JLG 600SJC Service And Maintenance Manual
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JLG 600SJC Service And Maintenance Manual

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Service and Maintenance Manual
Model
600SC
600SJC
660SJC
P/N 3120794
November 22, 2016

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  • Page 1 Service and Maintenance Manual Model 600SC 600SJC 660SJC P/N 3120794 November 22, 2016...

  • Page 3: Bhydraulic System Safety

    Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable control several times with the engine stopped and 3120794 – JLG Lift –...
  • Page 4 INTRODUCTION REVISON LOG Original Issue January 25, 2000 Revised July 28, 2000 Revised April 9, 2002 Revised November 22, 2016 – JLG Lift – 3120794...

  • Page 5: Table Of Contents

    Gaskets ..............2-3 3120794 – JLG Lift –...
  • Page 6 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 7 Assembly ..............5-5 3120794 – JLG Lift –...
  • Page 8 Removal ..............6-32 – JLG Lift –...
  • Page 9 Hydraulic Circuit Checks............8-1 3120794 – JLG Lift –...
  • Page 10 Boom Positioning and Support, Cylinder Repair ........5-9 – JLG Lift –...
  • Page 11 Hydraulic Schematic w/GFT24 Drive - Sheet 4 of 4 ........8-13 3120794 – JLG Lift –...
  • Page 12 Final Drive Required Tools - Installation ..........6-56 viii – JLG Lift – 3120794...

  • Page 13: Section 1. Specifications

    Battery - 1000 Cold Cranking Amps, 210 Minutes ReserveCapacity, 12 VDC. Fuel Consumption. Low RPM - 1.90 GPH (7.19 lph). High RPM - 2.50 GPH (9.46 lph). Horsepower - 65 @ 3000 RPM, full load. Engine - Diesel. (Water-Cooled) 3120794 – JLG Lift –...

  • Page 14: Performance Data

    Results should be recorded for a 50 ft. (15.2 m) course. Drive Forward, Record Time. Drive Reverse, Record Time. – JLG Lift – 3120794...

  • Page 15: Test Notes

    600 hours thereafter. (See paragraph on Swing Bearing in Section 2.) NOTE: When maintenance becomes necessary or a fas- tener has loosened, refer to the Torque Chart to determine proper torque value. 3120794 – JLG Lift –...

  • Page 16: Hydraulic Oil

    -20° F 6,200 Viscosity Index Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- tain the same required additives or be of comparable vis- cosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommenda- tions.

  • Page 17: Cylinder Specifications

    TERIES, FILLED TIRES, COUNTERWEIGHT, ENGINE & PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Table 1-8. Critical Stability Weights 600SJ 660SJ 600S Engine Ford Platform 6 ft. (1.83 M) 8 ft. (2.44 M) 3120794 – JLG Lift –...

  • Page 18: 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 1-1. Serial Number Locations – JLG Lift – 3120794...
  • Page 19 SECTION 1 - SPECIFICATIONS This page left blank intentionally. 3120794 – JLG Lift –...

  • Page 20: Lubrication Point Location

    SECTION 1 - SPECIFICATIONS Figure 1-2. Lubrication Point Location – JLG Lift – 3120794...

  • Page 21: Lubrication Chart

    (approximately 221 lent) degrees F) cooler will fill up within minutes; shut down and wait for approx- Multi-Purpose Grease imately two minutes. Check oil level, fill oil to max marking on the dipstick. 3120794 – JLG Lift –...
  • Page 22 SECTION 1 - SPECIFICATIONS 1-10 – JLG Lift – 3120794...

  • Page 23: Section 2. General

    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 24: 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 25: 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. 3120794 – JLG Lift –...

  • Page 26: 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 27: Cylinder Drift Test

    If the cylinder passes this test, it is acceptable. tion. NOTE: This information is based on 6 drops per minute cyl- inder leakage. 3120794 – JLG Lift –...

  • Page 28: 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 29: Inspection And Preventive Maintenance Schedule

    Hood, Hood Props, Hood Latches 1,2,5 Chassis Assembly Drive Motors Drive Hubs Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems 3120794 – JLG Lift –...
  • Page 30 ANSI and EMI Manuals/Handbooks Installed Capacity Decals Installed, Secure, Legible All Decals/Placards Installed, Secure, Legible Walk-Around Inspection Performed Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds – JLG Lift – 3120794...
  • Page 31 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 32 SECTION 2 - GENERAL This page left blank intentionally. 2-10 – JLG Lift – 3120794...

  • Page 33: Section 3. Turntable

    R - RETRACT INDICATOR 2 - POSITION 2 CW=RETRACT (AMBER) 3 - POSITION 3 CW=RETRACT E - EXTEND INDICATOR (AMBER) 4 - POSITION 4 CW=RETRACT C - CLUTCH INDICATOR (GREEN) F - FAILURE INDICATOR (RED) 3120794 – JLG Lift –...

  • Page 34: Failure Modes

    1. Recycle power to determine if the problem is inter- mittent. 2. The input voltage must be greater than 10.5 Vdc. 3. Check wiring for any damage and correct. 4. Disconnect engine harness and actuator connnec- tions. 5. If problem reoccurs return unit. – JLG Lift – 3120794...

  • Page 35: Swing Hub

    Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bear- ing bolt torque checks on JLG Lifts in service. This check must be performed after the first 50 hours of machine operation and every 600 hours of machine Action: operation thereafter.

  • Page 36: Wear Tolerance

    Use a a. Metal particles in the grease. suitable container to retain any residual hydrau- b. Increased drive power required. lic fluid. Immediately cap lines and ports. – JLG Lift – 3120794...

  • Page 37: Swing Bearing Tolerance Boom Placement

    SECTION 3 - TURNTABLE Figure 3-5. Swing Bearing Tolerance Boom Placement 3120794 – JLG Lift –...

  • Page 38: Swing Bearing Torque Values

    Connect the hydraulic lines to the rotary cou- pling as tagged prior to removal. JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING l. At ground control station, use boom lift control BOLTS BE DISCARDED AND REPLACED WITH NEW BOLTS. SINCE to lower boom to stowed position.

  • Page 39: Swing Brake - Mico

    2. Install new bearing (2) on shaft (51). ing (52). 3. Install shaft assembly and retaining ring (3) into 8. Remove retaining ring (3) from housing (52). housing (52). Figure 3-6. Swing Bearing Torque Sequence 3120794 – JLG Lift –...

  • Page 40: Swing Brake Assembly (Mico)

    SECTION 3 - TURNTABLE Figure 3-7. Swing Brake Assembly (Mico) – JLG Lift – 3120794...

  • Page 41: Tilt Alarm Switch

    (15) with holes in end cover. 12. Insert capscrews (12) and tighten evenly to draw end cover (13) to housing (52). Torque capscrews to 55 ft. lbs. (75 Nm). Figure 3-8. Tilt Switch Adjustment 3120794 – JLG Lift –...
  • Page 42 SECTION 3 - TURNTABLE This page left blank intentionally. 3-10 – JLG Lift – 3120794...

  • Page 43: Section 4. Boom & Platform

    (20 Nm) alternating between the two wire ropes and keeping approximately the same amount of thread beyond the adjusting nut. NOTE: Do not allow wire rope to rotate. This may damage the wire rope. 3120794 – JLG Lift –...

  • Page 44: Wear Pads

    When shims are removed, shorter bolts must be Figure 4-4. Location and Thickness of Wear Pads used so bolt does not protrude from insert and come into contact with boom surface. – JLG Lift – 3120794...

  • Page 45: Wire Rope

    5. Sheaves failing wearout gage inspection. 6. Ropes with 6 total broken wires in one rope lay, 3 in one strand in one rope lay, 1 valley break, or 1 break at any end termination. 3120794 – JLG Lift –...

  • Page 46: Boom Maintenance

    Using a suitable lifting equipment, adequately d. Telescope the fly section out approximately 20 inches (50.8 cm) to gain access to the slave lev- support powertrack weight along entire length. eling cylinder. – JLG Lift – 3120794...

  • Page 47: Location Of Components - Boom Powertrack

    Tag and disconnect hydraulic lines from tele- scope cylinder. Use a suitable container to retain any residual hydraulic fluid. Cap hydraulic lines and ports. c. Remove hardware securing the lift cylinder rod end to the base boom section. 3120794 – JLG Lift –...

  • Page 48: Boom Assembly Cutaway - S Models - Sheet 1 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-8. Boom Assembly Cutaway - S Models - Sheet 1 of 3 – JLG Lift – 3120794...

  • Page 49: Boom Assembly Cutaway - S Models - Sheet 2 Of 3

    SECTION 4 - BOOM & PLATFORM Figure 4-9. Boom Assembly Cutaway - S Models - Sheet 2 of 3 3120794 – JLG Lift –...

  • Page 50: Disassembly Of Boom Sections

    4. Remove hardware securing the wire rope adjust- cylinder with a suitable sling and lifting device at ment block to aft end of the base boom section and remove the block. approximately the center of gravity. – JLG Lift – 3120794...

  • Page 51: Inspection

    14. Using an overhead crane or suitable lifting device, remove fly boom section from mid section. Note: When removing fly boom section from mid boom section, retract wire rope must be dragged along with fly boom section. 3120794 – JLG Lift –...

  • Page 52: Assembly

    5. Inspect boom pivot pin for wear, scoring, tapering and ovality, or other damage. Replace pins as nec- essary. 6. Inspect telescope cylinder attach point for scoring, tapering and ovality. Replace pins as necessary. 4-10 – JLG Lift – 3120794...

  • Page 53: Routing Installation Of Retract Wire Ropes

    THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYLINDER boom section. Shim boom, if necessary, for a total of SLOWLY INTO POSITION. DAMAGE TO COMPONENTS MAY 2/10 inch (0.20 m) clearance. RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES. 3120794 – JLG Lift – 4-11...
  • Page 54 Attach push tube bracket to the side of the mid boom section with mounting hardware. NOTE: Do not over tighten attach bolt on push tube bracket. Figure 4-15. Reassembly of Components - Boom It should pivot freely. Powertrack Assembly 4-12 – JLG Lift – 3120794...

  • Page 55: Boom Powertrack Installation

    SECTION 4 - BOOM & PLATFORM Figure 4-16. Boom Powertrack Installation 3120794 – JLG Lift – 4-13...

  • Page 56: Installation

    Ensure pin 3. Remove mounting hardware from slave leveling cyl- surfaces are protected prior to installation. Replace inder pin #1. Using a suitable brass drift and ham- pins as necessary. 4-14 – JLG Lift – 3120794...

  • Page 57: Assembly

    Using a soft head mallet, install rotator support pin #6 into articulating jib boom and secure with mounting hardware. 4.7 LIMIT SWITCH ADJUSTMENT Adjust switches and cam valve as shown in Limit Switches Adjustment. 3120794 – JLG Lift – 4-15...

  • Page 58: Limit Switches Adjustments

    SECTION 4 - BOOM & PLATFORM Figure 4-18. Limit Switches Adjustments 4-16 – JLG Lift – 3120794...

  • Page 59: Rotator - Helac

    Axially, the shaft is separated from the housing by the upper and lower thrust washers. The end cap is adjusted for axial clearance and locked in position by set screws or pins. 3120794 – JLG Lift – 4-17...

  • Page 60: Rotator Assembly (Helac)

    SECTION 4 - BOOM & PLATFORM Figure 4-19. Rotator Assembly (Helac) 4-18 – JLG Lift – 3120794...

  • Page 61: Rotary Actuator - Exploded View

    204. O-ring Washer 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 4-20. Rotary Actuator - Exploded View 3120794 – JLG Lift – 4-19...

  • Page 62: Rotary Actuator - Assembly Drawing

    204. O-ring Washer 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 4-21. Rotary Actuator - Assembly Drawing 4-20 – JLG Lift – 3120794...

  • Page 63: Disassembly

    (4) by turning it counter clockwise. 16” (4.76mm). 3. Remove the lock pins using an ”Easy Out” (a size #2 is shown). If the pin will not come out with the ”Easy Out”, use 3120794 – JLG Lift – 4-21...
  • Page 64 9. Prior to removing the shaft, (2), use a felt marker to clearly indicate the timing marks between shaft and piston. This will greatly simplify timing during assem- bly. 4-22 – JLG Lift – 3120794...
  • Page 65 15. Remove the wear guides (302) from the end cap (4) 12. To remove the piston (3) use a rubber mallet and a and shaft (2). plastic mandrel so the piston is not damaged. 3120794 – JLG Lift – 4-23...
  • Page 66 17. Remove the thrust washers (304), from the end cap (4) and shaft (2). 18. Remove the wiper seal (304.1) from its groove in the end cap (4) and shaft (2). 4-24 – JLG Lift – 3120794...

  • Page 67: Inspection

    2. Inspect the thrust washers (304) for rough or worn edges and surfaces. Measure it’s thickness to make sure it is within specifications (Not less than 0.092” or 2.34 mm). 3120794 – JLG Lift – 4-25...
  • Page 68 (304). 6. Install the inner T-seal (200) into the piston (3) using a circular motion. Install the outer T-seal (202) by stretching it around the groove in a circular motion. 4-26 – JLG Lift – 3120794...
  • Page 69 (1) during disassembly line up as shown. Using Repeat this step for the outer seal (202). a rubber mallet, tap the piston into the housing up to the point where the gear teeth meet. 3120794 – JLG Lift – 4-27...
  • Page 70 13. Install the stop tube onto the shaft end. Stop tube is an available option to limit the rotation of an actua- tor. 4-28 – JLG Lift – 3120794...
  • Page 71 19. Insert the set screws (113) over the lock pins. it is threaded into the housing (1). Tighten them to 25 in. lbs. (2.825 Nm). 3120794 – JLG Lift – 4-29...

  • Page 72: Foot Switch Adjustment

    The controller will then provide [PWM] outputs to electrohydraulic valves and coils. The desired output (PWM) signals are fine tuned independently in each direc- tion. The OEM "OPTIMIZER" is used to perform this tuning. 4-30 – JLG Lift – 3120794...

  • Page 73: General Description

    +12VDC output whenever an input is turned on. Termi- 17. Output - Switched nal 17 can be used to advance a throttle or dump valve. 18. Not Used xxxx - Factory Use A,B,C,D - OPTIMIZER - Connections 3120794 – JLG Lift – 4-31...

  • Page 74: Wiring Diagram - Single Coil Uni-Directional Flow Control Valve - 1 Axis

    SECTION 4 - BOOM & PLATFORM Figure 4-23. Wiring Diagram - Single Coil Uni-Directional Flow Control Valve - 1 Axis 4-32 – JLG Lift – 3120794...

  • Page 75: Setup And Tuning

    In the Bench-Static mode, Joy- stick/DIGISENSORs may or may not be wired to the SUPERFLEX Controller. For best results, it is recom- mended that all adjustments be made in the Normal- Active mode. Figure 4-24. Controller Pattern 3120794 – JLG Lift – 4-33...

  • Page 76: How To Perform The Normal-Active Tuning Process

    The adjustment of the Ramp Down function is done in 0.1 second steps in the same manner as that for Ramp up. (Press RUN button on OPTI- MIZER to return to normal operation and store the new setting). 4-34 – JLG Lift – 3120794...

  • Page 77: How To Make Bench-Static Adjustments

    OPTIMiZER to the SUPERFLEX using terminal strip A.B.C.D. Adjustments can now be made. MAKING ADJUSTMENTS 1. Joystick/DIGISENSOR #1 [called Controller #1] is input terminals (1) and (2). 2. Joystick/DIGISENSOR #2 [called Controller #2] is input terminals (3) and (4). 3120794 – JLG Lift – 4-35...
  • Page 78 SECTION 4 - BOOM & PLATFORM 4-36 – JLG Lift – 3120794...

  • Page 79: Troubleshooting

    LED #2 turn on simultaneously. This position 1. Connect +9V(or 12VDC) to the red wire and the occurs in a narrow transition location between negative terminal to the black wire. steps A and B. Figure 4-26. Testing the SUPERFLEX 3120794 – JLG Lift – 4-37...

  • Page 80: Digisensor Troubleshooting

    SECTION 4 - BOOM & PLATFORM Figure 4-27. Digisensor Troubleshooting 4-38 – JLG Lift – 3120794...
  • Page 81 SECTION 4 - BOOM & PLATFORM 3120794 – JLG Lift – 4-39...

  • Page 82: Optimizer Keypad

    SECTION 4 - BOOM & PLATFORM Figure 4-29. OPTIMIZER Keypad 4-40 – JLG Lift – 3120794...

  • Page 83: Important Reminders

    SYSTEM displayed, check the power connections between the Optimizer and the Superflex, a poor com- munication link maybe the problem, check for proper wiring hook ups at both Optimizer connections, drive/ steer joystick and drive pump EDC connections 3120794 – JLG Lift – 4-41...

  • Page 84: Crawler Tracking Adjustments

    (low) and a 200 ft. (high) start to finish point to use as a measurement. Optimizer Plug: Red (1) Black (2) White (3) Green (4) ADJUSTMENT EXAMPLE: JLG Harness At Platform Control Box Optimizer Con- Position your machine inline with the two fixed landscape Wht/Blk 58-1 (1) Orn/Red 49-2 (2) Orn/Red nection:...
  • Page 85 2. Next, move the joystick into the left or right positions (STEER) (DS2), this will tell you the percentage of input traveling into the Superflex, the range of travel is 15% at Threshold to 23% Max Ou Threshold R= Rear F= Forward 3120794 – JLG Lift – 4-43...
  • Page 86 1. With the machine EMS up, foot switch pressed on, you will now see the following display; 3. Next push the ENTER key, this will now show the individual THRESHOLD settings. 4-44 – JLG Lift – 3120794...
  • Page 87 REV THRESHOLD settings on the display, the THRESHOLD setting on the display, the default set- default setting will blink now letting you know you ting will blink now letting you know you can adjust. can adjust. 3120794 – JLG Lift – 4-45...
  • Page 88 11. Next push the ENTER key, this will now show you MAX OUT adjustment mode. the LEFT MAX OUT FWD setting on the display, the default setting will blink now letting you know you can adjust. 4-46 – JLG Lift – 3120794...
  • Page 89 BOTH MAX OUT REV settings in the display, the RIGHT MAX OUT REV settings on the display, the default settings will now blink letting you know you default settings will now blink letting you know you can adjust. can adjust. 3120794 – JLG Lift – 4-47...
  • Page 90 19. Next push the ENTER key, this will now show you RAMP UP mode. the RAMP UP REV settings on the display, the default settings will now blink letting you know you can adjust. 4-48 – JLG Lift – 3120794...
  • Page 91 21. Now push the (+) key this should put you in the 23. Next push the ENTER key, this will show the RAMP RAMP DOWN mode. DOWN REVERSE setting on the display, the default setting will blink now letting you know you can adjust. 3120794 – JLG Lift – 4-49...
  • Page 92 27. Next push the ENTER key this will now show the LOW RANGE mode. RIGHT LOW RANGE FWD setting on the display, the default setting will blink now letting you know you can adjust. 4-50 – JLG Lift – 3120794...
  • Page 93 31. Next push the (+) key this should put you in the LOW RANGE REV settings on the display, the SYSTEM VOLTAGE mode this is a read only mode. default setting will blink now letting you know you can adjust. 3120794 – JLG Lift – 4-51...
  • Page 94 33. Next push the (+) key this will now show the SERIAL Currently this mode does not apply to the Crawler. NUMBER of the Superflex. 35. Next push the (+) key, this will put you in the TACHOMETER mode. 4-52 – JLG Lift – 3120794...
  • Page 95 LOAD SHED RAMP setting on the display, the HYSTERESIS setting on the display, the default set- default setting will blink letting you know you can ting will blink letting you know you can adjust. adjust. 3120794 – JLG Lift – 4-53...
  • Page 96 3.0 seconds Ramp Up 0.5 sec- Load Resume Ramp 5.0 seconds onds Ramp Down 0.5 sec- Shed Hysteresis 2553 (RPM) onds Low Range Resume Hysteresis 2553 (RPM) DS1 & DS2 128% Sensitivity 2553 (RPM) 4-54 – JLG Lift – 3120794...

  • Page 97: Superflex Inputs And Outputs

    Wire Org. 7/4 60 – 63 ma Steer: (Right) Wire Org. 8/4 60 – 63 ma Drive: (Fwd) Wire Org. 8/4 100 - 103 ma Drive: (Rev) Wire Org. 7/4 100 – 103 ma 3120794 – JLG Lift – 4-55...
  • Page 98 SECTION 4 - BOOM & PLATFORM This page left blank intentionally. 4-56 – JLG Lift – 3120794...

  • Page 99: Section 5. Hydraulics

    7. If extend port leakage is less than 6-8 drops per min- ute, carefully reconnect hose to extend port, than activate cylinder through one complete cycle and check for leaks. If leakage continues at a rate of 6-8 3120794 – JLG Lift –...

  • Page 100: Cylinders With Single Counterbalance Valve

    (Articulating Jib Boom Lift, and Slave), Slave Level, Lower tem and run cylinder through one complete cycle to Lift, Upright level, Main Telescope and Tower Telescope. check for leaks. – JLG Lift – 3120794...

  • Page 101: Cylinder Repair

    5. Mark cylinder head and barrel with a center punch 8. Using suitable protection, clamp the cylinder rod in for easy realignment. Using an allen wrench, loosen a vise or similar holding fixture as close to the piston as possible. 3120794 – JLG Lift –...

  • Page 102: Cleaning And Inspection

    6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston 16. Inspect the oil ports for blockage or the presence of as necessary. dirt or other foreign material. Repair as necessary. – JLG Lift – 3120794...

  • Page 103: Assembly

    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 104: Installation Of Head Seal Kit

    9. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and back-up rings are not damaged or dislodged. 10. Thread piston onto rod until it abuts the spacer end and install the tapered bushing. – JLG Lift – 3120794...

  • Page 105: Tapered Bushing Installation

    SECURELY. (SEE TABLE 2-1 AND 2-3. TORQUE SPECIFICATIONS). 11. Assemble the tapered bushing loosely into the pis- 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 106: Rod Assembly Installation

    (12 Nm) Lockout Cylinder 80 ft. lbs. (109 Nm) Articulating Slave 50 ft. lbs. 9 ft. lbs. Cylinder (68 Nm) (12 Nm) Articulating 50 ft. lbs. 9 ft. lbs. Master Cylinder (68 Nm) (12 Nm) – JLG Lift – 3120794...

  • Page 107: Cylinder Removal And Installation

    Figure 5-14. Boom Positioning and Support, Cylinder Repair 3120794 – JLG Lift –...

  • Page 108: Main Boom Lift Cylinder Removal

    (See Section 4 - Boom & Plat- boom functions. Check for correct operation and form) hydraulic leaks. Secure as necessary. 7. Check fluid level of hydraulic tank and adjust as nec- essary. 5-10 – JLG Lift – 3120794...

  • Page 109: Pressure Setting Procedures

    4. Install pressure gauge at quick disconnect on port M4 on main valve. 5. With the aid of an assistant, activate platform level backward. 6. While monitoring pressure gauge, adjust platform level relief to 1800 PSI (124.11 Bar). 3120794 – JLG Lift – 5-11...

  • Page 110: Main Control Valve Pressure Adjustments - Sheet 1 Of 2

    SECTION 5 - HYDRAULICS Figure 5-16. Main Control Valve Pressure Adjustments - Sheet 1 of 2 5-12 – JLG Lift – 3120794...

  • Page 111: Main Control Valve Pressure Adjustments - Sheet 2 Of 2

    SECTION 5 - HYDRAULICS Figure 5-17. Main Control Valve Pressure Adjustments - Sheet 2 of 2 3120794 – JLG Lift – 5-13...

  • Page 112: Location Of Components - Main Control Valve (Sheet 1)

    SECTION 5 - HYDRAULICS Figure 5-18. Location of Components - Main Control Valve (Sheet 1) 5-14 – JLG Lift – 3120794...

  • Page 113: Location Of Components - Main Control Valve (Sheet 2)

    SECTION 5 - HYDRAULICS Figure 5-19. Location of Components - Main Control Valve (Sheet 2) 3120794 – JLG Lift – 5-15...

  • Page 114: Variable Pump

    The orifice plugs for the FNR and NFPE are located inside the servo piston covers. The orifice plugs for the NFPH are located in the NFPH ports. Orifice plugs may be cleaned or replaced. 5-16 – JLG Lift – 3120794...

  • Page 115: Shim Adjustable Charge Relief Valve Components

    (with shims and O-ring) charge pressure (port M3) with the pump in stroke. into the pump housing [55-135 Nm (40-100 ft•lb)]. The charge pressure should level off when the relief setting is reached. 3120794 – JLG Lift – 5-17...

  • Page 116: Shaft Seal And Shaft Replacement

    5. Place the seal carrier in an arbor press with the shaft bearing side down, and press out the old seal. An appropriately sized pipe spacer or socket wrench can be used as a press tool. Once removed, the seal is not reusable. 5-18 – JLG Lift – 3120794...

  • Page 117: Shaft Components

    14. Install the retaining ring. 1. Key 4. Roller Bearing 2. Shaft Assem- 5. Shaft 3. Retaining Ring Figure 5-24. Shaft Components 3120794 – JLG Lift – 5-19...

  • Page 118: Charge Pump

    Install the charge pump cover screws and torque Always replace the O-rings and charge pump cover evenly [36-43 Nm (26-32 ft•lb)]. gasket. Inspect the journal bearing in the gerotor 15. If necessary, reinstall auxiliary pump. cover for excessive wear. 5-20 – JLG Lift – 3120794...

  • Page 119: Charge Pump Components

    SECTION 5 - HYDRAULICS Cover Retaining Screw O-ring Gerotor Cover Gerotor Assembly Drive Coupling Gerotor Cover Locating Pin Charge Pump Cover Locating Gerotor Drive Pin Gasket Figure 5-25. Charge Pump Components 3120794 – JLG Lift – 5-21...

  • Page 120: Gauge Port Locations

    Case Drain Port L2 (non-feed- back) Case Drain Port L2 Servo Pressure Gauge Port L4 Case Drain Port L1 Case Drain Port L1 (non-feed- back) Charge Pressure Gauge Charge Pump Inlet Port S Figure 5-26. Gauge Port Locations 5-22 – JLG Lift – 3120794...

  • Page 121: 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 5-27. Plugs/Fittings Size & Torque 3120794 – JLG Lift – 5-23...

  • Page 122: Hydraulic Component Start-Up Procedures And Recommendations

    Failure to do so may cause nent housing is as clean as possible, and store the considerable damage to the entire system. fill container in such a way as to prevent it from becoming contaminated. 5-24 – JLG Lift – 3120794...

  • Page 123: Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication

    If charge pres- sure is inadequate, shut down and determine the cause for improper pressure. INADEQUATE CHARGE PRESSURE WILL AFFECT THE OPERA- TOR'S ABILITY TO CONTROL THE MACHINE. 3120794 – JLG Lift – 5-25...
  • Page 124 SECTION 5 - HYDRAULICS This page left blank intentionally. 5-26 – JLG Lift – 3120794...

  • Page 125: Section 6. Undercarriage Prior To S/N 0300070975

    GREASE AND OIL ARE UNDER HIGH PRESSURE COMING OUT OF THE RELIEF VALVE AND CAN PENETRATE THE BODY. DO NOT WATCH THE RELIEF VALVE TO SEE IF GREASE IS ESCAPING. WATCH THE TRACK OR TRACK ADJUSTMENT TO SEE IF THE TRACK IS BEING LOOSENED. 3120794 – JLG Lift –...

  • Page 126: Installation

    Dispose of all fluids according to local regulations 1. Be sure the shaft of the track carrier roller and the and mandates. bore in the mounting bracket on the undercarriage frame are clean and free of dirt. – JLG Lift – 3120794...

  • Page 127: Track Carrier Roller - Exploded View

    SECTION 6 - UNDERCARRIAGE PRIOR TO S/N 0300070975 Figure 6-2. Track Carrier Roller - Exploded View 3120794 – JLG Lift –...

  • Page 128: Track Carrier Roller

    4.08 ± 0.17 oz. (120 ±5 mL). 3. Remove the three socket head bolts (1) and cover (3) from the track carrier roller. 6. Carefully remove the shaft assembly (8) from the track carrier roller. – JLG Lift – 3120794...

  • Page 129: Assembly

    Table 6-2. Track Carrier Roller Required Tools - Assembly Tool Part # Description Qty. 1P-0510 Driver Group 9U-5985 Seal Installer 8T-5096 Dial Indicator 1. Thoroughly clean all parts of the track carrier roller prior to assembly. 3120794 – JLG Lift –...
  • Page 130 (A) and a press to install bearing (12) in the out- side bore of the carrier roller. The outside bore can be identified by three threaded holes (H) in the track carrier roller. Install the bearing until the flange on – JLG Lift – 3120794...
  • Page 131 4.08 ± 0.17 oz. (120 ± 5 mL) of clean SAE 30 oil. Apply 5P-3413 Pipe Sealant on the threads of plug (2). Install plug (2). 13. Install the track carrier rollers. 3120794 – JLG Lift –...

  • Page 132: Track Roller

    7. Fasten a hoist to tooling (B). Put tooling (B) in posi- tion under track roller (2), as shown. Remove the bolts that hold the track roller. Remove the track roller. The weight of the track roller is 75 lb. (34 kg). – JLG Lift – 3120794...

  • Page 133: Track Roller - Exploded View

    SECTION 6 - UNDERCARRIAGE PRIOR TO S/N 0300070975 Figure 6-4. Track Roller - Exploded View 3120794 – JLG Lift –...

  • Page 134: Disassembly

    5. Remove Duo-cone seal kit (4) from end collar (3). 2. Drive plug (1) into the stopper in the end of the track roller. Drain the oil from the track roller into a suitable 6-10 – JLG Lift – 3120794...

  • Page 135: Assembly

    Install the bearings until the bearings make contact with the counterbore in the track roller. 3. Use the following procedure to determine the shaft end play. 3120794 – JLG Lift – 6-11...
  • Page 136 Use a press to install shaft (5) in end collar (8). shaft (5) from end collar (8). Be sure that the spring pin hole in the shaft is aligned with the spring pin hole in the end collar. 6-12 – JLG Lift – 3120794...
  • Page 137 0.2 inch (5 mm) above the end of the stopper. Be sure the plug is not recessed below the surface of the stopper after the plug is installed. 3120794 – JLG Lift – 6-13...

  • Page 138: Installation

    Install the four bolts that hold the roller in position. 5. Lift the machine off tooling (A). Remove tooling (A) from the machine. Lower the machine to the floor. 6. Tighten the tension of the track. 6-14 – JLG Lift – 3120794...

  • Page 139: Track

    2. Release the tension on the track assembly. Loosen relief valve (1) for one turn only. If the track assembly does not loosen after opening the relief valve, move the machine forward and backward until the tension 3120794 – JLG Lift – 6-15...

  • Page 140: Connect

    Figure 6-7. Track Shoe Connect Table 6-7. Track Required Tools - Connect Tool Part # Description Qty. 1P-3545 Coupling Tool 1P-3533 Carrier Bar 1P-7402 Coupling Tool 5P-6214 Track Block Assembly 1U-7631 Socket Figure 6-6. Track Link Assembly 6-16 – JLG Lift – 3120794...
  • Page 141 11. Tighten the tension of the track. 5. Install tooling (C) between the track links in the end of the track assembly as shown. Install 1P-3570 Hook (1) between the track links in the end of the 3120794 – JLG Lift – 6-17...

  • Page 142: Front Idler And Recoil Spring

    Make sure the bolts (2) are exposed. Remove the lift- ing device from the unit. Tighten bolt (2). 3. Use a pry bar to slide the front idler and the recoil spring into the undercarriage frame. 6-18 – JLG Lift – 3120794...

  • Page 143: Front Idler Disassembly

    Be prepared to collect the fluid with suitable contain- ers before opening any compartment or disassem- bling any component containing fluids. 5. Remove Duo-cone seal kits (3) from bearings (2). Dispose all fluids according to local regulations and mandates. 3120794 – JLG Lift – 6-19...

  • Page 144: Front Idler Assembly

    1. Thoroughly clean all parts of the front idler prior to assembly. 7. Remove two o-ring seals (5) from shaft (4). 2. Check the condition of bushings (7). If the bushings are worn or damaged, use new parts for replace- ments. 6-20 – JLG Lift – 3120794...
  • Page 145 Make sure that the marking "R" and the milled surface of the shaft is toward the rear of the bearing. 3120794 – JLG Lift – 6-21...

  • Page 146: Recoil Spring Disassembly

    RECOIL SPRING FORCE, IF NOT RELIEVED, CAN RESULT IN PER- SONAL INJURY OR DEATH. RELIEVE SPRING FORCE BEFORE REMOVING TH READED RETAINER, PERFORMING REPAIRS ON RECOIL SPRING HOUS- ING, OR REMOVING RECOIL SPRING. MAXIMUM RECOIL PRESSURE IS 3,000 PSI (20,700 KPA). 6-22 – JLG Lift – 3120794...
  • Page 147 4. Position two supports (1) of tooling (A) in order to support the recoil spring assembly. Make sure the two supports are level. NOTE: The lifting device is removed from the recoil spring assembly for photographic purposes. 3120794 – JLG Lift – 6-23...
  • Page 148 ING, OR REMOVING RECOIL SPRING. 11. Separate the components of the recoil spring MAXIMUM RECOIL SPRING PRESSURE IS 3000 PSI (20,700 assembly. Remove retaining rod (12), plate (11), KPA). spring (10), and support (9). 6-24 – JLG Lift – 3120794...

  • Page 149: Recoil Spring Assembly

    RECOIL SPRING FORCE, IF NOT RELIEVED, CAN RESULT IN PER- SONAL INJURY OR DEATH. RELIEVE SP RING FORCE BEFORE REMOVING THREADED RETAINER, PERFORMING REPAIRS ON RECOIL SPRING HOUS- ING, OR REMOVING RECOIL SPRING. MAXIMUM RECOIL SPRING PRESSURE IS 3000 PSI (20,700 KPA). 3120794 – JLG Lift – 6-25...
  • Page 150 10. Apply a rust inhibitor to the threads of rod (12). Install the washer and nut (8). Install nut (7). Tighten nut (7) to a torque of 350 ± 37 ft. lbs. (470 ±50 Nm). 6-26 – JLG Lift – 3120794...

  • Page 151: Track Adjuster

    4. Remove seal (7) from cylinder (5). 2. Remove the track adjuster. 5. Remove two o-ring seals (8) from piston (6). 6. Remove two rings (9) and remove two rings (10) from piston (6). 3120794 – JLG Lift – 6-27...

  • Page 152: Track Adjuster

    SECTION 6 - UNDERCARRIAGE PRIOR TO S/N 0300070975 Figure 6-10. Track Adjuster 6-28 – JLG Lift – 3120794...

  • Page 153: Assembly

    3. Apply Molybdenum Grease in the groove for lip seal (7). Use tooling (A) to install lip seal (7). Install lip seal (7) until the seal is 0.02 ± 0.02 inch (0.5 ± 0.5 3120794 – JLG Lift – 6-29...

  • Page 154: Installation

    Spring - Install" in this manual. links for the removal of the sprocket. 1. Lift the side of the machine. Install tooling (A) under the frame, as shown. 6-30 – JLG Lift – 3120794...

  • Page 155: Final Drive Sprocket

    1. Thoroughly Clean the mating surfaces of the frame. sprocket and final drive prior to installation of the sprocket. 5. Connect the track assembly. Refer to Disassembly and Assembly, "Track - Connect" in this manual. 3120794 – JLG Lift – 6-31...

  • Page 156: Removal

    Be prepared to collect the fluid with suitable contain- ers before opening any compartment or disassem- bling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 6-32 – JLG Lift – 3120794...

  • Page 157: Travel Motor

    SECTION 6 - UNDERCARRIAGE PRIOR TO S/N 0300070975 Figure 6-11. Travel Motor 3120794 – JLG Lift – 6-33...

  • Page 158: Travel Brake Valve

    (3). Carefully pull travel motor (4) from the machine. The weight of the travel motor is approximately 110 lb (50 kg). 5. Remove the O-ring seal from the body of the travel motor. 6-34 – JLG Lift – 3120794...

  • Page 159: Travel Brake Valve

    Tighten brake valve (7) to a torque of 175 ± 15 ft.lb. (240 ± 20 Nm). 4. Install two check valves (6) in travel brake valves (2). Tighten two check valves (6) to a torque of 110 ± 9 lb ft (150 ± 12 Nm). 3120794 – JLG Lift – 6-35...

  • Page 160: Installation Procedure

    8. Install the travel brake valve. Refer to Disassembly and Assembly, "Travel Brake Valve - Remove and 7. Fill the hydraulic oil tank with hydraulic oil to the cor- Install" in this manual. rect level. 6-36 – JLG Lift – 3120794...

  • Page 161: Travel Motor

    3. Use Tooling (A) to remove swash plate (4). Remove piston rod (5). 9S-9152 Pulling Attachment Start by removing the travel motor. Refer to Disassembly and Assembly, "Travel Motor - Remove" in this manual. 3120794 – JLG Lift – 6-37...

  • Page 162: Assembly

    6. Remove four bolts (8). Remove block assembly (9) from motor housing (2). 9. Remove cradles (13) from motor housing (2). Assembly Table 6-16. Travel Motor Required Tools - Assembly Tool Part # Description Qty. 154-9327 Pliers 6-38 – JLG Lift – 3120794...
  • Page 163 6. Install shaft (6) in motor housing (2). 3. Install pilot valve (10) on block assembly (9). 7. Use tooling (A) to install swash plate (4) in motor housing (2). Install piston rod (5). 3120794 – JLG Lift – 6-39...

  • Page 164: Installation

    Apply clean hydraulic oil to the O-ring seal. 4. Fasten Tooling (A) and a suitable lifting device to travel motor (4). Carefully position the travel motor on Tooling (B). Slide the travel motor into the final drive. 6-40 – JLG Lift – 3120794...

  • Page 165: Final Drive

    REMOVE THE TILLER CAP ONLY WHEN THE ENGINE IS STOPPED AND THE FILLER CAP IS COOL ENOUGH TO TOUCH. 1. Release the hydraulic system pressure. Refer to Dis- assembly and Assembly, Hydraulic System Pressure - Release" in this manual. 3120794 – JLG Lift – 6-41...

  • Page 166: Disassembly

    990 lb (450 kg). 11. Remove two forcing bolts (10) from the undercar- riage frame. 12. Remove the travel motor from the final drive. Refer to Disassembly and Assembly, "Travel Motor - Remove" in this manual. 6-42 – JLG Lift – 3120794...

  • Page 167: Final Drive

    SECTION 6 - UNDERCARRIAGE PRIOR TO S/N 0300070975 Figure 6-12. Final Drive 3120794 – JLG Lift – 6-43...
  • Page 168 7. Use suitable tooling in order to apply air pressure in the oil passage in order to partially remove piston (5). 4. Remove the bolts (2) and use the lifting strap in order to remove the travel motor from the final drive. 6-44 – JLG Lift – 3120794...
  • Page 169 15. Use lifting straps and tooling (D) in order to lift the final drive off tooling (A). 16. Carefully rotate the final drive so that the planetary cover is up. 17. Fasten the final drive to tooling (A). 3120794 – JLG Lift – 6-45...
  • Page 170 23. Repeat Step 21 and Step 22. 20. Remove the first stage of planetary gear assembly (16) from the final drive. 24. Use snap ring pliers to remove snap ring (20) from sun gear (21). 6-46 – JLG Lift – 3120794...
  • Page 171 32. Use snap ring pliers to remove snap ring (28) that Remove the disk from planetary carrier (25). secures planetary gear (29) to spindle (30). 33. Use tooling (E) to remove planetary gear (29) from spindle (30). 3120794 – JLG Lift – 6-47...
  • Page 172 (31). 40. Install the socket from tooling (F) over spindle nut (34), as shown. NOTE: The "notches" of the socket from Tooling (F) fit over the "ears" of spindle nut (34). 6-48 – JLG Lift – 3120794...
  • Page 173 46. Remove the second half of Duo-cone seal kit (37) from spindle (30). 43. Remove ring gear (36) from spindle (30). 47. Use tooling (G) to shape spindle threads (39), if the threads appear damaged. 3120794 – JLG Lift – 6-49...

  • Page 174: Assembly

    (33). The mark is used in Step 18. 6V-3965 Nipple Assembly 6V-4143 Coupler Assembly 6V-3014 Hose Assembly 8T-0855 Pressure Gauge 1U-5230 Hand Pump 5S-2403 Fitting 1S-8937 Valve 2D-7325 6V-3966 Nipple Assembly 6-50 – JLG Lift – 3120794...
  • Page 175 Use caution. The spindle nut threads are easy to cross thread. 11. Install spindle nut (34) onto spindle (30). 7. Install spindle (30) onto tooling (A). 12. Install the socket from tooling (F) on spindle nut (34). 3120794 – JLG Lift – 6-51...
  • Page 176 If the distance is less than 0.4 inch (10 mm), use a new spindle nut (34). 22. If necessary, heat gears (29) to 275° F (135° C). Install gears (29) on spindle (30). Use snap ring pli- 6-52 – JLG Lift – 3120794...
  • Page 177 25. if necessary, heat planetary gears (24) to 275° F (135° C). Install three planetary gears (18) on the (135° C). Install the disks and planetary gears (24) planetary carrier. Use snap ring pliers to install three onto the planetary carrier. 3120794 – JLG Lift – 6-53...
  • Page 178 Tighten twelve bolts (13) to a torque of 25 ± 6Nm(18 ± 4 ft.lbs.). 33. Use lifting straps and Tooling (D) in order to lift the final drive off tooling (A). 34. Carefully rotate the final drive so that the brake is up. 6-54 – JLG Lift – 3120794...
  • Page 179 Alternate between disks and plates. End the installation with a disk. 41. Install shaft link (6). NOTE: Lubricate the seals before installing the piston. Install the piston carefully in order to prevent dam- age to the seals. 3120794 – JLG Lift – 6-55...

  • Page 180: Installation

    2. Install the travel motor on the final drive. Refer to Dis- assembly and Assembly, "Travel Motor -Install" in this manual. 45. Install Tooling (J) into the oil supply port (42). 6-56 – JLG Lift – 3120794...

  • Page 181: Final Drive Oil - Change

    (3). Install new O-ring seals in the ends of the level plug, and/or the O-ring seals. hose assembly (4) and hose assembly (5). Install a 4. Install drain plug (1). new O-ring seal in elbow (6). 3120794 – JLG Lift – 6-57...

  • Page 182: Final Drive Oil Level Check

    7. Repeat the procedure for the other final drive. 10. Stop the engine. Check the oil level. 11. Check the drained oil for metal chips or for particles. If there are any chips or particles, consult your JLG 6.13 SWIVEL Distributor dealer.
  • Page 183 Put plugs in the ends of the hose assemblies in order to keep dirt and debris out of the hydraulic system. 4. Loosen and remove hose clamp (4) from the swivel joint. 3120794 – JLG Lift – 6-59...

  • Page 184: Swivel Assembly

    SECTION 6 - UNDERCARRIAGE PRIOR TO S/N 0300070975 Figure 6-14. Swivel Assembly 6-60 – JLG Lift – 3120794...

  • Page 185: Disassembly

    0-ring seals (6). 4. Install outside housing (8) over rotor (9). Install Dispose of all fluids according to local regulations retainer (7), two bolts (5) and the washers that hold and mandates. the retainer. 3120794 – JLG Lift – 6-61...

  • Page 186: Towing Information

    Attach the cable to the towing eye on the front of the machine if you are towing the machine forward. Attach the cable to the drawbar pin on the rear of the machine if you are towing the machine backward. 6-62 – JLG Lift – 3120794...

  • Page 187: Final Drive Sun Gear Removal

    ESCAPING. WATCH THE TRACK OR TRACK ADJUSTMENT CYLIN- DER TO SEE IF THE TRACK IS BEING LOOSENED. Do not tow a loaded machine. Consult your JLG Distributor for the equipment that is nec- LOOSEN THE RELIEF VALVE ONE TURN ONLY. essary for towing a disabled machine.

  • Page 188: Measuring Track Tension

    3. Listen for any abnormal noises while you are moving 3. Check the amount of sag. Adjust the track, as slowly in an open area. needed. 4. If abnormal wear exists or abnormal noises or leaks are found, consult your JLG Distributor. 6-64 – JLG Lift – 3120794...

  • Page 189: Section 7. Undercarriage S/N 0300070975 To Present

    Level, check, and fill (if needed) the oil content. Apply Never Seez to motor mount area. Re-align the motor in the nylon straps as needed & assemble to carbody. Secure 3120794 – JLG Lift –...

  • Page 190: Chassis Service Notes - Sheet 1 Of 2

    SECTION 7 - UNDERCARRIAGE S/N 0300070975 TO PRESENT Figure 7-1. Chassis Service Notes - Sheet 1 of 2 – JLG Lift – 3120794...

  • Page 191: Chassis Service Notes - Sheet 2 Of 2

    Torque to 230 ft-lbs, +15 -0 (322 Nm, +21 -0) Torque to 93 ft-lbs, +10 -0 (130 Nm, +14 -0) Torque to 53 ft-lbs, +5 -0 (74 Nm, +7 -0) Figure 7-2. Chassis Service Notes - Sheet 2 of 2 3120794 – JLG Lift –...
  • Page 192 22. Repeat process to opposite side: 23. Assemble fittings for hoses to both drive motors fin- ger tight until correct positioning is established. – JLG Lift – 3120794...
  • Page 193 SECTION 7 - UNDERCARRIAGE S/N 0300070975 TO PRESENT 28. Repeat hose routing process on LH side frame with correct hoses to drive motor. 3120794 – JLG Lift –...

  • Page 194: Hose Routing - Sheet 1 Of 2

    SECTION 7 - UNDERCARRIAGE S/N 0300070975 TO PRESENT Figure 7-3. Hose Routing - Sheet 1 of 2 – JLG Lift – 3120794...

  • Page 195: Hose Routing - Sheet 2 Of 2

    SECTION 7 - UNDERCARRIAGE S/N 0300070975 TO PRESENT Figure 7-4. Hose Routing - Sheet 2 of 2 3120794 – JLG Lift –...
  • Page 196 Route and connect hoses to fittings. Torque hoses according to chart specifications. 34. Move to drive motors. Starting with brake hose for easy access, torque (3) small hoses on both sides of – JLG Lift – 3120794...
  • Page 197 Insert special alignment pin through hole to temporarily hold track together. 46. Position wood blocks to frame rail for tracks to lay onto when connecting track ends to get proper extension for connecting end links. 3120794 – JLG Lift –...

  • Page 198: Track Tensioning

    & carrier roller with "level" and gage (0.781). Remove special fitting. 53. Repeat process on opposite side: 7.2 TRACK TENSIONING 1. In special grease fitting, pump in grease to add ten- sion to track. Check for proper adjustment between 7-10 – JLG Lift – 3120794...

  • Page 199: Rubber Track Pad Installation

    2. Apply Loctite #242 to the steel retaining plate bolts. Install the bolts and flat washers to the end of the rubber pad. 3. Torque the bolts to 70 ft-lbs. (97 Nm). 3120794 – JLG Lift – 7-11...
  • Page 200 SECTION 7 - UNDERCARRIAGE S/N 0300070975 TO PRESENT This page left blank intentionally. 7-12 – JLG Lift – 3120794...

  • Page 201: Section 8. Schematics

    Illustrated Parts Manual for hydraulic diagrams of the and electrical systems. various circuits. The first rule for troubleshooting any circuit that is hydrau- lically operated and electrically controlled is to determine 3120794 – JLG Lift –...

  • Page 202: Electrical Components Installation - Sheet 1

    SECTION 8 - SCHEMATICS Figure 8-1. Electrical Components Installation - Sheet 1 – JLG Lift – 3120794...

  • Page 203: Electrical Components Installation - Sheet 2

    SECTION 8 - SCHEMATICS Figure 8-2. Electrical Components Installation - Sheet 2 3120794 – JLG Lift –...

  • Page 204: Electrical Schematic - Deutz Or Isuzu - Sheet 1

    SECTION 8 - SCHEMATICS Figure 8-3. Electrical Schematic - Deutz or Isuzu - Sheet 1 – JLG Lift – 3120794...

  • Page 205: Electrical Schematic - Deutz Or Isuzu - Sheet 2

    SECTION 8 - SCHEMATICS 1870055 D Figure 8-4. Electrical Schematic - Deutz or Isuzu - Sheet 2 3120794 – JLG Lift –...

  • Page 206: Hydraulic Schematic - Sheet 1 Of 4

    SECTION 8 - SCHEMATICS Figure 8-5. Hydraulic Schematic - Sheet 1 of 4 – JLG Lift – 3120794...

  • Page 207: Hydraulic Schematic - Sheet 2 Of 4

    SECTION 8 - SCHEMATICS 2792323C Figure 8-6. Hydraulic Schematic - Sheet 2 of 4 3120794 – JLG Lift –...

  • Page 208: Hydraulic Schematic - Sheet 3 Of 4

    SECTION 8 - SCHEMATICS Figure 8-7. Hydraulic Schematic - Sheet 3 of 4 – JLG Lift – 3120794...

  • Page 209: Hydraulic Schematic - Sheet 4 Of 4

    SECTION 8 - SCHEMATICS 2792323 C Figure 8-8. Hydraulic Schematic - Sheet 4 of 4 3120794 – JLG Lift –...

  • Page 210: Hydraulic Schematic W/Gft24 Drive - Sheet 1 Of 4

    SECTION 8 - SCHEMATICS Figure 8-9. Hydraulic Schematic w/GFT24 Drive - Sheet 1 of 4 8-10 – JLG Lift – 3120794...

  • Page 211: Hydraulic Schematic W/Gft24 Drive - Sheet 2 Of 4

    SECTION 8 - SCHEMATICS 2792550 A Figure 8-10. Hydraulic Schematic w/GFT24 Drive - Sheet 2 of 4 3120794 – JLG Lift – 8-11...

  • Page 212: Hydraulic Schematic W/Gft24 Drive - Sheet 3 Of 4

    SECTION 8 - SCHEMATICS Figure 8-11. Hydraulic Schematic w/GFT24 Drive - Sheet 3 of 4 8-12 – JLG Lift – 3120794...

  • Page 213: Hydraulic Schematic W/Gft24 Drive - Sheet 4 Of 4

    SECTION 8 - SCHEMATICS 2792550 A Figure 8-12. Hydraulic Schematic w/GFT24 Drive - Sheet 4 of 4 3120794 – JLG Lift – 8-13...
  • Page 214 SECTION 8 - SCHEMATICS This page left blank intentionally. 8-14 – JLG Lift – 3120794...
  • Page 216 +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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