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

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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

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