JLG 600SC - Service And Maintenance Manual

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Service and Maintenance Manual

Models

600SC

660SJC

SN 0300236299 to Present

PN - 3121776

November 30, 2018 - Rev C

AS/NZS

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Main Page

General3
Bhydraulic System Safety3
Maintenance3
Table of Contents5
Specifications17
Operating Specifications17
Dimensional Data17
Capacities19
Engine Data19
Critical Stability Weights19
Hydraulic Oil20
Torque Requirements21
Maintenance and Lubrication24
General34
Machine Preparation, Inspection, and Maintenance34
Preparation, Inspection, and Maintenance34
Pre-Start Inspection34
Pre-Delivery Inspection and Frequent Inspection34
Annual Machine Inspection34
Preventive Maintenance34
Service and Guidelines35
General35
Safety and Workmanship35
Cleanliness35
Components Removal and Installation35
Component Disassembly and Reassembly36
Pressure-Fit Parts36
Bearings36
Gaskets36
Bolt Usage and Torque Application36
Hydraulic Lines and Electrical Wiring36
Hydraulic System36
Lubrication37
Battery37
Lubrication and Servicing37
Lubrication and Information37
Hydraulic System37
Hydraulic Oil37
Changing Hydraulic Oil37
Lubrication Specifications37
Cylinder Drift38
Theory38
Cylinder Leakage Test38
Cylinder Thermal Drift38
Pins and Composite Bearing Repair Guidelines39
Welding on JLG Equipment39
Do the Following When Welding on JLG Equipment39
Do NOT Do the Following When Welding on JLG Equipment39
Chassis & Turntable47
Chassis Components and Servicing47
Service Notes48
Track and Chain50
Replace Track51
Track Tensioning52
Rubber Track Pad Installation52
Rollers55
Idler Roller Assembly58
Swing Drive Hub59
Removal59
Assembly/Disassembly59
Installation59
Procedure for Setting Swing Gear Backlash60
Swing Drive Lubrication60
Swing Bearing61
Turntable Bearing Mounting Bolt Condition Check61
Wear Tolerance61
Swing Bearing Replacement63
Swing Bearing Torque Values64
Rotary Coupling67
Assembly/Disassembly67
Deutz TD2.9 L4 Engine70
Check Oil Level74
Change Engine Oil74
Change Oil Filter74
Change Fuel Filters75
Spark Arrester Cleaning Instructions75
Glow Plugs75
Deutz D2011L04 Engine97
Checking Oil Level101
Changing Engine Oil101
Changing Oil Filter102
Replace Fuel Filter102
Clean Fuel Strainer103
Spark Arrester Cleaning Instructions103
Glow Plugs103
Deutz TD 2.9 L4 GUO III Engine108
Counterweight112
Generator114
Every 250 Hours114
Every 500 Hours114
Overload Protection114
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings115
Boom & Platform117
Transport Position Sensing System117
Beyond Transport - Drive Speed Cutback System117
Dual Capacity System117
Platform Load Sensing System117
Electronic Platform Leveling117
Fuel Level Cutout System118
Platform118
Support Removal118
Support Installation119
Rotator and Slave Cylinder121
Removal121
Assembly/Disassembly121
Installation121
Main Boom Assembly123
Removal123
Boom Disassembly125
Assembly128
Installation131
Main Boom Lift Cylinder132
Removal132
Installation132
Main Boom Powertrack133
Installation133
Wire Rope136
Inspection136
Three Month Inspection137
Additional Inspection Required if137
Year or 7000 Hour Replacement137
Additional Replacement Criteria137
Wire Rope Tensioning Adjustment137
Wire Rope Tensioning Procedure137
Wire Rope Service Indicator138
Jib (if Equipped)138
Boom Cleanliness Guidelines139
Foot Switch Adjustment140
Platform Control Enable System140
Powertrack Maintenance141
Remove Link141
Install New Link144
Replace Fixed End Brackets147
Replace Moving End Brackets148
Skyguard150
Operation150
Function Test150
Diagnostics & Troubleshooting151
Basic Hydraulics Information & Schematics153
Lubricating O-Rings in the Hydraulic System153
Cup and Brush153
Dip Method154
Spray Method154
Brush-On Method154
Hydraulic Connection Assembly and Torque Specification155
Tapered Thread Types155
Straight Thread Types, Tube and Hose Connections155
Straight Thread Types, Port Connections156
Flange Connection Types156
Tightening Methods156
Assembly and Torque Specifications157
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections158
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections159
Assembly Instructions for 37° (JIC) Flare Fittings160
Assembly Instructions for 45° SAE Flare Fittings163
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings165
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)167
Assembly Instructions for Bulkhead (BH) Fittings169
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings179
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends186
Assembly Instructions for Adjustable Port End (BSPP) Fittings188
Assembly Instructions for Flange Connections: (FL61 and FL62)195
Double Wrench Method198
FFWR and TFFT Methods199
Adjustable Stud End Assembly199
O-Ring Installation (Replacement)200
Cylinder Locations201
Main Lift Cylinder202
Telescope Cylinder207
Platform Level (Slave) Cylinder213
Jib Lift Cylinder (660SJC Only)219
Hydraulic Pump (Gear)224
Removal224
Assembly/Disassembly224
Installation224
Variable Pump225
Removal225
Assembly/Disassembly225
Installation225
Load Sense Compensator226
Main Relief Valve226
Load Sense Relief Valve226
Turntable Swing Relief Valve226
Load Sense Compensator227
Main Relief Valve227
Load Sense Relief Valve227
Turntable Swing Relief Valve227
Main High Pressure Relief Valve229
Low Pressure Relief Valve229
Platform Jib down Relief Valve229
Hydraulic Schematics235

JLG 600SC - Service And Maintenance Manual

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