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Complete service repair manual for Deutz-Fahr / JLG Agrovectors Models, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Deutz-Fahr / JLG Agrovectors Models workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,221 pages
File Format: PDF
Language: English
MANUAL LIST:
25.5
31200725 – Illustrated Parts Manual Models G5-18A, 2505H Agrovector 25.5.pdf
31200751 – Operation & Safety Manual Agrovector 25.5.pdf
31200926 – Service Manual Models G5-18A & 2505H Agrovector 25.5.pdf
31200936 – Engine Parts Manual Models G5-18A, 2505H Agrovector 25.5.pdf
26.6 30.7 26.6 LP
307.1127.3.6 – Deutz-Fahr AGROVECTOR 26.6, AGROVECTOR 30.7 Workshop Manual.pdf
31200114 – Operation & Safety Manual Agrovector 26.6LP, 26.6 & 30.7.pdf
3126025 – Illustrated Parts Manual Models 266, 307, 266 LoPro & Agrovector 26.6, 30.7, 26.6 LP.pdf
29.6LP_29.6_35.7
31200566 – Illustated Parts Manual Models L2906H, 2906H, 3507H, 619A, 723A & Agrovector 29.6LP, 29.6, 35.7.pdf
31200568 – Service Manual Models L2906H, 2906H, 3507H, 619A, 723A Agrovector 29.6LP, 29.6, 35.7.pdf
31200570 – Operation & Safety Manual Agrovector 29.6LP, 29.6 & 35.7.pdf
30.6 35.7 40.8 35.10
31211097 – Operation & Safety Manual Agrovector 30.6, 35.7, 40.8, 35.10.pdf
31211226 – Illustrated Parts Manual Models 3006H, 30.6.pdf
Service Manual 30.6 35.7 40.8 35.10 CE+ AUS.pdf
33.7_37.6_37.7
31200722 – Illustrated Parts Manual Models 3706PS, 3707PS, 4014PS, 4017PS & Agrovector 33.7, 37.6, 37.7.pdf
31200755 – Operation & Safety Manual Agrovector 33.7, 37.6 & 37.7.pdf
31200800 – Service Manual Models 3706PS, 3707PS, 4014PS, 4017PS & Agrovector 33.7, 37.6, 37.7.pdf
35.10
31211097 – Operation & Safety Manual Agrovector 30.6, 35.7, 40.8, 35.10.pdf
31211227 – Illustrated Parts Manual Models 3510PS, 35.10.pdf
35.7
31211097 – Operation & Safety Manual Agrovector 30.6, 35.7, 40.8, 35.10.pdf
31211228 – Service Manual Models 3006H, 3507PS, 4008PS, 3510PS, 30.6, 35.7, 40.8, 35.10.pdf
31211270 – Illustrated Parts Manual Agrovector 35.7.pdf
40.8
31211097 – Operation & Safety Manual Agrovector 30.6,35.7, 40.8, 35.10.pdf
31211228 – Service Manual Models 3006H, 3507PS, 4008PS, 3510PS, 30.6, 35.7, 40.8, 35.10.pdf
31211271 – Illustrated Parts Manual Agrovector 40.8.pdf
25.5…………….2
31200725 – Illustrated Parts Manual Models G5-18A, 2505H Agrovector 25.5…………….3
31200725_H_G5-18A, 2505H & Agrovector 25.5_JLG_Parts…………….3
Effectivity Page…………….5
Machine Configuration…………….6
General Information…………….7
Table of Contents…………….9
SECTION 1 – FRAME AND ATTACHING PARTS…………….13
FIGURE 1-1. FRAME AND ATTACHING PARTS…………….14
FIGURE 1-2. COVERS…………….20
FIGURE 1-3. LICENSE PLATE HOLDER INSTALLATION…………….28
FIGURE 1-4. HITCHES…………….30
FIGURE 1-5. HITCH ASSEMBLY…………….34
FIGURE 1-6. HITCH ASSEMBLY…………….36
SECTION 2 – BOOM…………….39
FIGURE 2-1. BOOM ASSEMBLY – COMPONENTS…………….40
FIGURE 2-2. BOOM ASSEMBLY – PADS AND SHIMS…………….44
FIGURE 2-3. QUICK COUPLER…………….46
FIGURE 2-4. UNIVERSAL QUICK COUPLER…………….48
SECTION 3 – ATTACHMENTS…………….51
FIGURE 3-1. STANDARD CARRIAGE…………….52
FIGURE 3-2. UNIVERSAL STANDARD CARRIAGE…………….54
FIGURE 3-3. SIDE TILT CARRIAGE…………….56
FIGURE 3-4. UNIVERSAL SIDE TILT CARRIAGE (G5-18A)…………….58
FIGURE 3-5. UNIVERSAL SIDE SHIFT CARRIAGE…………….60
FIGURE 3-6. FORKS…………….62
FIGURE 3-7. GRAPPLE BUCKET (G5-18A, 2505H & 25.5 – AUS)…………….64
FIGURE 3-8. GRAPPLE BUCKET (2505H & 25.5) (Prior to SN 0160065890)…………….66
FIGURE 3-9. GRAPPLE BUCKET (2505H & 25.5) (SN 0160065890 to Present)…………….68
FIGURE 3-10. LIGHT MATERIAL BUCKETS…………….70
FIGURE 3-11. FORK MOUNTED HOOK…………….72
FIGURE 3-12. UNIVERSAL HITCH ATTACHMENT…………….76
FIGURE 3-13. SIDE SHIFT CARRIAGE ASSEMBLY (2505H)…………….78
FIGURE 3-14. CRANE HOOK…………….80
FIGURE 3-15. REFLECTIVE PLATES INSTALLATION (FORKS)…………….82
FIGURE 3-16. REFLECTIVE PLATES INSTALLATION (BUCKET) (ITALY)…………….84
SECTION 4 – ENGINE AND ATTACHING PARTS…………….87
FIGURE 4-1. ENGINE INSTALLATION…………….88
FIGURE 4-2. FUEL TANK AND LINES (Including 0160076806, Excluding 0160076010, 0160076011 and 0160076012)…………….92
FIGURE 4-3. FUEL TANK AND COMPONENTS INSTALLATION (SN 0160076806 to Present, Including 0160076010, 0160076011 and 060076012)…………….94
FIGURE 4-4. RADIATOR INSTALLATION…………….96
FIGURE 4-5. AIR CLEANER INSTALLATION…………….100
FIGURE 4-6. EXHAUST INSTALLATION…………….102
FIGURE 4-7. EXHAUST INSTALLATION…………….104
FIGURE 4-8. ENGINE HEATER INSTALLATION…………….106
FIGURE 4-9. LUBRICITY DOSER INSTALLATION…………….108
FIGURE 4-10. FILTER, PRECLEANER…………….110
SECTION 5 – DRIVE TRAIN…………….113
FIGURE 5-1. DRIVE TRAIN INSTALLATION…………….114
FIGURE 5-2. FRONT AXLE ASSEMBLY…………….116
FIGURE 5-3. CENTRAL HOUSING AND STEERING…………….118
FIGURE 5-4. DIFFERENTIAL…………….120
FIGURE 5-5. HUB REDUCTION…………….124
FIGURE 5-6. BRAKES…………….126
FIGURE 5-7. REAR AXLE ASSEMBLY…………….128
FIGURE 5-8. CENTRAL HOUSING AND STEERING…………….130
FIGURE 5-9. DIFFERENTIAL…………….132
FIGURE 5-10. HUB REDUCTION…………….134
FIGURE 5-11. FENDER INSTALLATION…………….136
FIGURE 5-12. TIRES AND RIMS…………….138
SECTION 6 – CAB…………….141
FIGURE 6-1. CAB INSTALLATION…………….142
FIGURE 6-2. OPEN CAB (G5-18A)…………….148
FIGURE 6-3. ENCLOSED CAB INSTALLATION…………….150
FIGURE 6-4. CAB INTERIOR…………….156
FIGURE 6-5. OVERHEAD CONSOLE INSTALLATION…………….160
FIGURE 6-6. SUSPENSION SEAT…………….162
FIGURE 6-7. WIPER INSTALLATION…………….164
FIGURE 6-8. HEATER AND AC…………….166
FIGURE 6-9. HEATER AND AC…………….170
FIGURE 6-10. AC CONDENSER INSTALLATION…………….174
FIGURE 6-11. AC SYSTEM INSTALLATION…………….176
FIGURE 6-12. HEATER ASSEMBLY…………….178
FIGURE 6-13. HEATER ASSEMBLY WITH AC…………….180
SECTION 7 – CONTROLS…………….183
FIGURE 7-1. BRAKE…………….184
FIGURE 7-2. ACCELERATOR…………….188
FIGURE 7-3. STEERING COLUMN…………….190
FIGURE 7-4. BOOM JOYSTICK…………….192
SECTION 8 – HYDRAULIC CIRCUITS…………….195
FIGURE 8-1. SUPPLY CIRCUIT…………….196
FIGURE 8-2. DUMP CIRCUIT…………….200
FIGURE 8-3. STEER SELECT…………….204
FIGURE 8-4. SERVICE/PARK BRAKE…………….206
FIGURE 8-5. BOOM JOYSTICK (G5-18A)…………….208
FIGURE 8-6. BOOM JOYSTICK (2505H & 25.5)…………….210
FIGURE 8-7. LIFT CYLINDER (G5-18A)…………….212
FIGURE 8-8. LIFT CYLINDER (2505H & 25.5)…………….214
FIGURE 8-9. EXTEND/RETRACT CYLINDER…………….216
FIGURE 8-10. TILT AND COMPENSATING…………….218
FIGURE 8-11. AUXILIARY HYDRAULICS…………….220
FIGURE 8-12. REAR AUXILIARY HYDRAULICS…………….222
FIGURE 8-13. AUXILIARY HYDRAULICS PRESSURE RELIEF…………….224
FIGURE 8-14. HYDRAULIC TANK BREATHER INSTALLATION…………….226
SECTION 9 – HYDRAULIC COMPONENTS…………….229
FIGURE 9-1. LIFT CYLINDER (G5-18A) (Prior to SN 0160076806, Excluding 0160076010, 0160076011 and 0160076012)…………….230
FIGURE 9-2. LIFT CYLINDER (G5-18A) (SN 0160076806 to Present, Including 0160076010, 0160076011 and 160076012)…………….232
FIGURE 9-3. LIFT CYLINDER (2505H & 25.5)…………….234
FIGURE 9-4. LIFT CYLINDER (2505H & 25.5)…………….236
FIGURE 9-5. EXTEND/RETRACT CYLINDER (Prior to SN 0160076806, Excluding 0160076010, 0160076011 and 0160076012)…………….238
FIGURE 9-6. EXTEND/RETRACT CYLINDER (SN 0160076806 to Present, Including 0160076010, 0160076011 and 0160076012)…………….240
FIGURE 9-7. TILT CYLINDER (Prior to SN 0160076806, Excluding 0160076010, 0160076011 and 0160076012)…………….242
FIGURE 9-8. TILT CYLINDER (SN 0160076806 to Present, Including 0160076010, 0160076011 and 0160076012)…………….244
FIGURE 9-9. COMPENSATING CYLINDER (Prior to SN 0160076806, Excluding 0160076010, 0160076011 and 0160076012)…………….246
FIGURE 9-10. COMPENSATING CYLINDER (SN 0160076806 to Present, Including 0160076010, 0160076011 and 0160076012)…………….248
FIGURE 9-11. FORK LOCKING CYLINDER…………….250
FIGURE 9-12. SIDE TILT CARRIAGE CYLINDER AND GRAPPLE BUCKET CYLINDER…………….252
FIGURE 9-13. UNIVERSAL SIDE SHIFT CYLINDER…………….254
FIGURE 9-14. MAIN CONTROL VALVE…………….256
FIGURE 9-15. FRONT DRIVE MOTOR…………….258
FIGURE 9-16. HYDROSTATIC DRIVE PUMP…………….260
FIGURE 9-17. GEAR PUMP…………….262
FIGURE 9-18. DIVERTOR VALVE…………….264
FIGURE 9-19. STEERING SELECT VALVE…………….266
FIGURE 9-20. PILOT SELECT VALVE…………….268
FIGURE 9-21. BRAKE VALVES…………….270
SECTION 10 – ELECTRICAL…………….273
FIGURE 10-1. ENGINE COMPARTMENT ELECTRICAL INSTALLATION…………….274
FIGURE 10-2. BOOM AND FRAME ELECTRICAL INSTALLATION…………….276
FIGURE 10-3. CAB ELECTRICAL INSTALLATION…………….282
FIGURE 10-4. CAB SWITCHES…………….284
FIGURE 10-5. WORK LIGHTS…………….286
FIGURE 10-6. DRIVE LIGHTS…………….290
FIGURE 10-7. ENGINE HARNESS…………….294
FIGURE 10-8. FRAME HARNESS…………….298
FIGURE 10-9. FRAME OPTION HARNESS…………….304
FIGURE 10-10. CAB HARNESS (Prior to SN 0160076806, Excluding 0160076010, 0160076011 and 0160076012)…………….310
FIGURE 10-11. CAB HARNESS (SN 0160076806 to Present, Including 0160076010, 0160076011 and 160076012)…………….316
FIGURE 10-12. CAB ROOF HARNESS…………….320
FIGURE 10-13. ROOF WORKLIGHT HARNESS…………….322
FIGURE 10-14. BOOM WORKLIGHT HARNESS…………….324
FIGURE 10-15. BEACON WORKLIGHT HARNESS…………….326
FIGURE 10-16. BOOM AUX HARNESS…………….328
FIGURE 10-17. LSI BOOM SENSOR HARNESS…………….330
FIGURE 10-18. IGNITION SWITCH JUMPER HARNESS…………….332
FIGURE 10-19. MODE SELECT HARNESS…………….334
FIGURE 10-20. HEATER JUMPER HARNESS…………….336
FIGURE 10-21. CLEARSKY ASSEMBLY…………….338
FIGURE 10-22. REVERSE SENSING SYSTEM INSTALLATION G5-18A…………….340
FIGURE 10-23. REVERSE SENSOR HARNESS G5-18A…………….342
FIGURE 10-24. TELEMATICS HARNESS INSTALLATION…………….344
FIGURE 10-25. TELEMATICS INSTALLATION, UNITED RENTALS…………….346
FIGURE 10-26. CLEARSKY CONTROLLER…………….348
FIGURE 10-27. AC CONDENSER HARNESS…………….350
SECTION 11 – DECALS…………….353
FIGURE 11-1. CAB AND FRAME DECALS…………….354
FIGURE 11-2. BOOM DECALS…………….360
SECTION 12 – RECOMMENDED SPARE PARTS…………….363
FIGURE 12-1. RECOMMENDED SPARE PARTS…………….364
PART NUMBER INDEX…………….367
31200751 – Operation & Safety Manual Agrovector 25.5…………….379
31200751_B_25.5_Deutz-Fahr_O&SM…………….379
Revision Log…………….381
Read This First…………….382
Table of Contents…………….385
Section 1 – General Safety Practices…………….389
1.1 Hazard Classification System…………….389
Safety Alert System and Safety Signal Words…………….389
1.2 General Precautions…………….389
1.3 Operation Safety…………….390
Electrical Hazards…………….390
Tip Over Hazard…………….392
Travel Hazard…………….395
Load Falling Hazard…………….396
Lifting Personnel…………….397
Driving Hazards on Slopes…………….398
Pinch Points and Crush Hazards…………….399
Fall Hazard…………….401
Chemical Hazards…………….402
1.4 ClearSky (if equipped)…………….403
Federal Communications Commission (FCC) Information for Users…………….403
Section 2 – Pre-Operation and Inspection…………….405
2.1 Pre-Operation Check and Inspection…………….405
2.2 Safety Decals…………….407
2.3 Walk-Around Inspection…………….410
2.4 Warm-Up and Operational Checks…………….412
Warm-Up Check…………….412
Operational Check…………….412
2.5 Operator Cab…………….413
2.6 Windows…………….414
Cab Door Window (if equipped)…………….414
Rear Window…………….415
Section 3 – Controls and Indicators…………….417
3.1 General…………….417
3.2 Controls…………….418
Park Brake…………….420
Parking Procedure…………….420
Ignition…………….421
Transmission Control Lever…………….422
Load Stability Indicator – LSI…………….424
LSI Override Switch…………….426
Steering Column Adjuster (if equipped)…………….427
Instrument Panel…………….428
Joystick…………….430
Right Hand Console…………….432
Accessory Control Lever (if equipped)…………….434
Reversing Fan (if equipped)…………….435
3.3 Steer Modes…………….436
Steer Mode Change…………….436
3.4 Operator Seat…………….437
Operator Presence…………….437
Adjustments…………….438
Seat Belt…………….439
3.5 Boom Angle and Extension Indicators…………….440
3.6 Reverse Sensing System…………….441
Section 4 – Operation…………….443
4.1 Engine…………….443
Starting the Engine…………….443
Cold Weather Starting…………….444
Battery Boosted Starting…………….445
Normal Engine Operation…………….446
Shut-Down Procedure…………….446
4.2 Operating with a Non-Suspended Load…………….447
Lift Load Safely…………….447
Before Picking Up a Load…………….447
Transporting a Load…………….448
Leveling Procedure…………….448
Placing a Load…………….449
Disengaging a Load…………….449
4.3 Operating with a Suspended Load (CE)…………….450
Lift Load Safely…………….450
Picking Up a Suspended Load…………….450
Transporting a Suspended Load…………….451
Leveling Procedure…………….451
Placing a Suspended Load…………….452
Disengaging a Suspended Load…………….452
4.4 Road Operation…………….453
4.5 Loading and Securing for Transport…………….454
Tiedown…………….454
Lifting…………….455
Section 5 – Attachments and Hitches…………….457
5.1 Approved Attachments…………….457
5.2 Unapproved Attachments…………….457
5.3 JLG Supplied Attachments…………….458
5.4 Telehandler/Attachment/Fork Capacity…………….460
5.5 Use of the Capacity Chart…………….461
Capacity Indicator Locations…………….461
Sample Capacity Chart (CE)…………….462
Sample Capacity Chart (AUS)…………….463
Example…………….464
5.6 Attachment Installation…………….465
Standard Quick Attach…………….465
Universal Quick Attach (UQC)…………….468
5.7 Hydraulic Operated Attachment…………….470
5.8 Adjusting/Moving Forks…………….471
5.9 Attachment Operation…………….472
Carriage with Forks…………….474
Fork Mounted Hook (CE)…………….475
Side Tilt Carriage…………….476
Side Shift Carriage…………….478
Bucket…………….480
Grapple Bucket…………….482
5.10 Hitches…………….484
Retrieval Hitch…………….484
Adjustable Auto Hitch…………….485
Pin Hitch – CUNA C…………….486
EEC Manual Pin Hitch…………….487
Section 6 – Emergency Procedures…………….489
6.1 Towing a Disabled Product…………….489
Moving Short Distances…………….489
Moving Longer Distances…………….489
6.2 Emergency Lowering of Boom…………….490
6.3 Emergency Exit from Enclosed Cab…………….491
Inside Cab…………….491
Outside Cab (if equipped)…………….491
Section 7 – Lubrication and Maintenance…………….493
7.1 Introduction…………….493
Clothing and Safety Gear…………….493
7.2 General Maintenance Instructions…………….494
7.3 Service and Maintenance Schedule…………….495
10 & 1st 50 & 50 Hour Maintenance Schedule…………….495
1st 250, 250 & 500 Hour Maintenance Schedule…………….496
1000 & 1500 Hour Maintenance Schedule…………….497
7.4 Lubrication Schedules…………….498
250 Hour Lubrication Schedule…………….498
7.5 Operator Maintenance Instructions…………….500
Fuel System…………….500
Engine Oil…………….502
Hydraulic Oil…………….503
Tires…………….504
Air Intake System…………….506
Engine Cooling System…………….508
Battery…………….509
Brake System…………….510
Windshield Washer System (if equipped)…………….511
Section 8 – Additional Checks…………….513
8.1 General…………….513
8.2 Load Stability Indicator System…………….513
8.3 Reverse Sensing System (if equipped)…………….514
Section 9 – Specifications…………….515
9.1 Product Specifications…………….515
Fluids…………….515
Capacities…………….518
Tires…………….519
Performance…………….520
Dimensions…………….521
Declaration of Vibration (CE)…………….522
Noise Emission Level (CE)…………….522
Machine Towing Capacity…………….522
Index…………….525
31200926 – Service Manual Models G5-18A & 2505H Agrovector 25.5…………….535
31200926_C_JLG_G5-18A,2505H,25.5_Service…………….535
Effectivity Page …………….537
Table of Contents …………….539
Section 1 Safety Practices…………….543
1.1 Introduction…………….544
1.2 Disclaimer…………….544
1.3 Operation & Safety Manual…………….544
1.4 Do Not Operate Tags…………….544
1.5 Safety Information…………….544
1.5.1 Safety Alert System and Signal Words…………….544
1.6 Safety Instructions…………….545
1.6.1 Personal Hazards…………….545
1.6.2 Equipment Hazards…………….545
1.6.3 General Hazards…………….545
1.6.4 Operational Hazards…………….546
1.7 Safety Decals…………….546
Section 2 General Information and Specifications…………….547
2.1 Replacement Parts and Warranty Information…………….549
2.2 Specifications…………….550
2.2.1 Travel Speed…………….550
2.2.2 Hydraulic Cylinder Performance Specifications…………….550
2.2.3 Electrical System…………….550
2.2.4 Steering Angle Specification…………….550
2.2.5 Engine Performance Specifications…………….551
2.2.6 Tires…………….551
2.3 Fluids, Lubricants and Capacities…………….552
2.3.1 Fluids…………….552
a. If Equipped for ULS…………….552
b. If Equipped for LS…………….554
2.3.2 Capacities…………….555
2.4 Maintenance Schedule…………….556
2.4.1 10,1st 50 & 50 Hour Maintenance Schedule…………….556
2.4.2 1st 250, 250 & 500 Hour Maintenance Schedule…………….557
2.4.3 1000 & 1500 Hour Maintenance Schedule…………….558
2.5 Lubrication Schedule…………….559
2.5.1 250 Hour Lubrication Schedule…………….559
2.6 Thread Locking Compound…………….560
2.7 Torque Charts…………….561
2.7.1 SAE Fastener Torque Chart…………….561
2.7.2 Metric Fastener Torque Chart…………….567
2.8 Hydraulic Connection Assembly and Torque Specification…………….571
2.8.1 Definitions…………….571
a. Tapered Thread Types…………….571
b. Straight Thread Types, Tube and Hose Connections…………….571
c. Straight Thread Types, Port Connections…………….572
d. Flange Connection Types…………….572
e. Tightening Methods…………….572
f. Assembly and Torque Specifications…………….572
g. General Tube Type FITTING ASSEMBLY INSTRUCTIONS…………….572
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections…………….573
a. NPTF Pipe Thread…………….574
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections…………….575
a. BSPT Pipe Thread…………….575
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings…………….576
a. 37° Flare (JIC) Thread – Steel…………….576
b. 37° Flare (JIC) Thread – Aluminum Brass…………….577
2.8.5 Assembly Instructions for 45° SAE Flare Fittings…………….578
a. 45° Flare (SAE)…………….579
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings…………….580
a. O-ring Face Seal (ORFS)…………….581
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)…………….582
a. DIN 24° CONE (MBTL & MBTS)…………….583
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings…………….584
a. Bulkhead Fittings (BH) – INCH…………….585
b. Bulkhead Fittings (BH) – METRIC…………….586
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings…………….588
a. O-ring Boss (ORB) – Table 1 of 6…………….589
b. O-ring Boss (ORB) – Table 2 of 6…………….590
c. O-ring Boss (ORB) – Table 3 of 6…………….591
d. O-ring Boss (ORB) – Table 4 of 6…………….592
e. O-ring Boss (ORB) – Table 5 of 6…………….593
f. O-ring Boss (ORB) – Table 6 of 6…………….594
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings…………….596
a. Metric Flat Face Port (MFF) L Series – Table 1 of 3…………….597
b. Metric Flat Face Port (MFF) L Series – Table 2 of 3…………….598
c. Metric Flat Face Port (MFF) L Series – Table 3 of 3…………….599
d. Metric Flat Face Port (MFF) S Series – Table 1 of 3…………….600
e. Metric Flat Face Port (MFF) S Series – Table 2 of 3…………….601
f. Metric Flat Face Port (MFF) S Series – Table 3 of 3…………….602
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends…………….604
a. Metric Pipe Parallel O-Ring Boss (MPP)…………….605
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings…………….606
a. British Standard Parallel Pipe Port (BSPP) – L Series – Table 1 of 3…………….607
b. British Standard Parallel Pipe Port (BSPP) – L Series – Table 2 of 3…………….608
c. British Standard Parallel Pipe Port (BSPP) L Series – Table 3 of 3…………….609
d. British Standard Parallel Pipe Port (BSPP) S Series – Table 1 of 3…………….610
e. British Standard Parallel Pipe Port (BSPP) S Series – Table 2 of 3…………….611
f. British Standard Parallel Pipe Port (BSPP) L Series – Table 3 of 3…………….612
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)…………….614
a. Flange Code (FL61 & FL62) – Inch Fasteners…………….615
b. Flange Code (FL61 & FL62) – Metric Fasteners…………….616
2.8.14 Double Wrench Method…………….617
2.8.15 FFWR and TFFT Methods…………….618
2.8.16 Adjustable Stud End Assembly…………….618
2.8.17 O-ring Installation (Replacement)…………….618
Section 3 Boom…………….619
3.1 Boom System Component Terminology…………….620
3.2 Safety Information…………….621
3.3 Two Section Boom System…………….621
3.3.1 Boom System Description…………….621
3.4 Boom Assembly Maintenance…………….621
3.4.1 Complete Boom Removal…………….621
3.4.2 Complete Boom Installation…………….623
3.4.3 Second Boom Section Removal…………….624
3.4.4 Second Boom Section Installation…………….625
3.4.5 Extend/Retract Cylinder Removal…………….626
3.4.6 Extend/Retract Cylinder Installation…………….627
3.5 Boom Wear Pads…………….628
3.5.1 Wear Pad Inspection…………….628
3.5.2 Wear Pad Installation and Lubrication…………….628
3.5.3 Boom Wear Pad Lubrication…………….629
3.6 Quick Attach Assembly…………….629
3.6.1 Quick Attach Assembly Removal…………….629
3.6.2 Quick Attach Assembly Installation…………….630
3.7 Forks…………….630
3.8 Boom Prop (if equipped)…………….631
3.8.1 Prop Installation…………….631
3.8.2 Prop Removal…………….631
3.9 Emergency Boom Lowering Procedure…………….632
3.9.1 Equipment and Supplies Required…………….632
3.9.2 Lowering Procedure…………….632
a. Retract the boom as follows:…………….632
b. Lower the boom as follows:…………….633
3.10 Troubleshooting…………….634
Section 4 Cab…………….637
4.1 Operator Cab Component Terminology…………….638
4.2 Safety Information…………….639
4.3 Operator Cab…………….639
4.3.1 Operator Cab Description…………….639
4.3.2 Serial Number Decal…………….639
4.4 Cab Components…………….639
4.4.1 Steering Wheel…………….639
a. Steering Wheel Removal…………….639
b. Steering Wheel Installation…………….639
4.4.2 Steering Column/Valve Replacement…………….640
a. Steering Column and Valve Removal…………….640
b. Steering Column and Valve Installation…………….640
c. Power Steering Test…………….640
4.4.3 Brake Pedal and Valve…………….641
a. Brake Valve Removal…………….641
b. Brake Valve Installation…………….641
c. Service Brake Pedal Removal…………….641
d. Service Brake Pedal Installation…………….641
4.4.4 Accelerator Pedal Replacement…………….642
a. Accelerator Pedal Removal…………….642
b. Accelerator Pedal Installation…………….642
4.4.5 Joystick Replacement…………….643
a. Joystick Removal…………….643
b. Joystick Installation…………….643
4.4.6 Windshield Wiper Assembly (if equipped)…………….643
4.4.7 Windshield Washer Assembly (if equipped)…………….643
4.4.8 Heater System (if equipped)…………….644
a. Removal…………….644
b. Installation…………….644
4.4.9 Heater and A/C System (if equipped)…………….645
a. Removal…………….645
b. Installation…………….646
4.4.10 Air Filter System (if equipped)…………….646
4.5 Cab Removal…………….647
4.6 Cab Installation…………….648
Section 5 Axles, Drive Shafts, Wheels and Tires…………….651
5.1 Axle, Drive Shaft and Wheel Component Terminology…………….652
5.2 Safety Information…………….653
5.3 General Information…………….653
5.4 Axle Assemblies…………….653
5.4.1 Axle Serial Number Plate…………….653
5.4.2 Axle Specifications…………….653
5.4.3 Axle Internal Service…………….653
5.4.4 Axle Maintenance…………….653
5.4.5 Axle Removal…………….654
5.4.6 Axle Installation…………….655
5.4.7 Axle Assembly and Drive Shaft Troubleshooting…………….656
5.5 Drive Shafts…………….659
5.5.1 Drive Shaft Inspection…………….659
5.5.2 Drive Shaft Maintenance…………….659
5.5.3 Drive Shaft Removal…………….659
5.5.4 Drive Shaft Cleaning and Drying…………….659
5.5.5 Drive Shaft Installation…………….659
5.6 Wheels and Tires…………….660
5.6.1 Removing Wheel and Tire Assembly from Machine…………….660
5.6.2 Installing Wheel and Tire Assembly onto Machine…………….661
5.7 Steering Angle Adjustment…………….661
5.8 Brakes…………….661
5.8.1 Brake Disc Inspection…………….661
5.9 Towing a Disabled Machine…………….662
5.9.1 Equipment and Supplies Required…………….662
5.9.2 Towing Procedure…………….663
Section 6 Transmission…………….665
6.1 Transmission Assembly Component Terminology…………….666
6.2 Safety Information…………….667
6.3 Transmission Description…………….667
6.4 Transmission Specifications…………….667
6.4.1 Transmission Maintenance…………….667
6.5 Transmission Replacement…………….667
6.5.1 Transmission Removal…………….667
6.5.2 Transmission Disassembly…………….668
6.5.3 Transmission Installation…………….668
Section 7 Engine…………….669
7.1 Introduction…………….670
7.1.1 Disclaimer and Scope…………….670
7.1.2 Engine Serial Number…………….670
7.1.3 Specifications and Maintenance Information…………….670
7.1.4 Component Terminology…………….671
7.2 Engine Cooling System…………….672
7.2.1 Surge Tank Cap…………….672
7.2.2 Radiator/Oil Cooler Replacement…………….672
a. Radiator/Oil Cooler Removal…………….673
b. Cooler/Fan Motor Removal…………….674
c. Cooler/Fan Motor Installation…………….675
d. Radiator/Oil Cooler Installation…………….675
7.3 Engine Electrical System…………….676
7.4 Fuel System…………….676
7.4.1 Diesel Fuel…………….676
7.4.2 Fuel/Hydraulic Tank – Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012…………….676
a. Cleaning and Drying…………….676
b. Inspection…………….676
c. Disassembly and Assembly…………….676
7.4.3 Fuel Tank – SN 0160076806 to Present including 0160076010, 0160076011, 0160076012…………….677
a. Fuel Tank Removal…………….677
b. Cleaning and Drying…………….677
c. Inspection…………….677
d. Fuel Tank Installation…………….677
7.4.4 After Fuel System Service…………….678
7.5 Engine Exhaust System…………….678
7.5.1 Exhaust System Removal…………….678
7.5.2 Exhaust System Installation…………….679
7.6 Air Cleaner Assembly…………….679
7.6.1 Air Cleaner Assembly Removal…………….679
7.6.2 Air Cleaner Assembly Installation…………….680
7.7 Engine Replacement…………….681
7.7.1 Engine Removal…………….682
7.7.2 Engine Disassembly, Inspection and Service…………….682
7.7.3 Engine Installation…………….682
Section 8 Hydraulic System…………….685
8.1 Hydraulic Component Terminology…………….687
8.2 Safety Information…………….688
8.3 General Information…………….688
8.4 Specifications…………….688
8.5 Hoses, Tube Lines, Fittings, Etc……………..688
8.5.1 Replacement Considerations…………….688
8.5.2 Hose, Tube, Line and Fitting Replacement…………….688
8.6 Hydraulic Pressure Diagnosis…………….689
8.6.1 Pressure Checks and Adjustments…………….689
8.6.2 Main Control Valve Pressure Checking…………….689
8.6.3 Charge Pressure Checking…………….690
8.6.4 Boom Function Pressure Checking…………….690
8.6.5 Steering Pressure Checking…………….690
8.6.6 Fan Speed Pressure and Direction Checking…………….690
8.7 Hydraulic Schematic…………….692
8.7.1 G5-18A (Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012)…………….692
8.7.2 G5-18A (SN 0160076806 to Present including 0160076010, 0160076011, 0160076012)…………….694
8.7.3 2505H & 25.5 (Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012)…………….696
8.7.4 2505H & 25.5 (SN 0160076806 to Present including 0160076010, 0160076011, 0160076012)…………….698
8.8 Hydraulic Reservoir…………….700
8.8.1 Pressurized Hydraulic Oil Fill Cap…………….700
8.8.2 Hydraulic Oil Reservoir Draining…………….700
8.8.3 Hydraulic Oil Reservoir Filling…………….700
8.8.4 Hydraulic Oil Reservoir Removal/ Installation (SN 0160076806 to Present including 0160076010, 0160076011, 0160076012)…………….700
a. Reservoir Removal…………….700
b. Cleaning and Drying…………….701
c. Inspection…………….701
d. Reservoir Installation…………….701
8.9 Hydraulic System Pump…………….702
8.9.1 Implement Pump Removal…………….702
8.9.2 Implement Pump Installation…………….702
8.9.3 Pump Test…………….703
8.10 Front Drive Motor…………….703
8.10.1 Front Drive Motor Removal…………….703
8.10.2 Front Drive Motor Installation…………….704
8.11 Control Valves…………….704
8.11.1 Main Control Valve…………….704
a. Main Control Valve Removal…………….704
b. Main Control Valve Disassembly…………….705
c. Main Control Valve Parts Cleaning…………….705
d. Main Control Valve Parts Inspection…………….705
e. Main Control Valve Assembly…………….705
f. Main Control Valve Installation…………….705
g. Main Control Valve Test…………….706
8.11.2 Service Brake Valve…………….706
a. Service Brake Valve Removal…………….706
b. Service Brake Valve Installation…………….706
c. Service Brake Bleeding Procedure…………….707
d. Brake Performance Test…………….707
8.11.3 Park Brake Valve (G5-18A)…………….707
a. Park Brake Valve Removal…………….707
b. Park Brake Valve Disassembly, Cleaning, Inspection and Assembly…………….708
c. Park Brake Valve Installation…………….708
d. Park Brake Valve Test……………..708
8.11.4 Hand Brake Valve (2505H & 25.5)…………….708
a. Hand Brake Valve Removal…………….708
b. Hand Brake Valve Disassembly, Cleaning, Inspection and Assembly…………….709
c. Hand Brake Valve Installation…………….709
d. Hand Brake Valve Test…………….709
8.11.5 Steering Orbital Valve…………….709
8.11.6 Pilot Select Valve…………….709
a. Pilot Select Valve Removal…………….710
b. Pilot Select Valve Disassembly, Cleaning, Inspection and Assembly…………….710
c. Pilot Select Valve Installation…………….710
d. Pilot Select Valve Test…………….710
8.11.7 Inching Valve…………….711
a. Inching Valve Removal…………….711
b. Inching Valve Disassembly, Cleaning, Inspection and Assembly…………….711
c. Inching Valve Installation…………….711
d. Inching Valve Bleeding Procedure…………….712
e. Inching Test…………….712
8.11.8 Priority Valve…………….713
a. Priority Valve Removal…………….713
b. Priority Valve Disassembly, Cleaning, Inspection and Assembly…………….713
c. Priority Valve Installation…………….713
d. Priority Valve Test…………….713
8.11.9 Steer Select Valve…………….714
a. Steer Select Manifold and Valve Removal…………….714
b. Steer Select Valve and Manifold Disassembly, Cleaning, Inspection and Assembly…………….714
c. Steer Select Manifold and Valve Installation…………….714
d. Steering Test…………….715
8.11.10 Quick Attach Valve…………….715
a. Quick Attach Valve Removal…………….715
b. Quick Attach Valve Disassembly, Cleaning, Inspection and Assembly…………….715
c. Quick Attach Installation…………….716
d. Quick Attach Valve Test…………….716
8.11.11 Variable Speed Fan Valve…………….716
a. Variable Speed Fan Valve Removal…………….716
b. Variable Speed Fan Valve Disassembly, Cleaning, Inspection and Assembly…………….716
c. Variable Speed Fan Valve Installation…………….717
d. Variable Speed Fan Valve Test…………….717
8.12 Hydraulic Cylinders…………….717
8.12.1 General Cylinder Removal Instructions…………….717
8.12.2 General Cylinder Disassembly…………….717
8.12.3 Cylinder Cleaning Instructions…………….718
8.12.4 Cylinder Inspection…………….719
8.12.5 General Cylinder Assembly…………….719
8.12.6 General Cylinder Installation…………….720
8.12.7 Steering Cylinders…………….720
8.12.8 Hydraulic Cylinder Torque Specifications…………….721
a. Lift Lower Cylinder…………….721
b. Extend/Retract Cylinder…………….721
c. Tilt Cylinder…………….721
d. Compensating Cylinder…………….721
a. Lift Lower Cylinder…………….722
b. Extend/Retract Cylinder…………….722
c. Tilt Cylinder…………….722
d. Compensating Cylinder…………….722
Section 9 Electrical System…………….723
9.1 Electrical Component Terminology…………….725
9.2 Safety Information…………….727
9.3 Fuses and Relays…………….727
9.3.1 Engine Compartment Relays and Fuses…………….727
9.3.2 Cab Compartment Fuses and Relays…………….727
9.3.3 Power Distribution Module…………….728
9.3.4 Cab Fuses / Relays…………….729
9.4 Electrical System Schematics…………….730
9.4.1 Prior to SN 0160076806 excluding 0160076010, 0160076011, 0160076012…………….730
a. Cab Schematic "A"…………….730
b. Cab Schematic “B”…………….731
c. Cab Roof, AC and Miscellaneous Schematic…………….732
d. Base Frame Schematic "A"…………….733
e. Base Frame Schematic "B"…………….734
f. Engine Schematic…………….735
g. Option Frame Schematic…………….736
h. Cables and Boom Schematic…………….737
9.4.2 SN 0160076806 to Present including 0160076010, 0160076011, 0160076012…………….738
a. Cab Schematic “A”…………….738
b. Cab Schematic “B”…………….739
c. Cab Roof, AC and Miscellaneous Schematic…………….740
d. Base Frame Schematic “A”…………….741
e. Base Frame Schematic “B”…………….742
f. Engine Schematic…………….743
g. Option Frame Schematic…………….744
h. Cables and Boom Schematic…………….745
i. ClearSky Schematic…………….746
j. Heater and HVAC Schematic…………….747
9.5 Dielectric Grease Application…………….748
9.5.1 Installation…………….748
9.5.2 Exclusions…………….749
9.6 Engine Start Circuit…………….751
9.6.1 Starter…………….751
a. Testing the Starter on the Engine…………….751
b. Starter Circuit Checks…………….751
c. Starter Removal…………….751
d. Starter Cleaning and Drying…………….752
e. Starter Periodic Maintenance…………….752
f. Starter Installation…………….752
9.7 Charging Circuit…………….753
9.7.1 Alternator…………….753
a. Alternator Removal…………….753
b. Alternator Installation…………….753
9.8 Battery…………….754
9.8.1 Battery Inspection…………….754
9.8.2 Battery Removal/Installation…………….754
a. Removal…………….754
b. Installation…………….755
9.8.3 Battery Disconnect/Connect…………….755
a. Disconnect…………….755
b. Connect…………….755
9.9 Electrical System Components…………….755
9.9.1 Back-up Alarm…………….755
a. Disassembly…………….755
b. Inspection and Replacement…………….755
9.9.2 Gauge Cluster…………….756
a. Removal…………….756
b. Installation…………….756
9.10 Window Wiper/Washer…………….757
9.10.1 Windshield Wiper Motor…………….757
a. Removal…………….757
b. Disassembly…………….757
c. Inspection and Replacement…………….757
d. Installation and Testing…………….757
9.10.2 Rear Window or Roof Wiper Motor (if equipped)…………….758
a. Removal…………….758
b. Disassembly…………….758
c. Inspection and Replacement…………….758
d. Installation and Testing…………….758
9.10.3 Windshield Washer Reservoir and Pump…………….758
a. Removal…………….758
b. Disassembly…………….759
c. Installation and Testing…………….759
9.11 Cab Heater/AC and Fan…………….759
9.11.1 Cab Heater/AC Controls…………….759
a. Cab Heater Controls Removal…………….759
b. Disassembly…………….759
c. Installation and Testing…………….760
9.12 Switches, Solenoids and Senders…………….760
9.12.1 Ignition Key Switch…………….760
a. Ignition Switch Removal…………….760
b. Disassembly…………….760
c. Inspection and Replacement…………….760
d. Ignition Switch Installation…………….761
9.12.2 Dash Switches…………….761
a. Switch Removal…………….761
b. Disassembly…………….761
c. Inspection and Replacement…………….761
d. Switch Installation…………….761
9.12.3 Fuel Level Indicator and Fuel Level Sender…………….761
a. Fuel Level Indicator Testing…………….761
b. Fuel Level Circuit Tests…………….761
9.12.4 Hourmeter…………….762
9.12.5 Coolant Temperature Sender…………….762
a. Coolant Temperature Sender Removal…………….762
b. Coolant Temperature Sender Inspection and Replacement…………….762
c. Coolant Temperature Sender Installation and Testing…………….762
9.12.6 Oil Pressure Sender…………….763
a. Oil Pressure Sender Removal…………….763
b. Oil Pressure Sender Inspection and Replacement…………….763
c. Oil Pressure Sender Installation and Testing…………….763
9.13 Load Stability Indicator (LSI) (2505H & 25.5)…………….764
9.13.1 Load Stability Indicator…………….764
9.13.2 LSI Sensor…………….764
a. LSI Sensor Removal…………….764
b. LSI Sensor Installation…………….765
9.13.3 LSI Boom Sensors…………….767
a. LSI Boom Sensor Removal…………….767
b. LSI Sensor Boom Installation…………….767
9.13.4 LSI Modules…………….767
a. LSI Module Removal…………….767
b. LSI Module Installation…………….768
9.13.5 LSI System Calibration…………….768
a. Standard Calibration…………….768
b. Field Calibration…………….770
9.13.6 LSI-CAN Check PT…………….772
9.13.7 500 Hour – LSI UGM Calibration Check…………….773
9.14 Analyzer…………….773
9.14.1 Hand Held Analyzer…………….773
9.14.2 Mobile Analyzer…………….774
9.14.3 Analyzer Usage…………….774
9.14.4 Analyzer Software – Version P1.1…………….775
9.15 Analyzer Software Accessibility…………….776
9.15.1 Access Level…………….776
9.15.2 Diagnostics…………….776
9.15.3 Machine Set-up…………….776
9.15.4 Personalities…………….777
9.15.5 Operator Tools…………….778
9.15.6 Calibrations…………….779
9.16 Diagnostic Trouble Codes (DTC) on Ground Module…………….780
9.16.1 Gauge Fault Code Display…………….780
9.16.2 Fault Codes…………….780
9.17 Engine Diagnostic Trouble Code…………….784
31200936 – Engine Parts Manual Models G5-18A, 2505H Agrovector 25.5…………….793
31200936_B_G5-18A 2505H 25.5 Engine (T4f)_JLG_Parts…………….793
Effectivity Page…………….795
Table of Contents…………….797
Section 1 ENGINE…………….799
Figure 1-1 Dipstick…………….800
Figure 1-2 Breather Line…………….802
Figure 1-3 Filler Cap…………….804
Figure 1-4 Oil Pan…………….806
Figure 1-5 Fly Wheel…………….808
Figure 1-6 V-Grooved Pulley…………….810
Figure 1-7 V-Grooved Pulley…………….812
Figure 1-8 Fastenings…………….814
Figure 1-9 Valve Mechanical Cover…………….816
Figure 1-10 Heat Protecting Shield…………….818
Figure 1-11 Front Cover…………….822
Figure 1-12 Lubrication Oil Pump…………….824
Figure 1-13 Lubricant Oil Filter…………….826
Figure 1-14 Oil Cooler…………….828
Figure 1-15 Oil Filter Assembly…………….830
Figure 1-16 Oil Suction Pipe…………….832
Figure 1-17 High Pressure Pump…………….834
Figure 1-18 Fuel Injector…………….836
Figure 1-19 Fuel Supply Pump…………….840
Figure 1-20 Fuel Filter…………….842
Figure 1-21 Fuel Prefilter…………….844
Figure 1-22 Rail…………….846
Figure 1-23 High Pressure Pipe…………….848
Figure 1-24 Fuel Line…………….850
Figure 1-25 Fuel Line…………….852
Figure 1-26 Intake Pipe…………….854
Figure 1-27 Charge Air Elbow…………….856
Figure 1-28 Charge Air Pipe…………….858
Figure 1-29 Control Unit…………….860
Figure 1-30 Coolant Pump…………….862
Figure 1-31 V-Grooved Pulley…………….864
Figure 1-32 Fastenings…………….866
Figure 1-33 Thermostat…………….868
Figure 1-34 Pipe/Line/Lead…………….870
Figure 1-35 Exhaust Manifold…………….872
Figure 1-36 Pipe/Line/Lead…………….874
Figure 1-37 EGR-Module…………….876
Figure 1-38 Turbocharger…………….878
Figure 1-39 V-Grooved Pulley…………….880
Figure 1-40 Generator…………….882
Figure 1-41 Fastenings…………….884
Figure 1-42 Starter…………….886
Figure 1-43 Cap…………….888
Figure 1-44 Cable Harness…………….890
Figure 1-45 Fastenings…………….892
Figure 1-46 Cable Harness…………….894
Figure 1-47 Tacho Generator…………….898
Figure 1-48 Temperature Transmitter…………….900
Figure 1-49 Pressure Sensor…………….902
Figure 1-50 Sensor…………….904
Figure 1-51 Connection Housing…………….906
Figure 1-52 Glow Plug…………….908
Figure 1-53 Inlet…………….910
Figure 1-54 Bracket…………….912
Figure 1-55 Mounting Material…………….914
Figure 1-56 Returns Elevator…………….916
Figure 1-57 Special Tools…………….918
RECOMMENDED SPARE PARTS…………….921
PART NUMBER INDEX…………….923
26.6 30.7 26.6 LP…………….927
307.1127.3.6 – Deutz-Fahr AGROVECTOR 26.6, AGROVECTOR 30.7 Workshop Manual…………….928
31200114 – Operation & Safety Manual Agrovector 26.6LP, 26.6 & 30.7…………….1071
31200114_F_26.6LP 26.6 30.7_SDF_Operation-Safety…………….1071
Revision Log…………….1073
Read This First…………….1074
Table of Contents…………….1077
Section 1 – General Safety Practices…………….1081
1.1 Hazard Classification System…………….1081
Safety Alert System and Safety Signal Words…………….1081
1.2 General Precautions…………….1081
1.3 Operation Safety…………….1082
Electrical Hazards…………….1082
Tip Over Hazard…………….1083
Travel Hazard…………….1086
Load Falling Hazard…………….1087
Lifting Personnel…………….1088
Driving Hazards on Slopes…………….1089
Pinch Points and Crush Hazards…………….1090
Fall Hazard…………….1092
Chemical Hazards…………….1093
Section 2 – Pre-Operation And Inspection…………….1095
2.1 Pre-Operation Checks and Inspection…………….1095
2.2 Safety Decals…………….1097
2.3 Walk-Around Inspection…………….1100
2.4 Warm-Up and Operational Checks…………….1102
Warm-Up Check…………….1102
Operational Check…………….1102
2.5 Operator Cab…………….1103
2.6 Windows…………….1104
Cab Door Window…………….1104
Rear Window…………….1104
Section 3 – Controls And Indicators…………….1105
3.1 General…………….1105
3.2 Controls…………….1106
Instrument Panel…………….1108
Ignition…………….1110
Park Brake…………….1111
Parking Procedure…………….1111
Transmission Control…………….1112
Wiper, Lights and Turn Signal Control Lever…………….1114
Steering Column Adjuster…………….1115
Joystick…………….1116
Load Stability Indicator (LSI)…………….1122
Control and Indicator Console…………….1123
Heater and Air Conditioner (If Equipped) Controls…………….1125
3.3 Steer Modes…………….1126
3.4 Operator Seat…………….1127
Adjustments…………….1127
Seat Belt…………….1129
3.5 Boom Angle and Extension Indicators…………….1130
Section 4 – Operation…………….1131
4.1 Engine…………….1131
Starting the Engine…………….1131
Battery Boosted Starting…………….1132
Normal Engine Operation…………….1133
Shut-Down Procedure…………….1133
4.2 Operating with a Non-Suspended Load…………….1134
Lift Load Safely…………….1134
Picking Up a Load…………….1134
Transporting the Load…………….1135
Leveling Procedure…………….1135
Placing the Load…………….1136
Disengaging the Load…………….1136
4.3 Operating with a Suspended Load…………….1137
Lift Load Safely…………….1137
Picking Up a Suspended Load…………….1137
Transporting a Suspended Load…………….1138
Leveling Procedure…………….1138
Placing a Suspended Load…………….1139
Disengaging a Suspended Load…………….1139
4.4 Road Operation…………….1140
4.5 Loading and Securing for Transport…………….1141
Tiedown…………….1141
Lifting…………….1142
Section 5 – Attachments and Hitches…………….1143
5.1 Approved Attachments…………….1143
5.2 Unapproved Attachments…………….1143
5.3 Telehandler/Attachment/Fork Capacity…………….1144
5.4 Use of the Capacity Chart…………….1145
Capacity Indicator Locations…………….1145
Sample Capacity Chart (CE)…………….1146
Example…………….1147
5.5 Attachment Installation…………….1149
Mechanical Quick-Switch Device…………….1150
Hydraulic Quick-Switch Device…………….1151
Hydraulic Operated Attachment…………….1152
5.6 Adjusting/Moving Forks…………….1153
5.7 Attachment Operation…………….1153
Carriage w/Forks…………….1154
Truss Boom…………….1155
Side Shift Carriage…………….1156
Bucket…………….1158
Manure Bucket…………….1160
Fork Extension…………….1162
Fork Mounted Hook…………….1164
Round Tine Bale…………….1165
Bale Handler…………….1166
Concrete Ladle…………….1168
5.8 Hitches…………….1170
Mechanical Hitch…………….1170
Hydraulic Hitch…………….1170
Section 6 – Emergency Procedures…………….1171
6.1 Towing a Disabled Product…………….1171
Moving Short Distances…………….1171
Moving Longer Distances…………….1171
6.2 Emergency Lowering of Boom…………….1172
Electronic Control Unit Failure…………….1172
Engine Failure…………….1173
6.3 Cab Emergency exit…………….1174
Section 7 – Lubrication and Maintenance…………….1175
7.1 Introduction…………….1175
Clothing and Safety Gear…………….1175
7.2 General Maintenance Instructions…………….1176
7.3 Service and Maintenance Schedule…………….1177
8 & 1st 50 Hour Maintenance Schedule…………….1177
50, 250 & 500 Hour Maintenance Schedule…………….1178
1000 & 1500 Hour Maintenance Schedule…………….1179
7.4 Lubrication Schedules…………….1180
8 Hour Lubrication Schedule…………….1180
50 Hour Lubrication Schedule…………….1181
7.5 Operator Maintenance Instructions…………….1182
Fuel System…………….1182
Air Intake System…………….1184
Engine Oil…………….1186
Hydraulic Oil…………….1187
Tires…………….1188
Brake System…………….1190
Engine Cooling System…………….1191
Battery…………….1192
Section 8 – Additional Checks…………….1193
8.1 General…………….1193
8.2 Load Stability Indicator Test…………….1193
Section 9 – Specifications…………….1195
9.1 Product Specifications…………….1195
Fluid and Lubrication Capacities…………….1195
Tires…………….1196
Performance…………….1197
Dimensions…………….1198
Noise Emission Level…………….1199
Telehandler Vibration…………….1199
Index…………….1201
Inspection, Maintenance and Repair Log…………….1203
3126025 – Illustrated Parts Manual Models 266, 307, 266 LoPro & Agrovector 26.6, 30.7, 26.6 LP…………….1209
3126025_J_266, 307, 266 LoPro, 26.6, 30.7, 26.6 LP_Parts…………….1209
EFFECTIVITY PAGE…………….1211
TABLE OF CONTENTS…………….1213
SECTION 1 – FRAME AND ATTACHING PARTS…………….1217
FIGURE 1-1. FRAME SHROUDING AND TRIM, COVERS (Prior to SN 1160005247)…………….1218
FIGURE 1-2. FRAME SHROUDING AND TRIM, COVERS (SN 1160005247 to Present)…………….1222
FIGURE 1-3. FRAME SHROUDING AND TRIM, CAB AND MIRRORS…………….1226
FIGURE 1-4. AXLE AND FENDER INSTALLATION…………….1228
FIGURE 1-5. AXLE AND FENDER INSTALLATION…………….1230
SECTION 2 – BOOM…………….1233
FIGURE 2-1. FIRST BOOM SECTION…………….1234
FIGURE 2-2. FIRST BOOM SECTION…………….1236
FIGURE 2-3. SECOND BOOM SECTION…………….1238
FIGURE 2-4. SECOND BOOM SECTION…………….1240
FIGURE 2-5. QUICK SWITCH ASSEMBLY…………….1242
FIGURE 2-6. HYDRAULIC QUICK SWITCH ASSEMBLY…………….1244
FIGURE 2-7. JD QUICK ATTACH…………….1246
SECTION 3 – ATTACHMENTS…………….1249
FIGURE 3-1. CARRIAGE ASSEMBLY…………….1250
FIGURE 3-2. BUCKETS…………….1252
FIGURE 3-3. MULTI-PURPOSE BUCKETS…………….1254
FIGURE 3-4. FORK MOUNTED HOOK…………….1256
FIGURE 3-5. TRUSS BOOM…………….1258
FIGURE 3-6. MANURE BUCKET…………….1260
FIGURE 3-7. FORK…………….1262
FIGURE 3-8. SIDE SHIFT CARRIAGE…………….1264
FIGURE 3-9. BALE HANDLER…………….1266
FIGURE 3-10. ROUND TINE FORK…………….1268
FIGURE 3-11. CONCRETE BUCKET…………….1270
SECTION 4 – ENGINE AND ATTACHING PARTS…………….1273
FIGURE 4-1. ENGINE ASSEMBLY…………….1274
FIGURE 4-2. DEUTZ ENGINE…………….1278
FIGURE 4-3. FUEL TANK AND LINES…………….1280
FIGURE 4-4. RADIATOR ASSEMBLY…………….1282
FIGURE 4-5. AIR CLEANER INSTALLATION…………….1284
FIGURE 4-6. EXHAUST INSTALLATION…………….1286
SECTION 5 – DRIVE TRAIN…………….1289
FIGURE 5-1. FRONT AXLE…………….1290
FIGURE 5-2. FRONT AXLE – HOUSING…………….1292
FIGURE 5-3. FRONT AXLE – HOUSING…………….1294
FIGURE 5-4. FRONT AXLE – HOUSING AND STEERING CYLINDER…………….1296
FIGURE 5-5. FRONT AXLE – HOUSING AND STEERING CYLINDER…………….1298
FIGURE 5-6. FRONT AXLE – BEVEL GEAR SET…………….1300
FIGURE 5-7. FRONT AXLE – DIFFERENTIAL…………….1302
FIGURE 5-8. FRONT AXLE – DOUBLE U-JOINT…………….1304
FIGURE 5-9. FRONT AXLE – DOUBLE U-JOINT…………….1306
FIGURE 5-10. FRONT AXLE – BRAKES…………….1308
FIGURE 5-11. FRONT AXLE – BRAKES…………….1310
FIGURE 5-12. FRONT AXLE – WHEEL HUB AND FINAL REDUCTION…………….1312
FIGURE 5-13. FRONT AXLE – WHEEL HUB AND FINAL REDUCTION…………….1314
FIGURE 5-14. FRONT AXLE – TRANSMISSION HOUSING…………….1316
FIGURE 5-15. FRONT AXLE – LOWER AND UPPER SHAFT…………….1318
FIGURE 5-16. FRONT AXLE – LOWER AND UPPER SHAFT…………….1320
FIGURE 5-17. REAR AXLE…………….1322
FIGURE 5-18. REAR AXLE – HOUSING…………….1324
FIGURE 5-19. REAR AXLE – SWIVEL HOUSING AND STEERING CYLINDER…………….1326
FIGURE 5-20. REAR AXLE – SWIVEL HOUSING AND STEERING CYLINDER…………….1328
FIGURE 5-21. REAR AXLE – BEVEL GEAR SET…………….1330
FIGURE 5-22. REAR AXLE – DIFFERENTIAL…………….1332
FIGURE 5-23. REAR AXLE – DIFFERENTIAL…………….1334
FIGURE 5-24. REAR AXLE – DOUBLE U-JOINT…………….1336
FIGURE 5-25. REAR AXLE – DOUBLE U-JOINT…………….1338
FIGURE 5-26. REAR AXLE – WHEEL HUB AND FINAL REDUCTION…………….1340
FIGURE 5-27. REAR AXLE – WHEEL HUB AND FINAL REDUCTION…………….1342
FIGURE 5-28. DRIVE SHAFT…………….1344
FIGURE 5-29. TIRES AND RIMS…………….1346
SECTION 6 – CAB…………….1349
FIGURE 6-1. CAB ASSEMBLY…………….1350
FIGURE 6-2. CAB INTERIOR ASSEMBLY…………….1354
FIGURE 6-3. SEAT ASSEMBLY…………….1356
FIGURE 6-4. CAB WINDOWS…………….1358
FIGURE 6-5. CAB DOOR ASSEMBLY…………….1360
FIGURE 6-6. WIPER ASSEMBLY…………….1362
FIGURE 6-7. AIR CIRCULATION INSTALLATION…………….1364
SECTION 7 – CONTROLS…………….1367
FIGURE 7-1. BOOM JOYSTICK…………….1368
FIGURE 7-2. STEERING COLUMN AND ATTACHING PARTS…………….1370
FIGURE 7-3. ACCELERATOR PEDAL ASSEMBLY…………….1372
FIGURE 7-4. BRAKE PEDAL ASSEMBLY…………….1374
SECTION 8 – HYDRAULIC CIRCUITS…………….1377
FIGURE 8-1. SUPPLY CIRCUIT…………….1378
FIGURE 8-2. DUMP CIRCUIT…………….1382
FIGURE 8-3. FRONT DRIVE CIRCUIT…………….1386
FIGURE 8-4. FRONT DRIVE CIRCUIT…………….1388
FIGURE 8-5. STEER SELECT…………….1390
FIGURE 8-6. SERVICE/PARK BRAKE…………….1392
FIGURE 8-7. LIFT CYLINDER…………….1394
FIGURE 8-8. CROWD CYLINDER…………….1396
FIGURE 8-9. CROWD CYLINDER…………….1398
FIGURE 8-10. TILT AND TILT COMPENSATING CYLINDER…………….1400
FIGURE 8-11. TILT AND TILT COMPENSATING CYLINDER…………….1402
FIGURE 8-12. AUXILIARY FUNCTION…………….1404
FIGURE 8-13. AUXILIARY FUNCTION…………….1406
FIGURE 8-14. REAR HYDRAULIC OUTLET…………….1408
SECTION 9 – HYDRAULIC COMPONENTS…………….1411
FIGURE 9-1. LIFT CYLINDER…………….1412
FIGURE 9-2. LIFT CYLINDER…………….1414
FIGURE 9-3. CROWD CYLINDER…………….1416
FIGURE 9-4. CROWD CYLINDER…………….1418
FIGURE 9-5. TILT CYLINDER…………….1420
FIGURE 9-6. TILT CYLINDER…………….1422
FIGURE 9-7. COMPENSATING CYLINDER…………….1424
FIGURE 9-8. COMPENSATING CYLINDER…………….1426
FIGURE 9-9. FORK LOCKING CYLINDER…………….1428
FIGURE 9-10. MAIN CONTROL VALVE (266;26.6 Prior to SN 1160003518; 307;30.7 Prior to SN 1160003514; 266 LoPro;26.6 LP Prior to SN 1160003525)…………….1430
FIGURE 9-11. MAIN CONTROL VALVE (266;26.6 SN 1160003518 to Present; 307;30.7 SN 1160003514 to Present; 266 LoPro;26.6 LP SN 1160003525 to Present)…………….1432
FIGURE 9-12. FRONT DRIVE MOTOR…………….1434
FIGURE 9-13. FRONT DRIVE MOTOR…………….1436
FIGURE 9-14. HYDROSTATIC TRANSMISSION PUMP…………….1438
FIGURE 9-15. HYDRAULIC TANK ASSEMBLY…………….1440
FIGURE 9-16. IMPLEMENT PUMP…………….1442
FIGURE 9-17. AUXILIARY DIVERTER VALVE…………….1444
SECTION 10 – ELECTRICAL…………….1447
FIGURE 10-1. ELECTRICAL INSTALLATION…………….1448
FIGURE 10-2. ENGINE HARNESS (266 & 26.6 Prior to SN 1160002246; 307 & 30.7 Prior to SN 1160002233; 266 LoPro & 26.6 LP Prior to SN 1160002238)…………….1452
FIGURE 10-3. ENGINE HARNESS (266 & 26.6 SN 1160002246 to Present; 307 & 30.7 SN 1160002233 to Present; 266 LoPro & 26.6 LP SN 1160002238 to Present)…………….1454
FIGURE 10-4. REAR CHASSIS HARNESS (Prior to SN 1160001559)…………….1456
FIGURE 10-5. REAR CHASSIS HARNESS (SN 1160001559 to Present)…………….1458
FIGURE 10-6. FRONT CHASSIS HARNESS…………….1460
FIGURE 10-7. PWM VALVE CONTROLLER ASSEMBLY…………….1462
FIGURE 10-8. ROOF HARNESS…………….1464
FIGURE 10-9. MAIN HARNESS (Prior to SN 1160001559)…………….1466
FIGURE 10-10. MAIN HARNESS (SN 1160001559 to Present)…………….1470
FIGURE 10-11. GROUND HARNESS…………….1474
FIGURE 10-12. BUCKET SHAKE SWITCH…………….1476
FIGURE 10-13. LMIS INSTALLATION…………….1478
FIGURE 10-14. LMIS AUDIBLE TOWER/BEACON INSTALLATION…………….1482
FIGURE 10-15. LSI SWITCH…………….1484
SECTION 11 – DECALS…………….1487
FIGURE 11-1. FRAME AND BOOM DECALS…………….1488
FIGURE 11-2. CAB DECALS…………….1492
FIGURE 11-3. MACHINE DECALS, 266 AND 266 LOPRO…………….1496
FIGURE 11-4. MACHINE DECALS, 307…………….1498
FIGURE 11-5. MACHINE DECALS, 26.6 AND 26.6 LP…………….1500
FIGURE 11-6. MACHINE DECALS, 30.7…………….1502
SECTION 12 – OPTIONS…………….1505
FIGURE 12-1. HITCH KIT ASSEMBLY…………….1506
FIGURE 12-2. AUTOMATIC HITCH ASSEMBLY…………….1508
FIGURE 12-3. HYDRAULIC HITCH INSTALLATION…………….1510
FIGURE 12-4. FRONT CAB GLASS SHIELD…………….1514
FIGURE 12-5. CAB WORKLIGHT INSTALLATIONS…………….1516
FIGURE 12-6. BOOM WORKLIGHT INSTALLATION…………….1518
FIGURE 12-7. ROTATING BEACON INSTALLATION…………….1520
FIGURE 12-8. AIR CONDITIONER INSTALLATION (Prior to SN 1160004769)…………….1522
FIGURE 12-9. AIR CONDITIONER INSTALLATION (SN 1160004769 to Present)…………….1524
FIGURE 12-10. WHEEL CHOCK INSTALLATION…………….1526
FIGURE 12-11. DRAW BAR COUPLING INSTALLATION…………….1528
FIGURE 12-12. DUAL BOOM AUX HYDRAULIC, MANUAL…………….1530
FIGURE 12-13. DUAL BOOM AUX HYDRAULIC, ELECTRICAL…………….1532
FIGURE 12-14. 6 TON HITCH INSTALLATION…………….1534
FIGURE 12-15. 14 TON HITCH INSTALLATION…………….1536
FIGURE 12-16. SPEEDOMETER INSTALLATION…………….1538
FIGURE 12-17. SUN SCREEN INSTALLATION…………….1540
FIGURE 12-18. GROUND WIRE INSTALLATION (Prior to SN 1160002125)…………….1542
FIGURE 12-19. DUMP VALVE INSTALLATION…………….1544
FIGURE 12-20. BOOM AUXILIARY ELECTRIC…………….1546
FIGURE 12-21. HYDRAULIC TRAILER BRAKES 266, 266 LOPRO, 26.6, 26.6 LP…………….1548
FIGURE 12-22. HYDRAULIC TRAILER BRAKES 307, 30.7…………….1550
FIGURE 12-23. OPTION HARNESS…………….1554
FIGURE 12-24. PRESSURE MODULATOR VALVE…………….1556
SECTION 13 – RECOMMENDED SPARE PARTS…………….1559
FIGURE 13-1. RECOMMENDED SPARE PARTS…………….1560
PART NUMBER INDEX…………….1563
29.6LP_29.6_35.7…………….1575
31200566 – Illustated Parts Manual Models L2906H, 2906H, 3507H, 619A, 723A & Agrovector 29.6LP, 29.6, 35.7…………….1576
PM 31200566_M_L2906H_2906H_3507H_619A_723A & Agrovector 29.6LP_29.6 & 35.7_JLG_Parts…………….1576
Effectivity Page…………….1578
Table of Contents…………….1580
SECTION 1 – FRAME AND ATTACHING PARTS…………….1584
FIGURE 1-1. FRAME SHROUDING AND TRIM…………….1585
FIGURE 1-2. ENGINE COVER INSTALLATION AND ENGINE POD INSULATION…………….1591
FIGURE 1-3. AXLE AND FENDER INSTALLATION…………….1593
FIGURE 1-4. DRAW BAR COUPLING L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7…………….1597
FIGURE 1-5. PIN HITCH – CUNA C AND CUNA D2…………….1599
FIGURE 1-6. EEC AUTO, EEC MANUAL AND EEC AUTO PITON-FRAME SWIVEL HITCH…………….1601
FIGURE 1-7. HYDRAULIC HITCH…………….1603
FIGURE 1-8. PINTLE HITCH…………….1605
SECTION 2 – BOOM…………….1608
FIGURE 2-1. BOOM INSTALLATION…………….1609
FIGURE 2-2. BOOM ASSEMBLY – PADS AND SHIMS…………….1613
FIGURE 2-3. QUICK ATTACH…………….1617
FIGURE 2-4. JD QUICK ATTACH L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7…………….1619
SECTION 3 – ATTACHMENTS…………….1622
FIGURE 3-1. CARRIAGE ASSEMBLY…………….1623
FIGURE 3-2. SIDE SHIFT CARRIAGE…………….1625
FIGURE 3-3. SIDE TILT CARRIAGE 619A & 723A…………….1627
FIGURE 3-4. SIDE TILT CARRIAGE 619A & 723A…………….1629
FIGURE 3-5. FORK POSITION/ SIDE SHIFT CARRIAGE L2906H, 3507H, 29.6LP, 35.7 & 723A…………….1631
FIGURE 3-6. FORKS AND FORK EXTENSIONS…………….1635
FIGURE 3-7. TRUSS BOOMS L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7…………….1637
FIGURE 3-8. BUCKETS…………….1639
FIGURE 3-9. MULTI-PURPOSE BUCKETS…………….1641
FIGURE 3-10. MANURE BUCKET…………….1643
FIGURE 3-11. FORK MOUNTED HOOK…………….1645
FIGURE 3-12. CONCRETE LADLE L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7…………….1649
FIGURE 3-13. ROUND FORK TINE…………….1651
FIGURE 3-14. BALE HANDLER…………….1653
FIGURE 3-15. UNIVERSAL HITCH ATTACH 619A & 723A…………….1655
FIGURE 3-16. FORK MOUNTED PLATFORM 619A & 723A…………….1657
FIGURE 3-17. CARRIAGE, CRANE HOOK L2906H, 2906H, 3507H…………….1659
FIGURE 3-18. CARRIAGE, JIB…………….1661
SECTION 4 – ENGINE AND ATTACHING PARTS…………….1664
FIGURE 4-1. ENGINE INSTALLATION…………….1665
FIGURE 4-2. DEUTZ ENGINE…………….1669
FIGURE 4-3. DEUTZ ENGINE, (LRC)…………….1671
FIGURE 4-4. FUEL TANK AND LINES…………….1673
FIGURE 4-5. RADIATOR INSTALLATION…………….1675
FIGURE 4-6. AIR CLEANER INSTALLATION…………….1679
FIGURE 4-7. EXHAUST INSTALLATION…………….1681
SECTION 5 – DRIVE TRAIN…………….1684
FIGURE 5-1. FRONT AXLE…………….1685
FIGURE 5-2. FRONT AXLE – HOUSING L2906, 2906H, 619A, 29.6LP & 29.6…………….1687
FIGURE 5-3. FRONT AXLE – HOUSING 3507H, 723A & 35.7…………….1689
FIGURE 5-4. FRONT AXLE – HOUSING AND STEERING CYLINDER…………….1691
FIGURE 5-5. FRONT AXLE – BEVEL GEAR SET…………….1693
FIGURE 5-6. FRONT AXLE – DIFFERENTIAL…………….1695
FIGURE 5-7. FRONT AXLE – DOUBLE U-JOINT…………….1697
FIGURE 5-8. FRONT AXLE – BRAKES…………….1699
FIGURE 5-9. FRONT AXLE – WHEEL HUB AND FINAL REDUCTION L2906, 2906H, 619A, 29.6LP & 29.6…………….1701
FIGURE 5-10. FRONT AXLE – WHEEL HUB AND FINAL REDUCTION 3507H, 723A & 35.7…………….1703
FIGURE 5-11. FRONT AXLE – TRANSMISSION HOUSING…………….1705
FIGURE 5-12. FRONT AXLE – LOWER AND UPPER SHAFT…………….1707
FIGURE 5-13. REAR AXLE…………….1709
FIGURE 5-14. REAR AXLE HOUSING…………….1711
FIGURE 5-15. REAR AXLE – STEERING COMPONENTS…………….1713
FIGURE 5-16. REAR AXLE – BEVEL GEAR SET…………….1715
FIGURE 5-17. REAR AXLE – DIFFERENTIAL L2906H, 2906H, 619A, 29.6LP & 29.6…………….1717
FIGURE 5-18. REAR AXLE – DIFFERENTIAL 3507H, 723A & 35.7…………….1719
FIGURE 5-19. REAR AXLE – DOUBLE U-JOINT…………….1721
FIGURE 5-20. REAR AXLE – WHEEL HUB AND FINAL REDUCTION L2906H, 2906H, 619A, 29.6LP & 29.6…………….1723
FIGURE 5-21. REAR AXLE – WHEEL HUB AND FINAL REDUCTION 3507H, 723A & 35.7…………….1725
FIGURE 5-22. DRIVE SHAFT ASSEMBLY…………….1727
FIGURE 5-23. TIRES AND WHEEL INSTALLATION…………….1729
SECTION 6 – CAB…………….1732
FIGURE 6-1. CAB INSTALLATION (Prior to SN 1160005989, Excluding 1160005189, 1160005314 and 1160005414)…………….1733
FIGURE 6-2. CAB INSTALLATION (SN 1160005989 to Present, Including 1160005189, 1160005314 and 1160005414)…………….1737
FIGURE 6-3. CAB COMMON ASSEMBLY…………….1741
FIGURE 6-4. INTERIOR INSTALLATION…………….1745
FIGURE 6-5. CAB DOOR AND WINDOW INSTALLATION…………….1749
FIGURE 6-6. WIPER INSTALLATIONS…………….1753
FIGURE 6-7. SEAT ASSEMBLIES…………….1755
FIGURE 6-8. HEATER INSTALLATION (Prior to SN 1160005989, Excluding 1160005189, 1160005314 and 1160005414)…………….1759
FIGURE 6-9. HEATER INSTALLATION (SN 1160005989 to Present, Including 1160005189, 1160005314 and 1160005414)…………….1761
FIGURE 6-10. HEAT AND A/C INSTALLATION (Prior to SN 1160005989, Excluding 1160005189, 1160005314 and 1160005414)…………….1763
FIGURE 6-11. HEAT AND A/C INSTALLATION (SN 1160005989 to Present, Including 1160005189, 1160005314 and 1160005414)…………….1769
FIGURE 6-12. FRONT CAB GLASS SHIELD…………….1775
FIGURE 6-13. GREASE GUN TOOL KIT INSTALLATION 619A & 723A…………….1777
FIGURE 6-14. OIL TEMP GAUGE INSTALLATION AND FIRE EXTINGUISHER INSTALLATION 723A…………….1779
FIGURE 6-15. RADIO PREP INSTALLATION…………….1781
SECTION 7 – CONTROLS…………….1784
FIGURE 7-1. JOYSTICK…………….1785
FIGURE 7-2. STEERING COLUMN…………….1787
FIGURE 7-3. THROTTLE ASSEMBLY…………….1789
FIGURE 7-4. BRAKE PEDAL COMPONENTS…………….1791
SECTION 8 – HYDRAULIC CIRCUITS…………….1794
FIGURE 8-1. SUPPLY CIRCUIT…………….1795
FIGURE 8-2. DUMP CIRCUIT…………….1799
FIGURE 8-3. ORBITAL STEERING AND STEERING SELECT CIRCUIT…………….1803
FIGURE 8-4. SERVICE AND PARK BRAKE CIRCUIT…………….1805
FIGURE 8-5. LIFT CYLINDER CIRCUIT…………….1807
FIGURE 8-6. EXTEND/RETRACT CYLINDER CIRCUIT…………….1809
FIGURE 8-7. TILT AND TILT COMPENSATION CYLINDER CIRCUIT…………….1811
FIGURE 8-8. AUXILIARY HYDRAULIC CIRCUIT…………….1813
FIGURE 8-9. REAR AUXILIARY HYDRAULIC INSTALLATION…………….1817
FIGURE 8-10. TRAILER BRAKES L2906H, 2906H & 3507H (Prior to SN 1160005189)…………….1819
FIGURE 8-11. TRAILER BRAKES 2906H & 3507H (SN 1160005189 through 1160006365)…………….1821
FIGURE 8-12. TRAILER BRAKES L2906H, 2906H & 3507H (SN 1160006366 to Present)…………….1823
SECTION 9 – HYDRAULIC COMPONENTS…………….1826
FIGURE 9-1. LIFT CYLINDER…………….1827
FIGURE 9-2. EXTEND/RETRACT CYLINDER…………….1829
FIGURE 9-3. TILT CYLINDER…………….1831
FIGURE 9-4. TILT COMPENSATION CYLINDER…………….1833
FIGURE 9-5. FORK LOCKING CYLINDER…………….1835
FIGURE 9-6. FORK SIDE SHIFT CYLINDER…………….1837
FIGURE 9-7. FORK SIDE TILT CYLINDER 619A & 723A…………….1839
FIGURE 9-8. MAIN CONTROL VALVE…………….1841
FIGURE 9-9. SERVICE BRAKE VALVE…………….1845
FIGURE 9-10. BOOM AUXILIARY DIVERTER VALVES…………….1847
FIGURE 9-11. REAR ELECTRIC AUXILIARY DIVERTER VALVE…………….1849
FIGURE 9-12. BRAKE VALVES…………….1851
FIGURE 9-13. STEERING SELECT VALVE…………….1853
FIGURE 9-14. HYDROSTATIC TRANSMISSION…………….1855
FIGURE 9-15. HYDRAULIC DRIVE MOTOR…………….1857
FIGURE 9-16. PISTON PUMP AND GEAR PUMP…………….1859
FIGURE 9-17. HYDRAULIC TANK…………….1861
SECTION 10 – ELECTRICAL…………….1864
FIGURE 10-1. ENGINE ELECTRICAL INSTALLATION…………….1865
FIGURE 10-2. CAB ELECTRICAL INSTALLATION…………….1867
FIGURE 10-3. BOOM AND FRAME ELECTRICAL INSTALLATION…………….1871
FIGURE 10-4. CAB SWITCHES L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7…………….1875
FIGURE 10-5. CAB SWITCHES 619A & 723A…………….1877
FIGURE 10-6. WORK LIGHT INSTALLATIONS…………….1879
FIGURE 10-7. DRIVING LIGHT INSTALLATIONS AND LICENSE PLATE LIGHT INSTALLATION L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7…………….1881
FIGURE 10-8. ENGINE HARNESS…………….1885
FIGURE 10-9. POWER/GROUND HARNESS…………….1887
FIGURE 10-10. CAB MAIN HARNESS (Prior to SN 1160005989, Excluding 1160005189, 1160005314 and 1160005414)…………….1889
FIGURE 10-11. CAB MAIN HARNESS (SN 1160005993 to Present, Including 1160005189, 1160005314 and 1160005414)…………….1893
FIGURE 10-12. CAB ROOF HARNESS…………….1897
FIGURE 10-13. BOOM AUXILIARY ELECTRIC HARNESS…………….1899
FIGURE 10-14. BOOM LIGHT HARNESS…………….1901
FIGURE 10-15. FRONT FRAME HARNESS…………….1903
FIGURE 10-16. REAR FRAME HARNESS (Prior to SN 1160005989, Excluding 1160005189, 1160005314 and 1160005414)…………….1905
FIGURE 10-17. REAR FRAME HARNESS (SN 1160005989 to Present, Including 1160005189, 1160005314 and 1160005414)…………….1907
FIGURE 10-18. LIGHT SHIFTER HARNESS 619A & 723A…………….1909
FIGURE 10-19. OIL TEMPERATURE HARNESS 723A…………….1911
FIGURE 10-20. SEAT SWITCH WIRE…………….1913
SECTION 11 – DECALS…………….1916
FIGURE 11-1. DECALS AND LOAD CHARTS L2906H, 2906H, 3507H, 619A & 723A…………….1917
FIGURE 11-2. DECALS AND LOAD CHARTS 29.6LP, 29.6 & 35.7…………….1923
SECTION 12 – RECOMMENDED SPARE PARTS…………….1928
FIGURE 12-1. RECOMMENDED SPARE PARTS…………….1929
PART NUMBER INDEX…………….1932
31200568 – Service Manual Models L2906H, 2906H, 3507H, 619A, 723A Agrovector 29.6LP, 29.6, 35.7…………….1944
31200568_B_L2906H 2906H 3507H 29.6LP 29.6 35.7 619A 723A_JLG_Service…………….1944
Effectivity…………….1946
Table of Contents…………….1948
Section 1 Safety Practices…………….1952
1.1 Introduction…………….1953
1.2 Disclaimer…………….1953
1.3 Operation & Safety Manual…………….1953
1.4 Do Not Operate Tags…………….1953
1.5 Safety Information…………….1953
1.5.1 Safety Alert System and Signal Words…………….1953
1.6 Safety Instructions…………….1954
1.6.1 Personal Hazards…………….1954
1.6.2 Equipment Hazards…………….1954
1.6.3 General Hazards…………….1954
1.6.4 Operational Hazards…………….1955
1.7 Safety Decals…………….1955
Section 2 General Information and Specifications…………….1956
2.1 Replacement Parts and Warranty Information…………….1957
2.2 Torques…………….1958
2.2.1 SAE Fastener Torque Chart…………….1958
2.2.2 Metric Fastener Torque Chart…………….1962
2.2.3 Hydraulic Hose Torque Chart…………….1965
2.3 Specifications…………….1966
2.3.1 Travel Speed…………….1966
2.3.2 Hydraulic Cylinder Performance Specifications…………….1966
2.3.3 Electrical System…………….1966
2.3.4 Engine Performance Specifications…………….1967
2.3.5 Tires…………….1967
2.4 Fluids, Lubricants and Capacities…………….1968
2.5 Maintenance Schedules…………….1970
2.5.1 10,1st 50 & 50 Hour Maintenance Schedule…………….1970
2.5.2 1st 150, 250 & 500 Hour Maintenance Schedule…………….1970
2.5.3 1500 Hour Maintenance Schedule…………….1970
2.6 Lubrication Schedule…………….1971
2.6.1 10 Hour Lubrication Schedule…………….1971
2.6.2 50 Hour Lubrication Schedule…………….1972
Section 3 Boom…………….1974
3.1 Boom System Component Terminology…………….1975
3.2 Safety Information…………….1976
3.3 Boom System – Two Section Boom…………….1976
3.3.1 Boom System Description…………….1976
3.4 Boom Assembly Maintenance…………….1976
3.4.1 Boom Removal…………….1976
3.4.2 Second Section Boom Removal…………….1977
3.4.3 Second Section Boom Installation…………….1978
3.4.4 Boom Installation…………….1978
3.4.5 Extend/Retract Cylinder Removal…………….1979
3.4.6 Extend/Retract Cylinder Installation…………….1980
3.5 Boom Wear Pads…………….1981
3.5.1 Wear Pad Inspection…………….1981
3.5.2 Wear Pad Installation and Lubrication…………….1981
3.6 Quick Attach Assembly…………….1982
3.6.1 Quick Attach Removal…………….1982
3.6.2 Quick Attach Installation…………….1982
3.7 Forks…………….1983
3.8 Boom Prop (If Equipped)…………….1983
3.8.1 Installation and Removal Procedures…………….1983
3.9 Emergency Boom Lowering Procedure…………….1984
3.9.1 Equipment and Supplies Required…………….1984
3.9.2 Lowering Procedure…………….1984
3.10 Troubleshooting…………….1986
Section 4 Cab and Covers…………….1988
4.1 Operator Cab and Covers Component Terminology…………….1989
4.2 Safety Information…………….1990
4.3 Operator Cab…………….1990
4.3.1 Operator Cab Description…………….1990
4.3.2 Serial Number Decal…………….1990
4.4 Cab Components…………….1990
4.4.1 Steering Wheel…………….1990
4.4.2 Steering Column/Valve Replacement…………….1991
4.4.3 Brake Pedal and Valve…………….1991
4.4.4 Throttle Pedal Replacement…………….1992
4.4.5 Throttle Cable Adjustment…………….1993
4.4.6 High Idle Adjustment…………….1993
4.4.7 Joystick Replacement…………….1994
4.4.8 Windshield Wiper Assembly (If Equipped)…………….1994
4.4.9 Windshield Washer Assembly (If Equipped)…………….1994
4.4.10 Heater/Air Conditioning System (If Equipped)…………….1994
4.4.11 Air Conditioning (If Equipped)…………….1995
4.5 Cab Removal…………….1995
4.6 Cab Installation…………….1996
Section 5 Axles, Drive Shafts, Wheels and Tires…………….1998
5.1 Axle, Drive Shaft and Wheel Component Terminology…………….1999
5.2 Safety Information…………….2000
5.3 General Information…………….2000
5.4 Axle Assemblies…………….2000
5.4.1 Axle Serial Number Plate…………….2000
5.4.2 Axle Specifications…………….2000
5.4.3 Axle Maintenance…………….2000
5.4.4 Axle Removal…………….2001
5.4.5 Axle Installation…………….2001
5.4.6 Axle Assembly and Drive Shaft Troubleshooting…………….2003
5.5 Drive Shafts…………….2006
5.5.1 Drive Shaft Inspection…………….2006
5.5.2 Drive Shaft Maintenance…………….2006
5.5.3 Drive Shaft Removal…………….2006
5.5.4 Drive Shaft Cleaning and Drying…………….2006
5.5.5 Drive Shaft Installation…………….2006
5.6 Wheels and Tires…………….2007
5.6.1 Removing Wheel and Tire Assembly from Machine…………….2007
5.6.2 Installing Wheel and Tire Assembly onto Machine…………….2007
5.7 Steering Angle Adjustment…………….2008
5.8 Brakes…………….2008
5.8.1 Brake Disc Inspection…………….2008
Section 6 Transmission…………….2010
6.1 Transmission Assembly Component Terminology…………….2011
6.2 Safety Information…………….2012
6.3 Transmission Description…………….2012
6.4 Transmission Specifications…………….2012
6.4.1 Transmission Maintenance…………….2012
6.5 Transmission Replacement…………….2012
6.5.1 Transmission Removal…………….2012
6.5.2 Transmission Installation…………….2013
6.5.3 After Transmission Replacement…………….2013
6.6 Transmission Filter Replacement…………….2014
6.6.1 Filter Removal…………….2014
6.6.2 Filter Installation…………….2014
6.7 Towing a Disabled Machine…………….2015
Section 7 Engine: Deutz TCD 2012…………….2016
7.1 Introduction…………….2017
7.1.1 Disclaimer and Scope…………….2017
7.1.2 Component Terminology…………….2018
7.2 Safety Information…………….2019
7.3 Engine Serial Number…………….2019
7.4 Specifications and Maintenance Information…………….2019
7.5 Engine Cooling System…………….2019
7.5.1 Radiator Pressure Cap…………….2019
7.5.2 Radiator/Oil and Charge Air Cooler Replacement…………….2019
7.6 Engine Electrical System…………….2020
7.7 Fuel System…………….2020
7.7.1 Diesel Fuel…………….2020
7.7.2 Fuel/Hydraulic Oil Tank…………….2021
7.7.3 After Fuel System Service…………….2021
7.8 Engine Exhaust System…………….2022
7.8.1 Exhaust System Removal…………….2022
7.8.2 Exhaust System Installation…………….2022
7.9 Air Cleaner Assembly…………….2023
7.9.1 Air Cleaner Assembly Removal…………….2023
7.9.2 Air Cleaner Assembly Installation…………….2023
7.10 Engine Replacement…………….2023
7.10.1 Engine Removal…………….2023
7.10.2 Engine Disassembly, Inspection and Service…………….2024
7.10.3 Engine Installation…………….2024
7.11 Engine Coupler…………….2025
7.11.1 Coupler Removal…………….2025
7.11.2 Coupler Installation…………….2025
7.12 Troubleshooting…………….2025
Section 8 Hydraulic System…………….2026
8.1 Hydraulic Component Terminology…………….2028
8.2 Safety Information…………….2029
8.3 General Information…………….2029
8.4 Specifications…………….2029
8.5 Hoses, Tube Lines, Fittings, Etc……………..2029
8.5.1 Replacement Considerations…………….2029
8.5.2 Hose, Tube, Line and Fitting Replacement…………….2029
8.6 Hydraulic Pressure Diagnosis…………….2030
8.6.1 Pressure Checks and Adjustments…………….2030
8.6.2 Main Control Valve Pressure Checking…………….2030
8.6.3 Charge Pressure Checking…………….2031
8.6.4 Drive Pressure Checking…………….2031
8.6.5 Boom Function Pressure Checking…………….2031
8.6.6 Steering Pressure Checking…………….2032
8.6.7 Brake Pressure Checking…………….2032
8.7 Hydraulic Schematic…………….2033
8.7.1 Gear Pump Schematic…………….2033
8.7.2 Piston Pump Schematic…………….2035
8.8 Hydraulic Reservoir…………….2037
8.8.1 Pressurized Hydraulic Oil Fill Cap…………….2037
8.8.2 Hydraulic Oil Reservoir Draining…………….2037
8.8.3 Hydraulic Oil Reservoir Filling…………….2037
8.9 Implement Pump (Piston or Gear)…………….2037
8.9.1 Implement Pump Replacement…………….2037
8.10 Front Drive Motor…………….2038
8.11 Control Valves…………….2039
8.11.1 Main Control Valve…………….2039
8.11.2 Service Brake Valve…………….2040
8.11.3 Parking Brake…………….2041
8.11.4 Brake Test…………….2042
8.11.5 Steering Orbitrol Valve…………….2043
8.11.6 Steer Select Valve…………….2043
8.11.7 Inching Valve…………….2044
8.11.8 Anti-Kick Valve…………….2045
8.12 Hydraulic Cylinders…………….2047
8.12.1 General Cylinder Removal Instructions…………….2047
8.12.2 General Cylinder Disassembly…………….2047
8.12.3 Cylinder Cleaning Instructions…………….2048
8.12.4 Cylinder Inspection…………….2048
8.12.5 General Cylinder Assembly…………….2048
8.12.6 General Cylinder Installation…………….2049
8.12.7 Steering Cylinders…………….2049
8.12.8 Hydraulic Cylinder Torque Specifications…………….2050
Section 9 Electrical System…………….2052
9.1 Electrical Component Terminology…………….2054
9.2 Specifications…………….2055
9.3 Safety Information…………….2055
9.4 Keypad and Display Screen…………….2055
9.4.1 Keypad…………….2055
9.4.2 Display Screen…………….2055
9.5 Software Level 2 Accessibility…………….2056
9.5.1 Operator Tools…………….2056
9.5.2 Personalities…………….2056
9.5.3 Calibrations…………….2056
9.6 Operator Tools…………….2057
9.6.1 Resetting the Anti theft Code…………….2057
9.6.2 Hardware Exchange…………….2057
9.6.3 Confirm Machine Service…………….2057
9.6.4 Review Service History…………….2057
9.6.5 Set Service Interval…………….2057
9.7 Instrument Panel…………….2058
9.8 Fuses and Relays…………….2058
9.8.1 Engine Compartment Relays and Fuses…………….2058
9.8.2 Power Distribution Module…………….2059
9.9 Electrical System Schematics…………….2061
9.9.1 Cab Harness Electrical Schematic 1 of 2…………….2061
9.9.2 Cab Harness Electrical Schematic 2 of 2…………….2065
9.9.3 Cab Roof and Boom Schematic…………….2069
9.9.4 Front and Rear Frame Schematic…………….2071
9.9.5 Engine Compartment Schematic…………….2073
9.9.6 Power Ground, ANSI Shifter and Oil Gauge Schematic…………….2075
9.10 Circuit Breakdowns…………….2077
9.10.1 Alternator Charge Circuit…………….2077
9.10.2 Starter Circuit…………….2078
9.10.3 Constant Power Circuit…………….2079
9.11 Engine electrical Components…………….2080
9.11.1 Starter…………….2080
9.11.2 Alternator…………….2081
9.12 Window Wiper/Washer…………….2082
9.12.1 Windshield Wiper Motor (if equipped)…………….2082
9.12.2 Rear Window Wiper Motor (if equipped)…………….2083
9.12.3 Windshield Washer Reservoir and Pump…………….2083
9.13 Cab Heater and Fan…………….2084
9.13.1 Cab Heater/Air Conditioning Controls…………….2084
9.14 Solenoids, Sensors and Senders…………….2085
9.14.1 Ignition Key Switch…………….2085
9.14.2 Dash Switches…………….2086
9.14.3 Fuel Level Indicator and Fuel Level Sender…………….2086
9.14.4 Hourmeter…………….2087
9.14.5 Coolant Temperature Sender…………….2087
9.14.6 Fuel Shut-off Solenoid…………….2088
9.14.7 Oil Pressure Sender…………….2088
9.14.8 Oil Temperature Sensor…………….2089
9.14.9 Back-up Alarm…………….2089
9.14.10 Boom Angle Sensor…………….2090
9.15 Load Stability Indicator – LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (Before S/N 1160005993 excluding 1160005943, 1160005945 & 1160005414)…………….2091
9.15.1 Load Stability Indicator…………….2091
9.15.2 LSI Sensor…………….2092
9.15.3 LSI System Calibration…………….2093
9.16 Load Stability Indicator – LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (S/N 1160005993 & After including 1160005943, 1160005945 & 1160005414)…………….2095
9.16.1 Load Stability Indicator…………….2095
9.16.2 LSI Sensor…………….2096
9.16.3 LSI System Calibration…………….2097
9.16.4 LSI-CAN Check PT…………….2098
9.16.5 500 Hour – LSI CAN SYSTEM CHECK…………….2099
9.17 Hand Held Analyzer…………….2099
9.17.1 Analyzer Usage…………….2099
9.17.2 Analyzer Software – Version 3.5…………….2100
9.18 Fault Codes…………….2102
9.18.1 Indicator Cross Reference Table…………….2102
9.18.2 Fault Code Table…………….2103
31200570 – Operation & Safety Manual Agrovector 29.6LP, 29.6 & 35.7…………….2152
31200570_B_29.6LP 29.6 35.7_Deutz-Fahr_Operation-Safety…………….2152
Revision Log…………….2154
Read This First…………….2155
Table of Contents…………….2158
Section 1 – General Safety Practices…………….2162
1.1 Hazard Classification System…………….2162
Safety Alert System and Safety Signal Words…………….2162
1.2 General Precautions…………….2162
1.3 Operation Safety…………….2163
Electrical Hazards…………….2163
Tip Over Hazard…………….2164
Travel Hazard…………….2167
Load Falling Hazard…………….2168
Lifting Personnel…………….2169
Driving Hazards on Slopes…………….2170
Pinch Points and Crush Hazards…………….2171
Fall Hazard…………….2173
Chemical Hazards…………….2174
Section 2 – Pre-Operation and Inspection…………….2176
2.1 Pre-Operation Check and Inspection…………….2176
2.2 Safety Decals…………….2178
2.3 Walk-Around Inspection…………….2181
2.4 Warm-Up and Operational Checks…………….2183
Warm-Up Check…………….2183
Operational Check…………….2183
2.5 Operator Cab…………….2184
2.6 Windows…………….2185
Cab Door Window (if equipped)…………….2185
Section 3 – Controls and Indicators…………….2186
3.1 General…………….2186
3.2 Controls…………….2187
Instrument Panel…………….2189
Display Screen…………….2191
Keypad…………….2193
Ignition…………….2195
Park Brake…………….2196
Parking Procedure…………….2196
Transmission Control Lever…………….2197
Load Stability Indicator – LSI…………….2199
Steering Column Adjuster…………….2202
Joystick…………….2203
Front and Side Console Switches…………….2207
Accessory Control Lever…………….2209
3.3 Anti Theft…………….2210
3.4 Steer Modes…………….2211
Manual Steering Alignment Mode Change…………….2211
Rear Wheel Assisted Steering Alignment Mode Change…………….2212
All Wheel Assisted Steering Alignment Mode Change (if equipped)…………….2213
3.5 Operator Seat…………….2214
Adjustments…………….2214
Seat Belt…………….2216
3.6 Boom Extension Indicators…………….2217
Section 4 – Operation…………….2218
4.1 Engine…………….2218
Starting the Engine…………….2218
Battery Boosted Starting…………….2219
Normal Engine Operation…………….2220
Shut-Down Procedure…………….2220
4.2 Operating with a Non-Suspended Load…………….2221
Lift Load Safely…………….2221
Picking Up a Load…………….2221
Transporting a Load…………….2222
Leveling Procedure…………….2222
Placing a Load…………….2223
Disengaging a Load…………….2223
4.3 Operating with a Suspended Load…………….2224
Lift Load Safely…………….2224
Picking Up a Suspended Load…………….2224
Transporting a Suspended Load…………….2225
Leveling Procedure…………….2225
Placing a Suspended Load…………….2226
Disengaging a Suspended Load…………….2226
4.4 Road Operation…………….2227
4.5 Loading and Securing for Transport…………….2228
Tiedown…………….2228
Lifting…………….2229
Section 5 – Attachments and Hitches…………….2230
5.1 Approved Attachments…………….2230
5.2 Unapproved Attachments…………….2230
5.3 Telehandler/Attachment/Fork Capacity…………….2231
5.4 Use of the Capacity Chart…………….2232
Capacity Indicator Locations…………….2232
Sample Capacity Chart…………….2233
Example…………….2234
5.5 Attachment Installation…………….2236
Quick Attach…………….2236
JD Quick Attach…………….2239
5.6 Hydraulic Operated Attachment…………….2241
5.7 Adjusting/Moving Forks…………….2242
5.8 Attachment Operation…………….2243
Carriage w/Forks…………….2244
Side Shift Carriage…………….2245
Fork Mounted Hook…………….2247
Fork Extension…………….2249
Truss Boom…………….2251
Carriage w/Round Fork…………….2252
Bale Handler…………….2253
Bucket…………….2255
Multi-Purpose Bucket…………….2257
Grapple Bucket…………….2259
Concrete Bucket…………….2261
5.9 Hitches…………….2263
Pin Hitch – CUNA C…………….2263
Pin Hitch – CUNA D2…………….2264
Pin Hitch…………….2265
Auto Hitch…………….2266
Piton Frame and Auto Hitch…………….2267
Hydraulic Hitch…………….2268
Section 6 – Emergency Procedures…………….2270
6.1 Towing a Disabled Product…………….2270
Moving Short Distances…………….2270
Moving Longer Distances…………….2270
6.2 Emergency Lowering of Boom…………….2271
6.3 Emergency Exit from Enclosed Cab…………….2271
Section 7 – Lubrication and Maintenance…………….2272
7.1 Introduction…………….2272
Clothing and Safety Gear…………….2272
7.2 General Maintenance Instructions…………….2273
7.3 Service and Maintenance Schedule…………….2274
10, 1st 50 & 50 Hour Maintenance Schedule…………….2274
1st 150, 250 & 500 Hour Maintenance Schedule…………….2275
1500 Hour Maintenance Schedule…………….2276
7.4 Lubrication Schedules…………….2277
10 Hour Lubrication Schedule…………….2277
50 Hour Lubrication Schedule…………….2278
7.5 Operator Maintenance Instructions…………….2279
Fuel System…………….2279
Air Intake System…………….2281
Engine Oil…………….2283
Hydraulic Oil…………….2284
Tires…………….2285
Brake System…………….2288
Engine Cooling System…………….2289
Battery…………….2290
Windshield Washer System (if equipped)…………….2291
Section 8 – Additional Checks…………….2292
8.1 General…………….2292
8.2 Load Stability Indicator Test…………….2292
Section 9 – Specifications…………….2294
9.1 Product Specifications…………….2294
Capacities…………….2294
Tires…………….2295
Performance…………….2296
Dimensions…………….2297
Declaration of Vibration (CE)…………….2298
Noise Emission Level (CE)…………….2298
Index…………….2300
Inspection, Maintenance and Repair Log…………….2304
30.6 35.7 40.8 35.10…………….2310
31211097 – Operation & Safety Manual Agrovector 30.6, 35.7, 40.8, 35.10…………….2311
31211097_C_30.6, 35.7, 40.8, 35.10_Deutz-Fahr_O&SM…………….2311
Revision Log…………….2313
Read This First…………….2314
Table of Contents…………….2317
Section 1 – General Safety Practices…………….2317
Section 2 – Pre-Operation and Inspection…………….2317
Section 3 – Controls and Indicators…………….2318
Section 4 – Operation…………….2319
Section 5 – Attachments and Hitches…………….2320
Section 6 – Emergency Procedures…………….2321
Section 7 – Lubrication and Maintenance…………….2321
Section 8 – Additional Checks…………….2322
Section 9 – Specifications…………….2322
Section 1 – General Safety Practices…………….2323
1.1 Hazard Classification System…………….2323
Safety Alert System and Safety Signal Words…………….2323
1.2 General Precautions…………….2323
1.3 Operation Safety…………….2324
Electrical Hazards…………….2324
Tip Over Hazard…………….2326
Travel Hazard…………….2329
Load Falling Hazard…………….2330
Lifting Personnel…………….2331
Driving Hazards on Slopes…………….2332
Pinch Points and Crush Hazards…………….2333
Fall Hazard…………….2335
Chemical Hazards…………….2336
1.4 ClearSky (if equipped)…………….2337
Federal Communications Commission (FCC) Information for Users…………….2337
Section 2 – Pre-Operation and Inspection…………….2339
2.1 Preparation, Inspection and Maintenance…………….2339
2.2 Pre-Operation Check and Inspection…………….2340
2.3 Safety Decals…………….2342
2.4 Walk-Around Inspection…………….2348
2.5 Warm-Up and Operational Checks…………….2351
Warm-Up Check…………….2351
Operational Check…………….2351
2.6 Cab…………….2352
2.7 Enclosed Cab Windows (if equipped)…………….2353
Cab Door Window…………….2353
Rear Window…………….2354
Section 3 – Controls and Indicators…………….2355
3.1 General…………….2355
3.2 Controls…………….2356
Instrument Panel…………….2358
LCD Display…………….2362
Left Dash Control Panel…………….2364
Right Dash Control Panel…………….2365
Agriculture Control Panel…………….2367
Ignition…………….2370
Park Brake…………….2371
Parking Procedure…………….2371
Transmission Control Lever (if equipped)…………….2372
Accessory Control Lever (if equipped)…………….2374
Reversing Fan Switch (if equipped)…………….2375
Load Stability Indicator – LSI…………….2376
Steering Column Adjuster…………….2378
Joystick…………….2380
3.3 Anti-Theft Functionality (if enabled)…………….2387
Instrument Panel Input…………….2387
Multifunction Display Input…………….2387
3.4 Steer Modes…………….2388
Manual Steering Alignment Mode Change…………….2388
All Wheel Assisted Steering Alignment Mode Change…………….2389
3.5 Operator Seat…………….2390
Operator Presence…………….2390
Adjustments…………….2391
Seat Belt…………….2394
3.6 Boom Indicators…………….2395
Boom Extension…………….2395
Boom Angle (if equipped)…………….2395
3.7 Reverse Systems (if equipped)…………….2396
Reverse Sensing System…………….2396
Reversing Camera (if equipped)…………….2396
3.8 Multifunction Display (if equipped)…………….2397
General Information…………….2397
Multifunction Display and Buttons…………….2398
Home Screen…………….2400
Main Menu…………….2403
Operation and Maintenance…………….2412
Troubleshooting…………….2430
Section 4 – Operation…………….2431
4.1 Engine…………….2431
Starting the Engine…………….2431
Extreme Cold Weather Starting (if equipped)…………….2432
Battery Boosted Starting…………….2433
Normal Engine Operation…………….2435
Shut-Down Procedure…………….2436
4.2 After-Treatment System (ATS) (if equipped for ULS)…………….2438
Stationary Exhaust System Cleaning…………….2438
4.3 Operating with a Non-Suspended Load…………….2440
Lift Load Safely…………….2440
Picking Up a Load…………….2440
Transporting a Load…………….2441
Leveling Procedure…………….2441
Placing a Load…………….2442
Disengaging a Load…………….2442
4.4 Operating with a Suspended Load…………….2443
Lift Load Safely…………….2443
Picking Up a Suspended Load…………….2443
Transporting a Suspended Load…………….2444
Leveling Procedure…………….2444
Placing a Suspended Load…………….2445
Disengaging a Suspended Load…………….2445
4.5 Road Operation (CE)…………….2446
4.6 Loading and Securing for Transport…………….2447
Tie Down…………….2447
Lifting…………….2448
Section 5 – Attachments and Hitches…………….2449
5.1 Approved Attachments…………….2449
5.2 Unapproved Attachments…………….2449
5.3 JLG Supplied Attachments…………….2450
5.4 Telehandler/Attachment/Fork Capacity…………….2453
5.5 Use of the Capacity Chart…………….2454
Capacity Indicator Locations…………….2454
Sample Capacity Chart (CE)…………….2455
Sample Capacity Chart (AUS)…………….2456
Example…………….2458
5.6 Attachment Installation…………….2459
Coupler…………….2459
Hydraulic Operated Attachment…………….2462
5.7 Adjusting/Moving Forks…………….2463
5.8 Attachment Operation…………….2464
Carriage with Forks…………….2465
Fork Positioning Carriage…………….2466
Side Tilt Carriage and Fork Rotator Carriage…………….2468
Side Shift Carriage…………….2470
Fork Extension…………….2472
Dual Tine Bale…………….2474
Bale Handler…………….2476
Bucket…………….2478
Multi-Purpose Bucket…………….2480
Grapple Bucket…………….2482
Manure Grapple…………….2484
Muck Fork…………….2486
Sweeper…………….2488
Auger…………….2490
Concrete Bucket Mixer…………….2492
Truss Boom…………….2494
Coupler Mounted Hook…………….2496
Fork Mounted Hook…………….2498
Trash Hopper – Fork Mounted…………….2500
5.9 Hitches and Trailer Brakes…………….2502
Retrieval Hitch…………….2502
Fixed Hitch…………….2503
Pin Hitch – CUNA C (Italy)…………….2504
Pin Hitch – CUNA D2 (Italy)…………….2505
EEC Manual Pin Hitch…………….2506
EEC Auto Hitch…………….2507
Piton Frame and EEC Auto Hitch…………….2508
Hydraulic Hitch…………….2509
Rear Auxiliary Hydraulics…………….2510
Trailer Brakes…………….2511
Section 6 – Emergency Procedures…………….2513
6.1 Towing a Disabled Product…………….2513
Moving Short Distances…………….2513
Moving Longer Distance…………….2513
6.2 Emergency Lowering of Boom…………….2514
6.3 Emergency Exit from Enclosed Cab…………….2515
Rear Window Inside Cab…………….2515
Rear Window Outside Cab (if equipped)…………….2516
Right Side Window (Agriculture)…………….2516
Section 7 – Lubrication and Maintenance…………….2517
7.1 Introduction…………….2517
Clothing and Safety Gear…………….2517
7.2 General Maintenance Instructions…………….2518
7.3 Service and Maintenance Schedules…………….2519
10 & 1st 50 Hour Maintenance Schedule – 30.6…………….2519
50, 1st 250 & 250 Hour Maintenance Schedule – 30.6…………….2520
500, 750 & 1000 Hour Maintenance Schedule – 30.6…………….2521
1500, 2000 & 3000 Hour Maintenance Schedule – 30.6…………….2522
10 & 1st 50 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….2523
50, 1st 250 & 250 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….2524
500, 750 & 1000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….2525
1500, 2000 & 3000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….2526
7.4 Lubrication Schedules…………….2528
30.6…………….2528
35.7, 40.8, 35.10…………….2529
7.5 Operator Maintenance Instructions…………….2531
Engine Maintenance Components…………….2531
Fuel System…………….2534
Emission System (if equipped for ULS)…………….2536
Engine Oil…………….2537
Air Intake System…………….2538
Tires…………….2540
Hydraulic Oil…………….2542
Transmission Oil (35.7, 40.8, 35.10)…………….2544
Brake Fluid…………….2546
Engine Cooling System…………….2547
Windshield Washer System (if equipped)…………….2548
Cab Air Filters (if equipped)…………….2550
Load Stability Indicator System…………….2552
Section 8 – Additional Checks…………….2555
8.1 General…………….2555
8.2 Reverse Sensing System (if equipped)…………….2555
Section 9 – Specifications…………….2557
9.1 Product Specifications…………….2557
Fluids…………….2557
Capacities…………….2561
Tires…………….2563
Performance…………….2564
Dimensions…………….2566
Declaration of Vibration (CE)…………….2569
Noise Emission Level (CE)…………….2570
Machine Towing Capacity…………….2571
Index…………….2573
31211226 – Illustrated Parts Manual Models 3006H, 30.6…………….2583
PM 31211226_D_3006H & 30.6_JLG Parts…………….2583
Effectivity Page…………….2585
Machine Configuration…………….2586
General information…………….2587
Table of Contents…………….2589
SECTION 1 – FRAME AND ATTACHING PARTS…………….2599
FIGURE 1-1. FRAME INSTALLATION (20IN WHEEL)…………….2600
FIGURE 1-2. FRAME INSTALLATION (24IN WHEEL)…………….2602
FIGURE 1-3. ENGINE ENCLOSURE INSTALLATION (JLG)…………….2604
FIGURE 1-4. ENGINE ENCLOSURE INSTALLATION (DEUTZ-FAHR)…………….2606
FIGURE 1-5. ENGINE ENCLOSURE COVER INSTALLATION…………….2608
FIGURE 1-6. HOOD INSTALLATION (JLG)…………….2610
FIGURE 1-7. HOOD INSTALLATION (DEUTZ-FAHR)…………….2612
FIGURE 1-8. COVER PLATES INSTALLATION (ULS)…………….2614
FIGURE 1-9. COVER PLATES INSTALLATION (LS)…………….2618
FIGURE 1-10. REAR COVER PLATES INSTALLATION…………….2622
FIGURE 1-11. COUNTERWEIGHT INSTALLATION…………….2624
FIGURE 1-12. TANKS INSTALLATION…………….2626
FIGURE 1-13. FUEL TANK INSTALLATION…………….2628
FIGURE 1-14. HYDRAULIC TANK INSTALLATION…………….2630
FIGURE 1-15. FUEL TANK ASSEMBLY…………….2632
FIGURE 1-16. HYDRAULIC TANK ASSEMBLY…………….2634
FIGURE 1-17. FUEL AND HYDRAULIC CAP INSTALLATION…………….2636
FIGURE 1-18. DEF TANK BRACKET INSTALLATION (NO TRAILER BRAKE)…………….2638
FIGURE 1-19. DEF TANK BRACKET INSTALLATION (TRAILER BRAKE)…………….2640
FIGURE 1-20. HITCH RETRIEVAL INSTALLATION…………….2642
FIGURE 1-21. HITCH INSTALLATION (EEC AUTO)…………….2644
FIGURE 1-22. HITCH INSTALLATION (PITON)…………….2646
FIGURE 1-23. HITCH ASSEMBLY (EEC AUTO)…………….2648
FIGURE 1-24. SLIDING HITCH ASSEMBLY (PITON)…………….2650
FIGURE 1-25. HITCH INSTALLATION (EEC MANUAL)…………….2652
FIGURE 1-26. HITCH ASSEMBLY (EEC MANUAL)…………….2654
FIGURE 1-27. HITCH INSTALLATION (CUNA CATEGORY C)…………….2656
FIGURE 1-28. HITCH ASSEMBLY (CUNA CATEGORY C)…………….2658
FIGURE 1-29. HITCH INSTALLATION (CUNA CATEGORY D2)…………….2660
FIGURE 1-30. HITCH ASSEMBLY (CUNA CATEGORY D2)…………….2662
FIGURE 1-31. HITCH INSTALLATION (FIXED)…………….2664
FIGURE 1-32. HITCH ASSEMBLY (FIXED)…………….2666
FIGURE 1-33. CAB PLUG INSTALLATION (NON HYDRAULIC HITCH)…………….2668
FIGURE 1-34. HITCH INSTALLATION (HYDRAULIC)…………….2670
FIGURE 1-35. HITCH ASSEMBLY (HYDRAULIC)…………….2672
FIGURE 1-36. FRONT RETRIEVAL HITCH PIN…………….2674
SECTION 2 – BOOM…………….2677
FIGURE 2-1. BOOM INSTALLATION (JLG)…………….2678
FIGURE 2-2. BOOM INSTALLATION (DEUTZ-FAHR)…………….2680
FIGURE 2-3. BOOM ASSEMBLY (JLG)…………….2682
FIGURE 2-4. BOOM ASSEMBLY (DEUTZ-FAHR)…………….2684
FIGURE 2-5. FIRST BOOM SECTION ASSEMBLY (JLG)…………….2686
FIGURE 2-6. FIRST BOOM SECTION ASSEMBLY (DEUTZ-FAHR)…………….2688
FIGURE 2-7. SECOND BOOM SECTION ASSEMBLY…………….2690
FIGURE 2-8. LINK ASSEMBLY…………….2692
FIGURE 2-9. LEVER ASSEMBLY…………….2694
FIGURE 2-10. MANUAL QUICK COUPLER INSTALLATION (20IN WHEEL)…………….2696
FIGURE 2-11. MANUAL QUICK COUPLER INSTALLATION (24IN WHEEL)…………….2698
FIGURE 2-12. HYDRAULIC QUICK COUPLER INSTALLATION (20IN WHEEL)…………….2700
FIGURE 2-13. HYDRAULIC QUICK COUPLER INSTALLATION (24IN WHEEL)…………….2702
FIGURE 2-14. BOOM ANGLE INDICATOR INSTALLATION…………….2704
FIGURE 2-15. BOOM PROP INSTALLATION…………….2706
FIGURE 2-16. BOOM BRUSHES INSTALLATION…………….2708
FIGURE 2-17. BOOM REMOTE GREASING INSTALLATION…………….2710
SECTION 3 – ATTACHMENTS…………….2713
FIGURE 3-1. PALLET FORK (50X100X1220)…………….2714
FIGURE 3-2. PALLET FORK (50X120X1200)…………….2716
FIGURE 3-3. PALLET FORK (60X100X1220)…………….2718
FIGURE 3-4. PALLET FORK (50X100X1070)…………….2720
FIGURE 3-5. PALLET FORK (2.36X4X48)…………….2722
FIGURE 3-6. PALLET FORK (2.36X5X48)…………….2724
FIGURE 3-7. BLOCKING FORK (50X50X1220)…………….2726
FIGURE 3-8. BLOCKING FORK (50X50X1220)…………….2728
FIGURE 3-9. CARRIAGE ASSEMBLY (1200MM) (CE AND AUS)…………….2730
FIGURE 3-10. CARRIAGE ASSEMBLY (1270MM)…………….2732
FIGURE 3-11. SIDE TILTING CARRIAGE (4.5 TON – 1225 MM)…………….2734
FIGURE 3-12. SIDE TILTING CARRIAGE (4.5 TON – 1270 MM)…………….2736
FIGURE 3-13. SIDE SHIFT CARRIAGE (4.0 TON – 1225 MM)…………….2738
FIGURE 3-14. SIDE SHIFT CARRIAGE (5.5 TON – 1270 MM)…………….2740
FIGURE 3-15. FORK POSITIONING CARRIAGE WITH FORKS (4.5 TON)…………….2742
FIGURE 3-16. DUAL FORK CARRIAGE ASSEMBLY…………….2744
FIGURE 3-17. DUAL FORK CARRIAGE VALVE ASSEMBLY…………….2746
FIGURE 3-18. DUAL TINE BAILING FORK CARRIAGE…………….2748
FIGURE 3-19. BUCKET 1.0 YD³ (ANSI – JLG)…………….2750
FIGURE 3-20. BUCKET 1.0 M³ (CE AND AUS)…………….2752
FIGURE 3-21. BUCKET 1.5 M³ (CE AND AUS)…………….2754
FIGURE 3-22. BUCKET 2.0 M³ (CE AND AUS)…………….2756
FIGURE 3-23. FORK MOUNTED BUCKET (1.0 M³)…………….2758
FIGURE 3-24. 4 IN 1 BUCKET 0.6 M³…………….2760
FIGURE 3-25. DIG BUCKET 1.0 M³ (CE AND AUS)…………….2762
FIGURE 3-26. MANURE GRAPPLE BUCKET (CE & AUS)…………….2764
FIGURE 3-27. MULTI-PURPOSE GRAPPLE BUCKET (1850MM) (ANSI – JLG)…………….2766
FIGURE 3-28. MULTI-PURPOSE GRAPPLE (WIDE GRIP – 1850MM) (CE & AUS)…………….2768
FIGURE 3-29. MULTI-PURPOSE GRAPPLE BUCKET (2100MM) (CE & AUS)…………….2770
FIGURE 3-30. MUCK FORK AND GRAB (CE & AUS)…………….2772
FIGURE 3-31. CUTTING EDGE (2100MM BUCKET)…………….2774
FIGURE 3-32. TRUSS BOOM (4 TON – 2.1M)…………….2776
FIGURE 3-33. TRUSS BOOM (1 TON – 3.4M)…………….2778
FIGURE 3-34. TRUSS BOOM (0.9 TON – 3.7M)…………….2780
FIGURE 3-35. TRUSS BOOM (1.8 TON – 1M FT WITH WINCH)…………….2782
FIGURE 3-36. TRUSS BOOM (3 FT WITH WINCH)…………….2784
FIGURE 3-37. TRUSS BOOM (0.9 TON – 3.7M WITH WINCH)…………….2786
FIGURE 3-38. TRUSS BOOM (1.8 TON – 3 FT WITH WINCH)…………….2788
FIGURE 3-39. TRUSS BOOM (0.9 TON – 12 FT WITH WINCH)…………….2790
FIGURE 3-40. CRANE HOOK (CE AND AUS)…………….2792
FIGURE 3-41. CRANE HOOK…………….2794
FIGURE 3-42. FORK MOUNTED HOOK (4 TON)…………….2796
FIGURE 3-43. FORK MOUNTED BASKET…………….2798
FIGURE 3-44. FORK MOUNTED PLATFORM…………….2800
FIGURE 3-45. FORK MOUNTED TRASH HOPPER…………….2802
FIGURE 3-46. CONCRETE BUCKET…………….2804
FIGURE 3-47. SWEEPER…………….2808
FIGURE 3-48. SWEEPER…………….2810
FIGURE 3-49. AUGER (COUPLER MOUNTED)…………….2812
FIGURE 3-50. FORK POSITIONING CARRIAGE WITH FORKS (4.0 TON)…………….2814
FIGURE 3-51. FORK ROTATING CARRIAGE (4.5 TON – 1270 MM)…………….2816
FIGURE 3-52. FORK ROTATING CARRIAGE (2.05 TON – 990 MM)…………….2820
FIGURE 3-53. DRIVE GROUP MOTOR…………….2824
FIGURE 3-54. DRIVE MOTOR…………….2826
FIGURE 3-55. FEM CARRIAGE AND FORKS…………….2828
FIGURE 3-56. BUCKET GUARD…………….2830
FIGURE 3-57. BALE HANDLER (TUBE CLAMP)…………….2832
FIGURE 3-58. BALE HANDLER (SPIKE CLAMP)…………….2834
FIGURE 3-59. BALE HANDLER KIT (SPIKES)…………….2836
FIGURE 3-60. BALE HANDLER KIT (SPIKES TO TUBE)…………….2838
FIGURE 3-61. FORK EXTENSION (50X100X1910)…………….2840
FIGURE 3-62. FORK EXTENSION (60X100X1920)…………….2842
FIGURE 3-63. TRANSPORT LATCHES…………….2844
FIGURE 3-64. MANITOU HYDRAULIC COUPLING…………….2846
FIGURE 3-65. MANITOU HYDRAULIC COUPLING…………….2848
FIGURE 3-66. JCB HYDRAULIC COUPLING INSTALLATION…………….2850
FIGURE 3-67. JCB HYDRAULIC COUPLING…………….2852
FIGURE 3-68. MERLO HYDRAULIC COUPLING INSTALLATION…………….2854
FIGURE 3-69. MERLO HYDRAULIC COUPLING…………….2856
SECTION 4 – ENGINE AND ATTACHING PARTS…………….2859
FIGURE 4-1. ENGINE INSTALLATION (74.4KW – ULS)…………….2860
FIGURE 4-2. ENGINE INSTALLATION (74.4KW – LS)…………….2862
FIGURE 4-3. ENGINE INSTALLATION (85KW – ULS)…………….2864
FIGURE 4-4. ENGINE INSTALLATION (85KW – LS)…………….2866
FIGURE 4-5. ENGINE MOUNTING INSTALLATION…………….2868
FIGURE 4-6. DIPSTICK INSTALLATION…………….2870
FIGURE 4-7. 3.6L ENGINE (85KW – ULS)…………….2872
FIGURE 4-8. 3.6L ENGINE (74.4KW – ULS)…………….2874
FIGURE 4-9. 3.6L ENGINE (85KW – LS)…………….2876
FIGURE 4-10. 3.6L ENGINE (74.4KW – LS)…………….2878
FIGURE 4-11. FUEL LINES INSTALLATION (ULS)…………….2880
FIGURE 4-12. FUEL LINES INSTALLATION (LS)…………….2882
FIGURE 4-13. EXHAUST INSTALLATION (ULS)…………….2884
FIGURE 4-14. EXHAUST INSTALLATION (LS) (Prior to SN 0160079089, Excluding 0160079084, 0160079085 and 0160079086)…………….2886
FIGURE 4-15. EXHAUST INSTALLATION (LS) (SN 0160079089 to Present, Including 0160079084, 0160079085 and 0160079086)…………….2888
FIGURE 4-16. ENGINE PARTS INSTALLATION (NO A/C)…………….2890
FIGURE 4-17. COOLING PACKAGE INSTALLATION (ULS)…………….2892
FIGURE 4-18. COOLING PACKAGE INSTALLATION (LS)…………….2894
FIGURE 4-19. RADIATOR COOLING PACKAGE INSTALLATION…………….2896
FIGURE 4-20. RADIATOR…………….2898
FIGURE 4-21. FAN INSTALLATION…………….2900
FIGURE 4-22. FAN LINES INSTALLATION…………….2902
FIGURE 4-23. FAN VALVE INSTALLATION…………….2904
FIGURE 4-24. PRIMARY FUEL FILTER INSTALLATION (ULS)…………….2906
FIGURE 4-25. PRIMARY FUEL FILTER INSTALLATION (LS)…………….2908
FIGURE 4-26. AIR CLEANER INSTALLATION (ULS)…………….2910
FIGURE 4-27. AIR CLEANER INSTALLATION (LS)…………….2912
FIGURE 4-28. AIR CLEANER FILTER…………….2914
FIGURE 4-29. COOLANT LINES INSTALLATION…………….2916
FIGURE 4-30. COOLER LINES INSTALLATION…………….2918
FIGURE 4-31. CAC LINES INSTALLATION (ULS)…………….2920
FIGURE 4-32. CAC LINES INSTALLATION (LS)…………….2922
FIGURE 4-33. SURGE TANK INSTALLATION…………….2924
FIGURE 4-34. BULKHEAD INSTALLATION…………….2926
FIGURE 4-35. DEF PUMP AND CONTROL INSTALLATION…………….2928
FIGURE 4-36. DEF TANK INSTALLATION…………….2930
FIGURE 4-37. DEF PUMP LINES INSTALLATION…………….2932
FIGURE 4-38. TRANSMISSION HYDROSTATIC ADAPTER INSTALLATION…………….2934
FIGURE 4-39. TRANSMISSION HYDROSTATIC DRIVE PUMP INSTALLATION…………….2936
FIGURE 4-40. IMPLEMENT PUMP INSTALLATION…………….2938
FIGURE 4-41. IMPLEMENT PUMP ASSEMBLY…………….2940
FIGURE 4-42. PULLEY COVER INSTALLATION…………….2942
FIGURE 4-43. HYDRAULIC FAN PUMP INSTALLATION…………….2944
FIGURE 4-44. HEATER LINES INSTALLATION (ULS)…………….2946
FIGURE 4-45. HEATER LINES INSTALLATION (LS)…………….2948
FIGURE 4-46. BLOCK HEATER INSTALLATION (230V)…………….2950
FIGURE 4-47. BLOCK HEATER INSTALLATION (120V)…………….2952
FIGURE 4-48. BLOCK HEATER (ULS)…………….2954
FIGURE 4-49. BLOCK HEATER (LS)…………….2956
FIGURE 4-50. A/C PUMP INSTALLATION…………….2958
FIGURE 4-51. A/C LINES INSTALLATION…………….2960
FIGURE 4-52. HYDROSTATIC PUMP INSTALLATION…………….2962
SECTION 5 – DRIVE TRAIN…………….2965
FIGURE 5-1. AXLES INSTALLATION (20IN WHEEL)…………….2966
FIGURE 5-2. AXLES INSTALLATION (24IN WHEEL)…………….2968
FIGURE 5-3. HYDROSTATIC MOTOR INSTALLATION…………….2970
FIGURE 5-4. HYDROSTATIC DRIVE MOTOR…………….2972
FIGURE 5-5. FRONT AXLE (20IN WHEEL)…………….2974
FIGURE 5-6. FRONT AXLE, CENTRAL HOUSING (20IN WHEEL)…………….2976
FIGURE 5-7. FRONT AXLE, DIFFERENTIAL (20IN WHEEL)…………….2978
FIGURE 5-8. FRONT AXLE, HUB REDUCTION (20IN WHEEL)…………….2980
FIGURE 5-9. FRONT AXLE, BRAKES (20IN WHEEL)…………….2982
FIGURE 5-10. FRONT AXLE, STEERING (20IN WHEEL)…………….2984
FIGURE 5-11. FRONT AXLE, GEAR BOX (20IN WHEEL)…………….2986
FIGURE 5-12. FRONT AXLE (24IN WHEEL)…………….2990
FIGURE 5-13. FRONT AXLE, CENTRAL HOUSING (24IN WHEEL)…………….2992
FIGURE 5-14. FRONT AXLE, DIFFERENTIAL (24IN WHEEL)…………….2994
FIGURE 5-15. FRONT AXLE, HUB REDUCTION (24IN WHEEL)…………….2996
FIGURE 5-16. FRONT AXLE, BRAKES (24IN WHEEL)…………….2998
FIGURE 5-17. FRONT AXLE, STEERING (24IN WHEEL)…………….3000
FIGURE 5-18. FRONT AXLE, GEAR BOX (24IN WHEEL)…………….3002
FIGURE 5-19. REAR AXLE (20IN WHEEL)…………….3006
FIGURE 5-20. REAR AXLE, CENTRAL HOUSING (20IN WHEEL)…………….3008
FIGURE 5-21. REAR AXLE, DIFFERENTIAL (20IN WHEEL)…………….3010
FIGURE 5-22. REAR AXLE, HUB REDUCTION (20IN WHEEL)…………….3012
FIGURE 5-23. REAR AXLE, STEERING (20IN WHEEL)…………….3014
FIGURE 5-24. TRUNNION…………….3016
FIGURE 5-25. REAR AXLE (24IN WHEEL)…………….3018
FIGURE 5-26. REAR AXLE, CENTRAL HOUSING (24IN WHEEL)…………….3020
FIGURE 5-27. REAR AXLE, DIFFERENTIAL (24IN WHEEL)…………….3022
FIGURE 5-28. REAR AXLE, HUB REDUCTION (24IN WHEEL)…………….3024
FIGURE 5-29. REAR AXLE, STEERING (24IN WHEEL)…………….3026
FIGURE 5-30. REAR AXLE, TRUNNION KIT (24IN WHEEL)…………….3028
FIGURE 5-31. DIFFERENTIAL KIT…………….3030
FIGURE 5-32. DIFFERENTIAL KIT…………….3032
FIGURE 5-33. REDUCTION BUSHING KIT…………….3034
FIGURE 5-34. STEERING CASE KIT, (LF, RR)…………….3036
FIGURE 5-35. STEERING CASE KIT, (RF, LR)…………….3038
FIGURE 5-36. STEERING CASE KIT, (LF, RR)…………….3040
FIGURE 5-37. STEERING CASE KIT, (RF, LR)…………….3042
FIGURE 5-38. STEERING ADJUST BOLT KIT…………….3044
FIGURE 5-39. PLANET GEAR KIT…………….3046
FIGURE 5-40. PLANET GEAR CARRIER KIT…………….3048
FIGURE 5-41. PLANET GEAR CARRIER KIT…………….3050
FIGURE 5-42. RING GEAR SUPPORT KIT…………….3052
FIGURE 5-43. RING GEAR SUPPORT KIT…………….3054
FIGURE 5-44. SUPPORT KIT…………….3056
FIGURE 5-45. DRIVE SHAFTS INSTALLATION…………….3058
FIGURE 5-46. FRONT DRIVE SHAFT…………….3060
FIGURE 5-47. REAR DRIVE SHAFT…………….3062
FIGURE 5-48. AXLE SHIM INSTALLATION (20IN WHEEL)…………….3064
FIGURE 5-49. AXLE SHIM INSTALLATION…………….3066
FIGURE 5-50. TIRE/WHEEL SET (20IN WHEEL – 405/70 – AIR)…………….3068
FIGURE 5-51. RIGHT TIRE/WHEEL ASSEMBLY (20IN WHEEL – 405/70 – AIR)…………….3070
FIGURE 5-52. WHEEL, RH RIM ASSEMBLY (20IN WHEEL – 405/70 – AIR)…………….3072
FIGURE 5-53. LEFT TIRE/WHEEL ASSEMBLY (20IN WHEEL – 405/70 – AIR)…………….3074
FIGURE 5-54. WHEEL, LH RIM ASSEMBLY (20IN WHEEL – 405/70 – AIR)…………….3076
FIGURE 5-55. TIRE/WHEEL SET (20IN WHEEL – 400/70 – AIR)…………….3078
FIGURE 5-56. RIGHT TIRE/WHEEL ASSEMBLY (20IN WHEEL – 400/70 – AIR)…………….3080
FIGURE 5-57. WHEEL, RH RIM ASSEMBLY (20IN WHEEL – 400/70 – AIR)…………….3082
FIGURE 5-58. LEFT TIRE/WHEEL ASSEMBLY (20IN WHEEL – 400/70 – AIR)…………….3084
FIGURE 5-59. WHEEL, LH RIM ASSEMBLY (20IN WHEEL – 400/70 – AIR)…………….3086
FIGURE 5-60. TIRE/WHEEL SET (24IN WHEEL – 405/70 – AIR)…………….3088
FIGURE 5-61. RIGHT TIRE/WHEEL ASSEMBLY (24IN WHEEL – 405/70 – AIR)…………….3090
FIGURE 5-62. WHEEL RH RIM ASSEMBLY (24IN WHEEL – 405/70 – AIR)…………….3092
FIGURE 5-63. LEFT TIRE/WHEEL ASSEMBLY (24IN WHEEL – 405/70 – AIR)…………….3094
FIGURE 5-64. WHEEL LH RIM ASSEMBLY (24IN WHEEL – 405/70 – AIR)…………….3096
FIGURE 5-65. TIRE/WHEEL SET (24IN WHEEL – 400/70 – XMCL – AIR)…………….3098
FIGURE 5-66. RIGHT TIRE/WHEEL ASSEMBLY (24IN WHEEL – 400/70 – XMCL – AIR)…………….3100
FIGURE 5-67. WHEEL RH RIM ASSEMBLY (24IN WHEEL – 400/70 – XMCL – AIR)…………….3102
FIGURE 5-68. LEFT TIRE/WHEEL ASSEMBLY (24IN WHEEL – 400/70 – XMCL – AIR)…………….3104
FIGURE 5-69. WHEEL, LH RIM ASSEMBLY (24IN WHEEL – 400/70 – XMCL – AIR)…………….3106
FIGURE 5-70. TIRE/WHEEL SET (24IN WHEEL – 400/70 – CL – AIR)…………….3108
FIGURE 5-71. RIGHT TIRE/WHEEL ASSEMBLY (24IN WHEEL – 400/70 – CL – AIR)…………….3110
FIGURE 5-72. WHEEL RH RIM ASSEMBLY ASSEMBLY (24IN WHEEL-400/70-CL-AIR)…………….3112
FIGURE 5-73. LEFT TIRE/WHEEL ASSEMBLY (24IN WHEEL – 400/70 – CL – AIR)…………….3114
FIGURE 5-74. WHEEL LH RIM ASSEMBLY (24IN WHEEL – 400/70 – CL – AIR)…………….3116
FIGURE 5-75. FENDER INSTALLATION (20IN WHEEL)…………….3118
FIGURE 5-76. FENDER INSTALLATION (24IN WHEEL)…………….3120
FIGURE 5-77. WHEEL CHOCK INSTALLATION…………….3122
SECTION 6 – CAB…………….3125
FIGURE 6-1. CAB MOUNTS INSTALLATION…………….3126
FIGURE 6-2. ENCLOSED CAB INSTALLATION (20IN WHEEL – JLG)…………….3128
FIGURE 6-3. ENCLOSED CAB INSTALLATION (20IN WHEEL – DEUTZ-FAHR)…………….3130
FIGURE 6-4. ENCLOSED CAB INSTALLATION (24IN WHEEL – JLG)…………….3132
FIGURE 6-5. ENCLOSED CAB INSTALLATION (24IN WHEEL – DEUTZ-FAHR)…………….3134
FIGURE 6-6. ENCLOSED CAB ASSEMBLY (20IN WHEEL – JLG)…………….3136
FIGURE 6-7. ENCLOSED CAB ASSEMBLY (20IN WHEEL – DEUTZ-FAHR)…………….3138
FIGURE 6-8. ENCLOSED CAB ASSEMBLY (24IN WHEEL – JLG)…………….3140
FIGURE 6-9. ENCLOSED CAB ASSEMBLY (24IN WHEEL – DEUTZ-FAHR)…………….3142
FIGURE 6-10. ENCLOSED CAB GROUP…………….3144
FIGURE 6-11. ENCLOSED CAB GROUP…………….3146
FIGURE 6-12. ENCLOSED CAB…………….3148
FIGURE 6-13. ENCLOSED CAB…………….3150
FIGURE 6-14. ENCLOSED CAB PLUG GROUP…………….3152
FIGURE 6-15. REAR WINDOW INSTALLATION…………….3154
FIGURE 6-16. REAR WINDOW ASSEMBLY…………….3156
FIGURE 6-17. DOOR INSTALLATION…………….3158
FIGURE 6-18. DOOR INSTALLATION…………….3160
FIGURE 6-19. DOOR ASSEMBLY (AG)…………….3162
FIGURE 6-20. DOOR ASSEMBLY (AG)…………….3164
FIGURE 6-21. CAB DOOR…………….3166
FIGURE 6-22. DOOR UPPER GLASS ASSEMBLY…………….3168
FIGURE 6-23. CAB LATCH ASSEMBLY…………….3170
FIGURE 6-24. CAB DOOR TRIGGER ASSEMBLY…………….3172
FIGURE 6-25. DOOR STRAP INSTALLATION…………….3174
FIGURE 6-26. ENCLOSED CAB TRIM INSTALLATION…………….3176
FIGURE 6-27. DASH COVER ASSEMBLY…………….3180
FIGURE 6-28. RECIRCULATION GRILLE COVER PANEL ASSEMBLY…………….3182
FIGURE 6-29. REAR PANEL COVER ASSEMBLY…………….3184
FIGURE 6-30. ADJUSTABLE ARMREST INSTALLATION…………….3186
FIGURE 6-31. HEADLINER INSTALLATION…………….3188
FIGURE 6-32. HEADLINER/RADIO READY INSTALLATION…………….3190
FIGURE 6-33. COMMON CAB TRIM INSTALLATION…………….3192
FIGURE 6-34. CAB TRIM INSTALLATION…………….3194
FIGURE 6-35. ROOF CAP INSTALLATION (A/C)…………….3196
FIGURE 6-36. ROOF CAP INSTALLATION (A/C)…………….3198
FIGURE 6-37. ROOF CAP INSTALLATION (NO A/C)…………….3200
FIGURE 6-38. ROOF CAP INSTALLATION (NO A/C)…………….3202
FIGURE 6-39. FRONT COVER INSTALLATION…………….3204
FIGURE 6-40. FILTER TRAY PANEL…………….3206
FIGURE 6-41. FRONT DUCT COVER…………….3208
FIGURE 6-42. HVAC CAB ACTUATOR…………….3210
FIGURE 6-43. SEAT INSTALLATION (MECHANICAL)…………….3212
FIGURE 6-44. SEAT INSTALLATION (MECHANICAL)…………….3214
FIGURE 6-45. SEAT ASSEMBLY…………….3216
FIGURE 6-46. SEAT INSTALLATION (AIR SUSPENSION – STANDARD)…………….3218
FIGURE 6-47. SEAT ASSEMBLY (AIR SUSPENSION – STANDARD)…………….3220
FIGURE 6-48. SEAT INSTALLATION (PREMIUM)…………….3222
FIGURE 6-49. SEAT INSTALLATION (PREMIUM)…………….3224
FIGURE 6-50. SEAT INSTALLATION (STANDARD)…………….3226
FIGURE 6-51. SEAT ASSEMBLY…………….3228
FIGURE 6-52. UPPER SEAT ASSEMBLY…………….3230
FIGURE 6-53. UPPER SEAT ASSEMBLY…………….3232
FIGURE 6-54. SUSPENSION KIT…………….3234
FIGURE 6-55. SEAT BELT INSTALLATION (2IN)…………….3236
FIGURE 6-56. SEAT BELT INSTALLATION (3IN)…………….3238
FIGURE 6-57. HEATER INSTALLATION…………….3240
FIGURE 6-58. HEATER AND A/C INSTALLATION…………….3242
FIGURE 6-59. HEATER ASSEMBLY…………….3246
FIGURE 6-60. HEATER AND A/C ASSEMBLY…………….3248
FIGURE 6-61. HEATER…………….3250
FIGURE 6-62. HEATER AND A/C…………….3252
FIGURE 6-63. CAB CONDENSER ASSEMBLY…………….3254
FIGURE 6-64. CONDENSER…………….3256
FIGURE 6-65. A/C RECEIVER DRIER…………….3258
FIGURE 6-66. ROOF WIPER INSTALLATION…………….3260
FIGURE 6-67. FRONT NOSE CONE INSTALLATION (ROADLIGHTS)…………….3262
FIGURE 6-68. FRONT NOSE CONE INSTALLATION (NO ROADLIGHTS)…………….3264
FIGURE 6-69. RETRACTABLE SUNSCREEN INSTALLATION…………….3266
FIGURE 6-70. FLOOR MAT INSTALLATION…………….3268
FIGURE 6-71. EXTERNAL WINDOW RELEASE INSTALLATION…………….3270
FIGURE 6-72. CAB GUARD INSTALLATION (TOP)…………….3272
FIGURE 6-73. CAB GUARD INSTALLATION (FRONT)…………….3274
FIGURE 6-74. CAB GUARD INSTALLATION (TOP AND FRONT)…………….3276
FIGURE 6-75. NUMBER PLATE BRACKET INSTALLATION (NO CAB GUARD)…………….3278
FIGURE 6-76. NUMBER PLATE BRACKET INSTALLATION (CAB GUARD)…………….3280
FIGURE 6-77. MIRROR INSTALLATION (20IN WHEEL)…………….3282
FIGURE 6-78. HITCH MIRROR INSTALLATION (FLAT)…………….3284
FIGURE 6-79. HITCH MIRROR INSTALLATION (CONVEX)…………….3286
FIGURE 6-80. MIRROR ASSEMBLY (CONVEX)…………….3288
FIGURE 6-81. INTERIOR MIRROR INSTALLATION…………….3290
FIGURE 6-82. INTERIOR MIRROR…………….3292
FIGURE 6-83. REAR VIEW MIRROR INSTALLATION…………….3294
FIGURE 6-84. FRONT WIPER INSTALLATION…………….3296
FIGURE 6-85. WASHER TANK INSTALLATION…………….3298
FIGURE 6-86. WASHER HOSES INSTALLATION…………….3300
FIGURE 6-87. HAMMER INSTALLATION…………….3302
FIGURE 6-88. HAMMER ATTACHMENT ASSEMBLY…………….3304
FIGURE 6-89. LEVEL INDICATOR INSTALLATION…………….3306
FIGURE 6-90. WASHER BOTTLE…………….3308
FIGURE 6-91. TOOL BOX INSTALLATION…………….3310
SECTION 7 – CONTROLS…………….3313
FIGURE 7-1. ACCELERATOR PEDAL INSTALLATION…………….3314
FIGURE 7-2. ACCELERATOR PEDAL…………….3316
FIGURE 7-3. BRAKE INSTALLATION (24IN WHEEL)…………….3318
FIGURE 7-4. BRAKE PEDAL (24IN WHEEL)…………….3320
FIGURE 7-5. BRAKE INSTALLATION (20IN WHEEL)…………….3322
FIGURE 7-6. BRAKE PEDAL (20IN WHEEL)…………….3324
FIGURE 7-7. BRAKE PEDAL PLATE…………….3326
FIGURE 7-8. BRAKE SENSOR INSTALLATION…………….3328
FIGURE 7-9. SWITCH PLATE ASSEMBLY…………….3330
FIGURE 7-10. PARKING BRAKE INSTALLATION (SAHR)…………….3332
FIGURE 7-11. STEERING COLUMN INSTALLATION (20IN WHEEL)…………….3334
FIGURE 7-12. STEERING COLUMN INSTALLATION…………….3336
FIGURE 7-13. TILT STEERING COLUMN…………….3338
FIGURE 7-14. WIPER-TURN SWITCH (NO SPEED)…………….3340
FIGURE 7-15. WIPER-TURN SWITCH (0 SPEED – FNR)…………….3342
FIGURE 7-16. STEERING WHEEL INSTALLATION (24IN WHEEL)…………….3344
FIGURE 7-17. STEERING WHEEL…………….3346
FIGURE 7-18. HORN BUTTON INSTALLATION (JLG)…………….3348
FIGURE 7-19. HORN BUTTON INSTALLATION (DEUTZ-FAHR)…………….3350
FIGURE 7-20. JOYSTICK INSTALLATION…………….3352
SECTION 8 – HYDRAULIC CIRCUITS…………….3355
FIGURE 8-1. COMMON HYDRAULICS INSTALLATION…………….3356
FIGURE 8-2. HYDRAULICS INSTALLATION (20IN WHEEL)…………….3358
FIGURE 8-3. HYDRAULICS INSTALLATION (24IN WHEEL)…………….3360
FIGURE 8-4. MAIN CONTROL VALVE INSTALLATION…………….3362
FIGURE 8-5. MAIN CONTROL VALVE LINES INSTALLATION…………….3364
FIGURE 8-6. STEERING SELECT VALVE INSTALLATION…………….3366
FIGURE 8-7. BRAKE LINES INSTALLATION (20IN WHEEL)…………….3368
FIGURE 8-8. BRAKE LINES INSTALLATION (24IN WHEEL)…………….3370
FIGURE 8-9. BRAKE AND STEERING INSTALLATION (20IN WHEEL)…………….3372
FIGURE 8-10. BRAKE AND STEERING INSTALLATION (24IN WHEEL)…………….3374
FIGURE 8-11. BRAKE AND STEERING PIPE ASSEMBLY (24IN WHEEL)…………….3376
FIGURE 8-12. BRAKE AND STEERING PIPE ASSEMBLY (20IN WHEEL)…………….3378
FIGURE 8-13. IMPLEMENT LINES INSTALLATION…………….3380
FIGURE 8-14. STEERING LINES INSTALLATION (20IN WHEEL)…………….3382
FIGURE 8-15. STEERING LINES INSTALLATION (24IN WHEEL)…………….3384
FIGURE 8-16. SUCTION LINES INSTALLATION…………….3386
FIGURE 8-17. RETURN LINES INSTALLATION…………….3388
FIGURE 8-18. BOOM RAISE HOSES INSTALLATION (NO RIDE CONTROL)…………….3390
FIGURE 8-19. BOOM RAISE HOSES INSTALLATION (RIDE CONTROL)…………….3392
FIGURE 8-20. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….3394
FIGURE 8-21. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….3396
FIGURE 8-22. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….3398
FIGURE 8-23. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….3400
FIGURE 8-24. AUX HYDRAULIC LINES INSTALLATION (NO REAR AUX)…………….3402
FIGURE 8-25. REAR AUX HYDRAULICS INSTALLATION (SINGLE)…………….3404
FIGURE 8-26. REAR AUX HYDRAULICS INSTALLATION (TWIN)…………….3406
FIGURE 8-27. TRAILER BRAKE INSTALLATION (CE)…………….3408
FIGURE 8-28. HYDROSTATIC LINES INSTALLATION…………….3410
FIGURE 8-29. BOOM HYDRAULIC TUBES INSTALLATION…………….3412
FIGURE 8-30. IMPLEMENT PUMP FILTER INSTALLATION…………….3414
FIGURE 8-31. IMPLEMENT PUMP FILTER ASSEMBLY…………….3416
FIGURE 8-32. LIFT CYLINDER INSTALLATION…………….3418
FIGURE 8-33. SPEED SELECT VALVE INSTALLATION…………….3420
FIGURE 8-34. BRAKE ACCUMULATOR INSTALLATION…………….3422
FIGURE 8-35. HYDRAULIC FILTER ASSEMBLY…………….3424
FIGURE 8-36. AUTO APPLY PARK BRAKE INSTALLATION…………….3426
SECTION 9 – HYDRAULIC COMPONENTS…………….3429
FIGURE 9-1. LIFT CYLINDER…………….3430
FIGURE 9-2. TILT CYLINDER…………….3432
FIGURE 9-3. EXTEND/RETRACT CYLINDER ASSEMBLY…………….3434
FIGURE 9-4. EXTEND/RETRACT CYLINDER…………….3436
FIGURE 9-5. COMPENSATION CYLINDER ASSEMBLY…………….3438
FIGURE 9-6. COMPENSATION CYLINDER…………….3440
FIGURE 9-7. COUPLER LOCKING CYLINDER ASSEMBLY…………….3442
FIGURE 9-8. COUPLER LOCKING CYLINDER…………….3444
FIGURE 9-9. SIDE TILT CYLINDER…………….3446
FIGURE 9-10. SIDE SHIFT CARRIAGE CYLINDER…………….3448
FIGURE 9-11. MULTI-PURPOSE GRAPPLE BUCKET CYLINDER (1850MM)…………….3450
FIGURE 9-12. FORK POSITIONING CYLINDER…………….3452
FIGURE 9-13. MAIN CONTROL VALVE…………….3454
FIGURE 9-14. IMPLEMENT PUMP…………….3458
FIGURE 9-15. HYDROSTATIC PUMP…………….3460
FIGURE 9-16. STEERING SELECT VALVE…………….3462
FIGURE 9-17. TRAILER BRAKE VALVE (CE)…………….3464
FIGURE 9-18. RIDE CONTROL VALVE…………….3466
FIGURE 9-19. SPEED CONTROL VALVE…………….3468
FIGURE 9-20. DIVERTOR VALVE…………….3470
FIGURE 9-21. DIVERTOR VALVE…………….3472
FIGURE 9-22. DIVERTOR VALVE…………….3474
FIGURE 9-23. DIVERTOR VALVE…………….3476
FIGURE 9-24. FLOW DIVIDER VALVE…………….3478
FIGURE 9-25. HYDRAULIC HITCH CONTROL VALVE (Prior to SN 1160008583)…………….3480
FIGURE 9-26. HYDRAULIC HITCH CONTROL VALVE (SN 1160008583 to Present)…………….3482
FIGURE 9-27. HYDRAULIC FILTER…………….3484
FIGURE 9-28. SAHR BRAKE MANIFOLD…………….3486
SECTION 10 – ELECTRICAL…………….3489
FIGURE 10-1. FRAME WIRING INSTALLATION…………….3490
FIGURE 10-2. ENGINE WIRING INSTALLATION (85KW – ULS)…………….3492
FIGURE 10-3. ENGINE ECU INSTALLATION (74.4KW – 85KW – ULS)…………….3494
FIGURE 10-4. ENGINE WIRING INSTALLATION (74.4KW – 85KW – LS)…………….3496
FIGURE 10-5. ENGINE ECU INSTALLATION (74.4KW – 85KW – LS)…………….3498
FIGURE 10-6. ELECTRICAL COMPONENTS INSTALLATION…………….3500
FIGURE 10-7. POWER DISTRIBUTION ELECTRICAL BOX…………….3502
FIGURE 10-8. 200 AMP RELAY INSTALLATION…………….3504
FIGURE 10-9. BATTERY INSTALLATION…………….3506
FIGURE 10-10. CAB ELECTRICAL INSTALLATION…………….3508
FIGURE 10-11. STANDARD ELECTRICAL BOARD ASSEMBLY…………….3512
FIGURE 10-12. OPTION 1 ELECTRICAL BOARD ASSEMBLY…………….3514
FIGURE 10-13. OPTION 2 ELECTRICAL BOARD ASSEMBLY…………….3516
FIGURE 10-14. DASH ELECTRICS INSTALLATION (ULS)…………….3518
FIGURE 10-15. REVERSE CAMERA INSTALLATION (NO HYDRAULIC HITCH)…………….3520
FIGURE 10-16. REVERSE CAMERA INSTALLATION (HYDRAULIC HITCH)…………….3522
FIGURE 10-17. REVERSE SENSOR INSTALLATION (NO HYDRAULIC HITCH)…………….3524
FIGURE 10-18. REVERSE SENSOR INSTALLATION (HYDRAULIC HITCH)…………….3526
FIGURE 10-19. CLEARSKY INSTALLATION (A/C – LONG ROOF CAP)…………….3528
FIGURE 10-20. CLEARSKY INSTALLATION (NO A/C – SHORT ROOF CAP)…………….3530
FIGURE 10-21. TELEMATICS CAP INSTALLATION…………….3532
FIGURE 10-22. HORN INSTALLATION…………….3534
FIGURE 10-23. REVERSE ALARM INSTALLATION…………….3536
FIGURE 10-24. DIP LIGHTS INSTALLATION (RHD)…………….3538
FIGURE 10-25. DIP LIGHTS INSTALLATION (LHD)…………….3540
FIGURE 10-26. LICENSE PLATE LAMP INSTALLATION…………….3542
FIGURE 10-27. CAB WORKLIGHTS INSTALLATION (NO A/C)…………….3544
FIGURE 10-28. CAB WORKLIGHTS INSTALLATION (A/C)…………….3546
FIGURE 10-29. BOOM WORKLIGHTS INSTALLATION…………….3548
FIGURE 10-30. BOOM LED WORKLIGHTS INSTALLATION…………….3550
FIGURE 10-31. BEACON BRACKET INSTALLATION…………….3552
FIGURE 10-32. BEACON LIGHT INSTALLATION…………….3554
FIGURE 10-33. TRAILER ELECTRICS INSTALLATION…………….3556
FIGURE 10-34. MULTIFUNCTION DISPLAY INSTALLATION…………….3558
FIGURE 10-35. ENGINE SPEED SET SWITCH INSTALLATION…………….3560
FIGURE 10-36. IGNITION SWITCH INSTALLATION…………….3562
FIGURE 10-37. IGNITION SWITCH INSTALLATION…………….3564
FIGURE 10-38. TRAVEL MODE SWITCH INSTALLATION…………….3566
FIGURE 10-39. LSI SENSOR INSTALLATION (20IN WHEEL)…………….3568
FIGURE 10-40. LSI SENSOR INSTALLATION (24IN WHEEL)…………….3570
FIGURE 10-41. LSI ASSEMBLY…………….3572
FIGURE 10-42. LSI SENSOR (20IN WHEEL)…………….3574
FIGURE 10-43. LSI SENSOR (24IN WHEEL)…………….3576
FIGURE 10-44. LMIS INSTALLATION…………….3578
FIGURE 10-45. LMIS MECHANICAL…………….3580
FIGURE 10-46. LMIS CONTROLLER…………….3582
FIGURE 10-47. LMIS WIRING INSTALLATION…………….3584
FIGURE 10-48. LMIS BEACON INSTALLATION…………….3586
FIGURE 10-49. BOOM ANGLE SENSOR INSTALLATION…………….3588
FIGURE 10-50. EARTH STRAP INSTALLATION…………….3590
FIGURE 10-51. RETRACT SENSOR EXTENSION LEED HARNESS…………….3592
FIGURE 10-52. BOOM RETRACT SENSOR INSTALLATION…………….3594
FIGURE 10-53. FRONT FRAME HARNESS…………….3596
FIGURE 10-54. HYDROSTATIC HARNESS…………….3600
FIGURE 10-55. REAR FRAME HARNESS…………….3602
FIGURE 10-56. ENGINE HARNESS (ULS)…………….3606
FIGURE 10-57. ENGINE HARNESS (LS)…………….3612
FIGURE 10-58. FUEL PUMP HARNESS…………….3616
FIGURE 10-59. GLOW PLUG RELAY HARNESS…………….3618
FIGURE 10-60. CAB HARNESS…………….3620
FIGURE 10-61. CAB OPTION HARNESS…………….3628
FIGURE 10-62. CAB HEATER HARNESS INSTALLATION…………….3630
FIGURE 10-63. CAB HEATER HARNESS…………….3632
FIGURE 10-64. A/C OPTION HARNESS…………….3634
FIGURE 10-65. BOOM HARNESS INSTALLATION…………….3636
FIGURE 10-66. BOOM HARNESS…………….3638
FIGURE 10-67. LMIS CHASSIS OPTION HARNESS…………….3640
FIGURE 10-68. REVERSE SENSOR HARNESS…………….3642
FIGURE 10-69. CLEARSKY HARNESS (A/C)…………….3644
FIGURE 10-70. LICENSE LIGHT HARNESS…………….3646
FIGURE 10-71. BOOM WORKLIGHTS HARNESS…………….3648
FIGURE 10-72. LINK TRAILER HARNESS…………….3650
FIGURE 10-73. NO ROAD LIGHTS INSTALLATION…………….3652
FIGURE 10-74. SEAT ADAPTOR HARNESS…………….3654
SECTION 11 – DECALS…………….3657
FIGURE 11-1. CAPACITY CHART HOLDER INSTALLATION…………….3658
FIGURE 11-2. CAPACITY CHART (JLG) (METRIC)…………….3660
FIGURE 11-3. CAPACITY CHART (DEUTZ-FAHR) (METRIC)…………….3662
FIGURE 11-4. CAPACITY CHART (JLG) (ANSI)…………….3664
FIGURE 11-5. CAPACITY CHART (JLG) (AUS)…………….3666
FIGURE 11-6. DECALS INSTALLATION (JLG)…………….3668
FIGURE 11-7. DECALS INSTALLATION (DEUTZ-FAHR)…………….3670
FIGURE 11-8. DECALS INSTALLATION (ISO – ULS)…………….3672
FIGURE 11-9. DECALS INSTALLATION (ISO – LS)…………….3676
FIGURE 11-10. DECALS INSTALLATION (AUS – LS)…………….3680
FIGURE 11-11. DECALS INSTALLATION (RUS – LS)…………….3684
FIGURE 11-12. DECALS INSTALLATION (NACD – ULS)…………….3688
FIGURE 11-13. REFLECTORS INSTALLATION…………….3692
SECTION 12 – RECOMMENDED SPARE PARTS…………….3695
FIGURE 12-1. RECOMMENDED SPARE PARTS…………….3696
PART NUMBER INDEX…………….3697
Service Manual 30.6 35.7 40.8 35.10 CE+ AUS…………….3713
31211228_B_3006H,3507PS,4008PS,3510PS, 30.6, 35.7, 40.8, 35.10_JLG_Service…………….3713
Effectivity Page…………….3715
Table of Contents…………….3717
Section 1 Safety Practices…………….3721
1.1 Introduction…………….3722
1.2 Disclaimer…………….3722
1.3 Operation & Safety Manual…………….3722
1.4 Do Not Operate Tags…………….3722
1.5 Safety Information…………….3722
1.5.1 Safety Alert System and Signal Words…………….3722
1.6 Safety Instructions…………….3723
1.6.1 Personal Hazards…………….3723
1.6.2 Equipment Hazards…………….3723
1.6.3 General Hazards…………….3723
1.6.4 Operational Hazards…………….3724
1.7 Safety Decals…………….3724
Section 2 General Information and Specifications…………….3725
2.1 Replacement Parts and Warranty Information…………….3727
2.2 Specifications…………….3728
2.2.1 Travel Speed – 3006H, 30.6…………….3728
2.2.2 Travel Speed – 3507PS, 35.7…………….3728
2.2.3 Travel Speed – 4008PS, 3510PS, 40.8, 35.10…………….3728
2.2.4 Hydraulic Cylinder Performance…………….3729
2.2.5 Cylinder Drift…………….3729
2.2.6 Electrical System…………….3730
2.2.7 Engine Performance Specifications…………….3731
2.2.8 Transmission Performance Specifications…………….3732
2.2.9 Steering Angle Specification…………….3732
2.2.10 Tires…………….3733
2.3 Fluid and Lubricant Capacities…………….3735
2.3.1 Fluids (if equipped for ULS)…………….3735
2.3.2 Fluids (if equipped for LS)…………….3737
2.3.3 Capacities…………….3739
2.4 Service and Maintenance Schedules…………….3741
2.4.1 Every 10 Hours…………….3741
2.4.2 First 50 Hours…………….3742
2.4.3 Every 50 Hours…………….3742
2.4.4 First 250 Hours…………….3742
2.4.5 Every 250 Hours…………….3743
2.4.6 Every 500 Hours…………….3743
2.4.7 Every 750 Hours…………….3743
2.4.8 Every 1000 Hours…………….3744
2.4.9 Every 1500 Hours…………….3745
2.4.10 Every 2000 Hours…………….3745
2.4.11 Every 3000 Hours…………….3745
2.5 Lubrication Schedule…………….3746
2.5.1 50 & 250 Hour…………….3746
2.6 Thread Locking Compound…………….3748
2.7 Torque Charts…………….3749
2.7.1 SAE Fastener Torque Chart…………….3749
2.7.2 Metric Fastener Torque Chart…………….3755
2.8 Hydraulic Connection Assembly and Torque Specification…………….3759
2.8.1 Definitions…………….3759
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections…………….3761
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections…………….3763
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings…………….3764
2.8.5 Assembly Instructions for 45° SAE Flare Fittings…………….3767
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings…………….3769
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)…………….3771
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings…………….3773
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings…………….3776
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings…………….3784
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends…………….3792
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings…………….3794
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)…………….3802
2.8.14 Double Wrench Method…………….3805
2.8.15 FFWR and TFFT Methods…………….3806
2.8.16 Adjustable Stud End Assembly…………….3806
2.8.17 O-ring Installation (Replacement)…………….3806
Section 3 Boom…………….3807
3.1 Boom System Component Terminology…………….3808
3.1.1 3006H, 30.6…………….3808
3.1.2 3507PS, 4008PS, 35.7, 40.8…………….3809
3.1.3 3510PS, 35.10…………….3810
3.2 Boom System…………….3811
3.2.1 Boom System Operation – 3006H, 3507PS, 4008PS, 30.6, 35.7, 40.8…………….3811
3.2.2 Boom System Operation – 3510PS, 35.10…………….3811
3.3 Boom Removal/Installation…………….3811
3.3.1 Complete Boom Removal…………….3811
3.3.2 Complete Boom Installation…………….3813
3.4 Boom Assembly Maintenance – 3006H, 3507PS, 4008PS, 30.6, 35.7, 40.8…………….3815
3.4.1 Second Boom Section Removal…………….3816
3.4.2 Second Boom Section Installation…………….3818
3.5 Boom Assembly Maintenance – 3510PS, 35.10…………….3820
3.5.1 Second and Third Boom Section Removal…………….3821
3.5.2 Third Boom Section Removal…………….3823
3.5.3 Third Boom Section Installation…………….3823
3.5.4 Second and Third Boom Section Installation…………….3824
3.6 Third Boom Section Removal/ Installation Only – 3510PS, 35.10…………….3826
3.6.1 Removal…………….3826
3.6.2 Installation…………….3827
3.7 Boom Wear Pads…………….3829
3.7.1 Wear Pad Inspection…………….3829
3.7.2 Boom Wear Pad Installation, Lubrication…………….3829
3.8 Quick Coupler…………….3830
3.8.1 Manual Coupler…………….3830
3.8.2 Hydraulic Coupler…………….3831
3.9 Forks…………….3832
3.10 Boom prop (if equipped)…………….3833
3.10.1 Prop Installation…………….3833
3.10.2 Prop Removal…………….3833
3.11 Emergency Boom Lowering Procedure…………….3834
3.11.1 Equipment and Supplies Required…………….3834
3.11.2 Lowering Procedure…………….3834
3.12 Troubleshooting…………….3836
Section 4 Cab…………….3839
4.1 Operator Cab Component Terminology…………….3840
4.2 Operator Cab…………….3841
4.2.1 Operator Cab Safety…………….3841
4.2.2 Serial Number Plate…………….3841
4.3 Cab Components…………….3841
4.3.1 Steering Wheel…………….3841
4.3.2 Steering Column/Orbital Valve…………….3842
4.3.3 Service Brake…………….3843
4.3.4 Electronic Throttle Pedal…………….3844
4.3.5 Joystick Assembly…………….3845
4.3.6 Window Wiper Assembly…………….3845
4.3.7 Heater System (If equipped)…………….3845
4.3.8 Heater/Air Conditioning System (If equipped)…………….3847
4.4 Cab Removal…………….3849
4.5 Cab Installation…………….3851
Section 5 Axles, Drive Shafts, Wheels and Tires…………….3853
5.1 Axle, Drive Shaft and Wheel Component Terminology…………….3854
5.1.1 3006H, 30.6…………….3854
5.1.2 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3855
5.2 Axle Serial Number…………….3856
5.3 Axle Specifications and Maintenance Information…………….3856
5.4 Axle Replacement…………….3856
5.4.1 Axle Removal…………….3856
5.4.2 Axle Installation…………….3859
5.5 Brake Inspection…………….3861
5.6 Steering Angle Adjustment…………….3861
5.7 Axle Assembly and Drive Shaft Troubleshooting…………….3862
5.8 Drive Shafts…………….3865
5.8.1 Drive Shaft Inspection…………….3865
5.8.2 Drive Shaft Maintenance…………….3865
5.8.3 Drive Shaft – 3006H, 30.6…………….3865
5.8.4 Drive Shaft – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3866
5.8.5 Drive Shaft Cleaning and Drying…………….3867
5.9 Wheels and Tires…………….3867
5.9.1 Removing Wheel and Tire Assembly from Machine…………….3867
5.9.2 Installing Wheel and Tire Assembly onto Machine…………….3867
5.10 Towing a Disabled Machine…………….3868
5.10.1 Manually Releasing the Park Brake…………….3868
5.10.2 Manually Resetting the Park Brake…………….3870
Section 6 Transmission…………….3871
6.1 Transmission Assembly Component Terminology…………….3872
6.2 Transmission Serial Number…………….3874
6.3 Specifications and Maintenance Information…………….3874
6.4 Hydrostatic Transmission Pump Replacement – 3006H, 30.6…………….3874
6.4.1 Transmission Removal…………….3874
6.4.2 Transmission Inspection and Internal Repair…………….3875
6.4.3 Transmission Installation…………….3875
6.4.4 After Transmission Service or Replacement…………….3876
6.5 Transmission Replacement – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3876
6.5.1 Transmission Removal…………….3876
6.5.2 Transmission Inspection and Internal Repair…………….3877
6.5.3 Transmission Installation…………….3877
6.6 Transmission Fluid/Filter Replacement…………….3878
6.7 Transmission Fluid Level Check…………….3878
6.8 Torque Converter Diaphragm – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3879
6.8.1 Torque Converter Diaphragm Removal…………….3879
6.8.2 Torque Converter Diaphragm Installation…………….3879
Section 7 Engine…………….3881
7.1 Introduction…………….3882
7.1.1 Disclaimer and Scope…………….3882
7.1.2 Component Terminology…………….3883
7.2 Engine Serial Number…………….3886
7.3 Specifications and Maintenance Information…………….3886
7.4 Engine Cooling System…………….3886
7.4.1 Surge Tank Cap…………….3886
7.4.2 Thermostat Replacement…………….3886
7.4.3 Radiator Assembly Replacement…………….3887
7.5 Engine Electrical System…………….3889
7.6 Fuel System…………….3889
7.6.1 Diesel Fuel…………….3889
7.6.2 Diesel Exhaust Fluid (DEF) Tank – 3006H, 30.6…………….3889
7.6.3 Diesel Exhaust Fluid (DEF) Filter – 3006H, 30.6…………….3890
7.6.4 Diesel Exhaust Fluid (DEF) Pump Filter – 3006H, 30.6…………….3891
7.6.5 Diesel Exhaust Fluid (DEF) Tank – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3892
7.6.6 Diesel Exhaust Fluid (DEF) Filter – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3894
7.6.7 Diesel Exhaust Fluid (DEF) Pump Filter – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3895
7.6.8 Diesel Exhaust Fluid (DEF) Tank Header Element Cleaning – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3896
7.6.9 Fuel Tank…………….3897
7.6.10 After Fuel System Service…………….3898
7.7 Engine Exhaust System…………….3899
7.7.1 If equipped for ULS…………….3899
7.7.2 If equipped for LS…………….3901
7.8 Air Cleaner Assembly…………….3903
7.8.1 Air Cleaner Assembly Removal…………….3903
7.8.2 Air Cleaner Assembly Installation…………….3904
7.9 Engine Replacement…………….3905
7.9.1 Engine/Transmission Removal…………….3905
7.9.2 Transmission Removal/Installation…………….3907
7.9.3 Engine Disassembly, Inspection and Service…………….3907
7.9.4 Engine/Transmission Installation…………….3907
7.10 Troubleshooting…………….3908
Section 8 Hydraulic System…………….3909
8.1 Hydraulic Component Terminology…………….3911
8.1.1 3006H, 30.6…………….3911
8.1.2 3507PS, 4008PS, 35.7, 40.8…………….3912
8.1.3 3510PS, 35.10…………….3913
8.2 Safety Information…………….3914
8.3 Specifications…………….3914
8.4 Hydraulic Pressure Diagnosis…………….3915
8.4.1 Pressure Checks and Adjustments…………….3915
8.5 Hydraulic Circuits…………….3915
8.5.1 Hydraulic Pressures…………….3915
8.6 Hydraulic Schematic…………….3919
8.6.1 3006H, 30.6…………….3919
8.6.2 3507PS, 4008PS, 35.7, 40.8…………….3921
8.6.3 3510PS, 35.10…………….3923
8.7 Hydraulic Reservoir…………….3925
8.7.1 Hydraulic Oil Reservoir Draining…………….3925
8.7.2 Hydraulic Oil Reservoir Filling…………….3926
8.7.3 Hydraulic Filter Replacement…………….3926
8.7.4 Hydraulic Oil Reservoir Removal/ Installation…………….3927
8.8 Implement Pump…………….3929
8.8.1 Pump Replacement…………….3929
8.9 Front Drive Motor – 3006H, 30.6…………….3931
8.10 Control Valves…………….3931
8.10.1 Main Control Valve…………….3931
8.10.2 Priority Valve – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3933
8.10.3 Service Brake Valve…………….3934
8.10.4 Service Brake Bleeding…………….3936
8.10.5 Service Brake Test…………….3939
8.10.6 Park Brake Bleeding (if equipped with Hydraulic Park Brake)…………….3939
8.10.7 Steering Orbital Valve…………….3940
8.10.8 Steer Select Valve…………….3940
8.10.9 Inching Valve – 3006H, 30.6…………….3941
8.11 Boom Ride Control…………….3943
8.11.1 General Accumulator Information…………….3943
8.11.2 Accumulators…………….3944
8.11.3 Pre-Charging Accumulator…………….3944
8.11.4 Checking Pre-Charge…………….3945
8.12 Hydraulic Cylinders…………….3946
8.12.1 General Cylinder Removal Instructions…………….3946
8.12.2 Cylinder Pressure Checking…………….3948
8.12.3 Steering Cylinders…………….3948
8.12.4 Extend/Retract Cylinder Bleeding Procedure – 3510PS, 35.10…………….3948
8.12.5 Cylinder Torque Specifications…………….3949
Section 9 Electrical System…………….3951
9.1 Electrical Component Terminology…………….3954
9.1.1 General Overview…………….3954
9.2 Specifications…………….3956
9.3 Safety Information…………….3956
9.4 Power Distribution Boards…………….3957
9.4.1 Cab Power Distribution Board…………….3957
9.4.2 Frame Power Distribution Board…………….3961
9.4.3 Option 1 Distribution Board…………….3963
9.4.4 Option 2 Distribution Board…………….3965
9.4.5 Engine Harness Fuses and Relays…………….3968
9.5 Electrical System Schematics…………….3971
9.5.1 3006H, 30.6…………….3971
9.5.2 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….3979
9.6 Dielectric Grease Application…………….3988
9.6.1 Installation…………….3988
9.6.2 Exclusions…………….3989
9.7 Engine Start Circuit…………….3991
9.7.1 Starter…………….3991
9.7.2 Charging Circuit…………….3993
9.7.3 Alternator…………….3993
9.8 Battery…………….3994
9.8.1 Battery Inspection…………….3994
9.8.2 Battery Removal/Installation…………….3994
9.8.3 Battery Disconnect/Connect…………….3995
9.9 Electrical Master Switch…………….3996
9.9.1 Electrical Master Switch Removal…………….3996
9.9.2 Electrical Master Switch Installation…………….3996
9.10 Window Wiper System (if equipped)…………….3997
9.10.1 Front Windshield Wiper Motor…………….3997
9.10.2 Rear Window Wiper Motor…………….3998
9.10.3 Roof Window Wiper Motor…………….3999
9.10.4 Washer Fluid Reservoir…………….4000
9.11 Cab Heater and A/C (if equipped)…………….4001
9.11.1 Cab Heater/Air Conditioning Controls…………….4001
9.12 Solenoids, Sensors and Senders…………….4002
9.12.1 Transmission Solenoid Valves – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….4002
9.12.2 Transmission Oil Temperature Switch…………….4002
9.12.3 Transmission Mounted Speed Sensor – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….4003
9.12.4 Engine Coolant Temperature Sensor…………….4003
9.12.5 Fuel Level Sender…………….4004
9.12.6 Boom Angle Sensor…………….4004
9.12.7 Back-up Alarm…………….4005
9.12.8 Boom Retract Sensor…………….4006
9.13 Dash Switches…………….4007
9.13.1 Ignition Key Switch…………….4007
9.13.2 Dash Switches…………….4008
9.14 Machine Data…………….4009
9.14.1 Machine Data Access…………….4009
9.14.2 Analyzer…………….4010
9.14.3 Analyzer Software Version P.2.0…………….4011
9.15 Analyzer Software Accessibility…………….4013
9.15.1 Access Level…………….4013
9.15.2 Diagnostics…………….4013
9.15.3 Machine Set-Up…………….4014
9.15.4 Personalities…………….4016
9.15.5 Operator Tools…………….4021
9.15.6 Calibrations…………….4023
9.16 Multifunction Display…………….4025
9.16.1 Technical Specification…………….4025
9.16.2 Removal…………….4026
9.16.3 Installation…………….4027
9.16.4 Multifunction Display and Control Buttons…………….4027
9.16.5 Main Menu…………….4028
9.16.6 Setup and Maintenance…………….4047
9.16.7 Troubleshooting…………….4049
9.17 Load Stability Indicator (LSI)…………….4050
9.17.1 Load Stability Indicator…………….4050
9.17.2 LSI Sensor…………….4050
9.17.3 LSI System Calibration…………….4053
9.18 Fault Codes…………….4054
9.19 Machine Fault Codes…………….4055
9.19.1 Help Comment (00X)…………….4055
9.19.2 Power Up (21X)…………….4056
9.19.3 Platform Controls (22X0)…………….4060
9.19.4 Cabin Controls (23X)…………….4062
9.19.5 Function Prevented (25X)…………….4072
9.19.6 Line Contactor Open-Circuit (31x)…………….4074
9.19.7 Line Contactor Short-Circuit (32x)…………….4075
9.19.8 Output Drivers (33X)…………….4076
9.19.9 Engine (43X)…………….4098
9.19.10 Battery Supply (44X)…………….4102
9.19.11 Transmission and Drive System (46X)…………….4103
9.19.12 Communications (66X)…………….4125
9.19.13 Envelope Control (84x)…………….4127
9.19.14 Tilt Sensor (81x)…………….4128
9.19.15 Load Moment (85X)…………….4129
9.19.16 Steering (86x)…………….4134
9.19.17 Service Required (87x)…………….4135
9.19.18 Hardware (99X)…………….4136
9.20 Hystat Fault Codes (3006H, 30.6)…………….4141
9.20.1 Power On…………….4141
9.20.2 Custom Condition For Power On…………….4141
9.20.3 ECU Monitor…………….4142
9.20.4 ECU Health…………….4142
9.20.5 Debug Functionally…………….4142
9.20.6 Trigger For Two Step Error Reactions…………….4143
9.20.7 Report Active Error Reactions…………….4143
9.20.8 Report Active Protections…………….4143
9.20.9 Pedals And Potis (AgSnsr)…………….4144
9.20.10 Switches With Multiple States…………….4144
9.20.11 Switches With Two States (SwtBtn)…………….4144
9.20.12 Joysticks…………….4144
9.20.13 Driver On Board…………….4145
9.20.14 Parking Brake Sensors…………….4145
9.20.15 Engine Sensors…………….4145
9.20.16 Pump Sensors…………….4145
9.20.17 Speed Signals…………….4145
9.20.18 Gearbox Sensors…………….4146
9.20.19 Motor Sensors…………….4146
9.20.20 Lamps…………….4146
9.20.21 Parking Brake Actuators…………….4146
9.20.22 Diesel Engine Actuators…………….4147
9.20.23 Pump Actuators…………….4147
9.20.24 Motors Actuators…………….4147
9.20.25 Motors Actuators…………….4147
9.20.26 CAN Bus…………….4148
9.20.27 J1939 Receive Messages…………….4148
9.21 Engine Diagnostic…………….4149
33.7_37.6_37.7…………….4173
31200722 – Illustrated Parts Manual Models 3706PS, 3707PS, 4014PS, 4017PS & Agrovector 33.7, 37.6, 37.7…………….4174
31200722_M_3706PS_3707PS_4014PS_4017PS & Agrovector 33.7_37.6 & 37.7_JLG_Parts…………….4174
Effectivity Page…………….4176
General Information…………….4177
Table of Contents…………….4180
SECTION 1 – FRAME AND ATTACHING PARTS…………….4186
FIGURE 1-1. FRAME AND ATTACHING PARTS…………….4187
FIGURE 1-2. COVERS…………….4195
FIGURE 1-3. OUTRIGGERS – 4014PS & 4017PS…………….4199
FIGURE 1-4. LICENSE PLATE INSTALLATION – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4201
FIGURE 1-5. RETRIEVAL HITCH…………….4205
FIGURE 1-6. PIN HITCH, AUTO HITCH AND PITON FRAME – AUTO HITCH – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4207
FIGURE 1-7. PIN HITCH – CUNA C AND CUNA D2 – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4209
FIGURE 1-8. HYDRAULIC HITCH – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4211
FIGURE 1-9. PIN HITCH – FIXED POSITION CEE 12T – 33.7…………….4213
SECTION 2 – BOOM…………….4216
FIGURE 2-1. BOOM INSTALLATION – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4217
FIGURE 2-2. BOOM INSTALLATION – 4014PS…………….4221
FIGURE 2-3. BOOM INSTALLATION – 4017PS…………….4223
FIGURE 2-4. FIRST BOOM SECTION – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4227
FIGURE 2-5. FIRST BOOM SECTION – 4014PS…………….4229
FIGURE 2-6. FIRST BOOM SECTION – 4017PS…………….4231
FIGURE 2-7. SECOND BOOM SECTION – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4233
FIGURE 2-8. SECOND BOOM SECTION – 4014PS…………….4235
FIGURE 2-9. SECOND BOOM SECTION – 4017PS…………….4237
FIGURE 2-10. THIRD BOOM SECTION – 4014PS…………….4239
FIGURE 2-11. THIRD BOOM SECTION – 4017PS…………….4241
FIGURE 2-12. FOURTH BOOM SECTION – 4017PS…………….4243
FIGURE 2-13. EXTEND CHAINS – 4014PS…………….4245
FIGURE 2-14. EXTEND CHAINS – 4017PS…………….4247
FIGURE 2-15. RETRACT CHAINS – 4014PS…………….4249
FIGURE 2-16. RETRACT CHAINS – 4017PS…………….4251
FIGURE 2-17. MANUAL QUICK ATTACH…………….4253
FIGURE 2-18. MANUAL QUICK ATTACH – 4014PS & 4017PS…………….4255
FIGURE 2-19. HYDRAULIC QUICK ATTACH – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4257
FIGURE 2-20. HYDRAULIC QUICK ATTACH – 4014PS & 4017PS…………….4259
FIGURE 2-21. HYDRAULIC QUICK ATTACH – 4014PS & 4017PS…………….4261
FIGURE 2-22. JD QUICK ATTACH – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4263
FIGURE 2-23. JCB MANUAL QUICK ATTACH – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4265
FIGURE 2-24. JCB HYDRAULIC QUICK ATTACH – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4267
FIGURE 2-25. MANITOU MANUAL QUICK ATTACH…………….4269
FIGURE 2-26. MANITOU HYDRAULIC QUICK ATTACH – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4271
FIGURE 2-27. MANUAL QUICK ATTACH INSTALLATION, (IF EQUIPPED WITH PLATFORM) – 4014PS & 4017PS…………….4273
SECTION 3 – ATTACHMENTS…………….4276
FIGURE 3-1. CARRIAGE ASSEMBLY…………….4277
FIGURE 3-2. SIDE SHIFT CARRIAGE ASSEMBLY…………….4279
FIGURE 3-3. FORK TINES…………….4281
FIGURE 3-4. FORK POSITIONING CARRIAGE W/FORKS…………….4283
FIGURE 3-5. FIXED PLATFORM INSTALLATION, 1.8M – 4014PS & 4017PS…………….4285
FIGURE 3-6. EXTENDABLE PLATFORM INSTALLATION, 4.5M – 4014PS & 4017PS…………….4291
FIGURE 3-7. EXTENDABLE PLATFORM INSTALLATION, 4.5M – 4014PS & 4017PS…………….4297
FIGURE 3-8. CONSOLE BOX ASSEMBLY – 4014PS & 4017PS…………….4301
FIGURE 3-9. FORK MOUNTED HOOK…………….4305
FIGURE 3-10. CRANE HOOK…………….4307
FIGURE 3-11. BUCKETS…………….4309
FIGURE 3-12. MANURE BUCKET…………….4311
FIGURE 3-13. CONCRETE BUCKET…………….4313
FIGURE 3-14. CONCRETE LADLE…………….4315
FIGURE 3-15. TRUSS BOOMS…………….4317
FIGURE 3-16. VOLVO ADAPTER…………….4319
FIGURE 3-17. FEM ADAPTER…………….4321
FIGURE 3-18. MUCK FORKS AND TOP GRAB – 37.6 & 37.7…………….4323
SECTION 4 – ENGINE AND ATTACHING PARTS…………….4326
FIGURE 4-1. ENGINE INSTALLATION…………….4327
FIGURE 4-2. DEUTZ ENGINE…………….4331
FIGURE 4-3. DEUTZ ENGINE…………….4335
FIGURE 4-4. DEUTZ ENGINE…………….4337
FIGURE 4-5. FUEL TANK AND LINES…………….4339
FIGURE 4-6. RADIATOR INSTALLATION…………….4343
FIGURE 4-7. AIR CLEANER INSTALLATION…………….4349
FIGURE 4-8. EXHAUST INSTALLATION…………….4351
FIGURE 4-9. EXHAUST INSTALLATION…………….4355
SECTION 5 – DRIVE TRAIN…………….4358
FIGURE 5-1. DRIVE TRAIN COMPONENTS…………….4359
FIGURE 5-2. FRONT AXLE ASSEMBLY…………….4363
FIGURE 5-3. FRONT AXLE – HOUSING – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4365
FIGURE 5-4. FRONT AXLE – HOUSING – 4014PS & 4017PS…………….4367
FIGURE 5-5. FRONT AXLE – SWIVEL HOUSING AND STEERING CYLINDER…………….4369
FIGURE 5-6. FRONT AXLE – BEVEL GEAR SET…………….4371
FIGURE 5-7. FRONT AXLE – DIFFERENTIAL…………….4373
FIGURE 5-8. FRONT AXLE – DOUBLE U-JOINT…………….4375
FIGURE 5-9. FRONT AXLE – BRAKES…………….4377
FIGURE 5-10. FRONT AXLE – WHEEL HUB…………….4379
FIGURE 5-11. FRONT AXLE – FINAL REDUCTION…………….4381
FIGURE 5-12. FRONT AXLE – BRAKE CALIPER…………….4383
FIGURE 5-13. REAR AXLE ASSEMBLY…………….4385
FIGURE 5-14. REAR AXLE – AXLE HOUSING…………….4387
FIGURE 5-15. REAR AXLE – SWIVEL HOUSING AND STEERING CYLINDER…………….4389
FIGURE 5-16. REAR AXLE – BEVEL GEAR SET…………….4391
FIGURE 5-17. REAR AXLE – DIFFERENTIAL…………….4393
FIGURE 5-18. REAR AXLE – DOUBLE U – JOINT…………….4395
FIGURE 5-19. REAR AXLE – WHEEL HUB…………….4397
FIGURE 5-20. REAR AXLE – FINAL REDUCTION…………….4399
FIGURE 5-21. TRANSMISSION…………….4401
FIGURE 5-22. TRANSFER GEARBOX ASSEMBLY…………….4403
FIGURE 5-23. TORQUE CONVERTER AND DRIVE…………….4405
FIGURE 5-24. GEARS AND BEARINGS…………….4407
FIGURE 5-25. 1ST/2ND CLUTCH SHAFT…………….4409
FIGURE 5-26. INPUT SHAFT…………….4411
FIGURE 5-27. FORWARD HIGH/3RD CLUTCH SHAFT…………….4413
FIGURE 5-28. ANCILLARY COMPONENTS…………….4415
FIGURE 5-29. FENDER GROUP…………….4419
FIGURE 5-30. REMOTE GREASE SYSTEM INSTALLATION…………….4421
FIGURE 5-31. TIRES AND WHEEL INSTALLATION…………….4425
FIGURE 5-32. FRONT AXLE ASSEMBLY, (4014PS) (HYDRAULIC PARK BRAKE)…………….4429
FIGURE 5-33. FRONT AXLE ASSEMBLY, (4017PS) (HYDRAULIC PARK BRAKE)…………….4443
FIGURE 5-34. REAR AXLE ASSEMBLY, (4014PS) (HYDRAULIC PARK BRAKE)…………….4457
FIGURE 5-35. REAR AXLE ASSEMBLY, (4017PS) (HYDRAULIC PARK BRAKE)…………….4471
FIGURE 5-36. STEERING ARM ASSY – 4014PS…………….4485
FIGURE 5-37. STEERING ARM ASSY – 4017PS…………….4487
FIGURE 5-38. STEERING CYLINDER – 4014PS…………….4489
FIGURE 5-39. STEERING CYLINDER – 4017PS…………….4491
FIGURE 5-40. STEERING CYLINDER – 4014PS…………….4493
FIGURE 5-41. BEVEL GEAR SET – 4014PS & 4017PS…………….4495
FIGURE 5-42. DIFFERENTIAL KIT…………….4497
FIGURE 5-43. DOUBLE JOINT – 4014PS…………….4499
FIGURE 5-44. DOUBLE JOINT – 4017PS…………….4501
FIGURE 5-45. WHEEL HUB KIT – 4014PS…………….4503
FIGURE 5-46. WHEEL HUB KIT – 4017PS…………….4505
SECTION 6 – CAB…………….4508
FIGURE 6-1. CAB INSTALLATION…………….4509
FIGURE 6-2. CAB ASSEMBLY…………….4515
FIGURE 6-3. CAB DOOR…………….4519
FIGURE 6-4. INTERIOR INSTALLATION…………….4523
FIGURE 6-5. WIPER INSTALLATIONS…………….4525
FIGURE 6-6. SEAT ASSEMBLIES…………….4529
FIGURE 6-7. HEATER INSTALLATION…………….4531
FIGURE 6-8. AIR CONDITIONING INSTALLATION…………….4535
FIGURE 6-9. CAB HYDRAULIC INSTALLATION (HYDRAULIC PARK BRAKE)…………….4541
SECTION 7 – CONTROLS…………….4544
FIGURE 7-1. BRAKE…………….4545
FIGURE 7-2. HAND BRAKE…………….4547
FIGURE 7-3. ACCELERATOR…………….4549
FIGURE 7-4. STEERING COLUMN…………….4551
FIGURE 7-5. BOOM JOYSTICK…………….4555
SECTION 8 – HYDRAULIC CIRCUITS…………….4558
FIGURE 8-1. SUPPLY CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4559
FIGURE 8-2. SUPPLY CIRCUIT – 4014PS, 4017PS & 33.7…………….4563
FIGURE 8-3. DUMP CIRCUIT – 3706PS, 33.7 & 37.6…………….4567
FIGURE 8-4. DUMP CIRCUIT – 4014PS & 4017PS…………….4573
FIGURE 8-5. STEER SELECT CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4577
FIGURE 8-6. STEER SELECT CIRCUIT – 4014PS & 4017PS…………….4579
FIGURE 8-7. SERVICE BRAKE CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4581
FIGURE 8-8. SERVICE BRAKE CIRCUIT WITH BOOM SUSPENSION – 4014PS & 4017PS…………….4583
FIGURE 8-9. LIFT CYLINDER CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4585
FIGURE 8-10. LIFT CYLINDER CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4587
FIGURE 8-11. LIFT CYLINDER CIRCUIT – 4014PS & 4017PS…………….4589
FIGURE 8-12. EXTEND/RETRACT CYLINDER CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4591
FIGURE 8-13. EXTEND/RETRACT CYLINDER CIRCUIT – 4014PS…………….4593
FIGURE 8-14. EXTEND/RETRACT CYLINDER CIRCUIT – 4017PS…………….4595
FIGURE 8-15. TILT AND TILT COMPENSATION CYLINDER CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4597
FIGURE 8-16. TILT AND TILT COMPENSATION CYLINDER CIRCUIT – 4014PS…………….4601
FIGURE 8-17. TILT AND TILT COMPENSATION CYLINDER CIRCUIT – 4017PS…………….4603
FIGURE 8-18. AUXILIARY HYDRAULIC CIRCUIT – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4607
FIGURE 8-19. AUXILIARY HYDRAULIC CIRCUIT – 4014PS…………….4611
FIGURE 8-20. AUXILIARY HYDRAULIC CIRCUIT – 4017PS…………….4613
FIGURE 8-21. FRAME LEVEL AND OUTRIGGER – 4014PS & 4017PS…………….4615
FIGURE 8-22. TRAILER BRAKES – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4617
FIGURE 8-23. TRAILER BRAKES – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4621
FIGURE 8-24. TRAILER BRAKES – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4623
FIGURE 8-25. TRAILER BRAKES – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4627
FIGURE 8-26. STEERING INSTALLATION, (HYDRAULIC PARK BRAKE) – 4014PS & 4017PS…………….4631
FIGURE 8-27. AUXILIARY VALVE GROUP INSTALLATION – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4637
SECTION 9 – HYDRAULIC COMPONENTS…………….4640
FIGURE 9-1. LIFT CYLINDER AND HARDWARE – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4641
FIGURE 9-2. LIFT CYLINDER AND HARDWARE – 4014PS…………….4643
FIGURE 9-3. LIFT CYLINDER AND HARDWARE – 4017PS…………….4645
FIGURE 9-4. EXTEND/RETRACT CYLINDER AND HARDWARE – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4647
FIGURE 9-5. EXTEND/RETRACT CYLINDER AND HARDWARE – 4014PS…………….4649
FIGURE 9-6. EXTEND/RETRACT CYLINDER AND HARDWARE – 4017PS…………….4651
FIGURE 9-7. TILT CYLINDER AND HARDWARE – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4653
FIGURE 9-8. TILT CYLINDER AND HARDWARE – 4014PS & 4017PS…………….4655
FIGURE 9-9. COMPENSATION CYLINDER AND HARDWARE – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4657
FIGURE 9-10. COMPENSATION CYLINDER AND HARDWARE – 4014PS & 4017PS…………….4659
FIGURE 9-11. FRAME LEVEL CYLINDER AND HARDWARE – 4014PS & 4017PS…………….4661
FIGURE 9-12. OUTRIGGER CYLINDER AND HARDWARE – 4014PS & 4017PS…………….4663
FIGURE 9-13. QUICK ATTACH CYLINDER…………….4665
FIGURE 9-14. MAIN CONTROL VALVE – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4667
FIGURE 9-15. MAIN CONTROL VALVE – 4014PS & 4017PS…………….4671
FIGURE 9-16. DIVERTER VALVE…………….4675
FIGURE 9-17. STEERING SELECT VALVE…………….4677
FIGURE 9-18. PISTON PUMP…………….4679
FIGURE 9-19. HYDRAULIC TANK…………….4681
FIGURE 9-20. COMBINATION VALVE…………….4683
FIGURE 9-21. TRAILER BRAKE VALVE…………….4685
FIGURE 9-22. TRAILER BRAKE VALVE…………….4687
FIGURE 9-23. DYNAMIC SELECT VALVE…………….4689
FIGURE 9-24. OUTRIGGER MAIN CONTROL VALVE…………….4691
FIGURE 9-25. ACTUATOR ASSEMBLY – 4014PS & 4017PS…………….4693
FIGURE 9-26. HYDRAULIC PARK BRAKE RELEASE VALVE…………….4695
FIGURE 9-27. RELAY VALVE INSTALLATION (HYDRAULIC PARK BRAKE)…………….4697
FIGURE 9-28. AUXILIARY POWER PUMP…………….4699
FIGURE 9-29. DIVERTER VALVE – 4014PS & 4017PS…………….4701
SECTION 10 – ELECTRICAL…………….4704
FIGURE 10-1. ENGINE COMPARTMENT ELECTRICAL INSTALLATION…………….4705
FIGURE 10-2. CAB ELECTRICAL INSTALLATION…………….4709
FIGURE 10-3. BOOM AND FRAME ELECTRICAL INSTALLATION…………….4713
FIGURE 10-4. CAB SWITCHES…………….4719
FIGURE 10-5. WORKLIGHT INSTALLATIONS…………….4721
FIGURE 10-6. DRIVING LIGHTS – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4723
FIGURE 10-7. DRIVING LIGHTS – 4014PS & 4017PS…………….4727
FIGURE 10-8. ENGINE BAY HARNESS (Prior to SN 1160006748, Excluding 11600065999)…………….4729
FIGURE 10-9. ENGINE BAY HARNESS (SN 1160006748 to Present, Including 11600065999)…………….4735
FIGURE 10-10. TRANSMISSION HARNESS…………….4739
FIGURE 10-11. CAB FLOOR HARNESS…………….4741
FIGURE 10-12. CAB ROOF HARNESS…………….4749
FIGURE 10-13. BOOM HARNESS…………….4751
FIGURE 10-14. BOOM LIGHT HARNESS…………….4753
FIGURE 10-15. FRONT FRAME HARNESS – 3706PS, 3707PS, 4014PS & 4017PS…………….4755
FIGURE 10-16. FRONT FRAME HARNESS – 33.7, 37.6 & 37.7…………….4757
FIGURE 10-17. REAR FRAME HARNESS…………….4759
FIGURE 10-18. RIDE AND FLOAT CHASSIS SIDE HARNESS – 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….4761
FIGURE 10-19. RIDE AND FLOAT CAB HARNESS…………….4763
FIGURE 10-20. RIDE AND FLOAT CONTROLLER HARNESS…………….4765
FIGURE 10-21. TOW HITCH HARNESS…………….4767
FIGURE 10-22. TRAILER BRAKE CAB HARNESS, ITALIAN…………….4769
FIGURE 10-23. TRAILER BRAKE CHASSIS HARNESS, ITALIAN…………….4771
FIGURE 10-24. A/C HARNESS…………….4773
FIGURE 10-25. BOOM EXTENSION HARNESS – 4017PS…………….4775
FIGURE 10-26. HEADLIGHT EXTENSION HARNESS…………….4777
FIGURE 10-27. LIGHT EXTENSION HARNESS…………….4779
FIGURE 10-28. WORKLIGHT HARNESS…………….4781
FIGURE 10-29. CAB AUXILIARY POWER HARNESS…………….4783
FIGURE 10-30. PLATFORM BOOM HARNESS – 4014PS…………….4785
FIGURE 10-31. PLATFORM BOOM HARNESS – 4017PS…………….4787
FIGURE 10-32. DUAL SEAT SWITCH HARNESS…………….4789
FIGURE 10-33. BEACON LMIS INSTALLATION – 4014PS & 4017PS…………….4791
FIGURE 10-34. LMIS INSTALLATION – 4014PS & 4017PS…………….4793
FIGURE 10-35. LMIS CAB HARNESS…………….4795
FIGURE 10-36. LMIS FRAME HARNESS…………….4797
FIGURE 10-37. PLATFORM SENSOR INSTALLATION…………….4799
FIGURE 10-38. PLATFORM RECOGNITION INSTALLATION…………….4801
FIGURE 10-39. AUXILIARY POWER UNIT INSTALLATION – 4014PS & 4017PS…………….4803
FIGURE 10-40. BOOM AUXILIARY ELECTRICAL HARNESS INSTALLATION…………….4807
FIGURE 10-41. PLATFORM ELECTRICAL INSTALLATION…………….4809
FIGURE 10-42. SOLENOID ASSEMBLY…………….4811
FIGURE 10-43. CAB TO BOOM HARNESS…………….4813
FIGURE 10-44. PLATFORM HARNESS…………….4815
FIGURE 10-45. PLATFORM RELAY BOX HARNESS…………….4817
FIGURE 10-46. EMERGENCY STOP LINK HARNESS…………….4819
FIGURE 10-47. BOOM EXTENSION LIMIT HARNESS…………….4821
FIGURE 10-48. AUXILIARY PLATFORM HARNESS…………….4823
FIGURE 10-49. 3B PLATFORM HARNESS…………….4825
SECTION 11 – DECALS…………….4828
FIGURE 11-1. CAB AND FRAME DECALS…………….4829
FIGURE 11-2. BOOM DECALS…………….4839
FIGURE 11-3. CAPACITY CHART – VOLVO ADAPTER…………….4843
FIGURE 11-4. CAPACITY CHART – FEM ADAPTER…………….4845
FIGURE 11-5. CAPACITY CHART – MUCK FORKS AND TOP GRAB – 37.6 & 37.7…………….4847
SECTION 12 – RECOMMENDED SPARE PARTS…………….4850
FIGURE 12-1. RECOMMENDED SPARE PARTS…………….4851
PART NUMBER INDEX…………….4854
31200755 – Operation & Safety Manual Agrovector 33.7, 37.6 & 37.7…………….4874
31200755_C_33.7, 37.6, 37.7_Deutz-Fahr_O&SM…………….4874
Revision Log…………….4876
Read This First…………….4877
Table of Contents…………….4880
Section 1 – General Safety Practices…………….4884
1.1 Hazard Classification System…………….4884
Safety Alert System and Safety Signal Words…………….4884
1.2 General Precautions…………….4884
1.3 Operation Safety…………….4885
Electrical Hazards…………….4885
Tip Over Hazard…………….4886
Travel Hazard…………….4889
Load Falling Hazard…………….4890
Lifting Personnel…………….4891
Driving Hazards on Slopes…………….4892
Pinch Points and Crush Hazards…………….4893
Fall Hazard…………….4895
Chemical Hazards…………….4896
Section 2 – Pre-Operation and Inspection…………….4898
2.1 Pre-Operation Check and Inspection…………….4898
2.2 Safety Decals…………….4900
2.3 Walk-Around Inspection…………….4903
2.4 Warm-Up and Operational Checks…………….4905
Warm-Up Check…………….4905
Operational Check…………….4905
2.5 Operator Cab…………….4906
2.6 Windows…………….4907
Cab Door Window…………….4907
Rear Window…………….4908
Section 3 – Controls and Indicators…………….4910
3.1 General…………….4910
3.2 Controls…………….4911
Instrument Panel…………….4913
Display Screen…………….4915
Keypad…………….4917
Ignition…………….4919
Park Brake…………….4920
Parking Procedure…………….4920
Transmission Control Lever (if equipped)…………….4921
Load Stability Indicator – LSI…………….4923
Steering Column Adjuster…………….4925
Joystick…………….4927
Front Console Switches…………….4931
Right Console Switches…………….4932
Accessory Control Lever…………….4933
Reversing Fan (if equipped)…………….4934
3.3 Anti Theft…………….4935
3.4 Steer Modes…………….4936
Manual Steering Alignment Mode Change…………….4936
All Wheel Assisted Steering Alignment Mode Change…………….4937
3.5 Operator Seat…………….4938
Operator Presence…………….4938
Adjustments…………….4939
Seat Belt…………….4941
3.6 Boom Indicators…………….4942
Boom Extension…………….4942
Section 4 – Operation…………….4944
4.1 Engine…………….4944
Starting the Engine…………….4944
Battery Boosted Starting…………….4945
Normal Engine Operation…………….4946
Shut-Down Procedure…………….4946
4.2 Operating with a Non-Suspended Load…………….4947
Lift Load Safely…………….4947
Picking Up a Load…………….4947
Transporting a Load…………….4948
Leveling Procedure…………….4948
Placing a Load…………….4949
Disengaging a Load…………….4949
4.3 Operating with a Suspended Load…………….4950
Lift Load Safely…………….4950
Picking Up a Suspended Load…………….4950
Transporting a Suspended Load…………….4951
Leveling Procedure…………….4951
Placing a Suspended Load…………….4952
Disengaging a Suspended Load…………….4952
4.4 Road Operation (CE)…………….4953
4.5 Loading and Securing for Transport…………….4954
Tiedown…………….4954
Lifting…………….4955
Section 5 – Attachments and Hitches…………….4956
5.1 Approved Attachments…………….4956
5.2 Unapproved Attachments…………….4956
5.3 JLG Supplied Attachments…………….4957
Standard Quick Attach…………….4957
5.4 Telehandler/Attachment/Fork Capacity…………….4959
5.5 Use of the Capacity Chart…………….4960
Capacity Indicator Locations…………….4960
Sample Capacity Chart (CE)…………….4961
Example…………….4962
5.6 Attachment Installation…………….4964
Quick Attach…………….4964
JD Quick Attach…………….4967
Manitou Quick Attach…………….4969
JCB Quick Attach…………….4972
Hydraulic Operated Attachment…………….4975
5.7 Adjusting/Moving Forks…………….4976
5.8 Attachment Operation…………….4977
Carriage w/Forks…………….4978
Side Shift Carriage…………….4979
Fork Rotator Carriage…………….4981
Fork Positioning Carriage…………….4983
Fork Extension…………….4985
Fork Mounted Hook…………….4987
Bucket…………….4989
Multi-Purpose Bucket…………….4991
Grapple Bucket…………….4993
Concrete Bucket Mixer…………….4995
Concrete Bucket – Fork Mounted…………….4997
Quick Attach Mounted Hook…………….4999
Truss Boom…………….5000
5.9 Hitches and Trailer Brakes…………….5001
Retrieval Hitch…………….5001
Pin Hitch – CUNA C (Italy)…………….5002
Pin Hitch – CUNA D2 (Italy)…………….5003
EEC Manual Pin Hitch…………….5004
EEC Auto Hitch…………….5005
Piton Frame and EEC Auto Hitch…………….5006
Hydraulic Hitch…………….5007
Trailer Brakes…………….5008
Section 6 – Emergency Procedures…………….5010
6.1 Towing a Disabled Product…………….5010
Moving Short Distances…………….5010
Moving Longer Distance…………….5010
6.2 Emergency Lowering of Boom…………….5011
6.3 Cab Emergency Exit…………….5011
Section 7 – Lubrication and Maintenance…………….5012
7.1 Introduction…………….5012
Clothing and Safety Gear…………….5012
7.2 General Maintenance Instructions…………….5013
7.3 Service and Maintenance Schedules…………….5014
10 & 1st 50 Hour Maintenance Schedule…………….5014
50 & 1st 250 Hour Maintenance Schedule…………….5015
250 & 500 Hour Maintenance Schedule…………….5016
1000, 1500 & 3000 Hour Maintenance Schedule…………….5017
7.4 Lubrication Schedules…………….5019
50 Hour Lubrication Schedule…………….5019
500 Hour Lubrication Schedule…………….5020
7.5 Operator Maintenance Instructions…………….5021
Fuel System…………….5021
Cab Air Filters (if equipped)…………….5023
Tires…………….5025
Engine Oil…………….5027
Engine Cooling System…………….5028
Hydraulic Oil…………….5029
Transmission Oil…………….5030
Air Intake System…………….5031
Battery…………….5033
Windshield Washer System (if equipped)…………….5034
Section 8 – Additional Checks…………….5036
8.1 General…………….5036
8.2 Load Stability Indicator System…………….5036
Section 9 – Specifications…………….5038
9.1 Product Specifications…………….5038
Fluids and Capacities…………….5038
Tires…………….5039
Performance…………….5040
Dimensions…………….5041
Declaration of Vibration…………….5043
Noise Emission…………….5043
Machine Towing Capacity…………….5044
Index…………….5046
Inspection, Maintenance and Repair Log…………….5050
31200800 – Service Manual Models 3706PS, 3707PS, 4014PS, 4017PS & Agrovector 33.7, 37.6, 37.7…………….5056
31200800_F_3706PS 3707PS 4014PS 4017PS 33.7 37.6 37.7_JLG_Service…………….5056
Effectivity Page…………….5058
2.1 Replacement Parts and Warranty Information 2-2…………….5060
2.2 Specifications 2-3…………….5060
2.3 Fluids, Lubricants and Capacities 2-7…………….5060
2.4 Service and Maintenance Schedules 2-10…………….5060
2.5 Lubrication Schedule 2-14…………….5060
2.6 Thread Locking Compound 2-19…………….5060
2.7 Torque Charts 2-20…………….5060
2.8 Hydraulic Connection Assembly and Torque Specification 2-30…………….5060
Table of Contents…………….5060
3.1 Boom System Component Terminology – 3706PS, 3707PS, 33.7, 36.6 & 37.7 3-3…………….5060
3.2 Boom System – Two Section 3-4…………….5060
3.3 Boom Assembly Maintenance 3-4…………….5060
3.4 Boom System Component Terminology – 4014PS 3-10…………….5060
3.5 Boom System – Three Section 3-11…………….5060
3.6 Boom Assembly Maintenance 3-11…………….5060
3.7 Boom Chain Removal/Installation 3-17…………….5060
3.8 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/Installation 3-19…………….5060
3.9 Extend/Retract Cylinder Removal/Installation 3-20…………….5060
3.10 Boom Sections Adjustment 3-21…………….5060
3.11 Boom System Component Terminology – 4017PS 3-22…………….5060
3.12 Boom System – Four Section Boom 3-23…………….5060
3.13 Boom Assembly Maintenance 3-23…………….5060
3.14 Boom Chain Removal/Installation 3-31…………….5060
3.15 Boom Sections Adjustment 3-32…………….5060
3.16 Boom Extend and Retract Chains – 4014PS & 4017PS 3-33…………….5060
3.17 Boom Wear Pads 3-38…………….5060
3.18 Quick Coupler 3-39…………….5060
3.19 Forks 3-40…………….5060
3.20 Boom Prop (If Equipped) 3-40…………….5060
3.21 Emergency Boom Lowering Procedure 3-41…………….5060
3.22 Troubleshooting 3-43…………….5060
Section 1 Safety Practices…………….5064
1.1 Introduction…………….5065
1.2 Disclaimer…………….5065
1.3 Operation & Safety Manual…………….5065
1.4 Do Not Operate Tags…………….5065
1.5 Safety Information…………….5065
1.6 Safety Alert System and Signal Words…………….5065
1.7 Safety Instructions…………….5066
1.7.1 Personal Hazards…………….5066
1.7.2 Equipment Hazards…………….5066
1.7.3 General Hazards…………….5066
1.7.4 Operational Hazards…………….5067
1.8 Safety Decals…………….5067
Section 2 General Information and Specifications…………….5068
2.1 Replacement Parts and Warranty Information…………….5069
2.2 Specifications…………….5070
2.2.1 Travel Speeds…………….5070
2.2.2 Hydraulic Cylinder Performance…………….5070
2.2.3 Platform Hydraulic Performance Specifications…………….5070
2.2.4 Electrical System…………….5071
2.2.5 Engine Fan Speed…………….5071
2.2.6 Engine Performance Specifications…………….5071
2.2.7 Transmission Performance Specifications…………….5071
2.2.8 Tires…………….5072
2.3 Fluids, Lubricants and Capacities…………….5074
2.3.1 3706PS, 3707PS, 4014PS & 4017PS…………….5074
2.3.2 33.7, 37.6 & 37.7…………….5075
2.4 Service and Maintenance Schedules…………….5077
2.4.1 10 & 1st 50 Hour…………….5077
2.4.2 50 & 1st 250 Hour…………….5078
2.4.3 250 & 500 Hour…………….5079
2.4.4 1000, 1500 & 3000 Hour…………….5080
2.5 Lubrication Schedule…………….5081
2.5.1 50 Hour Lubrication Schedule…………….5081
2.5.2 500 Hour Lubrication Schedule…………….5084
2.6 Thread Locking Compound…………….5086
2.7 Torque Charts…………….5087
2.7.1 SAE Fastener Torque Chart…………….5087
2.7.2 Metric Fastener Torque Chart…………….5093
2.8 Hydraulic Connection Assembly and Torque Specification…………….5097
2.8.1 Assembly Instructions for American Standard Pipe Thread Tapered Connections…………….5100
2.8.2 Assembly Instructions for British Standard Pipe Thread Tapered Connections…………….5101
2.8.3 Assembly Instructions for 37° (JIC) Flare Fittings…………….5102
2.8.4 Assembly Instructions for 45° SAE Flare Fittings…………….5104
2.8.5 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings…………….5106
2.8.6 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)…………….5108
2.8.7 Assembly Instructions for Bulkhead (BH) Fittings…………….5110
2.8.8 Assembly Instructions for O-Ring Boss (ORB) Fittings…………….5113
2.8.9 Assembly Instructions for Adjustable Port End Metric Fittings…………….5120
2.8.10 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends…………….5127
2.8.11 Assembly instructions for Adjustable Port End (BSPP) Fittings…………….5129
2.8.12 Assembly Instructions for Flange Connections: (FL61 and FL62)…………….5136
Section 3 Boom…………….5144
3.1 Boom System Component Terminology – 3706PS, 3707PS, 33.7, 36.6 & 37.7…………….5146
3.2 Boom System – Two Section…………….5147
3.2.1 Boom System Operation…………….5147
3.3 Boom Assembly Maintenance…………….5147
3.3.1 Complete Boom Removal…………….5147
3.3.2 Complete Boom Installation…………….5148
3.3.3 Second Section Boom Removal…………….5149
3.3.4 First Boom Section Removal…………….5149
3.3.5 Extend/Retract Cylinder Removal…………….5150
3.3.6 Extend/Retract Cylinder Installation…………….5151
3.3.7 First Boom Section Installation…………….5151
3.3.8 Second Boom Section Installation…………….5152
3.4 Boom System Component Terminology – 4014PS…………….5153
3.5 Boom System – Three Section…………….5154
3.5.1 Boom System Operation…………….5154
3.6 Boom Assembly Maintenance…………….5154
3.6.1 Boom Removal…………….5155
3.6.2 Second and Third Boom Section Removal…………….5155
3.6.3 Third Boom Section and Extend/ Retract Cylinder Removal…………….5156
3.6.4 Third Boom Section and Extend/ Retract Cylinder Installation…………….5157
3.6.5 Second and Third Boom Section Installation…………….5158
3.6.6 Complete Boom Installation…………….5160
3.7 Boom Chain Removal/ Installation…………….5160
3.7.1 Retract Chain Removal…………….5160
3.7.2 Retract Chain Installation…………….5161
3.7.3 Extend Chain Removal…………….5161
3.7.4 Extend Chain Installation…………….5162
3.8 Extend/Retract, Tilt and Auxiliary Circuit Hose Removal/Installation…………….5162
3.8.1 Extend/Retract Hose Removal…………….5162
3.8.2 Extend/Retract Hose Installation…………….5162
3.8.3 Tilt/Auxiliary Hose Removal…………….5162
3.8.4 Tilt/Auxiliary Hose Installation…………….5163
3.9 Extend/Retract Cylinder Removal/Installation…………….5163
3.9.1 Extend/Retract Cylinder Removal…………….5163
3.9.2 Extend/Retract Cylinder Installation…………….5163
3.10 Boom Sections Adjustment…………….5164
3.10.1 Chain Adjustments…………….5164
3.11 Boom System Component Terminology – 4017PS…………….5165
3.12 Boom System – Four Section Boom…………….5166
3.12.1 Boom System Operation…………….5166
3.13 Boom Assembly Maintenance…………….5166
3.13.1 Boom Removal…………….5166
3.13.2 Second, Third and Fourth Boom Section Removal…………….5167
3.13.3 Third and Fourth Boom Section Removal…………….5168
3.13.4 Fourth Boom Section Removal…………….5169
3.13.5 Hose Carrier Removal…………….5169
3.13.6 Hose Carrier Installation…………….5169
3.13.7 Fourth Boom Section Installation…………….5170
3.13.8 Third and Fourth Boom Section Installation…………….5170
3.13.9 Second, Third and Fourth Boom Section Installation…………….5171
3.13.10 Complete Boom Installation…………….5174
3.14 Boom Chain Removal/ Installation…………….5174
3.15 Boom Sections Adjustment…………….5175
3.15.1 Chain Adjustments…………….5175
3.16 Boom Extend and Retract Chains – 4014PS & 4017PS…………….5176
3.16.1 Boom Chain Inspection…………….5176
3.16.2 Inspection Guidelines – 4014PS…………….5177
3.16.3 Inspection Guidelines – 4017…………….5178
3.16.4 Expose Chains for Inspection…………….5180
3.16.5 Chain Lubrication…………….5180
3.17 Boom Wear Pads…………….5181
3.17.1 Wear Pad Inspection…………….5181
3.17.2 Boom Wear Pad Installation/ Lubrication…………….5181
3.18 Quick Coupler…………….5182
3.18.1 Quick Coupler Removal (3706PS, 3707PS, 33.7, 37.6 & 37.7)…………….5182
3.18.2 Quick Coupler Installation (3706PS, 3707PS, 33.7, 37.6 & 37.7)…………….5182
3.18.3 Quick Coupler Removal (4014PS & 4017PS)…………….5182
3.18.4 Quick Coupler Installation (4014PS & 4017PS)…………….5182
3.19 Forks…………….5183
3.20 Boom Prop (If Equipped)…………….5183
3.20.1 Installation and Removal Procedures…………….5183
3.21 Emergency Boom Lowering Procedure…………….5184
3.21.1 Equipment and Supplies Required…………….5184
3.21.2 Lowering Procedure…………….5185
3.22 Troubleshooting…………….5186
Section 4 Cab and Covers…………….5190
4.1 Operator Cab and Covers Component Terminology…………….5191
4.2 Operator Cab…………….5192
4.2.1 Operator Cab Safety…………….5192
4.2.2 Serial Number Plate…………….5192
4.3 Cab Components…………….5192
4.3.1 Steering Wheel…………….5192
4.3.2 Steering Column/Orbitrol Valve…………….5193
4.3.3 Service Brake…………….5193
4.3.4 Electronic Throttle Pedal…………….5194
4.3.5 Joystick Assembly…………….5195
4.3.6 Window Wiper Assembly…………….5196
4.3.7 Heater/Air Conditioning System (if Equipped)…………….5196
4.3.8 Cab Heater/Air Conditioning Controls…………….5197
4.3.9 Air Conditioning (if Equipped)…………….5198
4.4 Cab Removal…………….5198
4.5 Cab Installation…………….5200
Section 5 Axles, Drive Shafts, Wheels and Tires…………….5202
5.1 Axle, Drive Shaft and Wheel Component Terminology…………….5203
5.2 Axle Serial Number…………….5204
5.3 Axle Specifications and Maintenance Information…………….5204
5.4 Axle Replacement…………….5204
5.4.1 Axle Removal…………….5204
5.4.2 Axle Installation…………….5205
5.5 Mechanical Park Brake…………….5206
5.5.1 Mechanical Park Brake Removal…………….5206
5.5.2 Mechanical Park Brake Installation…………….5207
5.5.3 Mechanical Park Brake Adjustment…………….5207
5.6 Hydraulic Park Brake…………….5207
5.6.1 Park Brake Test…………….5208
5.7 Brake Inspection…………….5209
5.8 Steering Angle Adjustment…………….5209
5.9 Axle Assembly and Drive Shaft Troubleshooting…………….5210
5.10 Drive Shafts…………….5213
5.10.1 Drive Shaft Inspection…………….5213
5.10.2 Drive Shaft Maintenance…………….5213
5.10.3 Drive Shaft Removal…………….5213
5.10.4 Drive Shaft Cleaning and Drying…………….5213
5.10.5 Drive Shaft Installation…………….5213
5.11 Wheels and Tires…………….5214
5.11.1 Removing Wheel and Tire Assembly from Machine…………….5214
5.11.2 Installing Wheel and Tire Assembly onto Machine…………….5214
5.12 Towing a Disabled Machine…………….5215
Section 6 Transmission…………….5216
6.1 Transmission Assembly Component Terminology…………….5217
6.2 Transmission Serial Number…………….5218
6.3 Specifications and Maintenance Information…………….5218
6.4 Transmission Replacement…………….5218
6.4.1 Transmission Removal…………….5218
6.4.2 Transmission Installation…………….5219
6.4.3 After Transmission Service or Replacement…………….5220
6.4.4 Transmission Torque Converter Stall Test…………….5220
6.5 Torque Convertor Diaphragm…………….5220
6.5.1 Torque Convertor Diaphragm Removal/Installation…………….5220
6.6 Troubleshooting…………….5220
Section 7 Engine…………….5222
7.1 Introduction…………….5223
7.1.1 Disclaimer and Scope…………….5223
7.2 Engine Serial Number…………….5223
7.3 Specifications and Maintenance Information…………….5223
7.3.1 Component Terminology…………….5224
7.4 Engine Cooling System…………….5225
7.4.1 Surge Tank Cap…………….5225
7.4.2 Thermostat Replacement…………….5225
7.4.3 Radiator Assembly Replacement…………….5226
7.5 Engine Electrical System…………….5228
7.6 Fuel System…………….5228
7.6.1 Diesel Fuel…………….5228
7.6.2 Fuel Tank…………….5228
7.6.3 After Fuel System Service…………….5229
7.7 Engine Exhaust System…………….5230
7.7.1 Exhaust System Removal—ULS…………….5230
7.7.2 Exhaust System Installation—ULS…………….5230
7.7.3 Exhaust System Removal—LS…………….5231
7.7.4 Exhaust System Installation—LS…………….5232
7.8 Air Cleaner Assembly…………….5233
7.8.1 Air Cleaner Assembly Removal…………….5233
7.8.2 Air Cleaner Assembly Installation…………….5233
7.9 Engine Replacement…………….5234
7.9.1 Engine/Transmission Removal…………….5234
7.9.2 Transmission Removal/Installation…………….5235
7.9.3 Engine Disassembly, Inspection and Service…………….5235
7.9.4 Engine/Transmission Installation…………….5235
7.10 Troubleshooting…………….5236
Section 8 Hydraulic System…………….5238
8.1 Hydraulic Component Terminology…………….5239
8.2 Safety Information…………….5240
8.3 Specifications…………….5240
8.4 Hydraulic Pressure Diagnosis…………….5240
8.4.1 Pressure Checks and Adjustments…………….5240
8.5 Hydraulic Circuits…………….5241
8.5.1 Hydraulic Pressures…………….5241
8.6 Hydraulic Schematics…………….5243
8.6.1 3706PS, 3707PS, 33.7, 37.6 & 37.7…………….5243
8.6.2 4014PS & 4017PS…………….5246
8.7 Hydraulic Reservoir…………….5248
8.7.1 Hydraulic Oil Reservoir Draining…………….5248
8.7.2 Hydraulic Oil Reservoir Filling…………….5248
8.7.3 Hydraulic Oil Reservoir Removal/ Installation…………….5248
8.8 Engine Implement Pump…………….5250
8.8.1 Pump Replacement…………….5250
8.9 Auxiliary Pump (Platform Equipped Models Only)…………….5251
8.9.1 Auxiliary Pump Description…………….5251
8.9.2 Auxiliary Pump Replacement…………….5251
8.10 Control Valves…………….5251
8.10.1 Main Control Valve…………….5251
8.10.2 Reversing Fan Valve…………….5253
8.10.3 Service Brake Valve…………….5254
8.10.4 Service Brake Bleeding…………….5255
8.10.5 Service Brake Test…………….5255
8.10.6 Steering Orbitrol Valve…………….5255
8.10.7 Steer Select Valve…………….5256
8.11 Hydraulic Cylinders…………….5257
8.11.1 General Cylinder Removal Instructions…………….5257
8.11.2 Cylinder Pressure Checking…………….5259
8.11.3 Steering Cylinders…………….5259
8.11.4 Cylinder Torque Specifications…………….5260
8.12 Boom Ride Control (3706PS, 3707PS, 33.7, 37.6 & 37.7 – If Equipped)…………….5261
8.12.1 General Accumulator Information…………….5261
8.12.2 Accumulators…………….5262
8.12.3 Pre-Charging Accumulator…………….5262
8.12.4 Checking Pre-Charge…………….5263
Section 9 Electrical System…………….5264
9.1 Electrical Component Terminology…………….5266
9.1.1 General Overview…………….5266
9.2 Specifications…………….5267
9.3 Safety Information…………….5267
9.4 Keypad and Display Screen…………….5267
9.4.1 Keypad…………….5267
9.4.2 Display Screen…………….5267
9.5 Software Level 2 Accessibility…………….5268
9.5.1 Operator Tools…………….5268
9.5.2 Personalities…………….5270
9.5.3 Calibration…………….5271
9.6 Operator Tools…………….5274
9.6.1 Resetting the Anti theft Code…………….5274
9.6.2 Hardware Exchange…………….5274
9.6.3 Confirm Machine Service…………….5275
9.6.4 Review Service History…………….5275
9.6.5 Set Service Interval…………….5275
9.6.6 Cabin Joystick Telescope: X-Axis/ Roller…………….5275
9.7 Fuses and Relays…………….5276
9.7.1 Engine Compartment…………….5276
9.7.2 Power Distribution Board…………….5277
9.8 Electrical System Schematics…………….5279
9.8.1 Cab Harness Electrical Schematic 1 of 3…………….5279
9.8.2 Cab Roof, Ride, Float and Boom Extend LImit…………….5282
9.8.3 Power Distribution Board…………….5283
9.8.4 Transmission and Reverse Fan…………….5284
9.8.5 Front Frame and Boom Options…………….5285
9.8.6 Rear Frame…………….5286
9.8.7 Battery…………….5287
9.8.8 Platform…………….5288
9.8.9 LMIS…………….5289
9.8.10 Deutz Engine…………….5290
9.8.11 Platform MSSO Harness…………….5291
9.9 Engine Start Circuit…………….5292
9.9.1 Starter…………….5292
9.9.2 Charging Circuit…………….5293
9.9.3 Alternator…………….5293
9.10 Window Wiper/Washer Windshield Wiper Motor…………….5294
9.10.1 Windshield Wiper Motor…………….5294
9.10.2 Rear and Roof Window Wiper Motor…………….5294
9.10.3 Windshield/Rear Window/Roof Window Washer Reservoir…………….5295
9.11 Solenoids, Sensors and Senders…………….5296
9.11.1 Transmission Solenoid Valves…………….5296
9.11.2 Transmission Oil Temperature Switch…………….5297
9.11.3 Transmission Mounted Speed Sensor…………….5297
9.11.4 Engine Coolant Temperature Sensor…………….5298
9.11.5 Fuel Level Sender…………….5298
9.11.6 Front and Rear Axle Steering Sensors…………….5299
9.11.7 Boom Angle Sensor…………….5299
9.11.8 Back-up Alarm…………….5301
9.12 Dash Switches…………….5301
9.12.1 Ignition Key Switch…………….5301
9.12.2 Dash Switches…………….5302
9.13 Platform Interlock Checks…………….5303
9.14 Platform Load System Check…………….5303
9.15 Load Stability Indicator (LSI) (CE & AUS)…………….5304
9.15.1 Load Stability Indicator…………….5304
9.16 LSI Sensor…………….5305
9.16.1 LSI Sensor Removal…………….5305
9.16.2 LSI Sensor Installation…………….5305
9.17 LSI System Calibration…………….5308
9.17.1 Standard Calibration…………….5308
9.17.2 Field Calibration…………….5310
9.17.3 LSI-CAN Check PT…………….5312
9.17.4 500 Hour – LSI UGM Calibration Check…………….5313
9.18 Hand Held Analyzer…………….5313
9.18.1 Analyzer Usage…………….5313
9.18.2 Analyzer Software Version P4.5…………….5314
9.19 Fault Codes…………….5316
9.19.1 Indicator Cross Reference Table…………….5316
9.19.2 Machine Fault Codes…………….5317
9.19.3 Engine Fault Codes…………….5352
35.10…………….5380
31211097 – Operation & Safety Manual Agrovector 30.6, 35.7, 40.8, 35.10…………….5381
31211097_C_30.6, 35.7, 40.8, 35.10_Deutz-Fahr_O&SM…………….5381
Revision Log…………….5383
Read This First…………….5384
Table of Contents…………….5387
Section 1 – General Safety Practices…………….5387
Section 2 – Pre-Operation and Inspection…………….5387
Section 3 – Controls and Indicators…………….5388
Section 4 – Operation…………….5389
Section 5 – Attachments and Hitches…………….5390
Section 6 – Emergency Procedures…………….5391
Section 7 – Lubrication and Maintenance…………….5391
Section 8 – Additional Checks…………….5392
Section 9 – Specifications…………….5392
Section 1 – General Safety Practices…………….5393
1.1 Hazard Classification System…………….5393
Safety Alert System and Safety Signal Words…………….5393
1.2 General Precautions…………….5393
1.3 Operation Safety…………….5394
Electrical Hazards…………….5394
Tip Over Hazard…………….5396
Travel Hazard…………….5399
Load Falling Hazard…………….5400
Lifting Personnel…………….5401
Driving Hazards on Slopes…………….5402
Pinch Points and Crush Hazards…………….5403
Fall Hazard…………….5405
Chemical Hazards…………….5406
1.4 ClearSky (if equipped)…………….5407
Federal Communications Commission (FCC) Information for Users…………….5407
Section 2 – Pre-Operation and Inspection…………….5409
2.1 Preparation, Inspection and Maintenance…………….5409
2.2 Pre-Operation Check and Inspection…………….5410
2.3 Safety Decals…………….5412
2.4 Walk-Around Inspection…………….5418
2.5 Warm-Up and Operational Checks…………….5421
Warm-Up Check…………….5421
Operational Check…………….5421
2.6 Cab…………….5422
2.7 Enclosed Cab Windows (if equipped)…………….5423
Cab Door Window…………….5423
Rear Window…………….5424
Section 3 – Controls and Indicators…………….5425
3.1 General…………….5425
3.2 Controls…………….5426
Instrument Panel…………….5428
LCD Display…………….5432
Left Dash Control Panel…………….5434
Right Dash Control Panel…………….5435
Agriculture Control Panel…………….5437
Ignition…………….5440
Park Brake…………….5441
Parking Procedure…………….5441
Transmission Control Lever (if equipped)…………….5442
Accessory Control Lever (if equipped)…………….5444
Reversing Fan Switch (if equipped)…………….5445
Load Stability Indicator – LSI…………….5446
Steering Column Adjuster…………….5448
Joystick…………….5450
3.3 Anti-Theft Functionality (if enabled)…………….5457
Instrument Panel Input…………….5457
Multifunction Display Input…………….5457
3.4 Steer Modes…………….5458
Manual Steering Alignment Mode Change…………….5458
All Wheel Assisted Steering Alignment Mode Change…………….5459
3.5 Operator Seat…………….5460
Operator Presence…………….5460
Adjustments…………….5461
Seat Belt…………….5464
3.6 Boom Indicators…………….5465
Boom Extension…………….5465
Boom Angle (if equipped)…………….5465
3.7 Reverse Systems (if equipped)…………….5466
Reverse Sensing System…………….5466
Reversing Camera (if equipped)…………….5466
3.8 Multifunction Display (if equipped)…………….5467
General Information…………….5467
Multifunction Display and Buttons…………….5468
Home Screen…………….5470
Main Menu…………….5473
Operation and Maintenance…………….5482
Troubleshooting…………….5500
Section 4 – Operation…………….5501
4.1 Engine…………….5501
Starting the Engine…………….5501
Extreme Cold Weather Starting (if equipped)…………….5502
Battery Boosted Starting…………….5503
Normal Engine Operation…………….5505
Shut-Down Procedure…………….5506
4.2 After-Treatment System (ATS) (if equipped for ULS)…………….5508
Stationary Exhaust System Cleaning…………….5508
4.3 Operating with a Non-Suspended Load…………….5510
Lift Load Safely…………….5510
Picking Up a Load…………….5510
Transporting a Load…………….5511
Leveling Procedure…………….5511
Placing a Load…………….5512
Disengaging a Load…………….5512
4.4 Operating with a Suspended Load…………….5513
Lift Load Safely…………….5513
Picking Up a Suspended Load…………….5513
Transporting a Suspended Load…………….5514
Leveling Procedure…………….5514
Placing a Suspended Load…………….5515
Disengaging a Suspended Load…………….5515
4.5 Road Operation (CE)…………….5516
4.6 Loading and Securing for Transport…………….5517
Tie Down…………….5517
Lifting…………….5518
Section 5 – Attachments and Hitches…………….5519
5.1 Approved Attachments…………….5519
5.2 Unapproved Attachments…………….5519
5.3 JLG Supplied Attachments…………….5520
5.4 Telehandler/Attachment/Fork Capacity…………….5523
5.5 Use of the Capacity Chart…………….5524
Capacity Indicator Locations…………….5524
Sample Capacity Chart (CE)…………….5525
Sample Capacity Chart (AUS)…………….5526
Example…………….5528
5.6 Attachment Installation…………….5529
Coupler…………….5529
Hydraulic Operated Attachment…………….5532
5.7 Adjusting/Moving Forks…………….5533
5.8 Attachment Operation…………….5534
Carriage with Forks…………….5535
Fork Positioning Carriage…………….5536
Side Tilt Carriage and Fork Rotator Carriage…………….5538
Side Shift Carriage…………….5540
Fork Extension…………….5542
Dual Tine Bale…………….5544
Bale Handler…………….5546
Bucket…………….5548
Multi-Purpose Bucket…………….5550
Grapple Bucket…………….5552
Manure Grapple…………….5554
Muck Fork…………….5556
Sweeper…………….5558
Auger…………….5560
Concrete Bucket Mixer…………….5562
Truss Boom…………….5564
Coupler Mounted Hook…………….5566
Fork Mounted Hook…………….5568
Trash Hopper – Fork Mounted…………….5570
5.9 Hitches and Trailer Brakes…………….5572
Retrieval Hitch…………….5572
Fixed Hitch…………….5573
Pin Hitch – CUNA C (Italy)…………….5574
Pin Hitch – CUNA D2 (Italy)…………….5575
EEC Manual Pin Hitch…………….5576
EEC Auto Hitch…………….5577
Piton Frame and EEC Auto Hitch…………….5578
Hydraulic Hitch…………….5579
Rear Auxiliary Hydraulics…………….5580
Trailer Brakes…………….5581
Section 6 – Emergency Procedures…………….5583
6.1 Towing a Disabled Product…………….5583
Moving Short Distances…………….5583
Moving Longer Distance…………….5583
6.2 Emergency Lowering of Boom…………….5584
6.3 Emergency Exit from Enclosed Cab…………….5585
Rear Window Inside Cab…………….5585
Rear Window Outside Cab (if equipped)…………….5586
Right Side Window (Agriculture)…………….5586
Section 7 – Lubrication and Maintenance…………….5587
7.1 Introduction…………….5587
Clothing and Safety Gear…………….5587
7.2 General Maintenance Instructions…………….5588
7.3 Service and Maintenance Schedules…………….5589
10 & 1st 50 Hour Maintenance Schedule – 30.6…………….5589
50, 1st 250 & 250 Hour Maintenance Schedule – 30.6…………….5590
500, 750 & 1000 Hour Maintenance Schedule – 30.6…………….5591
1500, 2000 & 3000 Hour Maintenance Schedule – 30.6…………….5592
10 & 1st 50 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….5593
50, 1st 250 & 250 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….5594
500, 750 & 1000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….5595
1500, 2000 & 3000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….5596
7.4 Lubrication Schedules…………….5598
30.6…………….5598
35.7, 40.8, 35.10…………….5599
7.5 Operator Maintenance Instructions…………….5601
Engine Maintenance Components…………….5601
Fuel System…………….5604
Emission System (if equipped for ULS)…………….5606
Engine Oil…………….5607
Air Intake System…………….5608
Tires…………….5610
Hydraulic Oil…………….5612
Transmission Oil (35.7, 40.8, 35.10)…………….5614
Brake Fluid…………….5616
Engine Cooling System…………….5617
Windshield Washer System (if equipped)…………….5618
Cab Air Filters (if equipped)…………….5620
Load Stability Indicator System…………….5622
Section 8 – Additional Checks…………….5625
8.1 General…………….5625
8.2 Reverse Sensing System (if equipped)…………….5625
Section 9 – Specifications…………….5627
9.1 Product Specifications…………….5627
Fluids…………….5627
Capacities…………….5631
Tires…………….5633
Performance…………….5634
Dimensions…………….5636
Declaration of Vibration (CE)…………….5639
Noise Emission Level (CE)…………….5640
Machine Towing Capacity…………….5641
Index…………….5643
31211227 – Illustrated Parts Manual Models 3510PS, 35.10…………….5653
PM 31211227_C_3510PS & 35.10_JLG_ Parts Manual …………….5653
Effectivity Page …………….5655
Machine Configuration…………….5656
General information Page…………….5657
Table of Contents …………….5659
SECTION 1 – FRAME AND ATTACHING PARTS…………….5669
FIGURE 1-1. FRAME INSTALLATION…………….5670
FIGURE 1-2. ENGINE ENCLOSURE INSTALLATION (NO RHOC – JLG)…………….5672
FIGURE 1-3. ENGINE ENCLOSURE INSTALLATION (RHOC – JLG)…………….5674
FIGURE 1-4. ENGINE ENCLOSURE INSTALLATION (NO RHOC – DEUTZ-FAHR)…………….5676
FIGURE 1-5. ENGINE ENCLOSURE INSTALLATION (RHOC – DEUTZ-FAHR)…………….5678
FIGURE 1-6. ENGINE ENCLOSURE COVER INSTALLATION (NO RHOC)…………….5680
FIGURE 1-7. ENGINE ENCLOSURE COVER INSTALLATION (RHOC)…………….5682
FIGURE 1-8. AIR INTAKE SEAL INSTALLATION…………….5684
FIGURE 1-9. HOOD INSTALLATION (JLG)…………….5686
FIGURE 1-10. HOOD INSTALLATION (DEUTZ-FAHR)…………….5688
FIGURE 1-11. COVER PLATES INSTALLATION (NO OUTRIGGERS – ULS)…………….5690
FIGURE 1-12. COVER PLATES INSTALLATION (NO OUTRIGGERS – LS)…………….5692
FIGURE 1-13. COVER PLATE INSTALLATION (NO TRAILER BRAKES)…………….5694
FIGURE 1-14. COVER PLATE INSTALLATION (TRAILER BRAKES)…………….5696
FIGURE 1-15. COVER PLATE INSTALLATION (NO REAR AUX)…………….5698
FIGURE 1-16. COVER PLATE INSTALLATION (REAR AUX)…………….5700
FIGURE 1-17. COVER PLATE INSTALLATION (HYDRAULIC HITCH AND REAR AUX)…………….5702
FIGURE 1-18. REAR COVER PLATE INSTALLATION (NO HYDRAULIC HITCH)…………….5704
FIGURE 1-19. REAR COVER PLATE INSTALLATION (HYDRAULIC HITCH)…………….5706
FIGURE 1-20. COUNTERWEIGHT INSTALLATION (NO OUTRIGGERS)…………….5708
FIGURE 1-21. TANKS INSTALLATION…………….5710
FIGURE 1-22. FUEL TANK INSTALLATION…………….5712
FIGURE 1-23. HYDRAULIC TANK INSTALLATION…………….5714
FIGURE 1-24. FUEL TANK ASSEMBLY…………….5716
FIGURE 1-25. HYDRAULIC TANK ASSEMBLY…………….5718
FIGURE 1-26. FUEL AND HYDRAULIC CAP INSTALLATION…………….5720
FIGURE 1-27. HITCH RETRIEVAL INSTALLATION…………….5722
FIGURE 1-28. HITCH INSTALLATION (EEC AUTO)…………….5724
FIGURE 1-29. HITCH INSTALLATION (PITON)…………….5726
FIGURE 1-30. HITCH ASSEMBLY (EEC AUTO)…………….5728
FIGURE 1-31. SLIDING HITCH ASSEMBLY (PITON)…………….5730
FIGURE 1-32. HITCH INSTALLATION (EEC MANUAL)…………….5732
FIGURE 1-33. HITCH ASSEMBLY (EEC MANUAL)…………….5734
FIGURE 1-34. HITCH INSTALLATION (CUNA CATEGORY C)…………….5736
FIGURE 1-35. HITCH ASSEMBLY (CUNA CATEGORY C)…………….5738
FIGURE 1-36. HITCH INSTALLATION (CUNA CATEGORY D2)…………….5740
FIGURE 1-37. HITCH ASSEMBLY (CUNA CATEGORY D2)…………….5742
FIGURE 1-38. HITCH INSTALLATION (FIXED)…………….5744
FIGURE 1-39. HITCH ASSEMBLY (FIXED)…………….5746
FIGURE 1-40. HITCH INSTALLATION (HYDRAULIC)…………….5748
FIGURE 1-41. TOOL BOX INSTALLATION…………….5750
SECTION 2 – BOOM…………….5753
FIGURE 2-1. BOOM INSTALLATION (JLG)…………….5754
FIGURE 2-2. BOOM INSTALLATION (DEUTZ-FAHR)…………….5756
FIGURE 2-3. BOOM ASSEMBLY (JLG)…………….5758
FIGURE 2-4. BOOM ASSEMBLY (DEUTZ-FAHR)…………….5760
FIGURE 2-5. FIRST BOOM SECTION ASSEMBLY…………….5762
FIGURE 2-6. FIRST BOOM SECTION ASSEMBLY (DEUTZ-FAHR)…………….5764
FIGURE 2-7. SECOND BOOM SECTION ASSEMBLY…………….5766
FIGURE 2-8. THIRD BOOM SECTION ASSEMBLY…………….5768
FIGURE 2-9. LINK ASSEMBLY…………….5770
FIGURE 2-10. LEVER ASSEMBLY…………….5772
FIGURE 2-11. MANUAL QUICK COUPLER INSTALLATION…………….5774
FIGURE 2-12. HYDRAULIC QUICK COUPLER INSTALLATION…………….5776
FIGURE 2-13. BOOM ANGLE INDICATOR INSTALLATION…………….5778
FIGURE 2-14. BOOM PROP INSTALLATION…………….5780
FIGURE 2-15. BOOM BRUSHES INSTALLATION…………….5782
SECTION 3 – ATTACHMENTS…………….5785
FIGURE 3-1. CARRIAGE ASSEMBLY (1524MM) (CE & AUS)…………….5786
FIGURE 3-2. CARRIAGE ASSEMBLY (1829MM) (CE & AUS)…………….5788
FIGURE 3-3. CARRIAGE ASSEMBLY (1225MM) (CE & AUS)…………….5790
FIGURE 3-4. CARRIAGE ASSEMBLY (1270MM) (ANSI – JLG)…………….5792
FIGURE 3-5. CARRIAGE ASSEMBLY (1524 MM) (ANSI – JLG)…………….5794
FIGURE 3-6. CARRIAGE ASSEMBLY (1829 MM) (ANSI – JLG)…………….5796
FIGURE 3-7. SIDE TILTING CARRIAGE (4.5 TON – 1225 MM) (CE & AUS)…………….5798
FIGURE 3-8. SIDE TILTING CARRIAGE (4.5 TON – 1270 MM) (ANSI – JLG)…………….5800
FIGURE 3-9. SIDE TILTING CARRIAGE (4.5 TON – 1575 MM) (ANSI – JLG)…………….5802
FIGURE 3-10. SIDE TILTING CARRIAGE (4.0 TON – 1575 MM) (CE & AUS – JLG)…………….5804
FIGURE 3-11. SIDE TILTING CARRIAGE (4.5 TON – 1829 MM) (ANSI – JLG)…………….5806
FIGURE 3-12. SIDE TILTING CARRIAGE (4.0 TON – 1829 MM) (CE & AUS)…………….5808
FIGURE 3-13. SIDE SHIFT CARRIAGE (4.0 TON – 1225 MM) (CE & AUS)…………….5810
FIGURE 3-14. SIDE SHIFT CARRIAGE (5.5 TON – 1270 MM) (ANSI – JLG)…………….5812
FIGURE 3-15. FORK POSITIONING CARRIAGE WITH FORKS (4.0 TON) (CE & AUS)…………….5814
FIGURE 3-16. FORK POSITIONING CARRIAGE WITH FORKS (4.5 TON) (ANSI – JLG)…………….5816
FIGURE 3-17. DUAL FORK CARRIAGE ASSEMBLY…………….5818
FIGURE 3-18. DUAL FORK CARRIAGE VALVE ASSEMBLY…………….5820
FIGURE 3-19. FORK ROTATING CARRIAGE (2.05 TON – 990 MM) (CE & AUS – JLG)…………….5822
FIGURE 3-20. FORK ROTATING CARRIAGE (4.5 TON – 1270 MM) (CE & AUS – JLG)…………….5826
FIGURE 3-21. CARRIAGE ASSEMBLY (JOHN DEERE FIT) (CE & AUS)…………….5830
FIGURE 3-22. CARRIAGE ASSEMBLY (MANITOU FIT) (CE & AUS)…………….5832
FIGURE 3-23. DUAL TINE BAILING FORK CARRIAGE (CE & AUS)…………….5834
FIGURE 3-24. FEM CARRIAGE AND FORKS (CE & AUS)…………….5836
FIGURE 3-25. PALLET FORK (50X100X1070) (CE & AUS)…………….5838
FIGURE 3-26. PALLET FORK (50X100X1220) (CE & AUS)…………….5840
FIGURE 3-27. PALLET FORK (50X120X1200) (CE)…………….5842
FIGURE 3-28. PALLET FORK (50X120X1200) (CE & AUS – IF EQUIPPED WITH 1170002)…………….5844
FIGURE 3-29. PALLET FORK (2.36X4X48) (ANSI – JLG)…………….5846
FIGURE 3-30. PALLET FORK (2.36X5X48) (ANSI – JLG)…………….5848
FIGURE 3-31. PALLET FORK (2.00X6X72) (ANSI – JLG)…………….5850
FIGURE 3-32. PALLET FORK (60X100X1200) (AUS)…………….5852
FIGURE 3-33. BLOCKING FORK (50X50X1220) (CE & AUS – JLG)…………….5854
FIGURE 3-34. BLOCKING FORK (50X50X1220) (ANSI – JLG)…………….5856
FIGURE 3-35. LUMBER FORK (40X150X1540) (CE & AUS – JLG)…………….5858
FIGURE 3-36. LUMBER FORK (40X150X1540) (ANSI – JLG)…………….5860
FIGURE 3-37. LUMBER FORK (45X150X1540) CE & AUS – JLG)…………….5862
FIGURE 3-38. LUMBER FORK (50X180X1540) (ANSI – JLG)…………….5864
FIGURE 3-39. LUMBER FORK (60X150X1524) (ANSI – JLG)…………….5866
FIGURE 3-40. CARRIAGE ASSEMBLY (JCB FIT) (CE & AUS)…………….5868
FIGURE 3-41. BUCKET (1.15 M³) (ANSI – JLG)…………….5870
FIGURE 3-42. BUCKET (1 M³) (CE & AUS)…………….5872
FIGURE 3-43. BUCKET (1.5 M³) (CE & AUS)…………….5874
FIGURE 3-44. BUCKET (2 M³) (CE & AUS)…………….5876
FIGURE 3-45. BUCKET (2.5 M³) (CE & AUS)…………….5878
FIGURE 3-46. BUCKET (3 M³) (CE & AUS)…………….5880
FIGURE 3-47. FORK MOUNTED BUCKET (1.0 M³) (ANSI – JLG)…………….5882
FIGURE 3-48. DIRT BUCKET (1.0 M³) (CE & AUS)…………….5884
FIGURE 3-49. 4 IN 1 BUCKET (0.6 M³) (CE & AUS)…………….5886
FIGURE 3-50. 4 IN 1 BUCKET (1.0 M³) (CE & AUS)…………….5888
FIGURE 3-51. MULTI-PURPOSE GRAPPLE BUCKET (2450 MM) (ANSI – JLG)…………….5890
FIGURE 3-52. MULTI-PURPOSE GRAPPLE BUCKET (WIDE GRIP – 2450 MM) (CE & AUS)…………….5892
FIGURE 3-53. MANURE GRAPPLE BUCKET (CE & AUS)…………….5894
FIGURE 3-54. BOLT-ON EDGE (2450 MM)…………….5896
FIGURE 3-55. BUCKET GUARD…………….5898
FIGURE 3-56. BUCKET TEETH KIT…………….5900
FIGURE 3-57. BALE HANDLER KIT (SPIKES) (CE & AUS)…………….5902
FIGURE 3-58. BALE HANDLER KIT (SPIKES TO TUBE) (CE & AUS)…………….5904
FIGURE 3-59. TRUSS BOOM (4 TON – 2.1M) (CE & AUS)…………….5906
FIGURE 3-60. TRUSS BOOM (1 TON – 3.4M) (CE & AUS)…………….5908
FIGURE 3-61. TRUSS BOOM (0.9 TON – 3.7M) (ANSI – JLG)…………….5910
FIGURE 3-62. TRUSS BOOM (1.8 TON – 3 FT WITH WINCH) (CE)…………….5912
FIGURE 3-63. TRUSS BOOM (1.8 TON – 3 FT WITH WINCH) (ANSI – JLG)…………….5914
FIGURE 3-64. TRUSS BOOM (3 FT WITH WINCH)…………….5916
FIGURE 3-65. TRUSS BOOM (0.9 TON – 12 FT WITH WINCH) (CE)…………….5918
FIGURE 3-66. TRUSS BOOM (0.9 TON – 3.7M WITH WINCH) (ANSI – JLG)…………….5920
FIGURE 3-67. CRANE HOOK (CE & AUS)…………….5922
FIGURE 3-68. CRANE HOOK (ANSI – JLG)…………….5924
FIGURE 3-69. FORK MOUNTED HOOK (4 TON) (ANSI – JLG)…………….5926
FIGURE 3-70. FORK MOUNTED HOOK (4 TON) (CE)…………….5928
FIGURE 3-71. BALE HANDLER (TUBE CLAMP) (CE & AUS)…………….5930
FIGURE 3-72. BALE HANDLER (SPIKE CLAMP) (CE & AUS)…………….5932
FIGURE 3-73. MUCK FORK AND GRAB (CE & AUS)…………….5934
FIGURE 3-74. PIPE HANDLER CARRIAGE (CE & AUS – JLG)…………….5936
FIGURE 3-75. PIPE HANDLER CARRIAGE (ANSI – JLG)…………….5938
FIGURE 3-76. FORK MOUNTED BASKET (DOMESTIC) (ANSI – JLG)…………….5942
FIGURE 3-77. FORK MOUNTED BASKET (ISO) (ANSI – JLG)…………….5944
FIGURE 3-78. FORK MOUNTED BASKET (FRENCH) (ANSI – JLG)…………….5946
FIGURE 3-79. FORK MOUNTED PLATFORM…………….5948
FIGURE 3-80. FORK MOUNTED TRASH HOPPER…………….5950
FIGURE 3-81. CONCRETE BUCKET (CE)…………….5952
FIGURE 3-82. SWEEPER (CE & AUS)…………….5956
FIGURE 3-83. SWEEPER (ANSI)…………….5958
FIGURE 3-84. AUGER (COUPLER MOUNTED) (CE & AUS)…………….5960
FIGURE 3-85. AUGER BIT, (6INX4IN) (CE & AUS)…………….5962
FIGURE 3-86. AUGER BIT, (9INX4IN) (CE & AUS)…………….5964
FIGURE 3-87. AUGER BIT, (12INX4IN) (CE & AUS)…………….5966
FIGURE 3-88. AUGER BIT, (15INX4IN) (CE & AUS)…………….5968
FIGURE 3-89. AUGER BIT, (18INX4IN) (CE & AUS)…………….5970
FIGURE 3-90. AUGER BIT, (24INX4IN) (CE & AUS)…………….5972
FIGURE 3-91. AUGER BIT, (36INX4IN) (CE & AUS)…………….5974
FIGURE 3-92. FORK EXTENSIONS (62X163X2286) (ANSI – JLG)…………….5976
FIGURE 3-93. FORK EXTENSION (50X100X1910) (CE)…………….5978
FIGURE 3-94. FORK EXTENSION (60X100X1920) (AUS)…………….5980
FIGURE 3-95. FORK TRANSPORT LATCH INSTALLATION (CE & AUS)…………….5982
SECTION 4 – ENGINE AND ATTACHING PARTS…………….5985
FIGURE 4-1. ENGINE INSTALLATION (74.4KW – ULS – PISTON PUMP)…………….5986
FIGURE 4-2. ENGINE INSTALLATION (90KW – ULS – PISTON PUMP)…………….5988
FIGURE 4-3. ENGINE INSTALLATION (100KW – ULS – PISTON PUMP)…………….5990
FIGURE 4-4. ENGINE INSTALLATION (74.4KW – LS – PISTON PUMP)…………….5992
FIGURE 4-5. ENGINE INSTALLATION (90KW – LS – PISTON PUMP)…………….5994
FIGURE 4-6. ENGINE MOUNTING INSTALLATION (74.4KW)…………….5996
FIGURE 4-7. ENGINE MOUNTING INSTALLATION (90KW/100KW)…………….5998
FIGURE 4-8. 3.6L ENGINE (74.4KW – ULS – PISTON PUMP)…………….6000
FIGURE 4-9. 3.6L ENGINE (90KW – ULS – PISTON PUMP)…………….6002
FIGURE 4-10. 3.6L ENGINE (100KW – ULS – PISTON PUMP)…………….6004
FIGURE 4-11. 3.6L ENGINE (74.4KW – LS – PISTON PUMP)…………….6006
FIGURE 4-12. 3.6L ENGINE (90KW – LS – PISTON PUMP)…………….6008
FIGURE 4-13. BRACKET GUARD INSTALLATION…………….6010
FIGURE 4-14. FUEL LINES INSTALLATION (ULS)…………….6012
FIGURE 4-15. FUEL LINES INSTALLATION (ULS – RHOC)…………….6014
FIGURE 4-16. FUEL LINES INSTALLATION (LS)…………….6016
FIGURE 4-17. FUEL LINES INSTALLATION (LS – RHOC)…………….6018
FIGURE 4-18. EXHAUST INSTALLATION (ULS)…………….6020
FIGURE 4-19. EXHAUST INSTALLATION (LS)…………….6022
FIGURE 4-20. COOLING PACKAGE INSTALLATION (74.4KW – ULS)…………….6024
FIGURE 4-21. COOLING PACKAGE INSTALLATION (74.4KW – LS)…………….6026
FIGURE 4-22. COOLING PACKAGE INSTALLATION (90KW – ULS)…………….6028
FIGURE 4-23. COOLING PACKAGE INSTALLATION (90KW – LS)…………….6030
FIGURE 4-24. COOLING FAN INSTALLATION…………….6032
FIGURE 4-25. FAN LINES INSTALLATION (74.4KW)…………….6034
FIGURE 4-26. FAN LINES INSTALLATION (90KW)…………….6036
FIGURE 4-27. FAN DRIVE MOTOR (NO RHOC)…………….6038
FIGURE 4-28. FAN DRIVE MOTOR (RHOC)…………….6040
FIGURE 4-29. PRIMARY FUEL FILTER INSTALLATION (74.4KW – ULS)…………….6042
FIGURE 4-30. FUEL FILTER INSTALLATION (90/100KW – ULS)…………….6044
FIGURE 4-31. PRIMARY FUEL FILTER INSTALLATION (90KW – LS)…………….6046
FIGURE 4-32. PRIMARY FUEL FILTER INSTALLATION (74.4KW – LS)…………….6048
FIGURE 4-33. AIR CLEANER INSTALLATION (74.4KW – ULS)…………….6050
FIGURE 4-34. AIR CLEANER INSTALLATION (90/100KW)…………….6052
FIGURE 4-35. AIR CLEANER INSTALLATION (74.4KW – LS)…………….6054
FIGURE 4-36. AIR CLEANER ASSEMBLY (74.4KW)…………….6056
FIGURE 4-37. AIR CLEANER ASSEMBLY (90/100KW)…………….6058
FIGURE 4-38. AIR INTAKE LINES INSTALLATION (74.4KW – ULS)…………….6060
FIGURE 4-39. AIR INTAKE LINES INSTALLATION (90/100KW – ULS)…………….6062
FIGURE 4-40. AIR INTAKE LINES INSTALLATION (74.4KW – LS)…………….6064
FIGURE 4-41. AIR INTAKE LINES INSTALLATION (90KW – LS)…………….6066
FIGURE 4-42. COOLER INSTALLATION (74.4KW)…………….6068
FIGURE 4-43. COOLER INSTALLATION (90KW)…………….6070
FIGURE 4-44. RADIATOR COOLING PACKAGE (74.4KW)…………….6072
FIGURE 4-45. RADIATOR COOLING PACKAGE (90KW)…………….6074
FIGURE 4-46. REMOTE HOC INSTALLATION…………….6076
FIGURE 4-47. COOLANT LINES INSTALLATION (ULS)…………….6078
FIGURE 4-48. COOLANT LINES INSTALLATION (LS)…………….6080
FIGURE 4-49. COOLER LINES INSTALLATION (74.4KW) (Prior to SN 1160008434)…………….6082
FIGURE 4-50. COOLER LINES INSTALLATION (74.4KW) (SN 1160008434 to Present)…………….6084
FIGURE 4-51. COOLER LINES INSTALLATION (90KW)…………….6086
FIGURE 4-52. CAC LINES INSTALLATION (ULS)…………….6088
FIGURE 4-53. CAC LINES INSTALLATION (LS)…………….6090
FIGURE 4-54. SURGE TANK INSTALLATION…………….6092
FIGURE 4-55. TANK EXPANSION…………….6094
FIGURE 4-56. BULKHEAD INSTALLATION…………….6096
FIGURE 4-57. DEF CONTROL MODULE INSTALLATION (ULS)…………….6098
FIGURE 4-58. DEF TANK INSTALLATION (ULS)…………….6100
FIGURE 4-59. DEF LINES INSTALLATION (ULS)…………….6102
FIGURE 4-60. DEF TANK ASSEMBLY (ULS)…………….6104
FIGURE 4-61. REMOTE FUEL PUMP INSTALLATION (74.4KW)…………….6106
FIGURE 4-62. HYDRAULIC PUMP INSTALLATION (74.4KW)…………….6108
FIGURE 4-63. HYDRAULIC PUMP INSTALLATION (90KW)…………….6110
FIGURE 4-64. HEATER LINES INSTALLATION (ULS)…………….6112
FIGURE 4-65. HEATER LINES INSTALLATION (LS)…………….6114
FIGURE 4-66. BLOCK HEATER INSTALLATION (230V – LS)…………….6116
FIGURE 4-67. BLOCK HEATER INSTALLATION (120V – LS – JLG)…………….6118
FIGURE 4-68. BLOCK HEATER (ULS)…………….6120
FIGURE 4-69. BLOCK HEATER (LS)…………….6122
FIGURE 4-70. A/C PUMP INSTALLATION…………….6124
FIGURE 4-71. A/C LINES INSTALLATION…………….6126
SECTION 5 – DRIVE TRAIN…………….6129
FIGURE 5-1. AXLES INSTALLATION (NO HYDRAULIC PARK BRAKE)…………….6130
FIGURE 5-2. AXLES INSTALLATION (HYDRAULIC PARK BRAKE)…………….6132
FIGURE 5-3. FRONT AXLE INSTALLATION (NO HYDRAULIC PARK BRAKE)…………….6134
FIGURE 5-4. FRONT AXLE, CENTRAL HOUSING (NO HYDRAULIC PARK BRAKE)…………….6136
FIGURE 5-5. FRONT AXLE, DIFFERENTIAL (NO HYDRAULIC PARK BRAKE)…………….6138
FIGURE 5-6. FRONT AXLE, HUB REDUCTION (NO HYDRAULIC PARK BRAKE)…………….6140
FIGURE 5-7. FRONT AXLE, BRAKES (NO HYDRAULIC PARK BRAKE)…………….6142
FIGURE 5-8. FRONT AXLE, STEERING (NO HYDRAULIC PARK BRAKE)…………….6144
FIGURE 5-9. FRONT AXLE INSTALLATION (HYDRAULIC PARK BRAKE)…………….6146
FIGURE 5-10. FRONT AXLE, CENTRAL HOUSING (HYDRAULIC PARK BRAKE)…………….6148
FIGURE 5-11. FRONT AXLE, DIFFERENTIAL (HYDRAULIC PARK BRAKE)…………….6150
FIGURE 5-12. FRONT AXLE, HUB REDUCTION (HYDRAULIC PARK BRAKE)…………….6152
FIGURE 5-13. FRONT AXLE, BRAKES (HYDRAULIC PARK BRAKE)…………….6154
FIGURE 5-14. FRONT AXLE, STEERING (HYDRAULIC PARK BRAKE)…………….6156
FIGURE 5-15. REAR AXLE INSTALLATION…………….6158
FIGURE 5-16. REAR AXLE, CENTRAL HOUSING…………….6160
FIGURE 5-17. REAR AXLE, DIFFERENTIAL…………….6162
FIGURE 5-18. REAR AXLE, HUB REDUCTION…………….6164
FIGURE 5-19. REAR AXLE, BRAKES…………….6166
FIGURE 5-20. REAR AXLE, STEERING…………….6168
FIGURE 5-21. DIFFERENTIAL KIT…………….6170
FIGURE 5-22. REDUCTION BUSHING KIT…………….6172
FIGURE 5-23. PLANET GEAR CARRIER KIT…………….6174
FIGURE 5-24. STEERING CASE KIT, (LF, RR)…………….6176
FIGURE 5-25. STEERING CASE KIT, (RF, LR)…………….6178
FIGURE 5-26. STEERING ADJUST BOLT KIT…………….6180
FIGURE 5-27. RING GEAR SUPPORT KIT…………….6182
FIGURE 5-28. PISTON KIT (LH)…………….6184
FIGURE 5-29. PISTON KIT (RH)…………….6186
FIGURE 5-30. DIFFERENTIAL KIT…………….6188
FIGURE 5-31. PISTON KIT…………….6190
FIGURE 5-32. TRUNION KIT…………….6192
FIGURE 5-33. DRIVE SHAFTS INSTALLATION…………….6194
FIGURE 5-34. REMOTE GREASE SYSTEM INSTALLATION…………….6196
FIGURE 5-35. AXLE SHIM INSTALLATION (24IN WHEEL)…………….6198
FIGURE 5-36. TRANSMISSION INSTALLATION (4 SPD)…………….6200
FIGURE 5-37. TRANSMISSION INSTALLATION (6 SPD – 90KW)…………….6202
FIGURE 5-38. TRANSMISSION INSTALLATION (6 SPD – 97KW)…………….6204
FIGURE 5-39. TRANSMISSION (4 SPD)…………….6206
FIGURE 5-40. TRANSMISSION (6 SPD – 90KW)…………….6208
FIGURE 5-41. TRANSMISSION (6 SPD – HHP – 97KW)…………….6210
FIGURE 5-42. PLANETARY CASE AND PARTS GROUP…………….6212
FIGURE 5-43. TORQUE CONVERTER GROUP…………….6214
FIGURE 5-44. TORQUE CONVERTER GROUP…………….6216
FIGURE 5-45. TRANSFER GEAR AND CASE GROUP…………….6218
FIGURE 5-46. TRANSFER GEAR AND CASE GROUP…………….6220
FIGURE 5-47. TRANSMISSION HYDRAULIC CONTROL GROUP…………….6222
FIGURE 5-48. INPUT SHAFT GROUP…………….6224
FIGURE 5-49. TRANSMISSION CLUTCH GROUP…………….6226
FIGURE 5-50. CLUTCH AND GEAR GROUP…………….6228
FIGURE 5-51. TRANSMISSION PUMP GROUP…………….6230
FIGURE 5-52. OUTPUT SHAFT GROUP…………….6232
FIGURE 5-53. SPEED SENSOR…………….6234
FIGURE 5-54. IDLER GEAR…………….6236
FIGURE 5-55. REAR TRANSMISSION CASE…………….6238
FIGURE 5-56. PLANETARY CASE…………….6240
FIGURE 5-57. FRONT TRANSFER CASE…………….6242
FIGURE 5-58. REAR TRANSFER CASE…………….6244
FIGURE 5-59. FRONT TRANSFER CASE…………….6246
FIGURE 5-60. REAR TRANSFER CASE…………….6248
FIGURE 5-61. RELIEF VALVE…………….6250
FIGURE 5-62. SOLENOID VALVE…………….6252
FIGURE 5-63. SOLENOID VALVE…………….6254
FIGURE 5-64. FRONT TRANSMISSION CASE ASSEMBLY…………….6256
FIGURE 5-65. REAR TRANSMISSION CASE ASSEMBLY…………….6258
FIGURE 5-66. TIRE/WHEEL SET (AIR – 15.5/80-24 – 16PR)…………….6260
FIGURE 5-67. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 15.5/80-24 – 16PR)…………….6262
FIGURE 5-68. LEFT TIRE/WHEEL ASSEMBLY (AIR – 15.5/80-24 – 16PR)…………….6264
FIGURE 5-69. TIRE/WHEEL SET (AIR – 15.5 R25 XHA TL)…………….6266
FIGURE 5-70. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 15.5 R25)…………….6268
FIGURE 5-71. LEFT TIRE/WHEEL ASSEMBLY (AIR – 15.5 R25)…………….6270
FIGURE 5-72. TIRE/WHEEL SET (AIR – 460/70 R24 XMCL)…………….6272
FIGURE 5-73. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24)…………….6274
FIGURE 5-74. LEFT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24)…………….6276
FIGURE 5-75. TIRE/WHEEL SET (AIR – 500/70 R24 XMCL)…………….6278
FIGURE 5-76. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 500/70 R24)…………….6280
FIGURE 5-77. LEFT TIRE/WHEEL ASSEMBLY (AIR – 500/70 R24)…………….6282
FIGURE 5-78. TIRE/WHEEL SET (AIR – 440/80-24 POWER CL)…………….6284
FIGURE 5-79. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 440/80-24)…………….6286
FIGURE 5-80. LEFT TIRE/WHEEL ASSEMBLY (AIR – 440/80-24)…………….6288
FIGURE 5-81. TIRE/WHEEL SET (AIR – 400/80-24 POWER CL)…………….6290
FIGURE 5-82. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 400/80-24)…………….6292
FIGURE 5-83. LEFT TIRE/WHEEL ASSEMBLY (AIR – 400/80-24)…………….6294
FIGURE 5-84. TIRE/WHEEL SET (AIR – 370/75-28)…………….6296
FIGURE 5-85. TIRE/WHEEL ASSEMBLY (AIR – 370/75-28)…………….6298
FIGURE 5-86. TIRE/WHEEL SET (FOAM – 13X24)…………….6300
FIGURE 5-87. TIRE/WHEEL SET (AIR – 460/70 R24 – BIBLOAD)…………….6302
FIGURE 5-88. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24 – BIBLOAD)…………….6304
FIGURE 5-89. LEFT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24 – BIBLOAD)…………….6306
FIGURE 5-90. WHEEL CHOCK INSTALLATION…………….6308
FIGURE 5-91. FENDER INSTALLATION (NO AIR – 460/70 R24 XMCL, AIR – 500/70 R24 XMCL, AIR – 440/80-24 POWER CL)…………….6310
FIGURE 5-92. FENDER INSTALLATION (AIR – 460/70 R24 XMCL, AIR – 500/70 R24 XMCL, AIR – 440/80-24 POWER CL)…………….6312
FIGURE 5-93. FENDER ASSEMBLY…………….6314
FIGURE 5-94. FENDER ASSEMBLY…………….6316
FIGURE 5-95. FENDER ASSEMBLY…………….6318
FIGURE 5-96. FENDER ASSEMBLY…………….6320
FIGURE 5-97. FENDER ASSEMBLY…………….6322
FIGURE 5-98. FENDER ASSEMBLY…………….6324
FIGURE 5-99. FENDER ASSEMBLY…………….6326
FIGURE 5-100. FENDER ASSEMBLY…………….6328
SECTION 6 – CAB…………….6331
FIGURE 6-1. CAB MOUNTS INSTALLATION (JLG)…………….6332
FIGURE 6-2. ENCLOSED CAB INSTALLATION (DEUTZ-FAHR)…………….6334
FIGURE 6-3. ENCLOSED CAB INSTALLATION (JLG)…………….6336
FIGURE 6-4. ENCLOSED CAB ASSEMBLY (DEUTZ-FAHR)…………….6338
FIGURE 6-5. ENCLOSED CAB ASSEMBLY (JLG)…………….6340
FIGURE 6-6. ENCLOSED CAB GROUP (DEUTZ-FAHR)…………….6342
FIGURE 6-7. ENCLOSED CAB GROUP (JLG)…………….6344
FIGURE 6-8. ENCLOSED CAB (DEUTZ-FAHR)…………….6346
FIGURE 6-9. ENCLOSED CAB (JLG)…………….6348
FIGURE 6-10. ENCLOSED CAB PLUG GROUP…………….6350
FIGURE 6-11. OPEN CAB PLUG GROUP…………….6352
FIGURE 6-12. REAR WINDOW INSTALLATION…………….6354
FIGURE 6-13. REAR WINDOW ASSEMBLY…………….6356
FIGURE 6-14. DOOR INSTALLATION (DEUTZ-FAHR)…………….6358
FIGURE 6-15. DOOR INSTALLATION (JLG)…………….6360
FIGURE 6-16. DOOR ASSEMBLY (AG – DEUTZ-FAHR)…………….6362
FIGURE 6-17. DOOR ASSEMBLY (AG – JLG)…………….6364
FIGURE 6-18. CAB DOOR…………….6366
FIGURE 6-19. DOOR UPPER GLASS ASSEMBLY…………….6368
FIGURE 6-20. CAB LATCH ASSEMBLY…………….6370
FIGURE 6-21. CAB DOOR TRIGGER ASSEMBLY…………….6372
FIGURE 6-22. DOOR STRAP INSTALLATION…………….6374
FIGURE 6-23. ENCLOSED CAB TRIM INSTALLATION…………….6376
FIGURE 6-24. DASH COVER ASSEMBLY…………….6380
FIGURE 6-25. RECIRCULATION GRILLE COVER PANEL ASSEMBLY…………….6382
FIGURE 6-26. REAR PANEL COVER ASSEMBLY…………….6384
FIGURE 6-27. ADJUSTABLE ARMREST INSTALLATION…………….6386
FIGURE 6-28. HEADLINER INSTALLATION…………….6388
FIGURE 6-29. HEADLINER/RADIO READY INSTALLATION…………….6390
FIGURE 6-30. COMMON CAB TRIM INSTALLATION…………….6392
FIGURE 6-31. CAB TRIM INSTALLATION…………….6394
FIGURE 6-32. ROOF CAP INSTALLATION (A/C – JLG)…………….6396
FIGURE 6-33. ROOF CAP INSTALLATION (A/C – DEUTZ-FAHR)…………….6398
FIGURE 6-34. ROOF CAP INSTALLATION (NO A/C – JLG)…………….6400
FIGURE 6-35. ROOF CAP INSTALLATION (NO A/C – DEUTZ-FAHR)…………….6402
FIGURE 6-36. FRONT COVER INSTALLATION…………….6404
FIGURE 6-37. FILTER TRAY PANEL…………….6406
FIGURE 6-38. FRONT DUCT COVER…………….6408
FIGURE 6-39. SEAT ASSEMBLY…………….6410
FIGURE 6-40. SEAT INSTALLATION (STANDARD – JLG)…………….6412
FIGURE 6-41. SEAT ASSEMBLY (AIR SUSPENSION – STANDARD)…………….6414
FIGURE 6-42. SEAT INSTALLATION (STANDARD – DEUTZ-FAHR)…………….6416
FIGURE 6-43. SEAT ASSEMBLY…………….6418
FIGURE 6-44. SEAT INSTALLATION (PREMIUM – JLG)…………….6420
FIGURE 6-45. SEAT INSTALLATION (PREMIUM – DEUTZ-FAHR)…………….6422
FIGURE 6-46. SEAT INSTALLATION (MECHANICAL – JLG)…………….6424
FIGURE 6-47. SEAT INSTALLATION (MECHANICAL – DEUTZ-FAHR)…………….6426
FIGURE 6-48. UPPER SEAT ASSEMBLY…………….6428
FIGURE 6-49. UPPER SEAT ASSEMBLY…………….6430
FIGURE 6-50. SUSPENSION KIT…………….6432
FIGURE 6-51. SEAT BELT INSTALLATION (3IN)…………….6434
FIGURE 6-52. SEAT BELT INSTALLATION (2IN)…………….6436
FIGURE 6-53. HEATER INSTALLATION…………….6438
FIGURE 6-54. HEATER AND A/C INSTALLATION…………….6440
FIGURE 6-55. HEATER ASSEMBLY…………….6444
FIGURE 6-56. HEATER AND A/C ASSEMBLY…………….6446
FIGURE 6-57. HEATER…………….6448
FIGURE 6-58. HEATER AND A/C…………….6450
FIGURE 6-59. CAB CONDENSER ASSEMBLY…………….6452
FIGURE 6-60. CONDENSER…………….6454
FIGURE 6-61. A/C RECEIVER DRIER…………….6456
FIGURE 6-62. ROOF WIPER INSTALLATION…………….6458
FIGURE 6-63. FRONT NOSE CONE INSTALLATION (SIDELIGHT)…………….6460
FIGURE 6-64. RETRACTABLE SUNSCREEN INSTALLATION…………….6462
FIGURE 6-65. CAB STEP INSTALLATION…………….6464
FIGURE 6-66. FLOOR MAT INSTALLATION…………….6466
FIGURE 6-67. EXTERNAL WINDOW RELEASE INSTALLATION…………….6468
FIGURE 6-68. CAB GUARD INSTALLATION (TOP)…………….6470
FIGURE 6-69. CAB GUARD INSTALLATION (FRONT)…………….6472
FIGURE 6-70. CAB GUARD INSTALLATION (TOP AND FRONT)…………….6474
FIGURE 6-71. NUMBER PLATE BRACKET INSTALLATION (NO CAB GUARD)…………….6476
FIGURE 6-72. NUMBER PLATE BRACKET INSTALLATION (CAB GUARD)…………….6478
FIGURE 6-73. HITCH MIRROR INSTALLATION (CONVEX)…………….6480
FIGURE 6-74. HITCH MIRROR INSTALLATION (FLAT)…………….6482
FIGURE 6-75. MIRROR ASSEMBLY (CONVEX)…………….6484
FIGURE 6-76. INTERIOR MIRROR INSTALLATION…………….6486
FIGURE 6-77. INTERIOR MIRROR…………….6488
FIGURE 6-78. BASIC MIRROR INSTALLATION…………….6490
FIGURE 6-79. FRONT WIPER INSTALLATION…………….6492
FIGURE 6-80. WASHER TANK INSTALLATION…………….6494
FIGURE 6-81. WASHER HOSES INSTALLATION…………….6496
FIGURE 6-82. HAMMER INSTALLATION…………….6498
FIGURE 6-83. HAMMER ATTACHMENT ASSEMBLY…………….6500
FIGURE 6-84. LEVEL INDICATOR INSTALLATION…………….6502
FIGURE 6-85. HVAC CAB ACTUATOR…………….6504
FIGURE 6-86. MIRROR INSTALLATION…………….6506
SECTION 7 – CONTROLS…………….6509
FIGURE 7-1. ACCELERATOR PEDAL INSTALLATION…………….6510
FIGURE 7-2. ACCELERATOR PEDAL…………….6512
FIGURE 7-3. BRAKE PEDAL INSTALLATION…………….6514
FIGURE 7-4. BRAKE PEDAL…………….6516
FIGURE 7-5. BRAKE PEDAL PLATE…………….6518
FIGURE 7-6. BRAKE SENSOR INSTALLATION…………….6520
FIGURE 7-7. SWITCH PLATE ASSEMBLY…………….6522
FIGURE 7-8. PARKING BRAKE INSTALLATION (CABLE)…………….6524
FIGURE 7-9. PARKING BRAKE INSTALLATION (SAHR)…………….6526
FIGURE 7-10. PARKING BRAKE COVER (MECHANICAL)…………….6528
FIGURE 7-11. PARKING CABLE ASSEMBLY (MECHANICAL)…………….6530
FIGURE 7-12. STEERING WHEEL INSTALLATION…………….6532
FIGURE 7-13. STEERING WHEEL…………….6534
FIGURE 7-14. STEERING COLUMN INSTALLATION…………….6536
FIGURE 7-15. TILT STEERING COLUMN…………….6538
FIGURE 7-16. HORN INSTALLATION…………….6540
FIGURE 7-17. HORN BUTTON INSTALLATION (JLG)…………….6542
FIGURE 7-18. HORN BUTTON INSTALLATION (DEUTZ-FAHR)…………….6544
FIGURE 7-19. JOYSTICK INSTALLATION…………….6546
FIGURE 7-20. WIPER-TURN SWITCH (0 SPEED – FNR)…………….6548
FIGURE 7-21. WIPER-TURN SWITCH (NO SPEED)…………….6550
SECTION 8 – HYDRAULIC CIRCUITS…………….6553
FIGURE 8-1. COMMON HYDRAULICS INSTALLATION…………….6554
FIGURE 8-2. HYDRAULICS INSTALLATION…………….6556
FIGURE 8-3. MAIN CONTROL VALVE INSTALLATION…………….6558
FIGURE 8-4. PRIORITY VALVE INSTALLATION…………….6560
FIGURE 8-5. STEER SELECT VALVE INSTALLATION…………….6562
FIGURE 8-6. VALVE ASSEMBLY…………….6564
FIGURE 8-7. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….6566
FIGURE 8-8. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….6568
FIGURE 8-9. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….6570
FIGURE 8-10. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….6572
FIGURE 8-11. BRAKE LINES INSTALLATION…………….6574
FIGURE 8-12. BRAKE ACCUMULATOR INSTALLATION…………….6576
FIGURE 8-13. SAHR LINES INSTALLATION…………….6578
FIGURE 8-14. BRAKE LINES INSTALLATION…………….6580
FIGURE 8-15. BRAKE ACCUMULATOR…………….6582
FIGURE 8-16. STEERING LINES INSTALLATION…………….6584
FIGURE 8-17. SUCTION LINES INSTALLATION…………….6586
FIGURE 8-18. BOOM LINES INSTALLATION…………….6588
FIGURE 8-19. PRIORITY LINES INSTALLATION…………….6590
FIGURE 8-20. RETURN LINES INSTALLATION…………….6592
FIGURE 8-21. RETURN LINES INSTALLATION (SAHR)…………….6594
FIGURE 8-22. BOOM RAISE HOSES INSTALLATION (NO RIDE CONTROL)…………….6596
FIGURE 8-23. BOOM RAISE HOSES INSTALLATION (RIDE CONTROL)…………….6598
FIGURE 8-24. REAR AUX HYDRAULICS INSTALLATION (SINGLE)…………….6600
FIGURE 8-25. REAR AUX HYDRAULICS INSTALLATION (TWIN)…………….6602
FIGURE 8-26. TRAILER BRAKE INSTALLATION (NO ITALIAN)…………….6604
FIGURE 8-27. TRAILER BRAKE INSTALLATION (ITALIAN)…………….6606
FIGURE 8-28. BOOM HYDRAULIC INSTALLATION…………….6608
FIGURE 8-29. MAIN HYDRAULIC PUMP INSTALLATION…………….6610
FIGURE 8-30. IMPLEMENT PUMP INSTALLATION…………….6612
FIGURE 8-31. IMPLEMENT PUMP INSTALLATION…………….6614
FIGURE 8-32. LIFT CYLINDER INSTALLATION…………….6616
FIGURE 8-33. COMPENSATION CYLINDER INSTALLATION…………….6618
SECTION 9 – HYDRAULIC COMPONENTS…………….6621
FIGURE 9-1. LIFT CYLINDER…………….6622
FIGURE 9-2. TILT CYLINDER…………….6624
FIGURE 9-3. EXTEND/RETRACT CYLINDER ASSEMBLY…………….6626
FIGURE 9-4. INNER EXTEND/RETRACT CYLINDER…………….6628
FIGURE 9-5. OUTER EXTEND/RETRACT CYLINDER…………….6630
FIGURE 9-6. COMPENSATION CYLINDER…………….6632
FIGURE 9-7. COUPLER LOCKING CYLINDER ASSEMBLY…………….6634
FIGURE 9-8. COUPLER LOCKING CYLINDER…………….6636
FIGURE 9-9. SIDE TILT CYLINDER…………….6638
FIGURE 9-10. PIPE HANDLER CYLINDER…………….6640
FIGURE 9-11. SIDE SHIFT CARRIAGE CYLINDER…………….6642
FIGURE 9-12. FORK POSITIONING CYLINDER…………….6644
FIGURE 9-13. MAIN CONTROL VALVE (AG)…………….6646
FIGURE 9-14. PRIORITY FLOW MANIFOLD…………….6648
FIGURE 9-15. STEERING SELECT VALVE…………….6650
FIGURE 9-16. DIVERTOR VALVE ASSEMBLY (HI FLOW)…………….6652
FIGURE 9-17. DIVERTOR VALVE…………….6654
FIGURE 9-18. DIVERTOR VALVE…………….6656
FIGURE 9-19. DIVERTOR VALVE…………….6658
FIGURE 9-20. FLOW DIVIDER VALVE…………….6660
FIGURE 9-21. HYDRAULIC HITCH CONTROL VALVE (Prior to SN 1160008597)…………….6662
FIGURE 9-22. HYDRAULIC HITCH CONTROL VALVE (SN 1160008597 to Present)…………….6664
FIGURE 9-23. FAN MOTOR CONTROL VALVE…………….6666
FIGURE 9-24. BOOM CABLE ASSEMBLY…………….6668
FIGURE 9-25. IMPLEMENT PUMP…………….6670
FIGURE 9-26. IMPLEMENT PUMP…………….6672
FIGURE 9-27. VALVE, RIDE CONTROL…………….6674
FIGURE 9-28. VALVE, TRAILER BRAKE…………….6676
SECTION 10 – ELECTRICAL…………….6679
FIGURE 10-1. MAIN ELECTRICAL INSTALLATION…………….6680
FIGURE 10-2. FRONT FRAME HARNESS…………….6682
FIGURE 10-3. REAR FRAME HARNESS…………….6686
FIGURE 10-4. ENGINE WIRING INSTALLATION (ULS)…………….6690
FIGURE 10-5. ENGINE HARNESS (ULS)…………….6692
FIGURE 10-6. ENGINE ECU INSTALLATION (ULS)…………….6700
FIGURE 10-7. ENGINE WIRING INSTALLATION (LS)…………….6702
FIGURE 10-8. ENGINE HARNESS (LS)…………….6704
FIGURE 10-9. ENGINE ECU INSTALLATION (LS)…………….6710
FIGURE 10-10. FUEL PUMP HARNESS…………….6712
FIGURE 10-11. GLOW PLUG RELAY HARNESS…………….6714
FIGURE 10-12. ELECTRICAL COMPONENTS INSTALLATION…………….6716
FIGURE 10-13. POWER DISTRIBUTION ELECTRICAL BOX…………….6718
FIGURE 10-14. 200 AMP RELAY INSTALLATION…………….6720
FIGURE 10-15. BATTERY INSTALLATION (STANDARD)…………….6722
FIGURE 10-16. BATTERY INSTALLATION (DUAL)…………….6724
FIGURE 10-17. CAB ELECTRICAL INSTALLATION…………….6726
FIGURE 10-18. CAB HARNESS…………….6730
FIGURE 10-19. STANDARD ELECTRICAL BOARD ASSEMBLY…………….6738
FIGURE 10-20. OPTION 1 ELECTRICAL BOARD ASSEMBLY…………….6740
FIGURE 10-21. OPTION 2 ELECTRICAL BOARD ASSEMBLY…………….6742
FIGURE 10-22. CAB OPTION HARNESS…………….6744
FIGURE 10-23. CAB HEATER HARNESS INSTALLATION…………….6746
FIGURE 10-24. CAB HEATER HARNESS…………….6748
FIGURE 10-25. A/C OPTION HARNESS…………….6750
FIGURE 10-26. DASH ELECTRICS INSTALLATION (ULS)…………….6752
FIGURE 10-27. DASH ELECTRICS INSTALLATION (LS)…………….6754
FIGURE 10-28. REVERSE CAMERA INSTALLATION (TRAILER BRAKES)…………….6756
FIGURE 10-29. REVERSE CAMERA INSTALLATION (NO TRAILER BRAKES)…………….6758
FIGURE 10-30. REVERSE ALARM INSTALLATION…………….6760
FIGURE 10-31. REVERSE SENSOR INSTALLATION (NO HYDRAULIC HITCH)…………….6762
FIGURE 10-32. REVERSE SENSOR INSTALLATION (HYDRAULIC HITCH)…………….6764
FIGURE 10-33. REVERSE SENSOR HARNESS…………….6766
FIGURE 10-34. CLEARSKY INSTALLATION (A/C – LONG ROOF CAP)…………….6768
FIGURE 10-35. CLEARSKY INSTALLATION (NO A/C – SHORT ROOF CAP)…………….6770
FIGURE 10-36. CLEARSKY HARNESS (A/C)…………….6772
FIGURE 10-37. TELEMATICS CAP INSTALLATION…………….6774
FIGURE 10-38. DIP LIGHTS INSTALLATION (RHD – NO OUTRIGGERS)…………….6776
FIGURE 10-39. DIP LIGHTS INSTALLATION (LHD – NO OUTRIGGERS)…………….6778
FIGURE 10-40. LICENSE PLATE LAMP INSTALLATION…………….6780
FIGURE 10-41. LICENSE LIGHT HARNESS…………….6782
FIGURE 10-42. CAB WORKLIGHTS INSTALLATION (NO A/C)…………….6784
FIGURE 10-43. CAB WORKLIGHTS INSTALLATION (A/C)…………….6786
FIGURE 10-44. CAB WORKLIGHTS INSTALLATION (NO A/C – LED)…………….6788
FIGURE 10-45. CAB WORKLIGHTS INSTALLATION (A/C – LED)…………….6790
FIGURE 10-46. BOOM WORKLIGHTS INSTALLATION…………….6792
FIGURE 10-47. BOOM LED WORKLIGHTS INSTALLATION…………….6794
FIGURE 10-48. BOOM WORKLIGHTS HARNESS…………….6796
FIGURE 10-49. BEACON LIGHT INSTALLATION…………….6798
FIGURE 10-50. BEACON BRACKET INSTALLATION…………….6800
FIGURE 10-51. TRAILER ELECTRICS INSTALLATION…………….6802
FIGURE 10-52. LINK TRAILER HARNESS…………….6804
FIGURE 10-53. MULTIFUNCTION DISPLAY INSTALLATION…………….6806
FIGURE 10-54. ENGINE SPEED SET SWITCH INSTALLATION…………….6808
FIGURE 10-55. DECLUTCH SWITCH INSTALLATION…………….6810
FIGURE 10-56. FOG LAMP SWITCH INSTALLATION…………….6812
FIGURE 10-57. LSI SENSOR INSTALLATION…………….6814
FIGURE 10-58. LSI DISPLAY INSTALLATION…………….6816
FIGURE 10-59. LSI SENSOR…………….6818
FIGURE 10-60. LMIS INSTALLATION (NO MULTIFUNCTION DISPLAY)…………….6820
FIGURE 10-61. LMIS INSTALLATION (MULTIFUNCTION DISPLAY)…………….6822
FIGURE 10-62. LMIS CONTROLLER INSTALLATION…………….6824
FIGURE 10-63. LMIS CABLE REEL INSTALLATION (NO RIDE CONTROL)…………….6826
FIGURE 10-64. LMIS INSTALLATION MECH…………….6828
FIGURE 10-65. LMIS INSTALLATION MECH (RIDE CONTROL)…………….6830
FIGURE 10-66. LMIS WIRING INSTALLATION…………….6832
FIGURE 10-67. LMIS CHASSIS HARNESS…………….6834
FIGURE 10-68. LMIS BEACON INSTALLATION…………….6836
FIGURE 10-69. BOOM ANGLE SENSOR INSTALLATION…………….6838
FIGURE 10-70. EARTH STRAP INSTALLATION…………….6840
FIGURE 10-71. BOOM RETRACT SENSOR INSTALLATION…………….6842
FIGURE 10-72. IGNITION SWITCH INSTALLATION (JLG)…………….6844
FIGURE 10-73. IGNITION SWITCH INSTALLATION (DEUTZ-FAHR)…………….6846
FIGURE 10-74. BOOM HARNESS…………….6848
FIGURE 10-75. SEAT ADAPTOR HARNESS…………….6850
FIGURE 10-76. NO ROAD LIGHTS INSTALLATION…………….6852
SECTION 11 – DECALS…………….6855
FIGURE 11-1. CAPACITY CHART HOLDER INSTALLATION…………….6856
FIGURE 11-2. DECALS INSTALLATION (3510PS – JLG)…………….6858
FIGURE 11-3. DECALS INSTALLATION (35.10 – DEUTZ-FAHR)…………….6860
FIGURE 11-4. DECALS INSTALLATION (ULS) (CE)…………….6862
FIGURE 11-5. DECALS INSTALLATION (LS) (AUS – JLG)…………….6866
FIGURE 11-6. DECALS INSTALLATION (LS) (CIS – JLG)…………….6870
FIGURE 11-7. DECALS INSTALLATION (ULS) (ANSI – JLG)…………….6874
FIGURE 11-8. DECALS INSTALLATION (LS) (JLG)…………….6878
FIGURE 11-9. DECAL SOUND PLATE INSTALLATION (106DB)…………….6882
FIGURE 11-10. DECAL SOUND PLATE INSTALLATION (107DB)…………….6884
FIGURE 11-11. LOAD CHART 10M (JLG) (METRIC)…………….6886
FIGURE 11-12. LOAD CHART 10M (JLG) (AUS)…………….6888
SECTION 12 – RECOMMENDED SPARE PARTS…………….6891
FIGURE 12-1. RECOMMENDED SPARE PARTS…………….6892
PART NUMBER INDEX…………….6893
35.7…………….6911
31211097 – Operation & Safety Manual Agrovector 30.6, 35.7, 40.8, 35.10…………….6912
31211097_C_30.6, 35.7, 40.8, 35.10_Deutz-Fahr_O&SM…………….6912
Revision Log…………….6914
Read This First…………….6915
Table of Contents…………….6918
Section 1 – General Safety Practices…………….6918
Section 2 – Pre-Operation and Inspection…………….6918
Section 3 – Controls and Indicators…………….6919
Section 4 – Operation…………….6920
Section 5 – Attachments and Hitches…………….6921
Section 6 – Emergency Procedures…………….6922
Section 7 – Lubrication and Maintenance…………….6922
Section 8 – Additional Checks…………….6923
Section 9 – Specifications…………….6923
Section 1 – General Safety Practices…………….6924
1.1 Hazard Classification System…………….6924
Safety Alert System and Safety Signal Words…………….6924
1.2 General Precautions…………….6924
1.3 Operation Safety…………….6925
Electrical Hazards…………….6925
Tip Over Hazard…………….6927
Travel Hazard…………….6930
Load Falling Hazard…………….6931
Lifting Personnel…………….6932
Driving Hazards on Slopes…………….6933
Pinch Points and Crush Hazards…………….6934
Fall Hazard…………….6936
Chemical Hazards…………….6937
1.4 ClearSky (if equipped)…………….6938
Federal Communications Commission (FCC) Information for Users…………….6938
Section 2 – Pre-Operation and Inspection…………….6940
2.1 Preparation, Inspection and Maintenance…………….6940
2.2 Pre-Operation Check and Inspection…………….6941
2.3 Safety Decals…………….6943
2.4 Walk-Around Inspection…………….6949
2.5 Warm-Up and Operational Checks…………….6952
Warm-Up Check…………….6952
Operational Check…………….6952
2.6 Cab…………….6953
2.7 Enclosed Cab Windows (if equipped)…………….6954
Cab Door Window…………….6954
Rear Window…………….6955
Section 3 – Controls and Indicators…………….6956
3.1 General…………….6956
3.2 Controls…………….6957
Instrument Panel…………….6959
LCD Display…………….6963
Left Dash Control Panel…………….6965
Right Dash Control Panel…………….6966
Agriculture Control Panel…………….6968
Ignition…………….6971
Park Brake…………….6972
Parking Procedure…………….6972
Transmission Control Lever (if equipped)…………….6973
Accessory Control Lever (if equipped)…………….6975
Reversing Fan Switch (if equipped)…………….6976
Load Stability Indicator – LSI…………….6977
Steering Column Adjuster…………….6979
Joystick…………….6981
3.3 Anti-Theft Functionality (if enabled)…………….6988
Instrument Panel Input…………….6988
Multifunction Display Input…………….6988
3.4 Steer Modes…………….6989
Manual Steering Alignment Mode Change…………….6989
All Wheel Assisted Steering Alignment Mode Change…………….6990
3.5 Operator Seat…………….6991
Operator Presence…………….6991
Adjustments…………….6992
Seat Belt…………….6995
3.6 Boom Indicators…………….6996
Boom Extension…………….6996
Boom Angle (if equipped)…………….6996
3.7 Reverse Systems (if equipped)…………….6997
Reverse Sensing System…………….6997
Reversing Camera (if equipped)…………….6997
3.8 Multifunction Display (if equipped)…………….6998
General Information…………….6998
Multifunction Display and Buttons…………….6999
Home Screen…………….7001
Main Menu…………….7004
Operation and Maintenance…………….7013
Troubleshooting…………….7031
Section 4 – Operation…………….7032
4.1 Engine…………….7032
Starting the Engine…………….7032
Extreme Cold Weather Starting (if equipped)…………….7033
Battery Boosted Starting…………….7034
Normal Engine Operation…………….7036
Shut-Down Procedure…………….7037
4.2 After-Treatment System (ATS) (if equipped for ULS)…………….7039
Stationary Exhaust System Cleaning…………….7039
4.3 Operating with a Non-Suspended Load…………….7041
Lift Load Safely…………….7041
Picking Up a Load…………….7041
Transporting a Load…………….7042
Leveling Procedure…………….7042
Placing a Load…………….7043
Disengaging a Load…………….7043
4.4 Operating with a Suspended Load…………….7044
Lift Load Safely…………….7044
Picking Up a Suspended Load…………….7044
Transporting a Suspended Load…………….7045
Leveling Procedure…………….7045
Placing a Suspended Load…………….7046
Disengaging a Suspended Load…………….7046
4.5 Road Operation (CE)…………….7047
4.6 Loading and Securing for Transport…………….7048
Tie Down…………….7048
Lifting…………….7049
Section 5 – Attachments and Hitches…………….7050
5.1 Approved Attachments…………….7050
5.2 Unapproved Attachments…………….7050
5.3 JLG Supplied Attachments…………….7051
5.4 Telehandler/Attachment/Fork Capacity…………….7054
5.5 Use of the Capacity Chart…………….7055
Capacity Indicator Locations…………….7055
Sample Capacity Chart (CE)…………….7056
Sample Capacity Chart (AUS)…………….7057
Example…………….7059
5.6 Attachment Installation…………….7060
Coupler…………….7060
Hydraulic Operated Attachment…………….7063
5.7 Adjusting/Moving Forks…………….7064
5.8 Attachment Operation…………….7065
Carriage with Forks…………….7066
Fork Positioning Carriage…………….7067
Side Tilt Carriage and Fork Rotator Carriage…………….7069
Side Shift Carriage…………….7071
Fork Extension…………….7073
Dual Tine Bale…………….7075
Bale Handler…………….7077
Bucket…………….7079
Multi-Purpose Bucket…………….7081
Grapple Bucket…………….7083
Manure Grapple…………….7085
Muck Fork…………….7087
Sweeper…………….7089
Auger…………….7091
Concrete Bucket Mixer…………….7093
Truss Boom…………….7095
Coupler Mounted Hook…………….7097
Fork Mounted Hook…………….7099
Trash Hopper – Fork Mounted…………….7101
5.9 Hitches and Trailer Brakes…………….7103
Retrieval Hitch…………….7103
Fixed Hitch…………….7104
Pin Hitch – CUNA C (Italy)…………….7105
Pin Hitch – CUNA D2 (Italy)…………….7106
EEC Manual Pin Hitch…………….7107
EEC Auto Hitch…………….7108
Piton Frame and EEC Auto Hitch…………….7109
Hydraulic Hitch…………….7110
Rear Auxiliary Hydraulics…………….7111
Trailer Brakes…………….7112
Section 6 – Emergency Procedures…………….7114
6.1 Towing a Disabled Product…………….7114
Moving Short Distances…………….7114
Moving Longer Distance…………….7114
6.2 Emergency Lowering of Boom…………….7115
6.3 Emergency Exit from Enclosed Cab…………….7116
Rear Window Inside Cab…………….7116
Rear Window Outside Cab (if equipped)…………….7117
Right Side Window (Agriculture)…………….7117
Section 7 – Lubrication and Maintenance…………….7118
7.1 Introduction…………….7118
Clothing and Safety Gear…………….7118
7.2 General Maintenance Instructions…………….7119
7.3 Service and Maintenance Schedules…………….7120
10 & 1st 50 Hour Maintenance Schedule – 30.6…………….7120
50, 1st 250 & 250 Hour Maintenance Schedule – 30.6…………….7121
500, 750 & 1000 Hour Maintenance Schedule – 30.6…………….7122
1500, 2000 & 3000 Hour Maintenance Schedule – 30.6…………….7123
10 & 1st 50 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….7124
50, 1st 250 & 250 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….7125
500, 750 & 1000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….7126
1500, 2000 & 3000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….7127
7.4 Lubrication Schedules…………….7129
30.6…………….7129
35.7, 40.8, 35.10…………….7130
7.5 Operator Maintenance Instructions…………….7132
Engine Maintenance Components…………….7132
Fuel System…………….7135
Emission System (if equipped for ULS)…………….7137
Engine Oil…………….7138
Air Intake System…………….7139
Tires…………….7141
Hydraulic Oil…………….7143
Transmission Oil (35.7, 40.8, 35.10)…………….7145
Brake Fluid…………….7147
Engine Cooling System…………….7148
Windshield Washer System (if equipped)…………….7149
Cab Air Filters (if equipped)…………….7151
Load Stability Indicator System…………….7153
Section 8 – Additional Checks…………….7156
8.1 General…………….7156
8.2 Reverse Sensing System (if equipped)…………….7156
Section 9 – Specifications…………….7158
9.1 Product Specifications…………….7158
Fluids…………….7158
Capacities…………….7162
Tires…………….7164
Performance…………….7165
Dimensions…………….7167
Declaration of Vibration (CE)…………….7170
Noise Emission Level (CE)…………….7171
Machine Towing Capacity…………….7172
Index…………….7174
31211228 – Service Manual Models 3006H, 3507PS, 4008PS, 3510PS, 30.6, 35.7, 40.8, 35.10…………….7184
31211228_B_3006H,3507PS,4008PS,3510PS, 30.6, 35.7, 40.8, 35.10_JLG_Service…………….7184
Effectivity Page…………….7186
Table of Contents…………….7188
Section 1 Safety Practices…………….7192
1.1 Introduction…………….7193
1.2 Disclaimer…………….7193
1.3 Operation & Safety Manual…………….7193
1.4 Do Not Operate Tags…………….7193
1.5 Safety Information…………….7193
1.5.1 Safety Alert System and Signal Words…………….7193
1.6 Safety Instructions…………….7194
1.6.1 Personal Hazards…………….7194
1.6.2 Equipment Hazards…………….7194
1.6.3 General Hazards…………….7194
1.6.4 Operational Hazards…………….7195
1.7 Safety Decals…………….7195
Section 2 General Information and Specifications…………….7196
2.1 Replacement Parts and Warranty Information…………….7198
2.2 Specifications…………….7199
2.2.1 Travel Speed – 3006H, 30.6…………….7199
2.2.2 Travel Speed – 3507PS, 35.7…………….7199
2.2.3 Travel Speed – 4008PS, 3510PS, 40.8, 35.10…………….7199
2.2.4 Hydraulic Cylinder Performance…………….7200
2.2.5 Cylinder Drift…………….7200
2.2.6 Electrical System…………….7201
2.2.7 Engine Performance Specifications…………….7202
2.2.8 Transmission Performance Specifications…………….7203
2.2.9 Steering Angle Specification…………….7203
2.2.10 Tires…………….7204
2.3 Fluid and Lubricant Capacities…………….7206
2.3.1 Fluids (if equipped for ULS)…………….7206
2.3.2 Fluids (if equipped for LS)…………….7208
2.3.3 Capacities…………….7210
2.4 Service and Maintenance Schedules…………….7212
2.4.1 Every 10 Hours…………….7212
2.4.2 First 50 Hours…………….7213
2.4.3 Every 50 Hours…………….7213
2.4.4 First 250 Hours…………….7213
2.4.5 Every 250 Hours…………….7214
2.4.6 Every 500 Hours…………….7214
2.4.7 Every 750 Hours…………….7214
2.4.8 Every 1000 Hours…………….7215
2.4.9 Every 1500 Hours…………….7216
2.4.10 Every 2000 Hours…………….7216
2.4.11 Every 3000 Hours…………….7216
2.5 Lubrication Schedule…………….7217
2.5.1 50 & 250 Hour…………….7217
2.6 Thread Locking Compound…………….7219
2.7 Torque Charts…………….7220
2.7.1 SAE Fastener Torque Chart…………….7220
2.7.2 Metric Fastener Torque Chart…………….7226
2.8 Hydraulic Connection Assembly and Torque Specification…………….7230
2.8.1 Definitions…………….7230
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections…………….7232
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections…………….7234
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings…………….7235
2.8.5 Assembly Instructions for 45° SAE Flare Fittings…………….7238
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings…………….7240
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)…………….7242
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings…………….7244
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings…………….7247
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings…………….7255
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends…………….7263
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings…………….7265
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)…………….7273
2.8.14 Double Wrench Method…………….7276
2.8.15 FFWR and TFFT Methods…………….7277
2.8.16 Adjustable Stud End Assembly…………….7277
2.8.17 O-ring Installation (Replacement)…………….7277
Section 3 Boom…………….7278
3.1 Boom System Component Terminology…………….7279
3.1.1 3006H, 30.6…………….7279
3.1.2 3507PS, 4008PS, 35.7, 40.8…………….7280
3.1.3 3510PS, 35.10…………….7281
3.2 Boom System…………….7282
3.2.1 Boom System Operation – 3006H, 3507PS, 4008PS, 30.6, 35.7, 40.8…………….7282
3.2.2 Boom System Operation – 3510PS, 35.10…………….7282
3.3 Boom Removal/Installation…………….7282
3.3.1 Complete Boom Removal…………….7282
3.3.2 Complete Boom Installation…………….7284
3.4 Boom Assembly Maintenance – 3006H, 3507PS, 4008PS, 30.6, 35.7, 40.8…………….7286
3.4.1 Second Boom Section Removal…………….7287
3.4.2 Second Boom Section Installation…………….7289
3.5 Boom Assembly Maintenance – 3510PS, 35.10…………….7291
3.5.1 Second and Third Boom Section Removal…………….7292
3.5.2 Third Boom Section Removal…………….7294
3.5.3 Third Boom Section Installation…………….7294
3.5.4 Second and Third Boom Section Installation…………….7295
3.6 Third Boom Section Removal/ Installation Only – 3510PS, 35.10…………….7297
3.6.1 Removal…………….7297
3.6.2 Installation…………….7298
3.7 Boom Wear Pads…………….7300
3.7.1 Wear Pad Inspection…………….7300
3.7.2 Boom Wear Pad Installation, Lubrication…………….7300
3.8 Quick Coupler…………….7301
3.8.1 Manual Coupler…………….7301
3.8.2 Hydraulic Coupler…………….7302
3.9 Forks…………….7303
3.10 Boom prop (if equipped)…………….7304
3.10.1 Prop Installation…………….7304
3.10.2 Prop Removal…………….7304
3.11 Emergency Boom Lowering Procedure…………….7305
3.11.1 Equipment and Supplies Required…………….7305
3.11.2 Lowering Procedure…………….7305
3.12 Troubleshooting…………….7307
Section 4 Cab…………….7310
4.1 Operator Cab Component Terminology…………….7311
4.2 Operator Cab…………….7312
4.2.1 Operator Cab Safety…………….7312
4.2.2 Serial Number Plate…………….7312
4.3 Cab Components…………….7312
4.3.1 Steering Wheel…………….7312
4.3.2 Steering Column/Orbital Valve…………….7313
4.3.3 Service Brake…………….7314
4.3.4 Electronic Throttle Pedal…………….7315
4.3.5 Joystick Assembly…………….7316
4.3.6 Window Wiper Assembly…………….7316
4.3.7 Heater System (If equipped)…………….7316
4.3.8 Heater/Air Conditioning System (If equipped)…………….7318
4.4 Cab Removal…………….7320
4.5 Cab Installation…………….7322
Section 5 Axles, Drive Shafts, Wheels and Tires…………….7324
5.1 Axle, Drive Shaft and Wheel Component Terminology…………….7325
5.1.1 3006H, 30.6…………….7325
5.1.2 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7326
5.2 Axle Serial Number…………….7327
5.3 Axle Specifications and Maintenance Information…………….7327
5.4 Axle Replacement…………….7327
5.4.1 Axle Removal…………….7327
5.4.2 Axle Installation…………….7330
5.5 Brake Inspection…………….7332
5.6 Steering Angle Adjustment…………….7332
5.7 Axle Assembly and Drive Shaft Troubleshooting…………….7333
5.8 Drive Shafts…………….7336
5.8.1 Drive Shaft Inspection…………….7336
5.8.2 Drive Shaft Maintenance…………….7336
5.8.3 Drive Shaft – 3006H, 30.6…………….7336
5.8.4 Drive Shaft – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7337
5.8.5 Drive Shaft Cleaning and Drying…………….7338
5.9 Wheels and Tires…………….7338
5.9.1 Removing Wheel and Tire Assembly from Machine…………….7338
5.9.2 Installing Wheel and Tire Assembly onto Machine…………….7338
5.10 Towing a Disabled Machine…………….7339
5.10.1 Manually Releasing the Park Brake…………….7339
5.10.2 Manually Resetting the Park Brake…………….7341
Section 6 Transmission…………….7342
6.1 Transmission Assembly Component Terminology…………….7343
6.2 Transmission Serial Number…………….7345
6.3 Specifications and Maintenance Information…………….7345
6.4 Hydrostatic Transmission Pump Replacement – 3006H, 30.6…………….7345
6.4.1 Transmission Removal…………….7345
6.4.2 Transmission Inspection and Internal Repair…………….7346
6.4.3 Transmission Installation…………….7346
6.4.4 After Transmission Service or Replacement…………….7347
6.5 Transmission Replacement – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7347
6.5.1 Transmission Removal…………….7347
6.5.2 Transmission Inspection and Internal Repair…………….7348
6.5.3 Transmission Installation…………….7348
6.6 Transmission Fluid/Filter Replacement…………….7349
6.7 Transmission Fluid Level Check…………….7349
6.8 Torque Converter Diaphragm – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7350
6.8.1 Torque Converter Diaphragm Removal…………….7350
6.8.2 Torque Converter Diaphragm Installation…………….7350
Section 7 Engine…………….7352
7.1 Introduction…………….7353
7.1.1 Disclaimer and Scope…………….7353
7.1.2 Component Terminology…………….7354
7.2 Engine Serial Number…………….7357
7.3 Specifications and Maintenance Information…………….7357
7.4 Engine Cooling System…………….7357
7.4.1 Surge Tank Cap…………….7357
7.4.2 Thermostat Replacement…………….7357
7.4.3 Radiator Assembly Replacement…………….7358
7.5 Engine Electrical System…………….7360
7.6 Fuel System…………….7360
7.6.1 Diesel Fuel…………….7360
7.6.2 Diesel Exhaust Fluid (DEF) Tank – 3006H, 30.6…………….7360
7.6.3 Diesel Exhaust Fluid (DEF) Filter – 3006H, 30.6…………….7361
7.6.4 Diesel Exhaust Fluid (DEF) Pump Filter – 3006H, 30.6…………….7362
7.6.5 Diesel Exhaust Fluid (DEF) Tank – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7363
7.6.6 Diesel Exhaust Fluid (DEF) Filter – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7365
7.6.7 Diesel Exhaust Fluid (DEF) Pump Filter – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7366
7.6.8 Diesel Exhaust Fluid (DEF) Tank Header Element Cleaning – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7367
7.6.9 Fuel Tank…………….7368
7.6.10 After Fuel System Service…………….7369
7.7 Engine Exhaust System…………….7370
7.7.1 If equipped for ULS…………….7370
7.7.2 If equipped for LS…………….7372
7.8 Air Cleaner Assembly…………….7374
7.8.1 Air Cleaner Assembly Removal…………….7374
7.8.2 Air Cleaner Assembly Installation…………….7375
7.9 Engine Replacement…………….7376
7.9.1 Engine/Transmission Removal…………….7376
7.9.2 Transmission Removal/Installation…………….7378
7.9.3 Engine Disassembly, Inspection and Service…………….7378
7.9.4 Engine/Transmission Installation…………….7378
7.10 Troubleshooting…………….7379
Section 8 Hydraulic System…………….7380
8.1 Hydraulic Component Terminology…………….7382
8.1.1 3006H, 30.6…………….7382
8.1.2 3507PS, 4008PS, 35.7, 40.8…………….7383
8.1.3 3510PS, 35.10…………….7384
8.2 Safety Information…………….7385
8.3 Specifications…………….7385
8.4 Hydraulic Pressure Diagnosis…………….7386
8.4.1 Pressure Checks and Adjustments…………….7386
8.5 Hydraulic Circuits…………….7386
8.5.1 Hydraulic Pressures…………….7386
8.6 Hydraulic Schematic…………….7390
8.6.1 3006H, 30.6…………….7390
8.6.2 3507PS, 4008PS, 35.7, 40.8…………….7392
8.6.3 3510PS, 35.10…………….7394
8.7 Hydraulic Reservoir…………….7396
8.7.1 Hydraulic Oil Reservoir Draining…………….7396
8.7.2 Hydraulic Oil Reservoir Filling…………….7397
8.7.3 Hydraulic Filter Replacement…………….7397
8.7.4 Hydraulic Oil Reservoir Removal/ Installation…………….7398
8.8 Implement Pump…………….7400
8.8.1 Pump Replacement…………….7400
8.9 Front Drive Motor – 3006H, 30.6…………….7402
8.10 Control Valves…………….7402
8.10.1 Main Control Valve…………….7402
8.10.2 Priority Valve – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7404
8.10.3 Service Brake Valve…………….7405
8.10.4 Service Brake Bleeding…………….7407
8.10.5 Service Brake Test…………….7410
8.10.6 Park Brake Bleeding (if equipped with Hydraulic Park Brake)…………….7410
8.10.7 Steering Orbital Valve…………….7411
8.10.8 Steer Select Valve…………….7411
8.10.9 Inching Valve – 3006H, 30.6…………….7412
8.11 Boom Ride Control…………….7414
8.11.1 General Accumulator Information…………….7414
8.11.2 Accumulators…………….7415
8.11.3 Pre-Charging Accumulator…………….7415
8.11.4 Checking Pre-Charge…………….7416
8.12 Hydraulic Cylinders…………….7417
8.12.1 General Cylinder Removal Instructions…………….7417
8.12.2 Cylinder Pressure Checking…………….7419
8.12.3 Steering Cylinders…………….7419
8.12.4 Extend/Retract Cylinder Bleeding Procedure – 3510PS, 35.10…………….7419
8.12.5 Cylinder Torque Specifications…………….7420
Section 9 Electrical System…………….7422
9.1 Electrical Component Terminology…………….7425
9.1.1 General Overview…………….7425
9.2 Specifications…………….7427
9.3 Safety Information…………….7427
9.4 Power Distribution Boards…………….7428
9.4.1 Cab Power Distribution Board…………….7428
9.4.2 Frame Power Distribution Board…………….7432
9.4.3 Option 1 Distribution Board…………….7434
9.4.4 Option 2 Distribution Board…………….7436
9.4.5 Engine Harness Fuses and Relays…………….7439
9.5 Electrical System Schematics…………….7442
9.5.1 3006H, 30.6…………….7442
9.5.2 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7450
9.6 Dielectric Grease Application…………….7459
9.6.1 Installation…………….7459
9.6.2 Exclusions…………….7460
9.7 Engine Start Circuit…………….7462
9.7.1 Starter…………….7462
9.7.2 Charging Circuit…………….7464
9.7.3 Alternator…………….7464
9.8 Battery…………….7465
9.8.1 Battery Inspection…………….7465
9.8.2 Battery Removal/Installation…………….7465
9.8.3 Battery Disconnect/Connect…………….7466
9.9 Electrical Master Switch…………….7467
9.9.1 Electrical Master Switch Removal…………….7467
9.9.2 Electrical Master Switch Installation…………….7467
9.10 Window Wiper System (if equipped)…………….7468
9.10.1 Front Windshield Wiper Motor…………….7468
9.10.2 Rear Window Wiper Motor…………….7469
9.10.3 Roof Window Wiper Motor…………….7470
9.10.4 Washer Fluid Reservoir…………….7471
9.11 Cab Heater and A/C (if equipped)…………….7472
9.11.1 Cab Heater/Air Conditioning Controls…………….7472
9.12 Solenoids, Sensors and Senders…………….7473
9.12.1 Transmission Solenoid Valves – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7473
9.12.2 Transmission Oil Temperature Switch…………….7473
9.12.3 Transmission Mounted Speed Sensor – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….7474
9.12.4 Engine Coolant Temperature Sensor…………….7474
9.12.5 Fuel Level Sender…………….7475
9.12.6 Boom Angle Sensor…………….7475
9.12.7 Back-up Alarm…………….7476
9.12.8 Boom Retract Sensor…………….7477
9.13 Dash Switches…………….7478
9.13.1 Ignition Key Switch…………….7478
9.13.2 Dash Switches…………….7479
9.14 Machine Data…………….7480
9.14.1 Machine Data Access…………….7480
9.14.2 Analyzer…………….7481
9.14.3 Analyzer Software Version P.2.0…………….7482
9.15 Analyzer Software Accessibility…………….7484
9.15.1 Access Level…………….7484
9.15.2 Diagnostics…………….7484
9.15.3 Machine Set-Up…………….7485
9.15.4 Personalities…………….7487
9.15.5 Operator Tools…………….7492
9.15.6 Calibrations…………….7494
9.16 Multifunction Display…………….7496
9.16.1 Technical Specification…………….7496
9.16.2 Removal…………….7497
9.16.3 Installation…………….7498
9.16.4 Multifunction Display and Control Buttons…………….7498
9.16.5 Main Menu…………….7499
9.16.6 Setup and Maintenance…………….7518
9.16.7 Troubleshooting…………….7520
9.17 Load Stability Indicator (LSI)…………….7521
9.17.1 Load Stability Indicator…………….7521
9.17.2 LSI Sensor…………….7521
9.17.3 LSI System Calibration…………….7524
9.18 Fault Codes…………….7525
9.19 Machine Fault Codes…………….7526
9.19.1 Help Comment (00X)…………….7526
9.19.2 Power Up (21X)…………….7527
9.19.3 Platform Controls (22X0)…………….7531
9.19.4 Cabin Controls (23X)…………….7533
9.19.5 Function Prevented (25X)…………….7543
9.19.6 Line Contactor Open-Circuit (31x)…………….7545
9.19.7 Line Contactor Short-Circuit (32x)…………….7546
9.19.8 Output Drivers (33X)…………….7547
9.19.9 Engine (43X)…………….7569
9.19.10 Battery Supply (44X)…………….7573
9.19.11 Transmission and Drive System (46X)…………….7574
9.19.12 Communications (66X)…………….7596
9.19.13 Envelope Control (84x)…………….7598
9.19.14 Tilt Sensor (81x)…………….7599
9.19.15 Load Moment (85X)…………….7600
9.19.16 Steering (86x)…………….7605
9.19.17 Service Required (87x)…………….7606
9.19.18 Hardware (99X)…………….7607
9.20 Hystat Fault Codes (3006H, 30.6)…………….7612
9.20.1 Power On…………….7612
9.20.2 Custom Condition For Power On…………….7612
9.20.3 ECU Monitor…………….7613
9.20.4 ECU Health…………….7613
9.20.5 Debug Functionally…………….7613
9.20.6 Trigger For Two Step Error Reactions…………….7614
9.20.7 Report Active Error Reactions…………….7614
9.20.8 Report Active Protections…………….7614
9.20.9 Pedals And Potis (AgSnsr)…………….7615
9.20.10 Switches With Multiple States…………….7615
9.20.11 Switches With Two States (SwtBtn)…………….7615
9.20.12 Joysticks…………….7615
9.20.13 Driver On Board…………….7616
9.20.14 Parking Brake Sensors…………….7616
9.20.15 Engine Sensors…………….7616
9.20.16 Pump Sensors…………….7616
9.20.17 Speed Signals…………….7616
9.20.18 Gearbox Sensors…………….7617
9.20.19 Motor Sensors…………….7617
9.20.20 Lamps…………….7617
9.20.21 Parking Brake Actuators…………….7617
9.20.22 Diesel Engine Actuators…………….7618
9.20.23 Pump Actuators…………….7618
9.20.24 Motors Actuators…………….7618
9.20.25 Motors Actuators…………….7618
9.20.26 CAN Bus…………….7619
9.20.27 J1939 Receive Messages…………….7619
9.21 Engine Diagnostic…………….7620
31211270 – Illustrated Parts Manual Agrovector 35.7…………….7644
31211270_A_35.7_Deutz Fahr_Parts…………….7644
Effectivity Page…………….7646
Machine Configuration…………….7647
General Information…………….7648
Table of Contents…………….7650
SECTION 1 – FRAME AND ATTACHING PARTS…………….7660
FIGURE 1-1. FRAME INSTALLATION…………….7661
FIGURE 1-2. ENGINE ENCLOSURE INSTALLATION (NO RHOC)…………….7663
FIGURE 1-3. ENGINE ENCLOSURE INSTALLATION (RHOC)…………….7665
FIGURE 1-4. ENGINE ENCLOSURE COVER INSTALLATION (NO RHOC)…………….7667
FIGURE 1-5. ENGINE ENCLOSURE COVER INSTALLATION (RHOC)…………….7669
FIGURE 1-6. AIR INTAKE SEAL INSTALLATION…………….7671
FIGURE 1-7. HOOD INSTALLATION…………….7673
FIGURE 1-8. COVER PLATES INSTALLATION (NO OUTRIGGERS – ULS)…………….7675
FIGURE 1-9. COVER PLATES INSTALLATION (NO OUTRIGGERS – LS)…………….7677
FIGURE 1-10. COVER PLATE INSTALLATION (NO TRAILER BRAKES)…………….7679
FIGURE 1-11. COVER PLATE INSTALLATION (TRAILER BRAKES)…………….7681
FIGURE 1-12. COVER PLATE INSTALLATION (NO REAR AUX)…………….7683
FIGURE 1-13. COVER PLATE INSTALLATION (REAR AUX)…………….7685
FIGURE 1-14. COVER PLATE INSTALLATION (HYDRAULIC HITCH AND REAR AUX)…………….7687
FIGURE 1-15. REAR COVER PLATE INSTALLATION (NO HYDRAULIC HITCH)…………….7689
FIGURE 1-16. REAR COVER PLATE INSTALLATION (HYDRAULIC HITCH)…………….7691
FIGURE 1-17. TANKS INSTALLATION…………….7693
FIGURE 1-18. FUEL TANK INSTALLATION…………….7695
FIGURE 1-19. HYDRAULIC TANK INSTALLATION…………….7697
FIGURE 1-20. FUEL TANK ASSEMBLY…………….7699
FIGURE 1-21. HYDRAULIC TANK ASSEMBLY…………….7701
FIGURE 1-22. FUEL AND HYDRAULIC CAP INSTALLATION…………….7703
FIGURE 1-23. HITCH RETRIEVAL INSTALLATION…………….7705
FIGURE 1-24. HITCH INSTALLATION (EEC AUTO)…………….7707
FIGURE 1-25. HITCH INSTALLATION (PITON)…………….7709
FIGURE 1-26. HITCH ASSEMBLY (EEC AUTO)…………….7711
FIGURE 1-27. SLIDING HITCH ASSEMBLY (PITON)…………….7713
FIGURE 1-28. HITCH INSTALLATION (EEC MANUAL)…………….7715
FIGURE 1-29. HITCH ASSEMBLY (EEC MANUAL)…………….7717
FIGURE 1-30. HITCH INSTALLATION (CUNA CATEGORY C)…………….7719
FIGURE 1-31. HITCH ASSEMBLY (CUNA CATEGORY C)…………….7721
FIGURE 1-32. HITCH INSTALLATION (CUNA CATEGORY D2)…………….7723
FIGURE 1-33. HITCH ASSEMBLY (CUNA CATEGORY D2)…………….7725
FIGURE 1-34. HITCH INSTALLATION (FIXED)…………….7727
FIGURE 1-35. HITCH ASSEMBLY (FIXED)…………….7729
FIGURE 1-36. HITCH INSTALLATION (HYDRAULIC)…………….7731
SECTION 2 – BOOM…………….7734
FIGURE 2-1. BOOM INSTALLATION…………….7735
FIGURE 2-2. BOOM ASSEMBLY…………….7737
FIGURE 2-3. FIRST BOOM SECTION ASSEMBLY…………….7739
FIGURE 2-4. SECOND BOOM SECTION ASSEMBLY…………….7741
FIGURE 2-5. LINK ASSEMBLY…………….7743
FIGURE 2-6. LEVER ASSEMBLY…………….7745
FIGURE 2-7. MANUAL QUICK COUPLER INSTALLATION…………….7747
FIGURE 2-8. HYDRAULIC QUICK COUPLER INSTALLATION…………….7749
FIGURE 2-9. BOOM ANGLE INDICATOR INSTALLATION…………….7751
FIGURE 2-10. BOOM PROP INSTALLATION…………….7753
FIGURE 2-11. BOOM BRUSHES INSTALLATION…………….7755
SECTION 3 – ATTACHMENTS…………….7758
FIGURE 3-1. CARRIAGE ASSEMBLY (1524MM) (CE & AUS)…………….7759
FIGURE 3-2. CARRIAGE ASSEMBLY (1829MM) (CE & AUS)…………….7761
FIGURE 3-3. CARRIAGE ASSEMBLY (1225MM) (CE & AUS)…………….7763
FIGURE 3-4. CARRIAGE ASSEMBLY (JOHN DEERE FIT) (CE)…………….7765
FIGURE 3-5. CARRIAGE ASSEMBLY (MANITOU FIT) (CE)…………….7767
FIGURE 3-6. CARRIAGE ASSEMBLY (JCB FIT) (CE)…………….7769
FIGURE 3-7. DUAL TINE BAILING FORK CARRIAGE (CE & AUS)…………….7771
FIGURE 3-8. FEM CARRIAGE AND FORKS (CE & AUS)…………….7773
FIGURE 3-9. SIDE TILTING CARRIAGE (4.5 TON – 1225 MM) (CE & AUS)…………….7775
FIGURE 3-10. SIDE SHIFT CARRIAGE (4.0 TON – 1225 MM) (CE & AUS)…………….7777
FIGURE 3-11. FORK POSITIONING CARRIAGE WITH FORKS (4.0 TON) (CE & AUS)…………….7779
FIGURE 3-12. DUAL FORK CARRIAGE ASSEMBLY…………….7781
FIGURE 3-13. DUAL FORK CARRIAGE VALVE ASSEMBLY…………….7783
FIGURE 3-14. FORK ROTATING CARRIAGE (4.5 TON – 1270 MM)…………….7785
FIGURE 3-15. PALLET FORK (50X100X1070) (CE & AUS)…………….7789
FIGURE 3-16. PALLET FORK (50X100X1220) (CE & AUS)…………….7791
FIGURE 3-17. PALLET FORK (50X120X1200) (CE)…………….7793
FIGURE 3-18. PALLET FORK (50X120X1200) (CE & AUS – IF EQUIPPED WITH 1170002)…………….7795
FIGURE 3-19. BUCKET (1 M³) (CE & AUS)…………….7797
FIGURE 3-20. BUCKET (1.5 M³) (CE & AUS)…………….7799
FIGURE 3-21. BUCKET (2 M³) (CE & AUS)…………….7801
FIGURE 3-22. BUCKET (2.5 M³) (CE & AUS)…………….7803
FIGURE 3-23. BUCKET (3 M³) (CE & AUS)…………….7805
FIGURE 3-24. DIRT BUCKET (1.0 M³) (CE & AUS)…………….7807
FIGURE 3-25. 4 IN 1 BUCKET (0.6 M³) (CE & AUS)…………….7809
FIGURE 3-26. 4 IN 1 BUCKET (1.0 M³) (CE & AUS)…………….7811
FIGURE 3-27. MULTI-PURPOSE GRAPPLE BUCKET (WIDE GRIP – 2450 MM) (CE & AUS)…………….7813
FIGURE 3-28. MANURE GRAPPLE BUCKET (CE & AUS)…………….7815
FIGURE 3-29. BOLT-ON EDGE (2450 MM)…………….7817
FIGURE 3-30. BUCKET GUARD…………….7819
FIGURE 3-31. BUCKET TEETH KIT…………….7821
FIGURE 3-32. BALE HANDLER KIT (SPIKES) (CE & AUS)…………….7823
FIGURE 3-33. BALE HANDLER KIT (SPIKES TO TUBE) (CE & AUS)…………….7825
FIGURE 3-34. TRUSS BOOM (4 TON – 2.1M) (CE & AUS)…………….7827
FIGURE 3-35. TRUSS BOOM (1 TON – 3.4M) (CE & AUS)…………….7829
FIGURE 3-36. TRUSS BOOM (1.8 TON – 3 FT WITH WINCH) (CE)…………….7831
FIGURE 3-37. TRUSS BOOM (0.9 TON – 12 FT WITH WINCH) (CE)…………….7833
FIGURE 3-38. CRANE HOOK (CE & AUS)…………….7835
FIGURE 3-39. FORK MOUNTED HOOK (4 TON) (CE)…………….7837
FIGURE 3-40. BALE HANDLER (TUBE CLAMP) (CE & AUS)…………….7839
FIGURE 3-41. BALE HANDLER (SPIKE CLAMP) (CE & AUS)…………….7841
FIGURE 3-42. MUCK FORK AND GRAB (CE & AUS)…………….7843
FIGURE 3-43. CONCRETE BUCKET (CE)…………….7845
FIGURE 3-44. AUGER (COUPLER MOUNTED) (CE & AUS)…………….7847
FIGURE 3-45. FORK EXTENSION (50X100X1910) (CE)…………….7849
FIGURE 3-46. FORK EXTENSIONS (60X100X1920) (AUS)…………….7851
FIGURE 3-47. FORK TRANSPORT LATCHES INSTALLATION…………….7853
FIGURE 3-48. AUGER BIT (6INX4IN)…………….7855
FIGURE 3-49. AUGER BIT (9INX4IN)…………….7857
FIGURE 3-50. AUGER BIT (12INX4IN)…………….7859
FIGURE 3-51. AUGER BIT (15INX4IN)…………….7861
FIGURE 3-52. AUGER BIT (18INX4IN)…………….7863
FIGURE 3-53. AUGER BIT (24INX4IN)…………….7865
FIGURE 3-54. AUGER BIT (36INX4IN)…………….7867
SECTION 4 – ENGINE AND ATTACHING PARTS…………….7870
FIGURE 4-1. ENGINE INSTALLATION (74.4KW – ULS – PISTON PUMP)…………….7871
FIGURE 4-2. ENGINE INSTALLATION (90KW – ULS – PISTON PUMP)…………….7873
FIGURE 4-3. ENGINE INSTALLATION (74.4KW – LS – PISTON PUMP)…………….7875
FIGURE 4-4. ENGINE INSTALLATION (90KW – LS – PISTON PUMP)…………….7877
FIGURE 4-5. ENGINE MOUNTING INSTALLATION (74.4KW)…………….7879
FIGURE 4-6. ENGINE MOUNTING INSTALLATION (90KW/100KW)…………….7881
FIGURE 4-7. 3.6L ENGINE (74.4KW – ULS – PISTON PUMP)…………….7883
FIGURE 4-8. 3.6L ENGINE (90KW – ULS – PISTON PUMP)…………….7885
FIGURE 4-9. 3.6L ENGINE (74.4KW – LS – PISTON PUMP)…………….7887
FIGURE 4-10. 3.6L ENGINE (90KW – LS – PISTON PUMP)…………….7889
FIGURE 4-11. ENGINE ECU INSTALLATION (ULS)…………….7891
FIGURE 4-12. ENGINE ECU INSTALLATION (LS)…………….7893
FIGURE 4-13. BRACKET GUARD INSTALLATION…………….7895
FIGURE 4-14. FUEL LINES INSTALLATION (ULS)…………….7897
FIGURE 4-15. FUEL LINES INSTALLATION (ULS – RHOC)…………….7899
FIGURE 4-16. FUEL LINES INSTALLATION (LS)…………….7901
FIGURE 4-17. FUEL LINES INSTALLATION (LS – RHOC)…………….7903
FIGURE 4-18. EXHAUST INSTALLATION (ULS)…………….7905
FIGURE 4-19. EXHAUST INSTALLATION (LS)…………….7907
FIGURE 4-20. COOLING PACKAGE INSTALLATION (74.4KW – ULS)…………….7909
FIGURE 4-21. COOLING PACKAGE INSTALLATION (74.4KW – LS)…………….7911
FIGURE 4-22. COOLING PACKAGE INSTALLATION (90KW – ULS)…………….7913
FIGURE 4-23. COOLING PACKAGE INSTALLATION (90KW – LS)…………….7915
FIGURE 4-24. COOLING FAN INSTALLATION…………….7917
FIGURE 4-25. FAN LINES INSTALLATION (74.4KW)…………….7919
FIGURE 4-26. FAN LINES INSTALLATION (90KW)…………….7921
FIGURE 4-27. FAN DRIVE MOTOR (NO RHOC)…………….7923
FIGURE 4-28. FAN DRIVE MOTOR (RHOC)…………….7925
FIGURE 4-29. PRIMARY FUEL FILTER INSTALLATION (74.4KW – ULS)…………….7927
FIGURE 4-30. FUEL FILTER INSTALLATION (90/100KW – ULS)…………….7929
FIGURE 4-31. PRIMARY FUEL FILTER INSTALLATION (90KW – LS)…………….7931
FIGURE 4-32. PRIMARY FUEL FILTER INSTALLATION (74.4KW – LS)…………….7933
FIGURE 4-33. AIR CLEANER INSTALLATION (74.4KW – ULS)…………….7935
FIGURE 4-34. AIR CLEANER INSTALLATION (90/100KW)…………….7937
FIGURE 4-35. AIR CLEANER INSTALLATION (74.4KW – LS)…………….7939
FIGURE 4-36. AIR CLEANER ASSEMBLY (74.4KW)…………….7941
FIGURE 4-37. AIR CLEANER ASSEMBLY (90/100KW)…………….7943
FIGURE 4-38. AIR INTAKE LINES INSTALLATION (74.4KW – ULS)…………….7945
FIGURE 4-39. AIR INTAKE LINES INSTALLATION (90/100KW – ULS)…………….7947
FIGURE 4-40. AIR INTAKE LINES INSTALLATION (74.4KW – LS)…………….7949
FIGURE 4-41. AIR INTAKE LINES INSTALLATION (90KW – LS)…………….7951
FIGURE 4-42. COOLER INSTALLATION (74.4KW)…………….7953
FIGURE 4-43. COOLER INSTALLATION (90KW)…………….7955
FIGURE 4-44. RADIATOR COOLING PACKAGE (74.4KW)…………….7957
FIGURE 4-45. RADIATOR COOLING PACKAGE (90KW)…………….7959
FIGURE 4-46. REMOTE HOC INSTALLATION…………….7961
FIGURE 4-47. COOLANT LINES INSTALLATION (ULS)…………….7963
FIGURE 4-48. COOLANT LINES INSTALLATION (LS)…………….7965
FIGURE 4-49. COOLER LINES INSTALLATION (74.4KW)…………….7967
FIGURE 4-50. COOLER LINES INSTALLATION (90KW)…………….7969
FIGURE 4-51. CAC LINES INSTALLATION (ULS)…………….7971
FIGURE 4-52. CAC LINES INSTALLATION (LS)…………….7973
FIGURE 4-53. SURGE TANK INSTALLATION…………….7975
FIGURE 4-54. TANK EXPANSION…………….7977
FIGURE 4-55. BULKHEAD INSTALLATION…………….7979
FIGURE 4-56. DEF CONTROL MODULE INSTALLATION (ULS)…………….7981
FIGURE 4-57. DEF TANK INSTALLATION (ULS)…………….7983
FIGURE 4-58. DEF LINES INSTALLATION (ULS)…………….7985
FIGURE 4-59. DEF TANK ASSEMBLY (ULS)…………….7987
FIGURE 4-60. REMOTE FUEL PUMP INSTALLATION (74.4KW)…………….7989
FIGURE 4-61. HYDRAULIC PUMP INSTALLATION (74.4KW)…………….7991
FIGURE 4-62. HYDRAULIC PUMP INSTALLATION (90KW)…………….7993
FIGURE 4-63. HEATER LINES INSTALLATION (ULS)…………….7995
FIGURE 4-64. HEATER LINES INSTALLATION (LS)…………….7997
FIGURE 4-65. BLOCK HEATER INSTALLATION (230V – LS)…………….7999
FIGURE 4-66. BLOCK HEATER INSTALLATION (120V – LS)…………….8001
FIGURE 4-67. BLOCK HEATER (ULS)…………….8003
FIGURE 4-68. BLOCK HEATER (LS)…………….8005
FIGURE 4-69. A/C PUMP INSTALLATION…………….8007
FIGURE 4-70. A/C LINES INSTALLATION…………….8009
SECTION 5 – DRIVE TRAIN…………….8012
FIGURE 5-1. AXLES INSTALLATION (NO HYDRAULIC PARK BRAKE)…………….8013
FIGURE 5-2. AXLES INSTALLATION (HYDRAULIC PARK BRAKE)…………….8015
FIGURE 5-3. FRONT AXLE INSTALLATION (NO HYDRAULIC PARK BRAKE)…………….8017
FIGURE 5-4. FRONT AXLE, CENTRAL HOUSING (NO HYDRAULIC PARK BRAKE)…………….8019
FIGURE 5-5. FRONT AXLE, DIFFERENTIAL (NO HYDRAULIC PARK BRAKE)…………….8021
FIGURE 5-6. FRONT AXLE, HUB REDUCTION (NO HYDRAULIC PARK BRAKE)…………….8023
FIGURE 5-7. FRONT AXLE, BRAKES (NO HYDRAULIC PARK BRAKE)…………….8025
FIGURE 5-8. FRONT AXLE, STEERING (NO HYDRAULIC PARK BRAKE)…………….8027
FIGURE 5-9. FRONT AXLE INSTALLATION (HYDRAULIC PARK BRAKE)…………….8029
FIGURE 5-10. FRONT AXLE, CENTRAL HOUSING (HYDRAULIC PARK BRAKE)…………….8031
FIGURE 5-11. FRONT AXLE, DIFFERENTIAL (HYDRAULIC PARK BRAKE)…………….8033
FIGURE 5-12. FRONT AXLE, HUB REDUCTION (HYDRAULIC PARK BRAKE)…………….8035
FIGURE 5-13. FRONT AXLE, BRAKES (HYDRAULIC PARK BRAKE)…………….8037
FIGURE 5-14. FRONT AXLE, STEERING (HYDRAULIC PARK BRAKE)…………….8039
FIGURE 5-15. REAR AXLE INSTALLATION…………….8041
FIGURE 5-16. REAR AXLE, CENTRAL HOUSING…………….8043
FIGURE 5-17. REAR AXLE, DIFFERENTIAL…………….8045
FIGURE 5-18. REAR AXLE, HUB REDUCTION…………….8047
FIGURE 5-19. REAR AXLE, BRAKES…………….8049
FIGURE 5-20. REAR AXLE, STEERING…………….8051
FIGURE 5-21. DIFFERENTIAL KIT…………….8053
FIGURE 5-22. REDUCTION BUSHING KIT…………….8055
FIGURE 5-23. PLANET GEAR CARRIER KIT…………….8057
FIGURE 5-24. STEERING CASE KIT, (LF, RR)…………….8059
FIGURE 5-25. STEERING CASE KIT, (RF, LR)…………….8061
FIGURE 5-26. STEERING ADJUST BOLT KIT…………….8063
FIGURE 5-27. RING GEAR SUPPORT KIT…………….8065
FIGURE 5-28. PISTON KIT (LH)…………….8067
FIGURE 5-29. PISTON KIT (RH)…………….8069
FIGURE 5-30. DIFFERENTIAL KIT…………….8071
FIGURE 5-31. PISTON KIT…………….8073
FIGURE 5-32. DRIVE SHAFTS INSTALLATION…………….8075
FIGURE 5-33. REMOTE GREASE SYSTEM INSTALLATION…………….8077
FIGURE 5-34. AXLE SHIM INSTALLATION…………….8079
FIGURE 5-35. TRANSMISSION INSTALLATION (4 SPD)…………….8081
FIGURE 5-36. TRANSMISSION INSTALLATION (6 SPD – 90KW)…………….8083
FIGURE 5-37. TRANSMISSION (4 SPD)…………….8085
FIGURE 5-38. TRANSMISSION (6 SPD – 90KW)…………….8087
FIGURE 5-39. PLANETARY CASE AND PARTS GROUP…………….8089
FIGURE 5-40. TORQUE CONVERTER GROUP…………….8091
FIGURE 5-41. TRANSFER GEAR AND CASE GROUP…………….8093
FIGURE 5-42. TRANSFER GEAR AND CASE GROUP…………….8095
FIGURE 5-43. TRANSMISSION HYDRAULIC CONTROL GROUP…………….8097
FIGURE 5-44. INPUT SHAFT GROUP…………….8099
FIGURE 5-45. TRANSMISSION CLUTCH GROUP…………….8101
FIGURE 5-46. CLUTCH AND GEAR GROUP…………….8103
FIGURE 5-47. TRANSMISSION PUMP GROUP…………….8105
FIGURE 5-48. OUTPUT SHAFT GROUP…………….8107
FIGURE 5-49. SPEED SENSOR…………….8109
FIGURE 5-50. IDLER GEAR…………….8111
FIGURE 5-51. REAR TRANSMISSION CASE…………….8113
FIGURE 5-52. PLANETARY CASE…………….8115
FIGURE 5-53. FRONT TRANSFER CASE…………….8117
FIGURE 5-54. REAR TRANSFER CASE…………….8119
FIGURE 5-55. FRONT TRANSFER CASE…………….8121
FIGURE 5-56. REAR TRANSFER CASE…………….8123
FIGURE 5-57. RELIEF VALVE…………….8125
FIGURE 5-58. SOLENOID VALVE…………….8127
FIGURE 5-59. SOLENOID VALVE…………….8129
FIGURE 5-60. FRONT TRANSMISSION CASE ASSEMBLY…………….8131
FIGURE 5-61. REAR TRANSMISSION CASE ASSEMBLY…………….8133
FIGURE 5-62. TIRE/WHEEL SET (AIR – 15.5/80-24 – 16PR)…………….8135
FIGURE 5-63. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 15.5/80-24 – 16PR)…………….8137
FIGURE 5-64. LEFT TIRE/WHEEL ASSEMBLY (AIR – 15.5/80-24 – 16PR)…………….8139
FIGURE 5-65. TIRE/WHEEL SET (AIR – 15.5 R25 XHA TL)…………….8141
FIGURE 5-66. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 15.5 R25)…………….8143
FIGURE 5-67. LEFT TIRE/WHEEL ASSEMBLY (AIR – 15.5 R25)…………….8145
FIGURE 5-68. TIRE/WHEEL SET (AIR – 460/70 R24 XMCL)…………….8147
FIGURE 5-69. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24)…………….8149
FIGURE 5-70. LEFT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24)…………….8151
FIGURE 5-71. TIRE/WHEEL SET (AIR – 500/70 R24 XMCL)…………….8153
FIGURE 5-72. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 500/70 R24)…………….8155
FIGURE 5-73. LEFT TIRE/WHEEL ASSEMBLY (AIR – 500/70 R24)…………….8157
FIGURE 5-74. TIRE/WHEEL SET (AIR – 440/80-24 POWER CL)…………….8159
FIGURE 5-75. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 440/80-24)…………….8161
FIGURE 5-76. LEFT TIRE/WHEEL ASSEMBLY (AIR – 440/80-24)…………….8163
FIGURE 5-77. TIRE/WHEEL SET (AIR – 400/80-24 POWER CL)…………….8165
FIGURE 5-78. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 400/80-24)…………….8167
FIGURE 5-79. LEFT TIRE/WHEEL ASSEMBLY (AIR – 400/80-24)…………….8169
FIGURE 5-80. TIRE/WHEEL SET (AIR – 370/75-28)…………….8171
FIGURE 5-81. TIRE/WHEEL ASSEMBLY (AIR – 370/75-28)…………….8173
FIGURE 5-82. TIRE/WHEEL SET (FOAM – 13X24)…………….8175
FIGURE 5-83. TIRE/WHEEL SET (AIR – 460/70 R24 – BIBLOAD)…………….8177
FIGURE 5-84. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24 – BIBLOAD)…………….8179
FIGURE 5-85. LEFT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24 – BIBLOAD)…………….8181
FIGURE 5-86. WHEEL CHOCK INSTALLATION…………….8183
FIGURE 5-87. FENDER INSTALLATION (NO AIR – 460/70 R24 XMCL, AIR – 500/70 R24 XMCL, AIR – 440/80-24 POWER CL)…………….8185
FIGURE 5-88. FENDER INSTALLATION (AIR – 460/70 R24 XMCL, AIR – 500/70 R24 XMCL, AIR – 440/80-24 POWER CL)…………….8187
FIGURE 5-89. FENDER ASSEMBLY…………….8189
FIGURE 5-90. FENDER ASSEMBLY…………….8191
FIGURE 5-91. FENDER ASSEMBLY…………….8193
FIGURE 5-92. FENDER ASSEMBLY…………….8195
FIGURE 5-93. FENDER ASSEMBLY…………….8197
FIGURE 5-94. FENDER ASSEMBLY…………….8199
FIGURE 5-95. FENDER ASSEMBLY…………….8201
FIGURE 5-96. FENDER ASSEMBLY…………….8203
SECTION 6 – CAB…………….8206
FIGURE 6-1. CAB MOUNTS INSTALLATION…………….8207
FIGURE 6-2. ENCLOSED CAB INSTALLATION…………….8209
FIGURE 6-3. ENCLOSED CAB ASSEMBLY…………….8211
FIGURE 6-4. ENCLOSED CAB GROUP…………….8213
FIGURE 6-5. ENCLOSED CAB…………….8215
FIGURE 6-6. ENCLOSED CAB PLUG GROUP…………….8217
FIGURE 6-7. REAR WINDOW INSTALLATION…………….8219
FIGURE 6-8. REAR WINDOW ASSEMBLY…………….8221
FIGURE 6-9. DOOR INSTALLATION…………….8223
FIGURE 6-10. DOOR ASSEMBLY (AG)…………….8225
FIGURE 6-11. CAB DOOR…………….8227
FIGURE 6-12. DOOR UPPER GLASS ASSEMBLY…………….8229
FIGURE 6-13. CAB LATCH ASSEMBLY…………….8231
FIGURE 6-14. CAB DOOR TRIGGER ASSEMBLY…………….8233
FIGURE 6-15. DOOR STRAP INSTALLATION…………….8235
FIGURE 6-16. ENCLOSED CAB TRIM INSTALLATION…………….8237
FIGURE 6-17. DASH COVER ASSEMBLY…………….8241
FIGURE 6-18. RECIRCULATION GRILLE COVER PANEL ASSEMBLY…………….8243
FIGURE 6-19. REAR PANEL COVER ASSEMBLY…………….8245
FIGURE 6-20. ADJUSTABLE ARMREST INSTALLATION…………….8247
FIGURE 6-21. HEADLINER INSTALLATION…………….8249
FIGURE 6-22. HEADLINER/RADIO READY INSTALLATION…………….8251
FIGURE 6-23. COMMON CAB TRIM INSTALLATION…………….8253
FIGURE 6-24. CAB TRIM INSTALLATION…………….8255
FIGURE 6-25. ROOF CAP INSTALLATION (A/C)…………….8257
FIGURE 6-26. ROOF CAP INSTALLATION (NO A/C)…………….8259
FIGURE 6-27. FRONT COVER INSTALLATION…………….8261
FIGURE 6-28. FILTER TRAY PANEL…………….8263
FIGURE 6-29. FRONT DUCT COVER…………….8265
FIGURE 6-30. SEAT ASSEMBLY…………….8267
FIGURE 6-31. SEAT INSTALLATION (STANDARD)…………….8269
FIGURE 6-32. SEAT ASSEMBLY…………….8271
FIGURE 6-33. SEAT INSTALLATION (PREMIUM)…………….8273
FIGURE 6-34. SEAT INSTALLATION (MECHANICAL)…………….8275
FIGURE 6-35. SEAT ASSEMBLY…………….8277
FIGURE 6-36. UPPER SEAT ASSEMBLY…………….8279
FIGURE 6-37. UPPER SEAT ASSEMBLY…………….8281
FIGURE 6-38. SUSPENSION KIT…………….8283
FIGURE 6-39. SEAT BELT INSTALLATION (3IN)…………….8285
FIGURE 6-40. SEAT BELT INSTALLATION (2IN)…………….8287
FIGURE 6-41. HEATER INSTALLATION…………….8289
FIGURE 6-42. HEATER AND A/C INSTALLATION…………….8291
FIGURE 6-43. HEATER ASSEMBLY…………….8295
FIGURE 6-44. HEATER AND A/C ASSEMBLY…………….8297
FIGURE 6-45. HEATER…………….8299
FIGURE 6-46. HEATER AND A/C…………….8301
FIGURE 6-47. CAB CONDENSER ASSEMBLY…………….8303
FIGURE 6-48. CONDENSER…………….8305
FIGURE 6-49. A/C RECEIVER DRIER…………….8307
FIGURE 6-50. ROOF WIPER INSTALLATION…………….8309
FIGURE 6-51. FRONT NOSE CONE INSTALLATION (SIDELIGHT)…………….8311
FIGURE 6-52. RETRACTABLE SUNSCREEN INSTALLATION…………….8313
FIGURE 6-53. CAB STEP INSTALLATION…………….8315
FIGURE 6-54. FLOOR MAT INSTALLATION…………….8317
FIGURE 6-55. EXTERNAL WINDOW RELEASE INSTALLATION…………….8319
FIGURE 6-56. CAB GUARD INSTALLATION (TOP)…………….8321
FIGURE 6-57. CAB GUARD INSTALLATION (FRONT)…………….8323
FIGURE 6-58. CAB GUARD INSTALLATION (TOP AND FRONT)…………….8325
FIGURE 6-59. NUMBER PLATE BRACKET INSTALLATION (NO CAB GUARD)…………….8327
FIGURE 6-60. NUMBER PLATE BRACKET INSTALLATION (CAB GUARD)…………….8329
FIGURE 6-61. MIRROR INSTALLATION…………….8331
FIGURE 6-62. HITCH MIRROR INSTALLATION (CONVEX)…………….8333
FIGURE 6-63. HITCH MIRROR INSTALLATION (FLAT)…………….8335
FIGURE 6-64. MIRROR ASSEMBLY (CONVEX)…………….8337
FIGURE 6-65. INTERIOR MIRROR INSTALLATION…………….8339
FIGURE 6-66. INTERIOR MIRROR…………….8341
FIGURE 6-67. BASIC MIRROR INSTALLATION…………….8343
FIGURE 6-68. FRONT WIPER INSTALLATION…………….8345
FIGURE 6-69. WASHER TANK INSTALLATION…………….8347
FIGURE 6-70. WASHER BOTTLE…………….8349
FIGURE 6-71. WASHER HOSES INSTALLATION…………….8351
FIGURE 6-72. HAMMER INSTALLATION…………….8353
FIGURE 6-73. HAMMER ATTACHMENT ASSEMBLY…………….8355
FIGURE 6-74. LEVEL INDICATOR INSTALLATION…………….8357
SECTION 7 – CONTROLS…………….8360
FIGURE 7-1. ACCELERATOR PEDAL INSTALLATION…………….8361
FIGURE 7-2. ACCELERATOR PEDAL…………….8363
FIGURE 7-3. BRAKE PEDAL INSTALLATION…………….8365
FIGURE 7-4. BRAKE PEDAL…………….8367
FIGURE 7-5. BRAKE PEDAL PLATE…………….8369
FIGURE 7-6. BRAKE SENSOR INSTALLATION…………….8371
FIGURE 7-7. SWITCH PLATE ASSEMBLY…………….8373
FIGURE 7-8. PARKING BRAKE INSTALLATION (CABLE)…………….8375
FIGURE 7-9. PARKING BRAKE INSTALLATION (SAHR)…………….8377
FIGURE 7-10. PARKING BRAKE COVER (MECHANICAL)…………….8379
FIGURE 7-11. PARKING CABLE ASSEMBLY (MECHANICAL)…………….8381
FIGURE 7-12. STEERING WHEEL INSTALLATION…………….8383
FIGURE 7-13. STEERING WHEEL…………….8385
FIGURE 7-14. STEERING COLUMN INSTALLATION…………….8387
FIGURE 7-15. TILT STEERING COLUMN…………….8389
FIGURE 7-16. HORN INSTALLATION…………….8391
FIGURE 7-17. HORN BUTTON INSTALLATION…………….8393
FIGURE 7-18. JOYSTICK INSTALLATION…………….8395
FIGURE 7-19. WIPER-TURN SWITCH (0 SPEED – FNR)…………….8397
FIGURE 7-20. WIPER-TURN SWITCH (NO SPEED)…………….8399
SECTION 8 – HYDRAULIC CIRCUITS…………….8402
FIGURE 8-1. COMMON HYDRAULICS INSTALLATION…………….8403
FIGURE 8-2. HYDRAULICS INSTALLATION…………….8405
FIGURE 8-3. MAIN CONTROL VALVE INSTALLATION…………….8407
FIGURE 8-4. PRIORITY VALVE INSTALLATION…………….8409
FIGURE 8-5. STEER SELECT VALVE INSTALLATION…………….8411
FIGURE 8-6. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….8413
FIGURE 8-7. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….8415
FIGURE 8-8. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….8417
FIGURE 8-9. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….8419
FIGURE 8-10. BRAKE LINES INSTALLATION…………….8421
FIGURE 8-11. BRAKE LINES INSTALLATION…………….8423
FIGURE 8-12. SAHR LINES INSTALLATION…………….8425
FIGURE 8-13. BRAKE ACCUMULATOR…………….8427
FIGURE 8-14. BRAKE ACCUMLATOR INSTALLATION…………….8429
FIGURE 8-15. STEERING LINES INSTALLATION…………….8431
FIGURE 8-16. SUCTION LINES INSTALLATION…………….8433
FIGURE 8-17. BOOM LINES INSTALLATION…………….8435
FIGURE 8-18. PRIORITY LINES INSTALLATION…………….8437
FIGURE 8-19. RETURN LINES INSTALLATION (NO SAHR)…………….8439
FIGURE 8-20. RETURN LINES INSTALLATION (SAHR)…………….8441
FIGURE 8-21. BOOM RAISE HOSES INSTALLATION (NO RIDE CONTROL)…………….8443
FIGURE 8-22. BOOM RAISE HOSES INSTALLATION (RIDE CONTROL)…………….8445
FIGURE 8-23. REAR AUX HYDRAULICS INSTALLATION (SINGLE)…………….8447
FIGURE 8-24. REAR AUX HYDRAULICS INSTALLATION (TWIN)…………….8449
FIGURE 8-25. TRAILER BRAKE INSTALLATION (NO ITALIAN)…………….8451
FIGURE 8-26. TRAILER BRAKE INSTALLATION (ITALIAN)…………….8453
FIGURE 8-27. BOOM HYDRAULIC INSTALLATION…………….8455
FIGURE 8-28. MAIN HYDRAULIC PUMP INSTALLATION…………….8457
FIGURE 8-29. IMPLEMENT PUMP INSTALLATION…………….8459
FIGURE 8-30. LIFT CYLINDER INSTALLATION…………….8461
FIGURE 8-31. COMPENSATION CYLINDER INSTALLATION…………….8463
SECTION 9 – HYDRAULIC COMPONENTS…………….8466
FIGURE 9-1. LIFT CYLINDER…………….8467
FIGURE 9-2. TILT CYLINDER…………….8469
FIGURE 9-3. INNER EXTEND/RETRACT CYLINDER…………….8471
FIGURE 9-4. COMPENSATION CYLINDER…………….8473
FIGURE 9-5. COUPLER LOCKING CYLINDER ASSEMBLY…………….8475
FIGURE 9-6. SIDE SHIFT CARRIAGE CYLINDER…………….8477
FIGURE 9-7. FORK POSITIONING CYLINDER…………….8479
FIGURE 9-8. COUPLER LOCKING CYLINDER…………….8481
FIGURE 9-9. SIDE TILT CYLINDER…………….8483
FIGURE 9-10. PIPE HANDLER CYLINDER…………….8485
FIGURE 9-11. MAIN CONTROL VALVE…………….8487
FIGURE 9-12. PRIORITY FLOW MANIFOLD…………….8489
FIGURE 9-13. STEERING SELECT VALVE…………….8491
FIGURE 9-14. VALVE ASSEMBLY…………….8493
FIGURE 9-15. DIVERTOR VALVE ASSEMBLY (HI FLOW)…………….8495
FIGURE 9-16. DIVERTOR VALVE…………….8497
FIGURE 9-17. DIVERTOR VALVE…………….8499
FIGURE 9-18. DIVERTOR VALVE…………….8501
FIGURE 9-19. FLOW DIVIDER VALVE…………….8503
FIGURE 9-20. HYDRAULIC HITCH CONTROL VALVE…………….8505
FIGURE 9-21. TRAILER BRAKE VALVE…………….8507
FIGURE 9-22. FAN MOTOR CONTROL VALVE…………….8509
FIGURE 9-23. IMPLEMENT PUMP…………….8511
SECTION 10 – ELECTRICAL…………….8514
FIGURE 10-1. MAIN ELECTRICAL INSTALLATION…………….8515
FIGURE 10-2. CAB ELECTRICAL INSTALLATION…………….8517
FIGURE 10-3. IGNITION SWITCH INSTALLATION…………….8521
FIGURE 10-4. STANDARD ELECTRICAL BOARD ASSEMBLY…………….8523
FIGURE 10-5. OPTION 1 ELECTRICAL BOARD ASSEMBLY…………….8525
FIGURE 10-6. OPTION 2 ELECTRICAL BOARD ASSEMBLY…………….8527
FIGURE 10-7. CAB HEATER HARNESS INSTALLATION…………….8529
FIGURE 10-8. BOOM HARNESS INSTALLATION…………….8531
FIGURE 10-9. ENGINE WIRING INSTALLATION (ULS)…………….8533
FIGURE 10-10. ENGINE WIRING INSTALLATION (LS)…………….8535
FIGURE 10-11. ELECTRICAL COMPONENTS INSTALLATION…………….8537
FIGURE 10-12. POWER DISTRIBUTION ELECTRICAL BOX…………….8539
FIGURE 10-13. 200 AMP RELAY INSTALLATION…………….8541
FIGURE 10-14. BATTERY INSTALLATION (STANDARD)…………….8543
FIGURE 10-15. BATTERY INSTALLATION (DUAL)…………….8545
FIGURE 10-16. DASH ELECTRICS INSTALLATION (ULS)…………….8547
FIGURE 10-17. DASH ELECTRICS INSTALLATION (LS)…………….8549
FIGURE 10-18. MULTIFUNCTION DISPLAY INSTALLATION…………….8551
FIGURE 10-19. REVERSE CAMERA INSTALLATION (TRAILER BRAKES)…………….8553
FIGURE 10-20. REVERSE CAMERA INSTALLATION (NO TRAILER BRAKES)…………….8555
FIGURE 10-21. REVERSE ALARM INSTALLATION…………….8557
FIGURE 10-22. REVERSE SENSOR INSTALLATION (NO HYDRAULIC HITCH)…………….8559
FIGURE 10-23. REVERSE SENSOR INSTALLATION (HYDRAULIC HITCH)…………….8561
FIGURE 10-24. CLEARSKY INSTALLATION (A/C – LONG ROOF CAP)…………….8563
FIGURE 10-25. CLEARSKY INSTALLATION (NO A/C – SHORT ROOF CAP)…………….8565
FIGURE 10-26. TELEMATICS INSTALLATION (A/C – ULS)…………….8567
FIGURE 10-27. TELEMATICS INSTALLATION (A/C – LS)…………….8569
FIGURE 10-28. TELEMATICS INSTALLATION (NO A/C – ULS)…………….8571
FIGURE 10-29. TELEMATICS CAP INSTALLATION…………….8573
FIGURE 10-30. CAB WORKLIGHTS INSTALLATION (NO A/C)…………….8575
FIGURE 10-31. CAB WORKLIGHTS INSTALLATION (A/C)…………….8577
FIGURE 10-32. CAB WORKLIGHTS INSTALLATION (NO A/C – LED)…………….8579
FIGURE 10-33. CAB WORKLIGHTS INSTALLATION (A/C – LED)…………….8581
FIGURE 10-34. BOOM WORKLIGHTS INSTALLATION…………….8583
FIGURE 10-35. BOOM LED WORKLIGHTS INSTALLATION…………….8585
FIGURE 10-36. BEACON LIGHT INSTALLATION…………….8587
FIGURE 10-37. BEACON BRACKET INSTALLATION…………….8589
FIGURE 10-38. DIP LIGHTS INSTALLATION (RHD – NO OUTRIGGERS)…………….8591
FIGURE 10-39. DIP LIGHTS INSTALLATION (LHD – NO OUTRIGGERS)…………….8593
FIGURE 10-40. LICENSE PLATE LAMP INSTALLATION…………….8595
FIGURE 10-41. TRAILER ELECTRICS INSTALLATION…………….8597
FIGURE 10-42. ENGINE SPEED SET SWITCH INSTALLATION…………….8599
FIGURE 10-43. DECLUTCH SWITCH INSTALLATION…………….8601
FIGURE 10-44. FOG LAMP SWITCH INSTALLATION…………….8603
FIGURE 10-45. LSI SENSOR INSTALLATION…………….8605
FIGURE 10-46. LSI ASSEMBLY…………….8607
FIGURE 10-47. LSI SENSOR…………….8609
FIGURE 10-48. LMIS INSTALLATION (NO RIDE CONTROL)…………….8611
FIGURE 10-49. LMIS INSTALLATION (RIDE CONTROL)…………….8613
FIGURE 10-50. LMIS CONTROLLER INSTALLATION…………….8615
FIGURE 10-51. LMIS CABLE REEL INSTALLATION (NO RIDE CONTROL)…………….8617
FIGURE 10-52. LMIS CABLE REEL INSTALLATION (RIDE CONTROL)…………….8619
FIGURE 10-53. LMIS WIRING INSTALLATION…………….8621
FIGURE 10-54. LMIS BEACON INSTALLATION…………….8623
FIGURE 10-55. BOOM ANGLE SENSOR INSTALLATION…………….8625
FIGURE 10-56. EARTH STRAP INSTALLATION…………….8627
FIGURE 10-57. BOOM RETRACT SENSOR INSTALLATION…………….8629
FIGURE 10-58. FRONT FRAME HARNESS…………….8631
FIGURE 10-59. REAR FRAME HARNESS…………….8635
FIGURE 10-60. ENGINE HARNESS (ULS)…………….8639
FIGURE 10-61. ENGINE HARNESS (LS)…………….8647
FIGURE 10-62. FUEL PUMP HARNESS…………….8653
FIGURE 10-63. GLOW PLUG RELAY HARNESS…………….8655
FIGURE 10-64. BOOM HARNESS…………….8657
FIGURE 10-65. LMIS CHASSIS HARNESS…………….8659
FIGURE 10-66. CAB HARNESS…………….8661
FIGURE 10-67. CAB HARNESS…………….8663
FIGURE 10-68. CAB OPTION HARNESS…………….8669
FIGURE 10-69. CAB HEATER HARNESS…………….8671
FIGURE 10-70. A/C OPTION HARNESS…………….8673
FIGURE 10-71. REVERSE SENSOR HARNESS…………….8675
FIGURE 10-72. TELEMATICS HARNESS (A/C)…………….8677
FIGURE 10-73. TELEMATICS HARNESS (NO A/C)…………….8679
FIGURE 10-74. CLEARSKY HARNESS…………….8681
FIGURE 10-75. LICENSE LIGHT HARNESS…………….8683
FIGURE 10-76. LINK TRAILER HARNESS…………….8685
FIGURE 10-77. SEAT ADAPTOR HARNESS…………….8687
FIGURE 10-78. BOOM WORKLIGHTS HARNESS…………….8689
SECTION 11 – DECALS…………….8692
FIGURE 11-1. CAPACITY CHART HOLDER INSTALLATION…………….8693
FIGURE 11-2. CAPACITY CHART (METRIC)…………….8695
FIGURE 11-3. CAPACITY CHART (AUS)…………….8697
FIGURE 11-4. DECALS INSTALLATION (CE)…………….8699
FIGURE 11-5. DECALS INSTALLATION (CE & JAPAN)…………….8701
FIGURE 11-6. DECALS INSTALLATION (AUS)…………….8705
FIGURE 11-7. DECAL SOUND PLATE INSTALLATION (106DB)…………….8709
FIGURE 11-8. DECAL SOUND PLATE INSTALLATION (107DB)…………….8711
SECTION 12 – RECOMMENDED SPARE PARTS…………….8714
FIGURE 12-1. RECOMMENDED SPARE PARTS…………….8715
PART NUMBER INDEX…………….8718
40.8…………….8734
31211097 – Operation & Safety Manual Agrovector 30.6,35.7, 40.8, 35.10…………….8735
31211097_C_30.6, 35.7, 40.8, 35.10_Deutz-Fahr_O&SM…………….8735
Revision Log…………….8737
Read This First…………….8738
Table of Contents…………….8741
Section 1 – General Safety Practices…………….8741
Section 2 – Pre-Operation and Inspection…………….8741
Section 3 – Controls and Indicators…………….8742
Section 4 – Operation…………….8743
Section 5 – Attachments and Hitches…………….8744
Section 6 – Emergency Procedures…………….8745
Section 7 – Lubrication and Maintenance…………….8745
Section 8 – Additional Checks…………….8746
Section 9 – Specifications…………….8746
Section 1 – General Safety Practices…………….8747
1.1 Hazard Classification System…………….8747
Safety Alert System and Safety Signal Words…………….8747
1.2 General Precautions…………….8747
1.3 Operation Safety…………….8748
Electrical Hazards…………….8748
Tip Over Hazard…………….8750
Travel Hazard…………….8753
Load Falling Hazard…………….8754
Lifting Personnel…………….8755
Driving Hazards on Slopes…………….8756
Pinch Points and Crush Hazards…………….8757
Fall Hazard…………….8759
Chemical Hazards…………….8760
1.4 ClearSky (if equipped)…………….8761
Federal Communications Commission (FCC) Information for Users…………….8761
Section 2 – Pre-Operation and Inspection…………….8763
2.1 Preparation, Inspection and Maintenance…………….8763
2.2 Pre-Operation Check and Inspection…………….8764
2.3 Safety Decals…………….8766
2.4 Walk-Around Inspection…………….8772
2.5 Warm-Up and Operational Checks…………….8775
Warm-Up Check…………….8775
Operational Check…………….8775
2.6 Cab…………….8776
2.7 Enclosed Cab Windows (if equipped)…………….8777
Cab Door Window…………….8777
Rear Window…………….8778
Section 3 – Controls and Indicators…………….8779
3.1 General…………….8779
3.2 Controls…………….8780
Instrument Panel…………….8782
LCD Display…………….8786
Left Dash Control Panel…………….8788
Right Dash Control Panel…………….8789
Agriculture Control Panel…………….8791
Ignition…………….8794
Park Brake…………….8795
Parking Procedure…………….8795
Transmission Control Lever (if equipped)…………….8796
Accessory Control Lever (if equipped)…………….8798
Reversing Fan Switch (if equipped)…………….8799
Load Stability Indicator – LSI…………….8800
Steering Column Adjuster…………….8802
Joystick…………….8804
3.3 Anti-Theft Functionality (if enabled)…………….8811
Instrument Panel Input…………….8811
Multifunction Display Input…………….8811
3.4 Steer Modes…………….8812
Manual Steering Alignment Mode Change…………….8812
All Wheel Assisted Steering Alignment Mode Change…………….8813
3.5 Operator Seat…………….8814
Operator Presence…………….8814
Adjustments…………….8815
Seat Belt…………….8818
3.6 Boom Indicators…………….8819
Boom Extension…………….8819
Boom Angle (if equipped)…………….8819
3.7 Reverse Systems (if equipped)…………….8820
Reverse Sensing System…………….8820
Reversing Camera (if equipped)…………….8820
3.8 Multifunction Display (if equipped)…………….8821
General Information…………….8821
Multifunction Display and Buttons…………….8822
Home Screen…………….8824
Main Menu…………….8827
Operation and Maintenance…………….8836
Troubleshooting…………….8854
Section 4 – Operation…………….8855
4.1 Engine…………….8855
Starting the Engine…………….8855
Extreme Cold Weather Starting (if equipped)…………….8856
Battery Boosted Starting…………….8857
Normal Engine Operation…………….8859
Shut-Down Procedure…………….8860
4.2 After-Treatment System (ATS) (if equipped for ULS)…………….8862
Stationary Exhaust System Cleaning…………….8862
4.3 Operating with a Non-Suspended Load…………….8864
Lift Load Safely…………….8864
Picking Up a Load…………….8864
Transporting a Load…………….8865
Leveling Procedure…………….8865
Placing a Load…………….8866
Disengaging a Load…………….8866
4.4 Operating with a Suspended Load…………….8867
Lift Load Safely…………….8867
Picking Up a Suspended Load…………….8867
Transporting a Suspended Load…………….8868
Leveling Procedure…………….8868
Placing a Suspended Load…………….8869
Disengaging a Suspended Load…………….8869
4.5 Road Operation (CE)…………….8870
4.6 Loading and Securing for Transport…………….8871
Tie Down…………….8871
Lifting…………….8872
Section 5 – Attachments and Hitches…………….8873
5.1 Approved Attachments…………….8873
5.2 Unapproved Attachments…………….8873
5.3 JLG Supplied Attachments…………….8874
5.4 Telehandler/Attachment/Fork Capacity…………….8877
5.5 Use of the Capacity Chart…………….8878
Capacity Indicator Locations…………….8878
Sample Capacity Chart (CE)…………….8879
Sample Capacity Chart (AUS)…………….8880
Example…………….8882
5.6 Attachment Installation…………….8883
Coupler…………….8883
Hydraulic Operated Attachment…………….8886
5.7 Adjusting/Moving Forks…………….8887
5.8 Attachment Operation…………….8888
Carriage with Forks…………….8889
Fork Positioning Carriage…………….8890
Side Tilt Carriage and Fork Rotator Carriage…………….8892
Side Shift Carriage…………….8894
Fork Extension…………….8896
Dual Tine Bale…………….8898
Bale Handler…………….8900
Bucket…………….8902
Multi-Purpose Bucket…………….8904
Grapple Bucket…………….8906
Manure Grapple…………….8908
Muck Fork…………….8910
Sweeper…………….8912
Auger…………….8914
Concrete Bucket Mixer…………….8916
Truss Boom…………….8918
Coupler Mounted Hook…………….8920
Fork Mounted Hook…………….8922
Trash Hopper – Fork Mounted…………….8924
5.9 Hitches and Trailer Brakes…………….8926
Retrieval Hitch…………….8926
Fixed Hitch…………….8927
Pin Hitch – CUNA C (Italy)…………….8928
Pin Hitch – CUNA D2 (Italy)…………….8929
EEC Manual Pin Hitch…………….8930
EEC Auto Hitch…………….8931
Piton Frame and EEC Auto Hitch…………….8932
Hydraulic Hitch…………….8933
Rear Auxiliary Hydraulics…………….8934
Trailer Brakes…………….8935
Section 6 – Emergency Procedures…………….8937
6.1 Towing a Disabled Product…………….8937
Moving Short Distances…………….8937
Moving Longer Distance…………….8937
6.2 Emergency Lowering of Boom…………….8938
6.3 Emergency Exit from Enclosed Cab…………….8939
Rear Window Inside Cab…………….8939
Rear Window Outside Cab (if equipped)…………….8940
Right Side Window (Agriculture)…………….8940
Section 7 – Lubrication and Maintenance…………….8941
7.1 Introduction…………….8941
Clothing and Safety Gear…………….8941
7.2 General Maintenance Instructions…………….8942
7.3 Service and Maintenance Schedules…………….8943
10 & 1st 50 Hour Maintenance Schedule – 30.6…………….8943
50, 1st 250 & 250 Hour Maintenance Schedule – 30.6…………….8944
500, 750 & 1000 Hour Maintenance Schedule – 30.6…………….8945
1500, 2000 & 3000 Hour Maintenance Schedule – 30.6…………….8946
10 & 1st 50 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….8947
50, 1st 250 & 250 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….8948
500, 750 & 1000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….8949
1500, 2000 & 3000 Hour Maintenance Schedule – 35.7, 40.8, 35.10…………….8950
7.4 Lubrication Schedules…………….8952
30.6…………….8952
35.7, 40.8, 35.10…………….8953
7.5 Operator Maintenance Instructions…………….8955
Engine Maintenance Components…………….8955
Fuel System…………….8958
Emission System (if equipped for ULS)…………….8960
Engine Oil…………….8961
Air Intake System…………….8962
Tires…………….8964
Hydraulic Oil…………….8966
Transmission Oil (35.7, 40.8, 35.10)…………….8968
Brake Fluid…………….8970
Engine Cooling System…………….8971
Windshield Washer System (if equipped)…………….8972
Cab Air Filters (if equipped)…………….8974
Load Stability Indicator System…………….8976
Section 8 – Additional Checks…………….8979
8.1 General…………….8979
8.2 Reverse Sensing System (if equipped)…………….8979
Section 9 – Specifications…………….8981
9.1 Product Specifications…………….8981
Fluids…………….8981
Capacities…………….8985
Tires…………….8987
Performance…………….8988
Dimensions…………….8990
Declaration of Vibration (CE)…………….8993
Noise Emission Level (CE)…………….8994
Machine Towing Capacity…………….8995
Index…………….8997
31211228 – Service Manual Models 3006H, 3507PS, 4008PS, 3510PS, 30.6, 35.7, 40.8, 35.10…………….9007
31211228_B_3006H,3507PS,4008PS,3510PS, 30.6, 35.7, 40.8, 35.10_JLG_Service…………….9007
Effectivity Page…………….9009
Table of Contents…………….9011
Section 1 Safety Practices…………….9015
1.1 Introduction…………….9016
1.2 Disclaimer…………….9016
1.3 Operation & Safety Manual…………….9016
1.4 Do Not Operate Tags…………….9016
1.5 Safety Information…………….9016
1.5.1 Safety Alert System and Signal Words…………….9016
1.6 Safety Instructions…………….9017
1.6.1 Personal Hazards…………….9017
1.6.2 Equipment Hazards…………….9017
1.6.3 General Hazards…………….9017
1.6.4 Operational Hazards…………….9018
1.7 Safety Decals…………….9018
Section 2 General Information and Specifications…………….9019
2.1 Replacement Parts and Warranty Information…………….9021
2.2 Specifications…………….9022
2.2.1 Travel Speed – 3006H, 30.6…………….9022
2.2.2 Travel Speed – 3507PS, 35.7…………….9022
2.2.3 Travel Speed – 4008PS, 3510PS, 40.8, 35.10…………….9022
2.2.4 Hydraulic Cylinder Performance…………….9023
2.2.5 Cylinder Drift…………….9023
2.2.6 Electrical System…………….9024
2.2.7 Engine Performance Specifications…………….9025
2.2.8 Transmission Performance Specifications…………….9026
2.2.9 Steering Angle Specification…………….9026
2.2.10 Tires…………….9027
2.3 Fluid and Lubricant Capacities…………….9029
2.3.1 Fluids (if equipped for ULS)…………….9029
2.3.2 Fluids (if equipped for LS)…………….9031
2.3.3 Capacities…………….9033
2.4 Service and Maintenance Schedules…………….9035
2.4.1 Every 10 Hours…………….9035
2.4.2 First 50 Hours…………….9036
2.4.3 Every 50 Hours…………….9036
2.4.4 First 250 Hours…………….9036
2.4.5 Every 250 Hours…………….9037
2.4.6 Every 500 Hours…………….9037
2.4.7 Every 750 Hours…………….9037
2.4.8 Every 1000 Hours…………….9038
2.4.9 Every 1500 Hours…………….9039
2.4.10 Every 2000 Hours…………….9039
2.4.11 Every 3000 Hours…………….9039
2.5 Lubrication Schedule…………….9040
2.5.1 50 & 250 Hour…………….9040
2.6 Thread Locking Compound…………….9042
2.7 Torque Charts…………….9043
2.7.1 SAE Fastener Torque Chart…………….9043
2.7.2 Metric Fastener Torque Chart…………….9049
2.8 Hydraulic Connection Assembly and Torque Specification…………….9053
2.8.1 Definitions…………….9053
2.8.2 Assembly Instructions for American Standard Pipe Thread Tapered Connections…………….9055
2.8.3 Assembly Instructions for British Standard Pipe Thread Tapered Connections…………….9057
2.8.4 Assembly Instructions for 37° (JIC) Flare Fittings…………….9058
2.8.5 Assembly Instructions for 45° SAE Flare Fittings…………….9061
2.8.6 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings…………….9063
2.8.7 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)…………….9065
2.8.8 Assembly Instructions for Bulkhead (BH) Fittings…………….9067
2.8.9 Assembly Instructions for O-Ring Boss (ORB) Fittings…………….9070
2.8.10 Assembly Instructions for Adjustable Port End Metric Fittings…………….9078
2.8.11 Assembly Instructions for Metric ISO 6149 Port Assembly Stud Ends…………….9086
2.8.12 Assembly Instructions for Adjustable Port End (BSPP) Fittings…………….9088
2.8.13 Assembly Instructions for Flange Connections (FL61 and FL62)…………….9096
2.8.14 Double Wrench Method…………….9099
2.8.15 FFWR and TFFT Methods…………….9100
2.8.16 Adjustable Stud End Assembly…………….9100
2.8.17 O-ring Installation (Replacement)…………….9100
Section 3 Boom…………….9101
3.1 Boom System Component Terminology…………….9102
3.1.1 3006H, 30.6…………….9102
3.1.2 3507PS, 4008PS, 35.7, 40.8…………….9103
3.1.3 3510PS, 35.10…………….9104
3.2 Boom System…………….9105
3.2.1 Boom System Operation – 3006H, 3507PS, 4008PS, 30.6, 35.7, 40.8…………….9105
3.2.2 Boom System Operation – 3510PS, 35.10…………….9105
3.3 Boom Removal/Installation…………….9105
3.3.1 Complete Boom Removal…………….9105
3.3.2 Complete Boom Installation…………….9107
3.4 Boom Assembly Maintenance – 3006H, 3507PS, 4008PS, 30.6, 35.7, 40.8…………….9109
3.4.1 Second Boom Section Removal…………….9110
3.4.2 Second Boom Section Installation…………….9112
3.5 Boom Assembly Maintenance – 3510PS, 35.10…………….9114
3.5.1 Second and Third Boom Section Removal…………….9115
3.5.2 Third Boom Section Removal…………….9117
3.5.3 Third Boom Section Installation…………….9117
3.5.4 Second and Third Boom Section Installation…………….9118
3.6 Third Boom Section Removal/ Installation Only – 3510PS, 35.10…………….9120
3.6.1 Removal…………….9120
3.6.2 Installation…………….9121
3.7 Boom Wear Pads…………….9123
3.7.1 Wear Pad Inspection…………….9123
3.7.2 Boom Wear Pad Installation, Lubrication…………….9123
3.8 Quick Coupler…………….9124
3.8.1 Manual Coupler…………….9124
3.8.2 Hydraulic Coupler…………….9125
3.9 Forks…………….9126
3.10 Boom prop (if equipped)…………….9127
3.10.1 Prop Installation…………….9127
3.10.2 Prop Removal…………….9127
3.11 Emergency Boom Lowering Procedure…………….9128
3.11.1 Equipment and Supplies Required…………….9128
3.11.2 Lowering Procedure…………….9128
3.12 Troubleshooting…………….9130
Section 4 Cab…………….9133
4.1 Operator Cab Component Terminology…………….9134
4.2 Operator Cab…………….9135
4.2.1 Operator Cab Safety…………….9135
4.2.2 Serial Number Plate…………….9135
4.3 Cab Components…………….9135
4.3.1 Steering Wheel…………….9135
4.3.2 Steering Column/Orbital Valve…………….9136
4.3.3 Service Brake…………….9137
4.3.4 Electronic Throttle Pedal…………….9138
4.3.5 Joystick Assembly…………….9139
4.3.6 Window Wiper Assembly…………….9139
4.3.7 Heater System (If equipped)…………….9139
4.3.8 Heater/Air Conditioning System (If equipped)…………….9141
4.4 Cab Removal…………….9143
4.5 Cab Installation…………….9145
Section 5 Axles, Drive Shafts, Wheels and Tires…………….9147
5.1 Axle, Drive Shaft and Wheel Component Terminology…………….9148
5.1.1 3006H, 30.6…………….9148
5.1.2 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9149
5.2 Axle Serial Number…………….9150
5.3 Axle Specifications and Maintenance Information…………….9150
5.4 Axle Replacement…………….9150
5.4.1 Axle Removal…………….9150
5.4.2 Axle Installation…………….9153
5.5 Brake Inspection…………….9155
5.6 Steering Angle Adjustment…………….9155
5.7 Axle Assembly and Drive Shaft Troubleshooting…………….9156
5.8 Drive Shafts…………….9159
5.8.1 Drive Shaft Inspection…………….9159
5.8.2 Drive Shaft Maintenance…………….9159
5.8.3 Drive Shaft – 3006H, 30.6…………….9159
5.8.4 Drive Shaft – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9160
5.8.5 Drive Shaft Cleaning and Drying…………….9161
5.9 Wheels and Tires…………….9161
5.9.1 Removing Wheel and Tire Assembly from Machine…………….9161
5.9.2 Installing Wheel and Tire Assembly onto Machine…………….9161
5.10 Towing a Disabled Machine…………….9162
5.10.1 Manually Releasing the Park Brake…………….9162
5.10.2 Manually Resetting the Park Brake…………….9164
Section 6 Transmission…………….9165
6.1 Transmission Assembly Component Terminology…………….9166
6.2 Transmission Serial Number…………….9168
6.3 Specifications and Maintenance Information…………….9168
6.4 Hydrostatic Transmission Pump Replacement – 3006H, 30.6…………….9168
6.4.1 Transmission Removal…………….9168
6.4.2 Transmission Inspection and Internal Repair…………….9169
6.4.3 Transmission Installation…………….9169
6.4.4 After Transmission Service or Replacement…………….9170
6.5 Transmission Replacement – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9170
6.5.1 Transmission Removal…………….9170
6.5.2 Transmission Inspection and Internal Repair…………….9171
6.5.3 Transmission Installation…………….9171
6.6 Transmission Fluid/Filter Replacement…………….9172
6.7 Transmission Fluid Level Check…………….9172
6.8 Torque Converter Diaphragm – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9173
6.8.1 Torque Converter Diaphragm Removal…………….9173
6.8.2 Torque Converter Diaphragm Installation…………….9173
Section 7 Engine…………….9175
7.1 Introduction…………….9176
7.1.1 Disclaimer and Scope…………….9176
7.1.2 Component Terminology…………….9177
7.2 Engine Serial Number…………….9180
7.3 Specifications and Maintenance Information…………….9180
7.4 Engine Cooling System…………….9180
7.4.1 Surge Tank Cap…………….9180
7.4.2 Thermostat Replacement…………….9180
7.4.3 Radiator Assembly Replacement…………….9181
7.5 Engine Electrical System…………….9183
7.6 Fuel System…………….9183
7.6.1 Diesel Fuel…………….9183
7.6.2 Diesel Exhaust Fluid (DEF) Tank – 3006H, 30.6…………….9183
7.6.3 Diesel Exhaust Fluid (DEF) Filter – 3006H, 30.6…………….9184
7.6.4 Diesel Exhaust Fluid (DEF) Pump Filter – 3006H, 30.6…………….9185
7.6.5 Diesel Exhaust Fluid (DEF) Tank – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9186
7.6.6 Diesel Exhaust Fluid (DEF) Filter – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9188
7.6.7 Diesel Exhaust Fluid (DEF) Pump Filter – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9189
7.6.8 Diesel Exhaust Fluid (DEF) Tank Header Element Cleaning – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9190
7.6.9 Fuel Tank…………….9191
7.6.10 After Fuel System Service…………….9192
7.7 Engine Exhaust System…………….9193
7.7.1 If equipped for ULS…………….9193
7.7.2 If equipped for LS…………….9195
7.8 Air Cleaner Assembly…………….9197
7.8.1 Air Cleaner Assembly Removal…………….9197
7.8.2 Air Cleaner Assembly Installation…………….9198
7.9 Engine Replacement…………….9199
7.9.1 Engine/Transmission Removal…………….9199
7.9.2 Transmission Removal/Installation…………….9201
7.9.3 Engine Disassembly, Inspection and Service…………….9201
7.9.4 Engine/Transmission Installation…………….9201
7.10 Troubleshooting…………….9202
Section 8 Hydraulic System…………….9203
8.1 Hydraulic Component Terminology…………….9205
8.1.1 3006H, 30.6…………….9205
8.1.2 3507PS, 4008PS, 35.7, 40.8…………….9206
8.1.3 3510PS, 35.10…………….9207
8.2 Safety Information…………….9208
8.3 Specifications…………….9208
8.4 Hydraulic Pressure Diagnosis…………….9209
8.4.1 Pressure Checks and Adjustments…………….9209
8.5 Hydraulic Circuits…………….9209
8.5.1 Hydraulic Pressures…………….9209
8.6 Hydraulic Schematic…………….9213
8.6.1 3006H, 30.6…………….9213
8.6.2 3507PS, 4008PS, 35.7, 40.8…………….9215
8.6.3 3510PS, 35.10…………….9217
8.7 Hydraulic Reservoir…………….9219
8.7.1 Hydraulic Oil Reservoir Draining…………….9219
8.7.2 Hydraulic Oil Reservoir Filling…………….9220
8.7.3 Hydraulic Filter Replacement…………….9220
8.7.4 Hydraulic Oil Reservoir Removal/ Installation…………….9221
8.8 Implement Pump…………….9223
8.8.1 Pump Replacement…………….9223
8.9 Front Drive Motor – 3006H, 30.6…………….9225
8.10 Control Valves…………….9225
8.10.1 Main Control Valve…………….9225
8.10.2 Priority Valve – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9227
8.10.3 Service Brake Valve…………….9228
8.10.4 Service Brake Bleeding…………….9230
8.10.5 Service Brake Test…………….9233
8.10.6 Park Brake Bleeding (if equipped with Hydraulic Park Brake)…………….9233
8.10.7 Steering Orbital Valve…………….9234
8.10.8 Steer Select Valve…………….9234
8.10.9 Inching Valve – 3006H, 30.6…………….9235
8.11 Boom Ride Control…………….9237
8.11.1 General Accumulator Information…………….9237
8.11.2 Accumulators…………….9238
8.11.3 Pre-Charging Accumulator…………….9238
8.11.4 Checking Pre-Charge…………….9239
8.12 Hydraulic Cylinders…………….9240
8.12.1 General Cylinder Removal Instructions…………….9240
8.12.2 Cylinder Pressure Checking…………….9242
8.12.3 Steering Cylinders…………….9242
8.12.4 Extend/Retract Cylinder Bleeding Procedure – 3510PS, 35.10…………….9242
8.12.5 Cylinder Torque Specifications…………….9243
Section 9 Electrical System…………….9245
9.1 Electrical Component Terminology…………….9248
9.1.1 General Overview…………….9248
9.2 Specifications…………….9250
9.3 Safety Information…………….9250
9.4 Power Distribution Boards…………….9251
9.4.1 Cab Power Distribution Board…………….9251
9.4.2 Frame Power Distribution Board…………….9255
9.4.3 Option 1 Distribution Board…………….9257
9.4.4 Option 2 Distribution Board…………….9259
9.4.5 Engine Harness Fuses and Relays…………….9262
9.5 Electrical System Schematics…………….9265
9.5.1 3006H, 30.6…………….9265
9.5.2 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9273
9.6 Dielectric Grease Application…………….9282
9.6.1 Installation…………….9282
9.6.2 Exclusions…………….9283
9.7 Engine Start Circuit…………….9285
9.7.1 Starter…………….9285
9.7.2 Charging Circuit…………….9287
9.7.3 Alternator…………….9287
9.8 Battery…………….9288
9.8.1 Battery Inspection…………….9288
9.8.2 Battery Removal/Installation…………….9288
9.8.3 Battery Disconnect/Connect…………….9289
9.9 Electrical Master Switch…………….9290
9.9.1 Electrical Master Switch Removal…………….9290
9.9.2 Electrical Master Switch Installation…………….9290
9.10 Window Wiper System (if equipped)…………….9291
9.10.1 Front Windshield Wiper Motor…………….9291
9.10.2 Rear Window Wiper Motor…………….9292
9.10.3 Roof Window Wiper Motor…………….9293
9.10.4 Washer Fluid Reservoir…………….9294
9.11 Cab Heater and A/C (if equipped)…………….9295
9.11.1 Cab Heater/Air Conditioning Controls…………….9295
9.12 Solenoids, Sensors and Senders…………….9296
9.12.1 Transmission Solenoid Valves – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9296
9.12.2 Transmission Oil Temperature Switch…………….9296
9.12.3 Transmission Mounted Speed Sensor – 3507PS, 4008PS, 3510PS, 35.7, 40.8, 35.10…………….9297
9.12.4 Engine Coolant Temperature Sensor…………….9297
9.12.5 Fuel Level Sender…………….9298
9.12.6 Boom Angle Sensor…………….9298
9.12.7 Back-up Alarm…………….9299
9.12.8 Boom Retract Sensor…………….9300
9.13 Dash Switches…………….9301
9.13.1 Ignition Key Switch…………….9301
9.13.2 Dash Switches…………….9302
9.14 Machine Data…………….9303
9.14.1 Machine Data Access…………….9303
9.14.2 Analyzer…………….9304
9.14.3 Analyzer Software Version P.2.0…………….9305
9.15 Analyzer Software Accessibility…………….9307
9.15.1 Access Level…………….9307
9.15.2 Diagnostics…………….9307
9.15.3 Machine Set-Up…………….9308
9.15.4 Personalities…………….9310
9.15.5 Operator Tools…………….9315
9.15.6 Calibrations…………….9317
9.16 Multifunction Display…………….9319
9.16.1 Technical Specification…………….9319
9.16.2 Removal…………….9320
9.16.3 Installation…………….9321
9.16.4 Multifunction Display and Control Buttons…………….9321
9.16.5 Main Menu…………….9322
9.16.6 Setup and Maintenance…………….9341
9.16.7 Troubleshooting…………….9343
9.17 Load Stability Indicator (LSI)…………….9344
9.17.1 Load Stability Indicator…………….9344
9.17.2 LSI Sensor…………….9344
9.17.3 LSI System Calibration…………….9347
9.18 Fault Codes…………….9348
9.19 Machine Fault Codes…………….9349
9.19.1 Help Comment (00X)…………….9349
9.19.2 Power Up (21X)…………….9350
9.19.3 Platform Controls (22X0)…………….9354
9.19.4 Cabin Controls (23X)…………….9356
9.19.5 Function Prevented (25X)…………….9366
9.19.6 Line Contactor Open-Circuit (31x)…………….9368
9.19.7 Line Contactor Short-Circuit (32x)…………….9369
9.19.8 Output Drivers (33X)…………….9370
9.19.9 Engine (43X)…………….9392
9.19.10 Battery Supply (44X)…………….9396
9.19.11 Transmission and Drive System (46X)…………….9397
9.19.12 Communications (66X)…………….9419
9.19.13 Envelope Control (84x)…………….9421
9.19.14 Tilt Sensor (81x)…………….9422
9.19.15 Load Moment (85X)…………….9423
9.19.16 Steering (86x)…………….9428
9.19.17 Service Required (87x)…………….9429
9.19.18 Hardware (99X)…………….9430
9.20 Hystat Fault Codes (3006H, 30.6)…………….9435
9.20.1 Power On…………….9435
9.20.2 Custom Condition For Power On…………….9435
9.20.3 ECU Monitor…………….9436
9.20.4 ECU Health…………….9436
9.20.5 Debug Functionally…………….9436
9.20.6 Trigger For Two Step Error Reactions…………….9437
9.20.7 Report Active Error Reactions…………….9437
9.20.8 Report Active Protections…………….9437
9.20.9 Pedals And Potis (AgSnsr)…………….9438
9.20.10 Switches With Multiple States…………….9438
9.20.11 Switches With Two States (SwtBtn)…………….9438
9.20.12 Joysticks…………….9438
9.20.13 Driver On Board…………….9439
9.20.14 Parking Brake Sensors…………….9439
9.20.15 Engine Sensors…………….9439
9.20.16 Pump Sensors…………….9439
9.20.17 Speed Signals…………….9439
9.20.18 Gearbox Sensors…………….9440
9.20.19 Motor Sensors…………….9440
9.20.20 Lamps…………….9440
9.20.21 Parking Brake Actuators…………….9440
9.20.22 Diesel Engine Actuators…………….9441
9.20.23 Pump Actuators…………….9441
9.20.24 Motors Actuators…………….9441
9.20.25 Motors Actuators…………….9441
9.20.26 CAN Bus…………….9442
9.20.27 J1939 Receive Messages…………….9442
9.21 Engine Diagnostic…………….9443
31211271 – Illustrated Parts Manual Agrovector 40.8…………….9467
31211271_A_40.8_Deutz Fahr_Parts…………….9467
Effectivity Page…………….9469
Machine Configuration…………….9470
General Information…………….9471
Table of Contents…………….9473
SECTION 1 – FRAME AND ATTACHING PARTS…………….9483
FIGURE 1-1. FRAME INSTALLATION…………….9484
FIGURE 1-2. ENGINE ENCLOSURE INSTALLATION (NO RHOC)…………….9486
FIGURE 1-3. ENGINE ENCLOSURE INSTALLATION (RHOC)…………….9488
FIGURE 1-4. ENGINE ENCLOSURE COVER INSTALLATION (NO RHOC)…………….9490
FIGURE 1-5. ENGINE ENCLOSURE COVER INSTALLATION (RHOC)…………….9492
FIGURE 1-6. AIR INTAKE SEAL INSTALLATION…………….9494
FIGURE 1-7. HOOD INSTALLATION…………….9496
FIGURE 1-8. COVER PLATES INSTALLATION (NO OUTRIGGERS – ULS)…………….9498
FIGURE 1-9. COVER PLATES INSTALLATION (NO OUTRIGGERS – LS)…………….9500
FIGURE 1-10. COVER PLATE INSTALLATION (NO TRAILER BRAKES)…………….9502
FIGURE 1-11. COVER PLATE INSTALLATION (TRAILER BRAKES)…………….9504
FIGURE 1-12. COVER PLATE INSTALLATION (NO REAR AUX)…………….9506
FIGURE 1-13. COVER PLATE INSTALLATION (REAR AUX)…………….9508
FIGURE 1-14. COVER PLATE INSTALLATION (HYDRAULIC HITCH AND REAR AUX)…………….9510
FIGURE 1-15. REAR COVER PLATE INSTALLATION (NO HYDRAULIC HITCH)…………….9512
FIGURE 1-16. REAR COVER PLATE INSTALLATION (HYDRAULIC HITCH)…………….9514
FIGURE 1-17. COUNTERWEIGHT INSTALLATION…………….9516
FIGURE 1-18. TANKS INSTALLATION…………….9518
FIGURE 1-19. FUEL TANK INSTALLATION…………….9520
FIGURE 1-20. HYDRAULIC TANK INSTALLATION…………….9522
FIGURE 1-21. FUEL TANK ASSEMBLY…………….9524
FIGURE 1-22. HYDRAULIC TANK ASSEMBLY…………….9526
FIGURE 1-23. FUEL AND HYDRAULIC CAP INSTALLATION…………….9528
FIGURE 1-24. HITCH RETRIEVAL INSTALLATION…………….9530
FIGURE 1-25. HITCH INSTALLATION (EEC AUTO)…………….9532
FIGURE 1-26. HITCH INSTALLATION (PITON)…………….9534
FIGURE 1-27. HITCH ASSEMBLY (EEC AUTO)…………….9536
FIGURE 1-28. SLIDING HITCH ASSEMBLY (PITON)…………….9538
FIGURE 1-29. HITCH INSTALLATION (EEC MANUAL)…………….9540
FIGURE 1-30. HITCH ASSEMBLY (EEC MANUAL)…………….9542
FIGURE 1-31. HITCH INSTALLATION (CUNA CATEGORY C)…………….9544
FIGURE 1-32. HITCH ASSEMBLY (CUNA CATEGORY C)…………….9546
FIGURE 1-33. HITCH INSTALLATION (CUNA CATEGORY D2)…………….9548
FIGURE 1-34. HITCH ASSEMBLY (CUNA CATEGORY D2)…………….9550
FIGURE 1-35. HITCH INSTALLATION (FIXED)…………….9552
FIGURE 1-36. HITCH ASSEMBLY (FIXED)…………….9554
FIGURE 1-37. HITCH INSTALLATION (HYDRAULIC)…………….9556
SECTION 2 – BOOM…………….9559
FIGURE 2-1. BOOM INSTALLATION…………….9560
FIGURE 2-2. BOOM ASSEMBLY…………….9562
FIGURE 2-3. FIRST BOOM SECTION…………….9564
FIGURE 2-4. SECOND BOOM SECTION ASSEMBLY…………….9566
FIGURE 2-5. LINK ASSEMBLY…………….9568
FIGURE 2-6. LEVER ASSEMBLY…………….9570
FIGURE 2-7. MANUAL QUICK COUPLER INSTALLATION…………….9572
FIGURE 2-8. HYDRAULIC QUICK COUPLER INSTALLATION…………….9574
FIGURE 2-9. BOOM ANGLE INDICATOR INSTALLATION…………….9576
FIGURE 2-10. BOOM PROP INSTALLATION…………….9578
FIGURE 2-11. BOOM BRUSHES INSTALLATION…………….9580
SECTION 3 – ATTACHMENTS…………….9583
FIGURE 3-1. CARRIAGE ASSEMBLY (1524MM) (CE & AUS)…………….9584
FIGURE 3-2. CARRIAGE ASSEMBLY (1829MM) (CE & AUS)…………….9586
FIGURE 3-3. CARRIAGE ASSEMBLY (1225MM) (CE & AUS)…………….9588
FIGURE 3-4. SIDE TILTING CARRIAGE (4.5 TON – 1225 MM) (CE & AUS)…………….9590
FIGURE 3-5. SIDE SHIFT CARRIAGE (4.0 TON – 1225 MM) (CE & AUS)…………….9592
FIGURE 3-6. FORK POSITIONING CARRIAGE WITH FORKS (4.0 TON) (CE & AUS)…………….9594
FIGURE 3-7. DUAL FORK CARRIAGE ASSEMBLY…………….9596
FIGURE 3-8. DUAL FORK CARRIAGE VALVE ASSEMBLY…………….9598
FIGURE 3-9. FORK ROTATING CARRIAGE (4.5 TON – 1270 MM) (AUS)…………….9600
FIGURE 3-10. FORK ROTATING CARRIAGE (4.5 TON – 1270 MM) (AUS)…………….9602
FIGURE 3-11. CARRIAGE ASSEMBLY (JOHN DEERE FIT) (CE)…………….9606
FIGURE 3-12. CARRIAGE ASSEMBLY (MANITOU FIT) (CE)…………….9608
FIGURE 3-13. FORK ASSEMBLY (JCB FIT) (CE)…………….9610
FIGURE 3-14. DUAL TINE BAILING FORK CARRIAGE (CE & AUS)…………….9612
FIGURE 3-15. FEM CARRIAGE AND FORKS (CE & AUS)…………….9614
FIGURE 3-16. PALLET FORK (50X100X1220) (CE)…………….9616
FIGURE 3-17. PALLET FORK (50X120X1200) (CE)…………….9618
FIGURE 3-18. PALLET FORK (50X120X1200) (CE & AUS – IF EQUIPPED WITH 1170002)…………….9620
FIGURE 3-19. BUCKET (1 M³) (CE & AUS)…………….9622
FIGURE 3-20. BUCKET (1.5 M³) (CE & AUS)…………….9624
FIGURE 3-21. BUCKET (2 M³) (CE & AUS)…………….9626
FIGURE 3-22. BUCKET (2.5 M³) (CE & AUS)…………….9628
FIGURE 3-23. BUCKET (3 M³) (CE & AUS)…………….9630
FIGURE 3-24. BOLT-ON EDGE (2450 MM) (IF EQUIPPED WITH GENERAL BUCKET)…………….9632
FIGURE 3-25. DIRT BUCKET (1.0 M³) (CE & AUS)…………….9634
FIGURE 3-26. 4 IN 1 BUCKET (0.6 M³) (CE & AUS)…………….9636
FIGURE 3-27. 4 IN 1 BUCKET (1.0 M³) (CE & AUS)…………….9638
FIGURE 3-28. MULTI-PURPOSE GRAPPLE BUCKET (WIDE GRIP – 2450 MM) (CE & AUS)…………….9640
FIGURE 3-29. MANURE GRAPPLE BUCKET (CE & AUS)…………….9642
FIGURE 3-30. BUCKET GUARD…………….9644
FIGURE 3-31. BUCKET TEETH KIT…………….9646
FIGURE 3-32. BALE HANDLER (SPIKE CLAMP) (CE & AUS)…………….9648
FIGURE 3-33. BALE HANDLER KIT (SPIKES) (CE AND AUS)…………….9650
FIGURE 3-34. BALE HANDLER KIT (SPIKES TO TUBE) (CE & AUS)…………….9652
FIGURE 3-35. BALE HANDLER (TUBE CLAMP) (CE & AUS)…………….9654
FIGURE 3-36. TRUSS BOOM (4 TON – 2.1M) (CE AND AUS)…………….9656
FIGURE 3-37. TRUSS BOOM (1 TON – 3.4M) (CE AND AUS)…………….9658
FIGURE 3-38. TRUSS BOOM (1.8 TON – 3 FT WITH WINCH) (CE)…………….9660
FIGURE 3-39. TRUSS BOOM (0.9 TON – 12 FT WITH WINCH) (CE)…………….9662
FIGURE 3-40. CRANE HOOK (CE AND AUS)…………….9664
FIGURE 3-41. FORK MOUNTED HOOK (4 TON) (CE)…………….9666
FIGURE 3-42. MUCK FORK AND GRAB (CE & AUS)…………….9668
FIGURE 3-43. FORK MOUNTED PLATFORM…………….9670
FIGURE 3-44. CONCRETE BUCKET (CE)…………….9672
FIGURE 3-45. AUGER (CE & AUS)…………….9674
FIGURE 3-46. AUGER BIT, (6INX4IN) (CE & AUS)…………….9676
FIGURE 3-47. AUGER BIT, (9INX4IN) (CE & AUS)…………….9678
FIGURE 3-48. AUGER BIT, (12INX4IN) (CE & AUS)…………….9680
FIGURE 3-49. AUGER BIT, (15INX4IN) (CE & AUS)…………….9682
FIGURE 3-50. AUGER BIT, (18INX4IN) (CE & AUS)…………….9684
FIGURE 3-51. AUGER BIT, (24INX4IN) (CE & AUS)…………….9686
FIGURE 3-52. AUGER BIT, (36INX4IN) (CE & AUS)…………….9688
FIGURE 3-53. FORK EXTENSION (50X100X1910) (CE)…………….9690
FIGURE 3-54. FORK EXTENSIONS (60X100X1920) (AUS)…………….9692
FIGURE 3-55. FORK TRANSPORT LATCHES INSTALLATION…………….9694
SECTION 4 – ENGINE AND ATTACHING PARTS…………….9697
FIGURE 4-1. ENGINE INSTALLATION (74.4KW – ULS – PISTON PUMP)…………….9698
FIGURE 4-2. ENGINE INSTALLATION (90KW – ULS – PISTON PUMP)…………….9700
FIGURE 4-3. ENGINE INSTALLATION (100KW – ULS – PISTON PUMP)…………….9702
FIGURE 4-4. ENGINE INSTALLATION (74.4KW – LS – PISTON PUMP)…………….9704
FIGURE 4-5. ENGINE INSTALLATION (90KW – LS – PISTON PUMP)…………….9706
FIGURE 4-6. ENGINE MOUNTING INSTALLATION (74.4KW)…………….9708
FIGURE 4-7. ENGINE MOUNTING INSTALLATION (90KW/100KW)…………….9710
FIGURE 4-8. 3.6L ENGINE (74.4KW – ULS – PISTON PUMP)…………….9712
FIGURE 4-9. 3.6L ENGINE (90KW – ULS – PISTON PUMP)…………….9714
FIGURE 4-10. 3.6L ENGINE (100KW – ULS – PISTON PUMP)…………….9716
FIGURE 4-11. 3.6L ENGINE (74.4KW – LS – PISTON PUMP)…………….9718
FIGURE 4-12. 3.6L ENGINE (90KW – LS – PISTON PUMP)…………….9720
FIGURE 4-13. ENGINE ECU INSTALLATION (ULS)…………….9722
FIGURE 4-14. ENGINE ECU INSTALLATION (LS)…………….9724
FIGURE 4-15. BRACKET GUARD INSTALLATION…………….9726
FIGURE 4-16. FUEL LINES INSTALLATION (ULS)…………….9728
FIGURE 4-17. FUEL LINES INSTALLATION (ULS – RHOC)…………….9730
FIGURE 4-18. FUEL LINES INSTALLATION (LS)…………….9732
FIGURE 4-19. FUEL LINES INSTALLATION (LS – RHOC)…………….9734
FIGURE 4-20. EXHAUST INSTALLATION (ULS)…………….9736
FIGURE 4-21. EXHAUST INSTALLATION (LS)…………….9738
FIGURE 4-22. COOLING PACKAGE INSTALLATION (74.4KW – ULS)…………….9740
FIGURE 4-23. COOLING PACKAGE INSTALLATION (74.4KW – LS)…………….9742
FIGURE 4-24. COOLING PACKAGE INSTALLATION (90KW – ULS)…………….9744
FIGURE 4-25. COOLING PACKAGE INSTALLATION (90KW – LS)…………….9746
FIGURE 4-26. COOLING FAN INSTALLATION…………….9748
FIGURE 4-27. FAN LINES INSTALLATION (74.4KW)…………….9750
FIGURE 4-28. FAN LINES INSTALLATION (90KW)…………….9752
FIGURE 4-29. FAN DRIVE MOTOR (NO RHOC)…………….9754
FIGURE 4-30. FAN DRIVE MOTOR (RHOC)…………….9756
FIGURE 4-31. PRIMARY FUEL FILTER INSTALLATION (74.4KW – ULS)…………….9758
FIGURE 4-32. FUEL FILTER INSTALLATION (90/100KW – ULS)…………….9760
FIGURE 4-33. PRIMARY FUEL FILTER INSTALLATION (90KW – LS)…………….9762
FIGURE 4-34. AIR CLEANER INSTALLATION (74.4KW – ULS)…………….9764
FIGURE 4-35. AIR CLEANER INSTALLATION (90/100KW)…………….9766
FIGURE 4-36. AIR CLEANER INSTALLATION (74.4KW – LS)…………….9768
FIGURE 4-37. AIR CLEANER ASSEMBLY (74.4KW)…………….9770
FIGURE 4-38. AIR CLEANER ASSEMBLY (90/100KW)…………….9772
FIGURE 4-39. AIR INTAKE LINES INSTALLATION (74.4KW – ULS)…………….9774
FIGURE 4-40. AIR INTAKE LINES INSTALLATION (90/100KW – ULS)…………….9776
FIGURE 4-41. AIR INTAKE LINES INSTALLATION (74.4KW – LS)…………….9778
FIGURE 4-42. AIR INTAKE LINES INSTALLATION (90KW – LS)…………….9780
FIGURE 4-43. COOLER INSTALLATION (74.4KW)…………….9782
FIGURE 4-44. COOLER INSTALLATION (90KW)…………….9784
FIGURE 4-45. RADIATOR COOLING PACKAGE (74.4KW)…………….9786
FIGURE 4-46. RADIATOR COOLING PACKAGE (90KW)…………….9788
FIGURE 4-47. REMOTE HOC INSTALLATION…………….9790
FIGURE 4-48. COOLANT LINES INSTALLATION (ULS)…………….9792
FIGURE 4-49. COOLANT LINES INSTALLATION (LS)…………….9794
FIGURE 4-50. COOLER LINES INSTALLATION (74.4KW)…………….9796
FIGURE 4-51. COOLER LINES INSTALLATION (90KW)…………….9798
FIGURE 4-52. CAC LINES INSTALLATION (ULS)…………….9800
FIGURE 4-53. CAC LINES INSTALLATION (LS)…………….9802
FIGURE 4-54. SURGE TANK INSTALLATION…………….9804
FIGURE 4-55. TANK EXPANSION…………….9806
FIGURE 4-56. BULKHEAD INSTALLATION…………….9808
FIGURE 4-57. DEF CONTROL MODULE INSTALLATION (ULS)…………….9810
FIGURE 4-58. DEF TANK INSTALLATION (ULS)…………….9812
FIGURE 4-59. DEF LINES INSTALLATION (ULS)…………….9814
FIGURE 4-60. DEF TANK ASSEMBLY (ULS)…………….9816
FIGURE 4-61. REMOTE FUEL PUMP INSTALLATION (74.4KW)…………….9818
FIGURE 4-62. HYDRAULIC PUMP INSTALLATION (74.4KW)…………….9820
FIGURE 4-63. HYDRAULIC PUMP INSTALLATION (90KW)…………….9822
FIGURE 4-64. HEATER LINES INSTALLATION (ULS)…………….9824
FIGURE 4-65. HEATER LINES INSTALLATION (LS)…………….9826
FIGURE 4-66. BLOCK HEATER INSTALLATION (230V – LS)…………….9828
FIGURE 4-67. BLOCK HEATER INSTALLATION (120V – LS)…………….9830
FIGURE 4-68. BLOCK HEATER (ULS)…………….9832
FIGURE 4-69. BLOCK HEATER (LS)…………….9834
FIGURE 4-70. A/C PUMP INSTALLATION…………….9836
FIGURE 4-71. A/C LINES INSTALLATION…………….9838
SECTION 5 – DRIVETRAIN…………….9841
FIGURE 5-1. AXLES INSTALLATION (NO HYDRAULIC PARK BRAKE)…………….9842
FIGURE 5-2. AXLES INSTALLATION (HYDRAULIC PARK BRAKE)…………….9844
FIGURE 5-3. FRONT AXLE INSTALLATION (NO HYDRAULIC PARK BRAKE)…………….9846
FIGURE 5-4. FRONT AXLE, CENTRAL HOUSING (NO HYDRAULIC PARK BRAKE)…………….9848
FIGURE 5-5. FRONT AXLE, DIFFERENTIAL (NO HYDRAULIC PARK BRAKE)…………….9850
FIGURE 5-6. FRONT AXLE, HUB REDUCTION (NO HYDRAULIC PARK BRAKE)…………….9852
FIGURE 5-7. FRONT AXLE, BRAKES (NO HYDRAULIC PARK BRAKE)…………….9854
FIGURE 5-8. FRONT AXLE, STEERING (NO HYDRAULIC PARK BRAKE)…………….9856
FIGURE 5-9. FRONT AXLE INSTALLATION (HYDRAULIC PARK BRAKE)…………….9858
FIGURE 5-10. FRONT AXLE, CENTRAL HOUSING (HYDRAULIC PARK BRAKE)…………….9860
FIGURE 5-11. FRONT AXLE, DIFFERENTIAL (HYDRAULIC PARK BRAKE)…………….9862
FIGURE 5-12. FRONT AXLE, HUB REDUCTION (HYDRAULIC PARK BRAKE)…………….9864
FIGURE 5-13. FRONT AXLE, BRAKES (HYDRAULIC PARK BRAKE)…………….9866
FIGURE 5-14. FRONT AXLE, STEERING (HYDRAULIC PARK BRAKE)…………….9868
FIGURE 5-15. REAR AXLE INSTALLATION…………….9870
FIGURE 5-16. REAR AXLE, CENTRAL HOUSING…………….9872
FIGURE 5-17. REAR AXLE, DIFFERENTIAL…………….9874
FIGURE 5-18. REAR AXLE, HUB REDUCTION…………….9876
FIGURE 5-19. REAR AXLE, BRAKES…………….9878
FIGURE 5-20. REAR AXLE, STEERING…………….9880
FIGURE 5-21. DIFFERENTIAL KIT…………….9882
FIGURE 5-22. REDUCTION BUSHING KIT…………….9884
FIGURE 5-23. PLANET GEAR CARRIER KIT…………….9886
FIGURE 5-24. STEERING CASE KIT, (LF, RR)…………….9888
FIGURE 5-25. STEERING CASE KIT, (RF, LR)…………….9890
FIGURE 5-26. STEERING ADJUST BOLT KIT…………….9892
FIGURE 5-27. RING GEAR SUPPORT KIT…………….9894
FIGURE 5-28. PISTON KIT (LH)…………….9896
FIGURE 5-29. PISTON KIT (RH)…………….9898
FIGURE 5-30. PISTON KIT…………….9900
FIGURE 5-31. DIFFERENTIAL KIT…………….9902
FIGURE 5-32. TRUNION KIT…………….9904
FIGURE 5-33. DRIVE SHAFTS INSTALLATION…………….9906
FIGURE 5-34. REMOTE GREASE SYSTEM INSTALLATION…………….9908
FIGURE 5-35. AXLE SHIM INSTALLATION…………….9910
FIGURE 5-36. TRANSMISSION INSTALLATION (4 SPD)…………….9912
FIGURE 5-37. TRANSMISSION INSTALLATION (6 SPD – 90KW)…………….9914
FIGURE 5-38. TRANSMISSION INSTALLATION (6 SPD – 97KW)…………….9916
FIGURE 5-39. TRANSMISSION (4 SPD)…………….9918
FIGURE 5-40. TRANSMISSION (6 SPD – 90KW)…………….9920
FIGURE 5-41. TRANSMISSION (6 SPD – HHP – 97KW)…………….9922
FIGURE 5-42. PLANETARY CASE AND PARTS GROUP…………….9924
FIGURE 5-43. TORQUE CONVERTER GROUP…………….9926
FIGURE 5-44. TORQUE CONVERTER GROUP…………….9928
FIGURE 5-45. TRANSFER GEAR AND CASE GROUP…………….9930
FIGURE 5-46. TRANSFER GEAR AND CASE GROUP…………….9932
FIGURE 5-47. TRANSMISSION HYDRAULIC CONTROL GROUP…………….9934
FIGURE 5-48. INPUT SHAFT GROUP…………….9936
FIGURE 5-49. TRANSMISSION CLUTCH GROUP…………….9938
FIGURE 5-50. CLUTCH AND GEAR GROUP…………….9940
FIGURE 5-51. TRANSMISSION PUMP GROUP…………….9942
FIGURE 5-52. OUTPUT SHAFT GROUP…………….9944
FIGURE 5-53. SPEED SENSOR…………….9946
FIGURE 5-54. IDLER GEAR…………….9948
FIGURE 5-55. REAR TRANSMISSION CASE…………….9950
FIGURE 5-56. PLANETARY CASE…………….9952
FIGURE 5-57. FRONT TRANSFER CASE…………….9954
FIGURE 5-58. REAR TRANSFER CASE…………….9956
FIGURE 5-59. FRONT TRANSFER CASE…………….9958
FIGURE 5-60. REAR TRANSFER CASE…………….9960
FIGURE 5-61. RELIEF VALVE…………….9962
FIGURE 5-62. SOLENOID VALVE…………….9964
FIGURE 5-63. SOLENOID VALVE…………….9966
FIGURE 5-64. FRONT TRANSMISSION CASE ASSEMBLY…………….9968
FIGURE 5-65. REAR TRANSMISSION CASE ASSEMBLY…………….9970
FIGURE 5-66. TIRE/WHEEL SET (AIR – 15.5/80-24 – 16PR)…………….9972
FIGURE 5-67. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 15.5/80-24 – 16PR)…………….9974
FIGURE 5-68. LEFT TIRE/WHEEL ASSEMBLY (AIR – 15.5/80-24 – 16PR)…………….9976
FIGURE 5-69. TIRE/WHEEL SET (AIR – 15.5 R25 XHA TL)…………….9978
FIGURE 5-70. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 15.5 R25)…………….9980
FIGURE 5-71. LEFT TIRE/WHEEL ASSEMBLY (AIR – 15.5 R25)…………….9982
FIGURE 5-72. TIRE/WHEEL SET (AIR – 460/70 R24 XMCL)…………….9984
FIGURE 5-73. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24)…………….9986
FIGURE 5-74. LEFT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24)…………….9988
FIGURE 5-75. TIRE/WHEEL SET (AIR – 500/70 R24 XMCL)…………….9990
FIGURE 5-76. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 500/70 R24)…………….9992
FIGURE 5-77. LEFT TIRE/WHEEL ASSEMBLY (AIR – 500/70 R24)…………….9994
FIGURE 5-78. TIRE/WHEEL SET (AIR – 440/80-24 POWER CL)…………….9996
FIGURE 5-79. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 440/80-24)…………….9998
FIGURE 5-80. LEFT TIRE/WHEEL ASSEMBLY (AIR – 440/80-24)…………….10000
FIGURE 5-81. TIRE/WHEEL SET (AIR – 400/80-24 POWER CL)…………….10002
FIGURE 5-82. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 400/80-24)…………….10004
FIGURE 5-83. LEFT TIRE/WHEEL ASSEMBLY (AIR – 400/80-24)…………….10006
FIGURE 5-84. TIRE/WHEEL SET (AIR – 370/75-28)…………….10008
FIGURE 5-85. TIRE/WHEEL ASSEMBLY (AIR – 370/75-28)…………….10010
FIGURE 5-86. TIRE/WHEEL SET (FOAM – 13X24)…………….10012
FIGURE 5-87. TIRE/WHEEL SET (AIR – 460/70 R24 – BIBLOAD)…………….10014
FIGURE 5-88. RIGHT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24 – BIBLOAD)…………….10016
FIGURE 5-89. LEFT TIRE/WHEEL ASSEMBLY (AIR – 460/70 R24 – BIBLOAD)…………….10018
FIGURE 5-90. WHEEL CHOCK INSTALLATION…………….10020
FIGURE 5-91. FENDER INSTALLATION (NO AIR – 460/70 R24 XMCL, AIR – 500/70 R24 XMCL, AIR – 440/80-24 POWER CL, AIR – 460/70 R24 – BIBLOAD)…………….10022
FIGURE 5-92. FENDER ASSEMBLY…………….10024
FIGURE 5-93. FENDER ASSEMBLY…………….10026
FIGURE 5-94. FENDER ASSEMBLY…………….10028
FIGURE 5-95. FENDER ASSEMBLY…………….10030
FIGURE 5-96. FENDER INSTALLATION (AIR – 460/70 R24 XMCL, AIR – 500/70 R24 XMCL, AIR – 440/80-24 POWER CL, AIR – 460/70 R24 – BIBLOAD)…………….10032
FIGURE 5-97. FENDER ASSEMBLY…………….10034
FIGURE 5-98. FENDER ASSEMBLY…………….10036
FIGURE 5-99. FENDER ASSEMBLY…………….10038
FIGURE 5-100. FENDER ASSEMBLY…………….10040
SECTION 6 – CAB…………….10043
FIGURE 6-1. CAB MOUNTS INSTALLATION…………….10044
FIGURE 6-2. ENCLOSED CAB INSTALLATION…………….10046
FIGURE 6-3. ENCLOSED CAB ASSEMBLY…………….10048
FIGURE 6-4. ENCLOSED CAB GROUP…………….10050
FIGURE 6-5. ENCLOSED CAB…………….10052
FIGURE 6-6. ENCLOSED CAB PLUG GROUP…………….10054
FIGURE 6-7. REAR WINDOW INSTALLATION…………….10056
FIGURE 6-8. REAR WINDOW ASSEMBLY…………….10058
FIGURE 6-9. DOOR INSTALLATION…………….10060
FIGURE 6-10. DOOR ASSEMBLY (AG)…………….10062
FIGURE 6-11. CAB DOOR…………….10064
FIGURE 6-12. DOOR UPPER GLASS ASSEMBLY…………….10066
FIGURE 6-13. CAB LATCH ASSEMBLY…………….10068
FIGURE 6-14. CAB DOOR TRIGGER ASSEMBLY…………….10070
FIGURE 6-15. DOOR STRAP INSTALLATION…………….10072
FIGURE 6-16. ENCLOSED CAB TRIM INSTALLATION…………….10074
FIGURE 6-17. ENCLOSED CAB TRIM INSTALLATION…………….10076
FIGURE 6-18. DASH COVER ASSEMBLY…………….10078
FIGURE 6-19. RECIRCULATION GRILLE COVER PANEL ASSEMBLY…………….10080
FIGURE 6-20. REAR PANEL COVER ASSEMBLY…………….10082
FIGURE 6-21. ADJUSTABLE ARMREST INSTALLATION…………….10084
FIGURE 6-22. HEADLINER INSTALLATION…………….10086
FIGURE 6-23. HEADLINER/RADIO READY INSTALLATION…………….10088
FIGURE 6-24. COMMON CAB TRIM INSTALLATION…………….10090
FIGURE 6-25. CAB TRIM INSTALLATION…………….10092
FIGURE 6-26. ROOF CAP INSTALLATION (A/C)…………….10094
FIGURE 6-27. ROOF CAP INSTALLATION (NO A/C)…………….10096
FIGURE 6-28. FRONT COVER INSTALLATION…………….10098
FIGURE 6-29. FILTER TRAY PANEL…………….10100
FIGURE 6-30. FRONT DUCT COVER…………….10102
FIGURE 6-31. SEAT INSTALLATION (STANDARD)…………….10104
FIGURE 6-32. SEAT ASSEMBLY…………….10106
FIGURE 6-33. SEAT INSTALLATION (PREMIUM)…………….10108
FIGURE 6-34. UPPER SEAT ASSEMBLY…………….10110
FIGURE 6-35. UPPER SEAT ASSEMBLY…………….10112
FIGURE 6-36. SUSPENSION KIT…………….10114
FIGURE 6-37. SEAT INSTALLATION (MECHANICAL)…………….10116
FIGURE 6-38. SEAT ASSEMBLY…………….10118
FIGURE 6-39. SEAT BELT INSTALLATION (2IN)…………….10120
FIGURE 6-40. SEAT BELT INSTALLATION (3IN)…………….10122
FIGURE 6-41. HEATER INSTALLATION…………….10124
FIGURE 6-42. HEATER AND A/C INSTALLATION…………….10126
FIGURE 6-43. HEATER AND A/C INSTALLATION…………….10128
FIGURE 6-44. HEATER ASSEMBLY…………….10130
FIGURE 6-45. HEATER AND A/C ASSEMBLY…………….10132
FIGURE 6-46. HEATER…………….10134
FIGURE 6-47. HEATER AND A/C…………….10136
FIGURE 6-48. CAB CONDENSER ASSEMBLY…………….10138
FIGURE 6-49. CONDENSER…………….10140
FIGURE 6-50. A/C RECEIVER DRIER…………….10142
FIGURE 6-51. ROOF WIPER INSTALLATION…………….10144
FIGURE 6-52. FRONT NOSE CONE INSTALLATION (SIDELIGHT)…………….10146
FIGURE 6-53. RETRACTABLE SUNSCREEN INSTALLATION…………….10148
FIGURE 6-54. CAB STEP INSTALLATION…………….10150
FIGURE 6-55. FLOOR MAT INSTALLATION…………….10152
FIGURE 6-56. EXTERNAL WINDOW RELEASE INSTALLATION…………….10154
FIGURE 6-57. CAB GUARD INSTALLATION (TOP)…………….10156
FIGURE 6-58. CAB GUARD INSTALLATION (FRONT)…………….10158
FIGURE 6-59. CAB GUARD INSTALLATION (TOP AND FRONT)…………….10160
FIGURE 6-60. NUMBER PLATE BRACKET INSTALLATION (NO CAB GUARD)…………….10162
FIGURE 6-61. NUMBER PLATE BRACKET INSTALLATION (CAB GUARD)…………….10164
FIGURE 6-62. MIRROR INSTALLATION…………….10166
FIGURE 6-63. HITCH MIRROR INSTALLATION (CONVEX)…………….10168
FIGURE 6-64. HITCH MIRROR INSTALLATION (FLAT)…………….10170
FIGURE 6-65. MIRROR ASSEMBLY (CONVEX)…………….10172
FIGURE 6-66. INTERIOR MIRROR INSTALLATION…………….10174
FIGURE 6-67. INTERIOR MIRROR…………….10176
FIGURE 6-68. BASIC MIRROR INSTALLATION…………….10178
FIGURE 6-69. FRONT WIPER INSTALLATION…………….10180
FIGURE 6-70. WASHER TANK INSTALLATION…………….10182
FIGURE 6-71. WASHER BOTTLE…………….10184
FIGURE 6-72. WASHER HOSES INSTALLATION…………….10186
FIGURE 6-73. HAMMER INSTALLATION…………….10188
FIGURE 6-74. HAMMER ATTACHMENT ASSEMBLY…………….10190
FIGURE 6-75. LEVEL INDICATOR INSTALLATION…………….10192
SECTION 7 – CONTROLS…………….10195
FIGURE 7-1. ACCELERATOR PEDAL INSTALLATION…………….10196
FIGURE 7-2. ACCELERATOR PEDAL…………….10198
FIGURE 7-3. BRAKE PEDAL INSTALLATION…………….10200
FIGURE 7-4. BRAKE PEDAL…………….10202
FIGURE 7-5. BRAKE PEDAL PLATE…………….10204
FIGURE 7-6. BRAKE SENSOR INSTALLATION…………….10206
FIGURE 7-7. SWITCH PLATE ASSEMBLY…………….10208
FIGURE 7-8. PARKING BRAKE INSTALLATION (CABLE)…………….10210
FIGURE 7-9. PARKING BRAKE INSTALLATION (SAHR)…………….10212
FIGURE 7-10. PARKING BRAKE COVER (MECHANICAL)…………….10214
FIGURE 7-11. PARKING CABLE ASSEMBLY (MECHANICAL)…………….10216
FIGURE 7-12. STEERING WHEEL INSTALLATION…………….10218
FIGURE 7-13. STEERING WHEEL…………….10220
FIGURE 7-14. STEERING COLUMN INSTALLATION…………….10222
FIGURE 7-15. TILT STEERING COLUMN…………….10224
FIGURE 7-16. HORN INSTALLATION…………….10226
FIGURE 7-17. HORN BUTTON INSTALLATION…………….10228
FIGURE 7-18. JOYSTICK INSTALLATION…………….10230
FIGURE 7-19. WIPER-TURN SWITCH (0 SPEED – FNR)…………….10232
FIGURE 7-20. WIPER-TURN SWITCH (NO SPEED)…………….10234
SECTION 8 – HYDRAULIC CIRCUITS…………….10237
FIGURE 8-1. COMMON HYDRAULICS INSTALLATION…………….10238
FIGURE 8-2. HYDRAULICS INSTALLATION…………….10240
FIGURE 8-3. MAIN CONTROL VALVE INSTALLATION…………….10242
FIGURE 8-4. PRIORITY VALVE INSTALLATION…………….10244
FIGURE 8-5. STEER SELECT VALVE INSTALLATION…………….10246
FIGURE 8-6. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….10248
FIGURE 8-7. MANUAL COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….10250
FIGURE 8-8. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – SINGLE)…………….10252
FIGURE 8-9. HYDRAULIC COUPLER LINES INSTALLATION (FRONT BOOM – TWIN)…………….10254
FIGURE 8-10. BRAKE LINES INSTALLATION…………….10256
FIGURE 8-11. BRAKE ACCUMLATOR INSTALLATION…………….10258
FIGURE 8-12. SAHR LINES INSTALLATION…………….10260
FIGURE 8-13. BRAKE LINES INSTALLATION…………….10262
FIGURE 8-14. BRAKE ACCUMULATOR…………….10264
FIGURE 8-15. STEERING LINES INSTALLATION…………….10266
FIGURE 8-16. SUCTION LINES INSTALLATION…………….10268
FIGURE 8-17. BOOM LINES INSTALLATION…………….10270
FIGURE 8-18. PRIORITY LINES INSTALLATION…………….10272
FIGURE 8-19. RETURN LINES INSTALLATION…………….10274
FIGURE 8-20. RETURN LINES INSTALLATION (SAHR)…………….10276
FIGURE 8-21. BOOM RAISE HOSES INSTALLATION (NO RIDE CONTROL)…………….10278
FIGURE 8-22. BOOM RAISE HOSES INSTALLATION (RIDE CONTROL)…………….10280
FIGURE 8-23. REAR AUX HYDRAULICS INSTALLATION (SINGLE)…………….10282
FIGURE 8-24. REAR AUX HYDRAULICS INSTALLATION (TWIN)…………….10284
FIGURE 8-25. TRAILER BRAKE INSTALLATION (NO ITALIAN)…………….10286
FIGURE 8-26. TRAILER BRAKE INSTALLATION (ITALIAN)…………….10288
FIGURE 8-27. BOOM HYDRAULIC INSTALLATION…………….10290
FIGURE 8-28. MAIN HYDRAULIC PUMP INSTALLATION…………….10292
FIGURE 8-29. IMPLEMENT PUMP INSTALLATION…………….10294
FIGURE 8-30. LIFT CYLINDER INSTALLATION…………….10296
FIGURE 8-31. COMPENSATION CYLINDER INSTALLATION…………….10298
SECTION 9 – HYDRAULIC COMPONENTS…………….10301
FIGURE 9-1. LIFT CYLINDER…………….10302
FIGURE 9-2. TILT CYLINDER…………….10304
FIGURE 9-3. COMPENSATION CYLINDER…………….10306
FIGURE 9-4. EXTEND/RETRACT CYLINDER ASSEMBLY…………….10308
FIGURE 9-5. EXTEND/RETRACT CYLINDER…………….10310
FIGURE 9-6. FORK POSITIONING CYLINDER…………….10312
FIGURE 9-7. COUPLER LOCKING CYLINDER…………….10314
FIGURE 9-8. MAIN CONTROL VALVE…………….10316
FIGURE 9-9. PRIORITY FLOW MANIFOLD…………….10318
FIGURE 9-10. STEERING SELECT VALVE…………….10320
FIGURE 9-11. DIVERTOR VALVE ASSEMBLY (HI FLOW)…………….10322
FIGURE 9-12. DIVERTOR VALVE…………….10324
FIGURE 9-13. DIVERTOR VALVE…………….10326
FIGURE 9-14. DIVERTOR VALVE…………….10328
FIGURE 9-15. FLOW DIVIDER VALVE…………….10330
FIGURE 9-16. HYDRAULIC HITCH CONTROL VALVE…………….10332
FIGURE 9-17. TRAILER BRAKE VALVE…………….10334
FIGURE 9-18. FAN MOTOR CONTROL VALVE…………….10336
FIGURE 9-19. IMPLEMENT PUMP…………….10338
SECTION 10 – ELECTRICAL…………….10341
FIGURE 10-1. MAIN ELECTRICAL INSTALLATION…………….10342
FIGURE 10-2. CAB ELECTRICAL INSTALLATION…………….10344
FIGURE 10-3. IGNITION SWITCH INSTALLATION…………….10348
FIGURE 10-4. STANDARD ELECTRICAL BOARD ASSEMBLY…………….10350
FIGURE 10-5. OPTION 1 ELECTRICAL BOARD ASSEMBLY…………….10352
FIGURE 10-6. OPTION 2 ELECTRICAL BOARD ASSEMBLY…………….10354
FIGURE 10-7. CAB HEATER HARNESS INSTALLATION…………….10356
FIGURE 10-8. BOOM HARNESS INSTALLATION…………….10358
FIGURE 10-9. ENGINE WIRING INSTALLATION (ULS)…………….10360
FIGURE 10-10. ENGINE WIRING INSTALLATION (LS)…………….10362
FIGURE 10-11. ELECTRICAL COMPONENTS INSTALLATION…………….10364
FIGURE 10-12. POWER DISTRIBUTION ELECTRICAL BOX…………….10366
FIGURE 10-13. 200 AMP RELAY INSTALLATION…………….10368
FIGURE 10-14. BATTERY INSTALLATION (STANDARD)…………….10370
FIGURE 10-15. BATTERY INSTALLATION (DUAL)…………….10372
FIGURE 10-16. DASH ELECTRICS INSTALLATION (ULS)…………….10374
FIGURE 10-17. DASH ELECTRICS INSTALLATION (LS)…………….10376
FIGURE 10-18. MULTIFUNCTION DISPLAY INSTALLATION…………….10378
FIGURE 10-19. REVERSE CAMERA INSTALLATION (TRAILER BRAKES)…………….10380
FIGURE 10-20. REVERSE CAMERA INSTALLATION (NO TRAILER BRAKES)…………….10382
FIGURE 10-21. REVERSE ALARM INSTALLATION…………….10384
FIGURE 10-22. REVERSE SENSOR INSTALLATION (NO HYDRAULIC HITCH)…………….10386
FIGURE 10-23. REVERSE SENSOR INSTALLATION (HYDRAULIC HITCH)…………….10388
FIGURE 10-24. CLEARSKY INSTALLATION (A/C – LONG ROOF CAP)…………….10390
FIGURE 10-25. CLEARSKY INSTALLATION (NO A/C – SHORT ROOF CAP)…………….10392
FIGURE 10-26. TELEMATICS INSTALLATION (A/C – ULS)…………….10394
FIGURE 10-27. TELEMATICS INSTALLATION (A/C – LS)…………….10396
FIGURE 10-28. TELEMATICS INSTALLATION (NO A/C – ULS)…………….10398
FIGURE 10-29. TELEMATICS CAP INSTALLATION…………….10400
FIGURE 10-30. CAB WORKLIGHTS INSTALLATION (NO A/C)…………….10402
FIGURE 10-31. CAB WORKLIGHTS INSTALLATION (A/C)…………….10404
FIGURE 10-32. CAB WORKLIGHTS INSTALLATION (NO A/C – LED)…………….10406
FIGURE 10-33. CAB WORKLIGHTS INSTALLATION (A/C – LED)…………….10408
FIGURE 10-34. BOOM WORKLIGHTS INSTALLATION…………….10410
FIGURE 10-35. BOOM LED WORKLIGHTS INSTALLATION…………….10412
FIGURE 10-36. BEACON LIGHT INSTALLATION…………….10414
FIGURE 10-37. BEACON BRACKET INSTALLATION…………….10416
FIGURE 10-38. DIP LIGHTS INSTALLATION (RHD – NO OUTRIGGERS)…………….10418
FIGURE 10-39. DIP LIGHTS INSTALLATION (LHD – NO OUTRIGGERS)…………….10420
FIGURE 10-40. LICENSE PLATE LAMP INSTALLATION…………….10422
FIGURE 10-41. TRAILER ELECTRICS INSTALLATION…………….10424
FIGURE 10-42. ENGINE SPEED SET SWITCH INSTALLATION…………….10426
FIGURE 10-43. DECLUTCH SWITCH INSTALLATION…………….10428
FIGURE 10-44. FOG LAMP SWITCH INSTALLATION…………….10430
FIGURE 10-45. LSI SENSOR INSTALLATION…………….10432
FIGURE 10-46. LSI ASSEMBLY…………….10434
FIGURE 10-47. LSI SENSOR…………….10436
FIGURE 10-48. LMIS INSTALLATION (NO RIDE CONTROL)…………….10438
FIGURE 10-49. LMIS INSTALLATION (RIDE CONTROL)…………….10440
FIGURE 10-50. LMIS CONTROLLER INSTALLATION…………….10442
FIGURE 10-51. LMIS CABLE REEL INSTALLATION (NO RIDE CONTROL)…………….10444
FIGURE 10-52. LMIS CABLE REEL INSTALLATION (RIDE CONTROL)…………….10446
FIGURE 10-53. LMIS WIRING INSTALLATION…………….10448
FIGURE 10-54. LMIS BEACON INSTALLATION…………….10450
FIGURE 10-55. BOOM ANGLE SENSOR INSTALLATION…………….10452
FIGURE 10-56. EARTH STRAP INSTALLATION…………….10454
FIGURE 10-57. BOOM RETRACT SENSOR INSTALLATION…………….10456
FIGURE 10-58. FRONT FRAME HARNESS…………….10458
FIGURE 10-59. REAR FRAME HARNESS…………….10462
FIGURE 10-60. ENGINE HARNESS (ULS)…………….10466
FIGURE 10-61. ENGINE HARNESS (LS)…………….10474
FIGURE 10-62. FUEL PUMP HARNESS…………….10480
FIGURE 10-63. GLOW PLUG RELAY HARNESS…………….10482
FIGURE 10-64. BOOM HARNESS…………….10484
FIGURE 10-65. LMIS CHASSIS HARNESS…………….10486
FIGURE 10-66. CAB HARNESS…………….10488
FIGURE 10-67. CAB OPTION HARNESS…………….10496
FIGURE 10-68. CAB HEATER HARNESS…………….10498
FIGURE 10-69. A/C OPTION HARNESS…………….10500
FIGURE 10-70. REVERSE SENSOR HARNESS…………….10502
FIGURE 10-71. TELEMATICS HARNESS (A/C)…………….10504
FIGURE 10-72. TELEMATICS HARNESS (NO A/C)…………….10506
FIGURE 10-73. CLEARSKY HARNESS…………….10508
FIGURE 10-74. LICENSE LIGHT HARNESS…………….10510
FIGURE 10-75. LINK TRAILER HARNESS…………….10512
FIGURE 10-76. SEAT ADAPTOR HARNESS…………….10514
FIGURE 10-77. BOOM WORKLIGHTS HARNESS…………….10516
SECTION 11 – DECALS…………….10519
FIGURE 11-1. CAPACITY CHART HOLDER INSTALLATION…………….10520
FIGURE 11-2. CAPACITY CHART (METRIC)…………….10522
FIGURE 11-3. CAPACITY CHART (AUS)…………….10524
FIGURE 11-4. DECALS INSTALLATION…………….10526
FIGURE 11-5. DECALS INSTALLATION (CE & JAPAN)…………….10528
FIGURE 11-6. DECALS INSTALLATION (AUS)…………….10532
FIGURE 11-7. DECAL SOUND PLATE INSTALLATION (106DB)…………….10536
FIGURE 11-8. DECAL SOUND PLATE INSTALLATION (107DB)…………….10538
SECTION 12 – RECOMMENDED SPARE PARTS…………….10541
FIGURE 12-1. RECOMMENDED SPARE PARTS…………….10542
PART NUMBER INDEX…………….10545
Deutz-Fahr / JLG Agrovectors Models Repair Service Manuals
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