JLG 520AJ Boom Lift Service Manual
682 pages · Publication 31217155
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- Models
- 520AJ
- Manual type
- Service Manual
- Pages
- 682
- Publication
- 31217155
- Condition
- Brand new
What's inside
From the manual's own table of contents: 626 sections, 700 entries. See sample pages (PDF, 566 KB)
General
Hydraulic System Safety
Maintenance9 topics
- Operating Specifications
- Dimensional Data
- Capacities
- Tires
- Engine Data
- Hydraulic Oil
- Maintenance and Lubrication
- ThreadLocking Compound
- Torque Charts
SAE Fastener Torque Chart
SAE Fastener Torque Chart (Continued)
Metric Fastener Torque Chart
Metric Fastener Torque Chart (Continued)1 topic
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventive Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Show all 626 sections
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift
Theory
Cylinder Leakage Test
Cylinder Thermal 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
- Tires and Wheels
Tire Damage
Wheel and Tire Replacement
Wheel Installation8 topics
- Oscillating Axle System
- Lockout Cylinder Bleeding
- Oscillating Axle Lockout Test
- Cold Start System (Diesel)
- Drive Orientation System
- Chassis Tilt Indicator System
- Drive System
- Wheel Drive Assembly
Removal
Installation1 topic
- Torque Hub
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly for “B” Drives
Hub-Spindle Disassembly
Cover Disassembly
Carrier Disassembly
Assemble Carrier
Cover Sub-Assembly
Hub-Spindle Sub-Assembly
Main Assembly
Tool List1 topic
- Re-Align Torque Hub Input Coupling
Equipment Required
Procedure1 topic
- Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-Up Procedures2 topics
- Drive Brake
- Swing Bearing
Turntable Bearing Mounting Bolt Checks
Check Frame To Bearing Bolts
Check Turntable To Bearing Bolts
Wear Tolerance1 topic
- Swing Motor
Preparation Before Disassembly
Disassembly and Inspection
One Piece Stator Assembly
Two Piece Stator Assembly
Final Checks1 topic
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Brushes and Slip Rings
Generator Disassembly and Assembly
Lead Connection List for Generator
Generator Pulley1 topic
- Deutz Engine D2011L03
Checking Oil Level
Changing Engine Oil
Changing Oil Filter
Deutz EMR 21 topic
- Deutz Engine D2.9L4 (STAGE V)
General Maintenance
Check Oil Level
Replacing Engine Oil
Replacing the Oil Filter
Replacing the Fuel Filters
Deutz EMR51 topic
- HRC Engine Emission Characteristics
Terminology for Removing Soot1 topic
- Diesel Particulate Filter (If Equipped)
Standstill Cleaning
Maintenance Standstill Cleaning Initiation Methods
Canceling Maintenance Standstill
Unsuccessful Cleaning Event
DPF Filter Replacement due to Ash Load
Ash Load1 topic
- Bio Fuel in Deutz Engines
Bio Fuel
Biological Contamination In Fuels1 topic
- DGC Diagnostic Support and Trouble Code Definitions
Section Layout
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
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 Receipt 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 Table2 topics
- Counterweight
- Boom Systems
Platform Control Enable System
Transport Position Sensing System
Platform Load Sensing System (LSS)
Beyond Transport Position - Drive Speed Cutback System
Drive/Steer – Boom Function Interlock System
Jib Lift End of Stroke Dampening (if equipped)
Main Boom Lift End of Stroke Dampening
Emergency Decent System1 topic
- Platform
Platform/Support Removal
Platform/Support Installation4 topics
- Rotator
- Platform Level Cylinder
- Main Boom Powertrack
- Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets3 topics
- Boom Cleanliness Guidelines
- Boom Shimming Procedure
- Boom Assembly
Upper Boom Removal
Mid Boom Removal
Lower Boom Removal
Upper Boom Disassembly
Upper Boom Assembly
Lower Boom Installation
Mid Boom Installation
Upper Boom Installation1 topic
- Rotary Actuator
Theory of Operation
Required Tools
Before Disassembly
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Installation and Bleeding2 topics
- Foot Switch Adjustment
- Skyguard
Operation
Function Test
Diagnostics & Troubleshooting1 topic
- Lubricating O-rings In The Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Hydraulic Connection Assembly And Torque Specification
Tapered Thread Types
Straight Thread Types, Tube and Hose Connections
Straight Thread Types, Port Connections
Flange Connection Types
Tightening Methods
Assembly And Torque Specifications
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
Assembly Instructions for 37° (JIC) Flare Fittings
Assembly Instructions for 45° SAE Flare Fittings
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
Assembly Instructions for Bulkhead (BH) Fittings
Assembly Instructions for O-Ring Boss (ORB) Fittings
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
Assembly instructions for Adjustable Port End (BSPP) Fittings
Assembly Instructions for Flange Connections: (FL61 and FL62)
Double Wrench Method
FFWR and TFFT Methods
Adjustable Stud End Assembly
O-ring Installation (Replacement)1 topic
- Hydraulic Cylinders
Axle Lockout Cylinder
Platform Level Cylinder
Jib Lift Cylinder
Main Lift Cylinder
Tower Boom Lift Cylinder
Master Cylinder
Steer Cylinder
Telescope Cylinder1 topic
- Pressure Setting Procedure
Main System Relief
Steer Left Relief
Steer Right Relief
Boom Swing Relief
Jib Lift Down Relief
Platform Level Up Relief
Platform Level Down Relief3 topics
- Drive Pump Pre-Fill Procedure
- Hydraulic Schematics
- JLG Control System Analyzer Kit Instructions
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
Tilt Sensor Calibration
Ground Control Keyswitch System
Diagnostics/Controller Programming
Ground Control Console Display Gauge1 topic
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation4 topics
- Resetting the MSSO System
- Function Speed Control System
- Fuel Reserve / Cut-out System
- Machine Model Adjustment
Adjustment Notes
Machine Orientation When Performing Test2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- Dielectric Grease Application
AMP Mate-N-Lok
AMP Faston
AMP Micro-Fit
AMP Mini Fit Jr
Mini Fit Sr
DIN Connectors
Exceptions1 topic
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Telematics Gateway
Telematics - Ready (TCU) Plug1 topic
- Wiring Harness Connector Labels
Connector Labels
Component Labels3 topics
- Electrical Installation
- Wiring Harness
- Electrical Schematics
Maintenance and Lubrication Diagram
Deutz D2011L03 Engine Operating Temperature Specifications
Deutz D2011L03 Hydraulic Fluid Operating Specifications
Engine Operating Temperature Specifications - Deutz 2.9
Axle Installation
Steer Installation (Without Tow Package)
Steer Installation (With Tow Package)
Wheel Drive Installation
Bolt Tightening Sequence
Drive Hub and Brake Assembly (Rear) - Sheet 1 of 2
Drive Hub and Brake Assembly (Rear) - Sheet 2 of 2
Drive Hub (Front) -Sheet 1 of 2
Drive Hub (Front) -Sheet 2 of 2
Drive Hub (Cross-Section)
Cluster Gear Punch Marks
Drive Motor Cross Section
Removing 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
Drive Brake
Swing System
Swing Bearing Drive
Swing Bearing Lubrication Points
Swing Bearing Torque Sequence
Swing Bearing Alignment
Swing Bearing Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Tolerance Boom Placement - Sheet 1 of 2
Swing Bearing Tolerance Boom Placement - Sheet 2 of 2
Swing Bearing Removal
Swing Motor - Cutaway
Swing Motor Removal and Installation
Swing Motor Assembly
Generator Circuit Breaker Location (If Equipped with 2500W and 4000W)
Generator Circuit Breaker Location (If Equipped with 7500W)
Generator Brushes and Slip Rings
Generator Troubleshooting Circuit Diagram - Sheet 1 of 2
Generator Troubleshooting Circuit Diagram - Sheet 2 of 2
Generator Electrical Circuit Diagram
Power Board PC1 Electrical Circuit Diagram
Power Board PC2 Electrical Circuit Diagram - Sheet 1 of 2
Power Board PC2 Electrical Circuit Diagram - Sheet 2 of 2
Generator Pulley (7500W) - Deutz 2011L03
Generator Pulley (4000W) - Deutz 2011L03
Generator Pulley (2500W) - Deutz 2011L03
Generator Pulley (7500W/4000W) - Deutz Stage V
Deutz Engine D2011L03 - Sheet 1 of 3
Deutz Engine D2011L03 - Sheet 2 of 3
Deutz Engine D2011L03 - Sheet 3 of 3
Deutz Dipstick Markings
Engine Oil Viscosity
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
Deutz Engine D2.9L4 (Stage V) - Sheet 1 of 2
Deutz Engine D2.9L4 (Stage V) - Sheet 2 of 2
Location of the Oil Filter
Location of the Fuel Filter
Location of the Fuel Pre-Filter
EMR5 Engine Side Equipment
Deutz EMR5 Troubleshooting Flow Chart
Deutz EMR5 Power Harness
Deutz EMR5 Exhaust After Treatment Harness
Deutz EMR5 Equipment Harness - Sheet 1 of 5
Deutz EMR5 Equipment Harness - Sheet 2 of 5
Deutz EMR5 Equipment Harness - Sheet 3 of 5
Deutz EMR5 Equipment Harness - Sheet 4 of 5
Deutz EMR5 Equipment Harness - Sheet 5 of 5
EMR5 Engine Plug Pin Identification
EMR5 Vehicle Plug Pin Identification
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
Counterweight
Location of Components Platform Support
Platform Support Torque Values (with 1 Cell LSS)
Rotator Removal/Installation
Platform Level Cylinder Removal and Installation
Location of Components - Powertrack
Boom Assembly
Main Boom Assembly - Sheet 1 of 2
Main Boom Assembly - Sheet 2 of 2
Tower Boom Assembly
Jib Assembly
Fly Boom Wear Pads
Base Boom Wear Pads
Cables and Clamps Installation - Sheet 1 of 8
Cables and Clamps Installation - Sheet 2 of 8
Cables and Clamps Installation - Sheet 3 of 8
Cables and Clamps Installation - Sheet 4 of 8
Cables and Clamps Installation - Sheet 5 of 8
Cables and Clamps Installation - Sheet 6 of 8
Cables and Clamps Installation - Sheet 7 of 8
Cables and Clamps Installation - Sheet 8 of 8
Rotary Actuator - Exploded View
Rotary Actuator - Cutaway View
Rotator Counterbalance Valve
NPTF thread
BSPT thread
JIC Thread
SAE Thread
ORFS Thread
MTBL-MBTS Thread
Bulkhead Thread
MFF-BSPP Thread
ORB-MPP Thread
Torque Wrench Angle
FFWR Method
Cylinder Barrel Support
Cylinder Head Removal
Cylinder Rod Support
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Installation of Piston Seal Kit
Hydraulics Installation - Sheet 1 of 28
Hydraulics Installation - Sheet 2 of 28
Hydraulics Installation - Sheet 3 of 28
Hydraulics Installation - Sheet 4 of 28
Hydraulics Installation - Sheet 5 of 28
Hydraulics Installation - Sheet 6 of 28
Hydraulics Installation - Sheet 7 of 28
Hydraulics Installation - Sheet 8 of 28
Hydraulics Installation - Sheet 9 of 28
Hydraulics Installation - Sheet 10 of 28
Hydraulics Installation - Sheet 11 of 28
Hydraulics Installation - Sheet 12 of 28
Hydraulics Installation - Sheet 13 of 28
Hydraulics Installation - Sheet 14 of 28
Hydraulics Installation - Sheet 15 of 28
Hydraulics Installation - Sheet 16 of 28
Hydraulics Installation - Sheet 17 of 28
Hydraulics Installation - Sheet 18 of 28
Hydraulics Installation - Sheet 19 of 28
Hydraulics Installation - Sheet 20 of 28
Hydraulics Installation - Sheet 21 of 28
Hydraulics Installation - Sheet 22 of 28
Hydraulics Installation - Sheet 23 of 28
Hydraulics Installation - Sheet 24 of 28
Hydraulics Installation - Sheet 25 of 28
Hydraulics Installation - Sheet 26 of 28
Hydraulics Installation - Sheet 27 of 28
Hydraulics Installation - Sheet 28 of 28
Main Control Valve Identification
Main Control Valve Torque Values
Upright Valve Identification
Upright Valve Torque Values
Fly Boom Valve Identification
Fly Boom Valve Torque Values
Hydraulic Schematics - Sheet 1 of 4
Hydraulic Schematics - Sheet 2 of 4
Hydraulic Schematics - Sheet 3 of 4
Hydraulic Schematics - Sheet 4 of 4
Hand Held Analyzer
Tilt Sensor Location
Splash Screen
Diagnostic Screen
Engine Diagnostic Screen
Analyzer Connecting Points
Ground Control Module
Platform Control Module
Analyzer Flow Chart (Software Version P2.17) - Sheet 1 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 2 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 3 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 4 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 5 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 6 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 7 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 8 of 9
Analyzer Flow Chart (Software Version P2.17) - Sheet 9 of 9
Voltage Measurement (DC)
Current Measurement (DC)
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
Telematics Gateway Harness - Sheet 1 of 3
Telematics Gateway Harness - Sheet 2 of 3
Telematics Gateway Harness - Sheet 3 of 3
Electrical Installation - Sheet 1 of 10
Electrical Installation - Sheet 2 of 10
Electrical Installation - Sheet 3 of 10
Electrical Installation - Sheet 4 of 10
Electrical Installation - Sheet 5 of 10
Electrical Installation - Sheet 6 of 10
Electrical Installation - Sheet 7 of 10
Electrical Installation - Sheet 8 of 10
Electrical Installation - Sheet 9 of 10
Electrical Installation - Sheet 10 of 10
Platform Control Box Harness - Sheet 1 of 4
Platform Control Box Harness - Sheet 2 of 4
Platform Control Box Harness - Sheet 3 of 4
Platform Control Box Harness - Sheet 4 of 4
Platform Valve Harness - Sheet 1 of 2
Platform Valve Harness - Sheet 2 of 2
Low Temp Cutout Option Harness
LSS Harness
Tower Boom Harness - Standard
Tower Boom Harness - Arctic
Main Boom Harness - Standard
Main Boom Harness - Arctic
Turntable Harness - Sheet 1 of 13
Turntable Harness - Sheet 2 of 13
Turntable Harness - Sheet 3 of 13
Turntable Harness - Sheet 4 of 13
Turntable Harness - Sheet 5 of 13
Turntable Harness - Sheet 6 of 13
Turntable Harness - Sheet 7 of 13
Turntable Harness - Sheet 8 of 13
Turntable Harness - Sheet 9 of 13
Turntable Harness - Sheet 10 of 13
Turntable Harness - Sheet 11 of 13
Turntable Harness - Sheet 12 of 13
Turntable Harness - Sheet 13 of 13
Chassis Solenoid Harness - Sheet 1 of 3
Chassis Solenoid Harness - Sheet 2 of 3
Chassis Solenoid Harness - Sheet 3 of 3
Main Valve Harness - Sheet 1 of 7
Main Valve Harness - Sheet 2 of 7
Main Valve Harness - Sheet 3 of 7
Main Valve Harness - Sheet 4 of 7
Main Valve Harness - Sheet 5 of 7
Main Valve Harness - Sheet 6 of 7
Main Valve Harness - Sheet 7 of 7
Tower Upright Valve Harness - Sheet 1 of 4
Tower Upright Valve Harness - Sheet 2 of 4
Tower Upright Valve Harness - Sheet 3 of 4
Tower Upright Valve Harness - Sheet 4 of 4
Ground Control Panel Harness - Sheet 1 of 6
Ground Control Panel Harness - Sheet 2 of 6
Ground Control Panel Harness - Sheet 3 of 6
Ground Control Panel Harness - Sheet 4 of 6
Ground Control Panel Harness - Sheet 5 of 6
Ground Control Panel Harness - Sheet 6 of 6
Cribbing Option Harness - Sheet 1 of 2
Cribbing Option Harness - Sheet 2 of 2
Deutz D2.3L3 Harness - Sheet 1 of 2
Deutz D2.3L3 Harness - Sheet 2 of 2
Chassis Head and Tail Lights Harness - Sheet 1 of 5
Chassis Head and Tail Lights Harness - Sheet 2 of 5
Chassis Head and Tail Lights Harness - Sheet 3 of 5
Chassis Head and Tail Lights Harness - Sheet 4 of 5
Chassis Head and Tail Lights Harness - Sheet 5 of 5
Telematics Harness - Sheet 1 of 2
Telematics Harness - Sheet 2 of 2
Gen 2 Platform Interface - Sheet 1 of 2
Gen 2 Platform Interface - Sheet 2 of 2
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 1 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 2 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 3 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 4 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 5 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 6 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 7 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 8 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 9 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 10 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 11 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 12 of 13
Deutz D2.9L4 (Stage V) Engine Harness - Sheet 13 of 13
Electrical Schematic - Sheet 1 of 16
Electrical Schematic - Sheet 2 of 16
Electrical Schematic - Sheet 3 of 16
Electrical Schematic - Sheet 4 of 16
Electrical Schematic - Sheet 5 of 16
Electrical Schematic - Sheet 6 of 16
Electrical Schematic - Sheet 7 of 16
Electrical Schematic - Sheet 8 of 16
Electrical Schematic - Sheet 9 of 16
Electrical Schematic - Sheet 10 of 16
Electrical Schematic - Sheet 11 of 16
Electrical Schematic - Sheet 12 of 16
Electrical Schematic - Sheet 13 of 16
Electrical Schematic - Sheet 14 of 16
Electrical Schematic - Sheet 15 of 16
Electrical Schematic - Sheet 16 of 16
Deutz D2.9L4 Stage V
Mobilfluid 424
Quintolubric 888-46
Mobil EAL 224H Specs
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Drive System Mode 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
Swing Motor Troubleshooting
EMR5 Trouble Codes
DPF Operational Indicators
Maintenance Standstill Cleaning
Standstill Cleaning: DPF Filled with Soot
Ash Load DPF Filter Replacement
J1939 Diagnostic Lamp Configuration
Diagnostic Corrective Actions
Historic Fault Information Interface Functions
SkyGuard Function Table
NPTF Pipe Thread
BSPT Pipe Thread
37° Flare (JIC)Thread - Steel
37° Flare (JIC)Thread - Aluminum/Brass
45° Flare (SAE) - Steel
45° Flare (SAE) - Aluminum/Brass
O-ring Face Seal (ORFS) - Steel
O-ring Face Seal (ORFS) - Aluminum/Brass
DIN 24°Cone (MBTL & MBTS)
Bulkhead Fittings (BH) - INCH
Bulkhead Fittings (BH) - METRIC
O-ring Boss (ORB) - Table 1 of 6
O-ring Boss (ORB) - Table 2 of 6
O-ring Boss (ORB) - Table 3 of 6
O-ring Boss (ORB) - Table 4 of 6
O-ring Boss (ORB) - Table 5 of 6
O-ring Boss (ORB) - Table 6 of 6
Metric Flat Face Port (MFF) - L Series - Table 1 of 3
Metric Flat Face Port (MFF) - L Series - Table 2 of 3
Metric Flat Face Port (MFF) - L Series - Table 3 of 3
Metric Flat Face Port (MFF) - S Series - Table 1 of 3
Metric Flat Face Port (MFF) - S Series - Table 2 of 3
Metric Flat Face Port (MFF) - S Series - Table 3 of 3
Metric Pipe Parallel O-Ring Boss (MPP)
British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
Flange Code (FL61 & FL62) - Inch Fasteners
Flange Code (FL61 & FL62) - Metric Fasteners
Cartridge Torque Values
Coil Torque Values
Analyzer Abbreviations
Machine Configuration Programming Information (Software Version P2.17)
Inside this manual
Real pages from this service manual (682 pages). Open the sample pages (PDF, 563 KB)
- Troubleshooting, page 110: Table 3-9. Swing Motor Troubleshooting
- Specifications, page 500: SECTION 6 - JLG CONTROL SYSTEM
- Diagram, page 640: SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
- Color page, page 276: SECTION 4 - BOOM & PLATFORM
- Color page, page 327: SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
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This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 682 pages
Quantity one is the manual described above.
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