JLG 660SJ Service Manual

4 (1)

Service and Maintenance Manual

Models

600S/SJ

660SJ

600A/AJ

Prior to

S/N 0300080000

P/N - 3120718

September 23, 2005

ADE Identification

All 600S, 600SJ, and 660SJ machines from S/N 61927 incorporate ADE (JLG Control System). The following machine serial numbers prior to S/N 61927 also utilize ADE: 58993, 58998, 59222, 59223, 59275, 59281, 59315, 59319, 59352, 59358, 59631, 59769, 60253, 60254, 60286, 60642, 60645, 61120, 61257, 61402, 61440, 61491, 61833, 61840, 61875, and 61878.

All 600A and 600AJ machines from S/N 64249 incorporate ADE (JLG Control System). The following machine serial numbers prior to S/N 64249 also utilize ADE: 63908, 63912, 63932, 63936, 63938, 63954, 63959, and 63963.

A Machine that incorporates ADE (JLG Control System) can be outwardly identified by the analyzer connection at the base of the platform control box as shown by the arrow.

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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 VIOLA-

TION.

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 CON-

TROL OVER THE FIELD INSPECTION AND MAINTENANCE,

SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER-

ATOR.

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.

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 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.

•ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.

•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.

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A-1

INTRODUCTION

	REVISON LOG
Original Issue	- September, 1996
Revised	- March 15, 1999
Revised	- September 17, 1999
Revised	- February 29, 2000
Revised	- August 4, 2000
Revised	- February 6, 2001
Revised	- May 25, 2001
Revised	- June 12, 2002
Revised	- March 17, 2003
Revised	- December 22, 2003
Revised	- September 23, 2005

A-2

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TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH	PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

SECTION 1 - SPECIFICATIONS

1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Hydraulic System (Including Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Torque Hub, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Engine - Ford LRG-425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Engine - Ford LRG-423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Engine - Deutz F4M1011F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Engine - Continental TMD27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Engine - Caterpillar 3044C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Drive System (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Drive System (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Steer System (S Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Steer System (A Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Turning Radius (Outside) (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Turning Radius (Outside) (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Turning Radius (Inside) (S Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Turning Radius (Inside) (A Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Boom Elevation (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Boom Elevation (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Machine Weight approximately . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Machine Height (Stowed) (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Machine Height (Stowed) (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Machine Length (Stowed) (S Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Machine Length (Stowed) (A Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Machine Width (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Machine Width (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Wheel base (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Wheel base (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.4 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Machine Orientation When Doing Speed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 1.6 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Ford LRG423 & LRG425 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Deutz F4M1011F Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Continental TMD27 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH

PAGE NO.

1.7 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Rexroth Valve (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Rexroth Valve (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1.9 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1.10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

1.11 Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

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 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 2.6 Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Do NOT Do the Following When Welding on JLG Equipment . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.7 Applying Silicone Dielectric Compound to Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . .2-6 2.8 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Applying Silicone Dielectric Compound to AMP Connectors. . . . . . . . . . . . . . . . . . . . . . . . 2-7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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SUBJECT - SECTION, PARAGRAPH

PAGE NO.

2.9 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION 3 - CHASSIS & TURNTABLE

3.1 Drive Torque hub, Prior to S/N 75606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2 Torque Hub, Drive (Auburn Gear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.3 Drive Torque hub, S/N 75606 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Roll, Leak and Brake Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Hub-Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Spindle-Brake Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Cover Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Output Planet Gear Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Spindle - Brake Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Hub-Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Cover Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Main Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Integral Brake Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3.4 Drive Brake - Mico, Prior to S/N 75606 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.5 Free Wheeling Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc. . . . . . . . . . . . . . . . . 3-29 To Engage Drive Motors and Brakes (Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.6 Drive Motor (600S, 600A 4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Replacing the Drive Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Assembly Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Taper Roller Bearing Initial Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Testing and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.7 Drive Motor (600A 2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38 Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 3.8 Drive Motor Adjustment Procedure (S Models Only, Prior to S/N 75606) . . . . . . . . . . . . . . . . . . .3-38

3.9 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 Lockout Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 Oscillating Axle Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

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3.10 Steer Adjustments (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 3.11 Swing Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 3.12 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 Wear Tolerance (S & A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3.13 Swing Brake - Mico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3.14 Tilt Alarm Switch (Machines With External Tilt Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49 Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 3.15 Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

3.16 Rotary Coupling - 600s s/n 75606 TO pRESENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49 3.17 Dual Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54 Changing from Gasoline to LP Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Changing from LP Gas to Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3.18 Electric Governor Installation and Adjustments - Ford LRG Engine . . . . . . . . . . . . . . . . . . . . . . .3-54 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Quick-start Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 Mounting-Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 Mounting-Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Check-Out and Initial Start-Up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Multi-Turn Adjustment (High Engine, Mid Engine, Overspeed, Starter Lockout). . . . . . . . . 3-56 Single-Turn Adjustment (Gain, Factory Adjust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3.19 Throttle Checks and Adjustments - Deutz or Continental Engine (Prior to S/N 61927) . . . . . . . .3-61 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Failure Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

3.20 Automatic Choke Adjustment - Ford Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63 3.21 Cold Weather Starting Difficulty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63 Checking the Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 Checking the Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 Checking the Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65

3.22 GLow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65 3.23 Ford EFI Engine (machines after SN 48907) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66 Performing Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 EFI Diagnostics (600S prior to S/N 61927, 600A prior to S/N 64249) . . . . . . . . . . . . . . . . . 3-66 ECM AND SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

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3.24 Ford LPG System (S Models after S/N 79619 & A Models after S/N 79888) . . . . . . . . . . . . . . . . .3-78 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 Megajector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 Mixer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 Lockoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 Megajector Diagnostic Code Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80

SECTION 4 - BOOM & PLATFORM

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

Torque Procedures (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Tower Boom (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

4.3 Wire Rope (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

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

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

Seven Year Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

4.4 Boom Maintenance (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

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

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

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

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

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

4.5 Boom Maintenance (A Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

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

Disassembly of Boom Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

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

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.6 Tower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

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

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4.7 Articulating Jib Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.8 Limit Switches and Cam Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

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4.9 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Platform Sections Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4.10 Rotator - Helac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4.11 Drive Card Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Lift, Swing, and Drive Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Flow Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4.12 Foot Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

4.13 Boom Synchronizing Procedure (A Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

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 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder . . . . . . . . 5-1 Cylinders With Single Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Cylinders With Dual Counterbalance Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.4 Cylinder Removal and Installation (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

5.5 Cylinder Removal and Installation (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Main Boom Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Main Boom Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Main Boom Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Main Boom Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Upright Level Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Upright Level Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Tower Boom Lift Cylinder Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Tower Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Tower Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Tower Telescope Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

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5.6 Variable Displacement pump (M46 series). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Inspections and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Minor Repair and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5.7 Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42 Solenoid Control Valve - Rexroth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

5.8 Pressure Setting Procedures (S and A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43 Main Relief, Steer, Swing and Lift Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Articulating Jib Boom (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 4 Wheel Steer (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5.9 Hydraulic Component Start-Up Procedures and Recommendations . . . . . . . . . . . . . . . . . . . . . .5-47 5.10 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-48

SECTION 6 - JLG CONTROL SYSTEM

6.1	Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-1
6.2	To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-3
6.3	Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-3
6.4	Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-5
6.5	Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-7
6.6	Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-8
6.7	Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-8
6.8	Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-13
6.9	Analyzer Diagnostics Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	6-41

SECTION 7 - SCHEMATICS

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

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

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

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1-1. 600S Lug Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11 1-3. Lubrication Point Location - S Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12 1-4. Lubrication Point Location - A Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15 1-5. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17 2-1. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 2-2. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 2-3. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 2-4. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 2-5. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8 2-6. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 2-7. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 2-8. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 2-9. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 2-10. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 2-11. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 2-12. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 2-13. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12 2-14. Engine Operating Temperature Specifications - Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16 2-15. Engine Operating Temperature Specifications - Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17 2-16. Engine Operating Temperature Specifications - Caterpillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18 3-1. Torque Hub, Drive (Fairfield). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 3-2. Torque Hub, Drive (Auburn Gear). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 3-3. Main Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 3-4. Input Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 3-5. Planet Gear Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 3-6. Input Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 3-7. Planet Gear Subassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 3-8. Hub Spindle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 3-9. Spindle Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 3-10. Coupling Subassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19 3-11. Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 3-12. Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 3-13. Bearing Cup Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 3-14. Seal Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 3-15. Bearing Cup Pressing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 3-16. Drift Pin for Lining Up Thrust Washers with Output Planet Gear . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 3-17. Drive Brake Assembly (Mico) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 3-18. Disconnecting the Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 3-19. 600S Drive Motor Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 3-20. Flow Control Pilot Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36 3-21. Drive Motor Adjustment (S Models Prior to S/N 75606). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38 3-22. Oscillating Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 3-23. Brake Valve Wiring Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39 3-24. Drive Manual Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40 3-25. Steer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41 3-26. Swing Torque Hub Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42 3-27. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42 3-28. Swing Bearing Tolerance Boom Placement (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43 3-29. Swing Bearing Tolerance Boom Placement (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44 3-30. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45 3-31. Swing Bearing Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46 3-32. Swing Brake Assembly (Mico) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48 3-33. Tilt Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49

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TITLE

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3-34. Rotary Coupling - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50 3-35. Rotary Coupling - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51 3-36. Rotary Coupling Port Location - 2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52 3-37. Rotary Coupling Port Location - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53 3-38. Addco Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61 3-39. Malfunction Indicator Light and Test Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67 3-40. EFI Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-70 3-41. Typical Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-74 3-42. Ford LPG System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-79 3-43. Deutz Sensors for JLG Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-82 4-1. Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-2. Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 4-3. Location and Thickness of Wear Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 4-4. Location of Components - Platform Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 4-5. Location of Components - Rotator and Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 4-6. Location of Components - Boom Powertrack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 4-7. Boom Assembly Cutaway - S Models - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 4-8. Boom Assembly Cutaway - S Models - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 4-9. Boom Assembly Cutaway - S Models - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 4-10. Disassembly of Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 4-11. Disassembly Wire Rope Routing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 4-12. Dimension of Sheaves When New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 4-13. Routing Installation of Retract Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 4-14. Boom Powertrack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 4-15. Reassembly of Components - Boom Powertrack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 4-16. Reassembly of Components - Rotator and Slave Leveling Cylinder . . . . . . . . . . . . . . . . . . . . . . .4-14 4-17. Location of Components - Boom Powertrack (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 4-18. Location of Components - Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 4-19. Location of Components - Tower Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 4-20. Location of Components - Tower Boom Powertrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 4-21. Location of Components - Articulating Jib Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20 4-22. Limit Switches Adjustments (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 4-23. Limit Switches Adjustments (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 4-24. Platform Section Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 4-26. Removing Portion of End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 4-27. Heating Setscrew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 4-28. Removing Setscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24 4-25. Rotator Assembly (Helac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 4-29. Removing End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 4-30. Removing Shaft from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 4-31. Removing Sleeve from Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 4-32. Actuator Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 4-33. Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28 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. Composite 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 5-10. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5-11. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

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TABLE OF CONTENTS (Continued)

LIST OF FIGURES (continued)

FIGURE NO.

TITLE

PAGE NO.

5-12. Seating the Tapered Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 5-13. Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 5-14. Boom Positioning and Support, Cylinder Repair (S Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 5-15. Location of Components - Telescope and Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 5-16. Leveling Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 5-17. Overriding the Plunger Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13 5-18. Boom Positioning and Support, Cylinder Repair (A Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 5-19. Tower Telescope Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 5-20. 600S Axle Lockout Cylinder (Prior to S/N 75606). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 5-21. 600S Axle Lockout Cylinder (S/N 75606 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 5-22. 600S, 600SJ, 660SJ & 600A Level Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19 5-23. 600S Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 5-24. 600S & 600A Jib Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 5-25. 600S & 600A Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22 5-26. 600S & 600A Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23 5-27. 600S Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 5-28. 600A Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25 5-29. 600A Level (Upright) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-26 5-30. 600A Main Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 5-31. 600A Tower Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28 5-32. 600A Main Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29 5-33. 600A Main Boom Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 5-34. Troubleshooting - Neutral Difficult or Impossible to Find. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32 5-35. Troubleshooting - System Operating Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32 5-36. Troubleshooting - Transmission Operates in One Direction Only . . . . . . . . . . . . . . . . . . . . . . . . .5-33 5-37. Troubleshooting - System Response is Sluggish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 5-38. Troubleshooting - System Will Not Operate in Either Direction . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35 5-39. Variable Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38 5-40. Articulating Jib Boom Pressure Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43 5-41. Main Control Valve Pressure Adjustments - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-44 5-42. Main Control Valve Pressure Adjustments - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45 5-43. Location of Components - Main Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-46 6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6-2. ADE Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 6-3. Analyzer Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 6-4. Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 6-5. Analyzer Flow Chart - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 6-6. Analyzer Flow Chart - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 6-7. Analyzer Flow Chart - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11 6-8. Analyzer Flow Chart - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12 7-1. Electrical Harness - S Models (Prior to S/N 61927) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . .7-2 7-2. Electrical Harness - S Models (Prior to S/N 61927) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . .7-3 7-3. Electrical Harness - S Models (S/N 61927 to S/N 63909) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . .7-4 7-4. Electrical Harness - S Models (S/N 61927 to S/N 63909) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . .7-5 7-5. Electrical Harness - S Models (S/N 63909 to 75606) - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . .7-6 7-6. Electrical Harness - S Models (S/N 63909 to 75606) - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . .7-7 7-7. Electrical Harness - S Models (S/N 75606 to Present) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . .7-8 7-8. Electrical Harness - S Models (S/N 75606 to Present) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . .7-9 7-9. Electrical Harness - A Models (Prior to S/N 61927) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . .7-10 7-10. Electrical Harness - A Models (Prior to S/N 61927) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . .7-11 7-11. Electrical Harness - A Models (S/N 64249 to S/N 64270) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . .7-12 7-12. Electrical Harness - A Models (S/N 64249 to S/N 64270) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . .7-13 7-13. Electrical Harness - A Models (S/N 64270 to Present) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . .7-14 7-14. Electrical Harness - A Models (S/N 64270 to Present) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . .7-15

– JLG Lift –

3120718

TABLE OF CONTENTS

LIST OF FIGURES (continued)

FIGURE NO.

TITLE

PAGE NO.

7-15. Electrical Schematic - Deutz or Continental Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . .7-16 7-16. Electrical Schematic - Deutz or Continental Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . .7-17 7-17. Electrical Schematic (NCW) - Deutz or Continental Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . .7-18 7-18. Electrical Schematic (NCW) - Deutz or Continental Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . .7-19 7-19. Electrical Schematic - Ford LRG Engine - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 7-20. Electrical Schematic - Ford LRG Engine - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21 7-21. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22 7-22. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23 7-23. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24 7-24. Electrical Schematic (NCW) - Ford LRG Engine - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 7-25. Electrical Schematic - UL - Ford LRG Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 7-26. Electrical Schematic - UL - Ford LRG Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27 7-27. Electrical Schematic - UL - Ford LRG Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28 7-28. Electrical Schematic - UL - Ford LRG Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29 7-29. Electrical Schematic - UL Domestic -Deutz Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30 7-30. Electrical Schematic - UL Domestic -Deutz Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31 7-31. Electrical Schematic - UL Domestic - LP Gas Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 7-32. Electrical Schematic - UL Domestic - LP Gas Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 7-33. Electrical Schematic - UL Domestic - LP Gas Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 7-34. Electrical Schematic - UL Domestic - LP Gas Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 7-35. Electrical Schematic - ADE w/External Tilt - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36 7-36. Electrical Schematic - ADE w/External Tilt - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37 7-37. Electrical Schematic - Isuzu Engine - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38 7-38. Electrical Schematic - Isuzu Engine - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39 7-39. Electrical Schematic - Isuzu Engine - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 7-40. Electrical Schematic - Isuzu Engine - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41 7-41. Electrical Schematic - ADE - Sheet 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42 7-42. Electrical Schematic - ADE - Sheet 2 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43 7-43. Electrical Schematic - ADE - Sheet 3 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 7-44. Electrical Schematic - ADE - Sheet 4 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45 7-45. Hydraulic Schematic - S Models - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46 7-46. Hydraulic Schematic - S Models - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47 7-47. Hydraulic Schematic - S Models - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-48 7-48. Hydraulic Schematic - S Models - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-49 7-49. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . .7-50 7-50. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . .7-51 7-51. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . .7-52 7-52. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . .7-53 7-53. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . .7-54 7-54. Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . .7-55 7-55. Hydraulic Schematic - A Models - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-56 7-56. Hydraulic Schematic - A Models - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57 7-57. Hydraulic Schematic - A Models - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58 7-58. Hydraulic Schematic - A Models - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59

3120718

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TABLE OF CONTENTS (Continued)

LIST OF TABLES

TABLE NO.

TITLE

PAGE NO.

1-1 Function Speeds (In Seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 1-2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 1-3 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 1-4 Mobil DTE 13M Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6 1-5 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7 1-6 Cylinder Specifications (S Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 1-7 Cylinder Specifications (A Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8 1-8 Major Component Weights (S Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 1-9 Major Component Weights (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 1-10 Critical Stability Weights (S Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 1-11 Critical Stability Weights (A Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 1-12 Lubrication Chart - S Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13 1-13 Lubrication Chart - A Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16 2-1 Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2-3 Inspection and Preventive Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13 3-1 Coupling Port Information Table - 2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49 3-2 Coupling Port Information Table - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49 3-3 Position Controller Truth Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61 3-4 ECM Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68 4-1 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 4-2 Flow Control Card Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 4-3 Flow Control Card Ramp Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29 5-1 Cylinder Head and Tapered Bushing Torque Specifications. (S Models) . . . . . . . . . . . . . . . . . . .5-8 5-2 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 5-3 Cylinder Head and Tapered Bushing Torque Specifications. (A Models) . . . . . . . . . . . . . . . . . . .5-8 6-1 Personality Ranges/Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 6-2 Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66437. . . . . . . . . . . . . . . . .6-16 6-3 Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present . . . . . . . . . . . . . .6-20 6-4 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 6-5 Fault Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35 6-6 Adjustments - Personality Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41 6-7 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-44

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3120718

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 CAPACITIES

Fuel Tank

39 US. Gallons (147.6 l). (S Models)

30 U.S. Gallons (113.6 l). (A Models)

Hydraulic Oil Tank

Gasoline/Diesel Power - 31 U.S. Gallons (117.3 l) with 10% air space (S Models) - 30.6 Gallons (115.8 l) with 10% air space (A Models).

Hydraulic System (Including Tank)

Gasoline/Diesel Power - 37.2 U.S. Gallons (140.8 l) S Models 36.72 U.S. Gallons (139 l) A Models.

Torque Hub, Drive

17 ounces (0.50 l).

NOTE: Torque hubs should be one half full of lubricant.

Engine Crankcase

Ford LRG-425 Gas w/Filter - 4.5 quarts (4.25 l). Ford LRG-423 Gas w/Filter - 5.00 quarts (4.73 l). Deutz F4M1011F Diesel w/Filter - 11 quarts (10.5 l).

Continental TMD27 Diesel w/Filter - 7.00 quarts (6.65 l). Caterpillar 3044C Diesel w/Filter - 10.6 quarts (10 L)

1.2 COMPONENT DATA

Engine - Ford LRG-425

Fuel - Gasoline.

Oil Capacity.

4.5 Quarts (4.25 l) w/Filter. Idle RPM - 1000.

Low RPM - 1800.

High RPM - 2800.

Alternator - 40 Amp, Belt Drive.

Battery - 85 Amphour, 550 Cold Cranking Amps, 12 VDC.

Fuel Consumption.

Low RPM - 3.45 GPH (13.06 lph).

High RPM - 4.60 GPH (17.41 lph).

Horsepower - 54 @ 2400 RPM, full load.

Cooling System - 16 Quarts (15.14 l.).

Spark Plug - AWSF-52-C

Spark Plug Gap - 0.044 in. (1.117 mm)

Engine - Ford LRG-423

Fuel - Gasoline.

Oil Capacity.

5.00 Quarts (4.73 l) w/Filter.

4.00 Quarts (3.79 l) w/o Filter. Idle RPM - 1000.

Low RPM - 1800.

High RPM - 2800.

Alternator - 40 Amp, Belt Drive.

Battery - 85 Amphour, 550 Cold Cranking Amps, 12 VDC.

Fuel Consumption.

Low RPM - 3.45 GPH (13.06 lph).

High RPM - 4.60 GPH (17.41 lph).

Horsepower - 54 @ 2400 RPM, fill load.

Cooling System - 16 Quarts (15.14 l.).

Engine - Deutz F4M1011F

Fuel - Diesel.

Oil Capacity.

5 Quarts (4.5 l) Cooling System.

11 Quarts (10.5 l) w/Filter.

16 Quarts (15 l) Total Capacity. Idle RPM - 1000

Low RPM - 1800.

High RPM - 2800.

Alternator - 60 Amp, belt drive.

Battery - 1000 Cold Cranking Amps, 210 Minutes

Reserve Capacity, 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.

3120718

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1-1

SECTION 1 - SPECIFICATIONS

Engine - Continental TMD27

Fuel - Diesel.

Oil Capacity.

7.00 Quarts (6.65 l) w/Filter.

6.00 Quarts (5.7 l) w/o Filter. Low RPM - 1800.

High RPM - 2800.

Alternator - 63 Amps, Belt Drive.

Battery - 85 Amphour, 550 Cold Cranking Amps, 12 VDC.

Fuel Consumption.

Low RPM - 1.80 GPH (6.81 lph).

High RPM - 2.30 GPH (8.71 lph).

Horsepower - 66.5 @ 3000 RPM.

Coolant - 3.8 Gallons (3.6 l).

Engine - Caterpillar 3044C

Type - Four Stroke Cycle

Cylinders - 4 in-line

Bore - 3.70 inch (94 mm)

Stroke - 4.72 inch (120 mm)

Aspiration - turbocharged

Compression ratio - 19:1

Displacement - 203 in3 (3.33 L)

Firing Order - 1-3-4-2

Rotation (viewed from flywheel) - Counterclockwise Oil Capacity (w/filter) - 10.6 quarts (10 L)

Cooling System (Engine Only) - 5.8 quarts (5.5 L)

Drive System (S Models)

Tires - 15 x 19.5, G 14 ply rating, directional tread, pneumatic, tire pressure -95 PSI (6.5 Bar).

Drive Motor Displacement.

Standard - 2.8 cu. in. max. 1.1 cu. in. min.

(46 cm3] max. 18 cm3] min.).

Drive Hub Ratio.

Standard - 53.58:1 (2WD).

Standard - 43:1 (4WD).

Drive Brake - Automatic spring applied, hydraulically released disc brakes.

Drive System (A Models)

Tires - 14 x 17.5 NHS, G 14 ply rating, directional tread, pneumatic, tire pressure - 90 PSI (6 Bar).

Tires - 14 x 17.5, Super Heavy Duty (Airboss),

non directional tread. (n Models)

Drive Motor Displacement.

Standard - 2.8 cu. in. max. 1.1 cu. in. min.

(46 cm3] max. 18 cm3] min.).

Drive Hub Ratio.

Standard - 39.96:1.

Drive Brake - Automatic spring applied, hydraulically released disc brakes.

Tire Pressure - 14 x 17.5 NHS, 90 PSI (6 Bar).

Steer System (S Models)

Tires - 15 x 19.5, G 14 ply rating, directional tread, pneumatic, tire pressure -95 PSI (6.5 Bar).

Tires - 15 x 19.5, G 14 ply rating, directional tread, foam filled.

Toe-in, adjust for 1/4" (6.35 mm) overall.

Steer System (A Models)

Tires - 14 x 17.5 NHS, G 14 ply rating, directional tread, pneumatic.

Tires - 14 x 17.5 NHS, G 14 ply rating, directional tread, foam filled.

Tires - 14 x 17.5, Super Heavy Duty (Airboss).

NOTE: Tie rods are non-adjustable on A Models.

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 - 0.244 cu. in. (14 cm3]).

1-2

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3120718

SECTION 1 - SPECIFICATIONS

DC Motor.

Clockwise Rotation.

Hydraulic Filter - In-line.

Return - Bypass Type.

10 Microns Absolute.

Charge.

10 Microns Absolute.

Hydraulic Strainers (In Tank).

30Microns.

1.3PERFORMANCE DATA

Travel Speed 600S.

2WD - 4.5 MPH (7.25 Km/hr.).

4WD - 4 MPH (6.44 Km/hr.).

Travel Speed 600A.

2WD - 3.6 MPH (5.80 Km/hr.).

4WD - 4 MPH (6.44 Km/hr.).

Gradeability. (2WD) 30%. (4WD) 45%.

Turning Radius (Outside) (S Models)

2WS/2WD - 17 ft. 9 in. (5.41 m). 2WS/4WD - 20 ft. 4.6875 in. (6.21 m). 4WS/2WD - 11 ft. 4 in. (3.45 m). 4WS/4WD - 11 ft. 2.6875 in. (3.42 m).

Turning Radius (Outside) (A Models)

2WS/2WD - 17 ft. 7.625 in. (5.38 m). 2WS/4WD - 18 ft. 2.875 in. (6.22 m). 2WD/4WS - 11 ft. 7.875 in. (3.55 m). 4WS/4WD - 11 ft. 7.50 in. (3.54 m).

Turning Radius (Inside) (S Models)

2WS/2WD - 12 ft. (3.66 m). 2WS/4WD - 14 ft. 3.875 in. (5.25 m). 4WS/2WD - 5 ft. 5 in. (1.65 m). 4WS/4WD - 5 ft. 3.625 in. (1.22 m).

Turning Radius (Inside) (A Models)

2WS/2WD - 10 ft. 10 in. (3.30 m).

2WS/4WD - 11 ft. 10.50 in. (3.62 m). 2WD/4WS - 5 ft. 5.50 in. (1.66 m). 4WS/4WD - 5 ft. 4.50 in. (1.64 m).

Boom Elevation (S Models)

600S - +60 ft. 2 13/16 in. (18.36 m) -6 ft. 1 11/16 in. (1.87 m).

600SJ - +60 ft. 5 3/4 in. (18.43 m) -9 ft. 9 3/16 in. (2.98 m).

660SJ - +66 ft. 7 5/8 in. (20.31 m) -11 ft. 5 1/4 in. (3.49 m).

Boom Elevation (A Models)

600A - +60 ft. 5 3/8 in. (18.42 m) -11 in. (0.28 m).

600AJ - +60 ft. 6 3/4 in. (18.46 m) -2 ft. 8 13/16 in. (0.83 m).

Machine Weight approximately

(600S) - 2WD - 22,000 lbs. (9,979.2 kg). (600SJ) - 2WD - 23,500 lbs. (10,660 kg). (660SJ) - 2WD - 25,500 lbs. (11,567 kg). (600A) - 2WD - 20,700 lbs. (9,390 kg).

(600AJ) - 2WD - 21,100 lbs. (10,025 kg). (600S) - 4WD - 22,510 lbs. (10,211 kg). (600SJ) - 4WD - 23,980 lbs. (10,877 kg). (660SJ) - 4WD - 25,910 lbs. (11,753 kg). (600A) - 4WD - 21,150 lbs. (9594 kg).

(600AJ) - 4WD - 22,295 lbs. (10,113 kg).

Machine Height (Stowed) (S Models)

8 ft. 4.75 in. (2.56 m).

Machine Height (Stowed) (A Models)

8 ft. 3.75 in. (2.53 m).

Machine Length (Stowed) (S Models)

600S/600SJ/660SJ Models

Over Drive Axle - 27 ft. 11.125 in. (8.51 m). Over Drive Axle - 32 ft. 11.75 in. (10.05 m). Over Drive Axle - 35 ft. 2.875 in. (11.40 m).

3120718

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1-3

SECTION 1 - SPECIFICATIONS

Machine Length (Stowed) (A Models)

600A/600AJ Models

Over Drive Axle - 26 ft. 5 in. (8.05 m).

Over Drive Axle - 28 ft. 11.4375 in. (8.82 m).

Machine Width (S Models)

600S/600SJ/660SJ Models 2WS/2WD - 7 ft. 11.375 in. (2.42 m). 2WS/4WD - 7 ft. 11.4375 in. (242 m). 4WS/2WD - 7 ft. 11.4375 in. (2.42 m). 4WS/4WD - 7 ft. 11.375 in. (2.42 m).

Machine Width (A Models)

600A/600AJ Models 2WS/2WD - 8 ft. (2.44 m).

2WS/4WD - 8 ft. 0.50 in. (2.44 m). 2WD/4WS - 8 ft. 0.50 in. (2.44 m). 4WS/4WD - 8 ft. 0.50 in. (2.44 m).

Wheel base (S Models)

8 ft. 1.50 in. (2.48 m).

Wheel base (A Models)

8 ft. 0 in. (2.44 m).

1.4 FUNCTION SPEEDS

Machine Orientation When Doing Speed

Tests

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 and start the test when the turntable is centered up. This eliminates ramp up and down on the controller affecting times.

Telescope: Boom at Full Elevation; Telescope Retracted; Telescope Out, Record Time. Telescope In, Record Time.

Drive (Forward/Reverse): Test should be done on a smooth level surface. Drive Select Switch should be set to High Engine. Start approximately 25 ft. (7.62 m) from the starting point so that the unit is at maximum speed when starting the test. Results should be recorded for a 200 ft. (60.96 m) course. Drive Forward, Record Time. Drive Reverse, Record Time.

Drive (Above Horizontal): Test should be done on a smooth level surface. Drive Select Switch should be set to Low Engine. The boom should be raised above horizontal. Results should be recorded for a 50 ft. (15.24 m) course. Drive Forward, Record Time. Drive Reverse, Record Time.

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.

Test Notes

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.

Table 1-1. Function Speeds (In Seconds)

Function	600S	600A

Lift Up	46-60	26-32

Lift Down	33-43	26-32

Swing Right & Left*	79-101	79-101

Telescope Out	50-67	35-50

Telescope In	25-33	22-30

Platform Rotate Right & Left**	16-25	16-25

Jib Up	22-34	22-34

Jib Down	16-26	16-26

Lower Lift Up	N.A.	37-50

Lower Lift Down	N.A.	28-38

Lower Telescope Out	N.A.	15-23

Lower Telescope In	N.A.	09-15

Drive Forward & Reverse (2WD)	28-33	35-42

Drive Forward & Reverse (4WD)	31-37	31-37

Drive Above Horizontal - Forward &	43-136	43-136
Reverse (2WD & 4WD)

Drive Horizontal - Forward & Reverse	N.A.	84-70

*Max 10% Difference Between Left & Right

**Max 15% Difference Between Left & Right

4150130 - E

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1.5 TORQUE REQUIREMENTS

Table 1-2. Torque Requirements

Description	Torque Value	Interval
Description	(Dry)	Hours
	(Dry)	Hours


Bearing To Chassis	See Note	50/600*

Bearing To Turntable	See Note	50/600*

Wire Rope	15 ft. lbs (20 Nm)	150

Wheel Lugs (S Models)	See Figure 1-1.	150

Wheel Lugs (A Models)	170 ft. lbs. (231 Nm)	150

Engine Mounting Bolts	165 ft. lbs. (231 Nm)	A/R

Engine Manifold Mounting	30 ft. lbs. (42 Nm)	A/R
Bolts

*Check swing bearing bolts for security after first 50 hours of operation and every 600 hours thereafter. (See Swing Bearing in Section 3.)

NOTE: When maintenance becomes necessary or a fastener has loosened, refer to the Torque Chart to determine proper torque value.

Figure 1-1. 600S Lug Torques

1.6 LUBRICATION

Ford LRG423 & LRG425 Engine

Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD).

When Outside
Temperature is	Use SAE Viscosity Number
Consistently
-10°F. to +60°F	*10W
(-24°C. to +16°C.)	*10W
+10°F. to +90°F	*10W
(+12°C. to +32°C.)	20W-20
Above +32°F. (+0°C.)	30
Above +50°F. (+10°C.)	40

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

*Not recommended for severe service, including high RPM operation

When Outside
Temperature is	Use SAE Viscosity Number
Consistently
Below +10°F. (+12°C.)	*5W-20
Below +60°F. (+16°C.)	5W-30
-10°F. to +90°F. (-23°C. to	10W-30
+32°C.)
Above -10°F. (-23°C.)	10W-40 or 10W-50
Above +20°F. (+7°C.)	20W-40 or 20W-50

*Not recommended for severe service, including high RPM operation

NOTE: Crankcase oil must be high quality detergent type meeting API service classification SF, SH, SG.

Deutz F4M1011F Engine

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

When Outside Temperature is	Use SAE Viscosity
Consistently	Number
-20°F. to +25°F. (-29°C. to +4°C.)	*10W
+5°F. to +50°F. (+15°C. to +10°C.)	20W-20
+40°F. to +85°F. (+4°C. to +30°C.)	30
Above 75°F. (24°C.)	40

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

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

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When Outside
Temperature is	Use SAE Viscosity Number
Consistently
-40°F. to +75°F. (-40°C. to	*5W-30 (Synthetic)
+24°C.)
-15°F. to +70°F. (-26°C. to	10W-30
+21°C.)
-15°F. to +85°F. (-26°C. to	10W-40
+30°C.)
Above -5°F. (-21°C.)	15W-40
-5°F. to +75°F. (-21°C. to	15W-30
+24°C.)

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

NOTE: Crankcase oil should be MIL-L2104B/MIL-L2104C or have properties of API classification CC/CD grades.

Continental TMD27 Engine

Single Viscosity Oils (CC-CD).

When Outside
Temperature is	Use SAE Viscosity Number
Consistently
+32°F. to +77°F. (+0°C. to	20
+25°C.)
Above +77°F. (+25°C.)	30
Below +32°F. (+0°C.)	10W

Multi Viscosity Oil (CC-CD)

*Not recommended for severe service, including high RPM operation

When Outside
Temperature is	Use SAE Viscosity Number
Consistently
Below +32°F. (+0°C.)	10W-30

Hydraulic Oil

Table 1-3. Hydraulic Oil

HYDRAULIC SYSTEM
OPERATING	SAE VISCOSITY GRADE
TEMPERATURE RANGE

+0° to +180° F (-18° C to	10W
+83° C)

+0° F to +210° F (-18° C to	10W-20, 10W-30
+99° C)

+50° F to +210° F (+10° C to	20W-20
+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)

	Viscosity
at 40° C		33cSt

at 100° C		6.6 cSt
at 100° F		169 SUS
at 210° F		48 SUS
cp at -20° F		6,200
Viscosity Index		140

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 Kendall Hyken 052 or Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

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Lubrication Specifications

Table 1-5. Lubrication Specifications

KEY	SPECIFICATIONS
MPG	Multipurpose Grease having a mini-
	mum dripping point of 350° F. Excel-
	lent water resistance and adhesive
	qualities, and being of extreme pres-
	sure type.
	(Timken OK 40 pounds minimum.)
EPGL	Extreme Pressure Gear Lube (oil)
	meeting API service classification
	GL-5 or MIL-Spec MIL-L-2105
HO	Hydraulic Oil. API service classifica-
	tion GL-3, e.g. Mobilfluid 424.
EO	Engine (crankcase) Oil. Gas - API SF,
	SH, SG class, MIL-L-2104. Diesel -
	API CC/CD class, MIL-L-2104B/MIL-
	L-2104C.

NOTE: Refer to Lubrication Chart, for specific lubrication procedures.

1.7 PRESSURE SETTINGS

Rexroth Valve (S Models)

Main Relief - 3000 PSI (207 Bar).

Upper Boom Lift Down - 1500 PSI (103 Bar). Swing - 1700 PSI (117 Bar).

Steer - 1800 PSI (124 Bar).

Steer Reliefs - 4WS Front & Rear - 2500 PSI

(172 Bar).

Platform Level Forward - 2800 PSI (193 Bar).

Backward - 1800 PSI (124 Bar).

Articulating Jib Boom Up - 1500 PSI (103 Bar). Down - 1200 PSI (83 Bar).

Rexroth Valve (A Models)

Main Relief - 3000 PSI (206.85 Bar).

Upper Boom Lift Down - 1200 PSI (83 Bar). Swing - 1700 PSI (117.2 Bar).

Platform Level Forward - 2800 PSI (193 Bar).

Backward - 1800 PSI (124 Bar).

Steer - 1800 PSI (124 Bar).

Steer Reliefs - 4WS Front & Rear - 2500 PSI

(172 Bar).

Articulating Jib Boom Up - 1500 PSI (103 Bar). Down - 1200 PSI (83 Bar).

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1.8 CYLINDER SPECIFICATIONS

Table 1-6. Cylinder Specifications (S Models)

DESRIPTON		BORE			STROKE			ROD DIA.


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

Lift	6.00	6.00	6.00	44.6875	44.6875	44.6875	3	3	3
	(152.4)	(152.4)	(152.4)	(1135.1)	(1135.1)	(1135.1)	(76.2)	(76.2)	(76.2)

Telescope	3.5	3.5	3.5	143.1875	168.4375	177.75	2.5	2.5	2.5
	(88.9)	(88.9)	(88.9)	(3637)	(4278.3)	(4514.9)	(63.5)	(63.5)	(63.5)

Steer	2.5	2.5	2.5	10.75	10.75	10.75	1.25	1.25	1.25
	(63.5)	(63.5)	(63.5)	(273.1)	(273.1)	(273.1)	(31.8)	(31.8)	(31.8)

Lockout (2wd)	4	4	4	3.875	3.875	3.875	1.5	1.5	1.5
	(101.6)	(101.6)	(101.6)	(98.4)	(98.4)	(98.4)	(38.1)	(38.1)	(38.1)

Master	3.5	3.5	3	13.0625	13.0625	8.5	1.5	1.5	1.5
	(88.9)	(88.9)	(76.2)	(331.8)	(331.8)	(215.9)	(38.1)	(38.1)	(38.1)

Slave Level	3.5	3.5	3	13.0625	13.0625	8.5	1.5	1.5	1.5
	(88.9)	(88.9)	(76.2)	(331.8)	(331.8)	(215.9)	(38.1)	(38.1)	(38.1)

Lift (Articulating Jib	3	3	N/A	25.5	25.5	N/A	1.5	1.5	N/A
Boom)	(76.2)	(76.2)		(647.7)	(647.7)		(38.1)	(38.1)

Table 1-7. Cylinder Specifications (A Models)

DESRIPTON	BORE	STROKE	ROD DIA.

	600AJ	600A	600AJ	600A	600AJ	600A

Lower Lift	6.5	6.5	34.0625	34.0625	2.5	2.5
	(165.1)	(165.1)	(865.2)	(865.2)	(63.5)	(63.5)

Tower Telescope	3	3	63.75	63.75	2	2
	(76.2)	(76.2)	(1619.3)	(1619.3)	(50.8)	(50.8)

Upright Level	6	6	34.625	34.625	3	3
	(152.4)	(152.4)	(879.5)	(879.5)	(76.2)	(76.2)

Upper Lift	4	4	36.625	36.625	2.5	2.5
	(101.6)	(101.6)	(930.3)	(930.3)	(63.5)	(63.5)

Upper Telescope	3	3	134.375	177.75	2	2
	(76.2)	(76.2)	(3413.1)	(4514.9)	(50.8)	(50.8)

Steer (2WD/2WSl	2.5	2.5	8.812	8.812	1.25	1.25
	(63.5)	(63.5)	(204.7)	(204.7)	(31.8)	(31.8)

Steer (4WD/2WS)	2.5	2.5	10.75	10.75	1.25	1.25
	(63.5)	(63.5)	(273.1)	(273.1)	(31.8)	(31.8)

Lockout (2WD)	3.5	3.5	3.875	3.875	2.5	2.5
	(88.9)	(88.9)	(98.4)	(98.4)	(63.5)	(63.5)

Lockout (4WD	3.5	3.5	3.875	3.875	2.5	2.5
	(88.9)	(88.9)	(98.4)	(98.4)	(63.5)	(63.5)

Master	3.5	3	13.0625	8.5	1.5	1.5
	(88.9)	(76.2)	(331.8)	(215.9)	(38.1)	(38.1)

Slave	3.5	3	13.0625	8.5	1.5	1.5
	(88.9)	(76.2)	(331.8)	(215.9)	(38.1)	(38.1)

Lift (Articulating Jib Boom)	3	N/A	25.5	N/A	1.5	N/A
	(76.2)		(647.7)		(38.1)

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1.9 MAJOR COMPONENT WEIGHTS

Table 1-8. Major Component Weights (S Models)

		600SJ				660SJ				600S


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

Platform Control Console		250	113		250		113		250		113

Platform Level Cylinder		60	27		60		27		46		21

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

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

Chassis Complete (w/pneumatic tires)		11300	5126		11775		5341		10400		4718

Chassis Complete (w/foam-filled tires)		12580	5707		13055		5922		11680		5300

Machine Complete (GVW) - 2WD w/pneumatic tires		23500	10660		25500		11567		22000		9979

Machine Complete (GVW) - 4WD w/pneumatic tires		23980	10877		25910		11753		22510		10211

	Table 1-9. Major Component Weights (A Models)

				600AJ				600A


			LB.		KG.		LB.		KG.

	Platform Control Console		250		113		250		113

	Platform Level Cylinder		60		27		46		21

	Main Boom (Includes Lift Cyl., Rotator, and Support)		1685		764		1832		831

	Upright including Master Cylinder		547		248		547		248

	Upright Level Cylinder		316		143		316		143

	Tower Boom Complete		1218		553		1218		553

	Turntable Complete (including engine)		9740		4418		9240		4191

	Chassis Complete (w/pneumatic tires)		6834		3100		6834		3100

	Chassis Complete (w/foam-filled tires)		7918		3592		7918		3592

	Machine Complete (GVW) - 2WD w/pneumatic tires		22100		10025		20700		9390

	Machine Complete (GVW) - 4WD w/pneumatic tires		22295		10113		21150		9594

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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 & PLAT-

FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Table 1-10. Critical Stability Weights (S Models)

			600SJ		660SJ			600S


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

Tire and Wheel (Ballasted Only)	Size (15 - 19.5)	253		115	253	115	253		115

Engine	Ford	460		209	460	209	460		209

	Deutz	534		242	534	242	534		242

	Continental	558		253	558	253	558		253

Counterweight	Weight	3500		1588	4650	2109	2900		1315

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

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

Table 1-11. Critical Stability Weights (A Models)

			600AJ			600A


		LB.		KG.	LB.		KG.

Tire and Wheel (Ballasted Only)	Size (14-17.5)	165		75	165		75

Engine	Ford	460		209	460		209

	Deutz	534		242	534		242

	Continental	558		253	558		253

Counterweight	Weight	6200		2812	5700		2586

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

	8 ft. (2.44 M)	230		105	230		105

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1.11 SERIAL NUMBER LOCATIONS

the machine serial number is stamped on the left side of

the frame.

A serial number plate is affixed to the left rear side of the

frame. If the serial number plate is damaged or missing,

Figure 1-2. Serial Number Locations

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SECTION 1 - SPECIFICATIONS

Figure 1-3. Lubrication Point Location - S Models

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