far in 3 3614RS & 4017RS”.
excess of the design load. MZ1469
Note: DO NOT attempt to repair a chain. Replace a stretched
Either fractured plates (3) or 4 or damaged chain with a new part. Always replace both the
enlarged holes (4) can occur. If
either of these failures occurs, chain and the clevis. It is recommended that when any chain is
the chain should be replaced MZ1470 replaced, that all chains and clevis’ be replaced at the same
immediately. time.
• Tight Joints -
All joints in
the chain
should flex
freely. Tight
joints (5) 5 MZ1471
resist flexing.
If the problem is caused by dirt or foreign substance
packed in the joints, clean and lubricate thoroughly
before re-installing the chain.
If the problem is caused by corrosion and rust or bent
pins, replace the chain.
3614RS, 4017RS 31211333 3-37

Boom
3.15.5 Chain Lubrication 3.16 BOOM WEAR PADS

After inspection and before being returned to service,
chains must be lubricated with Multipurpose Grease-NLGI The boom wear pads are flat rectangular plastic blocks with
Grade 2. metal inserts.
The lubricant must penetrate the chain joint to prevent 3.16.1 Wear Pad Inspection
wear. Applying lubricant to the external surfaces will
prevent rust, but the chains should be articulated to make 1
sure the lubricant penetrates to the working surfaces
between the pins and links.
To prepare the chain for lubrication, the chain plates should
be brushed with a stiff brush or wire brush to clear the space
between the plates so that lubricant can penetrate to the
working surfaces.
Lubricant may be applied with a narrow paint brush or 1
directly poured on, but the chain should be well flooded
MAE2120
with lubricant and the boom should be extended and
retracted to be sure that the lubricant penetrates to the Inspect all wear pads for wear. If the angle indicators (1) on
working surfaces. All surplus lubricant should be wiped the ends of the wear pads are visible, the wear pads can be
away from the external surfaces. DO NOT use a solvent for reused. If the pads show uneven wear (front to back), they
this wiping operation.
should be replaced. Replace pads as a set if worn or
Regular application of lubricant is necessary to make sure damaged.
that all working surfaces are adequately lubricated. In
extremely dusty conditions, it may be necessary to lubricate 3.16.2 Boom Wear Pad Installation/Lubrication
the chains more often. Refer to Section 2.4, “Service and
Maintenance Schedules” and Section 2.5, “Lubrication The boom has been factory lubricated for proper wear pad
Schedule” for detailed information. break-in and will normally require minor further lubrication.
However, after replacing any wear pad(s), or after prolonged
Lubrication of chains on vehicles working consistently in
extreme hot or cold conditions requires special periods of inoperation, lubrication of the boom wear surfaces
consideration. Contact the JLG dealer for guidance. with Multipurpose Grease is recommended to keep the
boom wear surfaces lubricated properly. Lubrication of the
boom wear surfaces is also recommended when the
machine is stored, to help prevent rusting.
The following wear pad procedure must be followed to
insure the proper wear pad installation:
• The wear pad inserts and mounting bolts MUST be
clean before mounting bolts are installed.
• Apply Loctite® 243TM to all wear pad mounting bolts.
MAM1390
• A spacer (2) with holes must be used before any

shim (3) is used.
3-38 31211333 3614RS, 4017RS

Boom
• A shim (3) must inserted between the spacer (2) and Boom Section Wear Pad Pathway Lubrication:
wear pad support plate, block or boom section (4).
• Clean and lightly grease all wear pad pathways with
• The number of shims can vary at each shim point. Multipurpose Grease.
• The bottom wear pads must be shimmed equally on • Clean and lightly grease the hose carrier guide bar
each side. pathway with Multipurpose Grease.
3.17 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
5
to Operation & Safety Manual.
MZ7660
• Maintain a total boom section clearance of

0,5 - 1,5mm (0.020 - 0.060 in) between the wear pad and
the next boom section (5).
A
B 3
3 4
MY3620
• The length of the wear pad bolt depends on the

number of shims, spacers and washers being used. MZ7690
• The thickness of each threaded wear pad insert is 1 2
10 mm (0.393 in) (A).
3. Remove the bolts and lock bracket (1) holding the rod
• The bolt length should be determined by measuring end tilt cylinder pin to the quick coupler assembly.
the distance from the face of the insert to the face of the
Remove the rod end pin (2).
boom (B) including any spacer, shim(s) and washer(s).
• Bolt thread engagement in the wear pad insert should 4. Support the quick coupler assembly. Remove the
not extend. bolts (3) and pin (4) from the quick coupler assembly.
• One or two hardened washers are to be used on each 5. Inspect the above pins for nicks or surface corrosion.
wear pad bolt except where noted otherwise. Use fine emery cloth to fix minor nicks or corrosion. If
DO NOT use more than two hardened washers. damaged or if it cannot be repaired the pin must be
• Use only one hardened washer if mounting bolts are replaced.
recessed.
• Wear Pad Bolt Torque:
M12 x 20, 95 - 105 Nm - M12 x 25, 95 - 105 Nm
M12 x 30, 95 - 105 Nm - M12 x 35, 95 - 105 Nm
M12 x 40, 95 - 105 Nm - M12 x 80, 95 - 105 Nm
• Lubricate the face and pockets of each wear pad after
being installed.
3614RS, 4017RS 31211333 3-39

Boom
3.17.2 Quick Coupler Installation 2. Angle (7) between upper face of blade and front face of
shank should not exceed 93 degrees.
1. Apply Loctite® 243 to all mounting bolts.
™
3. Thickness of blade (5) and shank (6) should not be

2. Assemble the quick coupler to the boom head. Line up
reduced to 90 percent of original thickness.
the quick coupler between the mounts on the boom
head. The quick coupler should be centered in the Note: Contact the local JLG dealer with the fork part number to
boom head. find the manufactured dimensions of the fork blade.
3. Coat the quick coupler pivot pin with Anti-Seize Lube. 4. Ensure fork length (8) is adequate for intended loads.
Insert the quick coupler pivot pin (4) through the quick
5. Fork markings should be legible, re-stamp if required.
coupler and boom head. Secure with the previously
removed bolts (3). 6. Compare fork tips (9) when mounted on a carriage.
Maximum difference in height of fork tips is 3 percent of
4. Align the quick coupler with the rod end tilt cylinder
the length of the blade (8).
and insert the coupler pin (2) and replace the lock
bracket and bolt assembly (1).
3.19 BOOM PROP (IF EQUIPPED)
5. If equipped, reconnect the hydraulic attachment hoses
to the quick disconnect fittings on the left side of the
boom head.
WARNING
3.18 FORKS A raised boom can fall if a hydraulic component is
removed. Remove any load, retract the boom and install
Forks should be cleaned and inspected prior to being the boom prop or a suitable supporting stand before
attached to carriage. If the following criteria is not met, forks working under a raised boom.
must be removed from service immediately.
3.19.1 Installation and Removal Procedures
3
a. Prop Installation
6
1. Park the machine on a firm, level surface. Place the
7 5 transmission in (N) NEUTRAL, engage the park brake
4
switch.
2 2. Raise the boom to an angle of approximately
1 20 degrees. Stop engine.
6 switch and the steering wheel.
5 9
8 MH6460
Daily Inspection
1. Inspect forks (1) for cracks, paying special attention to
heel (2) and mounting tubes (3).
2. Inspect forks for broken or bent tips (4) and twisted
blades (5) and shanks (6).
Yearly Inspection
1. Straightness of the upper face of blade (5) and the front
face of shank (6) should not exceed 0.5 percent of the
length of blade or height of shank.
3-40 31211333 3614RS, 4017RS

Boom
4. Before installing the boom prop, inspect the prop for 3.20 EMERGENCY BOOM LOWERING
damage. DO NOT use if the prop is damaged or if the PROCEDURE
locking pins are damaged or missing.
WARNING
To avoid instability of the machine, the extend/retract
cylinder MUST BE fully retracted prior to retracting the
lift cylinder. If circumstances prevent retraction of the
extend/retract cylinder first, lower the lift cylinder the
minimum amount necessary and resume retraction of the
extend/retract cylinder as soon as possible.
3
3.20.1 Equipment and Supplies Required
Auxiliary Hydraulic Power Supply:
• Portable hydraulic unit or another machine with an
auxiliary hydraulic power supply with a capacity to
2 hold up to 35 L (9 gal) of hydraulic oil from the
1 machine during lowering process.
2
NOTICE
EQUIPMENT DAMAGE. Auxiliary Hydraulic Power Supply
hydraulic oil must be compatible with hydraulic oil shown
MAM4080
in Section 2.3.2, “Fluids (if equipped for LS)”.
5. Align lift cylinder prop (1) so the locking pins (2) are on Hoses:
the bottom side of the lift/lower cylinder rod (3). Install
the boom prop (1) onto the lift/lower • Two Hydraulic Hoses - Approximately 3,0 m
cylinder (1). Install locking pins (2). (10 ft) each, with a minimum I.D. of
9,5 mm (0.375 in) and a minimum rating of
6. Start the engine and SLOWLY lower the boom until 275,8 bar (4000 psi).
there is a clearance of 6 mm (0.25 in) between the end
of the boom prop and the lift/lower cylinder rod Fittings:
end (3). • Two -8 EO Caps
• Two -8 EO Plugs
NOTICE Adaptors:
EQUIPMENT DAMAGE. DO NOT operate with the boom • Two -8 EO Adaptors
prop in place. Damage to the boom prop and/or the Note: Machine extend/retract and lift/lower hoses are -8 ORFS.
lift/lower cylinder could occur. The adaptor size may vary depending on the hose ends of the
auxiliary hydraulic power supply.
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. Remove the locking pins (2) and boom prop (1) from
the lift cylinder. Return the boom prop to the proper
location and secure.
3. Lower boom, shut engine OFF.
3614RS, 4017RS 31211333 3-41

Boom
3.20.2 Lowering Procedure 7. Transfer any hydraulic oil into a suitable, covered
container, and label the container as “Used Oil”. Dispose
a. Retract the boom as follows: of used oil at an approved recycling facility.
1. Remove the cover at the rear corner of the cab. 8. Clean up all debris, hydraulic fluid, etc., in, on, near and
around the machine.
2. Place a suitable receptacle under the main control valve.
b. Lower the boom as follows:
1. Place a suitable receptacle under the main control valve.
2. Label and disconnect the lift/lower cylinder
hoses (3 and 4) from the main control valve. Install
plugs in hoses to prevent fluid loss. Cap all fittings and
openings to keep dirt and debris from entering the
4 hydraulic system.
2 Note: Loss of hydraulic oil is limited to the amount trapped

within each hose.
3. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
and the hoses removed from the main control valve
lift/lower section of the affected machine. Hose (4) is
the supply (lower) and hose (3) is the return. Connect
the hoses in the proper order to ensure that the boom is
1 lowered, not raised.
3 4. Use the auxiliary power supply to lower the boom.
5. Loosen and remove the jumper hoses and reconnect
the lift/lower cylinder hoses.
6. Transfer any hydraulic oil into a suitable, covered
MZ7710 container, and label the container as “Used Oil”. Dispose
VIEW FROM REAR OF CAB
of used oil at an approved recycling facility.
3. Label and disconnect the extend/retract cylinder 7. Clean up all debris, hydraulic fluid, etc., in, on, near and
hoses (1 and 2) from the main control valve. Install around the machine.
plugs in hoses to prevent fluid loss. Cap all fittings and 8. Install the previously removed rear cover.
hydraulic system.
Note: Loss of hydraulic oil is limited to the amount trapped
within each hose.
4. Using the hoses and fittings specified, connect the
hoses between the auxiliary hydraulic power supply
and the hoses removed from the main control valve
extend/retract section of the affected machine. Retract
hose (2) is the supply and extend hose (1) is the return.
Connect the hoses in the proper order to ensure that
the cylinder is retracted, not extended.
5. Use the auxiliary power supply to retract the
extend/retract cylinder.
6. Loosen and remove the jumper hoses and reconnect
the extend/retract cylinder hoses.
3-42 31211333 3614RS, 4017RS

Boom
3.21 TROUBLESHOOTING
This section provides an easy reference guide covering the
most common problems that occur during operation of the
boom.
Problem Possible Causes Remedy

1. Boom will not extend or retract 1. Broken hydraulic hose(s) or 1. Locate break, replace hose(s) or
tube(s) and/or connections tube(s), tighten connections.
leaking.
2. Extend/retract hydraulic system 2. Refer to Section 8.5, “Hydraulic

not operating properly. Circuits”.
3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to

Section 8.10.1, “General Cylinder
Removal Instructions”.
2. Boom shifts to right or left when 1. Boom side wear pads improperly 1. Shim wear pads to correct gap.
extending. shimmed or worn. Replace wear pads as needed.
Refer to Section 3.16, “Boom Wear
Pads”.
3. Excessive pivot pin noise and/or 1. Insufficient lubrication. 1. Lubricate at regular intervals.
wear. Refer to Section 2.5, “Lubrication
Schedule”. Replace worn pins as
needed.
2. Worn bearing(s). 2. Replace bearing(s) and lubricate

at regular intervals. Refer to
Section 2.5, “Lubrication
Schedule”.
4. Excessive Compensation 1. Insufficient lubrication. 1. Lubricate at regular intervals.

cylinder pivot pin noise and/or Refer to Section 2.5, “Lubrication
wear. Schedule”. Replace worn pins as
needed.
2. Worn bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals.
5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes 1. Locate break, replace hose(s) or
and/or connection leaks. tube(s), tighten connections.
2. Lift/lower hydraulic system not 2. Refer to Section 8.5, “Hydraulic

operating properly. Circuits”.
3. Faulty lift/lower cylinder. 3. Repair cylinder. Refer to Section

8.10.1, “General Cylinder Removal
Instructions”.
4. Seized boom pivot pin bushing. 4. Replace bushing.
3614RS, 4017RS 31211333 3-43

Boom

6. Drooping chain, or jerky boom 1. Chain(s) tension not properly 1. Adjust chain(s).
extend or retract functions. adjusted.
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, 3. Replace wear pad. Refer to Section

excessively worn or damaged. 3.16, “Boom Wear Pads”.
4. Contaminated, corroded or rusted 4. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
5. Extend/Retract hydraulic system 5. Refer to Section 8.5, “Hydraulic

not operating properly. Circuits”.
6. Damaged boom section. 6. Replace the damaged boom

section.
7. Excessive Lift/Lower cylinder 1. Insufficient lubrication. 1. Lubricate at regular intervals.

pivot pin noise and/or wear. Refer to Section 2.4, “Service and
Maintenance Schedules”. Replace
worn pins as needed. Refer to
Section 8.10.1, “General Cylinder
Removal Instructions”.
2. Worn self-aligning bushing(s). 2. Replace bushing(s) and lubricate

at regular intervals. Refer to
Section 2.5, “Lubrication
Schedule”.
8. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct
as needed. Refer to Section 3.16,
“Boom Wear Pads”.
2. Rapid cycle times with heavy 2. Reduce cycle times.

loads.
3. Contaminated, corroded or rusted 3. Remove contamination and/or

wear pad sliding surfaces. corrosion from wear pad sliding
surfaces and lubricate. If the
surfaces cannot be reconditioned,
replace the boom section(s).
4. Operating in extremely dusty/ 4. Clean equipment frequently.

abrasive conditions.
9. Auxiliary hydraulics will not 1. Auxiliary hydraulic system not 1. Refer to Section 8.5, “Hydraulic
operate. operating properly. Circuits”.
3-44 31211333 3614RS, 4017RS

Boom

10. Excessive chain wear. 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 2. Lubricate chain sheave. Refer to

lubricated. Section 2.4, “Service and
Maintenance Schedules”.
3. Chain sheave(s) not rotating 3. Lubricate chain sheave. Refer to

freely. Section 2.4, “Service and
Maintenance Schedules”. Repair
or replace chain sheave(s) as
needed.
4. Improper chain lubrication. 4. Lubricate at regular intervals.

Refer to Section 2.4, “Service and
Maintenance Schedules”. Replace
chains as needed.
3614RS, 4017RS 31211333 3-45

Boom
3-46 31211333 3614RS, 4017RS

Section 4
Cab
Contents

4.1 Operator Cab Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Operator Cab Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Serial Number Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.2 Steering Column/Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.3 Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.4 Electronic Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.5 Joystick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.6 Window Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.7 Heater System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.8 Heater and Air Conditioning System (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
3614RS, 4017RS 31211333 4-1

Cab
4.1 OPERATOR CAB COMPONENT

TERMINOLOGY
To understand safety, operation and maintenance
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.
LSI
INDICATOR
FRAME LEVEL
INDICATOR
INSTRUMENT
CLUSTER ACCESSORY
CONTROL
STEERING LEVER
STEERING IGNITION
WHEEL
COLUMN SWITCH
TRANSMISSION ADJUSTER
CONTROL LEVER
(IF EQUIPPED) CONSOLE
SWITCHES
CAPACITY
CHART JOYSTICK
CLIMATE
CONTROLS
CONSOLE
SWITCHES
FRAME LEVEL
SWITCH
ACCELERATOR
PEDAL
SERVICE BRAKE
PEDAL
12 VOLT POWER
HYDRAULIC PARK OUTLET
BRAKE LEVER
(4017RS)
MECHANICAL
PARK BRAKE LEVER
MAE34850
(3614RS)
4-2 31211333 3614RS, 4017RS

Cab
4.2 OPERATOR CAB 4.3 CAB COMPONENTS
4.3.1 Steering Wheel

WARNING
a. Steering Wheel Removal
DO NOT service the machine without following all safety
precautions as outlined in Section 1, “Safety Practices”, of 1. Park machine on a firm, level surface, level machine fully
this manual. retract boom, lower boom, place transmission in (N)
NEUTRAL, engage park brake and shut engine OFF.
4.2.1 Operator Cab Safety 2. Place a Do Not Operate Tag on both ignition key switch
and steering wheel.
WARNING 3. Open engine covers. Allow system fluids to cool.

4. Properly disconnect battery. Refer Section 9.8, “Battery”,
The protection offered by this ROPS/FOPS will be for procedure.
impaired if subjected to any modification or structural
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using fasteners of 1
correct size, grade, and torqued to their specified value.
WARNING 2
DO NOT weld, grind, drill, repair or modify the cab in any
way. Any modification or damage to cab structural
components requires cab replacement.
Refer to the appropriate parts manual for ordering 3
information.
4.2.2 Serial Number Plate

The cab serial number plate is located on the left side of the MAE8790
cab, below the seat. Information specified on the serial
number plate includes the cab model number, the cab serial 5. Remove steering insert (1) out of steering wheel (2).
number and other data. Write this information down in a 6. Mark steering wheel (2) and shaft to ensure proper
convenient location to use in cab correspondence. installation. Remove nut and washer (3) securing the
steering wheel (2) to splined steering column shaft.
7. Use a steering wheel puller to remove steering wheel (2)
from splined shaft.
b. Steering Wheel Installation

1. Install steering wheel (2) onto splined steering column
shaft.
2. Secure steering wheel with previously removed nut and
washer (3). Torque as required.
3. Install steering insert (1) on the steering wheel (2).
4. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
5. Close and secure engine covers.
6. Remove Do Not Operate Tag from ignition key switch
and steering wheel.
3614RS, 4017RS 31211333 4-3

Cab
4.3.2 Steering Column/Orbital Valve
a. Steering Column and Orbital 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. 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. 8
for procedure.
2
5. Remove lower dash panel in cab.
6
10
9 MAM3930
7. Label, disconnect and cap hydraulic hoses attached to

orbital valve (6).
4
8. Remove steering wheel (2). Refer to Section 4.3.1,
“Steering Wheel”.
9. Disconnect and remove the accessory control lever (7),
and if equipped, transmission control lever (8).
Disconnect control lever(s) harness from the main cab
5 harness.
10. Have an assistant hold the orbital valve (6) from outside
of cab. Remove bolts and washers (9) securing orbital
valve (6) to cab.
11. Remove the steering column (10) through the dash
panel opening.
MZ7771 Note: DO NOT disassemble orbital valve (6). The orbital
valve (6) is not serviceable and must be replaced fully, if
6. Remove access covers (4 and 5) from front of cab.
defective.
b. Steering Column and Orbital Valve Installation

1. Install steering column (10) to original orientation in
cab.
2. Have an assistant hold orbital valve (6) in original
orientation from outside cab. Install steering
column (10) to orbital valve (6) with previously removed
hardware. Torque as required.
3. Install accessory control lever (7) and if equipped,
transmission control lever (8). Connect control lever(s)
harness connector to main cab harness and install steering
wheel assembly. Refer to Section 4.3.1, “Steering Wheel”.
4. Uncap and connect previously labeled hydraulic hoses
to orbital valve (6).
4-4 31211333 3614RS, 4017RS

Cab
5. Carefully examine all connections one last time before 4.3.4 Electronic Throttle Pedal
engine start-up. Rectify any faulty conditions.
6. Properly connect battery. Refer Section 9.8, “Battery”, a. Throttle Pedal Removal
for procedure. 1. Park machine on a firm, level surface, level machine fully
7. Start engine and check operation of steering system. retract boom, lower boom, place transmission in (N)
Check for hydraulic fluid leaks. Check hydraulic fluid NEUTRAL, engage park brake and shut engine OFF.
level in tank and add fluid as required. 2. Place a Do Not Operate Tag on both ignition key switch
8. Install access covers (4 and 5) to front of cab. and steering wheel.
9. Install lower dash panel in cab. 3. Open engine covers. Allow system fluids to cool.
10. Close and secure engine cover. 4. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
and steering wheel.
c. Steering Test
Conduct a pressure check of the steering hydraulic circuits at
the main control valve. Refer to Section 8.4.1, “Pressure
Checks and Adjustments”. 4
4.3.3 Service Brake
a. Brake Valve Removal

Refer to Section 8.9.2, “Service Brake Valve”, for removal 5
information.
b. Brake Valve Installation

Refer to Section 8.9.2, “Service Brake Valve”, for installation
information.
MZ7771
11
MZ7790
6. Remove hardware (11) securing pedal assembly.
3614RS, 4017RS 31211333 4-5

Cab
4.3.5 Joystick Assembly
a. Joystick Assembly Removal

12 retract boom, lower boom, place transmission in (N)
NEUTRAL, engage park brake and shut engine OFF.
13
and steering wheel.
3. Open engine cover. Allow system fluids to cool.
for procedure.
MD0590
7. Disconnect electrical connection (12) to pedal

assembly (13).
8. Remove throttle pedal assembly (13) from cab.
15
b. Throttle Pedal Installation
1. Position throttle pedal (13) in its mounting location in
14
cab.
2. Reconnect electrical connection (12) to pedal
assembly (13).
3. Secure throttle pedal (13) into position with previously
used hardware (11).
4. Install access covers (4 and 5) to front of cab.
for procedure.
6. Close and secure engine cover.
and the steering wheel.
16
MAE3930
5. Raise rubber boot (14) from base of joystick.

6. Remove hardware (15) securing joystick assembly.
7. Lift joystick from its mounting position.
8. Label and disconnect electrical connector (16) attached
to joystick.
9. Remove joystick assembly.
4-6 31211333 3614RS, 4017RS

Cab
b. Joystick Assembly Installation

1. Connect previously labeled electrical connector (16)
to joystick.
2. Secure joystick assembly to cab using previously
removed hardware (15). Torque to 2 - 2.5 Nm
16
(1.5 - 1.8 lb-ft).
3. Seat rubber boot (14) to joystick base.
for procedure.
5. Test joystick functions.
6. Close and secure engine cover. MZ7850

and steering wheel. 9. Remove heater cover (16) inside cab.
4.3.6 Window Wiper Assembly

Refer to Section 9.9, “Wiper/Washer Wiper Motor”, for
removal and installation information.
4
4.3.7 Heater System (if equipped)
a. Heater Assembly Removal

retract boom, lower boom, place transmission in
(N) NEUTRAL, engage park brake and shut engine OFF. 5
and steering wheel.
3. Open engine covers. Allow system fluids to cool.
for procedure.
5. Place a suitable container beneath radiator. Slowly turn MZ7771
surge tank cap and allow any pressure to escape. 10. If equipped, remove windshield wiper assembly.
Remove surge tank cap.
6. Place a funnel at base of radiator to channel drained
coolant into container. Remove drain plug and allow
coolant to drain.
7. Transfer coolant to a container with a cover, and label as
“Used Coolant”. Dispose of used coolant at an approved
recycling facility.
8. Tighten radiator drain plug.
3614RS, 4017RS 31211333 4-7

Cab
b. Heater Assembly Installation

1. Position heater assembly to original orientation to cab.
Secure with previously removed hardware (18).
2. Connect previously labeled electrical connections.
18 3. Connect previously labeled heater hoses to appropriate
locations.
4. Fill cooling system completely with coolant, allowing
17 time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluids and
18
Lubricant Capacities”.
for procedure.
6. Start engine, run it briefly at low idle and check machine
for any visual sign of fluid leakage.
MZ7840
Note: STOP engine immediately if any leakage is noted, and

12. Label and disconnect electrical connections of
make any necessary repairs before continuing.
heater (17).
13. Remove hardware (18) securing heater assembly to cab. 7. Wait for engine to cool and check coolant level. Add
Remove heater assembly. coolant as required to bring coolant to proper level.
9. Install heater cover (16) inside cab.
and steering wheel.
19
17
19
MAE3980
14. Label and remove heater hoses (19) connected to the

heater assembly (17).
4-8 31211333 3614RS, 4017RS

Cab
4.3.8 Heater and Air Conditioning System

(if equipped)
a. Heater and Air Conditioning System Removal

(N) NEUTRAL, engage park brake and shut engine OFF. 4
and steering wheel.
3. Open engine covers. Allow system fluids to cool.
for procedure. 5
5. Place a suitable container beneath radiator. Slowly turn
surge tank cap and allow any pressure to escape.
Remove surge tank cap.
coolant into container. Remove drain plug and allow
coolant to drain.
MZ7771
11. If equipped, remove windshield wiper assembly.
recycling facility. 12. Remove access covers (4 and 5) from front of cab.
8. Tighten radiator drain plug. 13. If equipped, install windshield wiper assembly.
21
9. Drain the refrigerant from the air conditioning system. 20
Note: The local JLG dealer or certified air conditioning service
center or personnel to perform the refrigerant removal from the
system.
19
16
17
23
22
MZ7850
10. Remove heater cover (16) inside cab.

MAE3150
19
14. Label and disconnect hoses (20) attached to the
condenser assembly (21).
15. Label and disconnect all electrical connections attached
to the condenser assembly.
3614RS, 4017RS 31211333 4-9

Cab
16. Remove bolts securing the condenser assembly (21) to 13. Start engine, run it briefly at low idle and check machine
cab roof. Remove condenser assembly from rear of the for any visual sign of fluid leakage.
cab roof.
Note: STOP engine immediately if any leakage is noted, and
17. Label and disconnect all electrical connections attached make any necessary repairs before continuing.
to the heater assembly (17).
14. Wait for engine to cool and check coolant level. Add
18. Label and remove heater hoses (19) connected to the coolant as required to bring coolant to proper level.
19. Label and disconnect air conditioning hoses (22)
attached to heater assembly (17). 16. If equipped, install windshield wiper assembly.
20. Remove hardware securing heater assembly (17) to cab. 17. Install heater cover (16) inside cab.
Remove heater assembly (17). 18. Close and secure the engine cover.
21. Label and disconnect air conditioning hoses attached to 19. Remove Do Not Operate Tag from ignition key switch
compressor (23). and steering wheel.
22. Remove hardware securing compressor to engine.
Remove compressor (23).
b. Heater and Air Conditioning Installation

1. Install cab condenser assembly (21) to cab roof. Secure
with previously removed hardware.
2. Connect previously labeled electrical connections to
the condenser assembly (21).
3. Connect previously labeled hoses (20) to condenser
assembly (21).
4. Position heater assembly (17) to original orientation to
cab. Secure with previously removed hardware.
5. Connect previously labeled electrical connections to
6. Connect previously labeled heater hoses (19) to
appropriate locations.
7. Connect previously labeled air conditioning hoses (22)
to appropriate locations.
8. Connect previously labeled air conditioning hoses
attached to compressor (23).
9. Install compressor (23) to engine.
10. Fill cooling system completely with coolant, allowing
time for the coolant to fill the engine block. The cooling
system capacity is listed in Section 2.3, “Fluids and
11. Fill air conditioning system completely with refrigerant.
Refer Section 2.3, “Fluids and Lubricant Capacities”, for
refrigerant type and capacity.
Note: The local JLG dealer or certified air conditioning service
center or personnel to perform the refrigerant installation to
the system.
for procedure.
4-10 31211333 3614RS, 4017RS

Cab
4.4 CAB REMOVAL .
WARNING
The protection offered by this ROPS/FOPS will be
impaired if subjected to any modification or structural 1
damage, at which time replacement is necessary.
ROPS/FOPS must be properly installed using fasteners of
correct size and grade, and torqued to their specified
value.
Note: To help ensure safety and optimum performance,

replace cab if it is damaged. Refer to appropriate parts manual 2
for ordering information.
Inspect cab, its welds and mounts. If modification, damage, a
cracked weld and/or fatigued metal is discovered, replace
cab. Contact local JLG dealer with any questions about
suitability or condition of a cab.
Note: Remove and label cab components as needed before MZ7771
removing cab from machine. Label, disconnect and cap 8. If equipped, remove windshield wiper assembly.
hydraulic hoses. Transfer cab parts to replacement cab after
replacement cab is securely mounted on machine. 9. Remove access covers (1 and 2) from front of cab.
10. Label and disconnect cab heater hoses and/or air
1. Park machine on a firm, level surface. Allow sufficient
conditioning hoses. Refer to Section 4.3.7, “Heater
overhead and side clearance for cab removal. Level
System (if equipped)” or Section 4.3.8, “Heater and Air
machine, fully retract boom, lower boom, place
Conditioning System (if equipped)”.
transmission in (N) NEUTRAL position, engage park
brake and shut engine OFF.
2. Block all four wheels to help prevent machine from
moving. Assure that there is sufficient overhead and 3 4
side clearance for cab removal.
for procedure.
5. Place a funnel at base of cooling system to channel
drained coolant into suitable container. Remove drain
plug and allow coolant to drain.
MZ7840
recycling facility. 11. Label, disconnect and cap all hydraulic hoses attached
7. Replace and tighten drain plug. to the steering orbital valve (3). Cap all fittings and
openings to keep dirt and debris from entering
hydraulic system.
to the brake assembly (4). Cap all fittings and openings
to keep dirt and debris from entering hydraulic system.
3614RS, 4017RS 31211333 4-11

Cab
MAE34860
13. Remove and retain inside rear cover (5) and securing
hardware from cab.
6
MAE35020
14. Remove and retain right side rear cover (6) and securing
hardware from cab.
15. Disconnect cab ground strap.
16. Label and disconnect the rear frame harness connectors
(7). Move the harnesses clear of the cab to prevent
damage during cab removal.
8 8
MZ7910
17. Install four lifting eye bolts with a minimum lifting

capacity of 383 kg (844 lb) in the existing lifting holes (8)
at the top corners of the cab.
4-12 31211333 3614RS, 4017RS

Cab
18. Use a hoist or overhead crane and sling with a minimum 4.5 CAB INSTALLATION
lifting capacity of 383 kg (844 lb) attached to the four
eye bolts. DO NOT attempt to lift the cab at this point. 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
9 383 kg (844 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. Readjust position of sling as needed to help
balance cab during installation.
4. Install four cab to frame mount bolts, washers and nuts to
145 - 155 Nm (107 - 114 lb-ft).
5. Connect previously labeled rear frame harness
connectors (7) to their appropriate locations.
6. Reconnect cab ground strap.
7. Uncap and reconnect previously labeled hydraulic
hoses to their appropriate locations.
8. Reconnect any remaining electrical connections to their
appropriate locations.
9. Reconnect heater hoses to cab heater. Refer to
9 MAE34800
Section 4.3.7, “Heater System (if equipped)”.
19. Remove four mount bolts, washers and nuts (9)
10. Reconnect heater hoses and/or air conditioning hoses
securing cab to frame.
to cab heater. Refer to Section 4.3.7, “Heater System (if
20. Remove mirrors and all other cab components as equipped)” or Section 4.3.8, “Heater and Air
needed, if not previously removed. Conditioning System (if equipped)”.
21. When all wiring, hydraulic hoses and fasteners are 11. Fill cooling system completely with coolant, allowing
disconnected or removed, carefully and slowly lift cab time for coolant to fill engine block. The cooling system
and remove it from frame. Readjust position of sling as capacity is listed in Section 2.3, “Fluids and Lubricant
needed to help balance cab during removal. Capacities”.
22. When cab is completely clear of machine, carefully Note: If machine is equipped with air conditioning, air
lower it to ground. Block up or support cab so it does conditioning system must be charged by local distributor or
not move or fall. certified air conditioning service center.
23. Assure that no personnel enter cab while it is being
removed from machine.
24. Inspect and replace machine parts that are exposed
with cab removed. Repair or replace as required.
3614RS, 4017RS 31211333 4-13

Cab

for procedure.
13. Carefully examine all cab components, fasteners, etc.,
one last time before engine start-up. Rectify any faulty
conditions.
14. Start engine and check operation of all controls. Check for
hydraulic fluid leaks. Check hydraulic fluid level in tank
and add fluid as required.
Note: When engine is initially started, run it briefly at low idle
and check machine for any visual sign of fluid leakage. STOP
engine immediately if any leakage is noted. Make any
necessary repairs before continuing.
15. Wait for engine to cool and check coolant level. Add
coolant as required to bring coolant to proper level.
17. If equipped, install windshield wiper assembly.
18. Install the mirrors and all other cab components as
needed, if removed.
19. Reinstall right side rear cover (6) with previously
removed hardware to cab.
20. Reinstall inside rear cover (5) with previously removed
hardware to cab.
21. Unblock wheels.
and steering wheel.
4-14 31211333 3614RS, 4017RS

Section 5
Axles, Drive Shafts, Wheels and Tires
Contents

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.1 3614RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.2 4017RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2 Axle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Axle Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Axle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.1 Axle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.2 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6 Park Brake adjustment - 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.7 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.8 Axle Assembly and Drive Shaft Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.9 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.2 Drive Shaft Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.3 Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.9.5 Drive Shaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.10 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.1 Removing Wheel and Tire Assembly from Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.10.2 Installing Wheel and Tire Assembly onto Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.11 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.11.1 3614RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.11.2 4017RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.11.3 Manually Resetting the Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
3614RS, 4017RS 31211333 5-1

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TERMINOLOGY
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.
5.1.1 3614RS
REAR AXLE
ASSEMBLY
REAR STEERING
CYLINDER
TRANSMISSION
REAR AXLE
WHEEL HUB
REAR
DRIVE SHAFT
FRONT STEERING
CYLINDER
FRONT
DRIVE SHAFT
MZ8362
FRONT AXLE FRONT AXLE

ASSEMBLY WHEEL HUB
5-2 31211333 3614RS, 4017RS

5.1.2 4017RS
REAR AXLE
ASSEMBLY
REAR STEERING
CYLINDER
TRANSMISSION
REAR AXLE
WHEEL HUB
REAR
DRIVE SHAFT
FRONT STEERING
CYLINDER
FRONT
DRIVE SHAFT
FRONT AXLE
ASSEMBLY MZ8352
FRONT AXLE
WHEEL HUB
3614RS, 4017RS 31211333 5-3

5.4 AXLE REPLACEMENT
WARNING 5.4.1 Axle Removal

precautions as outlined in Section 1, “Safety Practices”, of
this manual.
WARNING
An improperly supported machine can fall. Safely raise
and adequately support the machine so that it will
5.2 AXLE SERIAL NUMBER
remain stable and in place before attempting to remove
an axle.
Front and rear axle serial number plate is located on top of
the center section. The front and rear axle assemblies differ in that front axle
Information on the serial number plate is required in assembly is equipped with a parking brake mechanism and a
correspondence regarding the axle. limited slip feature; rear axle has neither. The following steps
Supply information from the axle serial number plate when outline a typical axle removal procedure, suitable for either
communicating about the axle assembly or the front or rear axle assembly.
axle components. Cleanliness is extremely important. Before attempting to
remove the axle, thoroughly clean the machine. Avoid
5.3 AXLE SPECIFICATIONS AND spraying water or cleaning solution on electrical
MAINTENANCE INFORMATION components. If using a steam cleaner, seal all openings
before steam cleaning.
For axle, oil specifications and maintenance information,
Note: Clear the work area of all debris, unnecessary personnel,
refer to Section 2.3, “Fluids and Lubricant Capacities”.
etc. Allow sufficient space to raise the machine and to remove
Detailed axle service instructions are provided in the the axle.
following publications:
1. Park machine on a firm, level surface, level machine, fully
retract boom, lower boom, place transmission in (N)
Model Publication Type Publication # NEUTRAL, engage parking brake, and shut engine OFF.
3614RS, Service Manual 31200162 2. Place a Do Not Operate Tag on both ignition key switch
4017RS and steering wheel.
Parts Manual 31200939
for procedure.
5. Remove bolts securing fender assembly to axle.
5-4 31211333 3614RS, 4017RS

8. If axle will be disassembled after removal, place a

FRONT AXLE suitable receptacle under axle (1) and wheel hub (2)
4 drain plugs. Remove drain plugs and allow oil to drain
3 into receptacle. Transfer used oil into a suitable covered
container, and label container as “Used Oil.” Dispose of
used oil at an approved recycling facility.
9. Install previously removed drain plugs (1 and 2).
10. Label and disconnect the electrical connections.
11. Disconnect LSI sensor at the rear axle.
12. Label, disconnect and cap steering and brake lines at
MAE8800
axle. Wipe up any spilled oil.
13. 3614RS Front Axle Only - Disconnect park brake cable.
1
14. Block front and rear of both tires on axle that is not
being removed. Ensure that machine will remain in
place during axle removal before proceeding.
REAR AXLE 4
15. Raise machine using a suitable jack or hoist. Place
suitable supports under both sides of frame and lower
3
machine onto supports. Ensure that machine will
remain in place during axle removal.
16. Support axle that is being removed with a suitable jack,
hoist or overhead crane and sling. DO NOT raise axle or
machine.
17. Remove both the wheel and the tire assemblies
from the axle that is being removed. Refer to
MAE8810 Section 5.10.1, “Removing Wheel and Tire Assembly
from Machine”.
1 Note: The wheel and tire assemblies must be re-installed later
with the directional tread pattern “arrows” facing in the
direction of forward travel.
WHEEL HUB 18. Remove the drive shaft assembly. Refer toSection 5.9.3,
“Drive Shaft Removal”.
19. 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.
20. Remove bolts and locknuts securing axle to frame.
21. Remove axles from machine using jack, hoist or
overhead crane and sling supporting axle. DO NOT raise
MAE8830 or otherwise disturb machine while removing axle.
2 Balance axle and prevent it from tipping, turning or
falling while removing it from beneath machine. Place
6. Rotate axle hub until drain plug is positioned at the the axle on a suitable support or holding stand.
bottom of the hub.
7. Loosen and remove the axle oil fill plug (3) and check fill
plug (4).
3614RS, 4017RS 31211333 5-5

5.4.2 Axle Installation

FRONT AXLE
1. If applicable, raise machine using a suitable jack or
4
hoist. Place suitable supports beneath the frame and
lower the machine onto the supports, allowing enough 3
room for axle installation.
2. Before proceeding, ensure machine will remain in place
during axle installation.
3. Block front and rear of both tires on axle that is already
installed on machine.
4. Using a suitable jack, hoist or overhead crane and sling,
remove axle from its support or holding stand. Balance
MAE8800
axle and prevent it from tipping, turning or falling while
positioning it beneath machine. DO NOT raise or
1
otherwise disturb machine while installing the axle.
5. Keep axle supported and balanced on the jack, hoist or
REAR AXLE
4
overhead crane and sling throughout the installation
procedure. 3
6. Position axle under frame, and align axle housings with
holes in frame.
7. Apply Loctite® 262 to each mounting bolt.
8. Install axle mounting bolts and nuts. Tighten and torque
as required.
9. Install the drive shaft assemblies. Refer to Section 5.9.5,
“Drive Shaft Installation”.
MAE8810
10. If reinstalling an axle previously removed from machine,
position driveshaft yoke on axle according to alignment 1
marks made earlier.
11. If installing a new axle, note position of driveshaft yoke
at transmission. Align driveshaft yoke on axle in same WHEEL HUB
plane as yoke on transmission.
12. Connect the steering and brake lines at axle.
13. 3614RS Front Axle Only - Connect park brake cable.
MAE8850
14. Tighten axle oil drain plugs (1). Fill until oil level reaches
bottom of check fill plug. Refer to Section 2.3, “Fluids
and Lubricant Capacities”, for proper oil and capacities.
15. Rotate wheel hubs 90 degrees so wheel hub drain plug
becomes the fill plug (2). Refer to Section 2.3, “Fluids
and Lubricant Capacities”, for proper oil and capacities.
16. Install and tighten the axle oil fill plug (3) and check fill
plug (4).
5-6 31211333 3614RS, 4017RS

17. Install the wheel and tire assemblies. Refer to 5.6 PARK BRAKE ADJUSTMENT - 3614RS
Section 5.10.2, “Installing Wheel and Tire Assembly onto
Machine”. 1. Park the machine on a slight grade, fully retract boom,
18. Carefully remove jack, hoist or overhead crane and sling level the boom, place transmission in (N) NEUTRAL, set
supporting axle. the parking brake. The machine should not move. If the
machine moves, adjust the park brake.
19. Carefully raise machine using a suitable jack or hoist.
Remove supports from beneath frame and lower 2. Apply service brake and disengage the park brake.
machine to ground.
20. Remove blocks from front and rear of both tires on
2
other axle.
Note: ALWAYS use new O-rings when servicing machine.
21. Install new O-rings into fittings. Lubricate O-rings with
clean hydraulic oil.
22. Uncap and connect steering and brake lines at their axle
fittings.
1
23. Check hydraulic reservoir oil level.
24. 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.
MM
25. Install fender assembly. Torque as required. 60
3
for procedure.
and steering wheel.
Note: Service brake circuit will need to bled after axle MAM4100
installation. Refer to Section 8.9.3, “Service Brake Bleeding”.

3. Depress the release lever (1) and push the park brake
5.5 BRAKE INSPECTION lever (2) down.
4. Adjust the park brake cable by turning the adjuster
Detailed axle service instructions are provided in the Axle
knob (3) clockwise to increase park brake force. Turn the
Service Manual, refer to Section 5.3, “Axle Specifications and
adjuster knob counterclockwise to decrease park brake
Maintenance Information”.
force.
5. If park brake cannot be adjusted, refer to Section 5.3,
“Axle Specifications and Maintenance Information”, for
detailed axle information.
5.7 STEERING ANGLE ADJUSTMENT

Detailed axle service instructions are provided in the Axle
Service Manual, refer to Section 5.3, “Axle Specifications and
Maintenance Information”.
3614RS, 4017RS 31211333 5-7

5.8 AXLE ASSEMBLY AND DRIVE SHAFT TROUBLESHOOTING

1. Excessive axle noise while 1. Oil level too low. 1. Fill oil to correct level. Refer to
driving. Section 2.3, “Fluids and Lubricant
Capacities”.
2. Axle and/or wheel end housings 2. Drain axle and/or wheel end
filled with incorrect oil or oil level housings and fill to correct level.
low. Refer to Section 2.3, “Fluids and
3. Incorrect alignment of ring and 3. Correct alignment by adding or

pinion gears. removing shims as needed.
4. Incorrect pinion (input) shaft 4. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
5. Worn or damaged bearings. 5. Replace bearings as needed.
6. Worn or broken gear teeth. 6. Replace gears as needed.
7. Contamination in the axle. 7. Drain axle and/or wheel end

housings and fill to correct level.
Refer to Section 2.3, “Fluids and
8. Axle housing damaged. 8. Replace damaged parts.
2. Intermittent noise when 1. Universal joint(s) worn or 1. Repair or replace universal joints
traveling. damaged. as needed.
2. Differential ring and/or pinion 2. Determine cause and repair as

gears damaged. needed.
3. Vibration or intermittent noise 1. Drive shaft universal joint 1. Tighten capscrews to correct
when traveling. assembly(ies) incorrectly torque.
tightened.
2. Drive shaft universal joint(s) worn 2. Repair or replace universal joints

or damaged. as needed.
3. Drive shaft(s) damaged/ 3. Replace drive shaft(s) as needed.

unbalanced.
5-8 31211333 3614RS, 4017RS


4. Oil leaking from axle 1. Drain and/or inspection plugs 1. Replace O-rings as needed and
(differential housing and/or loose and/or O-rings damaged or tighten plugs to 130 Nm (96 lb-ft).
axle housings). missing.
2. Hose fittings loose. 2. Tighten fittings.
3. Axle shaft seal damaged or 3. Replace seal and/or joint coupling

missing and/or worn or damaged fork shaft (axle shaft).
shaft sealing surfaces.
4. Input shaft multi-seal ring 4. Replace multi-seal ring and/or

damaged or missing and/or worn input shaft. Adjust ring and pinion
or damaged pinion (input) shaft alignment and bearing preload as
sealing surfaces. described in the JLG Repair
Manuals.
5. Axle casing to brake housing 5. Replace O-rings and seals.

and/or brake housing to
differential assembly O-rings
and/or seals worn or damaged.
6. Axle housing mounting nuts and 6. Tighten housing nuts and

capscrews loose. capscrews. Refer torque value
described in the manufacturer
Service Manual.
7. Differential and/or axle housing(s) 7. Replace housing(s) as needed.

damaged.
5. Oil leaking from wheel end 1. Oil level plugs loose and/or 1. Replace O-rings as needed and
housing (planet carrier). O-rings damaged or missing. tighten plugs to 60 Nm (44 lb-ft).
2. O-ring between hub and housing 2. Replace O-ring.

(planet carrier) damaged or
missing.
3. Shaft seal damaged or missing 3. Replace seal and/or fork joint

and/or worn or damaged shaft shaft.
sealing surfaces.
4. Housing capscrews loose. 4. Tighten housing capscrews. Refer

torque value described in the
manufacturer Service Manual.
5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).
6. Oil leaking from steering 1. Hose fittings loose. 1. Tighten fittings.

cylinder.
2. Steering cylinder O-rings and/or 2. Replace O-rings and seals.
seals worn or damaged.
3. Piston rod seal worn or damaged. 3. Replace piston rod seal.
4. Cylinder tube damaged. 4. Replace cylinder tube.
3614RS, 4017RS 31211333 5-9


7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. Refer to
Section 2.3, “Fluids and Lubricant
Capacities”.
2. Axle and/or wheel end housings 2. Drain axle and fill to correct level.
filled with incorrect oil or oil Refer to Section 2.3, “Fluids and
contaminated or oil level low. Lubricant Capacities”.
3. Dragging park brake. 3. Adjust park brake cable as

needed. Refer to Section Note:,
“Service brake circuit will need to
bled after axle installation. Refer
to Section 8.9.3, “Service Brake
Bleeding”.”
8. High steering effort required. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Excessive joint housing swivel 2. Correct bearing preload by

bearing preload. adding or removing shims as
needed.
3. Worn or damaged swivel 3. Replace swivel bearings as

bearings. needed.
9. Slow steering response. 1. Steering (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Steering cylinder leaking 2. Repair or replace steering cylinder

internally. as needed.
10. Excessive noise when brakes are 1. Brake discs worn. 1. Check brake discs for wear. Refer
engaged. to Section 5.5, “Brake Inspection”.
2. Brake discs damaged. 2. Replace brake discs.
11. Brakes will not engage. 1. Brake (hydraulic) system not 1. Refer to Section 8.5, “Hydraulic
2. Brake piston O-rings and seals 2. Replace O-rings and seals.

damaged (leaking).
12. Brakes will not hold the 1. Brake discs worn. 1. Check brake discs for wear. Refer
machine or braking power to Section 5.5, “Brake Inspection”.
reduced.
2. Brake (hydraulic) system not 2. Refer to Section 8.9.3, “Service
operating properly. Brake Bleeding”.
3. Brake piston O-rings and seals 3. Replace O-rings and seals.

damaged (leaking).
5-10 31211333 3614RS, 4017RS

5.9 DRIVE SHAFTS

1 2
5.9.1 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 3 2
4 1
drive shafts and cross and bearing assemblies may cause an 1 2
excessive amount of vibration or noise.
Note: To ensure optimum performance, the driveshaft 3
4
assemblies are specially balanced as a unit at the factory. When
servicing any flange yoke, slip yoke or drive shaft tube, order a 3
4
complete assembly if components are bent or damaged. Refer 2
to the appropriate parts manual for ordering information. 1
MAE8870
Note: Any bolt removed from the drive shaft assembly MUST 3
be replaced. DO NOT re-torque. 4
5.9.2 Drive Shaft Maintenance 7. Remove bolts (1) and straps (2) securing bearing cross
to the transmission output shaft flange. Discard bolts.
Refer to Section 2.3, “Fluids and Lubricant Capacities”, for
8. Remove bolts (3) and straps (4) securing bearing crosses
information regarding the lubrication of the grease fittings
to front axle. Discard bolts.
on the drive shafts.
9. Remove front drive shaft assembly.
5.9.3 Drive Shaft Removal 10. Repeat above procedure on rear drive shaft.
1. Park machine on a firm, level surface, level machine, fully 5.9.4 Drive Shaft Cleaning and Drying
(N) NEUTRAL, engage parking brake, and shut engine 1. Disassemble and clean all parts using an approved
OFF. cleaning fluid. Allow to dry.
2. Place a Do Not Operate Tag on both ignition key switch 2. Remove any burrs or rough spots from all machined
and steering wheel. surfaces. Re-clean and dry as required.
3. Open engine cover. Allow system fluids to cool. 5.9.5 Drive Shaft Installation
4. Properly disconnect battery. Refer Section 9.8, “Battery”, 1. Raise drive shaft assembly into position. The slip yoke
for procedure. end of drive shaft mounts toward axle. If reinstalling a
5. Block the wheels. drive shaft previously removed, align flange yokes
according to the alignment marks made during
6. The drive shaft assembly is a balanced assembly. Mark removal.
the yoke and axle, transmission and the shaft and slip
yoke so that these components can be returned to their Note: Yokes at both ends of drive shaft must be in same plane
original positions when reinstalled. Yokes at both ends to help prevent excessive vibration.
of the drive shaft must be in the same plane to help 2. Apply Loctite® 243TM to all mounting bolts.
prevent excessive vibration.
3. Install two straps (2) and four new bolts (1) securing
front drive shaft bearing crosses to transmission. Install
two straps (4) and four new bolts (3) securing front drive
shaft bearing crosses to front axle. Torque bolts to
34 - 42 Nm (25 - 28 lb-ft).
4. Install two straps (4) and four new bolts (3) securing rear
drive shaft bearing crosses to transmission. Install two
straps (2) and four new bolts (1) securing rear drive
shaft bearing crosses to rear axle. Torque bolts to
74 - 82 Nm (55 - 60 lb-ft).
3614RS, 4017RS 31211333 5-11

5. Properly connect battery. Refer Section 9.8, “Battery”, 5.10.1 Removing Wheel and Tire Assembly from
for procedure. Machine
6. Close and secure engine cover. 1. Park machine on a firm, level surface, level machine, fully
7. Unblock wheels. retract boom, lower boom, place transmission in
(N) NEUTRAL, engage parking brake, and shut engine
OFF.
and steering wheel.
5.10 WHEELS AND TIRES and steering wheel.
3. Loosen but DO NOT remove the lug nuts on the wheel
and tire assembly to be removed.
WARNING 4. Place a suitable jack under axle pad closest to wheel
being removed. Raise machine and position a suitable
Mismatched tire sizes, ply ratings or mixing of tire types
support beneath axle. Allow sufficient room to lower
(radial tires with bias-ply tires) may compromise machine
machine onto support and to remove wheel and tire
stability and may cause machine to tip over.
assembly.
It is recommended that a replacement tire to be same size, 5. Lower machine onto support.
ply and brand as originally installed. Refer to appropriate
6. Remove lug nuts and washers in alternating pattern.
parts manual for ordering information. If not using an
approved replacement tire, it is recommended that 7. Remove wheel and tire assembly from machine.
replacement tires have following characteristics:
5.10.2 Installing Wheel and Tire Assembly onto
• Equal or greater ply/load rating and size of original Machine
• Tire tread contact width equal or greater than original
• Wheel diameter, width and offset dimensions equal to 1
original
• Approved for application by the tire manufacturer
(including inflation pressure and maximum tire load)
The rims installed have been designed for stability
requirements which consist of track width, tire pressure and
load capacity. Size changes such as rim width, center piece
location, larger or smaller diameter, etc., without written
factory recommendations, may result in unsafe condition
regarding stability.
Foam filled tires have a positive effect on the weight, stability
and handling characteristics of the machine, especially MZ6020
under load. The use of hydrofill as a tire-fill substance is not

recommended because of possible environmental impact. Note: The wheel and tire assemblies must be installed with
directional tread pattern “arrows” facing in direction of forward
Large-bore valve stems are used to help expedite tire
travel.
inflation and deflation. An inner tube may be used if a tire
does not provide an airtight seal. Check tire inflation Note: Verify valve stems face outward on all wheel and tire
pressures when the tires are cold. When mounting a tire on assemblies.
the wheel, the tire must be mounted on the wheel respective
1. Position wheel onto studs on wheel end of axle.
of the directional tread pattern of the tire; this produces a left
or right tire and wheel assembly. 2. Install wheel washers onto studs.
3. Start all lug nuts by hand to prevent cross threading.
Apply one drop of lubrication oil.
5-12 31211333 3614RS, 4017RS

5.11 TOWING A DISABLED MACHINE

1 8
Towing a disabled machine should only be attempted after
exhausting all other options. Make every effort to repair
6 3 machine and move it under its own power.
5.11.1 3614RS
9 10 1. Fully retract the boom. Position attachment
approximately 610 mm (24 in) above the ground.
Note: If total loss of power has occurred, refer to Section 3.20,
“Emergency Boom Lowering Procedure”.
4 5
7 2 MY4200 WARNING
DO NOT attempt to tow a machine that is loaded or the
4. Tighten lug nuts in an alternating pattern as indicated in
boom/attachment is raised more than approximately 610
previous figure. Torque to 440 - 480 Nm (325 - 354 lb-ft).
mm (24 in).
5. Remove machine from supports.
2. Remove load from machine.
and steering wheel. 3. Place transmission in (N) NEUTRAL, engage park brake
7. Connect analyzer diagnostic tool.
4. Block all four wheels.
8. Use Operator Tools > Tyre Selection, to select the tire
option that best matches presently installed tire.
Note: It is critical to select appropriate tire to display accurate WARNING
speed on the dash gauge. Block all four wheels when preparing the machine for
towing to prevent ay unexpected movement.
5. Remove front and rear drive shafts. Refer to Section 5.9,

“Drive Shafts”, for procedure.
3614RS, 4017RS 31211333 5-13

FRONT VIEW
WARNING
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.
11. Tow machine to a secure location.
Note: Tow machine at a very slow speed.
12. After towing is complete, engage park brake.
14. Reinstall front and rear drive shafts. Refer to Section 5.9,
1
“Drive Shafts”.
15. Repair machine as necessary.
REAR VIEW
Note: Block the wheels of the machine BEFORE attempting to
release the park brake. Once the park brake is released the
machine’s park brake AND service brakes are inoperable.
MAE34680
6. Secure machine to a suitable towing vehicle.

a. For towing or retrieval from front of machine, attach
towing equipment to lifting points (1).
b. For towing or retrieval from rear of machine, attach
towing equipment to the retrieval hitch (2).
5-14 31211333 3614RS, 4017RS

5.11.2 4017RS Note: After machine has been towed to a secure location,
reactivate parking brake. Carefully follow procedures from start
1. Fully retract the boom. Position attachment
to finish. Contact local JLG dealer if you are unsure about any
approximately 610 mm (24 in) above the ground.
part of the procedure, or for specific instructions concerning
Note: If total loss of power has occurred, refer to Section 3.20, your particular situation.
“Emergency Boom Lowering Procedure”.
WARNING FRONT VIEW
DO NOT attempt to tow a machine that is loaded or the

boom/attachment is raised more than approximately 610
mm (24 in).
2. Remove load from machine.

3. Place transmission in (N) NEUTRAL, engage park brake
WARNING
Block all four wheels when preparing the machine for
towing to prevent ay unexpected movement.
5. Remove front and rear drive shafts. Refer to Section 5.9,

“Drive Shafts”. 1
a. Manually Releasing the brake REAR VIEW

3 3
3 3
MZ1020
1. Loosen the nuts of the screws (3) for the manual release
of the braking units. Draw the nuts back approximately
6 mm.
2. Tighten the screws until they are gently seated on the 2
driving plate.
3. Carefully tighten each release screw a 1/4 turn at a time MAE34680
in sequence until all have been turned on full turn 360°.

4. Repeat steps 1 thru 3 for other side of differential.
3614RS, 4017RS 31211333 5-15

5. Secure machine to a suitable towing vehicle. 5.11.3 Manually Resetting the Park Brake
a. For towing or retrieval from front of machine, attach Note: Block the wheels of the machine BEFORE attempting to
towing equipment to lifting points (1). release the machine’s park brake. Once the park brake is
b. For towing or retrieval from rear of machine, attach released the machine’s park brake AND service brakes are
towing equipment to the retrieval hitch (2). inoperable.
3 3
WARNING
Use a vehicle of sufficient capacity to tow the machine.
Tow vehicle must be capable of providing braking for
both vehicle and machine.
6. Clear area of any unnecessary personnel.
7. Have an operator seated in machine operator cab. 3 3
8. Remove blocks from all four wheels. MZ1020
9. Disengage machine park brake.

10. Tow machine to a secure location. 1. Loosen each release screw (3), only 1/4 turn at a time, in
sequence, until each screw has lost contact with the
Note: Tow machine at a very slow speed. guide pin.
11. After towing is complete, engage park brake. 2. Remove screws along with nuts and seals. Replace seals,
12. Block all four wheels. lubricate screws with a silicone-based grease and
re-install screws along with nuts.
13. Reinstall front and rear drive shafts. Refer to Section 5.9,
“Drive Shafts”. 3. Adjust the nut of the screw heads in relation to the arm
by 1.18 in (30 mm).
14. Repair machine as necessary.
4. Repeat steps 1 thru 3 for other side of differential.
Note: Block the wheels of the machine BEFORE attempting to
5. After repairs to machine have been made, start machine
release the park brake. Once the park brake is released the
and check park brake and service brakes for proper
machine’s park brake AND service brakes are inoperable.
function. Refer to Section 8.9.3, “Service Brake
Bleeding”, Section 8.9.4, “Service Brake Test” and
Section 8.9.5, “Steering Orbital Valve”.
5-16 31211333 3614RS, 4017RS

Section 6
Transmission
Contents

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4 Transmission Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.4.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4.4 Transmission Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.5 Torque Converter Flex Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5.1 Torque Converter Flex Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5.2 Torque Converter Flex Plate Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
3614RS, 4017RS 31211333 6-1

Transmission
6.1 TRANSMISSION ASSEMBLY

COMPONENT TERMINOLOGY
of the major assemblies of the transmission. The following
ENGINE SPEED
SENSOR
TRANSMISSION
OIL FILTER
TRANSFER CASE
BREATHER
TRANSMISSION
BREATHER
TRANSFER CASE
OIL FILLER PLUG
TRANSMISSION
DIPSTICK
SHIFT
SOLENOIDS
FORWARD CLUTCH
PRESSURE CHECK
PORT OIL FILL
PLUG
MAGNETIC TRANSFER CASE
REVERSE CLUTCH DRAIN PLUG OIL LEVEL GLASS
PRESSURE CHECK
PORT
TRANSMISSION OIL
FILLER HOLE
MAGNETIC
DRAIN PLUG
TRANSMISSION LIFT
POINT
MZ7100
6-2 31211333 3614RS, 4017RS

Transmission
6.3 SPECIFICATIONS AND MAINTENANCE

WARNING INFORMATION
DO NOT service the machine without following all safety For transmission, oil specifications and maintenance
precautions as outlined in Section 1, “Safety Practices”, of information, refer to Section 2.3, “Fluids and Lubricant
this manual. Capacities”.
Note: These instructions cover only the routine maintenance, Detailed transmission service instructions are provided in
removal, installation and troubleshooting of the transmission. the following publications:
Refer to the local JLG dealer and the applicable Transmission
Service Manual for assistance with comprehensive Model Publication Type Publication #
transmission diagnosis, repair and component replacement.
3614RS, Service Manual 31200163
6.2 TRANSMISSION SERIAL NUMBER 4017RS Parts Manual 31200939
6.4 TRANSMISSION REPLACEMENT

Cleanliness is of extreme importance. Before attempting to
remove the transmission, thoroughly clean the exterior of
the transmission to help prevent dirt from entering during
the replacement process. Avoid spraying water or cleaning
solution onto or near the transmission shift solenoids and
other electrical components.
1
WARNING
NEVER lift a transmission alone; enlist the help of at least
one assistant or use a suitable hoist or overhead crane
and sling with a minimum lifting capacity of
454 kg (1000 lb).
MZ7110
The transmission serial number plate (1) is located on the 6.4.1 Transmission Removal
front of the transmission case behind the oil dipstick. 1. Park machine on a firm, level surface, level machine,
Information contained in the serial number is required in fully retract boom, lower boom, place transmission in
correspondence with the transmission manufacturer. (N) NEUTRAL, engage park brake and shut engine OFF.
switch and steering wheel.
5. Drain hydraulic oil reservoir. Refer to Section 8.7.1,
“Hydraulic Oil Reservoir Draining”.
6. If not previously removed, remove the implement
pump. Refer to Section 8.8.1, “Pump Replacement”.
7. Refer to Section 7.9, “Engine Replacement”, for detailed
removal instructions.
8. Thoroughly clean the transmission and the surrounding
area, including all hoses and fittings, before proceeding.
3614RS, 4017RS 31211333 6-3

Transmission
12. Turn engine over slowly by hand and align each of

torque convertor flex plate bolts to be accessed.
Remove them one at a time.
5
2 6
MAE18710
1
9. Place a suitable receptacle under transmission/transfer
case drain plugs. Remove the transmission drain plug
(1), and allow the transmission oil to drain into the
receptacle. Repeat the drain procedure with the transfer MZ7160
case (2). 13. Remove bolts and washers (5) holding transmission to
10. Transfer used transmission oil into a suitable, covered engine.
container, and label container as “Used Oil.” Dispose of 14. Use a suitable hoist or overhead crane, secure the
used oil at an approved recycling facility. Clean and transmission with a lifting strap or chain to lifting
reinstall the transmission and transfer case drain plugs. bracket secured to lifting point (6).
Note: Lifting bracket is NOT included with transmission.
15. Lift transmission clear of engine, and lower it onto
suitable supports or secure it to a stand built especially
for transmission or engine service. Secure transmission
so that it will not move or fall.
16. Remove any external transmission components as
required. Cover all transmission openings.
6.4.2 Transmission Inspection and Internal

4
Repair
Refer to Section 6.3, “Specifications and Maintenance Information”.
3
MZ7140
11. Remove access cover (3) from the engine bell

housing (4). This will allow access to remove torque
convertor flex plate bolts and washers from the engine
flywheel.
6-4 31211333 3614RS, 4017RS

Transmission
6.4.3 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.
Note: Apply Loctite® 243TM to all transmission bolts before
installation.
1. Use a suitable hoist or overhead crane, secure 7
transmission with a lifting strap or chain to transmission
lifting bracket.
2. Install transmission to engine and secure with
previously removed bolts and washers (5).
Torque to 72 Nm (53 lb-ft).
3. Remove hoist or overhead crane and sling. MZ7160
4. Turn engine over slowly by hand and align and install 11. Remove the transmission dipstick (7) and check the oil
each of torque convertor flex plate bolts and washers to level. The oil level should be at the MAX line.
engine flywheel through access opening on engine bell
12. If oil is low, add oil as required.
housing. Install them one at a time. DO NOT fully
tighten until all of bolts are in place. Torque flex plate 13. Replace the transmission dipstick (7).
bolts to 35 - 39 Nm (26 - 29 lb-ft). 14. Install the engine cover.
5. Install the hydraulic pump. Refer to Section 8.8.1, “Pump 15. Close and secure engine cover.
Replacement”.
16. Recheck all drain plugs, lines, connections, etc., for leaks,
6. Refer to Section 7.9.4, “Engine/Transmission and tighten where necessary. Close and secure the
Installation”, for detailed engine/transmission engine cover.
installation instructions.
17. Remove the Do Not Operate Tags from both the ignition
7. Fill the transmission. Refer to Section 2.3, “Fluids and key switch and the steering wheel.
Lubricant Capacities”, for proper capacity.
Note: Check transmission oil level with engine at idle and
transmission oil cold.
9. Apply park brake, place transmission in (N) NEUTRAL
position and lower the forks or attachment to the
ground.
10. Open engine cover
3614RS, 4017RS 31211333 6-5

Transmission
6.4.4 Transmission Fluid Level Check 10. Allow the engine to run at idle for 30 seconds.
Note: Final transmission oil level must always be checked with 11. Repeat steps 9 and 10 three more times, or until the
engine at idle and transmission oil at operating temperature transmission temperature warning light illuminates.
(minimum 80°C/176°F). 12. Place the transmission in (N) NEUTRAL and apply the
1. Start machine on a firm, level surface, level machine, park brake. Allow the engine to run at idle for
fully retract boom, lower boom, place transmission in 30 seconds.
(N) NEUTRAL, engage park brake and run engine at idle. 13. Open the engine cover.
2. Open engine cover. 14. Verify that top of transmission oil cooler is warm and oil
is circulating through the cooler. If the top tank of the
transmission oil cooler is not warm, repeat steps
6 thru 10.
15. Remove the transmission dipstick (7) and check the oil
level. The oil level should be in FULL level mark.
16. Add oil as required.
17. Replace the transmission dipstick.
19. Shut engine OFF.
MZ7160
3. Remove the transmission dipstick (7) and check the oil

level. The oil level after 2 - 3 minutes of idle must be
between the ADD and FULL oil level marks.
Note: Depending on the amount of fluid remaining in the
transmission oil cooler, the oil level may read substantially
above the MAX level mark at this time. The correct oil level can
be obtained after the transmission fluid is at operating
temperature.
4. If the oil is low, add oil as required.
5. Replace the transmission dipstick.
7. Ensure that the front of the machine is clear of persons
or obstacles.
8. Apply the service brake and disengage the park brake.
Place the transmission in (F) FORWARD at 3rd gear.
9. Stall the transmission against the service brake at full
throttle a maximum of 60 seconds. If transmission
temperature warning light illuminates, go to step 12.
6-6 31211333 3614RS, 4017RS

Transmission
6.5 TORQUE CONVERTER FLEX PLATE 6.6 TROUBLESHOOTING

Refer to Section 6.3, “Specifications and Maintenance
6.5.1 Torque Converter Flex Plate Removal Information”, for detailed Torque Converter Information.
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.
Note: In order to remove engine flex plates, engine and
transmission must be separated.
2. Refer to Section 6.4.1, “Transmission Removal” or
Section 7.9.1, “Engine/Transmission Removal”, for
transmission removal.
1
4 2
MAE9810
3
3. Remove eight bolts holding flex plates (1) to flywheel.
4. With transmission removed with flex plates (1) and
torque converter (2), loosen and remove six bolts and
washers (3) holding the support ring (4) and flex
plates (1) to the torque converter (2).
5. Replace three flex plates (1) if damaged.
6.5.2 Torque Converter Flex Plate Installation

1. Install three new flex plates (1) on torque converter (2)
with support ring (4) and previously removed bolts with
washers (3).
2. Refer to Section 6.4.2, “Transmission Inspection and
Internal Repair” or Section 7.9.4, “Engine/Transmission
Installation”, for transmission installation.
3614RS, 4017RS 31211333 6-7

Transmission
6-8 31211333 3614RS, 4017RS

Section 7
Engine
Contents

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.1 Surge Tank Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4.3 Radiator Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.6.2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.6.3 After Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.7.1 Prior to SN E160000342, excluding E160000328 thru E160000332 & E160000336 7-9
7.7.2 SN E160000342 to present, including E160000328 thru E160000332 & E1600003367-12
7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.8.2 Air Cleaner Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
7.9 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.9.1 Engine/Transmission Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.9.2 Transmission Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.9.3 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.9.4 Engine/Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
3614RS, 4017RS 31211333 7-1

Engine
7.1 INTRODUCTION
WARNING
precautions as outlined in Section 1, “Safety Practices,” of
this manual
WARNING
Engine fuel lines are pressurized. DO NOT attempt repairs
unless specific training has been completed.
7.1.1 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.
Note: Detailed engine service instructions (covering
disassembly, inspection, internal repair, assembly, adjustment
and troubleshooting information) are provided in appropriate
engine service manual. A gradual running-in (break-in) of a
new engine is not necessary. Full load can be applied to a new
engine as soon as the engine is put into service and the coolant
temperature is at least 60° C (140° F). Extended light-load
operation during the early life of the engine is not
recommended. DO NOT run the engine at high, no-load
speeds. DO NOT apply an overload to the engine.
7-2 31211333 3614RS, 4017RS

Engine
7.1.2 Component Terminology

of the engine components. The following illustration
identifies the components that are referred to throughout
this section.
ALTERNATOR
TURBO CHARGER
OIL FILTER
MZ7390
STARTER
FUEL INJECTOR PUMP MZ7400
3614RS, 4017RS 31211333 7-3

Engine
7.2 ENGINE SERIAL NUMBER 7.4 ENGINE COOLING SYSTEM

The engine serial number is stamped on the engine block,
above the oil filter. Information contained in the serial
7.4.1 Surge Tank Cap
number is required in correspondence with the engine A 1 Bar (14.5 psi) cap is used on the surge tank. An incorrect
manufacturer. or malfunctioning cap can result in the loss of coolant and a
hot running engine.
7.3 SPECIFICATIONS AND MAINTENANCE
INFORMATION 7.4.2 Thermostat Replacement
Before considering thermostat replacement, check the
For engine, coolant and oil specifications, and maintenance coolant level, fan belt tension and instrument cluster
information, refer to Section 2, “General Information and temperature indicator.
Specifications”.
• If engine seems to take a long time to warm up,
thermostat may be stuck in the open position and
requires replacement.
• If engine runs hot, check temperature of upper
radiator hose.
• If hose is not hot, thermostat may be stuck in closed
position.
• If engine has overheated, performance may suffer,
indicating other damage including a leaking
cylinder head gasket, cracked cylinder head or
block, and/or other internal engine damage.
a. Thermostat Removal
OFF.
and steering wheel.
for procedure.
5. Slowly turn surge tank cap to first stop and allow any
pressure to escape. Remove surge tank cap.
coolant into container. Loosen the drain plug and slowly
remove to allow coolant to drain. Transfer coolant into a
properly labeled container. Dispose of properly if
coolant needs to be replaced. Replace the radiator drain
plug.
7-4 31211333 3614RS, 4017RS

Engine
7.4.3 Radiator Assembly Replacement

1
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.
• If engine has overheated, performance may suffer,
indicating other damage including a leaking cylinder
head gasket, cracked cylinder head or block, and/or
other internal engine damage.
MAE8980
a. Radiator Assembly Removal
7. Remove capscrews securing thermostat housing (1) to
engine. 1. Park machine on a firm, level surface, level machine, fully
8. Remove thermostat housing, old gasket and
thermostat. Clean all gasket surfaces. DO NOT let any
OFF.
debris into thermostat opening.
Note: ALWAYS use correct thermostat and install a new gasket. and steering wheel.
NEVER operate engine without a thermostat, or engine
damage will result.
b. Thermostat Installation for procedure.
1. Install engine thermostat, thermostat gasket and
thermostat housing. Secure with the previously 2
removed capscrews.
for procedure.
3. Open surge tank cap, and fill the radiator completely
with a 50/50 mixture of ethylene glycol and water. Add
coolant solution at a maximum rate of 1.3 gallons per
minute (5 liters per minute). Replace and tighten
radiator cap. Add coolant to surge tank until 1/4 to 1/2
full. This overfilling will compensate for any air trapped 3
in cooling system.
4. Run engine to operating temperature. Visually check for
leaks with engine running. Check coolant level in surge
MZ7441
tank and fill, or drain, as necessary.
4
5. Remove hood (2), end cover (3) and belly pan (4) from
6. Remove Do Not Operate Tags from both ignition key
engine compartment.
switch and steering wheel.
6. Place a suitable receptacle under transmission drain
plug. Remove transmission drain plug, and allow the
transmission oil to drain into receptacle.
3614RS, 4017RS 31211333 7-5

Engine
7. Transfer used transmission oil into a suitable, covered

container, and label container as “Used Oil.” Dispose of 9
7 6
used oil at an approved recycling facility. Clean and
8
reinstall transmission drain plug.
8. Drain hydraulic oil reservoir. Refer to Section 8.7.1,
9. Slowly turn surge tank cap to first stop and allow any
pressure to escape. Remove surge tank cap.
10. Place a suitable container beneath radiator drain.
coolant into a container. Open drain plug and slowly
remove to allow coolant to drain. Transfer coolant into a
properly labeled container. Dispose of properly if
coolant needs replaced. Close radiator drain plug.
MZ7450
5
8 9
13. Label and disconnect both transmission cooler

hoses (6). Cap all fittings and openings to prevent dirt
and debris from entering hydraulic system.
14. Loosen and remove radiator assembly mounting bolts,
washers and (if equipped) shims. Note the number of
shims being used and there location.
15. Label, disconnect and cap hoses attached to coolant
recovery tank (7). Remove coolant recovery tank and
mounting plate.
16. Loosen and remove air intercooler tubes (8) from
5 radiator assembly.
17. Loosen and remove the radiator hoses (9) from radiator
assembly.
MZ7430 18. Carefully lift the radiator assembly out of the
engine compartment.
12. Label and disconnect the outer hydraulic cooler
hose (5). Cap all fittings and openings to prevent dirt Note: Fan Guard can be removed after radiator assembly is
and debris from entering hydraulic system. removed and placed in a secure location.
7-6 31211333 3614RS, 4017RS

Engine
b. Radiator Assembly Installation 7.5 ENGINE ELECTRICAL SYSTEM

1. Place radiator assembly in engine compartment at the
The engine electrical system, including the starter, alternator
original orientation. Secure with the previously used
and primary wiring, is described in Section 9.5, “Electrical
hardware.
System Schematics”.
2. Uncap and connect previously labeled hoses to radiator,
transmission cooler and oil cooler. 7.6 FUEL SYSTEM
3. Fill hydraulic oil reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling”.
7.6.1 Diesel Fuel
4. Fill transmission. Refer to Section 2.3, “Fluids and
Lubricant Capacities”. Fuel represents a major portion of machine operating costs
and therefore must be used efficiently. ALWAYS use a
5. Open surge tank cap and fill the radiator completely premium brand of high quality, clean diesel fuel. Low cost,
with coolant. Replace and tighten surge tank cap. Refer inferior fuel can lead to poor performance and expensive
to Section 2.3, “Fluids and Lubricant Capacities”, for engine repair.
proper capacities.
Refer Section 2.3, “Fluids and Lubricant Capacities”, for
6. Properly connect battery. Refer Section 9.8, “Battery”, for approved fuel specification.
procedure.
7. Run engine to operating temperature. Visually check for
leaks with engine running. Check all fluid levels for
correct levels.
8. Install the end cover, hood and belly pans on the engine
compartment.
and the steering wheel.
3614RS, 4017RS 31211333 7-7

Engine
7.6.2 Fuel Tank 9. Disconnect fuel sender.

Note: Fuel tank is a one piece unit. It is located under the cab. If it is 10. Remove fuel tank drain plug, and drain fuel into
determined that fuel tank must be removed, fuel must be drained an approved and suitable container. Dispose of
before tank removal. Always dispose of fuel properly. fuel properly.
a. Fuel Tank Removal b. Disassembly

1. Park machine on a firm, level surface, level machine, fully Fuel tank is a one-piece unit and cannot be disassembled.
retract boom, lower boom, place transmission in Fuel level indicator can be removed and reused on new
(N) NEUTRAL, engage parking brake, and shut engine replacement tank. Dispose of old tank according to local
OFF. regulations concerning hazardous materials disposal.
and steering wheel. c. Cleaning and Drying
3. Open engine cover. Allow system fluids to cool. If contaminated fuel or foreign material is in the tank, tank
4. Properly disconnect battery. Refer Section 9.8, “Battery”, can usually be cleaned.
for procedure. To clean the fuel tank:
Note: If replacing the tank, remove all internal and external 1. Have a dry chemical (Class B) fire extinguisher near work
components from the old tank, and retain for use on the area.
replacement tank. 2. Remove the fuel or oil tank drain plug, and safely drain
Note: Have a dry chemical (Class B) fire extinguisher near the any fuel into a suitable container. Dispose of fuel
work area. properly.
2 3. Clean fuel tank with a high pressure washer, or flush
tank with hot water for five minutes and drain water.
Dispose of contaminated water properly.
1 4. Add a diesel fuel emulsifying agent to tank. Refer to
manufacturer’s instructions for correct emulsifying
agent-to-water mixture ratio. Refill tank with water, and
agitate mixture for 10 minutes. Drain tank completely.
Dispose of contaminated water properly.
5. Refill fuel tank with water until it overflows. Completely
flush tank with water. Empty fuel tank, and allow it to
dry completely.
d. Assembly
Fuel level indicator can be removed and reused on new
replacement tank. Dispose of old tank according to
local regulations concerning hazardous materials
disposal regulations.
e. Inspection
1. Inspect fuel tank thoroughly for any cracks, slices, leaks
MZ7470 or other damage.
2. With fuel tank removed from machine, plug all
5. Remove hardware (1) securing fuel tank to frame.
openings except one elbow fitting. Install elbow fitting,
6. Support fuel tank with a floor jack or suitable supports. and apply approximately 7 - 10 kPa (1 - 1.5 psi) of air
Remove hardware (2) securing fuel tank pressure through elbow. Check reservoir for leaks by
support to cab. applying a soap solution to exterior and look for
7. Lower fuel tank and support bracket away from cab bubbles to appear at cracked or damaged area.
being careful to minimize fluid spillage.
8. Label, disconnect and cap fuel lines.
7-8 31211333 3614RS, 4017RS
Engine
f. Fuel Tank Installation 7.7 ENGINE EXHAUST SYSTEM

1. Using a floor jack, lift fuel tank and support bracket to
their original orientation on cab. 7.7.1 Prior to SN E160000342, excluding
2. Connect previously labeled fuel hoses to their E160000328 thru E160000332 &
appropriate locations. Secure with clamps. Connect fuel E160000336
sender. Note: Emission Sensitive Exhaust. Assembly must be replaced
3. Secure the fuel tank with previously used hardware. exactly as removed. Contact your local JLG dealer before
Remove floor jack. removing the muffler system.
4. Fill fuel tank according to specifications. Refer to a. Exhaust System Removal - if ULS equipped
Section 2.3, “Fluids and Lubricant Capacities”.
Note: Park machine on a firm, level surface, level machine, fully
5. Check fuel tank for leaks. retract boom, lower boom, place transmission in
6. Properly connect battery. Refer Section 9.8, “Battery”, (N) NEUTRAL, engage parking brake, and shut engine OFF.
for procedure. 4. Place a Do Not Operate Tag on both ignition key switch
7. Close and secure engine cover. and steering wheel.
8. Remove Do Not Operate Tag from ignition key switch 5. Open engine cover. Allow system fluids to cool.
and steering wheel. 6. Properly disconnect battery. Refer Section 9.8, “Battery”,
for procedure.
7.6.3 After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from fuel system in accordance with
instructions found in the appropriate Engine Operation
& Safety Manual. MZ7441
1
3. Fill the fuel tank with fresh, clean diesel fuel as required.
7. Remove belly pan (1).
2
3
MZ7490
8. Loosen and remove clamp (2) at exhaust pipe (3).
3614RS, 4017RS 31211333 7-9

Engine
9. Loosen and remove clamp (4) securing tail pipe (5). b. Exhaust System Installation - if ULS equipped
10. Remove tail pipe from exhaust pipe. Note: Keep all clamps loosened until entire exhaust system is in
place.
1. Install exhaust pipe (3) to after-treatment unit.
2. Install after-treatment unit and secure with hangers. DO
NOT tighten hangars.
6 7 3. Install the tail pipe (5) to the exhaust pipe (3) and secure
to frame with previously used clamps (2 and 4). DO NOT
3 9
tighten.
4. Install exhaust pipe V-band clamps (6) and exhaust
pipes (7). Adjust the after-treatment unit, tail and
exhaust pipes for proper clearance then tighten all
clamps.
5. Torque clamps (8) to 16 - 20 Nm (12 - 15 lb-ft).
8 MZ7500 6. Torque clamps (2 and 4) to 11 - 13 Nm (8 - 9.5 lb-ft).
7. Torque clamps (6) to 9 - 11 Nm (6.6 - 8 lb-ft).
11. Loosen and remove exhaust pipe V-band clamps (6) and
exhaust pipes (7). 8. Properly connect battery. Refer to Section 9.8, “Battery”.
12. At bottom of after-treatment unit, loosen both after- 9. Start engine and check for exhaust leaks at all exhaust
treatment unit hangers (8). connections. Adjust or repair as needed.
13. Carefully remove hangers and lower the after-treatment 10. Install belly pan.
unit from the machine. 11. Close and secure engine cover.
14. Loosen and remove V-band clamp (9) securing exhaust 12. Remove Do Not Operate Tag from ignition key switch
pipe (3) to after-treatment unit. and steering wheel.
15. Remove exhaust pipe (3).
c. Exhaust System Removal - if LS equipped
OFF.
and steering wheel.
for procedure.
MZ7441
1
7-10 31211333 3614RS, 4017RS

Engine
4
7
2 3 6
MZ7490
10
6. Loosen and remove clamp (2) at exhaust pipe (3).
7. Loosen and remove clamp (4) securing tail pipe (5). 3
8. Remove tail pipe from exhaust pipe.
MZ7480
9. Loosen and remove exhaust pipe clamps (6).

10. Loosen and remove V-band clamp (7) securing exhaust
pipe (8).
12. Remove hardware (9) securing muffler to frame.
13. Carefully lower muffler from machine.
14. Loosen and remove clamp (10) securing exhaust
pipe (3) to muffler.
15. Remove exhaust pipe.
3614RS, 4017RS 31211333 7-11

Engine
d. Exhaust System Installation - if LS equipped

Note: Keep all clamps loosened until entire exhaust system is in
place.
1. Install exhaust pipe (3) to muffler and secure with
MZ7441
clamp (10).
2. Install muffler and secure with hardware removed 1
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 and 4).
DO NOT Tighten. 4
4. Install exhaust pipe (8) to muffler with clamps (6).
DO NOT Tighten.
5. Secure exhaust pipe to engine exhaust pipe with
V-band clamp (7). DO NOT Tighten.
6. Adjust the muffler, tail and exhaust pipes for proper 5
clearance then tighten all clamps.
7. Torque clamps (7) to 16 - 20 Nm (12–15 lb-ft).
8. Torque clamps (2 and 4) to 11 - 13 Nm (8 - 9.5 lb-ft).
for procedure.
11. Start engine and check for exhaust leaks at all exhaust
connections. Adjust or repair as needed. 2
3
12. Install belly pan.
and steering wheel.
MZ7490
7.7.2 SN E160000342 to present, including 6. Loosen and remove clamp (2) at exhaust pipe (3).
E160000328 thru E160000332 &
E160000336 7. Loosen and remove clamp (4) securing tail pipe (5).
Note: Emission Sensitive Exhaust. Assembly must be replaced 8. Remove tail pipe from exhaust pipe.
exactly as removed. Contact your local JLG dealer before
removing the muffler system. 8
a. Exhaust System Removal - if ULS equipped

OFF.
and steering wheel.
MZ8820
3. Open engine cover. Allow system fluids to cool. 6 7
9. Label and disconnect both pressure sensor module
for procedure.
fittings (6)(7).
10. Label and disconnect both temperature sensors (8).
7-12 31211333 3614RS, 4017RS

Engine
b. Exhaust System Installation - if ULS equipped

Note: The emissions sensitive after-treatment unit must be
oriented properly as described below.
Note: DO NOT reinstall used gaskets or V-band clamps.
3 14 place.
10
11 1. Install exhaust pipe (3) and new gasket (14) to

after-treatment unit using new V-band clamp (13).
2. Install after-treatment unit and secure with
hangers (10). DO NOT tighten hangers.
13 9 3. Install the tail pipe (5) to the exhaust pipe (3) and secure
12 to frame with previously used clamps (2 and 4). DO NOT
tighten.
11. Loosen, remove and discard exhaust pipe V-band
clamps (9) and exhaust pipe (10). Discard gasket (11). 4. Install new exhaust pipe V-band clamps (9) and exhaust
pipe (10) with new gasket (11). DO NOT tighten.
12. At bottom of after-treatment unit, loosen both
hangers (12). 5. Ensure exhaust pipe (10) is
installed with axis straight and
13. Carefully remove hangers and lower the after-treatment without offset or bends. The
unit from the machine. flexible section of exhaust pipe
14. Loosen, remove and discard V-band clamp (13) securing should measure between
244-264 mm
exhaust pipe (3) to after-treatment unit. Discard gasket 244 - 264 mm (9.6 - 10.4 in) (9.6 - 10.4 in)
(14).
MZ8840
6 15
18°
4°
20°- 30°
3
MZ8830
6. Orient pressure sensor module fitting (6) approx 18°

from horizontal axis.
7. Orient exhaust pipe (3) 4° from horizontal axis.
8. Torque hangers (12) to 16 - 20 Nm (12 - 15 lb-ft).
10. Torque new V-band clamps (9 and 13) to 11 - 13 Nm
(8 - 9.5 lb-ft).
11. Orient both DPF clamps (15) 20°- 30° from horizontal
axis. Torque to 9 - 11 Nm (6.5 - 8 lb-ft).
12. Connect pressure sensor fitting (6). Ensure fitting is
oriented upward, as shown.
Torque to 27 - 29 Nm (20 - 21 lb-ft).
3614RS, 4017RS 31211333 7-13

Engine
13. Connect pressure sensor fitting (7). Ensure fitting is

oriented upward, as shown.
4
Torque to 19 - 21 Nm (14 - 15.5 lb-ft).
14. Connect both temperature sensors (8).
Torque to 40 - 50 Nm (29.5 - 40 lb-ft).
for procedure.
connections. Adjust or repair as needed.
and steering wheel.
c. Exhaust System Removal - if LS equipped

2 3
OFF.
and steering wheel. MZ7490
3. Open engine cover. Allow system fluids to cool. 6. Loosen and remove clamp (2) at exhaust pipe (3).
4. Properly disconnect battery. Refer Section 9.8, “Battery”, 7. Loosen and remove clamp (4) securing tail pipe (5).
for procedure.
8. Remove tail pipe from exhaust pipe.
MZ7441
1
7-14 31211333 3614RS, 4017RS

Engine
d. Exhaust System Installation - if LS equipped

7
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 and 4).
DO NOT Tighten.
8
4. Install exhaust pipe (8) to muffler with clamps (6).
DO NOT Tighten.
5. Secure exhaust pipe to engine exhaust pipe with
V-band clamp (7). DO NOT Tighten.
6
6. Adjust the muffler, tail and exhaust pipes for proper
clearance then tighten all clamps.
7. Torque clamps (7) to 16 - 20 Nm (12–15 lb-ft).
9
10 10. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
3
connections. Adjust or repair as needed.
MZ7480
and steering wheel.
9. Loosen and remove exhaust pipe clamps (6).

10. Loosen and remove V-band clamp (7) securing exhaust
pipe (8).
12. Remove hardware (9) securing muffler to frame.
13. Carefully lower muffler from machine.
14. Loosen and remove clamp (10) securing exhaust
pipe (3) to muffler.
3614RS, 4017RS 31211333 7-15

Engine
7.8 AIR CLEANER ASSEMBLY 7.8.2 Air Cleaner Assembly Installation

1. Install the air cleaner assembly (14) to the air cleaner
NOTICE mounting plate and secure with the previously used

hardware.
NEVER run the engine with only the inner safety element 2. Place the loosened clamp (12) over the air intake
installed. elbow (13) and install elbow on the air cleaner
assembly. Tighten clamp.
Note: Refer to the appropriate machine Operation & Safety
Manual for the correct element change procedure. 3. Properly connect battery. Refer Section 9.8, “Battery”,
for procedure.
7.8.1 Air Cleaner Assembly Removal 4. Close and secure engine cover.
1. Park machine on a firm, level surface, level machine, fully 5. Remove Do Not Operate Tag from ignition key switch
retract boom, lower boom, place transmission in and steering wheel.
OFF.
and steering wheel.
for procedure.
14
12
13
15
16
MZ7510
5. Loosen and remove clamp (12) securing air intake

tube (13) to air cleaner (14). Pull air intake elbow off air
cleaner.
6. Remove bolts (15) securing air cleaner straps (16) to air
cleaner (14). Remove air cleaner assembly.
7-16 31211333 3614RS, 4017RS

Engine
7.9 ENGINE REPLACEMENT

1
WARNING
NEVER lift a engine/transmission alone; Use a suitable
hoist or overhead crane and sling with a minimum lifting
capacity of 700 kg (1543 lb).
7.9.1 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 2
additional components must be removed before engine/
transmission removal. They will be addressed in the following
MZ7441
procedures.
retract boom, lower boom, place transmission in 9. Remove hood (1), end cover (2) and belly pan from
(N) NEUTRAL, engage parking brake, and shut engine engine compartment.
OFF. 10. Remove the heater and cooling hoses attached to the
2. Place a Do Not Operate Tag on both ignition key switch engine.
and steering wheel. 11. Label, disconnect and cap/plug all hydraulic
3. Open engine cover. Allow system fluids to cool. connections on the engine/transmission.
4. Properly disconnect battery(s) and remove. Refer Note: Engine/transmission harness is routed and attached to
Section 9.8, “Battery”, for procedure. engine/transmission using hold-down clamps and plastic wire
ties at various places on engine. Before removing
5. Remove the oil pan cover from underneath the engine
engine/transmission, ensure that harness has been completely
compartment.
separated (disconnected) from engine/transmission. Move
6. Properly drain hydraulic oil system. Refer to Section 8.7, harness clear of engine/transmission, and with help of an
“Hydraulic Reservoir”, for detailed instructions. observer, ensure that engine/transmission clears the harness
7. Properly drain transmission. Refer to Section 6.4.1, during removal.
“Transmission Removal,” for detailed instructions. 12. Label and disconnect all electrical wire connections on
8. Mark position of cover to help with cover adjustment engine/transmission.
when being reinstalled.
3614RS, 4017RS 31211333 7-17

Engine
19. Secure engine with a lifting strap or chain from

appropriate lifting points. Use a suitable hoist or
overhead crane.
5 MZ7551
20. Loosen and remove four engine/transmission mounting

bolts (5).
MZ7540 21. Slightly lift and pull engine/transmission out of
machine. Have an assistant ensure that
13. Disconnect and cap the fuel inlet line (3). engine/transmission clears all frame components
during removal.
22. Place engine/transmission on a flat, level surface.
7.9.2 Transmission Removal/Installation

1. Refer to Section 6.4, “Transmission Replacement,” for
detailed transmission removal and installation
instructions.
4
7.9.3 Engine Disassembly, Inspection
and Service
Engine disassembly, internal inspection, service, repair and
MZ7580 assembly procedures are covered in the Engine Service
Manual. Several special engine service tools are required to
14. Disconnect and cap the fuel return line (4) located near properly service the engine. Contact the local JLG dealer for
rear engine mount. further information.
15. Label and remove all clamps securing any fuel line on Note: If engine is being replaced, there may be external
engine. components that will be required to be transferred from original
16. Remove exhaust pipe from exhaust manifold. Refer to engine to replacement engine depending upon who you purchase
Section 7.7, “Engine Exhaust System”. new engine from and configuration of your replacement engine.
Refer to appropriate Engine user manual for detailed procedures
Note: Emission Sensitive Exhaust. Assembly must be replaced that cover transfer of original engine components to replacement
exactly as removed. engine.
17. Remove air cleaner assembly. Refer to Section 7.8, “Air
Cleaner Assembly”.
18. Remove drive shaft assemblies. Refer to Section 5.9.3,
“Drive Shaft Removal”.
7-18 31211333 3614RS, 4017RS

Engine
7.9.4 Engine/Transmission Installation 19. Check for proper fluid levels prior to startup.
Refer to Section 2.3.2, “Fluids (if equipped for LS)”.
1. Attach a lifting chain to the front and rear engine
lift brackets, and lift engine/transmission clear of 20. Start engine and run to normal operating temperature
the ground. then shut off engine. While engine is cooling, check for
leaks.
Note: Apply Loctite® 243TM to the engine mount bracket bolts
before installation. 21. Allow engine to cool. Check radiator coolant level. Add
coolant as required.
2. Refer to Section 2.2, “Thread Locking Compound”, for all
22. Check for leaks from engine, main hydraulic pump and
thread locking requirements.
lines, transmission, hydraulic reservoir and fuel tank.
3. Lift engine/transmission and slowly push and lower into Check levels of all fluids and lubricants. Fill as required.
engine compartment. Have an assistant ensure that
engine/transmission clears frame, hose and harness Note: During full throttle check:
components during engine/transmission installation. • DO NOT operate any hydraulic function.
Position engine/transmission brackets over frame
• DO NOT steer or apply any pressure to the
mounts.
steering wheel.
4. Align motor mount holes and install front mounting
• Keep transmission in (N) NEUTRAL.
bolts and washers.
5. Align motor mount holes and install rear mounting 23. Check engine rpm at full throttle.
bolts and washers. 24. Purge the hydraulic system of air by operating all boom
6. Lower engine onto mounts. functions through their entire range of motion several
times.
7. Install flat washer, lock washer and nut on front two
mounting bolts. 25. Check hydraulic oil level. If oil is warm, oil level should
be visible in gauge window.
8. Remove lifting chains.
26. Check for proper operation of all components.
9. Torque engine /transmission mounting bolts (5)
to 241 Nm (178 lb-ft). 27. Turn engine OFF.
10. Install air cleaner. Refer to Section 7.8.2, “Air Cleaner 28. Install the oil pan cover underneath the
Assembly Installation”. engine compartment.
11. Install exhaust pipe. Refer to Section b, “Exhaust System 29. Close and secure engine cover.
Installation - if ULS equipped”. 30. Remove Do Not Operate Tag from ignition key switch
12. Install radiator assembly. Refer to Section 7.4.3, and steering wheel.
“Radiator Assembly Replacement”.
7.10 TROUBLESHOOTING
13. Install drive shaft assemblies. Refer to Section 5.9.5,
“Drive Shaft Installation”. Refer to Section 7.3, “Specifications and Maintenance
14. Connect and secure all the previously labeled hydraulic Information”, for detailed engine service information.
hoses, fuel lines and electrical wire connections on
engine and transmission.
15. Install heater and cooling hoses to engine and tighten
clamps (if equipped).
16. Install hood (1), end covers (2) and belly pan from engine
compartment and adjust if necessary.
17. Install and properly connect battery(s). Refer
Section 9.8, “Battery”, for procedure.
18. Check that all hydraulic system, electrical system,
cooling system, fuel system and exhaust system
connections are correct and connected tightly.
Note: Have an assistant stand by with a Class B fire
extinguisher.
3614RS, 4017RS 31211333 7-19

Engine
7-20 31211333 3614RS, 4017RS

Section 8
Hydraulic System
Contents

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.1 Pressure Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.5 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5.1 Hydraulic Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.6 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.6.1 3614RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.6.2 4017RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8.7 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.1 Hydraulic Oil Reservoir Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.2 Hydraulic Oil Reservoir Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.7.3 Hydraulic Oil Reservoir Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.8 Engine Implement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.8.1 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.9 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8.9.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
8.9.3 Service Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
8.9.4 Service Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.9.5 Steering Orbital Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.9.6 Outrigger/Stabilizer Valve and Brake Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
8.9.7 Brake Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
8.9.8 Brake Damper Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.9.9 Pre-Charging Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21
8.9.10 Checking Pre-Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.9.11 Steer Select Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
8.10 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.10.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.10.2 Cylinder Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.10.3 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
8.10.4 Cylinder Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
3614RS, 4017RS 31211333 8-1

Hydraulic System
8.1 HYDRAULIC COMPONENT

TERMINOLOGY
To understand the safety, operation and service information
presented in this section, it is necessary that the operator/
mechanic be familiar with the name and location of the
hydraulic components of the machine. The following
8.1.1 3614RS
COMPENSATION
CYLINDER
MAIN
LIFT/LOWER CONTROL
CYLINDER VALVE
EXTEND/RETRACT
CYLINDER
HYDRAULIC FLUID
RESERVOIR
IMPLEMENT
PUMP TILT
CYLINDER
LEVELING CYLINDER
MAE19711
OUTRIGGER
CYLINDER
8-2 31211333 3614RS, 4017RS

Hydraulic System
8.1.2 4017RS
COMPENSATION
CYLINDER
MAIN
LIFT/LOWER CONTROL
CYLINDER VALVE
EXTEND/RETRACT
CYLINDER
HYDRAULIC FLUID
RESERVOIR
IMPLEMENT
PUMP TILT
CYLINDER
LEVELING CYLINDER
OUTRIGGER
CYLINDER MAE19721
3614RS, 4017RS 31211333 8-3

Hydraulic System
8.2 SAFETY INFORMATION Some hydraulic functions are actuated by interfacing with
electrical system components (switches, solenoids and
sensors). When the hydraulic system is not functioning
WARNING properly, check the electrical aspect of the malfunctioning
circuit also. Refer to Section 9.5, “Electrical System
DO NOT service the machine without following all safety Schematics” in this manual.
precautions as outlined in Section 1, “Safety Practices” of
this manual. 8.3 SPECIFICATIONS
Petroleum-based hydraulic fluids are used in this machine. Refer to Section 2.2, “Specifications”, for hydraulic system
The temperature of hydraulic fluid increases during the specifications.
operation of various hydraulic functions. A heated
petroleum-based hydraulic fluid presents a fire hazard,
8.4 HYDRAULIC PRESSURE DIAGNOSIS
especially when an ignition source is present.
Accordingly, periodically inspect all hydraulic system
components, hoses, tubes, lines, fittings, etc. Carefully 8.4.1 Pressure Checks and Adjustments
examine any deterioration and determine whether any When diagnosing trouble in the hydraulic system, use the
further use of the component would constitute a hazard. If in hydraulic testing information in Section 8.5.1, “Hydraulic
doubt, replace the component. Pressures”.
Whenever you disconnect a hydraulic line, coupler, fitting or In general, follow the steps below whenever conducting
other component, slowly and cautiously loosen the part pressure checks and performing adjustments:
involved. A hissing sound or slow seepage of hydraulic fluid
1. Park the machine on a firm, level surface. Engage the
may occur in most cases. After the hissing sound has ceased,
park brake, place the transmission in (N) NEUTRAL, level
continue removing the part. Any escaping oil should be
the boom and turn the engine OFF.
directed into an appropriate container. Cap or otherwise
block off the part to prevent further fluid seepage. 2. At the proper test port, install a pressure gauge capable
of measuring at least 10% more pressure than that
Hydraulic system maintenance will, at times, require that the
which the circuit being checked operates under.
engine be operated. Always follow safety precautions.
3. Start the engine. Operate machine functions several
A major cause of hydraulic component failure is
times to allow hydraulic oil to reach operating
contamination. Keeping the hydraulic fluid as clean as
temperature. The hydraulic oil temperature should be
possible will help avoid downtime and repairs. Dirty or
between 38 - 49° C (100 - 120° F). If a temperature gauge
contaminated hydraulic oil can damage internal
or thermometer is unavailable, the hydraulic oil reservoir
components and void the manufacturer’s warranty. When
should be warm to the touch.
servicing the system, cap or plug hydraulic fittings, hoses and
tube assemblies. Plug all cylinder ports, valves and the 4. Refer to Section 8.5.1, “Hydraulic Pressures”, for testing
hydraulic reservoir, and pump openings until installation procedures.
occurs. Protect threads from contamination and damage. 5. Fully depress the accelerator pedal if required. Place and
Manufacture’s recommended hydraulic oil cleanliness levels hold the joystick in the position needed to operate the
are based on the three digit ISO code for 4 micron/6 micron/ particular machine function being checked. Continue
14 micron particle sizes found in one ml of fluid (reference holding the joystick in position until pressure readings
ISO 4406: 199(E). The acceptable level is 19/17/14 or below; are taken.
anything higher requires system cleaning and filter 6. Check the pressure gauge reading. It should read as
replacement. specified in the Pressure Readings column of the charts
Note: The human eye can only distinguish particles down to found in Section 8.5.1, “Hydraulic Pressures”. If the
40 microns. reading is not as specified, turn the engine OFF and
check other components in the system. Verify that all
Reference Section 2.6, “Service and Maintenance Schedules”, related hydraulic components and electrical switches,
for the appropriate maintenance intervals based on hours of sensors, solenoids, etc. are operating correctly.
operation, but if your equipment is exposed to extremely
7. Adjust the relief valve by turning the adjustment screw.
dirty or hostile conditions service may be required more
Turning clockwise will increase the pressure; turning the
frequently. Always use OEM filters to assure the necessary
screw counterclockwise will decrease the pressure.
filtration requirements are met.
8-4 31211333 3614RS, 4017RS

Hydraulic System
8. Start the engine and check the pressure again. Turn the b. Adjusting Maximum Pump Pressure
engine OFF. If there is pressure reading in the gauge,
1. Set park brake, start the machine, level and retract the
bleed it off then disconnect or remove the pressure
boom.
gauge from the machine.
2. Loosen the jam nut on the relief (1). Turn the relief
8.5 HYDRAULIC CIRCUITS clockwise to increase pressure or counter-clockwise to
decrease pressure. Set to the correct pressure.
This section covers the hydraulic circuits and includes listings Note: Always adjust the Main Relief Valve pressure to the low
for all hydraulic function pressures, where and how to check side of the specification, i.e. 270 Bar (3916 psi).
those pressures and a hydraulic schematic.
3. Torque the jam nut to 17 - 23 Nm (12.5 - 17 lb-ft) and
Electrical and hydraulic functions are often related. Verify
recheck the pressure at full throttle. If the reading is
that the electrical components of the circuit are functioning
within specification, remove the gauge from the test
properly whenever troubleshooting the hydraulic circuit.
port.
Always check the following before beginning to
4. If the proper pressure cannot be set, use the
troubleshoot a circuit that is not functioning correctly.
accompanying hydraulic schematic and/or the electrical
1. Check the hydraulic oil level in the reservoir. If oil is cold, schematic to help troubleshoot and correct the
oil level should be visible in the lower gauge window problem.
with all cylinders retracted.
2. Check hoses, tubes, fittings and other hydraulic
components for leaks, bends, kinks, interference, etc.
3. Check for air in the hydraulic system. Erratic machine
performance and/or spongy cylinder operation are
signs of air in the hydraulic system.
If air in the hydraulic system is suspected, you will hear
air leakage when hydraulic fittings are loosened and see
air bubbles in the hydraulic fluid.
Loose fittings, faulty o-rings or seals, trapped oil, leaks,
system opened for service, etc., can cause air in the
system. Determine what is causing air to enter the
system and correct it. Bleed air from the system.
8.5.1 Hydraulic Pressures
a. Checking Pressure
1. Start the machine and warm the hydraulic system to
operating temperature.
2. Shut off the machine and install a digital or a
345 bar (5000 psi) gauge to the appropriate test port on
the main control valve.
3. Start the machine, run the engine at idle and bottom
the appropriate hydraulic function. Refer to
Section 8.5.1. c, “Pressure Specifications”, for the correct
pressure rating.
3614RS, 4017RS 31211333 8-5

Hydraulic System
c. Pressure Specifications
Note: All pressure check are to be performed at High Idle unless noted.
B
MZ7230
D
MZ7741
Hydraulic Adjustment
Test Port Procedure Pressure Range
Circuit Location
Connect gauge to A port on the boom
head, run engine at high idle, hold
Auxiliary 235 - 253 Bar
1 A auxiliary function and check pressure. NA
Pressure (3408 - 3669 PSI)
Note: Do not operate any other function
while checking pressure
Connect gauge to P1 (B) port, level
boom, run engine at high idle, and
Maximum Pump 270 - 275 Bar
2 P1 (B) bottom boom retract. 1
Pressure (3916 - 3988 PSI)
while checking pressure.
Connect gauge to LS1 (C) port, level
boom, run engine at high idle, and
256 - 261 Bar
3 Load Sense LS1 (C) bottom boom retract. NA
(3713 - 3785 PSI)
Connect gauge to V (D) port, level
boom, run engine at low idle. 34 - 36 Bar
4 Pilot Pressure V (D) NA
Note: Do not operate any functions (493 - 522 PSI)
8-6 31211333 3614RS, 4017RS

8.6
8.6.1
8 7 6 5 4 3 2 1
3614RS, 4017RS
COMP' CYLINDER
LIFT CYLINDER BORE: 75MM
ROD: 50MM
V1
BORE: 150
H ROD: 90 H
STROKE: 1292
CLOSED CENTRES: 1698
CBV RATIO: 4:1
CBV SETTING: 320 BAR (LEFT) STABILIZER CYLINDER (RIGHT) STABILIZER CYLINDER
RETRACT/EXTEND
CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
3614RS
V1 V2 STROKE: 400 STROKE: 400

BORE: 85 CLOSED CENTRES: 710 CLOSED CENTRES: 710
ROD: 65
STROKE: 3750 FRAME LEVELLING
CLOSED CENTRES: 4472 TILT CYLINDER
CBV RATIO: 4:1
CYLINDER
CBV SETTING: 320 BAR
BORE: 120
BORE: 95
ROD: 80
ROD: 50
STROKE: 368
STROKE: 168
V2 V2 V1 CLOSED CENTRES: 734
CLOSED CENTRES: 440
CBV RATIO: 3:1
T1
T2 T1 T2 T1
G G
MALE AUXILIARY COUPLING V2 V1 V2 V1

V1
FEMALE AUXILIARY COUPLING

A1 B1 A2 B2 A3 B3 A4 B4 V2
280 280 280 240 240
a. If equipped for 74,4 kW engine
BAR BAR BAR BAR BAR
T2
T1
HYDRAULIC SCHEMATICS
T2
CONTAMINATION TEST POINT
270
F BAR
F
35 BAR
2 MM LS
LS 1
L/MIN
14
E BAR E
LS1
P1
BOOM RAISE/LOWER BOOM EXTEND/RETRACT COUPLER TILT BOOM AUXILIARIES (OPTION)
FRAME LEVEL AND STABILIZERS VALVE
T P MAIN CONTROL VALVE L
WHEN MOUNTED ON THE MACHINE THE 'B' (RETRACT) SERVICE PORTS AND ELECTRICAL CONNECTIONS ARE UPPERMOST
P
B1
D D
31211333
FRONT AXLE L
STEERING STROKE: 208MM
ANNULUS AREA: 47.7CM²
BRAKE VOL (AT 50 BAR): 10.4CC
RETURN FILTER NOMINAL STEER SYSTEM

STANDBY PRESSURE: 7 BAR
L
5µ BETA RATIO: 1000 P
BYPASS OPENS AT: 3.5 BAR 240
BLOCKAGE INDICATED AT 2.5 BAR BAR
C C
R1
LD P T SERVICE BRAKE
180
MASTER CYLINDER &
BAR FOOT PEDAL ASSEMBLY
TOTAL DISPLACEMENT: 27.5 TO
49CC
240
BAR
T R CRAB 4WS
A B
EF CF STEERING ORBITAL
DISPLACEMENT 200CC/REV
0.5MM 0.75MM
COOLER BYPASS
B B
CRACKING PRESSURE: 4 BAR 1.3MM REAR AXLE
4 ANNULUS AREA: 47.7CM²
BAR BRAKE VOL (AT 50 BAR): 8.3CC
PUMP PTO RATIO TO ENGINE 1.03:1

DIRECTION OF ROTATION: CLOCKWISE
ENGINE LOW IDLE (UNLOADED): 950 RPM
ENGINE HIGH IDLE (UNLOADED): 2300 RPM
IMPLEMENT PUMP
AIR FILTER DISPLACEMENT: 43.98CC/REV
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM
RESERVOIR
A A
FILL VOLUME: 105L
APPROXIMATE SYSTEM VOLUME: 180L
Hydraulic System
8 7 6 5 4 3 2 1
MZ7750C
8-7
8-8
1 2 3 4 5 6 7 8
COMP' CYLINDER
LIFT CYLINDER
BORE: 75MM
ROD: 50MM
BORE: 150 V1
ROD: 90
STROKE: 1292
CBV RATIO: 4:1
C2 C1
H (LEFT) STABILISER CYLINDER (RIGHT) STABILISER CYLINDER H
TELE/EXTEND
1 3 CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
C1 V1 V2 STROKE: 400 STROKE: 400
BORE: 85 CLOSED CENTRES: 710 CLOSED CENTRES: 710
ROD: 65
3
CBV RATIO: 4:1
CYLINDER
BORE: 120
2
BORE: 95
ROD: 80
ROD: 50
STROKE: 368
V2 STROKE: 168
C2 CLOSED CENTRES: 734
2 CLOSED CENTRES: 440
CBV RATIO: 3:1
1
T1
T2 T1 T2 T1
G V1 G
MALE AUXILIARY COUPLING
CAT MACHINES: ISO16028
JLG MACHINES: ISO7241-1 (SERIES A) V2 V1 V2 V1
Hydraulic System
V2 V1
FEMALE AUXILIARY
COUPLING
A1 B1 A2 B2 A3 B3 A4 B4 JLG MACHINES: ISO7241-1 (SERIES A) V2
240 280 280 240 240
BAR BAR BAR BAR BAR
b. If equipped for 55,0 kW engine
T2
T1 T2
+5
270 BAR
0
F F
35 BAR
2 MM LS
P
1.5
0.6
LS 1
L/MIN
14
BAR
E LS1 1.0
E
T
1.1
P1
FRAME LEVEL AND STABILISERS VALVE
T PRESSURE DAMPER
P MAIN CONTROL VALVE L
31211333
B1
D D
R1
FRONT AXLE
STEERING STROKE:109.7MM
L
SERVICE BRAKE
MASTER CYLINDER &
FOOT PEDAL ASSEMBLY
RETURN FILTER TOTAL DISPLACEMENT: 27.5 TO
49CC
L S
RETURN FILTER WITH THERMAL
LOCKOUT SWITCH VM3 CD.1/-2MO-30C T 0
5µ BETA RATIO: 1000 180 -7
C BYPASS OPENS AT: 3.5 BAR BAR C
P
LS P T
NOMINAL STEER SYSTEM

R
P
CRAB 4WS
STEERING ORBITAL QAMP - RATIO 2:1 A B

EF CF DISPLACEMENT 100CC/REV
0.5MM 0.75MM
B B
COOLER BYPASS

STEERING STROKE: 109.7MM

IMPLEMENT PUMP
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM
A A
RESERVOIR
FILL VOLUME: 105L
1 2 3 4 5 6 7 8
MAE8880A
3614RS, 4017RS
8 7 6 5 4 3 2 1
8.6.2
3614RS, 4017RS
COMP' CYLINDER
ROD: 50MM
V1
BORE: 170
ROD: 100
H STROKE: 1333 H
CBV RATIO: 4:1
CBV SETTING: 320 BAR (LEFT) STABILIZER CYLINDER (RIGHT) STABILIZER CYLINDER
RETRACT/EXTEND
CYLINDER BORE: 125 BORE: 125
ROD: 55 ROD: 55
V1 V2 STROKE: 400 STROKE: 400
BORE: 110
4017RS
CLOSED CENTRES: 710 CLOSED CENTRES: 710

ROD: 80
CBV RATIO: 4:1
CYLINDER
BORE: 120
BORE: 105
ROD: 80
ROD: 55
STROKE: 368
STROKE: 168
V2 V2 V1 CLOSED CENTRES: 734
CLOSED CENTRES: 440
CBV RATIO: 3:1
T1
T2 T1 T2 T1
G G
MALE AUXILIARY COUPLING V2 V1 V2 V1

V1
FEMALE AUXILIARY COUPLING

A1 B1 A2 B2 A3 B3 A4 B4 V2
280 280 280 240 240
a. If equipped for 74,4 kW engine
BAR BAR BAR BAR BAR
T2
T1 T2
270
F BAR F
35 BAR
2 MM LS
LS 1
L/MIN
14
E BAR E
LS1
P1
FRAME LEVEL AND STABILIZERS VALVE
T P MAIN CONTROL VALVE L
P
B1
2
D D
31211333
3
L 1
FRONT AXLE
S
R B'
RETURN FILTER NOMINAL STEER SYSTEM

L N
5µ BETA RATIO: 1000 P
BYPASS OPENS AT: 3.5 BAR 240
BLOCKAGE INDICATED AT 2.5 BAR BAR
B
C R1 C
PARK BRAKE
LD P T SERVICE BRAKE VALVE
180
MASTER CYLINDER & VALVE SHOWN WITH
BAR FOOT PEDAL ASSEMBLY THE BRAKE
TOTAL DISPLACEMENT: 27.5 TO DISENGAGED.
49CC RELEASE PRESSURE:
21 TO 35 BAR
240
BAR
T R CRAB 4WS
A B
EF CF STEERING ORBITAL
DISPLACEMENT 200CC/REV
0.5MM 0.75MM
COOLER BYPASS
B B

IMPLEMENT PUMP
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
10W PER 100 RPM
RESERVOIR
A FILL VOLUME: 105L A
Hydraulic System
8 7 6 5 4 3 2 1
MZ7760C
8-9
8-10
1 2 3 4 5 6 7 8
COMP' CYLINDER
ROD: 50MM
BORE: 170 V1
ROD: 100
STROKE: 1333
H CBV RATIO: 4:1 H
CBV SETTING: 380 BAR C2 C1
(LEFT) STABILISER CYLINDER (RIGHT) STABILISER CYLINDER
1 TELE/EXTEND BORE: 125 BORE: 125

3 ROD: 55 ROD: 55
CYLINDER V2 STROKE: 400 STROKE: 400
C1 V1 CLOSED CENTRES: 710 CLOSED CENTRES: 710
BORE: 110 FRAME LEVELLING
ROD: 80 TILT CYLINDER
STROKE: 3610 CYLINDER
3
CBV RATIO: 4:1 BORE: 120
BORE: 105
2
CBV SETTING: 380 BAR ROD: 80
ROD: 55
STROKE: 368
STROKE: 168
CLOSED CENTRES: 734
V2 CLOSED CENTRES: 440
C2 2 CBV RATIO: 3:1
T1
1
T2 T1 T2 T1
G G
V1 MALE AUXILIARY COUPLING
Hydraulic System
V2 JLG MACHINES: ISO7241-1 (SERIES A) V2 V1 V2 V1

V1
FEMALE AUXILIARY
COUPLING
A1 B1 A2 B2 A3 B3 A4 B4 JLG MACHINES: ISO7241-1 (SERIES A) V2
240 280 280 240 240
BAR BAR BAR BAR BAR
b. If equipped for 55,0 kW engine
T2
T1 T2
+5
270 BAR
F 0 F
35 BAR
2 MM LS
P
1.5
0.6
LS 1
L/MIN
14
E BAR
E
LS1 1.0
1.1
P1
FRAME LEVEL AND STABILISERS VALVE
T PRESSURE DAMPER
P MAIN CONTROL VALVE L
B1
31211333
D D
2
R1 3
1
FRONT AXLE
STEERING STROKE: 109.7MM L
R B'
RETURN FILTER S
RETURN FILTER WITH THERMAL L N

LOCKOUT SWITCH VM3 CD.1/-2MO-30C
5µ BETA RATIO: 1000 T P
C BYPASS OPENS AT: 3.5 BAR 0 C
180 -7 B
BAR
PARK BRAKE
LS P VALVE
T
VALVE SHOWN WITH
NOMINAL STEER SYSTEM THE BRAKE
STANDBY PRESSURE: 7 BAR DISENGAGED.
R RELEASE PRESSURE:
P 21 TO 35 BAR
CRAB 4WS SERVICE BRAKE

MASTER CYLINDER &
A B FOOT PEDAL ASSEMBLY
EF CF STEERING ORBITAL QAMP - RATIO 2:1 TOTAL DISPLACEMENT: 27.5 TO
DISPLACEMENT 100CC/REV 49CC
0.5MM 0.75MM
B B
COOLER BYPASS

STEERING STROKE: 109.7MM

IMPLEMENT PUMP
COOLING CAPACITY
APPROX 270W AT
LOW IDLE MEDIA: 3µ
ADDITIONAL
A 10W PER 100 RPM A
RESERVOIR
FILL VOLUME: 105L
1 2 3 4 5 6 7 8
MAE8890A
3614RS, 4017RS
Hydraulic System
8.7 HYDRAULIC RESERVOIR 8.7.2 Hydraulic Oil Reservoir Filling

1 1. Be sure the reservoir is clean and free of all debris.
5
4 2. Install a new hydraulic oil filter.
3
3. Fill the reservoir with oil until oil level is visible in the
gauge window (3). Refer to Section 2.3, “Fluids and
Lubricant Capacities”
6 “Battery”, for procedure.
6 5. Close and secure the engine cover.
2
6. Start machine and check all hydraulic functions for
MZ8000 proper operation. Check for any hydraulic oil leaks. Shut
machine OFF and check hydraulic oil level. If oil is warm,
The hydraulic reservoir (1) is located under the cab. oil level should be visible in the gauge window (3). Add
hydraulic oil if necessary.
8.7.1 Hydraulic Oil Reservoir Draining 7. Close the hydraulic oil filler cab access panel at the
1. Park the machine on a firm, level surface, level the bottom left rear of the cab.
machine, fully retract the boom, lower the boom, place 8. Remove the Do Not Operate Tag from the ignition key
the transmission in (N) NEUTRAL, engage the park brake switch and the steering wheel.
2. Place a Do Not Operate Tag on both the ignition key 8.7.3 Hydraulic Oil Reservoir Removal/
switch and the steering wheel. Installation
3. Open the engine cover. Allow the system fluids to cool. If it is determined that the hydraulic oil reservoir must be
removed, the hydraulic oil must be drained before the
reservoir is removed. Always dispose of hydraulic oil
properly.
5. Open the hydraulic oil filler cab access panel at the
bottom left rear of the cab. a. Reservoir Removal
6. Open the filler cap on the hydraulic oil reservoir. 1. Park the machine on a firm, level surface, level the
Remove the drain plug (2) on the bottom of the machine, fully retract the boom, lower the boom, place
hydraulic oil reservoir. the transmission in (N) NEUTRAL, engage the park brake
7. Transfer the used hydraulic oil into a suitable covered and shut the engine OFF.
container, and label as “Used Oil”. Dispose of used oil at 2. Place a Do Not Operate Tag on both the ignition key
an approved recycling facility. Clean and reinstall the switch and the steering wheel.
drain plug. Torque drain plug to 35 Nm (25 lb-ft).
8. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area. 4. Properly disconnect the battery. Refer Section 9.8,
5. Drain the hydraulic oil reservoir. Refer to Section 8.7.1,
to the hydraulic oil reservoir. Cap all fittings and
hydraulic system.
7. Remove the two bolts securing the fill tube/bracket (4).
8. Remove the bolt (5), nuts and strap (6) securing the
hydraulic oil reservoir to the frame.
9. Remove the hydraulic oil reservoir.
3614RS, 4017RS 31211333 8-11

Hydraulic System
b. Disassembly d. Inspection
Dispose of the old reservoir according to local regulations 1. Inspect the hydraulic oil reservoir thoroughly for any
concerning hazardous materials disposal. 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.
Check the reservoir for leaks by applying a soap solution
to the exterior and look for bubbles to appear at the
cracked or damaged area.
e. Assembly
1. Install the previously removed fittings, adapters and
tubes in the correct orientation.
MZ8010
2. Properly torque all fittings and adapters as required.
1. Note the orientation of all fittings, adapters and tubes
f. Reservoir Installation
on the hydraulic tank.
2. Label and remove all fittings, adapters and tubes from 1. Place the hydraulic oil reservoir into its original
the hydraulic tank. orientation.
2. Secure the hydraulic oil reservoir to the frame with the
c. Cleaning and Drying previous mounting hardware.
If contaminated hydraulic oil or foreign material is in the 3. Uncap and connect the previously labeled hydraulic
tank, the tank can usually be cleaned. hoses to their appropriate locations. Be sure all lines are
free of kinks and sharp bends.
To clean the hydraulic oil reservoir:
4. Fill the reservoir with oil until oil level is visible in the
1. Have a dry chemical (Class B) fire extinguisher near the
gauge window. Refer to Section 2.3, “Fluids and
work area.
2. Remove the hydraulic oil reservoir drain plug, and safely
5. Check the hydraulic oil reservoir for leaks.
drain any hydraulic oil into a suitable container. Dispose
of hydraulic oil properly. 6. Properly connect the battery. Refer Section 9.8,
3. Clean the hydraulic oil reservoir with a high-pressure
washer, or flush the tank with hot water for five minutes 7. Close and secure the engine cover.
and drain the water. Dispose of contaminated water 8. Start machine and check all hydraulic functions for
properly. proper operation. Check for any hydraulic oil leaks. Shut
machine OFF and check hydraulic oil level. If oil is warm,
oil level should be visible in the gauge window. Add
hydraulic oil if necessary.
9. Remove the Do Not Operate Tag from the ignition key
8-12 31211333 3614RS, 4017RS

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
a. Pump Removal previously used hardware.
1. Park the machine on a firm, level surface, level the 3. Place the pump and a new, oiled o-ring into position on
machine, fully retract the boom, lower the boom, place the adapter plate. Align the pump shaft with the
the transmission in (N) NEUTRAL, engage the park brake internal gear, so that the machined teeth mesh
and shut the engine OFF. together.
2. Place a Do Not Operate Tag on both the ignition key 4. Align the bolt holes with the pump mount holes. Secure
switch and the steering wheel. the pump to the adapter plate with the two bolts and
3. Open the engine cover. Allow the system fluids to cool. washers. Torque as required.
4. Properly disconnect the battery. Refer Section 9.8, 5. Uncap and connect the previously labeled hydraulic hoses
“Battery”, for procedure. to their appropriate locations.
5. Drain the hydraulic reservoir. Refer to Section 8.7.1, Note: Prime the pump by filling the case with fresh, filtered
“Hydraulic Oil Reservoir Draining”. hydraulic oil from a clean container through suction port (3)
6. Thoroughly clean the pump and surrounding area, before installing hose and flanges.
including all hoses and fittings before proceeding. 6. Fill the hydraulic reservoir. Refer to Section 8.7.2,
Note: Cap all hoses as you remove them to prevent “Hydraulic Oil Reservoir Filling”.
unnecessary fluid spillage. 7. Check all routing of hoses and tubing for sharp bends or
interference with any rotating members.
7. Label, disconnect and cap the hydraulic hoses attached
to the pump. 8. Inspect for leaks and check all fluid levels. The hydraulic
3 reservoir oil level must be to the middle of the sight
2 gauge.
1
1 11. Start machine and verify proper operation.
c. Implement Pump Test

MZ8020
Refer to Section 8.4.1, “Pressure Checks and Adjustments”.
8. Remove the two bolts and two lockwashers (1) securing
the pump (2) to the adapter plate. Remove the o-ring
located between the plate and the pump. Wipe up any
hydraulic oil spillage.
9. If necessary, remove the four bolts securing the adapter
plate to the transmission. Remove the adapter plate.
Note: DO NOT disassemble the operating pump. The pump is
pre-set from the manufacturer.
3614RS, 4017RS 31211333 8-13

Hydraulic System
8.9 CONTROL VALVES 9. Label, disconnect and cap all the hydraulic hoses, tubes
and wires at the main control valve. Slowly turn hose
fittings to allow any trapped pressure in the hydraulic
8.9.1 Main Control Valve system to escape.
The main control valve is mounted at the rear of the cab. 10. Wipe up any hydraulic fluid spillage in, on, near and
around the machine and the work area.
2
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

1. To disassemble the individual sections of the main
3 control valve, remove the nuts from one end of the tie
rods.
4
2. Disassemble each section assembly as required.
5 Some sections include a pre-adjusted relief valve that
regulates pressure in a specific circuit.
1
Note: DO NOT adjust any of the relief valve assemblies.
Tampering with a relief valve will irrevocably alter pressure in the
affected circuit, requiring recalibration or a new relief valve.
MZ8060
Disassemble each Valve Section
6
1. Carefully separate the load sense outlet section (5) from the
The main control valve assembly (1) consists of working next section.
sections with their own valve assemblies, each providing a 2. Remove the o-rings from between the two sections.
specific hydraulic function. Those functions are:
lift/lower (2), extend/retract (3), tilt (4) and auxiliary (5). 3. Carefully separate each remaining section.
4. Remove any check valves, compensator valves, anti-
a. Main Control Valve Removal cavitation valves or shock valves from individual valve
section if equipped.
1. Park the machine on a firm, level surface, level the
machine, fully retract the boom, lower the boom, place 5. Keep all parts being removed from individual valve
the transmission in (N) NEUTRAL, engage the park brake sections tagged and kept together.
c. Main Control Valve Parts Cleaning
switch and the steering wheel. Clean all components with a suitable cleaner, such as
3. Open the engine cover. Allow the system fluids to cool. triclorethylene, before continuing. Blow dry.
4. Properly disconnect the battery. Refer Section 9.8, d. Main Control Valve Parts Inspection
Inspect all parts and internal passageways for wear, damage,
5. Remove the main control valve cover.
etc. If inner surfaces of any component DO NOT display an
6. Thoroughly clean the main control valve and ultra-smooth, polished finish, or are damaged in any way,
surrounding area, including all hoses and fittings, replace the damaged part. Often, dirty hydraulic fluid causes
before proceeding. failure of internal seals, damage to the polished surfaces
7. Place a suitable container to catch hydraulic fluid within the component, and wear of and/or harm to other
drainage beneath the cab. parts.
8. Drain the hydraulic oil reservoir. Refer to Section 8.7.1,
8-14 31211333 3614RS, 4017RS

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 10. Install main control valve cover.
seals and o-rings with clean hydraulic oil. 11. Close and secure the engine cover.
Assemble each Valve Section
1. Reassemble any check valves, compensator valves,
anti-cavitation valves or shock valves from each g. Main Control Valve Test
individual valve sections if equipped.
Conduct a pressure check of the hydraulic system in its
2. Install the end caps on each end of the valve section. entirety. Adjust pressure(s) as required. Refer to Section 8.5.1,
“Hydraulic Pressures”.
Assemble the Main Control Valve.
1. If removed, install all four tie rods into the end main
control valve section.
2. Stand the end main control valve section on end.
3. Install the proper o-rings and load sense shuttle on the
inner face of the end main control valve section. Align
the next valve section over the three tie rods and slide
onto the end main control valve section.
4. Using the proper o-rings and load sense shuttle, repeat
step three for the remaining valve sections and lastly
the inlet end valve section.
5. Install the nuts on the tie rods (6) and torque to
25 Nm (18.5 lb-ft).
f. Main Control Valve Installation

1. Install the main control valve onto the frame, aligning
the bolts with the holes in the end sections of the main
control valve. Slide the main control valve into position,
and tighten the bolts.
2. Prime the main control valve by filling the inlet
openings with fresh, filtered hydraulic oil from a clean
container, before attaching the hoses.
3. Use new oiled o-rings as required. Uncap and connect
all hoses, clamps, etc. to the main control valve.
4. Check the routing of all hoses, wiring and tubing for
sharp bends or interference with any rotating members,
and install tie wraps and/or protective conduit as
required. Tighten all tube and hose clamps.
5. Fill the hydraulic oil reservoir. Refer to Section 8.7.2,
“Hydraulic Oil Reservoir Filling”.
7. Start the engine and run at approximately one-third to
one-half throttle for about one minute without moving
the machine or operating any hydraulic functions.
8. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
3614RS, 4017RS 31211333 8-15
Hydraulic System
8.9.2 Service Brake Valve If equipped with 55,0 kW engine
a. Service Brake Valve Removal

machine, fully retract the boom, lower the boom, place
the transmission in (N) NEUTRAL, engage the park brake 7
10
9
5. Remove the access covers from the outside of the cab.
If equipped with 74,4 kW engine 8
MAE4200
6. Label, disconnect and cap all hoses attached to the

7 service brake valve (7).
7. Remove the cover panel in the cab (8).
8. Disconnect and remove the brake pedal (9).
9. Remove the two nuts (10) securing the service brake
10 valve to the cab.
10. Remove the valve through the front of the cab.
Note: DO NOT disassemble the service brake valve. The service
brake valve is not serviceable and must be replaced in its
9 entirety, if defective.
8 MZ7720
8-16 31211333 3614RS, 4017RS

Hydraulic System
b. Service Brake Valve Installation If equipped with 74,4 kW engine

1. Install the service brake valve to its original orientation
in the cab. Secure with the previously used hardware.
2. Install the service brake pedal.
3. Uncap and connect the previously labeled hydraulic
hoses to the service brake valve.
4. Check the routing of all hoses, and tubing for sharp
bends or interference with any rotating members, and
install tie wraps and/or protective conduit as required.
Tighten all tube and hose clamps.
6. Start the engine and run at approximately one-third to
one-half throttle for about one minute, without moving
11
7. Inspect the service brake valve and connections for
leaks, and check the level of the hydraulic fluid in the
reservoir. Shut the engine OFF.
9. Install the cover panel in the cab.
10. Install the access covers to the outside of the cab.
MZ8600
12. Remove the Do Not Operate Tag from the ignition key If equipped with 55,0 kW engine
8.9.3 Service Brake Bleeding

Carefully bleed the brake lines as soon as the brake valve is
installed in the machine. Air in the system will not allow the 11
brakes to apply properly. There are three brake bleeder
locations, two on the front and rear axles and one on the
brake valve. Work with an assistant to perform this
procedure.
Note: The brake bleeding procedure must be performed using
a Vacuum Bleeder System.
1. Place the transmission in (N) NEUTRAL, engage the park
brake, and start the engine.
MAE4210
2. If equipped with 74,4 kW engine: Remove the plastic

cap from the brake valve bleeder (11). Attach the end of
the transparent tubing from the vacuum unit over the
brake valve bleeder.
3614RS, 4017RS 31211333 8-17

Hydraulic System
3. Open the brake valve bleeder 1/4 turn. 9. Remove the plastic cap from the right rear axle brake
4. Pump the brake pedal until air bubbles no longer bleeder (2). Attach the end of the transparent tubing
appear in the oil. Release the brake pedal. Tighten the from the vacuum unit over the right axle bleeder.
brake valve bleeder. 10. Open the brake bleeder 1/4 turn.
5. Apply a small amount of pressure on the brake pedal, 11. Repeat steps 5, 6 and 7 until air bubbles no longer
open the brake valve bleeder and continue to apply appear in the oil.
brake pedal pressure until maximum brake pedal stroke 12. Repeat steps 5, 6 and 7 for the left rear axle brake
is achieved. bleeder, right front axle brake bleeder and left front axle
6. Closed brake valve bleeder and slowly release brake brake bleeder.
pedal. 13. Disconnect the vacuum unit from the pressurized air
7. Repeat steps 5 and 6 until air bubbles no longer appear connection.
in the oil. 14. Turn engine OFF.
8. Connect the vacuum unit to the pressurized air
connection. 8.9.4 Service Brake Test
4017RS 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.
3. If further testing is required, refer to Section 8.5.1,
“Hydraulic Pressures”.
8.9.5 Steering Orbital Valve

12
The steering orbital valve is located at the base of the
steering wheel shaft, concealed by the front access covers.
The valve is not serviceable and must be replaced in its
entirety if defective. For detailed information refer to Section
4.3.2, “Steering Column/Orbital Valve”.
3614RS
12
MZ8070
8-18 31211333 3614RS, 4017RS

Hydraulic System
8.9.6 Outrigger/Stabilizer Valve and Brake 8. Remove the outrigger/stabilizer valve from the
Damper machine. Wipe up any hydraulic fluid spillage in, on,
near and around the machine.
b. Outrigger/Stabilizer Valve Disassembly, Cleaning,

Inspection and Assembly
1. Place the outrigger/stabilizer valve assembly on a
suitable work surface.
14
2. Separate the outrigger/stabilizer valve 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.
13 Inspect the cartridge interior for contamination.
5. Inspect internal passageways of the steer select valve
MAE35040 for wear, damage, etc. If inner surfaces of the manifold
DO NOT display an ultra-smooth, polished finish, or
The outrigger/stabilizer valve (13) controls the direction of
components are damaged in any way, replace the
hydraulic fluid flow to each outrigger cylinder and the
manifold or appropriate part. Often, dirty hydraulic fluid
stabilizer cylinder. The outrigger/stabilizer valve (13) and
causes failure of internal seals and damage to the
brake damper (14) is attached inside the frame in front of the
polished surfaces within the secondary function
front axle.
manifold.
Verify the correct operation of the outrigger/stabilizer valve
solenoids before considering replacement of the valve. Refer Note: ALWAYS replace seals, o-rings, gaskets, etc., with new
to Section 9.5, “Electrical System Schematics” The body of the parts to help ensure proper sealing and operation. Lubricate
outrigger/stabilizer valve is not serviceable and must be seals and o-rings with clean hydraulic oil.
replaced if defective. 6. Install the solenoids in the outrigger/stabilizer valve
housing.
a. Outrigger/Stabilizer Valve Removal
1. Park the machine on a firm, level surface, level the c. Outrigger/Stabilizer Valve Installation
machine, fully retract the boom, raise and support the 1. Install the outrigger/stabilizer valve to the frame using
boom, place the transmission in (N) NEUTRAL, engage the previously removed nuts and washers.
the park brake, lower each outrigger and shut the engine
2. Connect all the hydraulic hoses, fittings, solenoid wire
OFF.
terminal leads, etc., to the outrigger/stabilizer valve
3. Open the engine cover. Allow the system fluids to cool. and install tie wraps and/or protective conduit as
4. Properly disconnect the battery. Refer Section 9.8, required. Tighten all hose clamps.
“Battery”, for procedure. 4. Properly connect the battery. Refer Section 9.8,
5. Remove the access cover from the top front of the “Battery”, for procedure.
frame. 5. Remove boom support.
6. Label, disconnect and cap the hydraulic hoses and the 6. Start the engine and run at approximately 1/3-1/2
electrical plugs connected to the outrigger/stabilizer throttle for about one minute without moving the
valve. machine or operating any hydraulic functions.
7. Remove the nuts holding the outrigger/stabilizer valve
to the frame.
3614RS, 4017RS 31211333 8-19

Hydraulic System
7. Inspect for leaks and check the level of the hydraulic 5. Pump the brake pedal several times to dissipate any
fluid in the reservoir. Shut the engine OFF. excess pressure in the brake system.
Note: Check for leaks and repair as required before continuing.
Add hydraulic fluid to the reservoir as needed.
9. Install the previously removed access cover.
14
15
d. Outrigger/Stabilizer Valve Test
Refer to Section 8.5.1, “Hydraulic Pressures”.
1. Conduct a pressure check of the outrigger/stabilizer
valve hydraulic circuit.
2. Check each outrigger/stabilizer valve mode for proper
function. MAE35040
6. Loosen and remove damper (14) from brake damper

8.9.7 Brake Damper
manifold (15).
The brake damper is a 250 bar (3626 psi) diaphragm damper. 7. Wipe up any hydraulic fluid spillage in, on, near and
The pneumatic damper is operated by compressed gas. Gas around the machine, work area and tools.
and hydraulic oil occupy the same container. When oil
pressure rises, incoming oil compresses the gas. When oil b. Damper Installation
pressure drops, the gas expands.
The gas is separated from the oil by a piston. This prevents 1. Install damper (14) to brake damper manifold (15).
the mixing of gas and oil and keeps gas out of the hydraulic 2. Remove the boom support.
system.
The damper must be “pre-charged” with gas before use in “Battery”, for procedure.
the hydraulic system. This is done by filling the gas chamber
with dry nitrogen to a pressure of 25 bar (507 psi). The
schrader valve is located under the protective cap at the top 5. Remove the Do Not Operate Tag from the ignition key
of the damper. The schrader valve is used for pre-charging switch and the steering wheel.
and testing the damper. 6. Refer to Section 8.9.9, “Pre-Charging Damper”, for
damper pre-charging instructions.
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 transmission in
(N) NEUTRAL, engage the park brake, shut the engine
OFF and chock wheels.
8-20 31211333 3614RS, 4017RS

Hydraulic System
8.9.8 Brake Damper Charging Use the following steps to properly pre-charge each damper:
This section covers the charging of the damper system.
20
The damper is located and mounted at the front of the
machine, between the frame rails. The internal parts of the 21
damper are not serviceable. If the internal piston is leaking,
or the seals on the top or bottom cap are leaking, the damper
requires replacement.
16
The damper pre-charge pressure will vary depending on the
ambient temperature that the damper was pre-charged at
and the actual operating temperature of the damper. 14 18
8.9.9 Pre-Charging Damper

19
Note: Replacement damper are pre-charged when shipped. 17
MZ8110
WARNING 1. Thoroughly clean the top of each damper (14).
NEVER fill an damper with oxygen! An explosion could 2. Make sure the nitrogen supply is shut off.
result if oil and oxygen are mixed under pressure. Only fill 3. Attach the damper fill kit (16) to the nitrogen bottle.
damper with dry nitrogen. 4. Remove the protective cap from the gas valve on the
Pre-charge the damper with nitrogen gas only. Nitrogen gas damper.
is free of water vapor and oxygen which makes it harmless to 5. Back the “T” handle (17) on the damper fill kit all the
internal parts and will not react if mixed with oil under way out (counter-clockwise). Attach the schrader
pressure. adaptor (18) to the gas valve on the damper. Tighten
securely.
NOTICE 6. Turn the gas valve/bleed valve (19) on the damper fill kit
all the way in.
Never fill an damper with air. Air contains moisture which can
7. Turn the “T” handle (17) all the way in to open the valve
cause corrosion. This corrosion may damage seals and ruin
core on the damper.
the damper.
8. Open the valve (20) on the nitrogen bottle.
Never charge an damper to a pressure more than specified.
9. Slowly adjust the regulator (21) on the nitrogen bottle
The proper pressure for the damper is 25 bar (507 psi).
to read 35 bar (507 psi).
Note: Make sure the nitrogen bottle, as well as the charging 10. Close the main valve (20) on the nitrogen bottle.
and gauge assembly used is compatible with the schrader valve
assembly on the damper. The nitrogen bottle and all 11. Back the “T” handle (17) on the damper fill kit all the
components must be rated for a pressure at least as high as the way out (counter-clockwise).
nitrogen source. It is strongly recommended that the nitrogen 12. Let the pre-charge on the damper set for 10-15 minutes.
bottle has a high pressure regulator. This will allow the gas temperature to stabilize. If the
desired pre-charged range is exceeded, turn the “T”
A damper fill kit is required to properly charge the damper.
handle (17) all the way in. With the main valve (20)
Refer to the parts manual or contact the local JLG dealer.
closed on the nitrogen bottle, turn the gas valve/
bleeder valve (19) out to bleed pressure off the damper.
Turn the valve all the way in and check the pressure
reading on the regulator gauge.
3614RS, 4017RS 31211333 8-21

Hydraulic System
13. When the correct pressure is reached, back the “T” 8.9.11 Steer Select Valve
handle (17) 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.
14. Turn the gas valve/bleed valve (19) all the way in and
remove the schrader adapter (18) from the valve on the
damper.
15. Reassemble the protective cap onto the gas valve on
the damper.
8.9.10 Checking Pre-Charge
a. Gas Leaks 24
22
MZ8080
The machine can be used in the front-wheel, four-wheel or

crab steering mode. The steer select valve (24) controls the
direction of hydraulic fluid flow to the steering cylinder
23 mounted on each axle. The steer select valve is attached
MZ8100 inside the frame between the can and the front axle.
1. If an external leak is suspected, apply soapy water to the Verify the correct operation of the steer select valve
gas valve (22) and the fitting of the gas bottle (23). If solenoids before considering replacement of the valve. Refer
bubbles form, the damper has to be replaced. to Section 9.5, “Electrical System Schematics”. The housing of
the steer select valve is not serviceable and must be replaced
2. If an internal leak is suspected, check for foaming oil in if defective.
the hydraulic reservoir and/or no damper action. If any
of these signs are evident, the damper has to be a. Steer Select Manifold and Valve Removal
replaced.
machine, fully retract the boom, lower the boom, place
5. Label, disconnect and cap the hydraulic hoses and the
electrical plugs connected to the steering select valve.
6. Remove the bolts holding the steer select valve to the
mounting plate on the frame.
7. Remove the steer select valve from the machine. Wipe
up any hydraulic fluid spillage in, on, near and around
the machine.
8-22 31211333 3614RS, 4017RS

Hydraulic System
b. Steer Select Manifold and Valve Disassembly, 9. Remove the Do Not Operate Tag from the ignition key
Cleaning, Inspection and Assembly switch and the steering wheel.
1. Place the steer select assembly on a suitable work
d. Steering Test
surface.
2. Separate the steer select solenoids from the spool. Refer to Section 8.5.1, “Hydraulic Pressures”.
Discard the o-rings. 1. Conduct a pressure check of the steering hydraulic
3. Clean all components with a suitable cleaner before circuit.
inspection. 2. Check each steering mode for proper function.
4. Inspect the solenoid cartridges for proper operation.
Check by shifting the spool to ensure that it is 8.10 HYDRAULIC CYLINDERS
functioning properly. Check that the spring is intact.
Inspect the cartridge interior for contamination. 8.10.1 General Cylinder Removal Instructions
5. Inspect internal passageways of the steer select valve 1. Remove any attachment from the machine. Park the
for wear, damage, etc. If inner surfaces of the manifold machine on a firm level surface and fully retract the
DO NOT display an ultra-smooth, polished finish, or boom. Allow sufficient work space around the hydraulic
components are damaged in any way, replace the cylinder being removed. Support the boom if the lift/
manifold or appropriate part. Often, dirty hydraulic fluid lower cylinder is being removed. Place the transmission
causes failure of internal seals and damage to the in (N) NEUTRAL, engage the park brake, shut the engine
polished surfaces within the secondary function OFF and chock wheels.
manifold.
Note: ALWAYS replace seals, o-rings, gaskets, etc., with new switch and the steering wheel.
parts to help ensure proper sealing and operation. Lubricate
seals and o-rings with clean hydraulic oil.
4. Label, disconnect and cap or plug hydraulic hoses in
6. Install the solenoids in the steer select housing. relation to the cylinder.
c. Steer Select Valve and Manifold Installation 5. Attach a suitable sling to an appropriate lifting device
and to the cylinder. Make sure the device used can
1. Install the steer select valve to the mounting plate actually support the cylinder.
under the left front side of the frame using the two
6. Remove the lock bolt and/or any retaining clips
bolts.
securing the cylinder pins. Remove the cylinder pins.
2. Connect all the hydraulic hoses, fittings, solenoid wire
7. Remove the cylinder.
terminal leads, etc., to the steer select valve
and install tie wraps and/or protective conduit as
required. Tighten all hose clamps.
5. Start the engine and run at approximately
1/3 - 1/2 throttle for about one minute without moving
6. Inspect for leaks and check the level of the hydraulic
fluid in the reservoir. Shut the engine OFF.
Note: Check for leaks and repair as required before continuing.
Add hydraulic fluid to the reservoir as needed. MZ0400

3614RS, 4017RS 31211333 8-23

Hydraulic System
a. General Cylinder Disassembly Some cylinder parts are sealed with a special organic sealant
and locking compound. Before attempting to disassemble
1. Clean the cylinder with a suitable cleaner before
these parts, remove any accessible seals from the area of the
disassembly. Remove all dirt, debris and grease from the
bonded parts. Wipe off any hydraulic oil, then heat the part(s)
cylinder.
uniformly to break the bond. A temperature of
2. Clamp the barrel end of the cylinder in a soft-jawed vise 149 - 204° C (300 - 400° F) will destroy the bond. Avoid
or other acceptable holding equipment if possible. overheating, or the parts may become distorted or damaged.
Apply sufficient torque for removal while the parts are still
WARNING hot. The sealant often leaves a white, powdery residue on

threads and other parts, which must be removed by
Significant pressure may be trapped inside the cylinder. brushing with a soft brass wire brush prior to reassembly.
Exercise caution when removing a counterbalance valve or a 9. Remove the piston head from the rod and carefully slide
pilot-operated check valve from a cylinder. the head gland off the end of the rod.
Note: Avoid using excessive force when clamping the cylinder 10. Remove all seals, back-up rings and o-rings from the
in a vise. Apply only enough force to hold the cylinder securely. piston head and all seals, back-up rings and o-rings
Excessive force can damage the cylinder tube. from the head gland.
3. If applicable, remove the counterbalance valve from the Note: The head gland bearing will need to be inspected to
side of the cylinder barrel. determine if replacement is necessary.
Note: DO NOT tamper with or attempt to adjust the DO NOT attempt to salvage cylinder seals, sealing rings or
counterbalance valve cartridge. If adjustment or replacement is o-rings. ALWAYS use a new, complete seal kit when
necessary, replace the counterbalance valve with a new part. rebuilding hydraulic components. Consult the parts catalog
for ordering information.
4. Extend the rod as required to allow access to the base of
the cylinder. b. Cylinder Cleaning Instructions
Note: Protect the finish of the rod at all times. Damage to the 1. Discard all seals, back-up rings and o-rings. Replace with
surface of the rod can cause seal failure. new items from seal kit to ensure proper cylinder
5. Using a pin spanner wrench, unscrew the head gland function.
from the tube. A considerable amount of force will be 2. Clean all metal parts with an approved cleaning solvent
needed to remove the head gland. Carefully slide the such as trichlorethylene. Carefully clean cavities,
head gland down along the rod toward the rod eye, grooves, threads, etc.
away from the cylinder barrel.
Note: If a white powdery residue is present on threads or parts,
Note: When sliding the rod and piston assembly out of the it can be removed by using a soft brass wire brush. Wipe clean
barrel, prevent the threaded end of the barrel from damaging with Loctite® Cleaner prior to reassembly.
the piston. Keep the rod centered within the barrel to help
prevent binding. c. Cylinder Inspection
6. Carefully pull the rod assembly along with the head 1. Inspect internal surfaces and all parts for wear, damage,
gland out of the cylinder barrel. etc. If the inner surface of the cylinder barrel does not
7. Fasten the rod eye in a soft-jawed vise, and place a display a smooth finish, or is scored or damaged in any
padded support under and near the threaded end of way, replace the barrel.
the rod to prevent any damage to the rod. 2. Remove light scratches on the piston, head gland, rod
8. Remove the set screw from the piston head. or inner surface of the cylinder barrel with a
400 - 600 grit emery cloth. Use the emery cloth in a
Note: It may be necessary to apply heat to break the bond of rotary motion to polish out and blend the scratch(es)
the sealant between the piston and the rod before the piston into the surrounding surface.
can be removed.
3. Check the piston rod assembly for run-out. If the rod is
bent, it must be replaced.
8-24 31211333 3614RS, 4017RS

Hydraulic System
d. General Cylinder Assembly Instructions e. General Cylinder Installation

1. Use the proper tools for specific installation tasks. Clean 1. Grease the bushings at the ends of the hydraulic
tools are required for installation. cylinder. Using an appropriate sling, lift the cylinder into
2. Install new seals, back-up rings and o-rings on the it’s mounting position.
piston and new seals, back-up rings, o-rings and 2. Align cylinder bushing and install pin, lock bolt or
bearing on the head gland. retaining clip.
Note: The extend/retract cylinder has a spacer that MUST be 3. Connect the hydraulic hoses in relation to the labels or
installed over the rod AFTER the head gland and BEFORE the markings made during removal.
piston head. 4. Before starting the machine, check fluid level of the
hydraulic fluid reservoir and if necessary fill to full mark
3. Fasten the rod eye in a soft-jawed vise, and place a
with oil.
padded support under and near the threaded end of
the rod to prevent any damage to the rod. 5. Start the machine and run at low idle for about one
minute. Slowly activate hydraulic cylinder function in
Note: Protect the finish on the cylinder rod at all times.
both directions allowing cylinder to fill with hydraulic
Damage to the surface of the rod can cause seal failure.
oil.
4. Lubricate and slide the head gland over the cylinder 6. Inspect for leaks and check level of hydraulic fluid in
rod. Install the piston head on to the end of the cylinder reservoir. Add hydraulic fluid if needed. Shut the engine
rod. Apply Loctite® 243TM and install the set screw in the OFF.
piston head. Refer to Section 8.10.4, “Cylinder Torque
Specifications”, for torque specifications for the piston
head and the set screw.
Note: Avoid using excess force when clamping the cylinder
barrel in a vise. Apply only enough force to hold the cylinder
8.10.2 Cylinder Pressure Checking
barrel securely. Excessive force can damage the cylinder barrel.
Attach a 345 bar (5000 psi) gauge to the test port on the
5. Place the cylinder barrel in a soft-jawed vise or other
P1 port on the hydraulic manifold to check the system
acceptable holding devise.
pressure. For more information, refer to Section 8.4.1,
Note: When sliding the rod and piston assembly into the “Pressure Checks and Adjustments”.
cylinder barrel, prevent the threaded end of the cylinder barrel
Note: If a hydraulic cylinder pressure is greater than the main
from damaging the piston head. Keep the cylinder rod centered
control valve pressure, increase the main control valve pressure
within the barrel to prevent binding.
by adjusting the main relief. Generally, one half turn clockwise
6. Carefully insert the cylinder rod assembly into the will be adequate to check an individual circuit. Activate the
cylinder barrel. circuit and if pressure is obtained turn the main relief counter
7. Screw the head gland into the cylinder barrel and clockwise one half turn. Re-check the main relief setting and
tighten with a spanner wrench. Refer to Section 8.10.4, adjust if necessary.
“Cylinder Torque Specifications”, for torque
specifications for the head gland. 8.10.3 Steering Cylinders
8. If applicable, install new counter balance valve into The steer cylinder is attached to each axle center housing.
block on the cylinder barrel. The steer cylinder is covered in the appropriate
manufacturer’s axle literature. Detailed axle service
instructions (covering the axle, differential, brakes and
wheel-end safety, repair, disassembly, reassembly,
adjustment and troubleshooting information) are provided
in the appropriate Axle Disassembly & Assembly Manual.
Refer to Section 5.3, “Axle Specifications and Maintenance
Information”, for details.
3614RS, 4017RS 31211333 8-25

Hydraulic System
8.10.4 Cylinder Torque Specifications
a. Lift/Lower Cylinder
Model Head Piston V1 Plug V2 Plug CB Valve

1500 Nm
3614 RS
(1106 lb-ft) 2000 Nm 85 Nm 85 Nm
N/A
480 Nm (1475 lb-ft) (63 lb-ft) (63 lb-ft)
4017RS
(354 lb-ft)
b. Extend/Retract Cylinder

900 Nm 1000 Nm
3614 RS
(664 lb-ft) (738 lb-ft) 100 Nm 170 Nm
N/A
1000 Nm 900 Nm (74 lb-ft) (125 lb-ft)
4017RS
(738 lb-ft) (664 lb-ft)
c. Tilt Cylinder

All 1200 Nm 1500Nm 85 Nm 85 Nm 85 Nm
Machines (885 lb-ft) (1106 lb-ft) (63 lb-ft) (63 lb-ft) (63 lb-ft)
d. Compensation Cylinder
Model Head Piston

800 Nm 1000 Nm
All Machines
(590 lb-ft) (738 lb-ft)
e. Frame Level Cylinder

1200 Nm 1700 Nm
3614 RS
(885 lb-ft) (1254 lb-ft) 85 Nm 85 Nm 40 Nm
1000 Nm 900 Nm (63 lb-ft) (63 lb-ft) (30 lb-ft)
4017RS
(738 lb-ft) (664 lb-ft)
f. Outrigger Cylinder

1500 Nm 1000 Nm 85 Nm 85 Nm 40 Nm
All Machines
(1106 lb-ft) (738 lb-ft) (63 lb-ft) (63 lb-ft) (30 lb-ft)
8-26 31211333 3614RS, 4017RS

Section 9
Electrical System
Contents

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.1.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Cab Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Frame Power Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.4.3 Option 1 Distribution Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
9.5 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
9.5.1 Prior to SN E160000342, excluding E160000328 thru E160000332 & E160000336 9-12
9.5.2 SN E160000342 to Present, including E160000328 thru E160000332 & E1600003369-19
9.6 Dielectric Grease Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27
9.6.2 Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28
9.7 Engine Start Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.7.1 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
9.7.2 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.7.3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
9.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.8.1 Battery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.8.2 Battery Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
9.8.3 Battery Disconnect/Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.9 Wiper/Washer Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.9.1 Front Windshield Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
9.9.2 Rear Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
9.9.3 Roof Window Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
9.9.4 Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
9.10 Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.10.1 Transmission Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.10.2 Transmission Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
9.10.3 Transmission Mounted Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
9.10.4 Engine Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.10.5 Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
9.10.6 Boom Retract Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
9.10.7 Boom Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
9.10.8 Reverse Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.11 Dash Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.11.1 Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
9.11.2 Dash Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
3614RS, 4017RS 31211333 9-1

Electrical System
9.12 Load Stability Indicator (LSI) (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44

9.12.1 Load Stability Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.12.2 LSI Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
9.12.3 LSI System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.13 Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.13.1 Machine Data Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-47
9.13.2 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.13.3 Mobile Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
9.13.4 Analyzer Software Version P14.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49
9.14 Analyzer Software Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.14.1 Access Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.14.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-56
9.14.3 Machine Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-57
9.14.4 Personalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-58
9.14.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-62
9.14.6 Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-64
9.15 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-67
9.16 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
9.16.1 Help Comment (00x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
9.16.2 Power-Up (21x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-68
9.16.3 Platform Controls (22x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-74
9.16.4 Cabin Controls (23x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-76
9.16.5 Other Inputs (24x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-92
9.16.6 F unction Prevented (25x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-92
9.16.7 Line Contactor Open-Circuit (31x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96
9.16.8 Line Contactor Short-Circuit (32x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96
9.16.9 Output Drivers (33x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-96
9.16.10 Engine (43x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-129
9.16.11 Battery Supply (44x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-135
9.16.12 Transmission & Drive System (46x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-136
9.16.13 Communications (66x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-193
9.16.14 Envelope Control (84x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-198
9.16.15 Tilt Sensor (81x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-199
9.16.16 Load Moment (85x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-199
9.16.17 Steering (86x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-208
9.16.18 Service Required (87x). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-208
9.16.19 Hardware (99x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-209
9.17 Engine Diagnostic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-217
9-2 31211333 3614RS, 4017RS

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
9.1.1 General Overview
CAB CONTROL
MODULE
BOOM ANGLE
SENSOR CAB POWER
DISTRIBUTION
BOARD
OPTION
REVERSE DISTRIBUTION
ALARM BOARD
LSI DISPLAY
JOYSTICK
DISPLAY
PANEL
IGNITION
LSI SENSOR KEY SWITCH
HORN
REAR FRAME
CONTROL
MODULE
ALTERNATOR
FRAME POWER
DISTRIBUTION BOARD ECM
CONTROL
STARTER
BATTERY
DISCONNECT
BATTERY
FRONT FRAME
CONTROL
MAE35050
MODULE
3614RS, 4017RS 31211333 9-3

Electrical System
9.2 SPECIFICATIONS 9.4 POWER DISTRIBUTION BOARD

Electrical system specifications are listed in Section 2,
“General Information and Specifications”.
9.4.1 Cab Power Distribution Board
Power distribution board is located in cab. For access,
9.3 SAFETY INFORMATION remove screws securing the small side panel at the left side
of the dash.
Note: Connectors XA, XB, XC, XD, XE, XF, XG, XH and XJ are
WARNING marked with pin designation.
precautions as outlined in Section 1, “Safety Practices” of
this manual.
B+ IGN GND
9 6 3
XD 8 5 2
P
E N 7 4 1
F D M
A C XB
G B L
H J K 1 4 1 4
XC 2 5 2 5
3 6 XG 3 6
K2
15 12 9 6 3
2 1 XF 14 11 8 5 2
4 3 XA 13 10 7 4 1
5 6 D1
1 4 7 10
XH 2 5 8 11
XE 1 2 3 4
3 6 9 12
F1 10 F6 5
F2 30 F7 5 12 9 6 3
F3 10 F8 10 XJ 11 8 5 2
F4 5 10 10 7 4 1
F9
F5 5 F10 5
B+ IGN GND
MAG9871
9-4 31211333 3614RS, 4017RS

Electrical System
FUSE/RELAY FUNCTION AMP RATING

F1 AUXILIARY POWER 10
F2 MODULE POWER 30
F3 DISPLAY IGNITION, JOYSTICK IGNITION, RS232 POWER 10
SWITCH IGNITION (2), HI BEAM POWER, SHIFT IGNITION, COLUMN IGNITION,

F4 5
SEAT IGNITION
F5 TELEMATICS B+ 5
F6 TELEMATICS IGNITION 5
F7 HAZARD POWER, KEY BATTERY, BRAKE POWER 5
F8 HORN B+ (3) 10
F9 REVERSE SENSOR POWER, DOME IGNITION, REAR WIPER POWER 10
F10 BEACON POWER 5
K2 HORN RELAY 10
CONNECTOR PIN FUNCTION

A KEY IGNITION
B CAN1 HIGH
C CAN1 LOW
D SPARE
E SPARE
F KEY PLAT
G IGNITION OUT
XB
H SPARE
J HVAC COMPRESSOR OUT
K REVERSE SIGNAL 2
L REVERSE SIGNAL 1
M BOOM WORK LIGHTS
N HORN OUT
P LSI ORANGE (PASSIVE MODE)
3614RS, 4017RS 31211333 9-5

Electrical System

1 B+
2 B+
3 GND
XA
4 IGNITION
5 CLEAN IGNITION
6 CLEAN IGNITION
1 REVERSE SIGNAL 1
2 REVERSE SIGNAL 2
3 HVAC COMPRESSOR OUT

XC
4 BOOM WORK LIGHTS
5 HORN SW
6 SPARE
1 RS232 RX
2 RS232 TX
3 KEY PLAT
4 CAN1 HIGH
XD 5 KEY IGNITION
67 SPARE
7 CAN1 LOW
8 SPARE
9 SPARE
1 RS232 POWER
2 RS232 RX
XE
3 RS232 TX
4 RS232 GND
1 GND
2 TELEMATICS B+
3 TELEMATICS IGNITION
XG
4 SHIELD
5 CAN 2 LOW
6 CAN2 HIGH
9-6 31211333 3614RS, 4017RS

Electrical System

1 HAZARD POWER
2 HORN B+
3 REVERSE SENSOR POWER
4 KEY BATTERY
5 MARKER LT MODULE
6 DOME IGNITION
XH
7 BRAKE POWER
8 D1
9 REAR WIPER POWER
10 IGNITION OUT
11 -
12 BEACON POWER
1 SHIELD
2 CAN2 LOW
3 CAN2 HIGH
4 SEAT IGNITION
5 COLUMN IGNITION
6 SHIFT IGNITION
7 HIGH BEAM POWER
XF 8 SWITCH IGNITION
9 SWITCH IGNITION
10 JOYSTICK IGNITION
11 JOYSTICK IGNITION
12 DISPLAY IGNITION
13 MODULE POWER
14 MODULE POWER
15 AUXILIARY POWER SOCKET
XJ ALL PINS GROUND
3614RS, 4017RS 31211333 9-7

Electrical System
9.4.2 Frame Power Distribution Board

Power distribution board is located at left side of the engine,
inside the frame.
K1
K4
K5
J2
K6
J6
K7
K2
F11
F12
F10
F8
F6
F9
F7
J7
K3
F1
F2
MEGA
MEGA
J1
FUSE
FUSE
J4
F5
F3
F4
J5
J3
MD0891
9-8 31211333 3614RS, 4017RS

Electrical System

F1 GLOW PLUGS 150
F2 ALTERNATOR 200
F3 REAR FRAME 80
F4 FRONT FRAME 80
F5 CAB 80
F6 ECM IGNITION 25
F7 FRAME IGNITION 15
F8 ECM B+ 30
F9 CAB B+ 25
F10 AC FANS 30
F11 STARTER 30
F12 CAB MODULE 30
K1 FRONT FRAME IGNITION 70
K2 REAR FRAME IGNITION 70
K3 SYSTEM IGNITION 70
K4 SYSTEM IGNITION 70
K5 ECM IGNITION 30
K6 AC FAN POWER 30
K7 START SIGNAL TO ENGINE (STARTER OUT) 30
HIGH POWER CONNECTIONS

LOCATION FUNCTION AMP RATING SIZE
J1 B+ 200 M10
J2 ALTERNATOR 200 M10
J3 GLOW PLUGS 150 M10
J4 FRONT FRAME 80 M8
J5 REAR FRAME 80 M8
J6 CAB 80 M8
3614RS, 4017RS 31211333 9-9

Electrical System
9.4.3 Option 1 Distribution Board

Option 1 distribution board is located in the cab. For access,
remove screws securing the rear panel at the right side of the
cab.
Note: Connectors XK, XL and XM are marked with pin
designation.
4 5 6
XK
K1 2 3
1
1 4 7 10
XL 2 5 8 11
10 F11 10 F16
3 6 9 12
10 F12 10 F17
10 F13 25 F18
12 9 6 3
10 F14 10 F19
XM 11 8 5 2
25 F15 5 F20
10 7 4 1
B+ IGN GND
MAE0911

F11 BOOM WORK LIGHTS 10
F12 FRONT WORK LIGHTS 10
F13 REAR WORLK LIGHTS 10
F14 REAR WIPER POWER 10
F15 WIPER POWER 25
F16 IGNITION 10
F17 ROOF WIPER POWER 10
F18 HVAC BLOWER POWER 25
F19 ROOF WIPER POWER 10
F20 AC FANS 5
K1 LIGHTS
9-10 31211333 3614RS, 4017RS

Electrical System

1 GND
2 GND
3 GND
XK
4 REAR WIPER POWER
5 WIPER POWER
6 LIGHTS ON SIGNAL
1 SW IGNITION
2 HVAC BLOWER POWER
3 ROOF WIPER POWER
4 COLUMN IGNITION
5 HVAC COMPRESSOR OUT
6 ROOF WIPER POWER

XL
7 HI BEAM IGNITION
8 AC CMD
9 IGNITION
10 BOOM WORKLIGHT POWER
11 FT WORKLIGHT POWER
12 RR WORKLIGHT POWER
XM ALL PINS GROUND
3614RS, 4017RS 31211333 9-11

9.5
9-12
9.5.1
1 2 3 4 5 6 7 8
DRAWING NUMBER LOCATED BEHIND DASH HEATER FAN MOTOR LOCATED BEHIND DASH LEFT STEERING WHEEL SWITCHES SWITCH,HAZARDS
LOCATED ON WASHER UNIT UNDER DASH LOCATED ON TOP OF REAR WINDOW
LEFT SWITCHES
TANK,DUAL WASHER,PUMPS LOCATED ON WASHER UNIT UNDER DASH SWITCH,TURN/WIPER COLUMN WIPER,REAR
LOCATED UNDER DASH RIGHT SWITCHES SWITCH,FAN
REAR FRONT WIPER, FRONT MOTOR
LOCATED IN FRONT OF CABIN
M
LAMP, HI BEAM & INDIC
M
HORN
+
+
+
+
+
+
+
+
M
M
M
[7,F]
[7,F]
SW769-2 INDIC HI BEAM
3
HI
GND
LOW
MED
6 LOCATED BEHIND REAR TRIM
12v
7
8
3
2
1
6
5
4
9
10
7
8
3
2
1
6
5
4
9
10
7
8
1
2
3
4
5
6
9
10
7
8
3
2
1
4
5
6
9
10
L
P
H
2 WHT 300-2 KEY STRT
+
+
PWR
LOW
MED
HI
P 31b
L 53
G 31
V+ 53a
5
LOCATED UNDER DASH

a. Cab Harness
1 TO ROOF WIPER X401
SW,DRIVING LIGHTS
RIGHT SWITCHES
LOCATED BEHIND DASH
SW410
SW411
SWITCH, FOG LIGHTS
0 (09B3)
RIGHT SWITCHES
RIGHT SWITCHES
LOCATED BEHIND DASH
LOCATED BEHIND DASH
SWITCH,REAR WIPER
SW412
SW409
P 4
STEERING WHEEL SWITCHES
6
3
10
9
8
7
5
2
4
1
+
2
3
4
1
3
4
1
2
1
2
3
4
5
6
2
1
2
1
6
5
4
3
2
1
2
1
4
3
2
1
LOCATED BEHIND DASH RIGHT
3 3
H
WH69
H
AH254
2
LB91
X523
WH384
BLK 028-6 GND
2
SW263
WH116-F
1
WH116-R
WH262-F
0 1
P
F.WIPE L
F.WIPE H
FLASH 49A
DRV LT
F.WIPE PWR
FLASH BATT
MAIN BEAM
LH TURN
LO BEAM
F.WASH
RH TURN
HORN
3
SW769
WHT 415-7 SW BACKLT

BLK 028-6 GND
BLK 028-5 GND
BLK 028-5 GND
BLK 028-4 GND
BLK 028-4 GND
BLK 028-3 GND
BLK 028-3 GND
BLK 028-2 GND
WHT 411 DR LT
2
YEL 206 SW IGN

401-1 FOG LT
1
2
8
12
2
1
10
9
11
6
7
4
3
5
6
BLK 028-3-1 GND

BLK 028-3-1 GND
BLK 028-2-1 GND
BLK 028-2-1 GND
WHT 608 R WASH

WHT 609 R WASH
WHT 608 R WASH
1
YEL 206-2 SW IGN

YEL 206-2 SW IGN
YEL 206-1 SW IGN
YEL 206-1 SW IGN
WHT 401-1 FOG LT
5
WHT 400-1 HAZ SW

0
BLK 030 GND

BLK 029 GND
BLK 046 GND
P
YEL 111 HORN
BLK 030-1 GND

BLK 030-1 GND
BLK 029-1 GND
BLK 029-1 GND
WHT 410 MARKER SW
BLK 028-2 GND
WHT 415-6 SW BACKLT

WHT 415-6 SW BACKLT
WHT 415-5 SW BACKLT
WHT 415-5 SW BACKLT
WHT 415-4 SW BACKLT
WHT 415-4 SW BACKLT
WHT 415-3 SW BACKLT
3 4
YEL 231 CLEARSKY IGN

WHT 418-9-1 HAZARDS
WHT 418-9-1 HAZARDS
WHT 609 R WASH

SW370-TURN
WHT 415-7 SW BACKLT
SW370-WASH
YEL 200-2 KEY IGN BLK 028-1 GND
RED 113 CLEARSKY PWR
WHT 607 R WIPE P1.5mm²
WHT 610 RF WASH

WHT 610 RF WASH
WHT 606 R WIPE L 1.5mm²
BLK 032 GND 1.5mm²

2
WHT 425 HAZ PWR 1.5mm²

3
WHT 604-1 F WIPE L

WHT 604-3 F WIPE P
BLK 050 GND 1.5mm²

BLK 038 GND 1.5mm²
WHT 415-3 SW BACKLT
WHT 425-1 HAZ PWR 1.5mm²

WHT 425-1 HAZ PWR 1.5mm²
1
YEL 218 R WIPE PWR 1.5mm²
WHT 419-1-1 LH TURN

WHT 418-1-1 RH TURN
7
WHT 401 FOG LT SW 0.75mm²
WHT 600 FAN L 1.5mm²

WHT 602 FAN H 1.5mm²

WHT 415-9 SW BACKLT
0
WHT 601 FAN M 1.5mm²

YEL 218-1 R WIPE PWR 1.5mm²
+
2

P WHT 415-2 SW BACKLT
WHT 611 F WASH 1.5mm²

RED 104-2 KEY BATT 8
WHT 605 F WIPE H 1.5mm²

1 WHT 421 2WS IND
3
YEL 229 FAN PWR 1.5mm²
WHT 409-1 HI BEAM 0.75mm²

YEL 111 HORN
YEL 227-1 F WIPE PWR 1.5mm²

WHT 411 DR LT
WHT 324 2WS
2
BLK 090 RF WIPER GND 1.5mm²

YEL 290 RF WIPER PWR 1.5mm²
SWITCH, IGNITION WHT 329 2WS LOCK
1
6
2
1
5
3
4
SW16C
YEL 240 PWR 1.5mm²
423 4WS IND
WHT 419-2 LH TURN
D3
WHT 418-2 RH TURN
TO SW16A WHT 405-3 RH TURN WHT 422 CRAB IND

(02E1)
WHT 604 F WIPE L 1.5mm²

D2
WHT 414 LO BEAM 0.75mm²

LOCATED UNDER DASH SWITCHES 6
YEL 210 COLUMN IGN 1.5mm²

WHT 310 STEER PWR
YEL 227-2 F WIPER 1.5mm²

5
(SHOWN IN 2WS)
[2,B]
FC518-XK WHT 406-3 LH TURN WHT 324 2WS
4
SWITCH,STEER SELECT
(03F7)
D1 9
BLK 038 GND 1.5mm²
+
1
10
LOCATED BEHIND DASH RIGHT SWITCHES

BLK 029 GND
2
Electrical System
G BLK 032 GND 1.5mm² SW376 G

3
WHT 604-2 F WIPE P BLK 028-7 GND
4 7
YEL 227 F WIPER 1.5mm² WHT 415-8 SW BACKLT +
5 8
S48 S115
6 1
YEL 215 KEY IGN
FC518-XL 2
YEL 178-2 WORKLIGHTS 1.5mm² WHT 214 JYSTK LOCK 0.75mm²
(03E7) 3
YEL 178 WORKLIGHTS 1.5mm² YEL 178-1 WORKLIGHTS 1.5mm² WHT 310 STEER PWR
1 4
YEL 229 FAN PWR 1.5mm² S795 YEL 216 KEY IGN
2 5
YEL 290 RF WIPER PWR 1.5mm² WHT 329 2WS LOCK
3 6
YEL 229-2 FAN PWR YEL 215 KEY IGN
LOCATED BEHIND DASH LEFT

4 9

WHT 955 J2L4 +
5 10
SWITCH,JOYSTICK OVERRIDE
6 SW142
7
WHT 956 AC
8 BLK 028-6 GND
YEL 179 RADIO IGN 1.5mm² [5,H]
9 WHT 415-7 SW BACKLT
[5,H]
10 CAB MODULE BLK 028-7 GND
7
11
OPTION 1 PDB
WHT 415-8 SW BACKLT +
CO516-J2 CO516-J1 8
12 LOCATED BEHIND REAR YEL 216 KEY IGN
YEL SYS CANH 0.75mm² CABINE TRIM
3
S362
FC518-XM [8,D] A1 CAN1H AI TYPE 1 A1 YEL 217 KEY IGN
YEL TELE CAN2H 2
(03D7) A2 CAN2H AI TYPE 1 A2 WHT 528 LSI CANCEL 0.75mm²
BLK 090 RF WIPER GND [4,E] 1
LOCATED BEHIND RIGHT SIDE REAR TRIM

1 A3 DI TYPE 3 DI TYPE 1 A3
F 4 F
GENERIC
BLK 081 GND 1.5mm² 5

3 B1 CAN1T AGND B1
BLK 082 GND 1.5mm² WHT TELE CAN2T WHT 414 LO BEAM 0.75mm² 6
D6
4 B2 CAN2T DI TYPE 1 B2
9
BLK 083 GND 1.5mm²

SWITCH,LSI OVERRIDE
5 B3 DI TYPE 3 DI TYPE 1 B3 +
BLK 084 GND 1.5mm² WHT 214 JYSTK LOCK 0.75mm² 10
6 B4 D1 TYPE 3 DI TYPE 1 B4
BLK 028-1 GND SW375
7 C1 CAN1S AI TYPE 1 C1
BLK 050 GND 1.5mm² WHT 409-3 HI BEAM 0.75mm² WHT 415-2 SW BACKLT
8 C2 CAN2S DI TYPE 1 C2
WHT 300 KEY STRT 0.75mm² BLK 028 SW GND
9 C3 DI TYPE 1 DI TYPE 1 C3 7
10 C4 D1 TYPE 1 DI TYPE 1 C4 8
BLK 028 SW GND GRN SYS CANL 0.75mm² WHT 524 LEVEL L 0.75mm²
11 [8,D] D1 CAN1L AI TYPE 1 D1 3
GRN TELE CAN2L WHT 419-2 LH TURN YEL 217 KEY IGN
12 D2 CAN2L DI TYPE 1 D2 2
WHT 314 DRIVE FWD 0.75mm² WHT 526 LEVEL R 0.75mm²
D3 D1 TYPE 1 D1 TYPE 1 D3 1
WHT 528 LSI CANCEL WHT J1-D4-1 4W STEER SWITCH 0.75mm² YEL 224 KEY PWR
[7,F] D4 D1 TYPE 1 DI TYPE 1 D4 4
LOCATED UNDER DASH SWITCHES E1 CAN1T AI TYPE 1 E1 5
WHT TELE CAN2T WHT 418-2 RH TURN
SW16 SW16B SW16A E2 CAN2T DI TYPE 1 E2 6
LOCATED UNDER RIGHT
CONSOLE TRIM
WHT 319 GEAR 3 0.75mm² WHT 315 DRIVE NEUT 0.75mm²

6 6 6 E3 DI TYPE 1 DI TYPE 1 E3 9
SWITCH,FRAME LEVEL
WHT 316 DRIVE REV 0.75mm² +

2 2 2 E4 D1 TYPE 3 DI TYPE 1 E4 10
YEL 200-1 KEY IGN YEL 200 KEY IGN 1.5mm²
1 1 1 F1 +5V AREF AI TYPE 1 F1 SW414
ELECTRICAL SYSTEM SCHEMATICS
S519 WHT 524 LEVEL L 0.75mm² D7

5 5 5 F2 +5V AREF DI TYPE 3 F2
D4
GD86
WHT 300-1 KEY STRT WHT 300 KEY STRT 0.75mm² WHT 526 LEVEL R 0.75mm²
3 3 3 F3 DI TYPE 1 DI TYPE 3 F3 NC CAN SHLD
RED 104-1 KEY BATT RED 104-1 KEY BATT 1.5mm² WHT 318 GEAR 2 0.75mm² WHT 523 PARK BRAKE SW 0.75mm²
E 4 4 4 F4 DI TYPE 1 DI TYPE 1 F4 14 E
WHT J1-G1-1 2W STEER SWITCH 0.75mm²
KEY SWITCH
G1 AGND DI TYPE 1 G1 13
WHT 323 SEAT SW1 D8 WHT 422 CRAB IND
G2 DI TYPE 3 DI TYPE 1 G2 12 4W CRAB STEER
WHT 317 GEAR 1 0.75mm² WHT 201 MARKER SW S651 S650 WHT 423 4WS IND
G3 DI TYPE 1 DI TYPE 1 G3 11 4W STEER
WHT 360 SEAT SW2 0.75mm² WHT 415 SW BACKLT WHT 421 2WS IND
SW415 G4 DI TYPE 1 DO TYPE 3 G4 10 2W STEER
FWD PWR YEL 212 KEY PWR WHT 003 RS232 TX 0.75mm² WHT J1-H1-1 CRAB STEER SWITCH 0.75mm² S652
1 H1 RS232 TX DI TYPE 1 H1 S540 9 STEERING PRES
NEUT F WHT 314 DRIVE FWD 0.75mm² WHT 002 RS232 RX 0.75mm²
4 H2 RS232 RX +5V AREF H2 8 PARK BRAKE
REV N WHT 315 DRIVE NEUT 0.75mm² WHT 250 IGN RLY D9 GRN SYS CANL 0.75mm²
3 H3 DI TYPE 1 DO TYPE 4 H3 7 CAN LO
DISPLAY
I R WHT 316 DRIVE REV 0.75mm² WHT 433 BUZZER OUT YEL SYS CANH 0.75mm²
5 H4 DI TYPE 1 DO TYPE 3 H4 6 CAN HI
II I WHT 317 GEAR 1 0.75mm²
6 J1 DI TYPE 2 5 FUEL SENSE
LOCATED BEHIND DASH
SWITCH,FNR
II WHT 318 GEAR 2 0.75mm² WHT 401-2 FOG LT SW 0.75mm² CO516-J3 BLK 040 DISP GND
2 J2 DI TYPE 1 4 GND
III III WHT 319 GEAR 3 0.75mm² CAN LO

7 J3 DI TYPE 1 DI TYPE 1 A1 3

8 J4 DI TYPE 1 DI TYPE 1 A2 2 CAN HI
WHT 500-1 LSI PWR 0.75mm² YEL 203 DISP PWR
K1 ANALYZER PWR DI TYPE 1 A3 1
LOCATED ON BRAKE PEDAL WHT 501 LSI GREEN1 0.5mm²
K2 ANALYZER GND DO TYPE 4 A4
SWITCH, BRAKE PEDAL WHT 502 LSI GREEN2 0.5mm² MS529
K3 DI TYPE 1 DO TYPE 4 B1
WHT 612 AC CMD 0.75mm² YEL SYS CANH 0.75mm²
1 K4 DI TYPE 1 DI TYPE 1 B2 [4,F] 1
YEL 205 BRK LT PWR 1.5mm² YEL 200-1 KEY IGN WHT 503 LSI GREEN3 0.5mm² YEL SYS CANH 0.75mm²
2 L1 DI TYPE 2 DO TYPE 4 B3 2
WHT 420 BRK LT SW 1.5mm² WHT 420 BRK LT SW 1.5mm² WHT 504 LSI GREEN4 0.5mm² YEL SYS CANH 0.75mm²
3 L2 DI TYPE 2 DO TYPE 4 B4 3
YEL 270-1 MOD IGN 0.75mm² YEL SYS CANH 0.75mm²
4 L3 AGND MASTER PWR/IGN C1 10
SW76 WHT 955 J2L4
L4 DI TYPE 3 DI TYPE 1 C2 11
WHT 400 HAZ SW
M1 DI TYPE 2 DI TYPE 1 C3 12
31211333
D BLK 060 MOD GND 1.5mm² WHT 505 LSI YELLOW 0.5mm² GRN SYS CANL 0.75mm²
D
FC517-XC M2 MASTER GND DO TYPE 4 C4 [4,F] 4
FC517-XA (03F4) WHT 951-1 CONT AUXILIARY PWR YEL 270-2 MOD IGN 0.75mm² GRN SYS CANL 0.75mm²
M3 DO TYPE 3 MASTER PWR/IGN D1 5
WHT 950 ASH LOAD PWR WHT 771 HEST/REGEN GRN SYS CANL 0.75mm²
CAN BUSS
1 1 M4 DO TYPE 3 DI TYPE 1 D2 6
UNDER CAB MODULE
GRN SYS CANL 0.75mm²

2 2 N/C D3 7
LOCATED BEHIND REAR TRIM
WHT 956 AC BLK 070 MOD GND 0.75mm²

3 3 MASTER GND D4 8
(03F1) YEL 260-1 MOD IGN 0.75mm²
4 4 MASTER PWR/IGN E1 9
5 5 DI TYPE 1 E2
YEL 229-2 FAN PWR SHIELD NC
6 6 N/C E3 YEL SYS CANH 0.75mm²
6 CAN HI
FC517-XD AI TYPE 1 E4 GRN SYS CANL 0.75mm²
YEL 260-2 MOD IGN 0.75mm² 5 CAN LO
(03F4) MASTER PWR/IGN F1
WHT 002 RS232 RX 0.75mm² WHT 506 LSI RED 0.5mm² 4 EMPTY
1 DO TYPE 4 F2 YEL 208 JOY IGN
WHT 003 RS232 TX 0.75mm² 3 IGNITION
2 N/C F3
JOYSTICK
YEL 209 JOY IGN

FC517-XB 2 IGNITION
3 AI TYPE 1 F4 BLK 031 JOY GND
D5
YEL SYS CANH 0.75mm² YEL 260-3 MOD IGN 1 GROUND
LOCATED UNDER RIGHT
CONSOLE TRIM
1 4 MASTER PWR/IGN G1
YEL 200-2 KEY IGN JS404
2 5 MASTER PWR/IGN G2 (09A1)
GRN SYS CANL 0.75mm² X524
4 7 MASTER PWR/IGN G4 WHT 501 LSI GREEN1 0.5mm²
2
5 8 MASTER PWR/IGN H1 WHT 502 LSI GREEN2 0.5mm²
WHT 507-1 LSI ORANGE 0.5mm² 3
4
(03F1) 7 FC517-XF MASTER PWR/IGN H3 WHT 504 LSI GREEN4 0.5mm²
5
C 8 (03E4) MASTER PWR/IGN H4 WHT 505 LSI YELLOW 0.5mm² C
6
S520
S539
9 1 WHT 506 LSI RED 0.5mm² TO LSI
7
10 2 S859 WHT 500 LSI PWR 0.75mm² LOCATED ON RIGHT PILLAR
1
11 3 S858 WHT 507 LSI ORANGE 0.5mm²
YEL 210 SEAT IGN 8
12 4
YEL 210 COLUMN IGN 1.5mm² 9
13 5 IP857
YEL 212 KEY PWR 10
14 6
YEL 240 PWR 1.5mm²
7
YEL 224 KEY PWR X122
8 YEL 231 CLEARSKY IGN
YEL 206 SW IGN 2 UNIVERSAL TELEMATICS
9 RED 113 CLEARSKY PWR
(09A6), (09D3)
HiBPwr
YEL 208 JOY IGN 1
10 BLK 056 CLEARSKY GND LOCATED UNDER CAB ON RIGHT SIDE
FC517-XE YEL 209 JOY IGN 3
11
YEL 203 DISP PWR
1 12 LB776
YEL 260 MOD IGN 1.5mm² BLK 064-4 GND
2 13 S851 6
(03F4) YEL 270 MOD IGN 1.5mm² WHT 951 CONT AUXILIARY PWR
3 14 3
YEL 207 PWR SKT 1.5mm² +
4 15 10
FC517-XH 9
AL

(03D4) 8
1 7
FC517-XG 2 IP854 5
BLK 064-4 GND
CA
1 3 2
RED 104-1 KEY BATT 1.5mm² BLK 064-3 GND BLK 064-3 GND
RIGHT SWITCHES
LOCATED BEHIND DASH
B 2 4 4 B
WHT 410 MARKER SW WHT 950 ASH LOAD PWR
(03D4) 3 5 [6,G] 1
CONT AUX/ASH LOAD
+
WHT 280 DOME IGN
4 6 S78 LB77
YEL 205 BRK LT PWR 1.5mm² BLK 064 GND IP855 BLK 064-1 GND 1.5mm²
5 7 6
WHT 201 MARKER SW S850 WHT J1H3 ODI 1.5mm²
6 8 3
YEL 218 R WIPE PWR 1.5mm² +
9 10
WHT 250 IGN RLY
10 9
DE
11 8
YEL 176 BEACON PWR
12 7
IP856 5
FC517-XJ
ST
(03C4) 2
RIGHT SWITCHES
LOCATED BEHIND DASH
BLK 030 GND BLK 064-2 GND 1.5mm²

1 4
BLK 064 GND WHT JIH4-1 OSI 1.5mm² WHT JIH4 OSI 1.5mm²
2 BLK 825-3 GND 1 +
BLK 033 BUZZER GND
LAMP,OUTRIGGER DEPLOYED
3 S849
BLK 825-2 GND
BLK 060 MOD GND 1.5mm²
4 BLK 825-1 GND BLK 825 GND
BLK 031 JOY GND S357
5 S825
BLK 040 DISP GND
6
BLK 046 GND
7
YEL 211 KEY 1

WHT 523 PARK BRAKE SW
BLK 070 MOD GND 0.75mm² S356
8
BLK 056 CLEARSKY GND
9
3
1
2
SW77
WHT 360 SEAT SW2

YEL 213 KEY 1
YEL 213 KEY 1
YEL 211 KEY 1

WHT 323 SEAT SW1
YEL 210 SEAT IGN
BLK 825 GND
BLK 033 BUZZER GND

WHT 433 BUZZER OUT
10
MAIN POWER BOARD

BLK 057 GND 1.5mm²
BLK 825-2 GND
11
WHT 700-2 J1C3 HEST
BLK 825-3 GND
A A
SN57
WHT 771 HEST/REGEN
4
3
2
1
BLK 080 DOME GND
BLK 825-1 GND
12
WHT 701-2 J3B1 REGEN
AH118-
AH118 PULSE
AH118 CONT
WHT 415-11 SW BACKLT

BLK 081 GND 1.5mm²
YEL 176 BEACON PWR
9
6
5
4
1
2
3
8
7
BLK 084 GND 1.5mm²

SW768
10
YEL 179 RADIO IGN 1.5mm²

MS369
YEL 178-1 WORKLIGHTS 1.5mm²

YEL 178-2 WORKLIGHTS 1.5mm²
BLK 083 GND 1.5mm²

BLK 082 GND 1.5mm²
BLK 037-2 IVS GND

YEL TELE CAN2H
BLK 037-1 PED GND
GRN TELE CAN2L

BLK 037 PED GND
WHT 307 PED SIG
WHT 308 PED PWR
WHT 309 IVS SIG
WHT 612 AC CMD 0.75mm²
WHT J1H3 ODI 1.5mm²
WHT JIH4-1 OSI 1.5mm²
WHT 700-2 J1C3 HEST
WHT 406-3 LH TURN

WHT 405-3 RH TURN
1
N/O
WHT 308-2 IVS PWR
WHT 309 IVS SIG
WHT 308-1 PED PWR
WHT 307 PED SIG
N/C
BLK 080 DOME GND YEL 207 PWR SKT 1.5mm²

+
+
2 2
X798
X792
X793
X811
2
1
5
4
3
2
1
3
2
1
3
2
1
1
2
3
4
5
6
7
8
9
X538A
WHT 280 DOME IGN BLK 057 GND 1.5mm²

10
11
12
1 3 SHOWN IN OFF POSN

SN749
TO RADIO X799 TO BEACON X250 TO OPT CLEARSKY

F
TO WORKLIGHTS X252
E
B
A
D
C
LB536 POWER SOCKET PARK BRAKE

HEST/ REGEN
DOME LIGHT (09D5) (09D6) (09B1) (09B8) SEAT SWITCH TO REAR FRAME X538B
RIGHT SWITCHES
LOCATED BEHIND DASH
LOCATED UNDER RIGHT BUZZER LOCATED NEAR SEAT THROTTLE PEDAL

LOCATED ON CEILING OF CABINE LOCATED BEHIND RIGHT LOCATED BEHIND RIGHT LOCATED BEHIND RIGHT LOCATED BEHIND RIGHT (05G1)
CONSOLE TRIM LOCATED UNDER DASH LOCATED UNDER SEAT LEFT SIDE LOCATED ON THROTTLE PEDAL LOCATED UNDER CAB ON RIGHT SIDE
SIDE REAR TRIM SIDE REAR TRIM SIDE REAR TRIM SIDE REAR TRIM
1001237508-C
1 2 3 4 5 6 7 8
MAE34700C
PRIOR TO SN E160000342, EXCLUDING E160000328 THRU E160000332 & E160000336
3614RS, 4017RS
1 2 3 4 5 6 7 8
3614RS, 4017RS
H H
MAIN POWER BOARD SECONDARY POWER BOARD

b. Cab Harness - PDB
HORN RELAY
G G
87
30
87a
85
86
4
1
3
2
5
1
1
K2
IGN
GND
HORN B+
HORN B+
HORN SW
HORN OUT
GND
GND
GND
GND
GND
XB XC
REVERSE SIGNAL 1 REVERSE SIGNAL 1
L 1
REVERSE SIGNAL 2 REVERSE SIGNAL 2
K 2
HVAC COMPRESSOR OUT HVAC COMPRESSOR OUT
J 3 (02D1)
BOOM WORKLIGHTS BOOM WORKLIGHTS
M 4
HORN OUT HORN SW
N 5
(SPARE) (SPARE)
H 6
IGNITION OUT
G XD
(05F1) CAN1 HI CAN1 HI
B 4 XK
CAN1 LO CAN1 LO GND
C 7 1
(SPARE) (SPARE) GND
D 8 2
KEY IGN KEY IGN GND
A 5 (02C1) 3
KEY PLAT KEY PLAT F14 - 10A REAR WIPER PWR REAR WIPER PWR (02G1)
F 3 6
(SPARE) (SPARE) F15 - 25A WIPER PWR WIPER PWR
E 6 5
LSI ORANGE LSI ORANGE LIGHTS ON SIGNAL
P 9
RS232 TX 4
2 K1
F RS232 RX F
1
GND LIGHTS ON SIGNAL
XA
IGN
4
GND
3
CLEAN IGN
(05F1) 5
CLEAN IGN
6 XE
B+ RS232 PWR
TO REAR FRAME HARNESS

1 1
B+ RS232 RX
2 2
RS232 TX (02B1)
3
RS232 GND
4
XL
F11 - 10A BM WKLT PWR BM WKLT PWR
10
XF F12 - 10A FT WKLT PWR FT WKLT PWR
F1 - 10A AUX POWER SOCKET AUX POWER SOCKET 11
15 F13 - 10A RR WKLT PWR RR WKLT PWR
MODULE POWER MODULE POWER 12
14 SW IGN SW IGN
F2 - 30A MODULE POWER MODULE POWER 1
13 F16 - 10A COLUMN IGN COLUMN IGN
DISPLAY IGN DISPLAY IGN 4
12
JOY IGN JOY IGN HI BEAM IGN HI BEAM IGN
11 7 (02G1)
F3 - 10A JOY IGN JOY IGN IGN IGN
10 9
RS232 PWR SWITCH IGN F17 - 10A ROOF WIPER PWR ROOF WIPER PWR
9 6
SWITCH IGN (02C1) F18 - 25A HVAC BLOWER PWR HVAC BLOWER PWR
8 2
SWITCH IGN HI BEAM POWER F19 - 10A ROOF WIPER POWER ROOF WIPER POWER
E 7 3 E
SWITCH IGN SHIFT IGN HVAC COMPRESSOR OUT
6 5
HI BEAM POWER COLUMN IGN F20 - 5A AC CMD AC CMD
5
SHIFT IGN SEAT IGN 8
4
COLUMN IGN SHIELD
1
F4 - 5A SEAT IGN CAN 2L
2
CAN 2H
3
XG XM
CAN 2H GND
6 1
F5 - 5A TELEMATICS B+ CAN 2L S149
5 2
SHIELD
4 3
GND
1 (02B1) 4
TELEMATICS B+
2 5
F6 - 5A TELEMATICS IGN TELEMATICS IGN
3 6 (02F1)
7
8
XH
HAZARD PWR HAZARD PWR 9
1
F7 - 5A KEY BAT KEY BAT 10
4
BRAKE PWR BRAKE PWR 11
7
HORN B+ HORN B+ 12
2
F8 - 10A HORN B+ MARKER LT MODULE
5
HORN B+ D1 (02B1)
D 8 D
REV SEN PWR REV SEN PWR
3
F9 - 10A DOME IGN DOME IGN
6
31211333
REAR WIPER PWR REAR WIPER PWR
9
IGNITION OUT
10
11
F10 - 5A BEACON PWR BEACON PWR
12
XJ
1
S124
2
3
4
5
6
7 (02A1)
8
9
10
11
12
C C
B+
IGN
GND
1
1
1
XD
B XB B
XC XG
K2
XA XF
XE
XH
A A
XJ
1001237508-C
Electrical System
8 7 6 5 4 3 2 1
MAE34710C
9-13
c.
9-14
1 2 3 4 5 6 7 8
LOCATED ON BASE OF RIGHT LOCATED ON BASE OF LEFT
STABILIZER STABILIZER LOCATED ON RIGHT LOCATED ON LEFT LOCATED ON LEFT
LOCATED ON RIGHT STABILIZER STABILIZER STABILIZER
RIGHT POS LEFT POS STABILIZER
SWITCH,PROX SWITCH,PROX RIGHT RET LEFT RET LEFT EXT
RIGHT EXT
SWITCH, PRES SWITCH, PRES SWITCH, PRES
SWITCH, PRES
+ - + -
SIG
SIG
SIG
GND
GND
GND
PWR
PWR
PWR
SIG
GND
PWR
A
B
C
A
B
C
A
B
C
H H
3
1
2
3
1
2
A
B
C
SN368
SN366
SN365
SN367
SN372
SN371
YEL 223-2 KEY IGN

YEL 223-1 KEY IGN
BLK 715-1 GND 1mm²

BLK 715-2 GND 1mm²
WHT 332 OUT LT POS
WHT 333 OUT RT POS

WHT 067 AGND 0.75mm²
WHT 267 5V REF 0.75mm²

WHT 365 OUT LT EXT 0.75mm²
WHT 366 OUT LT RET 0.75mm²
WHT 367 OUT RT EXT 0.75mm²

WHT 368 OUT RT RET 0.75mm²
Front Frame Harness
S370
G G
Electrical System
YEL 223 KEY IGN

X646
WHT 701 J1C3 HEST
A
WHT 700 J3B1 REGEN
B
C
WHT 337 TRANS TEMP 0.75mm²
D
WHT 230 SPD SIG 0.75mm²
E
RED 302 TRANS SPD PWR
F
WHT 328 TRANS 2 0.75mm²
G
F WHT 327 TRANS 1 0.75mm²
H F
WHT 326 TRANS R 0.75mm²
J
WHT 325 TRANS F 0.75mm²
K
WHT 313 CLUTCH SW 0.75mm²
L
(05C1)
WHT 338 ENG ST
M
YEL ENG CAN2H
N
GRN ENG CAN2L
O
P
LOCATED BETWEEN CAB AND FRAME

WHT J1H4 OSI 1.5mm²
Q
TO REAR FRAME X645

WHT 530 HYD FLTR 0.75mm²
R
BLK 035 FUEL GND 0.75mm²
S
WHT 321 FUEL LVL 0.75mm²
T
YEL 223 KEY IGN
U
V
YEL SYS CANH
W
GRN SYS CANL
X
HV576
WHT 515 FRAME LVL LH 0.75mm²
E 1 E
BLK 715-3 GND
F.FRAME MODULE 2
X644
FRM LVL LH
1 CO551-J2 CO551-J1
HV577
YEL SYS CANH WHT 365 OUT LT EXT 0.75mm² WHT 516 FRAME LVL RH 0.75mm²
2 A1 CAN1H AI TYPE 1 A1 1
YEL 274-2 IGN+ 10mm² YEL ENG CAN2H BLK 715-4 GND
STABS VALVE
3 A2 CAN2H 499 RES AI 3 A2 2

BLK 649-1 MSTR GND 10mm²
FR LEVEL
4 A3 LS CS 2 DO TYPE 2 (PWM) A3
(05C1)
FRM LV RH
WHT 515 FRAME LVL LH 0.75mm²

LOCATED ON LEVERING &
5 A4 LS CS 4 DO TYPE 2 A4
6 B1 CAN1L AI TYPE 1 B1
WHT J2B2 CAN2
B2 CAN2L 499 RES AI 2 B2 HV582
WHT 516 FRAME LVL RH 0.75mm² WHT 514 SPD VLV 0.75mm²
B3 LS CS 2 DO TYPE 2 B3 1
WHT 517 LH O/R UP 0.75mm² WHT 513 SPD VLV RTN 0.75mm²
LOCATED BETWEEN CAB AND FRAME

B4 LS CS 4 DO TYPE 2 (PWM) B4 2
TO REAR FRAME X647

C1 CAN1S AI TYPE 1 C1
OUT FR LVL SP
C2 CAN2S 499 RES AI 1 C2

WHT 701 J1C3 HEST HV578
C3 LS CS 3 DO TYPE 2 C3
WHT 518 LH O/R DN 0.75mm² WHT 517 LH O/R UP 0.75mm²
C4 LS CS 5 DO TYPE 2 C4 1
INSIDE STABILIZERS VALVE COMPARTMENT

LOCATED ON THE LEFT FRONT FRAME WALL
GRN SYS CANL WHT 367 OUT RT EXT 0.75mm² BLK 586-1 GND
D1 CAN1L AI TYPE 1 D1 2
LH O/R UP
GRN ENG CAN2L
31211333
D2 CAN2L 499 RES AI 4 D2
WHT 519 RH O/R UP 0.75mm² HV579
D3 LS CS 3 DO TYPE 2 D3
WHT 327 TRANS 1 0.75mm² WHT 518 LH O/R DN 0.75mm²
D4 LS CS 5 DO TYPE 2 (PWM) D4 1
WHT 321 FUEL LVL 0.75mm² BLK 586-2 GND
E1 CAN1T AI TYPE 1A E1 2
LH O/R DN
D WHT J2B2 CAN2 D

E2 CAN2T 499 RES AI 5 E2
OUTRIGGER
WHT J1E3 FUEL JUMP HV580

E3 LS CS 1 270 RES AI 5 E3
WHT 326 TRANS R 0.75mm² WHT 519 RH O/R UP 0.75mm²
E4 DO TYPE 1 (PWM) DO TYPE 2 (PWM) E4 1
WHT 265 5V REF 0.75mm² BLK 586-3 GND
F1 +5V AREF AI TYPE 1 F1 2
LOCATED ON LEVERING & STABS VALVE
RH O/R UP

F2 +5V AREF AI TYPE 1A F2
WHT 513 SPD VLV RTN 0.75mm² HV581
F3 LS CS 1 FI TYPE 1 F3
WHT 514 SPD VLV 0.75mm² WHT 520 RH O/R DN 0.75mm² WHT 520 RH O/R DN 0.75mm²
F4 DO TYPE 1 (PWM) DO TYPE 2 F4 1
BLK 586-4 GND
G1 RS232 RX FI TYPE 1 G1 2
RH O/R DN
G2 RS232 TX FI TYPE 1 G2
G3 AGND DO TYPE 2A (PWM) G3
G4 DO TYPE 1 (PWM) DO TYPE 2A (PWM) G4
WHT 333 OUT RT POS WHT 230 SPD SIG 0.75mm²
H1 DI TYPE 1 FI TYPE 1 H1
H2 DI TYPE 1 +5V AREF H2 HV584
WHT J1H3 ODI 1.5mm² WHT 522 CRAB STR 0.75mm²
H3 AGND DO TYPE 2A H3 1
WHT 325 TRANS F 0.75mm² WHT J1H4 OSI 1.5mm² BLK 714-2 GND
H4 DO TYPE 1 (PWM) DO TYPE 2A H4 2
J1 DI TYPE 1
WHT 332 OUT LT POS CO551-J3
J2 DI TYPE 1 HV583
BLK 035 FUEL GND 0.75mm² WHT 522 CRAB STR 0.75mm² WHT 521 4WS STR 0.75mm²
J3 AGND DO TYPE 2 A1 1
WHT 313 CLUTCH SW 0.75mm² WHT 268 5V REF 0.75mm² BLK 714-1 GND
STEERING
J4 DO TYPE 1 (PWM) +5V AREF A2 2

CRAB STR ALL WHL STR
RED 302 TRANS SPD PWR WHT 068 AGND 0.75mm²

K1 ANALYZER PWR AGND A3
LOCATED ON STEERING PUMP
C K2 ANALYZER GND DI TYPE 1A A4 C

WHT 067 AGND 0.75mm² WHT 700 J3B1 REGEN
K3 AGND DO TYPE 2 B1
K4 DO TYPE 1 (PWM) +5V AREF B2
BLK 649-2 MSTR GND 2mm² WHT 066 AGND 0.75mm² BLK 586-4 GND
L1 MASTER GND AGND B3
BLK 649-1 MSTR GND 10mm² BLK 586-3 GND
L2 +5V AREF DI TYPE 1A B4 T585
S649 WHT 418 RH TURN LT WHT 328 TRANS 2 0.75mm² BLK 586-2 GND BLK 586 MAIN GND 2.5mm²
L3 DO TYPE 3 DO TYPE 2 C1 1
WHT 338 ENG ST BLK 586-1 GND S586 BLK 714 GND 2.5mm²
L4 DO TYPE 3 +5V AREF C2
M1 MASTER GND AGND C3
M2 MASTER GND DI TYPE 1A C4 BLK 714-1 GND BLK 714 GND 2.5mm²
M3 DO TYPE 3 DO TYPE 1 (PWM) D1 BLK 714-2 GND S714
M4 DO TYPE 3 +5V AREF D2
+5V AREF D3
BLK 556-2 GND 2mm² S556
DI TYPE 1A D4 T711
BLK 556-1 GND 2mm² BLK 556 GND 4mm² BLK 556 GND 4mm²
DO TYPE 1 (PWM) E1 1
NEAR FRAME MODULE
WHT 337 TRANS TEMP 0.75mm² BLK 715 GND 4mm²

CHASSIS GND
CO551-J4 DI TYPE 4 E2
WHT J1E3 FUEL JUMP BLK 715-4 GND 1mm²
YEL 274-2 IGN+ 10mm² +5V AREF E3
LOCATED ON ON LEFT FRAME WALL
1 MASTER PWR IN WHT 366 OUT LT RET 0.75mm² BLK 715-3 GND 1mm² BLK 715 GND 4mm²
AI TYPE 2 E4
WHT 521 4WS STR 0.75mm² BLK 715-2 GND 1mm² S715
DO TYPE 2 F1
BLK 715-1 GND 1mm²
DI TYPE 4 F2
DI TYPE 1 F3
WHT 368 OUT RT RET 0.75mm²
B AI TYPE 2 F4 B
WHT 413 LH HI BEAM LT 1.5mm²
DO TYPE 3 G1
WHT 421 LH SIDE LT
DO TYPE 3 G2 LB308
WHT 412 LH LO BEAM LT 1.5mm² BLK 556-1 GND 2mm²
DO TYPE 3 G3 1
WHT 412 LH LO BEAM LT 1.5mm²
G4
DI TYPE 1 2
WHT 420 RH SIDE LT WHT 413 LH HI BEAM LT 1.5mm² HIGH
DO TYPE 3 H1 3
WHT 417 RH HI BEAM LT 1.5mm² WHT 421 LH SIDE LT
DO TYPE 3 H2 4
WHT 419 LH TURN LT WHT 419 LH TURN LT
DO TYPE 3 H3 5
WHT 416 RH LOW BEAM LT 1.5mm² SIDE
DO TYPE 3 H4 6
LIGHT,LEFT HEADLIGHT
LOCATED ON LEFT DRIVING LIGHT
TURN
TURN
WHT 418 RH TURN LT SIDE

5
WHT 420 RH SIDE LT
4
WHT 417 RH HI BEAM LT 1.5mm²
3
A WHT 416 RH LOW BEAM LT 1.5mm² HIGH A
2
BLK 556-2 GND 2mm²
1
LIGHT,RIGHT HEADLIGHT
LB309
LOCATED ON LEFT DRIVING LIGHT
LOW
1001237508-C
1 2 3 4 5 6 7 8
MAE34720C
3614RS, 4017RS
1 2 3 4 5 6 7 8
LOCATED ON LEFT EXTERIOR FRAME

WALL NEAR REAR FRAME MODULE
3614RS, 4017RS
BUSS LOCATED ON RIGHT EXTERIOR FRAME WALL NEAR POWER DISTRIBUTION BOX
TO ENGINE X590B TO X720

(07F8), (08F8) (07E8), (08E8)
9
8
7
6
5
4
3
2
1
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
1
2
3
4
12
11
10
H H
X590A
MS587
X722
R.FRAME MODULE
CO552-J1 LOCATED ON LEFT EXTERIOR CO552-J2
WHT 309 IVS SIG

WHT 307 PED SIG
BLK 037 PED GND
WHT 338 ENG ST
320 BM ANG FRAME WALL, BACK OF CAB YEL SYS CANH 0.75mm²
WHT 327 TRANS 1

WHT 328 TRANS 2
WHT 326 TRANS R

RED 230 SPD PWR
WHT 325 TRANS F

A1 AI TYPE 1 CAN1H A1
WHT 308 PED PWR

WHT 302 TRANS SPD
WHT 313 CLUTCH SW

A2 499 RES AI 3 CAN2H A2
WHT 337 TRANS TEMP
YEL SYS CANH 0.75mm²

WHT 700-1 J1C3 HEST WHT 501 TELE RTN 0.75mm² WHT 501 TELE RTN 0.75mm²

YEL ENG CAN2H 0.75mm²
12 A3 DO TYPE 2 (PWM) LS CS 2 A3 2
YEL 810 ECM IGN 3mm²
GRN ENG CAN2L 0.75mm²

RED 719-2 ENG B+ 3mm²
WHT 701-1 J3B1 REGEN WHT 525 AUX RTN 0.75mm² WHT 502 TELE IN 0.75mm²
TELE IN
11 A4 DO TYPE 2 LS CS 4 A4 1

WHT 405-2 RH TURN LT WHT SYS CANT 0.75mm²
10 B1 AI TYPE 1 CAN1L B1 HV295
WHT 406-2 LH TURN LT
9 B2 499 RES AI 2 CAN2L B2
WHT 503 TELE RTN 0.75mm² WHT 503 TELE RTN 0.75mm²
8 B3 DO TYPE 2 LS CS 2 B3 2
WHT J1H3 OSI 1.5mm² WHT 527 AUX RTN 0.75mm² WHT 504 TELE OUT 0.75mm²
d. Rear Frame Harness
7 B4 DO TYPE 2 (PWM) LS CS 4 B4 1
TELE OUT

6 C1 AI TYPE 1 CAN1S C1 HV294
(02A5)
WHT 612 AC CMD
5 [8,D] C2 499 RES AI 1 CAN2S C2
WHT 309 IVS SIG WHT 505 TILT RTN 0.75mm² WHT 505 TILT RTN 0.75mm²
4 C3 DO TYPE 2 LS CS 3 C3 2
WHT 308 PED PWR WHT 5071 LSI PASSIVE MODE 0.75mm² WHT 506 TILT UP 0.75mm²
TILT UP
3 C4 DO TYPE 2 LS CS 5 C4 1
CAB, REAR SIDE OF CAB

TO CAB 538A
WHT 307 PED SIG GRN SYS CANL 0.75mm²
2 D1 AI TYPE 1 CAN1L D1 HV296
LOCATED BETWEET FRAME AND

G BLK 037 PED GND G
1 D2 499 RES AI 4 CAN2L D2
WHT 507 TILT RTN 0.75mm² WHT 507 TILT RTN 0.75mm²
X538B D3 DO TYPE 2 LS CS 3 D3 2
WHT 508 TILT DN 0.75mm²
TILT DN
D4 DO TYPE 2 (PWM) LS CS 5 D4 1
WHT SYS CANT 0.75mm²
E1 AI TYPE 1A CAN1T E1 HV297
E2 499 RES AI 5 CAN2T E2
MCV
WHT 509 LIFT RTN 0.75mm² WHT 509 LIFT RTN 0.75mm²
WHT 5071 LSI PASSIVE MODE 0.75mm² E3 270 RES AI 5 LS CS 1 E3 2
P WHT 510 LIFT DN 0.75mm² WHT 510 LIFT DN 0.75mm²
LIFT DN
E4 DO TYPE 2 (PWM) DO TYPE 1 (PWM) E4 1

LOCATED UNDER CAB
N
ON MAIN CONTROL VALVE
F1 AI TYPE 1 +5V AREF F1 HV293

M
F2 AI TYPE 1A +5V AREF F2
L WHT 511 LIFT RTN 0.75mm² WHT 511 LIFT RTN 0.75mm²
F3 FI TYPE 1 LS CS 1 F3 2
K WHT 512 LIFT UP 0.75mm² WHT 512 LIFT UP 0.75mm²
LIFT UP
WHT 613 AC HS F4 DO TYPE 2 DO TYPE 1 (PWM) F4 1

J [8,D]
WHT 640-2 AC HS G1 FI TYPE 1 RS232 RX G1 HV292
H
WHT XAG IGN SIG G2 FI TYPE 1 RS232 TX G2
G [8,D] WHT 525 AUX RTN 0.75mm²
G3 DO TYPE 2A (PWM) AGND G3 2
F WHT 504 TELE OUT 0.75mm² WHT 526 AUX A 0.75mm²
AUX A
G4 DO TYPE 2A (PWM) DO TYPE 1 (PWM) G4 1

E
H1 FI TYPE 1 DI TYPE 1 H1 HV316
D
GRN SYS CANL 0.75mm² H2 +5V AREF DI TYPE 1 H2
C WHT 527 AUX RTN 0.75mm²
YEL SYS CANH 0.75mm² H3 DO TYPE 2A AGND H3
B WHT 502 TELE IN 0.75mm² WHT 528 AUX B 0.75mm²
TO CAB INTERFACE
AUX B
WHT XAL KEY ON H4 DO TYPE 2A DO TYPE 1 (PWM) H4 1

A [8,D] WHT 322 BM RETRACT 0.75mm²
DI TYPE 1 J1 HV317
X801-XB
CO552-J3 DI TYPE 1 J2
F F
A1 DO TYPE 2 AGND J3
-
WHT 508 TILT DN 0.75mm²

A2 +5V AREF DO TYPE 1 (PWM) J4
YEL 277 IGN 2mm² RED 306 LSI PWR 0.75mm² BLK 718-1 GND 1mm²
6 [8,D] A3 AGND ANALYZER PWR K1 2
YEL 276 IGN 2mm² WHT 322 BM RETRACT 0.75mm²
5 [8,D] A4 DI TYPE 1A ANALYZER GND K2 3
YEL 275 IGN+ 10mm² BLK 034 GND 0.75mm² YEL 221-1 FR IGN
4000017
4 [7,B] B1 DO TYPE 2 AGND K3 1
LOCATED IN CABINE ON MAIN POWER BOARD

BLK 013 CAB GND 10mm² WHT 506 TILT UP 0.75mm²
3 B2 +5V AREF DO TYPE 1 (PWM) K4
SWITCH, PROX
SN304
+
BOOM RETRACT
RED 280-2 CAB B+ 2mm² RED 280 CAB B+ BLK J2-L1 MASTER GND 2mm²
2 [8,D] B3 AGND MASTER GND L1
RED 280-1 CAB B+ 2mm² S800
WALL, TIED TO A HOSE
1 B4 DI TYPE 1A +5V AREF L2

LOCATED NEAR REAR FRAME
WHT 405-1 RH TURN LT

X800-XA C1 DO TYPE 2 DO TYPE 3 L3 AH313
WHT 400 REV ALARM WHT 400 REV ALARM
C2 +5V AREF DO TYPE 3 L4 1
BLK J2-M1 MASTER GND 2mm² BLK 717-5 GND 1mm²
TO CAB INTERFACE
C3 AGND MASTER GND M1 2
BLK J2-M2 MASTER GND 2mm²
C4 DI TYPE 1A MASTER GND M2
WHT 526 AUX A 0.75mm²
LOCATED ON REAR
ALARM,BACKUP
D1 DO TYPE 1 (PWM) DO TYPE 3 M3

RIGHT LIGHT BRACKET
WHT 401 FOG LT 1.5mm²

D2 +5V AREF DO TYPE 3 M4
D3 +5V AREF
SN303
D4 DI TYPE 1A 034 GND BLK
WHT 528 AUX B 0.75mm² 1
E1 DO TYPE 1 (PWM) 320 BM ANG
3
E2 DI TYPE 4 CO552-J4 YEL 221-2 FR IGN
2
E3 +5V AREF YEL 273 IGN+ 10mm²
WHT 307 LSI SIG1 0.75mm² MASTER PWR IN 1
E4 AI TYPE 2
LOCATED ON REAR
LEFT LIGHT BRACKET
E F1 DO TYPE 2 E
SENSOR, ANGLE, BOOM
F2 DI TYPE 4
F3 DI TYPE 1
WHT 305 LSI SIG2 0.75mm² X640
F4 AI TYPE 2 WHT 639-1 AC FANS 1.5mm²
S327
S653
WHT 407 LH STOP LT 1
(09C8)
WHT 530 HYD FLTR 0.75mm² G1 DO TYPE 3 WHT 639-2 AC FANS 1.5mm²
1 WHT 403 TAIL LT 1.5mm² 2
OF CABINE
BLK 556-4 GND 1mm² G2 DO TYPE 3 WHT 640-1 AC HS

2 3
TO AC OPTION
WHT 408 LH REV LT

LOCATED ON BACK
G3 DO TYPE 3
SN251
G4 DI TYPE 1
403-3 LICENSE LT
FILTER UNDER CAB

H1 DO TYPE 3 X641
HYD FILTER PRES

WHT 404 RH STOP LT WHT 640-2 AC HS
H2 DO TYPE 3 1
LOCATED ON HYDRAULIC OIL

YEL 221 FR IGN
H3 DO TYPE 3 2
WHT 402 RH REV LT WHT 612 AC CMD
(09C8)
H4 DO TYPE 3 3
OF CABINE
GRN SYS CANL 0.75mm² BLK 718-3 GND 1mm²

X 4
TO AC OPTION
LOCATED ON BACK

W
WHT 612 AC CMD
V [2,G]
YEL 223-1 KEY IGN
U
WHT 321 FUEL LVL 0.75mm² WHT 613 AC HS
T S642 [2,G]
S
R S639
WHT J1H3 OSI 1.5mm²
Q
P
D GRN ENG CAN2L 0.75mm² D
O
YEL ENG CAN2H 0.75mm²
N
(04F1)
WHT 338 ENG ST
31211333
M
WHT 313 CLUTCH SW
L
WHT 325 TRANS F
K
WHT 326 TRANS R
J
WHT 327 TRANS 1
H
WHT 328 TRANS 2
G
[2,F]
[2,F]
[2,F]
[2,F]
[2,F]
RED 230 SPD PWR
TO FRONT FRAME X646

F
WHT 302 TRANS SPD
E
WHT 337 TRANS TEMP
D
C
B
WHT 700-1 J1C3 HEST
A
X645
YEL 221 FR IGN
WHT XAL KEY ON

WHT XAG IGN SIG
RED 280 CAB B+
YEL 277 IGN
YEL 276 IGN
WHT 639 AC FANS 2mm²
BLK 718-2 GND 1mm²
WHT 640 AC HS
YEL 810 ECM IGN 3mm²

BLK 718-4 GND 1mm²
YEL 223-1 KEY IGN
LOCATED ON LEFT EXTERIOR FRAME WALL UNDER CABINE

9
4
5
8
7
6
3
2
1
19
18
17
16
14
13
11
10
15
12
FC632-J7
6
C 5 C
BLK 649 MSTR GND 10mm²
4
YEL 274-1 IGN+ 10mm²
F8
F7
(04E1)
F9
F12
2
1
X647
K6
TO FRONT FRAME X644

K5
F10
F6
WHT 405-2 RH TURN LT

K7

S789 WHT 405-1 RH TURN LT
S788 WHT 406-1 LH TURN LT

K4
SN302
F11

2
WHT 321 FUEL LVL 0.75mm² S588
1
UNDER CAB
S589
FC632-J6
YEL 275 IGN+ 10mm²
F5
K3
LOCATED ON FUEL TANK

SENSOR, FUEL LEVEL
[2,F] 1
B B
BLK 717-1 GND 2mm²
BLK 717-2 GND 2mm²
BLK 718-1 GND 1mm²
BLK 718-4 GND 1mm²
BLK 718-2 GND 1mm²
BLK 717-3 GND 1mm²

BLK 717-5 GND 1mm²
BLK 556-4 GND 1mm²
BLK 718-3 GND 1mm²
FC632-J5
YEL 273 IGN+ 10mm²
F3
K2
1
PDM
GENERIC
S717
S718
FUSE VALUE RELAY VALUE

LOCATED ON RIGHT INTERIOR FRAME WALL ON POWER DISTRIBUTION BOX
FC632-J4
YEL 274-1 IGN+ 10mm²
F4
K1
F1 200A K1 70A 1
F2 150A K2 70A FC632-J1

RED 01 BATT 00AWG
06-BATTERY-[2,C] 1
F3 80A K3 70A FC632-J2

RED 112 ALT B+ 2AWG
F1
07-ENGINE STAGE IIIB-[3,G] 1

RED 112 ALT B+ 2AWG
08-ENGINE STAGE V-[4,G] FC632-J3
F4 80A K4 70A RED 102 GLOW PWR 4AWG
F2
BLK 717-1 GND 2mm²

WHT 405 RH TURN LT
WHT 404 RH STOP LT
WHT 403-2 RH TAIL LT
WHT 402 RH REV LT
WHT 401-2 RH FOG LT
07-ENGINE STAGE IIIB-[6,G] 1

BLK 718 GND 4mm²
WHT 307 LSI SIG1 0.75mm²

RED 306 LSI PWR 0.75mm²
WHT 305 LSI SIG2 0.75mm²
BLK 717-2 GND 2mm²
WHT 401-1 LH FOG LT
WHT 408 LH REV LT
WHT 403-1 LH TAIL LT
WHT 407 LH STOP LT
WHT 406 LH TURN LT
403-3 LICENSE LT
BLK 717-3 GND 1mm²
BLK 717 GND 4mm²
BLK 013 CAB GND 10mm²
BLK 0-18 MASTER GND 10mm²
BLK 649 MSTR GND 10mm²
RED 103 GLOW PWR 4AWG

08-ENGINE STAGE V-[6,G]
F5 80A K5 30A
LB312
1
2
3
4
5
6
7
LB306
T716
T592
T591
T648
X654
1
2
1
2
3
4
5
6
7
1
1
1
1
1
B
A
C
LB314
SN305
NC
F6 25A K6 30A
F7 15A K7 30A -V
+V BUSSBAR GND
F8 30A LOCATED ON ENGINE FRONT SUPPORT UNDER ENGINE
A LIN BUS
LIGHT,LICENCE
A
LOCATED ON REAR
F9 25A FRAME WALL
SENSOR, LSI
LOCATED UNDER FRAME
TAIL
FOG
F10 30A
BACK
STOP
TURN
NEAR OIL COOLING PIPE

TAIL
FOG
BACK
STOP
TURN
LIGHT,RIGHT TAIL
F11 30A LIGHT,LEFT TAIL
LOCATED ON REAR
LOCATED ON REAR RIGHT LIGHT BRACKET
F12 30A LEFT LIGHT BRACKET
Electrical System
1001237508-C
1 2 3 4 5 6 7 8
MAE34730C
9-15
9-16
1 2 3 4
e. Battery Harness
LOCATED ON ENGINE STARTER
GENERIC
D D
M
Electrical System
1
1
1
EC599
EC599-B-
EC599-B+
05-RFH-[7,B]
C C
RED 01 BATT
BLK 001 00AWG
BLK 001 00AWG
BLK 002 00AWG
BLK 002 00AWG
BLK 005 00AWG
BLK 005 00AWG
BLK 004 00AWG
BLK 004 00AWG
RED 100 00AWG
31211333
RED 01 BATT
X790
X605
X635
X634
X602
X603
1
1
1
1
1
1
1
1
1
1
BT600-
BT600+
MS604-A-1
MS604-B-1
BATTERY
B B
GENERIC SWITCH FRAME
ENGINE BLOCK FRAME CAB
LOCATED ON ENGINE STARTER BATTERY DISCONNECT ENGINE BAY
LOCATED ON ENGINE NEAR LOCATED ON ENGINE LOCATED UNDER REAR
LOCATED ON ENGINE OIL LEVEL STICK FRONT SUPPORT TRIM
FRONT SUPPORT
LOCATED ON ENGINE DISCONNECT
SWITCH NEAR BATTERY
A A
1001237508-C
1 2 3 4
MAE34740C
3614RS, 4017RS
1 2
LOCATED ON LEFT SIDE
3 4
LOCATED ON FRAME WALL
NEAR ENGINE ECM
5 6
LOCATED ON FRAME WALL
NEAR CONTROL UNIT
7 8
f.
OF ENGINE NEAR STARTER PIN H-G 25A - FUEL PUM FUSE GENERIC PIN H-G 15A - GLOW PLUG FUSE
X985 X984 LOAD CENTER
LOCATED ON LEFT SIDE OF LOCATED ON TOP OF ENGINE LOCATED ON 200A CONTACTOR
WHT 730 TWISTED PAIR 3 + 1.5mm² WHT 730 TWISTED PAIR 3 + 1.5mm² PIN C-D-F-E - FUEL PUMP RELAY TRANSMISSION NEAR LAST INJECTOR
PIN F-E 5A - ALT D+ FUSE
33 62 LEFT SIDE OF ENGINE
BLK 731 TWISTED PAIR 3 - 1.5mm² BLK 731 TWISTED PAIR 3 - 1.5mm² LOCATED UNDER AIR CLEANEAR
16 35 LOCATED ON FUEL PUMP
3614RS, 4017RS
SWITCH, TRANS TEMP GLOW PLUGS PIN D-C 5A- DIAGNOSTIC FUSE
WHT 732 TWISTED PAIR 4 + 1.5mm² WHT 732 TWISTED PAIR 4 + 1.5mm² SWITCH, PRES, AIR FILTER NEAR WIP FILTER GLOW RELAY
48 42 LOCATED ON ALTERNATOR
BLK 733 TWISTED PAIR 4 - 1.5mm² BLK 733 TWISTED PAIR 4 - 1.5mm² FUEL PUMP PIN B-A - DIODE
18 37
WHT 734 TWISTED PAIR 5 + 1.5mm² WHT 734 TWISTED PAIR 5 + 1.5mm² ALTERNATOR 25A 15A 5A 5A
32 38
M
BLK 735 TWISTED PAIR 5 - 1.5mm² BLK 735 TWISTED PAIR 5 - 1.5mm² ALTERNATOR SHORT CAP
2 61
B+
L
W
WHT 736 TWISTED PAIR 6 + 1.5mm² WHT 736 TWISTED PAIR 6 + 1.5mm² LOCATED ON FUEL FILTER
H 46 40 H
BLK 737 TWISTED PAIR 6 - 1.5mm² BLK 737 TWISTED PAIR 6 - 1.5mm²
3 41
1
2
3
4
1
1
1
1
1
1
1
1
1
1
1
1
1
339 ENG START RL 0.75mm²
6 2
H
G
F
D
E
C
B
A
H
G
F
E
D
C
B
A
WHT 738 TWISTED PAIR 7 + 1.5mm² WHT 738 TWISTED PAIR 7 + 1.5mm²
X994
5 20
SN690
EC900
EC894-
EC894+
EC885-L
SN250-1
SN250-2
EC885-W
RL1037-1
RL1037-2
RL1037-3
EC885-B+
RL1037-4
MS783
MS736
4 19
YEL 740 TWISTED PAIR 8 + 0.75mm² YEL 740 TWISTED PAIR 8 + 0.75mm²
37 14
GRN 741 TWISTED PAIR 8 - 0.75mm² GRN 741 TWISTED PAIR 8 - 0.75mm²
52 13
01 TWISTED PAIR 8 SHLD 0.75mm² 01 TWISTED PAIR 8 SHLD 0.75mm²
53 9
YEL 742 TWISTED PAIR 9 + 0.75mm² YEL 742 TWISTED PAIR 9 + 0.75mm²
Engine Harness
39 15
525 ALT D+
GRN 743 TWISTED PAIR 9 - 0.75mm² GRN 743 TWISTED PAIR 9 - 0.75mm²
311 AIR FLTR

54 21
043-1 GND BLK

02 TWISTED PAIR 9 SHLD 0.75mm² 02 TWISTED PAIR 9 SHLD 0.75mm²
337 TRANS TEMP

38 1
352 RAIL PRESS 0.75mm² 352 RAIL PRESS 0.75mm²
730-3 IGN 3mm²

730-4 IGN 1mm²
730-4 IGN 1mm²
525 ALT D+ 1mm²
7 32
800 B+ RED 3mm²

801 B+ RED 3mm²
801 B+ RED 3mm²
044 GND BLK 1.5mm²
800 B+ RED 3mm²
334 FUEL PUMP 1.5mm²
730-2 IGN YEL 3mm²

730-1 IGN YEL 3mm²
8 57
335 GLOW IN 1.5mm²
106 GLOW RL RED
348 FUEL FLT WHT 0.75mm²

335 GLOW IN 1.5mm²
045 FUEL RL GND BLK

104 ENG START PWR RED 0.75mm²
112 ALT B+ RED 2AWG

228 KEY 1 YEL 1.5mm²
336 GLOW OUT 1.5mm²

9 3
334 FUEL PUMP 1.5mm²

RED 102 GLOW PWR 4AWG
10 4
11 5
590 GLOWPLUGS GRY 10mm²

047 GLOW RLY SW BLK 0.75mm²
12 6
590 GLOWPLUGS GRY 10mm²

13 7
14 8
15 10
05-RFH-[7,A]
05-RFH-[7,B]
17 11
G WHT 744 TWISTED PAIR 10 + 1.5mm² WHT 744 TWISTED PAIR 10 + 1.5mm² G
19 47
20 48
21 12
22 59
336 GLOW OUT 0.75mm² 348 FUEL FLT WHT 0.75mm²
23 16
351 BST PRESS 0.75mm² 354 BST PRESS 0.75mm²
24 22
353 RAIL PRESS 0.75mm² S995 353 RAIL PRESS 0.75mm²
LOCATED ON FRAME WALL ON CONTROL UNIT

25 31
354 RAIL PRESS 0.75mm² 354 RAIL PRESS 0.75mm²
26 25
355 BST PRESS 0.75mm² 355 BST PRESS 0.75mm²
27 29
356 COOL TEMP 0.75mm² 356 COOL TEMP 0.75mm²
28 24
357 OIL PRESS 0.75mm² 357 OIL PRESS 0.75mm² 357 OIL PRESS 0.75mm²
29 27
30 S1000 33
31 60
34 17
047 GLOW RLY SW BLK 0.75mm²
35 18
36 58 X590B
YEL 710 ENG CAN2 HI 6
1 30 A
358 BST PRESS 0.75mm² 358 BST PRESS 0.75mm² GRN 711 ENG CAN2 LO 6
40 28 B
366 ENG 0.75mm² 309 IVS SIG 0.75mm²
41 34 C
308 PED PWR 0.75mm²
42 36 D
359 BST PRESS 0.75mm² 359 BST PRESS 0.75mm² 307 PED SIG 0.75mm²
F 43 23 E F
360 OIL PRESS 0.75mm² 360 OIL PRESS 0.75mm² 037 PED GND BLK 0.75mm²
44 26 F
45 39 G
338 ENG STRT 0.75mm²
47 43 H
313 CLUTCH SW 0.75mm²
49 44 J
325 TRANS F
50 45 K
361 EXH GAS 0.75mm² 326 TRANS R
51 46 L
362 EXH GAS 0.75mm² 327 TRANS 1
55 49 M
(05H3)
363 EXH GAS 0.75mm² 328 TRANS 2

56 50 N
364 EXH GAS 0.75mm² 230 SPD PWR YEL
57 52 O
365 EXH GAS 0.75mm² 302 TRANS SPD WHT
58 51 P
337 TRANS TEMP
59 53 Q
60 54 R
55 S
X986 56 T
105-1 ECM PWR RED 2.5mm²
TO REAR FRAME HARNESS 590A
1 U
006-1 GND BLK 2.5mm²
2 V
LOCATED NEAR FRAME WALL LOWER LEVEL
3 W
4 X
5
6
E 105-1 ECM PWR RED 2.5mm² E
7 S880 X720
105-2 ECM PWR RED 2.5mm² 105 ECM PWR RED3mm² 105 ECM PWR RED3mm²
8 1
105-3 ECM PWR RED 2.5mm² 105-4 ECM PWR RED3mm² 105-4 ECM PWR RED 3mm²
9 2
006-1 GND BLK 2.5mm² 730 IGN YEL 3mm²
(05H3)
10 3
11 4
TO X722
006-3 GND BLK 2.5mm² 006 GND BLK 4mm²

12
345 COOLANT WHT 0.75mm² S902
13
336 GLOW OUT 0.75mm² 336 GLOW OUT FLRYW 1.5mm²
14
313 CLUTCH SW 0.75mm² S1052 313 CLUTCH SW 0.75mm² S24
15
309 IVS SIG 0.75mm²
16
17
532 GND BLACK
18
19
20
21
22
23
24
25
045 FUEL RL GND BLK
26
D 27 D
339 ENG START RL 0.75mm²
28
347 COOLANT WHT 0.75mm²
29 730-3 IGN YEL 3mm² 730 IGN YEL 3mm²
31211333
30 730-2 IGN YEL 3mm² 312 ECM IGN 0.75mm²
31 730-1 IGN YEL 3mm² S730
32
33
34 S1087
338 ENG STRT 0.75mm² 338 ENG STRT 0.75mm²
35
36 SN97
302 TRANS SPD WHT
37 2 GND
364 EXH GAS 0.75mm² 043-1 GND BLK 230 SPD PWR YEL
38 1 SIG
SPEED
531 GND BLK

SENSOR
043 GND BLK 1.5mm²

39
40 S354
41 HV272
043-3 GND BLK
42 2
327 TRANS 1
LOCATED ON FRAME WALL ON CONTROL UNIT

43 1
GENERIC
TRANS 1ST
363 EXH GAS 0.75mm²

44
45
308 PED PWR 0.75mm²
46 HV271
043-4 GND BLK
47 2
C 328 TRANS 2 C
48 1
GENERIC
TRANS 2ND
49
50
51 HV273
043-5 GND BLK
52 2
727 CAN LO 14 GRN 0.75mm² S351 326 TRANS R
53 1
GENERIC
LOCATED ON RIGHT SIDE OF TRANSMISSION
YEL 716 ENG CAN2 HI 9 S350

TRANS REV
54
55
366 ENG 0.75mm²
56 HV274
344 WATER/FUEL WHT 0.75mm² 043-6 GND BLK
57 2
325 TRANS F
58 1
GENERIC
TRANS FL
59
60 X08
349 FUEL FLT WHT 0.75mm² 228 KEY 1 YEL 1.5mm²
61 A
037 PED GND BLK 0.75mm² 007 GND BLK
62 B
307 PED SIG 0.75mm²
63 C
343 WATER/FUEL WHT 0.75mm²
64 D
65 E
S989 GRN 713 ENG CAN2 LO 7
66 F
S352 S915 721 CAN LO 11 GRN 0.75mm²
67 G
720 CAN HI 11 YEL 0.75mm²
B 68 H B
S916
69 J
LOCATED BETWEEN AIR
70 K
CLEANEAR BRACKET PLATES
71 L
362 EXH GAS 0.75mm² S990 YEL 712 ENG CAN2 HI 7
72 M
104 ENG START PWR RED 0.75mm²
73 NC
74
726 CAN HI 14 YEL 0.75mm² 722 CAN HI 12 YEL 0.75mm²
75 120 OHM
GRN 717 ENG CAN2 LO 9 S353
76 X917 X917T (09D3)
77 A LOCATED ON TOP OF 200A CONTACTOR
725 CAN LO 13 GRN 0.75mm² LEFT SIDE OF ENGINE
78 B
79 C
80
81
82
83
84
85

311 AIR FLTR
531 GND BLK
86
532 GND BLACK
GRN 719 ENG CAN2 LO 10

YEL 718 ENG CAN2 HI 10
729 CAN LO 15 GRN 0.75mm²
049 GND BLK
048 GND BLK
044 GND BLK 1.5mm²
043 GND BLK 1.5mm²
048 GND BLK
049 GND BLK
006 GND BLK 4mm²
007 GND BLK

87

312 ECM IGN 0.75mm²
88
X06
X07
A A
X903
X906
89
1
2
4
3
2
1
2
1
2
1
B
A
B
A
C
C
X895
X901
1
1
90 R
X13
X14
X348 X345
X349 X346
91 WIF COOLANT
LOCATED UNDER LOCATED ON
92 EXPANSION TANK
WIF FILTER
93
94 GND
LOCATED ON ENGINE FRONT SUPPORT
120 OHM
120 OHM
1.5K 1/4W
1.5K 1/4W
LOCATED ON FRAME WALL LOCATED ON FRAME WALL UNDER

NEAR CONTROL UNIT EXPANSION TANK
Electrical System
1001237508-C
1 2 3 4 5 6 7 8
MAE34750C
9-17
9-18
1 2 3 4 5 6 7 8
DRAWING NUMBER LOCATED BEHIND DASH RIGHT
LOCATED ON LEFT LOCATED ON RIGHT LOCATED ON LEFT LOCATED ON RIGHT
1001237508 PRODUCT LINK RADIO (1001243059) WORKLIGHTS REAR WORK LIGHT REAR WORK LIGHT FRONT WORK LIGHT FRONT WORK LIGHT
GENERIC
SWITCH,CAB WORKLIGHTS 2920206 2920206 2920206 2920206
(1001243057) WORKLIGHT RR WORKLIGHT FL WORKLIGHT FR
X801 X797 (1001146673) WORKLIGHT RL
750 CAN HI 18 YEL 0.75mm² RED 798 B+ 1.5mm² RED 798 B+ 1.5mm²
g. Option Harnesses
1 1 1
15A
751 CAN LO 18 GRN 0.75mm² RED 798-1 B+ 1.5mm²
2 2
RIGHT TRIM
REAR TRIM
+
+
3 FC796
CAB PDB B+
RADIO B+ FUSE
LOCATED BEHIND
LOCATED BEHIND
TO ENGINE X917
(07B8), (08B8)
RIGHT SIDE TRIM
LOCATED BEHIND
7
8
3
2
1
6
5
4
9
10
1
2
1
2
1
2
1
2
MS21-1
1
LB12
LB11
LB10
LB09
SW864
LOCATED BEHIND 2
D RIGHT SIDE TRIM 3
S803
747 CAN LO 16 GRN 0.75mm² 749 CAN LO 17 GRN 0.75mm² X877T RED 798-1 B+ 1.5mm²
12 X877 4 X799
746 CAN HI 16 YEL 0.75mm² 748 CAN HI 17 YEL 0.75mm² 224 RADIO IGN YEL D
11 C 5 1
Electrical System
S804 752 CAN LO 13 GRN 0.75mm² 053 GND BLK

10 B 6 2
(02A2)
050-1 GND BLK
051-1 GND BLK
051-2 GND BLK
REAR TRIM
051-4 GND BLK
753 CAN HI 13 YEL 0.75mm² 224 RADIO IGN YEL
430-1 F WRK LT
430-2 F WRK LT
431-2 R WRK LT
431-1 R WRK LT
429 SW BACKLT
050-2 GND BLK
9 A 7
TO CAB X798
LOCATED BEHIND
120 OHM 053 GND BLK
8 8
7 MS21
617 LH SPK+
RADIO
6 LOCATED BEHIND RIGHT SIDE TRIM 1 1 S357
225 F WRK LT YEL 1.5mm²

S358
226 R WRK LT YEL 1.5mm²

430 F WRK LT WHT 1.5mm²
431 R WRK LT WHT 1.5mm²

5 NEAR GROUND MODULE 2 MS392LH+
616 LH SPK- 616 LH SPK- X252
4 3 1 225 F WRK LT YEL 1.5mm² S356 S359
231 P.LINK IGNT YEL S808 231-1 P.LINK IGNT YEL 617 LH SPK+ 1
LH SPEAKER
MS392LH-
NEAR GROUND MODULE

3 2 4 226 R WRK LT YEL 1.5mm²
PRODUCTLINK PL421
S809 056-4 GND BLK TO CAB X122 2
056-3 GND BLK 618 RH SPK+
2 3 (02C8) 5
LOCATED BEHIND RIGHT SIDE TRIM

429 SW BACKLT
CEILING
113-1 P.LINK BATT RED 113-1 P.LINK BATT RED 619 RH SPK- 618 RH SPK+ 3
1 1 6 1 050 GND BLK 1.5mm²
(02A3)
LOCATED BEHIND RIGHT SIDE TRIM

4
X128 X122-2_1 7 MS393RH+ 051 GND BLK 1.5mm² 051-3 GND BLK 1.5mm²
LOCATED IN CABINE
231-2 P.LINK IGNT YEL 619 RH SPK- 5
8 1 S98
6
RH SPEAKER
MS393RH-
TO CAB X792
REAR TRIM ON PCB BOARD
LOCATED BEHIND
X145
231-2 P.LINK IGNT YEL
A 615-4 COND FAN 1.5mm²
056-6 GND BLK AIRCON CHASSIS
B 615-3 COND FAN 1.5mm² (05E8)
C 613-1 AC PRESS WHT LOCATED ON BACK
OF CABINE
D
(1001151260)
E SPL_CATHODE SPL_ANODE X996-1
749 CAN LO 17 GRN 0.75mm² 603 AC SW PWR WHT
F 1 TO X64
748 CAN HI 17 YEL 0.75mm² (05E8)
G 2
613-1 AC PRESS WHT LOCATED ON BACK
H 3 OF CABINE

056-1 GND BLK
PRODUCTLINK DIAG CONN

J 4
LOCATED ON TOP OF CABINE

C ON WIPER MOTOR
LOCATED BEHIND DASH AIRCON CAB C
RIGHT STEERING WHEEL SWITCHES
614 AC2 COMP WHT

WIPER,ROOF
BEACON ROOF WIPER
GND BLK 1 mm²

LOCATED BEHIND DASH RIGHT SWITCH,WIPER ROOF
(1001244134)
M
(1001146676) LOCATED ON TOP OF CABINE
(1001146677)
BEACON SWITCH UP TO REAR WINDOW
X777
1
SPL_COM
BEACON SOCKET LOCATED ON AC
+
+
V+ 53a
G 31
L 53
P 31b
COMPRESSOR
BRACKET BOLT
+
+
1
2
3
4
7
8
3
2
1
6
5
4
9
10
058 GND BLK
059 GND BLK
615-4 COND FAN 1.5mm²
059 GND BLK
615-3 COND FAN 1.5mm²
058 GND BLK
613-1 AC PRESS WHT
612 AC SWITCH SIG WHT
613-1 AC PRESS WHT
WH390
7
8
3
2
1
4
5
6
9
10
1
2
614 AC COMP WHT
603 AC SW PWR WHT
056-1 GND BLK
SW256
614 AC1 COMP WHT
X776
1
B
A
B
A
LB83
SW94
SN252
2
1
1
1
WH753-2
WH753-1
SN153-2
SN153-1
F
A
B
E
C
D
SW154
LOCATED ON FRAME LEFT
2
1
WH1260
EXTERIOR WALL
+
622 RF WASH
055-2 GND BLK

428 SW BACKLT
620 RF WIPE L 1.5mm²
053-2 GND BLK

621 RF WIPE P 1.5mm²
M
M
427 SW BACKLT
AC COMPRESSOR SWITCH, PRES, AC SWITCH,AC TEMP SWITCH,AC
620 RF WIPE L 1.5mm²

CONDENSOR FANS
621 RF WIPE P 1.5mm²

LOCATED ON AC LOCATED BEHIND DASH RIGHT
31211333
LOCATED ON AC LOCATED BEHIND RIGHT SIDE
LOCATED ON AC CONDENSOR FANS STEERING WHEEL SWITCHES
222-3 RF WIPE PWR YEL

222-3 RF WIPE PWR YEL
COMPRESSOR OF HVAC UNIT UNDER DASH
CONDENSOR FANS

X132
222-1 RF WIPE PWR YEL 1.5mm²

1
219 OPT PWR 1 YEL 1.5mm²

222-2 RF WIPE PWR YEL 1.5mm²
CLEARSKY
S400
2
3
X250 X401 (1001243058)
219 OPT PWR 1 YEL 1.5mm² 222 RF WIPE PWR YEL 1.5mm² S399 4
1 1
053 GND BLK 1.5mm² 055 GND BLK 1.5mm² 5 3
2 2 747 CAN LO 16 GRN 0.75mm² S813 751 CAN LO 18 GRN 0.75mm²
(02A3)
B 427 SW BACKLT S99 428 SW BACKLT 6 2
3 3 746 CAN HI 16 YEL 0.75mm² S814 750 CAN HI 18 YEL 0.75mm² B
(02A3)
622 RF WASH 7 1
(02H3)
4 748 CAN HI 17 YEL 0.75mm²
TO CAB X811
8 X811-1
REAR TRIM
SIDE REAR TRIM
5 749 CAN LO 17 GRN 0.75mm²
TO CAB X793
9
LOCATED BEHIND

LOCATED BEHIND RIGHT
6
10
TO CAB X523
11
12
13
14 LOCATED BEHIND RIGHT SIDE TRIM
231 CLEARSKY IGNT YEL S817 231-1 CLEARSKY IGNT YEL NEAR GROUND MODULE
X518-XK-1 15 2
FC518-XK-2 056-5 GND BLK S816 056-4 GND BLK
CLEARSKY MODULE
038-2 GND BLK 1.5mm² 16 3 TO CAB X122
1 1 WORKLIGHTS JUMPER 113 CLEARSKY BATT RED S815 113-1 CLEARSKY BATT RED
029-2 GND BLK 1mm² 17 1 (02C8)
2 2
032-2 GND BLK 1.5mm² 18 X122-1_1
3 3 (1001250544) 19 X136
LOCATED BEHIND RIGHT SIDE TRIM ON CAN TCU
4 4 056-6 GND BLK

20 A
TO XK
227-2 F WIPER YEL 1.5mm²
5 5
PDB XK
231-2 CLEARSKY IGNT YEL
178-2-2 FRONT WRKLTS YEL 1.5mm² 21 B
6 6 748 CAN HI 17 YEL 0.75mm²
22 C
23 D
E
F
SIDE REAR TRIM
G
LOCATED BEHIND RIGHT
113-2 CLEARSKY BATT RED

H
CLEARSKY DIAG CONN
FC518-XL-2 X518-XL-1TO XL
1 1
229-2 FAN PWR YEL 1.5mm²
2 2 UNIVERSAL TELEMATICS
290-2 RF WIPER YEL 1.5mm²
3 3
4 4
(1001205596)
955-2 J2L4 WHT 1mm² X1611 X122-3 A
5 5 RED 113-1 BATT PLUG INTO
A UNIVERSAL 1 1
6 6
2 2 X122 SHEET 3,
7 7 X252-1 TELEMATICS
X792-1 BLK 056-4 GND
TO XL
956-2 AC WHT 1mm² 178-2-2 FRONT WRKLTS YEL 1.5mm² 3 3 ZONE A3
8 8 1 1
PDB XL
PLUG YEL 231-1 IGNT
179-2 RADIO IGN YEL 1.5mm² 178-1-2 REAR WRKLTS YEL 1.5mm² 4
9 9 2 2
415-11-2 SW BACKLT BLK 1.5mm²
10 10 3 3 DRAWINGS CREATED IN RSDESIGNER.
11 11 4 4
12 12 5 5 THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES,INC.
6 6 AND CONTAINS PROPRIETARY AND CONFIDENTIAL
INFORMATION OF JLG. IT MAY NOT BE COPIED OR
TO X792 TO WORKLIGHTS X252 DISCLOSED TO ANY THIRD PARTY WITHOUT JLG'S
WRITTEN CONSENT AND IS PROVIDED FOR THE
LIMITED PURPOSE OF REVIEW AND EVALUATION.
1001237508F
1 2 3 4 5 6 7 8
MZ8740
3614RS, 4017RS
1 2 3 4 5 6 7 8
9.5.2
LOCATED BEHIND DASH HEATER FAN MOTOR LOCATED BEHIND DASH LEFT STEERING WHEEL SWITCHES SWITCH,HAZARDS
LOCATED ON WASHER UNIT UNDER DASH LOCATED ON TOP OF REAR WINDOW
LEFT SWITCHES
TANK,DUAL WASHER,PUMPS LOCATED ON WASHER UNIT UNDER DASH SWITCH,TURN/WIPER COLUMN WIPER,REAR
LOCATED UNDER DASH RIGHT SWITCHES SWITCH,FAN
3614RS, 4017RS
REAR FRONT WIPER, FRONT MOTOR
LOCATED IN FRONT OF CABIN
M
LAMP, HI BEAM & INDIC
M
HORN
+
+
+
+
+
+
+
+
M
M
M
[7,F]
[7,F]
SW769-2 INDIC HI BEAM
3
HI
GND
LOW
MED
6 LOCATED BEHIND REAR TRIM
12v
7
8
3
2
1
6
5
4
9
10
7
8
3
2
1
6
5
4
9
10
7
8
1
2
3
4
5
6
9
10
7
8
3
2
1
4
5
6
9
10
L
P
H
2 WHT 300-2 KEY STRT
+
+
PWR
LOW
MED
HI
P 31b
L 53
G 31
V+ 53a
5
LOCATED UNDER DASH

1 TO ROOF WIPER X401
SW,DRIVING LIGHTS
RIGHT SWITCHES
LOCATED BEHIND DASH
SW410
SW411
SWITCH, FOG LIGHTS
0 (09B3)
RIGHT SWITCHES
RIGHT SWITCHES
LOCATED BEHIND DASH
LOCATED BEHIND DASH
SWITCH,REAR WIPER
SW412
SW409
P 4
6
3
10
9
8
7
5
2
4
1
+
2
3
4
1
3
4
1
2
1
2
3
4
5
6
2
1
2
1
6
5
4
3
2
1
2
1
4
3
2
1
LOCATED BEHIND DASH RIGHT
3 3
WH69
AH254
2
LB91
X523
a. Cab Harness
WH384
BLK 028-6 GND
2
SW263
WH116-F
1
WH116-R
WH262-F
H H
0 1
P
F.WIPE L
F.WIPE H
FLASH 49A
DRV LT
F.WIPE PWR
FLASH BATT
MAIN BEAM
LH TURN
LO BEAM
F.WASH
RH TURN
HORN
3 SW769
WHT 415-7 SW BACKLT

BLK 028-6 GND
BLK 028-5 GND
BLK 028-5 GND
BLK 028-4 GND
BLK 028-4 GND
BLK 028-3 GND
BLK 028-3 GND
BLK 028-2 GND
WHT 411 DR LT
2
YEL 206 SW IGN

401-1 FOG LT
1
2
8
12
2
1
10
9
11
6
7
4
3
5
6
BLK 028-3-1 GND

BLK 028-3-1 GND
BLK 028-2-1 GND
BLK 028-2-1 GND
WHT 608 R WASH

WHT 609 R WASH
WHT 608 R WASH
1
YEL 206-2 SW IGN

YEL 206-2 SW IGN
YEL 206-1 SW IGN
YEL 206-1 SW IGN
WHT 401-1 FOG LT
5
WHT 400-1 HAZ SW

0
BLK 030 GND

BLK 029 GND
BLK 046 GND
P
YEL 111 HORN
BLK 030-1 GND

BLK 030-1 GND
BLK 029-1 GND
BLK 029-1 GND
WHT 410 MARKER SW
BLK 028-2 GND
WHT 415-6 SW BACKLT

WHT 415-6 SW BACKLT
WHT 415-5 SW BACKLT
WHT 415-5 SW BACKLT
WHT 415-4 SW BACKLT
WHT 415-4 SW BACKLT
WHT 415-3 SW BACKLT
3 4
WHT 418-9-1 HAZARDS
WHT 418-9-1 HAZARDS
WHT 609 R WASH

SW370-TURN
WHT 415-7 SW BACKLT
SW370-WASH
YEL 200-2 KEY IGN BLK 028-1 GND
WHT 610 RF WASH

WHT 610 RF WASH
BLK 032 GND 1.5mm²

2

3
WHT 604-1 F WIPE L

WHT 604-3 F WIPE P
BLK 050 GND 1.5mm²

BLK 038 GND 1.5mm²
YEL 218 R WIPE PWR 1.5mm²
WHT 419-1-1 LH TURN

WHT 418-1-1 RH TURN
7
WHT 401 FOG LT SW 0.75mm²


WHT 415-9 SW BACKLT
0

2
+
WHT 415-2 SW BACKLT

P

RED 104-2 KEY BATT 8

1 WHT 421 2WS IND
3
YEL 229 FAN PWR 1.5mm²

YEL 111 HORN
YEL 227-1 F WIPE PWR 1.5mm²

WHT 411 DR LT
WHT 324 2WS
2
BLK 090 RF WIPER GND 1.5mm²

YEL 290 RF WIPER PWR 1.5mm²
SWITCH, IGNITION WHT 329 2WS LOCK
1
6
2
1
5
3
4
SW16C
JLG
YEL 240 PWR 1.5mm²
WHT 419-2 LH TURN

423 4WS IND
D3
WHT 418-2 RH TURN
TO SW16A WHT 405-3 RH TURN WHT 422 CRAB IND

(02E1)
WHT 604 F WIPE L 1.5mm²

D2
WHT 414 LO BEAM 0.75mm²

LOCATED UNDER DASH SWITCHES 6
YEL 210 COLUMN IGN 1.5mm²

WHT 310 STEER PWR
YEL 227-2 F WIPER 1.5mm²

5
(SHOWN IN 2WS)
[1,B]
FC518-XK WHT 406-3 LH TURN WHT 324 2WS
4
SWITCH,STEER SELECT
(03F7)
D1 9
BLK 038 GND 1.5mm²
+
1
10
LOCATED BEHIND DASH RIGHT SWITCHES
BLK 029 GND

2
BLK 032 GND 1.5mm² SW376
G 3 G
WHT 604-2 F WIPE P BLK 028-7 GND
4 7
YEL 227 F WIPER 1.5mm² WHT 415-8 SW BACKLT +
5 8
YEL 178-2 WORKLIGHTS 1.5mm² S48 S115 WHT 214 JYSTK LOCK 0.75mm²
6 1
YEL 215 KEY IGN
FC518-XL 2
(03E7) 3
YEL 178-1 WORKLIGHTS 1.5mm² WHT 329 2WS LOCK
1 4
YEL 229 FAN PWR 1.5mm² YEL 216 KEY IGN
2 5
YEL 290 RF WIPER PWR 1.5mm² WHT 310 STEER PWR
3 6
YEL 229-2 FAN PWR YEL 215 KEY IGN
4 9
WHT 955 J2L4 +

5 10
SWITCH,JOYSTICK OVERRIDE
6 SW142
7
WHT 956 AC
8 BLK 028-6 GND
YEL 179 RADIO IGN 1.5mm² [5,H]
[5,H]
10 CAB MODULE BLK 028-7 GND
7
11
OPTION 1 PDB
1001209578 WHT 415-8 SW BACKLT +
CO516-J2 CO516-J1 8
12 LOCATED BEHIND REAR YEL 216 KEY IGN
YEL SYS CANH 0.75mm² CABINE TRIM
3
S362
FC518-XM [8,D] A1 CAN1H AI TYPE 1 A1 YEL 217 KEY IGN
YEL TELE CAN2H 2
(03D7) A2 CAN2H AI TYPE 1 A2 WHT 528 LSI CANCEL 0.75mm²
BLK 090 RF WIPER GND [4,E] 1

F 4 F
GENERIC

3 B1 CAN1T AGND B1
BLK 082 GND 1.5mm² WHT TELE CAN2T WHT 414 LO BEAM 0.75mm² 6
D6
4 B2 CAN2T DI TYPE 1 B2

SWITCH,LSI OVERRIDE
5 B3 DI TYPE 3 DI TYPE 1 B3 +
BLK 084 GND 1.5mm² WHT 214 JYSTK LOCK 0.75mm² 10
6 B4 D1 TYPE 3 DI TYPE 1 B4
BLK 028-1 GND SW375
7 C1 CAN1S AI TYPE 1 C1
BLK 050 GND 1.5mm² WHT 409-3 HI BEAM 0.75mm² WHT 415-2 SW BACKLT
8 C2 CAN2S DI TYPE 1 C2
WHT 300 KEY STRT 0.75mm² BLK 028 SW GND
9 C3 DI TYPE 1 DI TYPE 1 C3 7
10 C4 D1 TYPE 1 DI TYPE 1 C4 8
BLK 028 SW GND GRN SYS CANL 0.75mm² WHT 524 LEVEL L 0.75mm²
11 [8,D] D1 CAN1L AI TYPE 1 D1 3
GRN TELE CAN2L WHT 419-2 LH TURN YEL 217 KEY IGN
12 D2 CAN2L DI TYPE 1 D2 2
WHT 314 DRIVE FWD 0.75mm² WHT 526 LEVEL R 0.75mm²
D3 D1 TYPE 1 D1 TYPE 1 D3 1
WHT 528 LSI CANCEL WHT J1-D4-1 4W STEER SWITCH 0.75mm² YEL 224 KEY PWR
[7,F] D4 D1 TYPE 1 DI TYPE 1 D4 4
LOCATED UNDER DASH SWITCHES E1 CAN1T AI TYPE 1 E1 5
WHT TELE CAN2T WHT 418-2 RH TURN
SW16 SW16B SW16A E2 CAN2T DI TYPE 1 E2 6
WHT 319 GEAR 3 0.75mm² WHT 315 DRIVE NEUT 0.75mm²
LOCATED UNDER RIGHT
CONSOLE TRIM
6 6 6 E3 DI TYPE 1 DI TYPE 1 E3 9
SWITCH,FRAME LEVEL
WHT 316 DRIVE REV 0.75mm² +

2 2 2 E4 D1 TYPE 3 DI TYPE 1 E4 10
YEL 200-1 KEY IGN YEL 200 KEY IGN 1.5mm²
1 1 1 F1 +5V AREF AI TYPE 1 F1 SW414
S519 WHT 524 LEVEL L 0.75mm² D7
5 5 5 F2 +5V AREF DI TYPE 3 F2
D4
GD86
WHT 300-1 KEY STRT WHT 300 KEY STRT 0.75mm² WHT 526 LEVEL R 0.75mm²
3 3 3 F3 DI TYPE 1 DI TYPE 3 F3 NC CAN SHLD
RED 104-1 KEY BATT RED 104-1 KEY BATT 1.5mm² WHT 318 GEAR 2 0.75mm² WHT 523 PARK BRAKE SW 0.75mm²
4 4 4 F4 DI TYPE 1 DI TYPE 1 F4 14
E WHT J1-G1-1 2W STEER SWITCH 0.75mm² E
KEY SWITCH CAT

G1 AGND DI TYPE 1 G1 13
WHT 323 SEAT SW1 D8 WHT 422 CRAB IND
G2 DI TYPE 3 DI TYPE 1 G2 12 4W CRAB STEER
WHT 317 GEAR 1 0.75mm² WHT 201 MARKER SW S651 S650 WHT 423 4WS IND
G3 DI TYPE 1 DI TYPE 1 G3 11 4W STEER
WHT 360 SEAT SW2 0.75mm² WHT 415 SW BACKLT WHT 421 2WS IND
SW415 G4 DI TYPE 1 DO TYPE 3 G4 10 2W STEER
FWD PWR YEL 212 KEY PWR WHT 003 RS232 TX 0.75mm² WHT J1-H1-1 CRAB STEER SWITCH 0.75mm² S652
1 H1 RS232 TX DI TYPE 1 H1 S540 9 STEERING PRES
NEUT F WHT 314 DRIVE FWD 0.75mm² WHT 002 RS232 RX 0.75mm²
4 H2 RS232 RX +5V AREF H2 8 PARK BRAKE
REV N WHT 315 DRIVE NEUT 0.75mm² WHT 250 IGN RLY D9 GRN SYS CANL 0.75mm²
3 H3 DI TYPE 1 DO TYPE 4 H3 7 CAN LO
DISPLAY
I R WHT 316 DRIVE REV 0.75mm² WHT 433 BUZZER OUT YEL SYS CANH 0.75mm²
5 H4 DI TYPE 1 DO TYPE 3 H4 6 CAN HI
II I WHT 317 GEAR 1 0.75mm²
LOCATED BEHIND DASH
6 J1 DI TYPE 2 5 FUEL SENSE
SWITCH,FNR
II WHT 318 GEAR 2 0.75mm² WHT 401-2 FOG LT SW 0.75mm² CO516-J3 BLK 040 DISP GND
2 J2 DI TYPE 1 4 GND
III III WHT 319 GEAR 3 0.75mm²
DI TYPE 1 CAN LO

7 J3 DI TYPE 1 A1 3

8 J4 DI TYPE 1 DI TYPE 1 A2 2 CAN HI
WHT 500-1 LSI PWR 0.75mm² YEL 203 DISP PWR
K1 ANALYZER PWR DI TYPE 1 A3 1 IGN RUN
LOCATED ON BRAKE PEDAL WHT 501 LSI GREEN1 0.5mm²
K2 ANALYZER GND DO TYPE 4 A4
SWITCH, BRAKE PEDAL WHT 502 LSI GREEN2 0.5mm²
K3 DI TYPE 1 DO TYPE 4 B1
WHT 612 AC CMD 0.75mm²
1 K4 DI TYPE 1 DI TYPE 1 B2
YEL 205 BRK LT PWR 1.5mm² YEL 200-1 KEY IGN WHT 503 LSI GREEN3 0.5mm² MS529
2 L1 DI TYPE 2 DO TYPE 4 B3 YEL SYS CANH 0.75mm²
WHT 420 BRK LT SW 1.5mm² WHT 420 BRK LT SW 1.5mm² WHT 504 LSI GREEN4 0.5mm² [4,F] 1
3 L2 DI TYPE 2 DO TYPE 4 B4 YEL SYS CANH 0.75mm²
YEL 270-1 MOD IGN 0.75mm² 2
4 L3 AGND MASTER PWR/IGN C1 YEL SYS CANH 0.75mm²
WHT 955 J2L4 3
SW76 L4 DI TYPE 3 DI TYPE 1 C2 YEL SYS CANH 0.75mm²
WHT 400 HAZ SW 10
D M1 DI TYPE 2 DI TYPE 1 C3 D
BLK 060 MOD GND 1.5mm² WHT 505 LSI YELLOW 0.5mm² 11
31211333
FC517-XC M2 MASTER GND DO TYPE 4 C4
FC517-XA (03F4) WHT 951-1 CONT AUXILIARY PWR YEL 270-2 MOD IGN 0.75mm² 12
M3 DO TYPE 3 MASTER PWR/IGN D1 GRN SYS CANL 0.75mm²
WHT 950 ASH LOAD PWR WHT 771 HEST/REGEN [4,F] 4
1 1 M4 DO TYPE 3 DI TYPE 1 D2 GRN SYS CANL 0.75mm²
5
2 2 N/C D3 GRN SYS CANL 0.75mm²
CAN BUSS
WHT 956 AC BLK 070 MOD GND 0.75mm² 6

3 3 MASTER GND D4
UNDER CAB MODULE

(03F1) YEL 260-1 MOD IGN 0.75mm² 7
4 4 MASTER PWR/IGN E1
8
5 5 DI TYPE 1 E2
YEL 229-2 FAN PWR 9
6 6 N/C E3
FC517-XD AI TYPE 1 E4
YEL 260-2 MOD IGN 0.75mm²
(03F4) MASTER PWR/IGN F1 6 PLUGGED
WHT 002 RS232 RX 0.75mm² WHT 506 LSI RED 0.5mm²
1 DO TYPE 4 F2 5 PLUGGED
WHT 003 RS232 TX 0.75mm² GRN SYS CANL 0.75mm²
2 N/C F3 4 CANL
FC517-XB YEL SYS CANH 0.75mm²
3 AI TYPE 1 F4 3 CANH
D5
JOYSTICK
YEL SYS CANH 0.75mm² YEL 260-3 MOD IGN BLK 031 JOY GND
1 4 MASTER PWR/IGN G1 2 JS GND
YEL 200-2 KEY IGN YEL 209 JOY IGN
2 5 MASTER PWR/IGN G2 1 JS PWR
3 6 MASTER PWR/IGN G3 JS404
GRN SYS CANL 0.75mm² (03A3)
X524
WHT 507-1 LSI ORANGE 0.5mm² 2
3
(03F1) 7 FC517-XF MASTER PWR/IGN H3 WHT 503 LSI GREEN3 0.5mm²
C 4 C
8 (03E4) MASTER PWR/IGN H4 WHT 504 LSI GREEN4 0.5mm²
5
S520
S539
9 1 WHT 505 LSI YELLOW 0.5mm² TO LSI

6 LOCATED ON RIGHT PILLAR
10 2 WHT 506 LSI RED 0.5mm²
7
11 3 S859 WHT 500 LSI PWR 0.75mm²
YEL 210 SEAT IGN 1
12 4 S858 WHT 507 LSI ORANGE 0.5mm²
YEL 210 COLUMN IGN 1.5mm² 8
13 5
YEL 212 KEY PWR 9
14 6 IP857
YEL 240 PWR 1.5mm² 10
7
YEL 224 KEY PWR X122
8 YEL 231 CLEARSKY IGN
YEL 206 SW IGN 2 UNIVERSAL TELEMATICS
9 RED 113 CLEARSKY PWR
(09A6), (09D3)
HiBPwr
YEL 825-1 IGN 1mm² 1
10 BLK 056 CLEARSKY GND LOCATED UNDER CAB ON RIGHT SIDE
FC517-XE YEL 209 JOY IGN 3
11
YEL 203 DISP PWR
1 12 LB776
YEL 260 MOD IGN 1.5mm² BLK 064-4 GND
2 13 S851 6
(03F4) YEL 270 MOD IGN 1.5mm² WHT 951 CONT AUXILIARY PWR
3 14 3
YEL 207 PWR SKT 1.5mm² +
4 15 10
FC517-XH 9
AL

(03D4) 8
1 7
FC517-XG 2 IP854 5
BLK 064-4 GND
CA
B 1 3 2 B
RIGHT SWITCHES
LOCATED BEHIND DASH
RED 104-1 KEY BATT 1.5mm² BLK 064-3 GND BLK 064-3 GND
2 4 4
WHT 201 MARKER SW WHT 950 ASH LOAD PWR
3 5 1
CONT AUX/ASH LOAD
+
WHT 280 DOME IGN
4 6 S78 LB77
YEL 205 BRK LT PWR 1.5mm² BLK 064 GND IP855 BLK 064-1 GND 1.5mm²
5 7 6
WHT 410 MARKER SW [6,G] S850 WHT J1H3 ODI 1.5mm²
6 8 3
YEL 218 R WIPE PWR 1.5mm² +
9 10
(03D4) WHT 250 IGN RLY
10 9
DE
11 8
YEL 176 BEACON PWR
12 7
IP856 5
FC517-XJ
YEL 231 CLEARSKY IGN

ST
(03C4) 2
RED 113 CLEARSKY PWR

BLK 030 GND BLK 064-2 GND 1.5mm²
1 4
RIGHT SWITCHES
LOCATED BEHIND DASH
BLK 825-4 GND

BLK 064 GND WHT JIH4-1 OSI 1.5mm² WHT JIH4 OSI 1.5mm²
2 IP888 BLK 825-3 GND 1 +
BLK 033 BUZZER GND
LAMP,OUTRIGGER DEPLOYED
3 S849
S884
BLK 060 MOD GND 1.5mm²
4 IP887
BLK 031 JOY GND S357 S886
5 S825
BLK 040 DISP GND BLK 825-1 GND
6
BLK 046 GND BLK 825 GND
7
YEL 211 KEY 1
WHT 523 PARK BRAKE SW
BLK 070 MOD GND 0.75mm² S356 BLK 825-2 GND

8
BLK 056 CLEARSKY GND
9
3
1
2
SW77
WHT 360 SEAT SW2

YEL 213 KEY 1
YEL 213 KEY 1
YEL 211 KEY 1

WHT 323 SEAT SW1
YEL 210 SEAT IGN
BLK 825 GND

BLK 033 BUZZER GND
WHT 433 BUZZER OUT
A 10 A
MAIN POWER BOARD

BLK 057 GND 1.5mm²
11
SN57
YEL 825-1 IGN
SN E160000342 to Present, including E160000328 thru E160000332 & E160000336
4
3
2

B 3614RS 4017RS JLG Service English

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B 3614RS 4017RS JLG Service English

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Service Manual

April 17, 2019 - Rev B

An Oshkosh Corporation Company

DATE REVISION DESCRIPTION

3614RS, 4017RS 31211333 i

ii 31211333 3614RS, 4017RS

3614RS, 4017RS 31211333 i

ii 31211333 3614RS, 4017RS

3614RS, 4017RS 31211333 iii

iv 31211333 3614RS, 4017RS

PARAGRAPH TITLE PAGE

3614RS, 4017RS 31211333 1-1

1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS

The mechanic must not operate the machine until the

1-2 31211333 3614RS, 4017RS

1.6 SAFETY INSTRUCTIONS 1.6.3 General Hazards

3614RS, 4017RS 31211333 1-3

1-4 31211333 3614RS, 4017RS

PARAGRAPH TITLE PAGE

3614RS, 4017RS 31211333 2-1

2.8 Hydraulic Connection Assembly and Torque Specification . . . . . . . . . . . . . . . . . . . . . . . 2-27

2-2 31211333 3614RS, 4017RS

2.1 REPLACEMENT PARTS AND WARRANTY

Before ordering parts or initiating service inquiries, make

3614RS, 4017RS 31211333 2-3

2.2.1 Travel Speeds

APPROXIMATE MAXIMUM SPEED

2.2.2 Hydraulic Cylinder Performance

APPROXIMATE TIMES (seconds)

2-4 31211333 3614RS, 4017RS

2.2.3 Electrical System

2.2.4 Engine Performance Specifications

a. Prior to SN E160000342, excluding E160000328 thru E160000332 & E160000336

3614RS, 4017RS 31211333 2-5

b. SN E160000342 to present, including E160000328 thru E160000332 & E160000336

2.2.5 Transmission Performance Specifications

Engine kW (Horsepower) Transmission Stall Speed

2-6 31211333 3614RS, 4017RS

3614RS, 4017RS 31211333 2-7

2.3 FLUIDS AND LUBRICANT CAPACITIES

2.3.1 Fluids (if equipped for ULS)

2-8 31211333 3614RS, 4017RS

2.3.2 Fluids (if equipped for LS)

3614RS, 4017RS 31211333 2-9

Engine Crankcase Oil

2-10 31211333 3614RS, 4017RS

2.4 SERVICE AND MAINTENANCE

2.4.1 Every 10 Hours

OC0880 OC0910 OC0920 OC0890 OC0970 OC0930

2.4.2 First 50 Hours

OC1110 OC1130 MAE19460 OC0990

2.4.3 Every 50 Hours

OC0960 OC0950 MAE19470 OC1150 OC1020 MAE8060

3614RS, 4017RS 31211333 2-11

2.4.4 First 250 Hours

OC1070 OC1060 OC1040 OC1050

Check Change Transfer Change Axle Change Wheel End

2.4.5 Every 250 Hours

OC1100 MAE19480 OC1110 OC1130 MAE19490 MAE19460

2.4.6 Every 500 Hours

OC1220 OC1140 MAE19620 OC0990 MAE19470

2-12 31211333 3614RS, 4017RS

2.4.7 Every 1000 Hour