Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
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
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation3 topics
- Lockout Cylinder Bleeding
- Oscillating Axle Lockout Test
- Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing
To Engage Drive Motors and Brakes (Normal Operation)2 topics
- Wheel Drive Assembly
- Drive Hub
Main Disassembly
Input Carrier Disassembly
Hub-Spindle Disassembly
Spindle-Brake Disassembly
Cover Disassembly
Input Carrier Sub-Assembly
Output Planet Gear Sub-Assembly
Spindle - Brake Sub-Assembly
Hub-Spindle Sub-Assembly
Cover Sub-Assembly
Main Assembly
Integral Brake Check1 topic
Disassembly
Assembly
Bleeding
Spare Parts Kits
Replacing the Drive Shaft Seal
Disassembly and Assembly
Assembly Notes
Taper Roller Bearing Initial Tension
Testing and Setup
Shaft Seal Replacement
Description
Inspection
Initial Start-up Procedures
Troubleshooting
Speed Sensor Replacement
Loop Flushing Valve
Adjustment Procedures
Main Assembly Procedure
Hub Shaft Sub-Assembly
Carrier Sub-Assembly
Roll, Leak And Brake Testing
Tightening and Torquing Bolts
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Drive Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Assembly
Carrier Assembly
Main Drive Assembly
Motor and Brake Assembly
Motor Control Valve Assembly1 topic
Disassembly and inspection
One Piece Stator Construction1 topic
Procedure For Setting Swing Gear Backlash
Swing Drive Lubrication2 topics
- Swing Hub Removal
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values2 topics
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings2 topics
- Spark Arrester Cleaning Instructions
- Dual Fuel System (Gas Engine Only)
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline1 topic
Performing Diagnostics
Visual/Physical Engine Inspection Check
EFI Diagnostics
ECM and Sensors
Fuel System1 topic
Regulator
Megajector
Mixer
Lock off Solenoid
Megajector Diagnostic Code Descriptions2 topics
- Deutz EMR 2
- 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
- GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
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 Replacement2 topics
- LP Gas Fitting Inspection
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids1 topic
Platform Valve Removal
Platform Valve Installation
Support Removal
Support Installation3 topics
- Rotator and Slave Cylinder
- Main Boom Powertrack
- Main Boom Powertrack Maintenance
Round Bar/Poly Bar Removal
Remove link
Install new link
Installing a New Bar/Poly Roller
Replacing Fixed End Bracket
Replacing Moving End Bracket5 topics
- Boom Cleanliness Guidelines
- Main Boom Assembly
- Upright
- Tower Boom Assembly
- Tower Boom Powertrack Maintenance
Flat Bar Removal
Removing and Installing Links
Installing a New Flat Bar
Installing a New Round Bar/Poly Roller
Replacing a Fixed End Bracket
Replacing a Moving End Bracket
Replacing a One Piece Bracket1 topic
- Upright Monitoring System
Re-Synchronizing Upright
Tower Out of Sync3 topics
- Sequence for Hose Replacement in the Tower Boom
- Limit Switches and Cam Valve Adjustment
- Boom Valve Adjustment
Tower Boom
Main Boom1 topic
Theory of Operation
Required Tools
Making a Seal Tool
Before Disassembly
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Installation and Bleeding3 topics
- Foot Switch Adjustment
- Boom Synchronizing Procedure
- Skyguard
Operation
Functional Test
Diagnostic & Troubleshooting1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Cylinders - Theory Of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves1 topic
Axle Lockout Cylinder (USA Built Machines SN 0300087000 through 0300089731)
China Built Machines SN B300000100 to Present)
Platform Level Cylinder
Upright Level Cylinder
Jib Lift Cylinder (600AJ Only)
Main Boom Lift Cylinder
Tower Boom Lift Cylinder
Master Cylinder
Steer Cylinder (USA Built Machines SN 0300087000 through 0300142624)
Main Boom Telescope Cylinder
Tower Boom Telescope Cylinder1 topic
- Cylinder Removal and Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
Upright Level Cylinder Removal
Upright Level Cylinder Installation
Tower Boom Lift Cylinder Removal
Tower Boom Lift Cylinder Installation
Tower Telescope Cylinder Removal
Tower Telescope Cylinder Installation1 topic
- Variable Displacement Pump (M46 Series)
Inspections and Adjustments
Minor Repair and Replacement1 topic
- Valves - Theory of Operation
Solenoid Control Valve - Rexroth
Relief Valves1 topic
- Pressure Setting Procedures
Main Relief, Steer, Swing and Lift Down
Platform Level
Jib Boom (If Equipped)
Wheel Steer (If Equipped)4 topics
- Hydraulic Component Start-up Procedures And Recommendations
- Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
- 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 Description2 topics
- Machine Personality Settings and Function Speeds
- Machine Orientation When Setting Function Speeds
Test Notes
Analyzer Diagnostics Menu Structure2 topics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 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
Wedge Lock
Service - Voltage Reading1 topic
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly2 topics
- Electrical Component
- Electrical Schematics
Maintenance and Lubrication Diagram
Filter Lock Assembly
Serial Number Locations
Torque Chart (SAE Fasteners - Sheet 1 of 5)
Torque Chart (SAE Fasteners - Sheet 2 of 5)
Torque Chart (SAE Fasteners - Sheet 3 of 5)
Torque Chart (SAE Fasteners - Sheet 4 of 5)
Torque Chart (SAE Fasteners - Sheet 5 of 5)
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Ford
Engine Operating Temperature Specifications - Caterpillar
Engine Operating Temperature Specifications - GM
2WD Front Axle And Steering Installations
4WD Front Axle And Steering Installations
4WS Rear Steering Installations
Wheel Drive Assembly
Input Carrier
Planet Gear Sub Assembly
Planet Gear Subassembly
Hub Spindle
Spindle Brake
Coupling Subassembly
Hub Assembly
Bearing Cup Pressing Tool
Seal Pressing Tool
Drift Pin for Lining Up Thrust Washers with Output Planet Gear
Drive Brake
Flow Control Pilot Valves
Drive Motor Cross Section
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
Removing the Shaft Seal
Swing Torque Hub Adjustment
Swing Hub
Motor Control Valve
Motor and Brake
Hub-Shaft
Carrier
Swing Motor Assembly
Swing Drive Motor
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Boom Placement
Swing Bearing Tolerance Measuring Point
Swing Bearing Torque Sequence
Swing Bearing Removal - 600A
Swing Bearing Removal - 600AJ
Swing Brake Assembly - (USA Built Machines, SN 0300087000 through 0300137452)
Rotary Coupling Port Location (USA Built Machines, SN 0300087000 through 0300138648) - 2WS
Rotary Coupling Port Location (USA Built Machines, SN 0300087000 through 0300138648) - 4WS
Deutz Engine - Sheet 1 of 4
Deutz Engine - Sheet 2 of 4
Deutz Engine - Sheet 3 of 4
Deutz Engine - Sheet 4 of 4
Caterpillar Engine - Sheet 1 of 4
Caterpillar Engine - Sheet 2 of 4
Caterpillar Engine - Sheet 3 of 4
Caterpillar Engine - Sheet 4 of 4
GM Engine - Sheet 1 of 4
GM Engine - Sheet 2 of 4
GM Engine - Sheet 3 of 4
GM Engine - Sheet 4 of 4
Deutz Engine Installation - Sheet 1 of 2
Deutz Engine Installation - Sheet 2 of 2
Arctic Deutz Engine Installation - Sheet 1 of 2
Arctic Deutz Engine Installation - Sheet 2 of 2
CAT Engine Installation
Arctic CAT Engine Installation
Arctic GM Engine Installation - Sheet 1 of 2
Arctic GM Engine Installation - Sheet 2 of 2
GM Engine Installation - Sheet 1 of 2
GM Engine Installation - Sheet 2 of 2
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
EFI Component Location
Typical Fuel System
Ford LPG System
Deutz Sensors for JLG Control System
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
LP Gas Fitting Components
Hood Mounting Bracket Clearance
Location of Components Platform Support
Platform Support Torque Values
Removal of Components - Rotator and Leveling Cylinder
Installation of Components - Rotator and Leveling Cylinder
Main Boom Powertrack Components
Boom Powertrack Installation
Powertrack Installation Main Boom - USA Build Machine (600A)
Powertrack Installation Main Boom - China Build Machine (600A)
Powertrack Installation Main Boom (600AJ)
Removal - Main Boom
Installation - Main Boom
Removal - Upright
Installation - Upright
Removal - Tower Boom
Location Of Components - Tower Boom
Installation - Tower Boom
Releveling Valve
Boom Upright Positioning - Sheet 1 of 2
Boom Upright Positioning - Sheet 2 of 2
Removal and Installation - Jib
Boom Limit Switches Adjustment
Fiberglass Bar Installation
Transportation Switch Installation (CE only) - Sheet 1 of 2
Transportation Switch Installation (CE only) - Sheet 2 of 2
Rotator Assembly
Rotator - Exploded View
Rotator - Assembly Drawing
Rotator Counterbalance Valve
Skyguard
SkyGuard Harness
SkyGuard Harness Wiring Diagram
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation - 600A
Cylinder Head Seal Installation - 600AJ
Wiper Seal Installation
Installation of Head Seal Kit
Tapered Bushing Installation
Seating the Tapered Bearing
Hydrolock Piston Seal Installation
Piston Seal Kit Installation
Rod Assembly Installation
Cylinder Head Seal Installation
Spanner Nut Removal
Steer Cylinder USA Built Machines (SN 0300087000 through 0300142624)
Main Boom Telescopic Cylinder
Tower Boom Telescopic Cylinder
Location of Components - Telescope and Lift Cylinder
Overriding the Plunger Valve
Leveling Cylinder Removal
Boom Positioning and Support, Cylinder Repair
Troubleshooting - Neutral Difficult or Impossible to Find
Troubleshooting - System Operating Hot
Troubleshooting - Transmission Operates in One Direction Only
Troubleshooting - System Response is Sluggish
Troubleshooting - System Will Not Operate in Either Direction
Variable Displacement Pump
Jib Boom Pressure Adjustments
Main Valve Components (SN B300001393 to Present)
Main Valve Torque Values (SN B300001393 to Present)
Platform Control Valve Pressure Adjustments
Platform Control Valve Component Torque
Hydraulic Schematic (2 Wheel Steer)- Sheet 1 of 8
Hydraulic Schematic (2 Wheel Steer)- Sheet 2 of 8
Hydraulic Schematic (2 Wheel Steer)- Sheet 3 of 8
Hydraulic Schematic (2 Wheel Steer)- Sheet 4 of 8
Hydraulic Schematic (2 Wheel Steer)- Sheet 5 of 8
Hydraulic Schematic (2 Wheel Steer)- Sheet 6 of 8
Hydraulic Schematic (2 Wheel Steer)- Sheet 7 of 8
Hydraulic Schematic (2 Wheel Steer)- Sheet 8 of 8
Hydraulic Schematic (4 Wheel Steer)- Sheet 1 of 6
Hydraulic Schematic (4 Wheel Steer)- Sheet 2 of 6
Hydraulic Schematic (4 Wheel Steer)- Sheet 3 of 6
Hydraulic Schematic (4 Wheel Steer)- Sheet 4 of 6
Hydraulic Schematic (4 Wheel Steer)- Sheet 5 of 6
Hydraulic Schematic (4 Wheel Steer)- Sheet 6 of 6
Hand Held Analyzer
ADE Block Diagram
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
Analyzer Flow Chart Version 6.X Software -Sheet 1 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 2 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 3 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 4 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 5 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 6 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 7 of 8
Analyzer Flow Chart Version 6.X Software -Sheet 8 of 8
Fault Code Light Location
Analyzer Connecting Points
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Platform Control Module - Sheet 1 of 2
Platform Control Module - Sheet 2 of 2
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 without UGM - Sheet 1 of 2
Electrical Components Installation without UGM - Sheet 2 of 2
Electrical Components Installation with UGM (SN B300001393 to Present) - Sheet 1 of 2
Electrical Components Installation with UGM (SN B300001393 to Present) - Sheet 2 of 2
Platform and Ground Control Electrical Schematic - Sheet 1 of 10
Platform and Ground Control Electrical Schematic - Sheet 2 of 10
Generator Wiring and CAT interface Electrical Schematic - Sheet 3 of 10
Generator Wiring and CAT interface Electrical Schematic - Sheet 4 of 10
CAT Engine Electrical Schematic - Sheet 5 of 10
CAT Engine Electrical Schematic - Sheet 6 of 10
Deutz and GM/PSI Engine Electrical Schematic - Sheet 7 of 10
Deutz and GM/PSI Engine Electrical Schematic - Sheet 8 of 10
Deutz Tire 4 Final Engine Electrical Schematic - Sheet 9 of 10
Deutz Tire 4 Final Engine Electrical Schematic - Sheet 10 of 10
GM Electrical Schematic - Sheet 1 of 2
GM Electrical Schematic - Sheet 2 of 2
Capacities
Continental TMD27 Specifications
Ford LRG-423 Specifications
Ford LRG-425 Specifications
Deutz F4M1011F/F4M2011 Specifications
Deutz D2011L04 Specifications
Caterpillar 3044C/3.4
Tire Specifications
Torque Requirements
Mobilfluid 424 Specs
Mobil DTE 10 Excel 32 Specs
Exxon Univis HVI 26 Specs
Quintolubric 888-46
Mobil EAL 224H Specs (USA Build machine)
Mobil EAL Envirosyn H46 Specs
Mobil SHC Hydraulic EAL 46 Specs
Pressure Settings
Cylinder Specifications - 600A
Cylinder Specifications - 600AJ
Major Component Weights - 600A
Major Component Weights - 600AJ
Critical Stability Weights - 600A
Critical Stability Weights - 600AJ
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Coupling Port Information Table - 2WS
Coupling Port Information Table - 4WS
Coupling Port Information Table (7 port)
Coupling Port Information Table (9 port)
ECM Diagnostic Trouble Codes
LPG Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
SkyGuard Function Table
Cartridge Pressure Values
Cartridge Torque Values
Analyzer Abbreviations
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
Machine Configuration Programming Information
600A Machine Configuration Programming Settings
600AJ Machine Configuration Programming Settings
Machine Personality Settings
Function Speeds
ADJUSTMENTS - Personality Descriptions
Diagnostic Menu Descriptions
Diagnostic Trouble Code Listing