JLG 723A Service Manual

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An Oshkosh Corporation Company

Service Manual

Models

L2906H, 2906H,

3507H, 619A,

723A

Agrovector

29.6LP, 29.6, 35.7

31200568

Revised

March 7, 2011

EFFECTIV IT Y PAGE

May 30, 2009 - A - Original Issue Of Manual March 7, 2011 - B - Added Models 29.6LP, 29.6 & 35.7. Updated all Loctite

and pages 1-3 & 9-10 thru 9-100.

242TM with Loctite® 243TM. Revised covers

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

EFFECTIV IT Y PAGE

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Replacement Parts and Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.4 Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.5 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.8 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.9 Emergency Boom Lowering Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.4 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

L2906H, L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.5 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.7 Steering Angle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Section 6

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Transmission Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.6 Transmission Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Section 7

Engine: Deutz TCD 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.6 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7.8 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.9 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.10 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.11 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.5 Hoses, Tube Lines, Fittings, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.7 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.9 Implement Pump (Piston or Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-13

8.11 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.12 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.3 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.4 Keypad and Display Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.5 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.6 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

9.7 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.8 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.9 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

9.10 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26

9.11 Engine electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29

9.12 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31

9.13 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33

9.14 Solenoids, Sensors and Senders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34

9.15 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7

(Before S/N 1160005993 excluding 1160005943, 1160005945 & 1160005414) . . . . . . 9-40

9.16 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7

(S/N 1160005993 & After including 1160005943, 1160005945 & 1160005414) . . . . . . 9-44

9.17 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48

9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

iii

Section Subject Page

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.3 General Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

1-1

Safety Practices

1.1 INTRODUCTION

This service manual provides general directions for accomplishing servic e and re pai r proc edu res. Fo ll owi ng the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally appro ved safe ty p r actices, procedures, rules, codes, regulations and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during opera tion, maintenance, or testing. When additi onal information is desired consult the local JLG dealer.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator’s seat looking in a for ward direction.

Supplementary information is available from the manufacturer in the form of Service Bulletins, Service Campaigns, Service Training Schools, the service website, other literature, and through updates to the manual itself.

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the st ee ring wheel be f o r e att e mp t in g t o pe rf o rm an y service or maintenance. Remove key and disconnect battery leads.

1.5 S AFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.5.1 Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

1.2 DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication. The manufacturer reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3 O PERATION & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read and understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operation & Safety Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Safety Manual is missing, consult the local JLG dealer before proceeding.

1-2

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructi ons to prov ide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions before

1.6.1 Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2 Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tool s onl y as re co mme nde d.

proceeding.

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Im mediately clean, dress and report a ll injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure the machine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, it is recommended a maximum pressure of 52 bar (750 psi) at a minimum distance of 30,5 cm (12 in) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation.

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

1-3

Safety Practices

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specificall y instr uc ted othe rw is e.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must b e on a hard leve l surfa ce, wit h th e wh eel s blocked before performing any service.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

FLUID PRESSURE: Before loosenin g any hydr aul ic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic oil and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.

RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic oil are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the pr ope r manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery. Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7 S AFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.

1-4

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 2

General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.1 Travel Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2-11

2.3.3 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.4 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3.5 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5.1 10,1st 50 & 50 Hour Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5.2 1st 150, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . 2-15

2.5.3 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.6 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.6.1 10 Hour Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.6.2 50 Hour Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-1

General Information and Specifications

MZ5250

Model

SerialNumber

YearOfManufacture

MaximumWeightWithoutAttachments (lbs/kg)

MaximumCapacity(lbs/kg)

°Referto load capacity chartfor truck with attachment, and individual load ratings stamped onforks,if equipped. Use lowest capacity of all ratings.

Asreleasedfrom factory this truck meets specifications inASME B56.6-2002 Part III.

Oneormore of the following patentsmay apply to this truck; U.S. Nos. 4,954,041 6,349,969

5,639,1195,813,6975,230,399 5,052,532. Other patentspending.

1706910A

Manufacturedby

IndustrieterreinOudeBunders 1034, Breitwaterstraat 12 3630Maasmechelen- Belgium

JLGManufacturingEurope BVBA

L2906H, 2906H, 3507H, 29,6LP, 29.6 & 35.7

619A & 723A

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

Before ordering parts or initiating service inquiries, make note of the machine serial number. The machine serial number plate (1) is located as indicated in the figure.

Note: The replacement of any part on this machine with any other th a n fa ct o ry au t h or iz ed re pl acement parts ca n adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the local JLG dealer, signed by the purchaser and returned to the

manufacturer when the machine is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the local JLG dealer has returned the business reply card of the warranty registration form to the manufacturer.

2-2

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

General Information and Specifications

MY3141

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

or Vibra-

TITE

131)

Torque

Lubricated

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOTAPPLY TO CADMIUMPLATED FASTENERS

2. ALL TORQUE VALUESARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

2.2 TORQUES

2.2.1 SAE Fastener Torque Chart

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-3

General Information and Specifications

MY3151

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. *ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000 45 60 40 55 35 50 7900 50 70 45 60 35 50

9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120 16400 155 210 140 190 115 155 18250 170 230 155 210 130 175 20350 210 285 190 260 160 220 23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140) K=.18

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry orLoctite® 263)

K= 0.20

2.2.1 SAE Fastener Torque Chart (Continued)

2-4

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

General Information and Specifications

MY3161

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS.IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K = .17

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140 ORPrecoat 85®

K=0.16

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM

2.2.1 SAE Fastener Torque Chart (Continued)

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-5

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

4. CLAMPLOAD LISTED FOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K=.20

Torque

(Loctite® 242

or 271

OR Vibra-TITETM111 or

140 ORPrecoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARDAUDIT METHODSTOLERANCE = ±10%

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLYTO CADMIUM PLATEDFASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

MY3400

2.2.1 SAE Fastener Torque Chart (Continued)

2-6

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2.2.2 Metric Fastener Torque Chart

MY3171

SizePITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry orLoctite®

263

)

Torque

(Lub)

Torque

(Loctite® 262

OR Vibra-

TITE

131)

Torque

(Loctite®

242

or 271

OR Vibra-

TITE

111 or

140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT

METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

General Information and Specifications

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-7

General Information and Specifications

MY3181

SizePITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry orLoctite®

263

)

K =0.20

Torque

(Lub ORLoctite®

242

or 271TMOR

Vibra-TITE

111 or

140)

K= 0.18

Torque

(Loctite® 262

Vibra-TITE

131)

K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.25 36.60 22.8 36.5 32.8 27.4

10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150

16 2 157 97.8

315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

2.2.2 Metric Fastener Torque Chart (Continued)

2-8

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2.2.2 Metric Fastener Torque Chart

MY3191

SizePITCH

Tensile

Stress

Area

Clamp Load

See Note4

Torque

(Dry orLoctite®

263

)

K =.17

Torque

(Lub ORLoctite®

242

or 271

OR Vibra-TITE

111 or 140)

K =.16

Torque

(Loctite® 262

OR Vibra-TITE

131)

K=.15

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03

3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 ANDABOVE*

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

(Continued)

General Information and Specifications

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-9

General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart

Size ORFS JIC Flats Method

18 Nm

(13 lb-ft)

31 Nm

(23 lb-ft)

54 Nm

(40 lb-ft)

81 Nm

(60 lb-ft)

100 Nm

(136 lb-ft)

156 Nm

(115 lb-ft)

230 Nm

(170 lb-ft)

271 Nm

(200 lb-ft)

18 Nm

(13 lb-ft)

31 Nm

(23 lb-ft)

54 Nm

(40 lb-ft)

81 Nm

(60 lb-ft)

115 Nm

(85 lb-ft)

156 Nm

(115 lb-ft)

230 Nm

(170 lb-ft)

271 Nm

(200 lb-ft)

1.5 to 1.75

1 to 1.5

1.5 to 1.75

1.0 to 1.5

.75 to 1.0

Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 4 Nm (3 lb-ft).

2. Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it’s connecting to.

3. Use the double wrench method while tightening to avoid hose twist.

4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots indicating that the con necti on has been properly tightened.

32 N/A

366 Nm

(270 lb-ft)

.75 to 1.0

Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is not possible.

Torque Wrench:

1. Identify the appropriate application and refer to the above chart for the correct torque value.

2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 4 Nm (3 lb-ft).

3. Use the double wrench method while tightening to avoid hose twist.

4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks.

5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened.

2-10

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speed

L2906H, 2906H, 29.9LP, 29.6 & 619A 3507H, 35.7 & 723A

First Gear 10 kmph (6 mph) 7 kmph (4 mph) Second Gear 34 kmph (21 mph) 33 kmph (20 mph)

2.3.2 Hydraulic Cylinder Performance Specifications

Note: Machine with no load, engine at full throttle, hydraulic oil above 54° C (130° F) minimum, engine at operating temperature.

Function Approximate Times (sec.)

Boom Extend 6 Boom Retract 4 Boom Lift 6 Boom Lower 4 Quick Attach - UP 2 Quick Attach - DOWN 2

2.3.3 Electrical System

Note: Refer to Section 9.8, “Fuses and Relays,” for more information.

Battery

Type, Rating 12V, Negative (-) Ground, Tapered Top Post, Maintenance Free Quantity 1 Reserve Capacity 1000 Cold Cranking Amps @ -18° C (0° F) Group/Series BCI Group 31 Alternator 12V, 95 Amps Starter 12V, 3,0 KW Type EV (Gear Reduction)

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-11

General Information and Specifications

2.3.4 Engine Performance Specifications

Description

Engine Make/Model Deutz TCD2012L04V02 Tier III Low Idle 925 ±50 rpm High Idle 2370 ±50 rpm Horsepower 74.9 kW/100.4 BHP @ 2200 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements Average Fuel Consumption (dependant on load/duty) 6,1 I/hr (1.6 gal/hr)

2.3.5 Tires

Note: Standard wheel lug nut torque is 300 Nm (220 lb-ft). Note: Pressures for Foam filled tires are for initial fill ONLY.

Size Tire

405/70-20

(L2906H, 2906H & 3507H)

405/70-24

(2906H, 3507H, 29.6 & 35.7)

405/70-20

(L2906H, 2906H,3507H & 619A)

405/70-20

(619A)

405/70-24

(2906H, 3507H, 29.6, 35.7 & 723A)

405/70-24

(723A) 400/70R20 XMCL Radial Ply Pneumatic 4 bar (58 psi) 445/70R24

(3507H, 35.7 & 723A)

460/70R24

(3507H, 35.7 & 723A)

Minimum Ply/

Type

MPT-01 Bias - 14 Ply Pneumatic 3,5 bar (51 psi)

MPT-01 Bias - 14 Ply Pneumatic 4,0 bar (58 psi)

MPT-04 Bias - 14 Ply Pneumatic 3,5 bar (51 psi)

MPT-04 Bias - 14 Ply

MPT-04 Bias - 14 Ply Pneumatic 4 bar (58 psi)

MPT-04 Bias - 14 Ply

XMCL Radial Ply Pneumatic 4,1 bar (60 psi)

EM-01 Radial Ply Pneumatic 4 bar (58 psi)

Star Rating

Fill Type Pressure

Foam - Approx. 200 kg

(441 lb)

Foam - Approx. 240 kg

(529 lb)

2-12

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

General Information and Specifications

2.4 FLUIDS, LUBRICANTS AND CAPACITIES

Engine Crankcase Oil

Capacity w/Filter Change 10,4 liter (11 quart) Filter Capacity 1,0 liter (1.05 quart) Oil Type

L2906H, 2906H, 3507H, 619A & 723A 15W-40 CE

29.6LP, 29.6 & 35.7 DF Super ENGINE OIL 15W-40

Fuel Filters

Primary Fuel Filter Capacity Approx. 1,0 liter (1.05 quart) Fuel Filter Capacity 0,6 liter (0.16 quart)

Fuel Tank

Capacity

L2906H, 2906H, 29.6LP, 29.6 & 619A 95 liter (25 gallon) 3507H, 35.7 & 723A 102 liter (27 gallon)

Type of Fuel #2 Diesel

Cooling System

System Capacity w/o Heater 19 liter (5 gallon) Overflow Bottle Capacity 3 liter (3.2 gallon) Type of Fluid 50/50 mix of ethylene glycol & water

Hydraulic System

System Capacity

L2906H, 2906H, 29.6LP, 29.6 & 619A 98 liter (26 gallon) 3507H, 35.7 & 723A 102 liter (27 gallon)

Reservoir Capacity to FULL Mark

L2906H, 2906H, 29.6LP, 29.6 & 619A 60 liter (16 gallon) 3507H, 35.7 & 723A 95 liter (25 gallon)

Type of Fluid

L2906H, 2906H 3507H,619A & 723A Mobilfluid

424Tractor Hydraulic Fluid (ISO 46)

29.6LP, 29.6 & 35.7 DF UTTO Tractor Hydraulic Fluid

Air Conditioning

Capacity 1,1 kg (2.4 lb) Type of Refrigerant R-134a

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-13

General Information and Specifications

Axles

Differential Housing Capacity - Front

L2906H, 2906H, 29.6LP, 29.6 & 619A 9,5 liter (10 quart) 3507H, 35.7 & 723A 10 liter (10.6 quart)

Differential Housing Capacity - Rear

L2906H, 2906H, 29.6LP, 29.6 & 619A 5,5 liter (5,8 quart) 3507H, 35.7 & 723A 8 liter (8.5 quart)

Wheel End Capacity

L2906H, 2906H, 29.6LP, 29.6 & 619A 0,8 liter (0.8 quart) 3507H, 35.7 & 723A

Front - 0,6 liter (0.6 quart)

Rear - 0,7 liter (0.7 quart)

Transfer Box

Capacity 0,5 liter (0.5 quart) T ype of Flui d

Mobilube HDLS 80W-90,

L2906H, 2906H 3507H,619A & 723A

Mobilfluid

424Tractor Hydraulic Fluid (ISO 46), Shell Spirax LS,

Esso Torque Fluid 62, Selenia Ambra STF 80W-90

29.6LP, 29.6 & 35.7 DF GEAR 90 LS

Brakes

Master Cylinder Capacity 0,7 liter (0.7 quart)

2-14

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

General Information and Specifications

OAH18702

EVERY

Drain Fuel/

Water

Separator

Check Engine Coolant Level

Check

Battery

Lubrication

Schedule

Check Washer

Fluid Level

(if equipped)

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Engine

Oil and

Filter

Check Fuel

Level

EVERY

Lubrication

Schedule

Additional

Checks Section 8

Check

Air Precleaner

Check Engine

Oil Level

Check Hydraulic

Oil Level

Check Tire

Condition &

Pressure

Check Brake

Fluid Level

OAH18812

150

Change Axle

Differential Oil

Change Wheel

End Oil

250

EVERY

Check Axle

Differential Oil

Level

Check Wheel End Oil Level

Change Engine

Oil and Filter

Check

Fan Belt

Check Boom

Wear Pads

Check LSI Calibration

500

EVERY

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Fuel

Filters

OAH18902

1500

EVERY

Change

Engine Coolant

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

Change Axle

Differential Oil

Change Wheel

End Oil

Change

Brake Fluid

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

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-15

General Information and Specifications

OAH1900

EVERY

2.6 LUBRICATION SCHEDULE

2.6.1 10 Hour Lubrication Schedule

2-16

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2.6.2 50 Hour Lubrication Schedule

OAH1910

EVERY

General Information and Specifications

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2-17

General Information and Specifications

This Page Intentionally Left Blank

2-18

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 3

Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 Boom System - Two Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.4 Boom Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.4.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.4.2 Second Section Boom Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4.3 Second Section Boom Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.4 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.5 Extend/Retract Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.4.6 Extend/Retract Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.5 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.5.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.5.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.6 Quick Attach Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6.1 Quick Attach Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6.2 Quick Attach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.7 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3.8 Boom Prop (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.8.1 Installation and Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.9 Emergency Boom Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.9.1 Equipment and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.9.2 Lowering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

3-1

Boom

MZ3610

Second Boom

Section

First Boom

Section

Pivot Pin

Extend/Retract

Cylinder

Tilt Cylinder

Access

Panel

Compensating

Cylinder

Quick Attach

3.1 BOOM SYSTEM COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.

3-2

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Boom

MZ3630

MZ3640

3.2 SAFETY INFORMATION

WARNING

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

3.3 BOOM SYSTEM - TWO SECTION BOOM

3.3.1 Boom System Description

The boom operates via an interchange among the electrical, hydraulic and mechanical systems. Componen ts involved include the joystick, tilt cylinder, extend/retract cylinder, lift/lower cylinder, compensating cylinder, electronic sensors, various pivots, supporting hardw are and other componen ts.

3.4 BOOM ASSEMB LY MAINTENANCE

The boom assembly consists of the first and second section booms and supporting hardware.

3.4.1 Boom Removal

1. Remove any attachment from the quick switch assembly.

2. Be sure there is enough room in front of the machine to allow the boom sections to be removed. Park the machine on a hard, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

4. Properly disconnect the battery.

5. Open the engine cover. Allow the system fluids to cool.

6. Remove the qu ick swi tch asse mbly. Refer to Section

3.6.1, “Quick Attach Removal.”

Note: Before removing the boom or boom section, the carriage or any other attachment must be removed from the quick attach.

Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understa nd and follow thes e instructions.

During service of the boom, perform the following:

1. Check wear pads. (Refer to Section 3.5.1, “Wear Pad Inspection.”)

2. Apply grease at all lubrication points (grease fittings). (Refer to Section 2.6, “Lubrication Schedule.”)

3. Check for proper operation by operating all boom functions through their full ranges of motion several times.

Depending on your particular circumstance, the following procedures explain the removal/installation of individual boom sections or removal/installation of the complete boom.

7. Support the front of the boom by placing a sling behind the boom head. Support the lift/lower cylinder and remove the lock bolt (1) and pin from the rod end of the lift/lower cylinder (2). Lower the lift/lower cylinder onto the frame rails.

8. Label and disconnect the tilt and auxiliary hydraulic hoses attached to the machine at the rear of the boom. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

9. Label and disconnect the extend/retract hydraulic hoses at the extend/retract cylinder.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

3-3

Boom

MZ5630

MZ3650

MZ3660

10. Remove the lock bolt (3) and pin (4) from the rod end of the compensating cylinder on the first boom section. Rest the cylinder on the machine frame.

11. Lower the boom to a level position and place a suitable support under the rear of the boom. Reposition the slings to each end of the boom.

12. Remove the lock bolts (5), keeper plate (6) and pivot pin (7) from rear of first boom section.

13. Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the bottom of the boom.

3.4.2 Second S e c tion B o o m Remo v a l

1. Set the complete boom on level ground and by repositioning the slings, turn boom over on to the top side. Set the complete boom on suitable stands to begin tear down.

2. Remove the access cover from the boom head.

Note: With the complete boom setting upside down, the second boom section, tilt cylinder and hoses are made more accessible. This also eliminates the need to remove the hose rack on the bottom of the boom.

4. Remove the lo ck bolt (9) and pin (10) from the barrel end of tilt cylinder. Lift the tilt cylinder out of the boomhead.

5. From the access opening on the bottom front of the boom, label and disconnect both auxiliary hoses (11). Plug the hose ends to prevent dirt and debris from entering the hydraulic system.

6. Carefully pull the tilt, auxiliary and extend/retract hydraulic hoses (12) through the rear of the second boom section.

7. Remove the two snap rings and pin (13) from barrel end of the extend/retract cylinder.

8. Pull the second boom section out 15 cm to 20 cm (6 in to 8 in) to be able to loosen and remove all the bolts and remove all the wear pads, backing plates and shims from the front inside of the first section boom. Tag each pad, backing plate, shim and bolts

from each location.

WARNING

3. At the boom head, attach a sling through rod end of tilt cylinder. Label and disconnect both hoses (8) from tilt cylinder. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

3-4

NEVER weld or drill the boom. The structural integrity

of the boom will be impaired if subjected to any repair involving welding or drilling.

9. Remove the clip and pin from the rod end of the extend/retract cylinder and pull through the rear of the second boom section.

10. Pull out the remainder of the second boom section. 1 1. Inspect the boom and welds. Consult your local JLG

distributor if structural damage is detected.

12. Inspect hoses, hardware, wear pads, mounting points and other components visible with the first boom section. Replace any item if damaged.

13. Inspect all wear pads for wear. (Refer to Section

3.5.1, “Wear Pad Inspection.”)

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Boom

MZ5630

MZ3640

3.4.3 Second Section Boom Installation

1. Insert the extend/retract cylinder through the rear of the second boom section and attach the pin and clip to the rod end.

2. Install the bottom rear wear pads, washers and bolts into the first boom section. Apply Loctite torque to 90 Nm (66 lb-ft). Install the bottom rear left and right si de wear p ads, ba cking pl ate and bo lts (do not shim or tighten bolts). Install top rear wear pads, backing plates and bolts (front bolts are drilled and tapped for zerk fittings, do not shim or tighten bolts).

3. Grease the inside of the first boom section on areas where the second boom section wear pads will slide.

4. Using a suitable sling, carefully slide the second boom section 1 m to 1.5 m (3 ft to 4 ft) into the front of the first boom section. Set the second boom section head onto suitable supports and reset sling under the boom head of the second section. Carefully slide the second section into the first section. Leave 15 cm to 20 cm (6 in to 8 in) of the second section out to be able to install wear pads in front of the first boom section.

5. With the sling still under the boom head, install the top wear pads, washers and bolts in the front of the

first boom section. Apply Loctite

243TM and torque to 90 Nm (66 lb-ft). Lower the second boom section and install the bottom wear pads, backing plates, shims and bolts in the front of the first boom section.

Apply Loctite

243TM and torque to 90 Nm (66 lb-ft). Install both left and right side front wear pads, backing plates, shims and bolts in the front of the

first boom section. Apply Loctite

243TM and torque

to 90 Nm (66 lb-ft).

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly.

6. Tighten all rear wear pad bolts after ensuring the minimum gap requirements have been met. Refer to Section 3.5.1, “Wear Pad Inspection.”

7. Insert the pin and clip into the barrel end of the extend/retract cylinder.

8. Lift the tilt cylinder into place and insert the pins and clips to secure the cylinder to the boomhead.

9. Slide the tilt and auxiliary hoses between the boom sections.

10. Uncap and reconnect the tilt and auxiliary hoses and attach to their appropriate locations.

11. Install the access cover on the front of the boom head.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

243TM and

3.4.4 Boom Installation

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly . Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.

1. Park the machine on a hard, level surface, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Using suitable slings, turn boom back over to original orientation.

Note: Grease the boom pivot bore, compensating cylinder rod ends, lift/lower cylinder rod end and pins before installing.

5. Using suitable slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bore with the boom assembly pivot bore. Install boom pivot pin (14) with keeper plate slot facing down. Apply Loctite bolts (15). Install the keeper plate (16), lock bolts (15) and torque to 90 Nm (66 lb-ft).

243TM to the mounting

3-5

Boom

MZ3630

MZ3680

6. With the sling still in place, install the comp cylinder pin (1) and lock bolt (2). Apply Loctite

243TM and

torque to 90 Nm (66 lb-ft).

7. With the sling still in place, install the rod end of the lift/lower cylinder (3), pin (4) and lock bolt (5). App ly

Loctite

243TM and torque to 90 Nm (66 lb-ft).

Note: Raising the boom up or down with the sling may be necessary so the boom, compensating and lift/lower cylinder bores can be aligned for easier pin installation.

8. Uncap and reconnect the extend /re trac t cylin der fittings and plugs from extend/retract cylinder hoses. Attach each hose to the extend/retract cylinder fittings and tighten until wrench-tight. Mark the fitting, then tighten each hose firmly 1 to 1,5 flats.

9. Uncap and reconnect both the tilt and auxiliary hoses. Attach both sets to their appropriate tubes until wrench-tight. Mark the fitting, then tighten each hose firmly 1 to 1,5 flats.

10. Properly connect the battery.

11. Start the engine and operate all boom functions several times to bleed any air out of the hydraulic system. Check for oil leaks. Check the hydraulic oil level in the tank and add oil as required.

12. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

13. Close and secure the engine cover.

14. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3.4.5 Extend/Retract Cylinder Removal

1. Remove any attachment from the quick attach assembly. Refer to Section 3.6, “Quick Attach Assembly.”

2. Park the machine on a hard, level surface, extend the boom approximately 1 m (3 ft) to gain access to the extend/retract cylinder pin in the second boom section, level the boom assembly, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

Note: The boom must be properly aligned (level) with the access hole at the rear of the frame to allow removal of the extend/retract cylinder barrel mounting pin.

3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

4. Open the engine cover. Allow the system fluids to cool.

5. Properly disconnect the batter y.

6. Remove the cylinder rod eye snap rings and mounting pin (6) at the side of the second boom section.

3-6

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

7. Loosen and remove the cover plate from the rear of

MZ3690

the frame assembly.

8. Label and disconnect the tilt and auxiliary hydraulic hoses (7) attached to the tubes at the bottom rear of the boom. Plug and cap the hose and tube ends to prevent dirt and debris from entering the hydraulic system.

9. Label and disconnect the extend/retract cylinder hoses at the rear of the extend/retract cylinder (8). Plug the hose ends to prevent dirt and debris from entering the hydrauli c system.

10. Loosen and remove both fittings from the bottom of the extend/retract cylinder barrel. Plug the openings in the extend/retract cylinder barrel.

11. Remove the snap ring on each side of the extend/ retract cylinder mounting pin.

12. Remove the mounting pin (9).

13. Attach a sling or other suitable lifting device to the extend/retract cylinder and carefully pull the extend/ retract cylinder free of the machine through the rear of the boom/chassis assembly.

14. Place the extend/retract cylinder in a designated area for the next operation.

Boom

3.4.6 Extend/Retract Cylinder Installation

1. Using a suitable sling, carefully install the extend/ retract cylinder into the rear of the boom and line up the barrel end of the cylinder with the pin bores on the first boom section.

2. Install the mounting pin (9) through the frame access hole on the chassis and the first boom section bore and cylinder barrel. Secure with snap rings.

3. Remove the plugs in the bottom of the extend/retract cylinder and install the previously removed fittings.

4. Uncap and connect the hoses to the previously labeled fittings at the extend/retract cylinder (8). Apply Loctite

5. Uncap and reconnect the tilt hoses and auxiliary hoses (7) to their appropriate fittings until wrenchtight. Mark the fitting and torque to specification. Refer to Section 2.2.3, “Hydraulic Hose Torque Chart.”

6. Install the cover plate at the rear of the boom assembly.

7. Properly connect the battery.

8. Start the machine and extend the extend/r etrac t cylinder until the rod eye of the cylinder aligns with the pin bore in the second boom section .

9. Shut the engine OFF.

10. Install the mounting pin through the side of the second boom section (6) and secure with the snap rings.

11. Start the machine and cycle the extend/retr act cylinder to bleed any air out of the hydraulic system. Check for oil leaks or any alignment problems. Check the hydraulic oil level in the tank and add oil as required.

12. Close and secure the engine cover.

13. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

545TM to the fittings.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

3-7

Boom

Ma2070

MY3620

3.5 BOOM WEAR PADS

A total of 14 wear pads are installed on the boom. Twelve of the fourteen wear pads on this boom are flat

rectangular wear pads with metal inserts. Two wear pads on the bottom of the second section boom are channeled for tilt hose and auxiliary hose clearance.

3.5.1 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicators (1) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.

• Maintain a total boom section clearance (5) of 1,78 - 3,30 mm (0.070 - 0.130 in) both the horizontal and vertical directions.

3.5.2 Wear Pad Installation and Lubrication

Note: Inspect all wear pads. Replace as necessary.

The following wear pad procedure must be followed to insure the proper wear pad installation:

• The wear pad inserts and mounting bolts MUST be clean from any grease, oil or other contaminates before applying Locti te bolts.

• Apply Loctite

243TM to all wear pad mounting bolts.

• A spacer (2) with holes must be used before any shim (3) is used.

• A shim (3) must be inserted between the spacer (2) and wear pad support plate, block or boom section (4).

• The number of shims can vary at each shim point.

• The bottom wear pads must be shimmed equally on

each side.

243TM and installing mounting

• The length of the wear pad bolt depends on the number of shims, spacers and washers being used.

• The thickness of each threaded wear pad insert is 7,92 mm (0.312 in)(A).

• The bolt length should be determined by measuring the distance from the face of the insert to the face of the boom (B) including any spacer, shim(s) and washer(s).

• Bolt thread engagement in the wear pad insert should be 6,98 ± 1,0 mm (0.275 ± 0.040 in).

• One or two hardened washers are to be used on each wear pad bolt except where noted otherwise. DO NOT use more than two hardened washers.

• Use only one hardened washer if mounting bolts are recessed.

• Wear Pad Bolt Torque: M10x20 Bolt, 50 Nm (37 lb-ft) M10x25 Bolt, 50 Nm (37 lb-ft) M10x30 Bolt, 50 Nm (37 lb-ft) M10x40 Bolt, 50 Nm (37 lb-ft) M10x45 Bolt, 50 Nm (37 lb-ft) M10x50 Bolt, 50 Nm (37 lb-ft) M12x20 Bolt, 90 Nm (66 lb-ft) M12x25 Bolt, 90 Nm (66 lb-ft) M12x30 Bolt, 90 Nm (66 lb-ft)

• Torque wear pad bolts after shimming is completed.

• Lubricate the face and pockets of each wear pad

after being installed.

3-8

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Boom

MZ3700

Boom Section Wear Pad Pathway Lubrication:

• Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease.

• Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.

3.6 QUICK ATTACH ASSEMBLY

3.6.1 Quick Attach Removal

1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

3.6.2 Quick Attach Installation

1. Line up the quick attach between the mounts on the boom head. The quick attach should be centered in the boom head.

2. Coat the quick attach pivot pin (9) with an anti-seize compound. Insert the quick attach pivot pin through the quick attach (8) and boom head. Align the pivot pin and quick attach. Install the lock bolt and torque to 97 Nm (72 lb-ft).

3. Align the qu ick attach (8) with the tilt cylinder rod end and insert the tilt cylinder pin (7). Align the tilt cylinder pin and quick attach. Install the lock bolt and torque to 97 Nm (72 lb-ft).

4. If equipped, uncap and reconnect the hydraulic quick attach device hoses (6) to the valve on the left side of the boom head.

5. Properly connect the battery.

6. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

7. Close and secure the engine cover.

8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

5. If equipped with a hydraulic quick attach device, remove both hydraulic hoses (6) from the valve on the left side of the boom head. Plug and cap the hose ends to prevent dirt and debris from entering the hydraulic system.

6. Remove the lock bolt holding the tilt cylinder rod end pin (7) to the qui ck at tach assemb ly ( 8). Re move the tilt cylinder pin (7).

7. Support the quick attach asse mbl y (8). Remo ve the lock bolt holding the quick attach pin (9) to the quick attach assembly. Remove the pin from the quick attach assembly from either side.

8. Inspect the above pin for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired the pin must be replaced.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

3-9

Boom

MH6460

MAM1280

2 1

3.7 FORKS

Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately.

Daily Inspection

1. Inspect forks (8) for cracks, paying special attention to heel (9) and mounting tubes (10).

2. Inspect forks for broken or bent tips (11) and twisted blades (12) and shanks (13).

Yearly Inspection

1. Straightness of the upper face of blade (12) and the front face of shank (13) should not exceed 0.5 percent of the length of blade or height of shank.

2. Angle (14) between upper face of blade and front face of shank should not exceed 93 degrees.

3. Thickness of blade (15) and shank (16) should not be reduced to 90 percen t of origi na l thic kn ess.

Note: Contact the local JLG distributor with the fork part number to find the manufactured dimensions of the fork blade.

4. Ensure fork length (17) is adequate for intended loads.

5. Fork markings should be legible, re-stamp if required.

6. Compare fork tips (18) when mounted on a carriage. Maximum difference in height of fork tips is 3 percent of the length of the blade (15).

3.8 BOOM PROP (IF EQUIPPED)

3.8.1 Installation and Removal Procedures

WARNING

A raised boom can fall if a hydraulic component is removed. Remove any load, retract the boom and install the boom prop or a suitable supporting stand before working under a raised boom.

a. Prop Installation

1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park br ake switch.

2. Raise the boom to an angle of approximately 20 degrees. Shut engine OFF.

3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

4. Before installing the boom prop, inspect the prop for damage. Do not use if the prop is damaged or if the o-rings are damaged or missing.

3-10

5. Install the boom prop (1) onto the lift/lower cylinder. Install o-rings (2). Align lift cylinder lock so the o-rings are on the bottom side of the lift/lower cylinder rod.

6. Start the engine and SLOWLY lower the boom until there is a clearance of 6 mm (0.25 in) between the end of the boom prop and the lift/lower cylinder rod end (3).

7. Shut engine OFF.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

NOTICE

MZ5370

EQUIPMENT DAMAGE. DO NOT operate with the

boom prop in place. Damage to the boom prop and/or the lift/lower cylinder could occur.

Boom

3.9.1 Equipment and Supplies Required

Auxiliary Hydraulic Power Supply:

• Portable hydraulic unit or another machine with an auxiliary hydraulic power supply with a capacity to hold up to 11,4 L (3 gal) of hydraulic oil from the machine during lowering process.

b. Prop Removal

1. If needed, start machine and slowly raise the boom until the boom prop is clear of the lift/lower rod end.

2. Remove the o-rings (2) and boom prop (1) from the cylinder. Return the boom prop to the proper location and secure.

3. Lower boom, shut engine OFF.

3.9 EMERGENCY BOOM LOWERING PROCEDURE

In case of an emergency, engine, hydraulic or electrical failure, use the following procedure to retract and/or lower the boom.

WARNING

To avoid instabi lity of the m achine, the extend/retract cylinder MUST BE fully retracted prior to retracting the lift cylinde r. If circumstances preven t retraction of the extend/retract cylin der first, lower the lift cylinder the minimum amount necessary and resume retraction of the extend/retract cylinder as soon as possible.

NOTICE

EQUIPMENT DAMAGE. Auxiliary Hydraulic Power Supply hydr aulic o il must be compa tible w ith hy drauli c oil shown in Section 2.4, “Fluids, Lubricants and Capacities.”

Hoses:

• Two Hydraulic Hoses - Approximately 3,0 m (10 ft) each, with a minimum I.D. of 9,5 mm (0.375 in) and a minimum rating of 275,8 bar (4000 psi).

Fittings:

• Two 25,4 mm (1 in) - 14 ORFS Caps

• Two 25,4 mm (1 in) - 14 ORFS Plugs

Note: Machine extend/retract and lift/lower hoses are 14 ORFS. The adaptor size may vary depending on the hose ends of the auxiliary hydraulic power supply.

3.9.2 Lowering Procedure

a. Retract the boom as follows:

1. Place a suitable receptacle under the hose connections.

2. From the rear of the machine, locate the extend/ retract cylinder connection (4 & 5) at the rear of the main control valve.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

3-11

Boom

MZ5370

3. Label and disconnect both extend/retract hoses (4 & 5). Install plugs in hoses to prevent oil loss. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

Note: Loss of hydraulic oil is limited to the amount trapped within each hose.

4. Using the hoses and fittings specified previously, connect the jumper hoses betw een the aux il ia ry hydraulic power supply and the extend/retract hoses (4 & 5) of the affected machine. Ensure that the supply and return lines are installed in the proper order to ensure that the cylinder is retracted, not extended.

5. Use the auxiliary power supply to retract the extend/ retract cylinder.

6. Loosen and remove the jumper hoses and reconnect the extend/retr act cylin der hoses.

7. Transfer any hydraulic oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility.

8. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

b. Lower the boom as follows:

2. Label and disconnect the lift/lower cylinder hoses (6 & 7) from the main control valve. Install plugs in hoses to prevent oil loss. Cap all fittings and openings to keep dirt and debris from entering the hydraulic syst em.

Note: Loss of hydraulic oil is limited to the amount trapped within each hose.

3. Using the hoses and fittings specified, connect the hoses between the auxiliary hydraulic power supply and the hoses removed from the main control valve lift/lower section of the affected machine. Hose (7) is the supply (lower) and hose (6) is the return. Connect the hoses in the proper order to ensure that the boom is lowered, not raised.

4. Use the auxiliary power supply to retract the lift cylinder.

5. After the boom has been lowered, loosen and remove the jumper hoses and reconnect the lift/ lower cylinder hoses at the main control valve.

6. Transfer any hydraulic oil into a suitable, covered container, and label the container as “Used Oil.” Dispose of used oil at an approved recycling facility.

7. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

1. Place a suitable receptacle under the main control valve.

3-12

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

3.10 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that occur during operation of the boom.

Problem Possible Causes Remedy

Boom

1. Boom will not extend or retract.

2. Boom will not fully extend. 1. Extend/retract hydraulic system

3. Boom shifts to right or left when extending.

4. Excessive pivot pin noise and/or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Extend/Retract hydraulic system not operating properly.

3. Faulty extend/retract cylinder. 3. Repair cylinder (Refer to Section

not operating properly.

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn bushing(s). 2. Replace bushing(s) and

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8, “Hydraulic System.”

8.12.4, “Cylinder Inspection.”)

1. Refer to Section 8, “Hydraulic System.”

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.5.1, “Wear Pad Inspection.”

(Refer to Section 2.6, “Lubrication Schedule.”) Replace worn pins as needed.

lubricate at regular intervals (Refer to Section 2.6, “Lubrication Schedule.”)

5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes and/or connection leaks.

2. Lift/lower hydraulic system not operating properly.

3. Faulty lift cylinder . 3. Repair cylinder. (Refer to

4. Seized boom pivot pin bushing. 4. Replace bushing.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8, “Hydraulic System.”

Section 8.12.4, “Cylinder Inspection.”)

3-13

Boom

Problem Possible Causes Remedy

6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and

correct as needed. Refer to Section 3.5.1, “Wear Pad Inspection.”

7. Auxiliary hydraulics will not operate.

2. Rapid cycle times with heavy loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

1. Auxiliary hydraulic system not operating properly.

2. Reduce cycle times.

3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

4. Clean equipment frequently.

1. Refer to Section 8, “Hydraulic System.”

3-14

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 4

Cab and Covers

Contents

PARAGRAPH TITLE PAGE

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.1 Operator Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.2 Serial Number Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4.1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4.2 Steering Column/Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.4.3 Brake Pedal and Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.4.4 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4.5 Throttle Cable Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.4.6 High Idle Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.4.7 Joystick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.4.8 Windshield Wiper Assembly (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.4.9 Windshield Washer Assembly (If Equipped). . . . . . . . . . . . . . . . . . . . . . . 4-7

4.4.10 Heater/Air Conditioning System (If Equipped) . . . . . . . . . . . . . . . . . . . . . 4-7

4.5 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.6 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

4-1

Cab and Covers

MZ5300

FRONT CONSOLE

SWITCHES

SERVICE BRAKE PEDAL

JOYSTICK

TRANSMISSION

CONTROL LEVER

INSTRUMENT

PANEL

PARK BRAKE LEVER

ACCELERATOR PEDAL

IGNITION SWITCH

ADJUSTABLE

STEERING COLUMN

HYDRAULIC HITCH SAFETY

HOOK RELEASE

(IF EQUIPPED)

STEERING WHEEL

KEYPAD

ENGINE OIL

TEMPERATURE GAUGE

(723A, IF EQUIPPED)

FRAME LEVEL

INDICATOR

LSI INDICATOR

(L2906H, 2906H, 3507,

29.6LP, 29.6 & 35.7)

ACCESSORY CONTROL LEVER

(IF EQUIPPED)

SIDE CONSOLE

SWITCHES

4.1 OPERATOR CAB AND COVERS COMPONENT TE RMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.

4-2

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Cab and Covers

MAH0430

4.2 SAFETY INFORMATION

WARNING

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

4.3 OPERATOR CAB

4.3.1 Operator Cab Description

The welded metal cab features a modular design, allowing for a relatively quick, simple exchange of the entire cab and/or component pa rts. The cab is bolted directly to t he frame.

The operator cab is a protective structure. The cab itself contains rollover protective and falling object protective structures (ROPS/FOPS) for the operator.

WARNING

DO NOT weld, grind, drill, repair or modify the cab in

any way. Any modification or damage to cab structural components requires cab replacement.

4.4 CAB COMPONENTS

4.4.1 Steering Wheel

a. Steering Wheel Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine covers. Allow the system fluids to cool.

4. Properly disconnect the battery.

To help ensure optimum safety, protection and performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.

The cab contains the seat, operating controls, numerous panels, steering and brake components, and more.

Covers and mirrors on the machine exist for safety, protection and appearance. They are relatively simple to remove and replace.

4.3.2 Serial Number Decal

The cab serial number decal is located inside the cab, under the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.

5. Carefully pry the center button (1) out of the steering wheel.

6. Mark the steering wheel and shaft to ensure proper installation. Re mov e the nu t ( 2) securing the steering wheel (3) to the splined steering column shaft.

7. Use a steering wheel puller to remove the steering wheel (3) from the splined shaft.

b. Steering Wheel Installation

1. Install the steering wheel (3) onto the splined steering column shaft.

2. Secure the steering wheel with the nut (2).

3. Press the center button (1) onto the steering wheel.

4. Properly connect the battery.

5. Close and secure the engine covers.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

4-3

Cab and Covers

MY2440

4.4.2 Steering Column/Valve Replacement

a. Steering Column and Valve Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine covers. Allow the system fluids to cool.

4. Properly disconnect the battery.

b. Steering Column and Valve Installation

1. Install the four hex-flange capscrews (three if machine is equipp ed wi th til t co lumn ) thr ough th e steering column, mounting bracket and into the top of the orbitrol valve.

Note: ALWAYS use new o-rings when servicing the machine.

2. Uncap and if needed, install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.

3. Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations.

4. Install the dash cover.

5. Install the steering column cover.

6. Install the steering wheel (Refer to Section 4.4.1, “Steering Wheel.”), accessory lever and transmission control lever.

7. Properly connect the battery.

8. Start the engine and check the operation of all controls. Check for oil leaks. Check the hydraulic oil level in the tank and add oil as required.

9. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

10. Close and secure the engine covers.

11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

5. Remove the steering wheel (1) (Refer to Section

4.4.1, “Steering Wheel.”), transmission control lever (2) and accessory lever (if equipped)(3).

6. Loosen and remove the steering column cover.

7. Loosen and remove the dash cover.

8. Label, disconnect and cap the hydraulic hoses (4) and fittings on the steering orbitrol valve (5).

9. Remove the four hex-flange capscrews (6)(three if machine is equipped with tilt column) connecting the orbitrol valve to the steering column.

10. Pull the steering column assembly and orbitrol valve from the machine cab.

Note: DO NOT disassemble the steering orbitrol valve. The steering orbitrol valve is not serviceable and must be replaced in its entirety, if defective.

4-4

c. Power Steering Test

Conduct a pressure check of the steering hydraulic circuits at the test port on the implement pump. Refer to Section 8.6.6, “Steering Press ur e Checki ng.”

4.4.3 Brake Pedal and Valve

a. Brake Valve Removal

Refer to Section 8.11.2, a. “Service Brake Valve Removal,” for removal information.

b. Brake Valve Installation

Refer to Section 8.11.2, b. “Service Brake Valve Installation,” for installation information.

c. Service Brake Pedal Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Cab and Covers

MZ5310

MZ5320

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine covers. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the lower dash cover.

4.4.4 Throttle Pedal Replacement

a. Throttle Pedal Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine covers. Allow the system fluids to cool.

4. Properly disconnect the battery.

6. Remove the clip/pin (6) from the brake plunger fork link.

7. Remove the brake pedal return spring (7).

8. Remove the snap ring and washer (8).

9. Pull the brake pedal assembly (9) to the left to clear the pedal stop (10). Lift up the pedal, slide to the left and remove the brake pedal assembly from the cab.

d. Service Brake Pedal Installation

1. Position the brake pedal assembly (9) in its mounting location within the cab.

2. Install the brake pedal being careful to reposition the brake plunger yoke. Install clip/pin (6) in brake plunger fork link.

3. Install the washer and snap ring(8).

4. Install the brake pedal return spring (7).

5. Adjust the brake pedal as needed.

6. Install and secure th e lo wer da sh cove r.

7. Properly connect the battery.

8. Close and secure the engine covers

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

5. Loosen and remove the hex nut (11) securing the throttle cable to the throttle pedal assembly (12).

6. Remove the throttle pedal return spring (13).

7. Remove snap ring and washer (14) securing the throttle pedal assembly to the cab frame.

8. Remove the throttle pedal assembly from the cab.

b. Throttle Pedal Installation

1. Align the throttle pedal assembly with its mount holes under the cab dash.

2. Install the washer and snap ring (14) securing the throttle pedal assembly to the cab frame.

3. Install the throttle pedal return spring (13).

4. Install the hex nut (11) securing the throttle cable to the throttle pedal assembly (12).

5. Properly connect the battery.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

4-5

Cab and Covers

MZ5330

MY2940

4.4.5 Throttle Cable Adjustment

1. With the engine OFF, lightly depress the accelerator pedal (1) to the full-throttle position.

2. Block the accelerator pedal to the full throttle position, check the throttl e posit ion o n the fuel injector pump on the engine. The throt tle lever shou ld be bott omed against the limit-stop screw.

3. If there is an adjustment needed, return to the cab and adjust the throttle cable (2) so the lever on the fuel injector pump bottoms against the limit-stop just before the throttle pedal bottoms against the limitstop (3) in the cab.

4. Remove the block h oldin g the t hrott le befo re st artin g machine.

4.4.6 High Idle Adjustment

Note: Engine coolant temperature must be between 10 and 38° C (50 and 100° F).

CE Machines

1. Start the machine and allow engine to low idle for approximately 30 seconds.

2. Verify low idle (900 ± 50 rpm). Low idle is a factory non-adjustable settin g.

3. Bring engine to full throttle. If high idle rpm is greater than or equal to 2340 rpm, a thick throttle stop will need to be installed. If high idle rpm is less than 2340 rpm, a thin throttle stop will need to be installed.

4. Return engine to low idle and shut engine OFF.

5. Allow the engine to cool. Install proper throttle stop (4) and verify high idle is correct.

6. Restart engine, bring engine to high idle. High idle must be between 2005 and 2090 rpm.

Note: For the proper throttle stop, contact the local JLG dealer.

ANSI Machines

1. Start the machine and allow engine to low idle for approximately 30 seconds.

2. Verify low idle (900 ± 50 rpm). Low idle is a factory non-adjustable setting.

3. Bring engine to full throttle. If high idle rpm is not 2335 ± 75 rpm, readjust the throttle cable at the throttle pedal in the cab.

4-6

NOTICE

During the full throttle check:

• DO NOT operate any hydraul ic funct ion .

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in (N) NEUTRAL.

WARNING

Avoid breathing exhaust fumes, and prevent engine operation from becoming a cause of toxic emissions.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

WARNING

MZ53800

Exhaust system components reach high temperatures and can cause severe burns. DO NOT come into contact with hot exhaust system components.

Cab and Covers

5. Start the engine and test the boom joystick for proper functions.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.4.7 Joystick Replacement

a. Joystick Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine covers. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the access cover below the joystick.

6. Loose and remove the four capscrews (5) holding the joystick assembly (6) in place.

7. Lift the joystick assembl y (6) and unplug the three electrical connections (7).

8. Remove the joystick.

b. Joystick Installation

1. Reconnect the electrical connections (7) and set the

2. Install the four capscrews in the joystick base.

3. Replace the access cover below the joystick.

4. Properly connect the battery.

joystick assembly (6) in place.

4.4.8 Windshield Wiper Assembly (If Equipped)

Refer to Section 9.12.1, “Windshield Wiper Motor (if equipped),” for removal and installation information.

4.4.9 Windshield Washer Assembly (If Equipped)

Refer to Section 9.12.3, “Windshield Washer Reservoir and Pump,” for removal and installation information.

4.4.10 Heater/Air Conditioning System (If Equipped)

a. Heater Assembly Removal

Note: If machine is equipped with air conditioning, DO NOT loosen or disconnect any air conditioning hoses until the air conditioning system has been properly drained by the local JLG dealer or certified air conditioning service center.

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine covers. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Place a suitable container beneath the radiator drain plug or petcock. Slowly turn the cap on the coolant overflow bottle to allow any pressure to escape. Remove the overflow bottle cap.

6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open the radiator drain plug or petcock and allow the coolant to drain. Replace the drain plug, or close the petcock.

7. Transfer the coolant into a suitable, covered container, and label as "Used Coolant". Dispose of used coolant at an approved recycling facility.

Note: Label all hoses to ensure correct installation.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

4-7

Cab and Covers

MZ5390

8. Remove the seat/seat base.

9. Remove the seat plate (8) to expose the heater/ defroster element.

10. Loosen the hose clamps and disconnect the two heater hoses.

11. If equipped, loosen, label and disconnect the two air conditioning hoses.

12. Remove the capscrews, nuts and lockwashers securing the heater assembly to the cab.

13. Carefully pull out the heater assembly. Label and disconnect the wiring harness connections at the blower.

14. Remove the heater assembly.

b. Heater Assembly Ins tallation

1. Install the heater assembly to its original orientation.

2. Connect the wiring harness connections at the blower.

3. Install the capscrews, nuts and lockwashers to secure the heater assembly to the cab.

4. Reconnect the two heater hoses.

5. If equipped, reconnect the air conditioning hoses.

6. Refill the cooling system at the coolant overflow bottle with coolant allowing time for the coolant to fill the engin e block. See Section 2.4, “Fluids, Lubricants and Capacities,” for system capacities.

7. Recharge the air conditioning system. Refer to Section 4.4.11, “Air Conditioning (If Equipped).”

8. Properly connect the battery.

9. Start the engine, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the machine immediately if any leakage is

noted, and make any necessary repairs before continuing.

10. Install the seat plate (8) in the cab.

11. Install the seat/seat base.

12. Check the coolant level. Add or remove fluid as required.

13. Verify the proper operation of the heating and air conditioning (if equipped) system.

14. Close and secure the engine covers.

15. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.4.11 Air Conditioning (If Equipped)

If the air conditioning system requires servicing, contact the local JLG dealer or certified air conditioning service center. Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for refrigerant type and capacity.

4.5 CAB REMOVAL

WARNING

The protection offered by this ROPS/FOPS will be impaired if subjected to any modification or structural damage, at which time replacement is necess ary. ROPS/FOPS must be properly installed using fasteners or correct size and grade, and torqued to their specified value.

Note: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.

Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact the local JLG dealer with any questions about the suitability or condition of a cab.

Note: Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine.

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Block all four wheels to help prevent the machine from moving. Assure t hat ther e is suf ficien t overhe ad and side clearance for cab removal.

4-8

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Cab and Covers

MZ5400

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. If equipped with a cab heater, Refer to Section

4.4.10, b. “Heater Assembly Installation.”

6. Working underneath the cab, label, disconnect and cap all hydraulic hoses at the cab fittings. Cap all fittings and openings to keep dirt and debris from entering the hydrauli c system.

7. In the cab, disconnect the throttle cable at the throttle lever bracket. Route the cable away from the cab to prevent damage during removal.

8. Label and disconnect the cab harness connectors. Move the harnesses clear of the cab to prevent damage during cab removal.

9. Install two lifting eye bolts with a minimal lifting capacity of 363 kg (800 lb) in the existing holes at the top of the cab (1).

10. Use a hoist or overhead crane and sling with a minimal lifting capacity of 363 kg (800 lb) attached to the four lifting eye bolts. DO NOT attempt to lift the cab at this point.

1 1. Remove the bo lts (2), washers and nuts securing the

cab to the frame.

12. Remove the mirrors and all other cab components as needed, if not previously removed.

13. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the frame. Readjust the position of the sling as needed to help balance the cab during removal.

14. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall. Assure that no personnel enter the cab while it is being removed from the machine.

15. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

16. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

4.6 CAB INSTALLATION

1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation.

2. Attach a sling with minimal lifting capacity of 363 kg (800 lb) through the previously installed eye bolts.

3. Use a hoist or overhead crane and sling attached to the cab. Carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Take special note of the fuel fill tube as well. Readjust the position of the sling as needed to help balance the cab during installation.

4. Install the cab-to-frame bolts, washers and nuts (2). Torque the upper cab bolts to 461 Nm (340 lb-ft). Torque the lower cab bolts to 719 Nm (530 lb-ft).

5. Remove the eye bolts from the top of the cab (1).

6. Connect the throttle cable to the throttle bracket in the cab.

7. Uncap and reconnect the hydraulic hoses at the cab locations.

8. Secure the throttle cable to the hydrauli c hoses using nylon ties.

9. Install the cab-to-wiring harness connectors on side of the cab.

10. Uncap and connect the heater hoses to the engine. Secure with hose clamps.

11. If equipped with a cab heater, Refer to Section

4.4.10, “Heater/Air Conditioning System (If Equipped).”

12. Properly connect the battery.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

4-9

Cab and Covers

13. Start the engine and check the operatio n of all controls. Check for hydraulic oi l leak s. C heck the hydra ul ic o il level in the tank and add oil as required

NOTICE

When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.

14. Verify the proper operation of the heating and air conditioning (if equipped) system after the operating temperature is achieved ensuring that the thermostat has opened.

15. Turn engine off and wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.

16. Install the protective cover to the front of the cab.

17. Install the mirrors and all other components as needed, if removed.

18. Unblock the wheels

19. Close and secure the engine cover

20. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

WARNING

Avoid breathing exhaus t fumes, and prevent engine operation from becoming a cause of toxic emissions.

4-10

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5-2

5.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.3 Axle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.4 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.5 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.6 Axle Assembly and Drive Shaft T roubleshooting . . . . . . . . . . . . . . . . . . . 5-6

5.5 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.1 Drive Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.6.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-10

5.6.2 Installing Wheel and Tire Assembly onto Machine. . . . . . . . . . . . . . . . . . 5-10

5.7 Steering Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.8 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.8.1 Brake Disc Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

5-1

Axles, Drive Shafts, Wheels and Tires

MAH0190

REAR AXLE

ASSEMBLY

FRONT STEERING

CYLINDER

FRONT AXLE

ASSEMBLY

REAR STEERING

CYLINDER

DRIVE SHAFT

REAR AXLE WHEEL

HUBS (2)

FRONT AXLE WHEEL

HUBS (2)

5.1 AXLE, DRIVE SHAFT AND WHEEL

COMPONENT TE RMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.

5-2

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

5.2 SAFETY INFORMATION

WARNING

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

5.3 GENERAL INFORMATION

Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear.

5.4 AXLE ASSEMBLIES

5.4.1 Axle Serial Number Plate

The front and rear axle serial number plate is located on the inside of each axle on the right side of the center section. Inf ormation on the serial n umber plate is required in correspondence regarding the axl e.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

5.4.2 Axle Specifications

General axle specifications are found in Section 2, “General Information and Specifications.”

Detailed axle service instructions (covering the axle, differential, brakes and wheel end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the appropriate Axle Disassembly & Assembly Manual.

Axles, Drive Shafts, Wheels and Tires

Machine Manual P/N

L2906H, 2906H, 29.6LP,

29.6 & 619A

3507H, 35.7 & 723A

Front - 31200634

Rear - 31200635

Front - 31200636

Rear - 31200637

5.4.3 Axle Maintenance

CLEANING: Clean parts with machined or ground

surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant can cause gear and bearing failure. Remove old gasket material from all surfaces.

DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, coat components with oil or a rust-preventive chemical to help protect them from corrosion. If storing components for a prolonged period, wrap them in wax paper.

PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the machine far enough to cause the drivetrain components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity.

SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necess ar y.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

5-3

Axles, Drive Shafts, Wheels and Tires

MAH0440

MAH0990

5.4.4 Axle Removal

WARNING

Safely raise and adequately support the machine so that it will remain stable and in place before attempting to remove an axle.

The front and rear axle assemblies differ in that the front axle assembly is equipped with a hydraulic drive pump, parking brake mechanism and a limited-slip feature; the rear axle has none of these. The following steps outline a typical axle removal procedure, suitable for either the front or the rear axle assembly.

Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machi ne . Avoi d spraying water or cleaning solution on the stabilizer solenoids and other electrical components. If using a steam cleaner, seal all openings before steam cleaning.

IMPORTANT: C lea r the work area of all debr is, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as "Used Oil." Dispose of the used oil at an approved recycling facility.

6. Label, disconnect and cap the steering and brake lines at the axle. Wipe up any spilled oil.

7. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine wil l remain in place during axle removal before proceeding.

8. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal.

9. Support the ax le that is being r emoved with a sui table jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine.

10. Mark and remove both wheel and tire assemblies from the axle that is being removed. (Refer to Section 5.6.1, “Removing Wheel and Tire Assembly from Machine.”)

Note: The wheel and tire assemb lies must be re-inst alled later with the directional tread pattern “arrows” facing in the direction of forward travel.

11. Remove the drive shaft assembly. (Refer to Section

5.5.3, “Drive Shaft Removal.”)

12. Remove the capscrews, locknuts and axle plates securing the axle to the frame.

13. Remove the axle from the machine using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axl e. Bal an ce the axle and prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand.

5. If the axle will be disassembled after removal, place a suitable receptacle under the axle (1) and wheel hubs (2) drain plugs. Remove the drain plugs and

5-4

5.4.5 Axle Installation

1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the front and rear of both tires on the axle that is already installed on the machine.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Axles, Drive Shafts, Wheels and Tires

2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation.

3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure.

4. Position the axle under the frame, and align with the holes in the frame.

5. Install the axle with capscrews, locknuts and the axle plates. Torque the front and rear axles of the L2906H, 2906H, 29.6LP, 29.6 & 619A to 671 Nm (495 lb-ft). Torque the front axles of the 3507H, 35.7 & 723A to 1170 Nm (863 lb-ft) and the rear axles to 671 Nm (495 lb-ft).

6. Install the drive shaft assemblies. (Refer to Section

5.5.5, “Drive Shaft In stallat ion.”)

7. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaf t yo ke o n t he axle in the sam e pl a ne as th e yoke on the transmission.

8. Tighten the axle oil drain plug, loosen and remove the axle oil fill plug. Fill axle with the appropriate oil. Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.

9. Rotate wheel hubs 90 degrees so the drain plug becomes the fill plug. Fill wheel hubs with the appropriate oil. Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.

10. Install the wheel and tire assemblies. (Refer to Section 5.6.2, “Installing Wheel and Tire Assembly onto Machine.”)

11. Carefully remove the jack, hoist or overhead crane and sling supporting the axle.

12. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground.

13. Remove the blocks from the front and rear of both tires on the other axle.

14. Uncap and reconnect the steering and brake lines at their axle fittings. Refer to Section 8.10.4, “Brake Test,” for brake bleeding procedures.

15. Check the hydraulic reservoir oil level.

16. Properly connect the battery.

17. Close and secure the engine cover.

18. Start the engine. Turn the steering wheel several times lock to lock and check the function of the brakes. Check for hydraulic leaks, and tighten or repair as necessary.

19. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

5-5

Axles, Drive Shafts, Wheels and Tires

5.4.6 Axle Assembly and Drive Shaft Troubleshooting

Problem Possible Causes Remedy

1. Excessive axle noise while driving.

1. Oil level too low. 1. Fill oil to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

2. Axle and/or wheel end housings

filled with incorrect oil or oil level low.

3. Incorrect alignment of ring and

pinion gears.

4. Incorrect pinion (input) shaft

bearing preload.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end

8. Axle housing damaged. 8. Replace damaged parts.

2. Drain axle and/or wheel end housings and fill to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

3. Correct alignment by adding or removing shims as needed.

4. Correct bearing preload by adding or removing shims as needed.

housings and fill to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

2. Intermittent noise when traveling.

3. Vibration or intermittent noise when traveling.

1. Universal joint(s ) worn or damaged.

2. Differential ring and/or pinion gears damaged.

1. Drive shaft universal joint(s) assembly incorrectly tightened.

2. Drive shaft universal joint(s) worn or damaged.

3. Drive shaft damaged/ unbalanced.

1. Repair or replace universal joints as needed.

2. Determine cause and repair as needed.

1. Tighten capscrews to correct torque.

2. Repair or replace universal joints as needed.

3. Replace drive shaft as needed.

5-6

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Axles, Drive Shafts, Wheels and Tires

5.4.6 Axle Assembly and Drive Shaft Troubleshooting (Continued)

Problem Possible Causes Remedy

4. Oil leaking from axle (differential housing and/or axle housings).

1. Drain plugs loose and/or o-rings damaged or missing.

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surface s.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Replace o-rings as needed and tighten plugs 80 Nm (59 lb-ft).

3. Replace seal and/or joint coupling fork shaft (axle shaft).

4. Replace multi-se al ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Axle Repair Manuals.

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 320 Nm (236 lb-ft).

7. Replace housing(s) as needed.

5. Oil leaking from wheel end housing (planet carrier).

6. Oil leaking from steering cylinder.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

1. Hose fittings loose. 1. Tighten fittings.

2. Steering cylinder o-rings and/or seals worn or damaged.

3. Piston rod seal worn or damaged.

4. Cylinder tube damaged. 4. Replace cylinder tube.

1. Replace o-rings as needed and tighten plugs to 80 Nm (59 lb-ft).

2. Replace o-ring.

3. Replace seal and/or fork joint shaft.

55 Nm (41 lb-ft).

2. Replace o-rings and seals.

3. Replace piston rod seal.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

5-7

Axles, Drive Shafts, Wheels and Tires

5.4.6 Axle Assembly and Drive Shaft Troubleshooting (Continued)

Problem Possible Causes Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level. (Refer to

Section 2.4, “Fluids, Lubricants and Capacities.”)

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

8. High steering effort required. 1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

3. Worn or damaged swivel bearings.

9. Slow steering response. 1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally.

10. Excessive noise when brakes are engaged.

1. Brake discs worn. 1. Check brake discs for wear.

2. Brake discs damaged. 2. Replace brake discs.

2. Drain axle and/or wheel end housing and fill to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

1. Refer to the appropriate Axle Repair Manual.

2. Correct bearing preload by adding or removing shims as needed.

3. Replace swivel bearings as needed.

1. Refer to the appropriate Axle Repair Manual.

2. Repair or replace steering cylinder as needed.

Refer to appropriate Axle Repair Manual.

11. Brakes will not engage. 1. Brake (hydraulic) system not operating properly.

2. Brake piston o-rings and seals damaged (leaking).

12. Brakes will not hold the machine or braking power reduced.

5-8

1. Brake discs worn. 1. Check brake discs for wear.

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

1. Refer to the appropriate Axle Repair Manual.

2. Replace o-rings and seals.

Refer to the appropriate Axle Repair Manual.

2. Refer to the appropriate Axle Repair Manual.

3. Replace o-rings and seals.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Axles, Drive Shafts, Wheels and Tires

MZ6030

TO REAR AXLE

TO FRONT AXLE

5.5 DRIVE SHAFTS

5.5.1 Drive Shaft Inspection

Whenever servicing the machine, conduct a visual inspection of the drive shaft and cross and bearing assembly (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time lat er .

Inspect area where the drive shaft flange yoke and slip yoke mount to the drive shaft. Attempt to turn drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shaft and cross and bearing assembly may cause an excessive amount of vibration or noise.

5.5.2 Drive Shaft Maintenance

Refer to Section 2.6, “Lubrication Schedule,” for information regarding the lubrication of the grease fittings on the drive shafts.

5.5.3 Drive Shaft Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that th es e compo ne nts can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

6. Remove the four capscrews and four locknuts (1) securing the flange yoke (2) to the front axle flange.

7. Remove the four capscrew s (3) securing the flange yoke (4) to the rear axle flange.

8. Remove the drive shaft assembly (5).

5.5.4 Drive Shaft Cleaning and Drying

1. Disassemble and clean all parts. Allow to dry.

2. Remove any burrs or rough spots from all machined surfaces. Re-clean and dry as required.

5.5.5 Drive Shaft Installation

1. Raise the drive shaft as se mb l y (5) int o p osit i o n. Th e slip-yoke end of the drive shaft mounts toward the front axle. If reinstalling a drive shaft previously removed, align th e fl ange yok es a ccor din g to the alignment marks made during removal.

Note: Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

2. Install the four capscrews and four locknuts (1) securing the flange yoke (2) to the front axle using Loctite 139 Nm (102 lb-ft).

3. Install the four capscrews (3) securing the bearing crosses to the rear axle using Loctite torque the capscrews to 139 Nm (102 lb-ft).

4. Properly connect the battery.

5. Close and secure the engine cover.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

243TM and torque the capscrews to

243TM and

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

5-9

Axles, Drive Shafts, Wheels and Tires

MZ6020

MAH0460

TREAD “ARROWS” MUST

POINT FORWARD

INST ALL TIRES ONTO

WHEELS TO ROTATE IN

PROPER DIRECTION

5.6 WHEELS AND TIRES

WARNING

Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over.

It is recommended that a replacement tire to be the same size, ply and brand as originally installed. R efer to the appropriate parts manual f or ordering in formation. If not using an approved replacement tire, the replacement tires must have the following characteristics:

• Equal or greater ply/load rating and size of original.

• Tire tread contact width equal or greater than original.

• Wheel diameter , width and offset dimensions equal to the original.

• A pproved for the application by the tire m anufacturer (including inflation pressure and maximum tire load).

Unless specifically approved by JLG, do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. Due to size variations between tire brands, when selecting and installing a replacement tire ensure both tires on the axle are the same.

The rims installed have been designed for stability requirements which consi st of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written fact ory recommendations, may result in unsafe condition regarding stability.

5.6.1 Removing Wheel and Tire Assembly from Machine

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stati ng that the machi ne should not be operated.

3. Loosen but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.

4. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly.

5. Lower the machine onto the support.

6. Remove lug nuts and washers in an alternating pattern.

7. Remove the wheel and tire assembly from the machine.

5.6.2 Installing Wheel and Tire Assembly onto Machine

Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.

The wheel and tire assemblies must be installed with the directional tread pattern “ar rows” (6) facing in the direction of forward travel.

5-10

1. Position wheel onto studs on wheel end of axle.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

2. Install washers on th e wheel studs.

OAH0990

3. Start all lug nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 300 Nm (221 lb-ft).

5. Remove machine from supports,

6. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel.

Axles, Drive Shafts, Wheels and Tires

5.7 STEERING ANGLE ADJUSTMENT

Detailed axle serv ice instructio ns are provided in the Axle Disassembly & Assembly Manual, refer to Section 5.4.2, “Axle Specifications.”

5.8 BRAKES

5.8.1 Brake Disc Inspection

Detailed axle serv ice instructio ns are provided in the Axle Disassembly & Assembly Manual, refer to Section 5.4.2, “Axle Specifications.”

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

5-11

Axles, Drive Shafts, Wheels and Tires

This Page Intentionally Left Blank

5-12

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 6

Transmission

Contents

PARAGRAPH TITLE PAGE

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5.2 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.5.3 After Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.6 Transmission Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.6.1 Filter Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.6.2 Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.7 Towing a Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

6-1

Transmission

MZ5410

HYDROSTATIC

TRANSMISSION

REVERSE

RELIEF

VALVE

DIRECTIONAL

CONTROL VALVE

HYDROSTATIC

FILTER

FORWARD

RELIEF

VALVE

6.1 TRANS M ISSION ASSEMB LY COMPONENT TE RMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.

6-2

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Transmission

6.2 SAFETY INFORMATION

WARNING

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

6.3 TRANSMISSION DESCRIPTION

Instructions in this section p erta in mai nly to ge ne ral specifications, towing, m ainte nan ce i nf ormat ion , and transmission removal and installatio n proce dur es . For internal transmission service instructi ons and detailed specifications contact the local JLG dealer for a copy of the Rexroth Hydrostatic Transmission Repair Manual (P/N 31200124).

More info rmatio n can be obtain ed fr om the s erial number plate directly mounted on the transmission. Information specified on the serial number plate includes the transmission model number, the transmission serial number and other data. Information on the serial number plate is required in correspondence regarding the transmission.

6.4 TRANSMISSION SPECIFICATIONS

6.4.1 Transmission Maintenance

The transmission is a hydraulic component and requires the same maintenance as the hydraulic system. Refer to Section 2.5, “Maintenance Schedules.”

Performance criteria is based on full throttle engine speed unless otherwise specified or not applicable.

6.5 TRANSMISSION REPLACEMENT

Note: Contact the local JLG dealer if internal transmission repair is required during the warranty period.

Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other elect rica l com pon ents .

6.5.1 Transmission Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, turn rear wheels to give easier access to rear of engine compartment, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly discon ne ct th e ba t ter y.

5. Remove the air cleaner assembly.

6. Remove hood support at rear of engine.

7. Drain the hydraulic oil reservoir. Refer to Section

8.8.2, “Hydraulic Oil Reservoir Draining.”

8. Label, disconnect and cap all hydraulic hoses attached to transmission, cap all fittings and openings to keep dirt and debris from entering hydraulic system.

9. Label and disconnect all electrical connections attached to the transmission.

10. Wipe up any spilled hydraulic oil.Vertically secure transmission with a lifting strap or chain. Use a suitable hoist or overhead crane. Operate the hoist or crane to remove slack from the chain, but DO NOT raise the transmission at this time.

11. Remove the two Allen head bolts that attach the transmission to the engine.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

WARNING

The transmission may move while hoisting it out of the chassis. Carefully move the transmission and adjust the sling as needed. Keep fingers, hands, legs and other body parts clear of the transmission.

6-3

Transmission

12. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts.

13. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so

14. overed in the Transmission Disassembly & Assembly Manual (P/N 31200456).

6.5.2 T ransmission Installation

WARNING

NEVER lift a transmission alone; enlist the help of at

least one assistant or use a suitable hoist or overhead crane and sling.

1. Use a lifting strap or chain attached to a hoist or overhead crane to position the transmission within the chassis.

2. Insert the two Allen head bolts that attach the transmission to the engine. Torque to 210 Nm (154 lb-ft).

3. Remove the hoist or overhead crane and sling.

4. Uncap and reconnect the prev iou sl y lab ele d hos es and electrical connections to their appropriate locations.

5. Fill hydraulic reservoir and bleed the system.

6. Reinstall the hood support.

7. Reinstall the air cleaner assembly.

8. Properly connect the battery.

9. Close and secure the engine cover.

10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

6.5.3 After Transmission Replacement

1. Install new hydraulic filters.

2. Check the hydraulic oil level and add oil as required.

NOTICE

DO NOT use flushing compounds for cleaning purposes.

3. Reassemble all components and fill the hydraulic reservoir with clean, fresh oil. DO NOT overfill.

4. Run t he en gine fo r t w o m i nutes a t i d l e to help bleed any air from the hydraulic system.

5. Operate all boom functions to ensure any air is removed from the hydraulic system.

6. Retract and level the boom, recheck the level of the fluid in the reservoir.

7. Add oil as necessary to bring the fluid level up until it reaches the FULL mark on the reservoir. Recheck the oil level when it reaches operating temperature (83-94° C or 180-200° F).

8. Recheck all drain plugs, lines, connections, etc., for leaks, and tighten where necessary.

6-4

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

6.6 TRANSMISSION FILTER

MZ5420

REPLACEMENT

Transmission

The hydrostatic pump filter is located on the left (inside) of the pump (1).

Cleanliness is of extreme importance. Before attempting to remove the transmission filter, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission direction solenoids and other electrical components.

6.6.1 Filter Removal

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the batt ery.

5. Remove the air cleaner assembly.

6. To allow easier access to the filter, label, disconnect and cap all hydraulic hoses in the filter area, cap all fittings and openings to keep dirt and debris from entering hydraulic system.

7. Place a container or shop rags below the filter housing to contain any spilled hydraulic oil.

8. Using a 25 mm (15/16 in) wrench, loosen and remove the filter housing (2), filter (3) and spring (4).

6.6.2 Filter Installation

1. Clean the area surrounding the hydraulic pump filter.

2. Install a new o-ring (5) on the base of the filter housing and lubricate the new o-ring with clean hydraulic oil.

3. Install the small end of the filter spring (4) into the filter base (6).

4. Install the filter (3) into the filter base (6) directly behind th e filter spring.

5. Slowly screw the filter housing into the filter base keeping the filter and housing aligned.

6. Torque the filter housing to 45 Nm (33 lb-ft).

7. Uncap and reconnect the previously labeled hoses to their appropriate locations.

8. Fill hydraulic rese rv oi r and ble ed the system.

9. Reinstall the air cleaner assembly.

10. Properly connect the battery.

11. Close and secure the engine cover.

12. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

6-5

Transmission

MAH0770

MZ5420

6.7 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power.

Towing is only possible by using the "towing" feature built into the hydrostatic pump and disengaging the park brake on the front axle.

1. Securely block all four wheels.

WARNING

Block all four wheels when preparing the machine for towing to prevent any unexpected movement.

2. Locate the six brake release bolts (1) at the base of the front axle. Mark a line on the socket so you can accurately count the number of turns each bolt makes as you perform the procedure.

3. Alternately screw the release bolts clockwise in 1/2 turn increments. Turn until resistance is felt.

4. Alternately screw the bolts clockwise 5 to 5 1/2 turns in 1/2 turn increments.

5. Turn the tow option engagement screw (2) on the hydrostatic transmission counterclockwise three turns.

6. Carefully remove the blocking from each tire and tow the machine to a secure location.

Note: This procedure does not alter any relief settings.

7. After the machine has been towed to a secure location, reactivate the parking brake.

8. Block all four wheels.

WARNING

Do Not attempt to tow a machine that is loaded or the

boom/attachment is raised more than approximately 610 mm (24 in).

9. Turn the tow option screw (2) on the hydrostatic transmission clockwise three turns.

10. Using a torque wrench, alternately unscrew the brake release bolts (1) outward in 1/2 turn increments until the torque drops off sharply.

11. Again, alternately unscrew the bolts outward until you feel the bolts flange begin to contact against the special screw.

12. Screw the bolts inward (clockwise) 1/4 turn.

13. The parking brake should now be reactivated and the front wheels locked.

14. Remove the blocks from the four tires.

15. Verify that the parking brake works.

Note: If the parking brake does not work, check all activation operations step by step.

6-6

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 7

Engine: Deutz TCD 2012

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.1.2 Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.5 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.5.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.5.2 Radiator/Oil and Charge Air Cooler Replacement . . . . . . . . . . . . . . . . . . 7-4

7.6 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.7.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.7.2 Fuel/Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.7.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.8 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.8.1 Exhaust System Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.8.2 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.9 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.9.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.9.2 Air Cleaner Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.10 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.10.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.10.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7-9

7.10.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.11 Engine Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.11.1 Coupler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.11.2 Coupler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7.12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

7-1

Engine: Deutz TCD 2012

7.1 INTRODUCTION

7.1.1 Disclaimer and Scope

These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.

Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. For assistance with comprehensive engine diagnosis, repair and component replacement, contact the local Deutz dealer. A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 60° C (140° F). Extended lightload operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.

7-2

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

7.1.2 Component Terminology

MZ5430

STARTER

AIR CLEANER

ASSEMBLY

ALTERNATOR

FAN

IMPLEMENT

PUMP

COOLANT OVERFLOW

TANK

FUEL FILTER

OIL FILTER

HYDROSTATIC

TRANSMISSION

ENGINE

MOUNT

TURBOCHARGER

ENGINE MOUNT

RADIATOR/OIL

COOLER

CHARGE AIR

COOLER

AIR PRE-CLEANER

ENGINE MOUNT

ENGINE

MOUNT

MUFFLER/EXHAUST

FUEL PUMP PRIMER

PRE-FUEL

FILTER

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.

Engine: Deutz TCD 2012

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

7-3

Engine: Deutz TCD 2012

7.2 SAFETY INFORMATION

WARNING

DO NOT service the machine without following all

safety prec autions as outli ned in the “Safet y Practices” section of this manual.

7.3 ENGINE SERIAL NUMBER

The Deutz TCD 2012 serial number is located on a tag on top of the engine. Information contained in the serial number is required in correspondence with the engine manufacturer.

Supply the engine serial number and/or data tag information when communicating about an engine or engine components.

7.4 SPECIFICATIONS AND MAINTENANCE INFORMATION

For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specification s . ”

Detailed engine service instructions are provided in the following publicati on:

• Deutz Engine Operation Manual (P/N 31200638)

7.5 ENGINE COOLING SYSTEM

7.5.1 Radiator Pressure Cap

For a 110° C (230° F) system, use a 95 kPa (13 psi) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine.

7.5.2 Radiator/Oil and Charge Air Cooler Replacement

Before considering radiator, oil or charge air cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator.

• If the engine runs hot, check the temperature of the upper radiator hose.

• If the hose is not hot, the thermostat may be stuck in the closed position.

• If the engine has overheated, performance may suffer, indicating othe r damage inclu ding a leakin g cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage.

a. Radiator/Oil/Charge Air Cooler Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Thoroughly clean the engine and surrounding area, including all hoses and fittings before proceeding.

5. Properly disconnect the batter y.

6. Slowly turn the coolant overflow bottle cap and allow any pressure to escape. Remove the overflow bottle cap.

7. Place a suitable container beneath the radiator petcock.

7-4

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Engine: Deutz TCD 2012

MZ5440

8. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open the radiator petcock and drain the coolant into the funnel. Transfer the fluid into a properly labeled container. Dispose of properly if coolant needs to be replaced. Close the radiator petcock.

9. Label, disconnect and cap all charge air tubes attached to the radiator. Cap all openings to keep dirt and debris from entering the cooling system.

10. Label, disconnect and cap all coolant hoses attached to the radiator . Cap all fittings and openings to keep dirt and debris from entering the cooling system.

11. Label, disconnect and cap all hydraulic hoses attached to the radiator . Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

12. Detach the fan safety shroud.

b. Radiator/Oil Cooler Installation

1. Install the radiator assembly into the machine and secure in place with new locknuts.

2. Be sure the engine fan has clearance in regard to the radiator. Install the engine cover support (1) to the frame and radiator.

3. Attach the fan safety shroud.

4. Uncap and reconnect the previously labeled hydraulic hoses to the appropriate locations.

5. Uncap and reconnect all previously labeled coolant hoses to the appropriate locatio ns .

6. Fill the coolant overflow bottle with coolant.

7. Properly connect the battery.

8. Run the engine to operating temperature. Visually check for leaks with the engine running. Check the coolant level in the overflow bottle and fill, or drain, as necessary. Check the hydraulic fluid level in the tank and add fluid as required.

9. Close and secure the engine cover.

10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

13. Remove the locknuts (1) holding the radiator assembly at the side and bottom of the machine.

14. Connect a lifting strap to the radiator/oil cooler and carefully lift the radiator/oil cooler out of the machine.

7.6 ENGINE ELECTRICAL SYSTEM

The engine electrical system, including the starter, alternator and primary wiring, is described in Section 9, “Electrical System.”

7.7 FUEL SYSTEM

7.7.1 Diesel Fuel

Fuel represents a major portion of machine operating costs and therefore must be used efficiently. ALWAYS use a premium brand of high-quality, clean diesel fuel. Low cost, inferior fuel can lead to poor performance and expensive engine repair.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

7-5

Engine: Deutz TCD 2012

NOTICE

Due to the precise tolerances of diesel injection systems, keep the fuel clean, and free of dirt and water. Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles. Use #2 diese l fu el wit h a min im um Cetane rating of 40. #2 diesel fuel gives the best economy and performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to help prevent misfiring and excessive smok ing .

Inform the owner/operator of the machine to use #2 diesel fuel, unless ambient temperatures are below 0° C (32° F). When temperatures are below 0° C (32° F), a blend of #1 diesel and #2 diesel fuels (known as “winterized” #2 diesel) may be used.

Note: #1 diesel fuel may be used, however, fuel economy will be reduced.

Use a low-sulfur content fuel with a cloud point (the temperature at which wax crystals form in diesel fuel) at least 10° below the lowest expected fuel temperature. The viscosity of the fuel must be kept above 1.3 centistokes to provide adequate fuel system lubrication.

Note: When using diesel fuel with a sulfur content below

1.3 percent, the filter change interval must be reduced by 75 hours. The use of fuel with a sulfur content above

1.3 percent is not recommended.

7.7.2 Fuel/Hydraulic Oil Tank

To clean the fuel/hydraulic oil tank:

1. Have a dry chemical (Class B) fire extinguisher near the work area.

2. Depending on which side of the tank is contaminated (fuel or hydraulic oil), remove the fuel or oil tank drain plug, and safely drain any fuel or hydraulic oil into a suitable container. Dispose of fuel or hydraulic oil properly.

3. Clean the fuel/hydraulic oil tank with a high-pressure washer, or flush the tank with hot water for five minutes and drain the water. Dispose of contaminated water properly.

4. For the fuel tank side, add a diesel fuel emulsifying agent to the tank. Refer to the manufacturer’s instructions for the correct emulsifying agent-towater mixture ratio. Refill the tank with water, and agitate the mixture for 10 minutes. Drain the tank completely. Dispose of contaminated water properly.

5. Refill the fuel tank with water until it overflows. Completely flush the tank with water . Empty the fuel tank, and allow it to dry completely.

c. Inspection

Note: If a leak is suspected bet ween the fuel and h ydraulic oil tank, contact the local JLG dealer.

1. Inspect the fuel/hydraulic oil tank thoroughly for any cracks, slices, leaks or other damage.

2. Plug all openings except one elbow fitting. Install the elbow fitting, and apply approximately 0.07-0.10 bar (1-1.5 psi) of air pressure through the elbow. Check the tank for leaks by applying a soap solution to the exterior and look for bubbles to appear at the cracked or damaged area.

a. Cleaning and Drying

If contaminated fuel, hydraulic oil or foreign material is in the tank, the tank can usually be cleaned.

b. If a leak is suspected between the fuel and hydraulic oil

tank, contact the local JLG dealer.

7-6

d. Disassembly and Assembly

The fuel/hydraulic oil reservoir is a one piece-unit integral to the chassis frame and canno t be disassembled.

7.7.3 After Fuel System Service

1. Drain and flush the fuel tank if it was contaminated.

2. Fill the fuel tank with fresh, clean diesel fuel as required.

Note: If bleeding of the fuel system is required, contact the local Deutz dealer.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Engine: Deutz TCD 2012

MZ5450

MZ5460

7.8 ENGINE EXHAUST SYSTEM

7.8.1 Exhaust System Removal

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Loosen and remove the clamp (1)(hidden) connecting the muffler and tail pipe from the bracket on the side of the frame.

6. Loosen and remove the clamp (2) attaching the rear exhaust pipe section to the muffler.

7. Remove the muffler and tail pipe (3).

8. Loosen and remove the clamp (4) attaching the rear exhaust pipe section to the frame.

9. Remove the rear exhaust pipe section (5) from the front exhaust pipe section (6).

11. Remove the front exhaust pipe section (6) from the engine.

7.8.2 Exhaust System Installation

Note: Keep all clamps loosened until entire exhaust system is in place.

Note: Replace the nuts and the exhaust studs on the turbocharger if damaged.

1. Install the front exhaust pipe section (6) in place at the turbocharger with the previously used hardware. Torque the flange nuts (7) on the turbo charger to 30 ±7 Nm (22 ±5 lb-ft).

2. Install the rear exhaust pipe section (5) to the front exhaust pipe section (6) with the previously used clamp.

3. Install the muffler and tailpipe (3) to the exhaust pipe with the previously used hardware.

4. Install the muffler (3) to the frame brackets with the previously used hardware.

5. Adjust the muffler, exhaust and tail pipes for proper clearance then tighten all clamps.

6. Properly connect the battery.

7. Start engine and check for exhaust leaks at all exhaust connections. Adjust or repair as needed.

8. Close and secure the engine cover.

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

10. Loosen and remove the exhaust pipe flange nuts (7) at the turbocharger.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

7-7

Engine: Deutz TCD 2012

MZ5470

8119

7.9 AIR CLEANER ASSEMBLY

CAUTION

NEVER run the engine with only the inner safety

element installed.

Note: Refer to the Operation & Safety Manual (P/N 31200567) for the correct element change procedure.

7.9.1 Air Cleaner Assembly Removal

1. Park the machine on a firm, level surface, level the machine, full y ret rac t t he boom, lo we r th e bo om , place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Loosen the clamp (8) securing the air intake tube (9) to the air cleaner assembly (10). Pull the air intake elbow off the air cleaner.

6. Remove the hardware (11) securing the air cleaner/ bracket to the air cleaner mounting plate. Remove the air cleaner assembly (10).

7.9.2 Air Cleaner Assembly Installation

1. Install the air cleaner assembly (10) to the air cleaner mounting plate with the previously used hardware (11).

2. Place the loosened clamp (8) ov er the ai r intake tube (9) and install elbow on the air cleaner assembly.

3. Adjust and tighten clamps before starting the machine.

4. Properly connect the battery.

5. Close and secure the engine cover.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

7.10 ENGINE REPLACEMENT

7.10.1 Engine Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Thoroughly clean the engine and surrounding area, including all hoses and fittings before proceeding.

5. Properly disconnect the batter y.

6. Remove the engine cover, radiator cover and engine belly pan.

7. Remove front and rear engine cover supports.

8. Drain hydraulic reservoir. Refer to Section 8.8.2, “Hydraulic Oil Reservoir Draining.”

9. Drain radiator and overflow bottle. Refer to Section

7.5.2, “Radiator/Oil and Charge Air Cooler Replacement.”

10. Label, disconnect and cap all hydraulic hoses attached to engine and radiator, cap all fittings and plug hoses to keep dirt and debris from entering hydraulic syst em.

11. Label, disconnect and cap both air conditioning hoses.

12. Disconnect the fuel inlet (1) and return lines. Install a plug in the end of each line.

13. Remove hydraulic and fuel filters, and filter bracket assembly.

7-8

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Engine: Deutz TCD 2012

MZ5480

14. Unbolt and remove the fan safety shroud.

15. Remove bolts securing the radiator and lift it clear of engine compartment. Refer to section Section 7.5.2, “Radiator/Oil and Charge Air Cooler Replacement.”

16. Mark the engine fan orientation. Remove the engine fan.

17. Label and disconnect all wire connections on the engine.

18. Mark the location of the throttle cable (2) at the engine throttle lever. Disconnect the throttle cable.

19. Detach exhaust and air cleaner hoses from the engine. Cover air inlets to protect from dirt and debris.

20. Remove air cleaner assembly from engine compartment.

21. Completely disconnect exhaust pipe.

22. Remove the hydraulic reservoir fill tube.

23. Secure the engine with a lifting strap or chain from the appropriate lifting points (3). Use a suitable hoist or overhead crane.

24. Remove the four motor mount bolts (4) that attach the engine to the frame.

25. Carefully lift the engine from the machine. Avoid causing damage to the surrounding parts.

26. Lift the engine clear of the machine, and lower it onto suitable supports or stand. Secure the engine so that it will not move or fall.

7.10.2 Engine Disassembly, Inspection and Service

Engine disassembly, internal inspection, service, repair and assembly procedures are covered in the Deutz TCD 2012 service manual. Several special engine service tools are required to properly serv ice the Deutz engine. Contact the local Deutz dealer for further informati on.

Note: If the engine is being replaced, there may be external components that will be required to be transferred from the original engine to the replacement engine d epending up on who you purchase the new engine from and the configuration of your replacement engi n e . R e f e r to the appropriate Deutz user manual for d etailed proced ures that cover the transfer of original engine components to the replacement engine.

7.10.3 Engine Installation

Note: Refer to Section 2.2, “Torques,” for specific fastener torque specifications.

1. Position engine in engine compartment being sure to line up the 4 motor mount holes. Replace bolts (4) and torque to 97 Nm (71 lb-ft).

2. Connect the hydraulic reservoir fill tube.

3. Connect the exhaust pipe to the engine.

4. Install the air cleaner assembly into the engine compartment and attach hose to air intake.

5. Reconnect throttle cable (2) onto the engine, if necessary adjust for full travel.

6. Reattach any previously labeled wire connections on the engine.

7. Attach the engine fan.

8. Reinstall the front and rear engine cover supports.

9. Secure the radiator with the necessary bolts and attach the fan safety shroud. Check that the fan top clearance is adequate with regard to the radiator. Reattach the previously labeled hoses. Refer to Section 7.5.2, “Radiator/Oil and Charge Air Cooler Replacement.” Fill with coolant.

10. Install the filter bracket assembly. Secure the hydraulic and fuel filters.

11. Connect the fuel inlet line to the fuel filter (1) and reconnect the return fuel line to the engine.

12. Uncap and reconnect all hydraulic hoses and fittings to the engine and necessary hydraulic elements. Keep hoses free of dirt and debris.

13. Uncap and connect and cap both air conditioning hoses.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

7-9

Engine: Deutz TCD 2012

MY2550

14. Refill the hydraulic reservoir (Refer to the appropriate Operation & Safety Manual for information concerning the hydraulic oil and filter change).

15. Reinstall the engine cover and radiator cover.

16. Reconnect the battery terminals, being sure to start with the positive (+) terminal.

17. Check that all hydraulic, electrical, cooling, fuel and exhaust system connecti ons are co rrec t and connected tightly.

18. Recharge the air conditioning system. Refer to Section 4.4.11, “Air Conditioning (If Equipped).”

19. Run engine to normal operating t emperatur e then shut off the engine. While the engine is cooling, check for leaks.

20. Allow the engine to cool. Check the radiator coolant level, and top off with coolant. Replace the radiator cap.

21. Check for leaks from the eng ine, main hy draulic pump and lines, transmission, hydraulic reservoir and fuel tank. Check the levels of all fluids and lubricants. Fill

as required.

7.11 ENGINE COUPLER

7.1 1.1 Coupler Removal

1. Remove Hydrostatic transmission. Refer to Section

6.5.1, “Transmission Removal.” Be sure to follow all described safety guidelines.

2. After transmission has been removed, take out the 12 bolts that attach the Flywheel Cover Plate to the engine.

3. Pull off the Flywheel Cover Plate to expose the coupler assembly (1).

4. Remove the necessary bolts to detach the coupler assembly.

NOTICE

During the full throttle check:

• DO NOT operate any hydraulic function.

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in NEUTRAL (N).

22. Check the engine rpm at high idle. Refer to Section

4.4.5, “Throttle Cable Adjustment,” and Section

4.4.6, “High Idle Adjustment,” for adjustment procedure.

23. Purge the hydraulic system of air by operating all boom functions through their entire range of motion several times. Check the hydraulic oil level.

24. Check for proper operation of all components.

25. Turn the engine OFF.

26. Install the belly pan.

27. Install the engine cover.

28. Close and secure the cover.

29. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

7.11.2 Coupler Installation

1. Attach the coupler assembly (3) using the necessary bolts. Torque to 210 Nm (155 lb-ft).

2. Bolt on the Flywheel Cover Plate over the coupler and flywheel. Torque bolts to 50 Nm (37 lb-ft).

3. Reattach the hydrostatic transmission. Follow all guidelines in Section 6.5.2, “Transmission Installation.”

7.12 TROUBLESHOOTING

Refer to Section 7.4, “Specifications and Maintenance Information,” for detailed engine service information or contact the local Deutz dealer.

7-10

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Section 8

Hydraulic System

Contents

PARAGRAPH TITLE PAGE

8.1 Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.2 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.5 Hoses, Tube Lines, Fittings, Etc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.5.1 Replacement Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.5.2 Hose, Tube, Line and Fitting Replacement. . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.6 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.6.1 Pressure Checks and Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.6.2 Main Control Valve Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.6.3 Charge Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.6.5 Boom Function Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.6.6 Steering Pressure Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8.7 Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.7.1 Gear Pump Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

8.7.2 Piston Pump Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8.8 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.8.1 Pressurized Hydraulic Oil Fill Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.8.2 Hydraulic Oil Reservoir Draining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.8.3 Hydraulic Oil Reservoir Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.9 Implement Pump (Piston or Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.9.1 Implement Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8.10 Front Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

8.11 Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.11.1 Main Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8.11.2 Service Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

8.11.3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

8.11.4 Brake Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8.11.5 Steering Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8.11.6 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

8.11.7 Inching Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8.11.8 Anti-Kick Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

8.11.6 Steer Select Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-1

Hydraulic System

8.12 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8.12.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8.12.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

8.12.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

8.12.4 Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

8.12.5 General Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

8.12.6 General Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8.12.7 Steering Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24

8.12.8 Hydraulic Cylinder Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 8-25

8-2

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8.1 HYDRAULIC COMPONENT

MZ5490

EXTEND/RETRACT

CYLINDER

COMPENSATING

CYLINDER

TILT CYLINDER

HYDRAULIC

FILTER

IMPLEMENT

PUMP

MAIN CONTROL

VALVE

HYDRAULIC RESERVOIR AND

LIFT/LOWER CYLINDER

(UNDER BOOM)

HYDROSTATIC

DRIVE PUM P

FRONT AXLE,

DRIVE MOTOR,

STEERING CYLINDER

REAR AXLE,

STEERING CYLINDER

BRAKE VALVE

STEERING VALVE

TERMINOLOGY

To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.

Hydraulic System

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-3

Hydraulic System

8.2 SAFETY INFORMATION

WARNING

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

8.3 GENERAL INFORMATION

Petroleum-based hydraulic oils are used in this machine. The temperature of hydraulic oil increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic oil presents a fire hazard, especially when an ignition so ur ce is presen t.

Accordingly, periodically inspect all hydraulic system components, hoses, tubes, lines, fittings, etc. Carefully examine any deterioration and determine whether any further use of the component would constitute a hazard. If in doubt, replace the component.

Whenever you disconnect a hydraulic line, coupler, fitting or other component, slowly involved. A hissing sound or slow seepage of hydraulic oil may occur in most cases. After the hissing sound has ceased, continue removing the part. Any escaping oil should be directed into an appropriate container. Cap or otherwise block off the part to prevent further oil seepage.

Hydraulic system maintenance will, at times, require that the engine be operated. Always follow safety precautions.

A major cause of hydraulic component failure is contamination. Keeping the hydraulic oil as clean as possible will help avoid downtime and repairs. Sand, grit and other contaminants can damage the finely machined surfaces within hydraulic components. If operating in an exceptionally dirty environment, change filters and inspect the oil more often. When servicing the system, cap or plug hydraulic fittings, hoses and tube assemblies. Plug all cylinder ports, valves and the hydraulic reservoir, and pump openings until installation occurs. Protect threads from contamination and damage.

Some hydr aulic funct ions are act uated by in terfacin g with electrical system components (switches, solenoids and sensors). When the hydraulic system is not functioning properly, check the electrical aspect of the malfunctioning circuit also.

and cautiously loosen the part

8.4 SPECIFICATIONS

Refer to Section 2.3, “Specifications,” for hydraulic system specifications.

8.5 HOSES, TUBE LINES, FITTINGS, ETC.

There are numerous hydraulic hoses, tubes, fittings, etc. used on this machine. Periodically inspect all of these and carefully examine any signs of wear, abrasion and/or deterioration. Determine whether any further use of the component would constitute a hazard. If in doubt, replace the component.

8.5.1 Replacement Considerations

Conditions including, but not limited to, the following are sufficient for considering component replacement:

1. Any evidence of hydraulic oil leakage at the surface of a flexible hose or its junction with the metal and couplings.

2. Any blistering or abnormal deformation to the outer covering of a hydraulic hose.

3. Hydraulic oil leakage at any threaded or clamped joint that cannot be eliminated by normal tightening or other recommended procedures.

4. Evidence of excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or hydraulic fitting. Modification must be made to eliminate the interference of the elements in contact with one another, or to otherwise protect the components from contact with one another. Slightly moving a hose or adjusting a plastic tie wrap may often be all that is necessary to eliminate interference; evaluate each situation and proceed as required by the individual circumstances.

8.5.2 Hose, Tube, Line and Fitting Replacement

Before removing a hydraulic hose or component, always mark or otherwise label the related parts and the exact location of the hose or component to aid in proper reinstallation. Hydraulic oil is a good cleaner and can remove most liquid-ink type markings, so make sure the mark or label will remain intact. Alternative methods to using markers include color-coded tie wraps, number-tag sets, alpha-numeric stampin gs or ma rk ings, an d su it ab ly labeled pieces of tape. Select an appropriate marking method for the conditions and proceed accordingly.

8-4

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Hydraulic System

MZ5500

NEVER replace a hydraulic hose or other component

with a part not specifically designed for this machine. Use only factory approved parts for best performance and safety.

Removal and replacement of hoses, tube lines, fittings, etc. usually involves straightforward procedures. When removing a hydraulic hose or other component, be aware that o-rings are used throughout the hydraulic system. ALWAYS replace a used o-ring with a new part.

Check all routing of hoses, wiring and tubing for sharp bends or interference with any rotating members. Install appropriate protective devices such as tie wraps and conduit to help shield hoses from damage. All tube and hose clamps must be tight.

8.6 HYDRA ULIC PRESSURE DIAGNOSIS

8.6.1 Pressure Checks and Adjustments

In general, follow the steps below whenever conducting pressure checks and performing adjustments:

1. Park the machine on a firm, level surface. Engage the park brake, place the transmission control lever in (N) NEUTRAL, place the neutral lo ck lever in the (N) NEUTRAL LOCK position, level the boom and turn the engine OFF.

2. Pressure tee fittings are conveniently located in each hydraulic circuit. Install a pressure gauge capable of measuring at least 10% more pressure than that which the circuit being checked oper at es under.

3. Start the engine. Operate machine functions several times to allow hydraulic oil to reach operating temperature. The hydraulic oil temperature should be between 38-49° C (100-120° F). If a temperature gauge or thermometer is unavailable, the hydraulic oil reservoir should be warm to the tou ch.

4. Fully depress the accelerator pedal as required. Place and hold the joystick in the position needed to operate the particular machine function being checked. Continue holding the joystick in position until pressure readings are taken.

5. Check the pressure gauge reading. It should read as described in the appropriate section. If the reading is not as specified, turn the engine OFF and check other components in the system. Verify that all related hydraulic components and electrical switches, sensors, solenoids, etc. are operating correctly.

6. As a last resort, adjust the appropriate relief valve, if applicable. Turning the adjustment screw clockwise will increase the pressure; turning the screw counterclockwise will decrease the pressure.

8.6.2 Main Control V a lve Pre ssure Checking

Attach 345 bar (5000 psi) gauge to the test port (1) at the rear of the implement pump to check the system pressure. Make sure the gauge is visible from inside the cab.

See Section 8.6, “Hydraulic Pressure Diagnosis,” for start up procedure. Check the main control pressure with the park brake on and the service brake off at full throttle. Retract a boom circuit function until the cylinder bottoms. The main control valve pressure should be 250 ± 2,8 bar (3625 ± 40 psi) at full throttle. Repeat for each boom circuit to verify the correct main control valve pressure.

If a pressure adjustment is required, adjust the main relief cartridge (2) on the main control valve. Recheck pressure after any adjustment has been made.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-5

Hydraulic System

MZ5520

MZ5500

8.6.3 Charge Pressure Checking

Attach a pressure gauge to the test port (3) on the hydrostatic transmissio n (4) to check the system pressure. The pressure should be 26,2 ± 2 bar (380 ± 30 psi) with the engine at low idle.

The charge pressure relief valve is preset at the factory and is not adjustable.

8.6.4 Drive Pressure Checking

Attach a pressure gauge to the test fitting (5) on the hydrostatic transmissio n (4) to check the system pressure.

The following procedure must be performed to verify proper drive pressure:

• Connect a JLG handheld analyzer to the power distribution board (located below the rear cab window).

• Enter service code 01769 for access level 1.

• Navigate to CALIBRATION>TRACTION TEST,

select YES. (Note: this mode will return to the default setting NO when the power is cycled.)

• Check the drive pressure with the park brake on, wheels chocked and the service brake off at full throttle. The pressure reading should be 440 to 460 bar (6381 to 6671 psi).

Do NOT adjust any relief settings. The unit is preset at the factory and should not be tampered with. If the proper pressure is not read, the unit may be defective.

8.6.5 Boom Function Pressure Checking

Attach 345 bar (5000 psi) gauge to the test port (6) at the rear of the main control valve to check the system pressure. Make sure the gauge is visible from inside the cab.

See Section 8.6, “Hydraulic Pressure Diagnosis,” for start up procedure. Check the boom function pressure with the park brake on and the service brake off at full throttle. Retract each boom circuit function until the cylinder bottoms. Each circuit function pressure should be 250 ± 2,8 bar (3625 ± 40 psi) at full throttle.

Note: With the machine at operating temperature, the

250 ± 2,8 bar (3625 ± 40 psi) pressure reading at the main control valve is 13,3 bar (125 psi) HIGHER than the 241 bar ±4 bar (3500 ± 50 psi) of each individual valve section function. DO NOT adjust the main control valve relief pressure below 250 ± 2,8 bar (3625 ± 40 psi). To check individual valve section pressures, install a tee and test port between the cylinder being checked and the corresponding valve section on the main control valve.

The individual valve section relief valves are preset at the factory and are not adjustable.

8-6

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8.6.6 Steering Pressure Checking

MZ5310

Attach a pressure gauge to the test fitting (7) at the main control valve. The pressure reading should be 186 ± 4 bar (2700 ± 50 psi) with the steering wheel fully turned to the steering stop in one direction.

Do NOT adjust any relief settings. The unit is preset at the factory and should not be tampered with. If the proper pressure is not read, the unit may be defective.

8.6.7 Brake Pressure Checking

Hydraulic System

Attach a pressure gauge to the test fitting (8) at the brake valve in the cab. The pressure reading should be 30 bar (435 psi) with the brake pedal fully depressed.

Do NOT adjust any relief settings. The unit is preset at the factory and should not be tampered with. If the proper pressure is not read, the unit may be defective.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-7

Hydraulic System

8.7 HYDRAULIC SCHEMATIC

8.7.1 Gear Pump Schematic

(Sheet 1)

8-8

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8.7.1 Gear Pump Schematic (Continued) (Sheet 2)

Hydraulic System

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-9

Hydraulic System

ITEM LOC DESCRIPTION

D5 PUMP,DRIVEB1D3 MOTOR, DRIVE - 2906B2D3 MOTOR, DRIVE - 3507

C F5 PUMP,IMPLEMENT - PISTON

F3 VALVE,MAIN CONTROL - PISTON

E3 VALVE,STEER SELECT

G6 VALVE,STEERING

E5 VALVE,BRAKE INCHING

G7 VALVE,PARK BRAKE

H7 VALVE,SERVICE BRAKE

E6 VALVE,3 BAR CHECK - COOLER BYPASS

D6 COOLER,TRANSMISSIONLD6 FILTER,MAIN RETURN

M 2,D8 VALVE,FRONT/REAR AUX - OPTIONAL

2,E2 VALVE, 1ST/2ND FRONT AUX - OPTIONAL

O 2,H5 VALVE,TRAILER BRAKES - OPTIONAL

P H3 VALVE,ANTI-KICK

FRONT STEERING

CYLINDER

REAR STEERING

CYLINDER

LEVAGE

LIFT

INCLINGISON

TILT

CROWD

TELESCOPAGE

OUTILLAGE

AUX

COMPENSATION

SEE SHEET 2 FOR

AUXILIARY OPTIONS

SEE SHEET 2 FOR

TRAILER BRAKE OPTION

LEFT

RIGHT

LEFT

RIGHT

Vg max

Vg min

X1 X2

bar

240

bar

240

bar

180

5 bar

NC SWITCH

3 bar

V1V2C1

bar

280

bar

A T

280

bar

280

bar

A T

280

l/mn

(87)

l/mn

(87)

l/mn

(87)

(45)

l/mn

(85)

(55)

DLS

Tpr

12V

MY3290-B

8.7.2 Piston Pump Schematic

(Sheet 1)

8-10

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8.7.2 Piston Pump Schematic (Continued)

REAR AUX FRONT AUX

280280

REAR AUX

FRONT AUX

1ST

2ND

280280

OPTIONAL REAR

AUXILIARY

OPTIONAL SECOND

FRONT AUXILIARY

-MANUAL-

OPTIONAL REAR AUXWITH

MANUAL SECOND FRONT AUX

FRONT AUX

1ST

2ND

280280

TRAILER BRAKES

TRAILER BRAKE

VALVE

AUXILIARY OPTIONS

OPTIONAL SECOND

FRONT AUXILIARY

-ELECTRIC-

FRONT AUX

1ST

2ND

280280

REAR AUX

FRONT AUX

1ST

2ND

280280

OPTIONAL REAR AUXWITH

ELECTRIC SECOND FRONT AUX

bar

280

bar

A T

280

bar

280

bar

A T

280

l/mn

(87)

l/mn

(87)

l/mn

(87)

(45)

l/mn

(85)

(55)

DLS

Tpr

12V

PLS

RAP.PIL.1,3:1

TO PUMP X-PORT

MY3300-B

(Sheet 2)

Hydraulic System

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-11

Hydraulic System

MZ5510

PISTON PUMP SH OW N

8.8 HYDRAULIC RESERVOIR

The hydraulic reservoir and fuel tank are part of the frame. For this reason, neither tank can be removed. For cleaning instructions, see Section 7.7.2, “Fuel/Hydraulic Oil Tank.”

Occasionally, oil may seep, leak or be more forcefully expelled from the filter head when system pressure exceeds the rating of the filter head or filler cap. If the return filter becomes plugged, return hydraulic oil will bypass the filter when pressure reaches 1,5 bar (22 psi) and return to the reservoir unfiltered.

Carefully examine oil seepage or leaks from the hydraulic reservoir to determine the exact cause. Clean the reservoir and note where any seepage occurs.

Leaks from a cracked or damaged reservoir require that the reservoir be flushed completely with water and repaired by a certified welder using approved techniques. If these conditions cannot be met, the reservoir must be replaced in its entirety. Contact the local JLG dealer should reservoir welding be required.

8.8.1 Pressurized Hydraulic Oil Fill Cap

The fill cap will allow the hydraulic oil reservoir to pressurize to 0,14 bar (2 psi). Inspect the condition of the cap seal to maintain proper reservoir pressure.

8.8.2 Hydraulic Oil Reservoir Draining

1. Park the machine on a firm, level surface, fully retract the boom, support the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Remove the drain plug at the bottom of the hydraulic oil reservoir.

5. Transfer the used hydraulic oil into a suitable, covered container, and label as "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the drain plug.

6. Wipe up any spilled hydraulic oil.

8.8.3 Hydraulic Oil Reservoir Filling

1. Be sure the reservoir is clean and free of all debris.

2. Install new hydraulic oil filters.

3. Fill the reservoir with hydraulic oil. Refer to Section

2.4, “Fluids, Lubricants and Capacities.”

4. Start the machine. Run engine to normal operating temperature. Operate all hydraulic functions.

5. Close and secure the engine cover.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

8.9 I MPLEMENT PUMP (PISTON OR GEAR)

8.9.1 Implement Pump Replacement

a. Implement Pump Removal

1. Park the machine on a firm, level surface, fully retract the boom, support the boom, place the transmission control lever i n (N) NEU TRAL, en gage th e park bra ke and shut the engi ne O FF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Drain the hydraulic oil reservoir. Refer to Section

8.8.2, “Hydraulic Oil Res ervo ir Drai ning.”

8-12

6. Thoroughly clean the pump (1) and surrounding area, including all hoses and fittings before proceeding.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Hydraulic System

MZ5530

7. Label, disconnect and cap all hydraulic hoses attached to the pump, cap all fittings and plug hoses to keep dirt and debris from entering the hydraulic system.

8. Remove the two bolts that hold the pump in place.

b. Implement Pump Installation

1. Position pump in the mounting position.

Note: Use new o-rings where required. Never reuse orings.

2. Apply Loctite

243TM to the mounting bolts, secure

the pump into place. Torque to 95 Nm (70 lb-ft).

3. Uncap and reconnect previously labeled hydraulic hoses to their proper locations.

4. Fill the hydraulic reservoir with clean, filtered hydraulic oil.

5. Prime the pump by filling the case d rain port with f resh, filtered hydraulic oil from a clean container before installing the case drain connect or and hose.

6. Check all routing of hoses and tubing for sharp bends or inte rfer ence wit h any rot ati ng mem ber s. Al l tube and hose clamps must be tight.

7. Properly connect the battery.

8. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions.

9. Inspect for leaks and check all fluid levels.

a. Front Drive Motor Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the

machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Drain the hydraulic reservoir or attach a vacuum adapter fitting to the reservoir fill tube to reduce oil spillage.

5. Label and disconnect all hydraulic hoses attached to the motor, cap all fittings and plug hoses to keep dirt and debris from entering hydraulic system.

6. Label and disconnect the electri cal con nec ti on attached to the motor,

7. Support the motor and remove the four bolts attaching the motor to the front axle.

b. Front Drive Motor Installation

1. Install the motor onto the front axle. Torque the four bolts to 241 Nm (178 lb-ft). Use only new seals.

2. Uncap and reconnect the previously labeled hydraulic hoses to their appropriate locations.

3. Connect the electrical connection.

Note: Check for leaks and repair as requi red be fore continuing.

10. Close and secure the engine cover.

11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

c. Pump Test

1. Perform a flow meter test on the pump.

2. Check the system functions.

8.10 FRONT DRIVE MOTOR

For internal service instructions and detailed specificat ions , co nt ac t t h e l oc al JLG dealer for a copy of the Rexroth Drive Motor Repair Manual (P/N 31200123).

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

4. Fill the motor with hydraulic oil through the fill plug (1) before starting the machine.

5. Refill the hydraulic reservoir and inspect for leaks around the machine.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

8-13

Hydraulic System

MZ5500

FRONT OF MACHINE

8.11 CONTROL VALVES

8.11.1 Main Control Valve

The main control valve is mounted on the rear of the machine behind the rear access panel.

The main control valve assembly consists of various working sections with their own valve assemblies, each providing a specific hydraulic function. The section assemblies are the left-hand end cover (1), lift/lower (2), tilt (3), auxiliary (4), crowd (5) and right-hand end cover (6) sections.

a. Main Control Valve Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engag e the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Remove the rear panel. Allow the hydraulic oil to cool.

4. Thoroughly clean the main control valve and surrounding area, including all hoses and fittings, before proceeding.

5. Place a suitable container to catch hydraulic oil drainage beneath the fr ame.

6. Label, disconnect and cap all the hydraulic hoses attached to the main control valve. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

7. Wipe up any hydraulic oil spillage in, on, near and around the machine and the work area.

8. Remove the four bolts securing the main control valve to the frame bracket.

b. Main Control Valve Disassembly

1. To disassemble the individual sections of the main control valve, remove the nuts from the end of the tie rods. Pull the tie rods out through the sections.

2. Disassemble each section assembly as required.

Some sections include a pre-adjusted relief valve that regulates pressure in a specific circuit.

NOTICE

DO NOT adjust any of the relief valve assemblies!

Tampering with a relief valve will irrevocably alter pressure in the affected circuit, requiring re calibration or a new relief valve.

Disassemble each Valve Section

1. Carefully separate the end cover section from the lift/ lower section.

2. Remove the o-rings from between the two sections.

3. Carefully separate each remaining section and remove all o-rings and seals.

4. Remove any plugs, check valves, compensator valves, anti-cavitation valves, shock valves or the rectangular hydraulic remote positioners from each individual valve section if equipped.

5. Keep all parts being removed from individual valve sections tagged and kept together.

c. Main Control Valve Pa rts Cleaning

Clean all components with a suitable cleaner, such as trichlorethylene, before continuing. Blow dry.

d. Main Control Valve Parts Inspection

Inspect all parts and internal passageways for wear, damage, etc. If inner surfaces of any component DO NOT display an ult ra- smoo th, polis hed finis h, or ar e da mage d in any way, replace the damaged part. Often, dirty hydraulic oil causes failure of internal seals, damage to the polished surfaces within the component, and wear of and/or harm to other parts.

8-14

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Hydraulic System

e. Main Control Valve Assembly

Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.

Assemble each Valve Section

1. Reassemble any plugs, check valves, compensator valves, anti-cavitation valves, shock valves or hydraulic remote positioners from individual valve sections if equipped.

2. Install the end covers onto Lift/Lower and Crowd sections.

Assemble the Main Control Valve

1. Place all three tie rods with the washe r s and nut s through the end mai n co ntr ol valve section.

2. Stand the end main control valve section on end.

3. Install proper o-rings on the inner face of the end main control valve section. Align the Crowd section over the three tie rods and slide onto the end main control valve section.

4. Using proper o-rings and load sense shuttle, repeat step three for the remaining sections.

5. Install the washers and nuts on the tie rods and torque to 25 Nm (18.5 lb-ft).

f. Main Control Valve Installation

1. Loosely install the four main control valve mounting bolts through bracket on the rear of the machine.

2. Install the main control valve onto the bracket, aligning the bolts with the holes in the end sections of the main control valve. Slide the main control valve into position, and tighten the bolts.

3. Prime the main control valve by filling the inlet openings with fresh, filtered hydraulic oil from a clean container, before attaching the hoses.

4. Use new oiled o-rings as required. Uncap and reattach and secure all hoses, clamps, etc. to the main control valve.

5. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps.

6. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating a ny hydraulic functions.

7. Inspect for leaks and check the level of the hydraulic oil in the reservoir. Shut the engine OFF.

8. Wipe up any hydraulic oil spillage in, on, near and around the machine, work area and tools.

9. Install the rear panel.

10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

g. Main Control Valve Test

Conduct a pressure check of the hydraulic system in its entirety. Adjust pressure(s) as required. Refer to Section

8.6.2, “Main Control Valve Pressure Checking.”

8.1 1.2 Service Brake Valve

The service brake valve is at the base of the steering column support, concealed by the lower dash cover.

The service brakes themselves are part of the front axle. Refer to Section 5, “Axles, Drive Shafts, Wheels and Tir es,” for further information.

a. Service Brake Valve Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Remove the necessary dash panels.

5. Label, disconnect and cap the hydraulic hoses connected to the service brake valve. Cap all fittings and openings to keep dirt and debris from entering the brake system.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-15

Hydraulic System

MZ5310

MZ5600

6. Remove the cotter key and pin (7) from the top of the brake valve (8).

7. Remove the bolts (9) that mount the service brake valve to the bracket support (10).

Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective.

b. Service Brake Valve Installation

1. Install the service brake valve to the steering column support with the necessary hardware.

Note: AL WAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.

2. Use new oiled o-rings as required. Uncap and reconnect the previousl y label ed hyd ra uli c hoses to the appropriate locations.

3. Check the routing of all hoses, and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps

4. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the machine or operating any hydraulic functions.

5. Inspect the service brake valve and connections for leaks, and check the brake fluid level. Shut the engine OFF.

6. Replace the necessary dash panels.

7. Wipe up any hydraulic oil spillage in, on, near and around the machine, work area and tools.

8-16

8. Close and secure the engine cover.

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

8.11.3 Parking Brake

The park brake is secured with two capscrews and lockwashers (1) at the left side of the seat base.

a. Park Brake Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Loosen and remove the three bolts and washers holding the park brake valve cover. Remove the cover.

5. Label, disconnect and cap the hydraulic hoses on each side and bottom of the park brake valve. Disconnect and cap all hoses, fittings, etc.

6. Remove the two capscrews, and two lockwashers mounting the park brake valve to the left side of the seat base.

Note: DO NOT disassemble the park brake valve. The park brake valve is not serviceable and must be replaced in its entirety, if defective.

b. Park Brake Valve Installation

1. Install the park brake valve with the two lockwashers and two capscrews to mount the park brake valve to the left side of the seat base.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

Hydraulic System

MAH1060

Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.

2. Use new oiled o-rings as required. Uncap, reattach and secure the three hoses.

3. Check the routing of all hoses for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required.

4. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the machine or operating any hydraulic functions.

5. Inspect the park brake valve and connections for leaks, and check the level of the hydraulic oil in the reservoir. Shut the engine OFF.

6. Replace the brake valve cover.

7. Wipe up any hydraulic oil spillage in, on, near and around the machine, work area and tools.

8. Close and secure the engine cover.

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

Note: The park brake valve circuit will need to be bled after installation. Refer to Section 8.11.4, “Brake Test.”

1. Place the transmission control lever in (N) NEUTRAL, engage the park brake, and start the engine.

2. Remove the plastic cap from the brake bleeder. Attach one end of a length of transparent tubing over the brake bleeder. Place the other end of this tubing in a suitable transparent container that is partially filled with hydraulic oil. The end of the tubing must be below the oil level in the container.

3. DO NOT open the brake bleeder without holding the tubing firmly on the bleeder . There is pressure at the brakes. Carefully open the bleeder with a 12 mm wrench. Have an assistant depress the brake pedal. Close the brake bleeder when air bubbles no longer appear in the oil. Release the brake pedal. Remove the tubing from the brake bleeder.

4. Repeat steps 2 and 3 for the remaining brake bleeder.

5. If bleeding the service brake circuit, install a vacuum pump on the brake reservoir and remove the remainder of the trapped air from the brake system.

6. Check brake fluid level and add fluid if necessary. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

7. Conduct a pressure and function check of the brake.

8.11.4 Brake Test

Carefully bleed the brake lines as soon as the brake valve is installed in the machine. Air in the system will not allow the brakes to apply properly. There are four brake bleeder locations (3) on the front axle. The outside bleeders are used for the park brake circuit. The inside bleeders are used for the service brake circuit. Work with an assistant to perform this procedure.

c. Park Brake Valve Installation

1. Install the park brake valve with the two lockwashers and two capscrews to the cover.

Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.

2. Use new oiled o-rings as required. Uncap, reattach and secure the three hoses.

3. Check the routing of all hoses for sharp bends or interference with any rotating members, and install

tie wraps and/or protective conduit as required.

4. Start the engine and run at approximately one-third to one-half throttle for about one minute, without moving the machine or operating any hydraulic

functions.

5. Inspect the park brake valve and connections for leaks, and check the level of the hydraulic oil in the reservoir. Shut the engine OFF.

6. Install the park brake/cover wi th the four capscrews.

7. Wipe up any hydraulic oil spillage in, on, near and around the machine, work area and tools.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

8-17

Hydraulic System

MZ5540

8. Close and secure the engine cover.

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

d. Parking Brake Valve Test.

1. Start the machine and engage the shift lever to the forward position. Slowly depress the throttle to mid idle. The parking brake will not allow the machine to move.

2. If further troubleshooting is required, refer to the Section 8.7, “Hydraulic Schematic,” or Section 9.9, “Electrical System Schematics.”

8.11.5 Steering Orbitrol Valve

Refer to Section 4.4.2, “Steering Column/Valve Replacement,” for details.

8.11.6 Steer Select Valve

The steer select valve is attached to inside the frame near the front drive motor.

Verify the correct operation of the steer select valve solenoids before considering replacement of the valve. The housing of the steer select valve is not serviceable and must be replaced if defective.

a. Steer Select Manifold and Valve Removal

1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Label or otherwise mark the hydraulic hoses in relation to the steer select manifold. Disconnect and cap all hoses, fittings, solenoid wire terminal leads, etc.

5. Remove the capscrews that attach the manifold to the frame.

6. Remove the steer sele ct manif old wi th at tach ed steer select valve from the machine. Wipe up any hydraulic oil spillage in, on, near and around the machine.

b. Steer Select Valve and Manifold Disassembly,

Cleaning, Inspection and Assembly

1. Place the steer select assembly on a suitable work surface.

2. Separate the steer select val ve from t he manifold by removing the capscrews. Discard the old o-rings.

3. Remove the solenoid valves and cartridges (1) from the steer select housing.

4. Clean all components with a suitable cleaner before inspection.

5. Inspect the solenoid cartridges for proper operation. Check by shifting the spool to ensure that it is functioning properly. Check that the spring is intact. Inspect the cartridge interior for contamination.

6. Inspect internal passageways of the steer select manifold and valve for wear, damage, etc. If inner surfaces of the manifold DO NOT display an ultrasmooth, polished finish, or compo nen ts ar e damaged in any way, replace the manifold or appropriate part. Often, dirty hydraulic oil causes failure of internal seals and damage to the polished surfaces within the unit.

Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.

7. Install the solenoid valves and cartridges in the steer select housing.

8. Attach the steer select valve to the manifold using new, oiled o-rings and socket head capscrews.

c. Steer Select Manifold and Valve Installation

8-18

1. Attach the steer select manifold and valve to the mounting plate on the frame using the socket head capscrews.

L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7

JLG 723A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 INTRODUCTION

1.4 DO NOT OPERATE TAGS

1.5 S AFETY INFORMATION

1.5.1 Safety Alert System and Signal Words

1.2 DISCLAIMER

1.3 O PERATION & SAFETY MANUAL

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 S AFETY DECALS

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

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 ASSEMB LY MAINTENANCE

3.4.1 Boom Removal

3.4.2 Second S e c tion B o o m Remo v a l

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

3.9.1 Equipment and Supplies Required

3.9 EMERGENCY BOOM LOWERING PROCEDURE

3.9.2 Lowering Procedure

3.10 TROUBLESHOOTING

4.1 OPERATOR CAB AND COVERS COMPONENT TE RMINOLOGY

4.2 SAFETY INFORMATION

4.3 OPERATOR CAB

4.3.1 Operator Cab Description

4.4 CAB COMPONENTS

4.4.1 Steering Wheel

4.3.2 Serial Number Decal

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

5.2 SAFETY INFORMATION

5.3 GENERAL INFORMATION