Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- TABLE OF CONTENTS 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
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test1 topic
Removal
Installation1 topic
Oil Information
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-Spindle Disassembly
Spindle-Brake Disassembly
Cover Disassembly
Cover Assembly
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
Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel)
Engage Drive Motors and Brakes (Normal Operation)7 topics
- Drive Motor
- Steer Adjustments
- Chassis Tilt Indicator System
- Drive Orientation System
- Oscillating Axle System
- Drive System
- Swing Drive
Roll, Leak And Brake Testing
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
Assembly
One Piece Stator Construction2 topics
- Swing Hub Removal
- Swing Hub Installation
Procedure For Setting Swing Gear Backlash
Swing Drive Lubrication1 topic
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values3 topics
- Rotary Coupling
- Generator and Pulley
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
Troubleshooting
Generator Disassembly and Assembly
Lead Connection List for Generator1 topic
- Deutz D2.9 L4 (T4F) Engine
Check Oil Level
Change Engine Oil
Change Oil Filter
Change Fuel Filters1 topic
Checking Oil Level
Changing Engine Oil
Changing Oil Filter
Replace Fuel Filter
Clean Fuel Strainer4 topics
- Spark Arrester Cleaning Instructions
- Glow Plugs
- Deutz EMR 2
- Bio Fuel In Deutz Engines
Bio Fuel
Biological Contamination In Fuels10 topics
- Ford Engine
- Counterweight
- Platform Control Enable System
- Platform Load Control System
- Ground Control Keyswitch System
- Function Speed Control System
- Beyond Transport - Drive Speed Cutback System
- Transport Position Sensing System
- Drive/Steer - Boom Function Interlock System
- Platform
Support Removal
Support Installation3 topics
- Rotator and Platform Level Cylinder
- Main Boom Powertrack
- Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets1 topic
Disassembly
Inspection5 topics
- Upright
- Tower Boom Assembly
- Jib Assembly
- Boom Cleanliness Guidelines
- Rotator Assembly
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
- Bolt-on External Fall Arrest
Inspection Before Use1 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
- Cylinders - Theory of Operation
Systems With Double Acting Cylinders
Systems With 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
Cylinder Locations
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 Lift Cylinder Installation
Tower Telescope Cylinder Removal
Carefully slide telescope cylinder from boom. Place cylinder on a suitable work area
Tower Telescope Cylinder Installation1 topic
- TABLE OF CONTENTS Hydraulic Cylinder
Tower Boom Lift Cylinder
Upright Level Cylinder
Master Cylinder
Main Boom Lift Cylinder
Main Boom Telescope Cylinder
Tower Boom Telescope Cylinder
Platform Level Cylinder
Jib Lift Cylinder
Steer Cylinder
Axle Lockout Cylinder1 topic
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Placing Pump Back Into Service1 topic
Ports and Pressure Gauges
NFPE Control
Remove and Install FNR and NFPE Modules
Remove and Install FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
Charge Pump3 topics
- Hydraulic Component Start-Up
- Drive Pump Pre-Fill Procedure
- Main Valve Block Pressure Settings
Main Relief
Upper (Main) Lift Down
Swing
2-Wheel Steer1 topic
- Platform Valve Block Pressure Settings
Platform Level Extend
Platform Level Retract
Articulating Jib2 topics
- Hydraulic Schematics
- JLG Control System Analyzer Kit Instructions
Introduction
Connect 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
- Machine Orientation When Setting Function Speeds
Test Notes4 topics
- CANbus Communications
- MSSO (Machine Safety System Override)
- Tilt Sensor Calibration
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation4 topics
- Boom Angle Calibration
- Resetting The MSSO System (CE only)
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement2 topics
- Applying Silicone Dielectric Compound Electrical Connections
- Dielectric Grease Application
AMP Mate-N-Lok
AMP Faston
AMP Micro-Fit
AMP Mini Fit Jr
Mini Fit Sr
DIN Connectors
Exceptions
Enclosures
Carling Switch Connectors1 topic
Wedge Lock
Service - Voltage Reading1 topic
- TABLE OF CONTENTS Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
Telematics-Ready (TCU) Plug1 topic
Connector Labels
Component Labels2 topics
- Wiring Harness Breakdown
- Electrical Schematics
Operator Maintenance and Lubrication Diagram - Deutz D2011L04
Operator Maintenance and Lubrication Diagram - Deutz TD2.9L
Operator Maintenance and Lubrication Diagram - Ford MSG 425
Engine and Hydraulic Operating Temperature Specifications - Deutz
Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425
Wheel Lug Nut Tightening Sequence
Axle Installation - Without Tow Package
Axle Installation - With Tow Package
Steering Installation - Without Tow Package
Steering Installation - With Tow Package
Wheel Drive Installation
Bolt Tightening Sequence
Torque Hub
Torque Hub Main Disassembly
Output Carrier Disassemb
Hub Spindle Disassembly
Spindle Brake Disassembly
Torque Hub Cover
Hub Assembly
Bearing Cup Pressing Tool
Seal Pressing Tool
Drift Pin for Lining Up Thrust Washers with Output Planet Gear
Disconnecting Drive Hubs
Steer Adjustments
Swing System
Motor Control Valve
Motor and Brake
Hub-Shaft
Carrier
Swing Drive Assembly
Swing Motor and Brake Assembly
Bearing Cone Press Tool (T144566)
Bearing Cone Pressing Tool (T145741)
Bearing Cup Pressing Tool (T149013)
Locknut Wrench Tool (T151047)
Bearing Cup Pressing Tool (T155291)
Seal Press Tool (T175741)
Swing Drive Test Plate (T187845)
Leak Test Adapter Plate (T201476)
Swing Drive Motor
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Tolerance Measurement Location & Boom Placement
Swing Bearing Torque Sequence
Swing Bearing Removal
Rotary Coupling - Sheet 1 of 2
Rotary Coupling - Sheet 2 of 2
Rotary Coupling Port Location - 2WS
Generator and Pulley (2500W Deutz D2011)
Generator and Pulley (7500W Deutz D2011 and 2500W Ford DF 2.5L)
Generator and Pulley (7500W and 4000W Deutz T4F)
Generator and Pulley (4000W Deutz D2011)
Generator and Pulley (2500W Deutz T4F)
Generator and Pulley (7500W Ford DF 2.5L)
Generator Belt Tension
Generator Brushes and Slip Rings
Blow Out Generator
Generator Circuit Breaker Location
Inspecting Generator Brushes, Replacing Brushes, and Cleaning 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)
Deutz D2.9 L4 (T4F) Engine Installation - Sheet 1 of 2
Deutz D2.9 L4 (T4F) Engine Installation - Sheet 2 of 2
Deutz 2.9 T4F Dipstick Markings
Engine Oil Viscosity
Deutz D2011 (T4i) Engine Installation - Sheet 1 of 2
Deutz D2011 (T4i) Engine Installation - Sheet 2 of 2
Deutz Dipstick Markings
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
Ford Engine Installation Sheet 1 of 4
Ford Engine Installation Sheet 2 of 4
Ford Engine Installation Sheet 3 of 4
Ford Engine Installation Sheet 4 of 4
Turntable Counterweight Bolt Torque
Chassis Counterweight Bolt Torque
Telescope Retracted Sensor
Telescope Retracted Sensor Circuit
Capacity Sensors
Capacity Sensors Circuit - Unresticted 660 lb (299 kg) (Yellow)
Capacity Sensors Circuit - Resticted 750 lb (340 kg) (Blue)
Capacity Sensors Circuit - Resticted 1000 lb (454 kg) (Blue)
Angle Switch Installation - Sheet 1 of 2
Angle Switch Installation - Sheet 2 of 2
Location of Components Platform Support
Platform Support Torque Values
Rotator and Leveling Cylinder Components
Main Boom Powertrack Components
Main Boom Assembly Components
Tower Boom Components
Tower Boom Powertrack Components
Jib Assembly - Removal/Installation
Rotator - Exploded View
Rotator - Assembly Drawing
Rotator Counterbalance Valve
Foot Switch Adjustment
Bolt-On External Fall Arrest Cable Tension
NPTF Thread
BSPT Thread
JIC Thread
SAE Thread
ORFS Thread
MTBL-MBTS Thread
Bulkhead Thread
ORB-MPP Thread
MFF-BSPP Thread
Torque Wrench Angle
FFWR Method
Boom Positioning and Support
Hydraulic Cylinder Locations
Telescope and Lift Cylinder Installation
Plunger Valve Override
Leveling Cylinder Removal
Boom Positioning and Support, Cylinder Repair
Cylinder Clamp Holder
Cylinder Plug Removal
Staking Removal
Cylinder Head Cover Removal
Cylinder Rod Removal
Cylinder Rod Support
Piston Setscrew Removal
Piston Removal
Cylinder Head Disassembly
Piston Seal Disassembly
Cylinder Head Seal Disassembly
Bushing Installation
Cylinder Head Seal Assembly
Piston Seal Assembly
Cylinder Head Assembly
Piston Installation
Piston Setscrew Installation
Cylinder Rod Installation
Cylinder Head Cover Installation
Cylinder Barrel Support
Capscrew Removal
Tapered Bushing Removal
Piston Disassembly
Composite Bushing Installation
Head Seal Kit Installation
Cylinder Head Seals
Piston Seal Kit Installation
Piston Seals
Tapered Bushing Installation
Seating Tapered Bushing
Rod Assembly Installation
Cylinder Head Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Installation of Piston Seal Kit
Caulking
Marking Cylinder for Alignment
Main Boom Telescope Cylinder Assembly
Wear Pad Assembly
Tower Boom Telescope Cylinder Assembly
Seating the Tapered Bearing
Hydrolock Piston Seal Installation
Removing Spanner Nut
Steer Cylinder Assembly
Piston Seal and Wear Ring
Piston Seal and Wear Ring Assembly
Hydraulic Pump Installation
Variable Pump Installation
Shim Adjustable Charge Relief Valve Components
Gauge Port Locations
Plugs/Fittings Size & Torque
Screw Adjustable Charge Relief Valve Components
Shaft Seal Components
Shaft Seal Installation
Shaft Components
Charge Pump Components
Main Control Valve Identification
Main Control Valve Torque Values
Platform Control Valve Identification
Platform Control Valve Torque Value
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
Hand Held Analyzer
ADE Block Diagram
Analyzer Flow Chart Software Version P6.33 - Sheet 1 of 7
Analyzer Flow Chart Software Version P6.33 - Sheet 2 of 7
Analyzer Flow Chart Software Version P6.33 - Sheet 3 of 7
Analyzer Flow Chart Software Version P6.33 - Sheet 4 of 7
Analyzer Flow Chart Software Version P6.33 - Sheet 5 of 7
Analyzer Flow Chart Software Version P6.33 - Sheet 6 of 7
Analyzer Flow Chart Software Version P6.33 - Sheet 7 of 7
Control Module Locations
Analyzer Connecting Points
Ground Control Module Pin Connections
Platform Control Module Pin Connections
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 Components 1 of 2
Electrical Components 2 of 2
Platform Console Box
GEN 2 PLAT Interface Harness
Platform Valve Harness Assembly
Main Boom Harness
Main Boom Harness with Arctic Package
Tower Boom Cable Harness without Arctic Package
Tower Boom Cable Harness with Arctic Package
Main Valve Harness - Sheet 1 of 2
Main Valve Harness - Sheet 2 of 2
Deutz D2011 (T4i) Engine Harness
Deutz TD2.9L4 (T4F) Engine harness
Ford Engine Harness
Ground Control Box Harness - Sheet 1 of 2
Ground Control Box Harness - Sheet 2 of 2
Boom Angle Cable Harness
Tele In Prox Cable Harness
Mid Prox Cable Harness
Full Extension Cable Harness
Electrical Schematic - Sheet 1 of 17
Electrical Schematic - Sheet 2 of 17
Electrical Schematic - Sheet 3 of 17
Electrical Schematic - Sheet 4 of 17
Electrical Schematic - Sheet 5 of 17
Electrical Schematic - Sheet 6 of 17
Electrical Schematic - Sheet 7 of 17
Electrical Schematic - Sheet 8 of 17
Electrical Schematic - Sheet 9 of 17
Electrical Schematic - Sheet 10 of 17
Electrical Schematic - Sheet 11 of 17
Electrical Schematic - Sheet 12 of 17
Electrical Schematic - Sheet 13 of 17
Electrical Schematic - Sheet 14 of 17
Electrical Schematic - Sheet 15 of 17
Electrical Schematic - Sheet 16 of 17
Electrical Schematic - Sheet 17 of 17
Deutz TD2.9L Specifications
Standard UTTO Hydraulic Fluid Specs
Premium Hydraulic Fluid (VG 32) Specs
Quintolubric Fire RES Hydraulic Fluid Specs
Biodegradable Synthetic Hydraulic Fluid (VG 46) Specs
Premium Hydraulic Fluid (All Weather) Spec
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Drive Mode Speeds
Coupling Port Information Table - 2WS
Engine Fault Codes (Deutz Engine)
Fault Code Cross Reference List (Ford Engine)
CAN to DTC Cross Reference (Ford Engine)
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
Hydraulic Pump Bolt Torque Chart
Torque Values
Recommended Gauge Size
Cartridge Torque Values
Coil Torque Values
Analyzer Abbreviations
Machine Configuration Programming Information - Version P6.33
Machine Configuration Programming Settings - Version P6.33
Personality Ranges/Defaults
Function Speeds (In Seconds)
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
Fault Code List
Help Fault Codes, Displayed Faults, and Descriptions
Wiring Harness Connector Labels