JLG 600S, 660SJ Boom Lift Service Manual
576 pages · Publication 31215034
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What's inside
From the manual's own table of contents: 480 sections, 573 entries. See sample pages (PDF, 596 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Operating Specifications
Machine Specifications1 topic
- Dimensional Data
Machine Dimensional Data9 topics
- Capacities
- Engine Data
- Tires
- Critical Stability Weights
- Hydraulic Oil
- Torque Requirements
- Maintenance and Lubrication
- Thread Locking Compound
- Torque Charts
SAE Fastener Torque Chart
Metric Fastener Torque Chart1 topic
- 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
Show all 480 sections
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
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 Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Oscillating Axle Bleeding Procedure and Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test7 topics
- Chassis Tilt Indicator System
- Cold Start System (Diesel)
- Auxiliary Power System
- Drive Orientation System
- Oscillating Axle System
- Drive System
- Drive Hub
Removal
Installation1 topic
- Drive Motor
Assembly/Disassembly2 topics
- Steer Cylinder
- Swing Drive Hub
Procedure For Setting Swing Gear Backlash
Swing Drive Lubrication1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values3 topics
- Rotary Coupling
- Deutz TD2.9 L4 Engine (67hp)
- Deutz D2.9 L4 Engine (49hp)
Check Oil Level
Change Engine Oil
Change Oil Filter
Change Fuel Filters
Glow Plugs1 topic
- Deutz D2011L04 Engine
Checking Oil Level
Changing Engine Oil
Changing Oil Filter
Replace Fuel Filter
Clean Fuel Strainer
Spark Arrester Cleaning Instructions3 topics
- Ford Engine
- Counterweight
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings8 topics
- Transport Position Sensing System
- Beyond Transport - Drive Speed Cutback System
- Drive/Steer - Boom Function Interlock System
- Dual Capacity System
- Platform Load Sensing System
- Electronic Platform Leveling
- Fuel level Cutout System
- Platform
Support Removal
Support Installation2 topics
- Rotator and Slave Cylinder
- Main Boom Assembly
Boom Disassembly
Assembly3 topics
- Main Boom Lift Cylinder
- Main Boom Powertrack
- Wire Rope
Inspection
Three Month Inspection
Additional Inspection Required If
Year or 7000 Hour Replacement
Additional Replacement Criteria1 topic
- Wire Rope Tensioning Adjustment
Wire Rope Tensioning Procedure6 topics
- Wire rope Service indicator
- Jib (If Equipped)
- Boom Cleanliness Guidelines
- Foot Switch Adjustment
- Platform Control Enable System
- Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets1 topic
- Skyguard
Operation
Function Test
Diagnostics & Troubleshooting1 topic
- Bolt-on External Fall Arrest
Inspection Before Use1 topic
- Lubricating O-rings In The Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Hydraulic Connection Assembly and Torque Specification
Tapered Thread Types
Straight Thread Types, Tube and Hose Connections
Straight Thread Types, Port Connections
Flange Connection Types
Tightening Methods
Assembly And Torque Specifications
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
Assembly Instructions for 37° (JIC) Flare Fittings
Assembly Instructions for 45° SAE Flare Fittings
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
Assembly Instructions for Bulkhead (BH) Fittings
Assembly Instructions for O-Ring Boss (ORB) Fittings
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
Assembly instructions for Adjustable Port End (BSPP) Fittings
Assembly Instructions for Flange Connections: (FL61 and FL62)
Double Wrench Method
FFWR and TFFT Methods
Adjustable Stud End Assembly
O-ring Installation (Replacement)1 topic
- Hydraulic Cylinders
Main Lift Cylinder
Telescope Cylinder
DISASSEMBLY
Platform Level Cylinder
Jib Lift Cylinder (660SJ Only)
Steer Cylinder
Axle Lockout Cylinder3 topics
- Hydraulic Pump (Gear)
- Variable Pump
- Main Valve Block Pressure Setting Procedure
Load Sense Compensator
Main Relief Valve
Load Sense Relief Valve
Wheel Steer, Relief Valves
Wheel Steer, Front & Rear Steering Relief Valves
Rear Axle Relief Valves
Turntable Swing Relief Valve1 topic
- Platform Valve Block Pressure Setting Procedure
Main High Pressure Relief Valve
Low Pressure Relief Valve
Platform Jib Down Relief Valve2 topics
- Hydraulic Schematics
- JLG Control System Analyzer Kit Instructions
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 Notes2 topics
- CANBUS Communications
- System Test
Test from the Platform10 topics
- System Test Messages
- Machine Diagnostics Parameters
- Calibrating Tilt Sensor
- Calibrating Boom Angle
- Calibrating Level Up CRKPT
- Calibrating Level Down Crackpoint
- Calibrating Platform Angle Sensor
- Calibrating Load Sensing
- Calibrating MSSO
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation
LSS Service Mode
LSS Service Mode Event Log
Troubleshooting3 topics
- Machine Fault Codes
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement2 topics
- Applying Silicone Dielectric Compound to Electrical Connections
- Dielectric Grease Application
AMP Mate-N-Lok
AMP Faston
AMP Micro-Fit
AMP Mini Fit Jr
Mini Fit Sr
DIN Connectors
Exceptions
Enclosures
Carling Switch Connectors1 topic
- AMP Connector
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
- Wiring Harness
Connector Labels
Component Labels2 topics
- Wiring Harness Connector Label Diagrams
- Electrical Schematics
Maintenance and Lubrication Diagram - Deutz D2011L04
Maintenance and Lubrication Diagram - Deutz TD2.9/D2.9
Maintenance and Lubrication Diagram - Ford MSG425
Engine Operating Temperature Specifications - Deutz D2011L04
Engine Operating Temperature Specifications - Deutz TD2.9L4/D2.9L4
Engine Operating Temperature Specifications - Ford MSG425
Hydraulic Oil Operating Temperature Specifications
Wheel Lug Nut Tightening Sequence
Bleeder Valve Location
Axle Installation - Front
Axle Installation - Rear
Steering Installation
Drive Hub Installation
Drive Motor Installation
Drive Motor Assembly
Swing Drive Installation
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
Rotary Coupling - 2WS
Rotary Coupling - 4WS
Rotary Coupling Port Location - 2WS
Rotary Coupling Port Location - 4WS
Rotary Coupling Assembly
Deutz TD2.9 L4 (67hp) Engine Installation
Deutz TD2.9 L4 (67hp) Engine and Pumps Sub-Assembly
Deutz TD2.9 L4 (67hp) Engine Assembly - Sheet 1 of 2
Deutz TD2.9 L4 (67hp) Engine Assembly - Sheet 2 of 2
Deutz D2.9 L4 (49hp) Engine Installation
Deutz D2.9 L4 (49hp) Engine and Pumps Sub-Assembly
Deutz D2.9 L4 (49hp) Engine Assembly - Sheet 1 of 2
Deutz D2.9 L4 (49hp) Engine Assembly - Sheet 2 of 2
Deutz 2.9 T4F Dipstick Markings
Engine Oil Viscosity
Deutz D2011 Engine Installation
Deutz D2011 Engine and Pumps Sub-Assembly
Deutz D2011 Engine Assembly - Sheet 1 of 2
Deutz D2011 Engine Assembly - Sheet 2 of 2
Deutz Dipstick Markings
Ford MSG425 Engine Installation
Ford Engine and Pumps Sub-Assembly
Ford Engine Assembly - Sheet 1 of 2
Ford Engine Assembly - Sheet 2 of 2
Counterweight Bolt Torque
Generator Belt Tension
Generator Brushes and Slip Rings
Generator Cleaning
Generator Circuit Breaker Location
Generator Circuit Breaker Location (If Equipped with 4000W)
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Platform Support Torque Values
Removal of Components - Rotator and Slave Cylinder
Boom Assembly Removal and Installation
Main Boom Lift Cylinder Removal and Installation
Powertrack Components
Wire Rope Wire Breaks
Wire Rope Kink
Sheave Groove Wear
Dimensions of Boom Sections
Clamping Wire Ropes
Foot Switch Adjustment
Bolt-On External Fall Arrest Cable Tension
Bolt-On External Fall Arrest System
NPTF Thread
BSPT Thread
JIC Thread
SAE Thread
ORFS Thread
MTBL-MBTS Thread
Bulkhead Thread
ORB-MPP Thread
MFF-BSPP Thread
Torque Wrench Angle
FFWR Method
Hydraulic Cylinder Locations
Cylinder Barrel Support
Cylinder Head Removal
Cylinder Rod Support
Piston Disassembly
Cylinder Head Disassembly
Composite Bushing Installation
Cylinder Head Assembly
Piston Assembly
Cylinder Head Installation
Capscrew Removal
Bushing Installation
Marking Cylinder for Alignment
Platform Level Cylinder - 600S
Platform Level Cylinder - 660SJ
Cylinder Head Seal Installation
Piston Seal Installation
Jib Lift Cylinder (660SJ)
Tapered Bushing Removal
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
Removing Spanner Nut
Steer Cylinder Assembly
Piston Seal and Wear Ring
Spanner Nut Torque
Hydraulic Pump Installation
Variable Pump Installation
Main Control Valve Block (2WS)
Main Control Valve Block (4WS)
Platform Control Valve Block
Main Control Valve (2WS)
Main Control Valve (4WS)
Main Control Valve Torque Values (2WS) - Sheet 1 of 3
Main Control Valve Torque Values (2WS) - Sheet 2 of 3
Main Control Valve Torque Values (2WS) - Sheet 3 of 3
Main Control Valve Torque Values (4WS) - Sheet 1 of 3
Main Control Valve Torque Values (4WS) - Sheet 2 of 3
Main Control Valve Torque Values (4WS) - Sheet 3 of 3
Platform Valve Torque Values
2-Wheel Steer (2WS) without Jib Hydraulic Schematic - Sheet 1 of 2
2-Wheel Steer (2WS) without Jib Hydraulic Schematic - Sheet 2 of 2
2-Wheel Steer (2WS) with Jib Hydraulic Schematic - Sheet 1 of 2
2-Wheel Steer (2WS) with Jib Hydraulic Schematic - Sheet 2 of 2
4-Wheel Steer (4WS) without Jib Hydraulic Schematic - Sheet 1 of 2
4-Wheel Steer (4WS) without Jib Hydraulic Schematic - Sheet 2 of 2
4-Wheel Steer (4WS) with Jib Hydraulic Schematic - Sheet 1 of 2
4-Wheel Steer (4WS) with Jib Hydraulic Schematic - Sheet 2 of 2
4-Wheel Drive (4WD) Hydraulic Schematic - Sheet 1 of 2
4-Wheel Drive (4WD) Hydraulic Schematic - Sheet 2 of 2
2-Wheel Drive (2WD) Hydraulic Schematic - Sheet 1 of 2
2-Wheel Drive (2WD) Hydraulic Schematic - Sheet 2 of 2
Hydraulic Oil Cooler Schematic
Hand Held Analyzer
ADE Block Diagram
Analyzer Software P2.13 - Sheet 1 of 14
Analyzer Software P2.13 - Sheet 2 of 14
Analyzer Software P2.13 - Sheet 3 of 14
Analyzer Software P2.13 - Sheet 4 of 14
Analyzer Software P2.13 - Sheet 5 of 14
Analyzer Software P2.13 - Sheet 6 of 14
Analyzer Software P2.13 - Sheet 7 of 14
Analyzer Software P2.13 - Sheet 8 of 14
Analyzer Software P2.13 - Sheet 9 of 14
Analyzer Software P2.13 - Sheet 10 of 14
Analyzer Software P2.13 - Sheet 11 of 14
Analyzer Software P2.13 - Sheet 12 of 14
Analyzer Software P2.13 - Sheet 13 of 14
Analyzer Software P2.13 - Sheet 14 of 14
Control Module Locations
Ground Control Module Pin Connections
Platform Control Module Pin Connections
System Test Flow Chart - Platform Tests (Sheet 1 of 2)
System Test Flow Chart - Platform Tests (Sheet 2 of 2)
System Test Flow Chart - Ground Station Tests
Voltage Measurement (DC)
Current Measurement (DC)
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
Telematics Gateway Harness - Sheet 1 of 3
Telematics Gateway Harness - Sheet 2 of 3
Telematics Gateway Harness - Sheet 3 of 3
Platform Box Harness - Sheet 1 of 6
Platform Box Harness - Sheet 2 of 6
Platform Box Harness - Sheet 3 of 6
Platform Box Harness - Sheet 4 of 6
Platform Box Harness - Sheet 5 of 6
Platform Box Harness - Sheet 6 of 6
Main Boom Harness (Without Jib)
Main Boom Harness (With Jib)
Main Boom Harness (TT)
Proximity Switch Harness (Telescope In)
Boom Sensor Cable
Turntable Harness - Sheet 1 of 7
Turntable Harness - Sheet 2 of 7
Turntable Harness - Sheet 3 of 7
Turntable Harness - Sheet 4 of 7
Turntable Harness - Sheet 5 of 7
Turntable Harness - Sheet 6 of 7
Turntable Harness - Sheet 7 of 7
Universal Ground Control Module Harness
Boom Angle Sensor Harness
Main valve Harness (4WS) - Sheet 1 of 4
Main valve Harness (4WS) - Sheet 2 of 4
Main valve Harness (4WS) - Sheet 3 of 4
Main valve Harness (4WS) - Sheet 4 of 4
Main valve Harness (2WS) - Sheet 1 of 4
Main valve Harness (2WS) - Sheet 2 of 4
Main valve Harness (2WS) - Sheet 3 of 4
Main valve Harness (2WS) - Sheet 4 of 4
Ground Control Harness - Sheet 1 of 2
Ground Control Harness - Sheet 2 of 2
Lift Cylinder Harness
Deutz D2011L04 Engine Harness - Sheet 1 of 3
Deutz D2011L04 Engine Harness - Sheet 2 of 3
Deutz D2011L04 Engine Harness - Sheet 3 of 3
Deutz T4F Engine Harness - Sheet 1 of 5
Deutz T4F Engine Harness - Sheet 2 of 5
Deutz T4F Engine Harness - Sheet 3 of 5
Deutz T4F Engine Harness - Sheet 4 of 5
Deutz T4F Engine Harness - Sheet 5 of 5
Ford Engine Harness
Chassis Head and Tail Lights Harness - Sheet 1 of 2
Chassis Head and Tail Lights Harness - Sheet 2 of 2
Chassis Work Lights Harness - Sheet 1 of 2
Chassis Work Lights Harness - Sheet 2 of 2
ClearSky Harness
Platform Valve W/O Jib Harness - Sheet 1 of 2
Platform Valve W/O Jib Harness - Sheet 2 of 2
Platform Valve w/Jib Harness - Sheet 1 of 3
Platform Valve w/Jib Harness - Sheet 2 of 3
Platform Valve w/Jib Harness - Sheet 3 of 3
Skyguard GEN2 Platform Interface Harness
Boom sensor harness
Main lift harness
LSS Harness
Electrical Schematic - Sheet 2 of 20
Electrical Schematic - Sheet 3 of 20
Electrical Schematic - Sheet 4 of 20
Electrical Schematic - Sheet 5 of 20
Electrical Schematic - Sheet 6 of 20
Electrical Schematic - Sheet 7 of 20
Electrical Schematic - Sheet 8 of 20
Electrical Schematic - Sheet 9 of 20
Electrical Schematic - Sheet 10 of 20
Electrical Schematic - Sheet 11 of 20
Electrical Schematic - Sheet 12 of 20
Electrical Schematic - Sheet 13 of 20
Electrical Schematic - Sheet 14 of 20
Electrical Schematic - Sheet15 of 20
Electrical Schematic - Sheet 16 of 20
Electrical Schematic - Sheet 17 of 20
Electrical Schematic - Sheet 18 of 20
Electrical Schematic - Sheet 19 of 20
Electrical Schematic - Sheet 20 of 20
Deutz TD 2.9L4 (67hp) Specifications
Deutz D 2.9L4 (49hp) Specifications
Deutz D2011L04 Specifications
Ford MSG425-DF Specifications
Tire Specifications
Mobilfluid 424
Mobil DTE 10 Excel 32
Quintolubric 888-46
Mobil EAL 224 H
Mobil EAL Envirosyn H 46
Exxon Univis HVI 26 (Arctic)
Torque Requirements
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Coupling Port Information Table - 2WS
Coupling Port Information Table - 4WS
Deutz Trouble Codes (D2.9 L4\TD2.9 L4 Engine)
Deutz Trouble Codes (D2011L04 Engine)
CAN to DTC Cross Reference (Ford MSG425 Engine)
SkyGuard Function Table
NPTF Pipe Thread
BSPT Pipe Thread
37° Flare (JIC) Thread - Steel
37° Flare (JIC) Thread - Aluminum/Brass
45° Flare (SAE) - Steel
45° Flare (SAE) - Aluminum/Brass
O-ring Face Seal (ORFS) - Steel
O-ring Face Seal (ORFS) - Aluminum/Brass
DIN 24° Cone (MBTL & MBTS)
Bulkhead Fittings (BH) - INCH
Bulkhead Fittings (BH) - METRIC
O-ring Boss (ORB) - Table 1 of 6
O-ring Boss (ORB) - Table 2 of 6
O-ring Boss (ORB) - Table 3 of 6
O-ring Boss (ORB) - Table 4 of 6
O-ring Boss (ORB) - Table 5 of 6
O-ring Boss (ORB) - Table 6 of 6
Metric Flat Face Port (MFF) - L Series - Table 1 of 3
Metric Flat Face Port (MFF) - L Series - Table 2 of 3
Metric Flat Face Port (MFF) - L Series - Table 3 of 3
Metric Flat Face Port (MFF) - S Series - Table 1 of 3
Metric Flat Face Port (MFF) - S Series - Table 2 of 3
Metric Flat Face Port (MFF) - S Series - Table 3 of 3
Metric Pipe Parallel O-Ring Boss (MPP)
British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
Flange Code (FL61 & FL62) - Inch Fasteners
Flange Code (FL61 & FL62) - Metric Fasteners
Analyzer Abbreviations
Machine Configuration Programming Information - Version P2.13
Machine Configuration Programming Settings - Version P2.13
Machine Personality Settings and Function Speed (Software Release P2.13)
System Test Messages
Machine Diagnostics Parameters
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
Diagnostic Trouble Codes
Wiring Harness Connector Labels
Inside this manual
Real pages from this service manual (576 pages). Open the sample pages (PDF, 595 KB)
- Specifications, page 282: SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
- Troubleshooting, page 386: SECTION 6 - JLG CONTROL SYSTEM
- Diagram, page 546: Figure 7-72. Boom sensor harness
- Color page, page 166: SECTION 4 - BOOM & PLATFORM
- Color page, page 479: SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
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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, 576 pages
Quantity one is the manual described above.
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Other editions and similar models
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