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Jlg 600SC_660SJC Service Manual manuals

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Jlg 600SC_660SJC Service Manual User Manual (406 pages)


Brand: Jlg | Category: Special machinery | Size: 23.05 MB |

 

Table of contents

S/N 74875

1

A GENERAL

3

B HYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

10

11

LIST OF TABLES

17

SECTION 1. SPECIFICATIONS

19

SECTION 1 - SPECIFICATIONS

20

Dimensions

21

1.6 TORQUE REQUIREMENTS

21

1.7 PRESSURE SETTINGS

21

1.8 CYLINDER SPECIFICATIONS

21

1.9 MAJOR COMPONENT WEIGHTS

21

1.10 SERIAL NUMBER LOCATIONS

22

1.11 HYDRAULIC OIL

22

LUBRICATION

23

SOCKET HEAD CAP SCREWS

28

Magni Coating (Ref 4150701)*

32

SECTION 2. GENERAL

33

2.2 SERVICE AND GUIDELINES

34

Safety and Workmanship

34

Cleanliness

34

SECTION 2 - GENERAL

35

Changing Hydraulic Oil

37

Lubrication Specifications

37

2.4 CYLINDER DRIFT TEST

37

Platform Drift

37

Cylinder Drift

37

SECTION 3. GRADALL CHASSIS

45

SECTION 3 - GRADALL CHASSIS

46

3.2 TRACK TENSIONING

60

Assembly and Installation

63

4-2 – JLG Lift – 3121157

64

3121157 – JLG Lift – 4-3

65

4-4 – JLG Lift – 3121157

66

4.2 SYSTEM PRESSURE - RELEASE

67

Hydraulic Circuit

68

Multiple Hydraulic Circuits

69

4.3 TRACK CARRIER ROLLER

70

4.4 TRACK ROLLER

71

4.5 TRACK

73

Separation

73

Connection

74

3121157 – JLG Lift – 4-13

75

4-14 – JLG Lift – 3121157

76

4.7 RECOIL SPRING

77

4-16 – JLG Lift – 3121157

78

3121157 – JLG Lift – 4-17

79

3121157 – JLG Lift – 4-19

81

4.9 TRACK ADJUSTER

83

3121157 – JLG Lift – 4-23

85

4.10 SPROCKET

86

3121157 – JLG Lift – 4-25

87

4.12 TRACK ADJUSTMENT

89

Measuring Track Tension

89

Adjusting Track Tension

90

Track Adjustment - Inspect

91

4-30 – JLG Lift – 3121157

92

SECTION 5

93

Operation of Motor

94

Use of Parking Brake

95

Prevention of Overrun

95

Cases of Hydraulic Circuit

95

5-4 – JLG Lift – 3121157

96

Design of Drive Motor:

96

Features:

96

Design Type:

96

3121157 – JLG Lift – 5-5

97

Shuttle Valve Action

98

3121157 – JLG Lift – 5-7

99

Working of Relief Valve

99

Two-Speed Changeover System

100

3121157 – JLG Lift – 5-9

101

5-10 – JLG Lift – 3121157

102

3121157 – JLG Lift – 5-11

103

(PF1/4 / 2 locations / Hex.6)

104

Reduction Gear Ratio (i)

105

Inspection

106

Direction of Rotation

106

5.4 PRECAUTIONS AND WARNINGS

106

3121157 – JLG Lift – 5-15

107

Constant at 0.2 MPa or less

107

Precautions at Startup

108

5-18 – JLG Lift – 3121157

110

3121157 – JLG Lift – 5-19

111

Gauging Procedure

111

5.7 TROUBLESHOOTING

113

5-22 – JLG Lift – 3121157

114

3121157 – JLG Lift – 5-23

115

5-24 – JLG Lift – 3121157

116

3121157 – JLG Lift – 5-25

117

5-26 – JLG Lift – 3121157

118

3121157 – JLG Lift – 5-27

119

5-28 – JLG Lift – 3121157

120

3121157 – JLG Lift – 5-29

121

5-30 – JLG Lift – 3121157

122

3121157 – JLG Lift – 5-31

123

Brake Piston Positioning

123

5-32 – JLG Lift – 3121157

124

Snap Ring Assembly

124

3121157 – JLG Lift – 5-33

125

5-34 – JLG Lift – 3121157

126

Motor Bearing Assembly

126

Floating Seal Assembly

126

3121157 – JLG Lift – 5-35

127

Floating Seal #1 - Assembly

127

Floating Seal #2 - Assembly

127

5-36 – JLG Lift – 3121157

128

3121157 – JLG Lift – 5-37

129

5-38 – JLG Lift – 3121157

130

3121157 – JLG Lift – 5-39

131

5-40 – JLG Lift – 3121157

132

5.10 DISASSEMBLY INSTRUCTIONS

133

Motor Disassembly

133

5-42 – JLG Lift – 3121157

134

Reduction Gear Disassembly

135

5-44 – JLG Lift – 3121157

136

Motor Maintenance

137

5-46 – JLG Lift – 3121157

138

Reduction Gear Maintenance

139

5.12 REASSEMBLY

140

3121157 – JLG Lift – 5-49

141

5-50 – JLG Lift – 3121157

142

3121157 – JLG Lift – 5-51

143

5-52 – JLG Lift – 3121157

144

3121157 – JLG Lift – 5-53

145

5-54 – JLG Lift – 3121157

146

SECTION 6. TURNTABLE

147

Wear Tolerance

148

Swing Bearing Replacement

148

SECTION 6 - TURNTABLE

149

Swing Bearing Torque Values

151

6.3 SWING BRAKE - MICO

151

Disassembly

151

Assembly

153

6.4 GENERATOR

153

Every 250 hours

153

Every 500 hours

153

Overload Protection

154

6.5 SPARK ARRESTER CLEANING

154

INSTRUCTIONS

154

Diagnostic Trouble Codes

176

MIL Output

176

TAN/WHITE

177

BLACK/GREEN

177

DTC 117- ECT/CHT Low Voltage

178

DTC 118- ECT/CHT High Voltage

180

Diagnostic Aids

187

Pressure

191

DTC 524- Oil Pressure Low

192

Normally Closed Switch

193

SFC 555- RTI 2 Loss

208

SFC 556- RTI 3 Loss

210

SFC 513- A/D Loss

212

SFC 512- Invalid Interrupt

214

BLUE/RED or PINK

215

BLUE/WHITE

215

Spring Failure

225

DTC to SPN/FMI Table

226

7.1 PLATFORM

227

Platform Sections Replacement

227

Torque Procedures

227

7.3 WEAR PADS

228

Main Boom

228

3121157 – JLG Lift – 7-3

229

7-4 – JLG Lift – 3121157

230

3121157 – JLG Lift – 7-5

231

7-6 – JLG Lift – 3121157

232

3121157 – JLG Lift – 7-7

233

Disassembly of Boom Sections

234

3121157 – JLG Lift – 7-11

237

7-12 – JLG Lift – 3121157

238

Installation

239

7.6 ARTICULATING JIB BOOM

239

7.7 LIMIT SWITCH ADJUSTMENT

240

3121157 – JLG Lift – 7-15

241

0300132437)

242

3121157 – JLG Lift – 7-17

243

TO PRESENT)

245

Theory of Operation

245

Required Tools

246

3121157 – JLG Lift – 7-21

247

7-22 – JLG Lift – 3121157

248

7-24 – JLG Lift – 3121157

250

3121157 – JLG Lift – 7-25

251

7-26 – JLG Lift – 3121157

252

7-28 – JLG Lift – 3121157

254

3121157 – JLG Lift – 7-29

255

7-30 – JLG Lift – 3121157

256

3121157 – JLG Lift – 7-31

257

7-32 – JLG Lift – 3121157

258

7.10 FOOT SWITCH ADJUSTMENT

259

7-34 – JLG Lift – 3121157

260

SECTION 8. HYDRAULICS

261

Dip Method

262

Spray Method

262

Brush-on Method

262

SECTION 8 - HYDRAULICS

263

8.5 CYLINDER REPAIR

265

Cleaning and Inspection

266

8.6 CYLINDER REMOVAL AND

271

INSTALLATION

271

8.8 HYDRAULIC PUMP (GEAR)

280

Inspect Parts For Wear

282

General Information

283

8.9 VARIABLE PUMP

286

Ports and Pressure Gauges

286

NFPE Control

286

Control Orifices

287

Charge Relief Valve

287

Charge Pump

292

DRIVE COUPLING LUBRICATION

294

PROCEDURES AND

294

RECOMMENDATIONS

294

9.1 INTRODUCTION

297

9-2 – JLG Lift – 3121157

298

SYSTEM ANALYZER

299

9.3 USING THE ANALYZER

299

9-4 – JLG Lift – 3121157

300

HAND HELD ANALYZER

301

9-6 – JLG Lift – 3121157

302

9.6 MACHINE SETUP

304

9.7 LEVEL VEHICLE DESCRIPTION

304

3121157 – JLG Lift – 9-9

305

9-10 – JLG Lift – 3121157

306

3121157 – JLG Lift – 9-11

307

9-12 – JLG Lift – 3121157

308

3121157 – JLG Lift – 9-13

309

9-14 – JLG Lift – 3121157

310

3121157 – JLG Lift – 9-15

311

9-16 – JLG Lift – 3121157

312

3121157 – JLG Lift – 9-17

313

9-18 – JLG Lift – 3121157

314

3121157 – JLG Lift – 9-19

315

9-20 – JLG Lift – 3121157

316

3121157 – JLG Lift – 9-21

317

9-22 – JLG Lift – 3121157

318

3121157 – JLG Lift – 9-23

319

9-24 – JLG Lift – 3121157

320

3121157 – JLG Lift – 9-25

321

9-26 – JLG Lift – 3121157

322

3121157 – JLG Lift – 9-27

323

9-28 – JLG Lift – 3121157

324

3121157 – JLG Lift – 9-29

325

9-30 – JLG Lift – 3121157

326

3121157 – JLG Lift – 9-31

327

9-32 – JLG Lift – 3121157

328

3121157 – JLG Lift – 9-33

329

9-34 – JLG Lift – 3121157

330

3121157 – JLG Lift – 9-35

331

9-36 – JLG Lift – 3121157

332

3121157 – JLG Lift – 9-37

333

9-38 – JLG Lift – 3121157

334

3121157 – JLG Lift – 9-39

335

9-40 – JLG Lift – 3121157

336

3121157 – JLG Lift – 9-41

337

9-42 – JLG Lift – 3121157

338

3121157 – JLG Lift – 9-43

339

9-44 – JLG Lift – 3121157

340

3121157 – JLG Lift – 9-45

341

9-46 – JLG Lift – 3121157

342

3121157 – JLG Lift – 9-47

343

9-48 – JLG Lift – 3121157

344

3121157 – JLG Lift – 9-49

345

9-50 – JLG Lift – 3121157

346

3121157 – JLG Lift – 9-51

347

9-52 – JLG Lift – 3121157

348

3121157 – JLG Lift – 9-57

353

9-58 – JLG Lift – 3121157

354

3121157 – JLG Lift – 9-59

355

9-60 – JLG Lift – 3121157

356

3121157 – JLG Lift – 9-61

357

9-62 – JLG Lift – 3121157

358

STRUCTURE

359

9-64 – JLG Lift – 3121157

360

3121157 – JLG Lift – 9-65

361

9-66 – JLG Lift – 3121157

362

3121157 – JLG Lift – 9-67

363

9-68 – JLG Lift – 3121157

364

3121157 – JLG Lift – 10-1

365

Resistance Measurement

366

Continuity Measurement

366

Current Measurement

367

COMPOUND TO ELECTRICAL

367

CONNECTIONS

367

AMP Seal

368

AMP Mate-N-Lok

369

DIN Connectors

369

Exclusions

369

10-6 – JLG Lift – 3121157

370

AMP JUNIOR TIMER

370

SEALED ENCLOSURES

370

10.4 AMP CONNECTOR

371

AMP Connectors

371

10-8 – JLG Lift – 3121157

372

3121157 – JLG Lift – 10-9

373

Wedge Lock

374

Service - Voltage Reading

374

3121157 – JLG Lift – 10-11

375

10.5 DEUTSCH CONNECTORS

376

DT/DTP Series Assembly

376

DT/DTP Series Disassembly

376

HD30/HDP20 Series Assembly

377

HD30/HDP20 Series Disassembly

377

10-14 – JLG Lift – 3121157

378

3121157 – JLG Lift – 10-15

379

10-16 – JLG Lift – 3121157

380

3121157 – JLG Lift – 10-17

381

10-18 – JLG Lift – 3121157

382

3121157 – JLG Lift – 10-19

383

10-20 – JLG Lift – 3121157

384

3121157 – JLG Lift – 10-21

385

10-22 – JLG Lift – 3121157

386

3121157 – JLG Lift – 10-23

387

10-24 – JLG Lift – 3121157

388

3121157 – JLG Lift – 10-25

389

10-26 – JLG Lift – 3121157

390

3121157 – JLG Lift – 10-27

391

10-28 – JLG Lift – 3121157

392

3121157 – JLG Lift – 10-29

393

10-30 – JLG Lift – 3121157

394

3121157 – JLG Lift – 10-31

395

10-32 – JLG Lift – 3121157

396

3121157 – JLG Lift – 10-33

397

10-34 – JLG Lift – 3121157

398

3121157 – JLG Lift – 10-35

399

10-36 – JLG Lift – 3121157

400

3121157 – JLG Lift – 10-37

401

10-38 – JLG Lift – 3121157

402

3121157 – JLG Lift – 10-39

403

10-40 – JLG Lift – 3121157

404

JLG Worldwide Locations

406

Jlg 600SC_660SJC Service Manual User Manual (270 pages)


Brand: Jlg | Category: Special machinery | Size: 19.97 MB |

 

Table of contents

S/N 0300174703

1

A GENERAL

3

BHYDRAULIC SYSTEM SAFETY

3

C MAINTENANCE

3

REVISON LOG

4

TABLE OF CONTENTS

5

LIST OF FIGURES

11

14

SECTION 1. SPECIFICATIONS

15

1.5 FUNCTION SPEEDS

16

Test Notes

16

1.6 TORQUE REQUIREMENTS

16

1.7 HYDRAULIC OIL

17

1.8 MAJOR COMPONENT WEIGHTS

18

1.9 OPERATOR MAINTENANCE

19

SECTION 1 - SPECIFICATIONS

20

SECTION 2. GENERAL

27

2.2 SERVICE AND GUIDELINES

28

Safety and Workmanship

28

Cleanliness

28

SECTION 2 - GENERAL

29

3121607 – JLG Lift – 3-1

37

Service Notes

38

3121607 – JLG Lift – 3-3

39

Track and Chain

40

Replace Track

41

Track tensioning

42

Rubber Track Pad Installation

42

3121607 – JLG Lift – 3-7

43

3-8 – JLG Lift – 3121607

44

3121607 – JLG Lift – 3-9

45

ROLLER SEALS

45

TRACK ROLLER DISASSEMBLY

45

TRACK ROLLER ASSEMBLY

45

Idler Roller Assembly

46

3121607 – JLG Lift – 3-11

47

3.2 DRIVE MOTOR

49

3-14 – JLG Lift – 3121607

50

3121607 – JLG Lift – 3-15

51

3121607 – JLG Lift – 3-17

53

Install Motor Assembly

55

Rotary Coupling

56

3121607 – JLG Lift – 3-21

57

3-22 – JLG Lift – 3121607

58

3121607 – JLG Lift – 3-23

59

3.3 SWING DRIVE

60

3121607 – JLG Lift – 3-25

61

Drain Plug

62

Fill Plug

62

Motor and Brake Disassembly

63

Main Disassembly

64

Hub-Shaft Disassembly

64

Carrier Disassembly

65

Hub-Shaft Subassembly

66

Carrier Subassembly

67

Main Assembly

68

Motor and Brake Assembly

69

Motor Control Valve Assembly

69

3.4 SWING BEARING

70

Wear Tolerance

70

3121607 – JLG Lift – 3-35

71

Swing Bearing Replacement

72

Swing Bearing Torque Values

73

3.5 GENERATOR

74

Every 250 hours

74

Every 500 hours

74

Overload Protection

75

Cleaning Slip Rings

75

3-40 – JLG Lift – 3121607

76

3.6 DEUTZ D2.9 L4 ENGINE

77

3-42 – JLG Lift – 3121607

78

Check Oil Level

79

Change Engine Oil

79

Change Oil Filter

80

Change Fuel Filters

80

3.7 DEUTZ D2011 ENGINE

81

3-46 – JLG Lift – 3121607

82

Checking Oil Level

85

Changing Engine Oil

85

Changing Oil Filter

86

Replace Fuel Filter

86

Clean Fuel Strainer

87

3.9 GLOW PLUGS

87

3.10 DEUTZ EMR 2

88

3121607 – JLG Lift – 3-53

89

3-54 – JLG Lift – 3121607

90

3121607 – JLG Lift – 3-55

91

3-56 – JLG Lift – 3121607

92

3121607 – JLG Lift – 3-57

93

3-58 – JLG Lift – 3121607

94

3121607 – JLG Lift – 3-59

95

3-60 – JLG Lift – 3121607

96

3121607 – JLG Lift – 3-61

97

3-62 – JLG Lift – 3121607

98

3121607 – JLG Lift – 3-63

99

Bio Fuel

100

3121607 – JLG Lift – 3-65

101

SYMPTOMS

101

PREVENTIVE MEASURES

101

FUEL ADDITIVES

101

3-66 – JLG Lift – 3121607

102

4.1 BOOM SYSTEMS

103

4.2 WEAR PADS

104

REPLACEMENT

105

Boom Section Disassembly

105

4.4 WIRE ROPE

106

Inspection

106

Three Month Inspection

106

Eight Year Inspection

106

Replacement Criteria

106

3121607 – JLG Lift – 4-5

107

4-6 – JLG Lift – 3121607

108

3121607 – JLG Lift – 4-7

109

4-8 – JLG Lift – 3121607

110

Assembly

112

3121607 – JLG Lift – 4-11

113

4-12 – JLG Lift – 3121607

114

Installation

115

4.6 ARTICULATING JIB BOOM

116

Disassembly

116

4-16 – JLG Lift – 3121607

118

3121607 – JLG Lift – 4-17

119

4.9 ROTARY ACTUATOR

120

Theory of Operation

120

Required Tools

120

3121607 – JLG Lift – 4-19

121

4-20 – JLG Lift – 3121607

122

4-22 – JLG Lift – 3121607

124

3121607 – JLG Lift – 4-23

125

4-24 – JLG Lift – 3121607

126

3121607 – JLG Lift – 4-27

129

4-28 – JLG Lift – 3121607

130

3121607 – JLG Lift – 4-29

131

4-30 – JLG Lift – 3121607

132

Testing Actuator

133

Installation and Bleeding

133

Troubleshooting

134

4.10 FOOT SWITCH ADJUSTMENT

135

4.11 PLATFORM

135

Replace Platform Sections

135

4.12 POWERTRACK MAINTENANCE

136

Remove Link

136

3121607 – JLG Lift – 4-35

137

4-36 – JLG Lift – 3121607

138

Install New Link

139

4-38 – JLG Lift – 3121607

140

3121607 – JLG Lift – 4-39

141

Replace Fixed End Brackets

142

Replace Moving End Brackets

143

4-42 – JLG Lift – 3121607

144

SECTION 5. HYDRAULICS

145

Brush-On

146

SECTION 5 - HYDRAULICS

147

5.5 CYLINDER REPAIR

150

Cylinder Locations

151

Main Lift Cylinder

152

3121607 – JLG Lift – 5-9

153

Cleaning and Inspection

154

Master Cylinder

157



158

Telescope Cylinder

162

3121607 – JLG Lift – 5-19

163



163



167



167



167



167

5-24 – JLG Lift – 3121607

168



168



168

Jib Lift Cylinder (SJC Only)

172

3121607 – JLG Lift – 5-29

173



173

5.6 HYDRAULIC PUMP (GEAR)

177

Inspect Parts For Wear

179

General Information

180

M 8 x 1.25

182

M 10 x 1.5

182

M 12 x 1.75

182

5.7 VARIABLE PUMP

183

Ports and Pressure Gauges

183

NFPE Control

183

Charge Relief Valve

184

Lubrication

188

Charge Pump

189

6.1 INTRODUCTION

195



196



196



196

Using Analyzer

197

Changing Access Level

198

Adjust Parameters

199

Machine Setup

200

Level Vehicle Description

200

3121607 – JLG Lift – 6-7

201

6-8 – JLG Lift – 3121607

202

3121607 – JLG Lift – 6-9

203

6-10 – JLG Lift – 3121607

204

3121607 – JLG Lift – 6-11

205

6-12 – JLG Lift – 3121607

206

3121607 – JLG Lift – 6-13

207

6-14 – JLG Lift – 3121607

208

3121607 – JLG Lift – 6-15

209

4150365B

210

3121607 – JLG Lift – 6-17

211

6-18 – JLG Lift – 3121607

212

3121607 – JLG Lift – 6-19

213

6-20 – JLG Lift – 3121607

214

3121607 – JLG Lift – 6-21

215

6-22 – JLG Lift – 3121607

216

3121607 – JLG Lift – 6-23

217

6-24 – JLG Lift – 3121607

218

3121607 – JLG Lift – 6-25

219

6-26 – JLG Lift – 3121607

220

3121607 – JLG Lift – 6-27

221

6-28 – JLG Lift – 3121607

222

3121607 – JLG Lift – 6-29

223

6-30 – JLG Lift – 3121607

224

STOUCH/SKY

225

6-32 – JLG Lift – 3121607

226

4150364 G

227

FUNCTION SPEEDS

228

6.4 CANBUS COMMUNICATIONS

229

6-36 – JLG Lift – 3121607

230

3121607 – JLG Lift – 6-37

231

6-38 – JLG Lift – 3121607

232

3121607 – JLG Lift – 6-39

233

6-40 – JLG Lift – 3121607

234

3121607 – JLG Lift – 6-41

235

6-42 – JLG Lift – 3121607

236

3121607 – JLG Lift – 6-43

237

6-44 – JLG Lift – 3121607

238

3121607 – JLG Lift – 6-45

239

6-46 – JLG Lift – 3121607

240



240

3121607 – JLG Lift – 6-47

241

6-48 – JLG Lift – 3121607

242

3121607 – JLG Lift – 6-49

243



243

6-50 – JLG Lift – 3121607

244

3121607 – JLG Lift – 7-1

245

Resistance Measurement

246

Continuity Measurement

246

Current Measurement

247

TO ELECTRICAL CONNECTIONS

247

Dielectric Grease Application

248

AMP Seal

248

AMP Mate-N-Lok

249

DIN Connectors

249

Exclusions

249

7.4 AMP CONNECTOR

250

Contact Assembly

250

Connector Assembly

250

Wedge Lock

251

Service - Voltage Reading

251

7.5 DEUTSCH CONNECTORS

252

DT/DTP Series Assembly

252

DT/DTP Series Disassembly

252

HD30/HDP20 Series Assembly

253

HD30/HDP20 Series Disassembly

253

7-10 – JLG Lift – 3121607

254

3121607 – JLG Lift – 7-11

255

7-12 – JLG Lift – 3121607

256

3121607 – JLG Lift – 7-13

257

7-14 – JLG Lift – 3121607

258

Deutz EMR2 Engine

259

7-16 – JLG Lift – 3121607

260

3121607 – JLG Lift – 7-17

261

7-18 – JLG Lift – 3121607

262

3121607 – JLG Lift – 7-19

263

7-20 – JLG Lift – 3121607

264

3121607 – JLG Lift – 7-21

265

7-22 – JLG Lift – 3121607

266

3121607 – JLG Lift – 7-23

267

7-24 – JLG Lift – 3121607

268

JLG Worldwide Locations

270

Jlg 600SC_660SJC Service Manual User Manual (186 pages)


Brand: Jlg | Category: Special machinery | Size: 47.00 MB |

 

Table of contents

April 10, 2002

1

PRECAUTIONS

3

REVISON LOG

4

TABLE OF CONTENTS (continued)

8

SECTION 6 - UNDERCARRIAGE

8

10

LIST OF FIGURES (continued)

10

FIGURE NO. TITLE PAGE NO

10

TABLE OF CONTENTS

11

SECTION 1. SPECIFICATIONS

13

1-2 – JLG Lift – 3120898

14

SECTION 1 - SPECIFICATIONS

15

Te s t N o t e s

15

1.5 TORQUE REQUIREMENTS

15

1.6 LUBRICATION

15

Deutz F4M1011F Engine

15

Hydraulic Oil

16

Lubrication Specifications

16

1.7 PRESSURE SETTINGS

16

1.8 CYLINDER SPECIFICATIONS

17

1.9 MAJOR COMPONENT WEIGHTS

17

1.11 SERIAL NUMBER LOCATIONS

18

SECTION 2. GENERAL

23

2-2 – JLG Lift – 3120898

24

3120898 – JLG Lift – 2-3

25

2-4 – JLG Lift – 3120898

26

3120898 – JLG Lift – 2-5

27

SECTION 2 - GENERAL

28

SECTION 3. TURNTABLE

31

3-2 – JLG Lift – 3120898

32

SECTION 3 - TURNTABLE

33

Failure Modes

33

3-4 – JLG Lift – 3120898

34

IMPORTANT

35

Swing Bearing Torque Values

37

3.5 SWING BRAKE - MICO

38

Inspection

38

4.1 PLATFORM

41

Platform Sections Replacement

41

Torque Procedures

41

4.3 WEAR PADS

42

Main Boom

42

3120898 – JLG Lift – 4-3

43

4-4 – JLG Lift – 3120898

44

Disassembly of Boom Sections

45

4-6 – JLG Lift – 3120898

46

3120898 – JLG Lift – 4-7

47

4-8 – JLG Lift – 3120898

48

3120898 – JLG Lift – 4-11

51

4-12 – JLG Lift – 3120898

52

3120898 – JLG Lift – 4-13

53

4.6 ARTICULATING JIB BOOM

54

4.7 LIMIT SWITCH ADJUSTMENT

55

4-16 – JLG Lift – 3120898

56

4.8 ROTATOR - HELAC

57

4-18 – JLG Lift – 3120898

58

4.9 FOOT SWITCH ADJUSTMENT

60

4.10 SUPERFLEX CONTROLLER

60

System Overview

60

System Elements

60

General Description

61

4-22 – JLG Lift – 3120898

62

Setup and Tuning

63

4-24 – JLG Lift – 3120898

64

3120898 – JLG Lift – 4-25

65

4-26 – JLG Lift – 3120898

66

Troubleshooting

67

Controller

67

4-28 – JLG Lift – 3120898

68

3120898 – JLG Lift – 4-29

69

4-30 – JLG Lift – 3120898

70

Important Reminders

71

Ex: Max Out

73

4-34 – JLG Lift – 3120898

74

3120898 – JLG Lift – 4-35

75

4-36 – JLG Lift – 3120898

76

3120898 – JLG Lift – 4-37

77

4-38 – JLG Lift – 3120898

78

3120898 – JLG Lift – 4-39

79

4-40 – JLG Lift – 3120898

80

3120898 – JLG Lift – 4-41

81

4-42 – JLG Lift – 3120898

82

3120898 – JLG Lift – 4-43

83

4-44 – JLG Lift – 3120898

84

(Pump Side) EDC:

85

4-46 – JLG Lift – 3120898

86

SECTION 5. HYDRAULICS

87

Cleaning and Inspection

90

5.5 CYLINDER REMOVAL AND

95

INSTALLATION

95

Platform Level

97

SECTION 5 - HYDRAULICS

100

5-16 – JLG Lift – 3120898

102

SECTION 6. UNDERCARRIAGE

105

SECTION 6 - UNDERCARRIAGE

106

Installation

106

Disassembly

106

Assembly

109

6.2 TRACK ROLLER

112

6.3 TRACK

119

Separate

119

Front Idler Disassembly

123

Front Idler Assembly

124

Recoil Spring Disassembly

126

Recoil Spring Assembly

129

6.5 TRACK ADJUSTER

131

6.6 FINAL DRIVE SPROCKET

134

6.7 TRAVEL BRAKE VALVE

136

6.8 TRAVEL MOTOR

136

6.9 TRAVEL BRAKE VALVE

138

6.10 TRAVEL BRAKE VALVE

139

Installation Procedure

140

6.11 TRAVEL MOTOR

141

6.12 FINAL DRIVE

145

Final Drive Oil - Change

161

Final Drive Oil Level Check

162

6.13 SWIVEL

162

6.14 TOWING INFORMATION

166

Final Drive Sun Gear Removal

167

6-64 – JLG Lift – 3120898

168

SECTION 7. SCHEMATICS

169

SECTION 7 - SCHEMATICS

170

JLG Worldwide Locations

186




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