JLG 600A, 600AJ, 600S, 600SJ, 660SJ Boom Lift Service Manual
322 pages · Publication 3120718
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
What's inside
From the manual's own table of contents: 392 sections, 470 entries. See sample pages (PDF, 586 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Capacities
Fuel Tank
Hydraulic Oil Tank
Hydraulic System (Including Tank)
Torque Hub, Drive
Engine Crankcase1 topic
- 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 System1 topic
- 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)
Show all 392 sections
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 topic
- Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes2 topics
- Torque Requirements
- Lubrication
Ford LRG423 & LRG425 Engine
Deutz F4M1011F Engine
Continental TMD27 Engine
Hydraulic Oil
Lubrication Specifications1 topic
- Pressure Settings
Rexroth Valve (S Models)
Rexroth Valve (A Models)5 topics
- Cylinder Specifications
- Major Component Weights
- Critical Stability Weights
- Serial Number Locations
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
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 Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly1 topic
- Drive Torque hub, Prior to S/N 75606
Cleaning and Inspection
Repair2 topics
- Torque Hub, Drive (Auburn Gear)
- 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 Check1 topic
- Drive Brake - Mico, Prior to S/N 75606
Inspection1 topic
- Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc
To Engage Drive Motors and Brakes (Normal Operation)
Spare Parts Kits
Replacing the Drive Shaft Seal
Disassembly and Assembly
Assembly Notes
Taper Roller Bearing Initial Tension
Testing and Setup1 topic
- Drive Motor (600A 2WD)
Shaft Seal Replacement2 topics
- Drive Motor Adjustment Procedure (S Models Only, Prior to S/N 75606)
- Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test2 topics
- Steer Adjustments (S Models)
- Swing Hub
Adjustment Procedures1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance (S & A Models)
Swing Bearing Replacement
Swing Bearing Torque Values2 topics
- Swing Brake - Mico
- Tilt Alarm Switch (Machines With External Tilt Sensor)
Manual Adjustment3 topics
- Spark Arrester Cleaning Instructions
- Rotary Coupling - 600s s/n 75606 TO pRESENT
- Dual Fuel System
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline1 topic
- Electric Governor Installation and Adjustments - Ford LRG Engine
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)
Troubleshooting1 topic
- Throttle Checks and Adjustments - Deutz or Continental Engine (Prior to S/N 61927)
Procedure
Controller Status
Failure Modes2 topics
- Automatic Choke Adjustment - Ford Engine
- Cold Weather Starting Difficulty
Checking the Carburetor
Checking the Ignition
Checking the Fuel2 topics
- GLow Plugs
- Ford EFI Engine (machines after SN 48907)
Performing Diagnostics
ECM AND SENSORS
Fuel System1 topic
- Ford LPG System (S Models after S/N 79619 & A Models after S/N 79888)
Description
Regulator
Megajector
Mixer
Lockoff Solenoid
Megajector Diagnostic Code Descriptions1 topic
- Boom Rope Torquing Procedures
Torque Procedures (S Models)1 topic
- Wear Pads
Tower Boom (A Models)
Main Boom1 topic
- Wire Rope (S Models)
Three Month Inspection
Seven Year Inspection
Replacement Criteria1 topic
- Boom Maintenance (S Models)
Removal
Disassembly of Boom Sections
Installation5 topics
- Boom Maintenance (A Models)
- Tower Boom
- Articulating Jib Boom
- Limit Switches and Cam Valve Adjustment
- Platform
Platform Sections Replacement2 topics
- Rotator - Helac
- Drive Card Setup Procedures
Lift, Swing, and Drive Cards
Flow Control Card3 topics
- Foot Switch Adjustment
- Boom Synchronizing Procedure (A Models Only)
- Cylinders - Theory of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves2 topics
- Cylinder Repair
- 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 Installation1 topic
- Cylinder Removal and Installation (A Models)
Upright Level Cylinder Removal
Upright Level Cylinder Installation
Tower Boom Lift Cylinder Removal
Tower Lift Cylinder Installation
Tower Telescope Cylinder Removal
Tower Telescope Cylinder Installation1 topic
- Variable Displacement pump (M46 series)
Inspections and Adjustments
Minor Repair and Replacement1 topic
- Valves - Theory of Operation
Solenoid Control Valve - Rexroth
Relief Valves1 topic
- Pressure Setting Procedures (S and A Models)
Main Relief, Steer, Swing and Lift Down
Platform Level
Articulating Jib Boom (If Equipped)
Wheel Steer (If Equipped)14 topics
- Hydraulic Component Start-Up Procedures and Recommendations
- Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
- Introduction
- To Connect the JLG Control System Analyzer
- Using the Analyzer
- Changing the Access Level of the Hand Held Analyzer
- Adjusting Parameters Using the Hand Held Analyzer
- Machine Setup
- Level Vehicle Description
- Machine Personality Settings
- Analyzer Diagnostics Menu Structure
- General
- Troubleshooting
- Hydraulic Circuit Checks
600S Lug Torques
Serial Number Locations
Lubrication Point Location - S Models
Lubrication Point Location - A Models
Torque Chart
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Ford
Engine Operating Temperature Specifications - Caterpillar
Torque Hub, Drive (Fairfield)
Torque Hub, Drive (Auburn Gear)
Input Carrier
Planet Gear Sub Assembly
Planet Gear Subassembly
Hub Spindle
Spindle Brake
Coupling Subassembly
Hub Assembly
Bearing Cup Pressing Tool
Seal Pressing Tool
Drift Pin for Lining Up Thrust Washers with Output Planet Gear
Drive Brake Assembly (Mico)
Disconnecting the Drive Hubs
600S Drive Motor Cutaway
Flow Control Pilot Valves
Drive Motor Adjustment (S Models Prior to S/N 75606)
Oscillating Valve Adjustment
Brake Valve Wiring Connection
Drive Manual Control Valve
Steer Adjustments
Swing Torque Hub Adjustment
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Boom Placement (S Models)
Swing Bearing Tolerance Boom Placement (A Models)
Swing Bearing Tolerance Measuring Point
Swing Bearing Torque Sequence
Swing Brake Assembly (Mico)
Tilt Switch Adjustment
Rotary Coupling - Sheet 1 of 2
Rotary Coupling - Sheet 2 of 2
Rotary Coupling Port Location - 2WS
Rotary Coupling Port Location - 4WS
Addco Adjustments
Malfunction Indicator Light and Test Button
EFI Component Location
Typical Fuel System
Ford LPG System
Deutz Sensors for JLG Control System
Dimensions of Boom Sections
Clamping Wire Ropes
Location and Thickness of Wear Pads
Location of Components - Platform Support
Location of Components - Rotator and Leveling Cylinder
Location of Components - Boom Powertrack
Boom Assembly Cutaway - S Models - Sheet 1 of 3
Boom Assembly Cutaway - S Models - Sheet 2 of 3
Boom Assembly Cutaway - S Models - Sheet 3 of 3
Disassembly of Sheave Assembly
Disassembly Wire Rope Routing Procedure
Dimension of Sheaves When New
Routing Installation of Retract Wire Ropes
Boom Powertrack Installation
Reassembly of Components - Boom Powertrack Assembly
Reassembly of Components - Rotator and Slave Leveling Cylinder
Location of Components - Boom Powertrack (A Models)
Location of Components - Upright
Location of Components - Tower Boom
Location of Components - Tower Boom Powertrack
Location of Components - Articulating Jib Boom
Limit Switches Adjustments (S Models)
Limit Switches Adjustments (A Models)
Platform Section Replacement
Removing Portion of End Cap
Heating Setscrew
Removing Setscrew
Rotator Assembly (Helac)
Removing End Cap
Removing Shaft from Housing
Removing Sleeve from Housing
Actuator Timing
Control Card
Cylinder Barrel Support
Cap Screw Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Piston Seal Kit Installation
Tapered Bushing Installation
Seating the Tapered Bearing
Rod Assembly Installation
Boom Positioning and Support, Cylinder Repair (S Models)
Location of Components - Telescope and Lift Cylinder
Leveling Cylinder Removal
Overriding the Plunger Valve
Boom Positioning and Support, Cylinder Repair (A Models)
600S Axle Lockout Cylinder (Prior to S/N 75606)
600S Axle Lockout Cylinder (S/N 75606 to Present)
600S Lift Cylinder
600S & 600A Jib Lift Cylinder
600S & 600A Master Cylinder
600S & 600A Steer Cylinder
600S Telescope Cylinder
600A Axle Lockout Cylinder
600A Level (Upright) Cylinder
600A Main Boom Lift Cylinder
600A Tower Boom Lift Cylinder
600A Main Boom Telescope Cylinder
Troubleshooting - Neutral Difficult or Impossible to Find
Troubleshooting - System Operating Hot
Troubleshooting - Transmission Operates in One Direction Only
Troubleshooting - System Response is Sluggish
Troubleshooting - System Will Not Operate in Either Direction
Variable Displacement Pump
Articulating Jib Boom Pressure Adjustments
Main Control Valve Pressure Adjustments - Sheet 1 of 2
Main Control Valve Pressure Adjustments - Sheet 2 of 2
Location of Components - Main Control Valve
Hand Held Analyzer
ADE Block Diagram
Analyzer Connecting Points
Control Module Location
Analyzer Flow Chart - Sheet 1 of 4
Analyzer Flow Chart - Sheet 2 of 4
Analyzer Flow Chart - Sheet 3 of 4
Analyzer Flow Chart - Sheet 4 of 4
Electrical Harness - S Models (Prior to S/N 61927) - Sheet 1 of 2
Electrical Harness - S Models (Prior to S/N 61927) - Sheet 2 of 2
Electrical Harness - S Models (S/N 75606 to Present) - Sheet 1 of 2
Electrical Harness - S Models (S/N 75606 to Present) - Sheet 2 of 2
Electrical Harness - A Models (Prior to S/N 61927) - Sheet 1 of 2
Electrical Harness - A Models (Prior to S/N 61927) - Sheet 2 of 2
Electrical Harness - A Models (S/N 64270 to Present) - Sheet 1 of 2
Electrical Harness - A Models (S/N 64270 to Present) - Sheet 2 of 2
Electrical Schematic - Deutz or Continental Engine - Sheet 1 of 2
Electrical Schematic - Deutz or Continental Engine - Sheet 2 of 2
Electrical Schematic (NCW) - Deutz or Continental Engine - Sheet 1 of 2
Electrical Schematic (NCW) - Deutz or Continental Engine - Sheet 2 of 2
Electrical Schematic - Ford LRG Engine - Sheet 1 of 2
Electrical Schematic - Ford LRG Engine - Sheet 2 of 2
Electrical Schematic (NCW) - Ford LRG Engine - Sheet 1 of 4
Electrical Schematic (NCW) - Ford LRG Engine - Sheet 2 of 4
Electrical Schematic (NCW) - Ford LRG Engine - Sheet 3 of 4
Electrical Schematic (NCW) - Ford LRG Engine - Sheet 4 of 4
Electrical Schematic - UL - Ford LRG Sheet 1 of 4
Electrical Schematic - UL - Ford LRG Sheet 2 of 4
Electrical Schematic - UL - Ford LRG Sheet 3 of 4
Electrical Schematic - UL - Ford LRG Sheet 4 of 4
Electrical Schematic - UL Domestic -Deutz Sheet 1 of 2
Electrical Schematic - UL Domestic -Deutz Sheet 2 of 2
Electrical Schematic - UL Domestic - LP Gas Sheet 1 of 4
Electrical Schematic - UL Domestic - LP Gas Sheet 2 of 4
Electrical Schematic - UL Domestic - LP Gas Sheet 3 of 4
Electrical Schematic - UL Domestic - LP Gas Sheet 4 of 4
Electrical Schematic - ADE w/External Tilt - Sheet 1 of 2
Electrical Schematic - ADE w/External Tilt - Sheet 2 of 2
Electrical Schematic - Isuzu Engine - Sheet 1 of 4
Electrical Schematic - Isuzu Engine - Sheet 2 of 4
Electrical Schematic - Isuzu Engine - Sheet 3 of 4
Electrical Schematic - Isuzu Engine - Sheet 4 of 4
Electrical Schematic - ADE - Sheet 1 of 4
Electrical Schematic - ADE - Sheet 2 of 4
Electrical Schematic - ADE - Sheet 3 of 4
Electrical Schematic - ADE - Sheet 4 of 4
Hydraulic Schematic - S Models - Sheet 1 of 4
Hydraulic Schematic - S Models - Sheet 2 of 4
Hydraulic Schematic - S Models - Sheet 3 of 4
Hydraulic Schematic - S Models - Sheet 4 of 4
Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 1 of 6
Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 2 of 6
Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 3 of 6
Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 4 of 6
Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 5 of 6
Hydraulic Schematic - S Models, S/N 75606 to Present - Sheet 6 of 6
Hydraulic Schematic - A Models - Sheet 1 of 4
Hydraulic Schematic - A Models - Sheet 2 of 4
Hydraulic Schematic - A Models - Sheet 3 of 4
Hydraulic Schematic - A Models - Sheet 4 of 4
Function Speeds (In Seconds)
Torque Requirements
Mobil DTE 13M Specs
Cylinder Specifications (S Models)
Cylinder Specifications (A Models)
Major Component Weights (S Models)
Major Component Weights (A Models)
Critical Stability Weights (S Models)
Critical Stability Weights (A Models)
Lubrication Chart - S Models
Lubrication Chart - A Models
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Coupling Port Information Table - 2WS
Coupling Port Information Table - 4WS
Position Controller Truth Table
ECM Diagnostic Trouble Codes
Function Speeds
Flow Control Card Settings
Flow Control Card Ramp Time
Cylinder Head and Tapered Bushing Torque Specifications. (S Models)
Holding Valve Torque Specifications
Cylinder Head and Tapered Bushing Torque Specifications. (A Models)
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions - Prior to S/N 66437
Help Fault Codes, Displayed Faults, and Descriptions - S/N 66937 to Present
Machine Configuration Programming Information
Fault Code Listing
Adjustments - Personality Descriptions
Diagnostic Menu Descriptions
Inside this manual
Real pages from this service manual (322 pages). Open the sample pages (PDF, 585 KB)
- Specifications, page 19: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 199: SECTION 5 - HYDRAULICS
- Diagram, page 311: SECTION 7 - SCHEMATICS
- Color page, page 136: SECTION 3 - CHASSIS & TURNTABLE
- Color page, page 118: SECTION 3 - CHASSIS & TURNTABLE
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 3120718$69.63
Added to your cart. View cart
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 322 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).