JLG L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 Telehandlers Service Manual - 31200568

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This service manual PDF download for the L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 JLG Telescopic Handlers has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG L2906H
JLG 2906H
JLG 3507H
JLG 619A
JLG 723A
JLG Agrovector 29.6LP
JLG Agrovector 29.6
JLG Agrovector 35.7


TABLE OF CONTENTS :

    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
        1.6 Safety Instructions
        1.7 Safety Decals
        
    Section 2 General Information and Specifications
        2.1 Replacement Parts and Warranty Information
        2.2 Torques
        2.3 Specifications
        2.4 Fluids, Lubricants and Capacities
        2.5 Maintenance Schedules
        2.6 Lubrication Schedule
            
    Section 3 Boom
        3.1 Boom System Component Terminology
        3.2 Safety Information
        3.3 Boom System - Two Section Boom
        3.4 Boom Assembly Maintenance
        3.5 Boom Wear Pads
        3.6 Quick Attach Assembly
        3.7 Forks
        3.8 Boom Prop (If Equipped)
        3.9 Emergency Boom Lowering Procedure
        3.10 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
        4.2 Safety Information
        4.3 Operator Cab
        4.4 Cab Components
        4.5 Cab Removal
        4.6 Cab Installation
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 Safety Information
        5.3 General Information
        5.4 Axle Assemblies
        5.5 Drive Shafts
        5.6 Wheels and Tires
        5.7 Steering Angle Adjustment
        5.8 Brakes
            
    Section 6 Transmission
        6.1 Transmission Assembly Component Terminology
        6.2 Safety Information
        6.3 Transmission Description
        6.4 Transmission Specifications
        6.5 Transmission Replacement
        6.6 Transmission Filter Replacement
        6.7 Towing a Disabled Machine
        
    Section 7 Engine: Deutz TCD 2012
        7.1 Introduction
        7.2 Safety Information
        7.3 Engine Serial Number
        7.4 Specifications and Maintenance Information
        7.5 Engine Cooling System
        7.6 Engine Electrical System
        7.7 Fuel System
        7.8 Engine Exhaust System
        7.9 Air Cleaner Assembly
        7.10 Engine Replacement
        7.11 Engine Coupler
        7.12 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 General Information
        8.4 Specifications
        8.5 Hoses, Tube Lines, Fittings, Etc.
        8.6 Hydraulic Pressure Diagnosis
        8.7 Hydraulic Schematic
        8.8 Hydraulic Reservoir
        8.9 Implement Pump (Piston or Gear)
        8.10 Front Drive Motor
        8.11 Control Valves
        8.12 Hydraulic Cylinders
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Safety Information
        9.4 Keypad and Display Screen
        9.5 Software Level 2 Accessibility
        9.6 Operator Tools
        9.7 Instrument Panel
        9.8 Fuses and Relays
        9.9 Electrical System Schematics
        9.10 Circuit Breakdowns
        9.11 Engine electrical Components
        9.12 Window Wiper/Washer
        9.13 Cab Heater and Fan
        9.14 Solenoids, Sensors and Senders
        9.15 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (Before S/N 1160005993 excluding 1160005943, 1160005945 & 1160005414)
        9.16 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (S/N 1160005993 & After including 1160005943, 1160005945 & 1160005414)
        9.17 Hand Held Analyzer
        9.18 Fault Codes


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 31200568
Total Pages : 208


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31200568_B_L2906H 2906H 3507H 29.6LP 29.6 35.7 619A 723A_JLG_Service
    Effectivity
    Table of Contents
    
    Section 1 Safety Practices
        1.1 Introduction
        1.2 Disclaimer
        1.3 Operation & Safety Manual
        1.4 Do Not Operate Tags
        1.5 Safety Information
            1.5.1 Safety Alert System and Signal Words
        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 Safety Decals
        
    Section 2 General Information and Specifications
        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
            
    Section 3 Boom
        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 Assembly Maintenance
            3.4.1 Boom Removal
            3.4.2 Second Section Boom Removal
            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 Emergency Boom Lowering Procedure
            3.9.1 Equipment and Supplies Required
            3.9.2 Lowering Procedure
        3.10 Troubleshooting
        
    Section 4 Cab and Covers
        4.1 Operator Cab and Covers Component Terminology
        4.2 Safety Information
        4.3 Operator Cab
            4.3.1 Operator Cab Description
            4.3.2 Serial Number Decal
        4.4 Cab Components
            4.4.1 Steering Wheel
            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
        
    Section 5 Axles, Drive Shafts, Wheels and Tires
        5.1 Axle, Drive Shaft and Wheel Component Terminology
        5.2 Safety Information
        5.3 General Information
        5.4 Axle Assemblies
            5.4.1 Axle Serial Number Plate
            5.4.2 Axle Specifications
            5.4.3 Axle Maintenance
            5.4.4 Axle Removal
            5.4.5 Axle Installation
            5.4.6 Axle Assembly and Drive Shaft Troubleshooting
        5.5 Drive Shafts
            5.5.1 Drive Shaft Inspection
            5.5.2 Drive Shaft Maintenance
            5.5.3 Drive Shaft Removal
            5.5.4 Drive Shaft Cleaning and Drying
            5.5.5 Drive Shaft Installation
        5.6 Wheels and Tires
            5.6.1 Removing Wheel and Tire Assembly from Machine
            5.6.2 Installing Wheel and Tire Assembly onto Machine
        5.7 Steering Angle Adjustment
        5.8 Brakes
            5.8.1 Brake Disc Inspection
            
    Section 6 Transmission
        6.1 Transmission Assembly Component Terminology
        6.2 Safety Information
        6.3 Transmission Description
        6.4 Transmission Specifications
            6.4.1 Transmission Maintenance
        6.5 Transmission Replacement
            6.5.1 Transmission Removal
            6.5.2 Transmission Installation
            6.5.3 After Transmission Replacement
        6.6 Transmission Filter Replacement
            6.6.1 Filter Removal
            6.6.2 Filter Installation
        6.7 Towing a Disabled Machine
        
    Section 7 Engine: Deutz TCD 2012
        7.1 Introduction
            7.1.1 Disclaimer and Scope
            7.1.2 Component Terminology
        7.2 Safety Information
        7.3 Engine Serial Number
        7.4 Specifications and Maintenance Information
        7.5 Engine Cooling System
            7.5.1 Radiator Pressure Cap
            7.5.2 Radiator/Oil and Charge Air Cooler Replacement
        7.6 Engine Electrical System
        7.7 Fuel System
            7.7.1 Diesel Fuel
            7.7.2 Fuel/Hydraulic Oil Tank
            7.7.3 After Fuel System Service
        7.8 Engine Exhaust System
            7.8.1 Exhaust System Removal
            7.8.2 Exhaust System Installation
        7.9 Air Cleaner Assembly
            7.9.1 Air Cleaner Assembly Removal
            7.9.2 Air Cleaner Assembly Installation
        7.10 Engine Replacement
            7.10.1 Engine Removal
            7.10.2 Engine Disassembly, Inspection and Service
            7.10.3 Engine Installation
        7.11 Engine Coupler
            7.11.1 Coupler Removal
            7.11.2 Coupler Installation
        7.12 Troubleshooting
        
    Section 8 Hydraulic System
        8.1 Hydraulic Component Terminology
        8.2 Safety Information
        8.3 General Information
        8.4 Specifications
        8.5 Hoses, Tube Lines, Fittings, Etc.
            8.5.1 Replacement Considerations
            8.5.2 Hose, Tube, Line and Fitting Replacement
        8.6 Hydraulic Pressure Diagnosis
            8.6.1 Pressure Checks and Adjustments
            8.6.2 Main Control Valve Pressure Checking
            8.6.3 Charge Pressure Checking
            8.6.4 Drive Pressure Checking
            8.6.5 Boom Function Pressure Checking
            8.6.6 Steering Pressure Checking
            8.6.7 Brake Pressure Checking
        8.7 Hydraulic Schematic
            8.7.1 Gear Pump Schematic
            8.7.2 Piston Pump Schematic
        8.8 Hydraulic Reservoir
            8.8.1 Pressurized Hydraulic Oil Fill Cap
            8.8.2 Hydraulic Oil Reservoir Draining
            8.8.3 Hydraulic Oil Reservoir Filling
        8.9 Implement Pump (Piston or Gear)
            8.9.1 Implement Pump Replacement
        8.10 Front Drive Motor
        8.11 Control Valves
            8.11.1 Main Control Valve
            8.11.2 Service Brake Valve
            8.11.3 Parking Brake
            8.11.4 Brake Test
            8.11.5 Steering Orbitrol Valve
            8.11.6 Steer Select Valve
            8.11.7 Inching Valve
            8.11.8 Anti-Kick Valve
        8.12 Hydraulic Cylinders
            8.12.1 General Cylinder Removal Instructions
            8.12.2 General Cylinder Disassembly
            8.12.3 Cylinder Cleaning Instructions
            8.12.4 Cylinder Inspection
            8.12.5 General Cylinder Assembly
            8.12.6 General Cylinder Installation
            8.12.7 Steering Cylinders
            8.12.8 Hydraulic Cylinder Torque Specifications
            
    Section 9 Electrical System
        9.1 Electrical Component Terminology
        9.2 Specifications
        9.3 Safety Information
        9.4 Keypad and Display Screen
            9.4.1 Keypad
            9.4.2 Display Screen
        9.5 Software Level 2 Accessibility
            9.5.1 Operator Tools
            9.5.2 Personalities
            9.5.3 Calibrations
        9.6 Operator Tools
            9.6.1 Resetting the Anti theft Code
            9.6.2 Hardware Exchange
            9.6.3 Confirm Machine Service
            9.6.4 Review Service History
            9.6.5 Set Service Interval
        9.7 Instrument Panel
        9.8 Fuses and Relays
            9.8.1 Engine Compartment Relays and Fuses
            9.8.2 Power Distribution Module
        9.9 Electrical System Schematics
            9.9.1 Cab Harness Electrical Schematic 1 of 2
            9.9.2 Cab Harness Electrical Schematic 2 of 2
            9.9.3 Cab Roof and Boom Schematic
            9.9.4 Front and Rear Frame Schematic
            9.9.5 Engine Compartment Schematic
            9.9.6 Power Ground, ANSI Shifter and Oil Gauge Schematic
        9.10 Circuit Breakdowns
            9.10.1 Alternator Charge Circuit
            9.10.2 Starter Circuit
            9.10.3 Constant Power Circuit
        9.11 Engine electrical Components
            9.11.1 Starter
            9.11.2 Alternator
        9.12 Window Wiper/Washer
            9.12.1 Windshield Wiper Motor (if equipped)
            9.12.2 Rear Window Wiper Motor (if equipped)
            9.12.3 Windshield Washer Reservoir and Pump
        9.13 Cab Heater and Fan
            9.13.1 Cab Heater/Air Conditioning Controls
        9.14 Solenoids, Sensors and Senders
            9.14.1 Ignition Key Switch
            9.14.2 Dash Switches
            9.14.3 Fuel Level Indicator and Fuel Level Sender
            9.14.4 Hourmeter
            9.14.5 Coolant Temperature Sender
            9.14.6 Fuel Shut-off Solenoid
            9.14.7 Oil Pressure Sender
            9.14.8 Oil Temperature Sensor
            9.14.9 Back-up Alarm
            9.14.10 Boom Angle Sensor
        9.15 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (Before S/N 1160005993 excluding 1160005943, 1160005945 & 1160005414)
            9.15.1 Load Stability Indicator
            9.15.2 LSI Sensor
            9.15.3 LSI System Calibration
        9.16 Load Stability Indicator - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (S/N 1160005993 & After including 1160005943, 1160005945 & 1160005414)
            9.16.1 Load Stability Indicator
            9.16.2 LSI Sensor
            9.16.3 LSI System Calibration
            9.16.4 LSI-CAN Check PT
            9.16.5 500 Hour - LSI CAN SYSTEM CHECK
        9.17 Hand Held Analyzer
            9.17.1 Analyzer Usage
            9.17.2 Analyzer Software - Version 3.5
        9.18 Fault Codes
            9.18.1 Indicator Cross Reference Table
            9.18.2 Fault Code Table
            
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