JLG 600S Manuals

Manuals and User Guides for JLG 600S. We have 5 JLG 600S manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

JLG 600S Service And Maintenance Manual (332 pages)

Brand: JLG | Category: Lifting Systems | Size: 21 MB

A General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications

19
- Operating Specifications
  19
- Dimensional Data
  19
- Capacities
  20
- Tires
  20
- Engine Data
  20
- Function Speeds
  21
  - Machine Orientation When Doing Speed Tests
    21
  - Test Notes
    21
- Torque Requirements
  21
- Hydraulic Oil
  22
- Major Component Weights
  23
- Operator Maintenance
  24
- Torque Chart (SAE Fasteners - Sheet 1 of 7)
  29
- Torque Chart (SAE Fasteners - Sheet 2 of 7)
  30
- Torque Chart (SAE Fasteners - Sheet 3 of 7)
  31
- Torque Chart (SAE Fasteners - Sheet 4 of 7)
  32
- Torque Chart (METRIC Fasteners - Sheet 5 of 7)
  33
- Torque Chart (METRIC Fasteners - Sheet 6 of 7)
  34
- Torque Chart (METRIC Fasteners - Sheet 7 of 7)
  35
General

37
- Machine Preparation, Inspection, and Maintenance
  37
- Service and Guidelines
  38
  - General
    38
  - Safety and Workmanship
    38
  - Cleanliness
    38
  - Components Removal and Installation
    38
  - Component Disassembly and Reassembly
    39
  - Pressure-Fit Parts
    39
  - Bearings
    39
  - Gaskets
    39
  - Bolt Usage and Torque Application
    39
  - Hydraulic Lines and Electrical Wiring
    39
  - Hydraulic System
    39
  - Lubrication
    39
  - Battery
    39
  - Lubrication and Servicing
    39
- Lubrication and Information
  40
  - Hydraulic System
    40
  - Hydraulic Oil
    40
  - Changing Hydraulic Oil
    40
  - Lubrication Specifications
    40
- Cylinder Drift Test
  40
  - Platform Drift
    40
  - Cylinder Drift
    40
- Pins and Composite Bearing Repair Guidelines
  41
- Welding on JLG Equipment
  41
  - Do the Following When Welding on JLG Equipment
    41
  - Do NOT Do the Following When Welding on JLG Equipment
    41
- Deutz Engine and Hydraulic Operating Temperature Specifications
  45
- GM Engine and Hydraulic Operating Temperature Specifications
  46
Chassis & Turntable

47
- Tires & Wheels
  47
  - Tire Inflation
    47
  - Tire Damage
    47
  - Tire Replacement
    47
  - Wheel Replacement
    47
  - Wheel Installation
    47
- Torque Hub
  48
  - Oil Information
    48
  - Roll and Leak Testing
    48
  - Tightening and Torquing Bolts
    48
  - Torque Hub
    49
  - Main Disassembly
    50
  - Output Carrier Disassembly
    51
  - Input Carrier Disassembly
    51
  - Hub-Spindle Disassembly
    52
  - Spindle-Brake Disassembly
    53
  - Cover Disassembly
    54
  - Cover Assembly
    54
  - Input Carrier Assembly
    55
  - Spindle - Brake Assembly
    56
  - Hub-Spindle Assembly
    57
  - Output Planet Gear Assembly
    58
  - Main Assembly
    59
  - Integral Brake Check
    59
- Hub Assembly
  60
- Bearing Cup Pressing Tool
  61
- Bearing Cup Pressing Tool
  62
  - Free Wheeling Option
    63
    
    Engage Drive Motors & Brakes (Normal Operation)
    63
  - Drive Motor
    63
    
    Description
    63
    
    Shaft Seal Replacement
    64
    
    Loop Flushing Valve
    65
    
    Troubleshooting
    66
    
    Disassembly
    67
- End Cap
  68
- Cylinder Kit
  69
  - Shaft & Front Bearing
    70
  - Inspection
    71
  - Assembly
    73
- Swash Plate and Journal Bearing
  74
- Shaft and Front Bearing
  75
- Valve Plate and Rear Bearing
  76
- Shaft Seal
  77
  - Initial Start-Up Procedures
    78
  - Oscillating Axle Bleed Procedure and Lockout Test
    78
    
    Lockout Cylinder Bleeding
    78
    
    Oscillating Axle Lockout Test
    79
  - Steer Adjustments
    79
  - Swing Drive
    80
- Swing Motor and Brake Assembly
  81
  - Gear Backlash
    82
  - Swing Drive Lubrication
    82
  - Motor Control Valve Disassembly
    83
  - Motor and Brake Disassembly
    83
  - Main Disassembly
    84
  - Hub-Shaft Disassembly
    84
  - Carrier Disassembly
    85
  - Hub-Shaft Subassembly
    86
  - Carrier Subassembly
    87
  - Main Assembly
    88
  - Motor and Brake Assembly
    89
  - Motor Control Valve Assembly
    89
  - Swing Bearing
    90
    
    Turntable Bearing Mounting Bolt Condition Check
    90
    
    Wear Tolerance
    90
    
    Swing Bearing Replacement
    92
    
    Swing Bearing Torque Values
    93
  - Rotary Coupling
    94
- Rotary Coupling - Sheet 2 of 2
  95
- Rotary Coupling Port Location - 2WS
  96
- Rotary Coupling Port Location - 4WS
  97
  - Generator
    98
    
    Every 250 Hours
    98
    
    Every 500 Hours
    98
    
    Overload Protection
    99
    
    Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
    99
- Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
  100
  - Deutz D2.9 L4 Engine
    101
- Deutz D2.9 L4 Engine Installation - Sheet 2 of 2
  102
  - Check Oil Level
    103
  - Change Engine Oil
    103
  - Change Oil Filter
    104
  - Change Fuel Filters
    104
  - Deutz D2011 Engine
    105
- Deutz D2011 Engine Installation - Sheet 2 of 2
  106
  - Checking Oil Level
    107
  - Changing Engine Oil
    107
  - Changing Oil Filter
    108
  - Replace Fuel Filter
    108
  - Clean Fuel Strainer
    109
  - Spark Arrester Cleaning Instructions
    109
  - Glow Plugs
    109
  - Deutz EMR 2
    110
- EMR 2 Engine Plug Pin Identification
  115
- EMR 2 Vehicle Plug Pin Identification
  116
  - Bio Fuel in Deutz Engines
    122
    
    General
    122
    
    Bio Fuel
    122
    
    Biological Contamination in Fuels
    123
  - GM Engine General Maintenance
    124
    
    Drive Belt Maintenance
    124
    
    Engine Electrical System Maintenance
    124
    
    Checking/Filling Engine Oil Level
    124
    
    Changing Engine Oil
    125
    
    Coolant Fill Procedure - Dual Fuel Engine
    125
  - GM Engine Dual Fuel System
    126
    
    Fuel Filter
    126
- GM 3.0 Dual Fuel System Components
  127
  - Direct Electronic Pressure Regulator (DEPR)
    128
  - Air Fuel Mixer
    128
  - Electronic Throttle Control (ETC)
    129
  - Electric Lock off
    129
  - Engine Control Module (ECM)
    129
  - Heated Exhaust Gas Oxygen Sensor
    130
  - Gasoline Multi Point Fuel Injection System (MPFI)
    130
  - Gasoline Fuel Pump
    130
  - Gasoline Pressure and Temperature Sensor Manifold
    130
  - Fuel Filter
    131
  - Fuel Injector Rail
    131
  - Fuel Injector
    131
  - GM Engine Fuel System Repair
    131
    
    Propane Fuel System Pressure Relief
    131
    
    Propane Fuel System Leak Test
    131
    
    Propane Fuel Filter Replacement
    132
    
    Direct Electronic Pressure Regulator (DEPR) Maintenance and Inspection
    132
    
    Check/Drain Oil Build-Up in 2-Stage Vaporizer
    133
    
    Air Fuel Mixer/Throttle Control Device Maintenance and Inspection
    133
    
    Exhaust System and Catalytic Converter Inspection and Maintenance
    134
    
    Temperature Manifold Absolute Pressure (TMAP) Sensor
    134
    
    Throttle Body (ETC) Replacement
    134
    
    Mixer Replacement
    134
    
    Electronic Pressure Regulator (EPR) Replacement
    135
    
    Regulator Replacement
    135
    
    Coolant Hose Replacement
    135
    
    Vapor Hose Replacement
    135
    
    Engine Control Module Replacement
    136
    
    Heated Exhaust Gas Oxygen Sensor Replacement
    136
  - GM Engine LPG Fuel System Diagnosis
    137
    
    Fuel System Description
    137
    
    Diagnostic Aids
    137
Boom & Platform

151
- Boom Systems
  151
  - Removal
    151
- Wear Pads
  152
- Boom Disassembly/Assembly & Cable Replacement
  153
  - Boom Section Disassembly
    153
- Wire Rope
  154
  - Inspection
    154
  - Three Month Inspection
    154
  - Year or 7000 Hour Replacement
    154
  - Additional Replacement Criteria
    154
- Wire Rope Tensioning Adjustment
  155
  - Wire Rope Tensioning Procedure
    155
- Boom Assembly Cutaway - Sheet 1 of 3
  156
- Boom Assembly Cutaway - Sheet 2 of 3
  157
- Boom Assembly Cutaway - Sheet 3 of 3
  158
  - Inspection
    159
  - Assembly
    160
- Boom Powertrack Installation
  161
- Proximity Switch Installation
  162
  - Installation
    163
  - Articulating Jib Boom
    164
    
    Removal
    164
    
    Disassembly
    164
    
    Inspection
    164
    
    Assembly
    165
  - Limit Switches and Cam Valve Adjustment
    165
  - Boom Cleanliness Guidelines
    165
- Horizontal Limit and Dual Capacity Limit Switches Adjustments
  166
- Transport Switch Adjustments - CE Machines Only
  167
  - Rotary Actuator
    168
    
    Theory of Operation
    168
    
    Required Tools
    168
- Rotary Actuator - Exploded View
  169
- Rotary Actuator - Assembly Drawing
  170
  - Disassembly
    171
  - Inspection
    175
  - Assembly
    176
  - Installing Counterbalance Valve
    180
  - Testing Actuator
    181
  - Testing Actuator for Internal Leaks
    181
  - Installation and Bleeding
    181
  - Troubleshooting
    182
  - Foot Switch Adjustment
    183
  - Platform
    183
    
    Platform Support Torque Settings
    183
    
    Replace Platform Sections
    183
  - Powertrack Maintenance
    184
    
    Remove Link
    184
    
    Install New Link
    187
    
    Replace Fixed End Brackets
    190
    
    Replace Moving End Brackets
    191

JLG 600S Service And Maintenance Manual (334 pages)

Brand: JLG | Category: Boom Lifts | Size: 26 MB

A General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications

17
- Capacities
  17
- Component Data
  17
  - Engine Data
    17
  - Drive System
    18
  - Tires
    18
  - Swing System
    18
  - Auxiliary Power Pump
    18
  - Hydraulic Filters
    18
- Performance Data
  19
  - Machine Weight (Approximate)
    19
  - Dimensional Data
    19
- Function Speeds
  20
  - Machine Orientation When Doing Speed Tests
    20
  - Test Notes
    20
- Torque Requirements
  21
- Lubrication
  21
- Pressure Settings
  22
- Cylinder Specifications
  23
- Major Component Weights
  23
- Critical Stability Weights
  24
- Lubrication and Operator Maintenance
  25
- Serial Number Locations
  31
- Torque Chart (SAE Fasteners - Sheet 1 of 3)
  32
- Torque Chart (SAE Fasteners - Sheet 2 of 3)
  33
- Torque Chart (SAE Fasteners - Sheet 3 of 3)
  34
- Torque Chart (METRIC Fasteners - Sheet 1 of 3)
  35
- Torque Chart (METRIC Fasteners - Sheet 2 of 3)
  36
- Torque Chart (METRIC Fasteners - Sheet 3 of 3)
  37
Section 2 - General

39
- Machine Preparation, Inspection, and Maintenance
  39
- Service and Guidelines
  40
  - General
    40
  - Safety and Workmanship
    40
  - Cleanliness
    40
  - Components Removal and Installation
    40
  - Component Disassembly and Reassembly
    41
  - Pressure-Fit Parts
    41
  - Bearings
    41
  - Gaskets
    41
  - Bolt Usage and Torque Application
    41
  - Hydraulic Lines and Electrical Wiring
    41
  - Hydraulic System
    41
  - Lubrication
    41
  - Battery
    41
  - Lubrication and Servicing
    41
  - Hydraulic Oil
    42
  - Changing Hydraulic Oil
    42
  - Lubrication Specifications
    42
- Cylinder Drift Test
  42
  - Platform Drift
    42
  - Cylinder Drift
    43
- Pins and Composite Bearing Repair Guidelines
  43
- Welding on JLG Equipment
  43
- Engine Operating Temperature Specifications - Deutz
  47
- Engine Operating Temperature Specifications - Ford
  48
- Engine Operating Temperature Specifications - Caterpillar
  49
- Engine Operating Temperature Specifications - GM
  50
Section 3 - Chassis & Turntable

51
- Tires & Wheels
  51
  - Tire Inflation
    51
  - Tire Damage
    51
  - Tire Replacement
    51
  - Wheel Replacement
    51
  - Wheel Installation
    51
- Drive Torque Hub
  52
  - Roll, Leak and Brake Testing
    52
  - Tightening and Torquing Bolts
    53
  - Main Disassembly
    53
  - Main Disassembly
    54
  - Input Carrier
    55
- Planet Gear Sub Assembly
  56
  - Input Carrier Disassembly
    57
  - Hub-Spindle Disassembly
    58
  - Spindle-Brake Disassembly
    59
- Coupling Subassembly
  60
  - Cover Disassembly
    61
  - Input Carrier Sub-Assembly
    62
  - Output Planet Gear Sub-Assembly
    62
  - Spindle - Brake Sub-Assembly
    62
  - Hub-Spindle Sub-Assembly
    63
  - Cover Sub-Assembly
    64
  - Main Assembly
    64
  - Integral Brake Check
    64
- Hub Assembly
  65
- Bearing Cup Pressing Tool
  66
- Bearing Cup Pressing Tool
  67
  - Free Wheeling Option
    68
    
    To Disengage Drive Motors and Brakes (Free Wheel) for Towing, Etc
    68
    
    To Engage Drive Motors and Brakes (Normal Operation)
    68
  - Drive Motor (S/N 75606 to Present)
    68
    
    Description
    68
    
    Shaft Seal Replacement
    69
    
    Loop Flushing Valve
    70
    
    Troubleshooting
    71
    
    Disassembly
    72
- End Cap
  73
- Cylinder Kit
  74
  - Swash Plate & Servo Piston
    75
  - Inspection
    76
  - Assembly
    78
- Cylinder Kit Assembly
  79
- Shaft and Front Bearing
  80
- Valve Plate and Rear Bearing
  81
- Shaft Seal
  82
  - Initial Start-Up Procedures
    83
  - Oscillating Axle Bleeding Procedure and Lockout Test
    84
    
    Lockout Cylinder Bleeding
    84
    
    Oscillating Axle Lockout Test
    84
  - Steer Adjustments
    85
  - Swing Hub
    86
    
    Adjustment Procedures
    86
    
    Disassembly
    86
    
    Main Assembly Procedure
    87
    
    Hub Shaft Sub-Assembly
    90
    
    Carrier Sub-Assembly
    92
  - Swing Bearing
    95
    
    Turntable Bearing Mounting Bolt Condition Check
    95
    
    Wear Tolerance
    95
    
    Swing Bearing Replacement
    97
    
    Swing Bearing Torque Values
    98
  - Swing Brake - Mico
    99
    
    Disassembly
    99
    
    Inspection
    99
    
    Assembly
    99
- Swing Brake Assembly (Mico)
  100
  - Rotary Coupling
    101
  - Rotary Coupling - Sheet 1 of 2
    102
- Rotary Coupling - Sheet 2 of 2
  103
- Rotary Coupling Port Location - 2WS
  104
- Rotary Coupling Port Location - 4WS
  105
  - Generator
    106
    
    Every 250 Hours
    106
    
    Every 500 Hours
    106
    
    Overload Protection
    107
    
    Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
    107
- Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
  108
  - Spark Arrester Cleaning Instructions
    109
  - Glow Plugs
    109
  - Ford EFI Engine
    109
    
    Performing Diagnostics
    109
    
    ECM/EPM and Sensors
    110
    
    Fuel System
    115
- Typical Fuel System
  116
  - Ford LPG System
    120
    
    Description
    120
    
    Regulator
    120
    
    Megajector
    120
    
    Mixer
    120
    
    Lockoff Solenoid
    120
    
    Ford LPG System
    121
    
    Megajector Diagnostic Code Descriptions
    122
    
    Changing from Gasoline to LP Gas
    123
    
    Changing from LP Gas to Gasoline
    123
- Deutz Sensors for JLG Control System
  124
- Deutz Engine Installation - Sheet 1 of 2
  125
- Deutz Engine Installation - Sheet 2 of 2
  126
- Caterpillar Engine Installation - Sheet 1 of 2
  127
- Caterpillar Engine Installation - Sheet 2 of 2
  128
- Ford Engine Installation - Sheet 1 of 2
  129
- Ford Engine Installation - Sheet 2 of 2
  130
  - Deutz EMR 2 (S/N 84827 to Present)
    131
- EMR 2 Engine Side Equipment
  132
- EMR 2 Engine Plug Pin Identification
  137
- EMR 2 Vehicle Plug Pin Identification
  138
  - Bio Fuel in Deutz Engines
    144
    
    General
    144
    
    Bio Fuel
    144
    
    Biological Contamination in Fuels
    145
  - GM Engine General Maintenance
    146
    
    Maintenance of the Drive Belt
    146
    
    Engine Electrical System Maintenance
    146
    
    Checking/Filling Engine Oil Level
    146
    
    Changing the Engine Oil
    147
    
    Coolant Fill Procedure - Dual Fuel Engine
    147
  - GM Engine Dual Fuel System
    148
    
    Fuel Filter
    149
    
    Electric Lock off
    149
    
    EPR Assembly
    149
    
    Low Pressure Regulator (LPR)
    150
    
    Air Fuel Mixer
    150
    
    Electronic Throttle Control (ETC)
    151
    
    Engine Control Module
    151
    
    Heated Exhaust Gas Oxygen Sensor
    152
    
    Gasoline Multi Point Fuel Injection System (MPFI)
    152
    
    Gasoline Fuel Pump
    152
    
    Gasoline Pressure and Temperature Sensor Manifold
    152
    
    Fuel Filter
    153
    
    Fuel Injector Rail
    153
    
    Fuel Injector
    153
  - GM Engine Fuel System Repair
    153
    
    Propane Fuel System Pressure Relief
    153
    
    Propane Fuel System Leak Test
    153
    
    Propane Fuel Filter Replacement
    154
    
    Electronic Pressure Regulator (EPR) Assembly Replacement
    154
- Pressure Regulator Section
  155
  - Temperature Manifold Absolute Pressure (TMAP) Sensor
    156
  - Electronic Throttle Control Replacement
    156
  - Mixer Replacement
    157
  - Coolant Hose Replacement
    158
  - Vapor Hose Replacement
    158
  - Engine Control Module Replacement
    158
  - Heated Exhaust Gas Oxygen Sensor Replacement
    158
  - GM Engine LPG Fuel System Diagnosis
    159
    
    Fuel System Description
    159
    
    Diagnostic Aids
    159
- LPF Fuel System Diagnosis
  160
- Symptom Diagnosis
  163
- DTC to SPN/FMI Cross Reference Chart
  171
Section 4 - Boom & Platform

173
- Boom Rope Torquing Procedures
  173
- Wear Pads
  174
  - Main Boom
    174
- Wire Rope
  174
  - Inspection
    174
  - Three Month Inspection
    175
  - Eight Year Inspection
    175
  - Replacement Criteria
    175
- Boom Maintenance
  175
  - Removal
    175
- Location of Components - Boom Powertrack
  176
  - Disassembly of Boom Sections
    177
- Boom Assembly Cutaway - Sheet 1 of 3
  178
- Boom Assembly Cutaway - Sheet 2 of 3
  179
- Boom Assembly Cutaway - Sheet 3 of 3
  180
  - Inspection
    181
- Dimension of Sheaves When New
  182
  - Assembly
    183
- Boom Powertrack Installation
  184
- Installing the Proximity Switch
  185
  - Installation
    186
  - Articulating Jib Boom
    187
    
    Removal
    187
    
    Disassembly
    187
    
    Inspection
    187
    
    Assembly
    188
  - Limit Switches and Cam Valve Adjustment
    188
  - Boom Cleanliness Guidelines
    188
- Horizontal Limit and Dual Capacity Limit Switches Adjustments
  189
- Transport Switch Adjustments - CE Machines Only
  190
  - Platform
    191
    
    Platform Sections Replacement
    191
  - Rotator - Helac (Prior to S/N 0300130779)
    191
    
    Disassembly
    191
- Rotator Assembly (Helac)
  192
  - Inspection
    193
  - Assembly
    193
  - Rotary Actuator (S/N 0300130779 to Present)
    194
    
    Theory of Operation
    194
    
    Required Tools
    195
- Rotary Actuator - Exploded View
  196
- Rotary Actuator - Assembly Drawing
  197
  - Disassembly
    198
  - Inspection
    202
  - Assembly
    202
  - Installing Counterbalance Valve
    207
  - Testing the Actuator
    208
  - Installation and Bleeding
    208
  - Troubleshooting
    209
  - Foot Switch Adjustment
    210

JLG 600S Service And Maintenance Manual (271 pages)

Brand: JLG | Category: Lifting Systems | Size: 21 MB

A General
5
Capacities
19
Steer System (S Models)
20
Boom Elevation (S Models)
21
Test Notes
22
Lubrication
23
Lubrication Specifications
24
Cylinder Specifications
25
Major Component Weights
26
Critical Stability Weights
27
Lubrication Point Location - S Models
28
Lubrication Chart - S Models
29
Lubrication Point Location - a Models
30
Lubrication Chart - a Models
31
Serial Number Locations
32
Machine Preparation, Inspection, and Maintenance
35
Service and Guidelines
36
Torque Chart
37
Lubrication and Information
38
Cylinder Drift Test
39
Welding on JLG Equipment
40
AMP Connector
41
Connector Assembly Figure 2
42
Disassembly
43
Connector Installation
44
Deutsch Connectors
45
HD30/HDP20 Series Assembly
46
Inspection and Preventive Maintenance Schedule
47
Engine Operating Temperature Specifications - Deutz
50
Drive Torque Hub, Prior to S/N 75606
51
Torque Hub, Drive (Fairfield)
52
Repair
53
Assembly
55
Torque Hub, Drive (Auburn Gear)
59
Torque Hub, Drive (Auburn Gear)
60
Drive Torque Hub, S/N 75606 to Present
62
Main Disassembly
63
Input Carrier
64
Planet Gear Sub Assembly
65
Input Carrier Disassembly
66
Hub-Spindle Disassembly
67
Spindle-Brake Disassembly
68
Cover Disassembly
70
Input Carrier Sub-Assembly
71
Hub-Spindle Sub-Assembly
72
Cover Sub-Assembly
73
Hub Assembly
74
Bearing Cup Pressing Tool
75
Bearing Cup Pressing Tool
76
Drive Brake - Mico
77
Drive Brake Assembly (Mico)
78
Free Wheeling Option
79
Drive Motor (600S, 600A 4WD)
80
Replacing the Drive Shaft Seal
81
Disassembly and Assembly
82
Assembly Notes
86
Flow Control Pilot Valves
87
Testing and Setup
88
Oscillating Axle Bleeding Procedure and Lockout Test
89
Oscillating Axle Lockout Test
90
Steer Adjustments (S Models)
91
Swing Bearing
92
Wear Tolerance.(S & a Models)
93
Swing Bearing Replacement
96
Swing Bearing Torque Values
97
Swing Brake Assembly (Mico)
98
Inspection
99
Spark Arrester Cleaning Instructions
100
Addco Adjustments - Continental
101
Deutz Sensors for JLG Control System
102
Boom Rope Torquing Procedures
103
Wire Rope (S Models)
104
Three Month Inspection
105
Boom Assembly Cutaway - S Models - Sheet 1 of 3
106
Boom Assembly Cutaway - S Models - Sheet 2 of 3
107
Boom Assembly Cutaway - S Models - Sheet 3 of 3
108
Location of Components - Boom Powertrack
109
Disassembly of Boom Sections
110
Inspection
111
Assembly
112
Installing the Proximity Switch
113
Installation
114
Reassembly of Components - Rotator and Slave Leveling Cylinder
115
Boom Powertrack Installation
116
Disassembly of Boom Sections
117
Installation
118
Disassembly
119
Inspection
120
Articulating Jib Boom
121
Assembly
122
Main Boom Telescope Cylinder Installation
123
Main Boom Lift Cylinder Removal
124
Limit Switches Adjustments (S Models)
125
Limit Switches Adjustments (a Models)
126
Platform
127
Rotator Assembly (Helac)
128
Inspection
129
Drive Card Setup Procedures
130
Lift, Swing, and Drive Cards
131
Foot Switch Adjustment
132
Cylinders - Theory of Operation
133
Cylinders with Dual Counterbalance Valves
134
Cylinder Barrel Support
135
Cleaning and Inspection
136
Assembly
137
Piston Seal Kit Installation
138
Seating the Tapered Bearing
139
Cylinder Head and Tapered Bushing Torque Specifications. (S Models)
140
Cylinder Removal and Installation (S Models)
141
Main Boom Lift Cylinder Removal
142
Main Boom Lift Cylinder Installation
143
Main Boom Telescope Cylinder Installation
144
Main Boom Lift Cylinder Installation
145
Upright Level Cylinder Installation
146
Tower Telescope Cylinder Removal
147
Boom Positioning and Support, Cylinder Repair (a Models)
148
Tower Telescope Cylinder Installation
149
S Axle Lockout Cylinder (Prior to S/N 75606)
150
S Axle Lockout Cylinder (S/N 75606 to Present)
151
S, 600SJ, 660SJ & 600A Level Cylinder
152
S Lift Cylinder
153
S & 600A Jib Lift Cylinder
154
S & 600A Master Cylinder
155
S & 600A Steer Cylinder
156
S Telescope Cylinder
157
A Axle Lockout Cylinder
158
A Level (Upright) Cylinder
159
A Main Boom Lift Cylinder
160
A Tower Boom Lift Cylinder
161
A Main Boom Telescope Cylinder
162
A Main Boom Telescope Cylinder
163
Variable Displacement Pump (M46 Series)
164
Troubleshooting - System Operating Hot
165
Troubleshooting - System Response Is Sluggish
166
Inspections and Adjustments
167
Minor Repair and Replacement
170
Valves - Theory of Operation
175
Platform Level
176

JLG 600S Operation And Safety Manual (163 pages)

Brand: JLG | Category: Boom Lifts | Size: 19 MB

Table of Contents
8
Section 1. Safety Precautions

13
- General
  13
- Pre-Operation
  13
  - Operator Training and Knowledge
    13
  - Workplace Inspection
    14
  - Machine Inspection
    15
- Operation
  15
  - General
    15
  - Trip and Fall Hazards
    16
  - Electrocution Hazards
    17
- Minimum Approach Distances (M.A.D.)
  18
  - Tipping Hazards
    19
- Beaufort Scale (for Reference Only)
  21
  - Crushing and Collision Hazards
    22
  - Towing, Lifting, and Hauling
    23
  - Maintenance
    23
    
    Maintenance Hazards
    23
    
    Battery Hazards
    25
Section 2 - User Responsibilities, Machine Preparation, and Inspection

27
- 2.1 Personnel Training
  27
  - Operator Training
    27
  - Training Supervision
    27
  - Operator Responsibility
    27
  - Machine Familiarization
    28
  - Preparation, Inspection, and Maintenance
    28
- Inspection and Maintenance Table
  29
- Basic Nomenclature - 600S
  30
- Basic Nomenclature - 660SJ
  31
  - Pre-Start Inspection
    32
- Daily Walk-Around Inspection Diagram
  34
  - Walk-Around Inspection
    35
  - Function Check
    37
  - Skyguard Function Test
    39
Section 3 - Machine Controls and Indicators

41
Section 4 - Machine Operation

67
- Description
  67
- Operating Characteristics and Limitations
  68
  - Capacities
    68
  - Platform Load Sensing System (LSS)
    68
  - Stability
    69
- Position of Least Backward Stability
  69
- Position of Least Forward Stability
  70
  - Engine Operation
    71
    
    Starting Procedure
    71
    
    Shutdown Procedure
    72
    
    Air Shutoff Valve (ASOV) (if Equipped)
    73
- ASOV Reset (Closed to Open Position)
  73
  - Fuel Reserve / Shut-Off System
    74
- Traveling (Driving)
  75
  - Traveling Forward and Reverse
    76
  - Traveling on a Grade
    77
- Steering
  77
- Grade and Sideslope
  78
- Platform
  79
  - Platform Level Adjustment
    79
  - Platform Rotation
    79
- Boom
  79
- Shut down and Park
  80
- Battery Quick-Disconnect (if Equipped)
  81
- Machine Safety System Override
  81
- 4.10 Skyguard Operation
  81
  - Skyguard
    82
  - Skyguard Skyline
    82
  - Skyguard Skyeye
    83
  - Skyguard Function Table
    83
- Oscillating Axle Lockout Test (if Equipped)
  84
- Steer/Tow Selector (if Equipped)
  84
- Towing (if Equipped)
  84
- Drive Disconnect Hub
  86
- Auxiliary Power
  87
- Lifting Chart
  90
- 660SJ Decal Legend
  101
Section 5 - Emergency Procedures

105
- General
  105
- Incident Notification
  105
- Emergency Operation
  105
  - Operator Unable to Control Machine
    105
  - Platform or Boom Caught Overhead
    106
- Emergency Towing Procedures
  106
- Machine Safety System Override (Msso)(Ce Only)
  107

JLG 600S Operation And Safety Manual (150 pages)

Brand: JLG | Category: Boom Lifts | Size: 1 MB

Revision Log
6
Table of Contents
7
Section - Paragraph, Subject

12
Section 1. Safety Precautions

13
- General
  13
- Pre-Operation
  13
  - Operator Training and Knowledge
    13
  - Workplace Inspection
    14
  - Machine Inspection
    14
- Operation
  15
  - General
    15
  - Trip and Fall Hazards
    15
  - Electrocution Hazards
    16
- Minimum Approach Distances (M.A.D.)
  17
  - Tipping Hazards
    18
  - Crushing and Collision Hazards
    19
  - Towing, Lifting, and Hauling
    20
  - Additional Hazards / Safety
    21
- Beaufort Scale (for Reference Only)
  22
Ration, and Inspection

23
- 2.1 Personnel Training
  23
  - Operator Training
    23
  - Training Supervision
    23
  - Operator Responsibility
    23
- Preparation, Inspection, and Maintenance
  24
Section - 2 - User Responsibilities, Machine Prepa-

23
- Inspection and Maintenance Table
  25
  - Pre-Start Inspection
    26
  - Function Check
    27
  - Limit Switch Functional Check
    28
  - 3.1 General
    37
Section 3. Machine Controls and Indicators

37
- Controls and Indicators
  37
  - Ground Control Station
    37
  - Controls and Indicators
    39
  - Ground Control Indicator Panel
    41
  - Platform Station
    45
  - Platform Control Indicator Panel
    52
Section 4. Machine Operation

59
- Description
  59
- Operating Characteristics and Limitations
  59
  - Capacities
    59
  - Stability
    60
- Engine Operation
  60
  - Starting Procedure
    60
  - Shutdown Procedure
    61
- Traveling (Driving)
  63
  - Traveling Forward and Reverse
    63
Section - Paragraph, Subject Page

65
- Steering
  65
- Platform
  65
  - Platform Level Adjustment
    65
- Platform Rotation
  65
- Boom
  65
  - Swinging the Boom
    66
  - Raising and Lowering the Boom
    66
  - Telescoping the Boom
    66
- Shut down and Park
  66
- Oscillating Axle Lockout Test (if Equipped)
  67
- Steer/Tow Selector (if Equipped)
  67
- Towing (if Equipped)
  67
- Auxiliary Power - Non Ade Equipped Machines
  71
  - Activating from the Platform Control Station
    71
  - Activating from the Ground Control Station
    71
- Auxiliary Power - Ade Equipped Machines
  72
  - Activating from the Platform Control Station
    72
  - Activating from the Ground Control Station
    72
- Dual Fuel System (Gas Engine Only)
  73
  - Changing from Gasoline to LP Gas
    73
  - Changing from LP Gas to Gasoline
    73
- 4.15 Hydraulic Tool Circuit Instructions
  73
  - Tool Circuit
    73
  - 4.16 Tie down and Lifting
    75
- Machine Tie down
  76
- Lifting Chart
  77
- Decal Installation - Sheet 1 of 4
  78
- Decal Installation - Sheet 2 of 4
  79
- Decal Installation - Sheet 3 of 4
  80
- Decal Installation - Sheet 4 of 4
  81
- 600SJ Decal Legend
  90
Section 5. Emergency Procedures

103
- General
  103
- Incident Notification
  103
- Emergency Operation
  103
  - Operator Unable to Control Machine
    103
  - Platform or Boom Caught Overhead
    104
- Emergency Towing Procedures
  104
- Manual Descent (Machines Prior to S/N 70975)
  104

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