Document Outline

• Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
  • A General
  • B Hydraulic System Safety
  • C Maintenance
• Section 1. specifications
  • 1.1 Capacities
    • Fuel Tank
    • Hydraulic Oil Tank
    • Hydraulic System (Including Tank)
    • Torque Hub, Drive
    • Engine Crankcase
  • 1.2 Component Data
    • Engine - Ford LRG-425
    • Engine - Ford LRG-423
    • Engine - Deutz F4M1011F
    • Engine - Continental TMD27
    • Engine - Caterpillar 3044C
    • Drive System (S Models)
    • Drive System (A Models)
    • Steer System (S Models)
    • Steer System (A Models)
    • Swing System
  • 1.3 Performance Data
    • Turning Radius (Outside) (S Models)
    • Turning Radius (Outside) (A Models)
    • Turning Radius (Inside) (S Models)
    • Turning Radius (Inside) (A Models)
    • Boom Elevation (S Models)
    • Boom Elevation (A Models)
    • Machine Weight approximately
    • Machine Height (Stowed) (S Models)
    • Machine Height (Stowed) (A Models)
    • Machine Length (Stowed) (S Models)
    • Machine Length (Stowed) (A Models)
    • Machine Width (S Models)
    • Machine Width (A Models)
    • Wheel base (S Models)
    • Wheel base (A Models)
  • 1.4 Function Speeds
    • Machine Orientation When Doing Speed Tests
    • Test Notes
  • 1.5 Torque Requirements
  • 1.6 Lubrication
    • Ford LRG423 & LRG425 Engine
    • Deutz F4M1011F Engine
    • Continental TMD27 Engine
    • Hydraulic Oil
    • Lubrication Specifications
  • 1.7 Pressure Settings
    • Rexroth Valve (S Models)
    • Rexroth Valve (A Models)
  • 1.8 Cylinder Specifications
  • 1.9 Major Component Weights
  • 1.10 Critical Stability Weights
  • 1.11 Serial Number Locations
• Section 2. General
  • 2.1 Machine Preparation, Inspection, and Maintenance
    • General
    • Preparation, Inspection, and Maintenance
    • Pre-Start Inspection
    • Pre-Delivery Inspection and Frequent Inspection
    • Annual Machine Inspection
    • Preventative Maintenance
  • 2.2 Service and Guidelines
    • General
    • Safety and Workmanship
    • Cleanliness
    • Components Removal and Installation
    • Component Disassembly and Reassembly
    • Pressure-Fit Parts
    • Bearings
    • Gaskets
    • Bolt Usage and Torque Application
    • Hydraulic Lines and Electrical Wiring
    • Hydraulic System
    • Lubrication
    • Battery
    • Lubrication and Servicing
  • 2.3 Lubrication and Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.4 Cylinder Drift Test
    • Platform Drift
    • Cylinder Drift
  • 2.5 Pins and Composite Bearing Repair Guidelines
  • 2.6 Welding on JLG Equipment
    • Do the Following When Welding on JLG Equipment
    • Do NOT Do the Following When Welding on JLG Equipment
  • 2.7 Applying Silicone Dielectric Compound to Electrical Connections
  • 2.8 AMP Connector
    • Applying Silicone Dielectric Compound to AMP Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 2.9 Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly
• Section 3. chassis & turntable
  • 3.1 Drive Torque hub, Prior to S/N 75606
    • Disassembly
    • Cleaning and Inspection
    • Repair
    • Assembly
  • 3.2 Torque Hub, Drive (Auburn Gear)
    • Disassembly
    • Assembly
  • 3.3 Drive Torque hub, S/N 75606 to Present
    • Roll, Leak and Brake Testing
    • Tightening and Torquing Bolts
    • Main Disassembly
    • Input Carrier Disassembly
    • Hub-Spindle Disassembly
    • Spindle-Brake Disassembly
    • Cover Disassembly
    • Input Carrier Sub-Assembly
    • Output Planet Gear Sub-Assembly
    • Spindle - Brake Sub-Assembly
    • Hub-Spindle Sub-Assembly
    • Cover Sub-Assembly
    • Main Assembly
    • Integral Brake Check
  • 3.4 Drive Brake - Mico, Prior to S/N 75606
    • Disassembly
    • Inspection
    • Assembly
  • 3.5 Free Wheeling Option
    • To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
    • To Engage Drive Motors and Brakes (Normal Operation)
  • 3.6 Drive Motor (600S, 600A 4WD)
    • Spare Parts Kits
    • Replacing the Drive Shaft Seal
    • Disassembly and Assembly
    • Assembly Notes
    • Taper Roller Bearing Initial Tension
    • Testing and Setup
  • 3.7 Drive Motor (600A 2WD)
    • Shaft Seal Replacement
  • 3.8 Drive Motor Adjustment Procedure (S Models Only, Prior to S/N 75606)
  • 3.9 Oscillating Axle Bleeding Procedure and Lockout Test
    • Lockout Cylinder Bleeding
    • Oscillating Axle Lockout Test
  • 3.10 Steer Adjustments (S Models)
  • 3.11 Swing Hub
    • Adjustment Procedures
  • 3.12 Swing Bearing
    • Turntable Bearing Mounting Bolt Condition Check
    • Wear Tolerance (S & A Models)
    • Swing Bearing Replacement
    • Swing Bearing Torque Values
  • 3.13 Swing Brake - Mico
    • Disassembly
    • Inspection
    • Assembly
  • 3.14 Tilt Alarm Switch (Machines With External Tilt Sensor)
    • Manual Adjustment
  • 3.15 Spark Arrester Cleaning Instructions
  • 3.16 Rotary Coupling - 600s s/n 75606 TO pRESENT
  • 3.17 Dual Fuel System
    • Changing from Gasoline to LP Gas
    • Changing from LP Gas to Gasoline
  • 3.18 Electric Governor Installation and Adjustments - Ford LRG Engine
    • General
    • Quick-start Installations
    • Mounting-Actuator
    • Linkage
    • Mounting-Controller
    • Wiring
    • Check-Out and Initial Start-Up Procedures
    • Multi-Turn Adjustment (High Engine, Mid Engine, Overspeed, Starter Lockout)
    • Single-Turn Adjustment (Gain, Factory Adjust)
    • Troubleshooting
  • 3.19 Throttle Checks and Adjustments - Deutz or Continental Engine (Prior to S/N 61927)
    • General
    • Procedure
    • Controller Status
    • Failure Modes
  • 3.20 Automatic Choke Adjustment - Ford Engine
  • 3.21 Cold Weather Starting Difficulty
    • Checking the Carburetor
    • Checking the Ignition
    • Checking the Fuel
  • 3.22 GLow Plugs
  • 3.23 Ford EFI Engine (machines after SN 48907)
    • Performing Diagnostics
    • EFI Diagnostics (600S prior to S/N 61927, 600A prior to S/N 64249)
    • ECM AND SENSORS
    • Fuel System
  • 3.24 Ford LPG System (S Models after S/N 79619 & A Models after S/N 79888)
    • Description
    • Regulator
    • Megajector
    • Mixer
    • Lockoff Solenoid
    • Megajector Diagnostic Code Descriptions
• Section 4. boom & platform
  • 4.1 Boom Rope Torquing Procedures
    • Torque Procedures (S Models)
  • 4.2 Wear Pads
    • Tower Boom (A Models)
    • Main Boom
  • 4.3 Wire Rope (S Models)
    • Inspection
    • Three Month Inspection
    • Seven Year Inspection
    • Replacement Criteria
  • 4.4 Boom Maintenance (S Models)
    • Removal
    • Disassembly of Boom Sections
    • Inspection
    • Assembly
    • Installation
  • 4.5 Boom Maintenance (A Models)
    • Removal
    • Disassembly of Boom Sections
    • Inspection
    • Assembly
    • Installation
  • 4.6 Tower Boom
    • Removal
    • Disassembly
    • Inspection
    • Assembly
    • Installation
  • 4.7 Articulating Jib Boom
    • Removal
    • Disassembly
    • Inspection
    • Assembly
  • 4.8 Limit Switches and Cam Valve Adjustment
  • 4.9 Platform
    • Platform Sections Replacement
  • 4.10 Rotator - Helac
    • Disassembly
    • Inspection
    • Assembly
  • 4.11 Drive Card Setup Procedures
    • Lift, Swing, and Drive Cards
    • Flow Control Card
  • 4.12 Foot Switch Adjustment
  • 4.13 Boom Synchronizing Procedure (A Models Only)
• Section 5. hydraulics
  • 5.1 Cylinders - Theory of Operation
    • Systems Incorporating Double Acting Cylinders
    • Systems Incorporating Holding Valves
  • 5.2 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
    • Cylinders With Single Counterbalance Valve
    • Cylinders With Dual Counterbalance Valves
  • 5.3 Cylinder Repair
    • Disassembly
    • Cleaning and Inspection
    • Assembly
  • 5.4 Cylinder Removal and Installation (S Models)
    • Main Boom Telescope Cylinder Removal
    • Main Boom Telescope Cylinder Installation
    • Main Boom Lift Cylinder Removal
    • Main Boom Lift Cylinder Installation
  • 5.5 Cylinder Removal and Installation (A Models)
    • Main Boom Telescope Cylinder Removal
    • Main Boom Telescope Cylinder Installation
    • Main Boom Lift Cylinder Removal
    • Main Boom Lift Cylinder Installation
    • Upright Level Cylinder Removal
    • Upright Level Cylinder Installation
    • Tower Boom Lift Cylinder Removal
    • Tower Lift Cylinder Installation
    • Tower Telescope Cylinder Removal
    • Tower Telescope Cylinder Installation
  • 5.6 Variable Displacement pump (M46 series)
    • Troubleshooting
    • Inspections and Adjustments
    • Minor Repair and Replacement
  • 5.7 Valves - Theory of Operation
    • Solenoid Control Valve - Rexroth
    • Relief Valves
  • 5.8 Pressure Setting Procedures (S and A Models)
    • Main Relief, Steer, Swing and Lift Down
    • Platform Level
    • Articulating Jib Boom (If Equipped)
    • 4 Wheel Steer (If Equipped)
  • 5.9 Hydraulic Component Start-Up Procedures and Recommendations
  • 5.10 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
• Section 6. JLG Control SystEM
  • 6.1 Introduction
  • 6.2 To Connect the JLG Control System Analyzer
  • 6.3 Using the Analyzer
  • 6.4 Changing the Access Level of the Hand Held Analyzer
  • 6.5 Adjusting Parameters Using the Hand Held Analyzer
  • 6.6 Machine Setup

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