JLG 600S, 660SJ Boom Lift Service Manual
382 pages · Publication 3121298
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- Models
- 600S, 660SJ
- Serial coverage
- 0300171769-0300235167, B300000970-B300002654, Exclude Serial Number Range: 0300224266, 0300224267, 0300224755-0300224758, 0300233720-0300233722, 0300234973-0300234975, B300002216, B300002217, B300002382
- Manual type
- Service Manual
- Pages
- 382
- Publication
- 3121298
- Condition
- Brand new
What's inside
From the manual's own table of contents: 476 sections, 547 entries. See sample pages (PDF, 600 KB)
General
Hydraulic System Safety
Maintenance10 topics
- Operating Specifications
- Dimensional Data
- Capacities
- Tires
- Engine Data
- Torque Requirements
- Hydraulic Oil
- Major Component Weights
- Operator Maintenance
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventive 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
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Show all 476 sections
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 Equipment1 topic
- Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Torque Hub
Oil Information
Roll and Leak Testing
Tightening and Torquing Bolts
Main Disassembly
Output Carrier Disassembly
Input Carrier Disassembly
Hub-Spindle Disassembly
Spindle-Brake Disassembly
Cover Disassembly
Cover Assembly
Input Carrier Assembly
Spindle - Brake Assembly
Hub-Spindle Assembly
Output Planet Gear Assembly
Main Assembly
Integral Brake Check1 topic
- Free Wheeling Option
Disengage Drive Motors & Brakes for Towing, etc. (Free Wheel)
Engage Drive Motors & Brakes (Normal Operation)1 topic
- Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Disassembly
Inspection
Assembly
Initial Start-up Procedures1 topic
- Oscillating Axle Bleed Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test2 topics
- Steer Adjustments
- Swing Drive
Gear Backlash
Swing Drive Lubrication
Motor Control Valve Disassembly
Motor and Brake Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Subassembly
Carrier Subassembly
Motor and Brake Assembly
Motor Control Valve Assembly1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values2 topics
- Rotary Coupling
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings1 topic
- Deutz TD2.9L4 Engine
Check Oil Level
Change Engine Oil
Change Oil Filter
Change Fuel Filters1 topic
- Deutz D2011 Engine
Checking Oil Level
Changing Engine Oil
Changing Oil Filter
Replace Fuel Filter
Clean Fuel Strainer4 topics
- Spark Arrester Cleaning Instructions
- Glow Plugs
- Deutz EMR 2
- Bio Fuel in Deutz Engines
Bio Fuel
Biological Contamination In Fuels2 topics
- GM Engine
- GM Engine General Maintenance
Drive Belt Maintenance
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Coolant Fill Procedure - Dual Fuel Engine1 topic
- GM Engine Dual Fuel System
Fuel Filter
Direct Electronic Pressure Regulator (DEPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Electric Lock Off
Engine Control Module (ECM)
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
- GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
Check/Drain Oil Build-Up In 2-Stage Vaporizer
Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
Exhaust System And Catalytic Converter Inspection And Maintenance
Temperature Manifold Absolute Pressure (TMAP) Sensor
Throttle Body (ETC) Replacement
Mixer Replacement
Electronic Pressure Regulator (EPR) Replacement
Regulator Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement1 topic
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids1 topic
- Platform
Support Removal
Support Installation
Platform Support Torque Settings1 topic
- Rotator And Slave Cylinder
Removal
Installation1 topic
- Main Boom Assembly
Boom Disassembly3 topics
- Main Boom Powertrack
- Wear Pads
- Wire Rope
Three Month Inspection
Year or 7000 Hour Replacement
Additional Replacement Criteria1 topic
- Wire Rope Tensioning Adjustment
Wire Rope Tensioning Procedure3 topics
- Limit Switches and Cam Valve Adjustment
- Boom Cleanliness Guidelines
- Rotary Actuator
Theory of Operation
Required Tools
Installing Counterbalance Valve
Testing Actuator
Testing Actuator for Internal Leaks
Installation and Bleeding2 topics
- Foot Switch Adjustment
- Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets1 topic
- Skyguard
Operation
Functional Test
Diagnostic & Troubleshooting1 topic
- O-Ring Lubrication
Cup and Brush
Spray
Brush-On1 topic
- Cylinders - Theory of Operation
Systems With Double Acting Cylinders
Systems With 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
- Cylinder Removal and Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Boom Lift Cylinder Removal
Main Boom Lift Cylinder Installation1 topic
- Cylinder Repair
Cylinder Locations
Main Lift Cylinder
Cleaning and Inspection
Master Cylinder
Telescope Cylinder
Platform Level (Slave) Cylinder
Jib Lift Cylinder (SJ Only)
Steer Cylinder
Axle Lockout Cylinder1 topic
- Hydraulic Pump (Gear)
Inspect Parts For Wear
General Information
Reverse Shaft Rotation of Pump
Placing Pump Back Into Service1 topic
- Variable Pump
Ports and Pressure Gauges
NFPE Control
Remove and Install FNR and NFPE Modules
Remove and Install FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
Charge Pump2 topics
- Hydraulic Component Start-Up
- Main Valve Block Pressure Settings
Main Relief
Main Lift Down
Swing
2-Wheel Steer
4-Wheel Steer1 topic
- Platform (Slave) Valve Block Pressure Settings
Platform (Slave) Level Extend
Platform (Slave) Level Retract
Articulating Jib2 topics
- Hydraulic Schematics
- Introduction
Connect JLG Control System Analyzer
Using Analyzer
Changing Access Level
Adjust Parameters
Machine Setup
Level Vehicle Description2 topics
- Machine Personality Settings
- Machine Orientation When Setting Function Speeds
Test Notes3 topics
- CANbus Communications
- 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
Dielectric Grease Application
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 topic
- AMP Connector
Contact Assembly
Connector Assembly
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
- Telematics Gateway
Telematics-Ready (TCU) Plug1 topic
- Electrical Schematics
Operator Maintenance and Lubrication
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)
Deutz Engine and Hydraulic Operating Temperature Specifications
GM Engine and Hydraulic Operating Temperature Specifications
Wheel Lug Nut Tightening Sequence
Bolt Tightening Sequence
Torque Hub
Torque Hub Main Disassembly
Hub Spindle Disassembly
Spindle Brake Disassembly
Torque Hub Cover
Spindle-Brake Assembly
Hub Spindle Assembly
Hub Assembly
Bearing Cup Pressing Tool
Seal Pressing Tool
Drift Pin for Lining Up Thrust Washers with Output Planet Gear
Disengaging Drive Hubs
Drive Motor Cross Section
Removing Shaft Seal
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
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
Bleeder Valve Location
Steer Adjustments
Swing Drive Assembly
Swing Motor and Brake Assembly
Swing Drive Shim Placement
Swing Drive Pivot and Mounting Bolts
Swing Drive Jam Nut and Mounting Bolt
Main Control Valve Disassembly
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Tolerance Measurement Location & Boom Placement
Swing Bearing Torque Sequence
Swing Bearing Removal - 600S
Swing Bearing Removal - 660SJ
Rotary Coupling - Sheet 1 of 2
Rotary Coupling - Sheet 2 of 2
Rotary Coupling Port Location - 2WS
Rotary Coupling Port Location - 4WS
Generator Belt Tension
Generator Brushes and Slip Rings
Generator Cleaning
Generator Circuit Breaker Location
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Deutz TD2.9L4 Engine Installation - Sheet 1 of 2
Deutz TD2.9L4 Engine Installation - Sheet 2 of 2
Deutz 2.9 T4F Dipstick Markings
Engine Oil Viscosity
Deutz D2011 Engine Installation - Sheet 1 of 2
Deutz D2011 Engine Installation - Sheet 2 of 2
Deutz Dipstick Markings
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
GM Engine Installation Sheet 1 of 2
GM Engine Installation Sheet 2 of 2
GM Engine Oil Dip Stick
GM 3.0 Dual Fuel System Components
Direct Electronic Pressure Regulator
ELectronic Throttle Control Device
Electric Lock Off Assembly
ECM Assembly
ECM Input-Output Diagram
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Fuel Pressure and Temperature Manifold Assembly
Filter Lock Assembly
DEPR
Platform Support Torque Values
Rotator and Slave Cylinder
Boom Assembly Cutaway - Sheet 1 of 3
Boom Assembly Cutaway - Sheet 2 of 3
Boom Assembly Cutaway - Sheet 3 of 3
Routing Installation of Retract Wire Ropes
Proximity Switch Installation
Boom Powertrack Components
Boom Powertrack Assembly
Boom Powertrack Installation
Location and Thickness of Wear Pads
Wire Rope Wire Breaks
Wire Rope Kink
Sheave Groove Wear
Dimensions of Boom Sections
Clamping Wire Ropes
Horizontal Limit and Dual Capacity Limit Switches Adjustments
Transport Switch Adjustments - CE Machines Only
Rotary Actuator - Exploded View
Rotary Actuator - Assembly Drawing
Rotator Counterbalance Valve
Actuator Bleed Ports
Foot Switch Adjustment
Skyguard
Boom Positioning and Support, Cylinder Repair
Hydraulic Cylinder Locations
Cylinder Barrel Support
Marking Cylinder for Alignment
Cylinder Rod Support
Main Lift Cylinder Assembly
Tapered Bushing Removal
Composite Bushing Installation
Rod Seal Installation
Poly-Pak Piston Seal Installation
Wiper Seal Installation
Head Seal Kit Installation
Piston Seal Kit Installation
Tapered Bushing Installation
Rod Assembly Installation
Master Cylinder Assembly
Telescope Cylinder Assembly
Platform Level (Slave) Cylinder Assembly
Jib Lift Cylinder Assembly(660SJ)
Removing Spanner Nut
Steer Cylinder Assembly
Piston Seal and Wear Ring
Cylinder Head Disassembly
Cylinder Head Assembly
Spanner Nut Torque
Shim Adjustable Charge Relief Valve Components
Gauge Port Locations
Plugs/Fittings Size & Torque
Screw Adjustable Charge Relief Valve Components
Shaft Seal Components
Installation of Shaft Seal
Shaft Components
Charge Pump Components
Present), Deutz TD2.9L4 Engines (SN 0300188199 to Present)
Hydraulic Schematic
Hydraulic Schematic 2-Wheel Drive - 1 of 2
Hydraulic Schematic 2-Wheel Drive - 2 of 2
Hydraulic Schematic 4-Wheel Drive - 1 of 2
Hydraulic Schematic 4-Wheel Drive - 2 of 2
Hydraulic Schematic - 2 Wheel Steer - Sheet 1 of 2
Hydraulic Schematic - 2 Wheel Steer - Sheet 2 of 2
Hydraulic Schematic - 4 Wheel Steer - Sheet 1 of 2
Hydraulic Schematic - 4 Wheel Steer - Sheet 2 of 2
Hydraulic Schematic - 2 Wheel Drive - Sheet 1 of 2
Hydraulic Schematic - 2 Wheel Drive - Sheet 2 of 2
Hydraulic Schematic - 4 Wheel Drive - Sheet 1 of 2
Hydraulic Schematic - 4 Wheel Drive - Sheet 2 of 2
Hand-Held Analyzer
ADE Block Diagram
Analyzer Software Version 6.24 - Sheet 1 of 6
Analyzer Software Version 6.24 - Sheet 2 of 6
Analyzer Software Version 6.24 - Sheet 3 of 6
Analyzer Software Version 6.24 - Sheet 4 of 6
Analyzer Software Version 6.24 - Sheet 5 of 6
Analyzer Software Version 6.24 - Sheet 6 of 6
Control Module Locations
Analyzer Connecting Points
Ground Control Module Pin Connections 1 of 3
Ground Control Module Pin Connections 2 of 3
Ground Control Module Pin Connections 3 of 3
Platform Control Module Pin Connections 1 of 2
Platform Control Module Pin Connections 2 of 2
Voltage Measurement (DC)
Current Measurement (DC)
Applying Dielectric Grease
Deutsch Connector
Dielectric Grease On Female Contacts
Seal Plugs
AMP Mate-N-Lok Connector
DIN Connector
Brad Harrison/Phoenix Connectors
AMP Junior Timer
AMP Connector
AMP Contact Assembly
AMP Connector Assembly
AMP Contact Installation
Close Wedge Lock
Seating Wedge Lock
AMP Connector Disassembly
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
Telematics Gateway Harness
Telematics Gateway Harness - Sheet 2 of 3
Telematics Gateway Harness - Sheet 3 of 3
Electrical Components 1 of 2
Electrical Components 2 of 2
Platform and Ground Control Electrical Schematic - 1 of 2
Platform and Ground Control Electrical Schematic - 2 of 2
Generator Wiring Schematic 1 of 2
Generator Wiring Schematic 2 of 2
Deutz Engine Harness Electrical Schematic
GM/PSI Engine Harness Electrical Schematic
Deutz Tier 4 Final Engine Harness Electrical Schematic
Operating Specifications
Dimensional Data
Capacities
Tire Specifications
Deutz TD 2.9 Specifications
Torque Requirements
Mobilfluid 424
Mobil DTE 13M
UCon Hydrolube HP-5046
Quintolubric 888-46
Mobil EAL H 46
Mobil EAL Envirosyn H 46
Exxon Univis HVI 26
Mobil SHC EAL H 46 Specs
Component Weights
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Torque Hub Brake Release Pressure
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Coupling Port Information Table - 2WS
Coupling Port Information Table - 4WS
Deutz Trouble Codes (TD2.9 L4 Engine)
LP Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
SkyGuard Function Table
Hydraulic Pump Bolt Torque Chart
Recommended Gauge Size
Analyzer Abbreviations
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions
Machine Configuration Programming Information
Machine Configuration Programming Settings
Function Speeds (In Seconds)
Fault Code List
Inside this manual
Real pages from this service manual (382 pages). Open the sample pages (PDF, 597 KB)
- Specifications, page 23: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 163: Table 3-13. Symptom Diagnosis
- Diagram, page 288: SECTION 5 - HYDRAULICS
- Color page, page 223: SECTION 4 - BOOM & PLATFORM
- Color page, page 336: SECTION 6 - JLG CONTROL SYSTEM
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.
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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, 382 pages
Quantity one is the manual described above.
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Other editions and similar models
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