Oshkosh Corporation JLG M600 Manuals

Manuals and User Guides for Oshkosh Corporation JLG M600. We have 2 Oshkosh Corporation JLG M600 manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

Oshkosh Corporation JLG M600 Service And Maintenance Manual (374 pages)

Brand: Oshkosh Corporation | Category: Lifting Systems | Size: 45 MB

General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications
17
Operating Specifications
17
Capacities
17
Tires
17
Function Speed
17
Hydraulic Oil
18
Torque Requirements
19
Major Component Weights
19
Serial Number Location
19
Operator Maintenance
21
General
29
Machine Preparation, Inspection, and Maintenance
29
Preparation, Inspection, and Maintenance
29
Pre-Start Inspection
29
Pre-Delivery Inspection and Frequent Inspection
29
Annual Machine Inspection
29
Preventative 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
32
Battery
32
Lubrication and Servicing
32
Lubrication and Information
32
Hydraulic System
32
Hydraulic Oil
32
Changing Hydraulic Oil
32
Lubrication Specifications
32
Cylinder Drift
33
Theory
33
Cylinder Leakage Test
33
Cylinder Thermal Drift
33
Pins and Composite Bearing Repair Guidelines
34
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
Chassis & Turntable
39
Tires & Wheels
39
Tire Inflation
39
Tire Damage
39
Tire Replacement
39
Wheel Replacement
39
Wheel Installation
39
Spindle, 2WD
40
Setting Wheel Bearing End Play
40
Specifications
40
Checking
40
Greasing Requirements
40
Drive Hub
42
Roll and Leak Testing
42
Tightening and Torquing Bolts
43
Main Disassembly
44
Output Planet Gear Disassembly
46
Cover Disassembly
47
Housing-Spindle Disassembly
48
Housing-Spindle Subassembly
50
Output Planet Gear Subassembly
51
Cover Subassembly
51
Main Assembly
52
Drive Motor
56
Removal
56
Disassembly
56
Inspection
56
Assembly
57
Installation
57
Oscillating Axle Lockout Test (if Equipped)
60
Oscillation Cylinder Bleeding
60
Bleeding Procedure
60
Swing Drive
66
Roll, Leak and Brake Testing
66
Tightening and Torquing Bolts
66
Motor Control Valve Disassembly
70
Motor and Brake Disassembly
71
Main Disassembly
73
Hub-Shaft Disassembly
74
Carrier Disassembly
75
Hub-Shaft Sub-Assembly
76
Carrier Sub-Assembly
76
Main Assembly
77
Motor-Brake Subassembly
77
Motor-Brake Assembly
77
Motor Control Valve Assembly
78
Tube Fitting Assembly Procedures
78
Procedure for Setting Gear Backlash
78
Swing Bearing
79
Turntable Bearing Mounting Bolt Condition Check
79
Wear Tolerance
80
Replacement of Swing Bearing
82
Swing Bearing Torque Value
83
Swing Drive Installation
83
Battery Maintenance and Charging
84
Battery Maintenance, Quarterly
84
Optional on Board Generator
84
Battery Charging (on Board Charger)
84
Removing the Battery Box
85
Battery Charger
87
Operating Instructions
87
Maintenance Instructions
88
Battery Charger Fault Codes
88
Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell
91
Checking/Changing the Battery Charger Algorithm
91
Generator
92
Engine
92
Alternator
92
Dynamo and Dynamo Voltage Regulator
92
Dynamo Output Fuse
92
Control Fuse
92
Start Battery
94
Engine Starter
94
Start Control Relay
94
Fuel Control Relay
95
Glow Plug Control Relay
95
Glow Plug
95
Fuel Pump
96
Fuel Solenoid
96
Engine Low Oil Pressure Switch
96
Engine Oil Temperature Sensor
96
Alternator Output Current Sensor
97
Engine Speed Sensor
97
RBS Engine/Generator Controller
97
Warnings and Safety Precautions
98
System Controls
98
System Status and Performance Monitoring
98
System Settings
98
RBS Start
99
RBS Shutdown
99
RBS Alarms and Flash Codes
100
Resetting the RBS Controller
100
Maintenance Schedule
100
Troubleshooting
101
APU Engine Start Battery Boosting
102
Supplementary Fuse for APU
103
Tools and Material
103
Procedure
103
Boom & Platform
107
Platform
107
Platform Valve Removal
107
Support Removal
107
Support Installation
108
Platform Valve Installation
109
Boom Maintenance
111
Removal
111
Installation
115
Platform Rotator
118
Theory of Operation
118
Tools Required for Assembly/Disassembly
119
Disassembly
122
Inspection
126
Assembly
126
Greasing Thrust Washers
131
Jib Rotator
132
Operating Principle
132
Disassembly
132
Inspection
136
Reassembly
136
Installing Counterbalance Valve
138
Testing the Actuator
139
Installation and Bleeding
139
Skyguard
141
Operation
141
Function Test
141
Diagnostics & Troubleshooting
142
Bolt-On External Fall Arrest
143
Inspection before Use
143
Installation
143
Basic Hydraulic Information & Schematics
147
Lubricating O-Rings in the Hydraulic System
147
Cup and Brush
147
Dip Method
148
Spray Method
148
Brush-On Method
148
Hydraulic Cylinders
149
Axle Lockout Cylinder
149
Slave Cylinder (E/M600 Only)
151
Slave Cylinder (E/M600J/JP)
157
Jib Lift Cylinder (E/M600J/JP)
162
Main Lift Cylinder
167
Master Cylinder (E/M600)
173
Master Cylinder (E/M600J/JP)
178
Steer Cylinder
183
Telescope Cylinder
187
Cylinder Removal and Installation
194
Main Boom Telescope Cylinder Removal
195
Main Boom Telescope Cylinder Installation
196
Main Boom Lift Cylinder Removal
197
Main Boom Lift Cylinder Installation
198
Master Cylinder Removal
199
Master Cylinder Installation
200
Slave Cylinder Removal
201
Slave Cylinder Installation
202
Pressure Setting
203
Proportional Main Relief
203
Lift down
203
Lift up
203
Swing
203
Flow Control / Bang Bang Main Relief
203
Steer
203
Platform Level down
203
Platform Level up Relief
203
Jib Relief
203
Jlg Control System
209
Introduction
209
To Connect the JLG Control System Analyzer
210
Using the Analyzer
210
Changing the Access Level of the Hand Held Analyzer
211
Adjusting Parameters Using the Hand Held Analyzer
212
Machine Setup
213
Level Vehicle Description
213
Machine Personality Settings
221
Machine Orientation When Performing Test
221
Test Notes
230
Help Descriptions and Fault Flash Codes
231
Analyzer Diagnostics Menu Structure
241
System Self Test
247
Calibrating Steer
252
Calibrating Tilt Sensor
254
Calibrating Load Sensing
255
Calibration of Motor (with New ZAPI Module)
258
LSS System
260
Diagnostic Menu
261
Calibration Procedure
262
Testing & Evaluation
267
Troubleshooting
268
Resetting the MSSO System
269
Basic Electrical Information & Schematics
295
General
295
Multimeter Basics
295
Grounding
295
Backprobing
295
Min/Max
295
Polarity
295
Scale
295
Voltage Measurement
295
Resistance Measurement
296
Continuity Measurement
296
Current Measurement
297
Checking Switches
297
Basic Check
297
Limit Switches
297
Automatic Switches
298
Switch Wiring - Low Side, High Side
298
Installation of Dielectric Grease
299
Deutsch HD, DT, DTM, DRC Series
299
AWP Seal
299
AMP Mate-N-Lok
300
DIN Connectors
300
Exclusions
300
AMP Connector
302
Applying Silicone Dielectric Compound to AMP Connectors
302
Assembly
302
Disassembly
304
Wedge Lock
304
Service - Voltage Reading
304
DEUTSCH Connectors
306
DT/DTP Series Assembly
306
DT/DTP Series Disassembly
306
HD30/HDP20 Series Assembly
307
HD30/HDP20 Series Disassembly
307
Wiring Harness Connector Labels
308
Connector Labels
308
Component Labels
308

Oshkosh Corporation JLG M600 Operation And Safety Manual (102 pages)

Brand: Oshkosh Corporation | Category: Boom Lifts | Size: 3 MB

Table of Contents
7
Section - Paragraph, Subject Page

10
Table of Contents

10
Section - Paragraph, Subject

11
Section 1. Safety Precautions

11
- General
  11
- Pre-Operation
  11
  - Operator Training and Knowledge
    11
  - Workplace Inspection
    12
  - Machine Inspection
    12
- Operation
  13
  - General
    13
  - Trip and Fall Hazards
    13
  - Electrocution Hazards
    14
- Minimum Approach Distances (M.A.D.)
  15
  - Tipping Hazards
    16
  - Crushing and Collision Hazards
    17
  - Towing, Lifting, and Hauling
    18
  - Additional Hazards / Safety
    19
Section 2. User Responsibilities, Machine Preparation, and Inspection

21
- 2.1 Personnel Training
  21
  - Operator Training
    21
  - Training Supervision
    21
  - Operator Responsibility
    21
- Preparation, Inspection, and Maintenance
  22
  - Pre-Start Inspection
    24
  - Function Check
    25
Section 3. Machine Controls and Indicators

33
- General
  33
- Controls and Indicators
  33
  - Ground Control Station
    33
- Ground Control Station
  34
- Ground Control Station W/ Function Enable
  35
  - Platform Control Station
    38
- Platform Control Station
  40
  - Platform Control Indicator Panel
    43
Section 4. Machine Operation

47
- Description
  47
- Operating Characteristics and Limitations
  47
  - Capacities
    47
  - Stability
    47
- Motor Operation
  48
  - Power/Emergency Stop
    48
  - Platform/Ground Select Switch
    48
- Position of Least Forward Stability
  49
  - Traveling (Driving)
    51
  - Traveling Forward and Reverse
    51
- Grade and Side Slopes
  52
  - Steering
    53
  - Platform
    53
    
    Platform Level Adjustment
    53
    
    Platform Rotation
    53
  - Boom
    53
    
    Swinging the Boom
    54
    
    Raising and Lowering the Upper Boom
    54
Section - Paragraph, Subject

54
- Generator (Optional)
  54
- Function Speed Control
  55
- Oscillating Axle Lockout Test
  55
- 4.11 Shut down and Park
  55
- 4.12 Lifting and Tie down
  56
  - Lifting
    56
  - Tie down
    56
- Lifting and Tie down Chart
  57
- 4.13 Towing Instructions
  58
- 4.14 Drive Hub
  59
  - Disengaging for Towing
    59
  - Engaging after Towing Is Complete
    61
Section 5. Emergency Procedures

75
- General
  75
- Incident Notification
  75
- Emergency Operation
  75
  - Operator Unable to Control Machine
    75
  - Platform or Boom Caught Overhead
    76
- Emergency Towing Procedures
  76
- Manual Descent System
  76
- Manual Descent Decal
  79
Section 6. General Specifications & Operator Maintenance

81
- Introduction
  81
- Operating Specifications
  81
  - Capacities
    84
  - Tires
    84
  - Hydraulic Oil
    85
  - Major Component Weights
    86
  - Serial Number Location
    86
- Operator Maintenance and Lubrication Diagram
  87
- Operator Maintenance
  88
- Oscillating Axle Lockout Test (if Equipped)
  92
- Tires & Wheels
  93
  - Tire Inflation
    93
  - Tire Damage
    93
  - Tire Replacement
    93
  - Wheel Replacement
    94
  - Wheel Installation
    94
- Supplemental Information
  95
- Wheel Torque Chart
  95
- Inspection and Repair Log
  97

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Oshkosh Corporation JLG M600 Manuals

Oshkosh Corporation JLG M600 Service And Maintenance Manual (374 pages)

Table of Contents

Oshkosh Corporation JLG M600 Operation And Safety Manual (102 pages)

Table of Contents

Section - Paragraph, Subject Page

Table of Contents

Section - Paragraph, Subject

Section 1. Safety Precautions

Section 2. User Responsibilities, Machine Preparation, and Inspection

Section 3. Machine Controls and Indicators

Section 4. Machine Operation

Section - Paragraph, Subject

Section 5. Emergency Procedures

Section 6. General Specifications & Operator Maintenance

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