Jlg 600SC_660SJC Service Manual User Manual

Service and Maintenance ManualModel600SC600SJC660SJC3120898April 10, 2002

vi – JLG Lift – 3120898TABLE OF CONTENTS LIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.4-25. Removing Sleeve from Housing . . .

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3120898Figure 5-18. Location of Components - Main Control Valve (Sheet 1)

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-15Figure 5-19. Location of Components - Main Control Valve (Sheet 2)

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31208985.7 HYDRAULIC PUMP W/HAYES PUMP DRIVE COUPLING LUBRICATIONAny time pump or pump drive coupling is remov

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-17lines as soon as oil is observed to leak from them.When oil is observed to "leak" at the moto

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SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-1SECTION 6. UNDERCARRIAGE6.1 TRACK CARRIER ROLLERRemovalPERSONAL INJURY OR DEATH CAN RESULT FROM GREA

SECTION 6 - UNDERCARRIAGE6-2 – JLG Lift – 3120898after opening the relief valve, move the machine for-ward and backward until the tension is released.

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-3Figure 6-2. Track Carrier Roller - Exploded View

SECTION 6 - UNDERCARRIAGE6-4 – JLG Lift – 31208982. Remove plug (2). Drain the oil from the carrier rollerinto a suitable container for disposal. The

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-57. Remove Duo-cone seal kit (9) from the track carrierroller.8. Remove Duo-cone seal kit (10) from th

3120898 – JLG Lift – vii TABLE OF CONTENTSLIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.7-12. Hydraulic Schematic w/GFT24 Drive -

SECTION 6 - UNDERCARRIAGE6-6 – JLG Lift – 3120898NOTE: Do not reuse bearings (12) and (13). Use new partsfor replacement.NOTE: Bearing (13) is a strai

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-7NOTE: The rubber seal and all surfaces that make contactwith the seals must be clean and dry. After i

SECTION 6 - UNDERCARRIAGE6-8 – JLG Lift – 31208986.2 TRACK ROLLERRemovalNOTE: There is a track guide on each side of the machine.The procedure which f

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-9Figure 6-4. Track Roller - Exploded View

SECTION 6 - UNDERCARRIAGE6-10 – JLG Lift – 3120898Disassembly1. Thoroughly clean the outside of the track roller priorto disassembly.NOTE: Care must b

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-116. Remove the o-ring seal from shaft (5). Remove shaft(5) from roller (6).7. Remove Duo-cone seal ki

SECTION 6 - UNDERCARRIAGE6-12 – JLG Lift – 3120898NOTE: Do not install the Duo-cone seal kit in the track rolleror end collars at this time.NOTE: Repl

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-13NOTE: The rubber seals and all surfaces that make contactwith the seals must be clean and dry. After

SECTION 6 - UNDERCARRIAGE6-14 – JLG Lift – 3120898Installation1. Be sure the mounting surface on the track roller, thetrack guide, and the undercarria

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-156.3 TRACKSeparate1. Put the machine on a flat level surface.PERSONAL INJURY OR DEATH CAN RESULT FROM

viii – JLG Lift – 3120898TABLE OF CONTENTS This page left blank intentionally.

SECTION 6 - UNDERCARRIAGE6-16 – JLG Lift – 3120898PERSONAL INJURY CAN RESULT FROM THE TRACK COMINGOFF OF THE ROLLER FRAME.THE TRACK CAN MOVE OFF THE T

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-171. Install tooling (A) in the track link and on thesprocket as shown.2. Start the machine. Move the

SECTION 6 - UNDERCARRIAGE6-18 – JLG Lift – 31208986.4 FRONT IDLER AND RECOIL SPRINGRemoval1. Fasten a suitable lifting device to front idler (1), assh

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-19Front Idler Disassembly1. Thoroughly clean the outside of the front idler priorto assembly.NOTE: Car

SECTION 6 - UNDERCARRIAGE6-20 – JLG Lift – 31208986. Remove shaft (4) from the front idler.7. Remove two o-ring seals (5) from shaft (4).8. Remove the

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-213. Lower the temperature of bushings (7), and installone in each side of the front idler with a pres

SECTION 6 - UNDERCARRIAGE6-22 – JLG Lift – 312089811. Install spring pin (1). The illustration above showsthe positioning of the slit in spring pin (1

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-231. Prior to disassembling and assembling the recoilspring assembly, make sure that tooling (A) is on

SECTION 6 - UNDERCARRIAGE6-24 – JLG Lift – 31208987. Put a level gauge (4) on the recoil spring assembly.Reposition the recoil spring assembly until t

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-25Recoil Spring Assembly1. Check the condition of the threads on retaining rod(12), nut (7), and nut (

SECTION 1 - SPECIFICATIONS3120898 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESFuel Tank39 US. Gallons (147.6 l)Hydraulic Oil Tank31 U.S. G

SECTION 6 - UNDERCARRIAGE6-26 – JLG Lift – 3120898NOTE: Do not remove the lifting device from the recoilspring assembly until the unit is leveled, cen

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-2711. Fasten a suitable lifting device to the recoil springassembly. The weight of the recoil spring a

SECTION 6 - UNDERCARRIAGE6-28 – JLG Lift – 3120898Figure 6-10. Track Adjuster

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-29AssemblyNOTE: Make sure that all of the parts of the hydraulic trackadjuster are clean and free of d

SECTION 6 - UNDERCARRIAGE6-30 – JLG Lift – 3120898Installation1. Position track adjuster (2) in the undercarriage frameof the machine.2. Install the w

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-312. Remove 15 bolts (1) that hold the sprocket to thefinal drive.3. Fasten Tooling (B.) and a suitabl

SECTION 6 - UNDERCARRIAGE6-32 – JLG Lift – 31208986.7 TRAVEL BRAKE VALVERemovalAT OPERATING TEMPERATURE, THE HYDRAULIC OIL IS HOTAND UNDER PRESSURE. H

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-33Figure 6-11. Travel Motor

SECTION 6 - UNDERCARRIAGE6-34 – JLG Lift – 31208981. Drain the oil from the final drive into a suitable con-tainer for storage or disposal. The capaci

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-353. Remove O-ring seal (3) from travel brake valve (2).Remove brake valve (4) from the travel brake v

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 31208981.3 PERFORMANCE DATATravel Speed1.6 MPH (2.6 Km/hr.)Travel Speed - Out of Transport0.4 MPH (0.6 Km/h

SECTION 6 - UNDERCARRIAGE6-36 – JLG Lift – 31208985. Install valve (5) in travel brake valve (2). Tightenvalve (5) to a torque of 15 ± 1 ft.lb. (20 ±

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-378. Start the machine and check for leaks. Check theoperation of the travel motors.9. Install cover (

SECTION 6 - UNDERCARRIAGE6-38 – JLG Lift – 31208984. Remove shaft (6) from motor housing (2).5. Use tooling (B) to remove bearing (7) from shaft.6. Re

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-391. Install seal (12) in motor housing (2). Use the correctretaining ring pliers in order to install

SECTION 6 - UNDERCARRIAGE6-40 – JLG Lift – 31208988. Install control unit (3) in motor housing (2).9. Install rotary assembly (1) in motor housing (2)

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-416.12 FINAL DRIVERemovalStart by separating the track assembly. Refer to Disassem-bly and Assembly, &

SECTION 6 - UNDERCARRIAGE6-42 – JLG Lift – 31208986. Fasten tooling (A) and a suitable lifting device to finaldrive (7). as shown. Put a slight liftin

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-43Figure 6-12. Final Drive

SECTION 6 - UNDERCARRIAGE6-44 – JLG Lift – 31208982. Put an alignment mark across the sections of thetravel motor and the final drive for assembly pur

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-458. Remove Piston (5).9. Remove shaft link (6).10. Remove brake disks (7).11. Remove supporting ring

SECTION 1 - SPECIFICATIONS3120898 – JLG Lift – 1-3Platform Rotate: Platform level and completely rotatedone direction. Rotate the opposite direction,

SECTION 6 - UNDERCARRIAGE6-46 – JLG Lift – 312089818. Remove twelve bolts (13) that secure cover (14) tothe final drive. Remove the O-ring seal from t

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-4725. Remove sun gear (21) from planetary carrier (19).26. Remove the second stage of planetary gear a

SECTION 6 - UNDERCARRIAGE6-48 – JLG Lift – 312089834. Repeat Steps 32 and 33 for the other four planetarygears.35. Remove bolt (31), tab (32) and ball

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-4941. Use tooling (F) to remove spindle nut (34). Thetorque that is required to remove the spindle nut

SECTION 6 - UNDERCARRIAGE6-50 – JLG Lift – 3120898AssemblyNOTE: Make sure that all of the parts of the final drive andthe travel motor are thoroughly

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-513. Use tooling (G) to check assembled height (X) in atleast four places at 90 degree intervals. The

SECTION 6 - UNDERCARRIAGE6-52 – JLG Lift – 3120898NOTE: The notches of tooling (F) fit over the ears of spindlenut (34).NOTE: Rotate the spindle in on

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-5321. Repeat step 19 and 20 in order to install the remain-ing bolt assembly.22. If necessary, heat ge

SECTION 6 - UNDERCARRIAGE6-54 – JLG Lift – 312089828. Install sun gear (21) into planetary carrier (19).29. If necessary, heat planetary gears (18) to

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-5538. Use tooling (C) to install snap ring (9).39. Install supporting ring (8).40. Install brake disks

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120898Hydraulic OilNOTE: Hydraulic oils must have anti-wear qualities at leastto API Service Classificatio

SECTION 6 - UNDERCARRIAGE6-56 – JLG Lift – 312089844. Use Tooling (B) to compress the brake assembly.Use Tooling (C) to install the retaining ring.45.

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-573. Make sure that the mating surfaces of the final driveand the undercarriage frame are thoroughly c

SECTION 6 - UNDERCARRIAGE6-58 – JLG Lift – 31208985. Fill the final drive to the bottom of the opening onlevel plug (3). See Operation and Maintenance

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-59NOTE: Put marks on all of the hose assemblies. The marksare used to identify the hose assemblies for

SECTION 6 - UNDERCARRIAGE6-60 – JLG Lift – 3120898Figure 6-14. Swivel Assembly

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-61DisassemblyStart by removing the swivel joint. Refer to Disassemblyand Assembly, "Swivel - Remo

SECTION 6 - UNDERCARRIAGE6-62 – JLG Lift – 3120898NOTE: Replace the O-ring seals that are used in the ends ofthe eight hose assemblies with new O-ring

SECTION 6 - UNDERCARRIAGE3120898 – JLG Lift – 6-63Do not use a chain for pulling a disabled machine. A chainlink can break. This may cause personal in

SECTION 6 - UNDERCARRIAGE6-64 – JLG Lift – 3120898Measuring Track Tension1. Place a straight edge on the tracks. The straightedge should be tong enoug

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-1SECTION 7. SCHEMATICS7.1 GENERALThis section contains troubleshooting information to beused for locatin

SECTION 1 - SPECIFICATIONS3120898 – JLG Lift – 1-51.8 CYLINDER SPECIFICATIONS1.9 MAJOR COMPONENT WEIGHTS1.10 CRITICAL STABILITY WEIGHTSDO NOT REPLACE

SECTION 7 - SCHEMATICS7-2 – JLG Lift – 3120898Figure 7-1. Electrical Components Installation - Sheet 1

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-3Figure 7-2. Electrical Components Installation - Sheet 2

SECTION 7 - SCHEMATICS7-4 – JLG Lift – 3120898Figure 7-3. Electrical Schematic - Deutz or Isuzu - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-5Figure 7-4. Electrical Schematic - Deutz or Isuzu - Sheet 2 of 21870111 A

SECTION 7 - SCHEMATICS7-6 – JLG Lift – 3120898Figure 7-5. Electrical Schematic - Australian w/Deutz or Isuzu - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-7Figure 7-6. Electrical Schematic - Australian w/Deutz or Isuzu - Sheet 2 of 21870128 A

SECTION 7 - SCHEMATICS7-8 – JLG Lift – 3120898Figure 7-7. Hydraulic Schematic - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-9Figure 7-8. Hydraulic Schematic - Sheet 2 of 42792323C

SECTION 7 - SCHEMATICS7-10 – JLG Lift – 3120898Figure 7-9. Hydraulic Schematic - Sheet 3 of 4

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-11Figure 7-10. Hydraulic Schematic - Sheet 4 of 42792323 C

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 31208981.11 SERIAL NUMBER LOCATIONSA serial number plate is affixed to the left rear side of theframe. If t

SECTION 7 - SCHEMATICS7-12 – JLG Lift – 3120898Figure 7-11. Hydraulic Schematic w/GFT24 Drive - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-13Figure 7-12. Hydraulic Schematic w/GFT24 Drive - Sheet 2 of 42792550 A

SECTION 7 - SCHEMATICS7-14 – JLG Lift – 3120898Figure 7-13. Hydraulic Schematic w/GFT24 Drive - Sheet 3 of 4

SECTION 7 - SCHEMATICS3120898 – JLG Lift – 7-15Figure 7-14. Hydraulic Schematic w/GFT24 Drive - Sheet 4 of 42792550 A

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JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Customer Support Toll Free:

SECTION 1 - SPECIFICATIONS3120898 – JLG Lift – 1-7This page left blank intentionally.

JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444AustraliaPhone: (61) 2 65 811111Fax: (61) 2 65 810122JLG Industries (

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 3120898Figure 1-2. Lubrication Point Location

SECTION 1 - SPECIFICATIONS3120898 – JLG Lift – 1-9Table 1-9. Lubrication ChartComponentsNumber/TypeLube PointsCapacity LubeInterval HoursComments3 Mon

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 3120898Figure 1-3. Torque Chart

SECTION 2 - GENERAL3120898 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31208982.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3120898 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

SECTION 2 - GENERAL2-4 – JLG Lift – 31208982.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3120898 – JLG Lift – 2-52.4 CYLINDER DRIFT TESTMaximum acceptable cylinder drift is to be measuredusing the following methods.Platf

SECTION 2 - GENERAL2-6 – JLG Lift – 3120898Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveMa

SECTION 2 - GENERAL3120898 – JLG Lift – 2-7Swing Brakes 5Boom Synchronization/Sequencing Systems 5Manual Descent or Auxiliary Power 55Power System9Eng

INTRODUCTION3120898 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSA GENERALThis section contains the general safety precaut

SECTION 2 - GENERAL2-8 – JLG Lift – 3120898Function Test of All Systems 21 21 21, 22Paint and Appearance 77Stamp Inspection Date on Frame 22Notify JLG

SECTION 3 - TURNTABLE3120898 – JLG Lift – 3-1SECTION 3. TURNTABLE3.1 TILT ALARM SWITCHPERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI-MUM OF EVER

SECTION 3 - TURNTABLE3-2 – JLG Lift – 31208983.2 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZGeneralThe throttle control system on the Deutz engine include

SECTION 3 - TURNTABLE3120898 – JLG Lift – 3-3Clutch engaged actuator retractingController fault - clutch disengaged and no actuator movementFailure Mo

SECTION 3 - TURNTABLE3-4 – JLG Lift – 3120898Only green light on and no actuator movementAction:1. Adjust trim potentiometers.2. If problem continues,

SECTION 3 - TURNTABLE3120898 – JLG Lift – 3-52. Check the turntable to bearing. Attach bolts as fol-lows:a. Elevate the fully retracted boom to 70 deg

SECTION 3 - TURNTABLE3-6 – JLG Lift – 3120898Figure 3-6. Swing Bearing Tolerance Boom Placement

SECTION 3 - TURNTABLE3120898 – JLG Lift – 3-7e. Attach suitable overhead lifting equipment to thebase of the turntable weldment.f. Use a suitable tool

SECTION 3 - TURNTABLE3-8 – JLG Lift – 31208983.5 SWING BRAKE - MICODisassembly1. With shaft protrusion downward, remove end cover(13) by removing caps

SECTION 3 - TURNTABLE3120898 – JLG Lift – 3-9Figure 3-8. Swing Brake Assembly (Mico)

INTRODUCTIONA-2 – JLG Lift – 3120898REVISON LOGOriginal Issue - February 24, 2000Revised - July 21, 2000Revised - February 10, 2002

SECTION 3 - TURNTABLE3-10 – JLG Lift – 31208984. Install dowel pins (15), spring retainer (55), andsprings (5 & 6) into housing (52).NOTE: Be sure

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 PLATFORMPlatform Sections ReplacementThe platform is made up

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31208985. Repeat the torque procedure in step #4 to theextend wire ropes (turntable end).6. Extend the

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-34.4 WIRE ROPENOTE: The pictures in this paragraph are just samples toshow the replacement crite

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 3120898e. Using a suitable brass drift and hammer, removethe rotator shaft, then remove the support fr

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-5c. Remove hardware securing the lift cylinder rodend to the base boom section.d. Using a suitab

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3120898Figure 4-8. Boom Assembly Cutaway - S Models - Sheet 1 of 3

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-7Figure 4-9. Boom Assembly Cutaway - S Models - Sheet 2 of 3

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31208988. Carefully remove the telescope cylinder and sheaveassembly. Place telescope cylinder on a su

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-99. Remove hardware which secures the wear pads tothe front of base boom section; remove wear pa

3120898 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3120898NOTE: To check the size, contour and amount of wear, agroove gauge is used. Replace the sheave

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-114. Install retract wire ropes into aft end of fly section,route wire ropes thru holes in side

SECTION 4 - BOOM & PLATFORM4-12 – JLG Lift – 312089818. Secure the sling and lifting device at the telescopecylinder’s approximate center of gravi

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-13Figure 4-16. Boom Powertrack Installation

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3120898Installation1. Using a suitable lifting device, position boomassembly on turntable so that the

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-15InspectionNOTE: When inspecting pins and bearings refer to Pins andComposite Bearing Repair Gu

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 3120898Figure 4-18. Limit Switches Adjustments

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-174.8 ROTATOR - HELACDisassembly1. Place actuator on a clean workbench.2. Remove all hydraulic f

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3120898Figure 4-19. Rotator Assembly (Helac)

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-197. Remove the shaft (2) from piston sleeve (3) and theactuator housing (1).8. Remove piston sl

ii – JLG Lift – 3120898TABLE OF CONTENTS TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.Bolt Usage and Torque Appli

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3120898NOTE: The timing marks (the small punch marks on theface of each gear), must be aligned for pr

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-21OPTIMIZERThe hand-held programmer provides a simple means ofoptimizing the contra of the equip

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3120898SUPERFLEX Terminal IdentificationRefer to Figure 4-27., SUPERFLEX Terminal Identification.SUPE

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-23Setup and TuningThe operating parameters of the system: Threshold, MaxOut, Low Range, Ramp up,

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 3120898How to Perform the Normal-Active Tuning ProcessAttach the "OPTIMIZER" programmer wit

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-25RECORD THE VALUES SELECTEDWhen all adjustments are finalized for desired machineperformance, t

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 3120898Figure 4-30. Calibration Flow Diagram

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-27TroubleshootingTOOLS REQUIRED (INSTALL/REPLACE)Screwdriver (Flat blade), Voltmeter, Wire Strip

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 3120898Figure 4-32. Digisensor Troubleshooting

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-29Figure 4-33. Typical SUPERFLEX System Wiring Diagram

3120898 – JLG Lift – iii TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.4.6 Articulating Jib Boom .

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3120898Figure 4-34. OPTIMIZER Keypad

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-31Important RemindersOPTIMIZER:• The Optimizer only has (3) usable keys during thescrolling and

SECTION 4 - BOOM & PLATFORM4-32 – JLG Lift – 3120898Crawler Tracking AdjustmentsNOTE: Before making any tracking adjustments, make surethe tracks

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-331. When the optimizer is first plugged in, the followingwill be displayed.2. Next, move the jo

SECTION 4 - BOOM & PLATFORM4-34 – JLG Lift – 3120898NOTE: The following steps are adjusting parameters.THRESHOLD/ MAX OUT/ RAMP UP/ RAMP DOWN/LOW

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-354. Next push the ENTER key, this will now show theRIGHT FWD THRESHOLD setting in the display,

SECTION 4 - BOOM & PLATFORM4-36 – JLG Lift – 31208988. Next push the ENTER key, this will now show thenewly adjusted settings if you chose to chan

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-3712. Next push the ENTER key, this will now show youthe RIGHT MAX OUT FWD setting on the displa

SECTION 4 - BOOM & PLATFORM4-38 – JLG Lift – 312089816. Next push the ENTER key, this will now show thenewly adjusted settings if you chose to cha

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-3920. Next push the ENTER key, this will now show thenewly adjusted settings if you chose to cha

iv – JLG Lift – 3120898TABLE OF CONTENTS TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION 6 - UNDERCARRIAGE6

SECTION 4 - BOOM & PLATFORM4-40 – JLG Lift – 312089824. Next push the ENTER key, this will now show thenewly adjusted settings if you chose to cha

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-4128. Next push the ENTER key, this will now show theLEFT LOW RANGE REV settings on the display,

SECTION 4 - BOOM & PLATFORM4-42 – JLG Lift – 312089832. Next push the (+) key this will now show you theOEM PART NUMBER of the Superflex.33. Next

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-4336. Next push the ENTER key, this will now show youthe SET POINT ADJUSTMENT setting on the dis

SECTION 4 - BOOM & PLATFORM4-44 – JLG Lift – 312089840. Next push the ENTER key, this will show you theRESUME HYSTERESIS setting on the display, t

SECTION 4 - BOOM & PLATFORM3120898 – JLG Lift – 4-45Superflex Inputs And Outputs18 Pin Connector (Green)Optimizer PlugSuperflex LED’s• The Superfl

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SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 CYLINDERS - THEORY OF OPERATIONSystems Incorporating Double Acting CylindersCy

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 31208986-8 drops per minute or more, cylinder repairs mustbe made.Cylinders With Single Counterbalance ValveUpp

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-35.4 CYLINDER REPAIRNOTE: The following are general procedures that apply toall of the cylinders on this

3120898 – JLG Lift – v TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.6.14 Towing Information . . .

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 31208989. Loosen and remove the cap screw(s), if applicable,which attach the tapered bushing to the piston.10.

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-517. If applicable, inspect piston rings for cracks or otherdamage. Replace as necessary.AssemblyNOTE: Pr

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31208983. Place a new “o”ring and back-up seal in the applica-ble outside diameter groove of the cylinder head.

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-7NOTE: When installing the tapered bushing, piston and mat-ing end of rod must be free of oil.WHEN REBUIL

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 312089820. Secure the cylinder head gland using the washerring and socket head bolts. (See Table 5-1 .)21. Afte

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-95.5 CYLINDER REMOVAL AND INSTALLATIONMain Boom Telescope Cylinder Removal1. Place machine on a flat and

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31208984. Install extend cable mounting blocks to threadedends of cables. Loosely install nuts and jam nutsont

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-115.6 PRESSURE SETTING PROCEDURESMain Relief, Steer, Swing and Lift Down1. Install pressure gauge at quic

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3120898Figure 5-16. Main Control Valve Pressure Adjustments - Sheet 1 of 2

SECTION 5 - HYDRAULICS3120898 – JLG Lift – 5-13Figure 5-17. Main Control Valve Pressure Adjustments - Sheet 2 of 2