JLG 600SJ Service And Maintenance Manual
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JLG 600SJ Service And Maintenance Manual

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Download this manual See also: Service Maintenance Manual
Service and Maintenance Manual
Models
600S/SJ
660SJ
600A/AJ
Prior to
S/N 0300080000
P/N - 3120840
November 22, 2016

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Summary of Contents for JLG 600SJ

  • Page 1 Service and Maintenance Manual Models 600S/SJ 660SJ 600A/AJ Prior to S/N 0300080000 P/N - 3120840 November 22, 2016...
  • Page 3 ADE Identification All 600S, 600SJ, and 660SJ machines from S/N 61927 incorporate ADE (JLG Control Sys- tem). The following machine serial numbers prior to S/N 61927 also utilize EPBCS: 58993, 58998, 59222, 59223, 59275, 59281, 59315, 59319, 59352, 59358, 59631, 59769, 60253, 60254, 60286, 60642, 60645, 61120, 61257, 61402, 61440, 61491, 61833, 61840, 61875, and 61878.
  • Page 4 This page left blank intentionally. – JLG Lift –...

  • Page 5: A General

    MENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING Relieve system pressure by cycling the applicable SOLVENTS. control several times with the engine stopped and ignition on, to direct any line pressure back into the 3120840 – JLG Lift –...
  • Page 6 August 4, 2000 Revised November 15, 2000 Revised February 6, 2001 Revised August 29, 2001 Revised June 13, 2002 Revised March 21, 2003 Revised January 28, 2004 Revised September 26, 2005 Revised November 22, 2016 – JLG Lift – 3120840...
  • Page 7 Serial Number Locations............1-14 3120840 – JLG Lift –...
  • Page 8 Welding on JLG Equipment ............2-6 Do the Following When Welding on JLG Equipment ......2-6 Do NOT Do the Following When Welding on JLG Equipment .
  • Page 9 Swing Bearing Torque Values ..........3-47 3120840 – JLG Lift –...
  • Page 10 Main Boom Lift Cylinder Installation ......... . . 4-22 – JLG Lift –...
  • Page 11 Tower Telescope Cylinder Installation ......... 5-17 3120840 – JLG Lift –...
  • Page 12 To Connect the JLG Control System Analyzer ........
  • Page 13 Deutz Sensors for JLG Control System ........
  • Page 14 Tower Telescope Cylinder Removal ..........5-15 viii – JLG Lift – 3120840...
  • Page 15 600S, 600SJ, 660SJ & 600A Level Cylinder ........
  • Page 16 Hydraulic Schematic - A Models - Sheet 4 ......... . .7-43 – JLG Lift –...
  • Page 17 Diagnostic Menu Descriptions ........... .6-43 3120840 – JLG Lift –...
  • Page 18 TABLE OF CONTENTS (Continued) This page left blank intentionally. – JLG Lift – 3120840...

  • Page 19: Capacities

    Low RPM - 7.19 lph. Drive Brake - Automatic spring applied, hydraulically High RPM - 9.46 lph. released disc brakes. Horsepower - 65 @ 3000 RPM, full load. Tire Pressure - 14 x 17.5 NHS, 6 Bar. 3120840 – JLG Lift –...

  • Page 20: Steer System (S Models)

    Turning Radius (Inside) (A Models) Return - Bypass Type. 2WS/2WD - 3.3 m. 10 Microns Absolute. 2WS/4WD - 3.6 m. Charge. 2WD/4WS - 1.6 m. 10 Microns Absolute. 4WS/4WD - 1.6 m. Hydraulic Strainers (In Tank). 30 Microns. – JLG Lift – 3120840...

  • Page 21: Boom Elevation (S Models)

    4WS/4WD - 2.44 m. Machine Weight approximately Wheel base (S Models) (600S) - 2WD - 9,979.2 kg. 2.48 m. (600SJ) - 2WD - 10,660 kg. Wheel base (A Models) (660SJ) - 2WD - 11,567 kg. 2.44 m. (600A) - 2WD - 9,390 kg.

  • Page 22: Test Notes

    43-136 43-136 Reverse (2WD & 4WD) Drive Horizontal - Forward & Reverse N.A. 84-70 *Max 10% Difference Between Left & Right **Max 15% Difference Between Left & Right Figure 1-1. 600S Lug Torques 4150130 -E – JLG Lift – 3120840...

  • Page 23: Lubrication

    Viscosity Index Temperature is Use SAE Viscosity Number Consistently Aside from JLG recommendations, it is not advisable to +32°F. to +77°F. (+0°C. to mix oils of different brands or types, as they may not con- +25°C.) tain the same required additives or be of comparable vis- Above +77°F.

  • Page 24: Lubrication Specifications

    Platform Level Forward - 193 Bar. Backward - 124 Bar. Steer - 124 Bar. Steer Reliefs - 4WS Front & Rear - 172 Bar. Articulating Jib Boom Up - 103 Bar. Down - 83 Bar. – JLG Lift – 3120840...

  • Page 25: Cylinder Specifications

    (63.5) Lockout (4WD 3.875 3.875 (88.9) (88.9) (98.4) (98.4) (63.5) (63.5) Master 13.0625 (88.9) (76.2) (331.8) (215.9) (38.1) (38.1) Slave 13.0625 (88.9) (76.2) (331.8) (215.9) (38.1) (38.1) Lift (Articulating Jib Boom) 25.5 (76.2) (647.7) (38.1) 3120840 – JLG Lift –...

  • Page 26: Major Component Weights

    Chassis Complete (w/pneumatic tires) 6834 3100 6834 3100 Chassis Complete (w/foam-filled tires) 7918 3592 7918 3592 Machine Complete (GVW) - 2WD w/pneumatic 22100 10025 20700 9390 tires Machine Complete (GVW) - 4WD w/pneumatic 22295 10113 21150 9594 tires – JLG Lift – 3120840...

  • Page 27: Critical Stability Weights

    8 ft. (2.44 M) Table 1-11. Critical Stability Weights (A Models) 600AJ 600A Tire and Wheel (Ballasted Size (14-17.5) Only) Engine Deutz Continental Counterweight Weight 6200 2812 5700 2586 Platform 6 ft. (1.83 M) 8 ft. (2.44 M) 3120840 – JLG Lift –...

  • Page 28: Lubrication Point Location - S Models

    SECTION 1 - SPECIFICATIONS Figure 1-2. Lubrication Point Location - S Models 1-10 – JLG Lift – 3120840...

  • Page 29: Lubrication Chart - S Models

    (approximately 105 lent) degrees C) cooler will fill up within minutes; shut down and wait for approxi- Multi-Purpose Grease mately two minutes. Check oil level, fill oil to max marking on the dipstick. 3120840 – JLG Lift – 1-11...

  • Page 30: Lubrication Point Location - A Models

    SECTION 1 - SPECIFICATIONS Figure 1-3. Lubrication Point Location - A Models 1-12 – JLG Lift – 3120840...

  • Page 31: Lubrication Chart - A Models

    (approximately 105 degrees C) lent) cooler will fill up within minutes; shut down and wait for approximately two Multi-Purpose Grease minutes. Check oil level, fill oil to max marking on the dipstick. 3120840 – JLG Lift – 1-13...

  • Page 32: Serial Number Locations

    1.11 SERIAL NUMBER LOCATIONS the frame. A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, Figure 1-4. Serial Number Locations 1-14 – JLG Lift – 3120840...
  • Page 33 SECTION 1 - SPECIFICATIONS 3120840 – JLG Lift – 1-15...
  • Page 34 SECTION 1 - SPECIFICATIONS This page left blank intentionally. 1-16 – JLG Lift – 3120840...

  • Page 35: Machine Preparation, Inspection, And Maintenance

    JLG Service It is important to establish and conform to a comprehen- Training School for the subject JLG product model. Refer- sive inspection and preventive maintenance program. The ence the machine Service and Maintenance Manual and...

  • Page 36: Service And Guidelines

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

  • Page 37: Torque Chart

    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. 3120840 – JLG Lift –...

  • Page 38: Lubrication And Information

    1. Refer to Section 1 for recommendations for viscosity key designations appearing in the Lubrication Chart. ranges. 2. JLG recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below -15 degrees F (-26 degrees C) is not recom- mended.

  • Page 39: Cylinder Drift Test

    Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would dam- NOTE: This information is based on 6 drops per minute cyl- age the bearing during installation and opera- inder leakage. tion. 3120840 – JLG Lift –...

  • Page 40: Welding On Jlg Equipment

    Silicone Dielectric Compound must be used on all electri- machine on an external structure, or component, cal connections for the following reasons: Do the Following When Welding on JLG • To prevent oxidation at the mechanical joint between Equipment male and female pins.

  • Page 41: Amp Connector

    3. Install a hole plug into this and/or any unused wire lbs. to be sure the retention fingers are holding the seal that has silicone dielectric compound escaping contact (See Figure 2-3.). from it. Figure 2-2. AMP Connector 3120840 – JLG Lift –...

  • Page 42: Connector Assembly Figure 2

    (See Figure 2-5.). Release the locking latches by squeezing them inward (See Figure 2-4.). Figure 2-5. Connector Assembly Figure 4 Figure 2-4. Connector Assembly Figure 3 – JLG Lift – 3120840...

  • Page 43: Disassembly

    The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. 3120840 – JLG Lift –...

  • Page 44: Connector Installation

    SECTION 2 - GENERAL Figure 2-7. Connector Installation 2-10 – JLG Lift – 3120840...

  • Page 45: Deutsch Connectors

    The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way. NOTE: The receptacle is shown - use the same procedure for plug. 3120840 – JLG Lift – 2-11...

  • Page 46: Hd30/Hdp20 Series Assembly

    Figure 2-11. HD/HDP Locking Contacts Into Position Figure 2-13. HD/HDP Unlocking Contacts NOTE: For unused wire cavities, insert sealing plugs for full NOTE: Do not twist or insert tool at an angle. environmental sealing 2-12 – JLG Lift – 3120840...

  • Page 47: Inspection And Preventive Maintenance Schedule

    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 Outrigger or Extendable Axle Systems Steer Components Drive Motors Torque Hubs Functions/Controls Platform Controls 3120840 – JLG Lift – 2-13...
  • Page 48 Electrical Connections Instruments, Gauges, Switches, Lights, Horn 5,23 General Operators and Safety Manuals in Storage Box ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible Walk-Around Inspection Performed 2-14 – JLG Lift – 3120840...
  • Page 49 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 50: Engine Operating Temperature Specifications - Deutz

    SECTION 2 - GENERAL 4150548 A Figure 2-14. Engine Operating Temperature Specifications - Deutz 2-16 – JLG Lift – 3120840...

  • Page 51: Drive Torque Hub, Prior To S/N 75606

    With seal removed, outside bearing cone (4) can be removed. 10. If necessary, remove inner and outer bearing cones (3, 5) using a suitable slide hammer puller. WHEN REBUILDING TORQUE HUB, REMOVE AND REPLACE ALL O-RINGS AND RETAINING RINGS. 3120840 – JLG Lift –...

  • Page 52: Torque Hub, Drive (Fairfield)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-1. Torque Hub, Drive (Fairfield) – JLG Lift – 3120840...

  • Page 53: Repair

    (15). f. Repeat steps (a) through (e) for remaining two cluster gears. g. Clean and inspect all parts in accordance with Cleaning and Inspection procedures. Replace parts as necessary. 3120840 – JLG Lift –...
  • Page 54 Clean and inspect all parts in accordance with Cleaning and Inspection procedures. Replace parts as necessary. n. Line up cluster gear and thrust washers with hole in carrier and slide planet shaft through. – JLG Lift – 3120840...

  • Page 55: Assembly

    Assembly 4. Lower hub onto spindle (1) with large open end up. 1. Using a suitable press, press new bearing cups (3, 5), with large inside diameters facing out, into hub (7) counter bores. 3120840 – JLG Lift –...
  • Page 56 10. Install retaining ring (34) into input shaft retaining ring groove. EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION. 7. Install new retaining ring (9) completely into spindle groove and against bearing shim. Ensure retaining ring is entirely in groove. – JLG Lift – 3120840...
  • Page 57 14. Place o-ring (22) into hub counter bore. Use petro- leum or grease to hold o-ring in place. Slight stretch- 17. While holding ring gear, input gear, and cluster gears in mesh, place small side of cluster gears into 3120840 – JLG Lift –...
  • Page 58 90 degrees from oil fill plug in hub. 19. After inserting at least one shoulder bolt in the proper location, rotate the carrier. Check freedom of rotation and timing. – JLG Lift – 3120840...

  • Page 59: Torque Hub, Drive (Auburn Gear)

    1. If necessary press new bearing cups (7 & 10) in each end of the hub (9). It is recommended that bearing cups (7 & 10) and cones (6 & 11) be replaced in sets. 3120840 – JLG Lift –...

  • Page 60: Torque Hub, Drive (Auburn Gear)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-2. Torque Hub, Drive (Auburn Gear) 3-10 – JLG Lift – 3120840...
  • Page 61 13. Assemble cover (24), aligning holes of cover and into spindle (3). ring gear. Assemble the twelve bolts (25) and flat 8. Assemble the secondary carrier assembly (18) to washer (26). Torque bolts to 61 - 67 Nm. spindle (3) at splines. 3120840 – JLG Lift – 3-11...

  • Page 62: Drive Torque Hub, S/N 75606 To Present

    If a leak is detected in a seal, o-ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi for 20 minutes. 3-12 – JLG Lift – 3120840...

  • Page 63: Main Disassembly

    4. Remove the Cover Subassembly (6) from the unit. The unit can be carefully pressurized with air to pop the cover out of the unit. 6. Cover 6G. Retaining Ring 15. ID Plate Figure 3-3. Main Disassembly 3120840 – JLG Lift – 3-13...

  • Page 64: Input Carrier

    9. Loosen and remove the three Flat Head Bolts (19) that retain the Ring Gear (1E) to the Housing (1G). 10. Lift the Ring Gear (1E) off of the Housing (1D). 3-14 – JLG Lift – 3120840...

  • Page 65: Planet Gear Sub Assembly

    Spindle (1A). (4C) and the Thrust Spacer (4D) from the Second Stage Planet Gear (4F). 4B. Thrust Washer 4D. Thrust Spacer 4C. Needle Roller 4F. Planet Gear Figure 3-5. Planet Gear Sub Assembly 3120840 – JLG Lift – 3-15...

  • Page 66: Input Carrier Disassembly

    5. Remove the 14 needle Bearings (3C) from the bore 3C. Needle Bear- of the Planet Gear (3F). 3F. Planet Gear 6. Repeat steps 1 through 5 for each of the two remain- ing planet gears. Figure 3-7. Planet Gear Subassembly 3-16 – JLG Lift – 3120840...

  • Page 67: Hub-Spindle Disassembly

    (1C) out of Hub (1D). 4. While supporting the unit on Hub (1D) flange, press Spindle (1A) out of Hub (1D). 5. Lift Hub (1D) off of Spindle (1A). Remove Boot Seal (1Q) from Hub (1D) if applicable. 3120840 – JLG Lift – 3-17...

  • Page 68: Spindle-Brake Disassembly

    2. Using retaining ring pliers, remove Retaining Ring 7. Coupling (8C) from the groove in the Spindle (1A). 3. Back Flat Head Cap Screws (22) incrementally out Figure 3-10. Coupling Subassembly of Piston (8A) until spring force is relieved from the 3-18 – JLG Lift – 3120840...
  • Page 69 9. Remove Retaining Ring (1K) out of the internal groove using appropriate tool. 10. Remove the Spacer (1M) & Spring (1L) out of the bore of Coupling (7). 11. Remove Plastic Plug (12) & Pipe Plug (21) from Spindle (1A) if applicable. 3120840 – JLG Lift – 3-19...

  • Page 70: Cover Disassembly

    6. Remove two O-Ring Pipe Plugs (6F) from Cover 3. Unscrew two Hex Head Bolts (6C) and remove Dis- (6A). engage Cap (6B) from Cover (6A). 4. Pull Disengage Rod (6D) out from Cover (6A). 3-20 – JLG Lift – 3120840...

  • Page 71: Input Carrier Sub-Assembly

    Piston (8A). Make sure the O-Ring is seated on the bottom of the groove. NOTE: Some grease may need to be applied to the Thrust Washers (3B) to hold them in place while installing the planet gears. 3120840 – JLG Lift – 3-21...

  • Page 72: Hub-Spindle Sub-Assembly

    5. Place Hub (1D) into pressing base. Press nine Studs (1H) into Hub. NOTE: Use enough pressure to press in studs. Don t use excessively high pressure to press in studs or hub may crack. 3-22 – JLG Lift – 3120840...

  • Page 73: Cover Sub-Assembly

    9. Place Input Carrier Sub-Assembly (3A) onto Output Sun Gear (11) splines. Drop Input Sun (10) into mesh with planet gears for specific ratios, if required. (No timing required). 10. Grease O-Ring (17) and insert into groove in Cover Sub-Assembly (6). 3120840 – JLG Lift – 3-23...

  • Page 74: Hub Assembly

    8B. Pressure Plate 9. Input Shaft 20. Retaining Ring 1H. Stud 4B. Thrust Washer 6B. Disengage Cap 8C. Retaining Ring 10. Sun Gear 21. O-Ring Plug 1K. Retaining Ring 1L. Spring Figure 3-12. Hub Assembly 3-24 – JLG Lift – 3120840...

  • Page 75: Bearing Cup Pressing Tool

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-13. Bearing Cup Pressing Tool Figure 3-14. Seal Pressing Tool 3120840 – JLG Lift – 3-25...

  • Page 76: Bearing Cup Pressing Tool

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-15. Bearing Cup Pressing Tool Figure 3-16. Drift Pin for Lining Up Thrust Washers with Output Planet Gear 3-26 – JLG Lift – 3120840...

  • Page 77: Drive Brake - Mico

    4. Closely inspect bearings and bearing contact sur- 75 Nm. faces. Replace as necessary. NOTE: Bearings may be reused if, after thorough inspec- tion, they are inspection, they are found to be in good condition. 3120840 – JLG Lift – 3-27...

  • Page 78: Drive Brake Assembly (Mico)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-17. Drive Brake Assembly (Mico) 3-28 – JLG Lift – 3120840...

  • Page 79: Free Wheeling Option

    1. If equipped, move steer/tow valve to steer position by pushing valve knob in. 2. Connect both drive hubs by inverting disconnect DISCONNECT cap in center of hub. (REVERSED) DRIVE Drive Hub Disconnected Figure 3-18. Disconnecting the Drive Hubs 3120840 – JLG Lift – 3-29...

  • Page 80: Drive Motor (600S, 600A 4Wd)

    Same sealing kit like shown above only seal material 3.6 DRIVE MOTOR (600S, 600A 4WD) changed to Viton Spare Parts Kits Sealing kit, existing spare parts: shaft sealing ring, 6 differ- ent O-rings and a circlip (sealing mat.: perbunan) Drive shaft 3-30 – JLG Lift – 3120840...

  • Page 81: Replacing The Drive Shaft Seal

    Parts of the control device: control piston, piston rod, plug, spring stopper max hex. nut, and hex. head nut flow 3. Be careful while you seal the drive shaft, use an adhesive tape to protect the splines. 3120840 – JLG Lift – 3-31...

  • Page 82: Disassembly And Assembly

    6. Assemble the snap ring in the correct position. 3. Remove the port plate together with the valve plate (hold the valve plate so that the plate can’t fall down). 3-32 – JLG Lift – 3120840...
  • Page 83 9. Turn in the stopper max flow to get swivel angle zero. 6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position. 7. Unscrew the cap nut and remove it. 11. Disassemble the stopper - max. flow. 3120840 – JLG Lift – 3-33...
  • Page 84 18. Remove both bearing shells. 14. Disassemble the control piston while moving the swash plate. 19. Remove the drive shaft. 15. The swash plate must be lifted a little bit to disas- semble the piston rod. 3-34 – JLG Lift – 3120840...
  • Page 85 22. The external front bearing ring is pulled out of the pump housing. 25. The spring has additional pretension while you dis- assemble the three pressure pins inside the cylinder. 3120840 – JLG Lift – 3-35...

  • Page 86: Assembly Notes

    (Note spare parts exist as cw and ccw valve plates.) Taper Roller Bearing Initial Tension Cast iron pump housing must have initial tension of the bearings: 0..0,05 mm, grind Pos. 12 if necessary. 3-36 – JLG Lift – 3120840...

  • Page 87: Flow Control Pilot Valves

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Differential volume if you are rotating the threaded pin - each rotation is appr. 3,1 cm3. Figure 3-19. Flow Control Pilot Valves 3120840 – JLG Lift – 3-37...

  • Page 88: Testing And Setup

    3. Measure from top of jam nut to the end of adjust- ment screw. Refer to Figure 3-20., Drive Motor Adjustment (S Models). 4. Tighten jam nut, install cap nut. NOTE: The “o” ring must be seated in groove in cap nut. 3-38 – JLG Lift – 3120840...

  • Page 89: Oscillating Axle Bleeding Procedure And Lockout Test

    Figure 3-21. Oscillating Valve Adjustment Figure 3-23. Drive Manual Control Valve 7. Close bleeder screws when all air is dissipated (bled). 8. Perform oscillating axle lockout test. 9. If necessary, repeat steps 1 thru 8. 3120840 – JLG Lift – 3-39...

  • Page 90: Oscillating Axle Lockout Test

    (centered between drive wheels). When boom reaches center, stowed posi- tion, lockout cylinders should release and allow wheel to rest on ground, it may be necessary acti- vate DRIVE to release cylinders. 3-40 – JLG Lift – 3120840...

  • Page 91: Steer Adjustments (S Models)

    3. Install a pry bar into hole in turntable base plate and pry swing hub back tight against shim and bearing. 4. Torque bolts according to the torque chart in Section Figure 3-24. Steer Adjustments 3120840 – JLG Lift – 3-41...

  • Page 92: Swing Bearing

    NOTE: This check is designed to replace the existing bear- the .0015" feeler gauge between the bolt head ing bolt torque checks on JLG Lifts in service. This and hardened washer at the arrow indicated check must be performed after the first 50 hours of position.

  • Page 93: Wear Tolerance.(S & A Models)

    4. If a difference less than 1.40 mm is determined, and any of the following conditions exist, the bearing should be removed, disassembled, and inspected for the following: a. Metal particles in the grease. b. Increased drive power required. c. Noise. d. Rough rotation. 3120840 – JLG Lift – 3-43...
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE 3-44 – JLG Lift – 3120840...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE 3120840 – JLG Lift – 3-45...

  • Page 96: Swing Bearing Replacement

    JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING...

  • Page 97: Swing Bearing Torque Values

    6. Remove stack assembly, consisting of discs (21), return plate (8) and friction discs (20) from housing (52). 7. Remove dowel pins (15), springs (5 & 6) from hous- ing (52). 8. Remove retaining ring (3) from housing (52). 3120840 – JLG Lift – 3-47...

  • Page 98: Swing Brake Assembly (Mico)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-31. Swing Brake Assembly (Mico) 3-48 – JLG Lift – 3120840...

  • Page 99: Inspection

    9. Install new o-ring (17), new back-up ring (16), new o- ring (19) and new back-up ring (18) on piston (22). Insert piston (22) into end cover (13), being careful Figure 3-32. Tilt Switch Adjustment not to shear o-rings or back-up rings. 3120840 – JLG Lift – 3-49...

  • Page 100: Spark Arrester Cleaning Instructions

    When a failure condition occurs (i.e. position time-out) the has been air-vented or ‘bled’ of air. See Continental controller will release the clutch and turn off the actuator Instruction Manual for procedure. motor. This will prevent unnecessary motor wear. 3-50 – JLG Lift – 3120840...

  • Page 101: Addco Adjustments - Continental

    1. Remove bolt which secures engine tray to the turn- table. Swing engine tray out to gain access to RPM adjustments. 2. Disconnect wire harness from ADDCO, install JLG wire harness kit #4921850 to the ADDCO and engine harness as shown in diagram below. Start the engine and allow it to come up to operating tem- perature.

  • Page 102: Deutz Sensors For Jlg Control System

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-35. Deutz Sensors for JLG Control System 3-52 – JLG Lift – 3120840...

  • Page 103: Boom Rope Torquing Procedures

    When adding shims, longer bolts must be used to ensure proper thread engagement in insert. NOTE: Do not allow wire rope to rotate. This may damage the wire rope. 3120840 – JLG Lift –...

  • Page 104: Wire Rope (S Models)

    Dimension Of Sheaves for proper dimension.) used so bolt does not protrude from insert and 5. Inspect sheaves for condition of flanges. (See come into contact with boom surface. Dimension Of Sheaves for proper dimension.) – JLG Lift – 3120840...

  • Page 105: Three Month Inspection

    Machine is idle for an extended period. d. Boom is overloaded or sustained a shock load. e. Boom exposed to electrical arc...wires may be fused internally. Figure 4-4. Location of Components - Platform Support 3120840 – JLG Lift –...

  • Page 106: Boom Assembly Cutaway - S Models - Sheet 1 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-5. Boom Assembly Cutaway - S Models - Sheet 1 of 3 – JLG Lift – 3120840...

  • Page 107: Boom Assembly Cutaway - S Models - Sheet 2 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-6. Boom Assembly Cutaway - S Models - Sheet 2 of 3 3120840 – JLG Lift –...

  • Page 108: Boom Assembly Cutaway - S Models - Sheet 3 Of 3

    #3 from the fly boom. Figure 4-8. Location of Components - Rotator and Leveling Cylinder f. Tag and disconnect hydraulic lines to the slave leveling cylinder. Use a suitable container to – JLG Lift – 3120840...

  • Page 109: Location Of Components - Boom Powertrack

    4. Remove boom assembly from machine as follows: a. Using suitable lifting equipment, adequately support boom assembly weight along entire length. 3120840 – JLG Lift –...

  • Page 110: Disassembly Of Boom Sections

    Note: When removing mid and fly boom sec- tions from base boom section, retract wire rope must be dragged along with boom sections. – JLG Lift – 3120840...

  • Page 111: Inspection

    7. Inspect upper lift cylinder attach pin for wear, scor- ing, tapering and ovality, or other damage. Ensure Figure 4-12. Disassembly Wire Rope Routing Procedure pin surfaces are protected prior to installation. Replace pins as necessary. 3120840 – JLG Lift –...

  • Page 112: Assembly

    5 mm clearance. 9. Properly position the retraction wire rope sheaves assemblies at the aft end of the mid boom section; ensure all sheave-to-mounting block attachment holes align. Install the sheave pins and secure them 4-10 – JLG Lift – 3120840...

  • Page 113: Installing The Proximity Switch

    Align holes in powertrack rail with attachment ropes, care must be taken not to twist or cross the holes in side of the base boom section. Secure wire ropes. the rail with mounting hardware. Figure 4-15. Installing the Proximity Switch 3120840 – JLG Lift – 4-11...

  • Page 114: Installation

    #3 from the fly boom. 5. If necessary, gently tap pin into position with soft f. Tag and disconnect hydraulic lines to slave level- headed mallet. Secure pin mounting hardware. ing cylinder. Use suitable container to retain any 4-12 – JLG Lift – 3120840...

  • Page 115: Reassembly Of Components - Rotator And Slave Leveling Cylinder

    Remove hydraulic lines and electrical cables from powertrack. e. Using suitable lifting equipment, adequately support powertrack weight along entire length. f. Remove bolt #1 securing the push tube on the fly boom section. 3120840 – JLG Lift – 4-13...

  • Page 116: Boom Powertrack Installation

    SECTION 4 - BOOM & PLATFORM Figure 4-19. Boom Powertrack Installation 4-14 – JLG Lift – 3120840...

  • Page 117: Disassembly Of Boom Sections

    9. Align the cylinder with the slots at aft end of base scoring, distortion, wear, or other damage. Replace bearing as necessary. (See section 5 For Bearing boom section, then secure cylinder with mounting Replacement). hardware. 3120840 – JLG Lift – 4-15...

  • Page 118: Installation

    Remove mounting hardware from upper lift cyl- inder barrel end. Using a suitable brass drift and hammer remove pin #1 from tower upright. d. Tag and disconnect hydraulic lines to master cyl- inder. Use a suitable container to retain any 4-16 – JLG Lift – 3120840...

  • Page 119: Disassembly

    Figure 4-22. Location of Components - Tower Boom 3. Remove mounting hardware which secures the Powertrack push tubes to the tower fly boom section. 4. Remove mounting hardware which secures the push tubes to the powertrack, then remove push tubes. 3120840 – JLG Lift – 4-17...

  • Page 120: Inspection

    Using a soft head mallet, install the cylinder pin into tower fly boom and secure with 6. Connect all hydraulic lines running from aft end of mounting hardware. tower boom assembly to ground controls. 4-18 – JLG Lift – 3120840...

  • Page 121: Articulating Jib Boom

    Figure 4-23. Location of Components - Articulating necessary. Jib Boom 4. Remove mounting hardware from articulating jib boom pivot pin #2. Using a suitable brass drift and hammer, remove the pivot pin from boom assembly. 3120840 – JLG Lift – 4-19...

  • Page 122: Assembly

    15. Remove hardware securing cable adjustment block into articulating jib boom pivot weldment and secure to aft end of the base boom section and remove with mounting hardware.) block. Figure 4-24. Boom Positioning and Support, Cylinder Repair (S Models) 4-20 – JLG Lift – 3120840...

  • Page 123: Main Boom Telescope Cylinder Installation

    4. Install extend cable mounting blocks to threaded ends of cables. Loosely install nuts and jam nuts onto the threaded ends of cables. NOTE: When installing cables, care must be taken not to twist or cross the cables. 3120840 – JLG Lift – 4-21...

  • Page 124: Main Boom Lift Cylinder Removal

    Secure in place with the pin retaining hardware. 3. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports. 4-22 – JLG Lift – 3120840...

  • Page 125: Limit Switches Adjustments (S Models)

    SECTION 4 - BOOM & PLATFORM Figure 4-25. Limit Switches Adjustments (S Models) 3120840 – JLG Lift – 4-23...

  • Page 126: Limit Switches Adjustments (A Models)

    SECTION 4 - BOOM & PLATFORM Figure 4-26. Limit Switches Adjustments (A Models) 4-24 – JLG Lift – 3120840...

  • Page 127: Platform

    4.10 ROTATOR - HELAC 5. Remove the two (2) setscrew (4) from bottom of Disassembly actuator (1). Discard setscrew. 1. Place actuator on a clean workbench. 2. Remove all hydraulic fittings. Figure 4-31. Removing Setscrew 3120840 – JLG Lift – 4-25...

  • Page 128: Rotator Assembly (Helac)

    SECTION 4 - BOOM & PLATFORM Figure 4-28. Rotator Assembly (Helac) 4-26 – JLG Lift – 3120840...

  • Page 129: Inspection

    2. Install new seal (8), thrust ring (10) and bearing (9) on shaft (2). NOTE: Apply a coat of grease to the thrust ring before slid- ing onto the end cap. 3120840 – JLG Lift – 4-27...

  • Page 130: Drive Card Setup Procedures

    33-43 Articulating Jib Boom 22-29 Down 16-22 Swing Speed Full 360° 79-101 Platform Rotation Left 22-30 Figure 4-35. Actuator Timing Right 22-30 Drive Speed (2WD) 28-32 @ 200ft. Drive Speed (4WD) 32-36 @ 200ft. 4-28 – JLG Lift – 3120840...

  • Page 131: Lift, Swing, And Drive Cards

    Rotate the input potentiometer to its minimum set- ting and operate the telescope function. Adjust P4 2. Install test harness JLG P/N 4922012. until the meter reading matches the setting in table 1. This sets the minimum current setting for the card.

  • Page 132: Foot Switch Adjustment

    Ramp Down Time = 2:30 sec. Drive Reverse Ramp Up Time = 4:30 sec. Ramp Down Time = 2:30 sec. Flow Control Ramp Up Time = 3:00 sec. Ramp Down Time = 0:00 sec. 4-30 – JLG Lift – 3120840...

  • Page 133: Cylinders - Theory Of Operation

    4. If cylinder retract port leakage is less than 6-8 drops balance valve from the retract port. After initial dis- per minute, carefully reconnect hose to port and charge, there should be no further leakage from the 3120840 – JLG Lift –...

  • Page 134: Cylinders With Dual Counterbalance Valves

    After the initial discharge, there should be no further leakage from the ports. If leakage continues at a rate of 6-8 drops per minute or more, the counterbalance valve is defective and must be replaced. – JLG Lift – 3120840...

  • Page 135: Cylinder Barrel Support

    Pull the ring out of the groove toward the 13. Insert the cap screw(s) in the threaded holes in the wall mouth. Once one end of the retaining ring is outer piece of the tapered bushing. Progressively 3120840 – JLG Lift –...

  • Page 136: Cleaning And Inspection

    Repair as necessary. as necessary. 7. Inspect threaded portion of piston for damage. 17. If applicable, inspect piston rings for cracks or other Dress threads as necessary. damage. Replace as necessary. – JLG Lift – 3120840...

  • Page 137: Assembly

    SECTION 5 - HYDRAULICS Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual. Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.

  • Page 138: Piston Seal Kit Installation

    11. Assemble the tapered bushing loosely into the pis- alignment with each other. ton and insert JLG capscrews (not vendor cap- screws) through the drilled holes in the bushing and into the tapped holes in the piston.

  • Page 139: Seating The Tapered Bearing

    (See Figure 5-10.) as applicable. (See Table 5-2, Holding Valve Torque 17. Position the cylinder barrel in a suitable holding fix- Specifications). ture. 3120840 – JLG Lift –...

  • Page 140: Cylinder Head And Tapered Bushing Torque Specifications. (S Models)

    TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING RACINE - 1 3/8 HEX 1 3/16 - 12 THDS. 75-80 ft. lbs. ROD. (102-109 Nm) RACINE - 1 7/8 HEX 1 5/8 - 12 THDS. 100-110 ft. lbs. (136-149 Nm) – JLG Lift – 3120840...

  • Page 141: Cylinder Removal And Installation (S Models)

    NOTE: When installing cables care must be taken not to ble. twist or cross the cables. Figure 5-14. Boom Positioning and Support, Cylinder Repair (S Models) 3120840 – JLG Lift –...

  • Page 142: Main Boom Lift Cylinder Removal

    9. Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports. 10. Align holes in rod end of the telescope cylinder with holes in push bar. Install push bar pin and secure with mounting hardware. 5-10 – JLG Lift – 3120840...

  • Page 143: Main Boom Lift Cylinder Installation

    6. Using all applicable safety precautions, operate the hydraulic fluid. Cap hydraulic lines and ports. boom functions. Check for correct operation and hydraulic leaks. Secure as necessary. 7. Check fluid level of hydraulic tank and adjust as nec- essary. 3120840 – JLG Lift – 5-11...

  • Page 144: Main Boom Telescope Cylinder Installation

    5. Remove barrel end attach pin #3 retaining hard- rings. ware. Using a suitable brass drift drive out the barrel end attach pin from the upright. 6. Remove the cylinder from the boom and place in a suitable work area. 5-12 – JLG Lift – 3120840...

  • Page 145: Main Boom Lift Cylinder Installation

    7. Check fluid level of hydraulic tank and adjust as nec- 3. Remove the mounting hardware from pin #1, secur- essary. ing leveling cylinder to upright. Figure 5-16. Leveling Cylinder Removal 3120840 – JLG Lift – 5-13...

  • Page 146: Upright Level Cylinder Installation

    #1 using a suit- 3. Connect an auxiliary power source to the cylinder able rubber mallet. Secure pin with mounting hard- and extend cylinder rod until the cylinder rod bush- ware. ing aligns with bushings on boom. 5-14 – JLG Lift – 3120840...

  • Page 147: Tower Telescope Cylinder Removal

    7. Using all applicable safety precautions, operate the 3. Remove lower cover plate. boom functions. Check for correct operation and hydraulic leaks. Secure as necessary. 8. Check fluid level of hydraulic tank and adjust as nec- essary. 3120840 – JLG Lift – 5-15...

  • Page 148: Boom Positioning And Support, Cylinder Repair (A Models)

    SECTION 5 - HYDRAULICS Figure 5-19. Boom Positioning and Support, Cylinder Repair (A Models) 5-16 – JLG Lift – 3120840...

  • Page 149: Tower Telescope Cylinder Installation

    7. Using all applicable safety precautions, operate the boom functions. Check for correct operation and hydraulic leaks. Secure as necessary. 8. Check fluid level of hydraulic tank and adjust as nec- essary. 3120840 – JLG Lift – 5-17...

  • Page 150: S Axle Lockout Cylinder (Prior To S/N 75606)

    Shown) 6. Not Used 14. O-Ring 23. Washer Ring 7. Bolt 15. Back-Up Ring 24. Not Used 16. Wear Ring 25. Socket Head Screw Figure 5-20. 600S Axle Lockout Cylinder (Prior to S/N 75606) 5-18 – JLG Lift – 3120840...

  • Page 151: S Axle Lockout Cylinder (S/N 75606 To Present)

    SECTION 5 - HYDRAULICS 1. Barrel 4. Wear Ring 7. Bleeder 2. Rod 5. Wiper Ring 8. Cartridge Valve 3. Not Used 6. Rod Seal Figure 5-21. 600S Axle Lockout Cylinder (S/N 75606 to Present) 3120840 – JLG Lift – 5-19...

  • Page 152: S, 600Sj, 660Sj & 600A Level Cylinder

    13. Seal 23. Valve Cartridge 6. Spacer 14. Lock Ring 24. O-Ring Plug 7. Cartridge Valve 15. O-Ring 25. Socket Head Screw 16. Back-Up Ring Figure 5-22. 600S, 600SJ, 660SJ & 600A Level Cylinder 5-20 – JLG Lift – 3120840...

  • Page 153: S Lift Cylinder

    105. Knob 6. Spacer 14. Back-Up Ring 23. Not Used 106. Setscrew 7. Cartridge Valve 15. Wear Ring 24. Socket Head Screw 107. Clamp 16. O-Ring 25. O-Ring Plug Figure 5-23. 600S Lift Cylinder 3120840 – JLG Lift – 5-21...

  • Page 154: S & 600A Jib Lift Cylinder

    11. O-Ring Plug 17. Lock Ring 25. Loctite #609 (Not 5. Tapered Bushing 12. O-Ring Plug 18. O-Ring Shown) 6. Spacer 19. Back-Up Ring 26. Socket Head Capscrew Figure 5-24. 600S & 600A Jib Lift Cylinder 5-22 – JLG Lift – 3120840...

  • Page 155: S & 600A Master Cylinder

    10. Locking Primer (Not 17. Back-Up Ring 23. Not Used 4. Head Shown) 18. Rod Seal 24. Plug Fitting 5. Tapered Bushing 11. Seal 19. Wiper 12. Lock Ring Figure 5-25. 600S & 600A Master Cylinder 3120840 – JLG Lift – 5-23...

  • Page 156: S & 600A Steer Cylinder

    11. Lip Seal 2. Piston 7. Capscrew 12. Spanner Nut 3. Seal 8. O-Ring 13. Wiper 4. O-Ring 9. Back-Up Ring 14. Bushing 5. Barrel 10. Retainer Ring Figure 5-26. 600S & 600A Steer Cylinder 5-24 – JLG Lift – 3120840...

  • Page 157: S Telescope Cylinder

    16. Back-Up Ring 22. Loctite #242 (Not Shown) 5. Tapered Bushing 11. Capscrew 17. Wear Ring 23. Locking Primer (Not Shown) 6. Spacer 12. Capscrew 18. O-Ring 24. Not Used Figure 5-27. 600S Telescope Cylinder 3120840 – JLG Lift – 5-25...

  • Page 158: A Axle Lockout Cylinder

    12. O- Ring 18. Locking Primer (Not 6. Cartridge Valve 13. Back-Up Ring Shown) 7. Seal 14. Loctite RC #609 19. Not Used 20. Back-Up Ring 21. Bleeder Valve Figure 5-28. 600A Axle Lockout Cylinder 5-26 – JLG Lift – 3120840...

  • Page 159: A Level (Upright) Cylinder

    15. Wear Ring 23. Not Used 6. Tube Spacer 16. O-Ring 24. Bolt 7. Valve Cartridge 17. Back-Up Ring 25. O-Ring Plug 8. Valve Cartridge 26. Loctite #609 Figure 5-29. 600A Level (Upright) Cylinder 3120840 – JLG Lift – 5-27...

  • Page 160: A Main Boom Lift Cylinder

    22. Locking Primer (Not 3. Head 10. Washer Ring 17. O-Ring Shown) 4. Piston 11. O-Ring Plug 18. Back-Up Ring 23. Not Used 5. Spacer 12. Wiper 24. Bolt Figure 5-30. 600A Main Boom Lift Cylinder 5-28 – JLG Lift – 3120840...

  • Page 161: A Tower Boom Lift Cylinder

    24. Counterbalance Valve 4. Head 11. Loctite #242 (Not Shown) 18. O-Ring 25. Bolt 5. Tapered Bush- 12. Locking Primer (Not 19. Back-Up Ring 26. Loctite #609 Shown) Figure 5-31. 600A Tower Boom Lift Cylinder 3120840 – JLG Lift – 5-29...

  • Page 162: A Main Boom Telescope Cylinder

    12. Wear Ring 19. Rod Seal 25. Bolt 6. Tapered Bush- 13. Seal 20. Wiper 26. Flatwasher 14. O-Ring 21. Back-Up Ring 27. Not Used 7. Plate 28. Bolt Figure 5-32. 600A Main Boom Telescope Cylinder 5-30 – JLG Lift – 3120840...

  • Page 163: A Main Boom Telescope Cylinder

    5. Washer Ring 12. T-Seal 19. Wiper 6. Tapered Bush- 13. O-Ring 20. Locking Primer (Not Shown) 14. Back-Up Ring 21. Loctite #242 (Not Shown) 7. Valve Cartridge Figure 5-33. 600A Main Boom Telescope Cylinder 3120840 – JLG Lift – 5-31...

  • Page 164: Variable Displacement Pump (M46 Series)

    Servo Pressure 1000 PSI or 60 Bar Gauge 9/16-18 O-ring Fitting Servo Pressure 1000 PSI or 60 Bar Gauge 9/16-18 O-ring Fitting Figure 5-34. Troubleshooting - Neutral Difficult or Impossible to Find 5-32 – JLG Lift – 3120840...

  • Page 165: Troubleshooting - System Operating Hot

    SECTION 5 - HYDRAULICS Figure 5-35. Troubleshooting - System Operating Hot Figure 5-36. Troubleshooting - Transmission Operates in One Direction Only 3120840 – JLG Lift – 5-33...

  • Page 166: Troubleshooting - System Response Is Sluggish

    SECTION 5 - HYDRAULICS Figure 5-37. Troubleshooting - System Response is Sluggish 5-34 – JLG Lift – 3120840...

  • Page 167: Inspections And Adjustments

    Inspect for foreign material holding the poppet open, and for scoring or wear on the poppet and seat in the housing. Adjustments of the charge pressure is accomplished by changing the shim thickness behind the spring. 3120840 – JLG Lift – 5-35...
  • Page 168 5. Remove spacer, re-install orifices, gaskets, and cov- ers. Torque grade 5 bolts 8 to 11 ft.lbs. (10.8 to 14.9 Nm) and grade 8 bolts 11 to 13 ft.lbs. (14.9 to 17.8 Nm). 5-36 – JLG Lift – 3120840...
  • Page 169 7. Stop the engine. Connect the control input. Remove amount of rotation noted above. the servo pressure gauges. Return the machine to normal operating condition. Restart the engine and assure that the hydrostatic system is in neutral. 3120840 – JLG Lift – 5-37...

  • Page 170: Minor Repair And Replacement

    Polish the sealing area on the shaft if necessary. 4. Wrap the spline or key end of the shaft with thin plastic to prevent damage to the seal lip during installation. Lubricate the inside diameter of the new seal with petroleum jelly. 5-38 – JLG Lift – 3120840...
  • Page 171 Do not attempt to mix ate Service Parts Manual for more information. different vintage parts. 2. Reinstall the bypass valve into the housing. Torque to 7 to 10 ft. lbs. (9.5 - 13.6 Nm). 3120840 – JLG Lift – 5-39...
  • Page 172 2. Remove the spring and poppet from the housing. Do not alter the shims or interchange parts with another valve. Inspect the poppet and mating seat in the end cap for damage or foreign material. 5-40 – JLG Lift – 3120840...
  • Page 173 5. The control orifice plugs are located in threaded and replace the servo piston covers. passages under the servo piston cover. Remove the servo piston cover and gasket, and remove the ori- fice plugs using an internal hex wrench (7/32”). 3120840 – JLG Lift – 5-41...
  • Page 174 10. Install the four cover screws and torque to 18 to 24 in. lbs. (2.0 to 2.7 Nm). 11. Readjust the neutral position of the control. Refer to the instructions in the Inspections and Adjustment. 5-42 – JLG Lift – 3120840...

  • Page 175: Valves - Theory Of Operation

    WARMED TO NORMAL OPERATING TEMPERATURES PRIOR TO mit oil flow to the component in the selected circuit with CHECKING PRESSURES. JLG ALSO RECOMMENDS USING A CAL- the opposite work port opening to reservoir. Once the cir- IBRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF cuit is deactivated (control returned to neutral) the valve WITHIN +/- 5% OF SPECIFIED PRESSURES.

  • Page 176: Platform Level

    103 Bar. 4. With the aid of an assistant, activate articulating jib down. 5. While monitoring pressure gauge, adjust activate articulating jib down relief to 83 Bar. Figure 5-40. Articulating Jib Boom Pressure Adjustments 5-44 – JLG Lift – 3120840...

  • Page 177: Main Control Valve Pressure Adjustments - Sheet 1 Of 2

    SECTION 5 - HYDRAULICS NOTE: Torque all valve cartridges 18 to 20 ft.lbs. (24.5 to 27.2 Nm). Figure 5-41. Main Control Valve Pressure Adjustments - Sheet 1 of 2 3120840 – JLG Lift – 5-45...

  • Page 178: Main Control Valve Pressure Adjustments - Sheet 2 Of 2

    SECTION 5 - HYDRAULICS NOTE: Torque all valve cartridges 18 to 20 ft.lbs. (24.5 to 27.2 Nm). Figure 5-42. Main Control Valve Pressure Adjustments - Sheet 2 of 2 5-46 – JLG Lift – 3120840...

  • Page 179: Location Of Components - Main Control Valve

    SECTION 5 - HYDRAULICS Figure 5-43. Location of Components - Main Control Valve 3120840 – JLG Lift – 5-47...

  • Page 180: Hydraulic Component Start-Up Procedures And Recommendations

    Check the inlet line for property pump control until after initial start-up. This will ensure that tightened fittings and make sure it is free of restrictions the pump remains in its neutral position. and air leaks. 5-48 – JLG Lift – 3120840...

  • Page 181: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication

    Any time pump or pump drive coupling is removed coat, sure is inadequate, shut down and determine the cause pump and drive coupling splines with Lithium Soap Base for improper pressure. Grease (TEXACO CODE 1912 OR EQUIVALENT) coupling is greased prior to assembly. 3120840 – JLG Lift – 5-49...
  • Page 182 SECTION 5 - HYDRAULICS This page left blank intentionally. 5-50 – JLG Lift – 3120840...

  • Page 183: Introduction

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELEC- TRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE- The JLG Control System controller has a built in LED to WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI- indicate any faults. The system stores recent faults which CAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.

  • Page 184: Ade Block Diagram

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-2. ADE Block Diagram – JLG Lift – 3120840...

  • Page 185: To Connect The Jlg Control System Analyzer

    SECTION 6 - JLG CONTROL SYSTEM The top level menus are as follows: 6.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER HELP DIAGNOSTICS 1. Connect the four pin end of the cable supplied with SYSTEM TEST the analyzer, to the controller module located in the...

  • Page 186: Analyzer Connecting Points

    SECTION 6 - JLG CONTROL SYSTEM PLATFORM CONNECTION GROUND CONTROL CONNECTION Figure 6-3. Analyzer Connecting Points – JLG Lift – 3120840...

  • Page 187: Changing The Access Level Of The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM When a top level menu is selected, a new set of menu items may be offered: for example: DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu.

  • Page 188: Control Module Location

    SECTION 6 - JLG CONTROL SYSTEM Figure 6-4. Control Module Location – JLG Lift – 3120840...

  • Page 189: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 6 - JLG CONTROL SYSTEM Once the correct password is displayed, press ENTER. 6.5 ADJUSTING PARAMETERS USING THE The access level should display the following, if the pass- HAND HELD ANALYZER word was entered correctly: Once you have gained access to level 1, and a personality...

  • Page 190: Machine Setup

    To level machine chose: There is a setting that JLG strongly recommends that you CALIBRATION: do not change. This setting is so noted below: TILT SENSOR ELEVATION CUTBACK Press ENTER.
  • Page 191 SECTION 6 - JLG CONTROL SYSTEM 3120840 – JLG Lift –...
  • Page 192 SECTION 6 - JLG CONTROL SYSTEM 6-10 – JLG Lift – 3120840...
  • Page 193 SECTION 6 - JLG CONTROL SYSTEM 3120840 – JLG Lift – 6-11...
  • Page 194 SECTION 6 - JLG CONTROL SYSTEM 6-12 – JLG Lift – 3120840...

  • Page 195: Machine Personality Settings

    SECTION 6 - JLG CONTROL SYSTEM NOTE: Personality settings can be adjusted within the 6.8 MACHINE PERSONALITY SETTINGS adjustment range in order to achieve optimum machine performance. Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S DEFAULTS - 600A...
  • Page 196 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S DEFAULTS - 600A 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%...
  • Page 197 SECTION 6 - JLG CONTROL SYSTEM Table 6-1. Personality Ranges/Defaults FUNCTION PERSONALITY RANGE DEFAULTS - 600S DEFAULTS - 600A 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%...

  • Page 198: Help Fault Codes, Displayed Faults, And Descriptions - Prior To S/N 66437

    SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66437 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 the vehicle is not behaving as expected.
  • Page 199 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66437 Flash code 2/3 indicates problems with boom function selection. LIFT/SWING JOYSTICK FAULTY The lift or swing joystick center tap is out of valid range, or the wiper is wire-off.
  • Page 200 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66437 Flash code 3/2 indicates that a contactor did not open when energized. NOT REQUIRED Flash code 3/3 indicates that a driver is short-circuit.
  • Page 201 SECTION 6 - JLG CONTROL SYSTEM Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66437 Flash code 9/9 indicates problems with the controller. PLATFORM MODULE FAILURE: Platform module V(Low) FET has failed hwfs CODE 1...

  • Page 202: Help Fault Codes, Displayed Faults, And Descriptions - S/N 66937 To Present

    SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present 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 the vehicle is not behaving as expected.
  • Page 203 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault D/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when the center tap voltage is not between 3.08 volts and 3.83 volts.
  • Page 204 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BOOM PREVENTED – DRIVE A boom function is selected while a drive function is selected and drive cutout is config- SELECTED ured to prevent simultaneous drive &...
  • Page 205 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault LP START ASSIST SHORT TO GROUND LP START ASSIST OPEN CIRCUIT...
  • Page 206 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BASKET UP OVERRIDE SHORT TO Only occurs on machines with electronic leveling systems.
  • Page 207 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault TOWER UP SHORT TO GROUND TOWER UP OPEN CIRCUIT TOWER UP SHORT TO BATTERY...
  • Page 208 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault BASKET UP SHORT TO GROUND BASKET UP OPEN CIRCUIT BASKET UP SHORT TO...
  • Page 209 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault Flash code 4/3 indicates problems with the engine. Except where noted, these faults are not reported during 2 second power-up sequence.
  • Page 210 SECTION 6 - JLG CONTROL SYSTEM Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present Fault Flash Communicated (Displayed on Description Priority Code Analyzer) Fault PLATFORM MODULE Platform module code is too old to support the EIM or BPE load sensor and the machine SOFTWARE UPDATE REQUIRED is configured to use one of these two sensors.
  • Page 211 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Default Configuration Digit Number Description Number (Model #) 800A 800S 1350SJP 1200SJP 600C 510A 740A Ford LRG425 EFI Gas (Engine) Ford LRG425 EFI Gas with dual fuel Deutz F4M1011F Diesel...
  • Page 212 SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Default Configuration Digit Number Description Number 5 degree-reduces the maximum speed of all boom functions to creep when tilted and (Tilt Switch) above elevation. Reduces drive speed to creep when tilted.

  • Page 213: Machine Configuration Programming Information

    SECTION 6 - JLG CONTROL SYSTEM Table 6-4. Machine Configuration Programming Information Default Configuration Digit Number Description Number No Head and Tail Lights Installed (Head and Tail Lights) No Broken Cable Switch Installed (Broken Cable Switch) No Load Sensor installed - (DOM - STD) (Load Sensor) Functions in Creep, Overload Lamp Lit, Platform Alarm Beeps (5 sec.
  • Page 214 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code 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 215 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL FORD ECM POWER SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT HORN SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...

  • Page 216: Fault Code Listing

    SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL ALARM SHORT TO BATTERY REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT GENERATOR SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
  • Page 217 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL TOWER UP SHORT TO GROUND REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT TOWER UP OPEN CIRCUIT REQUIRES EMS TO BE RECYCLED TO CLEAR FAULT...
  • Page 218 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL FORD FAULT CODE 31 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 32 CLEARS WHEN FAULT IS REMOVED FORD FAULT CODE 33 CLEARS WHEN FAULT IS REMOVED...
  • Page 219 SECTION 6 - JLG CONTROL SYSTEM Table 6-5. Fault Code Listing HELP MESSAGE FAULT FAULT REMOVAL NO ALTERNATOR OUTPUT CLEARS WHEN FAULT IS REMOVED OIL PRESSURE LOW CLEARS WHEN FAULT IS REMOVED 485 COMMUNICATIONS LOST CLEARS WHEN FAULT IS REMOVED...

  • Page 220: Analyzer Diagnostics Menu Structure

    SECTION 6 - JLG CONTROL SYSTEM the next outer level. The LEFT/RIGHT arrow keys move 6.9 ANALYZER DIAGNOSTICS MENU between items in the same level. The UP/DOWN arrow STRUCTURE keys alter a value if allowed In the following structure descriptions, an intended item is selected by pressing ENTER;...
  • Page 221 SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Adjustments - Personality Descriptions SWING ACCEL … Displays/adjusts swing acceleration DECEL … Displays/adjusts swing deceleration MIN LEFT … Displays/adjusts minimum swing left speed MAX LEFT … Displays/adjusts maximum swing left speed CREEP LEFT …...

  • Page 222: Adjustments - Personality Descriptions

    SECTION 6 - JLG CONTROL SYSTEM Table 6-6. Adjustments - Personality Descriptions JIB LIFT Not displayed if JIB = NO ACCEL … Displays/adjusts jib acceleration DECEL … Displays/adjusts jib deceleration MIN UP … Displays/adjusts minimum jib up speed MAX UP …...

  • Page 223: Diagnostic Menu Descriptions

    SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Diagnostic Menu Descriptions DRIVE DRIVE FOR … Displays drive joystick direction & demand STEER … Displays steer switch direction & demand NOTE: steer demand is inversely proportional to vehicle speed BRAKES …...
  • Page 224 SECTION 6 - JLG CONTROL SYSTEM Table 6-7. Diagnostic Menu Descriptions PM BATTERY … Displays battery voltage at platform module TEMP ... Displays ground module temperature ELEV. CUTOUT … Displays elevation cutout switch status FUNC. CUTOUT … Displays function cutout switch status CREEP…...

  • Page 225: General

    For arising in the machine will be centered in the hydraulic aid in troubleshooting, refer to the Illustrated Parts Manual and electrical systems. for hydraulic diagrams of the various circuits 3120840 – JLG Lift –...

  • Page 226: Electrical Harness - S Models (Prior To S/N 61927) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-1. Electrical Harness - S Models (Prior to S/N 61927) - Sheet 1 of 2 – JLG Lift – 3120840...

  • Page 227: Electrical Harness - S Models (Prior To S/N 61927) - Sheet 2

    SECTION 7 - SCHEMATICS Figure 7-2. Electrical Harness - S Models (Prior to S/N 61927) - Sheet 2 3120840 – JLG Lift –...

  • Page 228: Electrical Harness - S Models (S/N 61927 To S/N 63909) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-3. Electrical Harness - S Models (S/N 61927 to S/N 63909) - Sheet 1 of 2 – JLG Lift – 3120840...

  • Page 229: Electrical Harness - S Models (S/N 61927 To S/N 63909) - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-4. Electrical Harness - S Models (S/N 61927 to S/N 63909) - Sheet 2 of 2 3120840 – JLG Lift –...

  • Page 230: Electrical Harness - S Models (S/N 63909 To 75606) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-5. Electrical Harness - S Models (S/N 63909 to 75606) - Sheet 1 of 2 – JLG Lift – 3120840...

  • Page 231: Electrical Harness - S Models (S/N 63909 To 75606) - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-6. Electrical Harness - S Models (S/N 63909 to 75606) - Sheet 2 of 2 3120840 – JLG Lift –...

  • Page 232: Electrical Harness - S Models (S/N 75606 To Present) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-7. Electrical Harness - S Models (S/N 75606 to Present) - Sheet 1 of 2 – JLG Lift – 3120840...

  • Page 233: Electrical Harness - S Models (S/N 75606 To Present) - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-8. Electrical Harness - S Models (S/N 75606 to Present) - Sheet 2 of 2 3120840 – JLG Lift –...

  • Page 234: Electrical Harness - A Models (Prior To S/N 61927) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-9. Electrical Harness - A Models (Prior to S/N 61927) - Sheet 1 of 2 7-10 – JLG Lift – 3120840...

  • Page 235: Electrical Harness - A Models (Prior To S/N 61927) - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-10. Electrical Harness - A Models (Prior to S/N 61927) - Sheet 2 of 2 3120840 – JLG Lift – 7-11...

  • Page 236: Electrical Harness - A Models (S/N 64249 To S/N 64270) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-11. Electrical Harness - A Models (S/N 64249 to S/N 64270) - Sheet 1 of 2 7-12 – JLG Lift – 3120840...

  • Page 237: Electrical Harness - A Models (S/N 64249 To S/N 64270) - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-12. Electrical Harness - A Models (S/N 64249 to S/N 64270) - Sheet 2 of 2 3120840 – JLG Lift – 7-13...

  • Page 238: Electrical Harness - A Models (S/N 64270 To Present) - Sheet 1 Of 2

    SECTION 7 - SCHEMATICS Figure 7-13. Electrical Harness - A Models (S/N 64270 to Present) - Sheet 1 of 2 7-14 – JLG Lift – 3120840...

  • Page 239: Electrical Harness - A Models (S/N 64270 To Present) - Sheet 2 Of 2

    SECTION 7 - SCHEMATICS Figure 7-14. Electrical Harness - A Models (S/N 64270 to Present) - Sheet 2 of 2 3120840 – JLG Lift – 7-15...

  • Page 240: Electrical Schematic - S & Sj Models With Deutz Engine - Sheet 1

    SECTION 7 - SCHEMATICS Figure 7-15. Electrical Schematic - S & SJ Models with Deutz Engine - Sheet 1 7-16 – JLG Lift – 3120840...

  • Page 241: Electrical Schematic - S & Sj Models With Deutz Engine - Sheet 2

    SECTION 7 - SCHEMATICS 1870054G Figure 7-16. Electrical Schematic - S & SJ Models with Deutz Engine - Sheet 2 3120840 – JLG Lift – 7-17...

  • Page 242: Electrical Schematic - A & Aj Models With Deutz Engine - Sheet 1

    SECTION 7 - SCHEMATICS Figure 7-17. Electrical Schematic - A & AJ Models with Deutz Engine - Sheet 1 7-18 – JLG Lift – 3120840...

  • Page 243: Electrical Schematic - A & Aj Models With Deutz Engine - Sheet 2

    SECTION 7 - SCHEMATICS 1870059E Figure 7-18. Electrical Schematic - A & AJ Models with Deutz Engine - Sheet 2 3120840 – JLG Lift – 7-19...

  • Page 244: Electrical Schematic - Australian Models With Deutz Engine - Sheet 1

    SECTION 7 - SCHEMATICS Figure 7-19. Electrical Schematic - Australian Models with Deutz Engine - Sheet 1 7-20 – JLG Lift – 3120840...

  • Page 245: Electrical Schematic - Australian Models With Deutz Engine - Sheet 2

    SECTION 7 - SCHEMATICS 1870071C Figure 7-20. Electrical Schematic - Australian Models with Deutz Engine - Sheet 2 3120840 – JLG Lift – 7-21...

  • Page 246: Electrical Schematic - Isuzu Engine - Sheet 1 Of 4

    SECTION 7 - SCHEMATICS Figure 7-21. Electrical Schematic - Isuzu Engine - Sheet 1 of 4 7-22 – JLG Lift – 3120840...

  • Page 247: Electrical Schematic - Isuzu Engine - Sheet 2 Of 4

    SECTION 7 - SCHEMATICS 1870131 A Figure 7-22. Electrical Schematic - Isuzu Engine - Sheet 2 of 4 3120840 – JLG Lift – 7-23...

  • Page 248: Electrical Schematic - Isuzu Engine - Sheet 3 Of 4

    SECTION 7 - SCHEMATICS Figure 7-23. Electrical Schematic - Isuzu Engine - Sheet 3 of 4 7-24 – JLG Lift – 3120840...

  • Page 249: Electrical Schematic - Isuzu Engine - Sheet 4 Of 4

    SECTION 7 - SCHEMATICS 1870131 A Figure 7-24. Electrical Schematic - Isuzu Engine - Sheet 4 of 4 3120840 – JLG Lift – 7-25...

  • Page 250: Electrical Schematic - Ade - Sheet 1 Of 4

    SECTION 7 - SCHEMATICS Figure 7-25. Electrical Schematic - ADE - Sheet 1 of 4 7-26 – JLG Lift – 3120840...

  • Page 251: Electrical Schematic - Ade - Sheet 2 Of 4

    SECTION 7 - SCHEMATICS 1870132G Figure 7-26. Electrical Schematic - ADE - Sheet 2 of 4 3120840 – JLG Lift – 7-27...

  • Page 252: Electrical Schematic - Ade - Sheet 3 Of 4

    SECTION 7 - SCHEMATICS Figure 7-27. Electrical Schematic - ADE - Sheet 3 of 4 7-28 – JLG Lift – 3120840...

  • Page 253: Electrical Schematic - Ade - Sheet 4 Of 4

    SECTION 7 - SCHEMATICS 1870132G Figure 7-28. Electrical Schematic - ADE - Sheet 4 of 4 3120840 – JLG Lift – 7-29...

  • Page 254: Hydraulic Schematic - S Models, Prior To S/N 75606 - Sheet 1

    SECTION 7 - SCHEMATICS Figure 7-29. Hydraulic Schematic - S Models, Prior to S/N 75606 - Sheet 1 7-30 – JLG Lift – 3120840...

  • Page 255: Hydraulic Schematic - S Models, Prior To S/N 75606 - Sheet 2

    SECTION 7 - SCHEMATICS 2792176F Figure 7-30. Hydraulic Schematic - S Models, Prior to S/N 75606 - Sheet 2 3120840 – JLG Lift – 7-31...

  • Page 256: Hydraulic Schematic - S Models, Prior To S/N 75606 - Sheet 3

    SECTION 7 - SCHEMATICS Figure 7-31. Hydraulic Schematic - S Models, Prior to S/N 75606 - Sheet 3 7-32 – JLG Lift – 3120840...

  • Page 257: Hydraulic Schematic - S Models, Prior To S/N 75606 - Sheet 4

    SECTION 7 - SCHEMATICS 2792176F Figure 7-32. Hydraulic Schematic - S Models, Prior to S/N 75606 - Sheet 4 3120840 – JLG Lift – 7-33...

  • Page 258: Hydraulic Schematic - S Models, S/N 75606 To Present - Sheet 1 Of 6

    SECTION 7 - SCHEMATICS Figure 7-33. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 1 of 6 7-34 – JLG Lift – 3120840...

  • Page 259: Hydraulic Schematic - S Models, S/N 75606 To Present - Sheet 2 Of 6

    SECTION 7 - SCHEMATICS 2792605 D Figure 7-34. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 2 of 6 3120840 – JLG Lift – 7-35...

  • Page 260: Hydraulic Schematic - S Models, S/N 75606 To Present - Sheet 3 Of 6

    SECTION 7 - SCHEMATICS Figure 7-35. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 3 of 6 7-36 – JLG Lift – 3120840...

  • Page 261: Hydraulic Schematic - S Models, S/N 75606 To Present - Sheet 4 Of 6

    SECTION 7 - SCHEMATICS 2792605 D Figure 7-36. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 4 of 6 3120840 – JLG Lift – 7-37...

  • Page 262: Hydraulic Schematic - S Models, S/N 75606 To Present - Sheet 5 Of 6

    SECTION 7 - SCHEMATICS Figure 7-37. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 5 of 6 7-38 – JLG Lift – 3120840...

  • Page 263: Hydraulic Schematic - S Models, S/N 75606 To Present - Sheet 6 Of 6

    SECTION 7 - SCHEMATICS 2792605 D Figure 7-38. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 6 of 6 3120840 – JLG Lift – 7-39...

  • Page 264: Hydraulic Schematic - A Models - Sheet 1

    SECTION 7 - SCHEMATICS Figure 7-39. Hydraulic Schematic - A Models - Sheet 1 7-40 – JLG Lift – 3120840...

  • Page 265: Hydraulic Schematic - A Models - Sheet 2

    SECTION 7 - SCHEMATICS Figure 7-40. Hydraulic Schematic - A Models - Sheet 2 3120840 – JLG Lift – 7-41...

  • Page 266: Hydraulic Schematic - A Models - Sheet 3

    SECTION 7 - SCHEMATICS Figure 7-41. Hydraulic Schematic - A Models - Sheet 3 7-42 – JLG Lift – 3120840...

  • Page 267: Hydraulic Schematic - A Models - Sheet 4

    SECTION 7 - SCHEMATICS 2792177D Figure 7-42. Hydraulic Schematic - A Models - Sheet 4 3120840 – JLG Lift – 7-43...
  • Page 268 SECTION 7 - SCHEMATICS This page left blank intentionally. 7-44 – JLG Lift – 3120840...
  • Page 270 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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