Document Outline

• 31200568_B_L2906H 2906H 3507H 29.6LP 29.6 35.7 619A 723A_JLG_Service
  • Effectivity
  • Table of Contents
  • Section 1 Safety Practices
    • 1.1 Introduction
    • 1.2 Disclaimer
    • 1.3 Operation & Safety Manual
    • 1.4 Do Not Operate Tags
    • 1.5 Safety Information
      • 1.5.1 Safety Alert System and Signal Words
    • 1.6 Safety Instructions
      • 1.6.1 Personal Hazards
      • 1.6.2 Equipment Hazards
      • 1.6.3 General Hazards
      • 1.6.4 Operational Hazards
    • 1.7 Safety Decals
  • Section 2 General Information and Specifications
    • 2.1 Replacement Parts and Warranty Information
    • 2.2 Torques
      • 2.2.1 SAE Fastener Torque Chart
      • 2.2.2 Metric Fastener Torque Chart
      • 2.2.3 Hydraulic Hose Torque Chart
    • 2.3 Specifications
      • 2.3.1 Travel Speed
      • 2.3.2 Hydraulic Cylinder Performance Specifications
      • 2.3.3 Electrical System
      • 2.3.4 Engine Performance Specifications
      • 2.3.5 Tires
    • 2.4 Fluids, Lubricants and Capacities
    • 2.5 Maintenance Schedules
      • 2.5.1 10,1st 50 & 50 Hour Maintenance Schedule
      • 2.5.2 1st 150, 250 & 500 Hour Maintenance Schedule
      • 2.5.3 1500 Hour Maintenance Schedule
    • 2.6 Lubrication Schedule
      • 2.6.1 10 Hour Lubrication Schedule
      • 2.6.2 50 Hour Lubrication Schedule
  • Section 3 Boom
    • 3.1 Boom System Component Terminology
    • 3.2 Safety Information
    • 3.3 Boom System - Two Section Boom
      • 3.3.1 Boom System Description
    • 3.4 Boom Assembly Maintenance
      • 3.4.1 Boom Removal
      • 3.4.2 Second Section Boom Removal
      • 3.4.3 Second Section Boom Installation
      • 3.4.4 Boom Installation
      • 3.4.5 Extend/Retract Cylinder Removal
      • 3.4.6 Extend/Retract Cylinder Installation
    • 3.5 Boom Wear Pads
      • 3.5.1 Wear Pad Inspection
      • 3.5.2 Wear Pad Installation and Lubrication
    • 3.6 Quick Attach Assembly
      • 3.6.1 Quick Attach Removal
      • 3.6.2 Quick Attach Installation
    • 3.7 Forks
    • 3.8 Boom Prop (If Equipped)
      • 3.8.1 Installation and Removal Procedures
    • 3.9 Emergency Boom Lowering Procedure
      • 3.9.1 Equipment and Supplies Required
      • 3.9.2 Lowering Procedure
    • 3.10 Troubleshooting
  • Section 4 Cab and Covers
    • 4.1 Operator Cab and Covers Component Terminology
    • 4.2 Safety Information
    • 4.3 Operator Cab
      • 4.3.1 Operator Cab Description
      • 4.3.2 Serial Number Decal
    • 4.4 Cab Components
      • 4.4.1 Steering Wheel
      • 4.4.2 Steering Column/Valve Replacement
      • 4.4.3 Brake Pedal and Valve
      • 4.4.4 Throttle Pedal Replacement
      • 4.4.5 Throttle Cable Adjustment
      • 4.4.6 High Idle Adjustment
      • 4.4.7 Joystick Replacement
      • 4.4.8 Windshield Wiper Assembly (If Equipped)
      • 4.4.9 Windshield Washer Assembly (If Equipped)
      • 4.4.10 Heater/Air Conditioning System (If Equipped)
      • 4.4.11 Air Conditioning (If Equipped)
    • 4.5 Cab Removal
    • 4.6 Cab Installation
  • Section 5 Axles, Drive Shafts, Wheels and Tires
    • 5.1 Axle, Drive Shaft and Wheel Component Terminology
    • 5.2 Safety Information
    • 5.3 General Information
    • 5.4 Axle Assemblies
      • 5.4.1 Axle Serial Number Plate
      • 5.4.2 Axle Specifications
      • 5.4.3 Axle Maintenance
      • 5.4.4 Axle Removal
      • 5.4.5 Axle Installation
      • 5.4.6 Axle Assembly and Drive Shaft Troubleshooting
    • 5.5 Drive Shafts
      • 5.5.1 Drive Shaft Inspection
      • 5.5.2 Drive Shaft Maintenance
      • 5.5.3 Drive Shaft Removal
      • 5.5.4 Drive Shaft Cleaning and Drying
      • 5.5.5 Drive Shaft Installation
    • 5.6 Wheels and Tires
      • 5.6.1 Removing Wheel and Tire Assembly from Machine
      • 5.6.2 Installing Wheel and Tire Assembly onto Machine
    • 5.7 Steering Angle Adjustment
    • 5.8 Brakes
      • 5.8.1 Brake Disc Inspection
  • Section 6 Transmission
    • 6.1 Transmission Assembly Component Terminology
    • 6.2 Safety Information
    • 6.3 Transmission Description
    • 6.4 Transmission Specifications
      • 6.4.1 Transmission Maintenance
    • 6.5 Transmission Replacement
      • 6.5.1 Transmission Removal
      • 6.5.2 Transmission Installation
      • 6.5.3 After Transmission Replacement
    • 6.6 Transmission Filter Replacement
      • 6.6.1 Filter Removal
      • 6.6.2 Filter Installation
    • 6.7 Towing a Disabled Machine
  • Section 7 Engine: Deutz TCD 2012
    • 7.1 Introduction
      • 7.1.1 Disclaimer and Scope
      • 7.1.2 Component Terminology
    • 7.2 Safety Information
    • 7.3 Engine Serial Number
    • 7.4 Specifications and Maintenance Information
    • 7.5 Engine Cooling System
      • 7.5.1 Radiator Pressure Cap
      • 7.5.2 Radiator/Oil and Charge Air Cooler Replacement
    • 7.6 Engine Electrical System
    • 7.7 Fuel System
      • 7.7.1 Diesel Fuel
      • 7.7.2 Fuel/Hydraulic Oil Tank
      • 7.7.3 After Fuel System Service
    • 7.8 Engine Exhaust System
      • 7.8.1 Exhaust System Removal
      • 7.8.2 Exhaust System Installation
    • 7.9 Air Cleaner Assembly
      • 7.9.1 Air Cleaner Assembly Removal
      • 7.9.2 Air Cleaner Assembly Installation
    • 7.10 Engine Replacement
      • 7.10.1 Engine Removal
      • 7.10.2 Engine Disassembly, Inspection and Service
      • 7.10.3 Engine Installation
    • 7.11 Engine Coupler
      • 7.11.1 Coupler Removal
      • 7.11.2 Coupler Installation
    • 7.12 Troubleshooting
  • Section 8 Hydraulic System
    • 8.1 Hydraulic Component Terminology
    • 8.2 Safety Information
    • 8.3 General Information
    • 8.4 Specifications
    • 8.5 Hoses, Tube Lines, Fittings, Etc.
      • 8.5.1 Replacement Considerations
      • 8.5.2 Hose, Tube, Line and Fitting Replacement
    • 8.6 Hydraulic Pressure Diagnosis
      • 8.6.1 Pressure Checks and Adjustments
      • 8.6.2 Main Control Valve Pressure Checking
      • 8.6.3 Charge Pressure Checking
      • 8.6.4 Drive Pressure Checking
      • 8.6.5 Boom Function Pressure Checking
      • 8.6.6 Steering Pressure Checking
      • 8.6.7 Brake Pressure Checking
    • 8.7 Hydraulic Schematic
      • 8.7.1 Gear Pump Schematic
      • 8.7.2 Piston Pump Schematic
    • 8.8 Hydraulic Reservoir
      • 8.8.1 Pressurized Hydraulic Oil Fill Cap
      • 8.8.2 Hydraulic Oil Reservoir Draining
      • 8.8.3 Hydraulic Oil Reservoir Filling
    • 8.9 Implement Pump (Piston or Gear)
      • 8.9.1 Implement Pump Replacement
    • 8.10 Front Drive Motor
    • 8.11 Control Valves
      • 8.11.1 Main Control Valve
      • 8.11.2 Service Brake Valve
      • 8.11.3 Parking Brake
      • 8.11.4 Brake Test
      • 8.11.5 Steering Orbitrol Valve
      • 8.11.6 Steer Select Valve
      • 8.11.7 Inching Valve
      • 8.11.8 Anti-Kick Valve
    • 8.12 Hydraulic Cylinders
      • 8.12.1 General Cylinder Removal Instructions
      • 8.12.2 General Cylinder Disassembly
      • 8.12.3 Cylinder Cleaning Instructions
      • 8.12.4 Cylinder Inspection
      • 8.12.5 General Cylinder Assembly
      • 8.12.6 General Cylinder Installation
      • 8.12.7 Steering Cylinders
      • 8.12.8 Hydraulic Cylinder Torque Specifications
  • Section 9 Electrical System
    • 9.1 Electrical Component Terminology
    • 9.2 Specifications
    • 9.3 Safety Information
    • 9.4 Keypad and Display Screen
      • 9.4.1 Keypad
      • 9.4.2 Display Screen
    • 9.5 Software Level 2 Accessibility
      • 9.5.1 Operator Tools
      • 9.5.2 Personalities
      • 9.5.3 Calibrations
    • 9.6 Operator Tools
      • 9.6.1 Resetting the Anti theft Code
      • 9.6.2 Hardware Exchange
      • 9.6.3 Confirm Machine Service
      • 9.6.4 Review Service History
      • 9.6.5 Set Service Interval
    • 9.7 Instrument Panel
    • 9.8 Fuses and Relays
      • 9.8.1 Engine Compartment Relays and Fuses
      • 9.8.2 Power Distribution Module
    • 9.9 Electrical System Schematics
      • 9.9.1 Cab Harness Electrical Schematic 1 of 2
      • 9.9.2 Cab Harness Electrical Schematic 2 of 2
      • 9.9.3 Cab Roof and Boom Schematic
      • 9.9.4 Front and Rear Frame Schematic
      • 9.9.5 Engine Compartment Schematic
      • 9.9.6 Power Ground, ANSI Shifter and Oil Gauge Schematic
    • 9.10 Circuit Breakdowns
      • 9.10.1 Alternator Charge Circuit
      • 9.10.2 Starter Circuit
      • 9.10.3 Constant Power Circuit
    • 9.11 Engine electrical Components
      • 9.11.1 Starter
      • 9.11.2 Alternator
    • 9.12 Window Wiper/Washer
      • 9.12.1 Windshield Wiper Motor (if equipped)
      • 9.12.2 Rear Window Wiper Motor (if equipped)
      • 9.12.3 Windshield Washer Reservoir and Pump
    • 9.13 Cab Heater and Fan
      • 9.13.1 Cab Heater/Air Conditioning Controls
    • 9.14 Solenoids, Sensors and Senders
      • 9.14.1 Ignition Key Switch
      • 9.14.2 Dash Switches
      • 9.14.3 Fuel Level Indicator and Fuel Level Sender
      • 9.14.4 Hourmeter
      • 9.14.5 Coolant Temperature Sender
      • 9.14.6 Fuel Shut-off Solenoid
      • 9.14.7 Oil Pressure Sender
      • 9.14.8 Oil Temperature Sensor
      • 9.14.9 Back-up Alarm
      • 9.14.10 Boom Angle Sensor
    • 9.15 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (Before S/N 1160005993 excluding 1160005943, 1160005945 & 1160005414)
      • 9.15.1 Load Stability Indicator
      • 9.15.2 LSI Sensor
      • 9.15.3 LSI System Calibration
    • 9.16 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (S/N 1160005993 & After including 1160005943, 1160005945 & 1160005414)
      • 9.16.1 Load Stability Indicator
      • 9.16.2 LSI Sensor
      • 9.16.3 LSI System Calibration
      • 9.16.4 LSI-CAN Check PT
      • 9.16.5 500 Hour - LSI CAN SYSTEM CHECK
    • 9.17 Hand Held Analyzer
      • 9.17.1 Analyzer Usage
      • 9.17.2 Analyzer Software - Version 3.5
    • 9.18 Fault Codes
      • 9.18.1 Indicator Cross Reference Table
      • 9.18.2 Fault Code Table