JLG 600S, 600SJ, 660SJ Boom Lift Service Manual
492 pages · Publication 3121202
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What's inside
From the manual's own table of contents: 518 sections, 598 entries. See sample pages (PDF, 595 KB)
General
Hydraulic System Safety
Maintenance3 topics
- Operating Specifications
- Capacities
- Component Data
Engine Data
Dimensional Data3 topics
- Torque Requirements
- Tires
- Lubrication
Hydraulic Oil
Drive System
Swing System
Auxiliary Power Pump
Hydraulic Filters7 topics
- Performance Data
- Cylinder Specifications
- Major Component Weights
- Critical Stability Weights
- Operator Maintenance
- Draining Oil Build Up From The Propane Regulator (Prior to SN 0300132529)
- Propane Fuel Filter Replacement
Removal
Installation3 topics
- Propane Fuel System Pressure Relief
- 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
Show all 518 sections
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift
Theory
Cylinder Leakage Test
Cylinder Thermal 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 Equipment1 topic
- Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Oscillating Axle Bleeding Procedure And Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test (If Equipped)2 topics
- Oscillating Axle Lockout Test
- Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc
To Engage Drive Motors and Brakes (Normal Operation)2 topics
- Wheel Drive Assembly
- Drive Hub
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
Spare Parts Kits
Replacing the Drive Shaft Seal
Disassembly and Assembly
Assembly Notes
Taper Roller Bearing Initial Tension
Testing and Setup
Shaft Seal Replacement
Description
Disassembly
Inspection
Assembly
Initial Start-up Procedures
Troubleshooting
Speed Sensor Replacement
Minor Repair
Speed Sensor Adjustment
Loop Flushing Valve3 topics
- Steer Adjustments
- Swing Hub Removal
- Swing Hub Installation
Procedure For Setting Swing Gear Backlash
Swing Drive Lubrication
Adjustment Procedures
Main Assembly Procedure
Hub Shaft Sub-Assembly
Carrier Sub-Assembly
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Drive Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Assembly
Carrier Assembly
Main Drive Assembly
Motor and Brake Assembly
Motor Control Valve Assembly1 topic
- Swing Motor Assembly
Disassembly and Inspection
One Piece Stator Construction1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values
Bleeding2 topics
- Rotary Coupling (USA Built Machines, SN 0300087000 through 0300138728)
- Engine
Engine Installation1 topic
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings3 topics
- Spark Arrester Cleaning Instructions
- Glow Plugs
- Dual Fuel System (Gas Engine only)
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline1 topic
- Ford EFI Engine
Performing Diagnostics
ECM/EPM and Sensors
Fuel System1 topic
- Ford LPG System
Regulator
Megajector
Mixer
Lockoff Solenoid
Megajector Diagnostic Code Descriptions2 topics
- Deutz EMR 2
- Bio Fuel In Deutz Engines
Bio Fuel
Approved Engines
Biological Contamination In Fuels1 topic
- GM Engine General Maintenance
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure - Dual Fuel Engine1 topic
- GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Injector Rail
Fuel Injector1 topic
- TABLE OF CONTENTS GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement2 topics
- LP Gas Fitting Inspection
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids1 topic
- Platform
Support Removal
Support Installation3 topics
- Rotator and Slave Cylinder
- Main Boom Powertrack
- Powertrack Maintenance
One Piece Bracket Maintenance
Two Piece Bracket Maintenance
Snap Rings and Screws2 topics
- Boom Cleanliness Guidelines
- Main Boom Assembly
Boom Disassembly2 topics
- Articulating Jib Boom
- Limit Switches and Cam Valve Adjustment
Platform Sections Replacement1 topic
- Boom Rope Torquing Procedure
Torque Procedures1 topic
- Wear Pads
Main Boom1 topic
- Wire Rope
Three Month Inspection
Year or 7000 Hour Inspection
Additional Replacement Criteria1 topic
- Rotator Assembly
Theory of Operation
Required Tools
Making a Seal Tool
Before Disassembly
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Installation and Bleeding2 topics
- Foot Switch Adjustment
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- 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 Valves1 topic
- Hydraulic Cylinders
Axle Lockout Cylinder (USA Built Machines, SN 0300087000 through 0300089728)
Platform Level Cylinder
Jib Lift Cylinder (600SJ/660SJ)
Main Boom Lift Cylinder
Master Cylinder
Steer Cylinder (USA Built Machines, SN 0300087000 through 0300142634)
Telescope Cylinder1 topic
- Cylinder Removal and Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation
Master Cylinder Removal
Master 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
- TABLE OF CONTENTS Pressure Setting Procedures
Main Relief, Steer, Swing and Lift Down
Platform Level
Articulating Jib Boom (If Equipped)
Wheel Steer (If Equipped)4 topics
- Hydraulic Component Start-up Procedures and Recommendations
- Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
- Hydraulic Schematics
- JLG Control System Analyzer Kit Instructions
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 Description2 topics
- Machine Personality Settings and Function Speeds
- Machine Orientation When Doing Speed Tests
Test Notes
Analyzer Diagnostics Menu Structure2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AWP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
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
- Electrical Schematics
Maintenance and Lubrication Diagram
Filter Lock Assembly
Serial Number Locations
Torque Chart (SAE Fasteners - Sheet 1 of 5)
Torque Chart (SAE Fasteners - Sheet 2 of 5)
Torque Chart (SAE Fasteners - Sheet 3 of 5)
Torque Chart (SAE Fasteners - Sheet 4 of 5)
Torque Chart (Metric Fasteners - Sheet 5 of 5)
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Ford
Engine Operating Temperature Specifications - Caterpillar
Engine Operating Temperature Specifications - GM
Front Axle And Steering Installations - With Tow Package (2WD) - Sheet 1 of 2
Front Axle And Steering Installations - With Tow Package (2WD) - Sheet 2 of 2
Front Axle And Steering Installations - Without Tow Package (2WD) - Sheet 1 of 2
Front Axle And Steering Installations - Without Tow Package (2WD) - Sheet 2 of 2
Front Axle And Steering Installations (4WD) - Sheet 1 of 2
Front Axle And Steering Installations (4WD) - Sheet 2 of 2
Rear Steering Installation - Sheet 1 of 2
Rear Steering Installation (4WS) - Sheet 2 of 2
Disconnecting the Drive Hubs
Drive Hub Installation
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
Flow Control Pilot Valves
Drive Motor Cross Section
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Removing the Shaft Seal
Steer Adjustments
Swing Drive Hub Adjustment
Swing Hub
Swing Hub Assembly
Motor Control Valve
Motor and Brake
Hub-Shaft
Carrier
Swing Drive Motor
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Boom Placement
Swing Bearing Tolerance Measuring Point
Swing Bearing Torque Sequence
Swing Bearing Removal - 600S
Swing Bearing Removal - 600SJ
Swing Bearing Removal - 660SJ
GM Engine without UGM - Sheet 1 of 3
GM Engine without UGM - Sheet 2 of 3
GM Engine without UGM - Sheet 3 of 3
GM Engine with UGM - Sheet 1 of 3
GM Engine with UGM - Sheet 2 of 3
GM Engine with UGM - Sheet 3 of 3
CAT Engine -Sheet 1 of 2
CAT Engine -Sheet 2 of 2
Deutz 2WD Engine Installation
Deutz 4WD Engine Installation
GM 2WD Engine Installation
GM 4WD Engine Installation
CAT 2WD Engine Installation
CAT 4WD Engine Installation
Deutz Arctic Engine Installation
CAT Arctic Engine Installation
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
EFI Component Location
Typical Fuel System
Ford LPG System
Deutz Sensors for JLG Control System
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
Engine Oil Dip Stick
Electric Fuel Lock Off
Low Pressure Regulators
ETC Throttle Control Device
LPG Engine Control Unit (ECM)
ECM Assembly
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Fuel Pressure and Temperature Manifold Assembly
Pressure Regulator Section
(TMAP) Sensor & Electronic Throttle Control (ETC)
Mixer Assembly
LP Gas Fitting Components
Hood Mounting Bracket Clearance
Location of Components Platform Support
Platform Support Torque Values
Removal of Components - Rotator and Leveling Cylinder
Main Boom Powertrack Components
Main Boom Powertrack0 Components
Powertrack Installation Main Boom - Sheet 1 of 2
Powertrack Installation Main Boom - Sheet 2 of 2
Boom Powertrack Installation
Boom Assembly Cutaway - Sheet 1 of 2
Boom Assembly Cutaway - Sheet 2 of 2
Dimension of Sheaves When New
Routing Installation of Retract Wire Ropes
Proximity Switch Adjustment
Reassembly of Components - Boom Powertrack Assembly
Location of Components - Articulating Jib Boom
Horizontal Limit and Dual Capacity Limit Switches Adjustments
Transport Switch Adjustments - CE Machines Only
Platform Section Replacement
Clamping Wire Ropes
Location and Thickness of Wear Pads
Rotary Actuator (Exploded View)
Rotary Actuator (Cutaway View)
Rotator Counterbalance Valve
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation of Head Seal Kit
Tapered Bushing Installation
Seating the Tapered Bearing
Hydrolock Piston Seal Installation
Piston Seal Kit Installation
Rod Assembly Installation
Spanner Nut Removal
Steer Cylinder USA Built Machines, SN 0300087000 through 0300142634)
Boom Positioning and Support
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 Valve Components
Main Valve Components Pressure Adjustments
Hydraulic Schematic - Sheet 1 of 6
Hydraulic Schematic - Sheet 2 of 6
Hydraulic Schematic - Sheet 3 of 6
Hydraulic Schematic - Sheet 4 of 6
Hydraulic Schematic - Sheet 5 of 6
Hydraulic Schematic - Sheet 6 of 6
Hand Held Analyzer
ADE Block Diagram
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4
Analyzer Flow Chart -Sheet 1 of 8
Analyzer Flow Chart -Sheet 2 of 8
Analyzer Flow Chart -Sheet 3 of 8
Analyzer Flow Chart -Sheet 4 of 8
Analyzer Flow Chart -Sheet 5 of 8
Analyzer Flow Chart -Sheet 6 of 8
Analyzer Flow Chart -Sheet 7 of 8
Analyzer Flow Chart -Sheet 8 of 8
Control Module Location
Analyzer Connecting Points
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Platform Control Module (With UGM) - Sheet 1 of 2
Platform Control Module (With UGM) - Sheet 2 of 2
Platform Control Module (Without UGM) - Sheet 1 of 2
Platform Control Module (Without UGM) - Sheet 2 of 2
Voltage Measurement (DC)
Current Measurement (DC)
Application to Plug/Male Contacts
Use of Seal Plugs
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
Electrical Components Installation (Without UGM) - Sheet 1 of 2
Electrical Components Installation (Without UGM) - Sheet 2 of 2
Electrical Components Installation (With UGM) - Sheet 1 of 2
Electrical Components Installation (With UGM) - Sheet 2 of 2
Electrical Schematic - Sheet 1 of 10
Electrical Schematic - Sheet 2 of 10
Electrical Schematic - Sheet 3 of 10
Electrical Schematic - Sheet 4 of 10
Electrical Schematic - Sheet 5 of 10
Electrical Schematic - Sheet 6 of 10
Electrical Schematic - Sheet 7 of 10
Electrical Schematic - Sheet 8 of 10
Electrical Schematic - Sheet 9 of 10
Electrical Schematic - Sheet 10 of 10
Electrical Schematic GM - Sheet 1 of 2
Electrical Schematic GM - Sheet 2 of 2
Capacities
Ford LRG - 425 Specifications
Deutz F4M1011F/F4M2011 Specifications
Deutz D2011L04 Specifications
Caterpillar 3044C/3.4
Torque Requirements
Tire Specifications
Mobilfluid 424 Specs
Mobil DTE 10 Excel 32 Specs
Exxon Univis HVI 26 Specs
Quintolubric 888-46
Mobil EAL 224H Specs (USA Build machine)
Mobil EAL Envirosyn H46 Specs
Mobil SHC Hydraulic EAL 46 Specs
Drive System Specifications
Swing System Specifications
Auxiliary Power Pump Specifications
Performance Data
Cylinder Specifications - 600S
Cylinder Specifications - 600SJ
Cylinder Specifications - 660SJ
Major Component Weights - 600S
Major Component Weights - 600SJ
Major Component Weights - 660SJ
Critical Stability Weights - 600S
Critical Stability Weights - 600SJ
Critical Stability Weights - 660SJ
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart - 9 Lug
Wheel Torque Chart - 10 Lug
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Coupling Port Information Table - 2WS
Coupling Port Information Table - 4WS
Coupling Port Information Table (7 port)
Coupling Port Information Table (9 port)
ECM Diagnostic Trouble Codes
LPG Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
Analyzer Abbreviations
Machine Configuration Programming Information Prior to Software Version P5.3
Machine Configuration Programming Information Software Version P5.3 to P6.1
Machine Configuration Programming Information Software Version P6.1 to Present
Machine Configuration Programming Information
600S Machine Configuration Programming Settings
600SJ Machine Configuration Programming Settings
660SJ Machine Configuration Programming Settings
Machine Personality Settings
Function Speeds (In Seconds)
ADJUSTMENTS - Personality Descriptions
Diagnostic Menu Descriptions
Help Fault Codes, Displayed Faults, and Descriptions
Diagnostic Trouble Code Listing
Inside this manual
Real pages from this service manual (492 pages). Open the sample pages (PDF, 593 KB)
- Specifications, page 22: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 358: SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
- Diagram, page 379: SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
- Color page, page 261: SECTION 4 - BOOM & PLATFORM
- Color page, page 466: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
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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, 492 pages
Quantity one is the manual described above.
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Other editions and similar models
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