JLG 600SC-660SJC Service Manual

Service and Maintenance Manual

Model

600SC
600SJC
660SJC

3120794

April 9, 2002

ANSI

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]

JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: [phone]
Fax: [phone]

JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: [phone]
Fax: [phone]

JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]

JLG Industries (Europe)
Kilmartin Place,
Tan n oc h s id e P a r k
Uddingston G71 5PH
Scotland
Phone: [phone]
Fax: [phone]

JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: [phone]
Fax: [phone]

JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: [phone]
Fax: [phone]

JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: [phone]
Fax: [phone]

Plataformas Elevadoras
JLG Iberica, S.L .
Trapadella, 2
P. I . C a s t e l l b i s b a l S u r
08755Castellbisbal
Spain
Phone: [phone]
Fax: [phone]

JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: [phone]
Fax: [phone]

JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A GENERAL

This section contains the general safety precautions which
must be observed during maintenance of the aerial plat­form. It is of utmost importance that maintenance person­nel pay strict attention to these warnings and precautions
to avoid possible injury to themselves or others, or dam­age to the equipment. A maintenance program must be
followed to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLA­TION.

The specific precautions to be observed during mainte­nance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component
parts.

Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support is
provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER­ATOR.

B HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pressures.
Every effort should be made to relieve any system pres­sure prior to disconnecting or removing any portion of the
system.

feed lines to system components can then be disconnected
with minimal fluid loss.

C MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.

• NO SMOKING IS MANDATORY. NEVER REFUEL DUR­ING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAU­TIONS ON MACHINE AND IN SERVICEMANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSUR­IZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED BOOM UNTIL
BOOM HAS BEEN SAFELY RESTRAINED FROM ANY
MOVEMENT BY BLOCKING OR OVERHEAD SLING,
OR BOOM SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTED­DURING REPLACEMENT OF ELECTRICAL COMPO­NENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH­MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

Relieve system pressure by cycling the applicable control
several times with the engine stopped and ignition on, to
direct any line pressure back into the reservoir. Pressure

3120794 – JLG Lift – A-1

INTRODUCTION

REVISON LOG

Original Issue - January 25, 2000
Revised - July 28, 2000
Revised - April 9, 2002

A-2 – JLG Lift – 3120794

TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

B Hydraulic System Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Hydraulic System (Including Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Engine - Diesel (Liquid-Cooled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Auxiliary Power Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Turning Radius (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Turning Radius (Inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Weight approximately. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Height (Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Length (Stowed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1.6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Deutz F4M1011F Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

SECTION 2 - GENERAL

2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

3120794 – JLG Lift – i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION 3 - TURNTABLE

3.1 Tilt Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Throttle Checks and Adjustments - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Failure Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 Swing Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Swing Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Swing Bearing Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.5 Swing Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

SECTION 4 - BOOM & PLATFORM

4.1 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Platform Sections Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Boom Rope Torquing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Torque Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Main Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Three Month Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Five Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.5 Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Disassembly of Boom Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

4.6 Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.7 Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

4.8 Rotator - Helac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.9 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4.10 SUPERFLEX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

System Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

SUPERFLEX Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

SUPERFLEX Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Setup and Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

How to Perform the Normal-Active Tuning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

How to make Bench-Static Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

How To Troubleshoot the SUPERFLEX Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

How to Troubleshoot the Digisensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Important Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Crawler Tracking Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Drive & Steer Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Superflex Inputs And Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

SECTION 5 - HYDRAULICS

5.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Systems Incorporating Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Systems Incorporating Holding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Solenoid Control Valve - Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder . . . . . . . . 5-1

Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.5 Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Main Boom Telescope Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Main Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.6 Pressure Setting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

Main Relief, Steer, Swing and Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Articulating Jib Boom (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.7 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

5.8 Hydraulic Component Start-Up Procedures and recommendations . . . . . . . . . . . . . . . . . . . . . . .5-16

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION 6 - UNDERCARRIAGE

6.1 Track Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.2 Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.3 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

Separate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.4 Front Idler and Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Front Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Front Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Recoil Spring Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Recoil Spring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

6.5 Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

6.6 Final Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

6.7 Travel Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6.8 Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32

6.9 Travel Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.10 Travel Brake Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6.11 Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

6.12 Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

Final Drive Oil - Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57

Final Drive Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

6.13 Swivel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-58

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-58

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-61

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SUBJECT - SECTION, PARAGRAPH PAGE NO.

6.14 Towing Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-62

Towing the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62

Final Drive Sun Gear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

6.15 Track Adjustment - Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63

Measuring Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Tightening the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Loosening the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

Track Adjustment - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-64

6.16 Undercarriage- Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-64

SECTION 7 - SCHEMATICS

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.3 Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2. Lubrication Point Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

3-1. Tilt Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2. Addco Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3-3. Swing Torque Hub Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-4. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-5. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-6. Swing Bearing Tolerance Boom Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-7. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-8. Swing Brake Assembly (Mico) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

4-1. Platform Section Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-2. Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-3. Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-4. Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-5. Location of Components - Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-6. Location of Components - Rotator and Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-7. Location of Components - Boom Powertrack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-8. Boom Assembly Cutaway - S Models - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-9. Boom Assembly Cutaway - S Models - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-10. Boom Assembly Cutaway - S Models - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-11. Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-12. Disassembly Wire Rope Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-13. Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-14. Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-15. Reassembly of Components - Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-16. Boom Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-17. Location of Components - Articulating Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-18. Limit Switches Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-20. Removing Portion of End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-21. Heating Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-22. Removing Setscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

4-23. Removing End Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-19. Rotator Assembly (Helac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-24. Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-25. Removing Sleeve from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

3120794 – JLG Lift – v

TABLE OF CONTENTS (Continued)

LIST OF FIGURES (continued)

FIGURE NO. TITLE PAGE NO.

4-26. Actuator Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-27. SUPERFLEX Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

4-28. Wiring Diagram - Single Coil Uni-Directional Flow Control Valve - 1 Axis. . . . . . . . . . . . . . . . . . .4-22

4-29. Controller Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

4-30. Calibration Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-31. Testing the SUPERFLEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4-32. Digisensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

4-33. Typical SUPERFLEX System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

4-34. OPTIMIZER Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-2. Cap Screw Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5-3. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-4. Tapered Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-5. Gar-Max Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-7. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-8. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-9. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-10. Piston Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-11. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-12. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-13. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-14. Boom Positioning and Support, Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-15. Articulating Jib Boom Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-16. Main Control Valve Pressure Adjustments - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-17. Main Control Valve Pressure Adjustments - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-18. Location of Components - Main Control Valve (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5-19. Location of Components - Main Control Valve (Sheet 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

6-1. Undercarriage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2. Track Carrier Roller - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

6-3. Track Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-4. Track Roller - Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6-5. Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-6. Track Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-7. Track Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-8. Front Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-9. Recoil Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-10. Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6-11. Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

6-12. Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-43

6-13. Tooling (J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56

6-14. Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-60

7-1. Electrical Components Installation - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2. Electrical Components Installation - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-3. Electrical Schematic - Deutz or Isuzu - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

7-4. Electrical Schematic - Deutz or Isuzu - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7-5. Hydraulic Schematic - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-6. Hydraulic Schematic - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7

7-7. Hydraulic Schematic - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

7-8. Hydraulic Schematic - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

7-9. Hydraulic Schematic w/GFT24 Drive - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-10. Hydraulic Schematic w/GFT24 Drive - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-11. Hydraulic Schematic w/GFT24 Drive - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-12. Hydraulic Schematic w/GFT24 Drive - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

vi – JLG Lift – 3120794

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-4 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-5 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-6 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-8 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-9 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3 Inspection and Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

3-1 Position Controller Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4-1 Adjusting Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

4-2 Adjustment Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

4-3 Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

5-1 Cylinder Head and Tapered Bushing Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

6-1 Track Carrier Roller Required Tools - Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Track Carrier Roller Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-3 Track Roller Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-4 Track Roller Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-5 Track Roller Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-6 Track Required Tools - Separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

6-7 Track Required Tools - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-8 Front Idler Required Tools - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

6-9 Recoil Spring Required Tools - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

6-10 Recoil Spring Required Tools - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

6-11 Track Adjuster Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29

6-12 Final Drive Sprocket Required Tools - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30

6-13 Final Drive Sprocket Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

6-14 Travel Motor Required Tools - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

6-15 Travel Motor Required Tools - Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-37

6-16 Travel Motor Required Tools - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-38

6-17 Travel Motor Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

6-18 Final Drive Required Tools - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

6-19 Final Drive Required Tools - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42

6-20 Final Drive Required Tools - Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-50

6-21 Final Drive Required Tools - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-56

3120794 – JLG Lift – vii

TABLE OF CONTENTS (Continued)

This page left blank intentionally.

viii – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank

39 US. Gallons (147.6 l)

Hydraulic Oil Tank

31 U.S. Gallons (117.3 l) with 10% air space

Hydraulic System (Including Tank)

37.2 U.S. Gallons (140.8 l)

Engine Crankcase

Deutz F4M1011F Diesel w/Filter - 11 quarts (10.5 l)

1.2 COMPONENT DATA

Engine - Diesel (Liquid-Cooled)

Manufacturer/Model- Deutz F4M1011F.

Oil Capacity.

5 Quarts (4.5 l) Cooling System.

11 Quarts (10.5 l) w/Filter.

16 Quarts (15 l) Total Capacity.

Low RPM - 1800.

Swing System

Swing Motor Displacement - 4.62 cu. in. (75 cm3]).

Swing Brake - Automatic spring applied hydraulically
released disc brakes.

Swing Hub Ratio - 50:1.

Hydraulic Gear Pump. (at 1800 RPM)

7.9 GPM (29.90 lpm).

Pump Displacement - 1.02 cu. in. (16 cm3]).

Clockwise Rotation.

Auxiliary Power Pump

2.6 GPM (9.84 lpm) @ 1200 PSI. (82.7 BAR.

Pump Displacement - .244 cu. in. (14 cm3]).

DC Motor.

Clockwise Rotation.

Hydraulic Filter - In-line.

Return - Bypass Type.

10 Microns Absolute.

Charge.

10 Microns Absolute.

Hydraulic Strainers (In Tank).

High RPM - 2800.

Alternator - 60 Amp, belt drive.

Battery - 1000 Cold Cranking Amps, 210 Minutes
ReserveCapacity, 12 VDC.

Fuel Consumption.

Low RPM - 1.90 GPH (7.19 lph).

High RPM - 2.50 GPH (9.46 lph).

Horsepower - 65 @ 3000 RPM, full load.

Engine - Diesel. (Water-Cooled)

30 Microns.

3120794 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

1.3 PERFORMANCE DATA

Travel Speed

1.6 MPH (2.6 Km/hr.)

Travel Speed - Out of Transport

0.4 MPH (0.6 Km/hr.)

Gradeability.

55%

Turning Radius (Outside)

8 ft. (2.4 m)

Turning Radius (Inside)

0

Boom Elevation

600SC - +60 ft. 2 13/16 in. (18.36 m)

-6 ft. 1 11/16 in. (1.87 m)

600SCJ - +60 ft. 5 3/4 in. (18.43 m)

-9 ft. 9 3/16 in. (2.98 m)

660SCJ - +66 ft. 7 5/8 in. (20.31 m)

-11 ft. 5 1/4 in. (3.49 m)

Machine Weight approximately

Steel Track - 25,900 lbs. (11,748 kg)

Rubber Track - 26,860 lbs. (12,184 kg)

Machine Height (Stowed)

Steel Track - 8’4" (2.54 m)

Rubber Track - 8’6" (2.59 m)

Machine Length (Stowed)

35’ 6" (10.8 m)

Machine Width

8 ft. (2.4 m)

1.4 FUNCTION SPEEDS

Table 1-1. Function Speeds (In Seconds)

Function Speed

Lift Up 46-60

Lift Down 33-43

Swing Right & Left* 79-101

Telescope In 22-33

Telescope Out 50-67

Platform Rotate Right & Le ft** 16-25

Jib Up 22-34

Jib Down 16-26

Drive (Forward & Reverse) 85-90

Drive Out of Transport (Forward & Reverse) 80-85

*Max 10% Difference Betwe en Left & Right
**Max 15% Difference Betwe en Left & Right

Machine Orientation When Doing Speed Te st s

Lift: Telescope Retracted. Lift Up, Record Time, Lift Down,

Record Time.

Swing: Boom at Full Elevation. Telescope Retracted.
Swing the Turntable off center and stop. Swing the oppo­site direction ana start the test wen the turntable is cen­tered up. This eliminates ramp up and down on the
controller affecting times.

Te l e sc o p e : Boom at Full Elevation; Telescope Retracted;
Telescope Out, Record Time. Telescope In, Record Time.

Trackin g : Test to be done on a gravelled level surface.
Position the machine driving at high speed at a reference
point. (No steer correction). Results should be 4 to 6
ft.(1.2 to 1.8 m) tracking error at 200 ft. (60.9 m).

Drive: Test should be done on a graveled level surface.
Drive select switch should be set at High Speed. Start
approx. 10 ft. from starting point so that the unit is at max­imum speed when starting the test. Results should be
recorded for a 200 ft. (60.9 m) course. Drive Forward,
Record Time. Drive Reverse, Record Time.

Drive (Out of Transport): Test should be done on a grav­eled level surface. Drive select switch should be set at
Low Engine, Low Drive (The platform speed knob control,
if equipped, could be selected to the creep speed to simu­late the boom above horizontal). Results should be
recorded for a 50 ft. (15.2 m) course. Drive Forward,
Record Time. Drive Reverse, Record Time.

1-2 – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

Platform Rotate: Platform level and completely rotated
one direction. Rotate the opposite direction, Record Time.
Rotate the other direction, Record Time.

Articulating Jib: Platform level and centered with the
boom. Start with the Jib down. Jib Up, Record Time. Jib
Down, Record Time.

Te s t N ot e s

1. Stop watch should be started with the function, not
with the controller or switch.

2. All speed tests are run from the platform. These
speeds do not reflect the ground control operation.

3. The platform speed knob control must be at full
speed (turned clockwise completely).

4. Function speeds may vary due to cold, thick hydrau­lic oil. Test should be run with the oil temperature

above 100° F (38° C).

5. Some flow control functions may not work with the
speed knob clicked into the creep position.

1.5 TORQUE REQUIREMENTS

Ta b le 1- 2. To r q u e R e q u i r em en ts

Description

Bearing To Chassis See Note 50/600*

Tor qu e Va lu e

(Dry)

Interval

Hours

1.6 LUBRICATION

Deutz F4M1011F Engine

Single Viscosity Oil (CD-SE, CD-SF).

When Outside Temperature is

Consistently

-20°F. t o + 2 5 °F. ( - 2 9 °C. to +4°C.) *10W

+5°F. t o + 5 0 °F. ( + 1 5 °C. to +10°C.) 20W-20

+40°F. t o + 8 5 °F. ( + 4°C. to +30°C.) 30

Above 75°F. ( 2 4 °C.) 40

Multi Viscosity Oil (CD-SE, CD-SF)

*This viscosity can be used at colder temperatures with
engine oil preheating.

When Outside

Temperature is

Consistently

-40°F. t o + 7 5 °F. ( - 4 0 °C. to
+24°C.)

-15°F. t o + 7 0 °F. ( - 2 6 °C. to
+21°C.)

-15°F. t o + 8 5 °F. ( - 2 6 °C. to
+30°C.)

Above -5°F. ( - 2 1 °C.) 15W-40

-5°F. t o +7 5 °F. ( - 21 °C. to
+24°C.)

*This viscosity can be used at colder temperatures with
engine oil preheating.

Use SAE Viscosity

Number

Use SAE Viscosity Number

*5W-30 (Synthetic)

10W-30

10W-40

15W-30

Bearing To Turntable See Note 50/600*

Wire Rope 15 ft.lbs.

(20 Nm)

M16 Travel motor
mounting bolts

M20 Final Drive
mounting bolts

M20 Track roller
mounting bolts

M24 Carrier roller
mounting bolts

*Check swing bearing bolts for security after first 50 hours
of operation and every 600 hours thereafter. (See para­graph on Swing Bearing in Section 2.)

NOTE: When maintenance becomes necessary or a fas-

tener has loosened, refer to the Torque Chart to
determine proper torque value.

175 ±30 ft.lbs.

(240±40 Nm)

390 ±50 ft.lbs.

(530±70 Nm)

340 ±44 ft.lbs.

(460±60 Nm)

600 ±70 ft.lbs.

(800±100 Nm)

150

As

required

As

required

As

required

As

required

NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C or

have properties of API classification CC/CD grades.

3120794 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

Hydraulic Oil

Ta b l e 1 - 3 . H y dr au li c O il

HYDRAULIC SYSTEM

OPERATING

TEMPERATURE RANGE

+0° to +180° F (-18° C to

+83° C)

+0° F to +210° F (-18° C to

+99° C)

+50° F to +210° F (+10° C to

+210° C)

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser­vice. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152 .

NOTE: When temperatures remain below 20° F (-7 degrees

C), JLG Industries recommends the use of Mobil
DTE 13M.

Table 1-4. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max -40 F (-40 C)

Flash Point, Min. 330 F (166 C)

at 40° C 33cSt

at 100° C6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

SAE VISCOSITY GRADE

10W

10W-20, 10W-30

20W-20

Viscosity

Lubrication Specifications

Ta b le 1 - 5. Lubrication Specifications

KEY SPECIFICATIONS

MPG

EPGL

HO

EO

Multipurpose Grease having a mini­mum dripping point of 350° F. E xc e l ­lent water resistance and adhesive
qualities, and being of extreme pres­sure type.
(Timken OK 40 pounds minimum.)

Extreme Pressu re Gear Lube (oil)
meeting API service classification
GL-5 or MIL-Spec MIL-L-2105

Hydraulic Oil. API service classifica­tion GL-3, e.g. Mobilfluid 424.

Engine (crankcas e) Oil. Gas - API SF,
SH, SG class, MIL-L-2104. Diesel ­AP I C C /C D c la ss , M IL- L-2 10 4B /M IL­L-2104C.

NOTE: Refer to Lubrication Chart, for specific lubrication

procedures.

1.7 PRESSURE SETTINGS

Main Relief - 3000 PSI (206.85 Bar).

Upper Boom Lift Down - 1500 PSI (103.4 Bar).

Swing - 1700 PSI (117.2 Bar).

Platform Level Forward - 2800 PSI (193.06 Bar).

Backward - 1800 PSI (124.11 Bar).

Articulating Jib Boom Up - 1500 PSI (103 Bar).

Down - 1200 PSI (82.7 Bar).

Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not con­tain the same required additives or be of comparable vis­cosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommenda­tions.

1-4 – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

1.8 CYLINDER SPECIFICATIONS

Table 1-6. Cylinder Specifications

DESRIPTON BORE STROKE ROD DIA.

600SJ 660SJ 600S 600SJ 660SJ 600S 600SJ 660SJ 600S

Lift 6.00

Telescope 3.5

Master 3.5

Slave Level 3.5

Lift (Articulating Jib
Boom)

(152.4)

(88.9)

(88.9)

(88.9)

(76.2)

3

6.00

(152.4)

3.5

(88.9)

3.5

(88.9)

3.5

(88.9)

3

(76.2)

6.00

(152.4)

3.5

(88.9)

3

(76.2)

3

(76.2)

N/A 25.5

44.6875
(1135.1)

143.1875
(3637)

13.0625
(331.8)

13.0625
(331.8)

(647.7)

44.6875

(1135.1)

168.4375
(4278.3)

13.0625
(331.8)

13.0625
(331.8)

25.5

(647.7)

44.6875
(1135.1)

177.75

(4514.9)

8.5

(215.9)

8.5

(215.9)

N/A 1.5

(76.2)

2.5

(63.5)

1.5

(38.1)

1.5

(38.1)

(38.1)

3

(76.2)

2.5

(63.5)

1.5

(38.1)

1.5

(38.1)

1.5

(38.1)

3

1.9 MAJOR COMPONENT WEIGHTS

Table 1-7. Major Component Weights

600SJ 660SJ 600S

LB.KG.LB.KG.LB.KG.

Platform Control Con sole 250 113 250 113 250 113

Platform Level Cylinder 602760274621

Main Boom (Includ es Lift Cyl., Rotator, and Support) 3483 1580 3783 1716 3527 1600

Turntable Complete (including engine) 7915 3590 9065 4112 7315 3318

(76.2)

2.5

(63.5)

1.5

(38.1)

1.5

(38.1)

N/A

3

1.10 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS
OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE:
BATTERIES, FILLED TIRES, COUNTERWEIGHT, ENGINE & PLAT­FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABIL­ITY.

Table 1-8. Critical Stability Weights

600SJ 660SJ 600S

LB.KG.LB.KG.LB.KG.

Engine Ford 460 209 460 209 460 209

Platform 6 ft. (1.83 M ) 205 93 205 93 205 93

8 ft. (2.44 M) 230 105 230 105 230 105

3120794 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

1.11 SERIAL NUMBER LOCATIONS

A serial number plate is affixed to the left rear side of the
frame. If the serial number plate is damaged or missing,

the machine serial number is stamped on the left side of
the frame.

Figure 1-1. Serial Number Locations

1-6 – JLG Lift – 3120794

SECTION 1 - SPECIFICATIONS

This page left blank intentionally.

3120794 – JLG Lift – 1-7

SECTION 1 - SPECIFICATIONS

Figure 1-2. Lubrication Point Location

1-8 – JLG Lift – 3120794

Table 1-9. Lubrication Chart

SECTION 1 - SPECIFICATIONS

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

Components

Number/Type

Lube Points

Capacity Lube

Lubrication

Swing Bearing

1

Swing Drive Hub

2

Final Drive Hub

3

Hydraulic Return Filter

4

Hydraulic Charge Filter

5

Hydraulic Oil

6

Suction Strainers (in

7

tank)

2 Grease Fittings A/R MPG X Remote Access

Level/Fill Plug 17 oz. (1/2 Full) EPGL X Check level every 150 hrs/change 1200 hours

Level/Fill Plug 2.1 gal. (1/2 Full) EPGL X Check level every 150 hrs/change 1200 hours

N/A N/A N/A X Change after first 50 hrs. and eve ry 300 hrs.

N/A N/A N/A X Change after first 50 hrs. and eve ry 300 hrs.

Fill Cap 30.6 gal. Tank

32.7 gal. System

2 N/A N/A X Remove and clean at time of hydraulic oil

HO X Check level daily/change 1200 hours

thereafter or as indicated by Condition Indica­tor.

thereafter or as indicated by Condition Indica­tor.

change.

Engines

Oil Change w/ Filter -

8

Deutz

Fuel Filter - Deutz

9

Air Filter - Deutz

10

NOTES: KEY TO LUBRICANTS

Lubrication intervals are based on machine operation under normal
conditions. For machines used in multi shift operations and/or
exposed to hostile environments or conditions, lubrication frequen­cies must be increased accordingly.

Fill Cap/Spin-on Element 11 Quarts Crankcase

Replaceab le Element N/A N/A X

Replaceabl e Element N/A N/A X Or as indicated b y Condition Indicat or.

**5 Quarts C ooler

** When changing oil in the Deutz oil cooled engine, drain both the crankcase and
the cooler. When refilling it is acceptable to overfill the crankcase (16 qts., capac­ity of both crankcase and cooler combined). Start engine, allow the engine to run
until the thermostat opens (approximately 221 degrees F) cooler will fill up within
minutes; shut down and wait for approximately two minutes. Check oil level, fill oil
to max mar king on th e dipstick.

EO X Check level daily/Change every 1000 hours

EPGL

or one year, whichever comes first. Adjust
final oil level by mark on dipstick.

EO

Engine Oil
Extreme Pressure Gear Lube

HO

Hydraulic F luid (Mobil #4 24 or equivalent )

MPG

Multi-Purpose Grease

3120794 – JLG Lift – 1-9

SECTION 1 - SPECIFICATIONS

Figure 1-3. Torque Chart

1-10 – JLG Lift – 3120794

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehen­sive inspection and preventive maintenance program.
The following table outlines the periodic machine inspec­tions and maintenance recommended by JLG Industries,
Inc. Consult your national, regional, or local regulations
for further requirements for aerial work platforms. The fre­quency of inspections and maintenance must be
increased as environment, severity and frequency of
usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to per­form a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Opera­tor’s and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operator and Safety Manual
must be read in its entirety and understood prior to per­forming the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recog­nized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.

The Pre-Delivery Inspection and Frequent Inspection pro­cedures are performed in the same manner, but at differ­ent times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in ser­vice for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be

increased as environment, severity and frequency of
usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the perfor­mance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance proce­dures.

Annual Machine Inspection

The Annual Machine Inspection must be performed by a
Factory-Certified Service Technician on an annual basis,
no later than thirteen (13) months from the date of the
prior Annual Machine Inspection. JLG Industries, Inc. rec­ognizes a Factory-Certified Service Technician as a per­son who has successfully completed the JLG Service
Training School for the subject JLG product model. Refer­ence the machine Service and Maintenance Manual and
appropriate JLG inspection form for performance of this
inspection.

Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this man­ual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, mainte­nance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, train­ing, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.

Reference the Preventative Maintenance Schedule and
the appropriate areas of this manual for servicing and
maintenance procedures. The frequency of service and
maintenance must be increased as environment, severity
and frequency of usage requires.

3120794 – JLG Lift – 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start Inspec­tion

Pre-Delivery

Inspection

Frequent Inspec-

tion

Annual Machine

Inspection

Preventative
Maintenance

Prior to use each day ; or

At each Operator change .

Prior to each sa le, lease, or

rental delivery.

In service for 3 mo nths or 150 hours, which-

ever comes first; or

Out of service for a period of more than 3

months; or

Purchased used.

Annually, no later than 13 months from the

date of the prior inspection.

At intervals as sp ecified in the Service and

Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

The following information is provided to assist you in the
use and application of servicing and maintenance proce­dures contained in this book.

Safety and Workmanship

Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.

Cleanliness

1. The most important single item in preserving the
long service life of a machine is to keep dirt and for­eign materials out of the vital components. Precau­tions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.

Primary

Responsibility

User or Operator User or Operato r Operator and S afety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Fa ctory-Certified

Owner, Dealer, or User Qualified JLG

2. At any time when air, fuel, or oil lines are discon­nected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or compo­nent is disconnected, cap or cover all openings to
prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or main­tenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
clean. Be sure all parts are clean before they are
installed. New parts should remain in their contain­ers until they are ready to be used.

Service

Qualification

Mechanic

Mechanic

Service Technician

Mechanic

Reference

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual and applicabl e JLG

inspection form.

Service and Main tenance

Manual

Components Removal and Installation

1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
lifted.

2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eye­bolt or similar bracket lessens, as the angle between
the supporting structure and the component
becomes less than 90 degrees.

3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc., have been
removed and that no adjacent parts are interfering.

2-2 – JLG Lift – 3120794

SECTION 2 - GENERAL

Component Disassembly and Reassembly

When disassembling or reassembling a component, com­plete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the
mating surface.

Bearings

1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed
air can be used but do not spin the bearing.

2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned.

3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are
ready to install.

4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bear­ing is to be installed on a shaft, apply pressure to the
inner race.

Gaskets

Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.

2. Unless specific torque requirements are given within
the text, standard torque values should be used on
heat-treated bolts, studs, and steel nuts, in accor­dance with recommended shop practices. (See
Torque Chart Section 1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.

Hydraulic System

1. Keep the system clean. If evidence of metal or rub­ber particles are found in the hydraulic system, drain
and flush the entire system.

2. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
required, to aid assembly.

Lubrication

Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section 1.

Bolt Usage and Torque Application

1. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications of the original, or one which is
equivalent.

3120794 – JLG Lift – 2-3

SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contam­ination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by
permitting the pump to cavitate due to insufficient
system warm-up or leaks in the pump supply (suc­tion) lines.

2. The design and manufacturing tolerances of the
component working parts are very close, therefore,
even the smallest amount of dirt or foreign matter
entering a system can cause wear or damage to the
components and generally results in faulty opera­tion. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the speci­fied intervals required in the Lubrication Chart in
Section 1. Always examine filters for evidence of
metal particles.

3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or cor­rosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or
types, as they may not contain the same required
additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is oper­ating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing compo­nents.

Hydraulic Oil

1. Refer to Section 1 for recommendations for viscosity
ranges.

3. The only exception to the above is to drain and fill
the system with Mobil DTE 13 oil or its equivalent.
This will allow start up at temperatures down to -20
degrees F (-29 degrees C). However, use of this oil
will give poor performance at temperatures above
120 degrees F (49 degrees C). Systems using DTE
13 oil should not be operated at temperatures above
200 degrees F (94 degrees C) under any condition.

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
oil on a regular basis. However, filter elements must
be changed after the first 50 hours of operation and
every 300 hours thereafter. If it is necessary to
change the oil, use only those oils meeting or
exceeding the specifications appearing in this man­ual. If unable to obtain the same type of oil supplied
with the machine, consult local supplier for assis­tance in selecting the proper equivalent. Avoid mix­ing petroleum and synthetic base oils. JLG
Industries recommends changing the hydraulic oil
annually.

2. Use every precaution to keep the hydraulic oil clean.
If the oil must be poured from the original container
into another, be sure to clean all possible contami­nants from the service container. Always clean the
mesh element of the filter and replace the cartridge
any time the system oil is changed.

3. While the unit is shut down, a good preventive main­tenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
placing the machine back in service.

Lubrication Specifications

Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
meet a variety of single purpose grease requirements.
Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evalua­tion. Refer to Section 1 for an explanation of the lubricant
key designations appearing in the Lubrication Chart.

2. JLG recommends Mobilfluid 424 hydraulic oil, which
has an SAE viscosity of 10W-30 and a viscosity
index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

below -15 degrees F (-26 degrees C) is not recom­mended. If it is necessary to start the system in a
sub-zero environment, it will be necessary to heat
the oil with a low density, 100VAC heater to a mini­mum temperature of -15 degrees F (-26 degrees C).

2-4 – JLG Lift – 3120794

SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured
using the following methods.

Platform Drift

Measure the drift of the platform to the ground. Lower
booms (if equipped) slightly elevated, upper boom fully
extended with the rated load in the platform and power off.
Maximum allowable drift is 2 inches (5 cm) in 10 minutes.
If the machine does not pass this test, proceed with the
following.

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temper­ature and temperature stabilized.

The cylinder must have the normal load, which is the nor­mal platform load applied.

If the cylinder passes this test, it is acceptable.

NOTE: This information is based on 6 drops per minute cyl-

inder leakage.

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

1. Pinned joints should be disassembled and
inspected if the following occurs:

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

2. Filament wound bearings should be replaced if any
of the following is observed:

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their hous-

ing.

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inspection):

a. Detectable wear in the bearing area.

b. Flaking, pealing, scoring, or scratches on the pin

surface.

c. Rusting of the pin in the bearing area.

4. Re-assembly of pinned joints using filament wound
bearings.

a. Housing should be blown out to remove all dirt

and debris...bearings and bearing housings
must be free of all contamination.

b. Bearing / pins should be cleaned with a solvent

to remove all grease and oil...filament wound
bearing are a dry joint and should not be lubri­cated.

c. Pins should be inspected to ensure it is free of

burrs, nicks, and scratches which would dam­age the bearing during installation and opera­tion.

3120794 – JLG Lift – 2-5

SECTION 2 - GENERAL

AREA

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

Boom Assembly

Boom Weldmen ts 1,2,4 1,2,4

Hose/Cable Carrie r Installations 1,2,9,12 1,2,9,12

Pivot Pins and Pin Retai ners 1,2 1,2

Sheaves, Sheave Pins 1,2 1,2

Bearings 1,2 1,2

Wear Pads 1,2 1,2

Covers or Shields 1,2 1,2

Extend/Retract Chain o r Cable Systems 1,2,3 1,2,3

Platform Assembly

Platform 1,2 1,2

Railing 1,2 1 1,2

Gate 511,5

Floor 1,2 1 1,2

Rotator 9,5

Lanyard Anchorage Point 2 1,2,10 1,2,10

Turntable Assembly

Swing Bearing or Worm Gea r 1,2,14 1,2,3,13,14

Oil Coupling 9

Swing Drive System 1,2,14 1,2,3,13,14

Turntable Lock 1,2,5 1,2,5

Hood, Hood Props, Hood L atches 5 1,2,5

Chassis Assembly

Drive Motors 1,2 1,2

To r qu e H ub s 11 11

Functions/Controls

Platform Cont rols 55 66

Ground Controls 55 66

Function Control Locks, Guards, or Detents 1,5 1,5 5 5

Footswitch 1,5 5 5

Emergency Stop Swit ches (Ground & Platform) 555

Function Limit or C utout Switch Systems 55

Capacity Indicator 5

Drive Brakes 5

9

9

9

9

9

2-6 – JLG Lift – 3120794

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Preventive

Maintenance

Weekly

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Swing Brakes 5

Boom Synchronization/ Sequencing Systems 5

Manual Descent or Aux iliary Power 55

Power System

9

Engine Idle, Throttl e, and RPM 33

Engine Fluids (Oil, Cool ant, Fuel) 11 9,11 11 11

Air/Fuel Filter 1,7 7 7

Exhaust Syste m 1,9 9 9

Batteries 51,9 19

Battery Fluid 11 11 11

Battery Charger 55

Fuel Reservoir, Cap, and Breather 11,9 2 1,5 1,5

Hydraulic/Electric System

9

Hydraulic Pumps 1,9 1,2,9

Hydraulic Cyli nders 1,9,7 2 1,2,9 1,2,9

Cylinder Attachment Pins and Pin Retainers 1,9 1,2 1,2

Hydraulic Hoses, Li nes, and Fittings 1,9 12 1,2,9,12 1,2,9,12

Hydraulic Reservoir, Cap, and Breather 11 1,9 2 1,5 1,5 24

Hydraulic Filter 1,9 7 7

Hydraulic Fluid 11 7,11 7,11

Electrical Connections 12020

Instruments, Gauges, S witches, Lights, Horn 15,23

General

Operators and Safety Manuals in Stora ge Box 21 21 21

ANSI and EMI Manuals/Handbooks Install ed 21

Capacity Decals Ins talled, Secure, Legible 21 21 21

All Decals/Placards Installed, Secure, Legible 21 21 21

Walk-Around Inspection Perform ed 21

Annual Machine Inspec tion Due 21

No Unauthorized Modificatio ns or Additions 21 21

All Relevant Safety Publ ications Incorporated 21 21

General Structural C ondition and Welds 2,4 2,4

All Fasteners, Pins , Shields, and Covers 1,2 1,2

Grease and Lubricate to Specifica tions 22 22

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

3120794 – JLG Lift – 2-7

SECTION 2 - GENERAL

Table 2-3. Inspection and Preventive Maintenance Schedule

INTERVAL

AREA

Pre-Start

Inspection

1

Maintenance

Weekly

Preventive

Monthly

Preventive

Maintenance

Pre-Delivery

or Frequent

Inspection

2

3

Function Test of All Systems 21 21 21, 22

Paint and Appearance 77

Stamp Inspection Date on Frame 22

Notify JLG of Machine Ownershi p 22

Footnotes:

1

Prior to use each day; or at each Operator change

2

Prior to each sale, lease, or delivery

3

In service for 3 m onths or 150 Hours; or Out of service for 3 months or more; or Purchased use d

4

Annually, no later than 13 months from the date of the prior inspection

Performance Codes:
1 - Check for pro per and secure installation
2 - Visual inspection for d amage, cracks, distortion or exces sive wear
3 - Check for proper adjustment
4 - Check for crack ed or broken welds
5 - Operates Properly
6 - Returns to neutral or "off" position when released
7 - Clean and free of de bris
8 - Interlocks funct ion properly
9 - Check for signs of leakage
10 - Decals inst alled and legible
11 - Check for proper fluid level
12 - Check for cha fing and proper routing
13 - Check for proper tolerances
14 - Properly lubri cated
15 - Torqued to proper spec ification
16 - No gouges, excess ive wear, or cords showing
17 - Properly inflate d and seated around rim
18 - Proper and authoriz ed components
19 - Fully charged
20 - No loose connecti ons, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Ref ill

Annual

(Yearly)

Inspection

4

Every 2

Yea rs

2-8 – JLG Lift – 3120794