Description
JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual
This is the complete JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual, document number 3121202, covering machines from serial number 0300080000 to present. Originally issued October 15, 2004 and revised through March 12, 2008, this manual gives technicians the full factory-level detail needed to service, troubleshoot, and repair these telescopic boom lifts.
File Details
- Manual Type: Service and Maintenance Manual
- Brand/Models: JLG 600S, 600SJ, 660SJ
- Language: English
- Page Count: 304 pages
- File Format: PDF
- Document Number: 3121202
- Revision Date: March 12, 2008
- Serial Number Range: 0300080000 to Present
Chapters Covered
- Introduction – Maintenance Safety Precautions
- Section 1 – Specifications
- Capacities, Component Data, Engine Data (Ford LRG-425, Deutz F4M1011F/F4M2011, Deutz D2011L04, Caterpillar 3044C, GM 3.0L)
- Performance Data, Machine Weight, Dimensional Data
- Function Speeds, Torque Requirements, Lubrication
- Pressure Settings, Cylinder Specifications
- Major Component Weights, Critical Stability Weights
- Lubrication and Operator Maintenance, Serial Number Locations
- Section 2 – General
- Machine Preparation, Inspection, and Maintenance
- Service and Guidelines, Lubrication and Information
- Cylinder Drift Test, Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual – P/N 3121202” are as follows:
+Section A. Introduction – Maintenance Safety Precautionsp. 3
A Generalp. 3
B Hydraulic System Safetyp. 3
C Maintenancep. 3
+Section 1. Specificationsp. 17
1.1 Capacitiesp. 17
+1.2 Component Datap. 17
Engine Datap. 17
Drive Systemp. 18
Tiresp. 18
Swing Systemp. 18
Auxiliary Power Pumpp. 18
Hydraulic Filtersp. 18
+1.3 Performance Datap. 19
Machine Weight (Approximate)p. 19
Dimensional Datap. 19
+1.4 Function Speedsp. 20
Machine Orientation When Doing Speed Testsp. 20
Test Notesp. 20
1.5 Torque Requirementsp. 21
+1.6 Lubricationp. 21
Ford Engine Oil Specificationsp. 21
Deutz Engine Oil Specificationsp. 21
Hydraulic Oilp. 22
1.7 Pressure Settingsp. 22
1.8 Cylinder Specificationsp. 23
1.9 Major Component Weightsp. 23
1.10 Critical Stability Weightsp. 24
+1.11 Lubrication and Operator Maintenancep. 25
Draining Oil Build Up From The Propane Regulatorp. 29
Propane Fuel Filter Replacementp. 30
Propane Fuel System Pressure Reliefp. 31
1.12 Serial Number Locationsp. 31
+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
Preventative Maintenancep. 35
+2.2 Service and Guidelinesp. 36
Generalp. 36
Safety and Workmanshipp. 36
Cleanlinessp. 36
Components Removal and Installationp. 37
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. 38
Batteryp. 38
Lubrication and Servicingp. 38
+2.3 Lubrication and Informationp. 38
Hydraulic Systemp. 38
Hydraulic Oilp. 38
Changing Hydraulic Oilp. 39
Lubrication Specificationsp. 39
+2.4 Cylinder Drift Testp. 39
Platform Driftp. 39
Cylinder Driftp. 39
2.5 Pins and Composite Bearing Repair Guidelinesp. 40
+2.6 Welding on JLG Equipmentp. 40
Do the Following When Welding on JLG Equipmentp. 40
Do NOT Do the Following When Welding on JLG Equipmentp. 40
+Section 3. Chassis & Turntablep. 49
+3.1 Drive Torque hubp. 49
Roll, Leak and Brake Testingp. 49
Tightening and Torquing Boltsp. 49
Main Disassemblyp. 50
Input Carrier Disassemblyp. 53
Hub-Spindle Disassemblyp. 54
Spindle-Brake Disassemblyp. 55
Cover Disassemblyp. 57
Input Carrier Sub-Assemblyp. 58
Output Planet Gear Sub-Assemblyp. 58
Spindle – Brake Sub-Assemblyp. 58
Hub-Spindle Sub-Assemblyp. 59
Cover Sub-Assemblyp. 60
Main Assemblyp. 60
Integral Brake Checkp. 60
+3.2 Free Wheeling Optionp. 64
To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.p. 64
To Engage Drive Motors and Brakes (Normal Operation)p. 64
+3.3 Drive Motor (S/N 75606 to Present)p. 64
Descriptionp. 64
Shaft Seal Replacementp. 65
Loop Flushing Valvep. 66
Troubleshootingp. 67
Disassemblyp. 68
Inspectionp. 72
Assemblyp. 74
Initial Start-up Proceduresp. 79
+3.4 Oscillating Axle Bleeding Procedure and Lockout Testp. 80
Lockout Cylinder Bleedingp. 80
Oscillating Axle Lockout Testp. 80
3.5 Steer Adjustmentsp. 81
+3.6 Swing Hubp. 82
Adjustment Proceduresp. 82
+3.7 Swing Bearingp. 82
Turntable Bearing Mounting Bolt Condition Checkp. 82
Wear Tolerancep. 83
Swing Bearing Replacementp. 85
Swing Bearing Torque Valuesp. 86
+3.8 Swing Brake – Micop. 87
Disassemblyp. 87
Inspectionp. 87
Assemblyp. 87
+3.9 Tires & Wheelsp. 89
Tire Inflationp. 89
Tire Damagep. 89
Tire Replacementp. 89
Wheel Replacementp. 89
Wheel Installationp. 89
3.10 Rotary Couplingp. 90
+3.11 Generatorp. 95
Every 250 hoursp. 95
Every 500 hoursp. 95
Overload Protectionp. 96
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Ringsp. 96
3.12 Spark Arrester Cleaning Instructionsp. 98
3.13 Glow Plugsp. 98
+3.14 Ford EFI Enginep. 98
Performing Diagnosticsp. 98
ECM/EPM and Sensorsp. 99
Fuel Systemp. 104
+3.15 Ford LPG Systemp. 109
Descriptionp. 109
Regulatorp. 109
Megajectorp. 109
Mixerp. 109
Lockoff Solenoidp. 109
Megajector Diagnostic Code Descriptionsp. 111
Changing from Gasoline to LP Gasp. 112
Changing from LP Gas to Gasolinep. 112
3.16 Deutz EMR 2 (S/N 84827 to Present)p. 120
+3.17 Bio Fuel in Deutz Enginesp. 133
Generalp. 133
Bio Fuelp. 133
Biological Contamination In Fuelsp. 134
+3.18 GM Engine General Maintenancep. 135
Maintenance of the Drive Beltp. 135
Engine Electrical System Maintenancep. 135
Checking/Filling Engine Oil Levelp. 135
Changing The Engine Oilp. 136
Coolant Fill Procedure – Dual Fuel Enginep. 136
+3.19 GM Engine Dual Fuel Systemp. 137
Fuel Filterp. 138
Electric Lock Offp. 138
EPR Assemblyp. 138
Low Pressure Regulator (LPR)p. 139
Air Fuel Mixerp. 139
Electronic Throttle Control (ETC)p. 140
Engine Control Modulep. 140
Heated Exhaust Gas Oxygen Sensorp. 141
Gasoline Multi Point Fuel Injection System (MPFI)p. 141
Gasoline Fuel Pumpp. 141
Gasoline Pressure And Temperature Sensor Manifoldp. 141
Fuel Filterp. 142
Fuel Injector Railp. 142
Fuel Injectorp. 142
+3.20 GM Engine Fuel System Repairp. 142
Propane Fuel System Pressure Reliefp. 142
Propane Fuel System Leak Testp. 142
Propane Fuel Filter Replacementp. 143
Electronic Pressure Regulator (EPR) Assembly Replacementp. 143
Temperature Manifold Absolute Pressure (TMAP) Sensorp. 145
Electronic Throttle Control Replacementp. 145
MIXER REPLACEMENTp. 146
Coolant Hose Replacementp. 147
Vapor Hose Replacementp. 147
Engine Control Module Replacementp. 147
Heated Exhaust Gas Oxygen Sensor Replacementp. 147
+3.21 GM Engine LPG Fuel System Diagnosisp. 148
Fuel System Descriptionp. 148
Diagnostic Aidsp. 148
+Section 4. Boom & Platformp. 163
4.1 Boom Rope Torquing Proceduresp. 163
+4.2 Wear Padsp. 164
+4.3 Wire Ropep. 164
Inspectionp. 164
Three Month Inspectionp. 165
Seven Year Inspectionp. 165
Replacement Criteriap. 165
+4.4 Boom Maintenancep. 165
Removalp. 165
Disassembly of Boom Sectionsp. 167
Inspectionp. 171
Assemblyp. 173
Installationp. 176
+4.5 Articulating Jib Boomp. 177
Removalp. 177
Disassemblyp. 177
Inspectionp. 177
Assemblyp. 178
4.6 Limit Switches and Cam Valve Adjustmentp. 178
+4.7 Platformp. 181
Platform Sections Replacementp. 181
+4.8 Rotator – Helacp. 181
Disassemblyp. 181
Inspectionp. 183
Assemblyp. 183
4.9 Foot Switch Adjustmentp. 184
+Section 5. Hydraulicsp. 187
+5.1 Cylinders – Theory of Operationp. 187
Systems Incorporating Double Acting Cylindersp. 187
Systems Incorporating Holding Valvesp. 187
+5.2 Cylinder Checking Procedurep. 187
Cylinders Without Counterbalance Valves – Master Cylinder and Steer Cylinderp. 187
Cylinders With Single Counterbalance Valvep. 187
Cylinders With Dual Counterbalance Valvesp. 188
+5.3 Cylinder Removal and Installationp. 188
Main Boom Telescope Cylinder Removalp. 188
Main Boom Telescope Cylinder Installationp. 189
Main Boom Lift Cylinder Removalp. 190
Main Boom Lift Cylinder Installationp. 190
+5.4 Cylinder Repairp. 190
Disassemblyp. 190
Cleaning and Inspectionp. 192
Assemblyp. 193
+5.5 Variable Displacement pump (M46 series)p. 204
Troubleshootingp. 204
Inspections and Adjustmentsp. 208
Minor Repair and Replacementp. 211
+5.6 Valves – Theory of Operationp. 215
Solenoid Control Valve – Rexrothp. 215
Relief Valvesp. 215
+5.7 Pressure Setting Proceduresp. 216
Main Relief, Steer, Swing and Lift Downp. 216
Platform Levelp. 216
Articulating Jib Boom (If Equipped)p. 216
4 Wheel Steer (If Equipped)p. 220
5.8 Hydraulic Component Start-Up Procedures and Recommendationsp. 220
5.9 Hydraulic Pump W/hayes Pump Drive Coupling Lubricationp. 221
+Section 6. JLG Control Systemp. 223
6.1 Introductionp. 223
6.2 To Connect the JLG Control System Analyzerp. 225
6.3 Using the Analyzerp. 225
6.4 Changing the Access Level of the Hand Held Analyzerp. 227
6.5 Adjusting Parameters Using the Hand Held Analyzerp. 229
6.6 Machine Setupp. 230
6.7 Level Vehicle Descriptionp. 230
6.8 Machine Personality Settingsp. 239
6.9 Analyzer Diagnostics Menu Structurep. 271
+Section 7. Basic Electrical Information & Schematicsp. 277
7.1 Generalp. 277
+7.2 Multimeter Basicsp. 277
Groundingp. 277
Backprobingp. 277
Min/Maxp. 277
Polarityp. 277
Scalep. 277
Voltage Measurementp. 277
Resistance Measurementp. 278
Continuity Measurementp. 278
Current Measurementp. 279
7.3 Applying Silicone Dielectric Compound to Electrical Connectionsp. 279
+7.4 AMP Connectorp. 280
Applying Silicone Dielectric Compound to AMP Connectorsp. 280
Assemblyp. 280
Disassemblyp. 282
Wedge Lockp. 282
Service – Voltage Readingp. 282
+7.5 Deutsch Connectorsp. 284
DT/DTP Series Assemblyp. 284
DT/DTP Series Disassemblyp. 284
HD30/HDP20 Series Assemblyp. 285
HD30/HDP20 Series Disassemblyp. 285
- Section 3 – Chassis & Turntable
- Drive Torque Hub Disassembly, Assembly and Testing
- Free Wheeling Option, Drive Motor Service and Troubleshooting
- Oscillating Axle Bleeding Procedure, Steer Adjustments
- Swing Hub, Swing Bearing, Swing Brake – Mico
- Tires & Wheels, Rotary Coupling, Generator
- Ford EFI Engine Diagnostics, ECM/EPM and Sensors, Fuel System
- Ford LPG System
- Section 4 – Boom & Platform
- Boom Rope Torquing Procedures, Wear Pads, Wire Rope Inspection
- Boom Maintenance – Removal, Disassembly, Assembly, Installation
- Articulating Jib Boom, Limit Switches and Cam Valve Adjustment
- Platform Sections Replacement, Rotator – Helac, Foot Switch Adjustment
- Section 5 – Hydraulics
- Cylinders – Theory of Operation, Cylinder Checking Procedure
- Cylinder Removal, Installation and Repair
- Variable Displacement Pump (M46 Series) Troubleshooting
- Valves – Theory of Operation, Pressure Setting Procedures
- Section 6 – JLG Control System
- Connecting and Using the JLG Control System Analyzer
- Machine Setup, Level Vehicle Description
- Machine Personality Settings, Diagnostics Menu Structure
- Section 7 – Basic Electrical Information & Schematics
- Multimeter Basics, AMP and Deutsch Connectors
- Electrical and Hydraulic Schematics
Together these sections give a technician everything needed to move from routine inspection through full component teardown and rebuild, with the specification tables and schematics needed to work to factory tolerances rather than guesswork.
What This JLG 600S 600SJ 660SJ Service Manual Covers
With this JLG 600S 600SJ 660SJ Boom Lift Service and Maintenance Manual you can diagnose drive hub and swing bearing wear, rebuild drive motors and hydraulic cylinders, set relief and pressure valve settings to factory specification, service the Ford, Deutz, Caterpillar and GM engine options fitted to these boom lifts, and work through the JLG Control System Analyzer for fault codes and machine personality settings. Having the correct torque values, cylinder bore and stroke dimensions, and pressure settings on hand means repairs are done to the same standard JLG technicians use, reducing comebacks and premature part failure. This JLG 600S 600SJ 660SJ manual downloads instantly as a PDF after purchase – no shipping wait, no physical book to store. Read it on a laptop, tablet, or phone in the shop, or print out the pages you need for a specific 600S, 600SJ, or 660SJ repair job.
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