Description
JLG 600A 660AJ Service and Maintenance Manual – P/N 3121616
This JLG 600A 660AJ Service and Maintenance Manual is the complete workshop reference for the 600A and 660AJ aerial work platforms, published under JLG part number 3121616 and dated February 3, 2015. It applies to machines from serial number 0300177361 to present, and a note on page 2 confirms it also covers machine with serial number 0300176207. Whether you are performing routine maintenance, diagnosing a hydraulic fault, rebuilding a cylinder, or troubleshooting the JLG Control System, this manual provides the procedures, specifications, and diagrams needed to do the job correctly.
File Details
- Manual Type: Service and Maintenance Manual
- Brand: JLG
- Models Covered: 600A, 660AJ
- Serial Numbers: 0300177361 to Present; also applies to 0300176207
- Document Number: 3121616
- Date: February 3, 2015
- Language: English
- Page Count: 348
- File Format: PDF
Chapters Covered
This JLG 600A 660AJ service manual is organized into seven major sections that together cover the entire machine:
- Section 1 – Specifications: Operating specifications, dimensional data, capacities, tire specifications, engine data for Deutz TD 2.9, Deutz D2011L04 and GM 3.0L, function speeds, torque requirements, hydraulic oil recommendations, major component weights, and operator maintenance and lubrication.
- Section 2 – General: Machine preparation, inspection and maintenance schedules, service and guidelines, lubrication information, cylinder drift test procedures, pins and composite bearing repair guidelines, and welding precautions for JLG equipment.
- Section 3 – Chassis & Turntable: Tires and wheels, torque hub disassembly and assembly, free wheeling option, drive motor service, oscillating axle bleeding and lockout test, steer adjustments, swing drive, swing bearing, swing brake, rotary coupling, generator service, Deutz D2.9 L4 and D2011 engine maintenance, spark arrester cleaning, glow plugs, Deutz EMR 2 diagnostics, bio fuel information, GM engine maintenance, GM dual fuel system, and GM fuel system repair and diagnosis.
- Section 4 – Boom: Main boom maintenance and disassembly, tower boom procedures, boom cleanliness guidelines, rotary actuator theory and repair, foot switch adjustment, platform section replacement, and powertrack maintenance including link replacement and end bracket service.
- Section 5 – Hydraulics and Hydraulic Schematics: O-ring lubrication methods, cylinder theory and checking procedures, cylinder removal and installation, hydraulic cylinder repair for all cylinders including tower boom lift, upright level, master, main boom lift, main boom telescope, tower boom telescope, platform level (slave), jib lift, steer and axle lockout cylinders, gear pump and variable pump service, hydraulic component start-up, main and platform valve block pressure settings, and complete hydraulic schematics for 2-wheel and 4-wheel drive systems.
- Section 6 – JLG Control System: Control system introduction, analyzer connection and operation, machine personality settings and ranges, machine orientation for function speed testing, CANbus communications, help fault codes and descriptions, fault code lists, and machine configuration programming information.
- Section 7 – Basic Electrical Information & Electrical Schematics: Multimeter basics, dielectric grease application, AMP and Deutsch connector service, electrical components, platform and ground control electrical schematics, generator wiring schematics, and engine harness schematics for Deutz and GM engines.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “JLG 600A 660AJ Service and Maintenance Manual 3121616 – PDF Download” are as follows:
+Section A. Introduction – Maintenance Safety Precautionsp. 3
A Generalp. 3
B Hydraulic System Safetyp. 3
C Maintenancep. 3
+Section 1. Specificationsp. 19
1.1 Operating Specificationsp. 19
1.2 Dimensional Datap. 19
1.3 Capacitiesp. 20
1.4 Tiresp. 20
1.5 Engine Datap. 20
+1.6 Function Speedsp. 21
Machine Orientation When Doing Speed Testsp. 21
Test Notesp. 21
1.7 Torque Requirementsp. 21
1.8 Hydraulic Oilp. 22
1.9 Major Component Weightsp. 23
1.10 Operator Maintenancep. 24
+Section 2. Generalp. 35
+2.1 Machine Preparation, Inspection, and Maintenancep. 35
Generalp. 35
Preparation, Inspection, and Maintenancep. 35
Pre-Start Inspectionp. 35
Pre-Delivery Inspection and Frequent Inspectionp. 35
Annual Machine Inspectionp. 35
Preventive Maintenancep. 35
+2.2 Service and Guidelinesp. 36
Generalp. 36
Safety and Workmanshipp. 36
Cleanlinessp. 36
Components Removal and Installationp. 36
Component Disassembly and Reassemblyp. 37
Pressure-Fit Partsp. 37
Bearingsp. 37
Gasketsp. 37
Bolt Usage and Torque Applicationp. 37
Hydraulic Lines and Electrical Wiringp. 37
Hydraulic Systemp. 37
Lubricationp. 37
Batteryp. 37
Lubrication and Servicingp. 37
+2.3 Lubrication and Informationp. 38
Hydraulic Systemp. 38
Hydraulic Oilp. 38
Changing Hydraulic Oilp. 38
Lubrication Specificationsp. 38
+2.4 Cylinder Drift Testp. 38
Platform Driftp. 38
Cylinder Driftp. 38
2.5 Pins and Composite Bearing Repair Guidelinesp. 39
+2.6 Welding on JLG Equipmentp. 39
Do the Following When Welding on JLG Equipment:p. 39
Do NOT Do the Following When Welding on JLG Equipment:p. 39
+Section 3. Chassis & Turntablep. 45
+3.1 Tires And Wheelsp. 45
Tire Inflationp. 45
Tire Damagep. 45
Pneumatic Tiresp. 45
Polyurethane Foam Filled Tiresp. 45
Tire Replacementp. 45
Wheel Replacementp. 45
Wheel Installationp. 45
+3.2 Torque Hubp. 46
Oil Informationp. 46
Roll and Leak Testingp. 46
Tightening and Torquing Boltsp. 46
Main Disassemblyp. 48
Output Carrier Disassemblyp. 49
Input Carrier Disassemblyp. 49
Hub-Spindle Disassemblyp. 50
Spindle-Brake Disassemblyp. 51
Cover Disassemblyp. 52
Cover Assemblyp. 52
Input Carrier Sub-Assemblyp. 53
Output Planet Gear Sub-Assemblyp. 53
Spindle – Brake Sub-Assemblyp. 53
Hub-Spindle Sub-Assemblyp. 54
Cover Sub-Assemblyp. 54
Main Assemblyp. 54
Integral Brake Checkp. 55
+3.3 Free Wheeling Optionp. 59
Disengage Drive Motors and Brakes for Towing, etc. (Free Wheel)p. 59
Engage Drive Motors and Brakes (Normal Operation)p. 59
+3.4 Drive Motorp. 59
Descriptionp. 59
Shaft Seal Replacementp. 60
Loop Flushing Valvep. 61
Troubleshootingp. 62
Disassemblyp. 63
Inspectionp. 66
Assemblyp. 68
Initial Start-up Proceduresp. 72
+3.5 Oscillating Axle Bleeding Procedure and Lockout Testp. 73
Lockout Cylinder Bleedingp. 73
Oscillating Axle Lockout Testp. 74
3.6 Steer Adjustmentsp. 74
+3.7 Swing Drivep. 75
Gear Backlashp. 77
Swing Drive Lubricationp. 77
Motor Control Valve Disassemblyp. 78
Motor and Brake Disassemblyp. 78
Main Disassemblyp. 79
Hub-Shaft Disassemblyp. 79
Carrier Disassemblyp. 80
Hub-Shaft Subassemblyp. 81
Carrier Subassemblyp. 82
Main Assemblyp. 83
Motor and Brake Assemblyp. 84
Motor Control Valve Assemblyp. 84
+3.8 Swing Bearingp. 85
Turntable Bearing Mounting Bolt Condition Checkp. 85
Wear Tolerancep. 85
Swing Bearing Replacementp. 87
Swing Bearing Torque Valuesp. 88
+3.9 Swing Brake – Micop. 89
Disassemblyp. 89
Inspectionp. 89
Assemblyp. 89
3.10 Rotary Couplingp. 90
+3.11 Generatorp. 94
Every 250 hoursp. 94
Every 500 hoursp. 94
Overload Protectionp. 95
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Ringsp. 95
+3.12 Deutz D2.9 L4 Enginep. 97
Check Oil Levelp. 99
Change Engine Oilp. 99
Change Oil Filterp. 100
Change Fuel Filtersp. 100
+3.13 Deutz D2011 Enginep. 101
Checking Oil Levelp. 103
Changing Engine Oilp. 103
Changing Oil Filterp. 104
Replace Fuel Filterp. 104
Clean Fuel Strainerp. 104
3.14 Spark Arrester Cleaning Instructionsp. 105
3.15 Glow Plugsp. 105
3.16 Deutz EMR 2p. 108
+3.17 Bio Fuel in Deutz Enginesp. 120
Generalp. 120
Bio Fuelp. 120
Biological Contamination In Fuelsp. 121
+3.18 GM Engine General Maintenancep. 122
Drive Belt Maintenancep. 122
Engine Electrical System Maintenancep. 122
Checking/Filling Engine Oil Levelp. 122
Changing Engine Oilp. 123
Coolant Fill Procedure – Dual Fuel Enginep. 123
+3.19 GM Engine Dual Fuel Systemp. 124
Fuel Filterp. 124
Direct Electronic Pressure Regulator (DEPR)p. 126
Air Fuel Mixerp. 126
Electronic Throttle Control (ETC)p. 127
Electric Lock Offp. 127
Engine Control Module (ECM)p. 127
Heated Exhaust Gas Oxygen Sensorp. 128
Gasoline Multi Point Fuel Injection System (MPFI)p. 128
Gasoline Fuel Pumpp. 128
Gasoline Pressure And Temperature Sensor Manifoldp. 128
Fuel Filterp. 129
Fuel Injector Railp. 129
Fuel Injectorp. 129
+3.20 GM Engine Fuel System Repairp. 129
Propane Fuel System Pressure Reliefp. 129
Propane Fuel System Leak Testp. 129
Propane Fuel Filter Replacementp. 130
Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspectionp. 130
Check/Drain Oil Build-Up In 2-Stage Vaporizerp. 131
Air Fuel Mixer/Throttle Control Device Maintenance And Inspectionp. 131
Exhaust System And Catalytic Converter Inspection And Maintenancep. 132
Temperature Manifold Absolute Pressure (TMAP) Sensorp. 132
Throttle Body (ETC) Replacementp. 132
Mixer Replacementp. 132
Electronic Pressure Regulator (EPR) Replacementp. 133
Regulator Replacementp. 133
Coolant Hose Replacementp. 133
Vapor Hose Replacementp. 133
Engine Control Module Replacementp. 134
Heated Exhaust Gas Oxygen Sensor Replacementp. 134
+3.21 GM Engine LPG Fuel System Diagnosisp. 135
Fuel System Descriptionp. 135
Diagnostic Aidsp. 135
+Section 4. Boom & Platformp. 149
+4.1 Main Boom Maintenancep. 149
Remove Rotatorp. 149
Remove Platform Level (Slave) Cylinderp. 149
Remove Jib Lift Cylinder (600AJ Only)p. 149
Remove Main Boom Powertrackp. 150
Remove Main Boomp. 151
+4.2 Tower Boomp. 152
Remove Tower Uprightp. 152
Remove Tower Boomp. 153
4.3 Boom Cleanliness Guidelinesp. 155
+4.4 Rotary Actuatorp. 156
Theory of Operationp. 156
Required Toolsp. 156
Disassemblyp. 158
Inspectionp. 162
Assemblyp. 163
Installing Counterbalance Valvep. 167
Testing Actuatorp. 168
Testing Actuator for Internal LeakSp. 168
Installation and Bleedingp. 168
Troubleshootingp. 169
4.5 Foot Switch Adjustmentp. 170
+4.6 Platformp. 170
Platform Support Torque Settingsp. 170
Replace Platform Sectionsp. 170
+4.7 Powertrack Maintenancep. 171
Remove Linkp. 171
Install New Linkp. 174
Replace Fixed End Bracketsp. 177
Replace Moving End Bracketsp. 178
+Section 5. Hydraulics And Hydraulic Schematicsp. 181
+5.1 O-Ring Lubricationp. 181
Cup and Brushp. 181
Dipp. 182
Sprayp. 182
Brush-Onp. 182
+5.2 Cylinders – Theory of Operationp. 183
Systems With Double Acting Cylindersp. 183
Systems With Holding Valvesp. 183
+5.3 Cylinder Checking Procedurep. 183
Cylinders Without Counterbalance Valves – Master Cylinder and Steer Cylinderp. 183
Cylinders With Single Counterbalance Valvep. 184
Cylinders With Dual Counterbalance Valvesp. 184
+5.4 Cylinder Removal and Installationp. 185
Cylinder Locationsp. 185
Main Boom Telescope Cylinder Removalp. 186
Main Boom Telescope Cylinder Installationp. 186
Main Boom Lift Cylinder Removalp. 187
Main Boom Lift Cylinder Installationp. 187
Upright Level Cylinder Removalp. 188
Upright Level Cylinder Installationp. 188
Tower Boom Lift Cylinder Removalp. 189
Tower Lift Cylinder Installationp. 190
Tower Telescope Cylinder Removalp. 190
Tower Telescope Cylinder Installationp. 190
+5.5 Hydraulic Cylinder repairp. 191
Tower Boom Lift Cylinderp. 191
Cleaning and Inspectionp. 194
Assemblyp. 195
Upright Level Cylinderp. 197
Cleaning and Inspectionp. 200
Assemblyp. 201
Master Cylinderp. 203
Cleaning and Inspectionp. 206
Assemblyp. 207
Main Boom Lift Cylinderp. 209
Cleaning and Inspectionp. 212
Assemblyp. 213
Main Boom Telescope Cylinderp. 215
Cleaning and Inspectionp. 218
Assemblyp. 219
Tower Boom Telescope Cylinderp. 221
Cleaning and Inspectionp. 224
Assemblyp. 225
Platform Level (Slave) Cylinderp. 227
Cleaning and Inspectionp. 230
Assemblyp. 231
Jib Lift Cylinder (AJ Only)p. 233
Cleaning and Inspectionp. 236
Assemblyp. 237
Steer Cylinderp. 239
Cleaning and Inspectionp. 241
Assemblyp. 242
Axle Lockout Cylinderp. 243
+5.6 Hydraulic Pump (Gear)p. 245
Disassemblyp. 245
Inspect Parts For Wearp. 247
General Informationp. 248
Reverse Shaft Rotation of Pumpp. 248
Assemblyp. 248
Placing Pump Back Into Servicep. 251
+5.7 Variable Pumpp. 251
Ports and Pressure Gaugesp. 251
NFPE Controlp. 251
Remove and Install FNR and NFPE Modulesp. 252
Remove and Install FNR and NFPE Control Orificesp. 252
Charge Relief Valvep. 252
Shaft Seal and Shaft Replacementp. 255
Hydraulic Pump W/Hayes Pump Drive Coupling Lubricationp. 256
Charge Pumpp. 257
5.8 Hydraulic Component Start-Upp. 258
+5.9 Main Valve Block Pressure Settingsp. 259
Main Reliefp. 259
Upper (Main) Lift Downp. 259
Swingp. 259
2-Wheel Steerp. 259
4-Wheel Steerp. 259
+5.10 PLATFORM Valve Block Pressure Settingsp. 259
Platform Level Extendp. 259
Platform Level Retractp. 259
Articulating Jibp. 259
5.11 Hydraulic Schematicsp. 262
+Section 6. JLG Control Systemp. 271
+6.1 introductionp. 271
Connect JLG Control System Analyzerp. 273
Using Analyzerp. 273
Changing Access Levelp. 274
Adjust Parametersp. 275
Machine Setupp. 276
Level Vehicle Descriptionp. 276
6.2 Machine Personality Settingsp. 285
+6.3 Machine Orientation When Setting Function Speedsp. 307
6.4 CANbus Communicationsp. 308
+Section 7. Basic Electrical Information & Electrical Schematicsp. 325
7.1 Generalp. 325
+7.2 Multimeter Basicsp. 325
Groundingp. 325
Backprobingp. 325
Min/Maxp. 325
Polarityp. 325
Scalep. 325
Voltage Measurementp. 325
Resistance Measurementp. 326
Continuity Measurementp. 326
Current Measurementp. 327
+7.3 Applying Silicone Dielectric Compound to Electrical Connectionsp. 327
Dielectric Grease Applicationp. 328
Deutsch HD, DT, DTM, DRC Seriesp. 328
AMP Sealp. 328
AMP Mate-N-Lokp. 329
DIN Connectorsp. 329
Exclusionsp. 329
+7.4 AMP Connectorp. 330
Contact Assemblyp. 330
Connector Assemblyp. 330
Disassemblyp. 331
Wedge Lockp. 331
Service – Voltage Readingp. 331
+7.5 Deutsch Connectorsp. 332
DT/DTP Series Assemblyp. 332
DT/DTP Series Disassemblyp. 332
HD30/HDP20 Series Assemblyp. 333
HD30/HDP20 Series Disassemblyp. 333
7.6 Electrical Schematicsp. 336
Together, these sections give a technician a complete service reference for the JLG 600A and 660AJ. The manual covers the full machine – from the chassis and turntable through the boom and platform, with dedicated engine sections for the Deutz and GM power plants, hydraulic schematics for both 2WD and 4WD configurations, and the complete JLG Control System diagnostic framework. Torque values, pressure settings, capacity charts, and service intervals are printed alongside the procedures, so you are not left guessing at specifications.
What This Manual Enables You to Do
With this JLG 600A 660AJ service and maintenance manual, you can perform scheduled maintenance, diagnose hydraulic and electrical faults, repair or rebuild cylinders and hydraulic components, service the Deutz D2.9 L4, Deutz D2011, or GM 3.0L engine, troubleshoot the JLG Control System using fault codes, adjust steer and swing systems, replace torque hub components, service the swing bearing and rotary coupling, maintain the powertrack, and much more. The manual includes the torque specifications, pressure settings, and clearance values needed to complete each procedure to JLG’s standards.
Correct procedures and specifications matter. The 600A and 660AJ are heavy aerial work platforms with high-pressure hydraulic systems and complex control electronics. Working without the correct torque values, pressure settings, or diagnostic flow charts risks equipment damage, premature failure, or unsafe operation. This manual gives you the information the manufacturer intended service personnel to use.
Instant PDF Delivery
This JLG 600A 660AJ service and maintenance manual is delivered as an instant PDF download after payment. There is no shipping, no waiting, and no physical book to handle. You can view it on any device – laptop, tablet, or smartphone – and print the pages you need for the shop. Keep it on hand for every service job on your 600A or 660AJ.
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