JLG Boom Lift EC600SJ H600SJ EC600SJP H600SJP Service & Maintenance Manual 3122317300

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JLG Boom Lift EC600SJ H600SJ EC600SJP H600SJP Service & Maintenance Manual 3122317300
Size: 84.59 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Service & Maintenance Manual, Electrical and Hydraulic Diagrams
Model: JLG EC600SJ H600SJ EC600SJP H600SJP Boom Lift
Part Number: 3122317300
Publication Date: 2024
Number of Pages: 668 Pages

Contents:
Safety

General​

1.1.1 Disclaimer​

1.1.2 Operation & Safety Manual​

Safety Information​

1.2.1 Safety Alert System and Signal Words​

Safety Hazards​

1.3.1 Personal Hazards​

1.3.2 Equipment Hazards​

1.3.3 General Hazards​

1.3.4 Operational Hazards​

Safety Decals​

Machine Verification​

General Machine Information and Specifications

Specifications​

2.1.1 Machine Specifications​

2.1.2 Machine Dimensional Data​

2.1.3 Batteries​

2.1.4 Tires​

2.1.5 Major Component Weights​

2.1.6 Torque Requirements​

2.1.7 Battery Charger Specifications​

Machine Temperature Chart​

Serial Number Location (concept)​

Fluids and Lubrication​

2.4.1 General Information​

2.4.2 Hydraulic Oil​

2.4.3 Changing Hydraulic Oil​

2.4.4 Lubrication Specifications​

2.4.5 Fluids​

2.4.6 Capacities​

2.4.7 Lubrication Schedule​

Machine Characteristics​

2.5.1 Ground Control Keyswitch System​

2.5.2 Platform Control Enable System​

2.5.3 Side Entry Platform​

2.5.4 Drive Orientation System​

2.5.5 Function Speed Control System​

2.5.6 Transport Position Interlock System​

2.5.7 Above Elevation (Above Horizontal) Cutout System​

2.5.8 Dual Capacity System​

2.5.9 Platform Load Control System​

2.5.10 All-Wheel Drive​

2.5.11 Automatic Traction Control System​

2.5.12 Oscillating Axle System​

2.5.13 Positive Opening Switch Systems​

2.5.14 Generator Charging Set​

2.5.15 Sustained Involuntary Operation (SIO) Protection​

2.5.16 Chassis Tilt Indicator System​

Clearsky Smart Fleet (If Equipped)​

2.6.1 General​

2.6.2 ClearSky Smart Fleet™ — Access Control​

Maintenance and Inspection Schedules

Machine Preparation, Inspection, and Maintenance​

3.1.1 General​

3.1.2 Preparation, Inspection, and Maintenance​

3.1.3 Pre-Start Inspection​

3.1.4 Pre-Delivery Inspection and Frequent Inspection​

3.1.5 Annual Machine Inspection​

3.1.6 Preventive Maintenance​

Service and Guidelines​

3.2.1 General​

3.2.2 Safety and Workmanship​

3.2.3 Cleanliness​

3.2.4 Components Removal and Installation​

3.2.5 Component Disassembly and Reassembly​

3.2.6 Pressure-Fit Parts​

3.2.7 Bearings​

3.2.8 Gaskets​

3.2.9 Bolt Usage and Torque Application​

3.2.10 Hydraulic Lines and Electrical Wiring​

3.2.11 Hydraulic System​

3.2.12 Lubrication​

3.2.13 Battery​

3.2.14 Welding on JLG Equipment​

Preventive Maintenance and Inspection Schedule​

3.3.1 Check Daily​

3.3.2 First 50 Hours​

3.3.3 Every 150 Hours or 3 Months​

3.3.4 Every 6 Months or 300 Hours​

3.3.5 Every 1200 Hours or 2 Years​

Pins and Composite Bearing Repair Guidelines​

Tires and Wheels​

3.5.1 Tire Inflation​

3.5.2 Tire Damage​

Fuel Tank Inspection​

Boom Inspection and Maintenance​

3.7.1 Boom Cleanliness Guidelines​

3.7.2 Boom Wear Pad Inspection​

Hydraulic Filter Replacement​

3.8.1 Hydraulic Filter Removal​

3.8.2 Hydraulic Filter Installation​

Turntable Bearing Inspection​

3.9.1 Turntable Bearing Mounting Bolt Condition Check​

3.9.2 Wear Tolerance​

Engine General Inspection​

3.10.1 General Maintenance​

3.10.2 Glow Plugs​

3.10.3 Replacing Engine Oil​

3.10.4 Replacing the Oil Filter​

3.10.5 Replacing the Primary Fuel Filters​

Battery Maintenance and Charging​

3.11.1 Battery Maintenance, Quarterly​

3.11.2 Optional On Board Generator​

3.11.3 Battery Charging (On Board Charger)​

Battery Charger​

3.12.1 Operating Instructions​

3.12.2 Battery Charger Fault Codes​

3.12.3 Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell​

3.12.4 Checking/Changing the Battery Charger Algorithm​

Generator​

3.13.1 Engine​

3.13.2 Alternator​

3.13.3 Dynamo and Dynamo Voltage Regulator​

3.13.4 Dynamo Output Fuse​

3.13.5 Control Fuse​

3.13.6 Start Battery​

3.13.7 Engine Starter​

3.13.8 Start Control Relay​

3.13.9 Fuel Control Relay​

3.13.10 Glow Plug Control Relay​

3.13.11 Glow Plug​

3.13.12 Fuel Pump​

3.13.13 Fuel Solenoid​

3.13.14 Engine Low Oil Pressure Switch​

3.13.15 Engine Oil Temperature Sensor​

3.13.16 Alternator Output Current Sensor​

3.13.17 Engine Speed Sensor​

3.13.18 RBS Engine/Generator Controller​

3.13.19 Warnings and Safety Precautions​

3.13.20 System Controls​

3.13.21 System Status and Performance Monitoring​

3.13.22 System Settings​

3.13.23 RBS Start​

3.13.24 RBS shutdown​

3.13.25 RBS Alarms and Flash Codes​

3.13.26 Resetting the RBS Controller​

3.13.27 Maintenance Schedule​

3.13.28 Troubleshooting​

3.13.29 APU Engine Start Battery Boosting​

Supplementary Fuse for APU​

3.14.1 Tools and Material​

3.14.2 Procedure​

Testing, Calibrations and Special Procedures

Special Tools​

4.1.1 Multimeter Basics​

4.1.2 Threadlocking Compound​

4.1.3 Tools Catalog​

Testing Procedures​

4.2.1 Starter​

4.2.2 SkyGuard​

4.2.3 LSS Testing and Evaluation​

4.2.4 Troubleshooting​

Calibration Procedures​

4.3.1 JLG Analyzer​

4.3.2 Calibration Preparation​

4.3.3 Load Sensing System Calibration​

4.3.4 Calibrating Tilt Sensor​

4.3.5 Calibrating Steer​

4.3.6 Calibrating Load Sensing​

4.3.7 Calibration of Motor (with New ZAPI Module)​

4.3.8 Resetting The MSSO System​

Special Procedures​

4.4.1 Drive Cutout Override Service Mode​

4.4.2 Fuel Tank Cleaning and Drying​

4.4.3 Cylinder Checking Procedure​

4.4.4 Cylinder Drift​

4.4.5 Hydraulic Circuits​

4.4.6 Hydraulic Pressure Settings and Adjustments​

4.4.7 Hydraulic Pressures​

4.4.8 Oscillating Axle Bleeding Procedure and Lockout Test​

Wheel Drive Hub​

4.5.1 Roll and Leak Testing​

4.5.2 Tightening and Torquing Bolts​

Swing Drive​

4.6.1 Roll, Leak and Brake Testing​

4.6.2 Tightening and Torquing Bolts​

System Software

Load Sensing System (LSS)​

5.1.1 Theory of Operation​

5.1.2 Load Sensing Gauge Removal/ Installation​

JLG Analyzer​

5.2.1 Machine Data Access​

5.2.2 Hand Held Analyzer​

5.2.3 Using the Analyzer​

5.2.4 Changing the Access Level of the Hand Held Analyzer​

5.2.5 Adjusting Parameters Using the Hand Held Analyzer​

5.2.6 Machine Setup​

5.2.7 Level Vehicle Description​

5.2.8 Analyzer Software​

Analyzer Software Accessibility​

5.3.1 Access Level​

5.3.2 Diagnostic​

5.3.3 Machine Set-Up​

5.3.4 Machine Personality Settings​

5.3.5 Operator Tools​

5.3.6 Calibrations​

Function Test​

5.4.1 Test Notes​

CANBUS Communications​

Service Mode​

5.6.1 Load Sensing System​

5.6.2 Drive Cutout Override​

ClearSky (CS550) Configuration and Troubleshooting​

5.7.1 ClearSky Smart FleetTM CS550 Configuration​

5.7.2 Troubleshooting​

Fault Codes

Fault Codes Introduction​

Machine Fault Codes​

6.2.1 General​

6.2.2 ClearSky CSV3 Smart Fleet DTC Fault Codes​

6.2.3 LSS Troubleshooting​

6.2.4 System Self Test​

Machine Diagnostics Parameters​

Hydraulics

General Information and Safety​

Theories of Operation​

7.2.1 Cylinders​

7.2.2 Valves​

Hydraulic Components​

7.3.1 Hydraulic Oil Tank​

7.3.2 Pressure Setting​

Torque Values​

7.4.1 Cylinder Torque Specifications​

7.4.2 Valve Torque Specifications​

Standard Hydraulic Diagram- Boom And Turntable​

7.5.1 2WD​

Hydraulic Diagram - Chassis​

7.6.1 4WD​

7.6.2 2WD Oscillating Axle​

7.6.3 Tow​

7.6.4 4WD Oscillating Axle​

Electricals

General Information​

8.1.1 Applying Silicone Dielectric Compound to Electrical Connections​

8.1.2 Dielectric Grease Application​

Electrical Connectors​

8.2.1 Deutsch Connectors​

Electrical Component Terminology​

Harness Layouts​

Board Layouts​

8.5.1 Ground Control Module Pin Connections​

8.5.2 Platform Control Module Pin Connections​

AMP Connector​

8.6.1 Assembly​

8.6.2 Disassembly​

8.6.3 Wedge Lock​

8.6.4 Service - Voltage Reading​

Wiring Harness and Connector Label Diagrams​

8.7.1 Connector Labels​

8.7.2 Component Labels​

Telematics Gateway​

8.8.1 Telematics-Ready (TCU) Plug​

Removal and Installation

Wheel and Tire​

Chassis/Frame Assembly​

9.2.1 Axle and Drive Assemblies Troubleshooting​

9.2.2 Front and Rear Axle Assembly​

9.2.3 Drive Hub and Drive Motor/Brake Assembly​

9.2.4 Spindle Assembly​

Boom​

9.3.1 Boom Components Terminology​

9.3.2 Troubleshooting​

9.3.3 Main Boom Powertrack​

9.3.4 Boom Maintenance​

9.3.5 Jib and Rotator Assembly​

9.3.6 Swing Jib and Rotator Assembly​

Platform​

9.4.1 Platform Support​

9.4.2 Bolt-On External Fall Arrest​

Engine Generator​

9.5.1 Component Terminology​

9.5.2 Engine Generator Replacement (H600SJ/H600SJP Only)​

9.5.3 Starter​

9.5.4 Fuel Tank (H600SJ/H600SJP Only)​

Transmission​

Hydraulic Cylinders​

9.7.1 Main Boom Telescope Cylinder​

9.7.2 Main Boom Lift Cylinder​

9.7.3 Master Cylinder​

9.7.4 Slave Cylinder​

9.7.5 Platform Level Cylinder​

9.7.6 Jib Lift Cylinder​

9.7.7 Axle Lockout Cylinder​

9.7.8 Steer Cylinder​

Hydraulic Valves​

9.8.1 Platform Valve​

9.8.2 Main Control Valve​

9.8.3 Drive Valve​

9.8.4 Axle Lockout Valve​

Hydraulic Pumps​

Electrical Components​

9.10.1 Battery Box and Battery​

Battery Charger​

9.11.1 Battery Charger (Delta Q)​

9.11.2 Battery Charger (Green Power)​

Turntable​

9.12.1 Replacement of Swing Bearing​

9.12.2 Counterweight​

ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

9.13.1 ClearSky® LED Motion / Amber Beacon (CS550) (if equipped)​

Disassembly and Assembly

Drive Assembly​

10.1.1 Drive Hub​

10.1.2 Drive Motor​

10.1.3 Spindle, 2WD​

Boom and Jib Assembly​

10.2.1 Main Boom Assembly​

10.2.2 Platform Rotator​

10.2.3 Jib Rotator​

Platform​

Engine Components​

10.4.1 Engine Disassembly, Inspection and Service​

10.4.2 Fuel Tank​

Pumps​

10.5.1 Function Pump​

10.5.2 Drive Pump​

Hydraulic Cylinders​

10.6.1 Axle Lockout Cylinder​

10.6.2 Slave Cylinder​

10.6.3 Jib Lift Cylinder​

10.6.4 Main Lift Cylinder​

10.6.5 Master Cylinder​

10.6.6 Steer Cylinder​

10.6.7 Telescope Cylinder​

Hydraulic Valves​

Hydraulic Components​

10.8.1 Hydraulic Oil Tank​

Turntable​

10.9.1 Swing Motor​

Generator Disassembly and Assembly​

Powertrack​

10.11.1 Remove Link​

10.11.2 Install New Link​

10.11.3 Replace Fixed End Brackets​

10.11.4 Replace Moving End Brackets​

Torque/Connection Information

Hydraulic Fittings​

11.1.1 Tapered Thread Types​

11.1.2 Straight Thread Types, Tube and Hose Connections​

11.1.3 Straight Thread Types, Port Connections​

11.1.4 Flange Connection Types​

11.1.5 Tightening Methods​

11.1.6 Assembly and Torque Specifications​

11.1.7 General Tube Type Fitting Assembly Instructions​

11.1.8 Assembly Instructions for American Standard Pipe Thread Tapered Connections.​

11.1.9 Assembly Instructions for British Standard Pipe Thread Tapered Connections​

11.1.10 Assembly Instructions for 37° (JIC) Flare Fittings​

11.1.11 Assembly Instructions for 45° SAE Flare Fittings​

11.1.12 Assembly Instructions for O-Ring Face Seal (ORFS) Fittings​

11.1.13 Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)​

11.1.14 Assembly Instructions for Bulkhead (BH) Fittings​

11.1.15 Assembly Instructions for O-Ring Boss (ORB) Fittings​

11.1.16 Assembly Instructions for Adjustable Port End Metric Fittings​

11.1.17 Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends​

11.1.18 Assembly instructions for Adjustable Port End (BSPP) Fittings​

11.1.19 Assembly Instructions for Flange Connections: (FL61 and FL62)​

11.1.20 Double Wrench Method​

11.1.21 FFWR and TFFT Methods​

11.1.22 Adjustable Stud End Assembly​

11.1.23 O-ring Installation (Replacement)​

Torque Charts​

11.2.1 SAE Fastener Torque Chart​

11.2.2 Metric Fastener Torque Chart​

Schematics

Hydraulic Schematics​

Electrical Schematics​