JLG 600A Service And Maintenance Manual
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JLG 600A Service And Maintenance Manual

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Service and Maintenance Manual
Model
600A
600AJ
S/N 0300080000 to
0300177361,
S/N B300000100 to Present
P/N - 3121201
October 23, 2017
AS/NZS

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  • Page 1 Service and Maintenance Manual Model 600A 600AJ S/N 0300080000 to 0300177361, S/N B300000100 to Present P/N - 3121201 October 23, 2017 AS/NZS...
  • Page 2 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 3: General

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A possible injury to themselves or others, or damage to the...
  • Page 4 INTRODUCTION REVISON LOG Original Issue - October 15, 2004 Revised - June 10, 2005 Revised - October 6, 2005 Revised - March 2, 2006 Revised - December 4, 2007 Revised - April 1, 2008 Revised - December 10, 2012 - October 23. 2017 Revised 3121201...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A-1 Hydraulic System Safety .
  • Page 6 Do NOT Do the Following When Welding on JLG Equipment....... .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.10 Drive Motor (USA Built Machine and China Built Machine, SN 0300098766 to Present and SN B300000100 to Present) ............... . . 3-38 Description .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 3.22 Spark Arrester Cleaning Instructions ..............3-141 3.23 Dual Fuel System (Gas Engine Only) .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 4 - BOOM & PLATFORM Platform ................... 4-1 Platform Valve Removal .
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. 4.14 Boom Valve Adjustment ................4-51 Tower Boom .
  • Page 11 To Connect the JLG Control System Analyzer........
  • Page 12 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Applying Silicone Dielectric Compound to Electrical Connections ........7-3 Installation of Dielectric Grease .
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram ............. 1-10 1-2.
  • Page 14 Swing Bearing Removal - 600A........
  • Page 15 Powertrack Installation Main Boom - China Build Machine (600A) ....... .
  • Page 16 Cylinder Head Seal Installation - 600A ........
  • Page 17 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-45. Seating the Tapered Bearing ............... 5-26 5-46.
  • Page 18 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-102. Installation of Head Seal Kit ............... . . 5-49 5-103.
  • Page 19 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-156. Main Valve Torque (SN 0300087000 through 0300177361, SN B300000100 through B300001392) ............. . 5-88 5-157.
  • Page 20 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-13. Connector Installation ................7-10 7-14.
  • Page 21 Major Component Weights - 600A ........
  • Page 22 600A Machine Configuration Programming Settings........
  • Page 23 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 24: Specifications

    Maximum Tire Load: 11,500 lbs. (5216 kg) 75 psi (5.3 kg/cm 600AJ Ground Bearing Pressure 94 psi (6.6 kg/cm 600A - narrow chassis 77 psi (5.4 kg/cm 600A 94 psi (6.6 kg/cm 600AJ - narrow chassis 75 psi (5.3 kg/cm...

  • Page 25: Capacities

    SECTION 1 - SPECIFICATIONS 1.2 CAPACITIES 1.3 COMPONENT DATA Engine Data Table 1-3. Capacities Fuel Tank 30 U.S. Gallons (113.6 L) Table 1-4. Continental TMD27 Specifications Hydraulic Oil Tank 30.6 Gallons (115.8 L) with Fuel Diesel 10% air space Oil Capacity Hydraulic System (Including Tank) 36.72 Gallons (139 L) w/Filter...
  • Page 26 SECTION 1 - SPECIFICATIONS Table 1-6. Ford LRG-425 Specifications Table 1-8. Deutz D2011L04 Specifications Fuel Diesel Fuel Gasoline Oil Capacity Crankcase Capacity 4.5 Quarts (4.25 L) w/Filter Cooling System 5 Quarts (4.5 L) Crankcase 11 Quarts (10.5 L) w/Filter Idle RPM 1000 Total Capacity 16 Quarts (15 L)

  • Page 27: Tires

    8 ft. 3.75 in. (2.53 m) No. of Cylinders Machine Length (Stowed) Gasoline 83 hp @ 3000 rpm 600A Over Drive Axle 26 ft. 5 in. (8.05 m) 75 hp @ 3000 rpm 600AJ Over Drive Axle 28 ft. 11.4375 in. (8.82 m) Bore 4.0 in.

  • Page 28: Pumps

    SECTION 1 - SPECIFICATIONS Pumps 1.4 TORQUE REQUIREMENTS Table 1-15. Pumps Table 1-17. Torque Requirements Hydraulic Gear Pump Interval Description Torque Value (Dry) Output @ 1800 RPM 7.9 GPM (29.90 lpm) Hours Displacement 1.02 cu. in. (16 cm Bearing To Chassis 190 ft.

  • Page 29: Lubrication

    0.85 Kg/l SAE viscosity index of 152. Density@ 60°F 0.03 lb/in³ NOTE: When temperatures remain below 20° F (-7 degrees C), JLG Table 1-21. Exxon Univis HVI 26 Specs Industries recommends the use of Mobil DTE 10. Specific Gravity 32.1...

  • Page 30: Pressure Settings

    Jib Boom Down 1200 PSI (83 Bar) ISO Viscosity Grade 1.7 CYLINDER SPECIFICATIONS Pour Point -49°F (-45°C) Flash Point, Min. 500°F (260°C) Table 1-27. Cylinder Specifications - 600A Viscosity at 40° C 48.8 cSt BORE STROKE ROD DIA. DESCRIPTON in. (mm) in.

  • Page 31: Major Component Weights

    SECTION 1 - SPECIFICATIONS 1.8 MAJOR COMPONENT WEIGHTS Table 1-28. Cylinder Specifications - 600AJ Table 1-29. Major Component Weights - 600A DESRIPTON BORE STROKE ROD DIA. Tower Lift 34.0625 (165.1) (865.2) (63.5) Platform Control Console Tower Telescope 63.75 (76.2) (1619.3) (50.8)

  • Page 32: Critical Stability Weights

    TERWEIGHT, ENGINE & PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Main Boom ( 1685 Includes Lift Cyl., Rotator, and Support Upright including Master Cylinder Table 1-31. Critical Stability Weights - 600A Upright Level Cylinder Tower Boom Complete 1218 Tire and Wheel (Ballasted Only) Size (14-17.5)
  • Page 33 SECTION 1 - SPECIFICATIONS Figure 1-1. Maintenance and Lubrication Diagram 1-10 3121201...

  • Page 34: Operator Maintenance

    SECTION 1 - SPECIFICATIONS 1.10 OPERATOR MAINTENANCE 2. Wheel Bearings NOTE: The following numbers correspond to those in Figure 1-1., Maintenance and Lubrication Diagram. Table 1-33. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C).
  • Page 35 SECTION 1 - SPECIFICATIONS 4. Wheel Drive Hub 7. Hydraulic Tank NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION Lube Point(s) - Level/Fill Plug Lube Point(s) - Fill Cap Capacity - 17 oz. (1/2 Full) Capacity - 31 gal. (117.3 L) Tank; 37.2 gal. (140.8 L) Lube - EPGL System Interval - Check level every 3 months or 150 hrs of oper-...
  • Page 36 Interval - 3 Months or 150 hours of operation Lube Point(s) - Fill Cap/Spin-on Element Comments - Check level daily/Change in accordance (JLG P/N 7027965) with engine manual. Capacity - 4.5 qt. (4.25 L) w/filter 12. Oil Change w/Filter - Deutz...
  • Page 37 SECTION 1 - SPECIFICATIONS 17. Fuel Filter - Deutz 21. Electronic Pressure Regulator (LP only) Interval - 3 Months or 150 hours of operation Comments - Drain oil build up. Refer to Draining Oil Lube Point(s) - Replaceable Element Build Up from the Propane Regulator (Prior to SN Interval - Every Year or 600 hours of operation 0300132529).

  • Page 38: Draining Oil Build Up From The Propane Regulator (Prior To Sn 0300132529)

    SECTION 1 - SPECIFICATIONS 1.11 DRAINING OIL BUILD UP FROM THE PROPANE 6. Remove the retainer clip for the LPG fuel temperature sensor and remove the sensor from the regulator body. REGULATOR (PRIOR TO SN 0300132529) During the course of normal operation oils may build inside the primary and secondary chambers of the propane pressure regulator.

  • Page 39: Propane Fuel Filter Replacement

    SECTION 1 - SPECIFICATIONS 1.12 PROPANE FUEL FILTER REPLACEMENT 1. Electric Lock Off Solenoid 8. Fuel Outlet 2. Mounting Plate 9. O-ring 3. Housing Seal 10. Filter 4. Filter Magnet 11. Fuel Inlet 5. Filter Housing 12. Retaining Bolt 6. Seal 13.

  • Page 40: Propane Fuel System Pressure Relief

    SECTION 1 - SPECIFICATIONS 1.13 PROPANE FUEL SYSTEM PRESSURE RELIEF 1.14 SERIAL NUMBER LOCATIONS A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 machine serial number is stamped on the left side of the frame.
  • Page 41 SECTION 1 - SPECIFICATIONS 1-18 3121201...
  • Page 42 SECTION 1 - SPECIFICATIONS 3121201 1-19...
  • Page 43 SECTION 1 - SPECIFICATIONS 1-20 3121201...
  • Page 44 SECTION 1 - SPECIFICATIONS 3121201 1-21...
  • Page 45 SECTION 1 - SPECIFICATIONS 1-22 3121201...
  • Page 46 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 47: General

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

  • Page 48: Service And Guidelines

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

  • Page 49: Bearings

    SECTION 2 - GENERAL Bearings 2. Disassemble and reassemble parts on clean work sur- face. Clean all metal parts with non-flammable cleaning 1. When a bearing is removed, cover it to keep out dirt and solvent. Lubricate components, as required, to aid abrasives.

  • Page 50: Hydraulic Oil

    2. JLG recommends Mobilfluid 424 hydraulic oil, which has the service container. Always clean the mesh element of an SAE viscosity of 10W-30 and a viscosity index of 152.

  • Page 51: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST Table 2-2. Cylinder Drift Max. Acceptable Drift Theory Cylinder Bore Diameter in 10 Minutes When a hydraulic cylinder is supporting a load, cylinder drift inches inches may occur as a result of any of the circumstances below: 76.2 0.026 0.66...

  • Page 52: Pins And Composite Bearing Repair Guidelines

    2. Filament wound bearings should be replaced if any of • Ground only to structure being welded. the following is observed: Do NOT Do the Following When Welding on JLG a. Frayed or separated fibers on the liner surface. Equipment b.
  • Page 53 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Boom Assembly Boom Weldments 1,2,4 1,2,4 Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12 Pivot Pins and Pin Retainers Sheaves, Sheave Pins Bearings Wear Pads Covers or Shields...
  • Page 54 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA Every 2 (Yearly) or Frequent Years Inspection Inspection Functions/Controls Platform Controls Ground Controls Function Control Locks, Guards, or Detents Footswitch Emergency Stop Switches (Ground & Platform) Function Limit or Cutout Switch Systems Drive Brakes Swing Brakes...
  • Page 55 21, 22 Paint and Appearance Stamp Inspection Date on Frame Notify JLG of Machine Ownership Footnotes: 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 56 SECTION 2 - GENERAL 4150548 E Figure 2-1. Engine Operating Temperature Specifications - Deutz 2-10 3121201...
  • Page 57 SECTION 2 - GENERAL 4150548 E Figure 2-2. Engine Operating Temperature Specifications - Ford 3121201 2-11...
  • Page 58 SECTION 2 - GENERAL 4150548 E Figure 2-3. Engine Operating Temperature Specifications - Caterpillar 2-12 3121201...
  • Page 59 SECTION 2 - GENERAL 4150548 E Figure 2-4. Engine Operating Temperature Specifications - GM 3121201 2-13...
  • Page 60 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 61: Chassis & Turntable

    The air pressure for pneumatic tires must be equal to the air on the same axle should be the same. pressure that is stenciled on the side of the JLG product or rim Wheel Replacement decal for safe and proper operational characteristics.

  • Page 62: Lockout Cylinder Bleeding

    SECTION 3 - CHASSIS & TURNTABLE 2. Tighten nuts in the following sequence. 1. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. Table 3-1. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage...
  • Page 63 SECTION 3 - CHASSIS & TURNTABLE N600 A/AJ (7 ft/2.1 m Wide Machine) 600 A/AJ (8 ft/2.4 m Wide Machine) 0273954 E 0274234 B 0274922 B 0274047 B 0274256 B Figure 3-1. 2WD Front Axle And Steering Installations 3121201...
  • Page 64 SECTION 3 - CHASSIS & TURNTABLE 1. Compound Locking 22. Bolt 43. Bearing Cup 64. Steer Cylinder Assembly 2. Wide Machine with Tow Package 23. Bolt 44. Screw 65. Hub 3. Plug 24. Bolt 45. Hub cap 66. Wheel Stud 4.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 0273954 E 0274234 B 1001113537 D Figure 3-3. 4WD Front Axle And Steering Installations 3121201...
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 1. Axle Weldment 11. Spacer 21. Pin 2. Bolt 12. Bolt 22. Kingpin 3. Bolt 13. Flatwasher 23. Keeper Pin 4. Bushing 14. Bolt 24. Keeper Pin 5. Pivot Pin 15. Bolt 25. Tie-Rod 6.
  • Page 67 SECTION 3 - CHASSIS & TURNTABLE 0274062 I 0274121 D 1. Bolt 10. Thrust Washer 19. Thrust Washer 2. Keeper 11. Spindle (Left Side) 20. Bushing 3. Pin 12. Bushing 21. Bushing 4. Steer Cylinder 13. Pin 22. Tie-Rod 5. Pin 14.

  • Page 68: Oscillating Axle Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE 3.3 OSCILLATING AXLE LOCKOUT TEST ground, it may be necessary activate DRIVE to release cylinders. 15. If lockout cylinders do not function properly, have trained personnel correct the malfunction prior to any LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- further operation.

  • Page 69: Wheel Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE 3.5 WHEEL DRIVE ASSEMBLY NOTE: The torque hub and drive motor assembly weighs approxi- mately 270 lbs. (122 kg). Removal 4. Use a supporting device capable of handling the weight of the torque hub and drive motor and unbolt the NOTE: The drive motor can be removed through the axle flange as torque hub from the frame.

  • Page 70: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DRIVE HUB THE BRAKE TEST Reference: Sample Model 7HBE01F0B30057. The underlined letter is the brake option. Options are A, B, C, D, E or X. ROLL, LEAK AND BRAKE TESTING Torque-Hub units should always be roll and leak tested before A Input Brake 2,200 in.

  • Page 71: Main Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Disassembly 6. Remove the Input carrier subassembly (3). 7. Remove the input shaft (9). 1. Perform roll check, leak check and brake check if appli- 8. Remove the second stage sun gear (11). cable prior to disassembling the unit.
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE 14. Using a 1/8 in. (3.175 mm) diameter punch, drive the roll pin (4G) out of the planet shaft (4E). NOTE: The roll pins (4G) should not be reused when reassembling the unit. 15. Slide the planet gear subassembly (4) out of the spindle (1A) being careful to not drop the needle bearings (4C) in the process.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE 16. Remove 4 Thrust Washer (4B), 28 needle rollers (4C) and the thrust spacer (4D) from the second stage planet gear (4F). 17. Repeat Steps 12 though 16 for the remaining two planet gears (4F). 18.

  • Page 74: Input Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Disassembly 3A. Carrier 3F. Planet Gear 3B. Thrust Washer 4G. Roll Pin 3E. Planet Shaft Figure 3-10. Input Carrier 3121201 3-15...
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE 1. Using a 1/8 in. (3.175 mm) diameter punch, drive the roll pin (4G) into the planet shaft (3E) until it bottoms against the carrier (3A). 2. Using a soft face hammer, tap the planet shaft (3E) out of the carrier (3A).

  • Page 76: Hub-Spindle Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Spindle Disassembly 1A. Barrel 1F. Bearing Nut 1B. Seal 1G. Setscrew 1C. Bearing Cone 1H. Stud 1D. Hub 1Q. Boot Seal Figure 3-12. Hub Spindle 1. Place unit on bench with spindle (1A) end down. 6.

  • Page 77: Spindle-Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Spindle-Brake Disassembly 1A. Spindle 8C. Retaining Ring 8H. Backup Ring 12. Plastic Plug 7. Coupling Subassembly 8D. O-Ring 8J. Rotor 21. Pipe Plug 8A. Piston 8E. Backup Ring 8K. Stator 22. Flat Head Capscrew 8B.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE 1. Compress the compression springs (8I) by installing two 1/4-20 x 5/8 in. flat head capscrews (22) through pres- sure plate (8B) and into piston (8A) and tightening incre- mentally until spring force has been taken off of the retaining ring (8C).

  • Page 79: Cover Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Cover Disassembly 2. Thrust Washer 6D. Disengage Rod 6A. Cover 6E . O-Ring 6B. Disengage Cap 6F. Pipe Plug 6C. Bolt 17. O-Ring Figure 3-15. Cover 1. Remove O-ring (17) from groove in cover (6A). 5.

  • Page 80: Input Carrier Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Input Carrier Sub-Assembly 4. Repeat Step 2 to put in second roll of needle rollers (4C). 5. Apply grease to hold two thrust washers (4B) together 1. Apply a liberal coat of grease to the bore of one Input and onto output planet gear (4F) counterbore.

  • Page 81: Hub-Spindle Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Spindle Sub-Assembly planet shaft that does not have the roll pin hole should be inserted into the spindle FIRST. NOTE: Spray a light film of oil on all component parts during 13. Now insert planet shaft (4E) through the first set of assembly.

  • Page 82: Integral Brake Check

    SECTION 3 - CHASSIS & TURNTABLE 8. With the modified spline end facing up, place the Integral Brake Check output gear (11) into mesh with the planet gears from the hub-spindle sub-assembly. 1. Using appropriate fittings, connect hydraulic line from hand pump to brake port.
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE DETAIL B SCALE 2.000 SEE DETAIL B 8F 8H 1C 1D 1A 1B 1Q SECTION A-A SCALE 1.400 1A. Spindle 1M. Thrust Washer 4C. Needle Bearing 6C. Bolt 8D. O-Ring 11. Sun Gear 1B. Lip Seal 1Q.
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE Figure 3-17. Bearing Cup Pressing Tool Figure 3-18. Seal Pressing Tool 3121201 3-25...
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE Figure 3-19. Bearing Cup Pressing Tool Figure 3-20. Drift Pin for Lining Up Thrust Washers with Output Planet Gear 3-26 3121201...

  • Page 86: Drive Brake

    SECTION 3 - CHASSIS & TURNTABLE 3.7 DRIVE BRAKE Assembly Disassembly LUBRICATE ALL RUBBER COMPONENTS FROM REPAIR KIT WITH CLEAN TYPE 1. Remove pressure plate (3) from cover plate (16) by FLUID USED IN THE SYSTEM. removing capscrews (1) and washers (2). 1.
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE 1. Capscrew 8. O-ring 15. Dowel Pin 2. Washer 9. Backup Ring 16. Cover Plate 3. Pressure Plate 10. Shaft 17. Oil Seal 4. Case Seal 11. Stator Disc 18. Bearing 5. O-ring 12. Rotor Disc 19.

  • Page 88: Bleeding

    SECTION 3 - CHASSIS & TURNTABLE Bleeding 3. Apply sufficient pressure to release brake and check for proper operation in system. 1. Install brake in system and connect pressure lines. 2. Bleed pressure release section of brake by pressurizing side inlet port and allowing air to escape from top port. Pressure should not exceed 100 psi (6.9 bar) during bleeding.

  • Page 89: Drive Motor - 4Wd (Sn 0300087000 Through 0300098765)

    SECTION 3 - CHASSIS & TURNTABLE 3.8 DRIVE MOTOR - 4WD (SN 0300087000 4. Bearing set/miscellaneous parts . THROUGH 0300098765) Spare Parts Kits 1. Sealing kit, existing spare parts: shaft sealing ring, 6 dif- ferent O-rings and a circlip (sealing mat: perbunan). 5.

  • Page 90: Replacing The Drive Shaft Seal

    SECTION 3 - CHASSIS & TURNTABLE 8. Spare parts kit DFR pilot valve. 4. Assemble the sealing ring. The fitting tool will hold the sealing ring in the correct position in the pump housing. Replacing the Drive Shaft Seal 1. Remove the snap ring. 5.

  • Page 91: Disassembly And Assembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly and Assembly 5. Disassemble the taper roller bearing. 1. Disassemble the pilot valve. 6. Remove the adjustment shim. 2. Mark the position of the port plate and remove the socket screw from the port plate. 7.
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE 9. Turn in the stopper max flow to get swivel angle zero. 13. Disassemble the plug. 14. Disassemble the control piston while moving the swash 10. Disassemble the rotary group in horizontal position. plate. 11.
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE 17. Remove the spring. 21. Disassemble the sealing ring. 18. Remove both bearing shells. 22. The external front bearing ring is pulled out of the pump housing. 19. Remove the drive shaft. 23. Remove the O-ring (Lifting of the valve plate is not shown).

  • Page 94: Assembly Notes

    SECTION 3 - CHASSIS & TURNTABLE 24. A usual commercial bearing puller is used to Assembly Notes disassemble the external bearing ring of the taper roller bearing inside the port plate. Take care not to damage 1. Measurement of the taper roller bearing pretension. the surface of the port plate.
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE Figure 3-22. Flow Control Pilot Valves 3-36 3121201...

  • Page 96: Taper Roller Bearing Initial Tension

    SECTION 3 - CHASSIS & TURNTABLE 4. Pumps counterclockwise driven must have a position of Testing and Setup the valve plate 4 degrees de-centered in ccw position. 1. DR: When pressure line is closed adjust the pressure of the controller (if it’s DFR design then open the adjust- able orifice and increase force of the spring - FR).

  • Page 97: Drive Motor - 2Wd (Sn 0300087000 Through 0300098765)

    SECTION 3 - CHASSIS & TURNTABLE 3.9 DRIVE MOTOR - 2WD (SN 0300087000 3.10 DRIVE MOTOR (USA BUILT MACHINE AND CHINA THROUGH 0300098765) BUILT MACHINE, SN 0300098766 TO PRESENT AND SN B300000100 TO PRESENT) Shaft Seal Replacement Description Lip type shaft seals are used an the drive motors. These seals can be replaced without major disassembly of the unit.

  • Page 98: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Disassembly NOTE: Removal of the endcap voids warranty. During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts will be lubricated during start-up. Replace all O-rings and gaskets. It is recommended that all O-rings be replaced.
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE 13. Using an 8 mm internal hex wrench, remove the 15. Remove the valve plate (25) and timing pin (26) from the endcapscrews (22). endcap. 14. Remove the endcap (23). Remove O-ring (24) from the NOTE: Each displacement has a unique valve plate.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE 19. Turn the housing on its side and remove the cylinder kit 20. Turn the housing over and remove the snap ring (32) assembly (31). Set the assembly aside, being careful not retaining the shaft seal and support washer. Remove the to scratch the running surface.
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE 21. Remove the inner snap ring (35) and the shaft / bearing 23. Turn housing over and remove the swashplate (39) by assembly. lifting on the end opposite the servo lever. 22. Remove the snap-ring (36) retaining the shaft front 24.

  • Page 102: Inspection

    SECTION 3 - CHASSIS & TURNTABLE 26. Remove pistons (44) and slipper retainer (45) from the Inspection cylinder block (46). After disassembly, wash all parts (including the end-cap and NOTE: The pistons are not selectively fitted, however units with housing) thoroughly with clean solvent and allow to air dry. high hourly usage may develop wear patterns.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE CYLINDER BLOCK tions shown in the drawing, provided resurfacing will not Measure the cylinder block height. Replace blocks worn reduce the block height below the minimum specification. beyond the minimum height specification. Inspect the run- Table 3-5, Cylinder Block Measurements.
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE SERVO PISTON AND MINIMUM ANGLE STOP Replace if necessary. Inspect the minimum angle stop, servo piston head, and servo piston ball-socket for damage or excessive wear. Replace swashplate if the difference in thickness from one side to the other exceeds specification.

  • Page 105: Assembly

    SECTION 3 - CHASSIS & TURNTABLE Assembly 3. Install the inner block spring washer (4), block spring (5), and outer washer (6) into the cylinder block. Using a 1. Install new O-ring (1) and piston seal (2) to the servo pis- press, compress the block spring enough to expose the ton (3).
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE 6. Install the journal bearings (13) into the housing seats. 8. Press front shaft bearing (15) onto shaft (16). Press Use assembly grease to keep the bearings seated during bearing onto shaft with lettering facing out. Lubricate assembly.
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE 10. Verify swashplate and bearings are properly seated. 12. Press the rear shaft bearing (22) into the endcap. Install Install the cylinder kit (19) onto the shaft. Install with the the bearing with letters facing out. Press until bearing slippers facing the swashplate.
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE 15. Install the endcap (25) onto the housing with the 17. Before installing the shaft seal, ensure the shaft turns endcapscrews (26). Check to ensure the endcap will smoothly with less than 120 in. lbs. (13.5 Nm) of force. If properly seat onto the housing without interference.
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE 19. Install remaining plugs and fittings to the housing. Refer 20. Install orifice poppet (30). to the Figure 3-42., Plugs and Fittings Installation for wrench sizes and installation torques. 11/16 in 1/4 in 5/16 in 27 ft.lbs.

  • Page 110: Initial Start-Up Procedures

    SECTION 3 - CHASSIS & TURNTABLE Initial Start-up Procedures 5. Install a 0-500 psi (0-35 bar) gauge in the charge pressure gauge port of the pump to monitor system Follow this procedure when starting-up a new motor or when pressure during start up. installing a motor that has been removed.

  • Page 111: Troubleshooting

    SECTION 3 - CHASSIS & TURNTABLE Troubleshooting Table 3-6. Excessive Noise and/or Vibration Item Description Action Check oil level in reservoir and oil Insufficient hydraulic fluid could lead to cavitation that would cause sys- Fill the reservoir to the proper level and ensure that oil supply to the motor supply to the motor.

  • Page 112: Shaft Seal Replacement

    SECTION 3 - CHASSIS & TURNTABLE Shaft Seal Replacement Speed Sensor Replacement REMOVAL REMOVAL 1. Disconnect the speed sensor electrical connector. 1. Remove the snap ring (1) retaining the shaft seal and 2. Using an 11/16 in. wrench, loosen the locknut. support washer.

  • Page 113: Loop Flushing Valve

    SECTION 3 - CHASSIS & TURNTABLE Loop Flushing Valve INSPECT THE COMPONENTS Inspect new O-rings and the sealing area for rust, wear, or con- tamination. Also check springs and poppet for wear. REMOVAL 1. Using a 11/16 in. (17.46 mm) internal hex wrench INSTALLATION remove plug (1) and (2).

  • Page 114: Swing Hub (Sn 0300087000 Through 0300137452)

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-46. Swing Torque Hub Adjustment 7. Remove the retaining ring (1I) from the output shaft (1A) 3.11 SWING HUB (SN 0300087000 THROUGH and discard. 0300137452) Adjustment Procedures EYE PROTECTION SHOULD BE WORN DURING RETAINING RING (1I) REMOVAL. NOTE: The swing bearing high spot is usually marked with a col- ored paint.

  • Page 115: Main Assembly Procedure

    SECTION 3 - CHASSIS & TURNTABLE Main Assembly Procedure 3. Place O-ring (5) into hub counterbore. Use petroleum jelly to hold O-ring in place. Also at this time locate and mark the 4 counter beamed holes in the face of the hub 1.
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE 6. With shoulder side of ring gear (4) facing down, place 8. Input gear (8) is installed, meshing with teeth of the ring gear over (into mesh with) large gears. Be sure that large diameter cluster gear (3F). The counterbore on the punch marks remain in correct location during ring gear input gear (8) locates on the shoulder of the thrust installation.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 11. Place O-ring (5) into cover (6) counterbore. Use 13. Install regular grade 8 bolts (12) into remaining holes. petroleum jelly to hold O-ring in place. BEWARE OF SHARP EDGES OF THE COUNTERBORE WHILE SEATING THIS O- RING.

  • Page 118: Hub Shaft Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub Shaft Sub-Assembly 4. Returning the hub (1G) to locate on the large diameter end, the output shaft (1A) is carefully installed into the 1. Press bearing cone (1D) onto shaft (1A). hub (1G). 5.
  • Page 119 SECTION 3 - CHASSIS & TURNTABLE 7. Pipe plugs (1J) & (1K) should be checked and/or 10. A soft metal punch should be used to ensure that this installed at this time in the assembly. retaining ring (1I) is completely seated in the groove of the output shaft (1A).

  • Page 120: Carrier Sub-Assembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Sub-Assembly 4. Place second set of sixteen needle rollers into cluster gear. 1. Apply a coat of grease or petroleum jelly to cluster gear bore. 5. Apply grease or petroleum jelly to the tang side of two thrust washers.
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE 7. Line up cluster gear and thrust washer with hole in 8. Drive anti-roll pin flush into carrier hole, thereby locking carrier and slide planet shaft through. Line up planet shaft into place. chamfered side of hole in planet shaft with pin hole in Repeat these steps for remaining two cluster gears to carrier.
  • Page 122 SECTION 3 - CHASSIS & TURNTABLE 3121201 3-63...

  • Page 123: Swing Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.12 SWING HUB (USA BUILT MACHINES AND CHINA Tightening and Torquing Bolts BUILT MACHINES, SN 0300137453 THROUGH If an air impact wrench is used to tighten bolts, extreme care 0300177361 AND SN B300000100 TO PRESENT) should be taken to ensure that the bolts are not tightened beyond their specified torque.

  • Page 124: Motor Control Valve Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor Control Valve Disassembly 4. Using a wrench, loosen jam nuts on elbow fittings (30) and remove fittings from brake (6) and Motor control valve (32). NOTE: Refer to Figure 3-48. 5. Remove O-ring plugs (23) from Motor control valve (32). 1.

  • Page 125: Motor And Brake Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Disassembly 4. Remove the springs (8L) from the piston. 5. Apply less than 50 psi (3.45 bar) air to the “brake port” to NOTE: Refer to Figure 3-49. remove Brake Piston (8A). 1.

  • Page 126: Main Drive Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Main Drive Disassembly 5. Remove thrust washer (11) from between brake housing (6) and carrier subassembly. NOTE: Refer to Figure 3-50. 6. Remove ring gear (4) from housing (1G). 7. Remove O-ring (5) from between ring gear (4) and hous- 1.

  • Page 127: Hub-Shaft Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Disassembly 3. While supporting the housing (1G) on the output shaft (1A) end, press the output shaft (1A) out of the housing (1G). NOTE: Refer to Figure 3-51. NOTE: The lip seal (1B) will be pressed out of the housing (1G) by 1.

  • Page 128: Carrier Disassembly

    SECTION 3 - CHASSIS & TURNTABLE Carrier Disassembly 2. Remove the planet shaft (3E) from the carrier (3A). Use a small punch to remove the roll pin (3D) from the planet shaft (3E). NOTE: Refer to Figure 3-52. 3. Slide the planet gear (3F), the two thrust washers (3B) out of the carrier (3A).

  • Page 129: Hub-Shaft Assembly

    SECTION 3 - CHASSIS & TURNTABLE Hub-Shaft Assembly Carrier Assembly NOTE: Refer to Figure 3-52. NOTE: Refer to Figure 3-51. 1. Apply a liberal Coat of grease to the bore of cluster gear 1. Press bearing cup (1C) into housing (1G) taking care to (3F).

  • Page 130: Main Drive Assembly

    SECTION 3 - CHASSIS & TURNTABLE Main Drive Assembly NOTE: If gears do not mesh easily or carrier assembly does not rotate freely, then remove the carrier and ring gear and check the cluster gear timing. NOTE: Refer to Figure 3-50. 9.

  • Page 131: Motor And Brake Assembly

    SECTION 3 - CHASSIS & TURNTABLE Motor and Brake Assembly Motor Control Valve Assembly NOTE: Refer to Figure 3-49. NOTE: Refer to Figure 3-48. 1. Alternate stators (8K) (O.D. lobes) with rotors (8J) (I.D. 1. Lay assembly down with motor ports facing up. Remove splines) into bore of brake housing (6).
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE 1001101061 A Figure 3-53. Swing Motor/Brake/Hub Assembly (USA Built Machines and China Built Machines, SN 0300137453 through 0300177361 and SN B300000100 to Present) - Sheet 1 of 3 3121201 3-73...
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE 1001101061 A Figure 3-54. Swing Motor/Brake/Hub Assembly (USA Built Machines and China Built Machines, SN 0300137453 through 0300177361 and SN B300000100 to Present) - Sheet 2 of 3 3-74 3121201...
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE 1. Housing/Shaft Assembly 4. Gear Ring 21. Bolt 104. Ring Seal 5. O-ring (Black) 22. Lock Washer 105. Assembly 1A. Output Shaft 1B. Lip Seal 5A. O-ring (White) 23. Pipe Plug 106. Ring 1C. Bearing Ki 6.
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE 1001110169 B 1. Bolt 6. Ring 12. Shaft Coupling 17. Backup Washer 2. End Cover 7. Manifold 13. Bronze Bushing 18. Housing 3. Commutator Seal 8. Rotor Set 14. Thrust Washer 19. Bearing 4. Ring Seal 9.

  • Page 136: Swing Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING MOTOR Disassembly and inspection 1. Place the Torqmotor™ in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.
  • Page 137 SECTION 3 - CHASSIS & TURNTABLE 5&6 Torque Bolts to 25-30 ft. lbs. (34-41 Nm) Assemble with wedge side down into commutator face. 1. Special Bolts 8A. Rotor 13. Inner Bearing/Bushing 19. Outer Bearing/Bushing 2. Special Bolts 8B. Stator or Stator Vane 14.
  • Page 138 SECTION 3 - CHASSIS & TURNTABLE 5. If the end cover (2) is equipped with shuttle valve com- 7. Remove commutator ring (6). Inspect commutator ring ponents, remove the two previously loosened plugs for cracks, or burrs. (21). BE READY TO CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE REMOVED.
  • Page 139 SECTION 3 - CHASSIS & TURNTABLE 9. Remove manifold (7) and inspect for cracks surface scor- NOTE: Series TG and TH may have a rotor set with two stator ing, brinelling or spalling. Replace manifold if any of halves (8B & 8D) with a seal ring (4) between them and two these conditions exist.
  • Page 140 SECTION 3 - CHASSIS & TURNTABLE 11. Place rotor set (8) and wear plate (9) on a flat surface 13. Remove thrust bearing (11) from top of coupling shaft and center rotor (8A) in stator (8B) such that two rotor (12).
  • Page 141 SECTION 3 - CHASSIS & TURNTABLE 15. Remove coupling shaft (12), by pushing on the output 17. Remove thrust bearing (15) and thrust washer (14) end of shaft. Inspect coupling shaft bearing and seal sur- Inspect for wear, brinelling, corrosion and a full comple- faces for spalling, nicks, grooves, severe wear or corro- ment of retained rollers.
  • Page 142 SECTION 3 - CHASSIS & TURNTABLE 19. Remove housing (18) from vise, invert it and remove and 21. If the housing (18) assembly has passed inspection to discard seal (20). A blind hole bearing or seal puller is this point, inspect the housing bearings/bushings (19) required.

  • Page 143: Assembly

    SECTION 3 - CHASSIS & TURNTABLE NOTE: The depth or location of bearing/bushing (13) in relation to Assembly the housing wear plate surface and the depth or location Replace all seals and seal rings with new ones each time you of bearing/bushing (19) in relation to the beginning of reassemble the Torqmotor™...
  • Page 144 SECTION 3 - CHASSIS & TURNTABLE 2. The Torqmotor™ inner housing bearing/bushing (13) can now be pressed into its counterbore in housing (18) flush to 0.03 in. (.76 mm) below the housing wear plate contact face. Use the opposite end of the bearing man- drel that was used to press in the outer bearing/ bush- ing (19).
  • Page 145 SECTION 3 - CHASSIS & TURNTABLE 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. 3. Press a new dirt and water seal (20) into the housing (18) outer bearing counterbore.
  • Page 146 SECTION 3 - CHASSIS & TURNTABLE 8. Be sure that a generous amount of clean corrosion resis- tant grease has been applied to the lower (outer) hous- ing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in the housings.
  • Page 147 SECTION 3 - CHASSIS & TURNTABLE 9. Install thrust bearing (11) onto the end of the coupling 11. Install drive link (10) the long splined end down into the shaft (12). coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines.
  • Page 148 SECTION 3 - CHASSIS & TURNTABLE 13. Apply a small amount of clean grease to a new seal ring 15. Apply clean grease to a new seal ring (4) and assemble it (4) and assemble it into the seal ring groove on the wear in the seal ring groove in the rotor set contact side of plate side of the rotor set stator (8B).
  • Page 149 SECTION 3 - CHASSIS & TURNTABLE 17. Apply grease to a new seal ring (4) and insert it in the 19. Assemble a new seal ring (3) flat side up, into commuta- seal ring groove exposed on the manifold. tor (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up.
  • Page 150 SECTION 3 - CHASSIS & TURNTABLE 20. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing (18).The correct 5 bolt end cover bolt hole relationship to housing port bosses.
  • Page 151 SECTION 3 - CHASSIS & TURNTABLE 21. Assemble the 5 or 7 special bolts (1) and screw in finger NOTE: The special bolts required for use with the relief or shuttle tight. Remove and replace the two alignment studs with valve (24) end cover assembly (2) are longer than the bolts bolts after the other bolts are in place.

  • Page 152: One Piece Stator Construction

    SECTION 3 - CHASSIS & TURNTABLE One Piece Stator Construction 4. Assemble six vanes (8C), or as many vanes that will read- ily assemble into the stator vane pockets. A disassembled rotor (8A) stator (8B) and vanes (8C) that can- not be readily assembled by hand can be assembled by the following procedures.

  • Page 153: Swing Hub Installation

    Jam Nut Jack Bolt 3. Apply JLG Threadlocker P/N 0100019 and torque pivot bolt to 205 ft. lbs. (280 Nm) (shown below). NOTE: Make sure the turntable is properly supported during the following step. The turntable can swing a few degrees when the turntable lock is removed if the turntable is not balanced properly.

  • Page 154: Swing Drive Lubrication

    SECTION 3 - CHASSIS & TURNTABLE 9. Torque mounting bolts to 340 ft. lbs. (Nm). 3.15 SWING HUB REMOVAL 1. Disconnect all wiring harness terminals connected to the swing motor. 2. Gently loosen the set screw. Do not remove. 3. Remove the pivot bolt using Allen Wrench. Jam Nut Jack Bolt 10.

  • Page 155: Swing Bearing

    Turntable Bearing Mounting Bolt Condition Check NOTE: This check is designed to replace the existing bearing 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 operation thereafter. If...
  • Page 156 SECTION 3 - CHASSIS & TURNTABLE 3121201 3-97...

  • Page 157: Swing Bearing Replacement

    JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING BOLTS BE DIS- CARDED AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY...

  • Page 158: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE Figure 3-61. Swing Bearing Torque Sequence 5. Using suitable lifting equipment, carefully position the Swing Bearing Torque Values turntable assembly above the machine frame. 1. Outer Race - 190 ft. lbs. (260 Nm) w/Loctite. 6.
  • Page 159 SECTION 3 - CHASSIS & TURNTABLE 3-100 3121201...
  • Page 160 SECTION 3 - CHASSIS & TURNTABLE 3121201 3-101...

  • Page 161: Disassembly

    SECTION 3 - CHASSIS & TURNTABLE 3.17 SWING BRAKE - (USA BUILT MACHINES, Assembly SN 0300087000 THROUGH 0300137452) NOTE: Lubricate all rubber component from repair kit with clean type of fluid used in the system. Disassembly 1. Use an alkaline wash to clean the parts before assembly. 1.
  • Page 162 SECTION 3 - CHASSIS & TURNTABLE 0920119 B 1. Capscre 11. Rotor Disc 2. Pressure Plate 12. Return Plate 3. Seal Case 13. Spring 4. O-ring 14. Spring Retainer 5. Backup Ring 15. Dowel pin 6. Piston 16. Cover 7. O-ring 17.

  • Page 163: Bleeding

    SECTION 3 - CHASSIS & TURNTABLE Bleeding Pressure should not exceed 6.9 bar (100 psi) during bleeding. 1. Install brake in system and connect pressure lines. 3. Apply sufficient pressure to release brake and check for proper operation in system. 2.

  • Page 164: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.18 ROTARY COUPLING - (USA BUILT MACHINES, SN Table 3-10. Coupling Port Information Table - 2WS 0300087000 THROUGH 0300138648) Operating Proof Port Port Use the following procedure to install the seal kit. Description Pressure Pressure Size PSI (Bar)
  • Page 165 SECTION 3 - CHASSIS & TURNTABLE DETAIL A 1. Rotary Coupling 5. Bolt 2. Torque Lug 6. Nut 3. Locknut 7. Bracket 4. Flatwasher Figure 3-65. Rotary Coupling (USA Built Machines, SN 0300087000 through 0300138648) - Sheet 1 of 2 3-106 3121201...
  • Page 166 SECTION 3 - CHASSIS & TURNTABLE 1. O-ring 6. Spring 11. Housing 16. Bearing 2. Plug 7. Valve Block Plunger 12. Retaining Ring 17. Cap Seal 3. Check Valve 8. Valve Block 13. Ring 18. O-ring 4. Screw 9. O-ring 14.
  • Page 167 SECTION 3 - CHASSIS & TURNTABLE 1660303 B Figure 3-67. Rotary Coupling Port Location (USA Built Machines, SN 0300087000 through 0300138648) - 2WS 3-108 3121201...
  • Page 168 SECTION 3 - CHASSIS & TURNTABLE 1660304 B Figure 3-68. Rotary Coupling Port Location (USA Built Machines, SN 0300087000 through 0300138648) - 4WS 3121201 3-109...

  • Page 169: And Sn B300000100 To Present)

    SECTION 3 - CHASSIS & TURNTABLE 3.19 ROTARY COUPLING - (USA BUILT MACHINES 6. Remove proximity switch. AND CHINA BUILT MACHINES, SN 0300138649 7. Assemble lip seals (2) in direction shown in Figure 3-69., Rotary Coupling Seal Installation (USA Built Machines TO PRESENT AND SN B300000100 TO and China Built Machines, SN 0300138649 to Present PRESENT)
  • Page 170 SECTION 3 - CHASSIS & TURNTABLE 1. Center Body 6. Thrust Ring 2. Seal 7. Snap Ring 3. Housing 8. Valve Block (Axle Oscillation) 4. O-ring 9. O-ring 5. Seal 10. Proximity Switch Figure 3-70. Rotary Coupling Cutaway (USA Built Machines and China Built Machines, SN 0300138649 to Present and SN B300000100 to Present) 3121201 3-111...
  • Page 171 SECTION 3 - CHASSIS & TURNTABLE 1001106974 B Figure 3-71. Rotary Coupling Port Location (7 Port) (USA Built Machines and China Built Machines, SN 0300138649 to Present and SN B300000100 to Present) 3-112 3121201...
  • Page 172 SECTION 3 - CHASSIS & TURNTABLE 1001106975 B Figure 3-72. Rotary Coupling Port Location (9 Port) (USA Built Machines and China Built Machines, SN 0300138649 to Present and SN B300000100 to Present) 3121201 3-113...
  • Page 173 SECTION 3 - CHASSIS & TURNTABLE 1. JLG Threadlocker 6. Rotary Coupling 11. Ring 16. O-ring 21. Bolt 2. Bolt 7. Spool 12. Seal 17. Valve 22. Nut 3. Bolt 8. Retaining Ring 13. O-ring 18. Check Valve 23. Washer 4.
  • Page 174 SECTION 3 - CHASSIS & TURNTABLE Table 3-13. Coupling Port Information Table (9 port) Table 3-12. Coupling Port Information Table (7 port) Operating Proof Operating Proof Port Port Port Size Description Pressure Pressure Outlets Port Size Description Pressure Pressure Outlets PSI (Bar) PSI (Bar) PSI (Bar)

  • Page 175: Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.20 ENGINE 3-116 3121201...
  • Page 176 SECTION 3 - CHASSIS & TURNTABLE 1. Gear Pump 11. Oil Cooler Hose 21. Air Cleaner Band 31. Engine mounting Plate 2. Piston Pump 12. Fitting 22. Clamp 32. Engine mounting Plate 3. Rear Engine Mounting Plate 13. Bolt 23. Elbow Pipe 33.
  • Page 177 SECTION 3 - CHASSIS & TURNTABLE 3-118 3121201...
  • Page 178 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 21. Rubber Panel 41. Jumper Cable 61. Starwasher 2. Locknut 22. Flanged Bushing 42. Relay 62. Flatwasher 3. Flatwasher 23. Pin Keeper 43. Trim Flex 63. Locknut 4. Battery Hold Down 24. Bolt 44.
  • Page 179 SECTION 3 - CHASSIS & TURNTABLE 3-120 3121201...
  • Page 180 SECTION 3 - CHASSIS & TURNTABLE 1. Flatwasher 41. Capscrew 81. Bolt 121. Bracket 2. Locknut 42. Tube Clip 82. Spark Arresting Muffler (Standard) 122. Pump Coupling 3. Coolant Overflow Container 43. Flatwasher 83. Muffler Band 123. Dipstick Oil level 4.
  • Page 181 SECTION 3 - CHASSIS & TURNTABLE 3-122 3121201...
  • Page 182 SECTION 3 - CHASSIS & TURNTABLE 1. Battery 16. Bolt 31. Bolt 46. Clamp Hose 2. Battery Hold-Down 17. Lanyard 32. Solenoid Assembly Relay 47. Bolt 3. Hold-Down Rod 18. Bolt 33. Solenoid Assembly Relay 48. Fitting 4. Flatwasher 19. Flatwasher 34.
  • Page 183 SECTION 3 - CHASSIS & TURNTABLE 1001114640 F 1001114642 F Figure 3-82. GM Engine - Sheet 1 of 4 3-124 3121201...
  • Page 184 SECTION 3 - CHASSIS & TURNTABLE 1. Bolt 35. Flatwasher Regular 69. Hose 103. Radiator 2. Hitch Pin 36. Engine Mount 70. Clamp 104. Radiator Mounting Plate 3. Flatwasher 37. Clamp 71. Oil Drain Valve 105. Seal 4. Locknut 38. Locknut 72.
  • Page 185 SECTION 3 - CHASSIS & TURNTABLE 1001114640 F 1001114642 F Figure 3-84. GM Engine - Sheet 3 of 4 3-126 3121201...
  • Page 186 SECTION 3 - CHASSIS & TURNTABLE 1. Straight Fitting 9. Locknut 17. High Pressure Fuel Line Hose 25. Fuel Line Clamp 2. Adapter Fitting 10. Flatwasher 18. Flatwasher 26. Fuel Line Hose 3. Straight Fitting 11. Bolt 19. Bolt 27. 90 Fitting 4.
  • Page 187 SECTION 3 - CHASSIS & TURNTABLE SUPPL 1001098266 E Figure 3-86. Deutz Engine Installation - Sheet 1 of 2 3-128 3121201...
  • Page 188 SECTION 3 - CHASSIS & TURNTABLE 1001098266 E 1. Engine 4. P - Clamp 2. Fuel Line 5. Battery 3. Engine Tray 6. J - Bolt Figure 3-87. Deutz Engine Installation - Sheet 2 of 2 3121201 3-129...
  • Page 189 SECTION 3 - CHASSIS & TURNTABLE 1001098474 F Figure 3-88. Arctic Deutz Engine Installation - Sheet 1 of 2 3-130 3121201...
  • Page 190 SECTION 3 - CHASSIS & TURNTABLE 1001098474 F 1. Engine 5. Fuel Tank 2. Fuel Line 6. Battery 3. Engine Tray 7. J - Bolt 4. P - Clamp 8. Battery heater Figure 3-89. Arctic Deutz Engine Installation - Sheet 2 of 2 3121201 3-131...
  • Page 191 SECTION 3 - CHASSIS & TURNTABLE 1001109067 C 1. Engine 3. Engine Tray 2. Fuel Pump Figure 3-90. CAT Engine Installation 3-132 3121201...
  • Page 192 SECTION 3 - CHASSIS & TURNTABLE 1001110208 D 1. Engine 3. Engine Tray 2. Fuel Pump 4. Heater Figure 3-91. Arctic CAT Engine Installation 3121201 3-133...
  • Page 193 SECTION 3 - CHASSIS & TURNTABLE 1001114642 F Figure 3-92. Arctic GM Engine Installation - Sheet 1 of 2 3-134 3121201...
  • Page 194 SECTION 3 - CHASSIS & TURNTABLE 1001114642 F 1. Engine 5. Fuel Line 9. Cord 3 Way Extension 2. Engine Tray 6. Fuel Regulator Valve 10. Battery Bracket 3. Fuel Pump 7. Battery 4. Fuel Filter 8. Battery Heater Figure 3-93. Arctic GM Engine Installation - Sheet 2 of 2 3121201 3-135...
  • Page 195 SECTION 3 - CHASSIS & TURNTABLE 1001114640 F Figure 3-94. GM Engine Installation - Sheet 1 of 2 3-136 3121201...
  • Page 196 SECTION 3 - CHASSIS & TURNTABLE 1001114640 F 1. Engine 5. Fuel Line 2. Engine Tray 6. Fuel Regulator Valve 3. Fuel Pump 7. Battery 4. Fuel Filter 8. Battery Bracket Figure 3-95. GM Engine Installation - Sheet 2 of 2 3121201 3-137...

  • Page 197: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.21 GENERATOR Overload Protection Every 250 hours STOP THE ENGINE WHENEVER CHECKING OR INSPECTING THE CIRCUIT Every 250 hours of operation, check the drive belt for proper BREAKER. tension. The circuit breaker protects the generator windings from overload.
  • Page 198 SECTION 3 - CHASSIS & TURNTABLE 1. Brush Holder Assembly 2. Brushes 3. Slip Rings Figure 3-96. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings 3121201 3-139...
  • Page 199 SECTION 3 - CHASSIS & TURNTABLE Table 3-14. Troubleshooting Trouble Remedy No generator output at platform AC receptacles. Be sure generator control switch is turned on at platform. Check and secure electrical connections at platform, generator, and control box. Be sure all equipment is turned off when starting unit. Reset circuit breaker CB1.
  • Page 200 Or, operate the engine as required by the applica- 4. If a diagnostic trouble code (DTC) is stored, contact a JLG tion for two to three minutes. distributor to make an effective repair. 4. Install the cleanout plug.

This manual is also suitable for:

600aj

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