JLG M600J Electric Boom Lift Manuals

Manuals and User Guides for JLG M600J Electric Boom Lift. We have 3 JLG M600J Electric Boom Lift manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

JLG M600J Service And Maintenance Manual (222 pages)

Brand: JLG | Category: Lifting Systems | Size: 11 MB

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

15
- Capacities
  15
- Operating Specifications
  15
- Generator
  15
- Battery Charger
  15
- Drive/Steer System
  15
- Tires
  15
- Function Speeds
  16
  - Machine Orientation When Doing Speed Tests
    16
  - Test Notes
    16
- Pressure Settings
  16
- Torque Requirements
  17
- Major Component Weights
  17
- Serial Number Location
  17
- Hydraulic Oil
  18
- Operator Maintenance
  19
- Torque Chart (SAE Fasteners - Sheet 1 of 7)
  22
- Torque Chart (SAE Fasteners - Sheet 2 of 7)
  23
- Torque Chart (SAE Fasteners - Sheet 3 of 7)
  24
- Torque Chart (SAE Fasteners - Sheet 4 of 7)
  25
- Torque Chart (METRIC Fasteners - Sheet 5 of 7)
  26
- Torque Chart (METRIC Fasteners - Sheet 6 of 7)
  27
- Torque Chart (METRIC Fasteners - Sheet 7 of 7)
  28
Section 2 - General

29
- Machine Preparation, Inspection, and Maintenance
  29
- Service and Guidelines
  30
  - General
    30
  - Safety and Workmanship
    30
  - Cleanliness
    30
  - Components Removal and Installation
    30
  - Component Disassembly and Reassembly
    31
  - Pressure-Fit Parts
    31
  - Bearings
    31
  - Gaskets
    31
  - Bolt Usage and Torque Application
    31
  - Hydraulic Lines and Electrical Wiring
    31
  - Hydraulic System
    31
  - Lubrication
    31
  - Battery
    31
  - Lubrication and Servicing
    31
- Lubrication and Information
  32
  - Hydraulic System
    32
  - Hydraulic Oil
    32
  - Changing Hydraulic Oil
    32
  - Lubrication Specifications
    32
- Cylinder Drift Test
  33
  - Platform Drift
    33
  - Cylinder Drift
    33
- Pins and Composite Bearing Repair Guidelines
  33
- Welding on JLG Equipment
  34
  - Do the Following When Welding on JLG Equipment
    34
  - Do NOT Do the Following When Welding on JLG Equipment
    34
- Applying Silicone Dielectric Compound to Electrical Connections
  34
- Operating Temperature Specifications - Kubota
  38
Section 3 - Chassis & Turntable

39
- Tires & Wheels
  39
  - Tire Inflation
    39
  - Tire Damage
    39
  - Tire Replacement
    39
  - Wheel Replacement
    39
  - Wheel Installation
    39
- Drive Hub -REAR (Prior to S/N 0300112585)
  40
  - Disengaging for Towing
    40
  - Engaging after Towing Is Complete
    41
- Torque Hub
  42
- Main Disassembly Drawing 1
  46
- Main Disassembly Drawing 2
  47
  - Output Carrier Disassembly
    48
- Planet Gear
  49
  - Input Carrier Disassembly
    50
  - Hub-Spindle Disassembly
    51
  - Cover Disassembly
    52
  - Input Carrier Assembly
    53
  - Output Planet Gear Assembly
    53
  - Output Carrier Assembly
    54
  - Hub-Spindle Assembly
    54
  - Cover Subassembly
    55
  - Main Assembly
    55
- Hub Assembly - Sheet 1 of 2
  56
- Hub Assembly - Sheet 1 of 2
  57
- Cup Pressing Tool
  58
  - Drive Brake - Mico
    59
    
    Disassembly
    59
    
    Assembly
    59
    
    Bleeding
    59
- Drive Brake
  60
  - Speed Sensor Adjustment
    62
    
    Adjustment Procedure
    62
- Speed Sensor Orientation
  63
- Drive Components
  64
  - Speed Sensor Installation Verification
    65
  - Verification W/ Analyzer Procedure
    65
- Oscillating Axle
  67
- Axle Oscillation Lockout Valve
  68
- Brake Disassembly
  73
  - Main Disassembly
    74
  - Hub-Shaft Disassembly
    75
  - Carrier Disassembly
    76
  - Hub-Shaft Sub-Assembly
    77
  - Carrier Sub-Assembly
    77
  - Main Assembly
    78
  - Motor-Brake Subassembly
    78
  - Motor-Brake Assembly
    78
  - Motor Control Valve Assembly
    79
  - Tube Fitting Assembly Procedures
    79
  - Procedure for Setting Gear Backlash
    79
  - Swing Bearing
    80
    
    Turntable Bearing Mounting Bolt Condition Check
    80
    
    Wear Tolerance
    81
- Swing Drive and Bearing Installation
  82
  - Replacement of Swing Bearing
    83
  - Swing Bearing Torque Value
    84
  - Swing Drive Installation
    84
  - Setting Backlash
    84
  - Battery Maintenance and Charging
    85
    
    Battery Maintenance, Quarterly
    85
    
    Optional on Board Generator
    85
    
    Battery Charging (on Board Charger)
    85
    
    Removing the Battery Box
    86
- Batteries and Battery Charger
  87
  - Battery Charger
    88
- Battery Charger Schematic
  89
  - Generator (Prior to S/N 88375)
    90
- Generator Components
  91
  - Timing Sequences
    92
  - To Connect the JLG Control System Analyzer to the Generator
    93
  - Alarms and Fault Flash Codes
    93
  - Output Current and Voltage Settings
    95
  - Priming the Fuel Line
    96
  - Generator (S/N 88375 to Present)
    97
    
    Engine
    97
    
    Alternator
    97
    
    Dynamo and Dynamo Voltage Regulator
    97
    
    Dynamo Output Fuse
    97
    
    Control Fuse
    97
    
    Generator
    98
    
    Start Battery
    99
    
    Engine Starter
    99
    
    Start Control Relay
    99
    
    Fuel Control Relay
    100
    
    Glow Plug Control Relay
    100
    
    Glow Plug
    100
    
    Fuel Pump
    101
    
    Fuel Solenoid
    101
    
    Engine Low Oil Pressure Switch
    101
    
    Engine Oil Temperature Sensor
    101
    
    Alternator Output Current Sensor
    102
    
    Engine Speed Sensor
    102
    
    RBS Engine/Generator Controller
    102
    
    Warnings and Safety Precautions
    103
    
    System Controls
    103
    
    System Status and Performance Monitoring
    103
    
    System Settings
    103
    
    RBS Start
    104
    
    RBS Shutdown
    104
    
    RBS Alarms and Flash Codes
    105
    
    Resetting the RBS Controller
    105
    
    Maintenance Schedule
    105
    
    Troubleshooting
    106
    
    APU Engine Start Battery Boosting
    107
  - Supplementary Fuse for Engine Generator Controller
    108
    
    Tools and Material
    108
    
    Procedure
    108
Section 4 - Boom & Platform

111
- Boom
  111
  - Removal
    111
- Boom Assembly - Sheet 1 of 3
  112
- Boom Assembly - Sheet 2 of 3
  113
- Boom Assembly - Sheet 3 of 3
  114
  - Installation
    115
- Boom Limit Switch Adjustment
  116
- Transport Limit Switch (CE Only)
  117
  - Load Cell Calibration Procedure
    118
- Load Sensor
  119
  - Platform Rotator (Prior to S/N 0300130810)
    120
    
    Theory of Operation
    120
    
    Disassembly and Inspection
    120
    
    Assembly and Testing
    120
- Platform Rotator Assembly - Cutaway
  121
  - Platform Rotator (S/N 0300130810 to Present)
    122
    
    Theory of Operation
    122
    
    Required Tools
    123
- Rotary Actuator - Exploded View
  124
- Rotary Actuator - Assembly Drawing
  125
  - Disassembly
    126
  - Inspection
    130
  - Assembly
    130
  - Jib Rotator
    135
    
    Operating Principle
    135
    
    Disassembly
    135
- Jib Rotator Assembly
  137
- Tool for Removing End Cap
  138
  - Inspection
    139
  - Reassembly
    139
  - Installing Counterbalance Valve
    141
  - Testing the Actuator
    142
  - Installation and Bleeding
    142
  - Troubleshooting
    143
Section 5 - Hydraulics

145
- Lubricating O-Rings in the Hydraulic System
  145
  - Cup and Brush
    145
  - Dip Method
    146
  - Spray Method
    146
  - Brush-On Method
    146
- Cylinders - Theory of Operation
  147
  - Lift, Telescope, Slave, Master, Oscillation (if Equipped), Jib (if Equipped), and Steer
    147
- Cylinder Checking Procedures
  147
- Cylinder Repair
  148
  - Disassembly
    148
- Axle Lockout Cylinder
  149
- Level Cylinder
  150
- Jib Lift Cylinder
  151
- Lift Cylinder
  152
- Master Cylinder
  153
- Steer Cylinder
  154
- Telescope Cylinder
  155
  - Cleaning and Inspection
    156
  - Assembly
    157
- Installation of Head Seal Kit
  158
- Tapered Bushing Installation
  159
- Rod Assembly Installation
  160
- Hydraulic Tank and Pump (Prior to S/N 51941)
  161
- Hydraulic Tank and Pump (S/N 51941 to Present)
  162
  - Pressure Settings
    163
    
    Proportional Main Relief
    163
    
    Lift down
    163
    
    Lift up
    163
    
    Swing
    163
    
    Flow Control / Bang Bang Main Relief
    163
    
    Steer
    163
    
    Platform Level down
    163
    
    Platform Level up Relief
    163
    
    Jib Relief
    163
- Hydraulic Control Valve - Main Valve
  164
- Hydraulic Control Valve - Platform Valve
  165
Section 6 - Jlg Control System

167
- Introduction
  167
- Control Module Location
  170
  - To Connect the JLG Control System Analyzer
    171
  - Using the Analyzer
    171
  - Changing the Access Level of the Hand Held Analyzer
    172
  - Adjusting Parameters Using the Hand Held Analyzer
    173
  - Machine Setup
    173
  - Machine Personality Settings
    175
  - Machine Configuration Programming Information
    178
  - Level Vehicle Description
    180
    
    Help Descriptions and Fault Flash Codes
    180
  - Analyzer Diagnostics Menu Structure
    188
  - System Self Test
    195
Section 7 - Basic Electrical Information & Schematics

201
- General
  201
- Multimeter Basics
  201
  - Grounding
    201
  - Backprobing
    201
  - Min/Max
    201
  - Polarity
    201
  - Scale
    201
  - Voltage Measurement
    201
  - Resistance Measurement
    202
  - Continuity Measurement
    202
  - Current Measurement
    203
- Checking Switches
  203
  - Basic Check
    203
  - Limit Switches
    203
  - Automatic Switches
    204
  - Switch Wiring - Low Side, High Side
    204
- Applying Silicone Dielectric Compound to Electrical Connections
  204
- AMP Connector
  205
  - Applying Silicone Dielectric Compound to AMP Connectors
    205
  - Assembly
    205
  - Connector Assembly Figure 2
    206
  - Disassembly
    207
  - Wedge Lock
    207
  - Service - Voltage Reading
    207
- Connector Installation
  208
  - Deutsch Connectors
    209
    
    DT/DTP Series Assembly
    209
    
    DT/DTP Series Disassembly
    209
    
    HD30/HDP20 Series Assembly
    210
    
    HD30/HDP20 Series Disassembly
    210
- Electrical Components Installation - Sheet 1
  212
- Electrical Components Installation - Sheet 2
  213
- Electrical Schematic - Sheet 1 of 4
  214
- Electrical Schematic - Sheet 2 of 4
  215
- Electrical Schematic - Sheet 3 of 4
  216
- Electrical Schematic - Sheet 4 of 4
  217
- Hydraulic Schematic - Sheet 1 of 2
  218
- Hydraulic Schematic - Sheet 2 of 2
  219

JLG M600J Operation And Safety Manual (122 pages)

Brand: JLG | Category: Boom Lifts | Size: 3 MB

Table of Contents
7
Section 1 - Safety Precautions
15
General
15
Pre-Operation
15
Operator Training and Knowledge
15
Workplace Inspection
16
Machine Inspection
17
Operation
17
General
17
Trip and Fall Hazards
18
Electrocution Hazards
19
Tipping Hazards
21
Crushing and Collision Hazards
24
Towing, Lifting, and Hauling
25
Maintenance
25
Maintenance Hazards
25
Battery Hazards
27
Section 2. User Responsibilities, Machine Preparation, and Inspection
29
2.1 Personnel Training
29
Operator Training
29
Training Supervision
29
Operator Responsibility
29
Preparation, Inspection, and Maintenance
30
Pre-Start Inspection
35
Daily Walk-Around Inspection
36
Function Check
40
Skyguard Function Test
41
Section 3 - Machine Controls and Indicators
43
General
43
Controls and Indicators
43
Ground Control Station
43
Platform Control Station
47
Platform Control Indicator Panel
53
Section 4 - Machine Operation
57
Description
57
Operating Characteristics and Limitations
57
Capacities
57
Stability
57
Motor Operation
58
Power/Emergency Stop
58
Platform/Ground Select Switch
58
Traveling (Driving)
61
Traveling Forward and Reverse
61
Traveling on a Grade
63
Steering
63
Platform
63
Platform Level Adjustment
63
Platform Rotation
63
Boom
64
Swinging the Boom
64
Raising and Lowering the Upper Boom
64
Generator (Optional)
64
Automatic Operating Mode
64
Battery Only Operating Mode
65
Manual (Charge) Operating Mode
65
Function Speed Control
65
Machine Safety System Override (Msso)
65
4.11 Skyguard Operation
66
Skyguard
66
Skyguard - Skyline
66
Skyguard - Skyeye
67
Skyguard Function Table
67
Oscillating Axle Lockout Test (if Equipped)
68
4.13 Shut down and Park
68
4.14 Lifting and Tie down
69
Lifting
69
Tie down
69
4.15 Towing Instructions
71
4.16 Drive Hub
72
Disengaging for Towing
72
Engaging after Towing Is Complete
74
Section 5 - Emergency Procedures
83
General
83
Incident Notification
83
Emergency Operation
83
Operator Unable to Control Machine
83
Platform or Boom Caught Overhead
84
Emergency Towing Procedures
84
Manual Descent System
84
Machine Safety System Override (Msso)(Ce Only)
88
Section 6 - Accessories
89
Fall Arrest Platform
90
Soft Touch
90
Bolt-On External Fall Arrest
92
Inspection before Use
93
Skyglazier
96
Capacity Specifications
96
Safety Precautions
97
Preparation and Inspection
97
Operation
97
Section 7 - General Specifications & Operator Maintenance
99
Introduction
99
Operating Specifications
99
Capacities
100
Tires
100
Hydraulic Oil
101
Major Component Weights
106
Serial Number Location
106
Operator Maintenance
108
Oscillating Axle Lockout Test (if Equipped)
112
Tires & Wheels
113
Tire Inflation
113
Tire Damage
113
Tire Replacement
113
Wheel Replacement
114
Wheel Installation
114
Supplemental Information
115
Section 8 - Inspection and Repair Log
117

JLG M600J Operation And Safety Manual (114 pages)

Brand: JLG | Category: Boom Lifts | Size: 3 MB

Revision Log
6
Table of Contents
7
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
  - Tipping Hazards
    19
  - Crushing and Collision Hazards
    22
- Towing, Lifting, and Hauling
  23
- Maintenance
  23
  - Maintenance Hazards
    23
  - Battery Hazards
    25
Section - 2 - User Responsibilities, Machine Preparation

27
- 2.1 Personnel Training
  27
  - Operator Training
    27
  - Training Supervision
    27
  - Operator Responsibility
    27
- Preparation, Inspection, and Maintenance
  28
  - Pre-Start Inspection
    30
  - Function Check
    31
  - Skyguard Function Test
    32
- Daily Walk-Around Inspection - Sheet 4 of 4
  39
Section 3 - Machine Controls and Indicators

41
- General
  41
- Controls and Indicators
  41
- Ground Control Station
  41
  - Ground Control Station
    42
- Ground Control Station W/ Function Enable
  43
- To Present
  45
  - Platform Control Station
    48
  - Platform Control Station
    50
- Platform Control Station - W/Drive Orientation
  51
  - Platform Control Indicator Panel
    54
Section 4 - Machine Operation

59
- Description
  59
- Operating Characteristics and Limitations
  59
  - Capacities
    59
  - Stability
    59
- Motor Operation
  60
  - Power/Emergency Stop
    60
  - Platform/Ground Select Switch
    60
- Position of Least Forward Stability
  61
  - Traveling (Driving)
    63
  - Traveling Forward and Reverse
    63
- Grade and Side Slopes
  64
  - Traveling on a Grade
    65
  - Steering
    65
  - Platform
    65
    
    Platform Level Adjustment
    65
    
    Platform Rotation
    65
  - Boom
    66
    
    Swinging the Boom
    66
  - Raising and Lowering the Upper Boom
    66
- Generator (Optional)
  66
- Function Speed Control
  67
- Machine Safety System Override (Msso)
  67
- 4.11 Skyguard Operation
  68
- Oscillating Axle Lockout Test (if Equipped)
  68
- 4.13 Shut down and Park
  69
- 4.14 Lifting and Tie down
  69
  - Lifting
    69
  - Tie down
    69
- Lifting and Tie down Chart
  70
- 4.15 Towing Instructions
  71
- 4.16 Drive Hub
  72
  - Disengaging for Towing
    72
  - Engaging after Towing Is Complete
    74
- Decal Installation - Sheet 1 of 4
  75
- Decal Installation - Sheet 2 of 4
  76
- Decal Installation - Sheet 3 of 4
  77
- Decal Installation - Sheet 4 of 4
  78
Section 5 - Emergency Procedures

87
- General
  87
- Incident Notification
  87
- Emergency Operation
  87
  - Operator Unable to Control Machine
    87
  - Platform or Boom Caught Overhead
    88
- Emergency Towing Procedures
  88
- Manual Descent System
  88
- Manual Descent Decal
  91
- Machine Safety System Override (Msso)
  92
Section 6 - General Specifications & Operator Maintenance

93
- Introduction
  93
- Operating Specifications
  93
  - Capacities
    96
  - Tires
    96
  - Hydraulic Oil
    97
  - Major Component Weights
    98
  - Serial Number Location
    98
- Operator Maintenance
  100
- Oscillating Axle Lockout Test (if Equipped)
  104
- Tires & Wheels
  105
  - Tire Inflation
    105
  - Tire Damage
    105
  - Tire Replacement
    105
  - Wheel Replacement
    106
  - Wheel Installation
    106
- Supplemental Information
  107

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JLG M600J Electric Boom Lift Manuals

JLG M600J Service And Maintenance Manual (222 pages)

Table of Contents

Section 1 - Specifications

Section 2 - General

Section 3 - Chassis & Turntable

Section 4 - Boom & Platform

Section 5 - Hydraulics

Section 6 - Jlg Control System

Section 7 - Basic Electrical Information & Schematics

JLG M600J Operation And Safety Manual (122 pages)

Table of Contents

JLG M600J Operation And Safety Manual (114 pages)

Table of Contents

Section 1 - Safety Precautions

Section - 2 - User Responsibilities, Machine Preparation

Section 3 - Machine Controls and Indicators

Section 4 - Machine Operation

Section 5 - Emergency Procedures

Section 6 - General Specifications & Operator Maintenance

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