One book stands between a 600 series boom lift and the rental yard's dead row: JLG publication 3120840, a JLG 600S service and maintenance manual PDF whose 272 pages cover five telescopic and articulating variants of this aerial work platform. Hydraulic schematics trace each circuit from the M46 variable displacement pump through the control valves, wiring diagrams map the electrical side, and a dedicated section teaches the hand held analyzer: connection, access levels, and machine personality settings. Cylinder work runs from theory of operation through repair, removal, and drift testing. Shim your main boom wear pads to within 0.8 mm, replace tower boom pads once wear passes 1.6 mm, and pull A model wheel lugs to 170 ft. lbs. (231 Nm). Troubleshooting a fault code from the basket is miserable. Buy this bookmarked, text-searchable PDF once and it is yours for as long as you run the machine.
What's Inside This JLG 600S-660SJ Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction - Maintenance Safety Precautions | 5-18 | Hydraulic System Safety, Maintenance |
| Specifications | 19-34 | Capacities, Component Data, Performance Data, Function Speeds, Torque Requirements, Lubrication, Pressure Settings, Cylinder Specifications |
| General | 35-50 | Machine Preparation, Inspection, And Maintenance, Service and Guidelines, Lubrication and Information |
| Chassis & Turntable | 51-102 | Drive Torque Hub, Prior to S/N 75606, Torque Hub, Drive, S/N 75606 to Present, Drive Brake - Mico, Free Wheeling Option |
| Boom & Platform | 103-132 | Boom Rope Torquing Procedures, Wear Pads, Wire Rope, Boom Maintenance, Tower Boom, Articulating Jib Boom, Limit Switches and Cam Valve Adjustment, Platform |
| Hydraulics | 133-182 | Cylinders - Theory of Operation, Cylinder Checking Procedure, Cylinder Repair, Cylinder Removal and Installation, Variable Displacement Pump, Valves - Theory of Operation |
| Jlg Control System | 183-226 | Introduction, To Connect the Jlg Control System Analyzer, Using the Analyzer, Changing the Access Level of the Hand Held Analyzer, Parameters Using the Hand Held Analyzer |
| Schematics | 227-272 | Troubleshooting, Hydraulic Circuit Checks |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Wheel Lugs (A Models) | 170 ft. lbs. (231 Nm) | p. 22 |
| Contact wire pull force | 1 or 2 lbs. | p. 43 |
| Screwdriver blade width for wedge lock disassembly | 4.8 mm (3/16") | p. 43 |
| Replace wear pads (Tower Boom A Models) when worn within | 1.6 mm | p. 103 |
| Shim up wear pads (Main Boom) to within | 0.8 mm | p. 103 |
| Torque retract adjusting nuts (S Models) | 20 Nm | p. 103 |
| Foot switch travel adjustment | 6.35 mm | p. 132 |
| Actuator end cap torque | 54 - 68 Nm | p. 130 |
| Maximum pressure for pressure-washing electrical/electronic components | 750 PSI (52 BAR) | p. 183 |
| Minimum distance for pressure-washing electrical/electronic components | 12 inches (30.5 cm) | p. 183 |
| 600S, 600SJ, 660SJ | ||
| Fuel Tank Capacity | 148 Liters | p. 19 |
| 600A, 600AJ | ||
| Fuel Tank Capacity | 114 Liters | p. 19 |
JLG 600S-660SJ Series Common Problems This Manual Covers
JLG 600S boom lift shows fault code 6/6 and won't drive, lift, or telescope
Check CAN harness connectors at the ground and platform modules before condemning either controller. Look up code 6/6 in the fault code listing starting on page 198, then trace the circuit on the wiring diagram on page 242. At each suspect connector, pull the contact wires with 1 or 2 lbs. of force to confirm the retention fingers hold.
Manual Section: JLG Control System Fault Codes p. 198Load sensing system shows overload fault with an empty platform, all boom functions locked out
Connect the hand held analyzer per the JLG Control System section starting on page 183 and check for an LSS calibration error before ordering a load sensor. Recalibrate the load sensing system with the platform empty. If someone pressure washed the machine, keep washers under 750 PSI (52 Bar) and 12 inches (30.5 cm) from electrical components going forward.
Manual Section: Jlg Control System p. 183Boom lift and telescope functions run slow, stall, or stop completely under load
Check main relief pressure at the test port; it should hold 207 Bar per the pressure settings on page 24. If relief checks good, test suspect cylinders for internal leakage with the checking procedure starting on page 133. Verify hydraulic oil level and run the circuit checks on page 227 before pulling the pump.
Manual Section: Hydraulics p. 133Telescope sections chatter, bang, or feel sloppy when extending or retracting the boom
Inspect the boom wear pads before condemning cables or sheaves. Measure each pad; replace any pad worn to within 3.2 mm and shim to hold 1.6 mm section clearance per the limits on page 112. Grease the sliding surfaces after shimming, then cycle the telescope fully and recheck clearance with the boom level.
Manual Section: Boom & Platform p. 112Foot switch dead or platform functions cut out intermittently, code 0011 FSW open displayed
Test the foot switch before replacing the platform control module. Adjust the switch so functions activate during the last 6.35 mm of pedal travel, per the procedure on page 132. Check the analyzer for code 0011 (FSW open) using the fault listing starting on page 198, and inspect the switch wiring for chafing or corrosion.
Manual Section: Boom & Platform p. 132Frequently Asked Questions
What are the torque specifications for the wheel lugs on a JLG 600AJ?
The torque specification for the wheel lugs on the 600AJ (A Models) is 170 ft. lbs. (231 Nm). p. 22
How do I clear a fault code on the JLG control system?
Most faults are cleared automatically when the fault condition is removed. However, some faults, such as 'FSW FAULTY' or 'KEYSWITCH FAULTY', require the Emergency Stop (EMS) to be recycled to clear the fault. p. 216
What is the capacity of the fuel tank for the 600S and 600A models?
The fuel tank capacity is 148 Liters for the 600S models and 114 Liters for the 600A models. p. 19
What is the recommended interval for checking the swing bearing bolts on a JLG 600S-660SJ Series aerial work platform?
The swing bearing bolts should be checked for security after the first 50 hours of operation and every 600 hours thereafter. p. 22
What is the torque specification for the main relief valve on the 600S and 600A models?
The main relief valve pressure setting for both S and A models is 207 Bar. p. 24
Do I get instant access to this JLG 600S Service and Maintenance Manual?
A single searchable PDF file of 272 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Is this JLG 600S manual print-friendly?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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