JLG 600SC, 660SJC Boom Lift Service Manual
270 pages · Publication 3121607
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: 351 sections, 407 entries. See sample pages (PDF, 605 KB)
General
Hydraulic System Safety
Maintenance5 topics
- Operating Specifications
- Dimensional Data
- Capacities
- Engine Data
- Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes5 topics
- 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
Show all 351 sections
Changing Hydraulic Oil
Lubrication Specifications1 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 Equipment1 topic
- Chassis Components and Servicing
Service Notes
Track and Chain
Replace Track
Track tensioning
Rubber Track Pad Installation
Rollers
Idler Roller Assembly1 topic
- Drive Motor
Disassembly
Assembly
Install Motor Assembly
Rotary Coupling1 topic
- Swing Drive
Gear Backlash
Swing Drive Lubrication
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Subassembly
Carrier Subassembly
Main Assembly
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 Values
See Figure 3-34. Swing Bearing Torque Sequence1 topic
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings1 topic
- Deutz D2.9 L4 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 Fuels1 topic
- Boom Systems
Removal2 topics
- Wear Pads
- Boom Disassembly/Assembly & Cable Replacement
Boom Section Disassembly1 topic
- Wire Rope
Inspection
Three Month Inspection
Year or 7000 Hour Replacement
Additional Replacement Criteria1 topic
- Wire Rope Tensioning Adjustment
Wire Rope Tensioning Procedure
Installation4 topics
- Articulating Jib Boom
- 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 Bleeding
Troubleshooting2 topics
- Foot Switch Adjustment
- Platform
Platform Support Torque Settings
Replace Platform Sections1 topic
- Powertrack Maintenance
Remove Link
Install New Link
Replace Fixed End Brackets
Replace Moving End Brackets1 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 (SJC Only)1 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
- Pressure Setting Procedures
Main Relief
Lift Down
Swing
Platform Level Up
Platform Level Down
Jib Up
Jib Down1 topic
- Introduction
Connect JLG Control System Analyzer
Using Analyzer
Changing Access Level
Adjust Parameters
Machine Setup
Level Vehicle Description5 topics
- Machine Personality Settings
- Machine Orientation When Setting Function Speeds
- 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 Disassembly
Maintenance and Lubrication
Torque Chart - Sheet 1 of 5 - (SAE Fasteners)
Torque Chart - Sheet 2 of 5 - (SAE Fasteners)
Torque Chart - Sheet 3 of 5 - (SAE Fasteners)
Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)
Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)
Deutz Engine and Hydraulic Operating Temperature Specifications
Chassis Assembly
Chassis Service Notes - 1 of 2
Chassis Service Notes - 2 of 2
Bottom Track Roller Assembly
Upper Carrier Track Roller Assembly
Idler Assembly
Spring & Shock Assembly
Crawler Drive Motor Control
Crawler Drive Motor Assembly
Crawler Drive - Gearbox
Rotary Coupling Installation
Hose Routing - 1 of 2
Hose Routing - 2 of 2
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
Generator Belt Tension
Generator Brushes and Slip Rings
Generator Cleaning
Generator Circuit Breaker Location
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Deutz D2.9 L4 Engine Installation - Sheet 1 of 2
Deutz D2.9 L4 Engine Installation - Sheet 2 of 2
Deutz 2.9 T4F Dipstick Markings
Engine Oil Viscosity
Deutz D2011 Engine (Battery Engine Side) Installation - 1 of 2
Deutz D2011 Engine (Battery Engine Side) Installation - 2 of 2
Deutz D2011 Engine (Battery Tank Side) Installation - 1 of 2
Deutz D2011 Engine (Battery Tank Side) Installation - 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
Location of Components - Platform Support
Rotator and Leveling Cylinder Locations
Boom Powertrack Components
Location and Thickness of Wear Pads
Clamping Wire Ropes
Proximity Switch Assembly Disassembly
Wire Rope Wire Breaks
Wire Rope Kink
Sheave Groove Wear
Dimensions of Boom Sections
Boom Assembly Cutaway - Sheet 1 of 3
Boom Assembly Cutaway - Sheet 2 of 3
Boom Assembly Cutaway - Sheet 3 of 3
Disassembly of Sheave Assembly
Wire Rope Routing Disassembly
Dimension of Sheaves When New
Routing Installation of Retract Wire Ropes
Boom Powertrack Installation
Proximity Switch Installation
Boom Powertrack Assembly
Articulating Jib Boom Components
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
Platform Support Torque Values
Platform Section Replacement
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(660SJC)
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
Location of Components - Main Control Valve
Articulating Jib Valve
Hand-Held Analyzer (WANALYZER Controls and Display Similar)
Controller Block Diagram
Analyzer Platform Connector
Analyzer Ground Control Box Connector
Analyzer Software Version 6.8 - Sheet 1 of 6
Analyzer Software Version 6.8 - Sheet 2 of 6
Analyzer Software Version 6.8 - Sheet 3 of 6
Analyzer Software Version 6.8 - Sheet 4 of 6
Analyzer Software Version 6.8 - Sheet 5 of 6
Analyzer Software Version 6.8 - Sheet 6 of 6
Control Module Locations
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
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
Deutz EMR2 Wiring Schematic
Deutz Engine Harness Electrical Schematic 1 of 2
Deutz Engine Harness Electrical Schematic 2 of 2
Hydraulic Schematic 1 of 2
Hydraulic Schematic 2 of 2
Crawler Hydraulic Drive Schematic 1 of 2
Crawler Hydraulic Drive Schematic 2 of 2
Hydraulic Port Schematic - 1 of 2
Hydraulic Port Schematic - 2 of 2
Crawler Drive Motor Hydraulic Schematic
Dimensional Data
Capacities
Deutz TD 2.9 Specifications
Function Speeds (In Seconds)
Torque Requirements
Mobilfluid 424
Mobil DTE 13M
UCon Hydrolube HP-5046
Mobil EAL H 46
Exxon Univis HVI 26
Major Component Weights
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Hydraulic Pump Bolt Torque Chart
Recommended Gauge Size
Analyzer Abbreviations
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions
Help Message/Fault Listing
Machine Configuration Programming Information
Fault Code List
Inside this manual
Real pages from this service manual (270 pages). Open the sample pages (PDF, 602 KB)
- Specifications, page 17: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 101: Biological Contamination In Fuels
- Diagram, page 261: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 140: SECTION 4 - BOOM & PLATFORM
- Color page, page 249: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
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 3121607$69.69
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, 270 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
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).