JLG 600S HC3 660SJ HC3 PVC 2001 Service & Maintenance Manual (31215908) – PDF DOWNLOAD
TABLE OF CONTENTS:
JLG 600S HC3 660SJ HC3 PVC 2001 Service & Maintenance Manual (31215908) – PDF DOWNLOAD
31215908_A_600S HC3 , 660SJ HC3 _JLG_Service_English.............................................. 1
Table of Contents............................................................................. 5
List of Figures............................................................................... 11
List of Tables................................................................................ 16
Section A. Introduction - Maintenance Safety Precautions...................................... 3
A General................................................................................. 3
B Hydraulic System Safety................................................................. 3
C Maintenance............................................................................. 3
Section 1. Specifications..................................................................... 19
1.1 Operating Specifications.............................................................. 19
1.2 Dimensional Data...................................................................... 19
1.3 Capacities............................................................................ 20
1.4 Engine Data........................................................................... 20
1.5 Tires................................................................................. 21
1.6 Critical Stability Weights............................................................ 21
1.7 Hydraulic Oil......................................................................... 22
1.8 Torque Requirements................................................................... 23
1.9 Maintenance and Lubrication........................................................... 27
1.10 Threadlocking Compound............................................................... 33
1.11 Torque Charts........................................................................ 34
SAE Fastener Torque Chart............................................................. 34
SAE Fastener Torque Chart (Continued)................................................. 35
SAE Fastener Torque Chart (Continued)................................................. 36
SAE Fastener Torque Chart (Continued)................................................. 37
SAE Fastener Torque Chart (Continued)................................................. 38
SAE Fastener Torque Chart (Continued)................................................. 39
Metric Fastener Torque Chart.......................................................... 40
Metric Fastener Torque Chart (Continued).............................................. 41
Metric Fastener Torque Chart (Continued).............................................. 42
Metric Fastener Torque Chart (Continued).............................................. 43
Section 2. General............................................................................ 45
2.1 Machine Preparation, Inspection, and Maintenance...................................... 45
General............................................................................... 45
Preparation, Inspection, and Maintenance.............................................. 45
Pre-Start Inspection.................................................................. 45
Pre-Delivery Inspection and Frequent Inspection....................................... 45
Annual Machine Inspection............................................................. 45
Preventive Maintenance................................................................ 45
2.2 Service and Guidelines................................................................ 46
General............................................................................... 46
Safety and Workmanship................................................................ 46
Cleanliness........................................................................... 46
Components Removal and Installation................................................... 46
Component Disassembly and Reassembly.................................................. 47
Pressure-Fit Parts.................................................................... 47
Bearings.............................................................................. 47
Gaskets............................................................................... 47
Bolt Usage and Torque Application..................................................... 47
Hydraulic Lines and Electrical Wiring................................................. 47
Hydraulic System...................................................................... 47
Lubrication........................................................................... 47
Battery............................................................................... 47
Lubrication and Servicing............................................................. 47
2.3 Lubrication and Information........................................................... 48
Hydraulic System...................................................................... 48
Hydraulic Oil......................................................................... 48
Changing Hydraulic Oil................................................................ 48
Lubrication Specifications............................................................ 48
2.4 Cylinder Drift........................................................................ 48
Theory................................................................................ 48
Cylinder Leakage Test................................................................. 48
Cylinder Thermal Drift................................................................ 49
2.5 Pins and Composite Bearing Repair Guidelines.......................................... 49
2.6 Welding on JLG Equipment.............................................................. 49
Do the Following When Welding on JLG Equipment:....................................... 49
Do Not Do The Following When Welding On Jlg Equipment:................................ 49
Section 3. Chassis & Turntable................................................................ 57
3.1 Tires & Wheels........................................................................ 57
Tire Damage........................................................................... 57
Tire Replacement...................................................................... 57
Wheel Replacement..................................................................... 57
Wheel Installation.................................................................... 57
3.2 Oscillating Axle Bleeding Procedure and Lockout Test.................................. 58
Lockout Cylinder Bleeding............................................................. 58
Oscillating Axle Lockout Test......................................................... 58
3.3 Chassis Tilt Indicator System......................................................... 59
3.4 Cold Start System (Diesel)............................................................ 59
3.5 Auxiliary Power System................................................................ 59
3.6 Drive Orientation System.............................................................. 59
3.7 Oscillating Axle System............................................................... 60
3.8 Drive System.......................................................................... 60
3.9 Drive Hub............................................................................. 66
Removal............................................................................... 66
Assembly/Disassembly.................................................................. 66
Installation.......................................................................... 66
3.10 Drive Motor.......................................................................... 67
Removal............................................................................... 67
Assembly/Disassembly.................................................................. 67
Installation.......................................................................... 67
3.11 Steer Cylinder....................................................................... 72
Removal............................................................................... 72
Installation.......................................................................... 72
3.12 Swing Drive Hub...................................................................... 73
Removal............................................................................... 73
Assembly/Disassembly.................................................................. 73
Installation.......................................................................... 73
Procedure For Setting Swing Gear Backlash............................................. 74
Swing Drive Lubrication............................................................... 74
3.13 Swing Bearing........................................................................ 75
Turntable Bearing Mounting Bolt Condition Check....................................... 75
Wear Tolerance........................................................................ 75
Swing Bearing Replacement............................................................. 77
Swing Bearing Torque Values........................................................... 78
3.14 Rotary Coupling...................................................................... 81
3.15 Deutz TD2.9 L4 Engine (67 hp)........................................................ 86
Check Oil Level....................................................................... 90
Change Engine Oil..................................................................... 90
Change Oil Filter..................................................................... 90
Change Fuel Filters................................................................... 91
Glow Plugs............................................................................ 91
3.16 Deutz D2011L04 Engine................................................................113
Checking Oil Level....................................................................117
Changing Engine Oil...................................................................117
Changing Oil Filter...................................................................118
Replace Fuel Filter...................................................................118
Clean Fuel Strainer...................................................................119
Spark Arrester Cleaning Instructions..................................................119
Glow Plugs............................................................................119
3.17 Ford Engine..........................................................................124
3.18 Counterweight........................................................................135
3.19 Generator Pulley.....................................................................136
3.20 Generator............................................................................143
Every 250 hours.......................................................................143
Every 500 hours.......................................................................143
Overload Protection...................................................................143
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings........................144
Section 4. Boom & Platform....................................................................145
4.1 Beyond Transport - Drive Speed Cutback System.........................................145
4.2 Transport Position Interlock System (CE only).........................................145
4.3 Platform Load Sensing System (LSS)....................................................145
4.4 Electronic Platform Leveling..........................................................145
4.5 Fuel level Cutout System..............................................................145
4.6 Platform Control Enable System........................................................146
4.7 Transport Position Sensing System.....................................................146
4.8 Triple Capacity System................................................................146
4.9 Platform..............................................................................151
Support Removal.......................................................................151
Support Installation..................................................................152
4.10 Rotator and Platform Level Cylinder..................................................154
Removal...............................................................................154
Assembly/Disassembly..................................................................154
Installation..........................................................................154
4.11 Main Boom Assembly...................................................................156
Removal...............................................................................156
Boom Disassembly......................................................................158
Assembly..............................................................................161
Installation..........................................................................164
4.12 Main Boom Lift Cylinder..............................................................165
Removal...............................................................................165
Installation..........................................................................165
4.13 Main Boom Powertrack.................................................................166
Installation..........................................................................166
4.14 Wire Rope............................................................................168
Inspection............................................................................168
Three Month Inspection................................................................169
Additional Inspection Required If:....................................................169
12 Year or 7000 Hour Replacement......................................................169
Additional Replacement Criteria.......................................................169
4.15 Wire Rope Tensioning Adjustment......................................................169
Wire Rope Tensioning Procedure........................................................169
4.16 Wire rope Service indicator..........................................................170
4.17 Jib (660SJ HC3 only).................................................................170
4.18 Boom Cleanliness Guidelines..........................................................172
4.19 Foot Switch Adjustment...............................................................172
4.20 Powertrack Maintenance...............................................................173
Remove Link...........................................................................173
Install New Link......................................................................176
Replace Fixed End Brackets............................................................179
Replace Moving End Brackets...........................................................180
4.21 Skyguard.............................................................................182
Operation.............................................................................182
Function Test.........................................................................182
Diagnostics & Troubleshooting.........................................................183
4.22 Bolt-on External Fall Arrest.........................................................184
Inspection Before Use.................................................................184
Installation..........................................................................185
Section 5. Basic Hydraulics Information & Schematics..........................................187
5.1 Lubricating O-rings In The Hydraulic System...........................................187
Cup and Brush.........................................................................187
Dip Method............................................................................188
Spray Method..........................................................................188
Brush-on Method.......................................................................188
5.2 Hydraulic Connection Assembly and Torque Specification................................189
Tapered Thread Types..................................................................189
Straight Thread Types, Tube and Hose Connections......................................189
Straight Thread Types, Port Connections...............................................190
Flange Connection Types...............................................................190
Tightening Methods....................................................................190
Assembly And Torque Specifications....................................................191
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections....192
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections.....193
Assembly Instructions for 37° (JIC) Flare Fittings....................................194
Assembly Instructions for 45° SAE Flare Fittings......................................198
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings............................200
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)............202
Assembly Instructions for Bulkhead (BH) Fittings......................................204
Assembly Instructions for O-Ring Boss (ORB) Fittings..................................208
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings...................216
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends...............224
Assembly instructions for Adjustable Port End (BSPP) Fittings.........................226
Assembly Instructions for Flange Connections: (FL61 and FL62).........................234
Double Wrench Method..................................................................237
FFWR and TFFT Methods.................................................................238
Adjustable Stud End Assembly..........................................................238
O-ring Installation (Replacement).....................................................239
5.3 Hydraulic Cylinders...................................................................240
Main Lift Cylinder....................................................................241
Telescope Cylinder....................................................................247
Platform Level Cylinder...............................................................252
Jib Lift Cylinder (660SJ HC3 Only)....................................................258
Steer Cylinder........................................................................264
Axle Lockout Cylinder.................................................................268
5.4 Hydraulic Pump (Gear).................................................................270
Removal...............................................................................270
Assembly/Disassembly..................................................................270
Installation..........................................................................270
5.5 Variable Pump.........................................................................271
Removal...............................................................................271
Assembly/Disassembly..................................................................271
Installation..........................................................................271
5.6 Main Valve Block Pressure Setting Procedure...........................................272
Load Sense Compensator................................................................272
Main Relief Valve.....................................................................272
Load Sense Relief Valve...............................................................272
2 Wheel Steer, Relief Valves..........................................................272
Turntable Swing Relief Valve..........................................................272
5.7 Platform Valve Block Pressure Setting Procedure.......................................274
Main High Pressure Relief Valve.......................................................274
Low Pressure Relief Valve.............................................................274
Platform Jib Down Relief Valve........................................................274
5.8 Hydraulic Schematics..................................................................282
Section 6. JLG Control System.................................................................295
6.1 JLG Control System Analyzer Kit Instructions..........................................295
Connect JLG Control System Analyzer...................................................296
Using Analyzer........................................................................296
Changing Access Level.................................................................297
Adjust Parameters.....................................................................298
Machine Setup.........................................................................299
Level Vehicle Description.............................................................299
6.2 Machine Personality Settings..........................................................332
6.3 Machine Orientation When Setting Function Speeds......................................334
Test Notes............................................................................334
6.4 CANbus Communications.................................................................335
6.5 System Test...........................................................................336
Test from the Platform................................................................336
6.6 System Test Messages..................................................................341
6.7 Machine Diagnostics Parameters........................................................346
6.8 Calibrating Tilt Sensor...............................................................354
6.9 Calibrating Boom Angle................................................................358
6.10 Calibrating Level Up CRKPT...........................................................363
6.11 Calibrating Level Down Crackpoint....................................................365
6.12 Calibrating Platform Angle Sensor....................................................367
6.13 Calibrating Load Sensing.............................................................371
6.14 Resetting The Msso System............................................................375
6.15 LSS System...........................................................................377
Diagnostic Menu.......................................................................378
Calibration Procedure.................................................................379
Testing & Evaluation..................................................................384
LSS Service Mode......................................................................385
LSS Service Mode Event Log............................................................385
Troubleshooting.......................................................................386
6.16 Machine Fault Codes..................................................................387
Section 7. Basic Electrical Information & Electrical Schematics...............................411
7.1 General...............................................................................411
7.2 Multimeter Basics.....................................................................411
Grounding.............................................................................411
Backprobing...........................................................................411
Min/Max...............................................................................411
Polarity..............................................................................411
Scale.................................................................................411
Voltage Measurement...................................................................411
Resistance Measurement................................................................412
Continuity Measurement................................................................412
Current Measurement...................................................................413
7.3 Applying Silicone Dielectric Compound to Electrical Connections.......................413
7.4 Dielectric Grease Application.........................................................414
Installation..........................................................................414
AMP Mate-N-Lok........................................................................414
AMP Faston............................................................................414
AMP Micro-Fit.........................................................................414
AMP Mini Fit Jr.......................................................................415
Mini Fit Sr...........................................................................415
DIN Connectors........................................................................415
Exceptions............................................................................415
7.5 AMP Connector.........................................................................416
Assembly..............................................................................416
Disassembly...........................................................................418
Wedge Lock............................................................................418
Service - Voltage Reading.............................................................418
7.6 Deutsch Connectors....................................................................420
DT/DTP Series Assembly................................................................420
DT/DTP Series Disassembly.............................................................420
HD30/HDP20 Series Assembly............................................................421
HD30/HDP20 Series Disassembly.........................................................421
7.7 Telematics Gateway....................................................................422
Telematics-Ready (TCU) Plug...........................................................423
7.8 Wiring Harness........................................................................424
Connector Labels......................................................................424
Component Labels......................................................................424
7.9 Wiring Harness Connector Label Diagrams...............................................427
7.10 Electrical Schematics................................................................537
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JLG 600S HC3 660SJ HC3 PVC 2001 Service & Maintenance Manual (31215908) – PDF DOWNLOADJLG 600S HC3 660SJ HC3 PVC 2001 Service & Maintenance Manual (31215908) – PDF DOWNLOAD
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