JLG 600SJC Service And Maintenance Manual
  1. Manuals
  2. Brands
  3. JLG Manuals
  4. Boom Lifts
  5. 600SJC
  6. Service and maintenance manual

JLG 600SJC Service And Maintenance Manual

Hide thumbs Also See for 600SJC:
Table of Contents

Advertisement

Quick Links

See also: Operator's and Safety Manual
Service and Maintenance Manual
Model
600SC
660SJC
S/N 0300174703
to Present
P/N - 3121607
March 10, 2014

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 600SJC and is the answer not in the manual?

Questions and answers

Related Manuals for JLG 600SJC

Summary of Contents for JLG 600SJC

  • Page 1 Service and Maintenance Manual Model 600SC 660SJC S/N 0300174703 to Present P/N - 3121607 March 10, 2014...

  • Page 3: Bhydraulic System Safety

    REPLACEMENT OF ELECTRICAL COMPONENTS. • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL- VENTS. 3121607 – JLG Lift –...
  • Page 4 INTRODUCTION REVISON LOG Original Issue - March 10, 2014 – JLG Lift – 3121607...

  • Page 5: Table Of Contents

    Do NOT Do the Following When Welding on JLG Equipment: .......
  • Page 6 Biological Contamination In Fuels ............. 3-65 – JLG Lift –...
  • Page 7 Cylinders With Dual Counterbalance Valves ........... . 5-4 3121607 – JLG Lift –...
  • Page 8 Connect JLG Control System Analyzer ........
  • Page 9 HD30/HDP20 Series Disassembly ............. . 7-9 3121607 – JLG Lift –...
  • Page 10 Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2......... 3-55 – JLG Lift –...
  • Page 11 Composite Bushing Installation..............5-15 3121607 – JLG Lift –...
  • Page 12 Analyzer Ground Control Box Connector ............6-3 viii – JLG Lift – 3121607...
  • Page 13 Crawler Drive Motor Hydraulic Schematic ............7-24 3121607 – JLG Lift –...
  • Page 14 Fault Code List ..............6-36 – JLG Lift –...

  • Page 15: Specifications

    173 ft.lbs. (234 Nm) @ 1800rpm Oil Capacity (Crankcase) 2.4 Gal (8.9 L) w/Filter Cooling System 3.3 Gal (12.5 L) Low RPM 1200 ±50 rpm High RPM 2600±50 rpm Alternator 95 Amp Fuel Consumption 0.65 GPH (2.48 lph) 3121607 – JLG Lift –...

  • Page 16: Function Speeds

    Set Drive Select Switch to High Engine, High Speed. Select Platform Speed Knob out of creep speed. Raise boom above horizontal. Results should be recorded for a 50 ft (15.2 m) course. Drive forward, record time. Drive reverse, record time. – JLG Lift – 3121607...

  • Page 17: Hydraulic Oil

    They may not contain required additives or be of comparable viscosities. If Specific Gravity 1.082 hydraulic oil other than Mobil 424 is desired, contact JLG Pour Point, Max -58°F (-50°C) Industries for proper recommendations.

  • Page 18: Major Component Weights

    7315 3318 (including engine) Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Viscosity at 40° C 25.8 cSt at 100° C 9.3 cSt Viscosity Index NOTE: ExxonMobil recommends checking oil viscosity yearly. – JLG Lift – 3121607...

  • Page 19: Operator Maintenance

    90 degree intervals until bearing is completely LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR- lubricated. MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/ OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. 3121607 – JLG Lift –...
  • Page 20 Interval - Check Level daily; Change every 2 years or 1200 hours of operation Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as shown by Condition Indica- tor. – JLG Lift – 3121607...
  • Page 21 Comments - Check level daily/Change in accordance Lube Point(s) - Replaceable Element with engine manual.. Interval - Every 6 months or 300 hours of operation or as shown by condition indicator MINIMUM OIL LEVEL MAXIMUM OIL LEVEL 3121607 – JLG Lift –...

  • Page 22: Torque Chart - Sheet 1 Of 5 - (Sae Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) – JLG Lift – 3121607...

  • Page 23: Torque Chart - Sheet 2 Of 5 - (Sae Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121607 – JLG Lift –...

  • Page 24: Torque Chart - Sheet 3 Of 5 - (Sae Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-10 – JLG Lift – 3121607...

  • Page 25: Torque Chart - Sheet 4 Of 5 - (Metric Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121607 – JLG Lift – 1-11...

  • Page 26: Torque Chart - Sheet 5 Of 5 - (Metric Fasteners)

    SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-12 – JLG Lift – 3121607...

  • Page 27: General

    Service Technician as a person who has successfully com- maintain its safe operating condition. For maximum service pleted the JLG Service Training School for the subject JLG life and safe operation, ensure all necessary inspections and product model. Reference the machine Service and Mainte-...

  • Page 28: Service And Guidelines

    Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual rental delivery. and applicable JLG inspection form. Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual comes first;...

  • Page 29: Component Disassembly And Reassembly

    If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those having the same specifications of the original, or one which is equivalent. 3121607 – JLG Lift –...

  • Page 30: Lubrication And Information

    Always clean filter Cylinder must have normal platform load applied. mesh element and replace cartridge any time system oil is changed. Cylinder is acceptable if it passes this test. – JLG Lift – 3121607...

  • Page 31: Pins And Composite Bearing Repair Guidelines

    2. Filament wound bearings should be replaced if any of • Ground only to structure being welded. the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing.

  • Page 32: Inspection And Preventive Maintenance Schedule

    Turntable Lock 1,2,5 1,2,5 Hood, Hood Props, Hood Latches 1,2,5 Chassis Assembly Tires 16,17 16,17,18 16,17,18 Wheel Nuts/Bolts Wheel Bearings 14,24 Oscillating Axle/Lockout Cylinder Systems Extendable Axle Systems Steer Components Spindle Thrust Bearing/Washers Drive Hubs – JLG Lift – 3121607...
  • Page 33 Electrical Connections Instruments, Gauges, Switches, Lights, Horn 5,23 General Operation and Safety Manuals in Storage Box ANSI and AEM Manuals/Handbooks Installed (ANSI Mar- kets Only) Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible 3121607 – JLG Lift –...
  • Page 34 Function Test of All Systems 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: Prior to use each day; or at each Operator change Prior to each sale, lease, or delivery In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used...

  • Page 35: Deutz Engine And Hydraulic Operating Temperature Specifications

    SECTION 2 - GENERAL 4150548 E Figure 2-1. Deutz Engine and Hydraulic Operating Temperature Specifications 3121607 – JLG Lift –...
  • Page 36 SECTION 2 - GENERAL NOTES: 2-10 – JLG Lift – 3121607...

  • Page 37: Chassis & Turntable

    4. Flat Washer 10. Bolt 16. Flat Washer 22. Spring Assembly 28. Counterweight (660SJC) 5. Drive Assembly 11. Bolt 17. Bolt 23. Capscrew 6. Drive Sprocket 12. Locknut 18. Lockwasher 24. Idler Assembly Figure 3-1. Chassis Assembly 3121607 – JLG Lift –...

  • Page 38: Service Notes

    SECTION 3 - CHASSIS & TURNTABLE Service Notes Figure 3-2. Chassis Service Notes - 1 of 2 – JLG Lift – 3121607...

  • Page 39: Chassis Service Notes - 2 Of 2

    Torque to 230 ft-lb, +15 -0 (322 Nm, +21 -0) Torque to 93 ft-lb, +10 -0 (130 Nm, +14 -0) Torque to 53 ft-lb, +5 -0 (74 Nm, +7 -0) Figure 3-3. Chassis Service Notes - 2 of 2 3121607 – JLG Lift –...

  • Page 40: Track And Chain

    1. Track Assembly 4. Bushing 7. Splice Hinge Pin 10. Bolt 2. Left Link 5. Hinge Pin 8. Spacer 11. Nut 3. Right Link 6. Splice Bushing 9. Track Cleat Figure 3-4. Track and Chain – JLG Lift – 3121607...

  • Page 41: Replace Track

    3. Position wood blocks to frame rail for tracks to lay onto when connecting track ends to get proper extension for connecting end links. 2. Remove four bolts (10), nuts (11), and track cleat (9) from chain assembly. Repeat with adjacent track cleat. 3121607 – JLG Lift –...

  • Page 42: Track Tensioning

    1. Seat rubber track pad over center rib of steel track. 2. Apply JLG Thread Locking Compound PN 0100011 to retaining plate bolts. Install bolts and flat washers to end of rubber pad.

  • Page 43: Bottom Track Roller Assembly

    SECTION 3 - CHASSIS & TURNTABLE 1. Guide Roller 4. Bearing 7. Mounting Bracket 2. Shaft 5. Ring 8. O-ring 3. Plug 6. Seal 9. Roll Pin Figure 3-5. Bottom Track Roller Assembly 3121607 – JLG Lift –...

  • Page 44: Upper Carrier Track Roller Assembly

    6. Roller Bearing 10. Collar 14. Cover Seal 3. Internal Cover 7. Not Used 11. Packing Ring 15. Lockwasher 4. Bolt 8. Seal Ring 12. Seal Ring 16. Bolt Figure 3-6. Upper Carrier Track Roller Assembly – JLG Lift – 3121607...

  • Page 45: Rollers

    3. Press collar on roller shaft and lock in place with dowel. 2. Apply JLG Thread Locking Compound PN 0100011 to 4. Invert roller assembly and perform steps 1 through 4. four bolts. Align roller on frame and secure with four 5.

  • Page 46: Idler Roller Assembly

    1. Idler 5. Mounting Bracket 9. Not Used 2. Shaft 6. Seal 10. O-ring 3. Bearing 7. Seal 11. Plug 4. Roll Pin 8. Seal Holder 12. Bracket Figure 3-7. Idler Assembly 3-10 – JLG Lift – 3121607...

  • Page 47: Spring & Shock Assembly

    SECTION 3 - CHASSIS & TURNTABLE 1. Mounting Flange 5. Roll Pin 9. Seal 2. Spring 6. Piston/Rod 10. Seal 3. Base Plate 7. Wiper 11. Fitting 4. Locknut 8. Barrel Figure 3-8. Spring & Shock Assembly 3121607 – JLG Lift – 3-11...
  • Page 48 Install using bolts, wash- 3. Press out bushing. (Bushing can only be removed by a ers, and JLG Thread Locking Compound PN 0100011. vertical press with correct tooling.) Torque to 165 ft-lb +15-0 (231 Nm, +21 -0).

  • Page 49: Drive Motor

    64. Pin 11. Spring Seat 24. Spring (Items 38 - 44) 51. Orifice 65. Pin 12. Cap Assembly 25. Plug 38. Spool 52. Plug (Items 13 - 18) Figure 3-9. Crawler Drive Motor Control 3121607 – JLG Lift – 3-13...

  • Page 50: Crawler Drive Motor Assembly

    14. Cylinder Block 19. Valve Plate 25. Piston Brake 5. Ball Bearing 10. Piston Assembly 15. Spring Seat 20. Ball Bearing 26. O-Ring 21. Disc Plate 27. O-Ring Figure 3-10. Crawler Drive Motor Assembly 3-14 – JLG Lift – 3121607...

  • Page 51: Crawler Drive - Gearbox

    28. Bolt 5. Shim 11. Needle bearing 17. Holder 23. Thrust Plate 29. Plug 6. Holder 12. Planetary Gear 18. Thrust Plate 24. Screw 30. O-Ring 31. Pin Figure 3-11. Crawler Drive - Gearbox 3121607 – JLG Lift – 3-15...

  • Page 52: Disassembly

    14. Using flat-tip screwdriver and remove another Floating 2. Remove O-Rings from Brake Piston. Remove three Disk Seal from Flange. Plates and two Friction Plates. 15. Wash parts with cleaning solvent. Apply rust preventa- tive if parts are stored before reassembly. 3-16 – JLG Lift – 3121607...
  • Page 53 (a) Serious damage, roughness, or deep scoring. 0.8a Base Plate Kit (B5) (b) Large clearance between Spool and bore. 0.060mm Relief Valve Assy (102-7) (a) Roughness or serious damage on Free Piston sliding <0.02mm(scoring depth) Relief Valve Assy (B4) 3121607 – JLG Lift – 3-17...

  • Page 54: Assembly

    7. Insert nine Piston Assemblies through flat side of Retainer Plate. 11. Apply High Strength Thread Locking Compound (JLG P/ N 0100019 to Socket Head Bolts and evenly tighten 8. Apply hydraulic fluid in bores of Cylinder Block and on them into flange.

  • Page 55: Install Motor Assembly

    Put both Caps on Base Plate. Tighten Socket Head Hook to crane using strap and alignment pin. Lift up and Bolts. place on motor drive. Secure with bolts and JLG Thread Install Motor Assembly Locking Compound PN 0100011. Torque to 230 ft-lb +1.

  • Page 56: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE Rotary Coupling 1. Coupling 3. Support 5. Keeper 2. Stabilizer 4. Spacer Figure 3-12. Rotary Coupling Installation 3-20 – JLG Lift – 3121607...

  • Page 57: Hose Routing - 1 Of 2

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-13. Hose Routing - 1 of 2 3121607 – JLG Lift – 3-21...

  • Page 58: Hose Routing - 2 Of 2

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-14. Hose Routing - 2 of 2 3-22 – JLG Lift – 3121607...
  • Page 59 SECTION 3 - CHASSIS & TURNTABLE 1. Assemble fittings for hoses to drive motor finger tight 6. Install swivel stabilizer and secure With JLG Thread Lock- until correct positioning is established. ing Compound PN 0100011. Torque to 93 ft-lb +10-0 (130 Nm, +14 -0).

  • Page 60: Swing Drive

    13. Dowel Pin 1C. Bearing 1I. Retaining Ring 4. Ring Gear 8. Sun Gear 20. Pipe Plug 1E. Bearing 1J. Pipe Plug 5. O-Ring 11. Thrust Washer 44. Internal Retaining Ring Figure 3-15. Swing Drive Assembly 3-24 – JLG Lift – 3121607...

  • Page 61: Swing Motor And Brake Assembly

    105. Commutator and Ring Assy 114. Thrust Washer 8J. Rotor Disc 29. Bolt 106. Ring 115. Thrust Bearing 8K. Stator Disc 30. Elbow 107. Manifold 116. Inner Seal Figure 3-16. Swing Motor and Brake Assembly 3121607 – JLG Lift – 3-25...

  • Page 62: Gear Backlash

    Set backlash to .010 - .015 in (0.254 to 0.381mm). bearing, then loosen jack bolt. 1. Insert shim (JLG P/N 4071009) between pinion and bear- 7. Apply JLG Thread locking compound P/N 0100019 to ing on the bearing high spot. The bearing high spot jack bolt threads.

  • Page 63: Motor Control Valve Disassembly

    5. Apply less than 50 psi air to brake port to remove Brake Piston (8A). 6. Remove Rotors (8J) and Stators (8K) from Brake Housing Figure 3-21. Main Control Valve Disassembly Figure 3-22. Motor and Brake Disassembly 3121607 – JLG Lift – 3-27...

  • Page 64: Main Disassembly

    10. Remove Internal Gear (2). NOTE: If bearing replacement is necessary, Bearing Cups (1C & 1F) can be removed with a slide hammer puller or driven out with a punch. Figure 3-24. Hub-Shaft Disassembly Figure 3-23. Main Disassembly 3-28 – JLG Lift – 3121607...

  • Page 65: Carrier Disassembly

    Carrier (3A). 4. Remove both rows of Needle Bearings (3C) and Spacer (3D) from bore of Planet Gear (3F). 5. Repeat Steps 1 thru 4 for remaining Cluster Gears (3F). Figure 3-25. Carrier Disassembly 3121607 – JLG Lift – 3-29...

  • Page 66: Hub-Shaft Subassembly

    11. Tap Retaining Ring (1I) with a soft metal punch to ensure Reinstall Drain Plug if not already installed (1P from Fig. it is completely seated in groove of Output Shaft (1A). 3-45). Torque to 23 - 24 ft-lb (31 - 32 Nm). 3-30 – JLG Lift – 3121607...

  • Page 67: Carrier Subassembly

    Thrust Washer (3B) into Carrier (3A). 9. Position non-chamfered side on Planet Shaft (3E) Roll Figure 3-27. Carrier Subassembly Pin hole in line with hole in Carrier (3A) using a 1/8 inch diameter punch. 3121607 – JLG Lift – 3-31...

  • Page 68: Main Assembly

    9. Install Thrust Washer (11) in counter bore on face of car- rier. Use grease to hold in place. 10. Place O-ring (5A) into counter bore of Brake Housing (6). Use grease to hold O-Ring in place. Figure 3-28. Main Assembly 3-32 – JLG Lift – 3121607...

  • Page 69: Motor And Brake Assembly

    Brake (6) against Motor flange. Torque to 80-100 ft-lb ing O-ring Plug (23) in Motor Control Valve (32). Torque (108-135 Nm). to 30-31 ft-lb (40-42 Nm). O-Ring Brake Port Figure 3-30. Motor Control Valve Assembly Figure 3-29. Motor and Brake Assembly 3121607 – JLG Lift – 3-33...

  • Page 70: Swing Bearing

    NOTE: This check is designed to replace existing bearing bolt IS HERE STRESSES OF LIFTING ARE CONCENTRATED, AT CENTER OF ROTATION. torque checks on JLG Lifts in service. This check must be BECAUSE OF THIS, PROPER MAINTENANCE OF SWING BEARING BOLTS IS A performed after first 50 hours of machine operation and MUST FOR SAFE OPERATION.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE 3121607 – JLG Lift – 3-35...

  • Page 72: Swing Bearing Replacement

    NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY JLG INDUSTRIES RECOMMENDS ALL REMOVED BEARING BOLTS BE DISCARDED PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCK- AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY ING.

  • Page 73: Swing Bearing Torque Values

    7. Remove lifting equipment. 2. Inner Race - 190 ft-lb (258 Nm). 8. Install rotary coupling retaining yoke brackets. Apply a light coating of Thread Locking Compound, JLG P/N 0100011 to attaching bolts. Secure yoke to turntable with mounting hardware.

  • Page 74: Generator

    Figure 3-36. Generator Brushes and Slip Rings Blow out inside of generator every 500 hours of service. If Figure 3-35. Generator Belt Tension operating in a hostile environment, clean monthly. Figure 3-37. Generator Cleaning 3-38 – JLG Lift – 3121607...

  • Page 75: Overload Protection

    3. Clean rings with 220 grit emery paper. Remove as little material as possible. If rings are deeply pitted and do not clean up, consult generator factory service. Figure 3-38. Generator Circuit Breaker Location 4. Reinstall belt, brush holder assembly, and end panel. 3121607 – JLG Lift – 3-39...

  • Page 76: Inspecting Generator Brushes, Replacing Brushes, And Cleaning Slip Rings

    Less - Replace 7/16 in - 1/2 in (11 - 12 mm ) New 1. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-39. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3-40 – JLG Lift – 3121607...

  • Page 77: Deutz D2.9 L4 Engine

    23. Oil Drain Hose 31. Front Engine/Generator Mount 39. Pulley 8. Temperature Sender 16. Catalytic Converter/Muffler 24. Oil Drain Valve 32. Oil Fill Cap Figure 3-40. Deutz D2.9 L4 Engine Installation - Sheet 1 of 2 3121607 – JLG Lift – 3-41...

  • Page 78: Deutz D2.9 L4 Engine Installation - Sheet 2 Of 2

    14. Air Filter Assembly 3. Air Filter Service Indicator 6. Fuel Pump 9. Power Module Relay 12. Hitch Pin 15. Engine Control Unit (ECU) Figure 3-41. Deutz D2.9 L4 Engine Installation - Sheet 2 of 2 3-42 – JLG Lift – 3121607...

  • Page 79: Check Oil Level

    6. Pour in new engine oil. Refer to Section 1 for capacity and Figure 3-49., Engine Oil Viscosity. MAXIMUM OIL LEVEL Figure 3-42. Deutz 2.9 T4F Dipstick Markings 5. Replace dipstick until fully seated. Figure 3-43. Engine Oil Viscosity 3121607 – JLG Lift – 3-43...

  • Page 80: Change Oil Filter

    8. Check oil level. 9. Check oil pressure. Check oil filter cartridge for leaks. 7. Connect water sensor connector (Pre-filter Only). 8. Open fuel shut-off valve. 9. Check for leaks. 3-44 – JLG Lift – 3121607...

  • Page 81: Deutz D2011 Engine

    23. Alternator 6. Oil Cooler Hose 12. Right Track Drive Pump 18. Right Front Engine Support 24. Left Front Engine/Generator Support Figure 3-44. Deutz D2011 Engine (Battery Engine Side) Installation - 1 of 2 3121607 – JLG Lift – 3-45...

  • Page 82: Deutz D2011 Engine (Battery Engine Side) Installation - 2 Of 2

    3. Radiator 7. Fuel Filter 11. Starter 15. Relay 18. Battery 4. Relay 8. Oil Pressure Sensor 12. Oil Lube Pump Figure 3-45. Deutz D2011 Engine (Battery Engine Side) Installation - 2 of 2 3-46 – JLG Lift – 3121607...

  • Page 83: Deutz D2011 Engine (Battery Tank Side) Installation - 1 Of 2

    17. Right Track Drive Pump 23. Starter 6. Glow Plug 12. Coupling 18. Left Track Drive Pump 24. Muffler 25. Alternator Figure 3-46. Deutz D2011 Engine (Battery Tank Side) Installation - 1 of 2 3121607 – JLG Lift – 3-47...

  • Page 84: Deutz D2011 Engine (Battery Tank Side) Installation - 2 Of 2

    7. Oil Filter 11. Oil Pressure Sensor 15. Starter 4. Relay 8. Fuel Filter 12. Throttle Actuator 16. Relay 17. Engine Tray Figure 3-47. Deutz D2011 Engine (Battery Tank Side) Installation - 2 of 2 3-48 – JLG Lift – 3121607...

  • Page 85: Checking Oil Level

    6. Pour in new engine oil. Refer to Section 1 for capacity and Figure 3-49., Engine Oil Viscosity. Figure 3-48. Deutz Dipstick Markings 5. Replace dipstick until fully seated. Figure 3-49. Engine Oil Viscosity 3121607 – JLG Lift – 3-49...

  • Page 86: Changing Oil Filter

    4. Apply light film of oil or diesel fuel to rubber gasket of new filter cartridge. 5. Screw in new filter by hand until gasket is flush. Hand- tighten filter another half-turn. 6. Open fuel shut-off valve. 7. Check for leaks. 3-50 – JLG Lift – 3121607...

  • Page 87: Clean Fuel Strainer

    4. Install cleanout plug. 3.9 GLOW PLUGS If glow plug option is enabled in the JLG Control System, glow plug and indicator lamp will be energized when Power/Emer- gency Stop switch is pulled on if ambient air temperature is less than 50°...

  • Page 88: Deutz Emr 2

    The EMR2 consists of sensors, control unit, and actuator. home) functions. In order to switch the engine off, the EMR2 is Engine-side controls and the JLG Control System are con- switched in a de-energized fashion over the ignition switch. A nected by separate cable harnesses to the EMR control unit.
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 3121607 – JLG Lift – 3-53...
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 3-54 – JLG Lift – 3121607...
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE 3121607 – JLG Lift – 3-55...
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE 3-56 – JLG Lift – 3121607...

  • Page 93: Emr 2 Engine Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-55. EMR 2 Engine Plug Pin Identification 3121607 – JLG Lift – 3-57...

  • Page 94: Emr 2 Vehicle Plug Pin Identification

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-56. EMR 2 Vehicle Plug Pin Identification 3-58 – JLG Lift – 3121607...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE 3121607 – JLG Lift – 3-59...
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE 3-60 – JLG Lift – 3121607...
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE 3121607 – JLG Lift – 3-61...
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE 3-62 – JLG Lift – 3121607...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 3121607 – JLG Lift – 3-63...

  • Page 100: Bio Fuel In Deutz Engines

    The use of US bio-diesel based on soy oil methylester is only permissible in mixtures with diesel fuel with a bio-diesel part of a max. 20 weight-%. The US bio-diesel used for the mixture must comply with the ASTM D6751-07a (B100) standard. 3-64 – JLG Lift – 3121607...

  • Page 101: Biological Contamination In Fuels

    Use of unsuitable additives watery phase, at phase boundary to the fuel phase, from which will result in loss of warranty. they draw their nutrition. There is an increased risk especially with bio-diesel (FAME). 3121607 – JLG Lift – 3-65...
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE NOTES: 3-66 – JLG Lift – 3121607...

  • Page 103: Boom & Platform

    Remove bolts #1 securing push tube on fly boom section. e. Support slave cylinder. Remove hardware from pin #3. Remove pin #3 from fly boom with a suitable g. Remove bolts #2 securing push tube on mid boom brass drift and hammer. section. 3121607 – JLG Lift –...

  • Page 104: Wear Pads

    Using a suitable brass drift and hammer, remove pivot pin from turntable upright. k. Using all applicable safety precautions, carefully lift boom assembly clear of turntable and lower to ground or suitably supported work surface. – JLG Lift – 3121607...

  • Page 105: Boom Disassembly/Assembly & Cable Replacement

    Remove bolts securing wire rope attach bar to top of fly boom section. Pull telescope cylinder and wire ropes partially from aft end of base boom section. Secure cylinder with a suit- able sling and lifting device at center of gravity. 3121607 – JLG Lift –...

  • Page 106: Wire Rope

    Ropes with 6 total broken wires in one rope lay, 3 in one Inspect sheaves with a groove wearout gauge for exces- strand in one rope lay, 1 valley break, or 1 break at any sive wear. end termination. – JLG Lift – 3121607...

  • Page 107: Wire Rope Tensioning Adjustment

    DO NOT CLAMP ON THREADS OR THREADS MAY BE DAMAGED. DO NOT ALLOW WIRE ROPE TO ROTATE OR WIRE ROPE MAY BE DAMAGED. CLAMP THREADED ENDS OF WIRE ROPE TO PREVENT ROTATION. Figure 4-11. Clamping Wire Ropes 3121607 – JLG Lift –...

  • Page 108: Boom Assembly Cutaway - Sheet 1 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-12. Boom Assembly Cutaway - Sheet 1 of 3 – JLG Lift – 3121607...

  • Page 109: Boom Assembly Cutaway - Sheet 2 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-13. Boom Assembly Cutaway - Sheet 2 of 3 3121607 – JLG Lift –...

  • Page 110: Boom Assembly Cutaway - Sheet 3 Of 3

    Remove sheave assemblies from mid boom section. Remove hardware which secures wear pads to front of mid boom section. Remove wear pads from top, sides, and bottom of the mid boom section. – JLG Lift – 3121607...

  • Page 111: Inspection

    When removing wire rope from fly boom section, push drawing. cable into fly boom. Route wire rope back through holes in side of fly boom section. Figure 4-17. Dimension of Sheaves When New Figure 4-16. Wire Rope Routing Disassembly 3121607 – JLG Lift –...

  • Page 112: Assembly

    ARE CLEAR OF CHAINS, TOOLS, AND OTHER OBSTRUCTIONS. Shim insides of boom sections for a total of 1/16 inch (0.062) clearance (if action is centered, there will be 1/32 inch clearance on each side). 4-10 – JLG Lift – 3121607...

  • Page 113: Boom Powertrack Installation

    SECTION 4 - BOOM & PLATFORM Figure 4-19. Boom Powertrack Installation 3121607 – JLG Lift – 4-11...

  • Page 114: Proximity Switch Installation

    Align holes in aft end of fly boom section with holes in der barrel and sheave assembly; secure pin with mount- wire rope mounting block. Secure with mounting hard- ing hardware. ware. Figure 4-20. Proximity Switch Installation 4-12 – JLG Lift – 3121607...

  • Page 115: Installation

    Tighten or install all clamping or securing apparatus to hoses or cables, as necessary. h. Install powertrack cover and push tube rods with mounting hardware. Figure 4-21. Boom Powertrack Assembly 3121607 – JLG Lift – 4-13...

  • Page 116: Articulating Jib Boom

    Inspect all threaded components for damage such as stretching, thread deformation, or twisting. Replace as necessary. Inspect structural units of articulating jib boom assem- bly for bending, cracking, separation of welds, or other damage. Replace boom sections as necessary. 4-14 – JLG Lift – 3121607...

  • Page 117: Assembly

    Align bottom tubes with attach holes in articulating jib the JLG Operation & Safety Manual and the JLG Service boom pivot weldment. Using a soft head mallet, install & Maintenance Manuals.

  • Page 118: Horizontal Limit And Dual Capacity Limit Switches Adjustments

    SECTION 4 - BOOM & PLATFORM Figure 4-23. Horizontal Limit and Dual Capacity Limit Switches Adjustments 4-16 – JLG Lift – 3121607...

  • Page 119: Transport Switch Adjustments - Ce Machines Only

    SECTION 4 - BOOM & PLATFORM Figure 4-24. Transport Switch Adjustments - CE Machines Only 3121607 – JLG Lift – 4-17...

  • Page 120: Rotary Actuator

    Axially, the shaft is separated from the housing by upper and lower thrust washers. End cap is adjusted for axial clearance and locked in position by set screws or pins. 4-18 – JLG Lift – 3121607...

  • Page 121: Rotary Actuator - Exploded View

    204. O-ring 420.2 Bushing 4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing 109 . Lock Pin 207. Backup Ring 113. Capscrew 304.1. Wiper Seal Figure 4-25. Rotary Actuator - Exploded View 3121607 – JLG Lift – 4-19...

  • Page 122: Rotary Actuator - Assembly Drawing

    204. O-ring 420.2 Bushing 4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing 109 . Lock Pin 207. Backup Ring 113. Capscrew 304.1. Wiper Seal Figure 4-26. Rotary Actuator - Assembly Drawing 4-20 – JLG Lift – 3121607...

  • Page 123: Disassembly

    Remove lock pins using an ”Easy Out” (Size #2 shown. If pin will not come out, use 5/16" drill bit 1/2" (12.7mm) Remove end cap (4) and set aside for later inspection. deep to drill out entire pin. 3121607 – JLG Lift – 4-21...
  • Page 124 This simplifies timing during assembly. Actuator has timing marks for proper engagement. Remove shaft (2). It may be necessary to strike threaded end of shaft with a rubber mallet. 4-22 – JLG Lift – 3121607...
  • Page 125 To remove piston (3), use a rubber mallet and plastic Remove O-ring (204) and backup ring (207) from end mandrel so piston is not damaged. cap (4) and set aside for inspection. 3121607 – JLG Lift – 4-23...
  • Page 126 Remove wiper seal (304.1) from end cap (4) and shaft (2). To remove main pressure seals (205), cut them with a sharp razor blade. Do not to damage seal groove. Remove piston O.D. seal (202). 4-24 – JLG Lift – 3121607...

  • Page 127: Inspection

    (not less than 0.123” or 3.12 mm). pressed air before inspecting. Carefully inspect all criti- cal areas for any surface finish abnormalities: Seal grooves, bearing grooves, thrust surfaces, rod surface, housing bore, and gear teeth. 3121607 – JLG Lift – 4-25...

  • Page 128: Assembly

    Install thrust washer (304) on shaft (2) and end cap (4). (2) and end cap (4). Use seal tool in a circular motion. Install wear guide (302) on end cap (4) and shaft (2). 4-26 – JLG Lift – 3121607...
  • Page 129 Using a rubber mallet, tap piston in ring in lower groove and feed the rest in using a circular housing to point where gear teeth meet. motion. Make sure wedged ends overlap correctly. Repeat for outer seal (202). 3121607 – JLG Lift – 4-27...
  • Page 130 Looking from view shown, use existing timing marks to line up gear teeth on shaft (2) with gear teeth on inside of piston (3). Tap flange end of shaft with rubber mallet until gear teeth engage. 4-28 – JLG Lift – 3121607...
  • Page 131 (1). Insert set screws (113) over lock pins. Tighten to 25 in-lb (2.825 Nm). Tighten end cap (4). Ensure holes for lock pins line up. 3121607 – JLG Lift – 4-29...

  • Page 132: Installing Counterbalance Valve

    Make sure new valve has the O-rings in counterbores of bolts to 140 in-lb (15.8 Nm). Do not torque over 145 in-lb valve to seal it to the actuator housing. (16.3 Nm). Figure 4-27. Rotator Counterbalance Valve 4-30 – JLG Lift – 3121607...

  • Page 133: Testing Actuator

    (8L) is purged. Repeat steps 2 & 3. After last 1/2 gallon is purged, close both bleed nipples before rotating away from end posi- tion. 3121607 – JLG Lift – 4-31...

  • Page 134: Troubleshooting

    Piston and/or shaft seal leak b. Remove plug and housing’s valve ports. Operate actuator through housing ports. Conduct internal leakage test. c. Purge air from actuator. See bleeding procedures c. Air in actuator 4-32 – JLG Lift – 3121607...

  • Page 135: Foot Switch Adjustment

    Replace rivets with 1/4 x 20 NC x 2 “grade 5 bolts, flat washers, and locknuts when installing a new gate to platform. 3121607 – JLG Lift – 4-33...

  • Page 136: Powertrack Maintenance

    1. Clamp bar and poly roller tightly so they do not spin when removing screw. With a small ¼” ratchet and a T- 20 Torx bit, remove 8-32 x 0.500 screw from one side. 4-34 – JLG Lift – 3121607...
  • Page 137 ¼” ball double cut bur attachment. insert tool into rolled over end of rivet. Grind out middle of rivet until rolled over part of rivet falls off. Repeat for all rivets to be removed. 3121607 – JLG Lift – 4-35...
  • Page 138 SECTION 4 - BOOM & PLATFORM Insert flat head screwdriver between links. Twist and pull Remove link from other section of powertrack using links apart. screwdriver. 4-36 – JLG Lift – 3121607...

  • Page 139: Install New Link

    Use screwdriver if neces- 1. Squeeze cut-out end of new link into half-shear (female) sary. end of track section. Round half-shears will not fit properly in cut-outs after new link is installed . 3121607 – JLG Lift – 4-37...
  • Page 140 Round half-shears will rotate into cut-outs. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed. Parts shown below connect new link to powertrack. 4-38 – JLG Lift – 3121607...
  • Page 141 Pull up on other end of round bar. Slide new poly roller properly. on bar. Incorrect Correct Install new 8-32 x 0.500 self-threading Torx head screw in end of new aluminum round bar. Torque to 18-20 in- lb (2-2.25 Nm). 3121607 – JLG Lift – 4-39...

  • Page 142: Replace Fixed End Brackets

    REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 1. Remove rivets as shown in link removal instructions.. NOTE: When tightening screws make sure screw head is seated against link with no space in between link and underside of screw head. 4-40 – JLG Lift – 3121607...

  • Page 143: Replace Moving End Brackets

    1. Remove existing pins and center rivet. Remove rivet as shown in link removal instructions on page 4-20. Repeat on other bracket if replaced. NOTE: Ensure snap rings are seated in pin groove and closed properly. Correct Incorrect 3121607 – JLG Lift – 4-41...
  • Page 144 Install center pin with snap ring in new bracket. properly. Incorrect Correct Make sure both brackets rotate correctly. Install radius pins and snap rings in original locations. Repeat with other moving end if replaced. 4-42 – JLG Lift – 3121607...

  • Page 145: Hydraulics

    Make sure entire O-ring is coated with hydraulic oil. 1. Hold fitting in one hand and dip brush into container with other hand. Remove excess hydraulic oil from brush so an even film of oil is applied to O-ring. 3121607 – JLG Lift –...

  • Page 146: Dip

    3. Brush an even coat of hydraulic oil on entire O-ring. oil. NOTE: O-ring boss-type fittings require more pressure to immerse more of fitting into saturated sponge. This also causes more oil to be dispersed from sponge. – JLG Lift – 3121607...

  • Page 147: Cylinders - Theory Of Operation

    If leakage continues at a rate of 6-8 drops per min- suspected. ute or more, repair cylinder. Boom at Horizontal Figure 5-1. Boom Positioning and Support, Cylinder Repair 3121607 – JLG Lift –...

  • Page 148: Cylinders With Single Counterbalance Valve

    6. Remove lifting device from upright or remove prop from below main boom. Activate hydraulic system and run cylinder through one complete cycle to check for leaks. – JLG Lift – 3121607...

  • Page 149: Cylinder Removal And Installation

    11. Pull telescope cylinder and cables partially from aft end of base boom section. Secure cylinder with a suitable sling and lifting device at center of gravity. 12. Carefully remove telescope cylinder and sheave assem- bly. Place telescope cylinder on a suitable trestle. 3121607 – JLG Lift –...

  • Page 150: Main Boom Lift Cylinder Removal

    5. Remove boom prop and overhead crane. Activate hydraulic system. 6. Using all applicable safety precautions, operate boom functions. Check for correct operation and hydraulic leaks. Secure as necessary. 7. Check fluid level of hydraulic tank. Adjust as necessary. – JLG Lift – 3121607...

  • Page 151: Cylinder Locations

    SECTION 5 - HYDRAULICS Cylinder Locations 600 SJC Only Item Cylinder Main Lift Master Telescope Platform Level (Slave) Jib Lift Figure 5-2. Hydraulic Cylinder Locations 3121607 – JLG Lift –...

  • Page 152: Main Lift Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-3. Cylinder Barrel Support Figure 5-5. Cylinder Rod Support – JLG Lift – 3121607...

  • Page 153: Main Lift Cylinder Assembly

    8. O-Ring Plug 14. Back-Up Ring 20. Locking Compound 3. Head 9. 5/16"-11x2 Bolt 15. Wear Ring 21. Locking Primer 4. Piston 10. O-Ring Plug 16. O-Ring 22. Ring Washer Figure 5-6. Main Lift Cylinder Assembly 3121607 – JLG Lift –...

  • Page 154: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 5-10 – JLG Lift – 3121607...

  • Page 155: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. NOTE: Upper telescope cylinder piston has an O-ring installed inside spacer. Figure 5-10. Poly-Pak Piston Seal Installation 3121607 – JLG Lift – 5-11...

  • Page 156: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, slave, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-15. Rod Assembly Installation Figure 5-14. Tapered Bushing Installation 5-12 – JLG Lift – 3121607...

  • Page 157: Master Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-16. Cylinder Barrel Support Figure 5-18. Cylinder Rod Support 3121607 – JLG Lift – 5-13...

  • Page 158: Master Cylinder Assembly

    6. Spacer 11. Seal 16. O-Ring 21. Capscrew 2a. Composite Bushing 7. Capscrew 12. Lock Ring 17. Back-Up Ring 3. Piston 8. Ring Washer 13. O-Ring 18. Rod Seal Figure 5-19. Master Cylinder Assembly 5-14 – JLG Lift – 3121607...

  • Page 159: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 3121607 – JLG Lift – 5-15...

  • Page 160: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. NOTE: Upper telescope cylinder piston has an O-ring installed inside spacer. Figure 5-23. Poly-Pak Piston Seal Installation 5-16 – JLG Lift – 3121607...

  • Page 161: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, slave, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-28. Rod Assembly Installation Figure 5-27. Tapered Bushing Installation 3121607 – JLG Lift – 5-17...

  • Page 162: Telescope Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-29. Cylinder Barrel Support Figure 5-31. Cylinder Rod Support 5-18 – JLG Lift – 3121607...

  • Page 163: Telescope Cylinder Assembly

    18. O-Ring 23. Locking primer 4. Piston 9. Capscrew 14. Rod Seal 19. Back-Up Ring 24. Not Used 5. Tapered Bushing 10. Ring Washer 15. O-Ring 20. T-Seal 25. Bolt Figure 5-32. Telescope Cylinder Assembly 3121607 – JLG Lift – 5-19...

  • Page 164: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 5-20 – JLG Lift – 3121607...

  • Page 165: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. NOTE: Upper telescope cylinder piston has an O-ring installed inside spacer. Figure 5-36. Poly-Pak Piston Seal Installation 3121607 – JLG Lift – 5-21...

  • Page 166: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, slave, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-41. Rod Assembly Installation Figure 5-40. Tapered Bushing Installation 5-22 – JLG Lift – 3121607...

  • Page 167: Platform Level (Slave) Cylinder

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-42. Cylinder Barrel Support Figure 5-44. Cylinder Rod Support 3121607 – JLG Lift – 5-23...

  • Page 168: Platform Level (Slave) Cylinder Assembly

    8. O-Ring Plug 14. Ring Lock 20. Rod Seal 25. Bolt 3. Piston 9. Capscrew 15. O-Ring 21. Wiper 4. Head 10. Ring Washer 16. Back-Up Ring Figure 5-45. Platform Level (Slave) Cylinder Assembly 5-24 – JLG Lift – 3121607...

  • Page 169: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 3121607 – JLG Lift – 5-25...

  • Page 170: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. NOTE: Upper telescope cylinder piston has an O-ring installed inside spacer. Figure 5-49. Poly-Pak Piston Seal Installation 5-26 – JLG Lift – 3121607...

  • Page 171: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, slave, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-54. Rod Assembly Installation Figure 5-53. Tapered Bushing Installation 3121607 – JLG Lift – 5-27...

  • Page 172: Jib Lift Cylinder (Sjc Only)

    6. Clamp barrel securely. Pull rod assembly and cylinder head from barrel. 7. Protect cylinder rod from damage and clamp in a vise or holding fixture as close to piston as possible. Figure 5-55. Cylinder Barrel Support Figure 5-57. Cylinder Rod Support 5-28 – JLG Lift – 3121607...

  • Page 173: Jib Lift Cylinder Assembly(660Sjc)

    3. Ring Washer 7. Not Used 12. Spacer 17. Back-Up Ring 22. Wear Ring 4. Capscrew 8. O-Ring Plug 13. Not Used 18. Rod Seal 23. Locking Compound Figure 5-58. Jib Lift Cylinder Assembly(660SJC) 3121607 – JLG Lift – 5-29...

  • Page 174: Cleaning And Inspection

    6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other Dress piston surface or replace piston as necessary. damage. Replace as necessary. 5-30 – JLG Lift – 3121607...

  • Page 175: Assembly

    Do not damage or dislodge wiper and rod seals. Push head along rod to rod end, as applicable. 5. Carefully slide piston spacer on rod. NOTE: Upper telescope cylinder piston has an O-ring installed inside spacer. Figure 5-62. Poly-Pak Piston Seal Installation 3121607 – JLG Lift – 5-31...

  • Page 176: Piston Seal Kit Installation

    NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts when rebuilding master, slave, lift, and telescope cylinders. 10. Install bolts in tapered bushing using loctite #242 Figure 5-67. Rod Assembly Installation Figure 5-66. Tapered Bushing Installation 5-32 – JLG Lift – 3121607...

  • Page 177: Hydraulic Pump (Gear)

    4. Remove key from drive shaft if applicable. bench. Make sure rear bearing block remains on drive and idler shafts. 5. Clamp mounting flange in a protected jaw vise with pump shaft facing down. 6. Loosen four metric hex head bolts. 3121607 – JLG Lift – 5-33...
  • Page 178 15. Remove oil seal from mounting flange. Do not mar or NOTE: Shaft seal will be replaced. scratch seal bore. 16. Remove dowel pins from gear housing. Do not lose pins. 17. Remove and discard seals from both bearing blocks. 5-34 – JLG Lift – 3121607...

  • Page 179: Inspect Parts For Wear

    There should not ation of shaft is allowable. be excessive wear, deep scratches, or gouges. 3. Inspect drive gear shaft and idler gear shafts at bearing points and seal area for rough surfaces and excessive wear. 3121607 – JLG Lift – 5-35...

  • Page 180: General Information

    (Note: W900 series pump - In center of backup ring and E- vent seal misalignment or damage. seal there is a notch. Make sure notches line up so backup ring will set flush with E-seal). Backup ring in W1500 pump is symmetrical. 5-36 – JLG Lift – 3121607...
  • Page 181 Remove seal sleeve from shaft. 9. Install idler gear shaft in remaining position in bearing block. Apply a light coat of clean oil to face of drive and idler gears. 3121607 – JLG Lift – 5-37...

  • Page 182: Hydraulic Pump Bolt Torque Chart

    17. Remove pump from vise. 18. Place a small amount of clean oil in pump inlet and rotate drive shaft away from inlet one revolution. If drive shaft binds, disassemble pump and check for assembly problems. Reassemble pump. 5-38 – JLG Lift – 3121607...

  • Page 183: Placing Pump Back Into Service

    O-rings. FNR and NFPE orifice plugs are located inside the servo piston covers. NFPH orifice plugs are located in the NFPH ports. Ori- fice plugs may be cleaned or replaced. 3121607 – JLG Lift – 5-39...

  • Page 184: Remove And Install Fnr And Nfpe Modules

    4 bar / 1.25 mm (58 psi / 0.050 in). Effective setting will vary. To confirm charge relief valve setting, measure charge pressure (port M3) with pump in stroke. Charge pressure should level off when relief setting is reached. 5-40 – JLG Lift – 3121607...

  • Page 185: Gauge Port Locations

    Case Drain Port L1 System Pressure Gauge Port M1 Case Drain Port L1 (non-feedback) Servo Pressure Gauge Port M5 Charge Pressure Gauge Case Drain Port L2 (non-feedback) Charge Pump Inlet Port S Figure 5-69. Gauge Port Locations 3121607 – JLG Lift – 5-41...

  • Page 186: Plugs/Fittings Size & Torque

    System Gauge M1 & M2 10 System Ports A&B 11 11/16 20-35 27-47 12 9/16 70-100 95-135 13 11/16 20-35 27-47 14 Servo Gauge M5 15 11/16 20-35 27-47 Figure 5-70. Plugs/Fittings Size & Torque 5-42 – JLG Lift – 3121607...

  • Page 187: Shaft Seal And Shaft Replacement

    1. O-Ring 4. Sealant may be used on outside diameter 2. Seal 5. Inside Lip (face down) 3. Seal Carrier 6. Press Seal to Bottom of Seal Carrier Figure 5-73. Installation of Shaft Seal 3121607 – JLG Lift – 5-43...

  • Page 188: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication

    Coat pump and drive coupling splines with Lithium Soap 14. Install retaining ring. Base Grease (TEXACO CODE 1912 OR EQUIVALENT) whenever pump or pump drive coupling is removed. Cou- pling is greased prior to assembly. 5-44 – JLG Lift – 3121607...

  • Page 189: Charge Pump

    Figure 5-75. Charge Pump Components 14. Install charge pump cover. Cover must engage gerotor cover and locating pins. Install charge pump cover screws. Torque evenly to 26 - 32 ft-lb (36-43 Nm). 15. Reinstall auxiliary pump if necessary. 3121607 – JLG Lift – 5-45...

  • Page 190: Hydraulic Component Start-Up

    Use highest possible case drain port. This ensures housing con- ervoir level and add filtered fluid if needed. tains as much oil as possible and offers the greatest amount of lubrication to internal components. Machine is ready for operation. 5-46 – JLG Lift – 3121607...

  • Page 191: Pressure Setting Procedures

    HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES Install pressure gauge at quick disconnect on port M3 PRIOR TO CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CALI- on main valve after releasing pressure. BRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF WITHIN +/- 5% OF 2.

  • Page 192: Location Of Components - Main Control Valve

    Not Used Direct Operated Relief Valve Load Shuttle Valve Directional Control Valve (Lower Lift) Pressure Compensated Flow Control (Fixed 0.2 GPM) Direct Operated Relief Valve Figure 5-76. Location of Components - Main Control Valve 5-48 – JLG Lift – 3121607...

  • Page 193: Articulating Jib Valve

    SECTION 5 - HYDRAULICS *60 in-lb (7 Nm) **18-20 ft-lb (25-27 Nm) Flow Control Cartridge 2.1. Directional Control Valve Assembly Relief Cartridge Relief Cartridge Figure 5-77. Articulating Jib Valve 3121607 – JLG Lift – 5-49...
  • Page 194 SECTION 5 - HYDRAULICS NOTES: 5-50 – JLG Lift – 3121607...

  • Page 195: Jlg Control System

    Each module has a label with JLG part number and a serial number smooth control of: acceleration, deceleration, creep, min containing a date code.

  • Page 196: Controller Block Diagram

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. Controller Block Diagram – JLG Lift – 3121607...

  • Page 197: Connect Jlg Control System Analyzer

    NOTE: Follow instructions provided with Wireless Analyzer (WAN- menu item press ESC . Scroll using right and left arrow ALYZER) kit. JLG Analyzer application must be downloaded keys to select a different menu item. and installed to your smartphone or tablet device.

  • Page 198: Changing Access Level

    SECTION 6 - JLG CONTROL SYSTEM If ENTER is selected at the HELP: PRESS ENTER display, Pressing ENTER with any of the above displayed menus, and a fault is present, the analyzer display scrolls the fault displays additional sub-menus within the selected menu. In across the screen.

  • Page 199: Adjust Parameters

    SECTION 6 - JLG CONTROL SYSTEM Adjust Parameters Press ENTER to select the ACCESS LEVEL menu. Once you have gained access to level 1, and a personality item Using the UP or DOWN arrow keys, enter first is selected, press the UP...

  • Page 200: Machine Setup

    SECTION 6 - JLG CONTROL SYSTEM Machine Setup There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK When a machine digit item is selected, press UP DOWN arrow keys to adjust its value, for example: CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFOR- MANCE OF YOUR MACHINE.

  • Page 201: Analyzer Abbreviations

    SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations ABBREVIATION MEANING ABBREVIATION MEANING LENGTH ACCEL ACCELERATE LIMIT ACTIVE LEFT ANALOG DIGITAL CONVERTER COUNT LEVEL AMB. AMBIENT MINUTES ANGLE MINIMUM AUXILIARY MAXIMUM BOOM CONTROL SYSTEM MAIN...

  • Page 202: Analyzer Software Version 6.8 - Sheet 1 Of 6

    SECTION 6 - JLG CONTROL SYSTEM MENU: HELP: (001) HELP:PRESS ENTER EVERYTHING OK LOG:(xxx) x:xxxxxxxxxxx DIAGNOSTICS: MENU: DIAGNOSTICS: DIAGNOSTICS: BOOM FUNCTIONS DIAGNOSTICS DRIVE/STEER ENGINE JOYSTICK LIFT: JOYSTICK DRIVE: MAIN UP XXX% FORWARD XXX% JOYSTICK STEER: LIFT OUTPUT: LEFT XXX% MAIN UP XXX%...

  • Page 203: Analyzer Software Version 6.8 - Sheet 2 Of 6

    SECTION 6 - JLG CONTROL SYSTEM From DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: ENGINE SYSTEM BOOM FUNCTIONS LOAD CHASSIS TILT START SEQUENCE: GROUND MODULE: NOT ACTIVE ANGLE: XX.X BATTERY: XX.XV UMS TO TURNTABLE BATTERY VOLTAGE: PLATFORM MODULE: ANGLE: XX.X XX.XV BATTERY: XX.XV...

  • Page 204: Analyzer Software Version 6.8 - Sheet 3 Of 6

    SECTION 6 - JLG CONTROL SYSTEM FROM DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS CAPACITY LENGTH CAN STATISTICS CALIBRATION DATA DATALOG: GROUND MODULE SWITCH: CLOSED RX/SEC: X LOAD ZERO: ON: XXXh XXm SOFTWARE: XX.XX...

  • Page 205: Analyzer Software Version 6.8 - Sheet 4 Of 6

    SECTION 6 - JLG CONTROL SYSTEM FROM MENU: DIAGNOSTICS MENU: SYSTEM TEST: SYSTEM TEST ACTIVATE? MENU: ACCESS LEVEL: ACCESS LEVEL CODE XXXXXX MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES DRIVE STEER LEFT TRACK RIGHT TRACK MAIN LIFT STEER: LEFT TRACK:...

  • Page 206: Analyzer Software Version 6.8 - Sheet 5 Of 6

    SECTION 6 - JLG CONTROL SYSTEM FROM PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE RIGHT TRACK MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE: ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS...

  • Page 207: Analyzer Software Version 6.8 - Sheet 6 Of 6

    SECTION 6 - JLG CONTROL SYSTEM FROM MENU: PERSONALITIES MENU: MODEL NUMBER: MARKET: ENGINE: FLYWHEEL TEETH: GLOW PLUG: MACHINE SETUP 600S PERKINS ECM 133 TEETH IN-CYLINDER STARTER LOCKOUT: ENGINE SHUTDOWN: TILT: JIB: 4 WHEEL STEER: DISABLED ENABLED 5 DEGREES STOUCH/SKYGUARD:...

  • Page 208: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM NOTE: Personality settings can be adjusted within the adjustment 6.2 MACHINE PERSONALITY SETTINGS range for optimum machine performance. Table 6-2. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S DRIVE ACCELeration 0.1s to 5.0s DECELeration 0.1s to 3.0s...
  • Page 209 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S SWING ACCELeration 0.1 to 5.0s DECELeration 0.1 to 3.0s MINimum LEFT speed 0 to 50% MAXimum LEFT speed 0 to 100% CREEP maximum LEFT speed...
  • Page 210 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S BASKET ROTATE ACCELeration 0.1 to 5.0 DECELeration 0.1 to 3.0 MlNimum LEFT speed 0 to 65% MAXimum LEFT speed 0 to 100% MINimum RIGHT speed...

  • Page 211: Help Fault Codes, Displayed Faults, And Descriptions

    SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault None No flash code is indicated for the following help messages. They are intended to hint at a possible problem if vehicle is not behaving as expected.
  • Page 212 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1 volts.
  • Page 213 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault l/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when center tap voltage is not between 3.08 volts and 3.83 volts.
  • Page 214 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault HORN SHORT TO BATTERY AUX POWER SHORT TO GROUND AUX POWER OPEN CIRCUIT AUX POWER SHORT TO...
  • Page 215 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault GROUND ALARM OPEN CIRCUIT GROUND ALARM SHORT TO BATTERY GENERATOR SHORT TO GROUND GENERATOR OPEN CIRCUIT...
  • Page 216 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BASKET RIGHT OPEN CIRCUIT BASKET RIGHT SHORT TO BATTERY JIB UP SHORT TO GROUND JIB UP OPEN CIRCUIT...
  • Page 217 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault LIFT UP DUMP SHORT TO BATTERY LIFT DOWN HOLDING SHORT TO GROUND LIFT DOWN HOLDING OPEN CIR-...
  • Page 218 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault JIB DOWN SHORT TO BATTERY JIB DOWN SHORT TO GROUND JIB DOWN OPEN CIRCUIT JIB LEFT SHORT TO BATTERY...
  • Page 219 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault FUEL SENSOR SHORT TO Indicates fuel sensor is reading below 0.2 volts. GROUND Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second power-up.

  • Page 220: Help Message/Fault Listing

    SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault Listing HELP MESSAGE FAULT FAULT REMOVAL CLEARS WHEN FAULT IS REMOVED DRIVING AT CREEP - TILTED CLEARS WHEN FAULT IS REMOVED FSW OPEN CLEARS WHEN FAULT IS REMOVED RUNNING AT CREEP - CREEP SWITCH OPEN...
  • Page 221 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault Listing HELP MESSAGE FAULT FAULT REMOVAL LP START ASSIST SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT LP START ASSIST OPEN CIRCUIT REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
  • Page 222 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault Listing HELP MESSAGE FAULT FAULT REMOVAL JIB DOWN SHORT TO BATTERY REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT JIB LEFT SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
  • Page 223 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Help Message/Fault Listing HELP MESSAGE FAULT FAULT REMOVAL FORD FAULT CODE 41 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 42 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 43 CLEARS WHEN FAULT IS REMOVED...

  • Page 224: Machine Configuration Programming Information

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: Machine configuration must be completed before any personality settings can be changed. Changing personality set- tings first and then changing the model number of the machine configuration will cause personality settings to return to...
  • Page 225 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number TILT: 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also reduces drive speed to creep.
  • Page 226 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number CABLE SWITCH: NO: No broken cable switch installed. YES: Broken cable switch installed. * Certain market selections will alter default setting. LOAD SYSTEM: NO: No load sensor installed.
  • Page 227 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Machine Configuration Programming Information Default Configuration Digit Number Description Number DISPLAY UNITS: IMPERIAL: DEG F, PSI, LBS METRIC: DEG C, KPA, KGS. * Certain market selections will alter default setting. DRIVE CONTROL: NORMAL: Drive coils are energized from the Ground Module.

  • Page 228: Machine Orientation When Setting Function Speeds

    SECTION 6 - JLG CONTROL SYSTEM 6.3 MACHINE ORIENTATION WHEN SETTING Test Notes FUNCTION SPEEDS 1. Personality settings can be adjusted anywhere within the adjustment range for optimum machine perfor- LIFT UP: from platform control, lowest elevation up to maxi- mance.

  • Page 229: Canbus Communications

    SECTION 6 - JLG CONTROL SYSTEM 6.4 CANBUS COMMUNICATIONS Interlocks: Any device that sends an electrical input. (For an example a limit switch, proximity switch, etc;) CANbus: CAN (Control Area Network) is a two wire differential Platform Level: The GROUND MODULE stores default values serial link between the Platform and Ground Modules provid- and handles interlocks.

  • Page 230: Fault Code List

    SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text EVERYTHING OK 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0011 FSW OPEN 0012 RUNNING AT CREEP - CREEP SWITCH OPEN 0013 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION...
  • Page 231 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 2371 FUNCTION PROBLEM - JIB LIFT DOWN PERMANENTLY SELECTED 2372 FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED 2373 FUNCTION PROBLEM - SWING RIGHT PERMANENTLY SELECTED 23104 BOOM TRANSPORT SWITCH DISAGREEMENT...
  • Page 232 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 3374 GEN SET/WELDER - OPEN CIRCUIT 3375 GEN SET/WELDER - SHORT TO BATTERY 3376 HEAD TAIL LIGHT - SHORT TO GROUND 3377 HEAD TAIL LIGHT - OPEN CIRCUIT...
  • Page 233 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 33281 GLOWPLUG - SHORT TO GROUND 33287 LIFT - CURRENT FEEDBACK READING TOO LOW 33295 SWING LEFT VALVE - OPEN CIRCUIT 33314 FLOW CONTROL VALVE - OPEN CIRCUIT...
  • Page 234 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 3419 JIB LIFT DOWN VALVE - SHORT TO BATTERY 3420 JIB LIFT DOWN VALVE - SHORT TO GROUND FUEL SENSOR - SHORT TO BATTERY FUEL SENSOR - SHORT TO GROUND...
  • Page 235 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Fault Code List Text 8211 LSS READING UNDER WEIGHT 8639 FRONT LEFT STEER VALVE - OPEN CIRCUIT 8640 FRONT LEFT STEER VALVE - SHORT TO BATTERY 8641 FRONT LEFT STEER VALVE - SHORT TO GROUND...
  • Page 236 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined num- bers indicate the default when the option is factory installed. 600SC ANSI USA ANSI EXPORT AUSTRALIA...
  • Page 237 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined num- bers indicate the default when the option is factory installed. 600SC ANSI USA ANSI EXPORT AUSTRALIA JAPAN NOTE: Bold Italic Numbers indicate the default setting.
  • Page 238 SECTION 6 - JLG CONTROL SYSTEM NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 660SJC ANSI USA ANSI EXPORT AUSTRALIA JAPAN NOTE: Bold Italic Numbers indicate the default setting.

  • Page 239: Control Module Locations

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-11. Control Module Locations 3121607 – JLG Lift – 6-45...

  • Page 240: Ground Control Module Pin Connections 1 Of 3

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-12. Ground Control Module Pin Connections 1 of 3 6-46 – JLG Lift – 3121607...

  • Page 241: Ground Control Module Pin Connections 2 Of 3

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-13. Ground Control Module Pin Connections 2 of 3 3121607 – JLG Lift – 6-47...

  • Page 242: Ground Control Module Pin Connections 3 Of 3

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-14. Ground Control Module Pin Connections 3 of 3 6-48 – JLG Lift – 3121607...

  • Page 243: Platform Control Module Pin Connections 1 Of 2

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-15. Platform Control Module Pin Connections 1 of 2 3121607 – JLG Lift – 6-49...

  • Page 244: Platform Control Module Pin Connections 2 Of 2

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-16. Platform Control Module Pin Connections 2 of 2 6-50 – JLG Lift – 3121607...

  • Page 245: Basic Electrical Information & Schematics

    "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while alone. For example, you can read voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held down. 3121607 – JLG Lift –...

  • Page 246: Resistance Measurement

    Meter should produce an audible alarm, indicating tance continuity • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads – JLG Lift – 3121607...

  • Page 247: Current Measurement

    Dielectric grease shall be applied to all electrical connectors at the time of connection (except those noted under Exclusions). JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE- RIAL APPROVED FOR USE AS A DIELECTRIC GREASE. NOTE: Do NOT apply dielectric grease to the following connec- tions: •...

  • Page 248: Dielectric Grease Application

    Figure 7-7. Dielectric Grease On Female Contacts Detail A Fill 1/2 full with dielectric grease After assembly, install a seal plug (JLG #4460905) to keep out (Thin layer of grease moisture. Seal plugs may also be installed by the wire harness may remain on connector manufacturer if an unused wire seal was damaged during face and adjacent areas.)

  • Page 249: Amp Mate-N-Lok

    O-ring seal for moisture integrity. Low-force contacts cannot displace dielectric grease to achieve electrical contact. Once contaminated, replacement of female contacts is required. The JLG Load Sensing System and 1250AJP Rotary Angle Sensors are examples of components with the M12 con- nector system.

  • Page 250: Amp Connector

    3. Pull on contact wire with a force of 1 - 2 lb to be sure shown in Figure 7-14. retention fingers are holding contact. 2. Crimp connector. Do not damage cutoff tab. Figure 7-16. AMP Contact Installation Figure 7-14. AMP Contact Assembly – JLG Lift – 3121607...

  • Page 251: Disassembly

    3. While rotating wire back and forth over a half turn (1/4 tem. Resulting pinholes in the insulation allows moisture to turn in each direction), gently pull wire until contact is enter by traveling along wire strands and could result in sys- removed. tem failure. 3121607 – JLG Lift –...

  • Page 252: Deutsch Connectors

    Rectangular wedges are not oriented. They may go in either way. NOTE: Receptacle shown - use same procedure for plug. Figure 7-21. DT/DTP Contact Removal Figure 7-20. DT/DTP Contact Installation – JLG Lift – 3121607...

  • Page 253: Hd30/Hdp20 Series Assembly

    NOTE: Do Not twist or insert tool at an angle. Figure 7-23. HD/HDP Locking Contacts Into Position Figure 7-25. HD/HDP Unlocking Contacts NOTE: Insert sealing plugs in unused wire cavities for full environ- mental sealing. 3121607 – JLG Lift –...

  • Page 254: Electrical Components 1 Of 2

    (ALL SPECS EXCEPT CE SPEC) TRANSPORT LIMIT SWITCH (CE SPEC) DRIVE DISABLE/ANGLE LIMIT SWITCH PLATFORM CONTROL BROKEN CABLE PROXIMITY SWITCH (AUS & CE SPECS) HEADLIGHTS GROUND CONTROL DIAGNOSTIC ANALYZER TAILLIGHTS Figure 7-26. Electrical Components 1 of 2 7-10 – JLG Lift – 3121607...

  • Page 255: Electrical Components 2 Of 2

    VALVE START GLOW RELAY STARTER PLUG HYDRAULIC RELAY PUMPS RELAY DRIVE ORIENTATION ALTERNATOR SWITCH (DEUTZ TD2.9L4) MAIN CONTROL VALVE UNUSED HORN CONNECTION VALVE FUEL ALARM LEVEL SENSOR Figure 7-27. Electrical Components 2 of 2 3121607 – JLG Lift – 7-11...

  • Page 256: Platform And Ground Control Electrical Schematic - 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-28. Platform and Ground Control Electrical Schematic - 1 of 2 7-12 – JLG Lift – 3121607...

  • Page 257: Platform And Ground Control Electrical Schematic - 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-29. Platform and Ground Control Electrical Schematic - 2 of 2 3121607 – JLG Lift – 7-13...

  • Page 258: Generator Wiring Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-30. Generator Wiring Schematic 7-14 – JLG Lift – 3121607...

  • Page 259: Deutz Emr2 Wiring Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Deutz EMR2 Engine Figure 7-31. Deutz EMR2 Wiring Schematic 3121607 – JLG Lift – 7-15...

  • Page 260: Deutz Engine Harness Electrical Schematic 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-32. Deutz Engine Harness Electrical Schematic 1 of 2 7-16 – JLG Lift – 3121607...

  • Page 261: Deutz Engine Harness Electrical Schematic 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-33. Deutz Engine Harness Electrical Schematic 2 of 2 3121607 – JLG Lift – 7-17...

  • Page 262: Hydraulic Schematic 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-34. Hydraulic Schematic 1 of 2 7-18 – JLG Lift – 3121607...

  • Page 263: Hydraulic Schematic 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-35. Hydraulic Schematic 2 of 2 3121607 – JLG Lift – 7-19...

  • Page 264: Crawler Hydraulic Drive Schematic 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-36. Crawler Hydraulic Drive Schematic 1 of 2 7-20 – JLG Lift – 3121607...

  • Page 265: Crawler Hydraulic Drive Schematic 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-37. Crawler Hydraulic Drive Schematic 2 of 2 3121607 – JLG Lift – 7-21...

  • Page 266: Hydraulic Port Schematic - 1 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-38. Hydraulic Port Schematic - 1 of 2 7-22 – JLG Lift – 3121607...

  • Page 267: Hydraulic Port Schematic - 2 Of 2

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-39. Hydraulic Port Schematic - 2 of 2 3121607 – JLG Lift – 7-23...

  • Page 268: Crawler Drive Motor Hydraulic Schematic

    SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS Figure 7-40. Crawler Drive Motor Hydraulic Schematic 7-24 – JLG Lift – 3121607...
  • Page 270 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

This manual is also suitable for:

600sc

Table of Contents

Save PDF