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600A
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INTRODUCTION
A-2
ā JLG Li
ft ā
3
121201
REVISON L
O
G
Original Issue
- October 15, 2004
Revised
- June 10, 2005
Revised
- October 6, 2005
Revised
- March 2, 2006
Revised
- December 4, 2007
Revised
- April 1, 2008
Revised
- December 10, 2012
3
5
Table of Contents
Main Page
Default Chapter
3
Ageneral
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications
17
Operating Specifications
17
Capacities
17
Component Data
17
Engine Data
17
Deutz F4M2011 Specifications
18
Tires
19
Drive System
19
Swing System
19
Pumps
19
Hydraulic Filters
19
Dimensional Data
19
Function Speeds
20
Machine Orientation When Doing Speed Tests
20
Test Notes
20
Torque Requirements
20
Lubrication
21
Hydraulic Oil
21
Pressure Settings
21
Cylinder Specifications
21
Major Component Weights
22
Critical Stability Weights
23
Serial Number Locations
23
Lubrication & Maintenance
24
Deutz Engine Dipstick
27
Draining Oil Build up from the Propane Regulator
28
Propane Fuel Filter Replacement
29
Propane Fuel System Pressure Relief
30
Torque Chart (SAE Fasteners - Sheet 1 of 7)
31
Torque Chart (SAE Fasteners - Sheet 2 of 7)
32
Torque Chart (SAE Fasteners - Sheet 3 of 7)
33
Torque Chart (SAE Fasteners - Sheet 4 of 7)
34
Torque Chart (METRIC Fasteners - Sheet 5 of 7)
35
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
36
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
37
Section 2 - General
39
Machine Preparation, Inspection, and Maintenance
39
General
39
Preparation, Inspection, and Maintenance
39
Pre-Start Inspection
39
Pre-Delivery Inspection and Frequent Inspection
39
Annual Machine Inspection
39
Preventative Maintenance
39
Service and Guidelines
40
General
40
Safety and Workmanship
40
Cleanliness
40
Components Removal and Installation
40
Component Disassembly and Reassembly
41
Pressure-Fit Parts
41
Bearings
41
Gaskets
41
Bolt Usage and Torque Application
41
Hydraulic Lines and Electrical Wiring
41
Hydraulic System
41
Lubrication
41
Battery
41
Lubrication and Servicing
41
Hydraulic Oil
42
Changing Hydraulic Oil
42
Lubrication Specifications
42
Cylinder Drift Test
42
Platform Drift
42
Cylinder Drift
43
Pins and Composite Bearing Repair Guidelines
43
Welding on JLG Equipment
43
Do the Following When Welding on JLG Equipment
43
Do NOT Do the Following When Welding on JLG Equipment
43
Inspection and Preventive Maintenance Schedule
44
Engine Operating Temperature Specifications - Deutz
47
Engine Operating Temperature Specifications - Ford
48
Engine Operating Temperature Specifications - Caterpillar
49
Engine Operating Temperature Specifications - GM
50
Section 3 - Chassis & Turntable
51
Tires & Wheels
51
Tire Inflation
51
Tire Damage
51
Wheel and Tire Replacement
51
Wheel Installation
51
Drive Torque Hub
52
Roll, Leak and Brake Testing
52
Tightening and Torquing Bolts
53
Main Disassembly
53
Main Disassembly
54
Input Carrier
55
Planet Gear Sub Assembly
56
Input Carrier Disassembly
57
Hub-Spindle Disassembly
58
Spindle-Brake Disassembly
59
Coupling Subassembly
60
Cover Disassembly
61
Input Carrier Sub-Assembly
62
Output Planet Gear Sub-Assembly
62
Spindle - Brake Sub-Assembly
62
Hub-Spindle Sub-Assembly
63
Cover Sub-Assembly
64
Main Assembly
64
Integral Brake Check
64
Hub Assembly
65
Bearing Cup Pressing Tool
66
Bearing Cup Pressing Tool
67
Drive Brake - Mico (S/N 56718 to 81836)
68
Disassembly
68
Assembly
68
Drive Brake - Mico
69
Bleeding
70
Free Wheeling Option
71
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, Etc
71
To Engage Drive Motors and Brakes (Normal Operation)
71
Drive Motor - 4WD (Prior to S/N 81836)
71
Spare Parts Kits
71
Replacing the Drive Shaft Seal
73
Disassembly and Assembly
74
Assembly Notes
77
Flow Control Pilot Valves
78
Taper Roller Bearing Initial Tension
79
Testing and Setup
79
Drive Motor - 2WD (Prior to S/N 81836)
80
Shaft Seal Replacement
80
Drive Motor (S/N 81836 to Present)
80
Description
80
Shaft Seal Replacement
81
Troubleshooting
82
Loop Flushing Valve
83
Disassembly
84
End Cap
85
Cylinder Kit
86
Swash Plate & Servo Piston
87
Inspection
88
Assembly
90
Cylinder Kit Assembly
91
Shaft and Front Bearing
92
Valve Plate and Rear Bearing
93
Shaft Seal
94
Initial Start-Up Procedures
95
Oscillating Axle Bleeding Procedure and Lockout Test
96
Lockout Cylinder Bleeding
96
Oscillating Axle Lockout Test
96
Swing Hub
97
Adjustment Procedures
97
Disassembly
98
Main Assembly Procedure
98
Hub Shaft Sub-Assembly
101
Carrier Sub-Assembly
103
Swing Bearing
106
Turntable Bearing Mounting Bolt Condition Check
106
Wear Tolerance
106
Swing Bearing Replacement
108
Swing Bearing Torque Values
109
Swing Brake - Mico
110
Disassembly
110
Inspection
110
Assembly
110
Swing Brake Assembly (Mico)
111
Rotary Coupling - S/N 81836 to Present
112
Rotary Coupling - Sheet 1 of 2
113
Rotary Coupling - Sheet 2 of 2
114
Rotary Coupling Port Location - 2WS
115
Rotary Coupling Port Location - 4WS
116
Generator
117
Every 250 Hours
117
Every 500 Hours
117
Overload Protection
117
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
117
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
118
Spark Arrester Cleaning Instructions
119
Dual Fuel System
119
Changing from Gasoline to LP Gas
119
Changing from LP Gas to Gasoline
119
Ford EFI Engine
119
Performing Diagnostics
119
Ecm and Sensors
120
ECM Diagnostic Trouble Codes
121
Fuel System
126
Typical Fuel System
127
Ford LPG System
131
Description
131
Regulator
131
Megajector
131
Mixer
131
Lockoff Solenoid
133
Megajector Diagnostic Code Descriptions
133
Deutz Sensors for JLG Control System
135
Deutz EMR 2 (S/N 84711 to Present)
136
EMR 2 Engine Side Equipment
137
EMR 2 Engine Plug Pin Identification
142
EMR 2 Vehicle Plug Pin Identification
143
GM Engine General Maintenance
149
Maintenance of the Drive Belt
149
Engine Electrical System Maintenance
149
Checking/Filling Engine Oil Level
149
Changing the Engine Oil
150
Coolant Fill Procedure - Dual Fuel Engine
150
GM Engine Dual Fuel System
151
Fuel Filter
152
Electric Lock off
152
EPR Assembly
152
Low Pressure Regulator (LPR)
153
Air Fuel Mixer
153
Electronic Throttle Control (ETC)
154
Engine Control Module
154
Heated Exhaust Gas Oxygen Sensor
155
Gasoline Multi Point Fuel Injection System (MPFI)
155
Gasoline Fuel Pump
155
Gasoline Pressure and Temperature Sensor Manifold
155
Fuel Filter
156
Fuel Injector Rail
156
Fuel Injector
156
GM Engine Fuel System Repair
156
Propane Fuel System Pressure Relief
156
Propane Fuel System Leak Test
156
Propane Fuel Filter Replacement
157
Electronic Pressure Regulator (EPR) Assembly Replacement
157
Pressure Regulator Section
158
Temperature Manifold Absolute Pressure (TMAP) Sensor
159
Electronic Throttle Control Replacement
159
Mixer Replacement
160
Coolant Hose Replacement
161
Vapor Hose Replacement
161
Engine Control Module Replacement
161
Heated Exhaust Gas Oxygen Sensor Replacement
161
LP Gas Fitting Inspection
162
GM Engine LPG Fuel System Diagnosis
163
Fuel System Description
163
Diagnostic Aids
163
LPF Fuel System Diagnosis
164
Symptom Diagnosis
167
DTC to SPN/FMI Cross Reference Chart
175
Section 4 - Boom & Platform
177
Wear Pads
177
Tower Boom
177
Main Boom
177
Boom Powertrack Installation
178
Boom Maintenance
179
Removal
179
Disassembly of Boom Sections
180
Inspection
180
Assembly
181
Installation
181
Tower Boom
182
Removal
182
Disassembly
183
Inspection
184
Assembly
184
Installation
185
Boom Cleanliness Guidelines
185
Articulating Jib Boom
186
Removal
186
Disassembly
186
Inspection
186
Assembly
186
Limit Switches and Cam Valve Adjustment
187
Boom Limit Switch Adjustments
188
Fiberglass Bar Installation
189
Platform
190
Platform Sections Replacement
190
Rotator - Helac (Prior to S/N 0300132474)
190
Disassembly
190
Rotator Assembly (Helac)
191
Inspection
192
Assembly
192
Rotary Actuator (S/N 0300132474 to Present)
193
Theory of Operation
193
Required Tools
194
Rotary Actuator - Exploded View
195
Rotary Actuator - Assembly Drawing
196
Disassembly
197
Inspection
201
Assembly
201
Installing Counterbalance Valve
206
Testing the Actuator
207
Installation and Bleeding
207
Troubleshooting
208
Foot Switch Adjustment
209
Boom Synchronizing Procedure
209
Section 5 - Hydraulics
211
Lubricating O-Rings in the Hydraulic System
211
Cup and Brush
211
Dip Method
212
Spray Method
212
Brush-On Method
212
Cylinders - Theory of Operation
213
Systems Incorporating Double Acting Cylinders
213
Systems Incorporating Holding Valves
213
Cylinder Checking Procedure
213
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
213
Cylinders with Single Counterbalance Valve
213
Cylinders with Dual Counterbalance Valves
214
Cylinder Repair
214
Disassembly
214
Cylinder Barrel Support
215
Cleaning and Inspection
216
Assembly
217
Piston Seal Kit Installation
218
Seating the Tapered Bearing
219
Cylinder Removal and Installation
220
Main Boom Telescope Cylinder Removal
220
Main Boom Telescope Cylinder Installation
220
Main Boom Lift Cylinder Removal
221
Main Boom Lift Cylinder Installation
222
Upright Level Cylinder Removal
222
Boom Positioning and Support, Cylinder Repair
223
Upright Level Cylinder Installation
224
Tower Boom Lift Cylinder Removal
225
Tower Lift Cylinder Installation
226
Tower Telescope Cylinder Removal
226
Tower Telescope Cylinder Installation
226
Axle Lockout Cylinder
227
Level Cylinder
228
Jib Lift Cylinder
229
Master Cylinder
230
Steer Cylinder
231
Level (Upright) Cylinder
232
Main Boom Lift Cylinder
233
Tower Boom Lift Cylinder
234
Main Boom Telescope Cylinder
235
Tower Boom Telescope Cylinder
236
Variable Displacement Pump (M46 Series)
237
Troubleshooting
237
Troubleshooting - System Operating Hot
238
Troubleshooting - System Response Is Sluggish
239
Inspections and Adjustments
240
Minor Repair and Replacement
243
Valves - Theory of Operation
247
Solenoid Control Valve - Rexroth
247
Relief Valves
247
Pressure Setting Procedures
248
Main Relief, Steer, Swing and Lift down
248
Platform Level
248
Articulating Jib Boom (if Equipped)
248
Main Control Valve Pressure Adjustments - Sheet 1 of 2
249
Main Control Valve Pressure Adjustments - Sheet 2 of 2
250
Location of Components - Main Control Valve
251
Wheel Steer (if Equipped)
252
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
253
Section 6 - Jlg Control System
255
Introduction
255
ADE Block Diagram
256
Using the Analyzer
257
To Connect the JLG Control System Analyzer
257
Analyzer Connecting Points
258
Changing the Access Level of the Hand Held Analyzer
259
Control Module Location
260
Adjusting Parameters Using the Hand Held Analyzer
261
Machine Setup
262
Level Vehicle Description
262
Machine Personality Settings
271
Help Fault Codes, Displayed Faults, and Descriptions
274
Machine Configuration Programming Information Prior to Software Version P5.3
285
Machine Configuration Programming Information Software Version P5.3 to P6.1
289
Machine Configuration Programming Information Software Version P6.1 to Present
294
Analyzer Fault Code Listing
302
Analyzer Diagnostics Menu Structure
310
Diagnostic Menu Descriptions
313
Section 7 - Basic Electrical Information & Schematics
315
General
315
Multimeter Basics
315
Grounding
315
Backprobing
315
Min/Max
315
Polarity
315
Scale
315
Voltage Measurement
315
Resistance Measurement
316
Continuity Measurement
316
Current Measurement
317
Applying Silicone Dielectric Compound to Electrical Connections
317
AMP Connector
318
Applying Silicone Dielectric Compound to AMP Connectors
318
Assembly
318
Connector Assembly Figure 2
319
Disassembly
320
Wedge Lock
320
Service - Voltage Reading
320
Connector Installation
321
Deutsch Connectors
322
DT/DTP Series Assembly
322
DT/DTP Series Disassembly
322
HD30/HDP20 Series Assembly
323
HD30/HDP20 Series Disassembly
323
Electrical Harness - S/N 80000 to 87000 - Sheet 1 of 2
324
Electrical Harness - S/N 80000 to 87000 - Sheet 2 of 2
325
Electrical Harness - S/N 87000 to Present - Sheet 1 of 2
326
Electrical Harness - S/N 87000 to Present - Sheet 2 of 2
327
Electrical Schematic - ADE - Sheet 1 of 6
328
Electrical Schematic - ADE - Sheet 2 of 6
329
Electrical Schematic - ADE - Sheet 3 of 6
330
Electrical Schematic - ADE - Sheet 4 of 6
331
Electrical Schematic - ADE - Sheet 5 of 6
332
Electrical Schematic - ADE - Sheet 6 of 6
333
Hydraulic Schematic - Sheet 1 of 6
334
Hydraulic Schematic - Sheet 2 of 6
335
Hydraulic Schematic - Sheet 3 of 6
336
Hydraulic Schematic - Sheet 4 of 6
337
Hydraulic Schematic - Sheet 5 of 6
338
Hydraulic Schematic - Sheet 6 of 6
339
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