JLG 600SC Service And Maintenance Manual
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JLG 600SC Service And Maintenance Manual

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Service and Maintenance Manual
Models
600SC
660SJC
SN 0300236299 to Present
PN - 3121776
November 30, 2018 - Rev C
AS/NZS

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Summary of Contents for JLG 600SC

  • Page 1 Service and Maintenance Manual Models 600SC 660SJC SN 0300236299 to Present PN - 3121776 November 30, 2018 - Rev C 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 general safety precautions which must be observed during aerial platform maintenance. It is of utmost importance that maintenance personnel pay strict FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION attention to these warnings and precautions to avoid possible COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A injury to themselves or others, or damage to the equipment.
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - October 25, 2017 Revised B - June 29, 2018 - Revised Covers Revised C - November 30, 2018 3121776...

  • Page 5: Table Of Contents

    Do NOT Do the Following When Welding on JLG Equipment .......
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 3 - CHASSIS & TURNTABLE Chassis Components and Servicing ..............3-1 Service Notes.
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Assembly/Disassembly ............... . 4-5 Installation.
  • Page 8 JLG Control System Analyzer Kit Instructions ........
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Diagnostic Menu ................6-82 Calibration Procedure .
  • Page 10 Boom Sensors Installation - 600SC ........
  • Page 11 Platform Level (Slave) Cylinder - 600SC........
  • Page 12 Hydraulic Schematic (600SC) - Sheet 1 of 2 ....... . .
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-10. DIN Connector ..................7-5 7-11.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-67. Platform Valve Harness - Sheet 2 of 2 ..............7-112 7-68.
  • Page 15 LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications ................1-1 Dimensional Data .
  • Page 16 LIST OF TABLES TABLE NO. TITLE PAGE NO. Machine Personality Settings and Function Speed ........... 6-38 System Test Messages .

  • Page 17: Specifications

    1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Table 1-2. Dimensional Data Table 1-1. Operating Specifications Machine Height (Stowed) 8 ft. 2.4 in. (2.5 m) Maximum Work Load (Capacity) - 600SC* Unrestricted: 600 lbs. (272 kg) Machine Length (Stowed) Restricted: 1000 lbs. (454 kg) 600SC...
  • Page 18 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 19: Capacities

    SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES Table 1-6. Deutz TD 2.9 L4 GUO III Specifications Table 1-3. Capacities Fuel Low Sulfur Diesel (500 ppm allowable sulfur content) Max Output (Power) 67 hp (50 kW) Fuel Tank 31 Gallons (117 L) Max Output (Torque) 173 ft.

  • Page 20: Hydraulic Oil

    Mobil DTE 10 Excel 32. Table 1-11. Mobil EAL 224 H NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types. They may not contain Type Biodegradable Vegetable required additives or be of comparable viscosities.

  • Page 21: Torque Requirements

    SECTION 1 - SPECIFICATIONS 1.7 TORQUE REQUIREMENTS Table 1-13. Exxon Univis HVI 26 (Arctic) Table 1-14. Torque Requirements Specific Gravity 0.89 Pour Point -76°F (-60°C) Interval Description Torque Value (Dry) Flash Point 217°F (103°C) Hours Viscosity Bearing To Chassis at 40° C 25.8 cSt Bearing To Turntable at 100°...
  • Page 22 SECTION 1 - SPECIFICATIONS 660SJC 600SC MAE24880 Figure 1-1. Maintenance and Lubrication Diagram - Deutz D2011L04 3121776...
  • Page 23 SECTION 1 - SPECIFICATIONS 660SJC 600SC MAE24870 Figure 1-2. Maintenance and Lubrication Diagram - Deutz TD 2.9 and TD 2.9 L4 GUO III 3121776...

  • Page 24: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.8 MAINTENANCE AND LUBRICATION 2. Swing Drive Hub NOTE: The following numbers correspond to those in Figure 1-1. and Figure 1-2. FILL PORT Table 1-15. Lubrication Specifications. SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 25 SECTION 1 - SPECIFICATIONS 4. Hydraulic Charge Filter 7. Hydraulic Tank  Interval - Change after first 50 hrs. and every 6 months Lube Point(s) - Fill Cap Capacity - 21 gal tank (79.5 L) or 300 hrs. 40.0 gal system (151 L) Lube - HO Interval - Check 5.
  • Page 26 SECTION 1 - SPECIFICATIONS 9. Fuel Filter - Deutz D2011L04 12. Fuel Pre-Filter - Deutz TD2.9 Lube Point(s) - Replaceable Element  Interval - Every Year or 600 hours of operation. 10. Oil Change w/Filter - Deutz TD2.9 Lube Point(s) - Replaceable Element Interval - Drain water daily;...
  • Page 27 SECTION 1 - SPECIFICATIONS 14. A. Air Filter - Deutz TD2.9L 15. A. Platform Filter - 600SC B. Air Filter - Deutz D2011L04 B. Platform Filter - 660SJC Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator.
  • Page 28 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 1 of 5) 1-12 3121776...
  • Page 29 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (SAE Fasteners - Sheet 2 of 5) 3121776 1-13...
  • Page 30 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (SAE Fasteners - Sheet 3 of 5) 1-14 3121776...
  • Page 31 SECTION 1 - SPECIFICATIONS Figure 1-6. Torque Chart (SAE Fasteners - Sheet 4 of 5) 3121776 1-15...
  • Page 32 SECTION 1 - SPECIFICATIONS Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 5 of 5) 1-16 3121776...
  • Page 33 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 34: General

    Service Technician as a person who has successfully com- ommendations with any and all discrepancies corrected, this pleted the JLG Service Training School for the subject JLG product will be fit for continued use. product model. Reference the machine Service and Mainte-...

  • Page 35: 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 36: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING your work to assure that nothing has been overlooked.

  • Page 37: Lubrication

    When recommended lubricants are not avail- 2. JLG recommends Mobil 424 hydraulic oil, which has an able, consult your local supplier for an equivalent that meets SAE viscosity of 10W and a viscosity index of 140.

  • Page 38: Cylinder Drift

    SECTION 2 - GENERAL CYLINDER DRIFT Cylinder Leakage Test Cylinder oil must be at stabilized ambient temperature Theory before beginning this test. When a hydraulic cylinder is supporting a load, cylinder drift Measure drift at cylinder rod with a calibrated dial indicator. may occur as a result of any of the circumstances below: In an area free of obstructions, cylinder must have load •...

  • Page 39: Pins And Composite Bearing Repair Guidelines

    Noise originating from joint during operation. • Ground only to structure being welded. 2. Filament wound bearings should be replaced if any of • Unplug all pressure transducers (Refer to Section 6 - JLG the following is observed: Control System.
  • Page 40 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent 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 Extend/Retract Chain or Cable Systems...
  • Page 41 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Swing Brakes Auxiliary Power Power System Engine Idle, Throttle, and RPM Engine Fluids (Oil, Coolant, Fuel) 9,11 9,11 Air/Fuel Filter Exhaust System Batteries 1,9,19...
  • Page 42 Frequent Inspection Inspection 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 Performance Codes:...
  • Page 43 SECTION 2 - GENERAL ENGINE OIL OPERATION CHART DEUTZ D2011 SERIES T4I NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.
  • Page 44 SECTION 2 - GENERAL ENGINE OIL OPERATION CHART DEUTZ 2.9 L04 T4F AND 3.6L4 TCD NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE.
  • Page 45 SECTION 2 - GENERAL NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FLUID OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM. 1001206353_B...
  • 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: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 CHASSIS COMPONENTS AND SERVICING MAE31670 1. Track Chain Assembly 7. Flanged Bolt 13. Carrier Track Roller 19. Grease Fitting 25. Nut 2. Undercarriage 8. Cover Plate 14. Bottom Track Roller 20.

  • Page 48: Service Notes

    SECTION 3 - CHASSIS & TURNTABLE Service Notes MAE31660 Figure 3-2. Chassis Service Notes - 1 of 2 3121776...
  • Page 49 SECTION 3 - CHASSIS & TURNTABLE Track tension adjustment to be made between the idler and carrier roller: 0.781 in (19.8 mm) Anti-Seize Compound to be used on master link pin before assembly. Torque Pad bolts over master link to 65 ft-lbs +6,-6 then tighten 1/3 (120°)turn further.

  • Page 50: Track And Chain

    SECTION 3 - CHASSIS & TURNTABLE Track and Chain 1. Track Assembly 4. Bushing 7. Splice Hinge Pin 10. Bolt 2. Left Link 5. Hinge Pin 8. Spacer 11. Nut 3. Right Link 6. Splice Bushing 9. Track Cleat Figure 3-4. Track and Chain 3121776...

  • Page 51: Replace Track

    SECTION 3 - CHASSIS & TURNTABLE TRACK SHOES 3. Use a portable press to push pin (5) out. Remove bush- ing (4). 1. Visually check for loose or missing bolts at the start of each operating shift. 2. Check bolt torque approximately every 100 hours. Torque track shoe bolts to 65 ft-lb, +6 (91 Nm, +8.4), then tighten 1/3 turn (120°) further.

  • Page 52: Track Tensioning

    1. Seat rubber track pad over center rib of steel track. 2. Apply JLG Thread Locking Compound PN 0100011 to retaining plate bolts. Install bolts and flat washers to end of rubber pad.
  • Page 53 SECTION 3 - CHASSIS & TURNTABLE 1. Guide Roller 4. Bearing 7. Mounting Bracket 2. Shaft 5. Ring 8. O-ring 3. Plug 6. Seal 9. Roll Pin Figure 3-5. Bottom Track Roller Assembly 3121776...
  • Page 54 SECTION 3 - CHASSIS & TURNTABLE 1. Guide Roller 5. Washer 9. Tension Ring 13. Cover 2. Shaft 6. Roller Bearing 10. Collar 14. Cover Seal 3. Internal Cover 7. Not Used 11. Packing Ring 15. Lockwasher 4. Bolt 8. Seal Ring 12.

  • Page 55: Rollers

    3. Press collar on roller shaft and lock in place with dowel. clean of grease and oil. 4. Invert roller assembly and perform steps 1 through 4. 2. Apply JLG Thread Locking Compound PN 0100011 to four bolts. Align roller on frame and secure with four 5. Fill roller with lube.
  • Page 56 SECTION 3 - CHASSIS & TURNTABLE Idler Roller Assembly The idler roller assembly is located at the front of each side frame and acts as a shock absorber for the track system. Compensation is accomplished by a tensioning spring and hydraulic cylinder. 1.
  • Page 57 SECTION 3 - CHASSIS & TURNTABLE 1. Mounting Flange 5. Roll Pin 9. Seal 2. Spring 6. Piston/Rod 10. Seal 3. Base Plate 7. Wiper 11. Fitting 4. Locknut 8. Barrel Figure 3-8. Spring & Shock Assembly 3121776 3-11...

  • Page 58: Idler Roller Assembly

    Install using bolts, wash- 3. Press out bushing. (Bushing can only be removed by a ers, and JLG Thread Locking Compound PN 0100011. vertical press with correct tooling.) Torque to 165 ft-lb +15-0 (231 Nm, +21 -0).

  • Page 59: Swing Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.2 SWING DRIVE HUB 5. Place swing drive hub in the clean area. 6. Refer to Section 3-9., Swing Drive Installation, for swing Removal drive maintenance. 1. Gently loosen the jack bolt (4). Do not remove. Assembly/Disassembly 2.

  • Page 60: Procedure For Setting Swing Gear Backlash

    SECTION 3 - CHASSIS & TURNTABLE Procedure For Setting Swing Gear Backlash 7. Apply JLG Threadlocker P/N 0100019 and torque jack bolt 50 ft. lbs. (68 Nm). Set backlash to 0.010 inch to 0.015 inch (0.254 mm - 0.381 mm) 8.

  • Page 61: Swing Bearing

    NOTE: This check is designed to replace existing bearing bolt Figure 3-12., Swing Bearing Tolerance Measurement torque checks on JLG Lifts in service. This check must be Location & Boom Placement A, using a magnetic base performed after first 50 hours of machine operation and dial indicator, measure and record distance between every 600 hours of machine operation thereafter.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE MAIN BOOM FULLY EXTENDED MEASURING POINT B MAIN BOOM FULLY RETRACTED AND ELEVATED. MEASURING POINT LEVEL SURFACE MAE25730 Figure 3-12. Swing Bearing Tolerance Measurement Location & Boom Placement 3-16 3121776...

  • Page 63: Swing Bearing Replacement

    600SC and Figure 3-15., Swing Bearing Removal - INE JLG HARDWARE IS HIGHLY RECOMMENDED. 660SJC. 2. Apply a light coating of JLG Threadlocker P/N 0100019 3. Using the front lifting eyes in the turntable and a loca- to the new bearing bolts, and loosely install the bolts...

  • Page 64: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE 11. Remove the lifting equipment. Swing Bearing Torque Values 12. Unsecure the boom from rear of turntable. 1. Outer Race - 190 ft-lb (260 Nm) w/Loctite. 13. At ground control station, use boom lift control to lower 2.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 3121776 3-19...
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 3-20 3121776...

  • Page 67: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.4 ROTARY COUPLING Assembly/Disassembly For detail assembly/disassembly instructions and seal  replacement of rotary coupling, contact JLG dealer. 3121776 3-21...
  • Page 68 SECTION 3 - CHASSIS & TURNTABLE MAE25710 1. Bolt 3. Washer 5. Spacer 2. Bolt 4. Washer 6. Mount Figure 3-16. Rotary Coupling Installation 3-22 3121776...
  • Page 69 SECTION 3 - CHASSIS & TURNTABLE MAE25720 1. Bolt 3. Proximity Switch 5. Bracket 2. Nut 4. Washer Figure 3-17. Rotary Coupling - Drive Orientation 3121776 3-23...

  • Page 70: Deutz Td2.9 L4 Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.5 DEUTZ TD2.9 L4 ENGINE MAE26630 1. Fuel Tank 2. Deutz TD2.9L4 Engine and Pump Assembly 3. Fuel Filter 4. Fuel Supply Pump Figure 3-18. Deutz TD2.9 L4 Engine Installation 3-24 3121776...
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE MAE26640 1. Gear Pump Assembly 3. Piston Pump Assembly - Front 5. Deutz TD2.9L4 Engine Assembly 7. Support 2. Piston Pump Assembly - Rear 4. Exhaust Pipe 6. Hydraulic Oil Cooler Figure 3-19. Deutz TD2.9 L4 Engine and Pumps Sub-Assembly 3121776 3-25...
  • Page 72 SECTION 3 - CHASSIS & TURNTABLE MAE26690 1. Radiator 5. Support 9. Adapter 13. Tray 2. Bracket 6. Pump Coupling 10. Fan 14. Bracket 3. Surge Tank 7. Bracket 11. Pulley 15. Engine Mount 4. Air Filter 8. Deutz TD2.9L4 Engine 12.
  • Page 73 SECTION 3 - CHASSIS & TURNTABLE MAE26660 Figure 3-21. Deutz TD2.9 L4 Engine Assembly - Sheet 2 of 2 3121776 3-27...

  • Page 74: Check Oil Level

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed operat- 6. Pour in new engine oil. Refer to Section 1 for capacity ing and maintenance instructions. and Figure 3-23., Engine Oil Viscosity. Check Oil Level 1.

  • Page 75: Change Fuel Filters

    4. Install cleanout plug. Glow Plugs If glow plug option is enabled in the JLG Control System, glow plug and indicator lamp will be energized when Power/Emer- gency Stop switch is pulled on if ambient air temperature is less than 50°...
  • Page 76 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification No detail information BusOff error CAN No detail information Hand throttle idle validation switch; short circuit to battery Hand throttle; short circuit to ground Plausibility error between sensor and idle switch, Acceleration Pedal Detection.
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification Electrical error charged air temperature. Signal range check low. Charged air cooler temperature. System reaction initiated.  High charged air cooler temperature. Warning threshold exceeded. High charged air cooler temperature.
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification DFC for fuel temperature plausibility check function. No detail information Sensor error oil temperature; signal range check high Sensor error oil temperature; signal range check low High oil temperature;...
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification Injector 5 (in firing order); interruption of electric connection Injector 5 (in firing order); short circuit High side to low side short circuit in the injector 5 (in firing order) Injector 6 (in firing order);...
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 1188 Turbocharger wastegate, EOL calibration error. 1188 Turbocharger wastegate, internal electrical error 1188 Turbocharger wastegate, learning process aborted. 1188 Turbocharger wastegate, current above maximum threshold. 1188 Turbocharger wastegate, supply voltage above maximum threshold.
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 2791 EGR actuator, CAN error 2791 EGR actuator, EOL calibration error 2791 EGR Actuator, internal electrical fault 2791 EGR actuator, learning process aborted 2791 EGR actuator current is above maximum threshold 2791 EGR actuator supply voltage is above the maximum threshold...
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 3361 DEF dosing valve; power at the end of injection too high 3361 DEF dosing valve; short circuit to battery on low side 3361 DEF dosing valve;...
  • Page 83 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 4345 SCR heater relay DEF return line secondary side; open load 4345 SCR heater relay DEF return line primary side; open load 4345 Over Temperature error No detail information 4345 SCR heater DEF return line;...
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 4768 Exhaust gas temperature sensors up and downstream DOC are physically swapped 4769 Temperature downstream DOC, plausibility error 4769 Sensor error exhaust gas temperature downstream (DOC); signal range check high 4769 Sensor error exhaust gas temperature downstream (DOC);...
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 523352 Injector cylinder-bank 2; short circuit 523354 Injector power stage output defect 523470 Pressure relief valve is forced to open, perform pressure increase. 523470 Pressure Relief Valve (PRV) forced to open.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 523612 Diagnosis fault check to report the demand for normal mode due to an error in the PoI2 quantity 523612 Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off 523612 Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor 523612...
  • Page 87 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 523632 Pump pressure SCR metering unit too low 523632 Pressure overload of SCR-System. 523632 Pressure build-up error SCR-System. 523632 Pump motor not available for actuation 523632 Signal error for CAN message No detail information 523632...
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 523757 special pattern for special cases No detail information 523758 special pattern for special cases No detail information 523759 special pattern for special cases No detail information 523760 special pattern for special cases No detail information 523766...
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 523911 Burner dosing valve (DV2); short circuit high side power stage 523912 Burner dosing valve (DV2) downstream pressure sensor; plausibility error 523912 Physical range check high for burner dosing valve (DV2) downstream pressure; shut off regeneration 523912 Physical range check low for burner dosing valve (DV2) downstream pressure;...
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 523921 Burner temperature, temperature above upper shutoff threshold 523921 Burner temperature, temperature below lower shutoff threshold 523921 Burner temperature sensor; Plausibility Check for burner temperature sensor Sensor burner temperature;...
  • Page 91 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 523960 High exhaust gas temperature EGR cooler downstream; warning threshold exceeded. 523969 Fault entry for override control mode. No detail information 523973 SCR Tamper detection; derating timer below limit 1 523974 SCR Tamper detection;...
  • Page 92 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 524025 Particulate filter regeneration. Regeneration after time X is not successful (The error occurs when the regeneration times (3x) over the max. has been aborted allowed recovery time) 524025 DPF system;...
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 524063 SCR heater main relay load side (K31) on heating valve (Y31), Short cut to ground. 524063 Relay Urea suction line: broken wiring detected (open load) Row engine: SCR suction line (K28)...
  • Page 94 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 524084 NOx-Sensor upstream SCR-CAT, NOx value above maximum value. 524085 NOx sensor upstream SCR-CAT, NOx value below lower physical threshold 524087 Urea Error Lamp; open load 524087 Urea Error Lamp;...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 524133 HMI system; set if restore button blocked 524134 DPF, ash load exceeds the shutoff threshold 524134 DPF, ash load exceeds the warning threshold 524135 DPF, soot load exceeds the shutoff threshold 524135...
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE Table 3-1. Deutz Trouble Codes (TD2.9 L4 Engine) Error Identification 524205 SCR Co2Off failure is in master ECU active. 524206 SCR disable DEF dosing failure is in master ECU active. 524230 Inducement HW Failure Slave. 524231 Inducement SCR Tamp.

  • Page 97: Deutz D2011L04 Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.6 DEUTZ D2011L04 ENGINE MAE26670 1. Fuel Tank 2. Deutz D2011 Engine and Pumps Sub-Assembly Figure 3-24. Deutz D2011 Engine Installation 3121776 3-51...
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE MAE26680 1. Gear Pump Assembly 3. Piston Pump Assembly - Front 5. DeutzD2011 Engine Assembly 7. Support 2. Piston Pump Assembly - Rear 4. Exhaust Pipe 6. Hydraulic Oil Cooler Figure 3-25. Deutz D2011 Engine and Pumps Sub-Assembly 3-52 3121776...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE MAE25230 1. Deutz D20111 Engine 4. Support 7. Glow Plug Harness 10. Tray 2. Radiator 5. Pump Coupling 8. Adapter 11. Bracket 3. Air Filter 6. Bracket 9. Fan 12. Engine Mount 13. Engine Mount Figure 3-26.
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE MAE25240 Figure 3-27. Deutz D2011 Engine Assembly - Sheet 2 of 2 3-54 3121776...

  • Page 101: Checking Oil Level

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed oper- Changing Engine Oil ating and maintenance instructions. 1. Allow engine to warm up. Engine oil should reach Checking Oil Level approximately 176° F (80° C). 1.

  • Page 102: Changing Oil Filter

    SECTION 3 - CHASSIS & TURNTABLE Changing Oil Filter Check oil filter cartridge for leaks. Replace Fuel Filter 1. Wipe area around filter to clean any dirt from area. 2. Using a suitable oil filter removal tool, loosen lube oil fil- ter cartridge and spin off.

  • Page 103: Clean Fuel Strainer

    4. Install cleanout plug. 3.8 GLOW PLUGS If glow plug option is enabled in the JLG Control System, glow plug and indicator lamp will be energized when Power/Emer- gency Stop switch is pulled on if ambient air temperature is less than 50°...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Deutz Trouble Codes (D2011L04 Engine) FAULT FAULT NO. FAULT LOCALITY/ CAUSE REMARKS HELP GROUP (IN SERDIA) FAULT DESCRIPTION Zero error display No faults 5 2 4 2 8 7 No active faults present Governor in emergency operation (if sensor 2 available).
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Deutz Trouble Codes (D2011L04 Engine) FAULT FAULT NO. FAULT LOCALITY/ CAUSE REMARKS HELP GROUP (IN SERDIA) FAULT DESCRIPTION Fault message (disappears Check engine (oil level, oil pump). Oil pressure below speed- when oil pressure is again Check oil pressure sensor and Oil pressure warning 1 0 0...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Deutz Trouble Codes (D2011L04 Engine) FAULT FAULT NO. FAULT LOCALITY/ CAUSE REMARKS HELP GROUP (IN SERDIA) FAULT DESCRIPTION Check actuator, replace if required. Feedback S ID 24 Check cable, check fault limits for Actuator not connected.
  • Page 107 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Deutz Trouble Codes (D2011L04 Engine) FAULT FAULT NO. FAULT LOCALITY/ CAUSE REMARKS HELP GROUP (IN SERDIA) FAULT DESCRIPTION Fault in parameter Parameter programming in the programming (write S ID 253 governor fixed value EEPROM) Switch ignition off and on again.

  • Page 108: Deutz Td 2.9 L4 Guo Iii Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.9 DEUTZ TD 2.9 L4 GUO III ENGINE MAE26780 1. Fuel Tank 3. Fuel Filter 2. Deutz TD2.9L4 Engine and Pump Assembly 4. Fuel Supply Pump Figure 3-30. Deutz TD 2.9 L4 GUO III Engine Installation 3-62 3121776...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE MAE26790 1. Gear Pump Assembly 4. Exhaust Pipe 7. Support 2. Piston Pump Assembly - Rear 5. Deutz TD2.9L4 GUO III Engine Assembly 3. Piston Pump Assembly - Front 6. Hydraulic Oil Cooler Figure 3-31. Deutz TD 2.9 L4 GUO III Engine and Pumps Sub-Assembly 3121776 3-63...
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE MAE26800 1. Radiator 5. Support 9. Adapter 13. Tray 2. Bracket 6. Pump Coupling 10. Fan 14. Bracket 3. Surge Tank 7. Bracket 11. Pulley 15. Engine Mount 4. Air Filter 8. Deutz TD2.9L4 GUO III Engine 12.
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE MAE26810 Figure 3-33. Deutz TD 2.9 L4 GUO III Engine Assembly - Sheet 2 of 2 3121776 3-65...

  • Page 112: Counterweight

    SECTION 3 - CHASSIS & TURNTABLE  3.10 COUNTERWEIGHT   If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-34., Counterweight Bolt Torque. MAE21750 *Torque the bolts to 346 ft-lb (469 Nm) Figure 3-34.
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE MAE26210 *Torque the bolts to 795 - 845 ft-lb (1078 - 1146 Nm) Figure 3-35. Counterweight Bolt Torque - Crawler (660SJC) 3121776 3-67...

  • Page 114: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.11 GENERATOR Overload Protection Every 250 hours STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER. Check drive belt tension every 250 hours of operation,. The circuit breaker protects generator windings from overload. Generator output stops if circuit breaker opens. If circuit breaker continues to open, check for faulty equip- ment connected to platform receptacles.

  • Page 115: Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings

    SECTION 3 - CHASSIS & TURNTABLE Inspecting Brushes, Replacing Brushes, and 3. Replace brushes if damaged, or if brush is at or near min- imum length. Cleaning Slip Rings CLEANING SLIP RINGS INSPECTING BRUSH POSITION 1. Visually inspect the slip rings. Under normal use, the Inspect brush alignment with slip rings.
  • Page 116 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 117: Boom & Platform

    600SC: 600 lb (270 kg) unrestricted, 1000 lb (450 kg) restricted 660SJC: 550 lb (250kg) unrestricted, 750 lb (340 kg) restricted.  cylinder is stopped. This leveling system operates like a con-...

  • Page 118: Fuel Level Cutout System

    SECTION 4 - BOOM & PLATFORM 4.6 FUEL LEVEL CUTOUT SYSTEM 4. Using a suitable lifting device, support the platform sup- port. The Fuel Shutoff System senses when the fuel level is getting  NOTE: The platform support weighs approximately 125 lbs. low and automatically shuts the engine down before the fuel (56.7 kg).

  • Page 119: Support Installation

    5. Remove tag and reconnect the hydraulic lines to the rotator. 6. Connect the electrical cables to the platform control console. MAE17180 2. Apply JLG Threadlocker P/N 0100011 to the bolts and washers securing the support to the rotator and install the bolts and washers. MAE17170 3121776...
  • Page 120 A, B, D C, D A - Torque to 40 ft-lb (55 Nm) B - JLG Threadlocker P/N 0100011 C - Torque to 586 ft-lb (795 Nm) D - Check torque every 150 hours of operation E - Torque to 65 ft-lb (88 Nm) NOTE: If any rotator bolts are replaced, all bolts on the rotator should be retorqued.

  • Page 121: Rotator And Slave Cylinder

    NOTE: Refer Figure 4-2., Removal of Components - Rotator and Actuator Manual (PN 3128848). Slave Cylinder. Installation Removal 600SC 600SC 1. Support the slave cylinder. Using a suitable brass drift 1. Tag and disconnect hydraulic lines from the rotator. Use and hammer, install pin (3) to the fly boom.
  • Page 122 SECTION 4 - BOOM & PLATFORM 660SJC SLAVE CYLINDER ROTATOR 600SC ROTATOR MAE24400 Figure 4-2. Removal of Components - Rotator and Slave Cylinder 3121776...

  • Page 123: Main Boom Assembly

    SECTION 4 - BOOM & PLATFORM 4.9 MAIN BOOM ASSEMBLY 11. Support the boom lift cylinder and remove retaining bolts, keeper pins, and pins (3 and 4) securing the lift cylinder and tower link to the boom assembly. Removal 12. Remove the boom assembly. NOTE: Refer to Figure 4-3., Boom Assembly Removal and Installa- 13.
  • Page 124 SECTION 4 - BOOM & PLATFORM BOOM LIFT CYLINDER BOOM BOOM SUPPORT STRAP SUPPORT STRAP BOOM ASSEMBLY TOWER LINK SUPPORT STRAP TENSION LINK TOWER LINK BOOM SUPPORT STRAP BOOM ASSEMBLY BOOM SUPPORT STRAP TOWER LINK SUPPORT STRAP TOWER LINK TENSION LINK MAE24130 Figure 4-3.

  • Page 125: Boom Disassembly

    SECTION 4 - BOOM & PLATFORM Boom Disassembly 5. Remove the hardware securing spring mounting plate and spring to the cable block. Remove the spring mounting plate and spring from the end of the boom 1. Tag and disconnect the hoses and electrical harnesses section.
  • Page 126 SECTION 4 - BOOM & PLATFORM 7. Remove hardware securing valve to telescope cylinder. 9. Attach an auxiliary hydraulic power source to the tele- Remove the valve assembly. scope cylinder and extend the cylinder rod enough to turn the trunnion in a vertical position. MAE22970 10.
  • Page 127 SECTION 4 - BOOM & PLATFORM 12. Remove the hardware that secure rope extend block to 16. Remove spacer and hardware that secure sheave guard the fly boom section. to the telescope cylinder. MAE23010 17. Remove the sheave assembly by adjusting the sheave guard then remove the bracket and cable.

  • Page 128: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly 9. Install sheave on the telescope cylinder secure with pin and bolts. NOTE: When installing fly section wear pads, install same number and thickness of shims as were removed during disassem- bly. 1. Measure inside dimensions of the base and mid sections to determine the number of shims required for proper lift.
  • Page 129 SECTION 4 - BOOM & PLATFORM 12. Install end of the extend cables into the extend rope 17. Insert the mid, fly and Tele cylinder assembly way into the boom base section enough to be able to pull the block. outer mid retract cables out through the hole at the bot- tom front of the boom base section.
  • Page 130 SECTION 4 - BOOM & PLATFORM 23. Install the four bolts, shims, and bars that secure the 25. Install the hardware securing spring mounting plate and telescope cylinder rod to the boom base section. Torque spring to the cable block. the bolts to 40.6 ft.

  • Page 131: Installation

    5. Use an adequate lifting device, lift the boom assembly and install pin, keeper pin, and retaining bolt (4) secur- ing the tower link to the boom assembly. Apply JLG Threadlocker (PN 0100011) and torque to 346 ft.lbs. (469 Nm).

  • Page 132: Main Boom Lift Cylinder

    SECTION 4 - BOOM & PLATFORM 4.10 MAIN BOOM LIFT CYLINDER Installation 1. Using an adequate lifting device, position the lift cylin- Removal der in tower link in the same manner that it was removed. NOTE: Refer to Figure 4-4., Main Boom Lift Cylinder Removal and Installation.

  • Page 133: Main Boom Powertrack

    SECTION 4 - BOOM & PLATFORM 4.11 MAIN BOOM POWERTRACK 6. Remove bolts (2) securing push tube on mid boom sec- tion. Removal 7. With powertrack support and using all applicable safety precautions, remove bolts (3) securing rail to the base 1.
  • Page 134 2. Screw 7. Proximity Sensor 12. Plate 17. Plate 3. Screw 8. Plate 13. Clip 4. Washer 9. Shield 14. Nut 5. Proximity Sensor 10. Boom Angle Sensor (Lower) 15. Bolt Figure 4-6. Boom Sensors Installation - 600SC 4-18 3121776...
  • Page 135 SECTION 4 - BOOM & PLATFORM MAE26860 1. Bolt 6. Bracket 11. Boom Angle Sensor (Upper) 16. Tie-Strap 2. Screw 7. Proximity Sensor 12. Plate 17. Plate 3. Screw 8. Plate 13. Clip 4. Washer 9. Shield 14. Nut 5. Proximity Sensor 10.

  • Page 136: Wire Rope

    IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION, LOWER PLATFORM TO STOWED POSITION, SHUT DOWN MACHINE, AND HAVE WIRE ROPES INSPECTED/SERVICED BY A QUALIFIED JLG MECHANIC. LOOSE OR MIS- ADJUSTED WIRE ROPES COULD RESULT IN SERIOUS INJURY OR DEATH.

  • Page 137: Three Month Inspection

    1. Position boom in fully down and retracted position. 2. Check wire rope tension by deflecting wire ropes by Model 600SC 660SJC hand. Properly tensioned ropes should have little or no movement. Dim. A 14.6"...

  • Page 138: Wire Rope Service Indicator

    SECTION 4 - BOOM & PLATFORM 4.15 JIB (IF EQUIPPED) NOTE: Using a suitable lifting device, support the jib. Removal 1. For platform and support removal see Section 4.7 - Plat- form. 2. Position the articulating jib boom level with ground. HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.

  • Page 139: Boom Cleanliness Guidelines

    Using a soft head mallet, install rotator sup- done using all applicable safety precautions outlined in port pin (3) into jib boom pivot weldment and secure the JLG Operation & Safety Manual and the JLG Service with mounting hardware. & Maintenance Manuals.

  • Page 140: Foot Switch Adjustment

    This is done by releasing all functions, then instructions outlined in the JLG Service & Maintenance releasing and re-depressing the footswitch. Manual to remove debris.

  • Page 141: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.19 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove screw from other side of track. Remove bar/poly roller from powertrack. Remove Link NOTE: Hoses shown in powertrack are for example only. Actual hose and cable arrangements are different. 1.
  • Page 142 SECTION 4 - BOOM & PLATFORM 3. To remove a link, rivets holding links together must be 5. After grinding it may be necessary to use a center punch removed. Use a right-angle pneumatic die grinder with with a hammer to remove rivet. a ¼”...
  • Page 143 SECTION 4 - BOOM & PLATFORM 6. Insert flat head screwdriver between links. Twist and pull 7. Remove link from other section of powertrack using links apart. screwdriver. 3121776 4-27...

  • Page 144: Install New Link

    SECTION 4 - BOOM & PLATFORM Install New Link 2. Spread half-shear (female) end of new link and slide cut- out end of track section into it. Use screwdriver if neces- 1. Squeeze cut-out end of new link into half-shear (female) sary.
  • Page 145 SECTION 4 - BOOM & PLATFORM 4. Pull moving end over track so new connection is posi- 6. Push pin through center hole. Slide washer on pin. tioned in curve of powertrack. Round half-shears will rotate into cut-outs. 7. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed.
  • Page 146 SECTION 4 - BOOM & PLATFORM NOTE: Make sure snap rings are seated in pin groove and closed 2. Pull up on other end of round bar. Slide new poly roller properly. on bar. Incorrect Correct 1. Install new 8-32 x 0.500 self-threading Torx head screw in end of new aluminum round bar.

  • Page 147: Replace Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM 3. Install new 8-32 x 0.500 self threading screw on other Replace Fixed End Brackets side. Torque to 18-20 in-lb (2-2.25 Nm). REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 1. Remove rivets as shown in link removal instructions. NOTE: When tightening screws make sure screw head is seated against link with no space in between link and underside of screw head.

  • Page 148: Replace Moving End Brackets

    SECTION 4 - BOOM & PLATFORM 2. Parts used: Bracket Center Pin and Center Pin Snap Ring. Replace Moving End Brackets 3. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it. REPOSITION CABLES AND HOSES.
  • Page 149 SECTION 4 - BOOM & PLATFORM 2. Install center pin with snap ring in new bracket. NOTE: Ensure snap rings are seated in pin groove and closed properly. Incorrect Correct 4. Make sure both brackets rotate correctly. 3. Install radius pins and snap rings in original locations. Repeat with other moving end if replaced.

  • Page 150: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.20 SKYGUARD Function Test SKYGUARD ONLY Operation Perform this function test if SkyGuard only is selected in SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-2). When the SkyGuard sensor is activated, functions in use at From the Platform Control Console in an area free from obstruc- the time of actuation will reverse or cutout.

  • Page 151: Diagnostics & Troubleshooting

    SECTION 4 - BOOM & PLATFORM Diagnostics & Troubleshooting If the status of the switch/relay remains CLOSED while the Sky- Guard sensor is actively engaged, a power or ground wire may If SkyGuard does not function when the sensor is engaged, not be making good contact or may be loose or broken.
  • Page 152 We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,...

  • Page 153: Basic Hydraulics Information & Schematics

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SECTION 5. BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container, brush an even film of oil around the entire o-ring in the SYSTEM fitting, making sure the entire o-ring is completely satu- rated.

  • Page 154: Dip Method

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Dip Method Spray Method This method requires a pump or trigger spray bottle. NOTE: This method works best with Face Seal o-rings, but will work for all o-ring fitting types. 1. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- 2.

  • Page 155: Hydraulic Connection Assembly And Torque Specification

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512 TORQUE SPECIFICATION Tapered Thread Types NPTF = national tapered fuel (Dry Seal) per SAE J476/J512 Figure 5-4. SAE Thread ORFS = o-ring face seal per SAE J1453 Figure 5-1.

  • Page 156: Straight Thread Types, Port Connections

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Straight Thread Types, Port Connections Flange Connection Types ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162 MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162 6149, DIN 3852 Figure 5-10.

  • Page 157: Assembly And Torque Specifications

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the correct torque values. Prior to selecting the appropriate torque from the tables a. Verify the material designation in the table head- within this section, it is necessary to properly identify the con- ings.

  • Page 158: Assembly Instructions For American Standard Pipe Thread Tapered (Nptf) Connections

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for American Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN- MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR Thread Tapered (NPTF) Connections. ALIGNMENT.

  • Page 159: Assembly Instructions For British Standard Pipe Thread Tapered (Bspt) Connections

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for British Standard Pipe NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN- MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR Thread Tapered (BSPT) Connections ALIGNMENT.

  • Page 160: Assembly Instructions For 37° (Jic) Flare Fittings

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table 5-3, 37° Flare (JIC) Thread - Steel or Table 5-4, 37° Flare (JIC) Thread - 1. Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench centricity issues with the tube OD.
  • Page 161 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-3. 37° Flare (JIC) Thread - Steel TYPE/FITTING IDENTIFICATION Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...
  • Page 162 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-4. 37° Flare (JIC) Thread - Aluminum/Brass TYPE/FITTING IDENTIFICATION Torque Flats from Thread Wrench ØA* ØB* [Ft-Lb] [N-m] Size Resistance Dash Size (F.F.W.R)** (UNF) (in) (mm) (in) (mm) 5/16-24 0.28 7.00 0.31 7.75 3/8-24...

  • Page 163: Assembly Instructions For 45° Sae Flare Fittings

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings 4. Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass 1. Inspect the flare for obvious visual squareness and con- while using the Double Wrench Method outlined in this centricity issues with the tube OD.
  • Page 164 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-5. 45° Flare (SAE) - Steel TYPE/FITTING IDENTIFICATION Torque Turns From Thread Size ØA* ØB* [Ft-Lb] [N-m] Finger Tight Dash Size (TFFT)** (UNF) (in) (mm) (in) (mm) 7/16-20 0.39 9.90 0.44 11.10 1/4 to 1/2 5/8-18...

  • Page 165: Assembly Instructions For O-Ring Face Seal (Orfs) Fittings

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal (ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu- Fittings minum/Brass while using the Double Wrench Method.
  • Page 166 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass Flats from Wrench TYPE/FITTING IDENTIFICATION Torque Resistance (F.F.W.R)** Thread Swivel & ØA* ØB* [Ft-Lb] [N-m] Dash Tube Size Hose Size Nuts Ends (UNF) (in) (mm) (in) (mm)

  • Page 167: Assembly Instructions For Din 24° Flare Bite Type Fittings (Mbtl And Mbts)

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS) A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND LEAKAGE. 1. Inspect the components to ensure free of contamina- tion, external damage, rust, splits, dirt, foreign matter, or burrs.
  • Page 168 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-9. DIN 24° Cone (MBTL & MBTS) DIN 24° CONE FLARELESS BITE FITTING TYPE/FITTING IDENTIFICATION (With or Without O-Ring) Torque Flats from Tube Thread M ØA* ØB* ØD* Wrench O.D. Size [Ft-Lb] [N-m] Resistance...

  • Page 169: Assembly Instructions For Bulkhead (Bh) Fittings

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for Bulkhead (BH) Fittings 1. Ensure threads and surface are free of rust, weld and brazing splatter, splits, burrs or other foreign material. If necessary replace fitting or adapter. 2. Remove the locknut from the bulkhead assembly. 3.
  • Page 170 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-10. Bulkhead Fittings (BH) - INCH FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Thread Size Dash Size [Ft-Lb] [N-m] (UNF) 9/16-18 11/16-16 13/16-16 1-14 1 3/16-12 1 5/16-12 1 7/16-12 1 11/16-12 2-12 Torque...
  • Page 171 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-11. Bulkhead Fittings (BH) - METRIC FASTENING JAM NUT TYPE/FITTING IDENTIFICATION for Bulkhead Connectors Torque Connecting Thread M Size Tube O.D. MATERIAL TYPE [Ft-Lb] [N-m] (mm) (metric) M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5...
  • Page 172 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru Tables 5-17, O-RING BOSS (ORB) while using the Double Fittings Wrench Method. 1. Inspect components to ensure that male and female NOTE: The table headings identify the straight thread O-ring port port threads are free of rust, splits, dirt, foreign matter, or and the type on the other side of the fitting.
  • Page 173 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-12. O-ring Boss (ORB) - Table 1 of 6 HEX TYPE PLUGS & STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb)
  • Page 174 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-13. O-ring Boss (ORB) - Table 2 of 6 STUD ENDS TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF) (in)
  • Page 175 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-14. O-ring Boss (ORB) - Table 3 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF)
  • Page 176 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-15. O-ring Boss (ORB) - Table 4 of 6 ADJUSTABLE STUD END TYPE/FITTING IDENTIFICATION with (ORFS) or S series DIN (MBTS) opposite end Torque Thread Size ØA* MATERIAL Dash Size Ft-Lb or (in-lb) [N-m] (UNF) (in)
  • Page 177 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-16. O-ring Boss (ORB) - Table 5 of 6 TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS Torque Thread Size ØA* Ft-Lb or (in-lb) [N-m] MATERIAL Dash Size (UNF) (in) (mm) 5/16-24 0.31 7.93 (30) (32) (33)
  • Page 178 1.19 30.10 1 5/16-12 1.31 33.30 Fitting size greater than -12 not typically specified on 1 5/8-12 1.63 41.30 JLG applications. Consult specific service procedure if encountered. 1 7/8-12 1.87 47.60 2 1/2-12 2.50 63.50 ZERO LEAK GOLD® TYPE/FITTING IDENTIFICATION...

  • Page 179: Assembly Instructions For Adjustable Port End Metric (Mff) Fittings

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18, Table 5-19, Table 5-20, Metric Flat Face Port (MFF) - L Metric (MFF) Fittings Series and Table 5-21, Table 5-22, Table 5-23, Metric Flat Face Port (MFF) - S Series while using the Double 1.
  • Page 180 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 181 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-19. Metric Flat Face Port (MFF) - L Series - Table 2 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with 37° (JIC) or L series DIN (MBTL) opposite end with 37°...
  • Page 182 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-20. Metric Flat Face Port (MFF) - L Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS Torque...
  • Page 183 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3 FORM A (SEALING WASHER) FORM B (CUTTING FACE) TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque...
  • Page 184 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-22. Metric Flat Face Port (MFF) - S Series - Table 2 of 3 FORM E (EOLASTIC SEALING RING) FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end...
  • Page 185 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-23. Metric Flat Face Port (MFF) - S Series - Table 3 of 3 BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING) TYPE/FITTING IDENTIFICATION with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS Torque...

  • Page 186: Assembly Instructions For Metric Iso 6149 (Mpp) Port Assembly Stud Ends

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24, Metric Pipe Parallel O-ring Boss (MPP) while using the Port Assembly Stud Ends Double Wrench Method.
  • Page 187 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP) STUD ENDS STUD ENDS TYPE/FITTING IDENTIFICATION with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end Torque Torque Thread...

  • Page 188: Assembly Instructions For Adjustable Port End (Bspp) Fittings

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25, Table 5-26, Table 5-27, British Standard Parallel Pipe Port (BSPP) Fittings (BSPP) - L Series and Table 5-28, Table 5-29, Table 5-30, British Standard Parallel Pipe Port (BSPP) - S Series while 1.
  • Page 189 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 3121776 5-41...
  • Page 190 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 5-42 3121776...
  • Page 191 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 3121776 5-43...
  • Page 192 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 5-44 3121776...
  • Page 193 G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 3121776 5-45...
  • Page 194 Service Manual. G 3/4A G 1A G 1-1/4A G 1-1/2A * Typical for JLG Straight Male Stud Fittings. ** Non typical for JLG Straight Male Stud Fittings, reference only. *** Typical for JLG Adjustable Fittings. 5-46 3121776...

  • Page 195: Assembly Instructions For Flange Connections: (Fl61 And Fl62)

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for Flange Connections: (FL61 and FL62) 1. Make sure sealing surfaces are free of rust, splits, scratches, dirt, foreign matter, or burrs. 2. See O-ring Installation (Replacement) for O-ring installa- tion instructions.
  • Page 196 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch GRADE 5 Screws GRADE 8 Screws Flange Size...
  • Page 197 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners STEEL 4-BOLT FLANGE SAE J518 TYPE/FITTING IDENTIFICATION (INCH FASTENERS) Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with Bolt Inch CLASS 8.8 Screws CLASS 10.9 Screws...

  • Page 198: Double Wrench Method

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Double Wrench Method improper joint load and leads to leaks. For hose connections, the ‘layline’ printed on the hose is a good indicator of proper To prevent undesired hose or connector rotation, two hose installation.

  • Page 199: Ffwr And Tfft Methods

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS FFWR and TFFT Methods Adjustable Stud End Assembly For Adjustable Stud End Connections; the following assembly FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed: 1. Lubricate the o-ring with a light coat of hydraulic oil. 1.

  • Page 200: O-Ring Installation (Replacement)

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Figure 5-14. Adjustable Stud End Assembly O-ring Installation (Replacement) 4. In ORB; ensure O-ring is properly seated in groove. On straight threads, ensure O-ring is seated all the way past the threads prior to installation. Care must be taken when installing O-rings over threads dur- ing replacement or installation.

  • Page 201: Cylinder Locations

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Cylinder Locations 600SC 660SJC MAE24380 1. Main Lift Cylinder 3. Platform Level Cylinder 2. Telescope Cylinder 4. Jib Lift Cylinder Figure 5-15. Hydraulic Cylinder Locations 5-54 3121776...

  • Page 202: Main Lift Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Main Lift Cylinder DISASSEMBLY NOTE: Refer to Figure 5-19. Main Lift Cylinder. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 1. Connect a suitable auxiliary hydraulic power source to cylinder port block fitting.
  • Page 203 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 10** 11*** 12**** * Torque 1106 ft-lb (1500 Nm) ** Torque 25-20 ft-lb (34-28 Nm) *** Torque 33-36 ft-lb (45-50 Nm) 1001184500-I **** Torque 33-40 ft-lb (45-55 Nm) MAE21930 1. Barrel 7. Setscrew 12.
  • Page 204 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 14. Remove and discard retaining ring (16), wiper (22), bearing ring (19), rod seal (20), and ring (21) from cylin- REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, der head (3).
  • Page 205 NOTE: Use proper cylinder seal kit for cylinder assembly. See your etc. to facilitate bearing installation.  JLG Parts Manual. b. Inspect steel bushing for wear or other damage. If  steel bushing is worn or damaged, rod/barrel must Apply a light film of hydraulic oil to all components before be replaced.
  • Page 206 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5. Install two seals (27) and O-rings (24) on piston. 12. Apply anti-seize to cylinder head (5) threads. Screw in cylinder head. Torque to 1106 ft-lb (1500 Nm). Adjust 6. Apply loctite 243 (Loxeal 55-03) to piston threads. Install cylinder head so screw hole is aligned between cylinder piston on rod.

  • Page 207: Telescope Cylinder

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Telescope Cylinder 5. Mark cylinder head (3) and barrel (13) with center punch marks (A) for later realignment. Remove eight cylinder head capscrews (9). DISASSEMBLY NOTE: Refer to Figure 5-30. Telescope Cylinder (SN 0300245151 to Present including 0300237157.
  • Page 208 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 1001175850 -D *Torque to 9 ft-lb (12 Nm) MAE21950 1. Bolt 6. Ring 10 A. Cartridge 11. Barrel 21. Wiper 16. Seal 2. Bushing 7. Capscrew 10 B. Cartridge 12. Rod 22. Seal 17.
  • Page 209 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 9*** 10A**** *Torque to 9.5 ft-lb (13 Nm) 10B**** **Torque to 18 ft-lb (25 Nm) ***Torque to 37 ft-lb (50 Nm) ****Torque to 50-55 ft-lb (68-75 Nm) 1001228079-A MAE31290A 1. Bolt 6. Ring 10 A.
  • Page 210 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 8. Using suitable protection, clamp cylinder rod in a vise or 7. Inspect threaded portion of piston for damage. Dress similar holding fixture as close to piston as possible. threads as necessary. 9.
  • Page 211 ASSEMBLY NOTE: Use proper cylinder seal kit for cylinder assembly. See your  JLG Parts Manual.  Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylin- der head gland groove.
  • Page 212 9. Thread piston onto rod until it aligns with spacer end and install tapered bushing. NOTE: Apply JLG Threadlocker P/N 0100011 or equivalent to tapered bushing bolts when rebuilding slave, lift, and tele- scope cylinders. 10. Install bolts in tapered bushing using JLG Threadlocker Figure 5-39.

  • Page 213: Platform Level (Slave) Cylinder

    Platform Level (Slave) Cylinder 5. Unscrew cylinder head with hook spanner wrench. DISASSEMBLY NOTE: Refer to Figure 5-43. Platform Level (Slave) Cylinder - 600SC and Figure 5-44. Platform Level (Slave) Cylinder - 660SJC. CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
  • Page 214 3. Head 9. O-Ring 15. Nut 21. Counterbalance Valve 4. Wiper 10. Backup Ring 16. Bearing 5. Retaining Ring 11. O-Ring 17. Plug 6. Rod Seal 12. Piston 18. Spacer Figure 5-43. Platform Level (Slave) Cylinder - 600SC 3121776 5-67...
  • Page 215 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 12*** * Torque 50 - 55 ft-lb (68 - 75 Nm) ** Torque 673.2 - 822.8 ft-lb (912 - 1115 Nm) 1001184957-C *** Torque 673.2 - 822.8 ft-lb (912 - 1115 Nm) MAE21920 1.
  • Page 216 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 8. Loosen setscrew (16) retaining ball (15) in piston (12). CLEANING AND INSPECTION 9. Screw piston counterclockwise and remove from rod. 1. Clean parts thoroughly with approved cleaning solvent. 10. Remove and discard O-ring (14) and seal (13). 2.
  • Page 217 INSTALLED. REFER TO CROSS SECTION ILLUSTRATIONS FOR CORRECT SEAL ORIENTATION. NOTE: Use correct cylinder seal kit for cylinder assembly. See your  JLG Parts Manual.  Apply a light film of hydraulic oil to all components before assembly. 1. Support rod in holding fixture.
  • Page 218 11. Position cylinder barrel in a suitable holding fixture. 8. Install seal (16) on piston. 9. Apply JLG thread locking compound (P/N 0100011) to INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES. piston threads. Install piston on rod.

  • Page 219: Jib Lift Cylinder (660Sjc Only)

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Jib Lift Cylinder (660SJC Only) 5. Mark cylinder head (1) and barrel (2) with center punch marks (3) for later realignment. Remove eight cylinder head capscrews (4). DISASSEMBLY NOTE: Refer to Figure 5-56. Jib Lift Cylinder Assembly (660SJ). CCONTAMINATION MAY DAMAGE EQUIPMENT.
  • Page 220 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 26** 16 17 19 18 *50 - 55 ft-lb (68 - 75 Nm) **5 ft-lb (9 Nm) 1001231956-A MAE23720 1. Barrel 5. Rod 9. O-Ring Plug 14. Seal 19. Wiper 24. Locking Primer 1A.
  • Page 221 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 8. Using suitable protection, clamp cylinder rod in a vise or 7. Inspect threaded portion of piston for damage. Dress similar holding fixture as close to piston as possible. threads as necessary. 9.
  • Page 222 ASSEMBLY NOTE: Use proper cylinder seal kit for cylinder assembly. See your  JLG Parts Manual.  Apply a light film of hydraulic oil to all components before assembly. 1. Use seal tool to install new rod seal into applicable cylin- der head gland groove.
  • Page 223 9. Thread piston onto rod until it aligns with spacer end and install tapered bushing. NOTE: Apply JLG Threadlocker P/N 0100011 or equivalent to tapered bushing bolts when rebuilding slave, lift, and tele- scope cylinders. 10. Install bolts in tapered bushing using JLG Threadlocker Figure 5-65.

  • Page 224: Hydraulic Pump (Gear)

    2. Remove bolts and washers secured on the gear pump. secure the gear pump using two bolts and washers. Apply JLG Threadlocker P/N 0100011 to end of bolts. 3. Carefully dislodge the gear pump shaft from the rear Torque bolts to 20-24 ft.lbs (27-33 Nm).

  • Page 225: Variable Pump

    2. Remove two bolts secured on the rear variable pump. 3. Carefully insert the shaft of front variable pump into the engine and secure it using two bolts. Apply JLG Thread- 3. Carefully dislodge the rear variable pump shaft from the locker P/N 0100011 to end of bolts.

  • Page 226: Load Sense Compensator

    3. Adjust load sense relief valve (3) to 3200 - 3250 psi  COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS. JLG INDUSTRIES INC. RECOMMENDS OPERATING THE MACHINE UNTIL THE (220.6 - 224.1 bar). Turn adjuster clockwise to increase or HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES counterclockwise to decrease pressure.

  • Page 227: Load Sense Compensator

    3. Adjust load sense relief valve (3) to 3200 - 3250 psi  COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS. JLG INDUSTRIES INC. RECOMMENDS OPERATING THE MACHINE UNTIL THE (220.6 - 224.1 bar). Turn adjuster clockwise to increase or HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES counterclockwise to decrease pressure.
  • Page 228 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS MAE24900 Figure 5-68. Main Control Valve Block 3121776 5-81...

  • Page 229: Main High Pressure Relief Valve

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.7 PLATFORM VALVE BLOCK PRESSURE SETTING Platform Jib Down Relief Valve PROCEDURE 1. Install a pressure gauge at port M5-6 of the platform control valve capable of reading pressures up to  Refer to Figure 5-69.
  • Page 230 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 600SC 660SJC MAE24910 5. Main High Pressure Relief Valve 7. Jib Relief Valve 9. High Pressure Relief Solenoid 6. Low Pressure Relief Valve 8. Low Pressure Relief Solenoid 10. Dump Directional Valve Figure 5-69.
  • Page 231 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS MAE24930 1. Load Sense Compensator 6. Check Valve 11. Pressure Compensator Valve 16. Solenoid Valve 2. Relief Valve Flow/Pressure Control Valve 12. Solenoid Valve 17. Orifice Plug 3. Relief Valve 8. Relief Valve 13.
  • Page 232 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 25-30 (10.8) (33.8-40.6) 40-45 40-45 121.7-132.8 30-35 (54-61) (54-61) (165-180) (40.6-47.4) 29-38 (39.8-51.5) 25-30 30-35 25-30 25-30 (33.8-40.6) (40.6-47.4) (33.8-40.6) 60-70 (33.8-40.6) (81.3-94.9) 25-35 (33.8-47.4) 25-30 30-35 30-35 (10.8) (33.8-40.6) (40.6-47.4) (40.6-47.4) NOTE: All values are in Foot-Pounds (Nm) 1001196595-C MAE24940...
  • Page 233 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS (10.8) (10.8) 40-49 (54-66.4) (10.8) 25-30 (33.8-40.6) 29-38 (39.3-51.5) (47.4) (16.2) 25-30 (33.8-40.6) (47.4) (59.6) (59.6) (10.8) (47.4) (10.8) (10.8) NOTE: All values are in Foot-Pounds (Nm) 1001196595-C MAE24950 Figure 5-72. Main Control Valve Torque Values - Sheet 2 of 2 5-86 3121776...
  • Page 234 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 40.5 - 44.3 (52 - 60) 29 - 38 (39 - 51) 28.8 - 37.6 (39 - 50) 40.5 - 44.3 (54 - 60) 25 - 30 (33 - 40.7) 25 - 30 (33 - 40.7) 34 - 38 25 - 30...

  • Page 235: Hydraulic Schematics

    SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.8 HYDRAULIC SCHEMATICS Figure 5-74. Hydraulic Schematic (600SC) - Sheet 1 of 2 5-88 3121776...
  • Page 236 FUNCTION PUMP DISPLACEMENT: 19 2 cc 1 17 cu .in/ rev) OPTIONAL TANK HEATER " TANK " SPEED BRAKE VALVE CRAWLER HYDR UL IC TAN SHEET 1 1001230009-B MAE24110B Figure 5-75. Hydraulic Schematic (600SC) - Sheet 2 of 2 3121776 5-89...
  • Page 237 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Figure 5-76. Hydraulic Schematic (660SJC) - Sheet 1 of 2 5-90 3121776...
  • Page 238 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS 1001230009-B MAE24120B Figure 5-77. Hydraulic Schematic (660SJC) - Sheet 2 of 2 3121776 5-91...

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