JLG 600S-SJ, 660SJ, 600A-AJ Lift Complete Workshop Service Repair Manual
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Print one or all pages of your manual
Illustrated Parts Manual
Models
600A
600AJ
Prior to
S/N 0300069000
P/N
3120719
July 24, 2012
REVISION LOG
3120719 A
NOTES:
ADE SYSTEM IDENTIFICATION
Most 600A and 600AJ machines from S/N 64249 incorporate the ADE System, but no clean S/N break exist. The following
machine serial numbers prior to S/N 64249 also utilize ADE System: 63908, 63912, 63932, 63936, 63938, 63954, 63959 and
63963. A machine that incorporates ADE System can be outwardly identified by the analyzer connection at the base of the
platform control box.
MANUAL REVISION LOG:
February 1996 - Original Issue Of Manual
September 1997 - Revised (Manual edited to 0010519 Revision 31)
February, 1998 - Change 1 (Manual edited to 0010519 Revision 37)
Pages Affected:
Cover
Effectivity Page: a
Table of Contents Pages: i & ii
Section 1 Pages: 1-1 & 1-28 to 1-30
Section 2 Pages: 2-1, 2-2, 2-4 to 2-6, 2-10, 2-20, 2-22 to 2-24, 2-26, 2-27, 2-29, 2-31 to 2-36,
2-38, 2-39, 2-42, 2-45, 2-48, to 2-51, 2-58 to 2-59B, 2-62 to 2-65 & 2-67 to 2-69
Section 3 Pages: 3-1, 3-13, 3-21 to 3-24
Section 4 Pages: 4-1, 4-5 to 4-9, 4-17 & 4-18
Section 5 Pages: 5-1 & 5-28 to 5-30
Section 7 Pages: 7-1 to 7-28
Section 8 Pages: 8-4 & 8-5
Section 9 Pages: 9-1
REVISION LOG
B 3120719
Section 10 Pages: 10-2
February 12, 1999 - Revised (Manual edited to 0010519 Revision 50)
September 30, 1999 - Revised (Manual edited to 0010519 Revision 58)
March 1, 2000 - Revised (Manual edited to 0010519 Revision 63)
August 22, 2001 - Revised (Manual edited to 0010519 Revision 73 & 0010577 Revision 6 With ADE System)
March 1, 2002 - Revised (Manual edited to 0010577 Revision 9)
July 31, 2002 - Revised (Manual edited to 0010577 Revision 18)
February 15, 2003 - Added "Prior to S/N 0300069000" to Front Cover. Refer to Parts Manual 3121177Manual for Machines
Built S/N 0300069000 to 0300087000.
March 6, 2003 - Revised Manual
June 16, 2003 - Revised Manual
May 5, 2004 - Revised Manual
April 11, 2005 - Revised Manual
November 15, 2005 - Revised Manual
April 18, 2006 - Revised Manual
July 19, 2006 - Revised Manual
December 12, 2006 - Revised Manual
May 1, 2007 - Revised Manual
August 16, 2007 - Revised Manual
December 4, 2007 - Revised Manual
March 31, 2008 - Revised Manual
September 15, 2008 - Revised Manual
February 15, 2009 - Revised Manual
August 1, 2009 - Revised Manual
March 25, 2010 - Revised Manual
August 15, 2010 - Revised Manual
May 27, 2011 - Revised Manual
August 29, 2011 - Revised Manual
December 23, 2011 - Revised Manual
April 27, 2012 - Revised Manual
July 24, 2012 - Revised Manual
3120719 i
FIGURE NO. TITLE PAGE NO.
TABLE OF CONTENTS
SECTION 1 - FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1-1 2WD FRONT AXLE AND STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 4WD FRONT AXLE AND STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 4WS REAR STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-5 DRIVE HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-6 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-7 DRIVE MOTOR ASSEMBLY - SUNSTRAND (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1-8 DRIVE MOTOR ASSEMBLY - REXROTH (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1-9 TOW PACKAGE INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
SECTION 2 - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2-1 CONTROL VALVES INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 MAIN VALVE BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 ACCESSORY VALVE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-4 SWING DRIVE, TURNTABLE BEARING & LOCK INSTALLATIONS . . . . . . . . . . . . . . . . 2-12
2-5 SWING HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-6 SWING BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2-7 SWING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-8 CONTINENTAL ENGINE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-9 GENERATOR INSTALLATION (OPTIONAL - CONTINENTAL ENGINE MACHINES) . .2-28
2-10 DEUTZ ENGINE INSTALLATION - WITHOUT NOISE REDUCTION
(PRIOR TO S/N 0300029930) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-11 DEUTZ ENGINE INSTALLATION - WITH NOISE REDUCTION (S/N 0300028190
TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2-12 GENERATOR INSTALLATION (OPTIONAL - DEUTZ ENGINE MACHINES) . . . . . . . . . . 2-46
2-13 FORD ENGINE INSTALLATIONS (PRIOR TO S/N 0300037117) . . . . . . . . . . . . . . . . . . 2-50
2-14 FORD ENGINE INSTALLATIONS - LRG425 WITH CARBURETOR
(S/N 0300037117 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
2-15 FORD ENGINE INSTALLATIONS - LRG-425 WITH EFI
(S/N 0300048907 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
2-16 DUAL FUEL INSTALLATION (OPTIONAL - FORD ENGINE WITH
CARBURETOR MACHINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2-17 DUAL FUEL INSTALLATION (OPTIONAL - FORD ENGINE MACHINES WITH EFI)
(S/N 0300048907 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
2-18 GENERATOR INSTALLATION (OPTIONAL - FORD ENGINE MACHINES) . . . . . . . . . . 2-78
2-19 ISUZU ENGINE INSTALLATION - 4JB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
2-20 PISTON PUMP ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
2-21 GEAR PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
2-22 TANKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
2-23 ROTARY COUPLING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
2-24 GROUND CONTROL BOX INSTALLATIONS (PRIOR TO
S/N 0300064249) 2-100
2-25 GROUND CONTROL BOX INSTALLATIONS (ADE SYSTEM)
(S/N 0300064249 TO S/N 0300069000) 2-106
2-26 ELECTRICAL OPTIONS INSTALLATIONS (TURNTABLE MOUNTED) . . . . . . . . . . . . 2-110
2-27 ENGINE TRAY JACK INSTALLATIONS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
2-28 HOODS INSTALLATIONS - WITHOUT NOISE REDUCTION . . . . . . . . . . . . . . . . . . . . 2-116
2-29 HOODS INSTALLATIONS - WITH NOISE REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
ii 3120719
TABLE OF CONTENTS
FIGURE NO. TITLE PAGE NO.
SECTION 3 - BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-1 BOOMS AND CYLINDERS INSTALLATION - 600A . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 BOOMS AND CYLINDERS INSTALLATION - 600AJ . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-3 TOWER BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-4 MAIN BOOM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-5 ROTATOR ASSEMBLIES (FRONT ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-6 ROTATOR ASSEMBLIES (SIDE ENTRY PLATFORM) . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-7 VALVES AND SWITCHES INSTALLATION (BOOM MOUNTED) . . . . . . . . . . . . . . . . . . 3-26
3-8 BOOM WIPERS INSTALLATIONS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
SECTION 4 - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-1 PLATFORM COMPONENTS INSTALLATION (FRONT ENTRY) . . . . . . . . . . . . . . . . . . 4-2
4-2 PLATFORM COMPONENTS INSTALLATION (SIDE ENTRY) . . . . . . . . . . . . . . . . . . 4-6
4-3 PLATFORM CONSOLE ASSEMBLY (PRIOR TO S/N 0300064249) . . . . . . . . . . . . . 4-10
4-4 PLATFORM CONSOLE ASSEMBLY (WITH ADE SYSTEM)
(S/N 0300064249 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-5 OEM CONTROLLER ASSEMBLY (SWING AND LIFT) (PRIOR TO
S/N 0300039749) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-6 OEM CONTROLLER ASSEMBLY (SWING AND LIFT) (S/N 0300039749 TO
S/N 0300064249) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-7 OEM CONTROLLER ASSEMBLY (SWING AND LIFT) (WITH ADE SYSTEM)
(S/N 0300064249 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4-8 OEM CONTROLLER ASSEMBLY (DRIVE/STEER) (PRIOR TO S/N 0300039749) . . . . . 4-32
4-9 OEM CONTROLLER ASSEMBLY (DRIVE/STEER) (S/N 0300039749 TO
S/N 0300064249) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4-10 OEM CONTROLLER ASSEMBLY (DRIVE/STEER) (WITH ADE SYSTEM)
(S/N 0300064249 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4-11 SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . 4-42
SECTION 5 - CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1 AXLE LOCKOUT CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 PLATFORM LEVEL CYLINDER ASSEMBLIES (PRIOR TO S/N 0300024714) . . . . . . . . 5-4
5-3 PLATFORM LEVEL CYLINDER ASSEMBLIES (S/N 0300024714 TO
S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-4 LEVEL (UPRIGHT) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-5 LIFT (ARTICULATING JIB) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-6 LIFT (MAIN BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-7 LIFT (TOWER BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-8 MASTER CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-9 STEER CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-10 TELESCOPE (MAIN BOOM) CYLINDER ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-11 TELESCOPE (TOWER BOOM) CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-12 CYLINDER BELLOWS INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
SECTION 6 - HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-1 DRIVE HYDRAULIC DIAGRAM - 2WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 DRIVE HYDRAULIC DIAGRAM - 4WD/2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-3 HYDRAULIC DIAGRAM - OSCILLATING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-4 HYDRAULIC DIAGRAM - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-5 HYDRAULIC DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
3120719 iii
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SECTION 7 - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
7-1 ELECTRICAL DIAGRAM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-2 ELECTRICAL SCHEMATIC - DIESEL MACHINES PRIOR TO S/N 0300035129
WITH COLORED WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-3 ELECTRICAL SCHEMATIC - DIESEL MACHINES S/N 0300035129 TO
S/N 0300069000 WITH NUMBERED COLORED WIRING . . . . . . . . . . . . . . . . . . . 7-10
7-4 ELECTRICAL SCHEMATIC - DIESEL UL MACHINES S/N 0300039457 TO
S/N 0300069000 WITH NUMBERED COLORED WIRING . . . . . . . . . . . . . . . . . . . 7-14
7-5 ELECTRICAL SCHEMATIC - GAS MACHINES PRIOR TO S/N 0300035129
WITH COLORED WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7-6 ELECTRICAL SCHEMATIC - GAS MACHINES S/N 0300035129 TO
S/N 0300048907 WITH NUMBERED COLORED WIRING . . . . . . . . . . . . . . . . . . . 7-22
7-7 ELECTRICAL SCHEMATIC - GAS MACHINES (S/N 0300048907 TO
S/N 0300069000) WITH EFI SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7-8 ELECTRICAL SCHEMATIC - GAS UL MACHINES S/N 0300039457 TO
S/N 0300069000 WITH NUMBERED COLORED WIRING . . . . . . . . . . . . . . . . . . . . 7-30
7-9 ELECTRICAL SCHEMATIC - UL MACHINES (LP ONLY) S/N 0300039457 TO
S/N 0300069000 WITH NUMBERED COLORED WIRING . . . . . . . . . . . . . . . . . . . . 7-34
7-10 ELECTRICAL SCHEMATIC - ISUZU ENGINE (S/N 0300063908 TO
S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-11 ELECTRICAL SCHEMATIC - DIESEL/GAS MACHINES (WITH ADE SYSTEM)
(S/N 0300064249 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
7-12 HARNESS COMPONENTS INSTALLATION (PRIOR TO S/N 0300064249) . . . . . . . . . 7-46
7-13 HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)
(S/N 0300064249 TO S/N 0300064270) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
7-14 HARNESS COMPONENTS INSTALLATION (WITH ADE SYSTEM)
(S/N 0300064270 TO S/N 0300069000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
SECTION 8 - DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
8-1 DECALS INSTALLATION - STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-2 DECAL INSTALLATION - COUNTRY SPEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
SECTION 9 - RECOMMENDED SERVICE PARTS STOCK . . . . . . . . . . . . . . . . . . . . . . . . .9-1
SECTION 10 - SPECIAL OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
SECTION 11 - PARTS NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
iv 3120719
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FIGURE DESCRIPTION PAGE
1-1 2WD FRONT AXLE AND STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 4WD FRONT AXLE AND STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-3 4WS REAR STEERING INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 TIRE AND WHEEL DRIVE INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-5 DRIVE HUB ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1-6 DRIVE BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1-7 DRIVE MOTOR ASSEMBLY - SUNSTRAND (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1-8 DRIVE MOTOR ASSEMBLY - REXROTH (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1-9 TOW PACKAGE INSTALLATION (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
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Thank you for considering this Complete Service Repair Workshop Manual for the JLG 600S-SJ, 660SJ, 600A-AJ Lift.
This comprehensive manual covers every Service & Repair Procedure necessary, making it useful for both professional mechanics and DIY enthusiasts.
With easy-to-follow step-by-step instructions and detailed pictures, this manual enables you to save money by performing your own repairs.
Once downloaded, the manual is yours to keep forever. You can print out specific pages, chapters, or the entire manual. It is also compatible with tablets and smartphones.
MODELS COVERED:
- All Models/Engines/Trim/Transmissions Types Are Covered.
CONTENTS:
- This high-quality Service Repair Workshop Manual covers all repair procedures A-Z.
- Every repair and service procedure is comprehensively detailed.
COMPUTER REQUIREMENTS:
- This downloadable Manual is compatible with All PC & MAC Computers, tablets, and mobile phones.
- The only software needed is Adobe Reader, which is usually pre-installed on most computers. If not, it can be downloaded for free.
INSTANT DELIVERY:
- Upon payment by Visa, MasterCard, or PayPal, the manual will be instantly emailed to the address used during checkout.
Customer Satisfaction Guaranteed.
