Jlg 660SJ ANSI Service Manual User Manual

Service and Maintenance ManualModels600S/SJ660SJ600A/AJPrior to S/N 0300080000P/N - 3120718September 23, 2005

iv – JLG Lift – 3120718TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.3.10 Steer Adjustments (S

SECTION 3 - CHASSIS & TURNTABLE3-46 – JLG Lift – 3120718c. Refer to the Torque Sequence diagram asshown in Figure 3-31., Swing Bearing TorqueSeque

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-473.13 SWING BRAKE - MICODisassembly1. With shaft protrusion downward, remove end cover(13)

SECTION 3 - CHASSIS & TURNTABLE3-48 – JLG Lift – 3120718Figure 3-32. Swing Brake Assembly (Mico)

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-493.14 TILT ALARM SWITCH (MACHINES WITH EXTERNAL TILT SENSOR)PERFORM TILT ALARM SWITCH LEVEL

SECTION 3 - CHASSIS & TURNTABLE3-50 – JLG Lift – 31207181. Rotary Coupling2. Torque Lug3. Locknut4. Flatwasher5. Bo lt6. Nu

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-511. O-ring2. Pl ug3. Check Valve4. Sc rew5. Pl ug6. Sp ri ng7.

SECTION 3 - CHASSIS & TURNTABLE3-52 – JLG Lift – 3120718Figure 3-36. Rotary Coupling Port Location - 2WS

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-53Figure 3-37. Rotary Coupling Port Location - 4WS

SECTION 3 - CHASSIS & TURNTABLE3-54 – JLG Lift – 31207183.17 DUAL FUEL SYSTEMIT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THEOTHER WITHOUT ALL

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-55Mounting-ActuatorThe Actuator may be mounted in any attitude — these isno preferred orient

3120718 – JLG Lift – v TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.3.24 Ford LPG System (S Models

SECTION 3 - CHASSIS & TURNTABLE3-56 – JLG Lift – 3120718Examine the system for springs, such as carburetor returnsprings. These should be removed.

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-574. Re-check voltage between terminal A & B as in step2. Voltage reading should be betw

SECTION 3 - CHASSIS & TURNTABLE3-58 – JLG Lift – 3120718

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-593.Incorrect electrical hook-up.4.No speed signal to Governor.5.Damaged Controller or Actua

SECTION 3 - CHASSIS & TURNTABLE3-60 – JLG Lift – 3120718If steps 1a. thru 1e. can be accomplished as described,the Governor is probably OK. It rec

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-613.19 THROTTLE CHECKS AND ADJUSTMENTS - DEUTZ OR CONTINENTAL ENGINE (PRIOR TO S/N 61927)Gen

SECTION 3 - CHASSIS & TURNTABLE3-62 – JLG Lift – 3120718Clutch engaged actuator retractingController fault - clutch disengaged and no actuator mov

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-63Only green light on and no actuator movementAction:1. Adjust trim potentiometers.2. If pro

SECTION 3 - CHASSIS & TURNTABLE3-64 – JLG Lift – 3120718Checking the CarburetorAfter cranking the engine for a period of time there may bewhite sm

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-652. Check the Spark Plugs for presence of spark. Ifthere is no spark at the plugs during cr

vi – JLG Lift – 3120718TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.4.9 Platform . . . . . .

SECTION 3 - CHASSIS & TURNTABLE3-66 – JLG Lift – 31207183.23 FORD EFI ENGINE (MACHINES AFTER SN 48907)Performing Diagnostics1. Verify the complain

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-67the on position to act as a self-test. If a DTC is present, thelight will illuminate and s

SECTION 3 - CHASSIS & TURNTABLE3-68 – JLG Lift – 3120718Table 3-4. ECM Diagnostic Trouble CodesDiagnosticTroubleCodeDescription11All Systems OK12T

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-69ENGINE COOLANT TEMPERATURE (ECT) SENSORThe engine coolant temperature (ECT) sensor is a g

SECTION 3 - CHASSIS & TURNTABLE3-70 – JLG Lift – 3120718Figure 3-40. EFI Component Location

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-71INTAKE AIR TEMPERATURE (IAT) SENSORThe intake air temperature (IAT) sensor is a thermistor

SECTION 3 - CHASSIS & TURNTABLE3-72 – JLG Lift – 3120718The ECM is designed to maintain exhaust emission levelsto government mandated standards wh

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-73ELECTROSTATIC DISCHARGE DAMAGEElectronic components used in the ECM are oftendesigned to c

SECTION 3 - CHASSIS & TURNTABLE3-74 – JLG Lift – 3120718FUEL METERING SYSTEM PURPOSEThe basic function of the air/fuel metering system is tocontro

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-75FUEL PRESSURE REGULATORThe fuel pressure regulator is a relief valve mounted in thefuel fi

3120718 – JLG Lift – vii TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.5.6 Variable Displacement pu

SECTION 3 - CHASSIS & TURNTABLE3-76 – JLG Lift – 3120718OPEN LOOP AND CLOSED LOOP OPERATIONThe ECM will operate in the following two modes:•Open l

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-77IGNITION COILThe electronic ignition system uses a coil pack with oneignition coil for eac

SECTION 3 - CHASSIS & TURNTABLE3-78 – JLG Lift – 31207183.24 FORD LPG SYSTEM (S MODELS AFTER S/N 79619 & A MODELS AFTER S/N 79888)NOTE: +20° F

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-79MegajectorRegulatorLockoff SolenoidMixerFigure 3-42. Ford LPG System

SECTION 3 - CHASSIS & TURNTABLE3-80 – JLG Lift – 3120718Lockoff SolenoidThe lockoff solenoid is used to reduce the possibility ofbackfires. The EP

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-81DTC 362 - Megajector voltage supply low.a. Voltage - Check battery voltage. If the voltage

SECTION 3 - CHASSIS & TURNTABLE3-82 – JLG Lift – 3120718Figure 3-43. Deutz Sensors for JLG Control System

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-1SECTION 4. BOOM & PLATFORM4.1 BOOM ROPE TORQUING PROCEDURESTorque Procedures (S Models)1.

SECTION 4 - BOOM & PLATFORM4-2 – JLG Lift – 31207184.2 WEAR PADS Tower Boom (A Models)1. Shim up wear pads until snug to adjacent surface.2. Repla

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-34.3 WIRE ROPE (S MODELS)Each day before using the machine:1. Raise the main boom to approximate

viii – JLG Lift – 3120718TABLE OF CONTENTS (Continued) LIST OF FIGURESFIGURE NO. TITLE PAGE NO.1-1. 600S Lug Torques . . . . . . . . . . . . . .

SECTION 4 - BOOM & PLATFORM4-4 – JLG Lift – 31207184.4 BOOM MAINTENANCE (S MODELS)Removal1. Remove the platform/support as follows:a. Disconnect e

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-5securing rail to the base boom section. Removepowertrack from boom section.4. Remove boom assem

SECTION 4 - BOOM & PLATFORM4-6 – JLG Lift – 3120718Figure 4-7. Boom Assembly Cutaway - S Models - Sheet 1 of 3

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-7Figure 4-8. Boom Assembly Cutaway - S Models - Sheet 2 of 3

SECTION 4 - BOOM & PLATFORM4-8 – JLG Lift – 31207188. Carefully remove the telescope cylinder and sheaveassembly. Place telescope cylinder on a su

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-99. Remove hardware which secures the wear pads tothe front of base boom section; remove wear pa

SECTION 4 - BOOM & PLATFORM4-10 – JLG Lift – 3120718NOTE: To check the size, contour and amount of wear, agroove gauge is used. Replace the sheave

SECTION 4 - BOOM & PLATFORM3120718 – 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 – 3120718Figure 4-14. Boom Powertrack Installation

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-1318. Secure the sling and lifting device at the telescopecylinder’s approximate center of gravi

3120718 – JLG Lift – ix TABLE OF CONTENTSLIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.3-34. Rotary Coupling - Sheet 1 of 2 . . .

SECTION 4 - BOOM & PLATFORM4-14 – JLG Lift – 3120718Installation1. Using a suitable lifting device, position boomassembly on turntable so that the

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-15HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-ATELY AFTER DISCONNECTING LINES TO AVOID ENT

SECTION 4 - BOOM & PLATFORM4-16 – JLG Lift – 31207183. Inspect upper lift cylinder attach pin for wear, scor-ing, tapering and ovality, or other d

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-174.6 TOWER BOOMRemoval1. Remove the tower upright as follows:HYDRAULIC LINES AND PORTS SHOULD B

SECTION 4 - BOOM & PLATFORM4-18 – JLG Lift – 3120718f. Remove tower boom assembly from turntableupright. Place tower boom assembly on a wellsuppor

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-19InspectionNOTE: Refer to Section 2 - General.1. Inspect tower boom pivot pin for wear, scoring

SECTION 4 - BOOM & PLATFORM4-20 – JLG Lift – 3120718Installation1. Using a suitable lifting device, position tower boomassembly on turntable so th

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-21InspectionNOTE: When inspecting pins and bearings refer to Section 2- General.1. Inspect artic

SECTION 4 - BOOM & PLATFORM4-22 – JLG Lift – 3120718Figure 4-22. Limit Switches Adjustments (S Models)

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-23Figure 4-23. Limit Switches Adjustments (A Models)

x – JLG Lift – 3120718TABLE OF CONTENTS (Continued) LIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.5-12. Seating the Tapered Bearing . . .

SECTION 4 - BOOM & PLATFORM4-24 – JLG Lift – 31207184.9 PLATFORMPlatform Sections ReplacementThe platform is made up of five sections: floor, righ

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-25Figure 4-25. Rotator Assembly (Helac)

SECTION 4 - BOOM & PLATFORM4-26 – JLG Lift – 31207186. Place two (2) 3/8"x16NC bolts in threaded holes inbottom of the actuator. Using a suit

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-273. Install new seals (11), back-up ring (12), cap bearing(13), bearing packing (14) and thrust

SECTION 4 - BOOM & PLATFORM4-28 – JLG Lift – 3120718Lift, Swing, and Drive Cards1. Center the input potentiometers. Power up the card,but do not s

SECTION 4 - BOOM & PLATFORM3120718 – JLG Lift – 4-294.12 FOOT SWITCH ADJUSTMENTAdjust so that functions will operate when pedal is at cen-ter of t

SECTION 4 - BOOM & PLATFORM4-30 – JLG Lift – 3120718This page left blank intentionally.

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-1SECTION 5. HYDRAULICS5.1 CYLINDERS - THEORY OF OPERATIONSystems Incorporating Double Acting CylindersCy

SECTION 5 - HYDRAULICS5-2 – JLG Lift – 31207184. To check piston seals, carefully remove the counter-balance valve from the retract port. After initia

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-34. Place the cylinder barrel into a suitable holding fix-ture.5. Mark cylinder head and barrel with a ce

3120718 – JLG Lift – xi TABLE OF CONTENTSLIST OF FIGURES (continued)FIGURE NO. TITLE PAGE NO.7-15. Electrical Schematic - Deutz or Conti

SECTION 5 - HYDRAULICS5-4 – JLG Lift – 312071813. Insert the cap screw(s) in the threaded holes in theouter piece of the tapered bushing. Progressivel

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-5AssemblyNOTE: Prior to cylinder assembly, ensure that the propercylinder seal kit is used. See your JLG

SECTION 5 - HYDRAULICS5-6 – JLG Lift – 31207184. Install washer ring onto rod, carefully install the headgland on the rod, ensuring that the wiper and

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-7b. Tap each space once; this means the taperedbushing is tapped 3 times as there are 3 spacesbetween the

SECTION 5 - HYDRAULICS5-8 – JLG Lift – 3120718IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ONTHE MACHINE, EXTREME CARE SHOULD BE USED TO INSU

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-95.4 CYLINDER REMOVAL AND INSTALLATION (S MODELS)Main Boom Telescope Cylinder Removal1. Place machine on

SECTION 5 - HYDRAULICS5-10 – JLG Lift – 31207183. Secure the sling and lifting device at the telescopecylinder’s approximate center of gravity, and li

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-113. Tag and disconnect hydraulic lines to telescope cyl-inder. Use suitable container to retain any resi

SECTION 5 - HYDRAULICS5-12 – JLG Lift – 3120718Main Boom Lift Cylinder Removal1. Place the machine on a flat and level surface. Startthe engine and pl

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-13Upright Level Cylinder Removal1. With the aid of an assistant, manually override thePlunger Valve with

xii – JLG Lift – 3120718TABLE OF CONTENTS (Continued) LIST OF TABLESTABLE NO. TITLE PAGE NO.1-1 Function Speeds (In Seconds) . . . . . . . . . .

SECTION 5 - HYDRAULICS5-14 – JLG Lift – 3120718Figure 5-18. Boom Positioning and Support, Cylinder Repair (A Models)

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-155. Tag, disconnect and cap the tower lift cylinderhydraulic lines and ports.6. Remove mounting hardware

SECTION 5 - HYDRAULICS5-16 – JLG Lift – 31207185. Remove caps from cylinder hydraulic lines and cor-rectly install lines to cylinder as previously tag

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-171. Barrel 1A. Bushing2. R od 2A. Bushing3. P is ton4. H ea d5. Ta pe re d B ush in

SECTION 5 - HYDRAULICS5-18 – JLG Lift – 31207181. Barrel 2. Rod 3. Not Used4. W ear Ri ng5. W ip er Ri ng6. Rod Seal7. B

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-191. Barrel 1A. Bushing2. R od 2A. Bushing3. P is ton4. H ea d5. Ta pe re d B ush in

SECTION 5 - HYDRAULICS5-20 – JLG Lift – 31207181. Barrel 1A. Bushing2. Rod 2A. Bushing3. Hea d4. Piston 5. Tapered Bushing6.

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-211. Barrel 1A. Bushing2. R od 2A. Bushing3. P is ton4. He ad5. Ta pe re d B ush in

SECTION 5 - HYDRAULICS5-22 – JLG Lift – 31207181. Barrel 1A. Bushing2. Rod 2A. Bushing3. Piston4. Hea d5. Tapered Bushing6.

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-231. Locknut2. P is ton 3. S ea l4. O -R ing5. B ar rel6. Rod7. Capscrew8.

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-1SECTION 1. SPECIFICATIONS1.1 CAPACITIESFuel Tank39 US. Gallons (147.6 l). (S Models)30 U.S. Gallons

SECTION 5 - HYDRAULICS5-24 – JLG Lift – 31207181. Barrel 2. Rod 3. Hea d4. P ist on5. Tapered Bushing6. Spacer7. Va

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-251. Barrel 2. Rod 3. Washer Ring4. Bo lt5. Bu sh in g6. Cartridge Valve7.

SECTION 5 - HYDRAULICS5-26 – JLG Lift – 31207181. Barrel 1A. Bushing2. Rod 2A. Bushing3. Hea d4. P is to n5. Tapered Bushing6

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-271. Barrel 1A. Bushing2. Rod 2A. Bushing3. Head4. Piston 5. Spacer6. Tapered Bu

SECTION 5 - HYDRAULICS5-28 – JLG Lift – 31207181. Barrel 1A. Bushing2. Rod 2A. Bushing3. P is to n4. Head 5. Tapered Bushing6.

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-291. Barrel 2. Rod 3. Piston4. Head 5. Spacer6. Tapered Bushing7. Plate8.

SECTION 5 - HYDRAULICS5-30 – JLG Lift – 31207181. Barrel 2. Rod 3. Piston4. Head 5. Washer Rin g6. Tapered Bushing7. Val

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-315.6 VARIABLE DISPLACEMENT PUMP (M46 SERIES)TroubleshootingGAUGE INSTALLATIONIt will be necessary to ins

SECTION 5 - HYDRAULICS5-32 – JLG Lift – 3120718Figure 5-34. Troubleshooting - Neutral Difficult or Impossible to FindFigure 5-35. Troubleshooting -

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-33Figure 5-36. Troubleshooting - Transmission Operates in One Direction Only

SECTION 1 - SPECIFICATIONS1-2 – JLG Lift – 3120718Engine - Continental TMD27Fuel - Diesel.Oil Capacity.7.00 Quarts (6.65 l) w/Filter.6.00 Quarts (5.7

SECTION 5 - HYDRAULICS5-34 – JLG Lift – 3120718Figure 5-37. Troubleshooting - System Response is Sluggish

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-35Inspections and AdjustmentsCHECK/HIGH PRESSURE RELIEF VALVESThe system check/relief valves have the dua

SECTION 5 - HYDRAULICS5-36 – JLG Lift – 3120718ELECTRICAL DISPLACEMENT CONTROL ORIFICESNOTE: The pump should have two control orifices locatedunder th

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-37SWASHPLATE NEUTRAL ADJUSTMENT1. Using a low pressure line (500 psi [35 Bar] min.),cross port servo port

SECTION 5 - HYDRAULICS5-38 – JLG Lift – 3120718Minor Repair and ReplacementMinor repairs may be performed, following the proceduresin this section.Cle

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-39NOTE: The outside diameter of the seal may be lightlycoated with sealant (such as Loctite High Perfor-m

SECTION 5 - HYDRAULICS5-40 – JLG Lift – 3120718The appropriate check valve kit and/ or check andrelief valve kit should be used. Refer to appropriateS

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-413. Remove the control sleeve from the pump.4. Remove the control inlet screen plug from the inletpassag

SECTION 5 - HYDRAULICS5-42 – JLG Lift – 31207189. Align the control sleeve so its slot will engage theswash plate feedback pin (slot positioned toward

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-435.8 PRESSURE SETTING PROCEDURES (S AND A MODELS)COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRES-SUR

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-3DC Motor.Clockwise Rotation.Hydraulic Filter - In-line.Return - Bypass Type.10 Microns Absolute.Char

SECTION 5 - HYDRAULICS5-44 – JLG Lift – 3120718Figure 5-41. Main Control Valve Pressure Adjustments - Sheet 1 of 2NOTE: Torque all valve cartridges 1

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-45Figure 5-42. Main Control Valve Pressure Adjustments - Sheet 2 of 2NOTE: Torque all valve cartridges 1

SECTION 5 - HYDRAULICS5-46 – JLG Lift – 3120718Figure 5-43. Location of Components - Main Control Valve

SECTION 5 - HYDRAULICS3120718 – JLG Lift – 5-474 Wheel Steer (If Equipped)1. At the platform console using the steer select switchactivate " 2 wh

SECTION 5 - HYDRAULICS5-48 – JLG Lift – 3120718Install a 60 bar (or 1000 psi) pressure gauge in the chargepressure gauge port in order to monitor the

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-1SECTION 6. JLG CONTROL SYSTEM6.1 INTRODUCTIONWHEN INSTALLING A NEW GROUND MODULE CONTROLLER ONT

SECTION 6 - JLG CONTROL SYSTEM6-2 – JLG Lift – 3120718Figure 6-2. ADE Block Diagram

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-36.2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER1. Connect the four pin end of the cable supplied

SECTION 6 - JLG CONTROL SYSTEM6-4 – JLG Lift – 3120718Figure 6-3. Analyzer Connecting PointsPLATFORM CONNECTIONGROUND CONTROL CONNECTION

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-5When a top level menu is selected, a new set of menuitems may be offered: for example: DRIVEBOOM

SECTION 1 - SPECIFICATIONS1-4 – JLG Lift – 3120718Machine Length (Stowed) (A Models)600A/600AJ ModelsOver Drive Axle - 26 ft. 5 in. (8.05 m).Over Driv

SECTION 6 - JLG CONTROL SYSTEM6-6 – JLG Lift – 3120718Figure 6-4. Control Module Location

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-7Once the correct password is displayed, press ENTER.The access level should display the followin

SECTION 6 - JLG CONTROL SYSTEM6-8 – JLG Lift – 31207186.6 MACHINE SETUPWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-9Figure 6-5. Analyzer Flow Chart - Sheet 1 of 4

SECTION 6 - JLG CONTROL SYSTEM6-10 – JLG Lift – 3120718Figure 6-6. Analyzer Flow Chart - Sheet 2 of 4

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-11Figure 6-7. Analyzer Flow Chart - Sheet 3 of 4

SECTION 6 - JLG CONTROL SYSTEM6-12 – JLG Lift – 3120718Figure 6-8. Analyzer Flow Chart - Sheet 4 of 4

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-136.8 MACHINE PERSONALITY SETTINGS NOTE: Personality settings can be adjusted within theadjustmen

SECTION 6 - JLG CONTROL SYSTEM6-14 – JLG Lift – 3120718SWING ACCELeration 0.1 to 5.0s 2.0 2.0DECELeration 0.1 to 3.0s 1.8 1.8MINimum LEFT speed 0 to 5

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-15BASKET ROTATE ACCELeration 0.1 to 5.0 1.8 1.8DECELeration 0.1 to 3.0 0.7 0.7MlNimum LEFT speed

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-51.5 TORQUE REQUIREMENTS 1.6 LUBRICATIONFord LRG423 & LRG425 EngineSingle Viscosity Oils (SF, SF-

SECTION 6 - JLG CONTROL SYSTEM6-16 – JLG Lift – 3120718Table 6-2. Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66437Fault Flash

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-172/3 Flash code 2/3 indicates problems with boom function selection. 3LIFT/SWING JOYSTICK FAULTY

SECTION 6 - JLG CONTROL SYSTEM6-18 – JLG Lift – 31207183/2 Flash code 3/2 indicates that a contactor did not open when energized.NOT REQUIRED3/3 Flash

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-199/9 Flash code 9/9 indicates problems with the controller. 11PLATFORM MODULE FAILURE: hwfs CODE

SECTION 6 - JLG CONTROL SYSTEM6-20 – JLG Lift – 3120718Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to PresentFault Fla

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-21D/S JOY. OUT OF RANGE HIGHResistive joysticks: These faults do not occur if the Vref voltage is

SECTION 6 - JLG CONTROL SYSTEM6-22 – JLG Lift – 3120718l/s joy. center tap bad Resistive joysticks: These faults occur when the center tap voltage is

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-23HOUR METER SHORT TO BATTERYHORN SHORT TO GROUNDHORN OPEN CIRCUITHORN SHORT TO BATTERYAUX POWER

SECTION 6 - JLG CONTROL SYSTEM6-24 – JLG Lift – 3120718STEER DUMP OPEN CIRCUITSTEER DUMP SHORT TO BATTERYTWO SPEED SHORT TO GROUNDTWO SPEED OPEN CIRCU

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-25BASKET DOWN SHORT TO BATTERYBASKET DOWN OVERRIDE SHORT TO GROUNDOnly occurs on machines with el

SECTION 1 - SPECIFICATIONS1-6 – JLG Lift – 3120718NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C orhave properties of API classification CC/CD gr

SECTION 6 - JLG CONTROL SYSTEM6-26 – JLG Lift – 3120718TOWER DOWN OPEN CIR-CUITTOWER DOWN SHORT TO BATTERYTOWER IN SHORT TO GROUNDTOWER IN OPEN CIRCUI

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-273/4 Flash code 3/4 indicates a driver problem on a platform valve block valve driver. All drive

SECTION 6 - JLG CONTROL SYSTEM6-28 – JLG Lift – 3120718JIB LEFT OPEN CIRCUITJIB RIGHT SHORT TO BAT-TERYJIB RIGHT SHORT TO GROUNDJIB RIGHT OPEN CIRCUIT

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-294/4 Flash code 4/4 indicates problems with the battery supply. Not reported during 2 second pow

SECTION 6 - JLG CONTROL SYSTEM6-30 – JLG Lift – 3120718CHASSIS TILT SENSOR NOT GAIN CALIBRATEDIndicates that the chassis tilt sensor calibration infor

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-31Table 6-4. Machine Configuration Programming InformationConfiguration Digit Number Description

SECTION 6 - JLG CONTROL SYSTEM6-32 – JLG Lift – 31207184(Engine Shutdown)01No Engine ShutdownShutdown engine when coolant temperature is greater than

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-3311(Gen Set/ Welder)012No Generator InstalledBelt DrivenHydraulic Driven012(Head and Tail Lights

SECTION 6 - JLG CONTROL SYSTEM6-34 – JLG Lift – 312071819*(Drive)014 Wheel Drive2 Wheel Drive*NOTE: On most machines when setting up Two Speed Wheel M

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-35Ta b l e 6 - 5 . F a u l t C o d e L i s t i n gHELP MESSAGE FAULT FAULT REMOVALOK 0 0 CLEAR

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-7Lubrication Specifications1.7 PRESSURE SETTINGSRexroth Valve (S Models)Main Relief - 3000 PSI (207 B

SECTION 6 - JLG CONTROL SYSTEM6-36 – JLG Lift – 3120718FORD ECM POWER SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTHORN SHORT TO GROU

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-37ALARM SHORT TO BATTERY 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTGENERATOR SHORT TO GROUND

SECTION 6 - JLG CONTROL SYSTEM6-38 – JLG Lift – 3120718TOWER UP SHORT TO GROUND 3 3 REQUIRES EMS TO BE RECYCLED TO CLEAR FAULTTOWER UP OPEN CIRCUIT 3

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-39FORD FAULT CODE 31 4 3 CLEARS WHEN FAULT IS REMOVEDFORD FAULT CODE 32 4 3 CLEARS WHEN FAULT IS

SECTION 6 - JLG CONTROL SYSTEM6-40 – JLG Lift – 3120718NO ALTERNATOR OUTPUT 4 3 CLEARS WHEN FAULT IS REMOVEDOIL PRESSURE LOW 4 3 CLEARS WHEN FAULT IS

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-416.9 ANALYZER DIAGNOSTICS MENU STRUCTURE In the following structure descriptions, an intended it

SECTION 6 - JLG CONTROL SYSTEM6-42 – JLG Lift – 3120718SWINGACCEL … Displays/adjusts swing accelerationDECEL … Displays/adjusts swing decelerationMIN

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-43JIB LIFT Not displayed if JIB = NOACCEL … Displays/adjusts jib accelerationDECEL … Displays/adj

SECTION 6 - JLG CONTROL SYSTEM6-44 – JLG Lift – 3120718Table 6-7. Diagnostic Menu DescriptionsDRIVEDRIVE FOR … Displays drive joystick direction &

SECTION 6 - JLG CONTROL SYSTEM3120718 – JLG Lift – 6-45PM BATTERY … Displays battery voltage at platform moduleTEMP ... Displays ground module temper

SECTION 1 - SPECIFICATIONS1-8 – JLG Lift – 31207181.8 CYLINDER SPECIFICATIONSTable 1-6. Cylinder Specifications (S Models)DESRIPTON BORE STROKE ROD DI

SECTION 6 - JLG CONTROL SYSTEM6-46 – JLG Lift – 3120718This page left blank intentionally.

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-1SECTION 7. SCHEMATICS7.1 GENERALThis section contains schematics to be used for locatingand correcting

SECTION 7 - SCHEMATICS7-2 – JLG Lift – 3120718Figure 7-1. Electrical Harness - S Models (Prior to S/N 61927) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-3Figure 7-2. Electrical Harness - S Models (Prior to S/N 61927) - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-4 – JLG Lift – 3120718Figure 7-3. Electrical Harness - S Models (S/N 61927 to S/N 63909) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-5Figure 7-4. Electrical Harness - S Models (S/N 61927 to S/N 63909) - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-6 – JLG Lift – 3120718Figure 7-5. Electrical Harness - S Models (S/N 63909 to 75606) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-7Figure 7-6. Electrical Harness - S Models (S/N 63909 to 75606) - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-8 – JLG Lift – 3120718Figure 7-7. Electrical Harness - S Models (S/N 75606 to Present) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-9Figure 7-8. Electrical Harness - S Models (S/N 75606 to Present) - Sheet 2 of 2

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-91.9 MAJOR COMPONENT WEIGHTSTable 1-8. Major Component Weights (S Models)600SJ 660SJ 600SLB.KG.LB.KG.

SECTION 7 - SCHEMATICS7-10 – JLG Lift – 3120718Figure 7-9. Electrical Harness - A Models (Prior to S/N 61927) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-11Figure 7-10. Electrical Harness - A Models (Prior to S/N 61927) - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-12 – JLG Lift – 3120718Figure 7-11. Electrical Harness - A Models (S/N 64249 to S/N 64270) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-13Figure 7-12. Electrical Harness - A Models (S/N 64249 to S/N 64270) - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-14 – JLG Lift – 3120718Figure 7-13. Electrical Harness - A Models (S/N 64270 to Present) - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-15Figure 7-14. Electrical Harness - A Models (S/N 64270 to Present) - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-16 – JLG Lift – 3120718Figure 7-15. Electrical Schematic - Deutz or Continental Engine - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-17Figure 7-16. Electrical Schematic - Deutz or Continental Engine - Sheet 2 of 21870039E

SECTION 7 - SCHEMATICS7-18 – JLG Lift – 3120718Figure 7-17. Electrical Schematic (NCW) - Deutz or Continental Engine - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-191870053EFigure 7-18. Electrical Schematic (NCW) - Deutz or Continental Engine - Sheet 2 of 2

SECTION 1 - SPECIFICATIONS1-10 – JLG Lift – 31207181.10 CRITICAL STABILITY WEIGHTSDO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMSOF DIFFERENT WE

SECTION 7 - SCHEMATICS7-20 – JLG Lift – 3120718Figure 7-19. Electrical Schematic - Ford LRG Engine - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-211870038DFigure 7-20. Electrical Schematic - Ford LRG Engine - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-22 – JLG Lift – 3120718Figure 7-21. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-23Figure 7-22. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 2 of 4

SECTION 7 - SCHEMATICS7-24 – JLG Lift – 3120718Figure 7-23. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 3 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-25Figure 7-24. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 4 of 4

SECTION 7 - SCHEMATICS7-26 – JLG Lift – 3120718Figure 7-25. Electrical Schematic - UL - Ford LRG Sheet 1 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-27Figure 7-26. Electrical Schematic - UL - Ford LRG Sheet 2 of 4

SECTION 7 - SCHEMATICS7-28 – JLG Lift – 3120718Figure 7-27. Electrical Schematic - UL - Ford LRG Sheet 3 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-29Figure 7-28. Electrical Schematic - UL - Ford LRG Sheet 4 of 4

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-111.11 SERIAL NUMBER LOCATIONSA serial number plate is affixed to the left rear side of theframe. If

SECTION 7 - SCHEMATICS7-30 – JLG Lift – 3120718Figure 7-29. Electrical Schematic - UL Domestic -Deutz Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-31Figure 7-30. Electrical Schematic - UL Domestic -Deutz Sheet 2 of 21870087A

SECTION 7 - SCHEMATICS7-32 – JLG Lift – 3120718Figure 7-31. Electrical Schematic - UL Domestic - LP Gas Sheet 1 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-33Figure 7-32. Electrical Schematic - UL Domestic - LP Gas Sheet 2 of 4

SECTION 7 - SCHEMATICS7-34 – JLG Lift – 3120718Figure 7-33. Electrical Schematic - UL Domestic - LP Gas Sheet 3 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-35Figure 7-34. Electrical Schematic - UL Domestic - LP Gas Sheet 4 of 4

SECTION 7 - SCHEMATICS7-36 – JLG Lift – 3120718Figure 7-35. Electrical Schematic - ADE w/External Tilt - Sheet 1 of 2

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-371870134BFigure 7-36. Electrical Schematic - ADE w/External Tilt - Sheet 2 of 2

SECTION 7 - SCHEMATICS7-38 – JLG Lift – 3120718Figure 7-37. Electrical Schematic - Isuzu Engine - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-39Figure 7-38. Electrical Schematic - Isuzu Engine - Sheet 2 of 41870131 A

– JLG Lift –A Machine that incorporatesADE (JLG Control System) canbe outwardly identified by theanalyzer connection at the baseof the platform cont

SECTION 1 - SPECIFICATIONS1-12 – JLG Lift – 3120718Figure 1-3. Lubrication Point Location - S Models

SECTION 7 - SCHEMATICS7-40 – JLG Lift – 3120718Figure 7-39. Electrical Schematic - Isuzu Engine - Sheet 3 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-41Figure 7-40. Electrical Schematic - Isuzu Engine - Sheet 4 of 41870131 A

SECTION 7 - SCHEMATICS7-42 – JLG Lift – 3120718Figure 7-41. Electrical Schematic - ADE - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-43Figure 7-42. Electrical Schematic - ADE - Sheet 2 of 41870132G

SECTION 7 - SCHEMATICS7-44 – JLG Lift – 3120718Figure 7-43. Electrical Schematic - ADE - Sheet 3 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-451870132GFigure 7-44. Electrical Schematic - ADE - Sheet 4 of 4

SECTION 7 - SCHEMATICS7-46 – JLG Lift – 3120718Figure 7-45. Hydraulic Schematic - S Models - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-47Figure 7-46. Hydraulic Schematic - S Models - Sheet 2 of 42792176F

SECTION 7 - SCHEMATICS7-48 – JLG Lift – 3120718Figure 7-47. Hydraulic Schematic - S Models - Sheet 3 of 42 WHEEL DRIVE

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-492792176FFigure 7-48. Hydraulic Schematic - S Models - Sheet 4 of 44 WHEEL DRIVE

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-13Table 1-12. Lubrication Chart - S ModelsComponentsNumber/TypeLube PointsCapacity LubeInterval Hours

SECTION 7 - SCHEMATICS7-50 – JLG Lift – 3120718Figure 7-49. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 1 of 6

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-51Figure 7-50. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 2 of 62792605 D

SECTION 7 - SCHEMATICS7-52 – JLG Lift – 3120718Figure 7-51. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 3 of 6

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-53Figure 7-52. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 4 of 62792605 D

SECTION 7 - SCHEMATICS7-54 – JLG Lift – 3120718Figure 7-53. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 5 of 6

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-55Figure 7-54. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 6 of 62792605 D

SECTION 7 - SCHEMATICS7-56 – JLG Lift – 3120718Figure 7-55. Hydraulic Schematic - A Models - Sheet 1 of 4

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-57Figure 7-56. Hydraulic Schematic - A Models - Sheet 2 of 42792177D

SECTION 7 - SCHEMATICS7-58 – JLG Lift – 3120718Figure 7-57. Hydraulic Schematic - A Models - Sheet 3 of 42 WHEEL DRIVE

SECTION 7 - SCHEMATICS3120718 – JLG Lift – 7-592792177DFigure 7-58. Hydraulic Schematic - A Models - Sheet 4 of 44 WHEEL DRIVE

SECTION 1 - SPECIFICATIONS1-14 – JLG Lift – 3120718NOTES: KEY TO LUBRICANTS* Machines after S/N 38047 will have composite bushings and no grease fitti

SECTION 7 - SCHEMATICS7-60 – JLG Lift – 3120718This page left blank intentionally.

JLG Worldwide LocationsCorporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USAPhone: (717) 485-5161Fax: (717) 485-6417JLG Indu

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-15Figure 1-4. Lubrication Point Location - A Models

SECTION 1 - SPECIFICATIONS1-16 – JLG Lift – 3120718Table 1-13. Lubrication Chart - A ModelsComponentsNumber/TypeLube PointsCapacity LubeInterval Hours

SECTION 1 - SPECIFICATIONS3120718 – JLG Lift – 1-17Figure 1-5. Torque Chart

SECTION 1 - SPECIFICATIONS1-18 – JLG Lift – 3120718This page left blank intentionally.

SECTION 2 - GENERAL3120718 – JLG Lift – 2-1SECTION 2. GENERAL2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCEGeneralThis section provides the nec

SECTION 2 - GENERAL2-2 – JLG Lift – 31207182.2 SERVICE AND GUIDELINESGeneralThe following information is provided to assist you in theuse and applicat

SECTION 2 - GENERAL3120718 – JLG Lift – 2-3Component Disassembly and ReassemblyWhen disassembling or reassembling a component, com-plete the procedura

– JLG Lift –This page left blank intentionally.

SECTION 2 - GENERAL2-4 – JLG Lift – 31207182.3 LUBRICATION AND INFORMATIONHydraulic System1. The primary enemy of a hydraulic system is contam-ination

SECTION 2 - GENERAL3120718 – 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 – 31207182.6 WELDING ON JLG EQUIPMENTNOTE: This instruction applies to repairs, or modifications tothe machine and t

SECTION 2 - GENERAL3120718 – JLG Lift – 2-72.8 AMP CONNECTORApplying Silicone Dielectric Compound to AMP ConnectorsSilicone Dielectric Compound must b

SECTION 2 - GENERAL2-8 – JLG Lift – 31207183. After all required contacts have been inserted, thewedge lock must be closed to its locked position.Rele

SECTION 2 - GENERAL3120718 – JLG Lift – 2-9Disassembly1. Insert a 4.8 mm (3/16") wide screwdriver bladebetween the mating seal and one of the red

SECTION 2 - GENERAL2-10 – JLG Lift – 3120718Figure 2-7. Connector Installation

SECTION 2 - GENERAL3120718 – JLG Lift – 2-112.9 DEUTSCH CONNECTORSDT/DTP Series Assembly1. Grasp crimped contact about 25mm behind the con-tact barrel

SECTION 2 - GENERAL2-12 – JLG Lift – 3120718HD30/HDP20 Series Assembly1. Grasp contact about 25mm behind the contactcrimp barrel.2. Hold connector wit

SECTION 2 - GENERAL3120718 – JLG Lift – 2-13Table 2-3. Inspection and Preventive Maintenance ScheduleAREAINTERVALPre-Start1InspectionWeeklyPreventiveM

INTRODUCTION3120718 – JLG Lift – A-1SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONSAGENERALThis section contains the general safety precauti

SECTION 2 - GENERAL2-14 – JLG Lift – 3120718Ground Controls 55 66Function Control Locks, Guards, or Detents 1,5 1,5 5 5Footswitch 1,5 5 5Emergency Sto

SECTION 2 - GENERAL3120718 – JLG Lift – 2-15Walk-Around Inspection Performed 21Annual Machine Inspection Due 21No Unauthorized Modifications or Additi

SECTION 2 - GENERAL2-16 – JLG Lift – 3120718Figure 2-14. Engine Operating Temperature Specifications - Deutz4150548 A

SECTION 2 - GENERAL3120718 – JLG Lift – 2-17Figure 2-15. Engine Operating Temperature Specifications - Ford4150548 A

SECTION 2 - GENERAL2-18 – JLG Lift – 3120718Figure 2-16. Engine Operating Temperature Specifications - Caterpillar4150548 A

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-1SECTION 3. CHASSIS & TURNTABLE3.1 DRIVE TORQUE HUB, PRIOR TO S/N 75606 Disassembly1.

SECTION 3 - CHASSIS & TURNTABLE3-2 – JLG Lift – 3120718Figure 3-1. Torque Hub, Drive (Fairfield)

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-3k. Turn cover over and push disconnect rod intocover cap. Rod will be held in place by fric

SECTION 3 - CHASSIS & TURNTABLE3-4 – JLG Lift – 3120718m. While keeping thrust washers in place, slidecluster gear into carrier with larger gear o

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-52. Place bearing cone (4) into bearing cup (3) in smallend of hub.3. Press new seal (2) int

INTRODUCTIONA-2 – JLG Lift – 3120718REVISON LOGOriginal Issue - September, 1996Revised - March 15, 1999Revised - September 17, 1999Revised - February

SECTION 3 - CHASSIS & TURNTABLE3-6 – JLG Lift – 31207188. Place internal gear (12) onto end of spindle.9. Install thrust washers and thrust bearin

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-7ing of o-ring may be necessary to insure properseating.15. Place carrier assembly on a flat

SECTION 3 - CHASSIS & TURNTABLE3-8 – JLG Lift – 312071820. Install thrust washers and thrust bearing (39, 40) intocarrier counter bore.21. Place o

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-9Figure 3-2. Torque Hub, Drive (Auburn Gear)

SECTION 3 - CHASSIS & TURNTABLE3-10 – JLG Lift – 31207182. Remove twelve bolts (25) and flat washers (26) andthe cover from the hub (9). The thrus

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-11NOTE: The brake must be released before performing theroll test. This can be accomplished

SECTION 3 - CHASSIS & TURNTABLE3-12 – JLG Lift – 31207184. Remove the Cover Subassembly (6) from the unit.The unit can be carefully pressurized wi

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-135. Remove the First Stage Sun Gear (10) if applicable.NOTE: On units with ratios greater t

SECTION 3 - CHASSIS & TURNTABLE3-14 – JLG Lift – 312071815. Slide the Planet Gear Subassembly (4) out of theSpindle (1A) being careful to not drop

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-15Input Carrier Disassembly3A. Carrier3B. Thrust Washer3E. Planet Shaft3F. Planet Gear4G

3120718 – JLG Lift – i TABLE OF CONTENTSTABLE OF CONTENTSSUBJECT - SECTION, PARAGRAPH PAGE NO.SECTION A - INTRODUCTION - MAINTENANCE SA

SECTION 3 - CHASSIS & TURNTABLE3-16 – JLG Lift – 31207181. Using a 1/8” diameter punch, drive the Roll Pin (4G)into the Planet Shaft (3E) until it

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-17Hub-Spindle Disassembly1. Place unit on bench with Spindle (1A) end down.2. Remove 2 Set S

SECTION 3 - CHASSIS & TURNTABLE3-18 – JLG Lift – 3120718Spindle-Brake Disassembly1A. Spindle7. Coupling Subassembly8A. Piston8B. Pressure P

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-19NOTE: This procedure applies only to units with integralInput Brake (8).EYE PROTECTION MUS

SECTION 3 - CHASSIS & TURNTABLE3-20 – JLG Lift – 3120718Cover Disassembly1. Remove O-Ring (17) from groove in Cover (6A).2. Remove Thrust Washer (

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-21Input Carrier Sub-Assembly1. Apply a liberal coat of grease to the bore of oneInput Planet

SECTION 3 - CHASSIS & TURNTABLE3-22 – JLG Lift – 31207189. Install small Backup Ring (8H) in the small-diametergroove near the top of the Piston (

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-23Cover Sub-Assembly1. Grease O-Ring (6E) and insert into internal groove inCover (6A).2. As

SECTION 3 - CHASSIS & TURNTABLE3-24 – JLG Lift – 31207181A. Spindle1B. Lip Seal1C. Tapered Bearing1D. Housing1E. Ring Gear1F. Bearing Nut1G.

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-25Figure 3-13. Bearing Cup Pressing ToolFigure 3-14. Seal Pressing Tool

ii – JLG Lift – 3120718TABLE OF CONTENTS (Continued) TABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.1.7 Pressure Settings .

SECTION 3 - CHASSIS & TURNTABLE3-26 – JLG Lift – 3120718Figure 3-15. Bearing Cup Pressing ToolFigure 3-16. Drift Pin for Lining Up Thrust Washer

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-273.4 DRIVE BRAKE - MICO, PRIOR TO S/N 75606Disassembly1. With shaft protrusion downward, re

SECTION 3 - CHASSIS & TURNTABLE3-28 – JLG Lift – 3120718Figure 3-17. Drive Brake Assembly (Mico)

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-293.5 FREE WHEELING OPTIONTo Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.

SECTION 3 - CHASSIS & TURNTABLE3-30 – JLG Lift – 3120718Bearing set/miscellaneous parts Rotary group complete 9 pistons, cylinder sub-assembly,val

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-31Spare parts kit DFR pilot valveReplacing the Drive Shaft Seal1. Remove the snap ring 2. Ch

SECTION 3 - CHASSIS & TURNTABLE3-32 – JLG Lift – 31207182. Mark the position of the port plate and remove thesocket screw from the port plate. 3.

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-3310. Disassemble the rotary group in horizontal position.11. Disassemble the stopper - max.

SECTION 3 - CHASSIS & TURNTABLE3-34 – JLG Lift – 312071818. Remove both bearing shells. 19. Remove the drive shaft. 20. Remove the snap ring. 21.

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-3525. The spring has additional pretension while you dis-assemble the three pressure pins in

3120718 – JLG Lift – iii TABLE OF CONTENTSTABLE OF CONTENTS (continued)SUBJECT - SECTION, PARAGRAPH PAGE NO.2.9 Deutsch Connectors . . .

SECTION 3 - CHASSIS & TURNTABLE3-36 – JLG Lift – 3120718NOTE: Differential volume if you are rotating the threaded pin -each rotation is appr. 3,1

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-374. Pumps counterclockwise driven must have a posi-tion of the valve plate 4 degrees de-cen

SECTION 3 - CHASSIS & TURNTABLE3-38 – JLG Lift – 31207183.7 DRIVE MOTOR (600A 2WD)Shaft Seal ReplacementLip type shaft seals are used an the drive

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-393.9 OSCILLATING AXLE BLEEDING PROCEDURE AND LOCKOUT TESTLockout Cylinder BleedingENSURE PL

SECTION 3 - CHASSIS & TURNTABLE3-40 – JLG Lift – 31207186. Start the engine, position drive control lever on themain hydraulic pump forward or rev

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-413.10 STEER ADJUSTMENTS (S MODELS)NOTE: Spindles do not stop on cylinder stroke. Adjust ste

SECTION 3 - CHASSIS & TURNTABLE3-42 – JLG Lift – 31207182. Check the turntable to bearing. Attach bolts as fol-lows:a. Elevate the fully retracted

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-43Figure 3-28. Swing Bearing Tolerance Boom Placement (S Models)

SECTION 3 - CHASSIS & TURNTABLE3-44 – JLG Lift – 3120718Figure 3-29. Swing Bearing Tolerance Boom Placement (A Models)

SECTION 3 - CHASSIS & TURNTABLE3120718 – JLG Lift – 3-455. If bearing inspection shows no defects, reassembleand return to service.THE SWING BEARI