JLG 4017 Service Manual - Manual (Page 94)

Engine: Perkins 1004-40T
7.8 4017
e. Inspection
1. Inspect the fuel tank thoroughly for any cracks,
slices, leaks or other damage.
2. With the fuel tank removed from the machine, plug
all openings except one elbow fitting. Install the
elbow fitting, and apply approximately, 07-1 kPa
(1-1.5 psi) of air pressure through the elbow. Check
the reservoir for leaks by applying a soap solution to
the exterior and look for bubbles to appear at the
cracked or damaged area.
f. Fuel Tank Installation
1. Set fuel tank between frame rails.
2. Install the fuel tank strap over the fuel tank.
3. Install the fuel sender with new gasket into the fuel
tank and secure with screws. DO NOT overtighten.
4. Connect the fuel supply hose and return line hose to
the tank. Secure with clamps.
5. Install the wire harness connections to the fuel
sender.
Note: ALWAYS replace elastic locknuts with new elastic
locknuts to help ensure proper fastening.
6. Fill the fuel tank according to specifications.Refer to
Section 2.4, “Fluids, Lubricants and Capacities.”
7. Check fuel tank for leaks.
8. Connect the negative (-) battery cable to the
negative battery terminal.
9. Close and secure the engine cover.
7.6.3 After Fuel System Service
1. Drain and flush the fuel tank if it was contaminated.
2. Vent air from the fuel system in accordance with the
instructions found in the appropriate Perkins Engine
Service Manual.
3. Fill the fuel tank with fresh, clean diesel fuel as required.
7.7 ENGINE EXHAUST SYSTEM
7.7.1 Exhaust System Removal
1. Park the machine on a firm, level surface, fully
retract the boom, lower the boom, place the
transmission control lever in NEUTRAL (N), engage
the park brake and shut off the engine.
2. Place an Accident Prevention Tag on both the
ignition key switch and the steering wheel, stating
that the machine should not be operated.
3. Open the engine hood. Allow the system fluids to
cool.
4. Remove the negative (-) battery cable from the negative
(-) battery terminal.
5. Remove the engine belly pan.
6. Loosen and remove the three nuts from the exhaust
pipe at the exhaust manifold.
Note: Replace the three nuts and the three exhaust
manifold studs if damaged.
7. Disconnect and remove the clamp attaching the
exhaust pipe to the frame under the engine.
8. Disconnect and remove the clamp connecting the
muffler and the exhaust pipe.
9. Disconnect and remove the clamp connecting the
tail pipe to the muffler and remove the tail pipe.
10. Loosen and remove the two bolts at the front and
one bolt at the rear of the muffler, and remove the
muffler.
7.7.2 Exhaust System Installation
Note: Keep all clamps loosened until entire exhaust
system is in place.
1. Install the exhaust pipe with a new seal to the
exhaust manifold.
Note: Replace the three nuts and the three exhaust
manifold studs if damaged.
2. Install the exhaust pipe clamp under the engine.
WARNING:
Exhaust fumes contain
carbon monoxide, a colorless, odorless gas
which is fatal when inhaled in a confined area.
Avoid breathing exhaust fumes, and prevent
engine operation from becoming a cause of
toxic emissions. Exhaust system components
reach high temperatures and can cause
severe burns. DO NOT come into contact with
hot exhaust system components.
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