JLG 600S/SJ, 660SJ & 600A/AJ Telescopic Boom Lift Service and Maintenance Manual (ANSI)

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This service manual PDF download for the 600S/SJ, 660SJ & 600A/AJ JLG Telescopic Boom Lift has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

JLG Lift 600S/SJ
JLG Lift 660SJ
JLG Lift 600A/AJ

Prior to S/N 0300080000


TABLE OF CONTENTS :

Section 1. specifications
    1.1 Capacities
    1.2 Component Data
    1.3 Performance Data
    1.4 Function Speeds
    1.5 Torque Requirements
    1.6 Lubrication
    1.7 Pressure Settings
    1.8 Cylinder Specifications
    1.9 Major Component Weights
    1.10 Critical Stability Weights
    1.11 Serial Number Locations
    
Section 2. General
    2.1 Machine Preparation, Inspection, and Maintenance
    2.2 Service and Guidelines
    2.3 Lubrication and Information
    2.4 Cylinder Drift Test
    2.5 Pins and Composite Bearing Repair Guidelines
    2.6 Welding on JLG Equipment
    2.7 Applying Silicone Dielectric Compound to Electrical Connections
    2.8 AMP Connector
    2.9 Deutsch Connectors
        
Section 3. chassis & turntable
    3.1 Drive Torque hub, Prior to S/N 75606
    3.2 Torque Hub, Drive (Auburn Gear)
    3.3 Drive Torque hub, S/N 75606 to Present
    3.4 Drive Brake - Mico, Prior to S/N 75606
    3.5 Free Wheeling Option
    3.6 Drive Motor (600S, 600A 4WD)
    3.7 Drive Motor (600A 2WD)
    3.8 Drive Motor Adjustment Procedure (S Models Only, Prior to S/N 75606)
    3.9 Oscillating Axle Bleeding Procedure and Lockout Test
    3.10 Steer Adjustments (S Models)
    3.11 Swing Hub
    3.12 Swing Bearing
    3.13 Swing Brake - Mico
    3.14 Tilt Alarm Switch (Machines With External Tilt Sensor)
    3.15 Spark Arrester Cleaning Instructions
    3.16 Rotary Coupling - 600s s/n 75606 to Present
    3.17 Dual Fuel System
    3.18 Electric Governor Installation and Adjustments - Ford LRG Engine
    3.19 Throttle Checks and Adjustments - Deutz or Continental Engine (Prior to S/N 61927)
    3.20 Automatic Choke Adjustment - Ford Engine
    3.21 Cold Weather Starting Difficulty
    3.22 GLow Plugs
    3.23 Ford EFI Engine (machines after SN 48907)
    3.24 Ford LPG System (S Models after S/N 79619 & A Models after S/N 79888)
        
Section 4. boom & platform
    4.1 Boom Rope Torquing Procedures
    4.2 Wear Pads
    4.3 Wire Rope (S Models)
    4.4 Boom Maintenance (S Models)
    4.5 Boom Maintenance (A Models)
    4.6 Tower Boom
    4.7 Articulating Jib Boom
    4.8 Limit Switches and Cam Valve Adjustment
    4.9 Platform
    4.10 Rotator - Helac
    4.11 Drive Card Setup Procedures
    4.12 Foot Switch Adjustment
    4.13 Boom Synchronizing Procedure (A Models Only)
    
Section 5. hydraulics
    5.1 Cylinders - Theory of Operation
    5.2 Cylinder Checking Procedure
    5.3 Cylinder Repair
    5.4 Cylinder Removal and Installation (S Models)
    5.5 Cylinder Removal and Installation (A Models)
    5.6 Variable Displacement pump (M46 series)
    5.7 Valves - Theory of Operation
    5.8 Pressure Setting Procedures (S and A Models)
    5.9 Hydraulic Component Start-Up Procedures and Recommendations
    5.10 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
    
Section 6. JLG Control SystEM
    6.1 Introduction
    6.2 To Connect the JLG Control System Analyzer
    6.3 Using the Analyzer
    6.4 Changing the Access Level of the Hand Held Analyzer
    6.5 Adjusting Parameters Using the Hand Held Analyzer
    6.6 Machine Setup
    6.7 Level Vehicle Description
    6.8 Machine Personality Settings
    6.9 Analyzer Diagnostics Menu Structure
    
Section 7. schematics
    7.1 General
    7.2 Troubleshooting
    7.3 Hydraulic Circuit Checks
    

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 3120718
Total Pages : 322


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Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
    A General
    B Hydraulic System Safety
    C Maintenance
    
Section 1. specifications
    1.1 Capacities
        Fuel Tank
        Hydraulic Oil Tank
        Hydraulic System (Including Tank)
        Torque Hub, Drive
        Engine Crankcase
    1.2 Component Data
        Engine - Ford LRG-425
        Engine - Ford LRG-423
        Engine - Deutz F4M1011F
        Engine - Continental TMD27
        Engine - Caterpillar 3044C
        Drive System (S Models)
        Drive System (A Models)
        Steer System (S Models)
        Steer System (A Models)
        Swing System
    1.3 Performance Data
        Turning Radius (Outside) (S Models)
        Turning Radius (Outside) (A Models)
        Turning Radius (Inside) (S Models)
        Turning Radius (Inside) (A Models)
        Boom Elevation (S Models)
        Boom Elevation (A Models)
        Machine Weight approximately
        Machine Height (Stowed) (S Models)
        Machine Height (Stowed) (A Models)
        Machine Length (Stowed) (S Models)
        Machine Length (Stowed) (A Models)
        Machine Width (S Models)
        Machine Width (A Models)
        Wheel base (S Models)
        Wheel base (A Models)
    1.4 Function Speeds
        Machine Orientation When Doing Speed Tests
        Test Notes
    1.5 Torque Requirements
    1.6 Lubrication
        Ford LRG423 & LRG425 Engine
        Deutz F4M1011F Engine
        Continental TMD27 Engine
        Hydraulic Oil
        Lubrication Specifications
    1.7 Pressure Settings
        Rexroth Valve (S Models)
        Rexroth Valve (A Models)
    1.8 Cylinder Specifications
    1.9 Major Component Weights
    1.10 Critical Stability Weights
    1.11 Serial Number Locations
    
Section 2. General
    2.1 Machine Preparation, Inspection, and Maintenance
        General
        Preparation, Inspection, and Maintenance
        Pre-Start Inspection
        Pre-Delivery Inspection and Frequent Inspection
        Annual Machine Inspection
        Preventative Maintenance
    2.2 Service and Guidelines
        General
        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 Servicing
    2.3 Lubrication and Information
        Hydraulic System
        Hydraulic Oil
        Changing Hydraulic Oil
        Lubrication Specifications
    2.4 Cylinder Drift Test
        Platform Drift
        Cylinder Drift
    2.5 Pins and Composite Bearing Repair Guidelines
    2.6 Welding on JLG Equipment
        Do the Following When Welding on JLG Equipment
        Do NOT Do the Following When Welding on JLG Equipment
    2.7 Applying Silicone Dielectric Compound to Electrical Connections
    2.8 AMP Connector
        Applying Silicone Dielectric Compound to AMP Connectors
        Assembly
        Disassembly
        Wedge Lock
        Service - Voltage Reading
    2.9 Deutsch Connectors
        DT/DTP Series Assembly
        DT/DTP Series Disassembly
        HD30/HDP20 Series Assembly
        HD30/HDP20 Series Disassembly
        
Section 3. chassis & turntable
    3.1 Drive Torque hub, Prior to S/N 75606
        Disassembly
        Cleaning and Inspection
        Repair
        Assembly
    3.2 Torque Hub, Drive (Auburn Gear)
        Disassembly
        Assembly
    3.3 Drive Torque hub, S/N 75606 to Present
        Roll, Leak and Brake Testing
        Tightening and Torquing Bolts
        Main Disassembly
        Input Carrier Disassembly
        Hub-Spindle Disassembly
        Spindle-Brake Disassembly
        Cover Disassembly
        Input Carrier Sub-Assembly
        Output Planet Gear Sub-Assembly
        Spindle - Brake Sub-Assembly
        Hub-Spindle Sub-Assembly
        Cover Sub-Assembly
        Main Assembly
        Integral Brake Check
    3.4 Drive Brake - Mico, Prior to S/N 75606
        Disassembly
        Inspection
        Assembly
    3.5 Free Wheeling Option
        To Disengage Drive Motors and Brakes (Free Wheel) for Towing, etc.
        To Engage Drive Motors and Brakes (Normal Operation)
    3.6 Drive Motor (600S, 600A 4WD)
        Spare Parts Kits
        Replacing the Drive Shaft Seal
        Disassembly and Assembly
        Assembly Notes
        Taper Roller Bearing Initial Tension
        Testing and Setup
    3.7 Drive Motor (600A 2WD)
        Shaft Seal Replacement
    3.8 Drive Motor Adjustment Procedure (S Models Only, Prior to S/N 75606)
    3.9 Oscillating Axle Bleeding Procedure and Lockout Test
        Lockout Cylinder Bleeding
        Oscillating Axle Lockout Test
    3.10 Steer Adjustments (S Models)
    3.11 Swing Hub
        Adjustment Procedures
    3.12 Swing Bearing
        Turntable Bearing Mounting Bolt Condition Check
        Wear Tolerance (S & A Models)
        Swing Bearing Replacement
        Swing Bearing Torque Values
    3.13 Swing Brake - Mico
        Disassembly
        Inspection
        Assembly
    3.14 Tilt Alarm Switch (Machines With External Tilt Sensor)
        Manual Adjustment
    3.15 Spark Arrester Cleaning Instructions
    3.16 Rotary Coupling - 600s s/n 75606 to Present
    3.17 Dual Fuel System
        Changing from Gasoline to LP Gas
        Changing from LP Gas to Gasoline
    3.18 Electric Governor Installation and Adjustments - Ford LRG Engine
        General
        Quick-start Installations
        Mounting-Actuator
        Linkage
        Mounting-Controller
        Wiring
        Check-Out and Initial Start-Up Procedures
        Multi-Turn Adjustment (High Engine, Mid Engine, Overspeed, Starter Lockout)
        Single-Turn Adjustment (Gain, Factory Adjust)
        Troubleshooting
    3.19 Throttle Checks and Adjustments - Deutz or Continental Engine (Prior to S/N 61927)
        General
        Procedure
        Controller Status
        Failure Modes
    3.20 Automatic Choke Adjustment - Ford Engine
    3.21 Cold Weather Starting Difficulty
        Checking the Carburetor
        Checking the Ignition
        Checking the Fuel
    3.22 GLow Plugs
    3.23 Ford EFI Engine (machines after SN 48907)
        Performing Diagnostics
        EFI Diagnostics (600S prior to S/N 61927, 600A prior to S/N 64249)
        ECM AND SENSORS
        Fuel System
    3.24 Ford LPG System (S Models after S/N 79619 & A Models after S/N 79888)
        Description
        Regulator
        Megajector
        Mixer
        Lockoff Solenoid
        Megajector Diagnostic Code Descriptions
        
Section 4. boom & platform
    4.1 Boom Rope Torquing Procedures
        Torque Procedures (S Models)
    4.2 Wear Pads
        Tower Boom (A Models)
        Main Boom
    4.3 Wire Rope (S Models)
        Inspection
        Three Month Inspection
        Seven Year Inspection
        Replacement Criteria
    4.4 Boom Maintenance (S Models)
        Removal
        Disassembly of Boom Sections
        Inspection
        Assembly
        Installation
    4.5 Boom Maintenance (A Models)
        Removal
        Disassembly of Boom Sections
        Inspection
        Assembly
        Installation
    4.6 Tower Boom
        Removal
        Disassembly
        Inspection
        Assembly
        Installation
    4.7 Articulating Jib Boom
        Removal
        Disassembly
        Inspection
        Assembly
    4.8 Limit Switches and Cam Valve Adjustment
    4.9 Platform
        Platform Sections Replacement
    4.10 Rotator - Helac
        Disassembly
        Inspection
        Assembly
    4.11 Drive Card Setup Procedures
        Lift, Swing, and Drive Cards
        Flow Control Card
    4.12 Foot Switch Adjustment
    4.13 Boom Synchronizing Procedure (A Models Only)
    
Section 5. hydraulics
    5.1 Cylinders - Theory of Operation
        Systems Incorporating Double Acting Cylinders
        Systems Incorporating Holding Valves
    5.2 Cylinder Checking Procedure
        Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinder
        Cylinders With Single Counterbalance Valve
        Cylinders With Dual Counterbalance Valves
    5.3 Cylinder Repair
        Disassembly
        Cleaning and Inspection
        Assembly
    5.4 Cylinder Removal and Installation (S Models)
        Main Boom Telescope Cylinder Removal
        Main Boom Telescope Cylinder Installation
        Main Boom Lift Cylinder Removal
        Main Boom Lift Cylinder Installation
    5.5 Cylinder Removal and Installation (A Models)
        Main Boom Telescope Cylinder Removal
        Main Boom Telescope Cylinder Installation
        Main Boom Lift Cylinder Removal
        Main Boom Lift Cylinder Installation
        Upright Level Cylinder Removal
        Upright Level Cylinder Installation
        Tower Boom Lift Cylinder Removal
        Tower Lift Cylinder Installation
        Tower Telescope Cylinder Removal
        Tower Telescope Cylinder Installation
    5.6 Variable Displacement pump (M46 series)
        Troubleshooting
        Inspections and Adjustments
        Minor Repair and Replacement
    5.7 Valves - Theory of Operation
        Solenoid Control Valve - Rexroth
        Relief Valves
    5.8 Pressure Setting Procedures (S and A Models)
        Main Relief, Steer, Swing and Lift Down
        Platform Level
        Articulating Jib Boom (If Equipped)
        4 Wheel Steer (If Equipped)
    5.9 Hydraulic Component Start-Up Procedures and Recommendations
    5.10 Hydraulic Pump W/hayes Pump Drive Coupling Lubrication
    
Section 6. JLG Control SystEM
    6.1 Introduction
    6.2 To Connect the JLG Control System Analyzer
    6.3 Using the Analyzer
    6.4 Changing the Access Level of the Hand Held Analyzer
    6.5 Adjusting Parameters Using the Hand Held Analyzer
    6.6 Machine Setup
    6.7 Level Vehicle Description
    6.8 Machine Personality Settings
    6.9 Analyzer Diagnostics Menu Structure
    
Section 7. schematics
    7.1 General
    7.2 Troubleshooting
    7.3 Hydraulic Circuit Checks
    
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