Oshkosh Corporation JLG 600S Service And Maintenance Manual
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Oshkosh Corporation JLG 600S Service And Maintenance Manual

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Service and Maintenance Manual
Models
600S
660SJ
PVC 2001
PN - 31215034
October 19, 2019 - Rev A
AS/NZS

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Ana Cristina Espinal
July 17, 2025

Good morning, this manual applies for S/N 0300063290?

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Summary of Contents for Oshkosh Corporation JLG 600S

  • Page 1 Service and Maintenance Manual Models 600S 660SJ PVC 2001 PN - 31215034 October 19, 2019 - Rev A AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Bhydraulic System Safety

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the mobile elevat- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION ing work platform. It is of utmost importance that mainte- COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A nance personnel pay strict attention to these warnings and SAFETY VIOLATION.
  • Page 4 INTRODUCTION REVISON LOG Original Issue A - October 19, 2019 31215034...

  • 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 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Welding on JLG Equipment ............... . . 2-5 Do the Following When Welding on JLG Equipment: .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO 3.20 Generator..................3-82 Every 250 hours .
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Lubricating O-rings In The Hydraulic System ............5-1 Cup and Brush .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Platform Valve Block Pressure Setting Procedure ........... . 5-88 Main High Pressure Relief Valve.
  • Page 10 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. DIN Connectors ................7-5 Exceptions .
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Maintenance and Lubrication Diagram - Deutz D2011L04 ......... . . 1-6 1-2.
  • Page 12 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 4-3. Boom Assembly Removal and Installation ............4-9 4-4.
  • Page 13 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-47. Cylinder Head Installation ................5-70 5-48.
  • Page 14 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 6-6. Analyzer Software P2.13 - Sheet 4 of 14 ............. 6-12 6-7.
  • Page 15 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 7-41. Main valve Harness (4WS) - Sheet 1 of 4 ............. 7-68 7-42.
  • Page 16 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 31215034...
  • Page 17 LIST OF TABLES TABLE NO. TITLE PAGE NO. Deutz TD 2.9L4 (67hp) Specifications ............. . . 1-2 Deutz D 2.9L4 (49hp) Specifications.
  • Page 18 LIST OF TABLES TABLE NO. TITLE PAGE NO. Machine Configuration Programming Information - Version P2.13 ........6-31 Machine Configuration Programming Settings - Version P2.13 .
  • Page 19 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 20: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA Machine Specifications Machine Dimensional Data Maximum Work Load (Capacity) - 600S Machine Height (Stowed) 8 ft. 2.4 in. (2.5 m) Unrestricted: 600 lb (272 kg) Machine Length (Stowed) Restricted: 1000 lb (454 kg) 600S...

  • Page 21: Capacities

    SECTION 1 - SPECIFICATIONS 1.3 CAPACITIES Table 1-3. Deutz D2011L04 Specifications Fuel Diesel Fuel Tank Max Output (Power) 49 hp (36.4kW) @ 2500 RPM) Diesel 31 Gallons (117 L) Diesel (Steel Tank) 52 Gallons (200 L) Oil Capacity Gasoline 31 Gallons (117 L) Cooling System 5 Quarts (4.5 L) Crankcase...

  • Page 22: Tires

    SECTION 1 - SPECIFICATIONS 1.5 TIRES 1.6 CRITICAL STABILITY WEIGHTS Table 1-5. Tire Specifications Size 355/55D 625 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT- Load Range FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Ply Rating Components Fill Type...

  • Page 23: Hydraulic Oil

    SECTION 1 - SPECIFICATIONS 1.7 HYDRAULIC OIL Table 1-9. Quintolubric 888-46 Table 1-6. Hydraulic Oil Density 0.92 @ 15°C (59°F) Hydraulic System S.A.E. Viscosity Pour Point <-22°F (<-30°C) Operating Temperature Range Grade Flash Point 572°F (300°C) +0° to + 180° F (-18° to +83° C) Fire Point 680°F (360°C) +0°...

  • Page 24: Torque Requirements

    SECTION 1 - SPECIFICATIONS 1.8 TORQUE REQUIREMENTS Table 1-12. Exxon Univis HVI 26 (Arctic) Table 1-13. 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 (104° F) 25.8 cSt Bearing To Turntable at 100°...
  • Page 25 SECTION 1 - SPECIFICATIONS 660SJ 600S MAE20570 Figure 1-1. Maintenance and Lubrication Diagram - Deutz D2011L04 31215034...
  • Page 26 SECTION 1 - SPECIFICATIONS 660SJ 600S MAE20580 Figure 1-2. Maintenance and Lubrication Diagram - Deutz TD2.9/D2.9 31215034...
  • Page 27 SECTION 1 - SPECIFICATIONS 660SJ 600S MAE20560 Figure 1-3. Maintenance and Lubrication Diagram - Ford MSG425 31215034...

  • Page 28: Maintenance And Lubrication

    SECTION 1 - SPECIFICATIONS 1.9 MAINTENANCE AND LUBRICATION Swing Drive Hub NOTE: The following numbers correspond to those in Figure 1-1., Figure 1-2. and Figure 1-3. FILL PORT Table 1-14. Lubrication Specifications SPECIFICATIONS Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460. MPG Multipurpose Grease having a minimum dripping point of 350°...
  • Page 29 SECTION 1 - SPECIFICATIONS Hydraulic Charge Filter Hydraulic Tank Interval - Change after first 50 hrs. and every 6 months Lube Point(s) - Fill Cap or 300 hrs. Capacity - 21 gal tank (79.5 L) 40.0 gal system (151 L) Hydraulic Return Filter Lube - HO Interval - Check Level daily;...
  • Page 30 SECTION 1 - SPECIFICATIONS Fuel Filter - Deutz D2011 Oil Change w/Filter - Deutz TD2.9 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element Capacity - 9.5 Quarts (9.0 L) Crankcase Interval - Every Year or 600 hours of operation. Lube - EO Interval - Every Year or 600 hours of operation Oil Change w/Filter - Deutz D2.9...
  • Page 31 SECTION 1 - SPECIFICATIONS Engine Coolant - Deutz D2.9 Engine Coolant - Ford MSG425 Lube Point(s) - Fill Cap Lube Point(s) - Fill Cap Capacity - 2 gal. (7.5 L) Capacity - 13.2 quart (12.5 L) Lube - Anti-Freeze Lube - Anti-Freeze Interval - Check level daily;...
  • Page 32 SECTION 1 - SPECIFICATIONS C. Air Filter - Ford MSG425 B. Platform Filter - 660SJ Lube Point - Replaceable Element Interval - Change after first 50 hours and then every year or 600 hours of operation, whichever comes first. Optional Fuel Filter - Deutz D2011 - China Market MAE34270 Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or...

  • Page 33: Thread Locking Compound

    SECTION 1 - SPECIFICATIONS 1.10 THREAD LOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 34: Torque Charts

    SECTION 1 - SPECIFICATIONS 1.11 TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 242™ or 271™ or (Loctite®...
  • Page 35 SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...
  • Page 36 SECTION 1 - SPECIFICATIONS Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area Vibra-TITE™ 111 or 140) Vibra-TITE™...
  • Page 37 SECTION 1 - SPECIFICATIONS Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite® 263) Area Vibra-TITE™...
  • Page 38 SECTION 1 - SPECIFICATIONS Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™...
  • Page 39 SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™ 111 or 140) or Vibra-TITE™...

  • Page 40: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Tensile Stress Clamp Load Torque (Loctite® 262™ or 271™ or Size Pitch Torque (Lube) (Loctite®...
  • Page 41 SECTION 1 - SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp Load (Loctite®...
  • Page 42 SECTION 1 - SPECIFICATIONS Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque Torque (Loctite® 262™ or Tensile Clamp Load (Lube or Loctite® 242™ or 271™ Size Pitch (Dry or Loctite® 263™) Stress Area See Note 4 or Vibra-TITE™...
  • Page 43 SECTION 1 - SPECIFICATIONS Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque Torque (Lube or Loctite® 242™ or 271™ Tensile Clamp (Loctite®...

  • Page 44: General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, AND Reference the JLG Pre-Delivery and Frequent Inspection Form and Inspection and Preventive Maintenance Schedule for MAINTENANCE items requiring inspection. Reference appropriate areas of this manual for servicing and maintenance procedures. General Annual Machine Inspection This section provides the necessary information needed by...

  • Page 45: Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Prior to use each day; or User or Operator User or Operator Operation and Safety Manual Inspection at each Operator change. Pre-Delivery Prior to each sale, lease, or Service and Maintenance Manual Owner, Dealer, or User Qualified JLG Mechanic...

  • Page 46: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Unless specific torque requirements are given within the text, use standard torque values on heat-treated bolts, studs, and steel nuts, in accordance with recommended Complete procedural steps in sequence when disassembling shop practices. (See “Torque Charts” on page 15.) or reassembling a component.

  • Page 47: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION While the unit is shut down, a good preventive mainte- nance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a Hydraulic System functional check of each system, before placing machine back in service.

  • Page 48: Cylinder Thermal Drift

    SECTION 2 - GENERAL Re-assembly of pinned joints using filament wound Table 2-2. Cylinder Drift bearings: Cylinder Bore Max. Acceptable Drift a. Blow out housing using compressed air to remove Diameter in 10 Minutes all dirt and debris. Bearings and bearing housings inches inches must be free of all contamination.
  • Page 49 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 50 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent 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 Auxiliary Power...
  • Page 51 SECTION 2 - GENERAL Table 2-3. Inspection and Preventive Maintenance Schedule INTERVAL Pre-Delivery Annual AREA (Yearly) or Frequent Inspection Inspection Annual Machine Inspection Due No Unauthorized Modifications or Additions All Relevant Safety Publications Incorporated General Structural Condition and Welds All Fasteners, Pins, Shields, and Covers Grease and Lubricate to Specifications Function Test of All Systems 21, 22...
  • Page 52 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 53 SECTION 2 - GENERAL ENGINE OIL OPERATION CHART DEUTZ 2.9 L04 T4F 3.6L4 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 54 SECTION 2 - GENERAL ENGINE OIL OPERATION CHART FORD MSG425 DUAL FUEL NOTES: 1. 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 55 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 Fluid Properties Base...

  • Page 56: Chassis & Turntable

    SECTION 3 - CHASSIS & TURNTABLE SECTION 3. CHASSIS & TURNTABLE 3.1 TIRES & WHEELS Wheel Installation It is extremely important to apply and maintain proper wheel Tire Damage mounting torque. For polyurethane foam filled tires, JLG Industries, Inc. recom- mends that when any of the following are discovered, mea- sures must be taken to remove the JLG product from service WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT PROPER TORQUE TO...

  • Page 57: Oscillating Axle Bleeding Procedure And Lockout Test

    SECTION 3 - CHASSIS & TURNTABLE Oscillating Axle Lockout Test The tightening of the nuts should be done in stages. Fol- lowing the recommended sequence, tighten nuts per wheel torque chart. Table 3-1. Wheel Torque Chart LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS- TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS TORQUE SEQUENCE SUSPECTED.

  • Page 58: Chassis Tilt Indicator System

    SECTION 3 - CHASSIS & TURNTABLE 3.3 CHASSIS TILT INDICATOR SYSTEM 3.6 DRIVE ORIENTATION SYSTEM The Chassis Tilt Indicator System measures the turntable angle The Drive Orientation System (DOS) indicates the conditions with respect to level ground. The control system reads the that could make the direction of movement of the chassis reading and compares it to a pre-set turntable tilt angle value.

  • Page 59: Oscillating Axle System

    SECTION 3 - CHASSIS & TURNTABLE 3.7 OSCILLATING AXLE SYSTEM 3.8 DRIVE SYSTEM The oscillating front axle is attached to the frame by a pivot The four wheel drive system consists of one variable displace- pin, which allows all four wheels to remain on the ground ment closed loop pump, four variable displacement piston when traveling on rough terrain.
  • Page 60 SECTION 3 - CHASSIS & TURNTABLE 1001181774-B MAE21090 1. Bolt 6. Washer 11. Wear Pad 2. Bolt 7. Bolt 12. Axle 3. Bearing 8. Shim 13. Pin 4. Keeper Pin 9. Shim 5. Washer 10. Axle Lockout Cylinder Figure 3-3. Axle Installation - Front 31215034...
  • Page 61 SECTION 3 - CHASSIS & TURNTABLE 1001181775-A MAE21100 MAE21100 1. Bolt 6. Keeper Pin 11. Shim 16. Shim 2. Bolt 7. Washer 12. Shim 17. Axle 3. Bolt 8. Washer 13. Pad 18. Bracket 9. Washer 14. Block 19. Pin 4.
  • Page 62 SECTION 3 - CHASSIS & TURNTABLE 1001181770-D MAF23580D 1. Bolt 5. Bracket 9. Kingpin 13. Pin 2. Pin 6. Bolt 10. Steer Cylinder Assembly 3. Keeper Pin 7. Nut 11. Tie-Rod 4. Washer 8. Knuckle 12. Bearing Figure 3-5. Steering Installation 31215034...

  • Page 63: Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.9 DRIVE HUB Remove the hub from machine and place in a clean work area. Removal Installation NOTE: Refer Figure 3-6., Drive Hub Installation Use suitable lifting device to support the drive hub. NOTE: The drive hub weighs approximately 110 lb (50 kg). Place machine on the firm level surface.

  • Page 64: Drive Motor

    SECTION 3 - CHASSIS & TURNTABLE 3.10 DRIVE MOTOR Installation Use suitable lifting device to support the drive motor. Removal NOTE: The drive motor weighs approximately 34 lb (15.4 kg). NOTE: Refer Figure 3-7., Drive Motor Installation. Install the drive motor to the machine. Place machine on the firm level surface.
  • Page 65 SECTION 3 - CHASSIS & TURNTABLE 3160350-B MAE22600 Figure 3-8. Drive Motor Assembly 3-10 31215034...
  • Page 66 SECTION 3 - CHASSIS & TURNTABLE 1. Journal Bearing 10. Slipper Retainer Guide 19. Retaining Ring 28. O-Ring 37. Servo Piston 2. Pin 11. Slipper Hold Down Pin 20. End - Axial Cap 29. Spring Seat 38. Bearing 3. Retaining Ring 12.

  • Page 67: Steer Cylinder

    SECTION 3 - CHASSIS & TURNTABLE 3.11 STEER CYLINDER Installation Using suitable lifting device, lift the steer cylinder into Removal position and install the pivot pin and retaining pin into the barrel end of the cylinder. Tag and disconnect the hoses running to the steer cylin- der.

  • Page 68: Swing Drive Hub

    SECTION 3 - CHASSIS & TURNTABLE 3.12 SWING DRIVE HUB Refer to Section 3-9., Swing Drive Installation, for swing drive maintenance. Removal Assembly/Disassembly Gently loosen the jack bolt (4). Do not remove. For detail assembly/disassembly instructions, Refer Swing Drive Hub Manual (PN 3128853) Remove the pivot bolt (7).

  • Page 69: Procedure For Setting Swing Gear Backlash

    SECTION 3 - CHASSIS & TURNTABLE Procedure For Setting Swing Gear Backlash Apply High Strength Threadlocking Compound and torque jack bolt 50 ft. lbs. (68 Nm). Set backlash to 0.010 - 0.015 inch (0.254 - 0.381 mm) using the Apply High Strength Threadlocking Compound and following procedure: tighten jam nut.

  • Page 70: Swing Bearing

    SECTION 3 - CHASSIS & TURNTABLE 3.13 SWING BEARING Wear Tolerance Turntable Bearing Mounting Bolt Condition Check From underside of the machine, at rear center, with the boom fully elevated and fully retracted, as shown in NOTE: This check is designed to replace existing bearing bolt Figure 3-12., Swing Bearing Tolerance Measurement torque checks on JLG Lifts in service.
  • Page 71 SECTION 3 - CHASSIS & TURNTABLE BOOM FULLY EXTENDED HORIZONTAL (ZERO DEGREES) MEASURING POINT LEVEL SURFACE BOOM FULLY RETRACTED AND ELEVATED MEASURING POINT LEVEL SURFACE LEVEL SURFACE MAE21740 Figure 3-12. Swing Bearing Tolerance Measurement Location & Boom Placement 3-16 31215034...

  • Page 72: Swing Bearing Replacement

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Replacement INSTALLATION Using suitable lifting equipment, carefully lower the REMOVAL swing bearing into position on the frame. Ensure the scribed line of the outer race of the bearing aligns with From Ground Control station, place the boom in a level the scribed line on the frame.

  • Page 73: Swing Bearing Torque Values

    SECTION 3 - CHASSIS & TURNTABLE Swing Bearing Torque Values Connect the hydraulic lines to the rotary coupling as tagged prior to removal. Outer Race - 190 ft-lb (260 Nm) w/Threadlocking Com- Remove the lifting equipment. pound. Unsecure the boom from rear of turntable. Inner Race - 190 ft-lb (260 Nm) w/Threadlocking Com- pound.
  • Page 74 SECTION 3 - CHASSIS & TURNTABLE 3-19 31215034...
  • Page 75 SECTION 3 - CHASSIS & TURNTABLE MAE24550 3-20 31215034...

  • Page 76: Rotary Coupling

    SECTION 3 - CHASSIS & TURNTABLE 3.14 ROTARY COUPLING Assemble lip seals (2) in direction shown in Figure 3-16., Rotary Coupling Use the following procedure to install the seal kit. Reassemble O-ring (5). If not already removed, remove axle oscillation valve Heat cap seals (8) in hydraulic oil for 5 minutes at 300°...
  • Page 77 SECTION 3 - CHASSIS & TURNTABLE MAE21600 1. Bolt 3. Nut 5. Washer 7. Rotary Coupling 2. Bolt 4. Nut 6. Mount Figure 3-17. Rotary Coupling - 2WS 3-22 31215034...
  • Page 78 SECTION 3 - CHASSIS & TURNTABLE MAE21590 1. Bolt 3. Nut 5. Washer 7. Mount 2. Bolt 4. Nut 6. Coupling Assembly Figure 3-18. Rotary Coupling - 4WS 3-23 31215034...
  • Page 79 SECTION 3 - CHASSIS & TURNTABLE 3-24 31215034...
  • Page 80 SECTION 3 - CHASSIS & TURNTABLE 3-25 31215034...
  • Page 81 SECTION 3 - CHASSIS & TURNTABLE MAE21610 1. Housing 6. Circlip 11. Seal 2. Shaft 7. Sensor 12. Wiper 3. Spacer 8. Bolt 13. Seal, Rod 4. Spacer 9. Washer 5. Fitting 10. Ring, Wear Figure 3-21. Rotary Coupling Assembly 3-26 31215034...
  • Page 82 SECTION 3 - CHASSIS & TURNTABLE Table 3-2. Coupling Port Information Table - 2WS Table 3-3. Coupling Port Information Table - 4WS Operating Operating Port Port Port Port Outlet Description Pressure Outlet Description Pressure Size Size PSI (Bar) PSI (Bar) Brake 450 (31) Brake...

  • Page 83: Deutz Td2.9 L4 Engine (67Hp)

    SECTION 3 - CHASSIS & TURNTABLE 3.15 DEUTZ TD2.9 L4 ENGINE (67HP) 1001186806-M MAE21800 1. Deutz TD2.9L4 (67hp) Engine and Pump 3. Hose 5. Battery Cable (-) 2. Fuel Filter 4. Bracket 6. Battery Cable (+) Figure 3-22. Deutz TD2.9 L4 (67hp) Engine Installation 3-28 31215034...
  • Page 84 SECTION 3 - CHASSIS & TURNTABLE 1001186811-G MAE21810 1. Piston Pump Assembly 2. Deutz TD2.9 L4 Engine Assembly 3. Gear Pump Assembly 4. Exhaust Pipe Figure 3-23. Deutz TD2.9 L4 (67hp) Engine and Pumps Sub-Assembly 3-29 31215034...
  • Page 85 SECTION 3 - CHASSIS & TURNTABLE 1001186812-T MAE21820T 1. Pump Coupling Kit 8. Relay 15. Hose, Radiator 22. Air Filter 29. Bracket 2. Pulley 9. Sensor, Coolant Level 16. Mount 23. Tray 30. Hose 3. Contactor 10. Tank, Surge 17. Deutz TD2.9L4 Engine 24.
  • Page 86 SECTION 3 - CHASSIS & TURNTABLE 1001186812-T MAE21830T Figure 3-25. Deutz TD2.9 L4 (67hp) Engine Assembly - Sheet 2 of 2 3-31 31215034...

  • Page 87: Deutz D2.9 L4 Engine (49Hp)

    SECTION 3 - CHASSIS & TURNTABLE 3.16 DEUTZ D2.9 L4 ENGINE (49HP) 1001243744-A MAE39600A 1. Deutz D2.9L4 (49hp)Engine and Pump 3. Hose 5. Battery Cable (-) 7. Fuel Filter 2. Fuel Pre-Filter 4. Bracket 6. Battery Cable (+) Figure 3-26. Deutz D2.9 L4 (49hp) Engine Installation 3-32 31215034...
  • Page 88 SECTION 3 - CHASSIS & TURNTABLE 1001243743-A MAE39610A 1. Piston Pump Assembly 2. Deutz TD2.9 L4 Engine Assembly 3. Gear Pump Assembly 4. Exhaust Pipe Figure 3-27. Deutz D2.9 L4 (49hp) Engine and Pumps Sub-Assembly 3-33 31215034...
  • Page 89 SECTION 3 - CHASSIS & TURNTABLE 1001243742-H MAF23590H Figure 3-28. Deutz D2.9 L4 (49hp) Engine Assembly - Sheet 1 of 2 3-34 31215034...
  • Page 90 SECTION 3 - CHASSIS & TURNTABLE 1001243742-H MAF23600H 1. Pump Coupling Kit 8. Relay 15. Hose, Radiator 22. Air Filter 29. Bracket 2. Pulley 9. Hose 16. Mount, Fuel Filter 23. Tray 30. Hose 3. Contactor 10. Tank, Surge 17. Deutz D2.9L4 Engine 24.

  • Page 91: Check Oil Level

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed operat- Open oil drain valve and drain oil. ing and maintenance instructions. Close oil drain valve. Check Oil Level Pour in new engine oil. Refer to Section 1 for capacity and Figure 3-31., Engine Oil Viscosity.

  • Page 92: Change Fuel Filters

    SECTION 3 - CHASSIS & TURNTABLE Hand-tighten filter another half-turn. Screw in new filter by hand until gasket is flush. Hand- tighten filter another half-turn. Check oil level. Check oil pressure. Check oil filter cartridge for leaks. Change Fuel Filters Connect water sensor connector (Pre-filter Only).
  • Page 93 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\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 94 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification Charged air cooler temperature. System reaction initiated. High charged air cooler temperature. Warning threshold exceeded. High charged air cooler temperature. Shut off threshold exceeded. Diagnostic fault check for charged air cooler downstream temperature sensor No detail information Sensor error air filter differential pressure;...
  • Page 95 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification Sensor error oil temperature; signal range check high Sensor error oil temperature; signal range check low High oil temperature; warning threshold exceeded High oil temperature; shut off threshold exceeded Customer oil temperature: signal unplausible Engine speed above warning threshold Over speed detection in component engine protection...
  • Page 96 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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); interruption of electric connection Injector 6 (in firing order);...
  • Page 97 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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. 1188 Turbocharger wastegate, supply voltage below minimum threshold.
  • Page 98 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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 2791...
  • Page 99 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 3361 DEF dosing valve; short circuit to battery on low side 3361 DEF dosing valve; short circuit to battery or open load on high side 3361 Urea dosing valve;...
  • Page 100 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 4345 SCR heater relay DEF return line primary side; open load 4345 Over Temperature error No detail information 4345 SCR heater DEF return line; short circuit to battery 4345 SCR heater DEF return line;...
  • Page 101 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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); signal range check low 4769 Sensor exhaust gas temperature OxiCat downstream (normal operation);...
  • Page 102 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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. Performed by pressure increase. 523470 Pressure Relief Valve (PRV) forced to open.
  • Page 103 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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 Internal ECU monitoring detection reported error 523612...
  • Page 104 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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 Sensor error urea pump pressure;...
  • Page 105 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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 Timeout Error of CAN-Receive-Frame Active TSC1AE 523767...
  • Page 106 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 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 107 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 523921 Burner temperature, temperature below lower shutoff threshold 523921 Burner temperature sensor; Plausibility Check for burner temperature sensor Sensor burner temperature; plausibility error 523922 Burner shut of valve;...
  • Page 108 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 523969 Fault entry for override control mode. No detail information 523973 SCR Tamper detection; derating timer below limit 1 523974 SCR Tamper detection; derating timer below limit 2 523975 Urea quality;...
  • Page 109 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 524025 DPF system; operating voltage error 524025 The standstill-regeneration mode time exceeds the long-limit. Vehicle was too long or too often in standstill mode. Make oil change and reset counter. 524025 The standstill-regeneration mode time exceeds the short-limit.
  • Page 110 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 524063 Relay Urea suction line: broken wiring detected (open load) Row engine: SCR suction line (K28) V-engine: Master: common SCR-suction line (K28) Slave: common SCR back flow line (K29) 524063 SCR heater supply module;...
  • Page 111 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 524087 Urea Error Lamp; open load 524087 Urea Error Lamp; temperature over limit 524087 Urea Error Lamp; short circuit battery 524087 Urea Error Lamp; short circuit ground 524096 Control of the SCR system;...
  • Page 112 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 524134 DPF, ash load exceeds the warning threshold 524135 DPF, soot load exceeds the shutoff threshold 524135 DPF, soot load exceeds the service request threshold 524135 DPF, soot load exceeds the warning threshold 524141...
  • Page 113 SECTION 3 - CHASSIS & TURNTABLE Table 3-4. Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine) Error Identification 524230 Inducement HW Failure Slave. 524231 Inducement SCR Tamp. Slave 524232 Inducement DEF Quality in Slave ECU 524239 SCR regeneration failure is in slave ECU active. 524248 NOX sensor downstream error in slave ECU 524249...

  • Page 114: Deutz D2011L04 Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.17 DEUTZ D2011L04 ENGINE 1001186808-K MAE21760K 1. Deutz D2011 Engine 3. Bracket 5. Batter y Cable (-) 2. Fuel Hose 4. Battery Cable (+) Figure 3-32. Deutz D2011 Engine Installation 3-59 31215034...
  • Page 115 SECTION 3 - CHASSIS & TURNTABLE 1001186815-E MAE21770 1. Piston Pump Assembly 2. Deutz D2011 Engine Assembly 3. Gear Pump Assembly 4. Exhaust Pipe Figure 3-33. Deutz D2011 Engine and Pumps Sub-Assembly 3-60 31215034...
  • Page 116 SECTION 3 - CHASSIS & TURNTABLE 1001186816-M MAE21780 1. Fan 6. Adapter 11. Engine Bracket - Rear 16. Tray 21. Air Filter 2. Relay 7. Clamp, Air Cleaner 12. Engine Bracket - Right 17. Radiator Support 22. Hose 3. Gasket, Air Intake Adapter 8.
  • Page 117 SECTION 3 - CHASSIS & TURNTABLE 1001186816-M MAE21790 Figure 3-35. Deutz D2011 Engine Assembly - Sheet 2 of 2 3-62 31215034...

  • Page 118: Checking Oil Level

    SECTION 3 - CHASSIS & TURNTABLE NOTE: Refer to engine manufacturer’s manual for detailed oper- Changing Engine Oil ating and maintenance instructions. Allow engine to warm up. Engine oil should reach Checking Oil Level approximately 176° F (80° C). Make sure machine and engine are level and switch Make sure machine and engine are level and switch off engine OFF before checking oil level.

  • Page 119: Changing Oil Filter

    SECTION 3 - CHASSIS & TURNTABLE Changing Oil Filter Screw in new filter by hand until gasket is flush. Wipe area around filter to clean any dirt from area. Using a suitable oil filter removal tool, loosen lube oil fil- ter cartridge and spin off.

  • Page 120: Clean Fuel Strainer

    SECTION 3 - CHASSIS & TURNTABLE Clean Fuel Strainer Spark Arrester Cleaning Instructions Remove cleanout plug in bottom of spark arrester (muf- fler). FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE Without causing deformation (or any type of damage to NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL spark arrester) repeatedly tap on arrester near cleanout SYSTEM.
  • Page 121 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. 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 122 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. 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 123 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. 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 124 SECTION 3 - CHASSIS & TURNTABLE Table 3-5. 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 125: Ford Engine

    SECTION 3 - CHASSIS & TURNTABLE 3.18 FORD ENGINE 1001215608-I MAF23630I 1. Hose 3. Battery Cable (+) 5. Ford Engine and Pumps 7. Hose 9. Hose 2. Battery Cable (-) 4. Bracket 6. Bracket 8. Hose 10. Hose Figure 3-38. Ford MSG425 Engine Installation 3-70 31215034...
  • Page 126 SECTION 3 - CHASSIS & TURNTABLE 1001215610-C MAE21850 1. Piston Pump Assembly 4. Exhaust Insulate 7. Muffler Insulate 2. Gear Pump Assembly 5. Exhaust Insulate 8. Exhaust Pipe 3. Ford Engine Assembly 6. Muffler Insulate 9. Exhaust Insulate Figure 3-39. Ford Engine and Pumps Sub-Assembly 3-71 31215034...
  • Page 127 SECTION 3 - CHASSIS & TURNTABLE EXHAUST SYSTEM 1001215612-I MAF23740I 1. Fuel Hose 4. Support 7. Motor Mount 10. Air Filter 13. Radiator 2. Hose 5. Bracket 8. Bracket 11. Support 14. Exhaust Pipe 3. Strap 6. Hose 9. Bracket 12.
  • Page 128 SECTION 3 - CHASSIS & TURNTABLE 1001215612-I MAF23750I 16. Exhaust Pipe 21. Plate 26. Air Intake Pipe 31. Bracket 36. Hose 17. Bracket 22. Support 27. Air Intake Pipe 32. Engine Mount (RH Front) 37. Surge Tank 18. Heat Shield 23.
  • Page 129 SECTION 3 - CHASSIS & TURNTABLE Table 3-6. CAN to DTC Cross Reference (Ford MSG425 Engine) Description Gov1/2/3 interlock failure RS-485 Rx inactive RS-485 Rx noise RS-485 Rx bad packet format RS-485 remote shutdown request FPP2 higher than IVS FPP2 lower than IVS FPP2 voltage high FPP2 voltage low TPS1-2 higher than expected...
  • Page 130 SECTION 3 - CHASSIS & TURNTABLE Table 3-6. CAN to DTC Cross Reference (Ford MSG425 Engine) Description IAT voltage high IAT voltage low IAT higher than expected stage 1 MAP voltage low MAP pressure high BP pressure high BP pressure low ECT higher than expected stage 2 CHT higher than expected stage 2 ECT voltage high...
  • Page 131 SECTION 3 - CHASSIS & TURNTABLE Table 3-6. CAN to DTC Cross Reference (Ford MSG425 Engine) Description CAN-J1939 Tx fault CAN-J1939 Rx fault J1939 CAN address / engine-number conflict Tach output short to power Tach output ground short Injector 1 open or short to ground Injector 1 coil shorted Injector 2 open or short to ground Injector 2 coil shorted...
  • Page 132 SECTION 3 - CHASSIS & TURNTABLE Table 3-6. CAN to DTC Cross Reference (Ford MSG425 Engine) Description AUX analog Pull-Up/Down 2 low voltage AUX analog Pull-Up/Down 3 high voltage AUX analog Pull-Up/Down 3 low voltage AUX digital 1 high voltage AUX digital 1 low voltage AUX digital 2 high voltage AUX digital 2 low voltage...
  • Page 133 SECTION 3 - CHASSIS & TURNTABLE Table 3-6. CAN to DTC Cross Reference (Ford MSG425 Engine) Description 1268 Spark coil 1 primary shorted 1269 Spark coil 2 primary open or short to ground 1269 Spark coil 2 primary shorted 1270 Spark coil 3 primary open or short to ground 1270 Spark coil 3 primary shorted...
  • Page 134 SECTION 3 - CHASSIS & TURNTABLE Table 3-6. CAN to DTC Cross Reference (Ford MSG425 Engine) Description 1385 ERWT1 higher than expected stage 2 1385 ERWT1 voltage high 1385 ERWT1 voltage low 1385 ERWT1 higher than expected stage 1 1386 ERWT2 higher than expected stage 2 1386 ERWT2 voltage high...
  • Page 135 SECTION 3 - CHASSIS & TURNTABLE Table 3-6. CAN to DTC Cross Reference (Ford MSG425 Engine) Description 3673 TPS2 voltage high 3673 TPS2 voltage low 4236 Closed-loop gasoline bank1 high 4236 Closed-loop LPG high 4236 Closed-loop NG high 4236 Closed-loop gasoline bank1 low 4236 Closed-loop LPG low 4236...

  • Page 136: Counterweight

    SECTION 3 - CHASSIS & TURNTABLE 3.19 COUNTERWEIGHT If the counterweight has been removed, ensure the retaining bolts are torqued to the proper value as shown in Figure 3-42., Counterweight Bolt Torque. MAE21750 *Torque the bolts to 346 ft-lb (469 Nm) Figure 3-42.

  • Page 137: Generator

    SECTION 3 - CHASSIS & TURNTABLE 3.20 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 138: Inspecting Brushes, Replacing Brushes, And Cleaning Slip Rings

    SECTION 3 - CHASSIS & TURNTABLE Inspecting Brushes, Replacing Brushes, and CLEANING SLIP RINGS Cleaning Slip Rings Visually inspect the slip rings. Under normal use, the rings turn dark brown. INSPECTING BRUSH POSITION If slip rings are corroded or their surface is uneven, Inspect brush alignment with slip rings.
  • Page 139 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 140: Boom & Platform

    SECTION 4 - BOOM & PLATFORM SECTION 4. BOOM & PLATFORM 4.4 DUAL CAPACITY SYSTEM DO NOT SUPPORT THE BOOM WITH A BOOM PROP OR CRANE OR ALLOW THE The dual capacity selection and indicator system consists of a capacity mode toggle switch at the platform control box, a set PLATFORM TO REST ON THE GROUND WHEN SERVICING BOOM COMPONENTS.

  • Page 141: Electronic Platform Leveling

    SECTION 4 - BOOM & PLATFORM 4.6 ELECTRONIC PLATFORM LEVELING 4.7 FUEL LEVEL CUTOUT SYSTEM The Electronic Platform Leveling System simulates a conven- The Fuel Shutoff System senses when the fuel level is getting tional master/slave cylinder arrangement by adjusting the lev- low and automatically shuts the engine down before the fuel eling cylinder stroke based on the boom angle changes tank is emptied.

  • Page 142: Platform

    SECTION 4 - BOOM & PLATFORM 4.8 PLATFORM Remove the bolts and washers securing the support to the rotator. Support Removal Disconnect electrical cables from control console. Tag and disconnect the hydraulic lines from the rotator. Use suitable container to retain any residual hydraulic fluid.

  • Page 143: Support Installation

    SECTION 4 - BOOM & PLATFORM Support Installation Torque the nut on the rotator center bolt to 586 ft. lbs. (795 Nm). Torque the retaining bolts to 40 ft. lbs. (55 Nm). Using a suitable lifting device, support the platform sup- port and position it on the rotator.
  • Page 144 SECTION 4 - BOOM & PLATFORM A, B, D C, D MAF22380 A- Torque to 40 ft-lb (55 Nm) B- Medium Strength Threadlocking Compound 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 re-torqued.

  • Page 145: Rotator And Slave Cylinder

    SECTION 4 - BOOM & PLATFORM 4.9 ROTATOR AND SLAVE CYLINDER Assembly/Disassembly For detail assembly/disassembly instruction, Refer Rotary NOTE: Refer Figure 4-2., Removal of Components - Rotator and Actuator Manual (PN 3128848). Slave Cylinder. Installation Removal 600S 600S Support the slave cylinder. Using a suitable brass drift Tag and disconnect hydraulic lines from the rotator.
  • Page 146 SECTION 4 - BOOM & PLATFORM 660SJ SLAVE CYLINDER ROTATOR 600S ROTATOR MAE22800 Figure 4-2. Removal of Components - Rotator and Slave Cylinder 31215034...

  • Page 147: Main Boom Assembly

    SECTION 4 - BOOM & PLATFORM 4.10 MAIN BOOM ASSEMBLY 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 Remove the boom assembly. NOTE: Refer to Figure 4-3., Boom Assembly Removal and Installa- If required, remove retaining bolt, keeper pin, and pin (5) tion.
  • Page 148 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 149: Boom Disassembly

    SECTION 4 - BOOM & PLATFORM Boom Disassembly 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 Tag and disconnect the hoses and electrical harnesses section.
  • Page 150 SECTION 4 - BOOM & PLATFORM Remove hardware securing valve to telescope cylinder. 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 Pull the mid and fly boom sections from the base boom MAE22950...
  • Page 151 SECTION 4 - BOOM & PLATFORM Remove the hardware that secure rope extend block to Remove spacer and hardware that secure sheave guard the fly boom section. to the telescope cylinder. MAE23010 Remove the sheave assembly by adjusting the sheave guard then remove the bracket and cable.

  • Page 152: Assembly

    SECTION 4 - BOOM & PLATFORM Assembly 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. Measure inside dimensions of the base and mid sections to determine the number of shims required for proper lift.
  • Page 153 SECTION 4 - BOOM & PLATFORM Install end of the extend cables into the extend rope 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 154 SECTION 4 - BOOM & PLATFORM Install the four bolts, shims, and bars that secure the 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. lbs. (55 Nm). MAE22960 MAE22930 Route extend cable through cable block and install the...

  • Page 155: Installation

    SECTION 4 - BOOM & PLATFORM Installation Lift and move forward the boom and tower link assem- bly. NOTE: Refer to Figure 4-3., Boom Assembly Removal and Installa- Remove metal rod from the turntable lifting eye holes tion. and level the boom assembly to normal position. NOTE: The boom alone weighs approximately 2792 lb (1269 kg).

  • Page 156: Main Boom Lift Cylinder

    SECTION 4 - BOOM & PLATFORM 4.11 MAIN BOOM LIFT CYLINDER Installation 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 Install trunnion pins (1), hardware and bearings securing Installation.

  • Page 157: Main Boom Powertrack

    SECTION 4 - BOOM & PLATFORM 4.12 MAIN BOOM POWERTRACK Remove bolts (2) securing push tube on mid boom sec- tion. Removal With powertrack support and using all applicable safety precautions, remove bolts (3) securing rail to the base boom section. Remove powertrack from boom section. Disconnect wiring harness from ground control box.

  • Page 158: Wire Rope

    SECTION 4 - BOOM & PLATFORM 4.13 WIRE ROPE Inspect ropes for kinks or abuse. NOTE: A kink is caused by pulling down a loop in a slack line during improper handling, installation, or operation. 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.

  • Page 159: Three Month Inspection

    SECTION 4 - BOOM & PLATFORM Three Month Inspection 4.14 WIRE ROPE TENSIONING ADJUSTMENT Remove boom covers and visually (with flashlight) Wire Rope Tensioning Procedure inspect the ropes for rust, broken wires, frays, abuse, or any signs of abnormalities. Position boom in fully down and retracted position. Check wire rope tension by deflecting wire ropes by Model 600S...

  • Page 160: Wire Rope Service Indicator

    SECTION 4 - BOOM & PLATFORM 4.15 WIRE ROPE SERVICE INDICATOR DO NOT CLAMP ON THREADS OR THREADS MAY BE DAMAGED. The wire rope service indicator is integrated into the mounting block that the extension wire ropes mount to at the end of the DO NOT ALLOW WIRE ROPE TO ROTATE OR WIRE ROPE MAY BE DAMAGED.
  • Page 161 SECTION 4 - BOOM & PLATFORM Assembly Remove mounting hardware from lift cylinder pin (7). Using a suitable brass drift and hammer, remove the cyl- inder pin from articulating jib boom. Align lift cylinder with attach holes in jib assembly. Using a soft head mallet, install cylinder pin (7) into jib and secure with mounting hardware.

  • Page 162: Boom Cleanliness Guidelines

    SECTION 4 - BOOM & PLATFORM 4.17 BOOM CLEANLINESS GUIDELINES 4.18 FOOT SWITCH ADJUSTMENT The following are guidelines for internal boom cleanliness for Adjust foot switch to operate functions when pedal is at center machines used in excessively dirty environments. of travel.

  • Page 163: Powertrack Maintenance

    SECTION 4 - BOOM & PLATFORM 4.20 POWERTRACK MAINTENANCE 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. Clamp bar and poly roller tightly so they do not spin when removing screw.
  • Page 164 SECTION 4 - BOOM & PLATFORM To remove a link, rivets holding links together must be 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 165 SECTION 4 - BOOM & PLATFORM Insert flat head screwdriver between links. Twist and pull Remove link from other section of powertrack using links apart. screwdriver. 4-26 31215034...

  • Page 166: Install New Link

    SECTION 4 - BOOM & PLATFORM Install New Link Spread half-shear (female) end of new link and slide cut- out end of track section into it. Use screwdriver if neces- Squeeze cut-out end of new link into half-shear (female) sary. end of track section.
  • Page 167 SECTION 4 - BOOM & PLATFORM Pull moving end over track so new connection is posi- Push pin through center hole. Slide washer on pin. tioned in curve of powertrack. Round half-shears will rotate into cut-outs. Install snap ring in groove on pin. Repeat pin installation steps for all center holes with rivets removed.
  • Page 168 SECTION 4 - BOOM & PLATFORM NOTE: Make sure snap rings are seated in pin groove and closed Pull up on other end of round bar. Slide new poly roller properly. on bar. Incorrect Correct Install new 8-32 x 0.500 self-threading Torx head screw in end of new aluminum round bar.

  • Page 169: Replace Fixed End Brackets

    SECTION 4 - BOOM & PLATFORM Replace Fixed End Brackets Install new 8-32 x 0.500 self threading screw on other side. Torque to 18-20 in-lb (2-2.25 Nm). REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT DAMAGE. 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 170: Replace Moving End Brackets

    SECTION 4 - BOOM & PLATFORM Replace Moving End Brackets Parts used: Bracket Center Pin and Center Pin Snap Ring. Take new bracket and install bracket center pin and snap ring. Repeat on other bracket if replacing it. REPOSITION CABLES AND HOSES. KEEP COVERED DURING GRINDING TO PRE- VENT DAMAGE.
  • Page 171 SECTION 4 - BOOM & PLATFORM NOTE: Ensure snap rings are seated in pin groove and closed Install center pin with snap ring in new bracket. properly. Incorrect Correct Make sure both brackets rotate correctly. Install radius pins and snap rings in original locations. Repeat with other moving end if replaced.

  • Page 172: Skyguard

    SECTION 4 - BOOM & PLATFORM 4.21 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 173: 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 174: Bolt-On External Fall Arrest

    SECTION 4 - BOOM & PLATFORM 4.22 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion. The Bolt-On External Fall Arrest system is designed to provide GAP SHOWING: a lanyard attach point while allowing the operator to access GAP SHOWING: INCORRECT areas outside the platform.

  • Page 175: Installation

    SECTION 4 - BOOM & PLATFORM Installation Without twisting the fall arrest cable, pull it thru the left hand bracket and mark the top of the swaged cable end. Install the retaining hardware (bolts, nuts, and washers) Install the fall arrest cable through the left hand bracket and secure the brackets to the platform rail.
  • Page 176 SECTION 4 - BOOM & PLATFORM 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal Figure 4-13. Bolt-On External Fall Arrest System 4-37 31215034...
  • Page 177 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.
  • Page 178 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS SECTION 5. BASIC HYDRAULICS INFORMATION & SCHEMATICS 5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 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 179 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. Fill the spray bottle with hydraulic oil. The following is needed to correctly oil the o-ring in this man- Hold the fitting over suitable catch can.
  • Page 180 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 181 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 182 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly And Torque Specifications 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 183 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 184 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for British Standard Pipe OCCUR.NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGNMENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN Thread Tapered (BSPT) Connections FOR ALIGNMENT. Inspect components to ensure male and female port Rotate male fitting the number of turns per Table 5-2, threads are free of rust, splits, dirt, foreign matter, or...
  • Page 185 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for 37° (JIC) Flare Fittings Torque assembly to value listed in Table 5-3, 37° Flare (JIC) Thread - Steel or Table 5-4, 37° Flare (JIC) Thread - Inspect the flare for obvious visual squareness and con- Aluminum/Brass while using the Double Wrench centricity issues with the tube OD.
  • Page 186 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 187 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Table 5-4. 37° Flare (JIC) Thread - Aluminum/Brass TYPE/FITTING IDENTIFICATION Torque Flats from Wrench Thread 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 188 SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel and Table 5-6, 45° Flare (SAE) - Aluminum/Brass Inspect the flare for obvious visual squareness and con- while using the Double Wrench Method outlined in this centricity issues with the tube OD.

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