JLG 600SJ Service Manual

334 pages

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Service and Maintenance Manual

Models

600S

600SJ

660SJ

S/N 0300080000

to 0300171769

P/N - 3121202

February 26, 2014

Questions and Answers:

K
Kenneth GallagherJul 26, 2025
Why is my JLG 600SJ system operating hot?
- V
  Veronica RodriguezJul 27, 2025
  Your JLG Boom Lifts system might be running hot due to several reasons. It could be due to an insufficient amount of hydraulic fluid, which fails to meet the system's cooling demands. In this case, fill the reservoir to the proper level. Another cause might be a failing or obstructed heat exchanger, which also prevents adequate cooling. Make sure the heat exchanger is receiving enough air flow and is in good condition; repair or replace it if needed. Finally, a system relief valve that's unseated for too long or malfunctioning could cause overheating. Repair or replace any faulty relief valves and check that the machine's loads aren't too high.
J
jennifer03Aug 10, 2025
How to fix excessive noise and vibration in JLG Boom Lifts?
- J
  jennazimmermanAug 10, 2025
  Excessive noise and vibration in your JLG Boom Lifts can stem from several issues. Insufficient hydraulic fluid can cause cavitation, leading to system noise; ensure the reservoir is filled to the correct level and that oil supply to the motor is adequate and unobstructed. Trapped air in system lines or the motor can also cause cavitation; make sure all system lines and components are purged of air. A loose or incorrect shaft coupling can produce vibrations; verify the correct coupling is used and fits properly. Misaligned shafts create frictional vibration; ensure shafts are properly aligned. Finally, hydraulic oil viscosity above acceptable limits can cause cavitation; replace the hydraulic oil with the appropriate fluid for your operating conditions.

JLG 600SJ Specifications

General

Brand	JLG
Model	600SJ
Category	Boom Lifts
Language	English

Summary

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

General safety precautions for aerial platform maintenance.

B HYDRAULIC SYSTEM SAFETY

Safety precautions for high-pressure hydraulic systems.

C MAINTENANCE

General maintenance safety guidelines and warnings.

SECTION 1 - SPECIFICATIONS

1.1 CAPACITIES

Details fluid capacities for various machine components.

1.2 COMPONENT DATA

Provides specifications for engine, drive system, tires, and swing system.

1.4 FUNCTION SPEEDS

Outlines test procedures and speeds for machine functions.

1.5 TORQUE REQUIREMENTS

Specifies torque values for critical fasteners and components.

1.6 LUBRICATION

Details lubrication specifications for engines and components.

1.7 PRESSURE SETTINGS

Lists system pressure settings for various hydraulic functions.

1.10 CRITICAL STABILITY WEIGHTS

Specifies critical weights for machine stability and safety.

1.11 LUBRICATION AND OPERATOR MAINTENANCE

Covers lubrication points, intervals, and operator maintenance.

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

Outlines procedures for machine readiness, inspections, and maintenance programs.

2.2 SERVICE AND GUIDELINES

Provides information on servicing, safety, workmanship, and component handling.

2.3 LUBRICATION AND INFORMATION

Covers hydraulic system cleanliness, oil changes, and lubrication specifications.

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Guidelines for inspecting and repairing pins and bearings.

2.6 WELDING ON JLG EQUIPMENT

Procedures and warnings for welding on JLG equipment.

SECTION 3 - CHASSIS & TURNTABLE

3.1 TIRES & WHEELS

Covers tire inflation, damage, replacement, and wheel installation procedures.

3.2 DRIVE TORQUE HUB

Details roll, leak, and brake testing, plus tightening and torquing bolts.

3.4 DRIVE MOTOR (S/N 75606 TO PRESENT)

Description of the drive motor's operation and components.

SECTION 4 - BOOM & PLATFORM

4.1 BOOM ROPE TORQUING PROCEDURES

Steps for torquing boom rope adjusting nuts.

4.3 WIRE ROPE

Daily inspection procedures and replacement criteria for wire ropes.

4.4 BOOM MAINTENANCE

Procedures for boom removal, disassembly, and inspection.

4.5 ARTICULATING JIB BOOM

Removal, disassembly, inspection, and assembly of the articulating jib.

4.7 BOOM CLEANLINESS GUIDELINES

Guidelines for maintaining internal boom cleanliness in dirty environments.

SECTION 5 - HYDRAULICS

5.1 CYLINDERS - THEORY OF OPERATION

Explains double-acting and holding valve cylinders and their functions.

5.2 CYLINDER CHECKING PROCEDURE

Procedures for checking cylinder seals and counterbalance valves.

5.3 CYLINDER REMOVAL AND INSTALLATION

Steps for removing and installing main boom telescope and lift cylinders.

5.4 CYLINDER REPAIR

General procedures for cylinder disassembly, cleaning, and inspection.

5.5 VARIABLE DISPLACEMENT PUMP (M46 SERIES)

Troubleshooting guide and gauge installation for variable displacement pumps.

5.7 PRESSURE SETTING PROCEDURES

Details pressure setting procedures for main relief, steer, swing, lift, platform, and jib functions.

SECTION 6 - JLG CONTROL SYSTEM

6.1 INTRODUCTION

Overview of the JLG Control System and its benefits.

6.3 USING THE ANALYZER

Guidance on navigating and using the analyzer's interface and menus.

6.5 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER

Steps for adjusting personality settings and parameters via the analyzer.

6.6 MACHINE SETUP

Procedures for configuring machine settings and options.

6.8 MACHINE PERSONALITY SETTINGS

Table of personality settings, ranges, and defaults for machine performance.

SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.2 MULTIMETER BASICS

Explains multimeter usage for circuit measurements like voltage and resistance.

7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS

Procedure for applying dielectric compound to prevent oxidation and malfunction.

7.4 AMP CONNECTOR

Instructions for applying dielectric compound and assembling AMP connectors.

7.5 DEUTSCH CONNECTORS

Procedures for assembling and disassembling DT/DTP series Deutsch connectors.

HD30/HDP20 Series Assembly

HD30/HDP20 Series Disassembly

Steps for disassembling HD30/HDP20 series connectors.

Figure 7-18. Electrical Harness - Prior to S/N 87000 - Sheet 1 of 2

Figure 7-19. Electrical Harness - Prior to S/N 87000 - Sheet 2 of 2

Continuation of the electrical harness schematic for units prior to S/N 87000.

Figure 7-20. Electrical Harness - S/N 87000 to Present - Sheet 1 of 2

Figure 7-21. Electrical Harness - S/N 87000 to Present - Sheet 2 of 2

Continuation of the electrical harness schematic for units from S/N 87000 onwards.

Figure 7-22. Electrical Schematic - ADE - Sheet 1 of 6

Figure 7-23. Electrical Schematic - ADE - Sheet 2 of 6

Electrical schematic for ADE system, sheet 2 of 6.

Figure 7-24. Electrical Schematic - ADE - Sheet 3 of 6

Electrical schematic for ADE system, sheet 3 of 6.

Figure 7-25. Electrical Schematic - ADE - Sheet 4 of 6

Figure 7-26. Electrical Schematic - ADE - Sheet 5 of 6

Electrical schematic for ADE system, sheet 5 of 6.

Figure 7-27. Electrical Schematic - ADE - Sheet 6 of 6

Electrical schematic for ADE system, sheet 6 of 6.

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