JLG 600SC, 660SJC Boom Lift Service Manual
400 pages · Publication 3121157
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What's inside
From the manual's own table of contents: 424 sections, 509 entries. See sample pages (PDF, 638 KB)
General
Hydraulic System Safety
Maintenance4 topics
- Operating specifications
- Capacities
- Engine Data
- Component Data
Swing System
Auxiliary Power Pump
Hydraulic Filters1 topic
- Performance Data
Function Speeds
Dimensions8 topics
- Torque Requirements
- Pressure Settings
- Cylinder Specifications
- Major Component Weights
- Serial Number Locations
- Hydraulic Oil
- Operator Maintenance and Lubrication
- 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
Show all 424 sections
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift6 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
- Assembly
- Track tensioning
- Rubber Track Pad Installation
- Duo-Cone Conventional Seals
Installation
Assembly and Installation
Acceptable Lubricants for Assembly1 topic
- System Pressure - Release
Procedure for Releasing Pressure
Release Of Hydraulic Pressure From A Single Hydraulic Circuit
Release Of Hydraulic Pressure From Multiple Hydraulic Circuits1 topic
- Track Carrier Roller
Removal2 topics
- Track Roller
- Track
Separation
Connection2 topics
- Front Idler and Recoil Spring
- Recoil Spring
Disassembly
Assembly4 topics
- Track Adjuster
- Sprocket
- Final Drive and Travel Motor
- Track Adjustment
Measuring Track Tension
Adjusting Track Tension
Track Adjustment - Inspect1 topic
- Precautions For Use
Hydraulic Fluid
Lubricating Oil for Reduction Gears
Motor Operation
Parking Brake
Overrun Prevention
Setting Self-Priming Circuit
Hydraulic Circuit2 topics
- General
- SECTION NO. TITLE PAGE NO. Construction and Function
Working Principle of Swash Plate Type Axial Piston Motor
Working Principle of Shuttle Valve
Working Principle of Relief Valve
Working Principle of Low Pressure Relief Valve
Two-Speed Changeover System
Working Principle of Parking Brake
Procedures for manually releasing parking brake (This mechanism is optional.)
Reduction Gears1 topic
- Precautions and warnings
Inspection
Direction of Rotation
Filters
Piping Work
Cautions in Using Parking Brake1 topic
- Operating Steps and Precautions
Precautions at Startup
Hydraulic Fluid Temperature during Operation
Maintenance and Inspection1 topic
- Periodic Inspection and Change Criteria
Gauging Procedure
New Lubricant Replacement Procedure
Inspection for Hydraulic Fluid and Lubricant Leaks, and Torque of Bolts and Plugs1 topic
- Troubleshooting
Troubleshooting for Piston Motor
Troubleshooting for Parking Brake
Troubleshooting for High Pressure Relief Valve
Troubleshooting for Low Pressure Shuttle Valve
Troubleshooting for 2-speed Controls
Troubleshooting for Low Pressure Relief Valve1 topic
- Maintenance and repair procedures
Tools for Disassembly and Reassembly2 topics
- Precautions for Disassembly
- Disassembly instructions
Motor Disassembly
Reduction Gear Disassembly
Maintenance Standards For Disassembled Parts4 topics
- Precautions for Reassembly
- Reassembly
- Quality Check After Reassembly
- Swing Hub
Adjustment Procedures1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values2 topics
- Swing Brake - Mico
- SECTION NO. TITLE PAGE NO. Generator
Every 250 hours
Every 500 hours
Overload Protection3 topics
- Spark Arrester Cleaning Instructions
- Deutz EMR 2 (S/N 85110 to Present)
- CAT DGC DIAGNOSTIC SUPPORT AND TROUBLE CODE DEFINITIONS
List of Abbreviations in this Section
Diagnostic Trouble Codes
MIL Output
DTC 116- ECT Higher Than Expected Stage 1
DTC 117- ECT/CHT Low Voltage
DTC 118- ECT/CHT High Voltage
DTC 122- TPS1 Signal Voltage Low
DTC 123- TPS1 Signal Voltage High
DTC 217- ECT Higher Than Expected 2
DTC 219- RPM Higher Than Max Allowed Governed Speed
DTC 336- Crank Signal Input Noise
DTC 337- Loss of Crank Input Signal
DTC 521- Oil Pressure Sender/Switch High Pressure
DTC 524- Oil Pressure Low
DTC 562- Battery Voltage (VBat) Low
DTC 563- Battery Voltage (VBat) High
DTC 601- Microprocessor Failure - FLASH
DTC 604- Microprocessor Failure - RAM
DTC 606- Microprocessor Failure - COP
DTC 642- 5 Volt External Low Voltage
DTC 643- 5 Volt External High Voltage
DTC 1612- Microprocessor Failure - RTI 1
DTC 1613- Microprocessor Failure - RTI 2
DTC 1614- Microprocessor Failure - RTI 3
DTC 1615- Microprocessor Failure - A/D
DTC 1616- Microprocessor Failure - interrupt
DTC 1625- CAN J1939 Shutdown Request
DTC 1626- CAN J1939 Transmit (Tx) Fault
DTC 1627- CAN J1939 Receive (Rx) Fault
DTC 1628- CAN Address Conflict Failure
DTC 1629- J1939 TSC1 Message Reciept Loss
DTC 1652- TPS1 Loss of Communications
DTC 2111- Unable to Reach Lower TPS
DTC 2112- Unable to Reach Higher TPS
DTC 9999- Throttle Actuator Failsafe Spring Failure
DTC to SPN/FMI Table1 topic
- Platform
Platform Sections Replacement1 topic
- Boom Rope Torquing Procedures
Torque Procedures1 topic
- Wear Pads
Main Boom1 topic
- Wire Rope
Three Month Inspection
Year or 7000 Hour Replacement
Additional Replacement Criteria1 topic
- Boom Maintenance
SECTION NO. TITLE PAGE NO. Removal
Disassembly of Boom Sections3 topics
- Articulating Jib Boom
- Limit Switch Adjustment
- Rotary Actuator (S/N 0300132437 to Present)
Theory of Operation
Required Tools
Installing Counterbalance Valve2 topics
- Foot Switch Adjustment
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Valves - Theory of Operation
Solenoid Control Valve
Relief Valves1 topic
- Cylinders - Theory of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves1 topic
- Cylinder Repair
Cleaning and Inspection1 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
- Pressure Setting Procedures
Main Relief
Lift Down
Swing
Platform Level Up
Platform Level Down
Jib Up
Jib Down1 topic
- Hydraulic Pump (Gear)
SECTION NO. TITLE PAGE NO. Disassembly
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
Removal and Installation of FNR and NFPE Modules
Removal and Installation of FNR and NFPE Control Orifices
Charge Relief Valve
Shaft Seal and Shaft Replacement
Charge Pump12 topics
- Hydraulic Pump W/Hayes Pump Drive Coupling Lubrication
- Hydraulic Component Start-Up Procedures and recommendations
- 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
- 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
AMP 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 Disassembly
Serial Number Locations
Operator Maintenance and Lubrication Diagram
Torque Chart (SAE Fasteners - Sheet 1 of 7)
Torque Chart (SAE Fasteners - Sheet 2 of 7)
Torque Chart (SAE Fasteners - Sheet 3 of 7)
Torque Chart (SAE Fasteners - Sheet 4 of 7)
Torque Chart (METRIC Fasteners - Sheet 5 of 7)
Torque Chart (METRIC Fasteners - Sheet 6 of 7)
Torque Chart (METRIC Fasteners - Sheet 7 of 7)
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Caterpillar
Chassis Service Notes - Sheet 1 of 2
Chassis Service Notes - Sheet 2 of 2
Chassis Components
Bottom Track Roller Assembly
Carrier Track Roller Assembly
Hose Routing - Sheet 1 of 2
Hose Routing - Sheet 2 of 2
Track Chain Assembly
Idler Assembly
Spring & Shock Assembly
Rotary Coupling Installation
Correct Assembly of Conventional Duo-Cone Seals
Examples of incorrect assembly
Structure of Drive Motor
Structure of Swash Plate Type Axial Piston Motor
Structure of Shuttle Valve
Shuttle Valve (Shuttle)
Structure of Relief Valve
Structure of Low Pressure Relief Valve
Structure of Two Speed Changeover System
Structure of Two Speed Changeover System at High Speed
Structure of Two Speed Changeover System at Low Speed
Parking Brake System
Position of Parking Brake Manual Release Ports
Procedures for Manually Releasing Parking Brake (step 1)
Procedures for Manually Releasing Parking Brake (step 2)
Procedures for Manually Releasing Parking Brake (step 3)
Structure of Reduction Gear
Oil level of hydraulic fluid at the initial stage
Lubricant Change
Inspection of oil leak, bolts and plugs
Exploded View of Motor
Exploded View of Reduction Gear Assembly
Swing Torque Hub Adjustment
Swing Bearing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Tolerance Boom Placement
Swing Bearing Torque Sequence
Swing Brake Assembly (Mico)
Deutz Engine Installation - Sheet 1 of 2
Deutz Engine Installation - Sheet 2 of 2
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
Caterpillar Engine Installation - Sheet 1 of 2
Caterpillar Engine Installation - Sheet 2 of 2
1st page of Diagnostic Information for a Given Fault
2nd Page of Diagnostic Information for a Given Fault
Platform Section Replacement
Dimensions of Boom Sections
Clamping Wire Ropes
Location and Thickness of Wear Pads
Boom Assembly Cutaway - Sheet 1 of 3
Boom Assembly Cutaway - Sheet 2 of 3
Boom Assembly Cutaway - Sheet 3 of 3
Location of Components - Platform Support
Location of Components - Rotator and Leveling Cylinder
Location of Components - Boom Powertrack
Disassembly of Sheave Assembly
Disassembly Wire Rope Routing Procedure
Dimension of Sheaves When New
Routing Installation of Retract Wire Ropes
Reassembly of Components - Boom Powertrack Assembly
Boom Powertrack Installation
Location of Components - Articulating Jib Boom
Limit Switches Adjustments
Removing Portion of End Cap
Heating Setscrew
Removing Setscrew
Removing End Cap
Rotator Assembly (Helac)
Removing Shaft from Housing
Removing Sleeve from Housing
Actuator Timing
Rotary Actuator - Exploded View
Rotary Actuator - Assembly Drawing
Rotator Counterbalance Valve
Platform Support Torque Values
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
Pressure Setting Adjustments - Sheet 1 of 2
Pressure Setting Adjustments - Sheet 2 of 2
Location of Components - Main Control Valve (Sheet 1 of 2)
Location of Components - Main Control Valve (Sheet 2 of 2)
Main Control Valve Torque Values
Platform Valve Identification
Platform Valve Torque Values
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
Hydraulic Schematic - Gradall Chassis - Sheet 2 of 4
Hydraulic Schematic - Gradall Chassis - Sheet 3 of 4
Hydraulic Schematic - Gradall Chassis - Sheet 4 of 4
Hydraulic Schematic - CAT Chassis - Sheet 1 of 4
Hydraulic Schematic - CAT Chassis - Sheet 2 of 4
Hydraulic Schematic - CAT Chassis - Sheet 3 of 4
Hydraulic Schematic - CAT Chassis - Sheet 4 of 4
Hand Held Analyzer
ADE Block Diagram
Analyzer Connecting Points
Control Module Location
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, Version 6.X Software - Sheet 1 of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 2 of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 3 of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 4 of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 5 of 6
Analyzer Flow Chart, Version 6.X Software - Sheet 6 of 6
Voltage Measurement (DC)
Current Measurement (DC)
Application to Female 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 - Sheet 1 of 2
Electrical Components - Sheet 2 of 2
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 1 of 2
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 2 of 4
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 3 of 4
Electrical Schematic - Pre EMR2 Deutz, Caterpillar - Sheet 4 of 4
Electrical Schematic - Deutz EMR2/Gradall - Sheet 1 of 4
Electrical Schematic - Deutz EMR2/Gradall - Sheet 2 of 4
Electrical Schematic - Deutz EMR2/Gradall - Sheet 3 of 4
Electrical Schematic - Deutz EMR2/Gradall - Sheet 4 of 4
Electrical Schematic - Deutz/CAT - Sheet 1 of 7
Electrical Schematic - Deutz/CAT - Sheet 2 of 7
Electrical Schematic - Deutz/CAT - Sheet 3 of 7
Electrical Schematic - Deutz/CAT - Sheet 4 of 7
Electrical Schematic - Deutz/CAT - Sheet 5 of 7
Electrical Schematic - Deutz/CAT - Sheet 6 of 7
Electrical Schematic - Deutz/CAT - Sheet 7 of 7
Operating Specifications
Capacities
Deutz F4M1011F/F4M2011 Specifications
Deutz D2011L04 Specifications
Caterpillar 3044C/Caterpillar 3.4
Torque Requirements
Pressure Settings
Cylinder Specifications
Major Component Weights
Mobilfluid 424 Specs
Mobil DTE 13M Specs
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Duo-Cone Required Tools - Installation
Track Carrier Roller Required Tools - Removal
Track Carrier Roller Required Tools - Installation
Track Roller Required Tools - Removal
Track Roller Required Tools - Installation
Track Required Tools - Separation
Track Required Tools - Connection
Front Idler & Recoil Spring Required Tools - Remove
Recoil Spring Required Tools - Assembly
Front Idler & Recoil Required Tools - Installation
Track Adjuster Required Tools - Installation
Sprocket Required Tools - Removal
Sprocket Required Tools - Installation
Final Drive Required Tools - Removal
Final Drive Required Tools - Installation
List of Standard Tools
List of Special Purpose Tools
List of Subsidiary Material
List of Tightening Torque
J1939 Diagnostic Lamp Configuration
Cylinder Head and Tapered Bushing Torque Specifications
Holding Valve Torque Specifications
Hydraulic Pump Bolt Torque Chart
Recommended Gauge Size
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions
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
Fault Code Listing
Adjustments - Personality Descriptions
Diagnostic Menu Descriptions
Inside this manual
Real pages from this service manual (400 pages). Open the sample pages (PDF, 637 KB)
- Specifications, page 19: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 115: SECTION 5 - CAT CHASSIS (S/N 0300128000 TO S/N 0300174703)
- Diagram, page 385: SECTION 10 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
- Color page, page 374: SECTION 10 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
- Color page, page 133: SECTION 5 - CAT CHASSIS (S/N 0300128000 TO S/N 0300174703)
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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, 400 pages
Quantity one is the manual described above.
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