Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- SECTION NO. TITLE PAGE NO. Cylinder Drift Test
Platform Drift
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation
Disassembly
Disassembly of Cover Unit (8)
Disassembly of First Stage Planetary Assembly
Disassembly of the Second Stage Planet Gears (1)
Assembly of First Stage Planetary Assembly (7)
Assembly Of End Cover Unit (8)
Final Assembly1 topic
- Torque Hub - 4WD (Machines built after S/N 0300076633)
Roll and Leak Testing
Tightening and Torquing Bolts
Oil Information
Main Disassembly for ”B” Drives
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Assembly of the Carrier
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Main Assembly
Tool List1 topic
- Re-Aligning Torque Hub Input Coupling
Equipment Required
Procedure1 topic
Pre-Installation Checks
Installation
Examination
Assembly1 topic
- SECTION NO. TITLE PAGE NO. Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Inspection
Initial Start-up Procedures3 topics
- Adjustment Procedure For Lockout Valve
- Toe-In Adjustment
- 2WD Hub
Removal & Disassembly
Cleaning & Inspection
Assembly & Installation3 topics
- Oscillating Axle Bleeding Procedure
- Oscillating Axle Lockout Test
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Replacement of Swing Bearing
Swing Bearing Torque Value
Swing Drive Installation1 topic
- Swing Brake (Prior to S/N 64802)
Brake Disassembly
Assembly Information2 topics
- Swing Brake S/N 64802 to Present
- Swing Drive Torque Hub
Disassembly Procedure
Hub Shaft Sub-Assembly Procedure
Carrier Sub-Assembly Procedure1 topic
Testing the Track
Removing the Track
Assuming Normal Wear
Adjustment1 topic
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings1 topic
Performing Diagnostics
Visual/Physical Engine Inspection Check
EFI Diagnostics (Prior to S/N 61718)
ECM AND SENSORS
Fuel System1 topic
- SECTION NO. TITLE PAGE NO. Throttle Checks and Adjustments - Deutz Engine (Prior to S/N 61718)
Controller Status
Failure Modes1 topic
- Tilt Alarm Switch (Prior to S/N 61718)
Manual Adjustment1 topic
Replacement of Weld Transformer
Replacement of Hydraulic Motor
Replacement of Fine Control
Rotor Replacement
Replacement of Flow Regulator
Replacement of Exciting Rectifier Bridge
Replacement of Weld Rectifier Bridge
Replace Brushes on Sky Welder
Replacing Range Switch
Replacing Selector Switch
Replacement of Couplings
Voltage Change Over - 120/240 Volt1 topic
- Troubleshooting of the Sky Welder
Low Sky Welder Speed
Low Welding Amps
No Output on Weld Receptacles or AC Receptacles
No Ac Output but Weld Output
No Output on Weld Receptacle but AC Receptacle Output OK
Welder Completely Dead - No AC or Weld Power
Intermittent Welder Operation2 topics
- Deutz EMR 2 (S/N 77682 to Present)
- GM Engine General Maintenance
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure - Dual Fuel Engine1 topic
- GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Injector Rail
Fuel Injector1 topic
- SECTION NO. TITLE PAGE NO. GM Engine Fuel System Repair
Propane Fuel System Leak Test
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement1 topic
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids1 topic
- Perkins Engine General Maintenance
Replacing the Engine Crankcase Breather
Engine Oil Level - Check
Engine Oil and Filter - Change
Fuel Filter/Water Separator
Setting the Actuator
Speed Sensor Installation2 topics
- Engine Radiator Fill Procedure - Perkins & Caterpillar
- DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
Section Layout
List of Abbreviations in this Section
Fault Code Broadcast
Diagnostic Trouble Codes
MIL Output
Diagnostic Calibration Configuration and Corrective Actions
Fault/Diagnostic Trouble Code Interaction
DBW Diagnostic Test1 topic
- Diagnostic Trouble Code Fault Descriptions
DTC 116- ECT Higher Than Expected Stage 1
DTC 117- ECT/CHT Low Voltage
DTC 118- ECT/CHT High Voltage
DTC 122- TPS1 Signal Voltage Low
DTC 123- TPS1 Signal Voltage High
DTC 217- ECT Higher Than Expected 2
DTC 219- RPM Higher Than Max Allowed Governed Speed
DTC 336- Crank Signal Input Noise
DTC 337- Loss of Crank Input Signal
DTC 521- Oil Pressure Sender/Switch High Pressure
DTC 524- Oil Pressure Low
DTC 562- Battery Voltage (VBat) Low
DTC 563- Battery Voltage (VBat) High
DTC 601- Microprocessor Failure - FLASH
DTC 604- Microprocessor Failure - RAM
SECTION NO. TITLE PAGE NO. DTC 606- Microprocessor Failure - COP
DTC 642- 5 Volt External Low Voltage
DTC 643- 5 Volt External High Voltage
DTC 1612- Microprocessor Failure - RTI 1
DTC 1613- Microprocessor Failure - RTI 2
DTC 1614- Microprocessor Failure - RTI 3
DTC 1615- Microprocessor Failure - A/D
DTC 1616- Microprocessor Failure - interrupt
DTC 1625- CAN J1939 Shutdown Request
DTC 1626- CAN J1939 Transmit (Tx) Fault
DTC 1627- CAN J1939 Receive (Rx) Fault
DTC 1628- CAN Address Conflict Failure
DTC 1629- J1939 TSC1 Message Reciept Loss
DTC 1652- TPS1 Loss of Communications
DTC 2111- Unable to Reach Lower TPS
DTC 2112- Unable to Reach Higher TPS
DTC 9999- Throttle Actuator Failsafe Spring Failure
DTC to SPN/FMI Table1 topic
Removal2 topics
- Articulating jib
- Limit Switch Adjustments
Boom Horizontal Limit Switch
Dual Capacity Angle Limit Switch
Boom Length Limit Switch1 topic
- Drive Card Setup Procedures
Machine Orientation When Doing Speed Tests
Test Notes
Lift, Swing, and Drive Cards
Flow Control Card1 topic
Theory Of Operation
Tools Required for Assembly/Disassembly
Installing Counterbalance Valve1 topic
- Cylinders - Theory of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves1 topic
Cylinders Without Counterbalance Valves
Cylinders With Dual Counterbalance Valves
Cleaning and Inspection1 topic
- Valves - Theory of Operation
Solenoid Control Valve
Relief Valves1 topic
- Pressure Setting Procedures
Bang-Bang Main Relief Valve
Steer
Platform Level Up
Platform Level Down
Articulating Jib Up
Articulating Jib Down
The Bang-Bang Main Relief Valve
The Proportional Main Relief Valve
Lift Down
Swing1 topic
- Hydraulic Motor Repair (H Series Char-lynn)
Reassembly Shaft End
Gerotor End
Timing Procedure
Standard Rotation
Reverse Rotation2 topics
- Hydraulic Pump “Neutral” Or Null Adjustment
- Non-feedback, Proportional Electrical Control - NFPE
Features and Benefits of the NFPE Control
Input Signal requirements10 topics
- Hydraulic Component Start-Up Procedures and Recommendations
- Introduction
- To Connect the JLG Control System Analyzer
- Using the Analyzer
- Changing the Access Level of the Hand Held Analyzer
- Adjusting Parameters Using the Hand Held Analyzer
- Machine Setup
- Level Vehicle Description
- Machine Personality Settings
- System Test
Test from the Platform
Test from the Ground Station3 topics
- Analyzer Diagnostics Menu Structure
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
Applying Silicone Dielectric Compound to AMP Connectors
Wedge Lock
Service - Voltage Reading1 topic
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Serial Number Location
Operator Maintenance and Lubrication Diagram
Deutz Engine Dipstick
Filter Lock Assembly
Torque Chart (SAE Fasteners - Sheet 1 of 7)
Torque Chart (SAE Fasteners - Sheet 2 of 7)
Torque Chart (SAE Fasteners - Sheet 3 of 7)
Torque Chart (SAE Fasteners - Sheet 4 of 7)
Torque Chart (METRIC Fasteners - Sheet 5 of 7)
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Ford
Engine Operating Temperature Specifications - Caterpillar
Engine Operating Temperature Specifications - GM
Engine Operating Temperature Specifications - Perkins
Drive Hub (Part No. 2780246-4WD Steer)
Cluster Gear Punch Marks
Drive Brake
Swing Brake Assembly
Drive Motor Cross Section
Removing the Shaft Seal
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Front Axle
2WD Hub
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Torque Sequence
Drive Motor Adjustment
Swing Motor
Swing Brake Prior to S/N 64802
Swing Brake S/N 64802 to Present
Swing Torque Hub
Auxiliary Pump - Sheet 1 of 2
Auxiliary Pump - Sheet 2 of 2
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Malfunction Indicator Light and Test Button
EFI Component Location
Typical Fuel System
Addco Adjustments - Deutz
Addco Throttle Actuator
Tilt Switch Adjustment
Valve Location - Chassis
Hyd Tank Installation
Hydraulic Welder 225-4 (sht 1 of 2)
Hydraulic Welder 225-4 (sht 2 of 2)
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
Engine Oil Dip Stick
Electric Fuel Lock Off
Low Pressure Regulators
ETC throttle control device
LPG Engine Control Unit (ECM)
ECM Assembly
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Fuel Pressure and Temperature Manifold Assembly
Pressure Regulator Section
(TMAP) Sensor & Electronic Throttle Control (ETC)
Mixer Assembly
GM 3.0L Engine - Sheet 1 of 2
GM 3.0L Engine - Sheet 2 of 2
Crankcase Breather - Perkins
Perkins Engine
Faults Page with Active Fault Message
Faults Page with Historic Fault Message
Custom Fault Variable Interface
Historic Fault Information Interface
Snapshot Data Interface
Flight Data Recorder Interface
Clear Faults Prompt
Exhaust Venturi Adjustment
Support - Side Entry Platform
Support - Rear Entry Platform
Location of Components - Boom Removal
Articulating Jib
Limit Switches - 750 LB (340 kg) Capacity
Limit Switches - CE Machines
Limit Switches - 460SJ
Control Card
Rotary Actuator (Exploded View)
Cutaway View
Rotator Counterbalance Valve
Boom Prop Configuration
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Axle Lockout Cylinder
Platform Level Cylinder
Jib Lift Cylinder (460SJ)
Lift Cylinder
Master Cylinder
Steer Cylinder
Telescope Cylinder
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Tapered Bushing Installation
Seating the Tapered Bearing
Poly-Pak Piston Seal Installation
Rod Assembly Installation
Main Valve
Main Valve Cartridge Torque Values
Char-Lynn H Series Hydraulic Motor
Variable Displacement Hydraulic Pump
Hand Held Analyzer
ADE Block Diagram
Analyzer Connecting Points
Control Module Location
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4
System Test Flow Chart - Platform Tests
System Test Flow Chart - Ground Station Tests
Voltage Measurement (DC)
Current Measurement (DC)
Application to Female Contacts
Use of Seal Plugs
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Components Installation w/o JLG Control System - Sheet 1 of 2
Electrical Components Installation w/o JLG Control System - Sheet 2 of 2
Electrical Components Installation with JLG Control System - Sheet 1 of 2
Electrical Components Installation with JLG Control System - Sheet 2 of 2
On Board Generator Electrical Schematic. (if equipped)
Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 1 of 4
Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 2 of 4
Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 3 of 4
Electrical Schematic - Ford Engine w/o JLG Control System - Sheet 4 of 4
Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 1 of 4
Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 2 of 4
Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 3 of 4
Electrical Schematic - Deutz Engine w/o JLG Control System - Sheet 4 of 4
Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 1 of 4
Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 2 of 4
Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 3 of 4
Electrical Schematic - Isuzu Engine w/o JLG Control System - Sheet 4 of 4
Electrical Schematic - Caterpillar Engine - Sheet 1 of 6
Electrical Schematic - Caterpillar Engine - Sheet 2 of 6
Electrical Schematic - Caterpillar Engine - Sheet 3 of 6
Electrical Schematic - Caterpillar Engine - Sheet 4 of 6
Electrical Schematic - Caterpillar Engine - Sheet 5 of 6
Electrical Schematic - Caterpillar Engine - Sheet 6 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 1 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 2 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 3 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 4 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 5 of 6
Electrical Schematic - Deutz EMR2 & GM Engine - Sheet 6 of 6
Electrical Schematic - Hydraulic Welder
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 1 of 6
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 2 of 6
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 3 of 6
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 4 of 6
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 5 of 6
Electrical Schematic - Deutz, GM, & CAT Engine - Sheet 6 of 6
Hydraulic Schematic - (Sheet 1 of 6)
Hydraulic Schematic - (Sheet 2 of 6)
Hydraulic Schematic - (Sheet 3 of 6)
Hydraulic Schematic - (Sheet 4 of 6)
Hydraulic Schematic - (Sheet 5 of 6)
Hydraulic Schematic - (Sheet 6 of 6)
Capacities
Ford LRG-425 (Gas or Dual Fuel)
Isuzu 4LE1
Caterpillar 3024/C2.2
Tires
Specifications and Performance Data - 400S
Specifications and Performance Data - 460SJ
Torque Requirements
Critical Stability Weights
Major Component Weights
Function Speeds (In Seconds)
Relief Settings
Cylinder Specifications
Mobilfluid 424 Specs
Mobil EAL H 46 Specs
Exxon Univis HVI 26 Specs
Welder Specifications - Model 225-4
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Adjustment Chart
ECM Diagnostic Trouble Codes
Position Controller Truth Table
LPF Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
J1939 Diagnostic Lamp Configuration
Diagnostic Corrective Actions
Historic Fault Information Interface Functions
Function Speeds
Flow Control Card Settings
Flow Control Card Ramp Time
Cylinder Head and Tapered Bushing Torque Specifications
Holding Valve Torque Specification
Pump Flow Direction with NFPE Control
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66995
Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present
Machine Configuration Programming Information Prior to Software Version P5.3
Machine Configuration Programming Information Software Version P5.3 to P6.1
Machine Configuration Programming Information Software Version P6.1 to Present
System Test Messages
Machine Configuration Parameters
Analyzer Fault Code Listing
ADJUSTMENTS - Personality Descriptions
Diagnostic Menu Descriptions