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JLG
Lifting Systems
E600
Page 4
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Manual
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INTRODUCTION
A-2
ā JLG Li
ft ā
31218
13
REVISON L
OG
Original Issue
- August 10, 2000
Revised
- November 22, 2000
Revised
- April 15, 2003
Revised
- F
ebruary 11, 2008
Revised
- December 18, 2012
3
5
Table of Contents
Main Page
Default Chapter
3
A General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Section 1 - Specifications
15
Capacities
15
Operating Specifications
15
Generator
15
Battery Charger
15
Drive/Steer System
15
Tires
15
Function Speeds
16
Machine Orientation When Doing Speed Tests
16
Test Notes
16
Pressure Settings
16
Torque Requirements
17
Major Component Weights
17
Serial Number Location
17
Hydraulic Oil
18
Operator Maintenance
19
Torque Chart (SAE Fasteners - Sheet 1 of 7)
22
Torque Chart (SAE Fasteners - Sheet 2 of 7)
23
Torque Chart (SAE Fasteners - Sheet 3 of 7)
24
Torque Chart (SAE Fasteners - Sheet 4 of 7)
25
Torque Chart (METRIC Fasteners - Sheet 5 of 7)
26
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
27
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
28
Section 2 - General
29
Machine Preparation, Inspection, and Maintenance
29
General
29
Preparation, Inspection, and Maintenance
29
Pre-Start Inspection
29
Pre-Delivery Inspection and Frequent Inspection
29
Annual Machine Inspection
29
Preventative Maintenance
29
Service and Guidelines
30
General
30
Safety and Workmanship
30
Cleanliness
30
Components Removal and Installation
30
Component Disassembly and Reassembly
31
Pressure-Fit Parts
31
Bearings
31
Gaskets
31
Bolt Usage and Torque Application
31
Hydraulic Lines and Electrical Wiring
31
Hydraulic System
31
Lubrication
31
Battery
31
Lubrication and Servicing
31
Lubrication and Information
32
Hydraulic System
32
Hydraulic Oil
32
Changing Hydraulic Oil
32
Lubrication Specifications
32
Cylinder Drift Test
33
Platform Drift
33
Cylinder Drift
33
Pins and Composite Bearing Repair Guidelines
33
Welding on JLG Equipment
34
Do the Following When Welding on JLG Equipment
34
Do NOT Do the Following When Welding on JLG Equipment
34
Applying Silicone Dielectric Compound to Electrical Connections
34
Operating Temperature Specifications - Kubota
38
Section 3 - Chassis & Turntable
39
Tires & Wheels
39
Tire Inflation
39
Tire Damage
39
Tire Replacement
39
Wheel Replacement
39
Wheel Installation
39
Drive Hub -REAR (Prior to S/N 0300112585)
40
Disengaging for Towing
40
Engaging after Towing Is Complete
41
Torque Hub
42
Disassembly
43
Disassembly of Cover
43
Disassembly of the First Stage Planetary Assembly (7)
43
Disassembly of Second Stage Planet Gears (1)
43
Assembly of First Stage Planetary Assembly (7)
43
Assembly of End Cover Unit (8)
44
Final Assembly
44
Initial Start-Up and after Repairs
44
Oil Change Interval-Gear Drive
44
Drive Hub (S/N 115723 to Present)
44
Roll and Leak Testing
44
Tightening and Torquing Bolts
45
Main Disassembly
45
Main Disassembly Drawing 1
46
Main Disassembly Drawing 2
47
Output Carrier Disassembly
48
Planet Gear
49
Input Carrier Disassembly
50
Hub-Spindle Disassembly
51
Cover Disassembly
52
Input Carrier Assembly
53
Output Planet Gear Assembly
53
Output Carrier Assembly
54
Hub-Spindle Assembly
54
Cover Subassembly
55
Main Assembly
55
Hub Assembly - Sheet 1 of 2
56
Hub Assembly - Sheet 1 of 2
57
Cup Pressing Tool
58
Drive Brake - Mico
59
Disassembly
59
Assembly
59
Bleeding
59
Drive Brake
60
Speed Sensor Adjustment
62
Adjustment Procedure
62
Speed Sensor Orientation
63
Drive Components
64
Speed Sensor Installation Verification
65
Verification W/ Analyzer Procedure
65
Oscillating Axle
67
Axle Oscillation Lockout Valve
68
Oscillating Axle Lockout Test (if Equipped)
69
Oscillation Cylinder Bleeding
69
Bleeding Procedure
69
Checking Oscillation Cylinders
69
Swing Drive
70
Roll, Leak and Brake Testing
70
Tightening and Torquing Bolts
70
Motor Control Valve Disassembly
70
Motor Control Valve Disassembly
71
Motor and Brake Disassembly
72
Brake Disassembly
73
Main Disassembly
74
Hub-Shaft Disassembly
75
Carrier Disassembly
76
Hub-Shaft Sub-Assembly
77
Carrier Sub-Assembly
77
Main Assembly
78
Motor-Brake Subassembly
78
Motor-Brake Assembly
78
Motor Control Valve Assembly
79
Tube Fitting Assembly Procedures
79
Procedure for Setting Gear Backlash
79
Swing Bearing
80
Turntable Bearing Mounting Bolt Condition Check
80
Wear Tolerance
81
Swing Drive and Bearing Installation
82
Replacement of Swing Bearing
83
Swing Bearing Torque Value
84
Swing Drive Installation
84
Setting Backlash
84
Battery Maintenance and Charging
85
Battery Maintenance, Quarterly
85
Optional on Board Generator
85
Battery Charging (on Board Charger)
85
Removing the Battery Box
86
Batteries and Battery Charger
87
Battery Charger
88
Battery Charger Schematic
89
Generator (Prior to S/N 88375)
90
Generator Components
91
Timing Sequences
92
To Connect the JLG Control System Analyzer to the Generator
93
Alarms and Fault Flash Codes
93
Output Current and Voltage Settings
95
Priming the Fuel Line
96
Generator (S/N 88375 to Present)
97
Engine
97
Alternator
97
Dynamo and Dynamo Voltage Regulator
97
Dynamo Output Fuse
97
Control Fuse
97
Generator
98
Start Battery
99
Engine Starter
99
Start Control Relay
99
Fuel Control Relay
100
Glow Plug Control Relay
100
Glow Plug
100
Fuel Pump
101
Fuel Solenoid
101
Engine Low Oil Pressure Switch
101
Engine Oil Temperature Sensor
101
Alternator Output Current Sensor
102
Engine Speed Sensor
102
RBS Engine/Generator Controller
102
Warnings and Safety Precautions
103
System Controls
103
System Status and Performance Monitoring
103
System Settings
103
RBS Start
104
RBS Shutdown
104
RBS Alarms and Flash Codes
105
Resetting the RBS Controller
105
Maintenance Schedule
105
Troubleshooting
106
APU Engine Start Battery Boosting
107
Supplementary Fuse for Engine Generator Controller
108
Tools and Material
108
Procedure
108
Section 4 - Boom & Platform
111
Boom
111
Removal
111
Boom Assembly - Sheet 1 of 3
112
Boom Assembly - Sheet 2 of 3
113
Boom Assembly - Sheet 3 of 3
114
Installation
115
Boom Limit Switch Adjustment
116
Transport Limit Switch (CE Only)
117
Load Cell Calibration Procedure
118
Load Sensor
119
Platform Rotator (Prior to S/N 0300130810)
120
Theory of Operation
120
Disassembly and Inspection
120
Assembly and Testing
120
Platform Rotator Assembly - Cutaway
121
Platform Rotator (S/N 0300130810 to Present)
122
Theory of Operation
122
Required Tools
123
Rotary Actuator - Exploded View
124
Rotary Actuator - Assembly Drawing
125
Disassembly
126
Inspection
130
Assembly
130
Jib Rotator
135
Operating Principle
135
Disassembly
135
Jib Rotator Assembly
137
Tool for Removing End Cap
138
Inspection
139
Reassembly
139
Installing Counterbalance Valve
141
Testing the Actuator
142
Installation and Bleeding
142
Troubleshooting
143
Section 5 - Hydraulics
145
Lubricating O-Rings in the Hydraulic System
145
Cup and Brush
145
Dip Method
146
Spray Method
146
Brush-On Method
146
Cylinders - Theory of Operation
147
Lift, Telescope, Slave, Master, Oscillation (if Equipped), Jib (if Equipped), and Steer
147
Cylinder Checking Procedures
147
Cylinder Without Counterbalance Valves
147
Cylinders with Single Counterbalance Valve
147
Cylinders with Dual Counterbalance Valve
148
Cylinder Repair
148
Disassembly
148
Axle Lockout Cylinder
149
Level Cylinder
150
Jib Lift Cylinder
151
Lift Cylinder
152
Master Cylinder
153
Steer Cylinder
154
Telescope Cylinder
155
Cleaning and Inspection
156
Assembly
157
Installation of Head Seal Kit
158
Tapered Bushing Installation
159
Rod Assembly Installation
160
Hydraulic Tank and Pump (Prior to S/N 51941)
161
Hydraulic Tank and Pump (S/N 51941 to Present)
162
Pressure Settings
163
Proportional Main Relief
163
Lift down
163
Lift up
163
Swing
163
Flow Control / Bang Bang Main Relief
163
Steer
163
Platform Level down
163
Platform Level up Relief
163
Jib Relief
163
Hydraulic Control Valve - Main Valve
164
Hydraulic Control Valve - Platform Valve
165
Section 6 - Jlg Control System
167
Introduction
167
Control Module Location
170
To Connect the JLG Control System Analyzer
171
Using the Analyzer
171
Changing the Access Level of the Hand Held Analyzer
172
Adjusting Parameters Using the Hand Held Analyzer
173
Machine Setup
173
Machine Personality Settings
175
Machine Configuration Programming Information
178
Level Vehicle Description
180
Help Descriptions and Fault Flash Codes
180
Analyzer Diagnostics Menu Structure
188
System Self Test
195
Section 7 - Basic Electrical Information & Schematics
201
General
201
Multimeter Basics
201
Grounding
201
Backprobing
201
Min/Max
201
Polarity
201
Scale
201
Voltage Measurement
201
Resistance Measurement
202
Continuity Measurement
202
Current Measurement
203
Checking Switches
203
Basic Check
203
Limit Switches
203
Automatic Switches
204
Switch Wiring - Low Side, High Side
204
Applying Silicone Dielectric Compound to Electrical Connections
204
AMP Connector
205
Applying Silicone Dielectric Compound to AMP Connectors
205
Assembly
205
Connector Assembly Figure 2
206
Disassembly
207
Wedge Lock
207
Service - Voltage Reading
207
Connector Installation
208
Deutsch Connectors
209
DT/DTP Series Assembly
209
DT/DTP Series Disassembly
209
HD30/HDP20 Series Assembly
210
HD30/HDP20 Series Disassembly
210
Electrical Components Installation - Sheet 1
212
Electrical Components Installation - Sheet 2
213
Electrical Schematic - Sheet 1 of 4
214
Electrical Schematic - Sheet 2 of 4
215
Electrical Schematic - Sheet 3 of 4
216
Electrical Schematic - Sheet 4 of 4
217
Hydraulic Schematic - Sheet 1 of 2
218
Hydraulic Schematic - Sheet 2 of 2
219
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